Abstract:
A bottom heated holder furnace (12) for containing a supply of molten metal includes a storage vessel (30) having sidewalls (32) and a bottom wall (34) defining a molten metal receiving chamber (36). A furnace insulating layer (42) lines the molten metal receiving chamber (36). A thermally conductive heat exchanger block (54) is located at the bottom of the molten metal receiving chamber (36) for heating the supply of molten metal. The heat exchanger block (54) includes a bottom face (65), side faces (66), and a top face (67). The heat exchanger block (54) includes a plurality of electrical heaters (70) extending therein and projecting outward from at least one of the faces of the heat exchanger block (54), and further extending through the furnace insulating layer (42) and one of the sidewalls (32) of the storage vessel (30) for connection to a source of electrical power. A sealing layer (50) covers the bottom face (65) and side faces (66) of the heat exchanger block (54) such that the heat exchanger block (54) is substantially separated from contact with the furnace insulating layer (42).
Abstract:
The present invention provides a method for maintaining a homogenized melt and controlled fields of a molten metal, by regulating the reciprocal combination of non‐intrusive electromagnetic members, which are connected to a heat loss compensator. The molten metal from the tundish is supplied to a caster, at uniform melt flow rate and temperature to a caster. The present invention also provides an apparatus and system for maintaining a homogenized melt and controlled fields of a molten metal in a tundish so as to facilitate an optimum melt superheat and melt flow rate at tundish outlets.
Abstract:
A method of producing a semi-solid material without stirring, including heating a metal alloy to form a metallic melt M, transferring a select amount of the melt M into a vessel 80, 200, 300, nucleating the melt M by regulating the transferring of the melt M into the vessel 80, 200, 300, and crystallizing the melt M within the vessel 80, 200, 300 by cooling the melt M at a controlled rate to produce a semi-solid material S having a microstructure comprising rounded solid particles dispersed in a liquid metal matrix. In one form of the invention, a temperature-controlled shot sleeve 80 is provided for receiving and cooling an amount of metallic melt M at a controlled rate to produce the semi-solid material S. The shot sleeve 80 has a number of heat transfer zones 102a, 102b adapted to independently control the temperature of the melt M disposed adjacent various portions of the shot sleeve 80. The shot sleeve 80 also includes a ram 84 operable to discharge the semi-solid material S directly into a die mold 90 to form a near-net-shape part.
Abstract:
A bottom heated holder furnace (10) for containing a supply of molten metal includes a storage vessel (20) having sidewalls (22) and a bottom wall (24) defining a molten metal receiving chamber (26). A furnace insulating layer (32) lines the molten metal receiving chamber (26). A thermally conductive heat exchanger block (50) is located at the bottom of the molten metal receiving chamber (26) for heating the supply of molten metal. The heat exchanger block (50) includes a bottom face (55), side faces (56), and a top face (57). The heat exchanger block (50) includes a plurality of electrical heaters (70) extending therein and projecting outward from at least one of the faces of the heat exchanger block (50), and further extending through the furnace insulating layer (32) and one of the sidewalls (22) of the storage vessel (20) for connection to a source of electrical power. A sealing layer (60) covers the bottom face (55) and side faces (56) of the heat exchanger block (50) such that the heat exchanger block (50) is substantially separated from contact with the furnace insulating layer (32). A gas pressurization valve (118) is in fluid communication with the molten metal receiving chamber (26) and the interior of the heat exchanger block (50) for pressurizing the interior of the holder furnace (10).
Abstract:
The invention relates to a method for controlling the temperature of a melt (10), preferably of a steel melt, in a distributing vessel (11), whereby the temperature of the melt is measured, the measured result is compared with a predetermined temperature range in the form of specified values, and as much heat is supplied or withdrawn from the melt such that the temperature remains inside said range. In order to control the melt temperature, a fireproof shaped part (20) which is closed on both sides and which is provided for accommodating a liquid-cooled induction coil (1) is immersed in the melt (10). The transmission of heat is carried out by means of thermal conduction out of the wall of the shaped part (20) which is coupled to the induced electromagnetic field and/or by means of a direct coupling to the liquid melt (10). The shaped part (20) accommodates the induction coil (1) in an interchangeable manner while leaving cooling channels (9) open and is positioned from the outside by a manipulator (16) which can be lifted, lowered and turned.
Abstract:
An open bottom electric induction cold crucible with a slotted wall extending below one or more induction coils surrounding the partial exterior height of the crucible is used in an electromagnetic casting process for the production of ingots. A bottom magnetic shield is provided around the outer perimeter of the crucible's slotted wall in the vicinity of the bottom opening and the bottom termination of the wall slots and the bottom connecting member.
Abstract:
A bottom heated holder furnace (10) for containing a supply of molten metal includes a storage vessel (20) having sidewalls (22) and a bottom wall (24) defining a molten metal receiving chamber (26). A furnace insulating layer (32) lines the molten metal receiving chamber (26). A thermally conductive heat exchanger block (50) is located at the bottom of the molten metal receiving chamber (26) for heating the supply of molten metal. The heat exchanger block (50) includes a bottom face (55), side faces (56), and a top face (57). The heat exchanger block (50) includes a plurality of electrical heaters (70) extending therein and projecting outward from at least one of the faces of the heat exchanger block (50), and further extending through the furnace insulating layer (32) and one of the sidewalls (22) of the storage vessel (20) for connection to a source of electrical power. A sealing layer (60) covers the bottom face (55) and side faces (56) of the heat exchanger block (50) such that the heat exchanger block (50) is substantially separated from contact with the furnace insulating layer (32). A gas pressurization valve (118) is in fluid communication with the molten metal receiving chamber (26) and the interior of the heat exchanger block (50) for pressurizing the interior of the holder furnace (10).
Abstract:
A method of skull-melting comprising the steps of providing a vessel (50) for skull-melting with an interior (56) and an underside, and an orifice (52) connecting the interior (56) to and underside. Disposing a waveguide (54) in the orifice (52) so that the waveguide (54) protrudes into the interior (56) to interact with the skull-melting process. Providing a signal energy transducer (14) in communication with the waveguide (54). Carrying out the skull-melting process so that a solidified skull of the working material is formed, the skull and vessel (50) having an interface therebetween, the skull being fused to the waveguide (54) so that the signal energy can be transmitted through the waveguide (54) and skull without interference from the interface. Activating the signal energy transducer (14) so a signal is transmitted through the waveguide (54), and controlling at least one variable of the skull-melting process utilizing feedback derived from the propagated signal energy.
Abstract:
A process to hold molten aluminum alloy in a refractory lined vessel using heating elements disposed within ceramic immersion heating tubes to provide accurate temperature metal for the casting industry. The vessel is lined with multi thicknesses of high insulating refractory materials to minimize heat loss with contoured corners to allow smooth flow of circulating metal provided by a gear drive with rotary shaft and impeller. The heating elements are housed in a ceramic protection tube to prevent aluminum leakage which would result in element failure. The receiving and outlet wells are separated by refractory arches. An insulated inert gas purged cover is used over the heat chamber to reduce heat loss and allow for an inert purge gas to minimize surface oxidation. A thermocouple for temperature control is positioned in the exit chamber. A ceramic drain plug is provided to remove metal for maintenance.