Utilizing Roll Couple Mold Patents (Class 164/480)
  • Patent number: 10711327
    Abstract: Provided are composite materials that may include a monophasic blend including at least one metal, and graphene. The graphene may be present in the monophasic blend at an amount of about 0.001% to about 90%, by weight, based on the weight of the composite material. Also provided are methods for continuously producing composite materials, and apparatuses.
    Type: Grant
    Filed: July 1, 2019
    Date of Patent: July 14, 2020
    Assignee: Invetal, Inc.
    Inventors: Roger Scherer, Jack L. McMillin, Scott Michael Hinojos
  • Patent number: 10538833
    Abstract: Disclosed are alloys for anodized-quality aluminum sheets with improved surface quality, and methods for making these sheets. The alloys are designed to minimize the formation of cathodic intermetallic particles that result in surface streaks of anodized sheet products formed from the alloys. Further, the alloys allow the incorporation of recycled scrap aluminum in anodized-quality sheets.
    Type: Grant
    Filed: June 27, 2017
    Date of Patent: January 21, 2020
    Assignee: NOVELIS INC.
    Inventors: Daehoon Kang, Wei Wen, Devesh Mathur
  • Patent number: 9156082
    Abstract: A method of improving control of thin strip produced by continuous casting including the steps of assembling a continuous casting apparatus having a pair of counter-rotating cooling rolls, having a nip there between and at least one enclosure downstream from the nip, introducing molten metal to form a casting pool supported on the cooling rolls above the nip and counter-rotating the cooling rolls forming cast strip downwardly from the nip, guiding the strip through the at least one enclosure downstream from the nip, the at least one enclosure having gas inlets for directing oxygen-containing gas into the enclosure, and directing oxygen-containing gas having a desired amount of oxygen through the inlets into the enclosure to provide an atmosphere 0.5% and 15% oxygen with between 3 and 10% humidity to oxidize at least one surface of the strip a desired thickness of scale on the surface of the strip to provide less mill force and downstream control of the strip.
    Type: Grant
    Filed: June 4, 2013
    Date of Patent: October 13, 2015
    Assignee: Nucor Corporation
    Inventors: Mark Schlichting, Charles Crabb
  • Patent number: 9126262
    Abstract: In a twin roll continuous caster, the casting nozzle in the continuous casting apparatus is arranged such that the outlet passages and/or tapered walls in the main portion within the casting nozzle provide flow of molten metal downwardly converging toward the nip between the casting rolls of a twin roll caster. The casting nozzle having a reservoir portion for directing molten metal converging toward the triple point region to inhibit the washing of shells forming on the casting surfaces of the casting rolls.
    Type: Grant
    Filed: May 29, 2014
    Date of Patent: September 8, 2015
    Assignee: Nucor Corporation
    Inventors: Gary McQuillis, Kevin Keown, Eric Fulbright
  • Patent number: 8978738
    Abstract: In a twin roll continuous caster, the casting nozzle in the continuous casting apparatus is arranged such that the outlet passages and/or tapered walls in the main portion within the casting nozzle provide flow of molten metal downwardly converging toward the nip between the casting rolls of a twin roll caster. The casting nozzle having a reservoir portion for directing molten metal converging toward the triple point region to inhibit the washing of shells forming on the casting surfaces of the casting rolls.
    Type: Grant
    Filed: May 29, 2014
    Date of Patent: March 17, 2015
    Assignee: Nucor Corporation
    Inventors: Gary McQuillis, Kevin Keown, Eric Fulbright
  • Publication number: 20150071816
    Abstract: An aluminum alloy product and method for producing the aluminum alloy product that, in some embodiments, includes an aluminum alloy strip having at least 0.8 wt. % manganese, at least 0.6 wt % iron, or at least 0.8 wt. % manganese and at least 0.6 wt % iron. A near surface of the aluminum alloy strip, in some embodiments, is substantially free of large particles having an equivalent diameter of at least 50 micrometers and includes small particles. Each small particle, in some embodiments, has a particular equivalent diameter that is less than 3 micrometers, and a quantity per unit area of the small particles having the particular equivalent diameter is at least 0.01 particles per square micrometer at the near surface of the aluminum alloy strip.
    Type: Application
    Filed: September 8, 2014
    Publication date: March 12, 2015
    Inventors: Ali Unal, Gavin F. Wyatt-Mair, David A. Tomes, Thomas N. Rouns, Lynette M. Karabin
  • Publication number: 20150064058
    Abstract: Provided are a method of manufacturing an aluminum-zinc-based alloy sheet using twin-roll casting and an aluminum-zinc-based alloy sheet manufactured thereby. Specifically, a method of manufacturing an aluminum-zinc-based alloy sheet, including preparing a melt by melting elements corresponding to an aluminum alloy including 0.5 wt % to 10 wt % of zinc, inevitable impurities and aluminum as a balance (step 1); and twin-roll casting by introducing the melt prepared in step 1 between a pair of rotating cooling rolls (step 2), and an aluminum-zinc-based alloy sheet manufactured thereby are provided. The present invention may manufacture an aluminum-zinc-based alloy sheet, in which twin-roll casting is known to be difficult due to a wide solid-liquid coexistence region, by twin-roll casting by using cooling rolls having high thermal conductivity and controlling a reduction force by the rotational speed of the rolls.
    Type: Application
    Filed: October 16, 2013
    Publication date: March 5, 2015
    Applicant: KOREA INSTITUTE OF MACHINERY AND MATERIALS
    Inventors: Hyoung-Wook KIM, Yun-Soo LEE, Cha Yong LIM, Jae Hyung CHO
  • Patent number: 8960265
    Abstract: Apparatus and method for continuously casting metal strip includes a pair of casting rolls having casting surfaces with a center portion, edge portions each having average surface roughness between 3 and 7 Ra, and intermediate portion between each edge portion and the center portion, the center portion average surface roughness between 1.2 and 4.0 times the edge portion surface roughness, and the intermediate portions average surface roughness between that of the edge and center portions. The surface roughness of the center portion is tapered across its width, and may be tapered across its width is in stepped zones. The center portion may have surface roughness varied across the surface to correspond to a desired variation in metal shell thickness across the cast strip. The center portion may be at least 60% of the casting roll width, and each edge portion may be up to 7% of the casting roll width.
    Type: Grant
    Filed: October 29, 2010
    Date of Patent: February 24, 2015
    Assignee: Nucor Corporation
    Inventors: Rama Ballav Mahapatra, David W. McGaughey, Jay Jon Ondrovic, Tim Patterson, Mike Schueren
  • Patent number: 8960264
    Abstract: Apparatus and method for continuously casting metal strip includes a pair of casting rolls having casting surfaces with a center portion, edge portions each having average surface roughness between 3 and 7 Ra, and intermediate portion between each edge portion and the center portion, the center portion average surface roughness between 1.2 and 4.0 times the edge portion surface roughness, and the intermediate portions average surface roughness between that of the edge and center portions. The surface roughness of the center portion is tapered across its width, and may be tapered across its width is in stepped zones. The center portion may have surface roughness varied across the surface to correspond to a desired variation in metal shell thickness across the cast strip. The center portion may be at least 60% of the casting roll width, and each edge portion may be up to 7% of the casting roll width.
    Type: Grant
    Filed: March 14, 2013
    Date of Patent: February 24, 2015
    Assignee: Nucor Corporation
    Inventors: Rama Ballav Mahapatra, David W. McGaughey, Jay Jon Ondrovic, Tim Patterson, Mike Schueren
  • Publication number: 20150030882
    Abstract: The invention relates to a steel plate, the chemical composition of which comprises, the contents being expressed by weight: 0.010%?C?0.20%, 0.06%?Mn?3%, Si?1.5%, 0.005%?Al?1.5%, S?0.030%, P?0.040%, 2.5%?Ti?7.2%, (0.45×Ti)?0.35%?B?(0.45×Ti)+0.70%, and optionally one or more elements chosen from: Ni?1%, Mo?1%, Cr?3%, Nb?0.1%, V?0.1%, the balance of the composition consisting of iron and inevitable impurities resulting from the smelting.
    Type: Application
    Filed: October 14, 2014
    Publication date: January 29, 2015
    Inventors: Frederic BONNET, Olivier BOUAZIZ, Jean-Claude CHEVALLOT
  • Patent number: 8915291
    Abstract: Plant for forming grids for electric battery plates, which comprises a grid forming machine with continuous casting provided with a rotary drum, and a sliding block mounted fixed and slideably sealingly coupled with the external surface of the rotary drum and provided with means for distributing molten lead, in order to insert the molten lead within grooves provided on the external peripheral surface of the rotary drum during the rotation of the latter. The plant is also provided with an ultrasound generator placed to intercept a feed duct for the molten lead, connected to the distribution means and provided with at least one tip immersed in the pressurized flow of molten lead that moves through the aforesaid feed duct in order to transmit the waves produced by the ultrasound generator to the molten lead flow.
    Type: Grant
    Filed: May 19, 2013
    Date of Patent: December 23, 2014
    Assignee: Sovema S.p.A.
    Inventor: Pietro Farina
  • Patent number: 8893768
    Abstract: A method of continuously casting metal strip having the steps of assembling a pair of counter-rotatable casting rolls, assembling a metal delivery system adapted to deliver molten metal above the nip to form a casting pool, the casting pool forming a meniscus with each casting surface of the casting rolls, delivering a shell thickness controlling gas to select areas within 300 mm of end portions of at least one casting roll downwardly toward the meniscus between the casting pool and the casting surface adapted to control thickness of the metal shell, and control attenuation of the casting roll, and sensing the temperature and thickness profiles of the cast strip downstream from the nip to determine high or low temperature areas of the cast strip within 300 mm of the end portions and causing the gas to be delivered to the high or low temperature areas to change the thickness of the metal shell.
    Type: Grant
    Filed: November 19, 2012
    Date of Patent: November 25, 2014
    Assignee: Nucor Corporation
    Inventors: Robert Nooning, Alan J. Deno, Mark Schlichting, Gary McQuillis, Dhiren Panda, Neal Ross, Leigh Woolley
  • Patent number: 8875777
    Abstract: A method of continuously casting steel strip includes steps of providing rails positioned beneath a casting position and extending in opposite directions there from to discharge stations, supporting first and second scrap receptacles movable along the rails, engaging a seal between the first scrap receptacle and an enclosure enabling support of a protective atmosphere beneath a pair of casting rolls, disengaging the seal between the first scrap receptacle and the enclosure and moving the first scrap receptacle along the rails in a direction away from the second scrap receptacle to a discharge station, and moving the second scrap receptacle into the casting position and sealingly engaging the second scrap receptacle and the enclosure.
    Type: Grant
    Filed: March 13, 2013
    Date of Patent: November 4, 2014
    Assignee: Nucor Corporation
    Inventors: Jay Jon Ondrovic, Eric Fulbright, Katsumi Nakayama
  • Patent number: 8813828
    Abstract: In a twin roll continuous caster, the casting nozzle in the continuous casting apparatus is arranged such that the outlet passages and/or tapered walls in the main portion within the casting nozzle provide flow of molten metal downwardly converging toward the nip between the casting rolls of a twin roll caster. The casting nozzle having a reservoir portion for directing molten metal converging toward the triple point region to inhibit the washing of shells forming on the casting surfaces of the casting rolls.
    Type: Grant
    Filed: December 10, 2012
    Date of Patent: August 26, 2014
    Assignee: Nucor Corporation
    Inventors: Gary McQuillis, Kevin Keown, Eric Fulbright
  • Patent number: 8763679
    Abstract: A casting roll for a two-roll casting device for the casting of metallic strip from a metal melt, in particular a steel melt, includes a roll body, on a casing surface of which a coating consisting of a coating material is applied by thermal spraying, which has a higher degree of hardness than the roll body. The casting roll according to the invention and the two-roll casting device, while easy to manufacture, has not only a long service life, but also allows for the manufacture of cast strips of optimum quality. This is achieved by the fact that the free surface of the coating, after thermal spraying, has a peak number RPc of at least 10 cm?1.
    Type: Grant
    Filed: January 24, 2008
    Date of Patent: July 1, 2014
    Assignee: Outokumpu Nirosta GmbH
    Inventors: Ulrich Albrecht-Früh, Roland Sellger, Johann Wilhelm Schmitz, Reiner Kopp, Jörg Lauscher, Martin Franzke
  • Patent number: 8752613
    Abstract: The present invention relates to the field of magnesium and magnesium alloy processing, and discloses the use of aluminum-zirconium-titanium-carbon (Al—Zr—Ti—C) intermediate alloy in wrought processing of magnesium and magnesium alloys, wherein the aluminum-zirconium-titanium-carbon intermediate alloy has a chemical composition of: 0.01% to 10% Zr, 0.01% to 10% Ti, 0.01% to 0.3% C, and Al in balance, based on weight percentage; the wrought processing is plastic molding; and the use is to refine the grains of magnesium or magnesium alloys. The present invention further discloses the method for using the aluminum-zirconium-titanium-carbon (Al—Zr—Ti—C) intermediate alloy in casting and rolling magnesium and magnesium alloys. The present invention provides an aluminum-zirconium-titanium-carbon (Al—Zr—Ti—C) intermediate alloy and the use thereof in the plastic wrought processing of magnesium or magnesium alloys as a grain refiner.
    Type: Grant
    Filed: July 18, 2011
    Date of Patent: June 17, 2014
    Assignee: Shenzhen Sunxing Light Alloys Materials Co., Ltd.
    Inventors: Xuemin Chen, Qingdong Ye, Yueming Yu, Jianguo Li
  • Patent number: 8746324
    Abstract: The present invention relates to the field of magnesium and magnesium alloy processing, and discloses a use of aluminum-zirconium-carbon (Al—Zr—C) intermediate alloy in wrought processing of magnesium and magnesium alloys, wherein the aluminum-zirconium-carbon intermediate alloy has a chemical composition of: 0.01% to 10% Zr, 0.01% to 0.3% C, and Al in balance, based on weight percentage; the wrought processing is plastic molding; and the use is to refine the grains of magnesium or magnesium alloys. The present invention further discloses the method for using the aluminum-zirconium-carbon (Al—Zr—C) intermediate alloy in casting and rolling magnesium and magnesium alloys. The present invention provides an aluminum-zirconium-carbon (Al—Zr—C) intermediate alloy and the use thereof in the plastic wrought processing of magnesium or magnesium alloys as a grain refiner.
    Type: Grant
    Filed: April 22, 2011
    Date of Patent: June 10, 2014
    Assignee: Shenzhen Sunxing Light Alloys Materials Co., Ltd.
    Inventors: Xuemin Chen, Qingdong Ye, Yueming Yu, Jianguo Li
  • Publication number: 20140099232
    Abstract: A method of forming a sheet of semiconductor material utilizes a system. The system comprises a first convex member extending along a first axis and capable of rotating about the first axis and a second convex member spaced from the first convex member and extending along a second axis and capable of rotating about the second axis. The first and second convex members define a nip gap therebetween. The method comprises applying a melt of the semiconductor material on an external surface of at least one of the first and second convex members to form a deposit on the external surface of at least one of the first and second convex members. The method further comprises rotating the first and second convex members in a direction opposite one another to allow for the deposit to pass through the nip gap, thereby forming the sheet of semiconductor material.
    Type: Application
    Filed: March 15, 2013
    Publication date: April 10, 2014
    Applicant: Corning Incorporated
    Inventors: Samir Biswas, Douglass Lane Blanding, Glen Bennett Cook, Prantik Mazumder, Kamal Kishore Soni, Balram Suman
  • Patent number: 8684068
    Abstract: An apparatus and method for controlling the horizontal oscillation of an edge dam of a twin roll strip caster is provided. The apparatus includes an oscillation unit which horizontally oscillates an oscillation plate in accordance with an oscillation waveform so that an edge dam refractory coupled to the oscillation plate horizontally oscillates, a servo valve which outputs the oscillation waveform to the oscillation unit, and a control unit which applies the oscillation waveform to the servo valve, thus controlling the horizontal oscillation of the oscillation unit. The amplitude, frequency and waveform of the oscillation are variably controlled depending on casting conditions. The edge dam horizontally oscillates, using the servo valve and a hydraulic cylinder, thus rapidly removing edge skull and suppressing the generation and growth of skull, thereby preventing a casting roll or edge dam from being damaged.
    Type: Grant
    Filed: December 16, 2010
    Date of Patent: April 1, 2014
    Assignee: Posco
    Inventors: Oh-Seong Kweon, Kwi-Ju Hwang, Yoon-Ha Kim, Ji-Woong Jun, Sang-Hoon Kim
  • Patent number: 8631853
    Abstract: An apparatus and method for continuously casting thin steel strip include a pair of counter-rotatable casting rolls in a roll cassette laterally positioned to form a nip there between through which thin cast strip can be cast, adapted to support a casting pool of molten metal on the casting surfaces, an enclosure to support a protective atmosphere immediately beneath the casting rolls in the casting position, and an upper cover positioned below the casting rolls to move between a closed position covering the upper portion of the enclosure maintaining the protective atmosphere in the enclosure in the closed position and a retracted position enabling cast strip to be cast into the enclosure. A scrap receptacle positioned beneath the casting position movable in either direction to a discharge stations. Further, a movable tundish adapted to be transferred from a heating station to the casting position.
    Type: Grant
    Filed: December 2, 2011
    Date of Patent: January 21, 2014
    Assignee: Nucor Corporation
    Inventors: Jay Jon Ondrovic, Eric Fulbright, Katsumi Nakayama
  • Patent number: 8607848
    Abstract: A method of continuously casting thin strip dynamically controlling roll casting surface configuration by controlling the temperature of water flowing through the longitudinal water flow passages in a cylindrical 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: Grant
    Filed: July 29, 2009
    Date of Patent: December 17, 2013
    Assignee: Nucor Corporation
    Inventors: Mark Schlichting, Walter N. Blejde, Mike Schueren, Rama Ballav Mahapatra
  • Patent number: 8607847
    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: Grant
    Filed: August 5, 2008
    Date of Patent: December 17, 2013
    Assignee: Nucor Corporation
    Inventors: Mark Schlichting, Walter N. Blejde, Mike Schueren, Rama Ballav Mahapatra
  • Patent number: 8602086
    Abstract: A method for producing an amorphous alloy foil strip having a large sheet thickness in an industrial scale includes: a pair of cooling rolls; a driving unit configured to rotate the pair of cooling rolls; and a crucible configured to supply a molten alloy sequentially to an outer circumferential surface of the pair of cooling rolls. The crucible is movable along a moving unit. A molten alloy is supplied alternately to the pair of cooling rolls while rotating and water-cooling the pair of cooling rolls.
    Type: Grant
    Filed: October 15, 2012
    Date of Patent: December 10, 2013
    Assignee: Nippon Steel & Sumitomo Metal Corporation
    Inventor: Takashi Sato
  • Patent number: 8567480
    Abstract: A twin roll caster and a method for operating a machine of this type. The machine includes two casting rolls, that delimit a casting gap between them on its longitudinal sides; two side plates that delimit the casting gap on its narrow sides; and at least one oscillation device, which moves the side plate in an oscillating manner about an axis of oscillation, extending substantially axially parallel to the axes of rotation of the casting rolls. Oscillation device includes two actuators, which are articulatedly coupled to the one side plate and each apply a torque rotating about the axis of oscillation on the one side plate, and a control device that emits control signals, upon which the actuators, individually or together with each other, carry out adjustment movements aligned against one another or parallel to one another.
    Type: Grant
    Filed: February 20, 2009
    Date of Patent: October 29, 2013
    Assignee: Outokumpu Nirosta GmbH
    Inventors: André d'Hone, René Leenen
  • Patent number: 8561671
    Abstract: A twin roll caster and method for producing strip cast from a molten metal using the twin roll caster. The twin roll caster has casting rolls which delimit a casting gap between them on its longitudinal sides and narrow sides sealed in each case by a side plate which is moved during the casting operation about an axis of oscillation in an oscillating manner. The inventive method and the twin roll caster enable the risk of operational disruptions from molten mass solidifying in the region of the side plate to be further minimized. This is achieved by changing the position of the axis of oscillation during the casting operation.
    Type: Grant
    Filed: February 20, 2009
    Date of Patent: October 22, 2013
    Assignee: Outokumpu Nirosta GmbH
    Inventor: André d'Hone
  • Publication number: 20130248136
    Abstract: The invention relates to a method and apparatus for direct chill casting ingots with in-situ homogenization. Large particles of eutectic material may form in the solid ingot and the metal may exhibit macrosegregation of alloying components, especially when large ingots are cast in this way. This can be alleviated by applying a first liquid coolant to the ingot emerging from the mold, removing the first liquid coolant at a certain distance along the ingot by means of a wiper, and then applying a second liquid coolant to perform a quench at a greater distance along the ingot. The quench raises the level of the molten sump in the ingot, which helps to overcome the indicated problems, without affecting the desired temperature rebound of the ingot shell (usually at least 425° C. (797° F.)) for a time effective to cause in-situ homogenization.
    Type: Application
    Filed: February 12, 2013
    Publication date: September 26, 2013
    Inventors: Wayne J. FENTON, Jeff McDERMOTT, Robert Bruce Wagstaff
  • Publication number: 20130216426
    Abstract: The present invention discloses a method of strip casting an aluminum alloy from immiscible liquids that yields a highly uniform structure of fine second phase particles. The results of the present invention are achieved by using a known casting process to cast the alloy into a thin strip at high speeds. In the method of the present invention, the casting speed is preferably in the region of about 50-300 feet per minute (fpm) and the thickness of the strip preferably smaller than 0.08-0.25 inches. Under these conditions, favorable results are achieved when droplets of the immiscible liquid phase nucleate in the liquid ahead of the solidification front established in the casting process. The droplets of the immiscible phase are engulfed by the rapidly moving freeze front into the space between the Secondary Dendrite Arms (SDA).
    Type: Application
    Filed: March 20, 2013
    Publication date: August 22, 2013
    Applicant: Alcoa Inc.
    Inventor: Alcoa Inc.
  • Publication number: 20130174942
    Abstract: The invention relates to a steel plate, the chemical composition of which comprises, the contents being expressed by weight: 0.010%?C?0.20%, 0.06%?Mn?3%, Si?1.5%, 0.005%?Al?1.5%, S?0.030%, P?0.040%, 2.5%?Ti?7.2%, (0.45×Ti)?0.35%?B?(0.45×Ti)+0.70%, and optionally one or more elements chosen from: Ni?1%, Mo?1%, Cr?3%, Nb?0.1%, V?0.1%, the balance of the composition consisting of iron and inevitable impurities resulting from the smelting.
    Type: Application
    Filed: June 25, 2010
    Publication date: July 11, 2013
    Applicant: ArcelorMittal France
    Inventors: Frederic BONNET, Olivier BOUAZIZ, Laure CALA
  • Publication number: 20130139964
    Abstract: A mirror or mirror assembly fabricated by molding, pressing, assembling, or depositing one or more bulk metal glass (BMG), bulk metal glass composite (BMGMC), or amorphous metal (AM) parts and where the optical surface and backing of the mirror can be fabricated without machining or polishing by utilizing the unique molding capabilities of this class of materials.
    Type: Application
    Filed: November 16, 2012
    Publication date: June 6, 2013
    Applicant: California Institute of Technology
    Inventor: California Institute of Technology
  • Patent number: 8453712
    Abstract: A twin roll caster and a method for operating comprising two casting rolls that delimit a casting gap on its longitudinal sides; two side plates that delimit the casting gap on its narrow sides; and at least one axial actuator associated with one of the side plates and impacting the respective side plate on its rear turned away from the front sides of the casting rolls with a force axially aligned toward the casting gap pressing the side plate against the front sides of the casting rolls. An axial actuator acts on the rear side of the side plate by means of a joint provided to adjust an angular offset between the normal level relative to the effective direction of the force applied by the axial actuator to the side plate and the normal level relative to the axes of rotation of the casting rolls.
    Type: Grant
    Filed: February 20, 2009
    Date of Patent: June 4, 2013
    Assignee: Outokumpu Nirosta GmbH
    Inventor: André d'Hone
  • Publication number: 20130089457
    Abstract: Provided is a composite material suitable for forming a part for continuous casting capable of producing cast materials of excellent surface quality for a long period of time and with which a molten metal is inhibited from flowing into a gap between a nozzle and a moving mold. A composite material (nozzle 1) includes a porous body 2 having a large number of pores and a filler incorporated in at least part of a portion that comes into contact with the molten metal, the portion being part of a surface portion of the porous body. The filler incorporated in the porous body 2 is at least one selected from a nitride, a carbide, and carbon.
    Type: Application
    Filed: June 3, 2011
    Publication date: April 11, 2013
    Applicant: Sumitomo Electric Industries Ltd
    Inventors: Michimasa Miyanaga, Takeshi Uchihara, Masatada Numano, Yukihiro Oishi, Nozomu Kawabe
  • Patent number: 8403027
    Abstract: The present invention discloses a method of strip casting an aluminum alloy from immiscible liquids that yields a highly uniform structure of fine second phase particles. The results of the present invention are achieved by using a known casting process to cast the alloy into a thin strip at high speeds. In the method of the present invention, the casting speed is preferably in the region of about 50-300 feet per minute (fpm) and the thickness of the strip preferably smaller than 0.08-0.25 inches. Under these conditions, favorable results are achieved when droplets of the immiscible liquid phase nucleate in the liquid ahead of the solidification front established in the casting process. The droplets of the immiscible phase are engulfed by the rapidly moving freeze front into the space between the Secondary Dendrite Arms (SDA).
    Type: Grant
    Filed: April 11, 2007
    Date of Patent: March 26, 2013
    Assignee: Alcoa Inc.
    Inventors: David A. Tomes, Jr., Gavin F. Wyatt-Mair, David W. Timmons, Ali Unal
  • Patent number: 8397794
    Abstract: Described herein is a twin roll caster including a pair of casting rolls arranged parallel to one another with a gap between the casting rolls and side dams parallel to one another forming a pool between the casting rolls and side dams. A side dam support is provided that applies a compression force on at least one of the side dams at a compression angle relative to the axis of the casting rolls.
    Type: Grant
    Filed: April 3, 2012
    Date of Patent: March 19, 2013
    Assignee: Castrip, LLC
    Inventors: Katsumi Nakayama, Atsushi Hirata, Kiroyuki Otsuka, Hisahiko Fukase
  • Patent number: 8381796
    Abstract: A method of making a functionally graded metal matrix composite (MMC) sheet having a central layer of particulate matter, the particulate matter having a size of at least about 30 microns. The method includes providing a molten metal containing particulate matter to a pair of advancing casting surfaces. Solidifying the molten metal while advancing the molten metal between the advancing casting surfaces to form a first solid outer layer, a second solid outer layer, and a semi-solid central layer having a higher concentration of particulate matter than either of the outer layers. Solidifying the central layer to form a solid metal product including a central layer sandwiched between the outer layers and withdrawing the metal product from between the casting surfaces.
    Type: Grant
    Filed: October 28, 2010
    Date of Patent: February 26, 2013
    Assignee: ALCOA Inc.
    Inventors: David A. Tomes, Jr., Gavin F. Wyatt-Mair, David W. Timmons, Ali Unal
  • Patent number: 8327917
    Abstract: An apparatus and a method for producing an amorphous alloy foil strip, which are capable of producing an amorphous alloy foil strip having a large sheet thickness in an industrial scale, are provided. A production apparatus 101 for an amorphous alloy foil strip S includes: a pair of cooling rolls 113a and 113b; a driving unit 111 configured to rotate the cooling rolls; and a crucible 114 configured to supply a molten alloy sequentially to an outer circumferential surface of the cooling roll 113a and an outer circumferential surface of the cooling roll 113b. The crucible 114 is movable along a moving unit 116. A molten alloy is supplied alternately to the cooling roll 113a and the cooling roll 113b while rotating and water-cooling the cooling rolls 113a and 113b.
    Type: Grant
    Filed: February 20, 2009
    Date of Patent: December 11, 2012
    Assignee: Nippon Steel Corporation
    Inventor: Takashi Sato
  • Patent number: 8322402
    Abstract: During continuously casting metal strip, delivering molten metal supported on the casting surfaces of the casting rolls, and counter rotating the casting rolls to form metal shells on the casting surfaces brought together at the nip to deliver cast strip downwardly with a controlled amount of mushy material between the metal shells, determining at a reference location downstream from the nip a target temperature for the cast strip corresponding to a desired amount of mushy material between the metal shells of the cast strip, sensing the temperature of the cast strip cast downstream from the nip at the reference location and producing a sensor signal corresponding to the sensed temperature, and causing an actuator to vary the gap at the nip between the casting rolls in response to the sensor signal received from the sensor and processed to determine the temperature difference between the sensed temperature and the target temperature.
    Type: Grant
    Filed: September 20, 2010
    Date of Patent: December 4, 2012
    Assignee: Nucor Corporation
    Inventors: Walter N. Blejde, Rama Ballav Mahapatra, Mark Schlichting
  • Patent number: 8316920
    Abstract: A metal strip casting apparatus and method of casting metal strip include assembling a pair of counter-rotatable casting rolls positioned laterally forming a nip between for casting, and assembling a pair of brush rolls, each of the brush rolls associated with one of each of the casting rolls. Each brush roll includes at least one spaced apart brush line extending substantially along the axial length of the casting roll. The brush lines may form a spiral, zigzag, wave or crisscross array about the brush roll. The brush roll may include one or more staggered rings with regularly or irregularly spaced apart bristles which form the brush lines. The brush lines may be between 10 to 50 mm apart and separated by between 2 mm to 45 mm of open space. The brush lines may be one line per 10 mm to 90 mm of axial length of brush roll.
    Type: Grant
    Filed: November 20, 2009
    Date of Patent: November 27, 2012
    Assignee: Nucor Corporation
    Inventors: Hiroyuki Otsuka, Hiroki Yoshizawa, Katsumi Nakayama, Kazuo Miyoshi
  • Patent number: 8312917
    Abstract: A method of controlling the formation of crocodile skin surface roughness on thin cast strip by forming a casting pool of molten metal of less than 0.065% carbon supported on casting surfaces above a nip, assembling a rotating brush to contact the casting surfaces in advance of contact with the molten metal, and controlling the energy exerted by rotating brushes against the casting surfaces of the casting rolls to clean and expose a majority of the projections of the casting surfaces of the casting rolls by providing wetting contact with the molten metal of the casting pool. The cleaning step is controlled by controlling the energy of the rotating brush against the casting rolls based on the difference between the detected light reflected from the casting surfaces and the light reflected when the casting surfaces are clean, and automating the method.
    Type: Grant
    Filed: June 29, 2007
    Date of Patent: November 20, 2012
    Assignee: Nucor Corporation
    Inventor: Mark Schlichting
  • Patent number: 8313553
    Abstract: A method of making a steel with low carbon less than 0.035% by weight including steps of preparing a heat of molten steel composition in a steelmaking furnace to a tapping temperature as desired for desulfurization at a VTD, tapping open into a ladle the molten steel composition with an oxygen level between about 600 and 1120 ppm, providing slag forming compound to the ladle to form a slag cover over the molten steel composition in the ladle, transporting the molten steel composition in the ladle to a VTD, decarburizing the molten steel composition at the VTD by drawing a vacuum of less than 650 millibars, after decarburizing, adding one or more deoxidizers to the molten steel composition and deoxidizing the molten steel composition, after deoxidizing, adding one or more flux compounds to desulfurize the molten steel composition, and casting the molten steel composition to form a steel with low carbon less than 0.035% by weight.
    Type: Grant
    Filed: March 30, 2009
    Date of Patent: November 20, 2012
    Assignee: Nucor Corporation
    Inventors: Jacobus Marthinus Andreas Geldenhuis, David John Sosinsky, Daniel Gene Murray, David Wayne McGaughey, Eugene B. Pretorius
  • Publication number: 20120273156
    Abstract: Described herein is a twin roll caster including a pair of casting rolls arranged parallel to one another with a gap between the casting rolls and side dams parallel to one another forming a pool between the casting rolls and side dams. A side dam support is provided that applies a compression force on at least one of the side dams at a compression angle relative to the axis of the casting rolls.
    Type: Application
    Filed: April 3, 2012
    Publication date: November 1, 2012
    Applicant: CASTRIP, LLC
    Inventors: Katsumi Nakayama, Atsushi Hirata, Hiroyuki Otsuka, Hisahiko Fukase
  • Publication number: 20120195787
    Abstract: The present invention relates to single-phase solid solution magnesium alloys suitable for the applications as cast or wrought. These alloys are prepared by multi-microalloying with rare earth elements (including gadolinium, yttrium, dysprosium, samarium, lanthanum, cerium, neodymium and praseodymium). Each alloy contains 0.5 to less than 5 wt. % rare earth elements with a content of 0.05-2.0% by weight. The total amount of rare earth elements is controlled below 5% by weight in order for economical considerations. The amount of grain refiner calcium or zirconium is in the range of 0.05-0.6% by weight. These alloys can be prepared by die casting, permanent casting, chill casting, semi-solid processes, continuous casting and continuous twin roll casting.
    Type: Application
    Filed: January 18, 2012
    Publication date: August 2, 2012
    Applicant: Helmholtz-Zentrum Geesthacht Zentrum fun Material-und Kustenforschung GmbH
    Inventors: Yuanding Huang, Qiumin Peng, Norbert Hort, Karl U. Kainer
  • Patent number: 8225845
    Abstract: A metal delivery apparatus for casting metal strip includes at least one elongated segment having a main portion extending longitudinally through the main portion with end walls at opposite ends thereof, the main portion communicating with outlets along opposite sides of each segment adapted to upwardly discharge flow of molten metal into a casting pool.
    Type: Grant
    Filed: December 4, 2009
    Date of Patent: July 24, 2012
    Assignee: Nucor Corporation
    Inventors: Mark Schlichting, Brian Bowman, Clark Ponder, Peter Woodberry
  • Patent number: 8220526
    Abstract: A method for continuous and efficient casting roll of magnesium alloy plates including providing plural induction furnaces, resistance furnace, casting roll and rollers; adding metal elements into the induction furnaces, the metal elements comprising Mg ingots or Mg alloy, the metal elements being smelted in the induction furnaces and then flow into the resistance furnace; controlling temperature of the Mg melt in the resistance furnace, wherein there are at least two temperature controlling areas communicated with each other, and a difference of temperatures is constant; transferring the Mg melt into biting area through a transferring pipe and modeling the mg melt into Mg plate, the temperature of the Mg melt into the biting area being 690±10° C.; Rolling the Mg plate in the rollers and each band of the rollers having a working temperature 250˜350° C., and the difference of temperature is ±10° C.
    Type: Grant
    Filed: May 10, 2010
    Date of Patent: July 17, 2012
    Assignee: Shenzhen Sunxing Light Alloys Materials Co., Ltd.
    Inventors: Xuemin Chen, Qingdong Ye, Jianguo Li, Chaowen Liu, Yueming Yu
  • Patent number: 8191610
    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: Grant
    Filed: November 24, 2009
    Date of Patent: June 5, 2012
    Assignee: Nucor Corporation
    Inventors: Rama Ballav Mahapatra, Brian E. Bowman
  • Publication number: 20120103555
    Abstract: A system of twin-roll casting an ultra-thin slab or thick-strip of metal with a liquid core still present inside the hollow shell of the casting as it exits the nip of the opposing counter rotating casting rolls. The wide sides of the cast shell are formed against a recessed casting surface on each roll and the narrow end walls of the shell are formed against the tapered ends of the recessed area so one half of the narrow end wall is formed on each roll and the two halves are joined together at the nip to form the full perimeter of the metal casting. A liquid-cooled copper mold liner provides continued support to each of the four sides of the casting below the twin-rolls and contact with those chilled copper mold liners continues to remove heat from the liquid core of the casting enabling the shell to continue growing in thickness.
    Type: Application
    Filed: July 20, 2011
    Publication date: May 3, 2012
    Inventor: James B. Sears, JR.
  • Patent number: 8162031
    Abstract: A method of making steel comprising assembling a steelmaking furnace, a thin strip caster, and a mold caster, inputting to a computer data on demand for production output, raw materials, furnace availability and capacity, sequence schedules and through-put, capacities and variability, forecasting by processing by computer from the inputted data a production schedule for the steelmaking furnace, and sequence schedules for the thin strip and the mold casters as a function of molten metal availability, the thin strip and mold caster sequence schedules and through-put, and demand for production output, directing production of molten metal alternatively to the delivery systems of the thin strip caster and mold caster responsive to said forecasting, and varying during casting the rate of metal delivery through the delivery system of the thin strip caster responsive to molten metal availability and the mold caster through-put.
    Type: Grant
    Filed: October 25, 2011
    Date of Patent: April 24, 2012
    Assignee: Nucor Corporation
    Inventor: Richard Wechsler
  • Patent number: 8141618
    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 therebetween 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: Grant
    Filed: June 24, 2008
    Date of Patent: March 27, 2012
    Assignee: Nucor Corporation
    Inventors: Walter N. Blejde, Mark Schlichting
  • Patent number: 8122940
    Abstract: A method for twin roll casting aluminum clad magnesium by joining one or more sheets of aluminum cladding to molten magnesium during twin roll casting. The method includes feeding aluminum cladding to at least one roll of a pair of rotating rolls, feeding a core of molten magnesium into a continuous casting mold formed by the roll, solidifying the magnesium core by heat extraction to the rolls and through the aluminum cladding, surface treating the aluminum cladding and the magnesium core to prevent inter-diffusion between the aluminum cladding and the magnesium core, bonding the aluminum cladding with the magnesium core and extruding the composite core and aluminum cladding out of the continuous casting mold by a casting load exerted by the rolls.
    Type: Grant
    Filed: July 16, 2008
    Date of Patent: February 28, 2012
    Assignee: Fata Hunter, Inc.
    Inventor: Christopher A. Romanowski
  • Patent number: 8113267
    Abstract: Provided is a twin-roll casting machine capable of suppressing irregularities in crosswise thickness distribution of a strip. The twin-roll casting machine comprises chilled rolls, side weirs, and nozzle pieces. A plurality of openings for supply of molten metal to between the chilled rolls are formed alternately on portions of each of the nozzle pieces adjacent to the one and the other rolls, respectively, and are spaced apart from each other axially of the rolls.
    Type: Grant
    Filed: June 18, 2008
    Date of Patent: February 14, 2012
    Assignee: IHI Corporation
    Inventors: Hiroyuki Otsuka, Katsumi Nakayama
  • Patent number: RE45414
    Abstract: A process and apparatus for continuous casting of amorphous alloy sheets having large sheet thickness using bulk solidifying amorphous alloys are provided. Thick continuous amorphous alloy sheets made of bulk solidifying amorphous alloys are also provided.
    Type: Grant
    Filed: August 29, 2012
    Date of Patent: March 17, 2015
    Assignee: Crucible Intellectual Property, LLC
    Inventor: William L. Johnson