Method and apparatus for electromagnetic confinement of molten metal in horizontal casting systems

An apparatus for strip casting of molten metal comprising:

• (a) a pair of opposing endless metal belts, each of the pair of opposing endless metal belts passing over a roller and having a periphery substantially aligned to a sidewall of the roller, said each of said opposing endless metal belts having a surface for accepting molten metal, wherein a vertical dimension separation the pair of opposing endless metal belts defines a molding zone;
• (b) an electromagnetic edge containment apparatus positioned on each side of the molding zone comprising an induction coil wound about a portion of a magnetic member to generate magnetic lines of force upon application of a current, wherein the current provides magnetic lines of force that contain the molten metal within a width and in contact to at least a portion of said pair of opposing endless metal belts with substantially no increase in temperature to the molten metal;
• and
• (c) a means for supplying said molten metal to the molding zone along a horizontal axis from a tundish, the tundish separated from said molding zone by a distance to substantially eliminate wave generation within the tundish by the magnetic lines of force.

A cast metal strip comprising:

• a first shell;
• a second shell;
• and
• a central portion between said first shell and said second shell, said central portion comprising grains having an equiaxed structure, wherein said cast metal strip has sidewall edges being substantially uniform.

A casting apparatus comprising:

• (a) a pair of casting rollers adapted to receive molten metal along a horizontal axis, wherein a vertical distance separating the pair of casting rollers defines a molding zone;
• (b) a tip delivery structure positioned to supply the molten metal to the molding zone along said horizontal axis from a tundish while ensuring said molten metal remains substantially non-oxidized;
• and
• (c) an edge containment apparatus positioned on each side of the molding zone, said edge containment apparatus comprising:
• a mechanical edge dam positioned overlying at least an end portion of said tip delivery structure and partially extending towards said molding zone, and
• an electromagnetic edge dam comprises a first and second magnetic pole positioned distal from and aligned to a sidewall of said pair of casting rollers and overlying a portion of said mechanical edge dam partially extending towards said molding zone, wherein said electromagnetic edge dam provides magnetic lines of force perpendicular to said horizontal axis that contain the molten metal in contact to the casting rollers.

A method of forming a cast metal strip comprising

• providing molten metal to a molding zone along a horizontal axis;
• containing said molten metal within said molding zone with a magnetic containment means;
• and
• casting said molten metal into a cast metal strip, wherein sidewall geometry of said cast metal strip is configured by adjusting said magnetic containment means.