Abstract: Provided herein is a system and method for parameter value determination of direct chill casting using artificial intelligence. The system may employ one or more image sensors configured to capture images of a surface of a direct chill cast billet or ingot, where the images depict one or more casting anomalies. A first machine learning model configured to process images is configured to identify, within the images, casting anomalies along with metrics of the casting anomalies or anomalies can be directly input to the first machine learning model. The casting anomalies are identified by the first machine learning model, classified through conditional statements according to anomaly type and scale. A second machine learning model is configured to process the casting anomaly type and scale as an input along with most parameters and set-up conditions that can cause the anomaly to generate changes to parameter values of the direct chill casting process to reduce or eliminate the casting anomalies.

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 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 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 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 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 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.