Roll-Clad Composite Strip Production Without Intermediate Welding
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Solution Overview
Problem
Conventional continuous casting-rolling plants have limited production capacity and cost-effectiveness due to the need for additional heat supply and intermediate welding steps, which restrict the maximum material speed and result in inefficient production of steel composite materials.
Innovation Solution
The method involves using at least two casting machines to produce continuous strands, merging and hot rolling slabs above the recrystallization temperature of steel, with an induction heater to adjust slab temperatures and ensure efficient bonding through roll cladding, increasing production capacity and product spectrum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single casting machine is used in conventional continuous casting-rolling plants, then the plant structure is simpler, but the production capacity is limited and the maximum material speed is restricted
Solution Approach 1:
The patent combines multiple casting machines (at least two) to produce multiple continuous strands simultaneously, which are then merged and hot rolled together to form composite material. This merging approach increases production capacity and maximum material speed while maintaining a relatively simple plant structure by integrating the casting machines in parallel configuration.
2Ease of operation
If the material dwell time in the plant is increased due to limited material speed, then the processing can be more thorough, but the material cools down and requires additional heat supply
Solution Approach 1:
The patent maintains continuous high-speed processing through multiple casting machines working in parallel, reducing the dwell time of material in the plant. The continuous production flow ensures that material remains at processing temperature throughout the hot rolling process, eliminating the need for additional heat supply and reducing energy costs.
3Adaptability or versatility
If plate-shaped sheets are welded together to form a plate package before hot rolling, then composite material can be produced, but additional effort and time are required which limits maximum production capacity
Solution Approach 1:
The patent replaces the mechanical welding process with a hot rolling bonding process. Multiple slabs produced by casting machines are heated to high temperature and then passed through rolling stands where they are bonded together through plastic deformation and diffusion bonding. This eliminates the separate welding step and integrates composite formation directly into the hot rolling process, significantly increasing production capacity.
4Ease of manufacture
If the temperature of slabs is not uniformly controlled before roll cladding, then the processing is simpler, but the bonding quality and material properties are compromised
Solution Approach 1:
The patent employs temperature influencing units (heating devices) positioned between the merging unit and roll-cladding unit to precisely control and equalize the temperature of each slab before bonding. By adjusting heating parameters and monitoring temperature distribution, the system ensures optimal bonding conditions are achieved without compromising processing efficiency or requiring complex manual intervention.
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 enhances the throughput and achievable thicknesses of steel composite materials, improves cost-effectiveness, and expands the product spectrum, allowing for the production of thicker, higher-quality composite strips with increased material properties.
Implementation Method 1
both slabs formed from the strands produced using the first/second casting machine are heated by means of an induction heater before step (iii) to intentionally influence the temperature of the slabs
Data Source
AI summary
A method and a device for producing a continuous strip-shaped composite material. The device has at least one first casting machine, using which a continuous strand is produced, in particular from steel, at least one rolling stand, which is arranged in line with the first casting machine and downstream thereof. A fully solidified slab of the strand produced using the first casting machine can be hot rolled, and at least one second casting machine, using which a further continuous strand is produced from metal. Between the casting machines, on the one hand, and the rolling stand, on the other hand, a merging unit is arranged, by means of which the slabs can be moved in the direction toward each other in the hot state. The rolling stand is designed as a roll-cladding unit, by which a composite formed from the merged slabs can be hot rolled.