Utilizing Continuously Advancing Surface Patents (Class 164/463)
  • 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
  • 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
  • Publication number: 20130126120
    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: Application
    Filed: November 19, 2012
    Publication date: May 23, 2013
    Applicant: NUCOR CORPORATION
    Inventor: NUCOR CORPORATION
  • Publication number: 20130122320
    Abstract: A martensitic stainless steel for use in tableware, knives, scissors and the like, containing in % by weight, 0.10 to 0.50% carbon and 11 to 16% chromium, and a production method therefore.
    Type: Application
    Filed: December 20, 2010
    Publication date: May 16, 2013
    Applicant: POSCO
    Inventors: Dong-Chul Chae, Jong-Heon Seok, Joon-In Kwon, Byoung-Jun Song, Ki-Hoon Jo, Mi-Nam Park
  • Publication number: 20130119094
    Abstract: A method of casting metal strip and equipment therefor where an elongated metal delivery nozzle extending along in a continuous caster with at least one segment having a main portion adapted to deliver molten metal in the casting pool above the nip along the metal delivery nozzle and an end portion adjacent side dams having a reservoir portion with first and second passages adapted to deliver molten metal into a molten metal pool adjacent the side dams while shells are forming on the casting rolls. The first passages are adapted to deliver molten metal shallowly into the casting pool adjacent the side dams, and the second passages adapted to deliver molten metal deeper into the casting pool than the first passages adjacent the side dams to inhibit formation of skulls during the formation of the cast strip during a casting campaign.
    Type: Application
    Filed: May 4, 2012
    Publication date: May 16, 2013
    Applicant: NUCOR CORPORATION
    Inventors: Rama Ballav Mahapatra, Hisahiko Fukase
  • Publication number: 20130092343
    Abstract: A method of casting metal strip and equipment therefor where an elongated metal delivery nozzle extending along in a continuous caster with at least one segment having a main portion adapted to deliver molten metal in the casting pool above the nip along the metal delivery nozzle and an end portion adjacent side dams having a reservoir portion with first and second pairs of passages adapted to deliver molten metal into a molten metal pool adjacent the side dams while shells are forming on the casting rolls. The first pair of passages adapted to deliver molten metal into the casting pool adjacent the side dams, and the second pair of passages adapted to deliver molten metal into the casting pool adjacent the molten metal from the first pair of passages adjacent the side dams to inhibit formation of skulls during the formation of the cast strip during a casting campaign.
    Type: Application
    Filed: November 6, 2012
    Publication date: April 18, 2013
    Applicant: NUCOR CORPORATION
    Inventor: NUCOR CORPORATION
  • Publication number: 20130042993
    Abstract: A method of equalizing a solidification process of molten metal produced, in particular, during strip casting, includes subjecting the molten metal to an electromagnetic stirring process, with a magnetic field is applied to the molten metal located upstream of the area of the electromagnetic stirring process. The electromagnetic stirring includes applying, during the solidification process, at least one electromagnetic field to an already solidified, external region (11) of the molten metal (10).
    Type: Application
    Filed: October 26, 2012
    Publication date: February 21, 2013
    Applicant: SMS SIEMAG AKTIENGESELLSCHAFT
    Inventor: SMS Siemag Aktiengesellschaft
  • Publication number: 20130037233
    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: Application
    Filed: October 15, 2012
    Publication date: February 14, 2013
    Applicant: NIPPON STEEL CORPORATION
    Inventor: Nippon Steel Corporation
  • Patent number: 8347948
    Abstract: Apparatus for preparing alloy sheet, comprising a container for melted alloy liquid positioned in an inductive heating coil; a liquid flow stabilization outfit comprising a barrel container with open bottom and a base board arranged below the open bottom, and the barrel container's upper part being positioned below the mouth of the container for melted alloy liquid; a quenching wheel positioned below the melted alloy liquid flown from the liquid flow stabilization outfit's base board, which carries the melted alloy liquid and spins it into strips, to make the strips become alloy sheets after collision; a transferring outfit positioned below the wheel for further cooling and transferring of the alloy sheets, wherein the quenching wheel is equipped with a means for differentiating cooling rate for various alloy sheets. The magnetic material made of these alloy sheets is good in orientation, easy for post-sinter processing, and suitable for mass production.
    Type: Grant
    Filed: May 28, 2008
    Date of Patent: January 8, 2013
    Assignee: Beijing Zhong Ke San Huan High-Tech Co., Ltd.
    Inventors: Boping Hu, Yizhong Wang, Xiaolei Rao, Jingdong Jia
  • Publication number: 20120321501
    Abstract: The present invention relates to a production method for high-carbon martensitic stainless steel as used in razorblades, knives and the like, which contains, as percentages by weight, 0.40 to 0.80% carbon and 11 to 16% chromium as main components. Provided is a production method for high-carbon martensitic stainless steel in a strip-casting device, wherein a stainless-steel thin sheet is cast by supplying a stainless molten steel containing, as percentages by weight, 0.40 to 0.80% carbon and from 11 to 16% chromium to a molten steel pool from a tundish via a nozzle, and the cast stainless-steel thin sheet is made into a hot-rolled annealed strip using in-line rollers to a rolling reduction of 5 to 40% immediately just after the casting so that the size of primary carbides within the microstructure of the hot-rolled annealed strip is 10 ?m or less, and also provided is martensitic stainless steel produced by means of the production method.
    Type: Application
    Filed: December 20, 2010
    Publication date: December 20, 2012
    Applicant: POSCO
    Inventors: Dong-Chul Chae, Bo-Sung Seo, Seung-Bae Ahn, Seong-In Jeong, Jae-Hwa Lee, Gyu-Jin Jo
  • 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
  • Publication number: 20120279677
    Abstract: In a method for producing a hot strip of steel with material properties that are adjustable over the strip cross-section, a steel melt is fed onto a revolving casting belt of a horizontal strip casting facility and solidifies to form a pre-strip having a thickness between 6 and 20 mm, and the pre-strip is subjected to a hot rolling process after complete solidification. A gas jet or plasma jet composed of metallic and/or non-metallic elements that affect the material properties of the hot strip influences the steel melt that is still liquid and/or just about to start to solidify. The concentration of the elements introduced into the melt by the gas jet or plasma jet and diffusing into the melt is adjusted across the strip thickness and strip width by changing the influencing kinetic energy of the gas jet or plasma jet, the partial gas pressure and/or the applied temperature.
    Type: Application
    Filed: July 14, 2010
    Publication date: November 8, 2012
    Applicant: SALZGITTER FLACHSTAHL GMBH
    Inventors: Karl-Heinz Spitzer, Volker Flaxa, Joachim Kroos, Hellfried Eichholz, Markus Schäperkötter, Rune Schmidt-Jürgensen
  • Patent number: 8272426
    Abstract: An apparatus for casting near-net-shape, rectangular metal strands includes a horizontally circulating metal conveyor belt (7) with a cooled bottom a melt feeder (3?) for casting the metal onto the conveyor belt(7), and an arrangement for feeding the solidified pre-strip under mechanical tension to a driver (16). A cooled pressure device (11, 12, 13) is arranged above the cast product (4) in a region of the deflection roller (8) of the metal conveyor belt (7) which is located downstream in a casting direction, for applying an adjustable pressure from above to the cast product (4) solidifying into the pre-strip (5); and immediately behind the metal conveyor belt (7) a cooling device (17, 19, 19?)for cooling the bottom of the pre-strip (5) over its entire width.
    Type: Grant
    Filed: August 1, 2008
    Date of Patent: September 25, 2012
    Assignee: SMS Siemag AG
    Inventors: Jörg Bausch, Hans Jürgen Hecken
  • Patent number: 8261812
    Abstract: A method of casting near-net-shape, rectangular metal strands includes providing a horizontally circulating metal conveyor belt (7) with a cooled bottom and a melt feeder (3?) for casting the metal melt onto the conveyor belt (7), smooth/pinch rollers (14) for feeding the solidified pre-strip under mechanical tension to a driver (16), a pressure device (11, 12, 13) arranged above the cast product (4) in a region of the deflection roller (8) of the metal conveyor belt (7) which is located downstream in a casting direction, for applying an adjustable pressure from above to the cast product (4) solidifying into the pre-strip (5). Immediately behind the metal conveyor belt (7) and upstream of the pinch rollers, a cooling device (17, 19, 19?) is provided for cooling the bottom of the pre-strip (5) after the pre-strip leaves the conveyor belt.
    Type: Grant
    Filed: May 4, 2011
    Date of Patent: September 11, 2012
    Assignee: SMS Siemag Aktiengesellschaft
    Inventors: Jörg Bausch, Hans Jürgen Hecken
  • Publication number: 20120222831
    Abstract: A method of continuously casting steel including steps of forming a casting pool of molten steel comprising a carbon content of less than 0.5% by weight on casting surfaces of a pair of internally cooled casting rolls having a nip formed between them, counter rotating the casting surfaces of the casting rolls toward each other to produce a cast steel strip moving downwardly away from the nip between the casting rolls, guiding the cast strip through a first enclosure adjacent the casting rolls as the strip moves away from the casting rolls, the first enclosure having a reducing atmosphere containing carbon monoxide and optionally hydrogen of at least 0.1%, establishing the reducing atmosphere in the first enclosure to control ingress of atmospheric air so as to maintain said atmosphere with a CO to CO2 ratio of at least 1.5 during steady state operation.
    Type: Application
    Filed: March 4, 2011
    Publication date: September 6, 2012
    Applicant: NUCOR CORPORATION
    Inventors: Dhiren Panda, Leigh Wooley, Neal Ross, Gary McQuillis, James D. Edwards
  • Patent number: 8235091
    Abstract: The present invention provides an amorphous ribbon take-up roll switching and method which use a take-up device provided with a plurality of take-up rolls magnetized on their surfaces so as to take up an amorphous alloy ribbon during which it is possible to simply and inexpensively switch take-up rolls stably without ribbon breaking, uneven take-up, or other trouble regardless of the amount of take-up, that is, a method of taking up amorphous ribbon having a magnetic property cast using a cooling roll by using two or more take-up rolls, which amorphous ribbon switching method characterized by, when switching the take-up rolls, bringing the amorphous ribbon into contact with the next take-up roll and cutting the amorphous ribbon being taken up in the state with the next take-up roll brought into proximity with the cooling roll or separating the next take-up roll and the cooling roll and cutting the amorphous ribbon between the take-up roll and the next take-up roll.
    Type: Grant
    Filed: May 10, 2007
    Date of Patent: August 7, 2012
    Assignee: Nippon Steel Corporation
    Inventors: Shigekatsu Ozaki, Takeshi Imai
  • Publication number: 20120132390
    Abstract: The invention relates to a device and a method for horizontal casting of a metal band (4). The device thereby comprises a dispensing vessel (3) for a melt (1) and a cooled conveyor belt (6) disposed downstream of the dispensing vessel (3) in the casting direction running between two deflecting rollers (77) and on which the metal band (4) can be transported, and wherein the device comprises at least one roller (8, 889, 9 that can be engaged with the metal band (4) for profiling. Early and therefore improved influence on the profile of a metal band (4), that is, the leader band (4), is made possible by said embodiment and further preferred embodiments of the device.
    Type: Application
    Filed: June 23, 2010
    Publication date: May 31, 2012
    Applicant: SMS SIEMAG AKTIENGESELLSCHAFT
    Inventors: Rolf Franz, Christian Mengel, Olaf Norman Jepsen, Karl-Heinz Spitzer, Hellfried Eichholz
  • Publication number: 20120121452
    Abstract: The invention relates to a method for producing a hot strip from a triplex lightweight steel, wherein a melt is cast into a roughed strip and the latter is subsequently rolled into a hot strip. For this purpose, it is provided that the melt is cast in a horizontal strip casting facility under conditions of a calm flow and free of bending into a roughed strip in the range between 6 and 20 mm and is subsequently rolled into hot strip having a degree of deformation of at least 50%.
    Type: Application
    Filed: March 11, 2009
    Publication date: May 17, 2012
    Applicant: SALZGITTER FLACHSTAHL GMBH
    Inventors: Karl-Heinz Spitzer, Bianca Springub, Joachim Konrad, Hellfried Eichholz, Markus Schäperkötter, Zacharias Georgeou
  • Publication number: 20120093677
    Abstract: The invention relates to a method for producing a hot strip from transformation-free ferritic steel, wherein a melt is cast into a roughed strip and the latter is subsequently rolled into a hot strip. For this purpose, it is provided that the melt is cast in a horizontal strip casting facility under conditions of a calm flow and free of bending into a roughed strip in the range between 6 and 20 mm and is subsequently rolled into hot strip having a degree of deformation of at least 50%.
    Type: Application
    Filed: March 11, 2009
    Publication date: April 19, 2012
    Applicants: SMS SIEMAG AG, Salzgitter Flachstahl GMBH
    Inventors: Karl-Heinz Spitzer, Bianca Springub, Joachim Konrad, Hellfried Eichholz, Markus Schäperkötter
  • Patent number: 8151865
    Abstract: One embodiment is a method. The method includes providing a casting apparatus including a first chamber and a second chamber, wherein the first chamber is isolated from the second chamber. The method includes charging a superalloy composition into a crucible present in the first chamber and melting the superalloy composition in the crucible to form a molten superalloy composition. The method includes discharging the molten superalloy composition into a casting mold present in the second chamber; applying a positive pressure to the first chamber to create a first chamber pressure; and applying a vacuum to the second chamber to create a second chamber pressure, wherein the first chamber pressure is greater than the second chamber pressure. The method further includes casting at least one filament from the molten superalloy composition in the casting mold. An apparatus for casting a plurality of filaments is also provided.
    Type: Grant
    Filed: March 30, 2011
    Date of Patent: April 10, 2012
    Assignee: General Electric Company
    Inventors: Laurent Cretegny, Bernard Patrick Bewlay
  • Publication number: 20120040206
    Abstract: A device for the production of a metallic strip using a rapid solidification technology is specified, which device comprises a movable heat sink with an external surface onto which a melt is poured and on which the melt solidifies to produce the strip, and which device comprises a rolling device which can be pressed against the external surface of the movable heat sink while the heat sink is in motion.
    Type: Application
    Filed: July 13, 2011
    Publication date: February 16, 2012
    Applicant: Vacuumschmelze GmbH & Co. KG
    Inventor: Robert SCHULZ
  • Patent number: 8096345
    Abstract: A method and apparatus are provided for producing an amorphous ribbon by ejecting and rapidly solidifying molten alloy on a circumferential surface of a rapidly rotating cooling roll, wherein the cooling roll is polished online during amorphous ribbon production. When the circumferential surface of the cooling roll after peeling off the ribbon is polished using a polishing member, the circumferential surface of the cooling roll is polished continuously or intermittently across its lateral direction while differentiating the polishing mode in accordance with the surface properties.
    Type: Grant
    Filed: April 16, 2008
    Date of Patent: January 17, 2012
    Assignee: Nippon Steel Corporation
    Inventors: Shigekatsu Ozaki, Takeshi Imai
  • Publication number: 20110303386
    Abstract: A thin cast strip is formed having at least one microstructure selected from the group consisting of polygonal ferrite, acicular ferrite, Widmanstatten, bainite and martinsite, a surface roughness of less than 1.5 microns Ra and a scale thickness of less than about 10 microns by applying a mixture of water and oil on the work rolls of the hot rolling mill, passing the thin cast strip at a temperature of less than 1100° C. through the hot rolling mill while the mixture of oil and water is applied to the work rolls, and shrouding the thin cast strip from the casting rolls through the hot rolling mill in an atmosphere of less than 5% oxygen to form the thin cast strip.
    Type: Application
    Filed: August 23, 2011
    Publication date: December 15, 2011
    Applicant: Nucor Corporation
    Inventors: Walter N. Blejde, Jay Jon Ondrovic
  • Publication number: 20110293464
    Abstract: A stainless steel and a flat cold product produced therefrom, which can be easily produced in an economical manner. A steel according to the invention, in the cold-rolled state, has a microstructure with 5-15% by volume ?-ferrite and austenite as the remainder. It contains (in % by weight): C: 0.05-0.14%, Si: 0.1-1.0%, Mn: 4.0-12.0%, Cr: >17.5-22.0%, Ni: 1.0-4.0%, Cu: 1.0-3.0%, N: 0.03-0.2%, P: max. 0.07%, S: max. 0.01%, Mo: max. 0.5%, optionally one or more elements from the group consisting of Ti, Nb, B, V, Al, Ca, As, Sn, Sb, Pb, Bi, and H wherein Ti: max. 0.02%, Nb: max. 0.1%, B: max. 0.004%, V: max. 0.1%, Al: 0.001-0.03%, Ca: 0.0005-0.003%, As: 0.003-0.015%, Sn: 0.003-0.01%, Pb: max. 0.01%, Bi: max. 0.01%, H: max. 0.0025%, and remainder Fe and unavoidable impurities.
    Type: Application
    Filed: September 3, 2009
    Publication date: December 1, 2011
    Applicant: THYSSENKRUPP NIROSTA GMBH
    Inventors: Cornel Abratis, Lutz Ernenputsch, Wilfried Klos, Hans-Joachim Krautschick, Michael Sachtleber
  • Publication number: 20110253339
    Abstract: The method of casting near net-shape rectangular strands made of metal and the subsequent further processing the strands into metal strips includes applying pressure from above to the cast product (4) solidifying into the preliminary strip (5), preferably to its strip edges (6) by means of a pressure device (11) disposed at the end of the metal conveyor belt (7) and, additionally cooling of the bottom of the preliminary strip in a predetermined area directly behind the metal conveyor belt (7).
    Type: Application
    Filed: May 4, 2011
    Publication date: October 20, 2011
    Inventors: Jörg BAUSCH, Hans Jurgen Hecken
  • Publication number: 20110132568
    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: Application
    Filed: December 4, 2009
    Publication date: June 9, 2011
    Applicant: NUCOR CORPORATION
    Inventors: Mark Schlichting, Brian Bowman, Clark Ponder, Peter Woodberry
  • Publication number: 20110108228
    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: October 29, 2010
    Publication date: May 12, 2011
    Applicant: NUCOR CORPORATION
    Inventors: Rama Ballav Mahapatra, David W. McGaughey, Jay Jon Ondrovic, Tim Patterson, Mike Schueren
  • Publication number: 20110073272
    Abstract: A method of producing an aluminum substrate for a planographic printing plate is provided in which a recycled material including a used planographic printing plate having a planographic printing plate support obtained by treating an aluminum substrate is prepared, a recycled bare metal is obtained from the recycled material, and a new aluminum bare metal and a trace-metal master alloy of necessary amounts are mixed into the recycled bare metal to produce a new aluminum substrate.
    Type: Application
    Filed: September 27, 2010
    Publication date: March 31, 2011
    Applicant: FUJIFILM CORPORATION
    Inventors: Takeshi SERIKAWA, Masakazu OSADA
  • Publication number: 20110048668
    Abstract: A method for producing strip cast from a molten metal by means of a twin roll caster and a twin roll caster. The machine 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: Application
    Filed: February 20, 2009
    Publication date: March 3, 2011
    Applicant: THYSSENKRUPP NIROSTA GMBH
    Inventor: Andre d'Hone
  • Publication number: 20110036532
    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: Application
    Filed: February 20, 2009
    Publication date: February 17, 2011
    Applicant: NIPPON STEEL CORPORATION
    Inventor: Takashi Sato
  • Patent number: 7867343
    Abstract: In a rare earth magnet, an added heavy rare earth element RH such as Dy is effectively used without any waste, so as to effectively improve the coercive force. First, a molten alloy of a material alloy for an R-T-Q rare earth magnet (R is a rare earth element, T is a transition metal element, and Q is at least one element selected from the group consisting of B, C, N, Al, Si, and P), the rare earth element R containing at least one kind of element RL selected from the group consisting of Nd and Pr and at least one kind of element RH selected from the group consisting of Dy Tb, and Ho is prepared. The molten alloy is quenched, so as to produce a solidified alloy. Thereafter, a thermal treatment in which the rapidly solidified alloy is held in a temperature range of 400° C. or higher and lower than 800° C. for a period of not shorter than 5 minutes nor longer than 12 hours is performed.
    Type: Grant
    Filed: June 26, 2007
    Date of Patent: January 11, 2011
    Assignee: Hitachi Metals, Ltd.
    Inventors: Hiroyuki Tomizawa, Yuji Kaneko
  • Publication number: 20100288464
    Abstract: The invention relates to a casting roll (1) for the casting of metal strip in the casting gap between two casting rolls with variable separation which are parallel and which can be cooled. The casting roll comprises a roll axle (3) with a roll casing (2) surrounding said axle and with adjustable convexity of the peripheral surface of said roll casing during operation by means of a hydraulic pressure cushion (14). The rotatable roll axle (3) is designed with a cylinder (9), comprising a piston (10), on at least one side (5, 7) of the casting roll (1), and a power system (11) is provided for exertion via the pistons (10) on the pressure medium to influence the convexity of the roll casing (2).
    Type: Application
    Filed: November 8, 2007
    Publication date: November 18, 2010
    Inventor: Hans Streubel
  • Patent number: 7806165
    Abstract: In a method for making hot strips, a workable lightweight construction steel is used which in particular can easily be deep-drawn cold and includes the main elements Si, Al and Mn, with high tensile strength and good TRIP and/or TWIP characteristics. The mass % are as follows for C 0.04 to <1.0, Al 0.05 to <4.0, SI 0.05 to ?6.0; Mn 9.0 to ?30.0, the remainder being iron with the common incidental steel elements. The melt is cast in a horizontal strip casting unit, close to the final dimensions at calm flow and without bending to form a pre-strip in the range between 6 and 15 mm, and subsequently is fed for further processing.
    Type: Grant
    Filed: December 22, 2004
    Date of Patent: October 5, 2010
    Assignees: Salzgitter Flachstahl GmbH, Max-Planck-Institut Für Eisenforschung GmbH
    Inventors: Joachim Kroos, Karl-Heinz Spitzer, Georg Frommeyer, Volker Flaxa, Udo Brüx, Klaus Brockmeier
  • Publication number: 20100243196
    Abstract: Exemplary embodiments of the invention provide a casting apparatus for continuously casting a metal strip article (e.g. a twin-belt metal caster or a twin-block metal caster). The apparatus has a casting cavity defined between a pair of moving elongated opposed casting surfaces, and the casting cavity has an entrance and an exit aligned in a direction of casting. The casting cavity is also provided with a molten metal injector at its entrance, the injector having an internal metal channel including a downstream opening for introducing molten metal into the casting cavity, and a pair of side dams at each lateral side of the casting cavity for confining molten metal from the injector within the cavity. At least one of the side dams comprises an elongated element that is movable laterally relative to the direction of casting during a casting operation.
    Type: Application
    Filed: March 24, 2010
    Publication date: September 30, 2010
    Inventors: Daniel Godin, Rejean Leblanc
  • Publication number: 20100236747
    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: Application
    Filed: November 20, 2009
    Publication date: September 23, 2010
    Applicant: CASTRIP, LLC
    Inventors: Hiroyuki Otsuka, Hiroki Yoshizawa, Katsumi Nakayama, Kazuo Miyoshi
  • Publication number: 20100230070
    Abstract: A metal strip casting apparatus and method of casting continuous metal strip include assembling a pair of counter-rotatable casting rolls having casting surfaces positioned laterally forming a nip between for casting, and delivering molten metal through a delivery nozzle disposed above the nip to form a casting pool supported on the casting rolls. The delivery nozzle comprises at least one segment having a main portion and an end portion and an inner trough extending longitudinally through the main portion and into the end portion with end walls at opposite ends thereof, the inner trough communicating with outlets adjacent bottom portions formed in each segment adapted to deliver molten metal to a casting pool and the end portion having a reservoir portion having passages adapted to deliver molten metal to a casting pool.
    Type: Application
    Filed: March 13, 2009
    Publication date: September 16, 2010
    Applicant: NUCOR CORPORATION
    Inventors: Brian E. Bowman, Rama Ballav Mahapatra, Mike Schueren, Walter N. Blejde
  • Publication number: 20100215539
    Abstract: A hot rolled steel strip made by the steps including assembling a twin roll caster, forming a casting pool of molten steel of such composition that the cast strip produced comprises by weight, greater than 0.25% and up to 1.1% carbon, between 0.40 and 2.0% manganese, between 0.05 and 0.50% silicon, less than 0.01% aluminum, counter rotating the casting rolls to solidify metal shells and forming a steel strip, hot rolling the steel strip such that mechanical properties at 10% and 35% reduction are within 10% for yield strength, tensile strength and total elongation, and coiling the hot rolled steel strip at a temperature between 550 and 750° C. to provide a majority of the microstructure comprising pearlite, along with bainite and acicular ferrite. The steel may have a free oxygen content between 5 and 50 ppm or between 25 and 45 ppm.
    Type: Application
    Filed: February 19, 2010
    Publication date: August 26, 2010
    Applicant: NUCOR CORPORATION
    Inventors: Daniel Geoffrey EDELMAN, Christopher Ronald KILLMORE
  • Publication number: 20100215981
    Abstract: A hot rolled steel strip made by the steps including assembling a twin roll caster, forming a casting pool of molten steel having a free oxygen content between 20 and 75 ppm and having a composition such that the cast strip comprises by weight, less than 0.25% carbon, between 0.9 and 2.0% manganese, between 0.05 and 0.50% silicon, greater than 0.01% and less than or equal to 0.15% phosphorus, and less than 0.01% aluminum, counter rotating the casting rolls forming the steel strip, hot rolling the strip such that mechanical properties at 10% and 35% reduction are within 10% for yield strength, tensile strength and total elongation, and coiling the strip at a temperature between 300 and 700° C. to provide a majority of the microstructure comprising bainite and acicular ferrite. Alternatively, the steel may have between 0.20 and 0.60% copper and manganese as low as 0.08%.
    Type: Application
    Filed: February 19, 2010
    Publication date: August 26, 2010
    Applicant: NUCOR CORPORATION
    Inventors: Daniel Geoffrey EDELMAN, Christopher Ronald KILLMORE, Mary E. ALWIN-BECKER
  • Publication number: 20100212855
    Abstract: The invention relates to a casting process for an aluminum alloy containing at least about 0.1% of Mg and/or at least about 0.1% of Li in which a liquid surface of said alloy is put into contact with a dried gas including at least about 2% of oxygen by volume and with a water partial pressure lower than about 150 Pa throughout most of the solidification process. The invention makes it possible to cast the most oxidable aluminum alloys, in particular aluminum alloys containing magnesium and/or lithium, without using additives such as beryllium and/or calcium and without using expensive devices and/or gases, to obtain cast ingots free from surface defects and pollution, in complete safety.
    Type: Application
    Filed: February 16, 2010
    Publication date: August 26, 2010
    Applicants: ALCAN RHENALU, ALCAN ALUMINIUM VALAIS
    Inventors: Guillaume Bes, Robert Rey-Flandrin, Olivier Ribaud, Stephane Vernede
  • Publication number: 20100132911
    Abstract: In the casting close-to-the final dimension of rectangular strands made of metal and the subsequent further processing thereof into metal strips according to the DSC method (direct strip casting) in a horizontal continuous casting installation the cast product (4) is deformed during the solidification thereof into the preliminary strip (5) due to uneven heat dissipation because the top of the strip is cooled only by convection of ambient air and by heat radiation, while the bottom of said strip is in direct contact with a cooled metal conveyor belt (7). In this manner, the initially complete contact between the cast product (4) and the metal conveyor belt (7) is lost and the strip edges of the cast product arch upwards.
    Type: Application
    Filed: August 1, 2008
    Publication date: June 3, 2010
    Inventors: Joerg Bausch, Hans Juergen Hecken
  • Publication number: 20100132912
    Abstract: Apparatus for continuously casting metal strip includes a pair of counter-rotatable casting rolls laterally positioned to form a nip there between through which thin strip can be cast, a pair of confining side dams adjacent the ends of the casting rolls capable of confining a casting pool of molten metal supported on the casting rolls above the nip, each side dam having a surface capable of contacting the molten metal of the casting pool, with unraised portions and raised portions to form troughs with the unraised portions as base between the raised portion of the side dam and the casting surfaces of the casting rolls to guide the flow of molten metal, and a metal delivery system disposed above the nip and capable of discharging molten metal to form the casting pool supported on the casting rolls.
    Type: Application
    Filed: November 24, 2009
    Publication date: June 3, 2010
    Applicant: NUCOR CORPORATION
    Inventors: Rama Ballav MAHAPATRA, Brian E. BOWMAN
  • Patent number: 7722726
    Abstract: The invention provides a method for producing alloy flakes for rare earth sintered magnets, which makes uniform the intervals, size, orientation, and shape of the R-rich region and the dendrites of the 2-14-1 phase, which inhibits formation of chill, and which produces flakes that are pulverized into powder of a uniform particle size in the pulverization step in the production of a rare earth sintered magnet, and that are pulverized into powder compactable into a product with a controlled shrink ratio, and alloy flakes for a rare earth sintered magnet obtained by the method, and a rare earth sintered magnet having excellent magnetic properties.
    Type: Grant
    Filed: March 31, 2005
    Date of Patent: May 25, 2010
    Assignee: Santoku Corporation
    Inventors: Kazumasa Shintani, Ryo Murakami, Kazuhiko Yamamoto
  • Publication number: 20100108286
    Abstract: Apparatus for continuously casting metal strip includes a pair of counter-rotatable casting rolls laterally positioned to form a nip there between through which thin strip can be cast, a pair of confining side dams adjacent the ends of the casting rolls capable of confining a casting pool of molten metal supported on the casting rolls and formed on the casting surfaces above the nip, a metal delivery system disposed above the nip and capable of discharging molten metal to form the casting pool supported on the casting rolls, side dam actuators each capable of applying cyclical axial force to the side dams without leakage, and a control system capable of actuating at least one side dam actuator to cyclically vary the apply force of the side dam against the ends of the casting rolls during a casting campaign.
    Type: Application
    Filed: November 6, 2008
    Publication date: May 6, 2010
    Applicant: NUCOR CORPORATION
    Inventors: Harold Bradley Rees, Nikolco S. Nikolovski
  • Patent number: 7695574
    Abstract: A method for producing an RE-containing alloy represented by formula R(T1?xAx)13?y (wherein R represents Ce, etc.; T represents Fe, etc.; and A represents Al, etc; 0.05?x?0.2; and ?1?y?1) including a melting step of melting alloy raw materials at 1,200 to 1,800° C.; and a solidification step of rapidly quenching the molten metal produced through the above step, to thereby form the first RE-containing alloy, wherein the solidification step is performed at a cooling rate of 102 to 104° C./second, as measured at least within a range of the temperature of the molten metal to 900° C.; and an RE-containing alloy, which is represented by a compositional formula of RrTtAa (wherein R and A represent the same meaning as above, T represents Fe, etc.; 5.0 at. %?r?6.8 at. %, 73.8 at. %?t?88.7 at. %, and 4.6 at. %?a?19.4 at. %) and has an alloy microstructure containing an NaZn13-type crystal structure in an amount of at least 85 mass % and ?-Fe in an amount of 5-15 mass % inclusive.
    Type: Grant
    Filed: October 22, 2003
    Date of Patent: April 13, 2010
    Assignee: Showda Denko K.K.
    Inventor: Kenichiro Nakajima
  • Publication number: 20100078146
    Abstract: The invention relates to a method for producing a cast steel strip of preferably hot crack-sensitive or hot-brittle steel quality by means of a strip casting plant and to a strip casting plant for carrying out this method. In this case, steel melt is conducted into a melt space formed by two casting rolls and two sideplates, slab shells are formed in the melt space on cooled surface areas of the casting rolls and are brought together in the strip forming cross section between the casting rolls to form an at least partly solidified steel strip, the cast steel strip is then guided along the surface area of one of the two casting rolls from a vertical casting direction into an essentially horizontal transport direction, and the cast steel strip is supplied essentially horizontally on a transport device to a strip winding device and is wound there into a coil.
    Type: Application
    Filed: December 3, 2009
    Publication date: April 1, 2010
    Inventors: Gerald HOHENBICHLER, Gerald ECKERSTORFER, Michael ZAHEDI
  • Publication number: 20100032128
    Abstract: A method of continuously casting thin strip dynamically controlling roll casting surface configuation by controlling the temperature of water flowing through the longitudinal water flow passages in a cyclindrical tube thickness of no more than 80 millimeters of counter rotated casting rolls, and varying the speed of the casting rolls with attenuation of the ends of the casting rolls with a casting roll drive system responsive to electrical signals received from sensors during a casting campaign.
    Type: Application
    Filed: August 5, 2008
    Publication date: February 11, 2010
    Applicant: NUCOR CORPORATION
    Inventors: Mark Schlichting, Walter N. Blejde, Mike Schueren, Rama Ballav Mahapatra
  • Publication number: 20100000705
    Abstract: An apparatus for continuously casting thin strip includes a caster having a pair of casting rolls having a nip there between capable of delivering cast strip downwardly from the nip and an first enclosure capable of forming a protective atmosphere into which the strip can be formed in loop to extend over a plurality of rollers into pinch rolls with the strip having a strain of less than 0.4%, which may be provided by a plurality of rollers at entry of the strip into the pinch rolls to carry the strip into the pinch rolls, with at least a first entry roller having a diameter between 200 and 650 millimeters and being below a majority of other rollers.
    Type: Application
    Filed: July 3, 2008
    Publication date: January 7, 2010
    Applicant: Nucor Corporation
    Inventors: Andrew Edward Dixon, Gary McQuillis, Rama Ballav Mahapatra, Leigh Wolley
  • Publication number: 20090314458
    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: June 24, 2008
    Publication date: December 24, 2009
    Applicant: NUCOR CORPORATION
    Inventors: Jay Jon ONDROVIC, Eric FULBRIGHT, Katsumi NAKAYAMA
  • Publication number: 20090314459
    Abstract: A method of continuously casting metal strip may include assembling a pair of casting rolls having casting surfaces laterally positioned to form a nip there between through which thin cast strip may be cast, a metal supply system capable of delivering molten steel above the nip, the casting rolls having a crown shape so that edge portions of the cast strip within 50 millimeters of edge of the cast strip have a higher temperature than the cast strip in center portions of the strip width and controlled edging up, forming a casting pool of molten steel supported on the casting surfaces above the nip and controlling side dams adjacent the ends of the nip to confine the casting pool, and forming a cast strip such that the edge portions of the cast strip within 50 millimeters of each edge of the cast strip is of a higher temperature than the strip in the center portions of the strip width.
    Type: Application
    Filed: June 24, 2008
    Publication date: December 24, 2009
    Applicant: NUCOR CORPORATION
    Inventors: Walter N. Blejde, Mark Schlichting
  • Publication number: 20090288798
    Abstract: An apparatus and method for continuously casting thin steel strip includes a pair of counter-rotatable casting rolls having a nip there between capable of delivering cast strip downwardly from the nip, a metal delivery system capable of forming a casting pool supported on casting surfaces of the casting rolls above the nip with side dams adjacent the ends of the nip to confine the casting pool, and a hot rolling mill having work rolls with work surfaces forming a gap between them through which hot strip delivered from the casting rolls is rolled, the work rolls having work surfaces relating to the desired strip profile across the work rolls. Misting jets may be in intervals along the path of the cast strip exiting from the hot rolling mill to form a cooling zone, the misting jets capable of directing toward surfaces of the cast strip a mixture of gas and water having a ratio of gas over water between 9 and 90 to cool the cast strip at more than 1.6° C. per liter of water used.
    Type: Application
    Filed: May 23, 2008
    Publication date: November 26, 2009
    Applicant: NUCOR CORPORATION
    Inventors: Jay Jon Ondrovic, Eric Fulbright, Katsumi Nakayama