Abstract: Provided herein is a system, apparatus, and method for continuous casting of metal, and more particularly, to a mechanism for controlling the shape of a direct chill casting mold to dynamically control a profile of an ingot cast from the mold during the casting process. Embodiments may provide an apparatus for casting material including: first and second opposing side walls; first and second end walls extending between the first and second side walls, where the first and second opposing side walls and the first and second opposing end walls form a generally rectangular shaped mold cavity. At least one of the first and second opposing side walls may include two or more contact regions, where each of the two or more contact regions may be configured to be displaced relative to a straight line along the side wall.

Abstract: The present invention relates to a method, system, and apparatus for improving the efficiency of a continuous casting operation. A continuous casting mold component described herein includes: a mold wall substrate defining a groove proximate a bottom of the mold wall substrate; a graphite liner having a bottom edge defining a first angled surface and a top edge defining a second angled surface, where the bottom edge is received into the groove of the mold wall substrate; and a clamping element defining an angled clamping surface attached to the mold wall substrate with at least one fastener, where the bottom angled surface of the graphite liner is driven into the groove defined in the substrate in response to the angled clamping surface of the clamping element engaging the second angled surface of the graphite liner and the fastener pressing the clamping element toward the mold wall substrate.

Abstract: The present disclosure relates to a system, apparatus, and method for a cooling water spray pattern for a direct chill casting mold, and more particularly, to a spiral water spray pattern for a direct chill billet casting mold. An example direct chill casting mold includes a mold body defining a mold cavity there through; and a plurality of spray jets arranged proximate an exit of the mold cavity, wherein the plurality of spray jets are angled with respect to the mold cavity such that streams of fluid exiting the plurality of spray jets impinge upon a casting exiting the mold cavity at an angle offset from a centerline of the casting.

Abstract: Provided herein is a system, apparatus, and method for venting a direct chill casting mold by venting excess casting gas and retaining oxide from atop a casting during the direct chill casting process. Methods of venting casting gas from a direct chill casting mold include: supplying the direct chill casting mold with molten metal through a transition plate; supplying a casting gas through a casting surface of the direct chill casting mold; venting the casting gas from a gas pocket in the transition plate, wherein venting the casting gas from the gas pocket in the transition plate is performed in response to a pressure of the casting gas in the gas pocket reaching a predetermined pressure.

Abstract: Provided herein is a system, apparatus, and method for continuous casting of metal, and more particularly, to a mechanism for controlling the shape of a direct chill casting mold to dynamically control a profile of an ingot cast from the mold during the casting process. Embodiments may provide an apparatus for casting material including: first and second opposing side walls; first and second end walls extending between the first and second side walls, where the first and second opposing side walls and the first and second opposing end walls form a generally rectangular shaped mold cavity. At least one of the first and second opposing side walls may include two or more contact regions, where each of the two or more contact regions may be configured to be displaced relative to a straight line along the side wall.

Abstract: Provided herein is a system, apparatus, and method for continuous casting of metal, and more particularly, to a mechanism for controlling the shape of a direct chill casting mold to dynamically control a profile of an ingot cast from the mold during the casting process. Embodiments may provide an apparatus for casting material including: first and second opposing side walls; first and second end walls extending between the first and second side walls, where the first and second opposing side walls and the first and second opposing end walls form a generally rectangular shaped mold cavity. At least one of the first and second opposing side walls may include two or more contact regions, where each of the two or more contact regions may be configured to be displaced relative to a straight line along the side wall.

Abstract: Provided herein are an apparatus and method for continuous casting of metal, and more particularly, to an apparatus and method to reduce macrosegregation through a mechanism for controlling the position of a spout tip or diffuser during the casting process to maintain the spout tip or diffuser near the solidification front, location of transition between liquid metal and solid metal in the cast part. An apparatus may include: a mold frame supporting a mold defining a mold cavity; a liquid diffuser; and an actuator configured to move at least one of the mold frame and the liquid diffuser relative to one another, wherein the actuator is configured to move at least one of the mold frame and the liquid diffuser relative to one another in response to a signal from at least one sensor.

Abstract: Provided herein is a system, apparatus, and method for continuous casting of metal, and more particularly, to a mechanism for controlling the shape of a direct chill casting mold to dynamically control a profile of an ingot cast from the mold during the casting process. Embodiments may provide an apparatus for casting material including: first and second opposing side walls; first and second end walls extending between the first and second side walls, where the first and second opposing side walls and the first and second opposing end walls form a generally rectangular shaped mold cavity. At least one of the first and second opposing side walls may include two or more contact regions, where each of the two or more contact regions may be configured to be displaced relative to a straight line along the side wall.

Abstract: Provided herein are an apparatus and method for continuous casting of metal, and more particularly, to an apparatus and method to reduce macrosegregation through a mechanism for controlling the position of a spout tip or diffuser during the casting process to maintain the spout tip or diffuser near the solidification front, location of transition between liquid metal and solid metal in the cast part. An apparatus may include: a mold frame supporting a mold defining a mold cavity; a liquid diffuser; and an actuator configured to move at least one of the mold frame and the liquid diffuser relative to one another, wherein the actuator is configured to move at least one of the mold frame and the liquid diffuser relative to one another in response to a signal from at least one sensor.

Abstract: Provided herein is a system, apparatus, and method for aligning a continuous casting mold and a starter block. The continuous casting mold alignment system may include: a continuous casting mold; a mold frame supporting the continuous casting mold; a starter block; and at least one bearing assembly. The at least one bearing assembly is movable between a lowered position and a raised position, where the at least one bearing assembly, in the raised position, engages and supports one of the continuous casting mold or the starter block. The at least one bearing assembly, in the raised position, enables the one of the continuous casting mold or the starter block to be moved into alignment with the other of the continuous casting mold or the starter block by a force below a predefined threshold.

Abstract: Provided herein is a system, apparatus, and method for continuous casting of metal, and more particularly, to a mechanism for controlling the shape of a direct chill casting mold to dynamically control a profile of an ingot cast from the mold during the casting process. Embodiments may provide an apparatus for casting material including: first and second opposing side walls; first and second end walls extending between the first and second side walls, where the first and second opposing side walls and the first and second opposing end walls form a generally rectangular shaped mold cavity. At least one of the first and second opposing side walls may include two or more contact regions, where each of the two or more contact regions may be configured to be displaced relative to a straight line along the side wall.

Abstract: A molten metal mold and bottom block system, including apparatus and method embodiments, which may include a mold cavity framework with a first side, a second side opposite the first side, a third side, and a fourth side opposite the third side, each side including an inner surface and the inner surfaces defining a mold cavity, and wherein one or more of the sides are movably mounted relative to the second side, and are controllably moved during the casting. This system may also include embodiments wherein the castpart produced has a tapered form at one or both of the castpart ends. Aspects of this invention may be considered to be a castpart shrinkage management system or a castpart form or profile control system due to the advantage of increased controls of castpart form during the casting process.

Abstract: An oxide control system (apparatus and process) for use in a continuous casting mold for controlling, directing and managing the flow of metal oxides which develop on the molten metal surface within the oxide dam. This invention discloses a new oxide dam which provides predetermined outlets which control and manage the flow of metal oxides to locations within the mold cavity and resulting castpart where oxides are acceptable, yet directing the metal oxides away from locations where the oxides are unacceptable on the resulting castpart.

Abstract: An oxide control system (apparatus and process) for use in a continuous casting mold for controlling, directing and managing the flow of metal oxides which develop on the molten metal surface within the oxide dam. This invention discloses a new oxide dam which provides predetermined outlets which control and manage the flow of metal oxides to locations within the mold cavity and resulting castpart where oxides are acceptable, yet directing the metal oxides away from locations where the oxides are unacceptable on the resulting castpart.

Abstract: A coolant or wiper control system for use in continuous casting mold for controlling and managing the coolants interaction with the castpart during casting. In some aspects of the process, the wiper framework is started sufficiently away from the bottom block so as not to interfere or cause/allow coolant to get into the bottom block; is then rapidly moved back to the emerging castpart during transient heat-up; and then moved away from the mold with the solidified castpart at a controlled rate to a predetermined steady state position or to a second transitory state of the casting.

Abstract: A continuous casting mold with a bleedout detection system is disclosed, which may include a casting mold framework, a molten metal casting mold with a mold inlet and a mold outlet, the mold outlet having a mold cavity perimeter; and a bleedout detection system which may include: a signal generator that provides a balanced current to a sensor/conductor at or near the mold outlet perimeter; a current detector electrically connected to the sensor/conductor; and a programmable controller configured to receive an electrical signal from the bleedout detection system regarding the status of the sensor/conductor.

Abstract: A continuous cast molten metal mold and casting system is disclosed, which may include a heat distribution or temperature management system for billet type molds, a mold assembly expansion system for continuous cast molds and/or an adjustable mold bore length mechanism.

Abstract: A gas flow control system for molten metal molds with permeable perimeter walls, wherein an approximately constant gas mass flow is maintained in individual molds and approximately equal gas mass flows are maintained in molds on the same mold table. A PLC is utilized in combination with a gas mass flow controller to continually monitor and maintain the approximately desired mass flow of gas to the mold cavities.

Abstract: A molten metal sensing and automation system for use with or in a metal casting mold. Aspects of the invention include a molten metal automation system which may include a bleedout detection system which provides an automated response, and an automated system for the preparation of the starting blocks for casting.

Abstract: A perimeter wall lubrication system for molten metal molds wherein the lubricant conduit within the permeable perimeter wall is configured with a K constant which is lower than 40 or more in the equation where X is the perimeter of the groove in the permeable perimeter wall and Y is the perimeter to area ratio, relative to the equation k=XY in a plot of the respective values.