Continuous Casting of Metal Clad Plates With Controlled Melt Bonding
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Solution Overview
Problem
Current methods for manufacturing metal composite strips, such as roll-bonded cladding, face challenges in achieving high production efficiency and cost-effectiveness for large-scale production due to complex billet assembly processes and difficulties in controlling the bonding of molten steel layers during continuous casting and rolling.
Innovation Solution
A device and method involving continuous casting and rolling with a setup that includes uncoilers, shot blasting machines, welding equipment, induction heating, and guiding rollers, allowing for the controlled merging of base material strips with molten steel, followed by secondary cooling and rolling to produce composite slabs and strips with improved bonding and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If roll-bonded cladding is used to achieve high composite strength, then bonding quality is improved, but production efficiency deteriorates due to complex billet assembly processes
Solution Approach 1:
The invention changes the temperature parameter by heating the base material strip to 100-1200°C before casting, enabling the molten steel to bond with the heated surface rather than requiring complex vacuum and rolling processes. This parameter change simplifies the assembly process while maintaining bonding quality
Solution Approach 2:
The invention utilizes the phase transition of steel from solid (heated base material strip) to liquid (molten steel) and back to solid (composite slab) to achieve bonding. The molten steel is poured onto the heated base material, penetrates the surface, and then solidifies to form a strong composite structure, eliminating the need for complex mechanical assembly
2Productivity
If continuous casting and rolling is implemented for large-scale production, then productivity is improved, but control difficulty increases due to challenges in bonding molten steel layers
Solution Approach 1:
The invention implements feedback control by using temperature sensors to monitor the base material strip temperature and adjusting the heating process accordingly. The temperature is controlled within 100-1200°C to ensure optimal bonding conditions, providing real-time feedback to maintain consistent bonding quality in continuous production
Solution Approach 2:
The invention performs preliminary heating of the base material strip to 100-1200°C before the molten steel is poured. This preliminary action prepares the surface to receive and bond with the molten steel, making the bonding process more controllable and predictable during continuous casting
3Productivity
If multiple moulds are used for continuous casting of composite plates, then productivity is improved, but device complexity increases
Solution Approach 1:
The invention merges the heating function and casting function into a single integrated device. The base material strip is heated in-situ and then the molten steel is poured directly onto it in the same equipment, eliminating the need for separate heating furnaces and multiple moulds while maintaining continuous production capability
Solution Approach 2:
The casting equipment is designed with multi-functionality, serving both as a heating device (through induction heating apparatus) and as a casting mould. This universal device performs multiple operations in sequence, reducing the overall number of equipment pieces needed for composite plate production
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 significantly enhances production efficiency and reduces costs by enabling continuous, large-scale production of composite plates with varying thickness specifications, including carbon steel, stainless steel, and other metals, while maintaining high composite strength and product performance.
Implementation Method 1
sending the shot-blasted base material strips to induction heating apparatus (6) for heating, wherein the induction heating apparatus is filled with nitrogen or argon protection atmosphere
Implementation Method 2
the base metal melt is solidified on the surface of the base material strip, so as to form a melt merging
Implementation Method 3
the composite slab formed in the mould passes through the mould from below and enters into secondary cooling section (10), where cooling water is sprayed on the upper and lower surfaces of the composite slab to further solidify the incompletely solidified composite slab
Data Source
Figure 1
AI summary
The device and method for manufacturing metal clad plates in way of continuous casting and rolling provided by the present invention, combines the continuous casting, rolling and heat treatment methods used for single material production with the continuous and large-scale production method of composite strip, greatly improves the production efficiency of composite plates. The present invention can be used for producing single-sided or double-sided composite plates with different thickness specifications, wherein the base material or the composited material can be selected in a wide range, including carbon steel, stainless steel, special alloy steel, titanium, copper and the like. The invention realizes the production of composite plates by continuous casting and rolling, and reduces energy consumption and costs.