14 results about "Direct chill casting" patented technology

Provided herein is a system and method for parameter value determination of direct chill casting using artificial intelligence. The system may employ one or more image sensors configured to capture images of a surface of a direct chill cast billet or ingot, where the images depict one or more casting anomalies. A first machine learning model configured to process images is configured to identify, within the images, casting anomalies along with metrics of the casting anomalies or anomalies can be directly input to the first machine learning model. The casting anomalies are identified by the first machine learning model, classified through conditional statements according to anomaly type and scale. A second machine learning model is configured to process the casting anomaly type and scale as an input along with most parameters and set-up conditions that can cause the anomaly to generate changes to parameter values of the direct chill casting process to reduce or eliminate the casting anomalies.

Provided herein is a system, apparatus, and method for providing casting gas to a direct chill casting mold, and more particularly, to supplying casting gas to a direct chill casting mold at a well-regulated pressure and volume using fluid injectors. Systems for supplying casting gas to a continuous casting mold can include: a continuous casting mold cavity; a casting gas supply line; an injector receiving casting gas from the casting gas supply line; and a post injector casting gas supply line, where the casting gas supply line provides casting gas at a pressure above 300 psi (pounds per square inch) to an input of the injector, where a controller controls the injector to supply casting gas via the post injector casting gas supply line to the continuous casting mold cavity.

Provided are aluminum 3xxx series alloy products having improved thermal and electrical stability, and methods for forming such products. Methods include DC casting a molten aluminum alloy, withdrawing the aluminum alloy from the mold to form an ingot, homogenizing the ingot at a homogenization temperature from 500 °C to 650 °C for a period of time from 1 to 5 hours. Methods include reducing the temperature to a soaking temperature from 350 °C to 550 °C and soaking the ingot for a period of time from 1 to 15 hours. Methods include hot rolling the homogenized ingot to produce a hot rolled aluminum alloy, and cold rolling the hot rolled aluminum alloy to produce to an aluminum alloy product.

Provided herein is a system, apparatus, and method for continuous casting of metal, and more particularly, to a mechanism for controlling the shape of a direct chill casting mold to dynamically control a profile of an ingot cast from the mold during the casting process. Embodiments may provide an apparatus for casting material including: first and second opposing side walls; first and second end walls extending between the first and second side walls, where the first and second opposing side walls and the first and second opposing end walls form a generally rectangular shaped mold cavity. At least one of the first and second opposing side walls may include two or more contact regions, where each of the two or more contact regions may be configured to be displaced relative to a straight line along the side wall.

A direct chill casting system includes a mold for forming an ingot. The mold defines an open-ended casting cavity having a casting axis and includes a plurality of discharge channels for discharging coolant the ingot. The plurality of discharge channels include first discharge channels which receive the coolant at a first flow rate and second discharge channels which receive the coolant at a second flow rate which is different from the first flow rate. Controllers may be at least partially within the first discharge channels or the second discharge channels for controlling the flow rates.

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

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

A method of controlling vertical folds during casting includes determining a fold control parameter of a skim dam 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 sump while controlling the skim dam to have the fold control parameter. A skim dam system for a casting system includes a skim dam and a control system for selectively controlling a skim dam submergence depth of the skim dam in a molten sump.

Provided herein is a system and method for parameter value determination of direct chill casting using artificial intelligence. The system may employ one or more image sensors configured to capture images of a surface of a direct chill cast billet or ingot, where the images depict one or more casting anomalies. A first machine learning model configured to process images is configured to identify, within the images, casting anomalies along with metrics of the casting anomalies or anomalies can be directly input to the first machine learning model. The casting anomalies are identified by the first machine learning model, classified through conditional statements according to anomaly type and scale. A second machine learning model is configured to process the casting anomaly type and scale as an input along with most parameters and set-up conditions that can cause the anomaly to generate changes to parameter values of the direct chill casting process to reduce or eliminate the casting anomalies.

A direct chill (DC) casting system may be used to cast a metal ingot from a molten metal such as aluminum or aluminum alloys. The DC casting system includes a steam condensation system that condenses steam generated during a DC casting process as recycled water. The recycled water may be used for subsequent cooling of the metal ingot during the DC casting process.

Methods for controlling cracking in an ingot during direct chill casting include introducing molten metal into a mold cavity of a casting mold of a casting system and into a metal sump of the ingot being cast. The method includes creating a plurality of low points in the metal sump. One or more of the low points may be offset from a central axis of the ingot. A casting system may include various means or mechanisms for creating a plurality of low points in the metal sump.

Provided herein is a system, apparatus, and method for continuous casting of metal, and more particularly, to a mechanism for controlling the shape of a direct chill casting mold to dynamically control a profile of an ingot cast from the mold during the casting process. Embodiments may provide an apparatus for casting material including: first and second opposing side walls; first and second end walls extending between the first and second side walls, where the first and second opposing side walls and the first and second opposing end walls form a generally rectangular shaped mold cavity. At least one of the first and second opposing side walls may include two or more contact regions, where each of the two or more contact regions may be configured to be displaced relative to a straight line along the side wall.

The direct chill (DC) casting system can be used to cast metal ingots from molten metal such as aluminum or aluminum alloys. The above-described DC casting system includes a steam condensation system that condenses the steam generated during the DC casting process into recycled water. The above-described recycled water can be used for subsequent cooling of the metal ingot during the DC casting process.

The invention discloses a low-carbon stainless steel evanescent mode direct casting process which solves the problem of low-carbon stainless steel direct casting. The process comprises the following steps: manufacturing a foamed plastic mold by using an aluminum mold according to design, and designing a pouring gate into a hollow conical shape; sTMMA is adopted for foaming to prepare a model piece, the model piece is dried, after assembly, the model piece is dip-coated with a special coating which is independently researched and developed and resistant to high temperature, high in air permeability and non-sticky to sand, and drying is conducted again; selecting ceramsite, and putting the model into a sand box for vibration molding; stainless steel is smelted, impurities are removed, pouring is conducted under negative pressure, the model is gasified, gas is discharged, and the cavity is filled with molten metal; shakeout and piece taking are conducted after pressure maintaining and cooling are conducted, and then surface shot blasting cleaning and hardness treatment are conducted; and finally detecting to ensure that the carbon content of the casting is lower than 0.07% and the casting leaves the factory after reaching the GB / T26658 quality evaluation standard. The process is low in cost and environment-friendly, and fills the blank in related fields.