Semi-Continuous Casting Hollow Ingot Mold Dynamics
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Solution Overview
Problem
Current methods for producing large diameter hollow ingots face issues such as out-of-center internal holes, frequent breakouts, inconsistent dimensions, long cooling times, and slow casting rates, making them inefficient and costly.
Innovation Solution
A semi-continuous casting method using a mold with an inner and outer pipe forming an annular space for cooling media, where the mold center is progressively moved downward, and the source material is melted using electron beam guns or other methods, with controlled cooling to form a metallic hollow ingot.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a stationary mandrel is used in a molten pool for casting hollow ingots, then hollow ingots can be produced, but the casting rate is slow and dimensions are inconsistent
Solution Approach 1:
The mandrel is made movable rather than stationary, allowing it to be progressively withdrawn from the molten pool during casting. This dynamic approach enables continuous casting while maintaining dimensional control through regulated mandrel movement, thereby increasing productivity without sacrificing manufacturing precision.
Solution Approach 2:
The casting process is made continuous by continuously feeding source material into the molten pool and progressively withdrawing the mandrel simultaneously. This eliminates the need to stop and reset the mandrel after each ingot, maintaining continuous productive action and significantly increasing casting rate.
2Temperature
If cooling media is circulated through an annular space to cool the ingot, then cooling efficiency improves, but device complexity increases
Solution Approach 1:
The mold is segmented into an inner mandrel and an outer mold with an annular cooling space between them. This segmentation allows independent optimization of each component and enables efficient cooling through the annular space without requiring a completely redesigned monolithic mold structure.
Solution Approach 2:
The annular space acts as an intermediary cooling channel between the molten metal and the cooling media. This intermediate space efficiently transfers heat from the ingot to the cooling media flowing through the annular region, improving cooling efficiency while adding only moderate structural complexity.
3Productivity
If source material is continuously fed and mandrel is progressively moved downward, then productivity increases, but process control difficulty increases
Solution Approach 1:
The process incorporates feedback mechanisms where the position of the mandrel, the rate of source material feeding, and the cooling media flow are monitored and adjusted to maintain optimal casting conditions. This feedback control enables continuous high-productivity casting while maintaining ease of operation through automated regulation.
Solution Approach 2:
The process dynamically adjusts parameters such as mandrel withdrawal rate, source material feeding rate, and cooling media flow rate to optimize casting conditions. By systematically controlling these parameter changes, the process achieves high productivity while maintaining operational simplicity through established parameter relationships.
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 method increases casting rate, reduces downstream processing time and cost, and ensures consistent dimensions and surface quality of the hollow ingots.
Implementation Method 1
circulating a cooling media in the annular space
Implementation Method 2
circulating a cooling media
Implementation Method 3
melting the source material using one or more electron beam guns
Implementation Method 4
melting the source material
Implementation Method 5
moving the mold center progressively downward relative to the outer mold
Implementation Method 6
solidifying the source material to form a metallic hollow ingot
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3B
AI summary
Methods and associated apparatus for semi-continuous casting of hollow ingots are described. In one embodiment a method for the semi-continuous casting of a metallic hollow ingot is provided. The method includes providing a mold comprising a mold center having an inner pipe and an outer pipe arranged to form an annular space for a cooling media and an outer mold, circulating a cooling media in the annular space, feeding a source material to the mold, heating the source material to produce a molten material, moving the mold center progressively downward relative to the outer mold, and solidifying the molten material to form a hollow ingot. Embodiments relating to an apparatus for semi-continuous casting of hollow ingots, and products resulting from the semi-continuous casting of hollow ingots are also described.