Continuous Casting Mold Laminate for Adhesion and Thermal Stress
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Solution Overview
Problem
In continuous casting, high thermal stress and non-uniform cooling lead to cracking and spalling in cast slabs and mold copper plates, particularly when using metals with low thermal conductivity in concave portions on the mold surface, necessitating improved adhesion and heat resistance to maintain casting speed and mold longevity.
Innovation Solution
A method for manufacturing a continuous casting mold involves forming concave portions on the mold surface with a nickel-based laminate filling, where each layer is stacked to enhance adhesion and heat resistance, with a gradient copper content to optimize thermal management and reduce stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal with low thermal conductivity is filled in concave portions on the mold surface, then heat resistance and stress distribution are improved, but adhesion strength between the filled metal and mold copper plate deteriorates due to thermal stress
Solution Approach 1:
The patent applies composite materials by filling concave portions with a multi-layered laminate structure consisting of a copper-based alloy layer and a nickel-based alloy layer. This composite structure combines the high thermal conductivity of copper with the high heat resistance and low thermal conductivity of nickel, achieving both improved heat resistance and maintained adhesion strength through controlled thermal stress distribution.
Solution Approach 2:
The patent changes the thermal conductivity parameter by using a nickel-based alloy layer with lower thermal conductivity than pure copper fillers. This parameter change improves heat resistance by reducing heat accumulation while the specific composition parameters of the laminate structure ensure adhesion strength is maintained through reduced thermal stress.
2Stress or pressure
If a metal with low thermal conductivity is filled in concave portions, then thermal stress is reduced, but heat resistance deteriorates due to heat accumulation in the filled metal
Solution Approach 1:
The patent uses a composite laminate structure where the copper-based alloy layer provides high thermal conductivity to dissipate heat and prevent accumulation, while the nickel-based alloy layer provides low thermal conductivity to reduce thermal stress. This composite approach simultaneously addresses both thermal stress reduction and heat resistance maintenance.
Solution Approach 2:
The patent applies local quality by creating a layered structure where different materials with different thermal properties are positioned at specific locations within the filler. The copper-based layer is positioned to handle heat dissipation while the nickel-based layer is positioned to manage thermal stress, optimizing local thermal properties to address both contradictions.
3Ease of manufacture
If a single-layer metal filler is used in concave portions, then manufacturing is simple, but adhesion strength and heat resistance are insufficient under high casting speeds
Solution Approach 1:
The patent employs a multi-layered composite laminate structure consisting of a copper-based alloy layer and a nickel-based alloy layer. This composite structure provides superior adhesion strength and heat resistance compared to single-layer fillers, while the manufacturing process remains feasible through sequential deposition or sintering methods.
Solution Approach 2:
The patent transitions from a single-layer (one-dimensional) filler to a multi-layered (multi-dimensional) laminate structure. This dimensional change in the filler architecture enables simultaneous optimization of adhesion strength and heat resistance by incorporating multiple materials with complementary properties, while maintaining manufacturing feasibility.
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
The method increases adhesion strength between the mold copper plate and the filled metal, reducing stress and cracking risks, while maintaining effective heat resistance and productivity by forming a multi-layered nickel-based alloy laminate with controlled copper diffusion and laser-beam buildup.
Implementation Method 1
each of the second layer and layers above the second layer is a nickel layer or a nickel-based alloy layer having a thickness of 0.2 mm to 2 mm formed by radiating a laser beam while feeding nickel powder or nickel-based alloy powder to a position irradiated with the laser beam to melt and solidify the nickel powder or the nickel-based alloy powder
Implementation Method 2
the metal filling the concave portion is a laminate formed of two or more layers in such a manner that the layers are stacked on top of one another from a bottom of each of the concave portions to an open of the concave portion... a gradient chemical composition with gradually decreasing copper content
Data Source
AI summary
A method for manufacturing a continuous casting mold in which cracking and spalling are less likely to occur in a filling laminate. The method includes filling a plurality of concave portions formed on an inner surface of a copper-made mold copper plate or a copper alloy-made mold copper plate used for continuously casting steel at least in a region including a meniscus position of molten steel in a casting process with a metal having a thermal conductivity different from that of the mold copper plate.