A method and apparatus are described for the casting of a composite metal ingot comprising at least two separately formed layers of one or more alloys. An open ended annular mould has a feed end and an exit end and divider wall for dividing the feed end into at least two separate feed chambers, where each feed chamber is adjacent at least one other feed chamber. For each pair of adjacent feed chambers a first alloy stream is fed through one of the pair of feed chambers into the mould and a second alloy stream is fed through another of the feed chambers. A self-supporting surface is generated on the surface of the first alloy stream and the second alloy stream is contacted with the first stream such that the upper surface of the second alloy stream is maintained at a position such that it first contacts the self-supporting surface where the self-supporting surface temperature is between the liquidus and solidus temperatures of the first alloy or it first contacts the self-supporting surface where the self-supporting surface temperature is below the solidus temperatures of the first alloy but the interface between the two alloys is then reheated to between the liquidus and solidus temperatures, whereby the two alloy streams are joined as two layers. The joined alloy layers are then cooled to form a composite ingot. This composite ingot has a substantially continuous metallurgical bond between alloy layers with dispersed particles of one or more intermetallic compositions of the first alloy in a region of the second alloy adjacent the interface.

Method for casting composite ingot

A direct chill casting of metals, particularly hot top casting of aluminum and its alloy, is improved by applying a gas pressure to the metals from directly below the overhang of a feed reservoir for receiving a melt to be cast. The direct chill casting is further improved by supplying a lubricating oil from a slit for conveying the gas to the inner wall of the mold. By using the process and the apparatus according to the invention, ingots having excellent smooth surfaces and reduced segregation can be reliably produced with a reduction in the amount of the lubricating oil used.

Process for direct chill casting of metals

One end opening of an open ended mold cavity has a diameter smaller than the peripheral wall of the cavity and a molten metal mass is introduced to the cavity by continuously filling the one end opening with the mass so that the molten metal splays about the inner peripheral edge of the opening to assume a cross-section between the ends of the cavity having a divergent/convergent outline, the intermediate continuum of which between the planes of maximum divergence and minimum convergence thereof, has a peripheral outline corresponding generally to the outline of the cavity at the peripheral wall thereof. A graphite or graphite-like ring is circumposed about the axis of the cavity in the peripheral wall thereof to form a solid but fluid permeable wall section that is disposed to define the peripheral outline of the intermediate continuum of the metallic mass. A lubricating oil and a gas are delivered to grooves on the outer peripheral portion of the ring, and are caused to diffuse simultaneously through the body of the ring so as to discharge into the cavity at the inner peripheral surface of the ring while the molten metal mass is chilled and the mold and a support are reciprocated in relation to one another axially of the cavity to form the chilled mass into an elongated body of the metal.

Direct chill metal casting apparatus and technique

A process for casting a material comprising a casting system for said material including a coolant application device. The coolant application device comprises a fluidized bed cooling system. The casting system may be a continuous or semi-continuous one and preferably employs an electromagnetic mold.

Process for cooling and solidifying continuous or semi-continuously cast material

This invention is directed to the process and system for controlling the level of molten metal in a plurality of vertically oriented, continuous or semicontinuous casting units, particularly electromagnetic casting units. The flows of molten metal to the individual casting units are adjusted automatically in response to a control set point signal from a master controller in order to maintain essentially the same molten metal level in all of the casting units. Improved startup and termination procedures are also given.

Molten metal level control in continuous casting

The invention relates to an electromagnetic casting apparatus having an annular coolant jacket wherein a ring-type electromagnetic inductor is employed as the innermost wall of the coolant jacket and the inductor is preferably provided with conduits to direct coolant from within the coolant jacket onto the metal being cast.

Electromagnetic casting apparatus

The invention relates to the application of coolant onto the surface of an electromagnetic D.C. cast ingot or billet where two coolant streams are directed to the solidified or partially solidified metal so that the two streams intersect a short distance away from the metal surface. By controlling the velocity and/or volume of one or both coolant streams, the point of impact on the metal surface can be brought closer to the discharge end of the inductor and thereby increase cooling rates. In this manner the excursions of molten metal which form the icicle-like appendages on EM cast ingot or billet can be effectively eliminated. When the end of the ingot or billet passes the area of coolant impact and the risk of such excursions is slight, the point of coolant impact can be lowered to a more conventional level for the remainder of the cast.

Coolant control in EM casting

Verfahren und einrichtung zum regeln des metallbadpegels in einer mehrzahl von vertikalen kontinuierlichen oder halbkontinuierlichen giesseinheiten

Sensing element (60, 62, 65) senses the level (61) of molten metal in the DC or EM casting apparatus and generates a signal proportional to the level sensed; the level signal is compared with a set point signal representing the desired molten metal level, an error signal is generated for differences between the signal representing the level sensed and the set point signal, and the flow of molten metal to the DC or EM casting apparatus is controlled by a control assembly which operates in response to and in a manner proportional to the error signal. A master controller (80) holds the set point signal and supplies it to individual local controllers (71) each of which by way of associated actuator (56) regulates molten metal flow to the associated casting zone. Melt flow is regulated by a pin or plug (40) which is raised or lowered directly or indirectly by the rotation of a cam shaped like an Archimedes spiral to ensure proportional regulation.

Goodrich David George

Papers

Electromagnetic casting apparatus

Molten metal level control in continuous casting

Coolant control in EM casting

Verfahren und einrichtung zum regeln des metallbadpegels in einer mehrzahl von vertikalen kontinuierlichen oder halbkontinuierlichen giesseinheiten

Controlling the molten metal level in DC or EM continuous casting