Bottom block for direct chill casting

Abstract

A bottom block for use in direct chill (DC) casting that includes a flared base providing additional surface area for contact with coolant used in the DC casting process. The bottom block includes a first end that substantially fits within a DC mold while a second end has a larger cross-sectional area than the first end. A transition between the first end and the second end provides a surface for coolant to contact despite film boiling and air gaps between the ingot and the coolant.

What is claimed: 
     
         1 . A bottom block for direct chill (DC) casting, comprising:
 a monolithic block defined by:
 an upper portion configured to interface with a DC casting mold; 
 a lower portion having a cross-sectional area that is less than a cross sectional area defined by a perimeter of the upper portion; 
 an external surface that tapers from the upper portion to the lower portion, the external surface having a slope that increases a width of the monolithic block as the external surface extends from the upper portion to the lower portion, wherein the external surface is configured to receive cooling fluid from a DC casting apparatus, the slope of the external surface configured to maintain the cooling fluid in contact along a height of the external surface; and 
 an interior surface configured to receive molten metal for solidification.