Apparatus for Horizontal Continuous Metal Casting in a Sealed Table Caster

Abstract

A method and apparatus for preparing and delivering various types of carbon and microalloy steel, free of oxygen with abundance of nuclei, when cast producing ultra fine grain steel free of internal defeats with excellent quality. A horizontal sealed table caster has a chamber, containing a suitable atmosphere for casting, with a tube connecting to a tundish so as to allow a liquid to flow into the chamber. The liquid metal is captured on a cooling belt along the bottom of the chamber and is maintained as a specific width and depth. The cooling belt serves as a heat sink causing the liquid metal to solidify from the bottom up, allowing inclusions to migrate to the surface of the steel. A layer of liquid metal is maintained on top of the solidifying steel until the solidification reaches the surface. The belt moves the solid metal toward the exit of the chamber. As the liquid metal solidifies, the impurities migrate in the liquid metal, reaching the surface and a solid metal body free of inclusions with the superior properties is produced.

1 . A table caster comprising:
 (a) a chamber that is sealed so as to confine a gas in the chamber;   (b) a suitable atmosphere inside the chamber;   (c) a circular belt running horizontally along a bottom of the chamber;   (d) an opening in the chamber so as to allow a liquid to flow into the chamber and onto the belt;   (e) two rectangular walls located on both sides and adjacent to a top of the belt;   (f) two rotating cylinders located on an interior the belt;   (g) multiple cooling fountains located under a top portion of the belt;   (h) water flowing from the fountains uniformly suspending the belt;   (i) a void located inside each of the two rectangular walls; and   (j) an opening located at an end portion of the chamber.   
   
   
       2 . the table caster in  claim 1 , wherein said liquid is a metal 
   
   
       3 . the table caster in  claim 1 , wherein said belt is made of copper. 
   
   
       4 . the table caster in  claim 1 , wherein said walls are adjustable angular to the belt. 
   
   
       5 . the table caster in  claim 1 , wherein the suitable atmosphere is an inert gas. 
   
   
       6 . the table caster in  claim 5 , wherein said chamber has an inlet for the gas to enter the chamber and an outlet for the gas to exit the chamber. 
   
   
       7 . A sealed table caster comprising
 (a) a sealed chamber that confine a gas in the chamber;   (b) an opening in a top portion of the chamber so as to allow a liquid to flow into the chamber;   (c) a circular deflector located under the opening, the deflector positioned such that the liquid will deflect towards the front of the chamber,   (d) a belt along a bottom of the chamber positioned so that liquid entering the chamber will be placed on the belt,   (e) two rectangular walls located on both sides and adjacent to a top of the belt,   (f) a first means for rotating the belt so that the belt moves toward the back of the chamber,   (g) a second means for cooling the belt   (h) a third means for cooling the rectangular walls   (i) a forth means for allowing a solid to exit the chamber.   
   
   
       8 . the table caster in  claim 7 , wherein said liquid is a metal 
   
   
       9 . the table caster in  claim 7 , wherein said belt is made of copper. 
   
   
       10 . the table caster in  claim 7 , wherein said walls are adjustable in width perpendicular to the belt. 
   
   
       11 . the table caster in  claim 7 , wherein said chamber is filled with a reducing gas. 
   
   
       12 . the table caster in  claim 11 , wherein said chamber has an inlet for the gas to enter the chamber and an outlet for the gas to exit the chamber. 
   
   
       13 . the table caster in  claim 7  wherein a rotating cooled drum contacts the liquid and a means for scraping debris from the cooled drum. 
   
   
       14 . the table caster in  claim 7  wherein said walls have a bottom groove filled with a pressurized gas. 
   
   
       15 . the table caster in  claim 7  wherein the chamber has a rectangular removable hood. 
   
   
       16 . the table caster in  claim 15  wherein said removable hood has a cooling conduit along a top of the chamber. 
   
   
       17 . the table caster in  claim 15  wherein a side portion of the removable hood is sealed by a trough filled with water