Independently positioned graphite inserts in annular metal casting molds

Abstract

A molten metal casting annulus comprising an insert support and cooling frame and a multiplicity of graphite casting annulus insert components supported entirely without clamping on said inset support and cooling frame and a method manufacturing the same are disclosed.

What is claimed is:  
     
       1. Molten metal continuous casting apparatus comprising: 
       a multiplicity of graphite casting annulus insert components ( 10 ), an annular insert support and cooling frame ( 100 ) defining an insert supporting surface, a annular closure plate ( 200 ), said insert support and cooling frame and said closure plate being configured and constructed to define, when secured together, an annular cooling fluid chamber, said insert support and cooling frame being configured and constructed to position said insert supporting surface in close thermal communication through a thermally conductive wall with the cooling fluid chamber, means securing the insert support and cooling frame and closure plate together to form said cooling fluid chamber, said multiplicity of graphite casting annulus insert components being secured without clamping in position on, supported by and receiving cooling from the insert support and cooling frame alone to define a planar annulus configured and constructed to serve as a surface against which molten metal can be cast for forming a metal ingot.  
     
     
       2. The casting annulus of  claim 1  wherein the graphite casting annulus insert components are composed of permeable graphite for solid state diffusion of submicron sized colloidal graphite and molybdenum sulfide and for transporting lubricating oil in liquid or vapor form there through. 
     
     
       3. The casting annulus of  claim 2  further comprising a coating of submicron size molybdenum disulfide and colloidal graphite on the graphite casting annulus insert components. 
     
     
       4. The casting annulus of  claim 2  wherein the graphite casting annulus insert components are composed of permeable graphite for transporting lubricating oil in liquid or vapor form there through. 
     
     
       5. The molten metal continuous casting apparatus of  claim 1  wherein the multiplicity of graphite casting annulus insert components ( 10 ) are secured by thermally induced force to the annular insert support and cooling frame ( 100 ). 
     
     
       6. The molten metal continuous casting apparatus of  claim 1  wherein the insert support and cooling frame ( 100 ) is configured and constructed to define an enclosed planar annular space, said frame defining an annular face that faces said annular space and that is generally perpendicular to the plane of said annular space, said frame further defining an annular groove ( 106 ,  112 ) adjacent said annular face, and said multiplicity of graphite casting annulus insert components ( 10 ) supported entirely without clamping on said insert support and cooling frame ( 100 ), said insert components being fitted edge to edge around said casting annulus to define said annulus, said insert components further comprising a lip snugly fitted in said annular groove for positioning and locking said insert components in said frame. 
     
     
       7. The molten metal continuous casting apparatus of  claim 6  wherein the graphite casting annulus insert components ( 10 ) are so configured and constructed as to define a hook ( 22 ) having a lip, said lip being snugly fitted in said annular groove for positioning and locking said insert components in said frame. 
     
     
       8. The molten metal continuous casting apparatus of  claim 6  wherein the graphite casting annulus insert components ( 10 ) are configured and constructed to define a downwardly extending insertion lip ( 32 ). 
     
     
       9. The molten metal continuous casting apparatus of  claim 6  wherein the frame defines a second annular groove adjacent said annular face and wherein the graphite casting annulus insert components are configured and constructed to define a downwardly extending insertion lip, said downwardly extending insertion lip being snugly fitted into said second annular groove. 
     
     
       10. The casting annulus of  claim 9  wherein the graphite casting insert components are composed of permeable graphite for solid state diffusion of submicron sized colloidal graphite and molybdenum sulfide and for transporting lubricating oil in liquid or vapor form there through. 
     
     
       11. The casting annulus of  claim 10  further comprising a coating of submicron size molybdenum disulfide and colloidal graphite on the graphite casting annulus insert components. 
     
     
       12. The casting annulus of  claim 10  wherein the graphite casting annulus insert components are composed of permeable graphite for transporting lubricating oil in liquid or vapor form there through. 
     
     
       13. The molten metal continuous casting apparatus of  claim 5  wherein the insert support and cooling frame ( 100 ) is configured and constructed to define an enclosed planar annular space, said frame defining an annular face that faces said annular space and that is generally perpendicular to the plane of said annular space, said frame further defining an annular groove ( 106 ,  112 ) adjacent said annular face, said multiplicity of graphite casting annulus insert components ( 10 ) being supported on said insert support and cooling frame ( 100 ), said insert components being fitted edge to edge around said casting annulus to define said annulus, said insert components further comprising a lip snugly fitted in said annular groove for positioning and locking said insert components in said frame. 
     
     
       14. The molten metal continuous casting apparatus of  claim 13  wherein the graphite casting annulus insert components ( 10 ) are so configured and constructed as to define a hook ( 22 ) having a lip, said hook lip being snugly fitted in said annular groove for positioning and locking said insert components in said frame. 
     
     
       15. The molten metal continuous casting apparatus of  claim 14  wherein the graphite casting annulus insert components ( 10 ) are configured and constructed to define a downwardly extending insertion lip ( 32 ). 
     
     
       16. The molten metal continuous casting apparatus of  claim 6  wherein the frame defines a second annular groove adjacent said annular face and wherein the graphite casting annulus insert components are configured and constructed to define a downwardly extending insertion lip, said downwardly extending insertion lip being snugly fitted into said second annular groove. 
     
     
       17. The invention of  claim 1  wherein the insert support and cooling frame and the graphite casting annulus insert components are constructed and configured to define a step of from about 0.01 to about 0.10 inch above the graphite casting surface and a step of from about 0.01 to about 0.10 inch between the bottom of the graphite casting surface and the structure below said casting surface. 
     
     
       18. The invention of  claim 16  wherein the insert support and cooling frame and the graphite casting annulus insert components are constructed and configured to define a step of from about 0.01 to about 0.10 inch above the graphite casting surface and a step of from about 0.01 to about 0.10 inch between the bottom of the graphite casting surface and the structure below said casting surface. 
     
     
       19. Molten metal continuous casting apparatus comprising: a multiplicity of graphite casting annulus insert components ( 10 ), an annular insert support and cooling frame ( 100 ) defining an insert supporting surface, a annular closure plate ( 200 ), said insert support and cooling frame and said closure plate being configured and constructed to define, when secured together, an annular cooling fluid chamber, said insert support and cooling frame being configured and constructed to position said insert supporting surface in close thermal communication through a thermally conductive wall with the cooling fluid chamber, means securing the insert support and cooling frame and closure plate together to form said cooling fluid chamber, said multiplicity of graphite casting annulus insert components being secured without clamping in position on, supported by and receiving cooling from the insert support and cooling frame alone to define a planar annulus configured and constructed to serve as a surface against which molten metal can be cast for forming an ingot, the number of graphite components being at least about 200 for each 100 inches of perimeter of metal casting annulus.