Leak-Proof Upper Tundish Nozzle

Abstract

A gas injected upper tundish nozzle including: a protective can; a ceramic inner portion disposed within the protective can, the ceramic inner portion having gas flow pathways therein; a gas injection port attached to the protective can allowing for the injection of gas through the protective can and into the gas flow pathways within the ceramic inner portion. A gas flow seal is formed between the protective can and the ceramic inner portion. The gas flow seal blocks gas leakage from the gap between the protective can and the ceramic inner portion. The gas flow seal is formed of nickel or an alloy of nickel.

What is claimed is: 
     
         1 - 14 . (canceled) 
     
     
         15 . A gas injected upper tundish nozzle, the nozzle comprising:
 a protective can;   a ceramic inner portion disposed within the protective can, the ceramic inner portion having gas flow pathways therein;   a gas injection port attached to said protective can, the gas injection port allowing for injection of gas through the protective can and into the gas flow pathways within said ceramic inner portion;   a gas flow seal formed between the protective can and the ceramic inner portion, the gas flow seal blocking gas leakage from the gap between the protective can and the ceramic inner portion, the gas flow seal being formed of nickel or an alloy of nickel.   
     
     
         16 . The gas injected upper tundish nozzle as recited in  claim 15  wherein the gas flow seal is formed by depositing the nickel or the nickel alloy into any gaps between the protective can and the ceramic inner portion by a method selected from the group consisting of electroplating, electroless plating, nickel or nickel alloy foil strip application, sputtering, plasma vapor deposition, and metal printing. 
     
     
         17 . The gas injected upper tundish nozzle as recited in  claim 16  wherein the gas flow seal is formed by electroplating the nickel or the nickel alloy into any gaps between the protective can and the ceramic inner portion. 
     
     
         18 . The gas injected upper tundish nozzle as recited in  claim 17  wherein the nickel or the nickel alloy is electroplated across the gap on an exterior of the protective can and the ceramic inner portion. 
     
     
         19 . The gas injected upper tundish nozzle as recited in  claim 18  wherein the nickel or the nickel alloy is electroplated after the protective can and the ceramic inner portion have been formed into a unitary piece. 
     
     
         20 . The gas injected upper tundish nozzle as recited in  claim 16  wherein the nickel or the nickel alloy is deposited onto one or both of an interior surface of the protective can and an exterior surface of the ceramic inner portion. 
     
     
         21 . The gas injected upper tundish as recited in  claim 20  wherein the nickel or the nickel alloy is deposited before the protective can and ceramic inner portion have been formed into a unitary piece. 
     
     
         22 . The gas injected upper tundish nozzle as recited in  claim 15  wherein the protective can is formed of a metal material. 
     
     
         23 . The gas injected upper tundish nozzle as recited in  claim 22  wherein the protective can is formed of a steel material. 
     
     
         24 . The gas injected upper tundish nozzle as recited in  claim 15  wherein the ceramic inner portion is formed from a porous ceramic material and the gas flow pathways include pores within the porous ceramic material. 
     
     
         25 . The gas injected upper tundish nozzle as recited in  claim 24  wherein the ceramic inner portion is formed from a gas permeable refractory material consisting of a ceramic oxide of one or more of aluminum, silicon, magnesium, chromium, or zirconium, or mixtures thereof. 
     
     
         26 . The gas injected upper tundish nozzle as recited in  claim 15  wherein the ceramic inner portion is not porous or gas permeable and the gas flow pathways are formed directly into the body of the ceramic inner portion. 
     
     
         27 . The gas injected upper tundish nozzle as recited in  claim 26  wherein the gas flow pathways include a gas distribution manifold and gas distribution channels. 
     
     
         28 . The gas injected upper tundish nozzle as recited in  claim 27  wherein the gas distribution channels having gas outlets to release the gas into steel flowing within the upper tundish nozzle.