US3670799A - Method and apparatus for siphoning molten metal to a continuous casting machine - Google Patents
Method and apparatus for siphoning molten metal to a continuous casting machine Download PDFInfo
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- US3670799A US3670799A US106384A US3670799DA US3670799A US 3670799 A US3670799 A US 3670799A US 106384 A US106384 A US 106384A US 3670799D A US3670799D A US 3670799DA US 3670799 A US3670799 A US 3670799A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
- B22D11/0637—Accessories therefor
- B22D11/064—Accessories therefor for supplying molten metal
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T137/00—Fluid handling
- Y10T137/2713—Siphons
- Y10T137/2842—With flow starting, stopping or maintaining means
Definitions
- ABSTRACT A method and system for siphoning molten metal, such as copper or aluminum.
- a first vessel with molten metal therein and a casting chamber are provided, the casting chamber receiving the molten metal from the first vessel.
- a continuous tubular member is provided and has a first section and initially has a second section.
- the first section has an inlet end which is positioned in the first vessel and in the molten metal and has an outlet end which is positioned in the casting chamber.
- the second section has a discharge end! which extends outside the casting chamber.
- This invention relates to a method and system for siphoning molten metal and it particularly relates to a method and system for starting the siphoning of molten metal, such as is involved in the casting of copper or aluminum rod or bars from molten metal.
- the transfer of molten metal from one location to a location where the metal is cast is accomplished either by siphoning metal from one vessel to the casting chamber or by pouring the molten metal from a storage vessel to the casting chamber.
- significant metering problems must be overcome.
- the prior art devices utilize rather complex arrangements to accomplish the pouring at the desired rate.
- Siphoning of the molten metal to the casting chamber is generally the preferred technique because of the elimination of the metering problem as the siphoning technique provides the important and desired result of accurate control of the level of the molten metal in the casting chamber. Also, in the siphoning technique, there is no turbulence, as is often true when the pouring technique is used. Such turbulence is undesired in casting aluminum. Further, if splashing of the metal occurs, in continuous casting techniques, metal may contact the casting wheel and/or belt while they are separated, trapping the metal particles between the belt and wheel when they come together. This may cause pitting of the casting wheel, which may have an adverse effect on its life.
- the siphoning of molten metal is accomplished by imparting a vacuum to the central, upper part of the siphon tube, in the shape of an inverted U, while one end is in the pot containing the molten metal to be siphoned while the opposite and lower end of the inverted U- shaped tube has its end blocked off as the vacuum is imparted to start the siphon.
- U.S. Pat. No. 2,549,790 shows a siphoning arrangement wherein a vacuum tube is inserted upwardly into the inlet end of a siphon tube where a vacuum is drawn so that the molten metal is pulled through the inlet leg by the vacuum in order to start the siphon.
- U.S. Pat. No. 3,066,364 utilizes a special design siphon tube wherein the siphoning is started by pouring the metal through the siphon tube. Particularly at columns 7 and 8 of this patent, the accurate level control of siphoning techniques is disclosed in some detail. This patent is also noteworthy in column in disclosing that several hundred pounds of copper may be run in order to start the siphon.
- molten metal such as copper or aluminum
- a method and system for starting the siphoning of molten metal wherein a first container having the molten metal therein is provided, a secondcontainer is provided for receiving the molten metal, a continuous tubular member having a first section and a second section is provided, the first section having .an inlet end in the first container and in the molten metal and also having an outlet end in the second container at a level at about that of the inlet end, the second section having a discharge end, the first section having a melting point higher than that of the molten metal, the second section having a melting point lower than that of the molten metal, and vacuum means are connected to the discharge end for drawing the molten metal completely through the first section and at least partially through the second section, molten metal melting substantially all of the portion of the second section which it contacts, the molten metal thereafter passing by siphoning from the first container to the second container and through the first tubular section.
- FIG. 1 is a schematic side elevational view of one preferred form of our invention
- FIG. 2 is an end view of the embodiment of FIG. 1;
- FIG. 3 is a schematic view of an alternate embodiment of our invention.
- FIG. 4 is a detailed, cross sectional view illustrating the place of connection between the two sections of the tubular member used for starting the siphoning.
- a tubular member having two separate and distinct sections is first provided.
- the first section has an inlet end arid an outlet end and has a melting point greater than the temperature of the molten metal.
- This first tubular section is ultimately used as the siphon tube for accomplishing the transfer.
- the second section of the tubular member has a discharge end and another end which is securely connected to the outlet end of the first tubular section.
- the second tubular section has a melting point less than the temperature of the molten metal.
- the inlet end of the first section is inserted into the molten metal in the crucible.
- the outlet end is inserted into the casting vessel at a level which is preferably slightly lower than the inlet end of the first tubular section.
- a vacuum is then applied to the outlet or discharge end of the second tubular section. The vacuum is sufficient to draw the molten metal through the first section and at least partially through the second section.
- the second tubular section has a melting point lower than that of the molten metal
- the molten metal such as copper or aluminum, melts a portion of the second section so that the molten metal passes continuously thereafter by siphoning from the storage crucible into the casting chamber and through the first tubular section.
- a vessel of crucible 10 made of refractory material, is provided for receiving and storing the molten metal 12.
- the molten metal is passed into the storage vessel of crucible from a furnace (not shown) wherein the metal is melted and transferred to the crucible 10.
- the molten metal 12 is transferred by siphoning to a continuous casting wheel 14.
- the continuous casting wheel 14 is mounted on a shaft 16 which is interconnected to a drive source (not shown) for rotating the wheel 14.
- the casting wheel 14 has a continuous peripheral groove 18 defined in its outer periphery, which functions as the casting chamber for the metal.
- a continuous metallic belt 26 passes approximately semicircularly around the outer periphery of the continuous wheel 14.
- the belt 26 encloses the groove 18 defined in the continuous casting wheel so as to provide the casting chamber.
- molten metal is poured into one end of the enclosed casting chamber defined in the groove 18 and the metal is solidified therein as the wheel is rotated at a desired rate of speed, all of which is accomplished with conventional techniques.
- the molten metal solidifies, it passes upwardly and outwardly from between the casting wheel 14 and the belt 26, from where it is passed in a solid, but flexible, state to a series of rollers which reduce the diameter of the bar to a desired dimension in stages.
- the belt 26 is held in firm engagement with the outer periphery of the wheel 14 by biasing rollers 28 which bear against the belt and move it against the outer periphery of the wheel 14, as best shown in FIG. I.
- the metal is introduced to the groove near one roller 28 and the cast bar is removed near another roller 28.
- the important and novel aspects of our invention lie in he system and method by which the molten metal 12 is transferred from the storage vessel or crucible 10 to the casting chamber defined in the continuous casting wheel 14 by the belt 26. More particularly, our invention resides in the method and system of starting the siphoning of the molten metal in a simple, effective and economical manner.
- a tubular member 30 is provided with two sections 32 and 34.
- the first section 32 is used throughout the siphoning of the molten metal 12 to the groove 18 while the second section 34 is used only during the starting of the siphoning.
- the section 32 will be referred to as the siphon section and the section 34 will be hereinafter referred to as the starter section.
- the starter section 34 is constructed of a metal having a lower melting point that the temperature of the molten metal 12.
- the starter section 34 is soft copper tubing.
- a nominal 1 inch, K Type soft copper tubing has been found to be particularly effective in starting the siphoning of molten copper. It is important that the wall thickness of the tube 34 be sufficiently thick so as it does not melt too fast. If the tube melts too early in the siphoning procedure, the siphon simply stops.
- a wall thickness of approximately 0.065 inches is preferred for the starter section 34.
- the internal diameter of the tubing 34 is to be sufficiently large so that enough melted metal is drawn from the refractory vessel 10 in order to properly and effectively start the flow of molten metal.
- an internal diameter of approximately 0.900 inches has been found to be desirable.
- the purpose of the starter tube is to permit a sufficient amount of copper to be pulled by vacuum from the vessel 10 and yet the starter tube is to be sufiiciently thick so it will not melt until enough copper or aluminum has been drawn through the tube to start the siphoning.
- the length of the starter section 34 this is not considered critical and is only to be of sufficient length so as to pass completely into the groove 18 and upwardly therefrom as shown.
- the siphon section 32 is reduced in diameter at its end 36 and is inserted into the expanded or enlarged inlet or upper end of the starter section 34 with a snug fit.
- the reduced outlet end of the siphon section 32 acts as a choke and effectively seals the outlet end of the siphon section 32 preventing entry of air where the molten metal does not wet the metal wall of the siphon tube. Without such a seal, an air bubble could pass up through the siphon tube and slow the metal flow or break the siphon.
- the siphon section 32 is preferably in the shape of an inverted U and is made of a metal having a higher melting point than the molten metal. It is important that the metal from which the siphon tube 32 is made is to be resistant to deterioration when subjected to the high temperatures of the molten metal for extended periods of time. Again, in the case of the casting of copper bars in continuous casting processes, we have found that a stainless steel tubing which is resistant to oxidation at temperatures of 2,200 F. is particularly effective, the temperature of the molten metal 12 being at approximately 2,l50 F. It has been found to be particularly desirable to provide a siphon section 32 which has a l-inch outside diameter and a 0.062 inch wall thickness. Referring to FIG.
- the internal diameter of the siphon section 32 be reduced at its outlet end 36 to a diameter of approximately three-quarters of an inch.
- the inlet end 38 is simultaneously inserted to a depth of about 6 inches below the level of the surface of the metal in the crucible.
- the outlet end 36 is desirably placed slightly below the level of the inlet end, preferably about 1 inch below.
- a siphon system provides an accurate level control in the mold and the crosssectional areas of the siphon tube and its discharge end, as well as the depth of insertion of the siphon inlet into the metal bath and of the discharge end into the mold cavity cooperate to provide such control.
- a vacuum hose 42 is interconnected to the outlet end 44 of the starter section 34.
- the vacuum hose or line 42 has a quick operating valve 50 interconnected therein and the opposite end of the hose 42 connects to a vacuum tank 46.
- a vacuum pump 52 is interconnected to the tank 46 for drawing a vacuum of the desired amount therein.
- a vacuum gauge 54 is provided so the operator can determine the vacuum level in the tank 46.
- the vacuum relief valve 56 is also connected to the tank 46.
- a vacuum pump 52 maintains the vacuum in the tank 46 at a substantially constant value, as determined by the relief valve 56 and the gauge 54.
- the starter section 34 is first inserted downwardly into the groove 18 of the casting wheel 14.
- the wheel is then rotated by the shaft 16 at a desired rate of speed and the soft tubing 34 is pulled into the groove 18 by such movement of the wheel 14.
- the inlet end of the starter tube 34 is adjusted to extend above the normal level to which the molten metal 12 flows in the groove 18 while its opposite end extends out of the groove 18, as shown in FIG. 1.
- the siphon section 32 is then connected to section 34 to form tubular member 30.
- the siphon section 32 is lowered into the molten metal bath 12, it is preheated, as manually with a torch, in order to assure that the copper or aluminum being transferred from the vessel to the groove 18 does not freeze and then plug up any section of the tubular member 30.
- the casting wheel 14 is rotated until the discharge end of the siphon section 32 is lowered about 6 inches into the metal bath, the horizontal portion of the section 32 resting on or engaging the porch 58 extending outwardly from the vessel 10.
- the quick operating valve 50 is opened so that the vacuum in the tank 46, at a desired level, draws a vacuum through the member 30.
- the tank 46 acts as a reservoir to provide a greater instant suction than normally provided by a vacuum pump alone.
- a fast start of siphoning is provided by the instantaneous vacuum of the described arrangement and assists in providing the desired results.
- a vacuum preferably ranging from 6 inches of mercury to about 12 inches of mercury is drawn through the tubular member in the case of the casting of copper.
- therequired vacuum is less, as about 2-4 inches of mercury, because of the lower specific gravity of aluminum.
- the vacuum is started substantially instantaneously as the siphon section has been moved into the molten bath l2the desired amount.
- the vacuum substantially instantaneously pulls the molten metal through the siphon section 32and through a portion of the starter section 34.
- the inlet portion of the starter section melts when the hot metal contacts because it has a lower melting pointthan the molten metal being drawn therethrough. As viewed in FIG. 1, about the first or initial 30 arc of the starter section 34 melts. The unmelted portion of the starter section 34 is removed from the casting groove and the vacuum is shut off by the quick operating valve 50. The siphon section 32, being of a higher melting point than the molten metal remains for continuing the siphoning of the molten metal from the vessel 10 to the casting groove 18. Desirably the starter section is of the same material as the molten metal. The molten metal and melted starter sections are fed to a rolling mill (not shown) where this portion is cut-off and discarded.
- FIG. 3 there is shown an alternate embodiment of the invention wherein no continuous casting wheel is provided.
- the system shown in FIG. 3 involves the use of vertical casting.
- a crucible or storage vessel for the molten metal 12 is provided.
- the starter section 34 and siphon section 32 make up a tubular member 30.
- the outlet end of the siphon section 32 and the starter section 34 are inserted into the casting chamber of the continuous vertical casting arrangement 48, and the starter section 34 and siphon section 32 are merely lowered until the inlet end of the siphon tube is submerged approximately 6 inches into the molten metal.
- the vacuum is then drawn and the copper is pulled through the siphon section 32 and at least partially through the starter section 34.
- the molten metal melts the starter section 34 upon siphoning to the casting chamber 48.
- the siphoning in the embodiment of P16. 3 is started, in a manner similar to that described with respect to the embodiment of F I08. 1 and 2.
- a method for siphoning of molten metal for transfer from a first vessel to a second vessel comprising the steps of filling said first vessel with said molten metal, provid ing a tubular member having two sections, the. first section having an inlet end, an outlet end, and a melting point greater, than the temperature of said molten metal, said second section having a discharge end and having a melting point less than the temperature of said molten metal,. inserting said inletend into said molten metal in said first vessel, positioning said outlet end in said second vessel, and applying a vacuum tosaid discharge end for drawing said molten metal through said first section and at least partially through said second section, said molten metal melting a portion of said second section which. said molten metal contacts, said molten metal thereafter passingby siphon from said first vesselto said second vessel through said first tubular section.
- said second vessel comprises a casting chamber wherein said molten metal is cast into a desired shape.
- said second vessel is a casting chamber wherein said molten metal is cast, said molten metal is copper, said first tubular section is stainless steel, and said second tubular section is soft copper tubing.
- said second vessel comprises a peripheral groove in a continuous castingwheelandj is enclosed by a metal belt member, said second tubular section is positioned in said groove, and said discharge. end extends outwardly from said enclosed groove.
- a system for siphoning molten, metal said system com,- prising a first vessel adapted to hold saidmolten metaltherein, a second vessel to which said molten metal is to be transferred, a tubular member having a first section and a second section, said first section having an inlet end in said first vessel to be disposed in said molten metal and having an outlet end in said second vessel, said second section having a discharge end, said first section formed of a metal having a relatively high melting point, said second section formed of a metal having a relative ly low melting point, and vacuum means connected to said discharge end for drawing said molten metal through said first section and at least partially through said second section, whereby said molten will initially melt a portion of said second section and thereafter continuously pass by siphon from said first vessel to said second vessel and through said first tubular section.
- said first tubular section adapted to impart a vacuum of about 6-12 inches of mercury. is stainless steel, and said second tubular section is soft 17.
- said vacuum means is copper. adapted to impart a vacuum of about 2-4 inchesof mercury.
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Abstract
A method and system for siphoning molten metal, such as copper or aluminum. A first vessel with molten metal therein and a casting chamber are provided, the casting chamber receiving the molten metal from the first vessel. A continuous tubular member is provided and has a first section and initially has a second section. The first section has an inlet end which is positioned in the first vessel and in the molten metal and has an outlet end which is positioned in the casting chamber. The second section has a discharge end which extends outside the casting chamber.
Description
United States Patent Vogel et al.
[ 51 June 20, 1972 [54] METHOD AND APPARATUS FOR SIPHONING MOLTEN METAL TO A CONTINUOUS CASTING MACHINE [72] Inventors: Ralph A. Vogel, Three Rivers; Harold 8.
Moss, Kalamazoo, both of Mich.
[73] Assignee: Essex International, Inc.
[22] Filed: Jan. 14, 1971 [21] Appl. No.: 106,384
[52] U.S.Cl ..164/63, 137/142, 164/87, 164/254, 164/281, 164/337, 222/204 [51] Int. Cl ..B22d 11/10 [58] Field of Search ..164/63, 87, 133, 136, 254, 164/278, 281, 337; 137/142; 222/204, 416
[56] References Cited UNITED STATES PATENTS 916,314 3/1909 I-litt ..164/337 X 1,184,523 5/1916 Field ..164/133 X 1,983,579 12/1934 Ennor et al.. ..164/337 1,983,580 12/1934 Nock ..164/337 UX 2,135,183 11/1938 Junghans" .....164/281 X 2,356,013 8/1944 Spooner ..164/281 UX 2,549,790 4/ 1951 Finkeldey et al ..164/324 X 2,683,294 7/1954 Ennor et all. ..164/281 X 3,066,364 12/ 1962 Baier ..164/281 X 3,174,197 3/1965 Stauffer ..164/281 X 3,321,007 5/1967 Cofer et al. ..164/278 X FOREIGN PATENTS OR APPLICATIONS 550,522 12/ 1957 Canada ..164/281 1,475,783 2/1967 France ..164/281 Primary Examiner-Robert D. Baldwin Attorney-Molinare, Allegretti, Newitt & Witcoff [5 7] ABSTRACT A method and system for siphoning molten metal, such as copper or aluminum. A first vessel with molten metal therein and a casting chamber are provided, the casting chamber receiving the molten metal from the first vessel. A continuous tubular member is provided and has a first section and initially has a second section. The first section has an inlet end which is positioned in the first vessel and in the molten metal and has an outlet end which is positioned in the casting chamber. The second section has a discharge end! which extends outside the casting chamber.
20 Claims, 4 Drawing Figures PATENTEHmzo 1972 METHOD AND APPARATUS FOR SIPHONING MOLTEN METAL TO A CONTINUOUS CASTING MACHINE BACKGROUND OF THE INVENTION, FIELD OF THE INVENTION AND DESCRIPTION OF THE PRIOR ART This invention relates to a method and system for siphoning molten metal and it particularly relates to a method and system for starting the siphoning of molten metal, such as is involved in the casting of copper or aluminum rod or bars from molten metal.
Generally speaking, the transfer of molten metal from one location to a location where the metal is cast is accomplished either by siphoning metal from one vessel to the casting chamber or by pouring the molten metal from a storage vessel to the casting chamber. In the pouring technique, significant metering problems must be overcome. The prior art devices utilize rather complex arrangements to accomplish the pouring at the desired rate.
Siphoning of the molten metal to the casting chamber is generally the preferred technique because of the elimination of the metering problem as the siphoning technique provides the important and desired result of accurate control of the level of the molten metal in the casting chamber. Also, in the siphoning technique, there is no turbulence, as is often true when the pouring technique is used. Such turbulence is undesired in casting aluminum. Further, if splashing of the metal occurs, in continuous casting techniques, metal may contact the casting wheel and/or belt while they are separated, trapping the metal particles between the belt and wheel when they come together. This may cause pitting of the casting wheel, which may have an adverse effect on its life.
ln U.S. Pat. No. l,944,733, the siphoning of molten metal is accomplished by imparting a vacuum to the central, upper part of the siphon tube, in the shape of an inverted U, while one end is in the pot containing the molten metal to be siphoned while the opposite and lower end of the inverted U- shaped tube has its end blocked off as the vacuum is imparted to start the siphon.
Another system is shown in U.S. Pat. No. 1,983,579, wherein a siphoning arrangement is used, but the siphon is started by use of a displacement device which acts to raise the level of the molten metal to be siphoned from one location to the other.
Still another system is shown in US. Pat. No. 2,135,183, in which the siphon first requires the use of pressure in a closed chamber to start the flow of molten metal from the first vessel to the casting mold.
U.S. Pat. No. 2,549,790 shows a siphoning arrangement wherein a vacuum tube is inserted upwardly into the inlet end of a siphon tube where a vacuum is drawn so that the molten metal is pulled through the inlet leg by the vacuum in order to start the siphon.
U.S. Pat. No. 2,683,194 again shows the siphoning of molten metal wherein the displacement method is used for starting the siphon.
U.S. Pat. No. 3,066,364 utilizes a special design siphon tube wherein the siphoning is started by pouring the metal through the siphon tube. Particularly at columns 7 and 8 of this patent, the accurate level control of siphoning techniques is disclosed in some detail. This patent is also noteworthy in column in disclosing that several hundred pounds of copper may be run in order to start the siphon.
In U.S. Pat. No. 3,174,197, the siphon is started by imparting the vacuum to the uppermost, central portion of an inverted U-shaped siphon tube, such as shown in U.S. Pat. No. 1,944,733.
While the foregoing prior art discloses siphoning techniques and techniques for starting the siphoning which may be beneficial in the systems discussed, such systems are considered undesirable for high production casting methods, particularly in continuous casting techniques utilizing a continuous casting wheel.
It is therefore an important object of this invention to provide an improved method and system for siphoning and start ing the siphoning of molten metal for transferring molten metal, such as copper or aluminum, from a first chamber or vessel to a second vessel, such as a casting mold.
It is also an object of this invention to provide a method and system for starting the siphoning and siphoning molten metal, wherein the method and system are particularly characterized by their simplicity and economy of construction, operation, and use.
It is yet another object of this invention to provide an improved method and system for starting the siphoning of molten metal wherein spillage and waste of the molten metal is starting the siphon is minimized.
It is a further object of this invention to provide a method and system for starting the siphoning of molten metal, such as copper or aluminum, wherein a tubular member having two sections is provided, one tubular section being of a material having a higher melting point than the metal which is being transferred, while the other tubular section has a lower melting point than the material being poured so that the second section melts as a vacuum draws the molten metal completely through the first section and at least partially through the second section.
It is yet a further object of this invention to provide a system and method for starting the siphoning of molten metal for casting thereof wherein the method and system are particularly useful in continuous casting systems.
Further purposes and objects of the invention will appear as the specification proceeds.
The foregoing objects are accomplished by providing a method and system for starting the siphoning of molten metal wherein a first container having the molten metal therein is provided, a secondcontainer is provided for receiving the molten metal, a continuous tubular member having a first section and a second section is provided, the first section having .an inlet end in the first container and in the molten metal and also having an outlet end in the second container at a level at about that of the inlet end, the second section having a discharge end, the first section having a melting point higher than that of the molten metal, the second section having a melting point lower than that of the molten metal, and vacuum means are connected to the discharge end for drawing the molten metal completely through the first section and at least partially through the second section, molten metal melting substantially all of the portion of the second section which it contacts, the molten metal thereafter passing by siphoning from the first container to the second container and through the first tubular section.
BRIEF DESCRIPTION OF THE DRAWINGS Particular embodiments of the present invention are illus trated in the accompanying drawings wherein:
FIG. 1 is a schematic side elevational view of one preferred form of our invention;
FIG. 2 is an end view of the embodiment of FIG. 1;
FIG. 3 is a schematic view of an alternate embodiment of our invention; and
FIG. 4 is a detailed, cross sectional view illustrating the place of connection between the two sections of the tubular member used for starting the siphoning.
DESCRIPTION OF THE PREFERRED EMBODIMENTS Our method and system for siphoning molten metal from one location to another are primarily used in connection with, but not limited to, the casting of copper and aluminum, and are particularly useful in the continuous casting of copper or aluminum rod or bar. Molten copper or aluminum is transferred from a crucible or storage vessel, which receives the molten metal from a furnace, to the chamber where the metal is cast.
In order to accomplish this transfer, a tubular member having two separate and distinct sections is first provided. The first section has an inlet end arid an outlet end and has a melting point greater than the temperature of the molten metal. This first tubular section is ultimately used as the siphon tube for accomplishing the transfer. The second section of the tubular member has a discharge end and another end which is securely connected to the outlet end of the first tubular section. The second tubular section has a melting point less than the temperature of the molten metal.
In order to start the siphoning of the molten metal into the casting vessel, for example, into the groove of a continuous casting wheel, the inlet end of the first section is inserted into the molten metal in the crucible. At the same time, the outlet end is inserted into the casting vessel at a level which is preferably slightly lower than the inlet end of the first tubular section. A vacuum is then applied to the outlet or discharge end of the second tubular section. The vacuum is sufficient to draw the molten metal through the first section and at least partially through the second section. Since the second tubular section has a melting point lower than that of the molten metal, the molten metal, such as copper or aluminum, melts a portion of the second section so that the molten metal passes continuously thereafter by siphoning from the storage crucible into the casting chamber and through the first tubular section. Our method and system will be more clearly understood by reference to the accompanying drawings and to the following discussion.
Referring to the embodiment of FIGS. 1 and 2, a vessel of crucible 10, made of refractory material, is provided for receiving and storing the molten metal 12. The molten metal is passed into the storage vessel of crucible from a furnace (not shown) wherein the metal is melted and transferred to the crucible 10.
The molten metal 12 is transferred by siphoning to a continuous casting wheel 14. The continuous casting wheel 14 is mounted on a shaft 16 which is interconnected to a drive source (not shown) for rotating the wheel 14. As shown in FIGS. 1 and 2, the casting wheel 14 has a continuous peripheral groove 18 defined in its outer periphery, which functions as the casting chamber for the metal.
A continuous metallic belt 26 passes approximately semicircularly around the outer periphery of the continuous wheel 14. The belt 26 encloses the groove 18 defined in the continuous casting wheel so as to provide the casting chamber. In continuous casting procedures, molten metal is poured into one end of the enclosed casting chamber defined in the groove 18 and the metal is solidified therein as the wheel is rotated at a desired rate of speed, all of which is accomplished with conventional techniques. As the molten metal solidifies, it passes upwardly and outwardly from between the casting wheel 14 and the belt 26, from where it is passed in a solid, but flexible, state to a series of rollers which reduce the diameter of the bar to a desired dimension in stages. The belt 26 is held in firm engagement with the outer periphery of the wheel 14 by biasing rollers 28 which bear against the belt and move it against the outer periphery of the wheel 14, as best shown in FIG. I. The metal is introduced to the groove near one roller 28 and the cast bar is removed near another roller 28.
The important and novel aspects of our invention lie in he system and method by which the molten metal 12 is transferred from the storage vessel or crucible 10 to the casting chamber defined in the continuous casting wheel 14 by the belt 26. More particularly, our invention resides in the method and system of starting the siphoning of the molten metal in a simple, effective and economical manner.
As shown in FIGS. 1 and 2, a tubular member 30 is provided with two sections 32 and 34. The first section 32 is used throughout the siphoning of the molten metal 12 to the groove 18 while the second section 34 is used only during the starting of the siphoning. Thus, hereinbefore the section 32 will be referred to as the siphon section and the section 34 will be hereinafter referred to as the starter section.
The starter section 34 is constructed of a metal having a lower melting point that the temperature of the molten metal 12. Preferably, in the case of casting copper rod, the starter section 34 is soft copper tubing. A nominal 1 inch, K Type soft copper tubing has been found to be particularly effective in starting the siphoning of molten copper. It is important that the wall thickness of the tube 34 be sufficiently thick so as it does not melt too fast. If the tube melts too early in the siphoning procedure, the siphon simply stops. A wall thickness of approximately 0.065 inches is preferred for the starter section 34. Also, the internal diameter of the tubing 34 is to be sufficiently large so that enough melted metal is drawn from the refractory vessel 10 in order to properly and effectively start the flow of molten metal. Thus, an internal diameter of approximately 0.900 inches has been found to be desirable. The purpose of the starter tube is to permit a sufficient amount of copper to be pulled by vacuum from the vessel 10 and yet the starter tube is to be sufiiciently thick so it will not melt until enough copper or aluminum has been drawn through the tube to start the siphoning. Regarding the length of the starter section 34, this is not considered critical and is only to be of sufficient length so as to pass completely into the groove 18 and upwardly therefrom as shown.
The siphon section 32, as best shown in FIG. 5, is reduced in diameter at its end 36 and is inserted into the expanded or enlarged inlet or upper end of the starter section 34 with a snug fit. The reduced outlet end of the siphon section 32 acts as a choke and effectively seals the outlet end of the siphon section 32 preventing entry of air where the molten metal does not wet the metal wall of the siphon tube. Without such a seal, an air bubble could pass up through the siphon tube and slow the metal flow or break the siphon.
The siphon section 32, as shown, is preferably in the shape of an inverted U and is made of a metal having a higher melting point than the molten metal. It is important that the metal from which the siphon tube 32 is made is to be resistant to deterioration when subjected to the high temperatures of the molten metal for extended periods of time. Again, in the case of the casting of copper bars in continuous casting processes, we have found that a stainless steel tubing which is resistant to oxidation at temperatures of 2,200 F. is particularly effective, the temperature of the molten metal 12 being at approximately 2,l50 F. It has been found to be particularly desirable to provide a siphon section 32 which has a l-inch outside diameter and a 0.062 inch wall thickness. Referring to FIG. 4, it is desirable that the internal diameter of the siphon section 32 be reduced at its outlet end 36 to a diameter of approximately three-quarters of an inch. When the siphon tube 32 is placed down into the molten metal 12, the inlet end 38 is simultaneously inserted to a depth of about 6 inches below the level of the surface of the metal in the crucible. The outlet end 36 is desirably placed slightly below the level of the inlet end, preferably about 1 inch below. As known from the prior art (see for example, US Pat. No. 3,066,364) a siphon system provides an accurate level control in the mold and the crosssectional areas of the siphon tube and its discharge end, as well as the depth of insertion of the siphon inlet into the metal bath and of the discharge end into the mold cavity cooperate to provide such control.
In the operation of our system, a vacuum hose 42 is interconnected to the outlet end 44 of the starter section 34. The vacuum hose or line 42 has a quick operating valve 50 interconnected therein and the opposite end of the hose 42 connects to a vacuum tank 46. A vacuum pump 52 is interconnected to the tank 46 for drawing a vacuum of the desired amount therein. A vacuum gauge 54 is provided so the operator can determine the vacuum level in the tank 46. The vacuum relief valve 56 is also connected to the tank 46. A vacuum pump 52 maintains the vacuum in the tank 46 at a substantially constant value, as determined by the relief valve 56 and the gauge 54.
Referring to FIGS. 1 and 2, the starter section 34 is first inserted downwardly into the groove 18 of the casting wheel 14.
The wheel is then rotated by the shaft 16 at a desired rate of speed and the soft tubing 34 is pulled into the groove 18 by such movement of the wheel 14. The inlet end of the starter tube 34 is adjusted to extend above the normal level to which the molten metal 12 flows in the groove 18 while its opposite end extends out of the groove 18, as shown in FIG. 1. The siphon section 32 is then connected to section 34 to form tubular member 30.
Preferably before the siphon section 32 is lowered into the molten metal bath 12, it is preheated, as manually with a torch, in order to assure that the copper or aluminum being transferred from the vessel to the groove 18 does not freeze and then plug up any section of the tubular member 30. The casting wheel 14 is rotated until the discharge end of the siphon section 32 is lowered about 6 inches into the metal bath, the horizontal portion of the section 32 resting on or engaging the porch 58 extending outwardly from the vessel 10.
In order to commence the siphoning of the molten metal, the quick operating valve 50 is opened so that the vacuum in the tank 46, at a desired level, draws a vacuum through the member 30. The tank 46 acts as a reservoir to provide a greater instant suction than normally provided by a vacuum pump alone. A fast start of siphoning is provided by the instantaneous vacuum of the described arrangement and assists in providing the desired results. I r
A vacuum, preferably ranging from 6 inches of mercury to about 12 inches of mercury is drawn through the tubular member in the case of the casting of copper. For aluminum, therequired vacuum is less, as about 2-4 inches of mercury, because of the lower specific gravity of aluminum.
Although it is important to provide a sufiicient vacuum to start the siphoning, if too muchvacuum is drawn, the copper or other molten metal could be pulled completely through the tubular member 30 and into the vacuum hose 42, an obviously undesirable situation. It has been found to be particularly effective to draw a vacuum of about 10 inches of mercury and this brings the molten metal, such as copper, up to about 1 to 2 feet of the upper end of the starter section 34.
Preferably, the vacuum is started substantially instantaneously as the siphon section has been moved into the molten bath l2the desired amount. The vacuum substantially instantaneously pulls the molten metal through the siphon section 32and through a portion of the starter section 34.
The inlet portion of the starter section melts when the hot metal contacts because it has a lower melting pointthan the molten metal being drawn therethrough. As viewed in FIG. 1, about the first or initial 30 arc of the starter section 34 melts. The unmelted portion of the starter section 34 is removed from the casting groove and the vacuum is shut off by the quick operating valve 50. The siphon section 32, being of a higher melting point than the molten metal remains for continuing the siphoning of the molten metal from the vessel 10 to the casting groove 18. Desirably the starter section is of the same material as the molten metal. The molten metal and melted starter sections are fed to a rolling mill (not shown) where this portion is cut-off and discarded.
Referring to FIG. 3, there is shown an alternate embodiment of the invention wherein no continuous casting wheel is provided. The system shown in FIG. 3 involves the use of vertical casting. In this embodiment, a crucible or storage vessel for the molten metal 12 is provided. Again, the starter section 34 and siphon section 32 make up a tubular member 30. The outlet end of the siphon section 32 and the starter section 34 are inserted into the casting chamber of the continuous vertical casting arrangement 48, and the starter section 34 and siphon section 32 are merely lowered until the inlet end of the siphon tube is submerged approximately 6 inches into the molten metal. The vacuum is then drawn and the copper is pulled through the siphon section 32 and at least partially through the starter section 34. The molten metal melts the starter section 34 upon siphoning to the casting chamber 48. Thus, the siphoning in the embodiment of P16. 3 is started, in a manner similar to that described with respect to the embodiment of F I08. 1 and 2.
It is thus seen that all of theobjects previously set forth have been accomplished. We have provided a simple and economical method and system for startingthe siphoning and continu: ing the siphoning of molten metal from, one position. to, another. The system is particularly efiective. in the. case of siphoning molten copper in a continuous casting process wherein a cast copper bar is rolled. to form a continuous copper rod.
While in the foregoing, there has been provided a detailed description of particular embodiments of the present invention, it is to be understood that all equivalents obvious to those having skill in the art are to be included within the scope of the invention as claimed.
What we claim is:
l. A method for siphoning of molten metal for transfer from a first vessel to a second vessel, saidmethod comprising the steps of filling said first vessel with said molten metal, provid ing a tubular member having two sections, the. first section having an inlet end, an outlet end, and a melting point greater, than the temperature of said molten metal, said second section having a discharge end and having a melting point less than the temperature of said molten metal,. inserting said inletend into said molten metal in said first vessel, positioning said outlet end in said second vessel, and applying a vacuum tosaid discharge end for drawing said molten metal through said first section and at least partially through said second section, said molten metal melting a portion of said second section which. said molten metal contacts, said molten metal thereafter passingby siphon from said first vesselto said second vessel through said first tubular section.
2. The method of claim 1 wherein said vacuum is substantially instantaneously applied to start the said siphon.
3. The method of claim 1 wherein said second vessel comprises a casting chamber wherein said molten metal is cast into a desired shape.
4. The method of claim 1 wherein said second vessel is a casting chamber wherein said molten metal is cast, said molten metal is copper, said first tubular section is stainless steel, and said second tubular section is soft copper tubing.
5. The method of claim 1 wherein said molten metal is copper, and the vacuum applied to said discharge, end isabout 6-l 2 inches of mercury.
6. The method of claim 1 wherein said molten metal is aluminum, and the vacuum applied to said discharge end is about 2-4 inches of mercury. 1
7. The method of claim 1 wherein saidoutlet end of said first section is positioned slightly below the level of the inlet end of said first section.
8. The method of claim 1 wherein said second vessel comprises a peripheral groove in a continuous castingwheelandj is enclosed by a metal belt member, said second tubular section is positioned in said groove, and said discharge. end extends outwardly from said enclosed groove.
9. The method of claim 8 wherein. said casting wheel. is
rotated while said second tubular section is positioned therein.
for carrying said discharge end through the selected portion of said enclosed groove.
10. The method of claim 1 wherein saidmolten metal is aluminum and said second tubular section. is aluminum.
11. A system for siphoning molten, metal, said system com,- prising a first vessel adapted to hold saidmolten metaltherein, a second vessel to which said molten metal is to be transferred, a tubular member having a first section and a second section, said first section having an inlet end in said first vessel to be disposed in said molten metal and having an outlet end in said second vessel, said second section having a discharge end, said first section formed of a metal having a relatively high melting point, said second section formed of a metal having a relative ly low melting point, and vacuum means connected to said discharge end for drawing said molten metal through said first section and at least partially through said second section, whereby said molten will initially melt a portion of said second section and thereafter continuously pass by siphon from said first vessel to said second vessel and through said first tubular section.
12. The system of claim 11 wherein said first tubular section adapted to impart a vacuum of about 6-12 inches of mercury. is stainless steel, and said second tubular section is soft 17. The system of claim 11 wherein said vacuum means is copper. adapted to impart a vacuum of about 2-4 inchesof mercury.
13. The system of claim 1 1 wherein said second tubular sec- 18- Th system of C aim 1 her in aid utlet end is placed tion is aluminum. below the level of said inlet end of said first tubular section.
14. The system of claim 11 wherein said second vessel is a The System of claim 11 wherein Said Outlet end has a casting chamber wherein i metal is lidifi d reduced internal diameter to provide a choke for said siphon- 15. The system of claim 14 wherein said casting chamber is 20. The system of claim 1 1 wherein said second tubular secan enclosed groove defined in the periphery of a continuous tion 18 copper.
casting wheel.
16. The system of claim 11 wherein said vacuum means is
Claims (20)
1. A method for siphoning of molten metal for transfer from a first vessel to a second vessel, said method comprising the steps of filling said first vessel with said molten metal, providing a tubular member having two sections, the first section having an inlet end, an outlet end, and a melting point greater than the temperature of said molten metal, said second section having a discharge end and having a melting point less than the temperature of said molten metal, inserting said inlet end into said molten metal in said first vessel, positioning said outlet end in said second vessel, and applying a vacuum to said discharge end for drawing said molten metal through said first section and at least partially through said second section, said molten metal melting a portion of said second section which said molten metal contacts, said molten metal thereafter passing by siphon from said first vessel to said second vessel throuGh said first tubular section.
2. The method of claim 1 wherein said vacuum is substantially instantaneously applied to start the said siphon.
3. The method of claim 1 wherein said second vessel comprises a casting chamber wherein said molten metal is cast into a desired shape.
4. The method of claim 1 wherein said second vessel is a casting chamber wherein said molten metal is cast, said molten metal is copper, said first tubular section is stainless steel, and said second tubular section is soft copper tubing.
5. The method of claim 1 wherein said molten metal is copper, and the vacuum applied to said discharge end is about 6-12 inches of mercury.
6. The method of claim 1 wherein said molten metal is aluminum, and the vacuum applied to said discharge end is about 2-4 inches of mercury.
7. The method of claim 1 wherein said outlet end of said first section is positioned slightly below the level of the inlet end of said first section.
8. The method of claim 1 wherein said second vessel comprises a peripheral groove in a continuous casting wheel and is enclosed by a metal belt member, said second tubular section is positioned in said groove, and said discharge end extends outwardly from said enclosed groove.
9. The method of claim 8 wherein said casting wheel is rotated while said second tubular section is positioned therein for carrying said discharge end through the selected portion of said enclosed groove.
10. The method of claim 1 wherein said molten metal is aluminum and said second tubular section is aluminum.
11. A system for siphoning molten metal, said system comprising a first vessel adapted to hold said molten metal therein, a second vessel to which said molten metal is to be transferred, a tubular member having a first section and a second section, said first section having an inlet end in said first vessel to be disposed in said molten metal and having an outlet end in said second vessel, said second section having a discharge end, said first section formed of a metal having a relatively high melting point, said second section formed of a metal having a relatively low melting point, and vacuum means connected to said discharge end for drawing said molten metal through said first section and at least partially through said second section, whereby said molten will initially melt a portion of said second section and thereafter continuously pass by siphon from said first vessel to said second vessel and through said first tubular section.
12. The system of claim 11 wherein said first tubular section is stainless steel, and said second tubular section is soft copper.
13. The system of claim 11 wherein said second tubular section is aluminum.
14. The system of claim 11 wherein said second vessel is a casting chamber wherein said metal is solidified.
15. The system of claim 14 wherein said casting chamber is an enclosed groove defined in the periphery of a continuous casting wheel.
16. The system of claim 11 wherein said vacuum means is adapted to impart a vacuum of about 6-12 inches of mercury.
17. The system of claim 11 wherein said vacuum means is adapted to impart a vacuum of about 2-4 inches of mercury.
18. The system of claim 11 wherein said outlet end is placed below the level of said inlet end of said first tubular section.
19. The system of claim 11 wherein said outlet end has a reduced internal diameter to provide a choke for said siphoning.
20. The system of claim 11 wherein said second tubular section is copper.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US10638471A | 1971-01-14 | 1971-01-14 |
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US3670799A true US3670799A (en) | 1972-06-20 |
Family
ID=22311121
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Application Number | Title | Priority Date | Filing Date |
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US106384A Expired - Lifetime US3670799A (en) | 1971-01-14 | 1971-01-14 | Method and apparatus for siphoning molten metal to a continuous casting machine |
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