Casting Nozzle Flow Deflectors for Meniscus Stability
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Solution Overview
Problem
Conventional casting nozzles experience flow instability and asymmetrical flow rates between side ports, leading to uneven meniscus levels and increased wear on refractory walls, which affects the quality of the metal product and lubricant distribution.
Innovation Solution
The introduction of flow deflectors protruding from the bore wall above each port inlet, with a continuously increasing cross-sectional area, helps to stabilize the molten metal flow by deflecting it towards the bore wall and central plane, reducing bias flows and vertical fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional casting nozzles are used without flow deflectors, then the structure is simple, but the flow rate between side ports is uneven and meniscus level fluctuates
Solution Approach 1:
Flow deflectors are installed locally above each side port inlet rather than modifying the entire nozzle structure. Each deflector is positioned at a specific location where it can locally guide the molten metal flow into the side port, creating localized flow control that ensures uniform distribution between ports without complex global restructuring
Solution Approach 2:
Flow deflectors act as intermediary elements between the main molten metal flow and the side ports. These deflectors mediate the flow by redirecting it towards the side port inlets, ensuring that the flow is evenly distributed between opposite ports while maintaining the overall simplicity of the nozzle structure
2Manufacturing precision
If conventional casting nozzles are used, then the device is simple to manufacture, but meniscus level varies excessively affecting lubricant distribution
Solution Approach 1:
Flow deflectors are positioned locally above each side port to specifically address the flow distribution issue at critical locations. This localized approach stabilizes the meniscus level by ensuring uniform flow between ports, which in turn ensures proper lubricant distribution, while keeping the overall manufacturing process relatively simple
Solution Approach 2:
Flow deflectors are positioned upstream above the side port inlets to preliminarily guide and condition the molten metal flow before it enters the side ports. This preliminary flow guidance prevents flow instability and meniscus fluctuations downstream, addressing the problem before it affects the casting process
3Duration of action of stationary object
If conventional casting nozzles are used, then the structure is straightforward, but wear on refractory walls increases reducing service time
Solution Approach 1:
Flow deflectors are strategically positioned above each side port to locally control the flow pattern. This localized flow control prevents turbulent flow and direct impingement of molten metal on the refractory walls, thereby reducing wear and extending nozzle service life without requiring a complete redesign of the nozzle structure
Solution Approach 2:
The flow deflectors convert the potentially harmful direct flow of molten metal into a beneficial controlled flow pattern. By redirecting the flow towards the side ports and away from the refractory walls, the deflectors transform what would be erosive flow into a protective flow configuration that reduces wear and extends service time
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 configuration results in a more homogeneous and balanced flow rate between side ports, minimizing meniscus level variations and reducing wear on the nozzle, thereby enhancing the quality and consistency of the metal casting process.
Implementation Method 1
one or two flow deflectors (3) protrude out of the bore wall and extend from an upstream deflector end remote from the port inlet to a downstream deflector end close to the port inlet
Implementation Method 2
Flow of metal melt out of the tundish is driven by gravity through the casting nozzle (1N)
Data Source
Figure 1~2(b)
Figure 3~8
Figure 4~5
AI summary
The present invention concerns a casting nozzle comprising an elongated body defined by an outer wall and comprising a bore (1) defined by a bore wall and extending along a longitudinal axis, X1, from a bore inlet (1u) to a downstream bore end (1d), said bore comprising two opposite side ports (2), each extending transversally to said longitudinal axis, X1, from an opening at the bore wall defining a port inlet (2u) adjacent to the downstream bore end (1d), to an opening at the outer wall defining a port outlet (2d) which fluidly connects the bore with an outer atmosphere, Characterized in that, upstream from, and directly above each port inlet (2u), one or two flow deflectors (3) protrude out of the bore wall and extend from an upstream deflector end remote from the port inlet to a downstream deflector end close to the port inlet, over a deflector height, Hd, measured parallel to the longitudinal axis, X1, and wherein an area of a cross-section normal to the longitudinal axis, X1, of each flow deflector increases continuously over at least 50% of the deflector height, Hd, in the direction extending from the upstream deflector end towards the downstream deflector end.