Flexible Launder for Direct Chill Casting
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Solution Overview
Problem
Existing metal casting equipment faces challenges in achieving a segregation-free, smooth surface during the casting of aluminium products, particularly during start-up, and requires complex control systems and additional intermediate reservoirs, making the process less safe and more difficult to manage.
Innovation Solution
The improved casting equipment features a flexible launder connection and a lifting arrangement that allows for relative movement of the casting table and metal supply launder, enabling easier metal filling and control during start-up, with a programmable logic control system to maintain zero metallostatic pressure in the contact point against the mould wall, simplifying and enhancing safety and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional direct chill casting equipment is used, then the casting process can be performed, but achieving a segregation-free smooth surface is difficult and the process requires complex control systems with intermediate reservoirs
Solution Approach 1:
The patent removes the intermediate reservoir component from the casting system, simplifying the equipment structure while maintaining the ability to produce high-quality surfaces through direct control of metal flow from the holding furnace to the mould
Solution Approach 2:
The patent controls the metal level in the holding furnace and the flow rate of metal to the mould to achieve zero metallostatic pressure at the contact point, thereby obtaining a segregation-free smooth surface without requiring complex intermediate reservoir systems
2Reliability
If known casting equipment with intermediate reservoirs is used, then metal level control is possible, but the start-up operation becomes difficult to control and safety is reduced
Solution Approach 1:
The patent enables the casting system to self-regulate the metal flow during start-up by controlling the metal level in the holding furnace and using the weight of the metal itself to maintain proper levels, eliminating the need for complex external control systems and intermediate reservoirs
Solution Approach 2:
The patent implements control mechanisms that monitor and adjust the metal level in the holding furnace and the flow rate to the mould, ensuring zero metallostatic pressure at the contact point throughout the casting process, thereby improving both safety and ease of operation
3Temperature
If vacuum lifting containers are used to lift metal during start-up, then metal can be lifted to higher levels, but the equipment becomes more complex and costly
Solution Approach 1:
The patent replaces the vacuum lifting container system with a hydraulic or pneumatic metal level control system that directly regulates the metal level in the holding furnace and flow to the mould, achieving the necessary metal elevation without complex vacuum equipment
Solution Approach 2:
The patent uses the metal itself as the intermediary medium, controlling its level and flow directly from the holding furnace to the mould through simplified control mechanisms, eliminating the need for separate vacuum lifting containers and associated infrastructure
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 configuration simplifies and improves the metal filling process during start-up, making the casting operation safer, more reliable, and easier to control, while maintaining a segregation-free and smooth surface, reducing equipment costs and complexity.
Implementation Method 1
a lifting arrangement is provided to raise and lower the casting table with the mould (3) and distribution chamber (5)
Implementation Method 2
a flexible launder connection (28) between the metal supply launder and the distribution chamber (5) enabling relative movement of the casting table and metal supply launder
Implementation Method 3
The lid (7) is further provided with a connection stub (27) for connection to a vacuum reservoir (not shown) to enable evacuation of air from the distribution chamber
Implementation Method 4
an outlet arranged in the mould with a support and devices for cooling the metal
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
An apparatus (1) for continuous or semi-continuous low pressure casting of metal, in particular directly-cooled (DC) casting of extended objects such as a rods, bars or billets (25) of aluminium. The apparatus includes a frame construction with at least one chill or mould (3) having a mould cavity that is provided with an upwardly open inlet (4) and an outlet with cooling means. The inlet of the mould is connected to a distribution chamber (5) receiving liquid metal from a metal store such as a holding furnace via a metal supply channel or launder (6). A flexible launder section (28) is provided between the launder (6) and the metal distribution chamber (5) whereby the frame construction with the moulds (3) and distribution chamber can be raised and lowered to enable complete filling of metal to the moulds. Subsequently it is possible to control the metal level in each respective mould cavity in relation to the metal level in the launder and thereby controlling the low pressure casting.