Continuous Casting Clad Plate Bonding Without Billet Assembly
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Solution Overview
Problem
Current methods for manufacturing metal composite strips, such as roll-bonded cladding, face challenges in achieving high production efficiency and cost-effectiveness for large-scale production due to complex billet assembly processes and difficulties in controlling the bonding of molten steel layers during continuous casting and rolling.
Innovation Solution
A device and method incorporating uncoiler, pinch roller, shot blasting machine, welding equipment, induction heating apparatus, and guiding rollers for continuous casting and rolling of metal clad plates, allowing for precise merging and solidification of base and molten steel layers, followed by secondary cooling and rolling to produce composite strips with varying thicknesses and specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If roll-bonded cladding is used to achieve high composite strength, then bonding quality improves, but production efficiency deteriorates due to complex billet assembly processes
Solution Approach 1:
The patent changes the physical state parameter of the base material from solid to liquid, allowing the molten metal to naturally bond with the base material strip during continuous casting, eliminating complex assembly processes while maintaining strong bonding
Solution Approach 2:
The patent implements continuous casting where molten metal flows continuously over the base material strip in a continuous caster, enabling uninterrupted production and eliminating the batch processing nature of roll-bonded cladding
2Productivity
If continuous casting with multiple moulds is used to improve production efficiency, then productivity improves, but device complexity increases due to cyclic movement of 2-3 moulds
Solution Approach 1:
The patent extracts and eliminates the complex multi-mould cyclic system from conventional continuous casting, using a single mould with a simple open-top structure that receives molten metal directly, dramatically reducing device complexity while maintaining continuous production capability
3Ease of manufacture
If simultaneous solidification of base layer and composited layer is used to simplify the process, then manufacturing steps reduce, but bonding control becomes difficult due to mixing prevention requirements
Solution Approach 1:
The patent performs preliminary heating of the base material strip to near-melting temperature before the molten metal contacts it, ensuring the surface is sufficiently hot to prevent rapid solidification and mixing, while still allowing controlled bonding to occur as the layers solidify together
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly enhances production efficiency and reduces costs by enabling continuous, large-scale production of composite plates with improved bonding and energy efficiency, accommodating a wide range of materials like carbon steel, stainless steel, and special alloys.
Implementation Method 1
sending it with pinch roller (2) to shot blasting machine (3) for surface cleaning
Implementation Method 2
sending the cleaned base material strip to induction heating apparatus (6) for heating
Implementation Method 3
The molten metal is solidified rapidly under the cooling action of the crystallizing roller
Implementation Method 4
the molten metal is solidified rapidly under the cooling action of the crystallizing roller
Data Source
AI summary
The device and method for manufacturing metal clad plates in way of continuous casting and rolling provided by the present invention, combines the continuous casting, rolling and heat treatment methods used for single material production with the continuous and large-scale production method of composite strip, greatly improves the production efficiency of composite plates. The present invention can be used for producing single-sided or double-sided composite plates with different thickness specifications, wherein the base material or the composited material can be selected in a wide range, including carbon steel, stainless steel, special alloy steel, titanium, copper and the like. The invention realizes the production of composite plates by continuous casting and rolling, and reduces energy consumption and costs.