Abstract: Sulfur-containing free-cutting steel may have an improved machinability and fewer defects by adding certain amounts of Te, Pb and Bi to prevent elongation of sulfide inclusion particles, and by lowering Al-content to decrease Al.sub.2 O.sub.3 of oxide inclusions or by lowering O-content to decrease large Al.sub.2 O.sub.3 inclusion particles. The free-cutting steel may be produced by continuous casting.

Abstract: The invention relates to a method and apparatus for changing the casting table, complete with the mold and the starter head in the casting machine, particularly a semi-continuous casting machine. In order to carry out the exchange, the casting table (7) complete with the mold (10) and the starter head (5) are first supported against each other, whereafter the casting table (7) and the starter head (5) are together shifted in between the casting position and the changing position.

Abstract: An apparatus and process for continuous horizontal casting of an ingot from molten metal. The apparatus comprises a mold for effecting rapid solidification of the molten metal into the ingot. A feed nozzle supplies the molten metal to the mold. Transition structure is disposed between the mold and the feed nozzle for solidifying the molten metal in the transition structure to prevent freeze back in the feed nozzle.

Abstract: A process for continuous direct chill casting of aluminum alloys, particularly aluminum-lithium alloys. The molten alloy is cast in a mold containing a header comprising delaminated vermiculite or spodumene or lithium aluminate. The header preferably comprises delaminated vermiculite blended with wollastonite, lime, silica, and wood fiber. The mixture is slurried with water, molded into shape, compressed to expel water, steam cured, and dried. The header forms ingots of good quality and has excellent resistance to attack by molten aluminum-lithium alloys.

Abstract: An apparatus for continuously sizing, preforming or forming metal objects includes a plurality of molds arranged in a substantially vertical column and which collectively define a mold cavity. Each mold is separable into at least two mold sections. A retaining mechanism retains the molds in the vertical column. A first and second screw arm assembly separates the bottom mold into sections and removes the mold sections from the bottom of the mold with a horizontally operable screw arm mechanism. The arm assemblies then move the mold sections from a bottom position to an uppermost position with a vertically movable screw arm mechanism. The horizontally movable screw arm mechanism then moves the mold sections to an uppermost position on the vertical mold column to form a top mold.

Abstract: A varying length vibrating mold assembly for a continuous caster comprises a cooling jacket with an upper stationary portion and a lower removable portion. A tubular mold and an inner wall of the cooling jacket can be made to correspond to the varying length for the cooling jacket.

Abstract: A process and an apparatus are disclosed for reducing macrosegregation adjacent to a longitudinal centerline of a solidified cast body. Such cast bodies are preferably large size aluminum alloy ingots made in a continuous casting mold. The ingot is formed from a pool of molten metal having flow currents present therein. The flow currents tend to detach the tips of dendrites growing around the edge of the liquid pool and transport them to the center of the ingot. These detached dendrites, which are lean in eutectic elements, cause negative macrosegregation of the cast ingot. The process includes the step of weakening the magnitude of the flow currents within the liquid pool by placing a mechanical damper therein. The mechanical damper reduces shear acting on the dendrites and minimizes detachment and transport of dendrite particles to the center of the solidified body.

Abstract: In a process and apparatus for forming an ingot having a length at least twice as great as its characteristic sectional dimension, droplets of molten metal are sprayed onto a catching surface of a dummy bar which is rotated about its axis and moved in a removal direction along its axis. Layers of spray built up on the catching surface form an ingot. Boundary surfaces may be provided for shaping one of the surfaces of the formed ingot. In the case of a hollow ingot, the boundary surfaces are in the form of a partially cylindrical mandrel extending axially into a hollow dummy bar.

Abstract: Metal slabs are continuously cast in a mold defined by a plurality of mold plates arranged to provide a mold cavity therebetween with the mold cavity open at the top and bottom. The mold surfaces which face the cavity are curved convexly and the degree of curvature changes at a non-linear rate along the height of the mold cavity.

Abstract: A process for forming a liquid-solid composition from a material which, when frozen from its liquid state without agitation, forms a dendritic structure. A material having a non-thioxotropic-type structure, in a solid form, is fed into an extruder. The material is heated to a temperature above its liquidus temperature. It is then cooled to a temperature less than its liquidus temperature and greater than its solidus temperature, while being subjected to sufficient shearing action to break at least a portion of the dendritic structures as they form. Thereafter, the material is fed out of the extruder.

Abstract: A process for producing a liquid-solid composition comprising heating a liquefiable material sufficiently to form a liquid phase with solid dendritic particles therein without completely liquefying the material and subjecting said liquid-solid material to a shearing action sufficient to break at least a portion of the dendritic structures. The process includes injection molding, forging or die casting the material produced by the process.

Abstract: A method and an apparatus for continuously sizing, preforming or forming metal objects include a plurality of molds arranged in a substantially vertical column and which collectively define a mold cavity. Each mold is separable into at least two mold sections. A retaining mechanism retains the molds in the vertical column. A mechanism separates the bottom mold into sections and removes the mold sections and positions the sections on a top mold of the column to form a new top mold. Preferably, the mechanism includes first and second arms which are rotatable between the bottom and the top mold positions and which grasp and move the mold sections from the bottom of the column to the top of the column.

Abstract: A method is provided for producing substantially austenitic stainless steel strip, particularly chromium-nickel grades, having ultra low sulfur levels up to 0.002% by conventionally continuously casting the slab and thereafter hot rolling the slab to hot-rolled band by improving the ability to achieve hot-rolled band having good surface quality as characterized by reduced metallurgical slivers.

Abstract: A device is described for collecting molten metal break-outs which may occur during direct chill casting of light metal, e.g. aluminum or aluminum alloy ingots. The device includes a water-cooled mould of the cross sectional shape of the ingot desired, this mould having a vertically moveable base portion to support the ingot formed and being disposed above a pit for receiving the resultant casting and means for applying water onto the freshly solidified surface of the ingot as it emerges from the mould downwardly into the pit. The novel feature consists of at least one hollow container adjacent the side or sides of the ingot being formed, each container being packed with dry, highly heat-absorptive, finely divided material having a large surface to volume ratio. Each container has an open top positioned a short distance below the mould such as to catch a break-out of molten metal at the exit of the mould.

Abstract: A method is described for continuously casting an ingot of a metal alloy of a type having a substantial liquidus-solidus temperature range to produce internal microstructure of a desired fineness. Molten alloy is flowed along an electron beam heated skulled hearth while controlling the electron beam to maintain a solids content in the alloy on the hearth of between about 15% and about 40%. The alloy is poured from the hearth into the top of a continuous casting mold at a rate which produces a thixotropic region at the upper end of the fully solidified alloy in the mold. The ingot produced is characterized by a macrostructure in excess of one millimeter average grain dimensions with a non-uniform shape, orientation, and distribution, and is characterized by a microstructure of the order of fifty micron cell spacing of dendritic crystallites comprising the microstructure.

Abstract: A device and method for the insertion of commercial grade separators into the mold of a continuous steel caster. The present invention discloses a device made from standard steel channel and a method for the use thereof to mechanically insert grade separators.

Abstract: A method and apparatus for casting an ingot with refined grain structure from a metallic melt supplied to a casting mold. The mold is intermittently cooled to form a zone of fine dendrites on the inner peripheral surface of the mold. Then, the fine dendrites are reheated to detach secondary dendritic arms therefrom. Finally, the detached secondary dendrite arms are mixed into the melt to serve as nuclei for grain refinement as the melt solidifies into a cast ingot having a refined grain structure.

Abstract: For alleviating the problem in continuous casting of beam blanks that cracks are frequently formed at the fillet parts thereof not only is the mold cavity provided with a taper at its web part in the casting direction, but also the curvature 1/R of the curved fillet parts of the mold cavity are successively varied in accordance with the amount of free shrinkage of the solidified shell of the beam blank strand. Such variation in curvature is particularly significant in the casting of beam blanks having a web height that is close to 1 m.

Abstract: Additional intermediate narrow side walls are provided between narrow side walls at an apparatus for continuous casting of metals for casting as desired of metal bars with slab boom cross-section or of at least two metal bars of smaller cross-section, where a plate mold is employed, which is provided with a water tank supporting the narrow side walls and the wide side walls. In order to use best the cross-sectional area available for the forming of a slab bloom and in order to maintain acceptable and favorable viewing conditions immediately below the mold, the copper plates of the wide side walls between the end side narrow side walls are in each case subdivided by at least one recess in the longitudinal direction of the advancing metal bar in order to be able to cast at least two bars concurrently.

Abstract: The invention provides an improved system for continuous processing of molten steel and other metals comprising continuous withdrawal, vacuum treatment and casting, employing a specialized post-treatment vessel stationed adjacent to a continually maintained supply of metal in a furnace bath. The post-treatment vessel incorporates a vacuum degassing column chamber section which is fed with metal through a withdrawal tube with the inlet inserted into the furnace bath and the outlet into the degassing column, the lower portion of which extends laterally into a tundish pouring section from which metal is poured through a nozzle directly into a continuous caster. Sealing of the continuous casting tundish cover, which is incorporated into the post-treatment vessel assembly, is a key element of the invention.

Abstract: Molten metal is supplied into a mold having an inlet and an outlet opening in such a manner that the molten metal may have a substantially zero pressure at the outlet opening of the mold, while the inner wall of the mold is maintained at a temperature sufficiently higher than the solidifying temperature of the molten metal so that the contiguous surface of the metal remains liquid until it has left the molten outlet. A dummy bar having a temperature lower than the solidifying temperature of the molten metal is brought into contact with the molten metal at the outlet opening of the mold, and moved away from the outlet opening, whereby a solidified body of the metal is formed continuously on the end of the dummy bar.

Abstract: A boron-treated steel comprises a carbon steel, or a low alloy steel containing 0.15 to 0.85% C, 0.15 to 2.0% Si, 0.3 to 1.5% Mn, not more than 1.0% Cr, not more than 0.020% of P and S each, and unavoidable quantities of Al and Ti not exceeding 0.008% and 0.010%, respectively, and further contains 6 to 30 ppm of acid-soluble boron. The steel produced is less likely to develop cracks and can be produced at substantially reduced costs.

Abstract: An apparatus and a method for forming a semi-solid thixotropic slurry. The apparatus includes a duplex mold arrangement for postponing solidification within the mold until the molten metal is within a magnetic field for providing magnetohydrodynamic stirring. The duplex mold includes a first portion of low thermal conductivity and a second portion of high conductivity.

Abstract: A process and apparatus for continuously and semi-continuously casting molten metals and alloys. Control of the initial stages of solidification is carried out through application of a thermal insulating layer on the coolant side of a casting mold wall. The layer modifies the heat flux characteristics of the mold along a selected length thereof.

Abstract: A method of enlarging the width of a continuously cast strand comprising partially immersing a metallic joint having an I-shaped transverse cross-section in the tail end of a firstly cast strand which is downwardly moving or stationary in a rectangular mold cavity defined by narrow and wide pairs of mold pieces, hold the joint in position until the tail end of the strand is solidified, outwardly moving the narrow mold pieces to define the desired enlarged width of the strand, filling the so-formed openings between the strand and walls of the mold pieces with a refractory material and then with a metallic cushioning material, restarting the continuous strand casting process.

Abstract: An improved method of continuously casting nickel containing steel wherein the formation of surface cracks is prevented. The molten steel which is cast contains less than 0.0020% S, less than 0.0045% N, Ca in an amount of from 0.0020 to 0.0070%, Ni in an amount from 5.5 to 10%, the remainder being Fe and unavoidable impurities.

Abstract: A continuous casting mold for producing polygonal steel profiles by continuous casting by the curved-mold method, comprises individual plates defining the sides of the molds. The four plates are provided with recesses at their extremities which form abutting joint edges and the edges are held flush with one another by shims inserted between opposing surfaces of the plates at the corners thereof. One pair of plates is provided with radius or bevels so that the cross section of the interior of the mold is octogonal. According to the invention, moreover, the chamfered or bevelled surfaces and the surfaces between them are machined and a corresponding insertion shim is provided to insure that the edges are flush with one another.

Abstract: This invention relates to mold flux powders for the continuous casting of steel. The mold flux powders comprise a plurality of sequential melting systems forming successive melts each of which assimilates the ingredients of the next system into the melt. In this way, the desired fluidity is achieved in the mold flux at a rate required by the particular continuous casting process in which the flux is being used without resorting to an excessively low melting flux. At least one of the systems comprises a finely-divided glass.

Abstract: A method of monitoring the mold geometry during the continuous casting of billets and blooms formed of steel. During the progress of the continuous casting operation there is measured the actual value of the withdrawal of heat at the continuous casting mold and this value is compared with a set or reference value. In the presence of a deviation exceeding a predetermined magnitude there is determined a damaging mold geometry.