Method for producing alloy blanks

Abstract

In order to provide a molten metal in a melting furnace with at least one alloy component or to increase the portion of the latter in the molten metal, a blank mixture has an alloy element containing the alloy component or being made of the latter, from water and a binding agent, and the blank mixture is processed into an alloy blank that can be placed in the melting furnace. At least as much water is added so that the blank mixture can be poured, and at least as much binding agent is added so that the alloy blank has a strength of at least 4/Nmm 2 after at the latest seven days setting time at 20° C., preferably at least 5 N/mm 2 . The blank mixture is poured into a casting mold and setting takes place without applying external pressing, with the alloy blank thus produced being removed from the mold.

1 . A method for producing alloy blanks in order to provide a molten metal in a melting furnace with at least one alloy component or to increase the portion of the latter in the molten metal, a blank mixture being produced using the alloy element containing the at least one alloy component or being made of the latter, from water and a binding agent, and the blank mixture being processed into an alloy blank that can be placed in the melting furnace, characterised in that when producing the blank mixture at least as much water is added so that the blank mixture can be poured, and that at least as much binding agent is added so that the alloy blank produced from the blank mixture has a strength of at least 4 N/mm 2  after at the latest seven days setting time at 20° C., preferably at least 5 N/mm 2 , and that the blank mixture is poured into a casting mould and setting takes place in the latter without applying any external pressing effect, and finally the alloy blank thus produced is removed from the mould. 
     
     
         2 . The method according to  claim 1 , characterised in that a metal, in particular iron, as well as iron alloy such as FeSi, FeMn, FeCr, FeNi, FeMo, FeTi, FeV, or copper, zinc, chrome, manganese, nickel, molybdenum, titanium, vanadiun, or as metal oxides and ores, such as FeO, Fe 2 O 3 , MnO, and/or a metallic silicon, especially in the form of SiC, and/or a carbon carrier and/or uncombined carbon, for example graphite, coke breeze, petrol coke, pitch coke, compact dust for the carburisation of the molten metal or a mixture of at least two of the aforementioned alloy components is used as at least one alloy element. 
     
     
         3 . The method according to  claim 1 , characterised in that as much water is added to the blank mixture so that the blank mixture is self-running, in particular self-levelling. 
     
     
         4 . The method according to  claim 1 , characterised in that a fluxing agent and/or an accelerator is added to the blank mixture. 
     
     
         5 . The method according to  claim 1 , characterised in that as much water and optionally fluxing agent is added to the blank mixture so that the latter has a spread value of at least 15 cm, preferably 19 cm and advantageously no more than 21 cm. 
     
     
         6 . The method according to  claim 1 , characterised in that the weight ratio of water to solid does not exceed a value of 0.8. 
     
     
         7 . The method according to  claim 1 , characterised in that the binding agent contains or is produced from a hydraulic binding agent, in particular cement. 
     
     
         8 . The method according to  claim 1 , characterised in that the addition of binding agent does not exceed 40% by weight, preferably 20% by weight in relation to the whole blank mixture. 
     
     
         9 . The method according to  claim 1 , characterised in that a support grain is added to the blank mixture, advantageously with a grain size of maximum 1.5 cm, the support grain preferably being sand, and in particular being present with a weight portion of 5 to 40% in relation to the whole blank mixture. 
     
     
         10 . The method according to  claim 1 , characterised in that the blank mixture is shaken in the casting mould and/or the open surface of the latter is smoothed. 
     
     
         11 . The method according to  claim 1 , characterised in that the surface of the blank mixture in the casting mould is preferably sprayed with water immediately after the casting process. 
     
     
         12 . The method according to  claim 1 , characterised in that the surface of the blank mixture in the casting mould, optionally after spraying with water, is provided with a covering impermeable to moisture or dispensing moisture. 
     
     
         13 . The method according to  claims 1 , characterised in that the alloy element for the production of the blank mixture is used in small piece form, preferably with an average extension of between 0.5 and 5 cm. 
     
     
         14 . The method according to  claim 1 , characterised in that the alloy element is added in dust or powder form, in particular with a grain size of less than 0.1 mm. 
     
     
         15 . The method according to  claim 13 , characterised in that the at least one alloy element is used both in small piece and in dust or powder form, and that the weight ratio of their portions is between 20:80 and 80:20. 
     
     
         16 . The method according to  claim 1 , characterised in that the blank mixture is poured into a large mould the interior of which is sub-divided into individual moulds which are filled with the blank mixture in one casting process. 
     
     
         17 . The method according to  claim 1 , characterised in that the blank mixture is poured into a large mould the interior of which is sub-divided into individual moulds which are filled with the blank mixture in one casting process and that the large mould is sub-divided into the individual moulds by bars reaching up, and the blank mixture is filled to a level higher than the bars, and that the large mould produced in this way is broken into individual chunky alloy blanks after hardening. 
     
     
         18 . An alloy blank with an alloy element, characterised in that it can be obtained by the method according to  claim 1 . 
     
     
         19 . The use of the alloy blank according to  claim 18  by placing in a metal melting furnace when melting metal, preferably in a cupola furnace, converter, blast furnace or induction furnace.