Apparatus and process for controlling the flow of a metal stream

Claim 2

Apparatus for controlling the flow of a metal stream, comprising: a frustoconical metallic nozzle body having a hollow wall, the hollow wall having an inner surface and an outer surface and extending from a first base to a second base, the body further having at least one slit extending from the first base to the second base so that the wall lacks electrical continuity across the slit; means for cooling the nozzle body to form a metal skull on the inner surface of the nozzle body hollow wall; an induction heating coil surrounding the nozzle body; a sensor that measures at least one performance characteristic of the apparatus selected from the group of performance characteristics including a diameter of the metal stream, a volume flow rate of the metal stream, a temperature of the nozzle body, a temperature of the metal skull; a controllable induction heating power supply connected to the induction heating coil; and a controller that controls the power provided to the induction heating coil by the induction heating power supply responsive to an output signal of the sensor, to maintain the selected performance characteristic of the apparatus.

Claim 3

The apparatus of claim 1, wherein the nozzle body is formed of a refractory metal selected from the group consisting of tungsten, tantalum and molybdenum.

Claim 4

The apparatus of claim 1, wherein the nozzle body is formed of a plurality of first hollow tubes positioned around a circumference and extending from the first base to the second base, each tube spaced from an adjacent tube sufficiently so that there is no electrical continuity between adjacent tubes.

Claim 5

The apparatus of claim 3 further including a second hollow tube within each of the plurality of first hollow tubes, each of the second hollow tubes having a diameter smaller than the diameter of the plurality of first hollow tubes so that cooling water supplied from a manifold positioned at the first base to each of the second hollow tubes flows through each of the second hollow tubes and returns to the manifold between an annulus between the plurality of first hollow tubes and each of the second tubes.

Claim 6

The apparatus of claim 1, wherein means for cooling includes a cooled heat sink attached to the nozzle body.

Claim 7

The apparatus of claim 1, wherein means for cooling includes cooling channels within the nozzle body through which cooling fluid flows.

Claim 8

The apparatus of claim 1 wherein means for cooling includes a cooling fluid flowing through the hollow nozzle body.

Claim 9

The apparatus of claim 1 wherein means for cooling includes a high velocity gas flowing around the nozzle exterior

Claim 10

The apparatus of claim 1, wherein the selected performance characteristic is the temperature of the nozzle body measured by a temperature sensor.

Claim 11

The apparatus of claim 9, wherein the temperature sensor is a thermocouple in contact with the nozzle body.

Claim 12

Apparatus for controlling the flow of a metal stream flowing from a water-cooled hearth, comprising: a frustoconical metallic nozzle body having a hollow wall, the hollow wall having an inner surface and an outer surface and extending from a first base to a second base, the body further having at least one slit extending from the first base to the second base so that the wall lacks electrical continuity across the slit, the nozzle body further having a flange at a first base thereof suitable for attachment to the water-cooled hearth; an induction heating coil surrounding the nozzle body exterior; a temperature sensor that senses the temperature of the nozzle body; a controllable induction heating power supply connected to the induction heating coil; and a controller that controls the power provided to the induction heating coil by the induction heating power supply responsive to the temperature measured by the temperature sensor.

Claim 13

Apparatus for controlling the flow of a metal stream flowing from a water-cooled hearth, comprising: a frustoconical metallic nozzle body having a hollow wall, the hollow wall having an inner surface and an outer surface and extending from a first base to a second base, the body further having at least one slit extending from the first base to the second base so that the wall lacks electrical continuity across the slit, the nozzle body further having a flange at a first base thereof suitable for attachment to the water-cooled hearth; an induction heating coil surrounding the nozzle body exterior; a temperature sensor that senses the temperature of the nozzle body; a controllable induction heating power supply connected to the induction heating coil; and a controller that controls the power provided to the induction heating coil by the induction heating power supply responsive to the temperature measured by the temperature sensor.

Claim 14

The apparatus of claim 11, wherein the nozzle body is formed of a refractory metal selected from the group consisting of tungsten, tantalum and molybdenum.

Claim 15

The apparatus of claim 11, wherein the nozzle body is formed of a plurality of hollow tubes positioned around a circumference and extending from the first base to the second base.

Claim 16

Apparatus for controlling the flow of a metal stream, comprising a hollow cylindrical nozzle body formed of a plurality of conductive hollow tubes disposed along a substantially cylindrical locus and extending parallel to an axis perpendicular to the plane of the cylindrical locus thereby forming a cylinder, the nozzle body having a flange at one end thereof suitable for attachment to a water-cooled hearth.

Claim 17

Apparatus for controlling the flow of a metal stream, comprising a hollow cylindrical nozzle body formed of a plurality of conductive hollow tubes disposed along a substantially cylindrical locus and extending parallel to an axis perpendicular to the plane of the cylindrical locus thereby forming a cylinder, the nozzle body having a flange at one end thereof suitable for attachment to a water-cooled hearth.

Claim 18

The apparatus of claim 14, further comprising: means for heating the nozzle body, the means for heating being external to the nozzle body.

Claim 19

The apparatus of claim 14, further including an induction heating coil surrounding the nozzle body exterior; a sensor that senses a performance characteristic of the apparatus; a controllable induction heating power supply connected to the induction heating coil; and a controller that controls the power provided to the induction heating coil by the induction heating power supply responsive to the temperature measured by the temperature sensor.

Claim 20

A process for controlling the flow of a stream of molten metal, comprising the steps of: providing an apparatus comprising a substantially frustoconical metallic nozzle body having a hollow wall, the hollow wall having an inner surface and an outer surface and extending from a first base to a second base, the body further having at least one slit extending from the first base to the second base so that the wall lacks electrical continuity across the slit. means for cooling the nozzle body to form a metal skull on the inner surface of the nozzle body hollow wall, an induction heating coil surrounding the nozzle body, a sensor that measures at least one performance characteristic of the apparatus selected from the group of performance characteristics including a diameter of the metal stream, a volume flow rate of the metal stream, a temperature of the nozzle body, a temperature of the metal skull, a controllable induction heating power supply connected to the induction heating coil, and a controller that controls the power provided to the induction heating coil by the induction heating power supply responsive to an output signal of the sensor, to maintain a selected performance characteristic of the apparatus; and controlling the power provided to the induction heating coil to maintain a preselected flow of metal in the stream.

Claim 21

A process for controlling the flow of a stream of molten metal, comprising the steps of: providing an apparatus comprising a substantially frustoconical metallic nozzle body having a hollow wall, the hollow wall having an inner surface and an outer surface and extending from a first base to a second base, the body further having at least one slit extending from the first base to the second base so that the wall lacks electrical continuity across the slit. means for cooling the nozzle body to form a metal skull on the inner surface of the nozzle body hollow wall, an induction heating coil surrounding the nozzle body, a sensor that measures at least one performance characteristic of the apparatus selected from the group of performance characteristics including a diameter of the metal stream, a volume flow rate of the metal stream, a temperature of the nozzle body, a temperature of the metal skull, a controllable induction heating power supply connected to the induction heating coil, and a controller that controls the power provided to the induction heating coil by the induction heating power supply responsive to an output signal of the sensor, to maintain a selected performance characteristic of the apparatus; and controlling the power provided to the induction heating coil to maintain a preselected flow of metal in the stream.

Claim 22

The process of claim 17, wherein the selected performance characteristic is the temperature of the nozzle body measured by a temperature sensor, and the preselected flow of metal in the stream is an amount of metal sufficient to maintain a preselected temperature as measured by the sensor.

Claim 23

The process of claim 17, wherein the selected performance characteristic is the diameter of the metal stream measured by a stream diameter sensor, and the preselected flow of metal in the stream is an amount of metal sufficient to have a preselected stream diameter.

Claim 24

The process of claim 17, wherein the selected performance characteristic is the stream volume flow rate of the metal stream measured by a stream volume flow rate sensor, and the preselected flow of metal in the stream is an amount of metal sufficient to have a preselected stream volume flow rate.

Claim 25

The apparatus of claim 1, wherein the nozzle body is formed of copper.

Claim 26

The apparatus of claim 11, wherein the nozzle body is formed of copper.