US3921699A - Method of and apparatus for producing metallic articles by electroslag melting - Google Patents
Method of and apparatus for producing metallic articles by electroslag melting Download PDFInfo
- Publication number
- US3921699A US3921699A US383057A US38305773A US3921699A US 3921699 A US3921699 A US 3921699A US 383057 A US383057 A US 383057A US 38305773 A US38305773 A US 38305773A US 3921699 A US3921699 A US 3921699A
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- US
- United States
- Prior art keywords
- molten metal
- pool
- central
- mould
- trough
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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Classifications
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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
- B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
- B22D23/06—Melting-down metal, e.g. metal particles, in the mould
- B22D23/10—Electroslag casting
Definitions
- ABSTRACT A method of producing a metallic article by feeding consumable electrodes consisting of a suitable metallic material continuously at a predetermined rate of speed into a slag bath formed in a water-cooled metal mould defining a moulding cavity of the same crosssectional shape as that of the desired metallic article, successively solidifying in said water-cooled metal mould the molten metal formed continuously by the electroslag melting of said consumable electrodes and continuously withdrawing said solidified metal from said mould at a predetermined rate of speed, characterized in that the consumable electrodes preferably have a transverse cross-sectional area larger than that of the desired metallic article are used, and the slag bath and the molten metal in the water-cooled metal mould are heated by non-consumable electrodes.
- This invention relates to improvements in the method of producing hollow metallic articles, such as tubes, pipes, bodies of pressure containers, spherical containers and bent tubes, and solid metallic articles having optional transverse cross-sectional shapes, from molten metals obtained by melting consumable electrodes of the desired metallic materials in a slag bath by electroslag melting.
- FIG. 1 type method comprising arranging consumable electrodes e in a shape corresponding to the transverse cross-sectional shape of a metallic article in desired to be produced, each of said consumable electrodes having a thickness 1 as shown in FIG. 1 relative to the wall thickness T of the metallic article in and a transverse cross-sectional shape substantially the same as that of said metallic article, and melting said consumable electrodes e in a slag bath S of relatively small volume by electroslag melting, as illustrated in FIG. 1.
- the rate of formation of the molten metal is very low and the rate of cooling of the same is also relatively low, and that accordingly there is the strong tendency for the dendritic structure D of the metallic article 111 to become coarse and the sizes of the metal grains thereof become relatively large.
- the conventional method has had the disadvantage that the production of the consumable electrodes is cumbersome and is difficult particularly when the metallic article 111 is small in thickness, because the consumable electrodes must be made for each metallic article desired to be produced in a transverse cross-sectional shape and dimensions matching with those of the particular metallic article.
- the present invention is proposed with a view to providing a method of producing metallic articles by electroslag melting, which is free of the above-described problems and disadvantage of the prior art method and in which the rate of formation and rate of cooling of molten metal are increased to provide for the production of quality metallic articles having fine grain structure.
- the present invention includes a method of producing a metallic article by feeding consumable electrodes consisting of a suitable metallic material continuously at a predetermined rate of speed into a slag bath formed in a water-cooled metal mould defining a moulding cavity of the same cross-sectional shape as that of the desired metallic article, successively solidifying in said water-cooled metal mould the molten metal formed continuously by the electroslag melting of said consumable electrodes and continuously withdrawing said solidified metal from said mould at a predetermined rate of speed, characterized in that consumable electrodes preferably having a transverse cross-sectional area larger than that of the desired metallic article are used. and the slag bath and the molten metal in the water-cooled metal mould are heated by non-consumable electrodes.
- FIG. 1 is a diagram briefly illustrating a prior art method
- FIG. 2 is a vertical cross-sectional view showing briefly one form of the apparatus for practicing the method of the present invention
- FIG. 3 is a transverse cross-sectional view of the apparatus of FIG. 2 in which a plurality of pairs of consumable electrodes are arranged in adjacent relation;
- FIG. 4 is a vertical cross-sectional view of another form of the apparatus for practicing the method of the invention.
- FIGS. 2 and 3 show an apparatus designed for producing a tubular metallic article according to the method of this invention.
- reference numeral 1 designates consumable electrodes consisting of a suitable metallic material.
- the consumable electrodes are made in a thickness 2 considerably larger than the wall thickness T of a tubular metallic article M desired to be produced.
- a plurality (16 in the apparatus shown) of the consumable electrodes 1 are arranged in adjacent relation circumferentially in a shape corresponding to the transverse cross-sectional shape of the tubular metallic article M, as shown in FIG. 3, and are continuously moved downwardly at a predetermined rate of speed by feed means not shown.
- Reference numeral 2 designates an annular wateracooled metal mould consisting of a water-cooled outer mould unit 20 and a water-cooled inner mould unit 2b arranged concentrically and defining therebetween an annular moulding cavity which is made up of an upper section, a central parallel section and a lower section.
- the central parallel section of the moulding cavity has a transverse cross-sectional shape same as that of the tubular metallic article M and a width equal to the wall thickness T of said metallic article, and its vertical length is longer than in the conventional apparatus shown in FIG. 1.
- the upper section of the moulding cavity is expanded upwardly and is formed with a step at the portion adjoining the central parallel portion, and the portion of said upper section above said step constitutes a slag bath receiving portion 3 and the portion of the same below said step constitutes a portion for accommodating a molten metal pool 4.
- Each of the consumable electrodes 1 is arranged to be submerged at its lower end into the central portion of a slag bath S filled in the slag bath receiving portion 3.
- Reference numeral 5 designates non-consumable electrodes. These non-consumable electrodes 5 are arranged on one or both sides of each consumable electrode 1 in adjacent relation thereto, with their lower end portions submerged deeply into the slag bath S in the slag bath receiving portion 3.
- These non-consumable electrodes 5 serve to heat the slag bath S and the molten metal in the molten metal pool 4 to prevent cooling of them and to alleviate the cooling action of the water-cooled metal mould 2 on said molten metal, and their lower ends are positioned close to the molten metal pool 4.
- each nonconsumable electrode 5 may be made to cause each nonconsumable electrode 5 to make a horizontal movement or oscillation circumferentially (as diagrammatically shown for one electrode 5 by arrow A in FIG, 3) in the slag bath 5 either alone or along with the associated consumable electrode 1.
- Reference numeral 6 designates a start piece fixed to article withdrawing means 7 provided beneath the water-cooled metal mould 2.
- the start piece 6 is formed such that its upper end portion can move into the central parallel section of the moulding cavity of the metal mould 2 and its top end face can close the upper open end of said central parallel section.
- drawing means 7 is moved up and down at a predetermined rate of speed by driving means not shown.
- Reference numeral 8 designates a power source connected with each consumable electrode 1 and the start piece 6, 9 a power source connected with each non-consumable electrode 5 and the start piece 6, and 10 a slag film formed on each of the inner and outer surfaces of the tubular metallic article M.
- the article withdrawing means 7 is elevated to insert the start piece 6 into the central parallel section of the moulding cavity of the water-cooled metal mould 2 from the underside and to close the upper open end of said central parallel section by the upper end face of said start piece 6.
- the consumable electrodes 1 are moved downwardly to locate the lower ends thereof within the upper section of the moulding cavity and a molten slag prepared separately is poured into the slag bath receiving portion 3 to form the slag bath S.
- the lower end portion of each consumable electrode 1 is submerged in the slag bath S and the lower end portion of each non-consumable electrode 5 is also submerged deep in said slag bath as it is previously positioned deep in the upper section of the moulding cavity.
- the power source 8 is closed to conduct a current across the start piece 6 and each consumable electrode 1, and each consumable electrode 1 is moved down atthe predetermined rate of speed.
- Each consumable electrode 1 is melted from its lower end by electroslag melting and the resultant droplets la of molten metal successively fall in the slag bath S and accumulate in the molten metal accommodating portion of the upper section of the moulding cavity to form a molten metal pool 4.
- the power source 9 is closed substantially concurrently to conduct a current from each non-consumable electrode 5 to the molten metal at through the slag bath 5 and to heat said slag bath and molten metal by said non-consumable electrodes.
- the molten metal m tends to cool rapidly by being cooled by the water-cooled metal mould 2 but, on the, other hand, said molten metal In and the slag bath 5 are heated by the nonconsumable electrodes 5 as stated above. Consequently, the cooling rate of the molten metal is reduced and the molten metal at remains in the molten state within the molten metal pool 4, without cooling and solidifying rapidly from the portion in contact with the metal mould 2 as is in the prior art method, and bonds with the top end face of the start piece 6 at its lower end.
- the article withdrawing means 7 is lowered at the predetermined rate of speed thereafter, the molten metal m moves down through the parallel section ofthe moulding cavity at the same rate of speed.
- a solidified metal having the predetermined 4 thickness T or the desired tubular metallic article M is produced.
- the article M is successively withdrawn from the metal mould 2 by the withdrawing means 7, at the predetermined rate of speed. Since the thickness t of the consumable electrodes 1 is considerably larger than the width T of the central parallel section of the moulding cavity, the droplets 1a of molten metal are formed at a higher rate and accordingly a larger amount of the molten metal In accumulates in the molten metal pool 4 in a unit time.
- the consumable electrodes r are generally submerged shallowly in the slag bath and the electroslag melting of said electrodes takes place at a portion of the slag bath close to the surface thereof,
- the temperature of the slag bath is relatively high at the upper portion and rel atively low at the bottom portion thereof and convection of the slag within the slag bath occurs only insufficiently.
- the nonconsumable electrodes 5 are used as auxiliary heating sources and their lower ends can be moved closely.
- the temperature of i This is because, if the current is passed only across the consumable electrodes and the molten metal, the temperature of the molten metal would rise and the depth of the molten metal pool would increase, but since the rate of formation of the molten metal droplets per unit time is constant, the heat of the molten metal would be useful only for maintaining the molten metal in a flowable state and not for increasing the supply of molten metal droplets, and it would be impossible to increase the molten metal withdrawing rate, with the consequence that the depth of the molten metal pool becomes excessively large and the molten metal being withdrawn is not solidified sufficiently only by the cooling effect of the water-cooled metal mould, and finally the metal emerges from the lower section of the moulding cavity as being melted.
- the current has been passed across the respective consumable electrodes to increase the rate of formation of molten metal droplets and has i been passed slightly to the molten metal pool.
- the current tends to pass in the surface layer of the slag bath where the temperature and electric conductivity are relatively high, it is impossible to submerge the consumable electrodes deep into the slag bath.
- the slag bath is formed in a relatively small depth and accordingly the amount of slag is small and the thermal inertia thereof is small, so that a powdered flux is usually supplied to replenish the slag.
- the flux takes much time before it is converted into slag and has detrimental effects of lowering the slag bath temperature and impairing the flowability of the slag.
- the slag bath is maintained at a uniform temperature and its lower portion has a high temperature and good electric conductivity, so that the consumable electrodes 1 can be penetrated deep into the slag bath S and sufficient current can be easily conducted across the respective consumable electrodes 1 and concurrently, across the consumable electrodes and the mo]- ten metal In.
- the depth of the slag bath S can also be made large, so that the powdered flux can be supplied without lowering the temperature of the slag bath S or impairing the flowability of the same, and stable electroslag melting can be obtained. Since the molten metal droplets can be supplied sufficiently to the molten metal pool 4, the withdrawing rate of the article withdrawing means 7 can be increased remarkably as compared with that in the prior art method and in no case will the depth of the molten metal pool become excessively large. Therefore, the molten metal being withdrawn is sufficiently cooled and solidified by the watercooled metal mould to give the desired article M and there is no fear of the molten metal emerging from the metal mould in the molten state.
- the slag bath S has a uniform temperature distribution, and is high in temperature and freely flowable. Therefore, slag films 10 formed between the water-cooled metal mould.2, and the molten metal in and the tubular article being produced, are very thin and attach uniformly to the inner and outer surfaces of the tubular article M, thus giving a beautiful appearance to the surfaces of and increasing the dimensional accuracy of the product tubular article M.
- one or a plurality of consumable electrodes having a total transverse cross-sectional area larger than the transverse cross-sectional area of a metallic article desired to be produced can be melted at a high rate by electroslag melting and the rate of withdrawal of the metallic article or the article production rate can be increased accordingly as compared with that in the prior art method.
- the molten metal cooling rate can also be increased, so that the dendritical structure of the metallic article does not grow so extensively as in metallic articles produced by the prior art method and the grain size is small. Therefore, the metallic article produced by the method of this invention has a remarkably improved quality over the articles produced by the prior art method.
- the impurities can be removed sufficiently and sufficient smelting of the molten metal can be attained.
- the molten slag in the slag bath is cooled by the water-cooled metal mould and shields the inner and outer surface of the metallic article in the form of a thin film, the surface appearance of the metallic article is improved and the dimensional accuracy thereof increases.
- the volume of the slag bath can be increased and, therefore, the electroslag melting can be achieved with stability and the production operation can be carried out smoothly.
- FIG. 4 is shown another form of the apparatus for practicing the method of this invention, in which pocket grooves 11 are respectively formed in the outer mould unit 2a and inner mould unit 2b of the watercooled metal mould 2 for accumulating therein impurities 12 which are not floatable.
- the apparatus of this form is advantageous in that the purity of the molten metal m can be maintained high and that the temperature thereof can be maintained at a higher level since the cooling effect of the metal mould 2 on the molten metal is moderated by the pocket grooves 11.
- a method as in claim 1 including further reducing the mould cooling effect on said molten metal pool by at least one pocket alongside said pool and accumulating non-floatable impurities in said pocket,
- a liquid cooled metal mould with inner and outer spaced parts and upper, central and lower sections with the facing sides of the central sections being parallel spaced the thickness of the side of said hollow article and that spacing being of the same cross-sectional shape as that of said metallic article, and with said upper sections having their inner sides sloping outwardly away from each other a significant angle to form a slag receiving trough with a central bottom well atop the open upper end of the space between said central parallel sections,
- a method as in claim 3 including moving at least one of the said electrodes in said slag bath to cause said heating of said molten metal pool and slag bath to be even more uniform.
- Apparatus for producing a desired metallic article comprising: i
- a liquid cooled metal mould having two vertically disposed spaced parts each of which has upper, central and lower sections with the central sections having facing inner parallel sides spaced the thickness of said article and with that spacing being of the same cross-sectional shape as that of said article,
- At least one of said upper sections having its inner side upwardly sloping outwardly a significant angle relative to the vertical to form with the inner side of the other upper section a slag receiving trough hava ing a bottom well atop the open upper end of the space between said central section facing sides for receiving molten slag,
- At least one non-consumable electrode disposed sub-' stantially at said angle into said trough adjacent at least said one sloping side thereof and deeply thereinto so that the bottom end of each said non-consumable electrode is adjacent said well
- each said non-consumable electrode for heating said molten metal pool to cause bond ing of molten metal from said pool to the topend face of said start piece and to cause a substantially uniform temperature distribution in said slag bath to reduce the cooling rate of the molten metal pool,
- said start piece upwardly moving means including means for withdrawing said start piece downwardly through said space between said parallel facing sides of said central sections of said mould to cause molten metal from said heated pool to move continuously downward therewith at the same rate of speed which is greater than if said molten metal pool heating had not occurred, and
- said liquid cooled metal mould including central and lower section cooling means for cooling said molten metal and successively solidifying same as it moves downwardly between said central section parallel faces for producing at the lower section of said mould a continuous solidified metallic article with reduced growth of dendritical structure and with a smaller grain size due to said pool heating.
- each said consumable electrode has a transverse cross-sectional area larger than that of the said desired metallic article.
- Apparatus as in claim 6 including means for moving at least said non-consumable electrode in said trough for causing said heating of said molten metal pool and slag bath to be more uniform.
- Apparatus as in claim 6 including means for moving said consumable and non-consumable electrodes in said trough and in addition to said feeding of said consumable electrode for more uniformly heating said molten metal pool and slag bath.
- Apparatus as in claim 6 including pocket means alongside said well for accumulating non-floatable impurities.
- Apparatus as in claim 6 wherein the inner side of said other upper section upwardly slopes outwardly at substantially said significant angle relative to the vertical and wherein there is at least one other nonconsumable electrode disposed at said angle into said trough adjacent said sloping inner side of said other upper section and deeply into said trough so that the bottom end of each said other non-consumable electrode is adjacent said well, said heating means being operable also to heat each said other non-consumable electrode.
- said liquid cooled metal mould, trough, start piece and spacing between said central section parallel facing sides being of the same cross-sectional shape as said desired metallic article
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacture And Refinement Of Metals (AREA)
- Continuous Casting (AREA)
- Discharge Heating (AREA)
- Furnace Details (AREA)
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP47085294A JPS511643B2 (de) | 1972-08-28 | 1972-08-28 |
Publications (1)
Publication Number | Publication Date |
---|---|
US3921699A true US3921699A (en) | 1975-11-25 |
Family
ID=13854547
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US383057A Expired - Lifetime US3921699A (en) | 1972-08-28 | 1973-07-27 | Method of and apparatus for producing metallic articles by electroslag melting |
Country Status (9)
Country | Link |
---|---|
US (1) | US3921699A (de) |
JP (1) | JPS511643B2 (de) |
AU (1) | AU451858B2 (de) |
CA (1) | CA998226A (de) |
DE (1) | DE2339979C3 (de) |
FR (1) | FR2197675B1 (de) |
GB (1) | GB1451924A (de) |
IT (1) | IT993786B (de) |
NL (1) | NL7310614A (de) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
AT406384B (de) * | 1996-01-29 | 2000-04-25 | Inteco Int Techn Beratung | Verfahren zum elektroschlacke-strangschmelzen von metallen |
CN115927865A (zh) * | 2022-12-29 | 2023-04-07 | 二重(德阳)重型装备有限公司 | 超百吨级电渣锭全重熔周期稳定化冶炼补渣工艺 |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS5121505A (en) * | 1974-08-16 | 1976-02-20 | Hitachi Ltd | Hojodenkyokuojusuru erekutorosuraguyokairo |
JPS52146704A (en) * | 1976-05-31 | 1977-12-06 | Venjukovsky Armaturny Zavod | Apparatus and process for remelting electroslag of metal and alloy |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2191480A (en) * | 1939-02-23 | 1940-02-27 | Kellogg M W Co | Apparatus for manufacturing alloy ingots |
US3571475A (en) * | 1967-08-07 | 1971-03-16 | Wolfgang Holzgruber | Electroslag refining apparatus |
US3650311A (en) * | 1969-05-14 | 1972-03-21 | Sandel Ind Inc | Method for homogeneous refining and continuously casting metals and alloys |
US3677323A (en) * | 1968-11-22 | 1972-07-18 | Rheinstahl Huettenwerke Ag | Process and apparatus for providing steel ingot |
US3683997A (en) * | 1971-06-09 | 1972-08-15 | Metsubishi Jukogyo Kk | Electroslag remelting process |
US3767831A (en) * | 1972-08-23 | 1973-10-23 | Boehler & Co Ag Geb | Process and apparatus for electro-slag remelting metals and in particular steel |
Family Cites Families (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR1596960A (de) * | 1967-12-21 | 1970-06-22 | ||
GB1251660A (de) * | 1968-10-17 | 1971-10-27 |
-
1972
- 1972-08-28 JP JP47085294A patent/JPS511643B2/ja not_active Expired
-
1973
- 1973-07-27 US US383057A patent/US3921699A/en not_active Expired - Lifetime
- 1973-07-31 NL NL7310614A patent/NL7310614A/xx unknown
- 1973-08-02 AU AU58849/73A patent/AU451858B2/en not_active Expired
- 1973-08-07 DE DE2339979A patent/DE2339979C3/de not_active Expired
- 1973-08-16 FR FR7329829A patent/FR2197675B1/fr not_active Expired
- 1973-08-16 GB GB3886073A patent/GB1451924A/en not_active Expired
- 1973-08-20 CA CA179,232A patent/CA998226A/en not_active Expired
- 1973-08-24 IT IT28229/73A patent/IT993786B/it active
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2191480A (en) * | 1939-02-23 | 1940-02-27 | Kellogg M W Co | Apparatus for manufacturing alloy ingots |
US3571475A (en) * | 1967-08-07 | 1971-03-16 | Wolfgang Holzgruber | Electroslag refining apparatus |
US3677323A (en) * | 1968-11-22 | 1972-07-18 | Rheinstahl Huettenwerke Ag | Process and apparatus for providing steel ingot |
US3650311A (en) * | 1969-05-14 | 1972-03-21 | Sandel Ind Inc | Method for homogeneous refining and continuously casting metals and alloys |
US3683997A (en) * | 1971-06-09 | 1972-08-15 | Metsubishi Jukogyo Kk | Electroslag remelting process |
US3767831A (en) * | 1972-08-23 | 1973-10-23 | Boehler & Co Ag Geb | Process and apparatus for electro-slag remelting metals and in particular steel |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
AT406384B (de) * | 1996-01-29 | 2000-04-25 | Inteco Int Techn Beratung | Verfahren zum elektroschlacke-strangschmelzen von metallen |
CN115927865A (zh) * | 2022-12-29 | 2023-04-07 | 二重(德阳)重型装备有限公司 | 超百吨级电渣锭全重熔周期稳定化冶炼补渣工艺 |
Also Published As
Publication number | Publication date |
---|---|
IT993786B (it) | 1975-09-30 |
JPS4940204A (de) | 1974-04-15 |
AU5884973A (en) | 1974-08-22 |
DE2339979B2 (de) | 1978-12-21 |
DE2339979C3 (de) | 1979-08-23 |
AU451858B2 (en) | 1974-08-02 |
FR2197675A1 (de) | 1974-03-29 |
GB1451924A (en) | 1976-10-06 |
JPS511643B2 (de) | 1976-01-19 |
DE2339979A1 (de) | 1974-03-21 |
FR2197675B1 (de) | 1976-04-30 |
CA998226A (en) | 1976-10-12 |
NL7310614A (de) | 1974-03-04 |
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