Automatic dam positioning system and method for controlling molten metal delivery to a continuous caster - Patents.com

Abstract

The metal delivery system includes an injector for distributing molten metal into a movable mold, a delivery vessel upstream of the injector and defining a receiving area for receiving the molten metal, and a dam system. The dam system includes a dam positionable in the receiving area and a controller capable of vertically positioning the at least one dam to control a flow of molten metal from the receiving area to the injector. A method of controlling the distribution of molten metal to a continuous casting apparatus includes at least partially blocking the flow of molten metal from the receiving area to the injector using at least one dam in the receiving area. The method may include detecting a temperature of the molten metal downstream of the at least one dam and controlling a vertical position of the at least one dam based on the detected temperature.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 63 / 362,135, filed March 30, 2022, and entitled “AUTOMATIC DAM POSITIONING SYSTEMS AND METHODS FOR CONTROLLING MOLTEN METAL DISTRIBUTION TO CONTINUOUS CASTERS,” the contents of which are incorporated by reference herein in their entirety.

[0002] This application relates to continuous casting of molten metal, and more particularly to systems and methods for controlling the flow of molten metal into a movable die for casting, the movable die including, but not limited to, a block, a belt, and / or a roll. [Background technology]

[0003] Metal products (such as metal strip, slabs, and plates), especially those made from aluminum and aluminum alloys, can be produced using continuous casting systems in which molten metal is introduced into a gap formed by a movable die. Metal products are continuously discharged from a casting cavity by the movable die and may be produced in unlimited length. Depending on the type of continuous casting system, various types of movable dies may be used. For example, one form of continuous caster system is a twin belt caster in which two opposing belts rotate continuously and introduce molten metal by a rounder or injector into a thin casting cavity formed between the opposing regions of the belts. An alternative form is a rotating block caster, in which the casting surface is formed by a block that rotates about a fixed path and forms a continuous surface that joins adjacent to the casting cavity. Yet another type of continuous casting system is a twin roll caster, in which metal is cast by using an injection device to supply molten metal into a gap formed between two rolls. When the metal comes into contact with the rolls, heat is rapidly extracted and the metal begins to solidify. The solidified metal is then compressed as it passes through the gap between the rolls.

[0004] In some continuous casting systems, such as twin roll casters, the exit cross-sectional profile of the cast metal product is directly related to the temperature profile of the molten metal at the tip of the injector that introduces the molten metal into the gap of the moving die. However, control of such temperature profile has traditionally been limited and requires an operator to manually exercise control in close proximity to the molten metal, thereby increasing the potential for industrial accidents. Furthermore, traditional controls are imprecise, cannot rapidly address problems, and are susceptible to variations, leading to cast metal products with undesirable shapes and / or cast metal products that must be corrected before further processing, reducing productivity. Summary of the Invention

[0005] The embodiments 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.

[0006] According to certain embodiments, a metal delivery system includes an injector for dispensing molten metal into a movable mold, a delivery vessel upstream of the injector and defining a receiving area for receiving the molten metal, and a dam system including at least one dam positionable within the receiving area and a controller operably coupled to the at least one dam for controlling a vertical position of the at least one dam within the receiving area and thereby controlling a flow of molten metal from the receiving area to the injector.

[0007] According to some embodiments, a dam system for a metal delivery system comprises a plurality of dams and a controller operatively coupled to each dam of the plurality of dams, the controller capable of controlling a vertical position of each dam of the plurality of dams independently of other dams of the plurality of dams.

[0008] According to certain embodiments, a method of controlling molten metal distribution to a continuous casting apparatus includes at least partially blocking a flow of molten metal from a receiving area to an injector using at least one dam in the receiving area, sensing a temperature of the molten metal downstream of the at least one dam, and controlling a vertical position of the at least one dam based on the sensed temperature.

[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 drawings, in which the use of like reference numerals in different drawings is intended to indicate the same or similar components. [Brief description of the drawings]

[0011] [Figure 1] FIG. 1 is a side view of a twin roll casting system having a metal delivery system, according to an embodiment. [Diagram 2] FIG. 2 is a top view of a portion of the metal delivery system of FIG. 1. [Diagram 3] 2 illustrates a portion of the dam system of the metal supply system of FIG. 1; [Figure 4] 1 illustrates a portion of a twin roll casting system having a metal delivery system, according to an embodiment. [Diagram 5] 5 shows a portion of the dam system of the metal supply system of FIG. 4. [Figure 6] 5 shows a portion of the dam system of the metal supply system of FIG. 4. [Figure 7] 5 shows an actuator of the dam system of the metal supply system of FIG. 4. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Described herein are systems and methods for controlling the distribution of molten metal to a continuous casting apparatus, including but not limited to a twin roll caster. The systems and methods described herein can be used for any metal, but they may be particularly useful for aluminum or aluminum alloys. In certain embodiments, a metal delivery system for delivering molten metal to a continuous casting apparatus includes a dam system having at least one movable dam and a controller. In various embodiments, the dam system includes a plurality of movable dams, including but not limited to two movable dams, three movable dams, four movable dams, five movable dams, six movable dams, seven movable dams, eight movable dams, nine movable dams, etc. In some embodiments, the dam system includes an odd number of movable dams, but in other embodiments this need not be the case.

[0013] The controller is operatively coupled to the at least one dam to control the vertical position of the at least one dam in the flow path of the molten metal (e.g., in the receiving area of ​​the supply vessel or tundish) to control the distribution of the molten metal to the continuous casting apparatus, providing improved profile control of the cast metal product. In various embodiments, the controller is mechanically coupled to the at least one dam to improve durability and reliability of the connection and control of the at least one dam in difficult operating conditions (e.g., in close proximity to the molten metal and in close proximity to the continuous casting apparatus). In certain embodiments, the dam system includes a sensor associated with the at least one dam, the sensor can detect a temperature of the molten metal downstream of the at least one dam. The controller can control the vertical position of the at least one dam based on the detected temperature to provide a desired temperature distribution of the molten metal entering the continuous casting apparatus, thereby improving profile control of the cast metal product. In certain embodiments, the dam system includes multiple dams, each of which may be independently controlled by the controller to improve control of the metal distribution and / or temperature distribution of the molten metal supplied to the continuous casting apparatus. Various other benefits and advantages may be realized by the systems and methods provided herein, and the above mentioned advantages should not be considered limiting.

[0014] 1-3 show a continuous casting system 100 including a continuous casting apparatus 102 and a metal delivery system 104 according to an embodiment.

[0015] In the example of FIG. 1-FIG. 3, the continuous casting apparatus 102 is a twin roll caster 106 with a pair of rolls 108A and 108B as movable dies. Each of the rolls 108A and 108B rotates about an axis represented by the arrows 110A and 110B. A gap 112 is defined between the rolls 108A and 108B, and during casting, molten metal is fed into the gap 112 by the metal feed system 104. When the metal comes into contact with the rolls 108A and 108B, heat is rapidly extracted and the metal begins to solidify. As the solidifying metal passes through the gap 112 between the rolls 108A and 108B, it is further compressed and is discharged from the continuous casting apparatus 102 as a cast metal product 114 (e.g., a sheet, plate, shade, etc.) (as represented by the arrow 144). Although the continuous casting apparatus 102 is shown as a twin roll caster 106, in other embodiments, the continuous casting apparatus 102 may be various other types of continuous casting apparatus, including, but not limited to, a belt caster, a block caster, and / or other casting apparatus, as desired.

[0016] The metal delivery system 104 generally includes an injector 116, a delivery vessel 118, and a dam system 120. The injector 116 includes a tip 122 through which molten metal may be introduced into the gap 112 of the casting apparatus 102. In the embodiment shown in FIGS. 1 and 2, the injector 116 includes a bottom wall 124 and a top wall 126 that converge toward the tip 122, as well as a side wall 128. However, the particular shape and profile of the injector 116 should not be considered limiting, and the injector 116 may have a variety of shapes and profiles suitable for delivering molten metal to the casting apparatus 102 as desired. As some non-limiting examples, the side wall 128 may be convergent, parallel, or divergent, and the walls 124, 126 may be convergent or parallel. The injector 116 may have additional walls and / or shapes as desired.

[0017] A supply vessel 118 (e.g., a tundish) is upstream of the injector 116 and generally defines a receiving area 130 (see FIGS. 2 and 3) for initially receiving the molten metal. In the illustrated embodiment, best shown in FIG. 2, the supply vessel 118 includes an introduction portion 132 where the molten metal may initially be received and a main portion 134 between the introduction portion 132 and the injector 116. However, the shape and profile of the supply vessel 118 should not be considered limiting, and the supply vessel 118 and / or the receiving area 130 may have various shapes, sizes, and profiles, as desired.

[0018] The dam system 120 includes at least one dam 136 and a controller 138 operably coupled to the at least one dam 136. In some embodiments, the dam system 120 includes a single dam, while in other embodiments, the dam system 120 includes multiple dams. In the embodiment of FIGS. 1 and 2, the dam system 120 includes five dams 136A-136E. In embodiments having multiple dams 136, each dam 136 may optionally be operably coupled to a controller 138. As best shown in FIG. 2, the dams 136 of the dam system 120 may be disposed along a width of the receiving area 130 of the supply vessel 118 (e.g., transverse to the direction of molten metal flow). In certain embodiments, the dams 136 need not be disposed along the entire width of the receiving area 130. In some non-limiting examples, the dams 136 are provided along at least 30% of the width of the receiving area 130, such as at least 40% of the width of the receiving area 130, at least 50% of the width of the receiving area 130, etc. However, in other embodiments, the dams 136 may be provided along any range of the width of the receiving area 130 as desired. As discussed in more detail below, the dam(s) 136 are vertically positionable within the receiving area 130 (represented by arrow 141 in FIG. 1) to control the flow of molten metal to the injector 116. FIG. 3 shows non-limiting examples of dams 136A-136E at various vertical positions within the receiving area 130.

[0019] The controller 138 is operatively coupled to the dam(s) 136 to control the vertical position of the dam(s) 136 within the receiving area 130. In embodiments having multiple dams 136, the controller 138 may control the vertical position of each dam 136 independently of the other dams 136. In other embodiments, the controller 138 may jointly control the vertical position of two or more dams 136 as desired. Controlling the vertical position of the dam(s) 136 can control the distribution of molten metal to the injectors 116 and thus the casting apparatus 102, which can control the profile of the cast metal product 114. In certain embodiments, as described below, controlling the vertical position of the dam(s) 136 can control the temperature distribution in the molten metal provided to the injectors 116, which can control the profile of the cast metal product 114. As shown in FIG. 3, when the dam system 120 includes multiple dams 136, the controller 138 may control the dams 136 to be in various vertical positions as needed, and the vertical position of one dam 136 need not be the same as another dam 136.

[0020] The controller 138 may include one or more processing units and / or one or more memory devices. The processing unit of the controller may be any suitable processing device or combination thereof, including, but not limited to, one or more application specific integrated circuits (ASICs), digital signal processors (DSPs), digital signal processors (DSPDs), programmable logic devices (PLDs), programmable logic controllers (PLCs), field programmable gate arrays (FPGAs), processors, controllers, microcontrollers, microprocessors, other electronic units, and / or combinations thereof. The one or more memory devices of the controller 138 may be any machine-readable medium accessible by a processor, including, but not limited to, any type of long-term, short-term, volatile, non-volatile, or other storage medium, and is not limited to any particular type or number of memories, or the type of medium on which the memories are stored. Additionally, as disclosed herein, the terms "storage medium," "storage," or "memory" may refer to one or more memories for storing data, including read-only memory (ROM), random access memory (RAM), magnetic RAM, core memory, magnetic disk storage media, optical storage media, flash memory devices, and / or other machine-readable media for storing information. The term "machine-readable medium" includes, but is not limited to, portable or fixed storage devices, optical storage devices, wireless channels, and / or various other storage media capable of storing or conveying instruction(s) and / or data. The foregoing examples of processing devices and memory devices should not be considered limiting, and controller 138 may include various types of processing devices and / or memory devices, as desired.

[0021] In certain embodiments, the controller 138 may optionally include an associated user interface, including but not limited to a graphical user interface, by which the controller 138 may obtain information from a user and / or provide information to a user. In such embodiments, the user interface may be located at the controller 138 itself or may be located remotely from the controller 138, including but not limited to another location within the casting system 100. Additionally or alternatively, the controller 138 may optionally include various communication modules to enable the controller 138 to receive and / or transmit information as needed. Non-limiting examples of communication modules may include systems and mechanisms that enable wired and / or wireless communication (e.g., short-range, cellular, Wi-Fi, Bluetooth, Bluetooth Low Energy (BLE), etc.).

[0022] In certain embodiments, the controller 138 comprises at least one actuator 140 for mechanically and operatively coupling the controller 138 to the dam(s) 136 of the dam system 120. The actual mechanical coupling between the actuator 140 and the dam 136 in FIG. 1 has been omitted for clarity of illustration. In embodiments having multiple dams 136, each dam 136 may optionally comprise a dedicated actuator 140, which may facilitate independent control of the dam 136. In certain embodiments, the mechanical coupling provided by the actuator 140 may improve the durability and reliability of the connection between the controller 138 and the dam 136 to control the vertical position of the dam 136 in difficult operating conditions (e.g., in close proximity to the molten metal and in close proximity to the continuous casting apparatus 102). The at least one actuator 140 may be a variety of devices, mechanisms, or systems as desired. In one non-limiting embodiment, the actuator 140 includes a motor with multiple flexible shafts driven by the motor.

[0023] 1 , in various embodiments, in addition to the dam(s) 136 and the controller 138, the dam system 120 includes at least one temperature sensor 142 associated with the at least one dam 136. The at least one temperature sensor may be various devices or mechanisms suitable for detecting the temperature of the molten metal downstream of the at least one dam 136. In some embodiments, the at least one temperature sensor 142 is provided upstream of the tip 122 of the injector 116, although the particular location of the sensor 142 should not be considered limiting.

[0024] In certain embodiments, at least one temperature sensor 142 is communicatively coupled to the controller 138, and the controller 138 may control the vertical position of at least one dam 136 based on the detected temperature from the corresponding temperature sensor 142. In embodiments having multiple dams 136, the dam system 120 may include multiple temperature sensors 142, with each temperature sensor 142 associated with a particular dam 136. As an example, as shown in FIG. 2, the dam system 120 may include five temperature sensors 142A-142E, with each temperature sensor associated with a corresponding dam 136A-136E. In this embodiment, the controller 138 may control the vertical position of each dam 136A-136E based on the temperature detected by each associated temperature sensor 142A-142E. As a non-limiting example, the controller 138 may raise the dam 136C to increase the flow of metal and the temperature of the molten metal downstream of the dam 136C based on the temperature detected by the temperature sensor 142C being below a predetermined value. Such independent control of the dams 136A-136E based on the corresponding temperature sensors 142A-142E may enable the controller 138 to distribute the molten metal at a desired flow rate and / or temperature distribution for a desired profile of the cast metal product.

[0025] Optionally, the dam system 120 includes at least one system sensor 146 for detecting parameters of the continuous casting system 100. The at least one system sensor 146 may be communicatively coupled to the controller 138, which may optionally control one or more of the dams 136 based on information detected by the at least one system sensor 146. The number, type, location, and parameters detected by the at least one system sensor 146 should not be considered limiting. In the illustrated embodiment, a single system sensor 146 is provided, which is a flatness sensor 148. In this embodiment, the flatness sensor 148 may detect the flatness of the cast metal product 114, and the controller 138 may optionally control the dam 136 based on the detected flatness from the flatness sensor 148. In certain embodiments, the flatness (or cross-sectional) profile detected by the flatness sensor 148 may be used to predict a temperature profile of the cast metal product 114 and / or the molten metal. Various other types of sensors may be used as the at least one system sensor 146, if desired.

[0026] 4-7 show another example of a continuous casting system 400 including a continuous casting apparatus 402 and a metal delivery system 404, according to an embodiment. Similar to casting apparatus 102, casting apparatus 402 is a twin roll caster 406 including a frame 407 for supporting rolls similar to rolls 108. However, in FIGS. 4-7, the rolls of twin roll caster 406 have been omitted for clarity of illustration.

[0027] Metal delivery system 404 is similar to metal delivery system 104 and includes an injector 416, a delivery vessel 418, and a dam system 420. Injector 416 is substantially similar to injector 116, except that injector 416 has a different profile. Delivery vessel 418 is substantially similar to delivery vessel 118, except that the shape and profile of delivery vessel 418 and receiving area 430 of delivery vessel 418 are different as compared to delivery vessel 118.

[0028] Dam system 420 is similar to dam system 120 and includes a plurality of dams 436A-436E and a controller 438 operably coupled to the dams 436A-436E for vertically positioning the dams 436A-436E within the receiving area 430. As best shown in FIGS. 5-7, similar to controller 138, controller 438 includes actuators 440 that mechanically couple controller 438 to each of the dams 436A-436E. In the embodiment shown in FIGS. 4-7, actuator 440 includes a motor 441 and a plurality of flexible shafts 443A-443E. Motor 441 is shown supported on frame 407. However, in other embodiments, motor 441 may be provided in various locations as desired. Each flexible shaft 443A-443E mechanically and operatively connects the motor 441 to a corresponding dam 436A-436E such that the dams 436A-436E are independently controllable.

[0029] Returning to FIGS. 1-3 , a method for controlling molten metal distribution to a continuous casting apparatus 102 using a metal delivery system 104 is described in detail below. In certain embodiments, the method includes delivering molten metal, such as a molten aluminum alloy, to a delivery vessel 118. In some embodiments, the method includes initially receiving the molten metal in an inlet portion 132 of the delivery vessel 118 such that the molten metal flows from the inlet portion 132 to a main portion 134. The method includes at least partially blocking the flow of molten metal through a receiving area 130 of the delivery vessel 118 using one or more dams 136 to control metal distribution to an injector 116. The method includes delivering the molten metal into a gap 112 of the casting apparatus 102 through a tip 122 of the injector 116 and casting the molten metal into a cast metal product 114 using the casting apparatus 102.

[0030] In certain embodiments, the method includes controlling the metal distribution and / or temperature distribution of the molten metal introduced into the gap 112 by controlling the vertical positions of the dams 136 using the controller 138. In some embodiments, the method includes vertically raising a particular dam 136 to increase the metal flow and / or increase the temperature of the molten metal downstream of the particular dam 136 and vertically lowering the particular dam 136 to decrease the metal flow and / or decrease the temperature of the molten metal downstream of the particular dam 136. In some embodiments, controlling the vertical positions of the dams 136 includes independently controlling each dam 136 of the multiple dams 136.

[0031] In some embodiments, controlling the dams 136 includes receiving a temperature of the molten metal downstream of the particular dam 136 from a corresponding temperature sensor 142 and controlling the particular dam 136 based on the detected temperature from the corresponding temperature sensor 142. As a non-limiting example, the method may include controlling dam 136A based on a detected temperature from temperature sensor 142A, controlling dam 136B based on a detected temperature from temperature sensor 142B, controlling dam 136C based on a detected temperature from temperature sensor 142C, controlling dam 136D based on a detected temperature from temperature sensor 142D, and / or controlling dam 136E based on a detected temperature from temperature sensor 142E.

[0032] In various embodiments, controlling the dams 136 based on the detected temperature from the temperature sensor 142 may include comparing the detected temperature to a predetermined temperature corresponding to a particular profile of the cast metal product 114 and controlling the dams 136 based on a difference between the detected temperature and the predetermined temperature. In certain embodiments, controlling the dams 136 may include controlling the dams 136 such that the molten metal delivered to the casting apparatus has a desired temperature profile or distribution along a width of the molten metal introduced into the gap 112. The desired temperature profile or distribution may be a uniform temperature profile or distribution in some embodiments. However, in other embodiments, the method includes controlling the dams 136 to provide a non-uniform temperature profile or distribution along a width of the molten metal introduced into the gap 112. In some embodiments, the method optionally includes predicting, by the controller 138, a temperature profile of the cast metal product 114 and / or the molten metal based on the detected flatness profile of the cast metal product. Optionally, the method may include comparing the predicted temperature profile to a desired temperature profile and controlling a vertical position of one or more of the dams 136 based on a difference between the predicted temperature profile and the predetermined temperature profile.

[0033] Optionally, the method includes controlling a vertical position of the one or more dams 136 based on information from the at least one system sensor 146. As a non-limiting example, the method may include receiving, by the controller 138, a detected flatness profile of the cast metal product from the at least one system sensor 146, comparing the detected flatness profile to a desired flatness profile, and controlling the one or more dams 136 based on a difference between the detected flatness profile and the desired flatness profile.

[0034] As discussed above, the systems and methods provided herein can enable improved distribution of molten metal to a continuous casting apparatus, such as a twin roll caster, which can enable improved control of the quality of the cast metal product. The systems and methods provided herein can enable improved control in an otherwise challenging working environment in close proximity to the molten metal and in close proximity to the continuous casting apparatus. Various other benefits and advantages can be realized by the systems and methods discussed herein.

[0035] Explanation example Provided below is a collection of example embodiments, including at least some explicitly listed as "illustrative examples" that provide further explanation of various example embodiments according to the concepts described herein. These illustrative examples are not intended to be mutually exclusive, exhaustive, or limiting, and the present disclosure is not limited to these illustrative illustrative examples, but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.

[0036] Illustrative Example 1. A metal supply system comprising: an injector for distributing molten metal into a movable mold; a supply vessel upstream of the injector defining a receiving area configured to receive the molten metal; and a dam system comprising at least one dam positionable within the receiving area; and a controller operably coupled to the at least one dam, the controller configured to vertically position the at least one dam within the receiving area to control a flow of molten metal from the receiving area to the injector.

[0037] Example 2. The metal delivery system of any preceding or following example or combination of examples, wherein the controller is mechanically coupled to the at least one dam.

[0038] Example 3. The metal supply system of any preceding or following example or combination of examples, wherein the dam system further comprises a temperature sensor configured to detect a temperature of the molten metal downstream of the at least one dam, the temperature sensor communicatively coupled to the controller, and the controller configured to control a vertical position of the at least one dam based on the temperature of the molten metal detected by the temperature sensor.

[0039] Example 4. The metal supply system of any preceding or subsequent example or combination of example, wherein the controller is configured to predict a temperature profile of the cast metal product based on a flatness profile of the cast metal product, compare the predicted temperature profile to a predetermined temperature profile, and control the vertical position of the at least one dam based on a difference between the predicted temperature profile and the predetermined temperature profile.

[0040] Example 5. The metal delivery system of any preceding or following example or combination of examples, wherein the temperature sensor is configured to detect the temperature of the molten metal upstream of a tip of the injector.

[0041] Example 6. The metal delivery system of any preceding or following example or combination of examples, wherein the at least one dam includes a plurality of dams disposed along at least a portion of a width of the receiving area and transverse to a flow direction of the molten metal from the receiving area to the injector, and the controller is operatively coupled to each dam of the plurality of dams and configured to independently control a vertical position of each dam of the plurality of dams.

[0042] Example 7. The metal supply system of any preceding or following example or combination of example, wherein the dam system further comprises a plurality of temperature sensors, each temperature sensor of the plurality of temperature sensors communicatively coupled to the controller and configured to detect a temperature of the molten metal downstream of a corresponding dam of the plurality of dams, and the controller is configured to independently control the vertical position of each dam of the plurality of dams based on the detected temperature of the molten metal from the corresponding temperature sensor.

[0043] Example 8. The metal delivery system of any preceding or following example or combination of examples, wherein the plurality of dams includes at least five dams.

[0044] Example 9. A twin roll casting system comprising a metal delivery system as described in any preceding or following example or combination of examples and a twin roll caster.

[0045] Example 10. The twin roll casting system of any preceding or following example or combination of examples, further comprising a flatness sensor downstream of the twin roll caster configured to detect a flatness profile of the cast metal product downstream of the twin roll caster, the flatness sensor being communicatively coupled to the controller, and the controller being configured to control a vertical position of the at least one dam based at least in part on the detected flatness profile.

[0046] Illustrative Example 11. A dam system for a metal supply system comprising a plurality of dams and a controller operably coupled to each dam of the plurality of dams, the controller configured to control a vertical position of each dam of the plurality of dams independently of other dams of the plurality of dams.

[0047] Example 12. The dam system of any preceding or following example or combination of examples, further comprising a plurality of temperature sensors, each temperature sensor of the plurality of temperature sensors configured to detect a temperature of the molten metal downstream of a corresponding dam.

[0048] Example 13. The dam system of any preceding or following example or combination of examples, wherein each temperature sensor of the plurality of temperature sensors is communicatively coupled to the controller, and the controller is configured to control each dam of the plurality of dams based on the detected temperature of the molten metal from the corresponding temperature sensor.

[0049] Example 14. The dam system of any preceding or following example or combination of examples, wherein the controller is mechanically coupled to each dam of the plurality of dams.

[0050] Example 15. The dam system of any preceding or following example or combination of examples, wherein the controller is configured to control the vertical position of each dam of the plurality of dams to control a temperature profile of the molten metal.

[0051] Illustrative Example 16. A method for controlling molten metal distribution to a continuous casting apparatus, the method comprising at least partially blocking a flow of molten metal from a receiving area to an injector using at least one dam in the receiving area, sensing a temperature of the molten metal downstream of the at least one dam, and controlling a vertical position of the at least one dam based on the sensed temperature.

[0052] Example 17. The method of any preceding or following example or combination of example embodiments, wherein the at least one dam includes a plurality of dams, and detecting the temperature of the molten metal includes detecting the temperature of the molten metal downstream of each dam of the plurality of dams.

[0053] Example 18. The method of any preceding or following example or combination of example embodiments, wherein controlling the vertical position of the at least one dam includes independently controlling the vertical position of each dam of the plurality of dams based on the detected temperature corresponding to the particular dam of the plurality of dams.

[0054] Example 19. The method of any preceding or following example or combination of examples, wherein the at least one dam includes a plurality of dams, and controlling the vertical position of the at least one dam includes controlling the vertical position of each dam of the plurality of dams.

[0055] Example 20. A method as described in any preceding or subsequent example or combination of examples, further comprising predicting a temperature profile of a cast metal product based on a detected flatness profile of the cast metal product, comparing the predicted temperature profile with a predetermined temperature profile, and controlling the vertical position of the at least one dam based on a difference between the predicted temperature profile and the predetermined temperature profile.

[0056] 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 between the various steps or elements, unless the order of the individual steps or arrangement of the elements is explicitly described. References to directions such as "upper", "lower", "top", "bottom", "left", "right", "front", and "rear" are intended to refer to the orientation as illustrated and described in the figure (or figures) in which the components and directions are referenced, among others. Throughout this disclosure, reference numerals accompanied by letters refer to specific instances of an element, while reference numerals without accompanying letters refer to elements generally or collectively. Thus, by way of example (not shown), device "12A" refers to an instance of a class of devices collectively referred to as device "12," any one of which may be referred to generically as device "12." In the drawings and description, like numerals are intended to represent like elements. As used herein, the meanings of "a," "an," and "the" include singular and plural references unless the context clearly dictates otherwise.

[0057] References are made herein to alloys identified by AA numbers and other related designations, such as "series" or "7xxx." For an understanding of the numbering systems most commonly used to name and identify aluminum and its alloys, see "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).

[0058] As used herein, a plate generally has a thickness of more than about 15 mm. For example, a plate may refer to an aluminum product having a thickness of more than about 15 mm, more than about 20 mm, more than about 25 mm, more than about 30 mm, more than about 35 mm, more than about 40 mm, more than about 45 mm, more than about 50 mm, or more than about 100 mm. As used herein, a shade (also called a sheet plate) generally has a thickness of about 4 mm to about 15 mm. For example, a shade may have a thickness of about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, or about 15 mm. As used herein, a sheet generally refers to an aluminum product having a thickness of less than about 4 mm. For example, the sheet can have a thickness of less than about 4 mm, less than about 3 mm, less than about 2 mm, less than about 1 mm, less than about 0.5 mm, or less than about 0.3 mm, (eg, about 0.2 mm).

[0059] As used herein, the terms "cast metal product," "cast product," "cast aluminum alloy product," and the like are used interchangeably and refer to products produced by DC (Direct Chill) casting (including direct chill co-casting), semi-continuous casting, continuous casting (including, for example, by use of a twin belt caster, twin roll caster, block caster, or any other continuous casting machine), electromagnetic casting, hot top casting, or any other casting process.

[0060] 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. an injector for dispensing molten metal into the movable die; a supply vessel upstream of the injector and defining a receiving area configured to receive the molten metal; a dam system, the dam system comprising: at least one dam positionable within the receiving area; a controller operably coupled to the at least one dam; the controller is configured to vertically position the at least one dam within the receiving area to control a flow of molten metal from the receiving area to the injector. The metal delivery system.

2. The metal delivery system of claim 1 , wherein the controller is mechanically coupled to the at least one dam.

3. 2. The metal delivery system of claim 1 , wherein the dam system further comprises a temperature sensor configured to detect a temperature of the molten metal downstream of the at least one dam, the temperature sensor communicatively coupled to the controller, and the controller configured to control a vertical position of the at least one dam based on the temperature of the molten metal detected by the temperature sensor.

4. 4. The metal supply system of claim 3, wherein the controller is configured to predict a temperature profile of the cast metal product based on a detected flatness profile of the cast metal product, compare the predicted temperature profile to a predetermined temperature profile, and control the vertical position of the at least one dam based on a difference between the predicted temperature profile and the predetermined temperature profile.

5. The metal delivery system of claim 3 , wherein the temperature sensor is configured to detect the temperature of the molten metal upstream of a tip of the injector.

6. 2. The metal delivery system of claim 1, wherein the at least one dam comprises a plurality of dams disposed along at least a portion of a width of the receiving area and transverse to a flow direction of the molten metal from the receiving area to the injector, and the controller is operatively coupled to each dam of the plurality of dams and configured to independently control a vertical position of each dam of the plurality of dams.

7. 7. The metal supply system of claim 6, wherein the dam system further comprises a plurality of temperature sensors, each temperature sensor of the plurality of temperature sensors communicatively coupled to the controller and configured to detect a temperature of the molten metal downstream of a corresponding dam of the plurality of dams, and the controller configured to independently control the vertical position of each dam of the plurality of dams based on the detected temperature of the molten metal from the corresponding temperature sensor.

8. The metal delivery system of claim 6 , wherein the plurality of dams comprises at least five dams.

9. A twin roll casting system comprising the metal delivery system of claim 1 and a twin roll caster.

10. 10. The twin roll casting system of claim 9, further comprising a flatness sensor downstream of the twin roll caster configured to detect a flatness profile of a cast metal product downstream of the twin roll caster, the flatness sensor communicatively coupled to the controller, the controller configured to control a vertical position of the at least one dam based at least in part on the detected flatness profile.

11. 1. A dam system for a metal supply system, comprising: Several dams and a controller operably coupled to each dam of the plurality of dams, the controller configured to control a vertical position of each dam of the plurality of dams independently of other dams of the plurality of dams. The dam system.

12. The dam system of claim 11 , further comprising a plurality of temperature sensors, each temperature sensor of the plurality of temperature sensors configured to detect a temperature of the molten metal downstream of a corresponding dam.

13. 13. The dam system of claim 12, wherein each temperature sensor of the plurality of temperature sensors is communicatively coupled to the controller, the controller configured to control each dam of the plurality of dams based on the detected temperature of the molten metal from a corresponding temperature sensor.

14. The dam system of claim 11 , wherein the controller is mechanically coupled to each dam of the plurality of dams.

15. The dam system of claim 11 , wherein the controller is configured to control the vertical position of each dam of the plurality of dams to control a temperature profile of the molten metal.

16. 1. A method for controlling molten metal delivery to a continuous casting system, comprising the steps of: using at least one dam in the receiving region to at least partially block the flow of molten metal from said receiving region to the injector; sensing a temperature of the molten metal downstream of the at least one dam; controlling a vertical position of the at least one dam based on the detected temperature; and The method comprising:

17. 17. The method of claim 16, wherein the at least one dam comprises a plurality of dams, and sensing the temperature of the molten metal comprises sensing the temperature of the molten metal downstream of each dam of the plurality of dams.

18. 20. The method of claim 17, wherein controlling the vertical position of the at least one dam comprises independently controlling the vertical position of each dam of the plurality of dams based on the detected temperature corresponding to a particular dam of the plurality of dams.

19. 17. The method of claim 16, wherein the at least one dam comprises a plurality of dams, and controlling the vertical position of the at least one dam comprises controlling the vertical position of each dam of the plurality of dams.

20. 17. The method of claim 16, further comprising predicting a temperature profile of the cast metal product based on a detected flatness profile of the cast metal product, comparing the predicted temperature profile to a predetermined temperature profile, and controlling the vertical position of the at least one dam based on a difference between the predicted temperature profile and the predetermined temperature profile.

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