Roll Couple Mold Patents (Class 164/428)
  • Patent number: 10532398
    Abstract: An enclosure having a sealing device, for a casting installation, having a first body and a second body that is removably joined to the first body along a bearing axis, the first and second bodies together delimiting an internal chamber. The sealing device comprises: at least one compression member, at least one seal having a lateral contact face extending substantially parallel to the bearing axis; the compression member and the seal being arranged with respect to one another such that the compression member is in contact with the lateral contact face of the seal and exerts a compression force thereon that is oriented orthogonally to the bearing axis.
    Type: Grant
    Filed: March 8, 2017
    Date of Patent: January 14, 2020
    Assignee: CONSTELLIUM ISSOIRE
    Inventors: Arnaud Ballu, Bernard Valentin, Soizic Blais
  • Patent number: 10449602
    Abstract: A magnesium alloy cast-rolling unit, including: a main body; a fluid supplier; an electric pushrod; a linkage mechanism; a horizontal platform; a screw; dovetail guide rails; and a bottom plate. The main body includes a base, a spring cylinder, a hydraulic adjustment cylinder, a connection portion, and a cast-rolling unit body. The connection portion includes an arc-shaped rail. The spring cylinder includes an actuation element. The actuation element includes a piston rod and a pressure strip. The piston rod includes an external thread at one end; and the pressure strip includes an internal thread corresponding to the external thread. The fluid supplier includes a head box, a corrugated pipe, a compression spring assembly including a gland cover, a connection pipe including a convex pipe joint and a concave pipe joint, a flat plate including a groove, a smelting furnace, and a horizontal operation platform.
    Type: Grant
    Filed: February 26, 2018
    Date of Patent: October 22, 2019
    Assignee: TAIYUAN UNIVERSITY OF SCIENCE AND TECHNOLOGY
    Inventors: Lifeng Ma, Jingfeng Zou, Xiao Hu, Rongjun Wang, Guangming Liu, Zhiquan Huang, Yanchun Zhu, Qingxue Huang
  • Patent number: 10434567
    Abstract: A method of making floor plate includes assembling a pair of casting rolls laterally disposed to form a nip, assembling a hot rolling mill downstream of the nip having work rolls with a surface pattern forming the negative of a raised slip-resistant pattern desired in a floor plate, introducing molten metal through at least one metal delivery nozzle to form a casting pool supported on the casting rolls above the nip; counter rotating the casting rolls to form shells on the casting surfaces of the casting rolls to cast metal strip of less than 2.2 mm thickness downwardly from the nip, and delivering the cast metal strip to and through the hot rolling mill to form by the negative of the slip-resistant pattern on the work rolls a raised slip-resistant pattern of between 0.3 and 0.7 mm in height in a floor plate of less than 1.7 mm thickness.
    Type: Grant
    Filed: September 6, 2018
    Date of Patent: October 8, 2019
    Assignee: Nucor Corporation
    Inventor: Eric Young
  • Patent number: 10293399
    Abstract: Apparatus and methods for casting a metal strip with a cross sectional form which varies along the length of the strip. One embodiment of the apparatus includes opposing cooling systems, a positionable molten metal feed system between the opposing cooling systems, and a form adjustment system. The form adjustment system may include at least one dam to determine, at least in part, the cross sectional form of a molten metal feed to the opposing cooling systems. In this way, it is possible to determine the cross sectional form of the solidified metal strip. The dam is moveable during operation of the apparatus to vary the cross sectional form of the molten metal feed to the opposing cooling systems.
    Type: Grant
    Filed: April 2, 2015
    Date of Patent: May 21, 2019
    Assignee: Cambridge Enterprise Limited
    Inventors: Julian M. Allwood, Martin McBrien
  • Patent number: 10259411
    Abstract: A cast component, in particular for a vehicle, has a surface structuring arranged on at least one wall portion of the cast component. The surface structuring forms a surface of the wall portion, and stiffens the wall portion. The surface structuring is formed by a plurality of evenly shaped depressions in the surface of the wall portion, which depressions are mutually spaced apart, leaving interconnected webs, and produce tapered sections on the wall portion.
    Type: Grant
    Filed: September 12, 2016
    Date of Patent: April 16, 2019
    Assignee: Bayerische Motoren Werke Aktiengesellschaft
    Inventor: Christian Haslauer
  • Patent number: 10173260
    Abstract: A method and apparatus for casting thin strip including assembling a pair of counter-rotating casting rolls forming a gap between the casting surfaces of the rolls at a nip between the rolls through which metal strip can be cast; assembling side dams adjacent end portions of the rolls to permit a casting pool of molten metal to be formed on the casting surfaces; counter-rotating the rolls such that the casting surfaces each travel inwardly toward the nip to form metal shells on the surfaces of the rolls and deliver a cast strip downwardly from the gap between the rolls with a mushy internal portion; and providing a drive mechanism to oscillate the gap amplitude between the casting rolls between ±5 and ±50 microns at a frequency between 1 and 7 hertz to vary thickness of the mushy internal portion in the cast strip and reduce chatter during casting.
    Type: Grant
    Filed: April 19, 2017
    Date of Patent: January 8, 2019
    Assignee: NUCOR CORPORATION
    Inventors: Peter Andrew Woodberry, Nikolco Nikolovski, Wai Yee Daniel Yuen
  • Patent number: 10058914
    Abstract: A metal delivery nozzle for a twin roll caster adapted to extend along and above a pair of casting rolls has a main portion with one or two refractory pieces with outlets adapted to deliver molten metal to a casting pool supported by the casting rolls during casting; refractory delivery end portions separately supported adapted to move relative to the main portion at each end portion of the metal delivery nozzle, each refractory delivery end portion having a reservoir portion with passages there through adapted to deliver molten metal to the casting pool adjacent the side dams and the end portions of the casting rolls; and a mechanism connected to each refractory delivery end portion adapted to move said refractory delivery end portion relative to the main portion as casting proceeds to maintain desired distance between the refractory delivery end portions and the side dams.
    Type: Grant
    Filed: August 5, 2016
    Date of Patent: August 28, 2018
    Assignee: Nucor Corporation
    Inventor: Robert Nooning
  • Patent number: 10046384
    Abstract: A side dam for a continuous twin roll caster with a body of refractory material shaped to form a side dam and having edge portions adapted to engage end portions of casting rolls of a twin roll caster and having a nip portion adapted to be adjacent a nip between the casting rolls and having upper portions extending across the side dam to form a lateral restraint for a casting pool of molten metal during operation in the twin roll caster; and a pocket between 5 and 50 mm in depth formed in the body between the edge portions and forming shoulder portions in the body between the edge portions and the pocket adapted to be worn as a casting campaign continues until the pocket is reached and continuing to be worn away at level of base portions of the pocket until casting is completed.
    Type: Grant
    Filed: September 7, 2016
    Date of Patent: August 14, 2018
    Assignee: Nucor Corporation
    Inventors: Kevin Keown, Tao Wang, Rama Ballav Mahapatra
  • Patent number: 9975170
    Abstract: There is provided a method of manufacturing a high nitrogen duplex stainless steel sheet through a twin roll strip casting process without the occurrence of surface swelling on the high nitrogen duplex stainless steel sheet.
    Type: Grant
    Filed: November 30, 2015
    Date of Patent: May 22, 2018
    Assignee: POSCO
    Inventors: Man Jin Ha, Jin Ho Kim, Suk Kyun Hwang, Sung Jin Park
  • Patent number: 9863015
    Abstract: A manufacturing method for strip casting 550 MPa-grade high strength atmospheric corrosion-resistant steel strip, comprising the following steps: 1) smelting, where the chemical composition of a molten steel is that: C is between 0.03-0.08%, Si?0.4%, Mn is between 0.6-1.5%, P is between 0.07-0.22%, S?0.01%, N?0.012%, Cu is between 0.25-0.8%, Cr is between 0.3-0.8%, and Ni is between 0.12-0.4%, additionally, also comprised is at least one micro-alloying element among Nb, V, Ti, and Mo, where Nb is between 0.01-0.08%, V is between 0.01-0.08%, Ti is between 0.01-0.08%, and Mo is between 0.1-0.4%, and where the remainder is Fe and unavoidable impurities; 2) strip casting, where a 1-5 mm-thick cast strip is casted directly; 3) cooling the strip, where the cooling rate is greater than 20° C./s; 4) online hot rolling the cast strip, where the hot rolling temperature is between 1050-1250° C.
    Type: Grant
    Filed: February 18, 2013
    Date of Patent: January 9, 2018
    Assignee: Baoshan Iron & Steel Co., Ltd.
    Inventors: Xiufang Wang, Yuan Fang, Yan Yu, Jianchun Wu, Bo Qin
  • Patent number: 9790566
    Abstract: A manufacturing method for strip casting 700 MPa-grade high strength atmospheric corrosion-resistant steel, comprising the following steps: 1) smelting, where the chemical composition of a molten steel in terms of weight percentage is that C is between 0.03-0.1%, Si?0.4%, Mn is between 0.75-2.0%, P is between 0.07-0.22%, S?0.01%, N?0.012%, Cu is between 0.25-0.8%, Cr is between 0.3-0.8%, and Ni is between 0.12-0.4%, additionally, also comprised is at least one micro-alloying element among Nb, V, Ti, and Mo, where Nb is between 0.01-0.1%, V is between 0.01-0.1%, Ti is between 0.01-0.1%, and Mo is between 0.1-0.5%, and where the remainder is Fe and unavoidable impurities; 2) strip casting, where a 1-5 mm-thick cast strip is casted directly; 3) cooling the cast strip, where the cooling rate is greater than 20° C./s; 4) online hot rolling the cast strip, where the hot rolling temperature is between 1050-1250° C.
    Type: Grant
    Filed: February 18, 2013
    Date of Patent: October 17, 2017
    Assignee: Baoshan Iron & Steel Co., Ltd.
    Inventors: Xiufang Wang, Yuan Fang, Yan Yu, Jianchun Wu, Bo Qin
  • Patent number: 9744589
    Abstract: Apparatus and method for continuously casting metal strip includes a pair of casting rolls having casting surfaces with a center portion, edge portions each having average surface roughness between 3 and 7 micrometers Ra, and intermediate portion between each edge portion and the center portion, the center portion average surface roughness between 1.2 and 4.0 times the edge portion surface roughness, and the intermediate portions average surface roughness between that of the edge and center portions. The surface roughness of the center portion is tapered across its width, and may be tapered across its width is in stepped zones. The center portion may have surface roughness varied across the surface to correspond to a desired variation in metal shell thickness across the cast strip. The center portion may be at least 60% of the casting roll width, and each edge portion may be up to 7% of the casting roll width.
    Type: Grant
    Filed: January 7, 2015
    Date of Patent: August 29, 2017
    Assignee: Nucor Corporation
    Inventors: Rama Ballav Mahapatra, David W. McGaughey, Jay Jon Ondrovic, Tim Patterson, Mike Schueren
  • Patent number: 9533347
    Abstract: There are provided a casting roll of a twin-roll strip caster and a method for manufacturing a high-nitrogen duplex stainless steel strip having no dimple. The casting roll has an average roughness Ra of 10 ?m to 30 ?m, and diagonal fine grooves having a width of 50 ?m to 500 ?m, an interval of 100 ?m to 1000 ?m, and a depth of 50 ?m to 200 ?m are formed in the casting roll. The diagonal fine grooves are symmetrically intersecting each other at an angle of 30° to 70° with respect to circumferential direction of the casting roll.
    Type: Grant
    Filed: November 12, 2014
    Date of Patent: January 3, 2017
    Assignee: POSCO
    Inventors: Byoung-Jun Song, Sung-Jin Park, Yoon-Ha Kim, Dae-Sung Lee, Seong-In Jeong
  • Patent number: 8978738
    Abstract: In a twin roll continuous caster, the casting nozzle in the continuous casting apparatus is arranged such that the outlet passages and/or tapered walls in the main portion within the casting nozzle provide flow of molten metal downwardly converging toward the nip between the casting rolls of a twin roll caster. The casting nozzle having a reservoir portion for directing molten metal converging toward the triple point region to inhibit the washing of shells forming on the casting surfaces of the casting rolls.
    Type: Grant
    Filed: May 29, 2014
    Date of Patent: March 17, 2015
    Assignee: Nucor Corporation
    Inventors: Gary McQuillis, Kevin Keown, Eric Fulbright
  • Patent number: 8960265
    Abstract: Apparatus and method for continuously casting metal strip includes a pair of casting rolls having casting surfaces with a center portion, edge portions each having average surface roughness between 3 and 7 Ra, and intermediate portion between each edge portion and the center portion, the center portion average surface roughness between 1.2 and 4.0 times the edge portion surface roughness, and the intermediate portions average surface roughness between that of the edge and center portions. The surface roughness of the center portion is tapered across its width, and may be tapered across its width is in stepped zones. The center portion may have surface roughness varied across the surface to correspond to a desired variation in metal shell thickness across the cast strip. The center portion may be at least 60% of the casting roll width, and each edge portion may be up to 7% of the casting roll width.
    Type: Grant
    Filed: October 29, 2010
    Date of Patent: February 24, 2015
    Assignee: Nucor Corporation
    Inventors: Rama Ballav Mahapatra, David W. McGaughey, Jay Jon Ondrovic, Tim Patterson, Mike Schueren
  • Patent number: 8960264
    Abstract: Apparatus and method for continuously casting metal strip includes a pair of casting rolls having casting surfaces with a center portion, edge portions each having average surface roughness between 3 and 7 Ra, and intermediate portion between each edge portion and the center portion, the center portion average surface roughness between 1.2 and 4.0 times the edge portion surface roughness, and the intermediate portions average surface roughness between that of the edge and center portions. The surface roughness of the center portion is tapered across its width, and may be tapered across its width is in stepped zones. The center portion may have surface roughness varied across the surface to correspond to a desired variation in metal shell thickness across the cast strip. The center portion may be at least 60% of the casting roll width, and each edge portion may be up to 7% of the casting roll width.
    Type: Grant
    Filed: March 14, 2013
    Date of Patent: February 24, 2015
    Assignee: Nucor Corporation
    Inventors: Rama Ballav Mahapatra, David W. McGaughey, Jay Jon Ondrovic, Tim Patterson, Mike Schueren
  • Patent number: 8915291
    Abstract: Plant for forming grids for electric battery plates, which comprises a grid forming machine with continuous casting provided with a rotary drum, and a sliding block mounted fixed and slideably sealingly coupled with the external surface of the rotary drum and provided with means for distributing molten lead, in order to insert the molten lead within grooves provided on the external peripheral surface of the rotary drum during the rotation of the latter. The plant is also provided with an ultrasound generator placed to intercept a feed duct for the molten lead, connected to the distribution means and provided with at least one tip immersed in the pressurized flow of molten lead that moves through the aforesaid feed duct in order to transmit the waves produced by the ultrasound generator to the molten lead flow.
    Type: Grant
    Filed: May 19, 2013
    Date of Patent: December 23, 2014
    Assignee: Sovema S.p.A.
    Inventor: Pietro Farina
  • Publication number: 20140367065
    Abstract: A method of casting a thin strip is disclosed. The method includes assembling a pair of side dams adjacent end portions of counter-rotating casting rolls through which a strip of metal can be cast to permit a casting pool of molten metal to be formed supported by the casting surfaces of the casting rolls, assembling a metal delivery system above the casting rolls delivering molten metal to form a casting pool supported on the casting surfaces of the casting rolls above the nip and confined by the pair of side dams, assembling a mechanical screw drive to move axially the side dams toward the casting pool, counter-rotating the casting rolls such that the casting surfaces of the casting rolls each travel inwardly to produce a cast strip downwardly from the nip, and moving the side dams axially inward toward the casting pool at a rate of between 0.4 and 5.0 mm/hour by actuation of the mechanical screw.
    Type: Application
    Filed: June 14, 2013
    Publication date: December 18, 2014
    Applicant: NUCOR CORPORATION
    Inventors: Gary MCQUILLIS, William M. KOVAL
  • Patent number: 8893768
    Abstract: A method of continuously casting metal strip having the steps of assembling a pair of counter-rotatable casting rolls, assembling a metal delivery system adapted to deliver molten metal above the nip to form a casting pool, the casting pool forming a meniscus with each casting surface of the casting rolls, delivering a shell thickness controlling gas to select areas within 300 mm of end portions of at least one casting roll downwardly toward the meniscus between the casting pool and the casting surface adapted to control thickness of the metal shell, and control attenuation of the casting roll, and sensing the temperature and thickness profiles of the cast strip downstream from the nip to determine high or low temperature areas of the cast strip within 300 mm of the end portions and causing the gas to be delivered to the high or low temperature areas to change the thickness of the metal shell.
    Type: Grant
    Filed: November 19, 2012
    Date of Patent: November 25, 2014
    Assignee: Nucor Corporation
    Inventors: Robert Nooning, Alan J. Deno, Mark Schlichting, Gary McQuillis, Dhiren Panda, Neal Ross, Leigh Woolley
  • Patent number: 8875777
    Abstract: A method of continuously casting steel strip includes steps of providing rails positioned beneath a casting position and extending in opposite directions there from to discharge stations, supporting first and second scrap receptacles movable along the rails, engaging a seal between the first scrap receptacle and an enclosure enabling support of a protective atmosphere beneath a pair of casting rolls, disengaging the seal between the first scrap receptacle and the enclosure and moving the first scrap receptacle along the rails in a direction away from the second scrap receptacle to a discharge station, and moving the second scrap receptacle into the casting position and sealingly engaging the second scrap receptacle and the enclosure.
    Type: Grant
    Filed: March 13, 2013
    Date of Patent: November 4, 2014
    Assignee: Nucor Corporation
    Inventors: Jay Jon Ondrovic, Eric Fulbright, Katsumi Nakayama
  • Publication number: 20140262117
    Abstract: In a twin roll continuous caster, the casting nozzle in the continuous casting apparatus is arranged such that the outlet passages and/or tapered walls in the main portion within the casting nozzle provide flow of molten metal downwardly converging toward the nip between the casting rolls of a twin roll caster. The casting nozzle having a reservoir portion for directing molten metal converging toward the triple point region to inhibit the washing of shells forming on the casting surfaces of the casting rolls.
    Type: Application
    Filed: May 29, 2014
    Publication date: September 18, 2014
    Applicant: NUCOR CORPORATION
    Inventors: Gary MCQUILLIS, Kevin KEOWN, Eric FULBRIGHT
  • Publication number: 20140262123
    Abstract: In a twin roll continuous caster, the casting nozzle in the continuous casting apparatus is arranged such that the outlet passages and/or tapered walls in the main portion within the casting nozzle provide flow of molten metal downwardly converging toward the nip between the casting rolls of a twin roll caster. The casting nozzle having a reservoir portion for directing molten metal converging toward the triple point region to inhibit the washing of shells forming on the casting surfaces of the casting rolls.
    Type: Application
    Filed: May 29, 2014
    Publication date: September 18, 2014
    Applicant: NUCOR CORPORATION
    Inventors: Gary MCQUILLIS, Kevin KEOWN, Eric FULBRIGHT
  • Publication number: 20140246164
    Abstract: An apparatus and method for continuously casting thin steel strip include a pair of counter-rotatable casting rolls in a roll cassette laterally positioned to form a nip there between through which thin cast strip can be cast, adapted to support a casting pool of molten metal on the casting surfaces, an enclosure to support a protective atmosphere immediately beneath the casting rolls in the casting position, and an upper cover positioned below the casting rolls to move between a closed position covering the upper portion of the enclosure maintaining the protective atmosphere in the enclosure in the closed position and a retracted position enabling cast strip to be cast into the enclosure. A scrap receptacle positioned beneath the casting position movable in either direction to a discharge stations. Further, a movable tundish adapted to be transferred from a heating station to the casting position.
    Type: Application
    Filed: May 12, 2014
    Publication date: September 4, 2014
    Applicant: NUCOR CORPORATION
    Inventors: Jay Jon ONDROVIC, Eric FULBRIGHT, Katsumi NAKAYAMA
  • Patent number: 8813828
    Abstract: In a twin roll continuous caster, the casting nozzle in the continuous casting apparatus is arranged such that the outlet passages and/or tapered walls in the main portion within the casting nozzle provide flow of molten metal downwardly converging toward the nip between the casting rolls of a twin roll caster. The casting nozzle having a reservoir portion for directing molten metal converging toward the triple point region to inhibit the washing of shells forming on the casting surfaces of the casting rolls.
    Type: Grant
    Filed: December 10, 2012
    Date of Patent: August 26, 2014
    Assignee: Nucor Corporation
    Inventors: Gary McQuillis, Kevin Keown, Eric Fulbright
  • Patent number: 8783332
    Abstract: A device and method are disclosed for positioning at least one of two casting rolls in a continuous casting process for producing a metal strip. The device and the method allow adjusting or modifying the casting gap between the casting rolls during the ongoing operation, thereby having an influence on the strip thickness and the strip profile of the produced metal strip.
    Type: Grant
    Filed: September 28, 2011
    Date of Patent: July 22, 2014
    Assignee: Siemens Aktiengesellschaft
    Inventor: Ansgar Grüss
  • Patent number: 8763679
    Abstract: A casting roll for a two-roll casting device for the casting of metallic strip from a metal melt, in particular a steel melt, includes a roll body, on a casing surface of which a coating consisting of a coating material is applied by thermal spraying, which has a higher degree of hardness than the roll body. The casting roll according to the invention and the two-roll casting device, while easy to manufacture, has not only a long service life, but also allows for the manufacture of cast strips of optimum quality. This is achieved by the fact that the free surface of the coating, after thermal spraying, has a peak number RPc of at least 10 cm?1.
    Type: Grant
    Filed: January 24, 2008
    Date of Patent: July 1, 2014
    Assignee: Outokumpu Nirosta GmbH
    Inventors: Ulrich Albrecht-Früh, Roland Sellger, Johann Wilhelm Schmitz, Reiner Kopp, Jörg Lauscher, Martin Franzke
  • Publication number: 20140099232
    Abstract: A method of forming a sheet of semiconductor material utilizes a system. The system comprises a first convex member extending along a first axis and capable of rotating about the first axis and a second convex member spaced from the first convex member and extending along a second axis and capable of rotating about the second axis. The first and second convex members define a nip gap therebetween. The method comprises applying a melt of the semiconductor material on an external surface of at least one of the first and second convex members to form a deposit on the external surface of at least one of the first and second convex members. The method further comprises rotating the first and second convex members in a direction opposite one another to allow for the deposit to pass through the nip gap, thereby forming the sheet of semiconductor material.
    Type: Application
    Filed: March 15, 2013
    Publication date: April 10, 2014
    Applicant: Corning Incorporated
    Inventors: Samir Biswas, Douglass Lane Blanding, Glen Bennett Cook, Prantik Mazumder, Kamal Kishore Soni, Balram Suman
  • Patent number: 8684068
    Abstract: An apparatus and method for controlling the horizontal oscillation of an edge dam of a twin roll strip caster is provided. The apparatus includes an oscillation unit which horizontally oscillates an oscillation plate in accordance with an oscillation waveform so that an edge dam refractory coupled to the oscillation plate horizontally oscillates, a servo valve which outputs the oscillation waveform to the oscillation unit, and a control unit which applies the oscillation waveform to the servo valve, thus controlling the horizontal oscillation of the oscillation unit. The amplitude, frequency and waveform of the oscillation are variably controlled depending on casting conditions. The edge dam horizontally oscillates, using the servo valve and a hydraulic cylinder, thus rapidly removing edge skull and suppressing the generation and growth of skull, thereby preventing a casting roll or edge dam from being damaged.
    Type: Grant
    Filed: December 16, 2010
    Date of Patent: April 1, 2014
    Assignee: Posco
    Inventors: Oh-Seong Kweon, Kwi-Ju Hwang, Yoon-Ha Kim, Ji-Woong Jun, Sang-Hoon Kim
  • Patent number: 8646513
    Abstract: A metal delivery apparatus for casting metal strip includes at least one elongated segment having a main portion extending longitudinally through the main portion with end walls at opposite ends thereof, the main portion communicating with outlets along opposite sides of each segment adapted to upwardly discharge flow of molten metal into a casting pool.
    Type: Grant
    Filed: June 26, 2012
    Date of Patent: February 11, 2014
    Assignee: Nucor Corporation
    Inventors: Mark Schlichting, Brian Bowman, Clark Ponder, Peter Woodberry
  • Patent number: 8631853
    Abstract: An apparatus and method for continuously casting thin steel strip include a pair of counter-rotatable casting rolls in a roll cassette laterally positioned to form a nip there between through which thin cast strip can be cast, adapted to support a casting pool of molten metal on the casting surfaces, an enclosure to support a protective atmosphere immediately beneath the casting rolls in the casting position, and an upper cover positioned below the casting rolls to move between a closed position covering the upper portion of the enclosure maintaining the protective atmosphere in the enclosure in the closed position and a retracted position enabling cast strip to be cast into the enclosure. A scrap receptacle positioned beneath the casting position movable in either direction to a discharge stations. Further, a movable tundish adapted to be transferred from a heating station to the casting position.
    Type: Grant
    Filed: December 2, 2011
    Date of Patent: January 21, 2014
    Assignee: Nucor Corporation
    Inventors: Jay Jon Ondrovic, Eric Fulbright, Katsumi Nakayama
  • Patent number: 8602086
    Abstract: A method for producing an amorphous alloy foil strip having a large sheet thickness in an industrial scale includes: a pair of cooling rolls; a driving unit configured to rotate the pair of cooling rolls; and a crucible configured to supply a molten alloy sequentially to an outer circumferential surface of the pair of cooling rolls. The crucible is movable along a moving unit. A molten alloy is supplied alternately to the pair of cooling rolls while rotating and water-cooling the pair of cooling rolls.
    Type: Grant
    Filed: October 15, 2012
    Date of Patent: December 10, 2013
    Assignee: Nippon Steel & Sumitomo Metal Corporation
    Inventor: Takashi Sato
  • Patent number: 8567480
    Abstract: A twin roll caster and a method for operating a machine of this type. The machine includes two casting rolls, that delimit a casting gap between them on its longitudinal sides; two side plates that delimit the casting gap on its narrow sides; and at least one oscillation device, which moves the side plate in an oscillating manner about an axis of oscillation, extending substantially axially parallel to the axes of rotation of the casting rolls. Oscillation device includes two actuators, which are articulatedly coupled to the one side plate and each apply a torque rotating about the axis of oscillation on the one side plate, and a control device that emits control signals, upon which the actuators, individually or together with each other, carry out adjustment movements aligned against one another or parallel to one another.
    Type: Grant
    Filed: February 20, 2009
    Date of Patent: October 29, 2013
    Assignee: Outokumpu Nirosta GmbH
    Inventors: André d'Hone, René Leenen
  • Patent number: 8561671
    Abstract: A twin roll caster and method for producing strip cast from a molten metal using the twin roll caster. The twin roll caster has casting rolls which delimit a casting gap between them on its longitudinal sides and narrow sides sealed in each case by a side plate which is moved during the casting operation about an axis of oscillation in an oscillating manner. The inventive method and the twin roll caster enable the risk of operational disruptions from molten mass solidifying in the region of the side plate to be further minimized. This is achieved by changing the position of the axis of oscillation during the casting operation.
    Type: Grant
    Filed: February 20, 2009
    Date of Patent: October 22, 2013
    Assignee: Outokumpu Nirosta GmbH
    Inventor: André d'Hone
  • Publication number: 20130248136
    Abstract: The invention relates to a method and apparatus for direct chill casting ingots with in-situ homogenization. Large particles of eutectic material may form in the solid ingot and the metal may exhibit macrosegregation of alloying components, especially when large ingots are cast in this way. This can be alleviated by applying a first liquid coolant to the ingot emerging from the mold, removing the first liquid coolant at a certain distance along the ingot by means of a wiper, and then applying a second liquid coolant to perform a quench at a greater distance along the ingot. The quench raises the level of the molten sump in the ingot, which helps to overcome the indicated problems, without affecting the desired temperature rebound of the ingot shell (usually at least 425° C. (797° F.)) for a time effective to cause in-situ homogenization.
    Type: Application
    Filed: February 12, 2013
    Publication date: September 26, 2013
    Inventors: Wayne J. FENTON, Jeff McDERMOTT, Robert Bruce Wagstaff
  • Publication number: 20130240170
    Abstract: A system of twin-roll casting an ultra-thin slab or thick-strip of metal with a liquid core still present inside the hollow shell of the casting as it exits the nip of the opposing counter rotating casting rolls. The wide sides of the cast shell are formed against a recessed casting surface on each roll and the narrow end walls of the shell are formed against the tapered ends of the recessed area so one half of the narrow end wall is formed on each roll and the two halves are joined together at the nip to form the full perimeter of the metal casting. A liquid-cooled copper mold liner provides continued support to each of the four sides of the casting below the twin-rolls and contact with those chilled copper mold liners continues to remove heat from the liquid core of the casting enabling the shell to continue growing in thickness.
    Type: Application
    Filed: April 22, 2013
    Publication date: September 19, 2013
    Inventor: James B. Sears, JR.
  • Publication number: 20130213599
    Abstract: A device and method are disclosed for positioning at least one of two casting rolls in a continuous casting process for producing a metal strip. The device and the method allow adjusting or modifying the casting gap between the casting rolls during the ongoing operation, thereby having an influence on the strip thickness and the strip profile of the produced metal strip.
    Type: Application
    Filed: September 28, 2011
    Publication date: August 22, 2013
    Inventor: Ansgar Grüss
  • Patent number: 8505611
    Abstract: In a twin roll continuous caster, the contour of the strip cast is controlled during casting by regulating the temperature of temperature-regulating medium circulated through temperature-regulating passages in the casting rolls spaced inward of cooling passages in the circumferential portion adjacent the casting surfaces. The temperature-regulating passages may be positioned in the circumferential portion or in the inner portion of the casting rolls, or both.
    Type: Grant
    Filed: June 10, 2011
    Date of Patent: August 13, 2013
    Assignee: Castrip, LLC
    Inventor: Hiroyuki Otsuka
  • Patent number: 8499820
    Abstract: An apparatus for casting metal strip includes a pair of counter-rotatable casting rolls having casting surfaces laterally positioned to form a nip therebetween through which cast strip can be cast, and on which a casting pool of molten metal can be formed supported on the casting surfaces above the nip, a pair of molten metal delivery nozzles disposed above the nip and capable of discharging molten metal to form the casting pool supported on the casting rolls, a pair of side dams adjacent ends of the pair of casting rolls capable of confining the casting pool, a pair of delivery nozzle actuators capable of positioning the delivery nozzles independently of the side dams and a pair of side dam actuators capable of positioning the side dams independently of the delivery nozzles during casting, and a control system capable of controlling desired distance between the delivery nozzles and the side dams.
    Type: Grant
    Filed: July 26, 2012
    Date of Patent: August 6, 2013
    Assignee: Nucor Corporation
    Inventors: Jay Jon Ondrovic, Eric Fulbright, Katsumi Nakayama
  • Publication number: 20130174995
    Abstract: Apparatus and method for continuously casting metal strip includes a pair of casting rolls having casting surfaces with a center portion, edge portions each having average surface roughness between 3 and 7 Ra, and intermediate portion between each edge portion and the center portion, the center portion average surface roughness between 1.2 and 4.0 times the edge portion surface roughness, and the intermediate portions average surface roughness between that of the edge and center portions. The surface roughness of the center portion is tapered across its width, and may be tapered across its width is in stepped zones. The center portion may have surface roughness varied across the surface to correspond to a desired variation in metal shell thickness across the cast strip. The center portion may be at least 60% of the casting roll width, and each edge portion may be up to 7% of the casting roll width.
    Type: Application
    Filed: March 14, 2013
    Publication date: July 11, 2013
    Applicant: Nucor Corporation
    Inventors: Rama Ballav Mahapatra, David W. McGaughey, Jay Jon Ondrovic, Tim Patterson, Mike Schueren
  • Publication number: 20130146245
    Abstract: In a twin roll continuous caster, the casting nozzle in the continuous casting apparatus is arranged such that the outlet passages and/or tapered walls in the main portion within the casting nozzle provide flow of molten metal downwardly converging toward the nip between the casting rolls of a twin roll caster. The casting nozzle having a reservoir portion for directing molten metal converging toward the triple point region to inhibit the washing of shells forming on the casting surfaces of the casting rolls.
    Type: Application
    Filed: December 10, 2012
    Publication date: June 13, 2013
    Inventors: Gary MCQUILLIS, Kevin KEOWN, Eric FULBRIGHT
  • Patent number: 8453712
    Abstract: A twin roll caster and a method for operating comprising two casting rolls that delimit a casting gap on its longitudinal sides; two side plates that delimit the casting gap on its narrow sides; and at least one axial actuator associated with one of the side plates and impacting the respective side plate on its rear turned away from the front sides of the casting rolls with a force axially aligned toward the casting gap pressing the side plate against the front sides of the casting rolls. An axial actuator acts on the rear side of the side plate by means of a joint provided to adjust an angular offset between the normal level relative to the effective direction of the force applied by the axial actuator to the side plate and the normal level relative to the axes of rotation of the casting rolls.
    Type: Grant
    Filed: February 20, 2009
    Date of Patent: June 4, 2013
    Assignee: Outokumpu Nirosta GmbH
    Inventor: André d'Hone
  • Publication number: 20130126121
    Abstract: In a twin roll continuous caster, the formation of skulls in the triple point region, the heat flux between the molten metal in the casting pool and the surfaces of the casting rolls, and consequently the casting speed and strip thickness, are controlled by controlling the level of carbon dioxide to at least 20% present in the casting area atmosphere above the casting pool supported on the casting surfaces of counter-rotating casting rolls. The carbon dioxide level in casting area may be more than 40%, 50%, 60%, 75% or 90%. The gas mixture in the casting area above the casting pool may be more than 0.05% free oxygen.
    Type: Application
    Filed: November 19, 2012
    Publication date: May 23, 2013
    Applicant: NUCOR CORPORATION
    Inventor: NUCOR CORPORATION
  • Patent number: 8397794
    Abstract: Described herein is a twin roll caster including a pair of casting rolls arranged parallel to one another with a gap between the casting rolls and side dams parallel to one another forming a pool between the casting rolls and side dams. A side dam support is provided that applies a compression force on at least one of the side dams at a compression angle relative to the axis of the casting rolls.
    Type: Grant
    Filed: April 3, 2012
    Date of Patent: March 19, 2013
    Assignee: Castrip, LLC
    Inventors: Katsumi Nakayama, Atsushi Hirata, Kiroyuki Otsuka, Hisahiko Fukase
  • Patent number: 8387682
    Abstract: In a twin roll continuous caster, the contour of the strip cast is controlled during casting by regulating the temperature of temperature-regulating medium circulated through temperature-regulating passages in the casting rolls spaced inward of cooling passages in the circumferential portion adjacent the casting surfaces. The temperature-regulating passages may be positioned in the circumferential portion or in the inner portion of the casting rolls, or both.
    Type: Grant
    Filed: June 10, 2011
    Date of Patent: March 5, 2013
    Assignee: Castrip, LLC
    Inventor: Hiroyuki Otsuka
  • Patent number: 8327917
    Abstract: An apparatus and a method for producing an amorphous alloy foil strip, which are capable of producing an amorphous alloy foil strip having a large sheet thickness in an industrial scale, are provided. A production apparatus 101 for an amorphous alloy foil strip S includes: a pair of cooling rolls 113a and 113b; a driving unit 111 configured to rotate the cooling rolls; and a crucible 114 configured to supply a molten alloy sequentially to an outer circumferential surface of the cooling roll 113a and an outer circumferential surface of the cooling roll 113b. The crucible 114 is movable along a moving unit 116. A molten alloy is supplied alternately to the cooling roll 113a and the cooling roll 113b while rotating and water-cooling the cooling rolls 113a and 113b.
    Type: Grant
    Filed: February 20, 2009
    Date of Patent: December 11, 2012
    Assignee: Nippon Steel Corporation
    Inventor: Takashi Sato
  • Patent number: 8322402
    Abstract: During continuously casting metal strip, delivering molten metal supported on the casting surfaces of the casting rolls, and counter rotating the casting rolls to form metal shells on the casting surfaces brought together at the nip to deliver cast strip downwardly with a controlled amount of mushy material between the metal shells, determining at a reference location downstream from the nip a target temperature for the cast strip corresponding to a desired amount of mushy material between the metal shells of the cast strip, sensing the temperature of the cast strip cast downstream from the nip at the reference location and producing a sensor signal corresponding to the sensed temperature, and causing an actuator to vary the gap at the nip between the casting rolls in response to the sensor signal received from the sensor and processed to determine the temperature difference between the sensed temperature and the target temperature.
    Type: Grant
    Filed: September 20, 2010
    Date of Patent: December 4, 2012
    Assignee: Nucor Corporation
    Inventors: Walter N. Blejde, Rama Ballav Mahapatra, Mark Schlichting
  • Patent number: 8316920
    Abstract: A metal strip casting apparatus and method of casting metal strip include assembling a pair of counter-rotatable casting rolls positioned laterally forming a nip between for casting, and assembling a pair of brush rolls, each of the brush rolls associated with one of each of the casting rolls. Each brush roll includes at least one spaced apart brush line extending substantially along the axial length of the casting roll. The brush lines may form a spiral, zigzag, wave or crisscross array about the brush roll. The brush roll may include one or more staggered rings with regularly or irregularly spaced apart bristles which form the brush lines. The brush lines may be between 10 to 50 mm apart and separated by between 2 mm to 45 mm of open space. The brush lines may be one line per 10 mm to 90 mm of axial length of brush roll.
    Type: Grant
    Filed: November 20, 2009
    Date of Patent: November 27, 2012
    Assignee: Nucor Corporation
    Inventors: Hiroyuki Otsuka, Hiroki Yoshizawa, Katsumi Nakayama, Kazuo Miyoshi
  • Patent number: 8312917
    Abstract: A method of controlling the formation of crocodile skin surface roughness on thin cast strip by forming a casting pool of molten metal of less than 0.065% carbon supported on casting surfaces above a nip, assembling a rotating brush to contact the casting surfaces in advance of contact with the molten metal, and controlling the energy exerted by rotating brushes against the casting surfaces of the casting rolls to clean and expose a majority of the projections of the casting surfaces of the casting rolls by providing wetting contact with the molten metal of the casting pool. The cleaning step is controlled by controlling the energy of the rotating brush against the casting rolls based on the difference between the detected light reflected from the casting surfaces and the light reflected when the casting surfaces are clean, and automating the method.
    Type: Grant
    Filed: June 29, 2007
    Date of Patent: November 20, 2012
    Assignee: Nucor Corporation
    Inventor: Mark Schlichting
  • Publication number: 20120285651
    Abstract: An apparatus for casting metal strip includes a pair of counter-rotatable casting rolls having casting surfaces laterally positioned to form a nip therebetween through which cast strip can be cast, and on which a casting pool of molten metal can be formed supported on the casting surfaces above the nip, a pair of molten metal delivery nozzles disposed above the nip and capable of discharging molten metal to form the casting pool supported on the casting rolls, a pair of side dams adjacent ends of the pair of casting rolls capable of confining the casting pool, a pair of delivery nozzle actuators capable of positioning the delivery nozzles independently of the side dams and a pair of side dam actuators capable of positioning the side dams independently of the delivery nozzles during casting, and a control system capable of controlling desired distance between the delivery nozzles and the side dams.
    Type: Application
    Filed: July 26, 2012
    Publication date: November 15, 2012
    Applicant: NUCOR CORPORATION
    Inventors: Jay Jon ONDROVIC, Eric FULBRIGHT, Katsumi NAKAYAMA
  • Patent number: RE45414
    Abstract: A process and apparatus for continuous casting of amorphous alloy sheets having large sheet thickness using bulk solidifying amorphous alloys are provided. Thick continuous amorphous alloy sheets made of bulk solidifying amorphous alloys are also provided.
    Type: Grant
    Filed: August 29, 2012
    Date of Patent: March 17, 2015
    Assignee: Crucible Intellectual Property, LLC
    Inventor: William L. Johnson