Belt casting system and method using mold release agent control

Abstract

A continuous belt casting system can control the heat flux during casting by controlling the application of a release agent to the elongated belt surface of the casting belt. A method for casting a metal slab includes introducing molten metal into a casting cavity defined by two casting belts, advancing the casting belts so that the molten metal solidifies through the casting cavity and while controlling the heat flux by controlling the application of a release agent on at least one of the two casting belts, and releasing the solidified metal as a metal slab from the outlet of the casting cavity.

Description

Technical Field

[0001] Reference to Related Applications This application claims the benefit of U.S. Provisional Patent Application No. 63 / 510,185, filed on June 26, 2023, entitled "BELT CASTING SYSTEMS AND METHODS WITH PARTING AGENT CONTROL", the content of which is hereby incorporated by reference in its entirety.

[0002] This application relates to continuous belt casting machines, and more particularly, to systems and methods for controlling heat flux and exit temperature in belt casting.

Background Art

[0003] Continuous belt casting machines, such as twin belt casting machines, single belt casting machines, and recycled block casting machines, are commonly used to manufacture metal castings from molten metals including, but not limited to, aluminum and aluminum alloys. In a continuous belt casting machine, a casting cavity is formed between continuously moving casting surfaces. During the casting process, molten metal is introduced (usually continuously) into the casting cavity. Heat is removed from the metal by the elongated belt surface, and the metal solidifies into a metal article, which is continuously removed from the casting cavity by the moving casting surface. Conventional belt casting techniques do not monitor the heat flux during casting.

Summary of the Invention

[0004] The embodiments covered by this patent are defined not by the summary of this invention, but by the claims set forth below. The summary of this invention is a high-level overview of various embodiments and introduces some of the concepts further described in the section on embodiments for carrying out the invention below. This summary is not intended to identify any important 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 referring to the entire specification of this patent, any or all of the drawings, and the appropriate parts of each claim.

[0005] According to a particular embodiment, the continuous belt casting system includes a casting belt having an elongated belt surface, a release agent applicator for applying a release agent to the elongated belt surface, and a release agent control system for controlling the heat flux during casting by controlling the application of the release agent to the elongated belt surface during casting.

[0006] According to various embodiments, a continuous belt casting system includes a sensor for detecting the heat flux within the casting machine of the continuous belt casting system, and a release agent control system for controlling the heat flux during casting by controlling the application of a release agent to the elongated belt surface of the casting belt based on the detected heat flux.

[0007] According to a particular embodiment, a method for casting a metal slab includes introducing molten metal into a casting cavity defined by two casting belts. The method includes advancing the casting belts to advance the molten metal through the casting cavity and allowing the molten metal to solidify while controlling the heat flux by controlling the application of a release agent to at least one of the two casting belts. The method further includes allowing the solidified metal to exit the casting cavity as a metal slab.

[0008] The various embodiments described herein may include additional systems, methods, features, and advantages, which are not necessarily expressly disclosed herein but will be apparent to those skilled in the art upon consideration of the following detailed description and accompanying drawings. All such systems, methods, features, and advantages are intended to be contained within this disclosure and protected by the accompanying claims.

[0009] This specification refers to the attached drawings described below, where the same reference numerals are used in different drawings, they are intended to indicate similar or analogous components. [Brief explanation of the drawing]

[0010] [Figure 1] This shows a continuous belt casting system equipped with a mold release agent control system according to an embodiment. [Figure 2] Figure 1 is a top view of a portion of the continuous belt casting system. [Figure 3] This is a partial top view of another continuous belt casting system equipped with a mold release agent control system according to an embodiment. [Figure 4] An embodiment of this method for controlling the heat flux during casting using the continuous belt system shown in Figure 1 is presented. [Modes for carrying out the invention]

[0011] This specification describes systems and methods for controlling the heat flux during casting of metal slabs using a continuous belt casting system. In various embodiments, the systems and methods described herein control the heat flux during casting by controlling the application of a release agent to the elongated belt surface of one or more casting belts of a continuous belt casting system. Compared to conventional approaches in which the heat flux is not monitored or controlled during casting, the systems and methods described herein provide online, real-time control of the heat flux and outlet temperature of the metal slab, thereby providing a metal slab with improved quality and uniformity. In various embodiments, the systems and methods described herein may enable the creation of a desired temperature profile across the entire width of the metal slab by controlling the application of the release agent in the width direction. Furthermore, or alternatively, by controlling the application of the release agent using the systems and methods described herein, the system may be able to minimize and / or eliminate the width direction temperature gradient, which is a common problem in conventional systems. For example, conventional systems may generally produce cast slabs where the center is colder than the edges, but the systems and methods described herein can minimize and / or eliminate temperature differences across the entire width of the casting belt by applying different amounts or levels of release agent across the entire width. The systems and methods described herein can enable more precise control of the exit temperature of the cast slab by applying a known amount of release agent, and in certain embodiments, reduce the time required to reach a steady-state exit temperature, thereby increasing productivity. In various embodiments, the systems and methods described herein can enable the casting of high-quality slabs regardless of the incoming metal temperature. Various other benefits and advantages can be realized with the systems and methods described herein, and the benefits and advantages described herein should not be considered limiting.

[0012] Figure 1 shows an example of a continuous belt casting system 100. The arrangement or components shown in Figure 1 should not be considered limiting. The continuous belt casting system 100 generally includes a molten metal source 102 and endless casting belts 104A-B.

[0013] In some examples, the metal 112 from the molten metal source 102 may be aluminum or aluminum alloys of the 1xxx, 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, 7xxx, and 8xxx series, and / or any other aluminum or aluminum alloy as needed.

[0014] The endless cast belts 104A-B may be supported on pulleys or other suitable support structures and may be driven by various suitable drive mechanisms. Support structures and drive mechanisms are omitted from Figure 1 for simplicity. The cast belts 104A-B may be constructed from various suitable materials, and in some cases, from suitable metals that can withstand sufficient tension. In some examples, the cast belts 104A-B may be constructed from steel, iron, iron alloys, copper, copper alloys, aluminum, aluminum alloys, and / or various other metal or non-metallic materials suitable for belt casting.

[0015] Each endless casting belt 104A-B includes an elongated belt surface 106 that forms at least partially the casting cavity 108. Although not shown, edges or side dams are provided on both sides of the system 100 to complete the enclosure of the casting cavity 108 at the edges. The endless casting belts 104A-B can be arranged substantially parallel to each other, but do not have to be in other examples. In some examples, the endless casting belts 104A-B may converge toward the exit 114 of the casting cavity 108. In various cases, the endless casting belts 104A-B are driven at substantially the same speed as the metal passes through the casting cavity 108, so that the casting cavity 108 forms a static movable mold for the metal introduced into the casting cavity 108.

[0016] One or more coolant nozzles 120 may be provided to cool the rear or surface 122 of each casting belt 104A-B opposite to the elongated belt surface 106 by supplying coolant. The supply of coolant then removes heat from the metal within the casting cavity 108. In various embodiments, one or more coolant nozzles 120 may include one or more coolant inlets for introducing coolant and one or more coolant outlets or drains for removing coolant. The coolant may be various types of coolant suitable for cooling the casting belts 104A-B as needed, and in a non-limiting example, the coolant may be water. One or more coolant nozzles 120 may be provided in various arrangements both in the casting direction 110 and in the width direction relative to the casting belts 104A-B. Therefore, the number, type, and arrangement of one or more coolant nozzles 120 should not be considered limiting.

[0017] During casting, the endless casting belts 104A-B can rotate (indicated by arrows 111), and molten metal 112 is introduced from the molten metal source 102 at the inlet 116 of the casting cavity 108. The molten metal 112 may be various metals as needed, including but not limited to aluminum, aluminum alloys, steel, or other metals as needed. The metal 112 advances through the casting cavity 108 in the casting direction 110 via the endless casting belts 104A-B. As the metal advances through the casting cavity 108, heat from the metal is transferred through the belts, and the molten metal gradually solidifies. The metal 112 may be completely solidified before reaching the outlet 114 and can exit the outlet 114 as a continuous solid casting metal substrate or slab 118.

[0018] In certain embodiments, the continuous belt casting system 100 includes a control system 124 for controlling the heat flux within the continuous belt casting system 100 and the outlet temperature of the metal slab 118. In certain embodiments, as will be described in detail below, the control system 124 controls the heat flux by controlling the application of a release agent 126 to one or more of the casting belts 104A-B. The release agent 126 may be a variety of release agents as needed, and in certain embodiments, the release agent 126 is a fluid or liquid release agent.

[0019] As illustrated in Figures 1 and 2, in various embodiments, the control system 124 includes one or more release agent applicators 128 and a controller 130. In certain embodiments, the control system 124 includes one or more release agent sensors 132, one or more temperature sensors 134, and one or more release agent removal devices 136. In certain embodiments, each casting belt 104 may include at least one release agent applicator 128, at least one release agent sensor 132, and at least one release agent removal device 136.

[0020] The release agent dispenser 128 can be a variety of devices or systems suitable for applying the release agent 126 onto the belt surface(s) 106. The release agent dispenser 128 can be provided at various locations along the casting belts 104A-B suitable for applying the release agent 126 onto the belt surface(s) 106. In the embodiments illustrated in Figures 1 and 2, the release agent dispenser 128 is located on the side of the casting belts 104A-B opposite to the casting cavity(s) 108. Optionally, the release agent dispenser 128 is located closer to the inlet(s) 116 than to the outlet(s) 114, but this is not required in other embodiments.

[0021] As best shown in Figure 2, the release agent dispenser 128 may be positioned to apply the release agent 126 across the entire width 138 of each belt surface 106, and before the belt surface 106 comes into contact with the molten metal 112. A single release agent dispenser 128 is shown extending across the entire width 138 of a particular casting belt 104, but in other embodiments, two or more release agent dispensers 128 may extend across the width 138 of a particular casting belt 104. Furthermore, if multiple release agent dispensers 128 are used, they do not necessarily have to be aligned along the width 138. As a non-limiting example, Figure 3 shows another example of a continuous belt casting system 300 which is substantially similar to the continuous belt casting system 100, except that the control system 124 includes three release agent dispensers 128, and the release agent dispensers are not aligned across the entire width 138 of the belt surface 106.

[0022] Optionally, as shown in Figures 1 and 2, the control system 124 includes one or more release agent dispensers 123 downstream of or after the release agent applicator 128. The release agent dispensers may further smooth and / or redistribute the release agent 126 on the belt surface 106 to provide, for example, a desired distribution, pattern, arrangement, coverage, etc., of the release agent 126 on the belt surface 106. Non-limiting examples of the release agent dispenser 123 include wipers, blades, rolls, combinations thereof, and / or other suitable devices as needed. In some non-limiting examples, the release agent dispenser 123 optionally distributes the release agent 126 without contacting the belt surface 106 (e.g., they are offset by a distance from the belt surface 106), but in other examples, offsetting is not required.

[0023] The release agent sensor 132 can be various devices or mechanisms suitable for detecting the release agent 126 on the belt surface 106 and / or the properties of the release agent 126 after the release agent 126 is applied by the release agent applicator 128. As a non-limiting example, the release agent sensor 132 can be a device or mechanism suitable for detecting the level or amount of the release agent 126 on the belt surface 106, the distribution or pattern of the release agent 126 across the width 138, combinations thereof, and / or other devices or mechanisms as required. The number and location of the release agent sensors 132 shown should not be considered limiting. In some examples, the release agent sensor 132 can be downstream of the corresponding release agent applicator 128 along the direction of movement 111 of the casting belt 104, which can optionally be upstream with respect to the casting direction 110. In the illustrated embodiment, the release agent sensor 132 is on the same side as the release agent applicator 128 of the casting belts 104A - B and is between the release agent applicator 128 and the inlet 116. In some embodiments, the release agent sensor 132 can be movable with respect to the belts 104A - B. As a non-limiting example, the release agent sensor 132 can move across the belts 104A - B via a sliding mechanism and / or other suitable mechanisms as required, enabling the release agent sensor 132 to measure the release agent level across the entire belt width.

[0024] The mold release agent removal device 136 may be a device or mechanism suitable for removing the mold release agent 126 from the elongated belt surface before the mold release agent 126 is applied by the mold release agent applicator 128. In various embodiments, the mold release agent removal device 136 removes the mold release agent 126 each time the casting belt 104A-B rotates. In certain embodiments, the mold release agent removal device 136 may be located downstream from the casting cavity 108. In other words, the mold release agent removal device 136 encounters the belt surface 106 after it has left the casting cavity 108 (for example, to remove the mold release agent) and before the belt surface 106 is recirculated to the mold release agent applicator 128. The mold release agent removal device 136 enables the rapid, efficient, and continuous removal of contaminated or otherwise used mold release agent layers from the belt surface so that the belt surface 106 of the belt 104 emerging from the casting cavity 108 is completely clean and ready to be coated with a fresh new layer of mold release agent before receiving molten metal again. Non-limiting examples of the mold release agent removal device 136 may include contact devices or mechanisms (e.g., wipers, scrapers, etc.) and / or non-contact devices or mechanisms. Non-limiting examples may include a spray assembly comprising a nozzle (optionally in a housing) that directs a high-pressure spray of cleaning fluid onto the belt surface 106. In such embodiments, any residual cleaning fluid or mold release agent may be removed by a scraper, doctor blade, and / or other suitable device. In various embodiments, the amount, distribution, and quality of the mold release agent 126 can be controlled by the mold release agent applicator 128 by the mold release agent removal device 136 and the application of fresh mold release agent 126 by the mold release agent applicator 128, thereby potentially improving the control of the heat flux by the control system 124.

[0025] One or more temperature sensors 134 can be various devices or mechanisms suitable for detecting or calculating the heat flux at various locations within the casting cavity 108. In various embodiments, the temperature sensors 134 may directly measure the heat flux or indirectly determine the heat flux. Therefore, the number, type, and location of the temperature sensors 134 should not be considered limiting. In various embodiments, one or more temperature sensors 134 can be used to determine the heat flux over the entire width of the casting cavity 108. In embodiments illustrated in Figures 1 and 2, the temperature sensors 134 may measure or detect the coolant temperature at the coolant inlet(s) and coolant outlet(s) of one or more coolant nozzles 120, and the heat flux may be determined based on the difference between the coolant outlet temperature and the coolant inlet temperature. In various embodiments, the temperature sensors 134 may enable the generation of a heat flux map of the casting cavity 108, which may illustrate and / or otherwise indicate where heat is removed and the amount of heat removed at such locations. The heat flux mapping may be generated for one or both sides (e.g., the top and / or bottom) of the casting cavity 108.

[0026] The controller 130 may include one or more processing units and / or one or more memory devices. The processing unit may be various suitable processing devices or combinations of devices including, but not limited to, one or more application specific integrated circuits, digital signal processors, digital signal processing devices, programmable logic devices, field programmable gate arrays, processors, controllers, microcontrollers, microprocessors, other electronic units, and / or combinations thereof. The one or more memory devices may be any machine-readable medium accessible by the 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 of memory or number of memories, or the type of medium on which the memory is stored. Further, as disclosed herein, the terms “storage medium,” “storage device,” or “memory” can represent 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 other various storage media that can store or contain instructions(s) and / or data and / or transmit the same. In certain embodiments, the controller 130 optionally includes a related user interface, including but not limited to a graphical user interface or a human-machine interface, whereby the controller 130 can obtain information from and / or provide information to the user. In such embodiments, the user interface and / or human-machine interface may be on the controller 130 itself or at a location remote from the controller 130.

[0027] The controller 130 may be communicatively coupled to one or more temperature sensors 134 so that the controller 130 receives temperature data and / or data corresponding to heat flux. The communication between the controller 130 and the one or more temperature sensors 134 may be of various types, including but not limited to, wired communication and / or wireless communication (e.g., short-range, cellular, Wi-Fi, Bluetooth®, Bluetooth® Low Energy, etc.), as needed.

[0028] In various embodiments, the controller 130 can determine the heat flux at one or more locations within the casting cavity 108 and / or determine a heat flux profile, mapping, etc., based on information from the temperature sensor 134. In certain embodiments, the controller 130 can determine the heat flux profile across the entire width of the casting cavity 108 at one or more locations. In various embodiments, based on the determined heat flux, the controller 130 can determine a control response of the release agent dispenser 128 to control one or more characteristics of the application of the release agent 126 onto the belt surface 106. In some embodiments, the control response may be based on a comparison of the detected heat flux with a desired heat flux, which may be provided, calculated based on input data and / or determined or input in other ways as needed. Non-limiting examples of control responses may include, but are not limited to, controlling the flow rate of release agent 126 from the release agent dispenser 128, the application profile or distribution of the release agent 126 across the width of the belt surface 106, the type of release agent 126, the location of the release agent 126, combinations thereof, and / or other desired methods. In various embodiments, controlling the application of the release agent 126 controls the amount of heat removed within the casting cavity 108, thereby obtaining an optimal and / or desired heat flux. In one non-limiting embodiment, the controller 130 may control the release agent dispenser 128 to minimize and / or eliminate a temperature gradient across the width of the casting cavity 108.

[0029] Figure 4 shows an overall method 400 for controlling the heat flux during casting using a continuous belt casting system 100. This method is for illustrative purposes only, and other methods and controls can be implemented using the systems described herein. This method may be implemented in whole or in part by one or more computer systems. One or more computer systems may include, or be combined with, systems for monitoring and / or controlling the casting operation and / or the application of release agents.

[0030] In block 402, the method includes receiving information relating to the actual heat flux within the casting cavity 108. The actual heat flux may be the heat flux relating to a single location, multiple locations, a distribution (e.g., across the entire width of the casting cavity 108), a mapping of the entire casting cavity 108, and / or other desired locations. In various embodiments, block 402 includes receiving information from one or more temperature sensors 134 that directly or indirectly measure the heat flux within the casting cavity 108. In a non-limiting example, block 402 includes receiving the coolant inlet temperature and coolant outlet temperature of one or more coolant nozzles 120. In embodiments where the heat flux is not directly measured by the temperature sensors 134, block 402 may include determining the actual heat flux. In a non-limiting example, block 402 may include determining the actual heat flux based on the difference between the coolant outlet temperature and the coolant inlet temperature.

[0031] In block 404, the heat flux received and / or determined in block 402 is compared with the desired heat flux. In block 404, the desired heat flux may be provided (e.g., by the operator) and / or determined by the system as needed.

[0032] In block 406, the method includes determining whether a mold release control response is required based on a comparison in block 404. Block 406 may include determining whether a mold release control response is required based on the difference between a desired heat flux and the actual heat flux. Optionally, block 406 is based on additional heat flux information. Additional heat flux information may include, but is not limited to, the material of the casting belt 104 and / or the texture of the belt surface 106.

[0033] In Block 408, the method may include determining and implementing a release agent control response. Block 408 may include, but is not limited to, controlling the type of release agent, the location of release agent application, the coverage of the release agent, the amount of the release agent, the distribution of the release agent, combinations thereof, and / or other desired control responses.

[0034] In block 410, the method can be continued as long as heat flux control is desired.

[0035] Other controls may be implemented using the systems described herein, and the examples described herein should not be considered limiting. In a non-limiting example, the nominal strip temperature may be controlled by controlling the application of a release agent and / or release agent to the belt surface. In this example, a temperature sensor can measure, calculate, and / or monitor the temperature of the metal substrate 118 as it exits the belt casting system 100. In certain embodiments, the measured, calculated, and / or monitored temperature of the metal substrate 118 may be compared to a desired strip temperature. Based on the deviation between the actual strip temperature and the desired strip temperature (e.g., the actual temperature is outside a threshold), the amount, location, pattern, and / or general distribution of the release agent 126 to be distributed may be controlled so that the metal substrate 118 has a desired temperature.

[0036] A set of exemplary embodiments is provided below, including at least some expressly listed as “Aspects” to provide further explanation of various exemplary embodiments based on the concepts described herein. These aspects are not intended to be mutually exclusive, exhaustive, or limiting, and this disclosure is not limited to these exemplary aspects but rather encompasses all feasible modifications and variations within the scope of the issued claims and their equivalents.

[0037] Embodiment 1. A continuous belt casting system comprising a casting belt having an elongated belt surface, a release agent applicator configured to apply a release agent to the elongated belt surface, and a release agent control system configured to control the heat flux during casting by controlling the application of the release agent to the elongated belt surface during casting.

[0038] Embodiment 2. A continuous belt casting system according to any of the preceding or subsequent embodiments or a combination of embodiments, further comprising a release agent sensor configured to detect the release agent on the surface of the elongated belt, wherein the release agent sensor is located downstream from the release agent applicator in the direction of movement of the casting belt.

[0039] Embodiment 3. A continuous belt casting system according to any of the preceding or subsequent embodiments or a combination of embodiments, further comprising a sensor configured to detect a heat flux in the continuous belt casting system, wherein the controller is configured to control the application of the release agent based on the detected heat flux.

[0040] Embodiment 4. A continuous belt casting system according to any of the preceding or subsequent embodiments or a combination of embodiments, wherein the controller is configured to control the application of the release agent across the entire width of the elongated belt surface.

[0041] Embodiment 5. A continuous belt casting system according to any of the preceding or subsequent embodiments or a combination of embodiments, wherein the casting belt at least partially defines a casting cavity, and the release agent application is configured to apply the release agent to the elongated belt surface opposite to the casting cavity.

[0042] Embodiment 6. A continuous belt casting system according to any of the preceding or subsequent embodiments or combination of embodiments, further comprising a release agent removal device configured to remove the release agent from the elongated belt surface located downstream of the release agent applicator.

[0043] Embodiment 7. A continuous belt casting system according to any of the preceding or subsequent embodiments or a combination thereof, wherein the release agent removal device is configured to remove the release agent each time the casting belt rotates.

[0044] Embodiment 8. A continuous belt casting system comprising: a sensor for detecting a heat flux within the casting machine of the continuous belt casting system; and a release agent control system configured to control the heat flux during casting by controlling the application of a release agent to the elongated belt surface of the casting belt based on the detected heat flux.

[0045] Embodiment 9. A continuous belt casting system according to any of the preceding or subsequent embodiments or a combination of embodiments, wherein the sensor is configured to detect the heat flux over the entire width of the casting belt.

[0046] Embodiment 10. A continuous belt casting system according to any of the preceding or subsequent embodiments or a combination of embodiments, wherein the sensor is configured to detect a heat flux based on the difference between the coolant inlet temperature and the coolant outlet temperature of one or more cooling nozzles.

[0047] Embodiment 11. A continuous belt casting system according to any of the preceding or subsequent embodiments or a combination of embodiments, wherein the release agent control system includes a release agent applicator configured to apply the release agent to the elongated belt surface, and a controller configured to control the application of the release agent to the elongated belt surface during casting.

[0048] Embodiment 12. A continuous belt casting system according to any of the preceding or subsequent embodiments or a combination of embodiments, wherein the release agent control system further includes a release agent sensor configured to detect the release agent on the elongated belt surface, the release agent sensor being movable relative to the elongated belt surface.

[0049] Embodiment 13. A continuous belt casting system according to any of the preceding or subsequent embodiments or a combination of embodiments, wherein the controller is configured to control the application of the release agent across the entire width of the elongated belt surface.

[0050] Embodiment 14. A continuous belt casting system according to any of the preceding or subsequent embodiments or a combination of embodiments, wherein the release agent control system includes a release agent applicator configured to apply the release agent to the elongated belt surface, and a release agent removal device configured to remove the release agent from the elongated belt surface before the release agent is applied by the release agent applicator.

[0051] Embodiment 15. A method for casting a metal slab, comprising: introducing molten metal into a casting cavity defined by two casting belts; advancing the casting belts so as to solidify the molten metal through the casting cavity and while controlling the heat flux by controlling the application of a release agent on at least one of the two casting belts; and discharging the solidified metal as a metal slab from the outlet of the casting cavity.

[0052] Embodiment 16. The method according to any of the preceding or subsequent embodiments or a combination of embodiments, further comprising: detecting the heat flux; and controlling the application of the release agent to the surface of at least one of the two casting belts based on the detected heat flux.

[0053] Embodiment 17. A method by which controlling the application of the release agent is performed by applying the release agent to the surface of at least one elongated belt of the two casting belts, and detecting the release agent across the entire width of the elongated belt surface, in any of the preceding, subsequent, or combination thereof.

[0054] Embodiment 18. The method of any of the preceding or subsequent embodiments or combinations of embodiments, further comprising removing the release agent from at least one of the two casting belts after a portion of at least one of the two casting belts has left the casting cavity.

[0055] Embodiment 19. The method of any preceding or subsequent embodiment or combination of embodiments, wherein controlling the heat flux further comprises detecting the heat flux based on the coolant inlet temperature and coolant outlet temperature of one or more cooling nozzles.

[0056] Embodiment 20. The method according to any of the preceding or subsequent embodiments or a combination of embodiments, wherein controlling the application of the release agent includes applying the release agent to at least one of the two casting belts on the side opposite to the casting cavity.

[0057] As used herein, the terms “invention,” “the invention,” “this invention,” and “the present invention” are intended to broadly refer to the subject matter of this patent application and all of the following claims. It should be understood that any statements containing these terms are not intended to limit the subject matter described herein, or the meaning or scope of the following claims.

[0058] This description refers to alloys identified by AA numbers and other related symbols, such as "System" or "5xxx". For an understanding of the most commonly used numbering system for 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 Composition Limits for Aluminum Alloys in the Form of Castings and Ingot" (both published by the Aluminum Association).

[0059] As used in this disclosure, the meanings of “a,” “an,” and “the” include singular and plural references, unless the context clearly indicates otherwise.

[0060] The subject matter of embodiments of this disclosure is described herein using specifics to satisfy statutory requirements, but 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 any particular order or arrangement in or between the various steps or elements, except when the order of individual steps or the arrangement of elements is explicitly described. Directional references such as “up,” “down,” “upper side,” “lower side,” “left,” “right,” “vertical,” “horizontal,” “sideways,” “vertical,” “front,” and “back” are intended, among other things, to refer to the orientation shown and described in one (or more) figures to which the components and directions refer.

[0061] The terms “comprising,” “having,” “including,” and “containing” should be interpreted as unrestricted terms (i.e., “including, but not limited to”) unless otherwise specified herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or unless the context clearly contradicts it. Any and all embodiments provided herein, or the use of exemplary language (e.g., “etc.”), are intended merely to better illustrate embodiments of the invention and do not impose limitations on the scope of the invention unless otherwise requested. Nothing expressed herein should be interpreted as indicating that an unclaimed element is essential to the practice of the invention.

[0062] The embodiments described above are merely possible examples of embodiments and are described solely to provide a clear understanding of the principles of this disclosure. Many variations and modifications can be made to the embodiments(s) described above without substantially departing from the spirit and principles of this disclosure. All such modifications and variations are intended to be incorporated herein within the scope of this disclosure, and all possible claims for individual embodiments or combinations of elements or steps are intended to be supported by this disclosure. Furthermore, certain terms are used herein and in the following claims, but they are used in a general and descriptive sense only and are not intended to limit the embodiments described or the following claims.

Claims

1. A continuous belt casting system having the following: A cast belt having an elongated belt surface, and A mold release agent control system having the following: A mold release agent applicator configured to apply a mold release agent to the surface of the elongated belt, and A controller configured to control the heat flux during casting by controlling the application of the release agent to the surface of the elongated belt during casting.

2. The continuous belt casting system according to claim 1, further comprising a release agent sensor configured to detect the release agent on the surface of the elongated belt, wherein the release agent sensor is located downstream from the release agent applicator along the direction of movement of the casting belt.

3. The continuous belt casting system according to claim 1, further comprising a sensor configured to detect a heat flux in the continuous belt casting system, wherein the controller is configured to control the application of the release agent based on the detected heat flux.

4. The continuous belt casting system according to claim 1, wherein the controller is configured to control the application of the release agent across the entire width of the elongated belt surface.

5. The continuous belt casting system according to claim 1, wherein the casting belt at least partially defines the casting cavity, and the release agent application is configured to apply the release agent to the elongated belt surface opposite to the casting cavity.

6. The continuous belt casting system according to claim 1, further comprising a release agent removal device configured to remove the release agent from the elongated belt surface located downstream of the release agent applicator.

7. The continuous belt casting system according to claim 6, wherein the mold release agent removal device is configured to remove the mold release agent each time the casting belt rotates.

8. A continuous belt casting system having the following: A sensor for detecting the heat flux inside the casting machine of the continuous belt casting system, and A mold release agent control system configured to control the heat flux during casting by controlling the application of a mold release agent to the elongated belt surface of a casting belt based on the detected heat flux.

9. The continuous belt casting system according to claim 8, wherein the sensor is configured to detect the heat flux over the entire width of the casting belt.

10. The continuous belt casting system according to claim 8, wherein the sensor is configured to detect a heat flux based on the difference between the coolant inlet temperature and the coolant outlet temperature of one or more cooling nozzles.

11. The aforementioned release agent control system A mold release agent applicator configured to apply the mold release agent to the surface of the elongated belt, and A controller configured to control the application of the release agent to the surface of the elongated belt during casting, A continuous belt casting system according to claim 8, comprising:

12. The continuous belt casting system according to claim 11, wherein the release agent control system further includes a release agent sensor configured to detect the release agent on the elongated belt surface, the release agent sensor being movable relative to the elongated belt surface.

13. The continuous belt casting system according to claim 11, wherein the controller is configured to control the application of the release agent across the entire width of the elongated belt surface.

14. The aforementioned release agent control system A mold release agent applicator configured to apply the mold release agent to the surface of the elongated belt, and A mold release agent removal device configured to remove the mold release agent from the elongated belt surface before the mold release agent is applied by the mold release agent applicator, A continuous belt casting system according to claim 8, comprising:

15. A method for casting metal slabs, including the following: Introducing molten metal into a casting cavity defined by two casting belts, By advancing the casting belt, the molten metal is advanced through the casting cavity, and the heat flux is controlled by controlling the application of the release agent on at least one of the two casting belts, thereby causing the molten metal to solidify. To expel the solidified metal as a metal slab from the outlet of the casting cavity.

16. Controlling the heat flux means Detecting heat flux, and Based on the detected heat flux, control the application of the release agent to the surface of at least one of the two elongated casting belts. The method according to claim 15, further comprising:

17. Controlling the application of the aforementioned release agent is Applying the release agent to the surface of at least one of the two elongated casting belts, and To detect the release agent across the entire width of the elongated belt surface, The method according to claim 15, including the method described in claim 15.

18. The method according to claim 15, further comprising removing the release agent from at least one of the two casting belts after a portion of at least one of the two casting belts has left the casting cavity.

19. The method according to claim 15, wherein controlling the heat flux further includes detecting the heat flux based on the coolant inlet temperature and coolant outlet temperature of one or more cooling nozzles.

20. The method according to claim 15, wherein controlling the application of the release agent includes applying the release agent to at least one of the two casting belts on the side opposite to the casting cavity.

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