Casting process and installation for a non-ferrous metal in the molten state

Claim 2

Process for gravity casting using a free jet of non-ferrous metal including zinc that can encounter the problem of a solid metal scum at the point of impact of the jet of cast metal coming from a storage reservoir of the molten metal to a receiving vessel for the same, the process comprising passing said receiving vessel under the molten metal storage reservoir, isolating the receiving vessel beneath the reservoir by covering the receiving vessel with an isolating wall so as to form a zone isolated from the ambient air, the receiving vessel being disposed directly below the molten metal storage reservoir so that there is a direct passage made between said storage reservoir and the receiving vessel such that the entire length of the molten metal casting jet is contained within the isolated zone, rendering said isolated zone inert by introducing into said zone an inert gas at a rate such that the atmosphere of an internal cavity of said receiving vessel has an oxygen content no greater than a predetermined subnormal oxygen content, said receiving vessel being rendered inert before passing under the molten metal jet, and maintaining the injection of said inert gas at a rate such that the atmosphere in the vicinity of said molten metal jet has an oxygen content less than said predetermined subnormal oxygen content.

Claim 3

Procedure according to claim 1, wherein a set of ingot molds, positioned transversely side-by-side, are caused to pass under the said molten metal storage tank and wherein each of the ingot molds is previously rendered inert before passing under the molten metal jet.

Claim 4

Process according to claim 1, wherein said subnormal oxygen content is maintained at less than 1%.

Claim 5

Process according to claim 1, wherein said subnormal oxygen content is maintained at less than 0.1%.

Claim 6

Metal casting apparatus for the gravity casting of non-ferrous metal including zinc that can encounter the problem of a solid metal scum at the point of impact of the jet with a receiving vessel therefor, the apparatus comprising a distribution tank containing the molten metal and having a casting outlet disposed in a bottom thereof; means for driving and guiding at least one receiving vessel underneath the distribution tank; isolating means integral with the distribution tank and arranged around the casting outlet and extending downwards so as to cover said at least one said receiving vessel for covering said vessel and forming a zone isolated from the ambient air, the isolated receiving vessel being disposed to pass under the casting outlet so that there is a direct passage made between said distribution tank and the receiving vessel such that the entire length of the molten metal casting jet is contained within the isolated zone; and means for supplying and distributing an inert gas into said isolated zone for rendering said isolated zone inert by introducing said inert gas into said zone at a rate such that the atmosphere of an internal cavity of said receiving vessel has an oxygen content no greater than a predetermined subnormal oxygen content, said means for supplying and distributing said inert gas including means rendering said vessel inert before the latter passes under the molten metal jet and maintaining the injection of said inert gas at such a rate that the atmosphere in the vicinity of said molten metal jet has an oxygen content less than said predetermined subnormal oxygen content.

Claim 7

Metal casting apparatus for the gravity casting of non-ferrous metal including zinc that can encounter the problem of a solid metal scum at the point of impact of the jet with a receiving vessel therefor, the apparatus comprising a distribution tank containing the molten metal and having a casting outlet disposed in a bottom thereof; means for driving and guiding at least one receiving vessel underneath the distribution tank; isolating means integral with the distribution tank and arranged around the casting outlet and extending downwards so as to cover said at least one said receiving vessel for covering said vessel and forming a zone isolated from the ambient air, the isolated receiving vessel being disposed to pass under the casting outlet so that there is a direct passage made between said distribution tank and the receiving vessel such that the entire length of the molten metal casting jet is contained within the isolated zone; and means for supplying and distributing an inert gas into said isolated zone for rendering said isolated zone inert by introducing said inert gas into said zone at a rate such that the atmosphere of an internal cavity of said receiving vessel has an oxygen content no greater than a predetermined subnormal oxygen content, said means for supplying and distributing said inert gas including means rendering said vessel inert before the latter passes under the molten metal jet and maintaining the injection of said inert gas at such a rate that the atmosphere in the vicinity of said molten metal jet has an oxygen content less than said predetermined subnormal oxygen content.

Claim 8

Apparatus according to claim 5, wherein the means of supplying and distributing an inert gas is connected to a source of liquefied inert gas and includes a supply and distribution manifold of a type which forms a phase separator with a liquid discharge orifice in a bottom section thereof and gas discharge orifices in an upper section thereof, placed within said means of insulation.

Claim 9

Apparatus according to one of the claims 5 or 6, further comprising means of driving and guiding (8) a set of receiving vessels (L) arranged transversely side-by-side, one after the other, and capable of moving under said means of insulation (12).

Claim 10

Apparatus according to claim 7, further comprising preheating means (33) before the molten metal storage tank (1) by reference to the direction of movement of the said series of vessels.

Claim 11

Apparatus according to either one of the claims 1 and 6 further comprising means for measuring the oxygen content (31) within the isolating means (12) in the vicinity of the distribution tank casting outlet (1).

Claim 12

Apparatus according to claim 5 or 6, wherein the isolating means includes a metal cover in the form of a rectangular solid of which an upper horizontal plate incorporates a rectangular opening having dimensions which are just large enough to fit onto the lower part of the distribution tank and having four vertical plates which descend from the horizontal plate substantially to upper edges of at least one of the receiving vessels.

Claim 13

Process for gravity casting using a free jet of non-ferrous metal including zinc that can encounter the problem of a solid metal scum at the point of impact of the jet of cast metal coming from a storage reservoir of the molten metal to an ingot mold serving as a receiving vessel for the same, the process comprising positioning a set of ingot molds transversely side-by-side, passing said ingot molds serially under the molten metal storage tank, isolating at least two adjacent said ingot molds by covering the same by an isolating wall so as to form a zone isolated from the ambient air, wherein at least two adjacent ingot molds in the set are covered at any one time by the isolating wall, placing the ingot molds with the isolating wall directly below the molten metal storage reservoir so that there is a direct passage made between said storage reservoir and the ingot molds such that the molten metal casting jet passes through the isolated zone over its entire length, rendering said isolated zone inert by introducing into said zone an inert gas at a rate such that the atmosphere of an internal cavity of each said ingot mold has an oxygen content no greater than a predetermined subnormal oxygen content, the ingot molds being rendered inert before passing under the molten metal jet, and maintaining the injection of said inert gas at a rate such that the atmosphere in the vicinity of said molten metal jet has an oxygen content less than said predetermined subnormal content.

Claim 14

Process for gravity casting using a free jet of non-ferrous metal including zinc that can encounter the problem of a solid metal scum at the point of impact of the jet of cast metal coming from a storage reservoir of the molten metal to an ingot mold serving as a receiving vessel for the same, the process comprising positioning a set of ingot molds transversely side-by-side, passing said ingot molds serially under the molten metal storage tank, isolating at least two adjacent said ingot molds by covering the same by an isolating wall so as to form a zone isolated from the ambient air, wherein at least two adjacent ingot molds in the set are covered at any one time by the isolating wall, placing the ingot molds with the isolating wall directly below the molten metal storage reservoir so that there is a direct passage made between said storage reservoir and the ingot molds such that the molten metal casting jet passes through the isolated zone over its entire length, rendering said isolated zone inert by introducing into said zone an inert gas at a rate such that the atmosphere of an internal cavity of each said ingot mold has an oxygen content no greater than a predetermined subnormal oxygen content, the ingot molds being rendered inert before passing under the molten metal jet, and maintaining the injection of said inert gas at a rate such that the atmosphere in the vicinity of said molten metal jet has an oxygen content less than said predetermined subnormal content.

Claim 15

Process according to either one of the claims 2 or 11, wherein each of the ingot molds is preheated before passing into the isolating zone.

Claim 16

Process according to one of the claims 2, 11 or 1, wherein the inert gas is nitrogen or argon.