Melt Flow Deflection Chamber Layout for Wear-Resistant Ingot Casting
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Solution Overview
Problem
In ingot casting, existing deflection devices face issues with thermo-mechanical corrosion and abrasive wear due to high melt flow rates, leading to contamination and reduced steel quality.
Innovation Solution
A deflection device with a flow chamber and impact chamber design, featuring a tapered inlet channel, widening outlet channel, and strategically positioned outlet and inlet openings to reduce flow rates and mitigate wear, along with a modular construction for ease of production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional deflection device with direct flow from inlet to outlet is used, then the device structure is simple, but the melt flow rate is high causing thermo-mechanical corrosion and abrasive wear
Solution Approach 1:
The deflection device is segmented into distinct functional chambers: an impact chamber for initial melt flow deceleration and a flow chamber for controlled distribution. This segmentation allows the high-velocity melt to be slowed before entering the distribution system, reducing wear and corrosion while maintaining structural organization through clear functional separation.
Solution Approach 2:
The impact chamber serves as an intermediary element between the inlet and the flow chamber. It mediates the transition by capturing the initial high-velocity melt flow, dissipating energy through impact, and then allowing the slowed melt to enter the flow chamber for distribution, thereby protecting the overall device from excessive wear.
2Reliability
If the inlet opening edge is positioned outside the access opening, then the manufacturing is simpler, but the pouring stream impinges on the outer edge causing abrasive wear and contamination
Solution Approach 1:
The design proactively prevents abrasive wear by positioning the inlet opening edge within the access opening before the melt flow can impinge on vulnerable external surfaces. This preliminary protective positioning eliminates the harmful impingement effect that would otherwise cause material detachment and contamination, addressing the wear problem before it occurs.
3Manufacturing precision
If a single-piece deflection device is used, then the production is more efficient, but the internal surfaces for melt flow control are harder to process and reach
Solution Approach 1:
The deflection device is constructed from multiple separable components (impact chamber component and flow chamber component) that can be independently manufactured and processed. This allows precise machining and surface treatment of internal flow control surfaces on each component separately, while still enabling efficient production through modular assembly rather than requiring complex single-piece manufacturing.
Solution Approach 2:
The components are designed to nest together during assembly, with the impact chamber component fitting into or alongside the flow chamber component. This nested arrangement allows for precise internal surface processing of each component while maintaining a compact overall structure, and enables efficient production through separate manufacturing followed by straightforward assembly.
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 design effectively lowers melt flow rates, reduces thermo-mechanical corrosion and abrasive wear, enhancing steel quality and facilitating cost-effective production.
Implementation Method 1
the mold is filled with the liquid steel melt solely by the hydrostatic pressure generated in the vertical tube
Implementation Method 2
the impact chamber favors a lowering of the flow rate of the melt stream in the deflection device
Implementation Method 3
the inlet channel has a cross section which tapers towards the inlet opening of the flow chamber... the outlet channel has a cross section which widens towards the at least one outlet
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a deflection device (1) for deflecting a molten stream in an undercasting jig during ingot casting. The deflection device (1) comprises a base body (2) which has a flow chamber (3), an inlet (4) to the flow chamber (3), and at least one outlet (5) from the flow chamber (3). The flow chamber (3) in turn comprises a bottom surface (3.2), an inlet opening (6) opposite the bottom surface (3.2), and at least one outlet opening (7). The inlet opening (6) is bounded by a circumferential rim (15) and is flow-connected to the inlet (4) via an inlet channel (8). Furthermore, the at least one outlet opening (7) is flow-connected to the at least one outlet (5) via an outlet channel (9).Furthermore, the base body (2) comprises an impact chamber (10) which is fluidically connected to the flow chamber (3) via an access opening (12), the access opening (12) facing the inlet opening (6) and having an opening surface (16) arranged transversely to a central axis (30) of the inlet channel (8) in the region of the inlet opening (6). It is provided that at least a section of the edge (15) of the inlet opening (6) lies within the impact chamber (10). The invention further comprises a casting jig. In addition, the invention includes a press tool for manufacturing a deflecting device (1) and a corresponding manufacturing process.