System and method for controlling vertical wrinkling during direct chill casting

Abstract

A method for controlling vertical wrinkling during casting includes determining a wrinkling control parameter for a dam body of a casting system. The method also includes introducing molten metal into a mold cavity of a casting mold of the casting system and forming a molten metal sump while controlling the dam body to have the wrinkling control parameter. A dam body system for a casting system includes a dam body and a control system for selectively controlling a immersion depth of the dam body in the molten metal sump.

Description

[Technical field]

[0001] REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 63 / 269,849, filed March 24, 2022, and entitled “SYSTEMS AND METHODS FOR CONTROLLING VERTICAL FOLDS DURING DIRECT CHILL CASTING,” the contents of which are incorporated by reference in their entirety herein.

[0002] This application relates to the casting of metals, and more particularly to a system and method for controlling wrinkles during casting. [Background technology]

[0003] During direct chill (DC) casting, particularly during DC casting of aluminum alloys, oxide layers tend to cause creases on the rolled surface of the ingot. Typically, such creases are cast vertically along the casting direction on the rolled surface, a defect that may be referred to as "vertical creases." Defects such as these may be observed in aluminum alloys with high magnesium content (e.g., greater than 2 wt%), such as those used as can end stock (CES). For example, FIG. 11 shows an example of an ingot 1101 that is a 5182 aluminum alloy cast using a conventional DC casting process. As shown, the ingot 1101 includes vertical creases 1103 cast on the rolled surface 1105 of the ingot 1101. Such creases 1103 may be of various forms, including periodic creases 1103A, centerline creases 1103B, and / or corner creases 1103C. Regardless of the type of ripple marks 1103, these defects have a detrimental effect on further processing because if these defects need to be removed prior to additional processing (e.g., prior to hot rolling), material will be wasted (e.g., by requiring more peeling) and / or such ripple marks may form crack initiation points during the casting operation. Summary of the Invention

[0004] The embodiments of the invention covered by this patent are defined by the claims below, and not by this Summary. This Summary is a high level overview of various embodiments and introduces some of the concepts that are further described in the Detailed Description section below. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used alone to determine the scope of the claimed subject matter. The subject matter should be understood by reference to the entire specification of this patent, any or all of the drawings, and appropriate portions of the claims.

[0005] According to certain embodiments, a method for controlling vertical wrinkling during casting includes determining a wrinkling control parameter for a dam body of a casting system, the method includes introducing molten metal into a mold cavity of a casting mold of the casting system, and forming a molten metal sump while controlling the dam body to have the wrinkling control parameter.

[0006] According to various embodiments, a method for controlling vertical wrinkling during casting includes introducing molten metal into a mold cavity of a casting mold of a casting system by introducing the molten metal into a molten metal sump of a solidifying ingot, the method including controlling a calcium level as a first wrinkling control parameter and controlling a weir body as a second wrinkling control parameter while introducing the molten metal.

[0007] According to some embodiments, a dam body system for a casting system includes a dam body and a control system for the dam body. The control system can selectively control a immersion depth of the dam body within a molten metal sump.

[0008] According to certain embodiments, a casting system includes a plurality of casting dies for receiving molten metal, a plurality of dam bodies, each positionable within a corresponding casting die, and a control system for coordinated control of a dam body immersion depth of each dam body in a molten metal sump within the corresponding casting die.

[0009] The various embodiments described herein may include additional systems, methods, features, and advantages that may not necessarily be expressly disclosed herein, but will become apparent to one of ordinary skill in the art upon review of the following detailed description and the accompanying drawings. All such systems, methods, features, and advantages are intended to be included within this disclosure and protected by the accompanying claims.

[0010] This specification refers to the following accompanying figures, in which the use of like reference numbers in different figures is intended to indicate the same or similar components. [Brief description of the drawings]

[0011] [Figure 1] 1 illustrates a portion of a DC casting system, according to an embodiment. [Diagram 2] FIG. 2 is another view of the DC casting system of FIG. 1. [Diagram 3] 2 illustrates a dam and dam control system of the DC casting system of FIG. 1, according to an embodiment. [Figure 4] 4 shows the weir and weir control system of FIG. 3 with the support plate removed. [Diagram 5] 4 is another view of the weir and weir control system of FIG. 3, according to an embodiment. [Figure 6] 4 is a cross-sectional view of a wall of the dam of FIG. 3 according to an embodiment. [Figure 7] FIG. 1 illustrates a top view of multiple dams for a mold of a DC casting system, according to an embodiment. [Figure 8] 8 illustrates a DC casting system including one of the dam bodies of FIG. 7, according to an embodiment. [Figure 9] 8 illustrates a DC casting system with another one of the dam bodies of FIG. 7, according to an embodiment. [Figure 10] 8 illustrates a DC casting system with another one of the dam bodies of FIG. 7, according to an embodiment. [Figure 11] 1 shows an ingot with vertical ripples. [Figure 12]1 illustrates a casting system, according to an embodiment. [Figure 13] 1 illustrates a casting system, according to an embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Described herein are systems and methods for controlling vertical ripples cast on the rolling surface of an ingot during DC casting using at least one dam body. The techniques include controlling one or more ripple control parameters of at least one dam body of a casting system to control vertical ripples on the ingot. Additionally, the techniques may include controlling one or more additional ripple control parameters, which may include, but are not limited to, calcium level, ingot head level in the die cavity, casting speed, and / or titanium carbide (TiC) level. In certain embodiments, by controlling at least the dam body, vertical ripples in cast ingots, particularly ingots with high magnesium content, may be minimized and / or eliminated. Although it is possible to cast ingots without ripples by controlling calcium levels in the molten metal instead of using dam bodies during casting, the omission of dam bodies during casting is currently not preferred. In particular, dam bodies advantageously trap oxides in the molten metal and improve safety by minimizing operator intervention. Thus, the techniques described herein allow for minimizing or eliminating wrinkles in the ingot while also allowing for the use of dams during casting. Various other benefits and advantages may be realized by the systems and methods described herein, and the above-mentioned advantages should not be considered limiting.

[0013] 1-6 illustrate an example of a metal casting system 100, according to various embodiments. The metal casting system 100 includes one or more open-ended molds 102, a feed system 112, and a dam system 120.

[0014] The mold 102 includes a top end 104, a bottom end 106, and a mold wall 108 that define a mold cavity 110. The mold 102 may be surrounded by a cooling jacket through which a cooling fluid, such as water, is continuously circulated to externally cool the mold wall 108. A bottom block 160 (see FIG. 10) may be initially positioned within or near the bottom end 106 of the mold cavity 110 to close the bottom end 106 of the mold cavity 110. In certain embodiments, as shown in FIGS. 1 and 2, the mold cavity 110 may be generally rectangular in shape, although in other embodiments the mold cavity 110 may have a variety of shapes as desired. Although a single mold 102 is shown in FIGS. 1-6, in other embodiments the metal casting system 100 may have any number of molds as desired. By way of example, FIGS. 12 and 13, as described below, show a casting system with multiple molds. In one non-limiting example, a casting system can include between 6 and 10 molds, although in other embodiments, a casting system can include fewer than 6 molds or more than 10 molds.

[0015] The delivery system 112 may be any of a variety of suitable devices or mechanisms for delivering molten metal to the mold cavity 110. In the illustrated embodiment, the delivery system 112 includes a trough 114 and a gate 116 (see FIG. 2). A control pin 118 may be movable relative to and within the gate 116 to adjust and / or terminate the flow of molten metal through the gate 116.

[0016] The dam body system 120 includes one or more dam bodies 122 and, optionally, a dam body control system 124. Although a single dam body 122 is shown in FIGS. 1-6, in other embodiments, the dam body system 120 may include multiple dam bodies 122 (see, for example, FIGS. 12 and 13). In certain embodiments, the dam body 122 may be centered relative to the gate 116, while in other embodiments, the dam body 122 may be positioned as needed. With reference to FIGS. 3-6, the dam body 122 generally includes a wall 126, defines a closed perimeter, and has a top end 128 and a bottom end 130. As shown in FIGS. 1 and 2, the dam body 122 may be provided around the gate 116 to facilitate distribution of the molten metal introduced into the mold cavity 110 and / or to reduce the formation of metal oxides on the top surface of the head region of the molten metal during casting. In various embodiments, as best shown in Figures 3-5, the dam body 122 includes one or more support features 134 for engaging the control system 124. The number, location, and type of support features 134 shown should not be considered limiting. Optionally, the dam body 122 includes at least two support features 134 located at or adjacent opposing ends of the dam body 122. In the illustrated embodiment, the dam body 122 includes two support features 134 proximate a first end 135 of the dam body 122 and two support features 134 proximate a second end 137 of the dam body 122.

[0017] Weir body 122 shown in Figures 1-6 has a small rectangular shape or profile. However, the particular shape of dam body 122 shown in Figures 1-6 should not be considered limiting. Figure 7 shows non-limiting examples of dam bodies having a number of shapes or profiles, including dam body 122 having a first rectangular profile, dam body 222 having a second rectangular profile, dam body 322 having a bulging rectangular profile, and dam body 422 having an hourglass rectangular profile. Figure 8 shows a casting system 800 for casting an ingot 801 from 5812 aluminum alloy, which is substantially similar to casting system 100, except that dam body system 120 includes dam body 222. Figure 9 illustrates a casting system 900 for casting an ingot 901 from 5812 aluminum alloy, which is substantially similar to casting system 100, except that dam body system 120 includes dam body 322. Figure 10 illustrates a casting system 1000, which is substantially similar to casting system 100, except that dam body system 120 includes dam body 422. The bottom block 160 of casting system 1000 is shown in Figure 10.

[0018] Referring back to FIG. 7, each dam body 122, 222, 322, and 422 has a length and a width. In certain embodiments, dam body 122 may have a maximum length and a maximum width, and dam body 122 may have a minimum distance between dam body wall 126 and mold wall 108. The length and width of dam body 222 may be less than the length and width of dam body 122, and in certain embodiments, the length and width of dam body 222 are a minimum length and a minimum width. In various embodiments, dam body 222 may have a maximum distance between dam body wall 126 and mold wall 108 compared to the other dam bodies. In the embodiment shown in FIG. 7, the length and width of dam body 322 may be less than dam body 122 and greater than dam body 222. In comparison to dam body 122, at least two of the dam body walls 126 of dam body 322 may have a convex curvature that is greater than the curvature of any of the dam body walls 126 of dam body 122. The length and width of dam body 422 may be less than the length and width of dam body 122 and / or dam body 322. In comparison to dam body 122, at least two of the dam body walls 126 of dam body 422 may have a concave curvature. The dam body shown in FIG. 7 is shown for illustrative purposes only, and in other embodiments, dam body system 120 may include dam bodies having various shapes or contours as desired. In certain embodiments, the shape or contour of dam body 122 is controlled as a wrinkling control parameter of dam body system 120, as described in more detail below.

[0019] Optionally, as shown in FIGURE 6, the dam wall 126 may include a tapered section 132 between the top end 128 and the bottom end 130. If included, the tapered section 132 may further facilitate distribution of the molten metal and / or control of metal oxides. In some embodiments, as described in more detail below, the tapered section 132 may optionally facilitate positioning of the dam 122 to an immersion depth within the molten metal in the mold cavity 110.

[0020] 3-5, if included, the dam body control system 124 may control the vertical position of the dam body 122 relative to the mold 102. The dam body control system 124 generally includes a rotating arm 136, a controller 138, and a support arm 140 extending from the rotating arm 136. The dam body control system 124 may optionally include a linking arm 142 connecting the support arm 140 with the dam body 122. The number of rotating arms 136, controllers 138, support arms 140, and / or linking arms 142 should not be considered limiting of the present disclosure. For example, while FIGS. 3-5 show the dam body control system 124 with two rotating arms 136, two controllers 138, four support arms 140, and four linking arms 142, in other embodiments, a single rotating arm 136 and a single controller 138 may be provided for the dam body 122. Additionally, although the weir control system 124 is shown as controlling a single weir 122, in other embodiments, the weir control system 124 may be operably coupled to multiple weir bodies 122 such that the weir control system 124 controls multiple weir bodies 122.

[0021] 3, the dam control system 124 may be supported on one or more supports 146 of the casting system 100. In the illustrated embodiment, the support 146 is a plate, although in other embodiments, the support 146 may be a variety of devices or mechanisms as desired.

[0022] 4 and 5, each rotating arm 136 is rotatable about an axis 144. One or more mounting devices 149 may optionally support the rotating arms 136 on the support 146 while allowing the rotating arms 136 to rotate. Optionally, as shown in FIGS. 4 and 5, one or more of the rotating arms 136 include a stopper 148 to define the angle or rotation of the rotating arm 136 about the axis 144. In the illustrated embodiment, the stopper 148 includes opposing ends 150, 152 that selectively engage the support 146 based on the rotation of the rotating arm 136 to limit the rotation of the rotating arm 136 about the axis 144. However, the illustrated stopper 148 should not be considered limiting and the stopper 148 may be a variety of suitable devices or mechanisms for limiting the rotation of the rotating arm 136 about the axis 144.

[0023] In certain embodiments, each rotating arm 136 is operably coupled to a corresponding controller 138. In other embodiments, a single controller 138 may be operably coupled to multiple rotating arms 136. The controller 138 may be a variety of suitable devices or mechanisms for selectively rotating the rotating arms 136 about the axis 144. In one non-limiting example, the controller 138 may include a drive mechanism (e.g., an electric motor) and a gear reduction box to improve positioning of the weir body 122. In one non-limiting example, the gear reduction box may be a 60:1 gear reduction box, but need not be in other embodiments. Optionally, the controller 138 may include a processor and / or memory as needed, but need not be in other embodiments. In some embodiments, the controller 138 may be communicatively coupled to a control device (e.g., a device with a processor and / or memory and / or a user interface), and the controller 138 may control the rotation of the rotating arms 136 based on data or information received from the control device.

[0024] Each support arm 140 extends outwardly from a corresponding rotating arm 136. In certain embodiments, each support arm 140 may extend substantially perpendicular to an axis 144 of the rotating arm 136. In embodiments in which multiple support arms 140 extend from the rotating arm 136 as shown in FIGS. 3-5 , the support arms 140 may be aligned along the axis 144. In various embodiments, each support arm 140 is fixed relative to the rotating arm 136 such that rotation of the rotating arm 136 about the axis 144 similarly rotates the support arm 140 about the axis 144.

[0025] A linking arm 142 may connect the support arm 140 to the dam body 122. In certain embodiments, the linking arm 142 may rigidly connect the dam body 122 to the support arm 140 and / or the rotating arm 136 such that the dam body 122 can be positioned as needed based on the rotation of the rotating arm 136. Such a rigid connection may also allow for full control of the position of the dam body 122 within the head of molten metal during the entire casting and / or selectively lifting the dam body 122 from the head of ingot as needed. With reference to FIGS. 4 and 5 , each linking arm 142 includes a first end 156 and a second end 158 opposite the first end 156. In some embodiments, the length of the linking arm 142, or the distance between the first end 156 and the second end 158, is fixed, while in other embodiments, the length of the linking arm 142 may be adjustable as needed. The first end 156 may be pivotally coupled to an end 154 of a corresponding support arm 140 that is spaced from the axis 144. In such embodiments, the pivotable connection between the linking arm 142 and the corresponding support arm 140 may allow the linking arm 142 to maintain a vertical orientation while the support arm 140 rotates about the axis 144. A variety of suitable devices or mechanisms may be used to pivotally couple the linking arm 142 to the corresponding support arm 140. The second end 158 of each linking arm 142 may be coupled to a corresponding support feature 134 on the dam body 122. In some embodiments, the second end 158 is coupled to the corresponding support feature 134 such that the linking arm 142 is not pivotable relative to the dam body 122.

[0026] In certain embodiments, as described in more detail below, the vertical height (or immersion depth) of the dam body 122 relative to the top surface of the molten metal in the mold cavity 110 may be controlled by the dam body control system 124 as a wrinkling control parameter. In some non-limiting examples, the dam body control system 124 may control the immersion depth to be about 15 mm or less, such as about 13 mm or less, such as about 10 mm or less, such as about 7 mm or less, relative to the top surface of the molten metal. In one non-limiting example, the dam body control system 124 may control the immersion depth of the dam body 122 to be about 3 mm to about 5 mm. In some embodiments, the dam body control system 124 may control the immersion depth of the dam body 122 by further centering the dam body 122 relative to the gate 116. In various embodiments, the fixed support arm 140 and / or the fixed linkage arm 142 may provide improved control of the immersion depth of the dam body 122 during casting.

[0027] In various embodiments, the weir body control system 124 includes a sensor 162 (see FIG. 2 ) for detecting the position of the weir body 122, and the position detected by the sensor 162 may be used by the weir body control system 124 so that the weir body 122 is at a desired height. A variety of suitable sensors may be utilized for the sensor at various positions. In one non-limiting embodiment, the sensor 162 may be a laser-based sensor. The sensor 162 may be communicatively coupled to the control device and / or controller(s) 138 such that the position detected by the sensor may be used to control the weir body 122.

[0028] Where multiple rotating arms 136 and / or controller 138 include weir body control system 124, the rotating arms 136 may be operably coupled to one another such that the rotational speed and / or direction of the rotating arms 136 are synchronized and the weir body 122 is selectively raised or lowered by the weir body control system 124 while maintaining a generally horizontal orientation. However, in other embodiments, the weir body control system 124 may be controlled as desired, for example such that the weir body 122 is angled and / or otherwise positioned relative to a horizontal plane as desired.

[0029] A method of casting an ingot using the casting system 100 includes feeding molten metal using the feed system 112 into the die cavity 110 where the bottom block 160 initially closes the bottom end 106 of the die cavity 110. As the molten metal is introduced into the chill die 102, it solidifies in an area adjacent the inner periphery of the die 102 and the bottom block 160 moves downward and / or away from the bottom end 106 of the die 102. Effective continuous movement of the platform and corresponding continuous feeding of molten aluminum metal into the die 102 may produce an ingot of any desired length, limited only by the space available below the die 102. When the ingot emerges from the bottom end 106 of the die 102 during DC casting, it is solid on the outside but its central core is still molten. In other words, the pool of molten metal within the die 102 extends downward into the center of the ingot, which moves downward for a distance below the die 102 as a molten metal sump. The sump has a cross section that gradually decreases in a downward direction as the ingot solidifies from the outer surface inward until the core of the ingot is completely solid. A cooling fluid, such as water, directly contacts the outer surface of the nascent ingot advancing just below the die, thereby creating a direct chill of the metal surface. This direct chill of the ingot surface serves both to maintain the periphery of the ingot in a solid state and to promote internal cooling and solidification of the ingot.

[0030] In certain embodiments, the method includes controlling one or more wrinkling control parameters of the casting system 100 while casting the ingot to control wrinkling formation on the ingot. In some embodiments, the method includes controlling a plurality of wrinkling control parameters while casting the ingot. In various embodiments, at least one wrinkling control parameter of the casting system 100 is a wrinkling control parameter of the weir body system 120.

[0031] As previously mentioned, in some embodiments, the shape or contour of the dam body 122 may be a ripple control parameter. In certain embodiments, the shape or contour of the dam body 122 is controlled to maximize the distance between the dam body wall 126 and the mold wall 108 in the mold cavity 110. With reference to FIG. 7, in one non-limiting example, the dam body is controlled to have a shape of the dam body 222. In other embodiments, the shape of the dam body may be controlled to be other shapes as a ripple control parameter. In certain embodiments, the shape of the dam body 122 is controlled in combination with at least one additional or alternative ripple control parameter to control vertical ripples in the ingot.

[0032] In various embodiments, the immersion depth of the dam body 122 relative to the top surface of the molten metal in the mold cavity 110 may be a water wrinkle control parameter. In such embodiments, the dam body control system 124 may control the immersion depth of the dam body 122 by raising or lowering the dam body 122 in the mold cavity 110 so that the dam body 122 is at a predetermined immersion depth. In some non-limiting examples, the predetermined immersion depth may be 0 mm to 15 mm, such as less than 13 mm, such as about 3 mm to about 5 mm. In other embodiments, the immersion depth of the dam body 122 may be controlled to be other immersion depths as a water wrinkle control parameter. Optionally, controlling the water wrinkle control parameter may include controlling both the shape of the dam body and the immersion depth of the dam body.

[0033] In various embodiments, the wrinkle control parameters may include various other parameters, including, but not limited to, calcium level, ingot head level within the mold cavity, casting speed, and / or TiC level.

[0034] In one non-limiting example, controlling the wrinkling control parameters may include controlling the calcium level in the molten metal to be at a predetermined calcium level. In this embodiment, controlling the calcium level may control the percentage or amount of calcium introduced into the molten metal during casting. In one non-limiting example, the predetermined calcium level may be controlled to be between about 70 ppm and 110 ppm, such as between about 90 ppm and 105 ppm. In other embodiments, the calcium level may be less than 70 ppm and / or greater than 110 ppm and / or in combination with other wrinkling control parameters.

[0035] In another non-limiting example, controlling the wrinkling control parameters may include controlling the ingot head level in the mold cavity 110 (e.g., the distance between the top surface of the molten metal in the mold cavity 110 and the bottom end 106 of the mold cavity 110) to be minimal. In one non-limiting example, controlling the ingot head level may include controlling the ingot head level to be about 40 mm to about 50 mm, such as about 42 mm to about 46 mm, such as about 44 mm. In other embodiments, the ingot head level may be controlled to be other heights as needed and / or in combination with other wrinkling control parameters.

[0036] In a further non-limiting example, controlling the wrinkling control parameters can include controlling the casting speed to be a predetermined casting speed. In one non-limiting example, the predetermined casting speed can be about 50 mm / min to about 70 mm / min, such as about 56 mm / min to about 65 mm / min, such as about 62 mm / min, such as about 60 mm / min. In other embodiments, the casting speed can be controlled to be other speeds as needed and / or in combination with other wrinkling control parameters.

[0037] In another non-limiting example, controlling the wrinkling control parameters may include controlling the TiC level in the molten metal to be at a predetermined level. In this embodiment, controlling the TiC level may control the proportion or amount of TiC introduced into the molten metal during casting. In one non-limiting example, the predetermined TiC level may be about 0 ppm to about 10 ppm, for example, about 3 ppm to about 10 ppm, for example, about 5 ppm to about 10 ppm, for example, about 3 ppm to about 5 ppm.

[0038] As mentioned above, in certain embodiments, controlling one or more flow wrinkle control parameters during casting may include controlling a plurality of flow wrinkle control parameters. As a non-limiting example, controlling the plurality of flow wrinkle control parameters may include controlling the weir body to be the weir body 322, controlling the calcium level to be 70 ppm to 85 ppm, controlling the TiC level to be 0 ppm to 5 ppm, controlling the immersion depth to be 10 mm to 15 mm, controlling the casting speed to be 50 mm / min to 60 mm / min, and controlling the head level to be 42 mm to 46 mm. As another non-limiting example, controlling the plurality of flow wrinkle control parameters may include controlling the weir body to be the weir body 422, controlling the calcium level to be 75 ppm to 90 ppm, and controlling the immersion depth to be 3 mm to 5 mm.

[0039] In one non-limiting example, the wrinkling control parameters may be controlled to minimize and / or eliminate vertical wrinkling, optionally by at least one of reducing the dam body immersion depth, maximizing the distance between the dam body wall and the mold wall, lowering the head height, providing calcium at a level between 92 ppm and 105 ppm, and / or optionally providing TiC at a level of 5 ppm or less. Various other combinations of wrinkling control parameters may be controlled as needed, and the preceding example should not be considered limiting.

[0040] FIG. 12 illustrates a metal casting system 1200 that is substantially similar to metal casting system 100, except that metal casting system 1200 includes multiple dies 102A-C, each including an associated dam body 122A-C. In the particular embodiment of FIG. 12, metal casting system 1200 includes three dies 102, although other embodiments may utilize any number of dies as desired. In the embodiment of FIG. 12, each dam body 122A-C is controlled by a corresponding dam body control system 124A-C. In these embodiments, the position of one dam body may be controlled independently of another dam body.

[0041] FIG. 13 illustrates a metal casting system 1300 that is substantially similar to the metal casting system 1200, except that a single dam body control system 124 controls the dam bodies 122A-C. In these embodiments, the positions of the dam bodies 122A-C may be coordinated. In certain embodiments, the metal casting system 1300 may be alloyed for ease of control and design by allowing measurement and control based on one of the dam bodies used to approximate control of the other dam bodies (i.e., each dam body does not necessarily have to be measured independently). As an example, the rotating arm 136 of the dam body control system 124 may extend across the multiple molds 120A-C, and multiple support arms 140 may extend from the rotating arm 136. Multiple linking arms 142 may also be included that link a corresponding support arm 140 to one of the dam bodies 122A-C. In this manner, a common rotating arm 136 may be coupled to each of the weir bodies 122A-C, and rotation of the rotating arm 136 positions the multiple weir bodies 122A-C relative to the rotating arm 136. In other embodiments, a variety of other couplings or controls may be implemented, and the foregoing examples should not be considered limiting.

[0042] Provided below is a collection of example embodiments, including at least some explicitly listed as "exemplary," that provide further description of various example embodiments in accordance with the concepts described herein. These examples are not intended to be mutually exclusive, exhaustive, or limiting, and the present disclosure is not limited to these example examples, but rather encompasses all feasible modifications and variations within the scope of the issued claims and their equivalents.

[0043] Example 1. A method for controlling vertical wrinkling during casting, comprising: determining a wrinkling control parameter for a weir body of a casting system; and introducing molten metal into a mold cavity of a casting mold of the casting system to form a molten metal sump while controlling the weir body to have the wrinkling control parameter.

[0044] Example 2. A method as in any of the preceding or following examples or combinations of examples, wherein the dam body is a first dam body, the mold cavity is a first mold cavity, the molten metal sump is a first molten metal sump, and the casting mold is a first casting mold, the method further comprising: introducing molten metal into a second mold cavity of a second casting mold of the casting system; and forming a second molten metal sump while controlling the second dam body in parallel with the first dam body.

[0045] Example 3. A method as described in any of the preceding or following examples or combinations of examples, wherein the wrinkling control parameters include a weir body immersion depth, and controlling the weir body includes controlling the weir body to be at a predetermined immersion depth in the molten metal sump.

[0046] Example 4. The method according to any of the preceding or following examples or combinations of examples, wherein said predetermined immersion depth is between 0 mm and 15 mm, inclusive.

[0047] Example 5. The method of any of the preceding or following examples or combinations of examples, wherein said predetermined immersion depth is less than 13 mm.

[0048] Example 6. The method according to any of the preceding or following examples or combinations of examples, wherein the predetermined immersion depth is between 3mm and 5mm, inclusive.

[0049] Example 7. The method of any of the preceding or following examples or combinations of examples, wherein controlling the dam body to be at the predetermined immersion depth further comprises centering the dam body relative to a gate of the casting system for introducing the molten metal into the mold cavity.

[0050] Example 8. A method as described in any of the preceding or following examples or combinations of examples, wherein the wrinkling control parameters include a dam body shape, and controlling the dam body includes controlling the dam body to have a predetermined shape.

[0051] Example 9. The method of any of the preceding or following example or combination of examples, wherein the predetermined shape includes at least one of a first rectangle having a first length and a first width, a bulging rectangle having a second length and a second width, an hourglass rectangle having a third length and a third width, or a second rectangle having a fourth length and a fourth width, wherein the fourth length is less than the first length and the fourth width is less than the first width.

[0052] Example 10. The method of any of the preceding or following example or example combinations, wherein the predetermined shape comprises the second rectangle, the fourth length is a minimum length, and the fourth width is a minimum width.

[0053] Example 11. The method according to any of the preceding or following examples or combinations of examples, wherein the wrinkling control parameter is a first wrinkling control parameter of the dam body, the first wrinkling parameter including a dam body immersion depth, and the method further includes controlling a second wrinkling control parameter of the dam body, the second wrinkling parameter including a dam body shape.

[0054] Example 12. The method according to any of the preceding or following examples or combinations of examples, wherein the wrinkling control parameter is a first wrinkling control parameter of the casting system, and the method further comprises controlling a second wrinkling control parameter of the casting system.

[0055] Example 13. The method of any of the preceding or following examples or combinations of examples, wherein the second wrinkling control parameter includes at least one of a calcium level in the molten metal, an ingot head level in the mold cavity, a casting speed, or a titanium carbide level in the molten metal.

[0056] Example 14. The method according to any of the preceding or following examples or combinations of examples, wherein the method comprises controlling vertical wrinkles during DC casting.

[0057] Example 15. A method for controlling vertical wrinkling during casting, comprising: introducing molten metal into a mold cavity of a casting mold of a casting system, wherein introducing the molten metal comprises introducing the molten metal into a molten metal sump of a solidifying ingot; and controlling a calcium level in the molten metal as a first wrinkling control parameter and a weir as a second wrinkling control parameter while introducing the molten metal.

[0058] Example 16. The method of any of the preceding or following examples or combinations of examples, wherein controlling the calcium level comprises controlling the calcium level to be between 70 and 110 ppm (inclusive).

[0059] Example 17. The method of any of the preceding or following examples or combinations of examples, wherein controlling the calcium level comprises controlling the calcium level to be between 90 and 105 ppm (inclusive).

[0060] Example 18. The method of any one of the preceding or following examples or combinations of examples, wherein controlling the dam body includes controlling a shape of the dam body.

[0061] Example 19. The method of any of the preceding or following examples or combinations of examples, wherein controlling the weir body includes controlling a weir body immersion depth.

[0062] Example 20. The method of any preceding or following example or combination of examples, wherein controlling the dam body immersion depth includes controlling the dam body immersion depth to be less than 13 mm.

[0063] Example 21. The method of any one of the preceding or following examples or combinations of examples, wherein controlling the immersion depth of the weir body includes controlling the immersion depth of the weir body to be 3 to 5 mm (inclusive).

[0064] Example 22. The method according to any of the preceding or following examples or combinations of examples, wherein the method comprises controlling vertical wrinkles during DC casting.

[0065] Example 23. A dam body system for a casting system, comprising: a dam body; and a control system configured to selectively control a dam body immersion depth of the dam body within a molten metal sump.

[0066] Example 24. A dam body system as described in any of the preceding or following examples or combinations of examples, wherein the control system includes a rotating arm rotatable about an axis, a controller configured to rotate the rotating arm about the axis, a support arm extending from the rotating arm, the support arm fixed relative to the rotating arm and rotatable together with the rotating arm about the axis, and a connecting arm connecting the support arm and the dam body, wherein rotation of the rotating arm positions the dam body relative to the rotating arm.

[0067] Example 25. The dam system of any of the preceding or following examples or combinations of examples, wherein the linking arm is pivotally coupled to the support arm.

[0068] Example 26. A dam system as described in any of the preceding or following examples or combinations of examples, further comprising a stopper on the rotating arm, the stopper defining a rotation angle of the rotating arm about the axis.

[0069] Example 27. The dam body system of any of the preceding or following examples or combinations of examples, wherein the control system further includes a support, and the stopper is configured to engage the support at a first position corresponding to a maximum dam body immersion depth of the dam body and at a second position corresponding to a minimum dam body immersion depth of the dam body.

[0070] Example 28. The dam body system of any of the preceding or following examples or combinations of examples, wherein the connecting arm is adjustable such that the distance between the support arm and the dam body is adjustable.

[0071] Example 29. A dam body system as described in any of the preceding or following examples or combinations of examples, wherein the support arm is a first support arm, the connecting arm is a first connecting arm, and the control system further includes a second support arm extending from the rotating arm, and a second connecting arm connecting the second support arm to the dam body.

[0072] Example 30. A dam body system as described in any of the preceding or following examples or combinations of examples, wherein the rotating arm is a first rotating arm, the support arm is a first support arm, the connecting arm is a first connecting arm, and the control system further includes a second rotating arm, a second support arm extending from the second rotating arm, and a second connecting arm connecting the second support arm to the dam body.

[0073] Example 31. The dam body system of any of the preceding or following examples or combinations of examples, wherein the dam body is a first dam body, the dam body system includes a second dam body, and the control system is configured to selectively control a dam body immersion depth of the second dam body in the molten metal sump.

[0074] Example 32. A casting system comprising: a dam system according to any of the preceding or following examples or combinations of examples; and a casting mold for receiving molten metal in a molten metal sump, wherein the dam is positionable within the casting mold.

[0075] Example 33. The casting system of any of the preceding or following examples or combinations of examples, wherein the casting system is a DC casting system.

[0076] Example 34. A dam body system as described in any of the preceding or following examples or combinations of examples, further comprising a sensor configured to detect a position of the dam body, and the control system configured to control an immersion depth of the dam body based on the detected position from the sensor.

[0077] Example 35. A dam system according to any preceding or following example or combination of examples, wherein the sensor is laser-based.

[0078] Example 36. The dam body system of any of the preceding or following examples or combinations of examples, further comprising a rigid arm coupled to the dam body, and a controller configured to move the rigid arm to control the dam body immersion depth.

[0079] Example 37. The weir system of any of the preceding or following examples or combinations of examples, wherein the controller includes a motor and a gear reduction box.

[0080] Example 38. The dam system of any of the preceding or following examples or combinations of examples, wherein the gear reduction box is a 60:1 gear reduction box.

[0081] Example 39. A dam body system as described in any of the preceding or following examples or combinations of examples, wherein the control system further includes a plurality of dam bodies and a connecting arm connecting the support arm and the plurality of dam bodies, wherein rotation of the rotating arm positions the plurality of dam bodies relative to the rotating arm.

[0082] Example 40. A casting system including a plurality of casting dies for receiving molten metal, a plurality of dam bodies, each dam body positionable within a corresponding casting die, and a control system configured to coordinately control a dam body immersion depth of each dam body in a molten metal sump within the corresponding casting die.

[0083] Example 41. A casting system as described in any of the preceding or following examples or combinations of examples, wherein the control system includes a controller, a rotating arm, a plurality of support arms extending from the rotating arm, and a plurality of linkage arms, each linkage arm being connected to a corresponding support arm and a corresponding dam body, and rotation of the rotating arm positions the plurality of dam bodies relative to the rotating arm.

[0084] Although the subject matter of the embodiments has been described herein with specificity to meet statutory requirements, this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be construed as implying a particular order or arrangement among or between the various steps or elements, unless the order of the individual steps or arrangement of the elements is explicitly described. In particular, directional references such as "upper", "lower", "top", "bottom", "left", "right", "front", and "rear" are intended to refer to the orientation as shown and described in the figure (or figures) to which the components and directions refer. In the drawings and description, like numerals are intended to represent like elements. As used herein, the meaning of "a", "an" or "the" includes singular and plural references unless the context clearly indicates otherwise. All ranges disclosed herein should be understood to encompass all subranges subsumed therein. For example, the stated range "1 to 10" should be considered to include all subranges having a minimum value of 1 to a maximum value of 10 (and inclusive), i.e. all subranges beginning with a minimum value of 1 or greater (e.g., 1 to 6.1) and ending with a maximum value of 10 or less (e.g., 5.5 to 10).

[0085] While the systems and methods described herein can be used with any metal, they may be particularly useful for aluminum or aluminum alloys. In this description, reference is made to alloys identified by aluminum industry designations such as "series" or "7xxx." For an understanding of the numbering systems most commonly used in naming and identifying aluminum and its alloys, please refer to "International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys" or "Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot" (both published by the Aluminum Association).

[0086] The above-mentioned aspects are merely possible examples of implementations and are described merely for a clear understanding of the principles of the present disclosure. Many variations and modifications may be made to the above-mentioned embodiment(s) without substantially departing from the spirit and principles of the present disclosure. All such modifications and modifications are intended to be included herein within the scope of the present disclosure, and all possible claims directed to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Moreover, although specific terms are used in the present specification and the following claims, they are used in a generic and descriptive sense only and not for the purpose of limiting the described embodiments, nor the scope of the following claims.

Claims

1. 1. A method for controlling vertical wrinkles during casting, comprising the steps of: Determining a wrinkling control parameter of a weir body of a casting system; introducing molten metal into a mold cavity of a casting mold of the casting system and forming a molten metal sump while controlling the weir body to have the wrinkling control parameter; The method comprising:

2. the dam is a first dam, the mold cavity is a first mold cavity, the molten metal sump is a first molten metal sump, and the casting mold is a first casting mold; 10. The method of claim 1, further comprising: introducing molten metal into a second mold cavity of a second casting mold of the casting system to form a second molten metal sump while controlling the second dam body to be in parallel with the first dam body.

3. The method of claim 1 , wherein the wrinkling control parameters include a weir body immersion depth, and controlling the weir body includes controlling the weir body to be at a predetermined immersion depth in the molten metal sump.

4. The method of claim 3, wherein the predetermined immersion depth is between 0 mm and 15 mm inclusive.

5. 4. The method of claim 3, wherein controlling the dam body to be at the predetermined immersion depth further comprises centering the dam body relative to a gate of the casting system for introducing the molten metal into the mold cavity.

6. The method of claim 1 , wherein the wrinkling control parameters include a dam shape, and controlling the dam includes controlling the dam to have a predetermined shape.

7. The predetermined shape is a first rectangle having a first length and a first width; a bulging rectangle having a second length and a second width; an hourglass shaped rectangle having a third length and a third width; or a second rectangle having a fourth length and a fourth width, the fourth length being less than the first length and the fourth width being less than the first width; The method of claim 6 , comprising at least one of:

8. 2. The method of claim 1, wherein the wrinkling control parameter is a first wrinkling control parameter of the dam body, the first wrinkling control parameter including a dam body immersion depth, and the method further includes controlling a second wrinkling control parameter of the dam body, the second wrinkling control parameter including a dam body shape.

9. The method of claim 1 , wherein the wrinkling control parameter is a first wrinkling control parameter of the casting system, the method further comprising controlling a second wrinkling control parameter of the casting system.

10. 10. The method of claim 9, wherein the second wrinkling control parameter comprises at least one of a calcium level in the molten metal, an ingot head level in the mold cavity, a casting speed, or a titanium carbide level in the molten metal.

11. 10. The method of claim 9, wherein controlling the second crease control parameter comprises controlling a calcium level to be between 70 and 110 ppm, inclusive.

12. The method of claim 1 , wherein the method comprises controlling vertical wrinkles during DC casting.

13. 1. A dam system for a casting system, comprising: Weir body, and a control system configured to selectively control a weir body immersion depth of the weir body within a molten metal sump.

14. The control system includes: A rotating arm that is rotatable about an axis; a controller configured to rotate the rotating arm about the axis; a support arm extending from the rotating arm, the support arm being fixed relative to the rotating arm and rotatable with the rotating arm about the axis; and a connecting arm connecting the support arm and the dam body; Including, The dam system of claim 13 , wherein rotation of the rotating arm positions the dam relative to the rotating arm.

15. 15. The dam system of claim 14, wherein the linkage arm is pivotally coupled to the support arm, the linkage arm being adjustable such that the distance between the support arm and the dam is adjustable.

16. 15. The dam system of claim 14, further comprising a stop on the rotating arm, the stop defining an angle of rotation of the rotating arm about the axis, and the control system further comprising a support, the stop configured to engage the support at a first position corresponding to a maximum dam body immersion depth of the dam body and at a second position corresponding to a minimum dam body immersion depth of the dam body.

17. A dam system according to claim 23, and a casting mold for receiving molten metal in the molten metal sump, the dam being positionable within the casting mold; 1. A DC casting system comprising:

18. 20. The dam body system of claim 17, further comprising a sensor configured to sense a position of the dam body, and the control system configured to control the dam body immersion depth of the dam body based on the sensed position from the sensor.

19. a plurality of casting dies for receiving molten metal; a plurality of dam bodies, each dam body positionable within a corresponding casting mold; and a control system configured to coordinately control a weir body immersion depth of each weir body in a molten metal sump within the corresponding casting mold; 4. A casting system comprising:

20. The control system includes: controller, Rotating arm, a plurality of support arms extending from the rotating arm; and a plurality of linkage arms, each linkage arm being connected to a corresponding support arm and a corresponding dam; Including, 20. The casting system of claim 19, wherein rotation of the pivot arm positions the plurality of dams relative to the pivot arm.

Images