Horizontal direct chill casting apparatus and method

Abstract

A casting apparatus ( 10 ) for direct chill casting metal includes a tundish ( 12 ) containing a supply of molten metal, a casting mold ( 14 ), and a starter block ( 44 ) associated with the casting mold ( 14 ). The casting mold ( 14 ) is in fluid communication with the tundish ( 12 ) through a passage ( 22 ) defined in the tundish wall. The casting mold ( 14 ) includes a header plate ( 24 ), a casting ring ( 26 ), and a feed ring ( 28 ). The header plate ( 24 ) defines an arcuate shaped opening ( 36 ) connected to the passage ( 22 ). The header plate ( 24 ) has an upstream side ( 38 ) and a downstream side ( 40 ). The casting ring ( 26 ) is connected to the downstream side ( 40 ) of the header plate ( 24 ) and defines a groove ( 52 ) proximate to the sidewall ( 48 ) of the header plate ( 24 ). The feed ring ( 28 ) is disposed in the groove.

1 . A casting mold for direct chill casting metal, comprising: 
 a header plate defining an arcuate shaped opening, the header plate having an upstream side and a downstream side, the downstream side defining a recess having a tapered sidewall;    a casting ring connected to the downstream side of the header plate and defining a groove proximate to the sidewall of the header plate; and    a feed ring disposed in the groove for cooling and at least partially solidifying molten metal flowing through the casting mold.    
   
   
       2 . The casting mold of  claim 1 , wherein the sidewall tapers outward from a central axis of the casting mold.  
   
   
       3 . The casting mold of  claim 2 , wherein the sidewall tapers to the feed ring.  
   
   
       4 . The casting mold of  claim 1 , wherein the feed ring is made of graphite.  
   
   
       5 . The casting mold of  claim 1 , wherein the feed ring is fluid permeable and the casting ring is configured to supply cooling and lubricating fluid to the feed ring.  
   
   
       6 . The casting mold of  claim 1 , further comprising a cooling ring connected to the casting ring.  
   
   
       7 . The casting mold of  claim 6 , the cooling ring defining a plurality of raised teeth and cooperating with the casting ring such that the teeth form a plurality of spray nozzles for delivering cooling fluid sprays at least to the casting ring during operation of the casting mold.  
   
   
       8 . The casting mold of  claim 7 , the cooling ring defining an annular chamber in fluid communication with the spray nozzles, the annular chamber adapted to supply cooling fluid to the spray nozzles for application at least to the casting ring during operation of the casting mold.  
   
   
       9 . The casting mold of  claim 1 , wherein the feed ring is connected to the casting ring by a threaded connection.  
   
   
       10 . The casting mold of  claim 1 , wherein the arcuate opening comprises a diverging opening.  
   
   
       11 . A casting apparatus for direct chill casting metal, comprising: 
 a tundish for containing a supply of molten metal;    a casting mold in fluid communication with the tundish through a passage defined in the tundish wall, the casting mold further comprising: 
 a header plate defining an arcuate shaped opening connected to the passage, the header plate having an upstream side and a downstream side, the downstream side defining a recess having a tapered sidewall;  
 a casting ring connected to the downstream side of the header plate and defining a groove proximate to the sidewall of the header plate; and  
 a feed ring disposed in the groove for cooling and at least partially solidifying molten metal flowing through the casting mold; and  
   a starter block associated with the casting ring.    
   
   
       12 . The casting apparatus of  claim 11 , wherein the sidewall tapers outward from a central axis of the casting mold.  
   
   
       13 . The casting apparatus of  claim 12 , wherein the sidewall tapers to the feed ring.  
   
   
       14 . The casting apparatus of  claim 11 , wherein the feed ring is made of graphite.  
   
   
       15 . The casting apparatus of  claim 11 , wherein the feed ring is fluid permeable and the casting ring is configured to supply cooling and lubricating fluid to the feed ring.  
   
   
       16 . The casting apparatus of  claim 11 , further comprising a cooling ring connected to the casting ring.  
   
   
       17 . The casting apparatus of  claim 16 , the cooling ring defining a plurality of raised teeth and cooperating with the casting ring such that the teeth form a plurality of spray nozzles for delivering cooling fluid sprays at least to the casting ring during operation of the casting mold.  
   
   
       18 . The casting apparatus of  claim 17 , the cooling ring defining an annular chamber in fluid communication with the spray nozzles, the annular chamber adapted to supply cooling fluid to the spray nozzles for application at least to the casting ring during operation of the casting mold.  
   
   
       19 . The casting apparatus of  claim 11 , wherein the feed ring is connected to the casting ring by a threaded connection.  
   
   
       20 . The casting apparatus of  claim 11 , wherein the arcuate shaped opening comprises a diverging opening.  
   
   
       21 . The casting apparatus of  claim 11 , wherein the passage defined in the tundish wall is at least partially convergent.  
   
   
       22 . A method of casting metal in a direct chill casting apparatus, comprising: 
 a tundish containing a supply of molten metal;    a casting mold in fluid communication with the tundish through a passage defined in the tundish wall, the casting mold further comprising: 
 a header plate defining an arcuate shaped opening connected to the passage, the header plate having an upstream side and a downstream side, the downstream side defining a recess having a tapered sidewall;  
 a casting ring connected to the downstream side of the header plate and defining a groove proximate to the sidewall of the header plate; and  
 a feed ring disposed in the groove for cooling and at least partially solidifying molten metal flowing through the casting mold; and  
   a starter block associated with the casting ring;    the method comprising the steps of:    withdrawing the starter block in the casting ring;    delivering molten metal to the casting mold through the passage in the tundish wall and the arcuate shaped opening in the header plate; and    cooling and at least partially solidifying the molten metal at the feed ring to form a metal article.    
   
   
       23 . The method of  claim 22 , the step of delivering molten metal comprising the molten metal diverging outward in the casting mold along the sidewall of the header plate before contacting the feed ring.  
   
   
       24 . The method of  claim 22 , wherein the feed ring is fluid permeable and the casting ring is configured to supply cooling and lubricating fluid to the feed ring, the method further comprising supplying the cooling and lubricating fluid to the feed ring to cool and at least partially solidify the molten metal at the feed ring.  
   
   
       25 . The method of  claim 22 , further comprising a cooling ring connected to the casting ring, the cooling ring defining a plurality of raised teeth and cooperating with the casting ring such that the teeth form a plurality of spray nozzles, the method further comprising delivering cooling fluid sprays at least to the casting ring through the spray nozzles to cool the casting ring during operation of the casting mold.  
   
   
       26 . The method of  claim 25 , the cooling ring defining an annular chamber in fluid communication with the spray nozzles, the method further comprising supplying cooling fluid to the spray nozzles from the annular chamber.