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: 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: 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 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 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 mould for horizontal casting of molten metal comprising a mould body forming an open-ended mould cavity having an inlet end and an outlet end. An annular permeable wall member is mounted in the mould body adjacent the inlet end of the mould cavity with an inner face thereof forming an interior face of the mould. A refractory transition plate is mounted at the inlet end of the mould cavity, this transition plate providing a mould inlet opening having a cross-section less than that of the mould cavity. This provides an annular shoulder at the inlet end of the cavity. Means are provided for feeding molten aluminum through the inlet opening. Separate conduits are also provided for feeding a gas into the shoulder and via the permeable wall means for providing a layer of gas between the metal and the inner face of the mould. A gas that is more reactive with molten aluminum is fed into the shoulder and a less reactive gas is fed via the permeable wall.

Abstract: A mold for horizontal casting of molten metal comprising a mold body forming an open-ended mold cavity having an inlet end and an outlet end. An annular permeable wall member is mounted in the mold body adjacent the inlet end of the mold cavity with an inner face thereof forming an interior face of the mold. A refractory transition plate is mounted at the inlet end of the mold cavity, this transition plate providing a mold inlet opening having a cross-section less than that of the mold cavity. This provides an annular shoulder at the inlet end of the cavity. Means are provided for feeding molten aluminum through the inlet opening. Separate conduits are also provided for feeding a gas into the shoulder and via the permeable wall means for providing a layer of gas between the metal and the inner face of the mold. A gas that is more reactive with molten aluminum is fed into the shoulder and a less reactive gas is fed via the permeable wall.

Abstract: An apparatus is described for starting and stopping a horizontal casting machine, e.g. a caster for continuous casting of metal ingots. The caster comprises a feed trough for carrying molten metal, at least one casting mould and a connecting trough separately connecting each casting mould to the feed trough. A shutoff gate is associated with each connecting trough and movable between an open position and a closed position. Each connecting trough includes a drop-down portion located between the shutoff gate and the casting mould, this drop-down portion being adapted to swing downwardly and thereby rapidly drain molten metal from the connecting trough and an entrance of the mould. The apparatus may also include an elongated starter block, adapted to be inserted into the casting mould and having a threaded recess formed therein for receiving molten metal. An O-ring is fitted to the starter block to seal the block against the casting mould.

Abstract: A trough is described for carrying molten metal, comprising an outer shell defined by a bottom wall and two side walls, an insulating layer filling the outer shell and a conductive U-shaped refractory trough body for carrying molten metal, the trough body being embedded in the insulating layer. At least one heating element is positioned in the insulating layer, adjacent to but spaced apart from the trough body, to provide an air gap between the heating element and the trough body.

Abstract: A mould for horizontal casting of molten metal comprising a mould body forming an open-ended mould cavity having an inlet end and an outlet end. An annular permeable wall member is mounted in the mould body adjacent the inlet end of the mould cavity with an inner face thereof forming an interior face of the mould. A refractory transition plate is mounted at the inlet end of the mould cavity, this transition plate providing a mould inlet opening having a cross-section less than that of the mould cavity. This provides an annular shoulder at the inlet end of the cavity. Means are provided for feeding molten aluminum through the inlet opening. Separate conduits are also provided for feeding a gas into the shoulder and via the permeable wall means for providing a layer of gas between the metal and the inner face of the mould. A gas that is more reactive with molten aluminum is fed into the shoulder and a less reactive gas is fed via the permeable wall.

Abstract: A trough is described for carrying molten metal, comprising an outer shell defined by a bottom wall and two side walls, an insulating layer filling the outer shell and a conductive U-shaped refractory trough body for carrying molten metal, the trough body being embedded in the insulating layer. At least one heating element is positioned in the insulating layer, adjacent to but spaced apart from the trough body, to provide an air gap between the heating element and the trough body.

Abstract: An apparatus is described for starting and stopping a horizontal casting machine, e.g. a caster for continuous casting of metal ingots. The caster comprises a feed trough for carrying molten metal, at least one casting mould and a connecting trough separately connecting each casting mould to the feed trough. A shutoff gate is associated with each connecting trough and movable between an open position and a closed position. Each connecting trough includes a drop-down portion located between the shutoff gate and the casting mould, this drop-down portion being adapted to swing downwardly and thereby rapidly drain molten metal from the connecting trough and an entrance of the mould. The apparatus may also include an elongated starter block, adapted to be inserted into the casting mould and having a threaded recess formed therein for receiving molten metal. An O-ring is fitted to the starter block to seal the block against the casting mould.

Abstract: In direct cooling an ingot emerging from a mold, two sets 136 and 142 of liquid coolant streams are discharged onto the ingot from an annulus 62 circumposed about the lower end opening 72 of the mold. One set of streams, 136, is discharged downwardly at 22.5 degrees to the axis 12 of the mold, and the other, 142, is discharged downwardly at 45 degrees to the axis of the mold. The two sets are staggered to one another circumferentially of the mold, and because of the high angle of incidence of the 45 degree set to the axis of the mold, substantial portions of the 45 degree streams rebound from the surface of the ingot at their points 144 of impact with the ingot, and mushroom into corolla-like masses of air borne liquid coolant spray 146 lying crosswise the paths of the 22.5 degree streams, which in turn entrain the spray and impact the successive layers 138 of coolant therebelow with the spray.

Abstract: The apparatus includes a first chamber disposed about the mold cavity and defined by a top, a bottom, and walls extending between the top and bottom at the inner and outer peripheries of the first chamber. A liquid coolant is supplied under pressure to the first chamber through an inlet. A step is formed adjacent one of the corners between the top and bottom .and the inner peripheral wall of the first chamber, a circumferential groove is formed in the outer peripheral wall of the step, and an elastomeric sealing ring is sealingly engaged with the mouth of the groove to define a second chamber in the groove. Meanwhile, the shoulder of the step is spaced apart from the other corner of the first chamber, and a series of holes is formed in the shoulder to permit the coolant to pass into the second chamber at a reduced pressure. A passage then discharges the reduced pressure coolant onto a body of metal emerging from the discharge end opening of the cavity.