Abstract: A magnesium hot rolling mill system including a rolling mill having at least two work rolls for rolling of magnesium sheet or plate, a hot coiler positioned on either side of the rolling mill for heating and maintaining a desired temperature of the magnesium sheet or plate, active thermal roller tables, a mill drive system for independently driving the work rolls for asymmetrical rolling of the magnesium sheet and a warm coil loading and payoff station.

Abstract: A method for twin roll casting aluminum clad magnesium by joining one or more sheets of aluminum cladding to molten magnesium during twin roll casting. The method includes feeding aluminum cladding to at least one roll of a pair of rotating rolls, feeding a core of molten magnesium into a continuous casting mold formed by the roll, solidifying the magnesium core by heat extraction to the rolls and through the aluminum cladding, surface treating the aluminum cladding and the magnesium core to prevent inter-diffusion between the aluminum cladding and the magnesium core, bonding the aluminum cladding with the magnesium core and extruding the composite core and aluminum cladding out of the continuous casting mold by a casting load exerted by the rolls.

Abstract: A variable tip width adjustment system for use in continuous casting of a molten metal includes a feed tip nozzle downstream from a distribution box, the nozzle including a pair of feed tip nozzle members spaced apart to define a feed tip opening at a downstream edge of the feed tip nozzle members and a pair of end dams located on a drive side and an operator side of the roll casters, the end dams slidably engaged inside the tip nozzle, each dam being axially moveable in two directions inside the tip nozzle. The end dams are preferably actuated using a programmable controller and a stepper motor that is responsive to the signals of the programmable controller. The stepper motor is preferably connected to the end dam via flex connector and a connecting guide rod directed through a guide tube.

Abstract: An improved molten metal feed system is provided for high speed, continuous casting of metals and alloys. The feed system includes a distributor box having an insulative lining which supports an internal flow distributor board. The flow distributor board includes a plurality of openings of various sizes and shapes spaced apart along the width of the board. The presence of the flow distributor board effectively separates the box into lower and upper sections and restricts the flow of liquid metal through the board and thus, forces entering liquid metal to fill the entire width of the distributor box below the flow distributor board. In addition, the liquid metal is stabilized across the width of the distributor box resulting in a balanced temperature gradient. Once the lower section of the distributor box is filled, the metal flows through the openings in the board into the upper section of the distributor box and into the feed tip nozzle.

Abstract: An improved molten metal feed system is provided for high speed, continuous casting of metals and alloys. The feed system includes a distributor box having an insulative lining which supports an internal flow distributor board. The flow distributor board includes a plurality of openings of various sizes and shapes spaced apart along the width of the board. The presence of the flow distributor board effectively separates the box into lower and upper sections and restricts the flow of liquid metal through the board and thus, forces entering liquid metal to fill the entire width of the distributor box below the flow distributor board. In addition, the liquid metal is stabilized across the width of the distributor box resulting in a balanced temperature gradient. Once the lower section of the distributor box is filled, the metal flows through the openings in the board into the upper section of the distributor box and into the feed tip nozzle.

Abstract: A continuous chain caster has upper and lower mold assemblies comprising endless belts and chains traveling at synchronized speeds. The mold assemblies meet to form a mold channel which is filled with molten metal from a headbox and feed tip. As the molten metal passes through the mold channel, the metal solidifies into the shape of the mold channel. Each belt is positioned outside the corresponding chain so that the smooth surface of the belt defines the surface of the mold channel thereby preventing the formation of fins between mold blocks which make up the chain, protecting the chain blocks, and neutralizing deformations in the chain blocks. The upper and lower blocks of the chains have protrusions at opposite ends which engage the opposing blocks to form the sides of the mold channel. By sliding the chains relative to each other, the width of the mold channel is adjustable.

Abstract: A roll coating system for coating strip metal having a plurality of coating head rolls mounted on support sleds capable of linear translation along a single rail. Precision linear actuators are located between each support sled and between one of the sleds and a fourth sled. A splice traverse mechanism actuated by a piston/cylinder displaces the fourth sled. Each of the rolls can be independently displaced or the entire head can be displaced by the splice traverse mechanism. Force measurement sensors are located in the support sleds for an accurate measurement of nip pressures between the respective rolls. The elastic response of the support sleds may be varied to alter the natural resonant frequency of the coating system. The movement of a pan lift mechanism is coupled to the movement of the pickup roll so as to eliminate the chance for collision therebetween.

Abstract: The parting agent spray system is used with a roll casting machine to reduce the parting problems associated with releasing the casting-strip from the rolls. The parting system comprises a bank of self-cleaning spray nozzles for each of the upper roll and the lower roll of the caster. Each bank of nozzles is enclosed in its own individual housing which terminates proximal to the surface of the roll, and is movably located on a track. The housing is utilized to contain any excess graphite spray and prevent it from escaping from the area around the roll caster and contaminating the surrounding environment. The nozzles are grouped into zones, each zone connected to a parting agent solution source via an influent parting agent solution line, and connected to an air source via an air supply line for controlling the flow of the parting agent solution through each of the nozzles and atomizing the same, thus allowing the nozzles in each zone to be independently manipulated.

Abstract: The local thickness across the width of a cast sheet is regulated by controlling the crown of the work rolls in a twin roll continuous casting machine producing the sheet. The work roll crowns are controlled by providing differential cooling in a plurality of cooling subsystems along the length of the rolls. The work rolls contain inlet and outlet water plenums which are connected to peripheral cooling channels between a core and an outer shell of each roll. Water flow to the cooling subsystems is controlled by a movable sleeve within the outlet plenum. In a first position of the sleeve, water is permitted to flow through all areas of the work rolls providing an even heat removal. In a second position, a greater portion of water flows through cooling subsystems in the center portion of the work rolls resulting in increased removal of heat from the center area of the core, reducing the temperature in this area, and thus reducing the crown of the work roll.

Abstract: The local thickness across the width of a cast sheet is regulated by controlling the crown of the work rolls in a twin roll continuous casting machine producing the sheet. The work roll crowns are controlled by providing differential cooling in a plurality of cooling subsystems along the length of the rolls. The work rolls contain inlet and outlet water plenums which are connected to peripheral cooling channels between a core and an outer shell of each roll. Water flow to the cooling subsystems is controlled by a movable sleeve within the outlet plenum. In a first position of the sleeve, water is permitted to flow through all areas of the work rolls providing an even heat removal. In a second position, a greater portion of water flows through cooling subsystems in the center portion of the work rolls resulting in increased removal of heat from the center area of the core, reducing the temperature in this area, and thus reducing the crown of the work roll.

Abstract: A continuous chain caster has upper and lower mold assemblies comprising endless belts and chains traveling at synchronized speeds. The mold assemblies meet to form a mold channel which is filled with molten metal from a headbox and feed tip. As the molten metal passes through the mold channel, the metal solidifies into the shape of the mold channel. Each belt is positioned outside the corresponding chain so that the smooth surface of the belt defines the surface of the mold channel thereby preventing the formation of fins between mold blocks which make up the chain, protecting the chain blocks, and neutralizing deformations in the chain blocks. The upper and lower blocks of the chains have protrusions at opposite ends which engage the opposing blocks to form the sides of the mold channel. By sliding the chains relative to each other, the width of the mold channel is adjustable.