Abstract: A method and apparatus are disclosed for sequentially direct chill casting a composite ingot made of metals having similar freezing ranges. Poor adhesion between the layers and low reliability of casting are addressed by adjusting the position of secondary cooling (created by applying water streams to the emerging ingot) relative to the upper surfaces of the molten metal pools compared to the conventional positions of first application of the secondary cooling. This can be achieved by moving one or more walls of the mold (when the secondary cooling emanates from the bottom of such walls), or adjusting the height of the molten metal pools within the mold and moving cooled divider walls between the pools. The relative temperatures and conditions of the metals at positions where they meet at the metal interface may therefore be optimized.

Abstract: A method and apparatus is disclosed for sequentially direct chill casting a composite ingot made of metals having similar freezing ranges. Poor adhesion between the layers and low reliability of casting are addressed by adjusting the position of secondary cooling (created by applying water streams to the emerging ingot) relative to the upper surfaces of the molten metal pools compared to the conventional positions of first application of the secondary cooling. This can be achieved by moving one or more walls of the mold (when the secondary cooling emanates from the bottom of such walls), or adjusting the height of the molten metal pools within the mold and moving cooled divider walls between the pools. The relative temperatures and conditions of the metals at positions where they meet at the metal interface may therefore be optimized.

Abstract: The exemplary embodiments relate to the removal of cooling water used to cool the surface of an ingot as it is formed during casting. The cooling water is removed from the surface by directing jets of water onto the surface at an angle, and with a momentum, that causes the cooling water to be stripped from the surface when contacted with the jets, and to follow a path that prevents the cooling water from again coming into contact with the ingot surface at a position beyond the point of removal. The apparatus for this includes nozzles to create the water jets, and equipment for supplying water under sufficient pressure and rate of flow to the nozzles.