Electrolytic Copper Coating for Continuous Casting Mold Restoration
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Solution Overview
Problem
Existing methods for reconditioning copper molds used in continuous metal casting are costly and do not provide adequate wear resistance, leading to short service life and suboptimal casting results.
Innovation Solution
Mechanical removal of worn inner surfaces to the maximum depth of wear marks followed by electrolytic copper coating, optionally with SiC particles, and post-treatment with deep rolling to enhance surface hardness and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nickel coating with SiC particles is applied to restore worn mold surfaces, then wear resistance is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive nickel-based coatings with a cheaper copper coating system. The copper coating is applied electrolytically to restored mold surfaces, providing adequate wear resistance at lower cost. The copper coating serves as a cost-effective alternative to the previously used nickel-SiC particle composite coatings.
Solution Approach 2:
The patent changes the material parameter from nickel-based coating to copper-based coating. By altering the coating material and application method (electrolytic deposition), the patent achieves comparable functional performance with reduced manufacturing cost. The copper coating thickness and deposition parameters are optimized to ensure sufficient durability.
2Ease of manufacture
If copper is applied electrolytically to restore mold dimensions, then manufacturing cost decreases, but wear resistance may be insufficient
Solution Approach 1:
The patent creates a composite structure consisting of the base copper mold material and an electrolytically deposited copper coating. This layered composite provides both dimensional restoration and enhanced surface properties. The coating is applied over the mechanically restored surface to rebuild worn dimensions while providing a harder, more wear-resistant surface layer.
Solution Approach 2:
The patent optimizes the electrolytic deposition parameters including current density, deposition time, and electrolyte composition to control coating thickness and microstructure. By adjusting these parameters, the patent achieves a coating with sufficient hardness and wear resistance while maintaining cost-effectiveness. The fine-grained structure resulting from electrolytic deposition contributes to enhanced wear performance.
3Duration of action of stationary object
If electrolytic copper coating is applied to restore worn surfaces, then service life increases, but surface roughness may affect casting quality
Solution Approach 1:
The patent performs preliminary mechanical removal of worn surface layers before applying the electrolytic copper coating. This pre-treatment step includes grinding or polishing to eliminate deep wear marks and create a smooth substrate. By preparing the surface in advance, the subsequent copper coating can be applied to a smoother base, reducing overall surface roughness and improving casting quality.
Solution Approach 2:
The patent controls the electrolytic deposition parameters to produce a fine-grained, smooth coating surface. By optimizing current density and deposition conditions, the patent achieves a coating with low surface roughness. The controlled deposition process prevents excessive roughness while building up the necessary coating thickness for dimensional restoration and extended service life.
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
The method achieves longer service life and improved wear resistance, resulting in finer, more homogeneous, and defect-free copper layers with enhanced bonding to the base material, outperforming nickel coatings in terms of durability and cost-effectiveness.
Implementation Method 1
the inner surface(s) worn through continuous casting is (are) mechanically removed down to the maximum depth of the wear marks and then electrolytically coated again with copper
Data Source
AI summary
The invention relates to a copper die or copper die plate, and to a method for reworking such worn dies or die plates used for the continuous casting of metals or metal alloys. According to the invention, a coating consisting of electrolytically applied copper is applied to the inner wall of the die or the die plate side facing the cast billet.