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US 10,464,127 B2Granted
Non-contacting molten metal flow control
AssigneeNovelis Inc.
InventorsSamuel R. Wagstaff, Wayne J. Fenton, Robert B. Wagstaff, Milan Felberbaum, Todd F. Bischoff, Tina J. Kosmicki
Life of this patent
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Abstract
Systems and methods are disclosed for using magnetic fields (e.g., changing magnetic fields) to control metal flow conditions during casting (e.g., casting of an ingot, billet, or slab). The magnetic fields can be introduced using rotating permanent magnets or electromagnets. The magnetic fields can be used to induce movement of the molten metal in a desired direction, such as in a rotating pattern around the surface of the molten sump. The magnetic fields can be used to induce metal flow conditions in the molten sump to increase homogeneity in the molten sump and resultant ingot.
Claims30
An apparatus comprising:
- a mold for accepting molten metal, wherein the mold comprises one or more stationary mold walls for solidifying the molten metal into a solidifying ingot;
- a bottom block lowerable to support the solidifying ingot, wherein a molten sump of the solidifying ingot extends from a surface of the molten metal to a point below the one or more mold walls;
- a submersible feed tube couplable to a metal source and positioned to supply the molten metal to the molten sump;
- and
- at least one non-contact flow inducer positioned above the surface of the molten metal for generating a changing magnetic field proximate the surface of the molten metal for inducing molten flow in the molten metal, wherein the induced molten flow is configured to excite a velocity of the molten metal adjacent a transitional region between the molten metal and the solidifying ingot.
2 more elements
A method comprising:
- introducing molten metal into a mold cavity comprising one or more stationary mold walls for solidifying the molten metal into a solidifying ingot, wherein introducing the molten metal comprises passing the molten metal from a metal source to a molten sump of the solidifying ingot using a submersible feed tube;
- lowering a bottom block of a mold cavity as the molten metal begins to solidify within the mold cavity, wherein the molten sump extends from an upper surface of the molten metal to a point below the one or more mold walls;
- generating a changing magnetic field proximate the upper surface of the molten metal;
- and
- inducing molten flow in the molten metal by generating the changing magnetic field using at least one non-contact flow inducer positioned above the surface of the molten metal, wherein the induced metal flow is configured to excite a velocity of the molten metal adjacent a transitional region between the molten metal and the solidifying ingot.
2 more elements
A system comprising:
- a mold for accepting molten metal, wherein the mold comprises one or more stationary mold walls for solidifying the molten metal into a solidifying ingot;
- a bottom block lowerable to support the solidifying ingot, wherein a molten sump of the solidifying ingot extends from a surface of the molten metal to a point below the one or more mold walls;
- a submersible feed tube couplable to a metal source and positioned to supply the molten metal to the molten sump;
- a non-contacting flow inducer positioned directly above the surface of the molten metal;
- and
- a magnetic source included in the non-contacting flow inducer for generating a changing magnetic field for inducing molten flow under the surface of the molten metal and increasing mixing of the molten metal.
3 more elements
An apparatus comprising:
- a mold for accepting molten metal, wherein the mold comprises one or more stationary mold walls for solidifying the molten metal into a solidifying ingot;
- a bottom block lowerable to support the solidifying ingot, wherein a molten sump of the solidifying ingot extends from a surface of the molten metal to a point below the one or more mold walls;
- a submersible feed tube couplable to a metal source and positioned to supply the molten metal to the molten sump;
- and
- at least one magnetic source positioned above the mold for generating an alternating magnetic field proximate the surface of the molten metal for directing movement of metal oxides on the surface of the molten metal and increasing mixing and velocity of the molten metal adjacent a transitional region between the molten metal and the solidifying ingot.
2 more elements
Dependencies are inferred from the claim text.