Dynamic Wiper System for Continuous Casting Mold Coolant Control
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Solution Overview
Problem
The existing cooling systems for castparts during the casting process often result in uneven cooling, leading to internal stresses and defects, particularly in aerospace alloys, due to uncontrolled coolant flow and trapped water, which can cause cracking and other defects in the butt portion of the castpart.
Innovation Solution
A process that dynamically positions and moves a wiper system relative to the castpart during three stages of the casting process: startup, transient heat-up, and steady-state, to optimize coolant control and prevent undesirable cooling, using a wiper actuator to divert coolant effectively and avoid trapping it between the wiper, starting block, and castpart.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a wiper system is positioned close to the mold cavity to control coolant flow, then cooling uniformity is improved, but water may be trapped between the wiper, starting block, and castpart causing defects
Solution Approach 1:
The wiper system is made dynamically positionable through a wiper actuator that can move the wiper between a retracted position (during startup to avoid trapping water) and an extended position (during steady-state to control coolant flow). This dynamic positioning resolves the contradiction by allowing the system to optimize for cooling uniformity when safe, and prevent water trapping when necessary.
Solution Approach 2:
The system changes the positional parameter of the wiper based on the casting stage. During startup, the wiper is retracted; during steady-state casting, the wiper is extended to its working position. This parameter change allows the system to avoid trapped water defects during startup while achieving uniform cooling during the main casting process.
2Manufacturing precision
If coolant flow is increased to improve solidification control, then casting quality is improved, but uneven cooling and internal stresses increase
Solution Approach 1:
The wiper system applies coolant control locally and uniformly across the castpart surface. By positioning the wiper in close proximity to the mold cavity and using it to distribute coolant evenly, the system achieves uniform cooling without the internal stresses that result from uneven cooling patterns. This local quality approach ensures consistent thermal conditions across the entire castpart.
Solution Approach 2:
The system uses feedback from the casting process stage (detected through the control system) to adjust wiper positioning and coolant flow characteristics. During transient heat-up phase, the wiper is retracted; during steady-state, it is extended. This feedback mechanism ensures optimal coolant application that maintains casting quality while preventing internal stresses.
3Device complexity
If the wiper is positioned in a fixed location, then the system is simple, but it cannot adapt to different casting stages (startup, transient heat-up, steady-state)
Solution Approach 1:
The wiper system transitions from a fixed position to a dynamically adjustable position through the wiper actuator. The actuator enables the wiper to move between retracted and extended positions based on the casting stage, providing adaptability to different phases (startup, transient heat-up, steady-state) while adding only minimal complexity to the overall system.
Solution Approach 2:
The wiper system serves multiple functions across different casting stages: during startup, it is retracted to avoid interfering with molten metal flow; during transient heat-up, it transitions to its working position; during steady-state, it actively controls coolant distribution. This multi-functionality allows a single system to adapt to all casting stages without requiring completely separate systems for each phase.
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 ensures better annealing of the castpart, reduces the incidence of cracks and defects, and maintains optimal cooling characteristics throughout the casting process, thereby improving the quality and reducing scrap rates.
Implementation Method 1
a castpart wiper configured to conform around an outer surface of the castpart and thereby direct the flow of coolant away from the outer surface of the castpart
Implementation Method 2
As molten metal is poured into the mold bore or cavity and cooled (typically by water), the starting block is slowly lowered
Implementation Method 3
the starting block is slowly lowered at a pre-determined rate by a hydraulic cylinder or other device
Data Source
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AI summary
A coolant or wiper control system for use in continuous casting mold for controlling and managing the coolants interaction with the castpart during casting. In some aspects of the process, the wiper framework is started sufficiently away from the bottom block so as not to interfere or cause/allow coolant to get into the bottom block; is then rapidly moved back to the emerging castpart during transient heat-up; and then moved away from the mold with the solidified castpart at a controlled rate to a predetermined steady state position or to a second transitory state of the casting.