Continuous Roll Cladding of Cast Steel Strip for Higher Throughput
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Solution Overview
Problem
Existing methods for producing continuous strip-shaped composite materials, such as roll welding and hot welding, are limited by additional production effort and reduced maximum production capacity, and the use of moving molds for continuous casting results in limited production speed and cost-effectiveness.
Innovation Solution
A method involving continuous casting of a base material and unwinding a metal cladding material, where both are heated above the recrystallization temperature of steel for hot rolling, forming a single continuous strip-shaped composite material using a device with a casting machine, coil unwinding unit, and roll-cladding unit, optimizing production speed and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plate-shaped sheets are welded together to form a plate package and then hot rolled, then composite material is formed, but additional production effort is required and maximum production capacity is limited
Solution Approach 1:
The invention extracts and eliminates the intermediate welding step from the production sequence. Instead of welding plate-shaped sheets together before hot rolling, the method feeds individual plates directly into the hot rolling mill, where they are joined and rolled in one continuous operation. This removes the bottleneck caused by welding operations and prepares the material for subsequent continuous processing without interruption.
2Productivity
If a core strip is directly cast and cladded with cold strip, then production speed increases, but cost-effectiveness is limited due to the two-roll casting method
Solution Approach 1:
The invention changes the temperature parameter of the cladding material from cold strip to hot strip. By heating the cladding strip to a temperature above the recrystallization point before feeding it into the hot rolling mill, the material becomes more ductile and easier to process. This parameter change enables continuous processing at high speeds while improving cost-effectiveness through elimination of the two-roll casting method.
3Productivity
If a moving mold system is used for continuous casting, then continuous strip production is achieved, but production speed is limited and cost-effectiveness is reduced
Solution Approach 1:
The invention maintains continuous casting action while eliminating the moving mold system. Plates are continuously fed into the hot rolling mill at controlled intervals, ensuring uninterrupted processing. The continuous operation is maintained through automated plate feeding and positioning systems that keep the rolling mill running without stops, achieving continuous production without the complexity and cost of moving molds.
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 increases production throughput and cost-effectiveness, allowing for a broader range of material properties and improved bonding of different material qualities, enhancing the production of continuous strip-shaped composite materials.
Implementation Method 1
the strip formed by solidification from the strand produced using the casting machine and the metal strip unwound by the coil unwinding unit are heated by means of an induction heater, so that the slab and the metal strip are brought together in step (ii) in the hot state at a temperature which is greater than the recrystallization temperature
Data Source
AI summary
A device and a method for producing a continuous strip-shaped composite material. For this purpose, a base material, which is produced using at least one casting machine as a continuous strand, in particular made of steel, and providing at least one cladding material, which is unwound in the form of at least one metal strip by a coil unwinding unit are provided. Subsequently, a slab which has formed by solidification from the strand produced by the casting machine and the metal strip unwound by the coil unwinding unit, in the hot state are brought together, wherein the materials, which are moved in the direction toward one another, formed from the slab and the unwound metal strip are hot rolled, so that a single continuous strip-shaped composite material is thus produced by roll cladding. The base material is continuously cast in the vertical direction in the casting direction.