Continuous Clad Plate Casting With Molten Pool Bonding Control
Find Innovative SolutionsGenerate Solutions
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 variability.
Innovation Solution
A production apparatus and method combining continuous casting, rolling, and heat treatment, utilizing a base material supply device with uncoiler, shot blasting, induction heating, and molding cooling rolls to form a molten metal pool, allowing for single-sided or double-sided clad plate production with varying thicknesses, and implementing online cooling and rolling to enhance bonding and reduce energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If roll-bonded cladding is used to achieve high composite strength, then bonding quality is improved, but production efficiency deteriorates due to multiple processes and inability to realize continuous production
Solution Approach 1:
The patent utilizes phase transition by immersing the base material strip into a molten metal pool, where the molten metal solidifies upon contact to form a metallurgically bonded cladding layer. This phase change from liquid to solid enables continuous production while achieving high composite strength through complete metallurgical bonding at the interface.
Solution Approach 2:
The patent replaces the mechanical rolling and heating processes of traditional roll-bonded cladding with a molten metal pool immersion system. The molten metal is cast onto or into the base material strip, eliminating the need for complex mechanical assembly, vacuuming, and heating steps, thereby enabling continuous production.
2Productivity
If continuous casting and rolling is used to improve production efficiency, then productivity is improved, but control of bonding and thickness variability deteriorates
Solution Approach 1:
The patent incorporates a control system that monitors and adjusts the immersion depth, casting speed, and molten metal flow rate in real-time. This feedback mechanism ensures consistent cladding thickness and bonding quality during continuous production, eliminating thickness variability while maintaining high productivity.
Solution Approach 2:
The patent precisely controls critical parameters including molten metal temperature, casting speed, and immersion depth to optimize bonding quality and thickness consistency. By maintaining the molten metal temperature above the melting point of the base material and controlling the cooling rate during solidification, the process achieves reliable metallurgical bonding with minimal thickness variation.
3Reliability
If multiple processes are used in billet assembly to achieve high quality cladding, then product performance is improved, but device complexity and cost increase
Solution Approach 1:
The patent merges multiple separate processes (cleaning, heating, bonding, rolling) into a single integrated molten metal pool immersion process. The base material strip is directly immersed into the molten metal pool where bonding occurs simultaneously with solidification, eliminating the need for separate vacuuming, heating, and rolling steps, thereby reducing device complexity while maintaining product performance.
Solution Approach 2:
The molten metal pool system performs multiple functions simultaneously: it acts as the bonding agent, the heat source, and the forming medium. This multi-functional approach replaces multiple specialized equipment pieces, simplifying the overall device complexity while achieving high-quality cladding with complete metallurgical bonding.
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 improves production efficiency, enables continuous and large-scale production of clad plates with diverse thicknesses, and reduces energy consumption and costs, while allowing for selection of various base and cladding materials.
Implementation Method 1
induction heating equipment (6), and further includes: a flow distributor (7), two molding cooling rolls (8)... the flow distributor (7) is arranged above the molding cooling rolls (8), and is used to cast molten steel between the two molding cooling rolls (8) to form a molten metal pool (B)... the base material strip heated by step 2) enters the molten metal pool between the molding cooling rolls
Implementation Method 2
two molding cooling rolls (8)... the flow distributor (7) is arranged above the molding cooling rolls (8), and is used to cast molten steel between the two molding cooling rolls (8) to form a molten metal pool (B)... the base material strip heated by step 2) enters the molten metal pool between the molding cooling rolls (8) along the molding cooling roll to melt and clads the base layer and the base material strip to form a cladding slab (C)
Implementation Method 3
the secondary cooling leveling roll (9) is used to flatten the cladding slab (C) conveyed from the two molding cooling rolls (8)... 4) after coming out of the molding cooling roll, the cladding slab enters the secondary cooling leveling roll (9) to be cooled again and makes the surface of the cladding slab deformed and flattened
Implementation Method 4
the rolling mill (11) is used to roll the cladding slab conveyed from the rolling mill pinch roll (10) to form a cladding strip... 5) the cladding slab after further cooling and flattening is sent to the rolling mill pinch roll (10), and then enters the rolling mill (11) to be rolled into the cladding strip (D) with different thicknesses of 0.5～100mm
Implementation Method 5
the online cooling equipment (12) is used to cool the cladding strip conveyed from the rolling mill (11)... 6) the rolled cladding strip (D) is cooled online by the online cooling equipment (12), an online cooling speed is 1～60℃/s, and a final cooling temperature is 50-600℃
Data Source
Figure 1
AI summary
A production apparatus for short-process metal composite plate manufacturing, comprising a parent metal supply device consisting of an uncoiler (1), a pinch roll (2), a shot blasting machine (3), a welding device (4), a welding pinch roll (5), and an induction heating apparatus (6), further comprising a metal delivery machine (7), two crystallization cooling rolls (8), a secondary cooling leveling roll (9), a rolling mill pinch roll (10), a rolling mill (11), an on-line cooling apparatus (12), a 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 production 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, and carbon steel, stainless steel, a special alloy, titanium, copper and the like are comprised. Continuous casting and rolling of the composite plate, saving energy consumption, and reducing the costs are achieved.