Prevention of Al2 O3 formation in pouring nozzles and the like

Claim 2

An article for use in casting molten metal wherein said article includes a molten metal contacting surface of a carbon-bonded refractory composition for resisting oxide buildup consisting essentially of, by weight: (a) carbon from about 4% to about 50% supplied predominantly from a graphite source; (b) fully reacted SiALON in an amount of from about 20% to about 90% and wherein the SiALONhas a composition represented by a formula Si 6-z Al z O z N 8-z having one or more z values between a number greater than zero and less than or equal to five; (c) an antioxidant constituent comprising at least one member selected from the group consisting of silicon and boron-containing compounds in an amount from about 2% to about 8%; and (d) a diluent constituent comprising at least one member selected from the group consisting of clay, alumina, zirconia, zircon, silica, silicon carbide, mullite, chromia, iron chromite, magnesia, magnesium aluminate, aluminum nitride, boron nitride and the like, in an amount of from a trace amount up to about 70% by weight.

Claim 3

The article of claim 1 wherein a portion of said carbon content is supplied by a non-graphite carbonaceous binder material in an amount of up to about 13% by weight.

Claim 4

The article of claim 2 wherein the non-graphite carbonaceous binder material is supplied from a source comprising at least one member selected from the group consisting of pitch and resin.

Claim 5

The article of claim 1 wherein said article is a refractory subentry nozzle for continuous casting.

Claim 6

The article of claim 4 wherein the nozzle comprises a body portion of alumina-graphite material, said body having an internal bore having a lining therearound comprising said oxide buildup resisting refractory composition.

Claim 7

The article of claim 6 wherein the subentry nozzle includes an external slagline sleeve area comprising a refractory material resistant to molten slag attack.

Claim 8

The article of claim 6 wherein the slagline sleeve material is zirconia-graphite.

Claim 9

The article of claim 6 wherein the slagline sleeve includes a carbon-bonded, SiAlON-graphite material.

Claim 10

The article of claim 4 wherein the nozzle is for use in the continuous casting of low-carbon, killed steel.

Claim 11

The article of claim 1 wherein the fully reacted SiALON is produced by a carbothermal reduction of alumina-silica materials in nitrogen.

Claim 12

A subentry nozzle for use in continuous casting of molten steel comprising: a body portion of a refractory material having a central axial bore for conveyance of molten steel therethrough from an inlet end to an outlet end of said body; a lining portion surrounding said central bore and adapted to be in contact with said molten steel, said lining portion of a carbon-bonded refractory composition consisting essentially of, by weight: (a) carbon from about 4% to about 50% supplied predominantly from a graphite source; (b) fully reacted SiALON in an amount of from about 20% to about 90% and wherein the SiALON has a composition represented by a formula Si 6-z Al z O z N 8-z having one or more z values between a number greater than zero and less than or equal to five; (c) an antioxidant constituent selected from the group consisting of silicon and boron-containing compounds in an amount from about 2% to about 8%; and (d) a diluent constituent comprising at least one member selected from the group consisting of clay, alumina, zirconia, zircon, silica, silicon carbide, mullite, chromia, iron chromite, magnesia, magnesium aluminate, aluminum nitride, boron nitride and the like, in an amount of from a trace amount up to about 70% by weight.

Claim 13

A subentry nozzle for use in continuous casting of molten steel comprising: a body portion of a refractory material having a central axial bore for conveyance of molten steel therethrough from an inlet end to an outlet end of said body; a lining portion surrounding said central bore and adapted to be in contact with said molten steel, said lining portion of a carbon-bonded refractory composition consisting essentially of, by weight: (a) carbon from about 4% to about 50% supplied predominantly from a graphite source; (b) fully reacted SiALON in an amount of from about 20% to about 90% and wherein the SiALON has a composition represented by a formula Si 6-z Al z O z N 8-z having one or more z values between a number greater than zero and less than or equal to five; (c) an antioxidant constituent selected from the group consisting of silicon and boron-containing compounds in an amount from about 2% to about 8%; and (d) a diluent constituent comprising at least one member selected from the group consisting of clay, alumina, zirconia, zircon, silica, silicon carbide, mullite, chromia, iron chromite, magnesia, magnesium aluminate, aluminum nitride, boron nitride and the like, in an amount of from a trace amount up to about 70% by weight.

Claim 14

The subentry nozzle of claim 11 including a slagline sleeve portion formed around an exterior circumferential surface of said body adapted to contact a layer of fluid slag in a continuous casting mold during a casting operation.

Claim 15

The subentry nozzle of claim 12 wherein the body portion is constructed of an alumina-graphite refractory material and the slagline sleeve is of a zirconia-graphite refractory material.

Claim 16

The subentry nozzle of claim 12 wherein the body portion is composed of an alumina-graphite refractory material and the slagline sleeve is formed of a refractory material identical to that of the lining portion.

Claim 17

The subentry nozzle of claim 12 wherein the body portion and the slagline sleeve portion are formed of a refractory material identical to that of the lining portion.