Abstract: A unitary-layer partially metallic, suitably adherent, mechanically and thermally durable, non-wetting, fusion-bonded matrix coating on endless, flexible metallic casting belts for continuous casting machines is described. This fusion-bonded matrix coating is also advantageous for coating other molten-metal-contacting surfaces, in continuous casting machines, such as edge-dam blocks that define moving side walls of a mold cavity. The fusion-bonded matrix (or reticulum) coating provides advantageous accessible porosity throughout the coating and comprises a nonmetallic refractory material interspersed substantially uniformly throughout a matrix of heat-resistant metal or metal alloy, for example nickel or nickel alloy, which is fusion-bonded to the grit-blasted surface of the belt and anchors and holds the nonmetallic material. The coating is applied by thermally spraying a powdered mixture directly on the roughened surface.

Abstract: An improved process and apparatus for casting a strip with laterally extending lugs by introducing molten metal at the inlet of a molding zone having a bottom and sidewalls, the bottom of the molding zone being formed by the upper surface of a moving endless belt and the sidewalls being formed by a first and second moving endless sidedam. The sidedams move with the belt from the inlet to the outlet of the molding zone and return from the outlet to the inlet. Each sidedam comprises an endless strap and a multiplicity of blocks strung thereon. Some of the blocks form lug molding pockets, the height of each pocket being lower than the height of the molding zone. A cast strip with laterally extending lugs is extracted at the outlet of the molding zone. The passage of lug molding pockets or blocks forming these pockets in each sidedam is detected.

Abstract: Continuous casting methods and apparatus are described wherein a defect in the cast surfaces consisting of longitudinal bands of sinkage, sometimes called "sinks", which are spaced relatively far inwardly from the edges of wide, relatively thin slab or strip, usually being spaced inwardly away from the edges by a distance of 3 to 7 times (sometimes up to 9 times) the thickness of the cast slab, is practically eliminated by means of a coating or covering of non-wettable refractory ceramic material of low heat conductivity applied to the inner faces of the edge-dam blocks for reducing heat flow out of the edges of the slab or strip being cast. Numerous such blocks are strung onto a flexible metal band or cable to constitute each of the two edge dams which define the edges of the mold space.

Abstract: The casting belt is preheated with steam closely ahead of the entrance to the casting zone by providing wrap-around steam feed tubes having nozzles, such tubes being positioned in very deep circumferential grooves in input pulley or nip pulley which moves the casting belt into the input end of the casting zone. These circumferential grooves of the input or nip pulley also house wrap-around liquid coolant feed tubes for cooling the casting belt near the beginning of the casting zone. The wrap-around steam feed tubes also have radial ports positioned to direct steam toward the reverse side of the endless belt, with the port being spaced from the nozzle thereby providing a staged elevation of temperature in the flexible casting belt on the input or nip pulley, while the belt is in contact therewith before the belt reaches the casting zone.

Abstract: Laterally "floating" thermal spray gun traversing apparatus and system for laterally tracking a revolving casting belt being thermal spray coated for applying uniformly spaced passes of thermal spraying on the revolving casting belt regardless of any lateral (edgewise) movements of the casting belt in either direction and regardless of any chamber in the edge of the belt. The thermal spray gun is traversed by a leadscrew and an adjustable speed drive for the leadscrew, both the leadscrew and its adjustable drive being carried by a frame mounted on a carriage freely movable along a trackway extending parallel to the axis of the leadscrew. A roller senses the lateral position of the edge of the revolving belt, and the carriage is moved by a source of motive power responsive to the sensed lateral position of the belt for causing the carriage together with the frame, leadscrew and leadscrew drive automatically to track the belt.

Abstract: Machine for producing insulative and protective coatings on endless flexible metallic belts of continuous casting machines is described. The coating is applied to a revolving belt being supported and driven by pulleys in the machine. The coating is applied by thermally spraying a powdered mixture directly onto the roughened casting surface of the belt. The machine holds the revolving belt under tension and applies cooling to the rear (inner) surface of the revolving belt opposite to the region where the thermal spray gun is applying the coating to the belt.

Abstract: An improvement in continuous metal casting machines of the type having a pair of flexible, moving casting belts which revolve along endless paths for defining a casting region therebetween and moving side dams which revolve along with the casting belts for confining the cast strip, slab or bar laterally. The casting belts are individually supported by upper and lower carriage means. The machine is provided with sensors such as load cells for sensing the displacement forces existing between the upper and lower carriages at selected points along the path of belt travel, and for sensing the side pressures exerted upon the side dams by the cooling, solidifying metal. This sensing permits the maintenance of predetermined, desired contact pressures along the length of the solidifying metal to thereby improve the physical characteristics of the cast product.

Abstract: Improved casting method and side dam apparatus for use in twin-belt continuous metal casting machines are described particularly adapted for casting rectangular copper bar providing a casting speed almost double that obtained in prior twin-belt machines and a damblock lifetime which is more than doubled, while producing a more homogeneous and symmetrical casting structure. The side dams are formed by stringing slotted damblocks along the entire length of a flexible metal strap, except for end portions of the strap. An end-to-end weld forms an endless strap loop of accurately predetermined length, and special damblocks having two mating interlocking halves are inserted into the remaining space along the strap, whereby all blocks are free to slide on the strap but with little cumulative space between blocks, which are preferably made of a bronze alloy presenting better resistance to heat cracking and higher heat conductivity than in previous damblocks.

Abstract: Method and apparatus are described for continuously casting metal slab, strip or bar with integral lugs projecting therefrom. These lugs project from the edge of the cast product and lie in the casting plane, but they have a partial thickness as compared with the thickness of the product. Continuous wide slabs of unrefined copper or other electrolytically refinable metal having partial thickness lugs on both edges can be cut to form electrode plates for subsequent refining by suspending in an electrolytic bath. These partial thickness lugs serve as supports and provide electrical connection from the side rails of the electrolytic cell. Their partial thickness conserves metal and weight. In the continuous casting method and apparatus the revolving edge dams include special dam blocks defining partial thickness mold pockets for casting the integral lugs.

Abstract: Continuous apparatus for impression molding products containing thermoplastic material and having three-dimensional patterns on one or both surfaces, similar or dissimilar, with or without continuously changing profile or shaped edges. The thermoplastic material to be formed may or not contain foamants, fillers, strata or plys of differing composition to reinforce, decorate or protect, and is heated above its glass transition temperature before introduction between revolving flexible belt molds, which revolve in opposed relationship, being cooled, forming a travelling mold channel, at least one having a flexible three-dimensional pattern form on its front face. Opposed nip rolls press the revolving belt molds against the entering thermoplastic material. At least one belt mold travels partially around the nip roll impressing its three-dimensional pattern form in the heated material in a progressive localized rolling squeezing action in the nip region.

Abstract: Continuous casting apparatus is described wherein the temperature of the flexible casting belts in twin-belt machines having two or more main rolls in each belt carriage is controllably elevated prior to contact with the molten metal to improve the casting conditions and the operation of the thin flexible casting belts; the temperature elevation preferably being relatively gradual may be carried out while the travelling belts are approaching the nip rolls or while the belts are in contact with the nip rolls, or both. Zone control of belt pre-heating is disclosed, and control of the coolant streams issuing from the curved nip roll tubes by use of fingernail-like extenders may be provided to aid in pre-heating the belts and in controlling their operation. Intensive infra-red heaters are shown directed at close range toward the casting surfaces of the belts, these heaters serving also to cure and dry any coating material on the belts.

Abstract: Continuous casting methods and apparatus are described wherein the flexible casting belts in twin-belt machines having two or more main rolls in each belt carriage are sensed by mechanical probes, and belt temperatures are controllably elevated prior to contact with the molten metal to improve the casting conditions and the operation of the thin flexible casting belts; the temperature elevation preferably being relatively gradual may be carried out while the travelling belts are approaching the nip rolls or while the belts are in contact with the nip rolls, or both. Zone control of belt pre-heating is disclosed, and control of the coolant streams issuing from the curved nip roll tubes by use of fingernail-like extenders may be provided to aid in pre-heating the belts and in controlling their operation. Intensive infra-red heaters are shown directed at close range toward the casting surfaces of the belts, these heaters serving also to cure and dry any coating material on the belts.

Abstract: Continuous casting apparatus is described wherein the temperature of the flexible casting belts in twin-belt machines having two or more main rolls in each belt carriage is controllably elevated prior to contact with the molten metal to improve the casting conditions and the operation of the thin flexible casting belts; the temperature elevation preferably being relatively gradual may be carried out while the travelling belts are approaching the nip rolls or while the belts are in contact with the nip rolls, or both. Zone control of belt pre-heating is disclosed, and control of the coolant streams issuing from the curved nip roll tubes by use of fingernail-like extenders may be provided to aid in pre-heating the belts and in controlling their operation. Intensive infra-red heaters are shown directed at close range toward the casting surfaces of the belts, these heaters serving also to cure and dry any coating material on the belts.

Abstract: A symmetrical belt-steering and tensioning system and apparatus for twin-belt continuous metal casting machines are disclosed. A rigid squaring shaft passes through a hollow tension and steering roll and is rigidly secured to torque arms at opposite ends of the roll assuring that this roll remains parallel with the driving roll at the other end of the carriage throughout the range of tensioning travel, these arms each being associated with tension thrust means and steering means. The geometrical relationships assure that tension in the casting belts remains essentially directly proportional to the fluid pressure in the thrust cylinders, while a pre-loading arrangement removes back lash from the pivots to improve steering precision and also provides mechanical advantage. A symmetrical synchronized steering action is applied to both ends of the tension-steering roll, and axial thrust control means operate to force the roll skewing movement to center at a predetermined point.

Abstract: Improved casting side dam apparatus for use in twin-belt continuous metal casting machines is described particularly adapted for casting rectangular copper bar providing a casting speed almost double that obtained in prior twin-belt machines and a damblock lifetime which is more than doubled, while producing a more homogeneous and symmetrical casting structure. The side dams are formed by stringing slotted damblocks along the entire length of a flexible metal strap, except for end portions of the strap. An end-to-end weld forms an endless strap loop of accurately predetermined length, and special damblocks having two mating interlocking halves are inserted into the remaining space along the strap, whereby all blocks are free to slide on the strap but with little cumulative space between blocks, which are preferably made of a bronze alloy presenting better resistance to heat cracking and higher heat conductivity than in previous damblocks.

Abstract: A symmetrical belt tensioning system and apparatus for twin-belt continuous casting machines are disclosed. A rigid squaring shaft passes through a hollow tension roll and is rigidly secured to torque arms at opposite ends of the roll assuring that this roll remains parallel with the driving roll at the other end of the carriage throughout the range of tensioning travel, these arms each being associated with tension thrust means. The geometrical relationships assure that tension in the casting belts remains essentially directly proportional to the fluid pressure in the thrust cylinders, while a pre-loading arrangement removes back lash from the pivots to improve steering precision and also provides mechanical advantage. Independent adjustment of the displacement of each end of the tension-steering roll from the pass line is provided by sleeves associated with the squaring shaft and bearings in the interior of the hollow roll.

Abstract: In twin-belt casting machines for continuously casting molten metal improved belt back-up apparatus and coolant application means are provided. The front faces of the casting belts are held firmly against the moving edge dams by wide belt-supporting elements in the form of cylindrical collars on the back-up rollers or longitudinally extending fixed guide members engaging the reverse surfaces of the belts and positioned in alignment with the respective side dams and laterally spaced apart a distance no greater than the lateral spacing of the moving side dams. Nozzles are absent from the coolant supply means in the positions where the belt-supporting elements are engaging the reverse surfaces of the casting belts.

Abstract: Continuous casting methods are described wherein the temperature of the flexible casting belts in twin-belt machines having two or more main rolls in each belt carriage is controllably elevated prior to contact with the molten metal to improve the casting conditions and the operation of the thin flexible casting belts; the temperature elevation preferably being relatively gradual may be carried out while the travelling belts are approaching the nip rolls or while the belts are in contact with the nip rolls, or both. Zone control of belt pre-heating is disclosed, and control of the coolant streams issuing from the curved nip roll tubes by use of fingernail-like extenders may be provided to aid in pre-heating the belts and in controlling their operation. Intensive infra-red heaters are shown directed at close range toward the casting surfaces of the belts, these heaters serving also to cure and dry any coating material on the belts.