Spherical Tundish Impact Pad to Reduce Turbulence and Dead Zones
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Solution Overview
Problem
Existing impact pads in tundishes cause undesirable turbulence, dead zones, and slag entrainment, leading to impurities and inefficiencies in molten metal casting.
Innovation Solution
Utilizing a non-wavy spherical top impact pad in the tundish to deflect and accelerate the molten metal flow, maintaining a constant metal level and optimizing flow volume, while minimizing dead zones and slag entrainment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a flat-topped impact pad is used to deflect the molten metal stream, then the bottom surface of the tundish is protected from erosion, but undesirable turbulence is generated in the liquid metal flow
Solution Approach 1:
The impact pad top surface is formed with a spherical curvature instead of a flat surface. This curved geometry allows the molten metal stream to follow a smoother path as it deflects off the surface, reducing abrupt flow changes and minimizing turbulence generation while still providing erosion protection to the tundish bottom.
2Strength
If the impact pad deflects the molten metal stream away from the bottom, then erosion is reduced, but dead zones are formed in the tundish
Solution Approach 1:
The spherical curvature is concentrated specifically at the top surface of the impact pad where the molten metal stream makes contact. This localized curvature optimization ensures effective stream deflection and erosion protection at the critical impact zone, while the overall pad geometry and positioning are designed to maintain proper flow distribution throughout the tundish, preventing dead zone formation in non-critical areas.
3Ease of operation
If the impact pad is positioned to intercept the molten metal stream, then flow control is improved, but slag entrainment increases
Solution Approach 1:
The spherical top surface of the impact pad creates a gradual, curved deflection path for the molten metal stream. This smooth curvature allows the flow to redirect away from the tundish bottom and towards the outlet nozzles in a controlled manner, improving flow distribution while minimizing the violent splashing and turbulence that would otherwise cause slag to be entrained into the metal stream.
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
Enhances metal purity by reducing turbulence and dead zones, preventing slag entrainment, and maintaining consistent flow, thereby improving the quality and efficiency of molten metal casting.
Implementation Method 1
a non-wavy spherical top which receives and outwardly deflects the initial impact of a stream 13 of molten metal discharged from a ladle
Implementation Method 2
upon impacting the spherical top the flow of molten metal is accelerated and optimized in terms of total volume
Data Source
AI summary
A method of molten metal continuous casting utilizing an impact pad having a non-wavy spherical top in the tundish that is impacted by the stream of molten metal entering into the tundish wherein the flow of molten metal within the tundish is optimized to improve flow patterns, reduce dead zone areas, prevent splashing while filling the empty tundish, and eliminating the open “red” eye forming in the molten metal surface layer.