Utilizing Roll Couple Mold Patents (Class 164/480)
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Publication number: 20080311423Abstract: The invention is to provide a magnesium alloy material such as a magnesium alloy cast material or a magnesium alloy rolled material, excellent in mechanical characteristics and surface precision, a producing method capable of stably producing such material, a magnesium alloy formed article utilizing the rolled material, and a producing method therefor. The invention provides a producing method for a magnesium alloy material, including a melting step of melting a magnesium alloy in a melting furnace to obtain a molten metal, a transfer step of transferring the molten metal from the melting furnace to a molten metal reservoir, and a casting step of supplying a movable mold with the molten metal from the molten metal reservoir, through a pouring gate, and solidifying the molten metal to continuously produce a cast material. In a process from the melting step to the casting step, parts contacted by the molten metal are formed by a low-oxygen material having an oxygen content of 20 mass % or less.Type: ApplicationFiled: June 28, 2005Publication date: December 18, 2008Inventors: Masatada Numano, Yoshihiro Nakai, Toshiya Ikeda, Taichiro Nishikawa
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Patent number: 7464746Abstract: Twin roll casters for casting thin steel strip comprise cooled casting rolls mounted on carriers. One roll is fixed and the other is moveable laterally and biased toward the other roll by carrier drive units acting on the moveable roll carriers. A casting pool of molten steel is supported on the rolls which are rotated to produce a solidified steel strip delivered downwardly from the nip therebetween. A gap is regulated between the rolls such that unsolidified molten metal passes through the nip between the solidified shells of the forming strip and solidifies below the nip. The carrier drive units are effective to apply to the biased roll substantially intermediate biasing forces such that the roll separation force at the casting rolls is regulated to a value between 2 and 4.5 Newtons per millimeter.Type: GrantFiled: August 9, 2006Date of Patent: December 16, 2008Assignee: Nucor CorporationInventor: Jim Edwards
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Publication number: 20080257524Abstract: Discharge device for discharging liquid steel into a roller crystallizer for the continuous casting of thin strip capable of reducing turbulence at the meniscus to a minimum so as to eliminate the relative defects on the cast strip by passing the steel between two crystallizer rollers. A relative casting process is also described, said process providing for particular expedients for improving the steel feeding from the tundish to the crystallizer. Advantageously, the feeding of guided steel jet streams inside the nozzle, or delivery nozzle, eliminates the disturbance at the meniscus caused by the air bubbles which form when free-falling jet streams come into contact with the air, as occurs in the known devices and plants.Type: ApplicationFiled: December 20, 2006Publication date: October 23, 2008Applicant: DANIELI & C. OFFICINE MECCANICHE S.P.A.Inventors: Nuredin Kapaj, Alfredo Poloni, Fabio Vecchiet
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Patent number: 7404431Abstract: A method of controlling in a twin roll strip caster the thickness of as-cast strip by determining and operating at a target depth of the casting pool and a target speed of the casting rolls. The as-cast strip may be cast to a customer-specified thickness or may be subsequently rolled to a customer-specified thickness.Type: GrantFiled: April 17, 2003Date of Patent: July 29, 2008Assignee: Nucor CorporationInventors: Walter N. Blejde, Rama Ballav Mahapatra
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Publication number: 20080169082Abstract: When a molten steel (106) is supplied into a moving mold defined by concave rolls (101, 102) and side checks (103, 104), the molten steel (106) is cooled by the surfaces of the rolls (surfaces except steps) to form solidified shells (111, 112). Both solidified shells (111, 112) are pressure bonded, and pulled out as a cast piece (113). A heat insulator (ceramic coating) has been applied to the circumferential surfaces of steps (101a, 101b, 102a, 102b) which are opposite end portions of the rolls. Thus, at these portions, heat dissipation does not proceed, and no solidified shells are formed. Hence, clearances are formed between the opposite ends of the solidified shells (111, 112) and the side checks (103, 104), and the solidified shells (111, 112) do not contact the side checks (103, 104), with the result that the wear of the side checks (103, 104) is prevented.Type: ApplicationFiled: November 15, 2005Publication date: July 17, 2008Applicant: MITSUBISHI-HITACHI METALS MACHINERY, INC.Inventors: Kanji Hayasi, Kiyoshi Kagehira, Hideaki Takatani, Tatsunori Sugimoto, Shigeki Sueda
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Patent number: 7398817Abstract: A twin roll caster for an apparatus for confining the impurities in a molten metal fed by means of a discharger and contained into an area of a strip continuous casting mold delimited by the side surfaces of two casting rolls with counter-rotating horizontal axis and by two containment side plates positioned in contact with the rolls' bases is provided.Type: GrantFiled: October 31, 2003Date of Patent: July 15, 2008Assignees: Thyssenkrupp Acciai Speciali Terni S.p.A, Thyssenkrupp Nirosta GmbHInventors: Romeo Capotosti, Riccardo Tonelli, Franco Macci
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Patent number: 7367378Abstract: A method of producing cast steel strip having low surface roughness and low porosity by casting with molten steel having a total oxygen content of at least about 100 ppm and a temperature that allows a majority of any oxide inclusions to be in a liquidus state. The steel strip produced by the method may have a per unit area density of at least about 120 oxide inclusions per square millimeter to a depth of about 2 microns from the strip surface.Type: GrantFiled: March 28, 2006Date of Patent: May 6, 2008Assignee: Nucor CorporationInventors: Walter Blejde, Rama Mahapatra, Lazar Strezov
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Patent number: 7337827Abstract: The invention relates to a method of operating a strip casting machine for producing a metal strip, during which molten metal is continuously poured between two casting rolls (1, 2) that form a casting gap. Lateral seals (10) having sealing plates (11) are provided for laterally delimiting the casting gap, whereby the sealing plates (11) are placed or pressed with a preset placement or pressing force, whose magnitude can be set, against the end surfaces of the casting rolls (1, 2). The sealing plates (11) are, in repeatable stop-and-go steps, placed with a preset force and time against the end surfaces of the casting rolls (1, 2) and are held in the placing position for a preset time. This enables a distinct reduction in the wear of the sealing plates and of the casting roll end surfaces.Type: GrantFiled: June 25, 2004Date of Patent: March 4, 2008Assignees: SMS Demag AG, Main Management Inspiration AGInventors: Heinrich Marti, Jacques Barbé, Hans Streubel
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Publication number: 20080047681Abstract: The method of producing thin cast strip by continuous casting is disclosed. At least two sensors are operationally connected to at least one end of at least one of a pair of casting rolls or of a pair of brushes, to continuously measure at least two force-related parameters during casting. At least two time domain signals corresponding to the measured force-related parameters are generated. The time domain signals are continuously monitored and transformed into corresponding frequency domain spectrums. The frequency domain spectrums are analyzed and composite intensity values are continuously calculated from the intensity levels of at least a portion of the frequency component signals within the frequency spectrums. Casting parameters are adjusted in response to reduce strip defects.Type: ApplicationFiled: August 28, 2006Publication date: February 28, 2008Applicant: NUCOR CORPORATIONInventors: Nikolco NIKOLOVSKI, Peter Woodberry
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Publication number: 20080035302Abstract: Twin roll casters for casting thin steel strip comprise cooled casting rolls mounted on carriers. One roll is fixed and the other is moveable laterally and biased toward the other roll by carrier drive units acting on the moveable roll carriers. A casting pool of molten steel is supported on the rolls which are rotated to produce a solidified steel strip delivered downwardly from the nip therebetween. A gap is regulated between the rolls such that unsolidified molten metal passes through the nip between the solidified shells of the forming strip and solidifies below the nip. The carrier drive units are effective to apply to the biased roll substantially intermediate biasing forces such that the roll separation force at the casting rolls is regulated to a value between 2 and 4.5 Newtons per millimeter.Type: ApplicationFiled: August 9, 2006Publication date: February 14, 2008Applicant: NUCOR CORPORATIONInventor: Jim Edwards
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Patent number: 7308930Abstract: A method of continuously casting thin strip where, at the start of a casting campaign, the side dams are pressed against the end surfaces of the casting rolls with a pressure of less than 3.0 kg/cm2 but more than 1.25 kg/cm2 and after the target casting pool height is reached, reducing the pressure exerted by the side dams against the end surfaces of the casting rolls to below 1.25 kg/cm2 to reduce wear of the side dams against the end surfaces of the casting rolls.Type: GrantFiled: March 9, 2006Date of Patent: December 18, 2007Assignee: Nucor CorporationInventors: John Huffman, Brian Bowman, Jason Gilliland, Chad Slavens
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Patent number: 7299856Abstract: A thin steel strip with low surface roughness and low porosity produced by casting with molten steel having a total oxygen content of at least about 100 ppm and a temperature that allows a majority of any oxide inclusions to be in a liquidus state. The steel strip produced by the method may have a per unit area density of at least about 120 oxide inclusions per square millimeter to a depth of about 2 microns from the strip surface.Type: GrantFiled: December 1, 2004Date of Patent: November 27, 2007Assignee: Nucor CorporationInventors: Walter Blejde, Rama Mahapatra, Lazar Strezov
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Patent number: 7299857Abstract: A method of and apparatus for localized control of heat flux in continuous casting of thin cast strip comprising removing oxides from the casting surface of each casting roll by contacting the casting surface of each casting roll with the rotating brush in advance of the casting area, and delivering gas at the casting surface between the rotating brush and entry to the casting area to form a gas layer on the casting surface of each casting roll where the oxides have been removed. The delivering of gas at the casting surface between the rotating brush and entry to the casting area is preferably done in at least three zones along the casting roll axes to form a gas layer on the casting surface of each casting roll where the oxides have been removed, where the gas projected in the respective zones can be of different composition, mixture, pressure, or combination thereof.Type: GrantFiled: December 13, 2005Date of Patent: November 27, 2007Assignee: Nucor CorporationInventors: Mark Schlichting, Walter Blejde, Eugene B. Pretorius
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Patent number: 7296614Abstract: A method of controlling the formation of crocodile skin surface roughness on thin cast strip of plain carbon steel forming a casting pool of molten metal of plain carbon steel of less than 0.065% carbon supported on a 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 provide wetting contact with the molten metal of the casting pool. The cleaning step may be done by controlling the energy of the rotating brush against the casting rolls based on the difference between the measured heat flux and the initially measured heat flux when the casting surfaces are clean, and automating the method.Type: GrantFiled: December 13, 2005Date of Patent: November 20, 2007Assignee: Nucor CorporationInventors: Mark Schlichting, Joel D. Sommer, Shiro Osada, Hisahiko Fukase
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Patent number: 7281569Abstract: A method of producing cast steel strip having low surface roughness and low porosity by casting with molten steel having a total oxygen content of at least about 70 ppm and a free oxygen content between 20 and 60 ppm, and a temperature that allows a majority of any oxide inclusions to be in a liquidus state. The total oxygen content may be at least 100 ppm and the free oxygen content between 30 and 50 ppm. The steel strip produced by the method may have a per unit area density of at least about 120 oxide inclusions per square millimeter to a depth of about 2 microns from the strip surface.Type: GrantFiled: January 21, 2004Date of Patent: October 16, 2007Assignee: Nucor CorporationInventors: Walter N. Blejde, Rama Mahapatra, Lazar Strezov
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Publication number: 20070221358Abstract: The method of producing thin cast strip by continuous casting having a side dam assembly. The side dam assembly includes a side dam having opposite outer surfaces, one surface contacting molten metal and the opposite outer surface having fastening portions capable of attaching the side dam to a side dam holder, to hold the side dam in place during casting without exposed portions of the side dam holder extending substantially, beyond the opposite outer surface toward the outer surface for contacting molten metal.Type: ApplicationFiled: March 24, 2006Publication date: September 27, 2007Applicant: Nucor CorporationInventors: Brian E. Bowman, Alan J. Deno, Gordon D. Emmert
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Patent number: 7258157Abstract: The invention relates to a side wall (1) of a plant for the continuous casting of metal strip (5) between two counter-rotating rolls (2, 2?) having horizontal axes and being internally cooled, the surfaces of which define a casting space confined laterally by two side walls (1) made of refractory, of the type comprising: a support plate (6) on the front face of which a recess (7) is made; an insert (9) made of hard material placed around the periphery of the recess (7); a lining (11) that fills the remainder of the recess (7); characterized in that the front face (12), turned towards the casting space, of the said lining (11) is set back by a maximum distance (d) from the front face (13) of the insert (9) over at least part of its length.Type: GrantFiled: July 11, 2003Date of Patent: August 21, 2007Assignees: Unisor, Thyssenkrupp Nirosta GmbH, Voest-Alpine Industrieanlagenbau GmbH & Co.Inventors: Jean-Michel Damasse, Pietro Tolve, Romeo Capotosti, Philippe Guillo
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Patent number: 7246651Abstract: A twin roll casting machine that can reduce an amount of inert gas to be fed for prevention of oxidization. The machine includes an enclosure enclosing a strip in a range from chilled rolls to pinch rolls, a first swing wall within the enclosure and having a tip end movable toward and away from a surface of the strip, a sealing roll rotatably supported by the tip end of the first swing wall, a second swing wall within the enclosure and having a tip end movable toward and away from the other surface of the strip, a sealing roll rotatably supported by the tip end of the second swing wall, sealing members between peripheral edges of the swing walls and an inner surface of the enclosure, and conduits for supplying inert gas into the enclosure. The respective swing walls are swung to bring the sealing rolls close to the strip to thereby suppress flow of the inert gas from a first space to a second space.Type: GrantFiled: May 2, 2006Date of Patent: July 24, 2007Assignee: Ishikawajima-Harima Heavy Industries Co., Ltd.Inventors: Isamu Nakayama, Katsumi Nakayama, Shiro Osada
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Patent number: 7243702Abstract: In a method of manufacturing a plurality of coil-shaped thin cast strips while molten metal r is being supplied to the molten metal pool 3 formed by a pair of cooling drums 1, 1 and a pair of side dams, when a casting operation corresponding to one coil of the coil-shaped thin cast strip has been completed, gas is made to blow from the gas nozzles 7b toward the scum s floating on the molten metal, so that the scum s drifts, due to the gas flow to one meniscus m2, and the thus drifted scum is attached to a surface of the cast strip and circumferential faces of the cooling drums and is then discharged from the molten metal pool.Type: GrantFiled: February 1, 2005Date of Patent: July 17, 2007Assignee: Nippon Steel CorporationInventors: Tadahiro Izu, Takashi Arai, Mamoru Yamada
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Patent number: 7234509Abstract: A molten metal containment device between the crystallizing rollers (38, 39) of a continuous casting machine comprises a lateral containment plate (47) able to press against the shoulder surfaces (40, 41) of the crystallizing rollers (38, 39); means of providing pressure (37) able to move said lateral containment plate (47) so as to move it close to and press it against said shoulder surfaces (40, 41). The lateral containment plate (47) is fixed to the means of providing pressure (37) through an articulated joint which comprises a flexible tubular sleeve (1), corrugated like bellows and able to support said lateral containment plate (47) allowing the horizontal pivoting at least around one axis of pivoting (X) horizontal and not parallel to the axes of rotation (A1, A2) of the rollers (38, 39). In a second aspect of the invention the containment plate (47) is fixed to the means of providing pressure (37) through more supports (20).Type: GrantFiled: August 26, 2003Date of Patent: June 26, 2007Assignee: Danieli & C. Officine Meccaniche S.p.A.Inventors: Alfredo Poloni, Andrea De Luca, Nuredin Kapaj
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Patent number: 7208433Abstract: Ceramic plates for side dams of twin-drum continuous strip casters comprising a REAG phase of 10 to 90 vol. %, a Sialon phase of 5 to 50 vol. %, a BN phase of 5 to 50 vol. % and an amorphous phase of over 0 to 20 vol. %, with the REAG phase comprising at least one rare-earth aluminum garnet phase selected from YAG, ErAG, YbAG and DyAG phases and the Sialon phase having a chemical formula, Si6?zAlzOzN8?z, wherein Z is between 0.05 and 1.9.Type: GrantFiled: March 31, 2003Date of Patent: April 24, 2007Assignee: Nippon Steel CorporationInventors: Tetsuro Nose, Tomohide Takeuchi
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Patent number: 7195054Abstract: 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: GrantFiled: September 13, 2002Date of Patent: March 27, 2007Assignees: SMS Demag AG, Main Management Inspiration AGInventors: Heinrich Marti, Jacques Barbé, Dominique Salathè, Alfred Koch
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Patent number: 7191819Abstract: Thin cast strip is produced in a twin roll caster by delivering molten steel between the rolls to form a casting pool. The casting pool is confined between the rolls by a pair of side dams adjacent the ends of the casting rolls. Steel strip is delivered downwardly to the nip through a metal delivery system having a tundish and core nozzles. One or more of the refractory components, including without limitation the tundish, core nozzles and side dams, or portions thereof, are replaced by first preheating the refractory component(s) to be replaced at a removed location, and then rapidly transferring the preheated component(s) from the preheating position and installing the same in the operating position by a transfer device. The desired refractory component is rapidly removed and the preheated replacement refractory component rapidly transferred and installed in the operating position in an amount of time that avoids thermal shock to the refractories that are not replaced.Type: GrantFiled: December 7, 2004Date of Patent: March 20, 2007Assignee: Nucor CorporationInventors: W. Kent Cooper, Steven R. Gage
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Patent number: 7168478Abstract: A system and method for producing thin cast strip by continuous casting is disclosed. The system includes a twin-roll casting apparatus having a pair of casting rolls positioned laterally adjacent each other to form a nip between the casting rolls through which metal strip may be continuously cast. A drive mechanism of the system is capable of individually driving the rotational speed of the casting rolls in a counter-rotational direction to cause the strip to pass through the nip between the casting rolls. A control mechanism of the system is capable of varying an alignment angle between the casting rolls to reduce effects of eccentricity in the casting rolls on a profile of the strip produced by the casting rolls.Type: GrantFiled: June 28, 2005Date of Patent: January 30, 2007Assignee: Nucor CorporationInventors: Jim Edwards, Walter N. Blejde
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Patent number: 7160398Abstract: A melt of an alloy, represented (Fe1-mTm)100-x-y-zQxRyMz, where T is Co and/or Ni, Q is B and/or C, R is at least one rare-earth element, M is selected from Al, Si, Ti, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb; 10 at %?x?35 at %; 2 at %?y?10 at %; 0 at %?z?10 at %; and 0?m?0.5, is prepared. Next, the melt is brought into contact with, and rapidly cooled and solidified by, the surface of a rotating chill roller. The melt is teemed onto a guide member, of which the guide surface defines a tilt angle with a horizontal plane, runs down on the guide surface, and then is fed through at least one tubular hole onto a contact area on the surface of the chill roller.Type: GrantFiled: June 27, 2003Date of Patent: January 9, 2007Assignee: Neomax Co., Ltd.Inventor: Hirokazu Kanekiyo
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Patent number: 7156151Abstract: A method of casting steel strip by introducing molten plain carbon steel on casting surfaces at least one casting roll with the molten steel having a free nitrogen content below 120 ppm and a free hydrogen content below about 6.5 ppm measured at atmospheric pressure. The free nitrogen content maybe below about 100 ppm or below about 85 ppm. The free hydrogen content maybe between 1.0 and 6.5 ppm at atmospheric pressure. Novel cast strip of plain carbon steel is produced having a strip thickness less than 5 mm or less than 2 mm by use of the method.Type: GrantFiled: October 8, 2004Date of Patent: January 2, 2007Assignee: Nucor CorporationInventors: Rama Ballay Mahapatra, Eugene B. Pretorius, David J. Sosinsky
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Patent number: 7156152Abstract: A process for the continuous production of a thin steel strip, in which a steel melt from a melt reservoir is introduced onto one or more, in particular two, cooled shaping wall surfaces which move synchronously with a casting strip, in particular rotate in the form of casting rolls and at least partially solidifies at the shaping wall surface to form the casting strip. The steel melt, in terms of the crucial alloying constituents, contains less than 1% by weight of Ni and less than 1% by weight of Cr and less than 0.8% by weight, in particular less than 0.4% by weight, of C and at least 0.55% by weight of Mn. In the process, recesses are arranged on the shaping wall surface in a random pattern, distributed uniformly over the shaping wall surface, and the roll separating force (RSF) at the shaping wall surface is set to a value of between 5 and 150 N/mm, in particular between 5 and 100 N/mm.Type: GrantFiled: April 15, 2005Date of Patent: January 2, 2007Assignee: Voest-Alpine Industrieanlagenbau GmbH & Co.Inventor: Gerald Hohenbichler
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Patent number: 7156150Abstract: A two-roll casting installation with two casting rolls which rotate in opposite directions about horizontal axes and forming a casting gap for forming and discharging a thin cast metal strip. A sealed housing which has a base and surrounds a conveying path for the metal strip which leaves the casting gap and which strip is from a vertical casting direction into an approximately horizontal conveying direction. Diverter devices divert the metal strip within the housing. A displaceable scrap collection container removes scrap and scale produced from the two-roll casting installation. To minimize the penetration of external air into the housing, the base of the housing, at least in a subregion, forms a collection trough for the scrap, which is part of an emptying device, and a displaceable scrap collection container is arranged in a receiving position below the emptying device.Type: GrantFiled: April 22, 2004Date of Patent: January 2, 2007Assignee: Voest-Alpine Industrieanlagenbau GmbH & Co.Inventors: Michael Zahedi, Thomas Stepanek, Gerald Hohenbichler, Franz Plöckinger, Karl Klima
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Patent number: 7156153Abstract: To start up a casting operation in a two-roll casting device without the use of a start-up strand, the method comprises setting an operating casting thickness and rotating the casting rolls at a casting-roll circumferential velocity which corresponds to a starting casting velocity, which is lower than a steady-state operating casting velocity, feeding metal melt into a melt space formed by the rotating casting rolls and the side plates to form a cast metal strip with a substantially constant, predetermined cross-sectional format while at the same time increasing the casting velocity to a strip-forming casting velocity, then increasing the casting velocity to a strip-separating casting velocity, which is significantly higher than a casting velocity which is sufficient for the prevailing full solidification conditions, and separating off the metal strip which has been cast thus far, setting a steady-state operating casting velocity, diverting the subsequent cast metal strip to a strip-conveying device and commeType: GrantFiled: August 18, 2003Date of Patent: January 2, 2007Assignee: Voest-Alpine Industrieanlagenbau GmbH & Co.Inventors: Gerald Hohenbichler, Gerald Eckerstorfer
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Patent number: 7147035Abstract: A method for casting metal strip by controlling the distance between the confining side plates confining the casting pool and the outer nozzle ends of discrete nozzle pieces of the delivery nozzle delivering the molten melt. The nozzle pieces defining the outer nozzle ends may be moved and control separately from the position of the confining plates, or with the position of the confining plates, by a nozzle delivery drive. The distance between the outer nozzle ends and the confining plates may be set before casting and maintained during casting with wear and thermal expansion of the confining plates, nozzle pieces, or both, or varied during the casting operation, to inhibit the formation of skulls in the casting pool and the formation of “snake eggs” in the cast strip.Type: GrantFiled: September 27, 2004Date of Patent: December 12, 2006Assignee: Castrip LLCInventors: John Andrew Fish, Heiji Kato
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Patent number: 7140418Abstract: A continuous metallic strip casting plant comprising an ingot mould, a device for the evacuation of casting wastes formed by a trolley which can host two chests. The trolley is located below the ingot mould and on the trolley is deposited the full chest in the free space next to the spare empty chest. The trolley is then moved and the spare empty chest is fixed under the ingot mould. A metal waste evacuation method is also described.Type: GrantFiled: July 10, 2003Date of Patent: November 28, 2006Assignee: Danieli & C. Officine Meccaniche S.p.A.Inventors: Brian W. Botham, Andrea De Luca, Edi Faggiani, Alfredo Poloni, Nuredin Kapaj
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Patent number: 7134481Abstract: A casting roll unit (U) with side weirs (6) and a delivery nozzle (8) being detachably attached thereto is fixed at a casting position. Side-weir and delivery-nozzle preheating furnaces (29, 30) are arranged away from the casting roll unit (U). Arranged adjacent to the roll unit (U) are replacing robots (31, 32) which can selectively clamp the side weirs (6) or the delivery nozzle or nozzles (8) and which can move between the roll unit (U) and the side-weir or delivery-nozzle preheating furnace (29 or 30) for installation/removal of the side weirs (6) or delivery nozzle or nozzles (8).Type: GrantFiled: November 11, 2003Date of Patent: November 14, 2006Assignee: Ishikawajima-Harima Heavy Industries Co., Ltd.Inventors: Shiro Osada, Osamu Takeuchi, Shu Ogawa
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Patent number: 7121322Abstract: The invention relates to a strip-casting machine for production of a metal strip, comprising two adjacent case-width casting rollers (22, 24), forming a casting gap (15?), with side seals (25) arranged on the front face thereof. The rotating casting rollers are mounted on a machine mount (32). Between the above and the side seals (25), the metal melt, introduced by means of at least one casting tube (13), or similar, is protected by at least one gaseous medium. At least said casting rollers (22, 24) are surrounded on at least the case width and front face thereof as well as the side seals by a preferably multi-component housing (30, 60, 80). An optimal sealing of the casting rollers as well as the metal strip and the metal strip appearing from between the rollers can thus be achieved in a simple manner.Type: GrantFiled: September 19, 2001Date of Patent: October 17, 2006Assignees: Main Management Inspiration AG, SMS Demag AGInventors: Heinrich Marti, Jacques Barbé
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Patent number: 7117925Abstract: A cast carbon steel strip is prepared by continuously casting in a twin roll caster and cooling to transform the strip from austenite to ferrite at a temperature range between 400° C. and 850° C. at cooling the strip to transform the austenite to ferrite within a temperature range between 400° C. and 850° C. at a cooling rate of greater than 100° C./sec without inhibiting the cooling rate to form cast strip that is less than about 1% austenite and has a packet size of at least 10% greater than 300 ?m, is either (i) a mixture of polygonal ferrite and low temperature transformation products or (ii) predominantly low temperature transformation products, and has a yield strength of at least 450 MPa. The cast strip before cooling is passed through a hot rolling mill to reduce the thickness of strip by at least 15% and up to 50%.Type: GrantFiled: August 4, 2005Date of Patent: October 10, 2006Assignee: Nucor CorporationInventors: Lazar Strezov, Kannappar Mukunthan, Walter Blejde, Rama Mahaptra
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Patent number: 7108047Abstract: The invention relates to a method for operating a strip casting machine (10), whereby molten metal (18) is poured between two rotatable casting rolls (11, 12). A gaseous film (G) is formed between the respective surfaces (11?, 12?) of the casting rolls and the strip skin (D1, D2, D3) forming on the molten metal, the gas being introduced essentially into the inerting chamber (24 ) above the metal bath. During the casting, a controlled quantity of a gas consisting of argon, nitrogen and/or another gas is introduced into the inerting chamber (24) in such a way that the heat transfer from the strip skin to the casting rolls (11, 12) can be influenced by the thickness of the gaseous film (G) in such a way that the surfaces (11, 12?) of the casting rolls can be provided with or without cavities (51). A smooth surface can thus also be obtained on the strip cast.Type: GrantFiled: December 21, 2001Date of Patent: September 19, 2006Assignees: SMS Demag AG, Main Management Inspiration AGInventors: Heinrich Marti, Jacques Barbé
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Patent number: 7100673Abstract: Support device for an assembly (14) of the casting rolls (11, 11?) of a continuous metallic strip casting line comprising a movable support at each axial end. Such supports (17, 17?, 19, 19?) are provided with a hydraulic bearing (13) to reduce friction during motion with respect to the assembly. Between the movable supports of one of the rolls (11) and the assembly is located a hydraulic actuator (18), which thrusts the first roll (11?) towards the second roll (11?) against a stop (16). Between the second roll (11?) and the assembly there are located magnetostrictive actuators which thrust the second roll (11?) against the first roll (11). The device has a joint provided with a housing (22) inside which a telescopic tube (21) for the supply of the cooling water to conduits present in the rolls may slide. The housing (22) is connected to the assembly (14) by means of a bellows (27) allowing for oscillation.Type: GrantFiled: July 10, 2003Date of Patent: September 5, 2006Assignee: Danieli & C. Officine Meccaniche, S.p.A.Inventors: Brian W. Botham, Andrea De Luca, Alfredo Poloni, Edi Faggiani, Nuredin Kapaj
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Patent number: 7100674Abstract: Disclosed herein is a method for drawing a strip initially cast by means of a twin roll strip casting apparatus. The method comprises a roll gap maintenance step where roll gap is maintained, a casting initiation step where a stopper is disengaged from a tundish hole so that molten metal is poured into a space between the rolls, and the rolls are rotated at speed v0 of each of the rolls if the position of the stopper is higher than the actually poured position of the molten metal, a casting speed acceleration step where a roll repulsive force is detected when the molten metal is solidified to the leader strip and passes between the rolls, and the casting speed is accelerated if the roll repulsive force reaches a load threshold, and a normal control step where the casting speed is detected, and if the casting speed reaches a target value.Type: GrantFiled: November 12, 2003Date of Patent: September 5, 2006Assignee: Posco Co., Ltd.Inventors: Yoon-Ha Kim, Wan-Soo Kim, Dae-Sung Lee
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Patent number: 7098159Abstract: A refractory article for use in casting operations wherein said article is subject to prolonged contact with molten metal of at least 1500° C. for at least three hours, said article comprises a ceramic composite consisting essentially of about 10 to about 40 wt. % mullite; about 35 to about 5 wt. % aluminium nitride; and at least about 20 wt. % boron nitride, for forming a reactive coating layer covering at least 80% of exposed surfaces and providing corrosion/erosion protection for said article against molten metal.Type: GrantFiled: January 23, 2003Date of Patent: August 29, 2006Assignee: General Electric CompanyInventor: Cathryn R. Krolikowski
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Patent number: 7066237Abstract: Methods for casting an austenitic stainless steel thin strip casting through a continuous caster, e.g., a twin-drum type caster, in which the mold walls move synchronous with the casting to obtain a casting, wherein defects, e.g., salt-and-pepper unevenly glossy defects, on a steel sheet formed after cold rolling or cold forming are prevented. In particular, casting an austenitic stainless steel thin strip casting by regulating a pressing force P of mold wall faces against the casting in the range from more than 1.0 to less than 2.5 t/m, and preferably from more than 1.1 to not more than 1.6 t/m. The continuous caster used may be a twin-drum type continuous caster, with a drum radius R(m) and a pressing force P(t/m) of mold wall faces satisfying the relation 0.5?(?{square root over (R)})×P?2.0, and preferably 0.8?(?{square root over (R)})×P?1.2.Type: GrantFiled: March 27, 2003Date of Patent: June 27, 2006Assignee: Nippon Steel CorporationInventors: Masafumi Miyazaki, Shuichi Inoue, Toshikazu Nishimura, Hiroshige Inoue
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Patent number: 7066238Abstract: A process and apparatus for producing a metal strip using a two-roller casting device formed by two oppositely rotating casting rollers with parallel casting-roller axes and two side plates which bear against end sides of the casting rollers. The metal melt is conveyed out of the casting gap formed by the casting rollers as an at least partially solidified metal strip. To improve the sealing of the melt pool at the start of casting and in the event of parasitic solidifications passing through the casing gap, the side plates during a first time interval are moved onto the end sides of the casting rollers in a first direction of movement parallel to the casting-roller axes, and the side plates during a second time interval, are moved onto a portion of the lateral surfaces of the casting rollers in a second direction of movement parallel to the casting direction in the casting gap.Type: GrantFiled: June 18, 2003Date of Patent: June 27, 2006Assignee: Voest-Alpine Industrieanlagenbau GmbH & Co.Inventors: Gerald Hohenbichler, Gerald Eckerstorfer, Armin Schertler
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Patent number: 7059384Abstract: Disclosed is a method and apparatus for continuously casting a metal strip. A casting pool of molten metal is formed, and a metal strip is solidified onto a casting surface. The temperature of the casting surface is maintained above a predetermined critical value. By maintaining the surface temperature above the predetermined critical value, either the heat transfer uniformity or the heat transfer capacity or both are improved.Type: GrantFiled: June 14, 2002Date of Patent: June 13, 2006Assignee: National Research Council of CanadaInventors: Dominique Bouchard, Jean-Paul Nadeau, Francois Hamel, Daniel Simard, Serge F. Turcotte
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Patent number: 7048032Abstract: A device for casting a molten metal comprising casting rolls and a housing arranged downstream from the rolls for the cast strip. The aim of the invention is to be able to replace the casting rolls with minimum mounting, and to simultaneously reduce the thermal load of the casting rolls and the adjacent units. A casting roll screen which forms a displaceable structural unit with a frame used to support the casting rolls.Type: GrantFiled: February 25, 2003Date of Patent: May 23, 2006Assignees: Voest Alpine Industrieanlagenbau GmbH & Co., Thyssenkrupp Nirosta GmbHInventors: Gerald Hohenbichler, Michael Zahedi, Karl Klima, Thomas Stepanek, Guido Stebner, Wilhelm Mankau, Werner Schümers
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Patent number: 7048033Abstract: A method of producing strip comprising the steps of assembling a pair of casting rolls with a nip between them, introducing between the casting rolls to form a casting pool of molten carbon steel having a total oxygen content of at least 70 ppm usually less than 250 ppm, and a free oxygen content 20 and 60 ppm, counter rotating the casting rolls, solidifying the molten steel on the rolls to form metal shells with levels of oxide inclusions reflected by the total oxygen content of the molten steel, and forming thin steel strip through the nip between the casting rolls from the solidified shells. The molten steel may have a total oxygen content is at least 100 ppm and the free oxygen content may be between 30 and 50 ppm. A unique steel strip may be obtained using the method having ductile properties.Type: GrantFiled: January 21, 2004Date of Patent: May 23, 2006Assignee: Nucor CorporationInventors: Walter N. Blejde, Rama Ballav Mahapatra, Lazar Strezov
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Patent number: 7044193Abstract: In a method for the continuous casting of a thin metal strip according to the two-roll method, metal melt is cast into a casting gap formed by two casting rolls of the thickness of the metal strip to be cast, under formation of a melting bath. In order to form a particular texture within the cast metal strip and/or to influence the geometry of the metal strip, continuous casting is carried out by an on-line calculation based upon an arithmetic model describing the formation of the particular texture of the metal and/or the formation of the geometry of the metal strip, wherein variables of the continuous casting method affecting the formation of the texture and/or the geometry are adjusted in an on-line dynamic fashion, i.e. while casting takes place.Type: GrantFiled: June 1, 2004Date of Patent: May 16, 2006Assignee: Voest-Alpine Industrieanlagenbau GmbH & Co.Inventors: Kurt Etzelsdorfer, Gerald Hohenbichler, Christian Chimani, Gerhard F Hubmer, Dietmar Auzinger
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Patent number: 7028749Abstract: A process for the production of magnesium alloy strip, by twin roll casting, includes the steps of passing molten alloy from a source of supply to a feeding device; feeding the alloy from the feeding device through an elongate outlet of a nozzle and a pair of substantially parallel rolls spaced to define a bite therebetween; rotating said rolls whereby alloy is drawn from the chamber through the bite; and flowing coolant fluid through each roll and thereby cool alloy received in the chamber by heat energy extraction by the rolls whereby substantially complete solidification of the alloy is achieved in the chamber prior to alloy passing through the bite as hot rolled alloy strip.Type: GrantFiled: February 28, 2005Date of Patent: April 18, 2006Assignee: Commonwealth Scientific and Industrial Research OrganisationInventors: Daniel Dong Liang, Wendy Borbidge, Daniel Raymond East, Ross Victor Allen
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Patent number: 6948550Abstract: A process for manufacturing a strip of aluminum alloy having high surface homogeneity with an upper side showing after a 1 ?m thick sulphur anodic treatment, an optical roughness value SN measured on three 5 cm longitudinal sections and three 5 cm transverse sections, such that its mean variation on each section, defined by the ratio: (Maximum SN?minimum SN)/Mean SN is less than 20%, and the difference ?SN=SN max ?SN min is less than 20. The strip is manufactured by continuous casting between two cooled rolls from a casting tank containing the liquid metal connected to an injector, and feeding the liquid metal into the gap between the two rolls. The injector has an upper lip recessed by at least 2 mm with reference to a lower lip of the injector.Type: GrantFiled: December 13, 2001Date of Patent: September 27, 2005Assignee: Pechiney RhenaluInventors: Jean-Luc Hoffmann, Pierre-Yves Menet, Klaus Maiwald, Regine Debreux, Martin-Peter Schmidt, Yves Scelles
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Patent number: 6943874Abstract: The invention concerns an apparatus for inspecting a surface, in particular the surface of a mill roll, comprising a housing wherein are arranged means for transmitting and receiving a light beam, and an optical coupling device arranged on the outer surface of a front wall of the housing. The optical coupling device comprises: (a) a component (5), called fluid dispenser, (b) a hollow cylindrical nozzle (11), and (c) a mobile tubular component (16), successively traversed by the light beam. The mobile tubular component (18) is arranged partly inside the cylindrical nozzle (11), so as to be able to slide inside said cylindrical nozzle, and partly exits therefrom in the extension thereof, towards the surface to be inspected (2). Different cross-sections (shoulders 14, 19) are provided in the cylindrical nozzle (11) and in the mobile tubular component (16), in particular for limiting said sliding movement.Type: GrantFiled: August 1, 2002Date of Patent: September 13, 2005Assignee: Centre de Recherches Metallurgiques, A.S.B.L.Inventors: Roger Franssen, Hogo Uijtdebroeks
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Patent number: 6942013Abstract: In twin roll casting of steel strip, molten steel is introduced into the nip between parallel casting rolls to create a casting pool supported on casting surfaces of the rolls and the rolls are rotated to deliver solidified strip downwardly from the nip. Casting surfaces are textured by a random pattern of discrete projections at least some of which include peaks having a surface distribution of between 5 and 200 projections per mm2 and an average height of at least 10 microns. The random texture may be produced by grit blasting the casting surfaces on a substrate covered by a protective coating. Alternatively the texture may be produced by chemical deposition or electrodeposition of a coating onto a substrate to form the casting surfaces.Type: GrantFiled: June 5, 2002Date of Patent: September 13, 2005Inventors: Lazar Strezov, Kannappar Mukunthan
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Patent number: 6923245Abstract: The invention concerns a method for producing a metal strip, whereby molten 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: GrantFiled: September 13, 2002Date of Patent: August 2, 2005Assignees: SMS Demag Aktiengesellschaft, Main Management Inspiration AGInventors: Heinrich Marti, Jacques Barbe, Dominique Salathe, Alfred Koch
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Patent number: 6920912Abstract: Roll caster (11) produces thin steel strip (12) formed on casting surfaces (22A) of casting roll (22) that passes through first enclosure (37) adjacent casting roll surfaces (22A) and, optionally, thereafter second enclosure (61). Enclosure (37) and/or enclosure (61) may be fitted with spray nozzles (71,72) and/or (67, 68) operable to spray fine water mist adjacent strip (12) to produce hydrogen gas in enclosure (37) while tending to avoid liquid water contact with steel strip (12) and casting surfaces (22A). If hydrogen gas is produced only in enclosure (61), the two enclosures (37, 61) are interconnected so that gas can flow from enclosure (61) to enclosure (37). Enclosure (37) and, if present, enclosure (61) are sealed to maintain positive pressure and oxygen levels less than the surrounding atmosphere, and with the presence of hydrogen gas, reduce formation of scale on the strip in enclosure (37) and, if present, enclosure (61).Type: GrantFiled: April 11, 2003Date of Patent: July 26, 2005Assignee: Nucor CorporationInventors: Walter N. Blejde, Andrew Glutz