Molten Metal Shaped By Electromagnetic Field Patents (Class 164/467)
  • Patent number: 12151285
    Abstract: Systems and methods may utilize magnetic rotors to heat molten metal in the corner regions of a mold during casting (e.g., casting of an ingot, billet, or slab). The magnetic rotors are positioned adjacent to the corners of the mold and heat the molten metal in the corner region to increase the temperature of the molten metal adjacent the corners. The increased temperature of the molten metal in the mold corners can prevent intermetallics from forming in the molten metal or otherwise reduce such formation.
    Type: Grant
    Filed: February 26, 2021
    Date of Patent: November 26, 2024
    Assignee: Novelis Inc.
    Inventors: Brent Opdendries, Robert Bruce Wagstaff, Ravindra Tarachand Pardeshi, Samuel Robert Wagstaff
  • Patent number: 10689747
    Abstract: An evaporation device including an evaporation chamber and mask supporting coils is provided. The mask supporting coils include at least a first coil and a second coil disposed opposite to each other. A mask disposing area is disposed between the first coil and the second coil. A first current is provided in the first coil, and a second current is provided in the second coil, so that a magnetic field with a homogeneous magnetic field strength is generated in the mask disposing area.
    Type: Grant
    Filed: April 14, 2017
    Date of Patent: June 23, 2020
    Assignees: SHANGHAI TIANMA MICRO-ELECTRONICS CO., LTD., TIANMA MICRO-ELECTRONICS CO., LTD.
    Inventors: Yaoyang Liu, Jian Xu
  • Patent number: 10022787
    Abstract: A system and method for sensing the position of an ingot within a segmented mold of a vacuum metallurgical system. An inductive sensory system measures the variations in current between a power source and load of an induction heating coil. The system and method is particularly suitable for determining the position of an ingot within a melting system mold where the mold has a relatively reduced or small cross-sectional area.
    Type: Grant
    Filed: August 24, 2015
    Date of Patent: July 17, 2018
    Assignee: Retech Systems, LLC
    Inventors: Robert E. Haun, Paul G. Meese
  • Patent number: 9266167
    Abstract: An oxide control system (apparatus and process) for use in a continuous casting mold for controlling, directing and managing the flow of metal oxides which develop on the molten metal surface within the oxide dam. This invention discloses a new oxide dam which provides predetermined outlets which control and manage the flow of metal oxides to locations within the mold cavity and resulting castpart where oxides are acceptable, yet directing the metal oxides away from locations where the oxides are unacceptable on the resulting castpart.
    Type: Grant
    Filed: February 24, 2015
    Date of Patent: February 23, 2016
    Assignee: Wagstaff, Inc.
    Inventor: Craig Shaber
  • Publication number: 20150034269
    Abstract: A pulling-up-type continuous casting apparatus that lets molten metal solidify while pulling up a drawing section for drawing the molten metal from a molten-metal surface of the molten metal held in a holding furnace, and thereby shapes the molten metal, includes means for applying a non-contact force to held molten metal, the held molten metal being molten metal that has been drawn from the molten-metal surface by the drawing section but has not solidified yet.
    Type: Application
    Filed: July 3, 2014
    Publication date: February 5, 2015
    Applicant: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Fumiki TANAHASHI, Hiroyuki IKUTA, Naoaki SUGIURA
  • Patent number: 8371021
    Abstract: A process of manufacturing segments, an anisotropic direction of which is continuously changed in a plane vertically by a uniform magnetic field maintained in a constant direction and a process of arranging a plurality of segments on a circumference, extruding the segments in a ring shape by rheology based on the viscous deformation of the segments, from one thrust-direction end surface of the segments, and subsequently compressing the segments from both thrust-direction end surfaces of the segments are necessarily included. A ring magnet, anisotropy of which is controlled in a continuous direction, is provided, and a source for generating a static magnetic field has energy density (BH) max?160 to 180 kJ/m3.
    Type: Grant
    Filed: May 20, 2009
    Date of Patent: February 12, 2013
    Assignee: Panasonic Corporation
    Inventors: Fumitoshi Yamashita, Kiyomi Kawamura, Yukihiro Okada, Hiroshi Murakami
  • Patent number: 8177925
    Abstract: In a high-tensile steel plate according to the invention, the carbon equivalent Pcm represented in Expression (1) is from 0.180% to 0.220%, the surface hardness is a Vicker's hardness of 285 or less, the ratio of a Martensite Austenite constituent in the surface layer is not more than 10%, the ratio of a mixed structure of ferrite and bainite inside beyond the surface layer is not less than 90%, the ratio of the bainite in the mixed structure is not less than 10%, the thickness of the lath of bainite is not more than 1 ?m, the length of the lath is not more than 20 ?m, and the segregation ratio as the ratio of the Mn concentration in the center segregation part relative to the Mn concentration at a part in a depth equal to ¼ of the thickness of the plate from the surface is not more than 1.3. Pcm=C+Si/30+(Mn+Cu+Cr)/20+Ni/60+Mo/15+V/10+5B . . . (1) where the element symbols in Expression (1) represent the % by mass of the respective elements.
    Type: Grant
    Filed: March 8, 2006
    Date of Patent: May 15, 2012
    Assignee: Sumitomo Metal Industries, Ltd.
    Inventors: Nobuaki Takahashi, Masahiko Hamada, Shuji Okaguchi, Akihiro Yamanaka, Ichirou Seta
  • Publication number: 20100059197
    Abstract: The present invention provides a continuous casting method of molten metal using electromagnetic force to improve the cast slab surface properties and reduce the nonmetallic inclusions and bubbles trapped inside the cast slab. An alternating current is run through an electromagnetic coil 4 arranged around a casting mold 1 so as to surround a casting space 8 to control the meniscus shape to improve the cast slab surface properties, the discharge ports 6 of a submerged entry nozzle 5 are made upward oriented, and the direction of the discharge flow 14 from the discharge ports 6 is made one to above the intersection A of the casting mold short side and meniscus. Due to this, the nonmetallic inclusions and bubbles in the discharge flow are absorbed by the continuous casting mold flux of the meniscus 11 at the part of the meniscus reached.
    Type: Application
    Filed: December 3, 2007
    Publication date: March 11, 2010
    Inventors: Takehiko Toh, Masahiro Tani, Kazuhisa Tanaka, Shinichi Fukunaga
  • Patent number: 7305271
    Abstract: A computer program product for controlling an apparatus for continuous casting of metals. The computer program product includes a computer readable medium and computer program instructions recorded on the computer readable medium executable by a processor for performing the steps of supplying a molten metal to a casting mold with an elongated horizontal cross section, applying at least one magnetic field to the to exert an influence on the movement of the molten metal, generating a stationary magnetic field with a variable strength across the elongated cross section of the casting mold in the vicinity of, or below, where the molten metal is supplied, and generating a variable magnetic field in an area of the upper surface of molten metal in a region that is centrally located with respect to the elongated cross section and in the vicinity of where the molten metal is supplied.
    Type: Grant
    Filed: July 29, 2005
    Date of Patent: December 4, 2007
    Assignee: ABB AB
    Inventor: Jan-Erik Eriksson
  • Patent number: 7195054
    Abstract: The reliable sealing of a gap (10), between a roller front face (7) and a side seal (3) on a roller-strip-casting machine is achieved by the generation of an electrical eddy field in the region of the gap (10), such as to produce a local gradient field (13). The eddy currents generated in the metal melt for casting prevent the ingress of the metal into the gap (10) or eject the metal from the gap (10). The risk of escape of liquid metal is essentially eliminated and the formation of ridges on the narrow edge of the metal strip avoided.
    Type: Grant
    Filed: September 13, 2002
    Date of Patent: March 27, 2007
    Assignees: SMS Demag AG, Main Management Inspiration AG
    Inventors: Heinrich Marti, Jacques Barbé, Dominique Salathè, Alfred Koch
  • Patent number: 7037462
    Abstract: An apparatus for transferring molten metal from a melting furnace to a casting furnace is provided. A sensing and control system for the transfer of molten metal from a transfer furnace to a casting furnace is also described. The combination of the transfer apparatus with the sensing and control system provides for the introduction of reduced oxide molten metal into a casting furnace.
    Type: Grant
    Filed: October 14, 2004
    Date of Patent: May 2, 2006
    Assignee: Alcoa Inc.
    Inventors: Marshall A. Klingensmith, Michael J. Kinosz, Rick A. Borns
  • Publication number: 20040244939
    Abstract: The invention concerns a method for producing a metal strip, whereby molten metal is continuously poured between two casting rolls (1, 2) of a strip casting machine with rolls. Above the molten bath (4) and respectively proximate to the molten bath (5)/casting rolls (1, 2) transition surface a rotating magnetic field is produced which generates, in the molten metal, local turbulent flows, so that a surface current is formed in said molten metal, which surface current is directed by the casting rolls (1, 2) towards the central plane (E) of the molten bath (4), that is towards the plane for output of the metal strip (8), thereby enabling to largely prevent supernatant impurities at the surface of the molten bath and oxides located on the surface of the rolls from being deposited, and the molten metal particles from being prematurely solidified.
    Type: Application
    Filed: March 9, 2004
    Publication date: December 9, 2004
    Inventors: Heinrich Marti, Jacques Barbe, Dominique Salathe, Alfred Koch
  • Publication number: 20040050530
    Abstract: A method and apparatus for electromagnetic confinement of molten metal during strip casting of molten metal between two belts that wrap around entry pulleys to create a molding zone. The molten metal is delivered to a curved surface of each belt to form strip metal. The molten metal is contained within the molding zone by a pair of edge containment devices. The edge containment devices have a C-shaped magnetic member with an upper pole having an upper pole face and a lower pole having a lower pole face. Current flows through a coil wrapped around a core region of the magnetic member to create magnetic lines of force that flow between the upper pole face and the lower pole face. The C-shaped magnetic member is positioned such that magnetic lines of force pass through the edges of the two belts and the molten metal, and keep the molten metal within the molding zone.
    Type: Application
    Filed: June 13, 2003
    Publication date: March 18, 2004
    Inventor: Jagan Bhamidipati
  • Patent number: 6520246
    Abstract: Device and corresponding method for the continuous casting of molten materials, comprising a vertical duct having the shape of a funnel made of refractory material for receiving molten material, and a second duct where the molten material is cooled off, the two ducts being set one on top of the other and being axially aligned. The molten material is injected into the channel, around a stretch of which electromagnetic means are set for generating magnetic forces on the molten material, the said means consisting of a plurality of windings of electrically conductive material and of a ferromagnetic core and may be electrically supplied to produce a magnetic flux along the direction of the channel, thus producing a set of forces acting on the molten material which are directed orthogonally with respect to the direction of the said magnetic flux so as to maintain detachment of the outer surface of the molten material from the walls of the channel.
    Type: Grant
    Filed: February 14, 2001
    Date of Patent: February 18, 2003
    Assignee: Danieli & C. Officine Meccaniche S.p.A.
    Inventors: Alfredo Poloni, Milorad Pavlicevic, Anatoly Kolesnichenko, Andrea Codutti
  • Patent number: 6453983
    Abstract: A device for casting strips of metal, in particular steel, in twin-roll continuous casting machines having counter-rotating casting rolls. Liquid metal is fed into a space bound by two side walls, between the rotating casting rolls. The gaps, which are formed between the side walls. The rotating casting rolls are sealed by a sealing device for generating electrodynamic forces, that, following the gap profile, act essentially parallel to the casting-roll surface. The sealing device is constructed so as to continuously adapt the electrodynamic forces to the metallostatic pressure or approximately to the metallostatic pressure of the liquid metal.
    Type: Grant
    Filed: January 12, 2000
    Date of Patent: September 24, 2002
    Assignee: Siemens Aktiengesellschaft
    Inventors: Meinolf Schelte, Franz Fikus
  • Patent number: 5941298
    Abstract: An oscillating mold for continuously casting slabs, preferably of steel, has long side walls and short side walls freely movable relative to the long side walls, and an immersion outlet. The long side walls define a center-symmetrical casting funnel having a funnel shape which is configured such that the distance between the long side walls in the casting funnel is reduced toward the outlet end of the mold and that in the meniscus area and at least along the length of the immersion outlet the funnel shape corresponds to or follows the outer cross-sectional size of the immersion outlet. The long side walls have adjacent the casting funnel a shape which is linear and planar over the mold length and center-symmetrical and concave transversely of the mold length.
    Type: Grant
    Filed: March 12, 1998
    Date of Patent: August 24, 1999
    Assignee: SMS Schloemann-Siemag Aktiengesellschaft
    Inventor: Fritz-Peter Pleschiutschnigg
  • Patent number: 5848635
    Abstract: A continuous casting device includes a pair of cooling rolls (1, 2) that rotate in opposite directions to each other. A pair of side weirs (11) have inner surfaces (11a) that covers the end surfaces (1a, 2a) of the cooling rolls (1, 2) and circular surfaces (12b) that covers the peripheral surfaces (1b, 2b) of the cooling rolls (1, 2). At least one of the side weirs (11) is movable in an axial direction of the cooling rolls (1, 2). The continuous casting device also includes electromagnets for forming a magnetic flux in a direction parallel with a contact surface of the side weirs (11) with the molten metal (4) the contact surface extending along the peripheral surfaces (1b, 2b) of the cooling rolls (1, 2) at the portions opposite to the peripheral surfaces (1b, 2b) of the cooling rolls (1, 2) of the side weirs (11).
    Type: Grant
    Filed: July 25, 1996
    Date of Patent: December 15, 1998
    Assignee: Mitsubishi Jukogyo Kabushiki Kaisha
    Inventors: Tatsufumi Aoi, Noriyuki Kawada, Hiroshi Nakajima, Kenichi Unoki, Motomi Nakashima, Youichi Wakiyama
  • Patent number: 5695001
    Abstract: An electromagnetic dam is employed to confine a vertically disposed pool of molten metal at the open end of the space between two counter-rotating, casting rolls in a continuous strip caster. The dam comprises three magnetic flux conductors each having a pair of spaced-part surfaces adjacent to and facing in the direction of the pool of molten metal. Two such surfaces of a first flux conductor define a relatively wide air gap adjacent the top part of the molten metal pool; two such surfaces of a second flux conductor define a relatively narrow air gap adjacent the bottom part of the pool, at the nip between the casting rolls; and two pool-facing surfaces of a third magnetic flux conductor are disposed between the spaced-apart surfaces of the first flux conductor in the wide air gap.
    Type: Grant
    Filed: March 20, 1996
    Date of Patent: December 9, 1997
    Assignee: Inland Steel Company
    Inventors: Kenneth E. Blazek, Walter F. Praeg
  • Patent number: 5513692
    Abstract: An electromagnetic confining apparatus prevents the escape of molten metal through the open end of a vertically extending gap between two horizontally extending members, such as two counter-rotating rolls of a continuous strip caster. The molten metal is located between the two members. The apparatus includes a vertically disposed coil through which flows a time-varying electric current to generate a first horizontal magnetic field adjacent the open end of the gap. A time-varying conduction current is directed through the pool of molten metal adjacent the open end of the gap, in a vertical direction opposite that of the current flow in the adjacent portion of the coil. The flow of conduction current through the molten metal pool generates a second horizontal magnetic field adjacent the open end of the gap and which augments the first horizontal magnetic field to provide a repulsive body pressure which urges the pool of molten metal inwardly away from the open end of the gap.
    Type: Grant
    Filed: March 31, 1994
    Date of Patent: May 7, 1996
    Assignee: Inland Steel Company
    Inventor: Howard L. Gerber
  • Patent number: 5495886
    Abstract: A magnetic confining method and apparatus in accordance with the present invention generates, adjacent the open side of the roller gap, a primary vertical magnetic field (a) resulting from direct current (D.C.) or alternating current (A.C.) flowing through a coil surrounding a core of a primary electromagnet or (b) resulting from an induced horizontal current flowing through roller shafts, roller sleeves and the edge of the molten metal. There are one or more additional vertical magnetic fields, that serve to concentrate and/or shape the primary magnetic field, and the vertical fields combine to provide electromagnetic forces sufficient for containment of the molten metal in the vertical gap between the rollers. Both the primary vertical field and one or more additional or secondary vertical magnetic fields extend through the open side of the gap to the molten metal in the gap.
    Type: Grant
    Filed: April 29, 1994
    Date of Patent: March 5, 1996
    Assignee: Inland Steel Company
    Inventor: Anatoly F. Kolesnichenko
  • Patent number: 5487421
    Abstract: A strip casting apparatus comprises a pair of counter-rotating casting rolls having a vertically extending, arcuately tapering gap therebetween for containing a pool of molten metal. The gap has an open end near which is an electromagnetic dam for preventing the escape of molten metal through that open end. Various expedients are provided for improving the operation and efficiency of the dam. In one embodiment, projections of magnetic material extend from the dam in mutually overlapping relation with peripheral lips on the casting rolls. In another embodiment, the dam has a confining coil with a front surface (a) facing the open end of the gap and (b) having an arcuately tapering contour conforming to the contour of the gap.
    Type: Grant
    Filed: June 22, 1994
    Date of Patent: January 30, 1996
    Assignee: Inland Steel Company
    Inventor: Howard L. Gerber
  • Patent number: 5469911
    Abstract: A method for improving the surface quality of electromagnetically cast aluminum alloy ingot includes the addition of an effective amount of calcium prior to the ingot head of an ingot mold of an electromagnetic casting station. The addition of calcium is regulated such that the aluminum alloy cast ingot contains a maximum of 0.05 weight percent calcium. Addition of the calcium prior to the ingot head produces a cast ingot which is generally free of surface imperfections on side surfaces thereof so that the cast ingot can be directly worked or rolled to a desired gauge without a scalping or surface conditioning treatment. The calcium can be added during melting, alloying, filtering, degassing or transferring of the molten aluminum prior to casting. An electromagnetically cast aluminum alloy ingot is produced, preferably an AA5182 can end stock alloy, which is essentially free of surface imperfections to permit direct rolling or other working of the cast ingot without a surface conditioning treatment.
    Type: Grant
    Filed: April 12, 1994
    Date of Patent: November 28, 1995
    Assignee: Reynolds Metals Company
    Inventor: Gary B. Parker
  • Patent number: 5439046
    Abstract: In a continuous casting process in a twin-roll system, a gap is provided between end faces of cooling rolls and side gates or between the circumferential surface of the cooling rolls and side faces of the side gates. A DC magnetic field is applied to the molten metal in a pouring basin in the vicinity of the side gates in a vertical direction to the molten metal and direct current (DC) is intensively fed to the end portion of the molten metal to generate an electromagnetic force mainly at a corner portion of the molten metal. The electromagnetic force is directed toward the center portion of the molten metal, and thereby prevents leakage of molten metal from the gap, penetration into the gap or the formation of hot bands. In order to intensively feed the direct current to the end portion of the molten metal, an electrode is placed in sliding contact with the end face of the cooling roll.
    Type: Grant
    Filed: August 18, 1993
    Date of Patent: August 8, 1995
    Assignee: Nippon Steel Corporation
    Inventors: Kenichi Miyazawa, Takehiko Toh, Toshiaki Mizoguchi, Yoshiyuki Ueshima
  • Patent number: 5390725
    Abstract: The casting machine features a mold (10), a deflection plate (66) with a lower surface (80) for guiding cooling water (20) which is sprayed at high pressure and/or a supporting plate with an upper surface for guiding cooling water (20) flowing at low pressure. Both surfaces for guiding the cooling water (20) are made of insulating material. The electromagnetic shield (18, 76) is cooled on the inside at least in the active region. The mold housing (32) is preferably made out of a perforated sheet (34) which has been bent several ways. The active region of the shield is preferably in the form of a U-shaped or V-shaped shielding sheet and features an insert or coating for reducing the magnetic field of the inductor (12) increasingly in the upwards direction. The water-jetted surface (80) for guiding the cooling water is moved continuously backwards and forwards and/or tilted in a given rhythmic manner.
    Type: Grant
    Filed: September 20, 1993
    Date of Patent: February 21, 1995
    Assignee: Alusuisse-Lonza Services Ltd.
    Inventors: Georges Berclaz, Bertrand Carrupt, Miroslaw Plata
  • Patent number: 5385201
    Abstract: An apparatus for confining molten metal with a horizontal alternating magnetic field. In particular, this invention employs a magnet that can produce a horizontal alternating magnetic field to confine a molten metal at the edges of parallel horizontal rollers as a solid metal sheet is cast by counter-rotation of the rollers.
    Type: Grant
    Filed: July 23, 1993
    Date of Patent: January 31, 1995
    Assignee: ARCH Development Corporation
    Inventor: Walter F. Praeg
  • Patent number: 5279350
    Abstract: A magnetic confining apparatus prevents the escape of molten metal through the open side of a vertically extending gap between two horizontally separated members and in which the molten metal is located. The apparatus includes a current conducting coil for generating a horizontal magnetic field and non-magnetic fins for concentrating the current in the surface of the coil which is closest to the open side of the gap. The magnetic field generated by the apparatus extends through the open side of the gap and exerts a confining pressure against the molten metal in the gap.
    Type: Grant
    Filed: March 22, 1993
    Date of Patent: January 18, 1994
    Assignee: Inland Steel Company
    Inventor: Howard L. Gerber
  • Patent number: 5251685
    Abstract: Molten metal, in the gap between two counter-rotating rolls of a continuous strip-casting apparatus, is prevented from leaking out of an open side of the gap by a magnetic confining apparatus which produces a horizontal magnetic field extending through the open side of the gap. The apparatus includes structure for confining the magnetic field substantially to the open side of the gap and for preventing dissipation of the magnetic field away from the open side of the gap.
    Type: Grant
    Filed: August 5, 1992
    Date of Patent: October 12, 1993
    Assignee: Inland Steel Company
    Inventor: Walter F. Praeg
  • Patent number: 5197534
    Abstract: Molten metal, in the gap between two counter-rotating rolls of a continuous strip-casting apparatus, is prevented from leaking out of an open side of the gap by a magnetic confining apparatus employing the proximity effect to produce a horizontal magnetic field extending through the open side of the gap. The apparatus includes structure for confining the magnetic field substantially to the open side of the gap and for preventing dissipation of the magnetic field away from the open side of the gap.
    Type: Grant
    Filed: June 22, 1992
    Date of Patent: March 30, 1993
    Assignee: Inland Steel Company
    Inventors: Howard L. Gerber, Richard T. Gass
  • Patent number: 5184667
    Abstract: During electromagnetic continuous casting of rolled bars from aluminum/magnesium alloys defects in the form of vertical ripples and oxide deposits arise on the bar surface as a consequence of the greatly increased rate of oxidation at the melt surface due to the presence of magnesium in the melt, which defects make it necessary to mill over the rolled surfaces of the bar in the case of stringent requirements with respect to the surface quality of rolled products. The said surface defects can be prevented using an oxide barrier which dips into the melt head, extends at least over the longitudinal sides of the inductor and is arranged approximately parallel to and at a distance from said longitudinal sides, which oxide barrier is moved backwards and forwards horizonally in its longitudinal direction.
    Type: Grant
    Filed: October 28, 1991
    Date of Patent: February 9, 1993
    Assignee: Alusuisse-Lonza Services Ltd.
    Inventors: Bertrand Carrupt, Maurice Constantin, Michel Ebener
  • Patent number: 5052470
    Abstract: A process for continuous production of an extruded section, in particular of aluminum or an aluminum alloy, wherein a prefabricated rod is fed to a die by means of a friction wheel and extruded through the die. The rod is formed by casting the molten metal in an electromagnetic mold and the solidified rod fed directly to the friction wheel the circumference of which advances the rod at the same speed as the rate of casting of the rod in the electromagnetic mold. The process enables high quality extruded sections to be produced at a economic cost.
    Type: Grant
    Filed: October 16, 1989
    Date of Patent: October 1, 1991
    Assignee: Swiss Aluminum Ltd.
    Inventor: Kurt Buxmann
  • Patent number: 5042559
    Abstract: The trouble free operation of a continuous casting process utilizing a moving electromagnetic field for levitation requires information of sufficient accuracy concerning the position and extent of the solidification front inside the continuous casting die. The method and structure according to the invention for monitoring the solidification process employs signals from at least two sensor coils arranged concentrically around the continuous casting die. These signals are fed to a measuring transducer and processed in an appropriate manner. The configuration of the sensor coils inside the levitation coil generating the moving field is particularly preferred.
    Type: Grant
    Filed: February 21, 1990
    Date of Patent: August 27, 1991
    Assignee: KM-Kabelmetal Aktiengesellschaft
    Inventor: Andreas Krause
  • Patent number: 4989666
    Abstract: In a process for electromagnetic casting of round and hollow ingots, in particular such of aluminum and aluminum alloys, the ingot (7) is rotated about its longitudinal axis (x) during casting. This is achieved by way of a rotatable dummy base (6). With that the metal feed and cooling of the ingot is made symmetrical and, as a result, a more uniform shape is obtained and a more uniform cell structure across the ingot cross-section. In order to promote a stronger stirring effect, a stationary stirrer (8) dipping into the molten part of the ingot (7) can be provided attached to the metal inlet system (3).
    Type: Grant
    Filed: November 13, 1989
    Date of Patent: February 5, 1991
    Assignee: Swiss Aluminium Ltd.
    Inventor: Jean-Claude Weber
  • Patent number: 4982796
    Abstract: An apparatus and method adapted to confine a molten metal to a region by means of an alternating electromagnetic field. As adapted for use in the present invention, the alternating electromagnetic field given by B.sub.y =(2.mu..sub.o .rho.gy).sup.1/2 (where B.sub.y is the vertical component of the magnetic field generated by the magnet at the boundary of the region; y is the distance measured downward form the top of the region, .rho. is the metal density, g is the acceleration of gravity and .mu..sub.o is the permeability of free space) induces eddy currents in the molten metal which interact with the magnetic field to retain the molten metal with a vertical boudnary. As applied to an apparatus for the continuous casting of metal sheets or rods, metal in liquid form can be continuously introduced into the region defined by the magnetic field, solidified and conveyed away from the magnetic field in solid form in a continuous process.
    Type: Grant
    Filed: October 18, 1988
    Date of Patent: January 8, 1991
    Assignee: ARCH Development Corp.
    Inventors: Robert J. Lari, Walter F. Praeg, Larry R. Turner
  • Patent number: 4936374
    Abstract: An apparatus for confining molten metal with a horizontal alternating magnetic field. In particular, this invention employs a magnet that can produce a horizontal alternating magnetic field to confine a molten metal at the edges of parallel horizontal rollers as a solid metal sheet is cast by counter-rotation of the rollers.
    Type: Grant
    Filed: November 17, 1988
    Date of Patent: June 26, 1990
    Assignee: The United States of America as represented by the United States Department of Energy
    Inventor: Walter F. Pareg
  • Patent number: 4934446
    Abstract: An apparatus and process for recrystallization of thin strip material includes a device for electromagnetically melting the thin strip material to provide a molten surface layer and a substantially solid core. Apparatus provides relative movement between the thin strip and the device for electromagnetically melting. Also, an apparatus resolidifies the molten surface layer to provide a preferred crystal structure in the thin strip material.
    Type: Grant
    Filed: October 12, 1984
    Date of Patent: June 19, 1990
    Assignee: Olin Corporation
    Inventor: Joseph Winter
  • Patent number: 4905756
    Abstract: An apparatus capable of producing a combination of magnetic fields that can retain a metal in liquid form in a region having a smooth vertical boundary including a levitation magnet that produces low frequency magnetic field traveling waves to retain the metal and a stabilization magnet that produces a high frequency magnetic field to produce a smooth vertical boundary. As particularly adapted to the casting of solid metal sheets, a metal in liquid form can be continuously fed into one end of the confinement region produced by the levitation and stabilization magnets and removed in solid form from the other end of confinement region. An additional magnet may be included for support at the edges of the confinement region where eddy currents loop.
    Type: Grant
    Filed: October 18, 1988
    Date of Patent: March 6, 1990
    Assignee: United States Department of Energy
    Inventors: Robert J. Lari, Walter F. Praeg, Larry R. Turner
  • Patent number: 4865116
    Abstract: Dense, homogeneous tubular metal products such as pipe is cast in long lengths continuously by introducing liquid metal into the lower portion of an annular-shaped casting vessel. The liquid metal is withdrawn in the presence of an outer elongated upwardly travelling alternating electromagnetic levitation field and a second inner electromagnetic levitation field for maintaining the tubular liquid metal column in a substantially weightless and pressureless contact condition while solidifying. The resulting solidified tubular metal product is withdrawn from the upper portion of the field, cooled and further processed to result in a desired and product/and has a homogeneous, fully dense, fine grain structure due to continuous eddy current stirring by the levitating electromagnetic fields and a ripply, shiny exterior surface.
    Type: Grant
    Filed: June 28, 1988
    Date of Patent: September 12, 1989
    Assignee: General Electric Company
    Inventors: Jeffrey N. Peterson, Robert T. Frost
  • Patent number: 4800950
    Abstract: A substrate for a lithographic printing plate is made of a rolled aluminum alloy sheet of following composition: 0.8 to 2.0% Fe, up to 0.8% Si and up to 1.0% Mn, such that the sum of the Si and Mn contents lies between 0.3 and 1.3%, up to 0.3% Cu, up to 0.8% Mg, up to 2.0% Zn and 0.3% each of other constituents in total up to 1.0%, rest aluminum. A process for manufacturing such a substrate is such that this composition is cast as a 5 to 12 mm thick strip then fabricated to a 0.03 to 0.6 mm thick rolled sheet.
    Type: Grant
    Filed: December 29, 1987
    Date of Patent: January 31, 1989
    Assignee: Swiss Aluminium Ltd.
    Inventors: Theodore J. Crona, Heinz Bichsel, Jurgen Timm
  • Patent number: 4796687
    Abstract: An apparatus and method for monitoring the liquid/solid interface position of an alloy ingot being formed by either direct chill or electromagnetically enhanced direct chill casting systems comprising an inductive sensor wire disposed about the mold wall of the casting system, driving the sensor wire to cause a magnetic flux to penetrate into the ingot, and sensing the change in the impedance or components of the impedance of the system. Monitoring the liquid/solid interface position allows ready adjustment to operating controls, such as, containment/stirring inductors, cooling systems and casting parameters, thereby producing a desirable ingot.
    Type: Grant
    Filed: July 10, 1987
    Date of Patent: January 10, 1989
    Assignee: Olin Corporation
    Inventors: Brian G. Lewis, John C. Yarwood
  • Patent number: 4796689
    Abstract: An electromagnetic mold for vertical continuous casting of rolling slabs, featuring an inductor and an electromagnetic screen partly covering the induction is such that the vertical distance between the lower edge of the inductor and the lower edge of the screen is greater at the narrow sides of the mold than at the broad sides of the mold. As a result of this arrangement it is possible to prevent metal running out of the ingot head at the narrow sides during the start-up phase. The foregoing is achieved at the expense of an insignificant amount of melt circulation occurring in the molten head of the ingot.
    Type: Grant
    Filed: March 14, 1988
    Date of Patent: January 10, 1989
    Assignee: Swiss Aluminium Ltd.
    Inventor: Jean-Claude Weber
  • Patent number: 4777999
    Abstract: The continuous casting of heavy metals in a magnetic field is improved by using a magnetic field in the form of essentially uniform flux lines closely parallel to the casting surface. The instability experienced with the liquid meniscus is minimized and higher intensity fields, permitting casting of heavier metals, can be achieved.
    Type: Grant
    Filed: September 30, 1987
    Date of Patent: October 18, 1988
    Assignee: J. Mulcahy Enterprises
    Inventor: Joseph A. Mulcahy
  • Patent number: 4770724
    Abstract: The products of this invention are produced in an elongated casting vessel disposed in upright position to receive liquid metal for solidification within an electromagnetic field generating means disposed around the vessel along a portion of its length. The electromagnetic field generating means produces an upward lifting effect on liquid metal in the vessel together with a containment effect wherein the liquid metal is continuously urged upwardly into contact with the lower end of the solidifying product and maintained in a pressureless contact condition with respect to the walls of the casting vessel. In this way, voids and flaws are avoided and fully dense homogeneous products of uniform, small grain cross section result without wear on the casting vessel. The novel products of the invention are long metal bodies which are fully dense and of substantially uniform, fine grain cross section and constant composition throughout in each instance.
    Type: Grant
    Filed: May 19, 1987
    Date of Patent: September 13, 1988
    Assignee: General Electric Company
    Inventors: Hugh R. Lowry, Robert T. Frost
  • Patent number: 4762653
    Abstract: The invention relates to the preparation of especially metallic or semi-metallic bands or sheets, particularly with a microcrystalline or amorphous structure.According to this process, an electrically conductive molten material is made to flow from a tank through a nozzle, to form a strip of substantially rectangular cross-section, which is subsequently solidified. According to the invention, the form of the strip of liquid material is stabilized, after it has been shaped and before solidification, as a result of a mechanical surface effect induced by an alternating magnetic field.
    Type: Grant
    Filed: October 30, 1986
    Date of Patent: August 9, 1988
    Assignee: Union Siderurgique du nord et de l'Est de la France (USINOR)
    Inventors: Claude Senillou, Remy de Framond, Marcel Garnier, Ali R. Yavari, Jean-Charles Joud
  • Patent number: 4756357
    Abstract: A process for controlling the rate of cooling an ingot emerging from a continuous casting mold, said ingot being cooled by application of a fluid coolant directly onto the ingot surface, comprises continuous measurement of the cooling capacity and influencing the composition and/or the quantity of coolant employed per unit time i.e. in the sense of matching up to the required coolant capacity. As such the measurement of the coolant capacity is performed at least at one place outwith the ingot and using coolant not coming into contact with the ingot.
    Type: Grant
    Filed: December 2, 1986
    Date of Patent: July 12, 1988
    Assignee: Swiss Aluminium Ltd.
    Inventors: Urs Banninger, Kurt Buxmann, Miroslaw Plata
  • Patent number: 4741383
    Abstract: Thin metal sheets are cast by magnetically suspending molten metal deposited within a ferromagnetic yoke and between AC conducting coils and linearly displacing the magnetically levitated liquid metal while it is being cooled to form a solid metal sheet. Magnetic flux increases as the molten metal sheet moves downward and decreases as the molten metal sheet moves upward to stabilize the sheet and maintain it in equilibrium as it is linearly displaced and solidified by cooling gases. A conducting shield is electrically coupled to the molten metal sheet by means of either metal sheet engaging rollers or brushes on the solidified metal, and by means of an electrode in the vessel containing the molten metal thereby providing a return path for the eddy currents induced in the metal sheet by the AC coil generated magnetic flux.
    Type: Grant
    Filed: March 23, 1987
    Date of Patent: May 3, 1988
    Assignee: The United States of America as represented by the United States Department of Energy
    Inventors: John R. Hull, Robert J. Lari, Walter F. Praeg, Larry R. Turner
  • Patent number: 4724896
    Abstract: An apparatus for improving the surface characteristics of a continuously cast metal ingot comprises: a skim dam having outer lateral edges which diverge downwardly into an upper molten surface of the ingot during casting in a mold; and means for suspending the skim dam in the upper molten surface. Preferably, the outer lateral edges intersect the upper molten surface at an angle between about 105.degree. and 150.degree., and more preferably at about a 120.degree. angle. The outer lateral edges maintain an acutely angled meniscus inwardly of the meniscus between the upper molten surface and the side surfaces of the ingot. A method for inhibiting the formation of vertical folds and oxide releases on a metal ingot continuously cast in an electromagnetic mold comprises suspending a skim dam in an upper molten surface of the ingot during casting, said skim dam having outer lateral edges which are not wetted by the upper molten surface and diverge downwardly into same.
    Type: Grant
    Filed: February 9, 1987
    Date of Patent: February 16, 1988
    Assignee: Aluminum Company of America
    Inventors: Robert M. Rose, Jeffrey J. Wiesner, Clarence J. Cox, Jr.
  • Patent number: 4719965
    Abstract: The method of this invention is practiced within an elongated casting vessel disposed in upright position to receive liquid metal for solidification together with means for delivering liquid metal into the lower portion of the vessel. Heat exchange means are associated with the vessel for cooling and solidifying the liquid metal therein and means are provided for removing solidified metal from the upper portion of the vessel. Electromagnetic field generating means are disposed around the vessel along a portion of its length which includes a plurality of electromagnetic coils for connection to successive phases of a polyphase electric current source to produce both an upward lifting effect on liquid metal in the vessel and a containment field effect. By "lifting effect" is meant that liquid metal is continuously urged upwardly into contact with the lower end of the solidifying product. In this way, voids and flaws are avoided and fully dense homogeneous products of uniform, small grain cross section result.
    Type: Grant
    Filed: September 30, 1982
    Date of Patent: January 19, 1988
    Assignee: General Electric Company
    Inventors: Hugh R. Lowry, Robert T. Frost
  • Patent number: 4699204
    Abstract: A device for contactless, vertically downwards continuous casting of metals in an electromagnetic alternating field, has an inductor and an electrically conductive, non-ferromagnetic screen that tapers downwards and features at a vertical distance 9 from this screen an electrically conductive, non-ferromagnetic counter screen that tapers upwards, the distance 9 between the said screen and counter screen being at least 2 mm, at most equal of the height of the inductor and in a continuous process which employs this device the circulation of the melt in the molten head of the ingot is reduced at least in the steady-state phase of casting. The process is particularly suitable for continuous casting aluminum alloys having a magnesium content of at least 2%.
    Type: Grant
    Filed: November 13, 1986
    Date of Patent: October 13, 1987
    Assignee: Swiss Aluminium Ltd.
    Inventors: Raoul Sautebin, Jean-Claude Weber, Carlo Alborghetti
  • Patent number: RE32529
    Abstract: The present invention relates to a process for the electromagnetic casting of metals. The process is characterized by simultaneously using a stationary field and a variable field at a suitable frequency for producing both radial vibrations within the metal which is not yet in a solidified condition and limiting agitation of the metal. The invention can be used in any circumstance where both the structure and the surface condition of the cast products are to be improved.
    Type: Grant
    Filed: May 21, 1986
    Date of Patent: October 27, 1987
    Assignee: Aluminum Pechiney
    Inventor: Charles Vives
  • Patent number: RE32596
    Abstract: An apparatus and process for casting metals wherein the molten metal is contained and formed into a desired shape by the application of an electromagnetic field. The apparatus includes an inductor and a non-magnetic shield. Changes in the location or the location of the top surface of the molten metal head are continuously displayed during the casting run by monitoring electrical parameters of the electromagnetic casting system including at least one electrical parameter of the nonmagnetic shield.
    Type: Grant
    Filed: May 12, 1986
    Date of Patent: February 9, 1988
    Assignee: Olin Corporation
    Inventors: Peter J. Kindlmann, Gary L. Ungarean, John C. Yarwood, Derek E. Tyler