Ingot casting method

Claim 2

In a method for continuously casting light metal ingots wherein molten metal is continuously supplied to an open-ended mold, wherefrom an ingot is continuously withdrawn, wherein liquid coolant is directed to the surface of the ingot emerging from the mold to extract heat therefrom, and wherein casting is initiated by withdrawing from the mold a starting block initially closing the mold, wherein the improvement comprises: at the initial stage of casting, mixing a gas with the liquid coolant before direction of the liquid coolant to the ingot and directing said liquid coolant carrying said gas in a substantially continuous liquid phase to an initial portion of ingot length as it emerges from said mold thereby to extract heat at a retarded rate from said initial portion of ingot length, and, thereafter, reducing the amount of gas mixed with said liquid coolant directed to said ingot emerging from said mold to provide for an increased rate of heat extraction by said liquid coolant for subsequent portions of emerging ingot length.

Claim 3

The method as set forth in claim 1 wherein the liquid coolant is water.

Claim 4

The method as set forth in claim 1 wherein the light metal is selected from the group consisting of aluminum, magnesium and their alloys.

Claim 5

The method as set forth in claim 1 wherein the gas comprises at least one gas selected from the group consisting of carbon dioxide, air and nitrogen.

Claim 6

The method as set forth in claim 1 wherein at least 50% of the gas mixed with the coolant is dissolved into the coolant.

Claim 7

The method as set forth in claim 5 wherein gas is dissolved under pressure in said liquid coolant prior to its application to the ingot and whereupon dissolved gas comes out of solution in response to a decrease in pressure as the liquid coolant is directed to the ingot.

Claim 8

In a method for continuously casting ingots of aluminum, magnesium or their alloys comprising the steps of substantially continuously introducing molten metal to an open-ended mold; continuously applying liquid cooling medium to the mold to effectuate at least partial solidification of the molten metal therein; and continuously withdrawing an ingot from the mold, said ingot having its periphery, at least, solidified, while simultaneously directing liquid cooling medium comprising water to the exterior surfaces of the ingot emerging from the mold to extract heat therefrom; the improvement comprising: dissolving a soluble gas into said liquid cooling medium comprising water prior to its direction to the emerging ingot surface and directing said liquid cooling medium as a substantially continuous liquid phase containing said dissolved gas to a portion of ingot length emerging from the mold, whereupon dissolved gas comes out of solution to retard the rate of heat extraction from said ingot length portion by said liquid cooling medium, and subsequently reducing said dissolving of said gas to increase the cooling effect of said liquid cooling medium and directing said cooling medium to different portions of ingot length emerging from said mold to increase the rate of heat extraction from said different portions of ingot length.

Claim 9

In a method for continuously casting ingots of aluminum, magnesium or their alloys comprising the steps of substantially continuously introducing molten metal to an open-ended mold; continuously applying liquid cooling medium to the mold to effectuate at least partial solidification of the molten metal therein; and continuously withdrawing an ingot from the mold, said ingot having its periphery, at least, solidified, while simultaneously directing liquid cooling medium comprising water to the exterior surfaces of the ingot emerging from the mold to extract heat therefrom; the improvement comprising: dissolving a soluble gas into said liquid cooling medium comprising water prior to its direction to the emerging ingot surface and directing said liquid cooling medium as a substantially continuous liquid phase containing said dissolved gas to a portion of ingot length emerging from the mold, whereupon dissolved gas comes out of solution to retard the rate of heat extraction from said ingot length portion by said liquid cooling medium, and subsequently reducing said dissolving of said gas to increase the cooling effect of said liquid cooling medium and directing said cooling medium to different portions of ingot length emerging from said mold to increase the rate of heat extraction from said different portions of ingot length.

Claim 10

The method as set forth in claim 7 wherein the gas comprises carbon dioxide.

Claim 11

The method as set forth in claim 7 wherein the soluble gas comprises any gas able to be dissolved into the liquid cooling medium under pressure and which gas comes out of solution in response to a decrease in pressure.

Claim 12

The method as set forth in claim 7 wherein the soluble gas comprises at least one gas selected from the group consisting of carbon dioxide, air, and nitrogen.

Claim 13

The method as set forth in claim 7 wherein said ingot portion which is cooled at said retarded rate of heat extraction is withdrawn from said mold at a slower rate than said different portions cooled at said increased rate of heat extraction.

Claim 14

In a method for continuously casting a substantially rectangular cross-sectional aluminum alloy ingot having a width to thickness ratio greater than one comprising the steps of substantially continuously introducing molten aluminum to an open-ended mold having an inlet end, a generally rectangular passageway therethrough and an outlet end, the outlet end being initially closed by a movable starting block; continuously directing water to the mold to effect at least partial solidification of the molten aluminum therein to provide a peripherally solidified ingot; continuously advancing the peripherally solidified ingot by withdrawing the starting block and ingot connected thereto from the outlet end of the mold at a starting casting rate of approximately two inches per minute while simultaneously directing cooling water to the exterior surfaces of the ingot emerging from the mold to extract heat therefrom; the improvement comprising: dissolving at atmospheric pressure or higher a gas comprising carbon dioxide into, at least, the cooling water which is directed to the ingot surface, thereby to carbonate said water prior to its direction to the ingot surface, directing said carbonated water as a substantially continuous liquid phase containing said gas to the ingot emerging from the mold, whereupon dissolved carbon dioxide comes out of solution, thereby to retard the rate of heat extraction from the ingot, said retarded rate of heat extraction being maintained for a period of, at least, from when the ingot withdrawal from the mold begins until the ingot has emerged about two to four inches from the mold, and thereafter progressively reducing the amount of carbon dioxide dissolved into the cooling water thereby to increase the heat extraction rate from subsequent portions of the ingot while simultaneously increasing the casting rate.

Claim 15

In a method for continuously casting a substantially rectangular cross-sectional aluminum alloy ingot having a width to thickness ratio greater than one comprising the steps of substantially continuously introducing molten aluminum to an open-ended mold having an inlet end, a generally rectangular passageway therethrough and an outlet end, the outlet end being initially closed by a movable starting block; continuously directing water to the mold to effect at least partial solidification of the molten aluminum therein to provide a peripherally solidified ingot; continuously advancing the peripherally solidified ingot by withdrawing the starting block and ingot connected thereto from the outlet end of the mold at a starting casting rate of approximately two inches per minute while simultaneously directing cooling water to the exterior surfaces of the ingot emerging from the mold to extract heat therefrom; the improvement comprising: dissolving at atmospheric pressure or higher a gas comprising carbon dioxide into, at least, the cooling water which is directed to the ingot surface, thereby to carbonate said water prior to its direction to the ingot surface, directing said carbonated water as a substantially continuous liquid phase containing said gas to the ingot emerging from the mold, whereupon dissolved carbon dioxide comes out of solution, thereby to retard the rate of heat extraction from the ingot, said retarded rate of heat extraction being maintained for a period of, at least, from when the ingot withdrawal from the mold begins until the ingot has emerged about two to four inches from the mold, and thereafter progressively reducing the amount of carbon dioxide dissolved into the cooling water thereby to increase the heat extraction rate from subsequent portions of the ingot while simultaneously increasing the casting rate.

Claim 16

The method as set forth in claim 12 wherein substantially no carbon dioxide is being dissolved into the cooling water after the ingot has emerged about eight to ten inches from the mold.

Claim 17

The method as set forth in claim 13 wherein a casting rate of at least four inches per minute is attained when substantially no carbon dioxide is being dissolved into the cooling water.

Claim 18

The method as set forth in claim 12 wherein the improvement further comprises reducing heat loss through the bottom surface of the emerging ingot by positioning an insulation pad between the starting block and the ingot, said pad covering at least 50% of said bottom surface.

Claim 19

The method as set forth in claim 15 wherein the insulation pad is ceramic fiber.

Claim 20

In a method for continuously casting aluminum alloy ingot having a width of 40 to 72 inches and a thickness of 20 to 26 inches comprising the steps of substantially continuously introducing molten aluminum to an open-ended mold having an inlet end, and an outlet end, the outlet end being intially closed by a movable starting block; continuously directing from 200 to 350 gallons per minute of cooling water at a temperature of from about 32° to 90° F. to the mold to effect at least partial solidification of the molten aluminum therein to provide a peripherally solidified ingot; continuously advancing the peripherally solidified ingot by withdrawing the starting block and the ingot connected thereto from the outlet end of the mold at a starting casting rate of approximately two inches per minute while simultaneously directing from 200 to 350 gallons per minute of cooling water at a temperature of from about 32° to 90° F. to substantially the entire periphery of the ingot emerging from the mold to extract heat therefrom; and maintaining a relatively constant head of from 1.25 to 3.50 inches of molten aluminum in the mold throughout the casting operation; the improvement comprising: dissolving at a pressure of about five psig or higher about 10 to 30 SCFM of a gas comprising carbon dioxide into, at least, the cooling water which is directed to the ingot periphery thereby to carbonate said water prior to its direction to the ingot periphery emerging from the mold; directing said carbonated water as a substantially continuous liquid phase containing said gas to the ingot periphery emerging from the mold, whereupon dissolved gas comes out of solution in response to a pressure decrease thereby to retard the rate of heat extraction from said emerging ingot by said cooling water for a period, at least, from the time when the ingot begins its emergence from the mold until the time when the ingot has emerged about two to four inches from the mold; for the next four to eight inches of ingot emergence, progressively reducing the amount of gas comprising carbon dioxide dissolved into the cooling water directed to the ingot periphery emerging from the mold, thereby to increase the rate of heat extraction from the ingot emerging from the mold while simultaneously increasing the casting rate, such that substantially no carbon dioxide is being dissolved into the cooling water, and a casting rate of from four to six inches per minute is attained when the ingot has emerged a total of from six to twelve inches from the mold; and reducing heat loss through the bottom surface of the emerging ingot by positioning an insulation pad between the starting block and the bottom surface of the ingot, said pad covering at least 50% of said bottom surface.

Claim 21

In a method for continuously casting aluminum alloy ingot having a width of 40 to 72 inches and a thickness of 20 to 26 inches comprising the steps of substantially continuously introducing molten aluminum to an open-ended mold having an inlet end, and an outlet end, the outlet end being intially closed by a movable starting block; continuously directing from 200 to 350 gallons per minute of cooling water at a temperature of from about 32° to 90° F. to the mold to effect at least partial solidification of the molten aluminum therein to provide a peripherally solidified ingot; continuously advancing the peripherally solidified ingot by withdrawing the starting block and the ingot connected thereto from the outlet end of the mold at a starting casting rate of approximately two inches per minute while simultaneously directing from 200 to 350 gallons per minute of cooling water at a temperature of from about 32° to 90° F. to substantially the entire periphery of the ingot emerging from the mold to extract heat therefrom; and maintaining a relatively constant head of from 1.25 to 3.50 inches of molten aluminum in the mold throughout the casting operation; the improvement comprising: dissolving at a pressure of about five psig or higher about 10 to 30 SCFM of a gas comprising carbon dioxide into, at least, the cooling water which is directed to the ingot periphery thereby to carbonate said water prior to its direction to the ingot periphery emerging from the mold; directing said carbonated water as a substantially continuous liquid phase containing said gas to the ingot periphery emerging from the mold, whereupon dissolved gas comes out of solution in response to a pressure decrease thereby to retard the rate of heat extraction from said emerging ingot by said cooling water for a period, at least, from the time when the ingot begins its emergence from the mold until the time when the ingot has emerged about two to four inches from the mold; for the next four to eight inches of ingot emergence, progressively reducing the amount of gas comprising carbon dioxide dissolved into the cooling water directed to the ingot periphery emerging from the mold, thereby to increase the rate of heat extraction from the ingot emerging from the mold while simultaneously increasing the casting rate, such that substantially no carbon dioxide is being dissolved into the cooling water, and a casting rate of from four to six inches per minute is attained when the ingot has emerged a total of from six to twelve inches from the mold; and reducing heat loss through the bottom surface of the emerging ingot by positioning an insulation pad between the starting block and the bottom surface of the ingot, said pad covering at least 50% of said bottom surface.

Claim 24

The method as set forth in claim 18 wherein the liquid cooling medium is water.

Claim 25

The method as set forth in claim 18 wherein the soluble gas comprises at least one gas selected from the group consisting of carbon dioxide, air and nitrogen.

Claim 26

The method as set forth in claim 18 wherein the ingot is a light metal selected from the group consisting of aluminum, magnesium and their alloys.

Claim 27

In a method for continuous casting of metal ingots wherein a mold is continuously supplied at its entrance end with molten metal and wherein a solidified or partially solidified ingot is continuously withdrawn from its exit end and wherein heat is extracted from the ingot emerging from the exit end of the mold by directing a liquid cooling medium to the ingot surface, the improvement comprising: (a) retarding the rate of heat extraction from the ingot by said liquid cooling medium for a portion of ingot length by mixing a gas into the liquid cooling medium and applying said liquid cooling medium carrying said gas in a substantially continuous liquid phase to said portion of ingot length as it emerges from said mold; (b) thereafter increasing the rate of heat extraction for a subsequent portion of ingot length as it emerges from the mold by reducing the amount of gas mixed with the liquid cooling medium directed to said subsequent ingot length portion.

Claim 28

In a method for continuous casting of metal ingots wherein a mold is continuously supplied at its entrance end with molten metal and wherein a solidified or partially solidified ingot is continuously withdrawn from its exit end and wherein heat is extracted from the ingot emerging from the exit end of the mold by directing a liquid cooling medium to the ingot surface, the improvement comprising: (a) retarding the rate of heat extraction from the ingot by said liquid cooling medium for a portion of ingot length by mixing a gas into the liquid cooling medium and applying said liquid cooling medium carrying said gas in a substantially continuous liquid phase to said portion of ingot length as it emerges from said mold; (b) thereafter increasing the rate of heat extraction for a subsequent portion of ingot length as it emerges from the mold by reducing the amount of gas mixed with the liquid cooling medium directed to said subsequent ingot length portion.

Claim 29

In the method according to claim 41 wherein the liquid cooling media is water.

Claim 30

In the method according to claim 22 wherein the gas comprises one or more gases selected from the group consisting of carbon dioxide, air and nitrogen.

Claim 31

In the method according to claim 22 wherein the gas comprises carbon dioxide.

Claim 32

In the method according to claim 22 wherein the metal is selected from the group consisting of aluminum, magnesium, or alloys thereof.

Claim 33

In the method according to claim 22 wherein said retarding of said heat extraction rate is performed in association with the commencement of casting and ingot withdrawal from said mold.

Claim 34

In the method according to claim 22 wherein the ingot is withdrawn at a slower rate during the period of said retarded rate of heat extraction and at a higher rate during the period of said increased rate of heat extraction.

Claim 35

In the method according to claim 22 wherein gas is dissolved in said liquid cooling medium prior to its direction to the ingot and whereupon dissolved gas comes out of solution as said liquid cooling medium is directed to said ingot to retard the heat extraction by said cooling medium.

Claim 36

In the method according to claim 22 wherein gas is dissolved under pressure in said liquid cooling medium prior to its direction to the ingot and whereupon dissolved gas comes out of solution as the cooling medium is directed to said ingot and said pressure is reduced.

Claim 37

In the method according to claim 30 wherein said gas comprises carbon dioxide.

Claim 38

In the method according to claim 29 wherein said gas comprises carbon dioxide.

Claim 39

In the method according to claim 30 wherein said liquid containing said gas dissolved under pressure is used to cool the mold prior to being directed to said ingot.

Claim 40

In the method according to claim 30 wherein said liquid containing said gas dissolved under pressure is used to cool the mold prior to being directed to said ingot and said gas is substantially retained in solution while cooling said mold.

Claim 41

In the method according to claim 22 wherein said gas forms a gaseous layer of insulation between the liquid cooling medium and said ingot during said retarded heat extraction.

Claim 42

In the method according to claim 22 wherein said retarding of said heat extraction rate is performed at the commencement of casting and wherein the withdrawal of the ingot is initiated by withdrawing from the mold a temporary closure attached to the emerging ingot, the improvement further comprising reducing heat extraction through the ingot front surface by providing an insulation pad between said temporary closure and said ingot front surface.

Claim 43

In the method according to claim 22 wherein said ingot has a width to thickness ratio of more than one.

Claim 44

In the method according to claim 22 wherein a relatively constant and relatively low molten metal head of about 1.25 to 1.75 inches is maintained in the mold substantially throughout the casting operation.

Claim 45

In the method according to claim 22 wherein relatively constant molten metal head within 1.25 to 3.5 inches is maintained substantially throughout casting.

Claim 46

In the method according to claim 22 wherein the molten metal head is changed during casting.

Claim 47

In the method according to claim 22 wherein the rate of liquid cooling media is substantially the same during both retarded and increased heat extraction periods.

Claim 48

In the method according to claim 12 wherein a relatively low head of about 1.25 to 1.75 inches of molten aluminum is maintained substantially thoughout the casting operation.

Claim 49

In the method according to claim 12 wherein a head of 2.5 to 3.5 inches of molten aluminum is maintained thoughout the casting operation.

Claim 50

In the method according to claim 5 wherein the gas comprises carbon dioxide.

Claim 51

In the method according to claim 6 wherein the gas comprises carbon dioxide.

Claim 52

In the method according to claim 12 wherein a gas comprising carbon dioxide is dissolved under positive pressure and carbon dioxide comes out of solution as the cooling water is directed to the ingot emerging from the mold.

Claim 53

In the method according to claim 15 wherein 10 to 30 SCFM of said gas comprising carbon dioxide is continuously dissolved into said water coolant before its direction to the ingot emerging from the mold and said water coolant is directed to said ingot at a rate of more than 200 gallons per minute.

Claim 54

In the method according to claim 12 wherein said aluminum alloy is alloy 3003 or alloy 3004.

Claim 55

In the method according to claim 22 wherein gas is dissolved in said liquid cooling medium prior to its direction to the ingot and whereupon dissolved gas comes out of solution as said liquid cooling medium is directed to said ingot to retard the heat extraction by said cooling medium and wherein the ingot is withdrawn at a slower rate during the period of said retarded rate of heat extraction and at a higher rate during the period of said increased rate of heat extraction.