Continuous Metal Clad Plate Casting for Bonding and Thickness Control
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Solution Overview
Problem
Current methods for producing metal clad plates face challenges in achieving high production efficiency and cost-effectiveness, particularly in continuous and large-scale production, due to limitations in bonding control and thickness of composite layers.
Innovation Solution
A production apparatus and method combining continuous casting, rolling, and heat treatment, utilizing a base material supply device with uncoiler, pinch roll, shot blasting machine, welding device, induction heating equipment, molding cooling rolls, and online cooling equipment to form a molten metal pool for bonding and rolling the clad plates, allowing for single-sided or double-sided clad plates with varying thicknesses.
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 multiple manual processes
Solution Approach 1:
The patent implements continuous production by replacing discrete manual operations with a continuous casting process. The billet assembly line is transformed into a continuous casting machine that operates without interruption, maintaining metallurgical bonding quality while achieving large-scale production. The molten metal flows continuously through the casting mold, eliminating the need for separate cleaning, alignment, and rolling steps.
Solution Approach 2:
The patent replaces manual mechanical operations with automated casting technology. Instead of workers manually cleaning surfaces, aligning billets, and operating rolling mills, the invention uses a continuous casting machine with automated mold systems, induction heating, and robotic handling to achieve the same bonding result with continuous operation.
2Productivity
If continuous casting methods are used to improve production efficiency, then productivity improves, but control of bonding and thickness precision deteriorates
Solution Approach 1:
The patent incorporates real-time monitoring and feedback control systems in the continuous casting process. Sensors measure temperature, flow rate, and dimensional parameters of the molten metal, feeding this data back to control systems that adjust casting parameters dynamically. This ensures precise control of composite layer thickness and bonding quality while maintaining continuous production.
Solution Approach 2:
The patent achieves precise control by dynamically adjusting key process parameters during continuous casting. The casting speed, molten metal temperature, mold cooling rate, and pull speed are continuously optimized based on real-time conditions. This parameter control enables precise thickness management and bonding quality while maintaining high production efficiency.
3Strength
If multiple separate processes are used for billet assembly, then bonding quality improves, but device complexity and cost increase
Solution Approach 1:
The patent merges multiple separate processes (surface cleaning, alignment, heating, rolling, and bonding) into a single integrated continuous casting machine. The casting mold system combines functions of all these processes, with the molten metal being cast directly onto the substrate in one continuous operation, eliminating the need for separate equipment and reducing overall system complexity.
Solution Approach 2:
The continuous casting machine performs multiple functions simultaneously: it heats the molten metal, forms the composite structure, controls bonding, and produces the final clad plate in one universal device. This multi-functional system replaces the need for specialized equipment for each individual process step, reducing device complexity while maintaining bonding quality.
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, reduces energy consumption, and lowers costs by enabling continuous and large-scale production of clad plates with improved bonding and thickness flexibility.
Implementation Method 1
induction heating equipment, and the heated base material strip enters the molten metal pool
Implementation Method 2
the molten metal pool is formed by solidification of the liquid metal in the casting mold
Implementation Method 3
the molten metal pool is formed by solidification of the liquid metal in the casting mold
Implementation Method 4
a base material supply device with uncoiler, pinch roll, shot blasting machine
Data Source
AI summary
A production apparatus for short-process metal composite plate manufacturing, the apparatus including a metal supply device including an uncoiler (1), pinch roll (2), shot blasting machine (3), welding device (4), welding pinch roll (5), induction heating apparatus (6), metal delivery machine (7), two crystallization cooling rolls (8), secondary cooling leveling roll (9), rolling mill pinch roll (10), rolling mill (11), on-line cooling apparatus (12), straightener (13), and at least one of a dividing shear (14) and a recoiling machine (15). Also disclosed is a production method for short-process metal composite plate manufacturing. The apparatus and method combine continuous casting, rolling, and heat-treating means for single material production with continuous and large-scale production of composite plate strips, and production efficiency of composite plates is sharply improved. Single-sided or double-sided composite plate production having different thickness specifications can be performed, the optional range of a base layer or cladding material is wide.