U.S. patent application number 10/115808 was filed with the patent office on 2002-10-03 for mold with a function ring.
Invention is credited to Instone, Stephen, Langen, Manfred, Schneider, Wolfgang.
Application Number | 20020139508 10/115808 |
Document ID | / |
Family ID | 7679827 |
Filed Date | 2002-10-03 |
United States Patent
Application |
20020139508 |
Kind Code |
A1 |
Schneider, Wolfgang ; et
al. |
October 3, 2002 |
Mold with a function ring
Abstract
The invention relates to a hot-top mold for a strand casting
apparatus, consisting of a hot-top, which lies on the upper side of
a parting agent distributor and presses it with its underside
against the surface of a mold, an overhang being formed on the
radially inner surface of the hot-top, which protrudes beyond the
parting agent distributor in the direction of take off of the
strand, the hot-top being centered and held by an outer ring, which
is releasably fastened to the mold. The mold surrounds a function
ring toward the bearing surface of the mold which, together with
the parting agent distributor, forms function surfaces with
adjustable roughness on the surfaces. In the parting agent
distributor, radial channels are formed at the upper side and the
underside, the channel cross sections at the upper side and the
underside being in a ratio of 1:3 to 1:5 to one another.
Inventors: |
Schneider, Wolfgang; (St.
Augustin, DE) ; Langen, Manfred; (Bonn, DE) ;
Instone, Stephen; (Bonn, DE) |
Correspondence
Address: |
DARBY & DARBY P.C.
805 Third Avenue
New York
NY
10022
US
|
Family ID: |
7679827 |
Appl. No.: |
10/115808 |
Filed: |
March 28, 2002 |
Current U.S.
Class: |
164/444 ;
164/487 |
Current CPC
Class: |
B22D 11/0401 20130101;
B22D 11/07 20130101 |
Class at
Publication: |
164/444 ;
164/487 |
International
Class: |
B22D 011/049 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 30, 2001 |
DE |
10115999.4-24 |
Claims
We claim:
1. A hot-top mold for a strand casting apparatus comprising a mold
(3), a parting agent distributor (2), a hot-top ring (1a, 1b) lying
on the top (2a) of the parting agent distributor (2) and pressing
its bottom (2b) against the top surface (3a) of the mold (3), an
overhang being formed at the radially interior surface of the
hot-top ring (1a, 1b) protruding beyond the parting agent
distributor (2) in the withdrawal direction of the strand and
forming an annular gap (11) with the mold surface, an outer ring
(4) releasably fastened to the mold (3), for centering and holding
the hot-top ring, a function ring (5) surrounded by the mold
positioned toward the inner surface of the mold, the function ring
and parting agent distributor (2) forming function surfaces with
adjustable roughnesses on the surfaces, and radial passages formed
on the top and bottom surfaces (2a, 2b) of the parting agent
distributor, the passage cross sections between the upper and
bottom surfaces being in a ratio of 1:3 to 1:5.
2. The hot-top mold of claim 1, wherein the function ring (5)
includes copper or copper alloys.
3. The hot-top mold of claim 1, wherein the function ring (5)
includes ceramic or composite materials.
4. The hot-top mold of claim 1, wherein the function ring (5)
includes graphite material.
5. The hot-top mold of claim 1, wherein a clamping ring (6) is
disposed above the hot-top (1a, 1b), by which the hot-top (1a, 1b),
the parting agent distributor (3), the function ring (5) and the
mold (3) are clamped.
6. The hot-top mold of claim 5, wherein the function ring (5) has a
closed porosity of 0-20% and a density of 1.5-10 g/cc.
7. The hot-top mold of claim 6, wherein the radial channels,
incorporated into the upper side 2a of the parting agent
distributor (2), are connected to a pressurized gaseous medium and
that radial passages are formed at the underside (2b) of the
parting agent distributor (2) and are connected to a pressurized
liquid reservoir.
8. The hot-top mold of claim 7, wherein the lower radial passages
of the parting agent distributor are configured in the manner of a
diffuser, an approximately square cross section being given to the
radially outward lying passage carrying the parting agent
distributor (2) and a rectangular cross section with a surface
ratio of at least 1:2 being formed on the radially inward-lying
exit side.
9. The hot-top mold of claim 8, wherein cooling passages (15) are
disposed in the mold (3), which reach into the area underneath the
parting agent distributor (2) and the function ring (5), heat
removal being performed in the annular gap (14) through a foam
layer (16) produced by the gas and liquid medium and issuing in the
descending direction of the strand.
10. The hot-top mold of claim 9, wherein the bottom part of the
thermal conductivity of the hot-top (1b) is 1.5 to 2.0 times
greater than that of the upper part of the hot-top (1a).
11. The hot-top mold of claim 10, wherein the upper part (2a) of
the parting agent distributor (2) is covered by an activator ring
(7).
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates to an apparatus for strand casting of
molten metal, and more particularly, to a hot-top mold for
improving the surface quality of hard-to-cast alloys.
[0002] Strand casting, also known as continuous casting, involves a
process in which molten metal is introduced into a mold. During its
residence time in the mold, the metal solidifies in contact with
the wall of the mold and can be drawn downward via a movable bottom
portion of the mold. A reserve of molten metal is positioned above
the mold. The reserve is also referred to as a feeder head or a
"hot-top". A parting agent, or release agent, is applied to the
surface of the continuous casting being formed, such that direct
contact with the surface of the mold is avoided, thereby
facilitating easy removal of the casting. Parting agents may
include mixtures of oils and gases. It is particularly desirable if
the oil-gas mixture is first formed close to the mold.
[0003] Hot-top molds of the kind described above are well known in
the art. European Pat. No. EP 0566 865 to VAW discloses a hot-top
mold where a parting agent, by way of a parting agent distributor,
reaches the surface of the cast strand. Two different parting
agents such as oil and gas, may be fed separately or as a
mixture.
[0004] Certain hard-to-cast alloys, such as aluminum alloys
containing lead, zinc, tin and copper, pose casting problems that
can result in poor surface quality. Recently, such alloys have been
gaining importance in the production of special alloys and
machining alloy stock, which are to be used at a high cutting
speed.
[0005] Another problem is the precise control of the gas pressure,
which determines whether the parting agent reaches the entire
surface of the metal strand. Pressure fluctuations can result in
surface flaws, and pressure that is too high may pose a risk that
gas might escape through the molten metal.
[0006] U.S. Pat. No. 4,732,209 to Pechiney attempts to solve this
problem by using a graphite ring on the inside of the mold. The
porosity of the graphite ring is established so that a gas under
pressure is forced from the outside through the open pores of the
graphite material to the inside of the mold and thereby acts as a
parting agent between the surface of the forming metal strand and
the mold surface. However, while this solution addresses the
problem of controlling gas pressure, this solution cannot be
applied to hard-to-cast alloys.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to a hot-top mold that
permits different types of alloys, in particular hard-to-cast
alloys, to be made with an improved surface quality.
[0008] The present invention comprises a hot-top ring, which lies
on top of a parting agent distributor and presses it against the
surface of a mold. An overhang on the inner surface of the hot-top
ring extends beyond the parting agent distributor in the downward
direction of the movement of the strand and forms an annular gap
with the running surface of the mold. A function ring is position
on the inner surface of the mold and forms a function surface with
the parting agent distributor through which gaseous and liquid
parting agents are delivered.
[0009] The hot top can be disassembled for use with different
alloys. A gaseous parting agent and a liquid (e.g. oil) are
introduced into the parting agent distributor. The parting agent
distributor and function ring may produce a foam layer to be used
as a parting agent which permits improved surface quality,
particularly for hard-to-cast alloys.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is an exploded view of a hot-top mold, in accordance
with a preferred embodiment of the invention; and
[0011] FIG. 2 is a representation of a hot-top mold used in strand
casting, in accordance with the preferred embodiment of the
invention.
DESCRIPTION OF PREFERRED EMBODIMENT
[0012] As shown in FIG. 1, a hot-top mold 1 comprises an upper ring
1a and a lower ring 1b. Rings 1a, 1b are secured within the
radially inside surface of an outer ring 4 which is releasably
fastened to a mold 3. Mold 3 surrounds at its inner surface a
function ring 5, whose upper end forms a function surface with a
parting agent distributor 2. A clamping ring 6 secures hot-top
rings 1a, 1b, parting agent distributor 2, mold 3, and outer ring
4. An activator ring 7 lies between outer ring 4 and the top
section 2a of parting agent distributor 2. A bottom part 8 and
pressure plate 9 compete the lower portion of mold 3.
[0013] Rings 1a, 1b of hot-top mold 1 are easy to assemble and
disassemble, facilitating the quick exchange of different parting
agent distributors and function rings according to the desired type
of alloy. Loosening clamping ring 6 and outer ring 4 permits
replacement of the parting agent distributor 2 and function ring
5.
[0014] Parting agent distributor 2 comprises a plate provided on
both sides with radial channels. The cross sections of the channels
may be in a ratio of 1:3 to 1:5 between top and bottom sides. This
ratio is important for controlling the composition of the parting
agent mixture. By matching the surface and channel cross sections,
foam production is easily possible. Foam is especially effective as
a highly viscous parting agent and permits an improved surface
quality, particularly for hard-to-cast alloys.
[0015] Function ring 5 includes surfaces facing the parting agent
distributor 2 and the mold surface. Function ring 5 may comprise
copper or copper alloys. It may also comprise ceramic, composite
materials or graphite. The function ring surfaces form walls with a
defined roughness for the channels formed by the parting agent
distributor 2. It is especially desirable if the function surface
forms one wall face for the liquid-bearing channel. With a
precisely adjusted surface roughness and temperature of the
function surfaces, a defined change in the viscosity of the fluid
parting agent can be achieved for producing a stable foam
layer.
[0016] It is advantageous if a defined, tight porosity of function
ring 5 and a specific density is chosen within narrow limits, such
as a closed porosity of 0-20% and a density of 1.5-10 g/cc.
Additional improvements in the stability of the parting agent foam
can be achieved by cooling the function ring 5 in order to keep the
viscosity properties on the function surfaces constant. The
construction and manner of operation of the function surfaces and
the cooling is further explained below.
[0017] The top surface 2a of parting agent distributor 2 is used
preferably to form gas-carrying passages, and bottom surface 2b of
parting agent distributor 2 is used for a liquid parting agent. The
passages incorporated into the upperside 2a are connected to a
pressurized gaseous medium, while the passages on the underside 2b
are connected to a pressurized liquid reservoir. The passages must
be made with very great precision, which can be achieved by laser
machining, a chemical etching method, or other techniques. The
cross-sectional shape of the radial passages is important for the
air content in the parting agent foam, and the surface area ratio
of the passages is important for the formation of a parting agent
foam distributed uniformly over the circumference. It is preferred
that the lower radial passages be configured in the manner of a
diffuser, with an approximately square cross section being given to
the radially outward lying passage carrying parting agent
distributor 2, and also a rectangular cross section with a surface
ratio of at least 1:2 formed on the radially inward lying exit
side. Under these circumstances the parting agent is formed with
especially fine cells and hence it is strong, thereby reducing the
liquid component of the parting agent.
[0018] Function ring 5 is preferably cooled by arranging cooling
passages 15 (See FIG. 2), in mold 3, which extend into the area
underneath parting agent distributor 2 and function ring 5. In this
primary cooling zone, a temperature is established for the optimum
action of the parting agent. An adjoining secondary cooling zone
permits a rapid removal of heat in the annular gap 14 through a
foam layer 16, since the cooling passages here run in the direction
of the descent of the strand and lead into a slot nozzle. Here, the
pressure of the coolant is lowered, so that the coolant is in
contact with the aluminum strand, thereby permitting heat
dissipation. Lower ring 1b has a thermal conductivity of
approximately 1.5 to 2.0 times greater than that of upper ring
1a.
[0019] The formation of certain function surfaces is critical to
the formation of a stable parting agent foam. The function surfaces
are situated above and below the parting agent distributor as well
as on the inside of the function ring 5. The latter is in direct
contact with the passages of the parting agent distributor 3 and
cooperates in the formation of the foam.
[0020] As an innovative and supplementing feature of the function
surfaces, activator ring 7, which can be made of various materials,
lies between outer ring 4 and the top 2a of the parting agent
distributor 2. It thus covers the top of the passages made in
parting agent distributor 2. Its roughness values differ from those
of the hot-top ring 1b and can be adjusted to the particular
requirements of the parting agent. At the same time, the thermal
gradient of the parting agent distributor 2 underneath the hot-top
1b can thereby be controlled.
[0021] Mold 3 is supplemented by an outside ring 4 and a function
ring 5. By means of a clamping ring 6, the system parts are
assembled together with the inclusion of an activator ring 7. The
mold 3 is completed by a bottom part 8 and a pressure plate 9.
[0022] FIG. 2 illustrates the basic construction of the hot-top
mold. An annular gap 11 exists underneath the overhang of hot-top
ring 1b, the side walls of annular gap 11 being formed by the
hot-top overhang and by the inside radius of the parting agent
distributor 2 and by the function ring 5. Upon the introduction of
gaseous and liquid parting agents within the volumetric ratio of
the invention, a stable parting agent foam 12 is formed, which
develops as a continuous layer of foam between the mold 3 and the
metal strand 10.
[0023] Initially, the viscosity of the parting agent is controlled
by the surface roughness in the gas region as well as in the liquid
region. The viscosity of the parting agent is the essential factor
in the formation of the foam. Furthermore, the pressure and rate of
flow of the delivered gaseous and liquid medium can be controlled,
so that the composition of the parting agent foam can be regulated
within wide limits. In turn, a controlled heat removal can be
performed, or else an insulating effect can be produced with the
parting agent. This is particularly advantageous for hard-to-cast
alloys.
* * * * *