Continuous Metal Clad Strip Casting for Strong Bonded Interfaces
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Solution Overview
Problem
Current methods for manufacturing metal clad strips face challenges in achieving high productivity and cost-effectiveness, particularly in continuous and large-scale production, with existing techniques often resulting in low efficiency and high costs due to complex processes and difficulties in controlling the clad interface during solidification.
Innovation Solution
A device and method that combines continuous casting, rolling, and heat treatment, utilizing a decoiler, shot blasting, welding, induction heating, and on-line cooling to merge and solidify base and molten steel layers within a mold, allowing for continuous production of clad strips with varying thicknesses and specifications, while minimizing energy consumption and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If roll-bonded cladding is used to achieve complete metallurgical bonding and high bonding strength, then the bonding strength is improved, but the productivity decreases due to multiple processes and difficulty in continuous production
Solution Approach 1:
The invention utilizes the phase transition of steel from solid to liquid and back to solid. The base steel strip is heated to austenite phase (above Ac3 transformation point), then molten clad steel is poured onto it. The molten steel solidifies on the heated strip surface, creating metallurgical bonding through controlled phase transition. This resolves the contradiction by enabling continuous production while maintaining high bonding strength.
Solution Approach 2:
The invention changes the temperature parameter dynamically: the base strip is heated to high temperature (austenite phase) to facilitate bonding, then rapidly cooled during solidification of the clad layer. This parameter change enables continuous processing while achieving complete metallurgical bonding, thus improving productivity without sacrificing bonding strength.
2Productivity
If thin-strip continuous casting is used to enable continuous production, then the productivity is improved, but the thickness of the solidified clad layer is limited and cannot produce thick clad layers
Solution Approach 1:
The base steel strip is preheated to the austenite phase region before the molten clad steel is poured onto it. This preliminary heating action ensures that when the molten steel contacts the strip, it solidifies properly on the heated surface, enabling continuous production of thick clad layers without the thickness limitations of thin-strip continuous casting methods.
3Productivity
If both base layer and clad layer are formed by solidification of molten steel simultaneously, then the continuous casting is achieved, but it is difficult to control the clad interface and prevent mixing of two types of molten steel
Solution Approach 1:
The base steel strip is preheated to austenite phase before molten clad steel is poured onto it. This preliminary action creates a temperature gradient that prevents mixing: the heated strip surface acts as a template that directs the molten steel to solidify in a controlled manner, forming a clear interface without mixing while enabling continuous casting.
Solution Approach 2:
The invention uses parameter changes in temperature to control the interface. The base strip is heated to high temperature, then rapidly cooled when molten steel is poured, creating a controlled thermal field that prevents mixing and ensures proper interface formation during continuous casting.
4Speed
If explosive cladding is used to achieve instant high temperature welding, then the production speed is improved, but the bonding strength becomes insufficient and compound quality is low
Solution Approach 1:
Instead of using explosive energy for bonding, the invention uses controlled phase transition of steel from solid to liquid and back to solid. The base strip is heated to austenite phase, molten clad steel is poured onto it, and the molten steel solidifies on the heated surface, creating strong metallurgical bonding through phase transition rather than explosive welding.
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 productivity and reduces manufacturing costs by enabling continuous casting and rolling of metal clad strips with improved bonding strength and flexibility in material selection, while optimizing energy use and product performance.
Implementation Method 1
induction heating, and on-line cooling to merge and solidify base and molten steel layers
Implementation Method 2
shot blasting, welding, induction heating
Implementation Method 3
welding, welding pinch roll
Implementation Method 4
merge and solidify base and molten steel layers within a mold
Implementation Method 5
on-line cooling to merge and solidify base and molten steel layers
Data Source
AI summary
The device and method for manufacturing metal clad strip continuously provided by the present invention, combines casting, rolling and heat treatment used for the single material manufacture with the continuous and large-scale manufacture method for the clad strip, greatly improves the productivity of clad strip. The present invention can be used for manufacturing single-sided or double-sided clad strips with different thickness specifications, wherein the base layer material or the clad layer material can be selected in a wide range, including carbon steel, stainless steel, special alloy steel, titanium, copper and the like. In the present application, continuous casting and rolling clad strip is implemented, which decrease the energy consumption and costs.