# US 2024/0198413 A1 · Nosetip design for high-performance continuous casting > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2024/0198413 A1 - Document ID: US20240198413A1 - Status: Published application - Kind: A1 - Application number: 18/555,401 - Filed: 2022-06-01 - Published: 2024-06-20 - Earliest claimed: 2021-06-02 - Assignees: Novelis Inc. - Applicants: Novelis Inc. - Inventors: Samuel Robert Wagstaff; Simon William Barker - Web page: https://patentgrep.com/patent/US20240198413A1 ## CPC - B22D 11/064: {for supplying molten metal (supplying molten metal to open-ended moulds B22D11/10)} - B22D 11/0605: {formed by two belts, e.g. Hazelett-process} - B22D 11/0622: {formed by two casting wheels} - B22D 11/0642: {Nozzles (nozzles used in open-ended moulds B22D41/50)} - B22D 11/115: by using magnetic fields - B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22) ## Abstract Described are nosetips for continuous casting of a metal alloy. The nosetip may include a first portion having a first surface parallel to a second surface opposite the first surface. The nosetip may include a second portion having a third surface directed toward an extended first surface. The extended first surface may be in a common plane with the first surface. The nosetip may include a third portion having an arcuate surface connecting the third surface to the extended first surface. The arcuate surface may include a point of curvature at a vertical distance from the extended first surface. The vertical distance may be configured to limit a maximum meniscus height for liquid metal, cast using the nosetip, between the nosetip and a continuous casting surface. Also described are methods of continuous casting a metal alloy at a casting speed of greater than 12 m/min. ## Claims ### Claim 1 A nosetip for continuous casting of a metal alloy, the nosetip comprising: a first portion having a first surface parallel to a second surface, the second surface opposite the first surface; a second portion having a third surface directed toward an extended first surface, the extended first surface in a common plane with the first surface; and a third portion having an arcuate surface connecting the third surface to the extended first surface. ### Claim 2 (depends on 1) The nosetip of claim 1, wherein the arcuate surface includes a point of curvature. ### Claim 3 (depends on 2) The nosetip of claim 2, wherein the point of curvature is a vertical distance from the extended first surface, the vertical distance configured to limit a maximum meniscus height for liquid metal, cast using the nosetip, between the nosetip and a continuous casting surface. ### Claim 4 (depends on 2) The nosetip of claim 2, wherein the third portion includes a cutback between the point of curvature and the extended first surface. ### Claim 5 (depends on 1) The nosetip of claim 1, wherein the third portion includes a turbulence generating mechanism. ### Claim 6 (depends on 5) The nosetip of claim 5, wherein the turbulence generating mechanism is at least one chosen from a plurality of dimples, a plurality of ribs, a plurality of piers, or a surface roughness greater than a surface roughness of the first surface, the second surface, or the extended first surface. ### Claim 7 (depends on 1) The nosetip of claim 1, wherein the nosetip comprises a refractory material. ### Claim 8 A method of continuous casting a metal alloy, the method comprising: providing an arcuate nosetip, the arcuate nosetip including: a first portion having a first surface parallel to a second surface, the second surface opposite the first surface; a second portion having a third surface directed toward an extended first surface, the extended first surface in a common plane with the first surface; and a third portion having an arcuate surface connecting the third surface to the extended first surface; and flowing liquid metal, through the arcuate nosetip, to a casting cavity to form a cast product. ### Claim 9 (depends on 8) The method of claim 8, wherein a meniscus length of the liquid metal flowing through the arcuate nosetip is at most equal to a distance from a point of curvature to a casting surface partially defining the casting cavity. ### Claim 10 (depends on 9) The method of claim 9, wherein the meniscus length is from 0.5 mm to 2.0 mm. ### Claim 11 (depends on 8) The method of claim 8, wherein the third portion of the arcuate nosetip further comprises a turbulence generating mechanism. ### Claim 12 (depends on 11) The method of claim 11, wherein the turbulence generating mechanism is at least one chosen from a surface roughness, a plurality of dimples, a plurality of ribs, a plurality of piers, and combinations thereof. ### Claim 13 (depends on 8) The method of claim 8, further comprising generating turbulence in the liquid metal at the arcuate surface using a magnetic oscillation technique. ### Claim 14 (depends on 8) The method of claim 8, wherein the nosetip is a refractory material. ### Claim 15 (depends on 8) The method of claim 8, wherein the cast product has a surface roughness of at most 10 μm. ### Claim 16 (depends on 8) The method of claim 8, wherein the cast product has a composition near the surface having a decrease in Fe and Mn at the cast surface as compared with a reference conventionally cast standard. ### Claim 17 (depends on 16) The method of claim 16, wherein the composition is characterized by Glow Discharge Optical Emission Spectroscopy. ### Claim 18 (depends on 8) The method of claim 8, wherein the cast product has an exudate frequency of at most 30 exudates/cm2. ### Claim 19 (depends on 18) The method of claim 18, wherein the exudate frequency is determined by 3D image analysis. ### Claim 20 (depends on 8) The method of claim 8, wherein the method provides a casting speed of greater than 12 m/min.