Systems and methods for producing texturized casting molds of a continuous belt caster

Abstract

A method of texturizing a casting mold of a continuous belt casting system includes providing at least one endless belt having an elongated belt surface. The elongated belt surface includes at least a first region and at least a second region adjacent to the first region across a width of the elongated belt surface, and the elongated belt surface is configured to at least partially define a casting cavity of the continuous belt casting system. The method includes texturizing the elongated belt surface by applying a predetermined texture to the first region.

1 . A method of texturizing a casting mold of a continuous belt casting system, the method comprising:
 providing at least one endless belt comprising an elongated belt surface, wherein the elongated belt surface comprises at least a first region and at least a second region adjacent to the first region across a width of the elongated belt surface, and wherein the elongated belt surface is configured to at least partially define a casting cavity of the continuous belt casting system; and   texturizing the elongated belt surface by applying a predetermined texture to the first region and such that the second region does not comprise the predetermined texture.   
     
     
         2 . The method of  claim 1 , wherein providing the at least one endless belt comprises providing at least one of a copper-based endless belt, an iron-based endless belt, an aluminum-based endless belt, or a steel-based endless belt. 
     
     
         3 . The method of  claim 1 , wherein the at least one endless belt is a first endless belt and the elongated belt surface is a first elongated belt surface, and wherein the method comprises:
 providing a second endless metal belt comprising a second elongated belt surface, wherein the second elongated belt surface is configured to at least partially define the casting cavity, and wherein the second elongated belt surface comprises a first region and a second region; and   texturizing the second elongated belt surface by applying the predetermined texture to the first region of the second elongated belt surface and such that the second region of the second elongated belt surface does not comprise the predetermined texture.   
     
     
         4 . The method of  claim 1 , wherein texturizing the elongated belt surface comprises:
 applying a masking agent on at least the second region of the elongated belt surface;   etching the first region of the elongated belt surface with an etchant to form the predetermined texture; and   removing the masking agent from the second region of the elongated belt surface.   
     
     
         5 .- 10 . (canceled) 
     
     
         11 . The method of  claim 1 , wherein texturizing the elongated belt surface comprises laser texturing the first region of the elongated belt surface. 
     
     
         12 .- 15 . (canceled) 
     
     
         16 . The method of  claim 1 , wherein texturing comprises mechanical texturing, and wherein mechanical texturing comprises:
 providing a texturing tool comprising a roller, wherein the roller comprises a roller surface, and wherein the roller surface comprises at least one rib;   contacting the roller with the elongated belt surface and such that the at least one rib contacts the first region of the elongated belt surface; and   moving the roller along the elongated belt surface such that the at least one rib forms the predetermined texture on only the first region of the elongated belt surface.   
     
     
         17 . (canceled) 
     
     
         18 . The method of  claim 1 , wherein the elongated belt surface comprises a plurality of first regions, wherein the second region is between adjacent first regions across the width of the elongated belt surface, and wherein the method further comprises:
 texturizing the elongated belt surface by applying the predetermined texture to the plurality of first regions.   
     
     
         19 . (canceled) 
     
     
         20 . (canceled) 
     
     
         21 . The method of  claim 1 , wherein applying the predetermined texture to the first region comprises forming a crater having a depth from 20 μm to 1000 μm. 
     
     
         22 .- 26 . (canceled) 
     
     
         27 . A method of texturizing a casting mold of a continuous belt casting system, the method comprising:
 providing at least one endless belt comprising an elongated belt surface, wherein the elongated belt surface comprises a plurality of first regions and a plurality of second regions, wherein adjacent first regions of the plurality of first regions are separated by one of the plurality of second regions, and wherein the elongated belt surface is configured to at least partially define a casting cavity of the continuous belt casting system; and   texturizing the elongated belt surface by applying a predetermined texture only to the plurality of first regions and such that a distance between adjacent first regions of the plurality of first regions is from 0.01 mm to 1.0 mm.   
     
     
         28 . The method of  claim 27 , wherein applying the predetermined texture only to the plurality of first regions comprises applying the predetermined texture such that the distance between the adjacent first regions of the plurality of first regions is from 0.1 μm to 0.3 μm. 
     
     
         29 . The method of  claim 27 , wherein applying the predetermined texture only to the plurality of first regions comprises forming a crater having a depth from 20 μm to 1000 μm in each first region of the plurality of first regions. 
     
     
         30 . The method of  claim 29 , wherein applying the predetermined texture only to the plurality of first region comprises forming the crater having the depth from 200 μm to 250 μm in each first region of the plurality of first regions. 
     
     
         31 . The method of  claim 27 , wherein applying the predetermined texture only to the plurality of first regions comprises forming a groove in each first region of the plurality of first regions that is elongated in a casting direction and comprises a depth from 20 μm to 1000 μm. 
     
     
         32 . A continuous belt casting system comprising an endless belt comprising an elongated belt surface, wherein the elongated belt surface comprises a predetermined texturized pattern defined in the elongated belt surface, wherein the elongated belt surface at least partially defines a casting cavity of the continuous belt casting system. 
     
     
         33 . The continuous belt casting system of  claim 32 , wherein the predetermined texturized pattern comprises a ridge pattern, a groove pattern, a cross-hatch pattern, or a diamond pattern formed on the elongated belt surface. 
     
     
         34 . The continuous belt casting system of  claim 32 , wherein the endless belt is a first endless belt and the elongated belt surface is a first elongated belt surface, and wherein the continuous belt casting system comprises a second endless belt comprising a second elongated belt surface at least partially defining the casting cavity, wherein the second elongated belt surface comprises a predetermined texturized pattern. 
     
     
         35 . The continuous belt casting system of  claim 34 , wherein the predetermined texturized pattern of the second elongated belt surface is the same as the predetermined texturized pattern of the first elongated belt surface. 
     
     
         36 . A method of casting a metal slab using the continuously belt casting system of  claim 32  comprising the endless belt and a second endless belt, the method comprising:
 introducing molten metal into a casting cavity defined by the endless belt and the second endless belt; 
 advancing the molten metal through the casting cavity by advancing the endless belts and such that the molten metal solidifies; and 
 causing the solidified molten metal to emerge from an exit of the casting cavity as a metal slab and such that the as-cast metal slab comprises a surface texture pattern corresponding to the texturized pattern of the belt surface. 
 
     
     
         37 . The method of  claim 36 , wherein the predetermined texturized pattern on the belt surface comprises a ridge pattern, a, groove pattern, a cross-hatch pattern, or a diamond pattern. 
     
     
         38 . The method of  claim 36 , further comprising changing the predetermined texturized pattern from a first pattern to a second pattern based on a type of metal being cast. 
     
     
         39 .- 42 . (canceled)