Continuous Clad Strip Casting and Rolling for Strong Bonding
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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, as they often result 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 secondary cooling to merge and solidify molten steel with a base material strip within a mold, allowing for continuous production of clad strips with varying thickness and specifications, while reducing 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 and continuous production becomes difficult
Solution Approach 1:
The patent utilizes phase transition by injecting molten metal (liquid phase) onto the base material surface, which then solidifies to form the clad layer. This liquid-solid phase transition enables continuous casting and rolling operations, dramatically improving productivity compared to solid-state roll bonding while maintaining metallurgical bonding quality through controlled solidification and subsequent hot rolling.
Solution Approach 2:
The patent replaces the mechanical pressure-based roll bonding process with a metallurgical bonding approach using molten metal injection and controlled solidification. This substitution eliminates the need for high-pressure rolling and complex vacuum systems, enabling continuous production while achieving sufficient bonding strength through chemical metallurgical bonding during solidification.
2Productivity
If continuous casting and rolling is used to improve productivity and enable continuous production, then the productivity is improved, but the cost increases due to complex processes
Solution Approach 1:
The patent merges multiple discrete operations (surface preparation, molten metal injection, solidification, and rolling) into a single continuous integrated process. The base material enters the rolling mill continuously, receives molten metal injection at the rolling gap, and undergoes solidification and rolling in one pass, eliminating the need for separate batch processing steps and reducing overall process complexity.
Solution Approach 2:
The patent implements continuous action by maintaining uninterrupted flow of base material through the rolling mill while continuously injecting molten metal and performing solidification and rolling operations. This eliminates idle time between batches and allows sustained high-speed production, improving productivity without proportionally increasing complexity through automation of the continuous process flow.
3Productivity
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
Solution Approach 1:
The patent changes the key parameter of clad layer thickness by controlling the injection rate, temperature, and composition of molten metal, as well as the rolling speed and temperature. By adjusting these parameters, the system can produce clad layers of varying thicknesses (from thin to thick) while maintaining continuous production capability, overcoming the thickness limitation of conventional thin-strip continuous casting.
Solution Approach 2:
The patent introduces dynamic control by adjusting molten metal injection parameters and rolling conditions in real-time based on desired clad thickness. The system can dynamically modify the solidification rate and rolling pressure during the continuous process, enabling flexible production of different clad layer thicknesses without interrupting continuous operation, thus maintaining both high productivity and thickness versatility.
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 minimizing energy consumption and optimizing clad interface formation.
Implementation Method 1
induction heating apparatus, wherein the induction heating apparatus is filled with nitrogen or argon protection atmosphere, the heating temperature ranges from 200℃ to 1000℃
Implementation Method 2
the molten steel and the base material strip are merged and solidified successively to form a clad plate or strip
Implementation Method 3
shot blasting machine for surface cleaning
Implementation Method 4
welding equipment adapted to weld shot-blasted base material strips head-to-tail
Data Source
Figure 1
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.