USOO6491087B1

(12) United States Patent (10) Patent No.: US 6,491,087 B1

(54) DIRECT CHILL CASTING MOLD SYSTEM 5,846,481. A 12/1998 Tilak .......................... 266/217
5,873,405 A 2/1999 Carrier et al. .............. 164/472
(76) Inventor: Ravindra V. Tilak, 5261 Nantucket 5,915,455 A 6/1999 Kittilsen et al. ............ 164/440
La., Anaheim Hills, CA (US) 92807 5,932,037 A 8/1999 Holroyd et al. ............. 148/689
6,032,721 A 3/2000 Steen ......................... 164/268
c: -- - 6,056,040 A 5/2000 Weaver et al. .............. 164/436
(*) Notice: Subject
patent istoextended
any disclaimer, the term
or adjusted of this
under 35 6,056,041. A 5/2000 Caron et al. ................ 164/455
U.S.C. 154(b) by 0 days. FOREIGN PATENT DOCUMENTS
(21) Appl. No.: 09/571,507 WO WO 97/46342 * 5/1997
(22) Filed: May 15, 2000 OTHER PUBLICATIONS
(51) Int. Cl. .............................................. B22D 11/124 The Minerals, Metals & Materials Society, 1995/Practical
(52) U.S. Cl. ........................ 164444. 164,487. 164443 LOW Head Casting (LHC) Mold for Aluminum Ingot Cast
(58) Field of Search ................................. 14,487. 444, ing. Pp. 1071-1075.
164/443, 436, 438, 491 * cited by examiner
(56) References Cited Primary Examiner M. Alexandra Elve
ASSistant Examiner-Len Tran
U.S. PATENT DOCUMENTS (74) Attorney, Agent, or Firm-Blakely Sokoloff Taylor &
3,598,173 A 8/1971 Dore et al. ................. 164/268 Zafman, LLP
3,770,046 A 11/1973 Dore et al. ... ... 164/283
4,307,770 A * 12/1981 Haller ....... ... 164/467 (57) ABSTRACT
4,572.280 A * 2/1986 Haller ... ... 164/467
4,582,118 A 4/1986 Jacoby et al......... ... 16447s An embodiment includes a casting mold. The casting mold
4,598.763 A 7/1986 Wagstaff et al. ..... ... 164/472 may include a mold body having a direction Surface and a
4,610,295 A 9/1986 Jacoby et al. .................. 164/5 coolant box coupled to the mold body. The casting mold
4,693.298 A * 9/1987 Wagstaff .............. ... 164/486 further may include a coolant ring having a regulation
4,699.204 A * 10/1987 Sautebin et al. ..... ... 164/467 Surface where the coolant ring may be coupled to the coolant
4,709,747 A 12/1987 Yu et al. - - - - - - - - - - - - - - - - - - - - - 164/487 box So as to bring the regulation Surface and the direction
... A : 3. Sgt. t al. ....... 1.E. Surface together to form a nozzle. The casting mold further
2- ---Y-2 agSlalTel al. . . . . . . . . . . . . may include a mold Starting head
5,632,323 A * 5/1997 Naess, Jr. et al............ 164/444
5,678,623 A 10/1997 Steen et al. .......... ... 164/268
5,685,359 A 11/1997 Wagstaff et al. ............ 164/444 32 Claims, 10 Drawing Sheets

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U.S. Patent Dec. 10, 2002 Sheet 1 of 10 US 6,491,087 B1

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U.S. Patent Dec. 10, 2002 Sheet 3 of 10 US 6,491,087 B1
U.S. Patent Dec. 10, 2002 Sheet 4 of 10 US 6,491,087 B1

-300
Mold starting head 112 of Figure 1 may be position adjacent 3O2
to heat absorbing ring 120 such that there is a gap between
mold Starting head 112 and heat absorbing ring 120,

- -- - 3O4
Coolant ring 118 may be adjusted to obtain the desired
nozzle opening 170,

-----rm- 3O6
Coolant Supply box 206 may be activated to force COOlant 134
through nozzle Opening 170 (Figure 2) as COOlant Curtain 130.

3O8
Material box 208 may be activated to deliver molten material
152 to the inside Offeeder tube 114,

Molten material head 154 may harden on Contacting mold 31 O

As molten material head 154 hardens, base 148 may be 3/2

-- J/4
Coolant 134 may impact billet 132 at surface 133 to further
dra WaWay heat,

316
Over time, base 148 further may be lowered until the desired
length of billet 132 is obtained

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U.S. Patent Dec. 10, 2002 Sheet 6 of 10 US 6,491,087 B1
U.S. Patent Dec. 10, 2002 Sheet 7 of 10 US 6,491,087 B1

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U.S. Patent Dec. 10, 2002 Sheet 8 of 10
U.S. Patent Dec. 10, 2002 Sheet 9 of 10 US 6,491,087 B1
U.S. Patent US 6,491,087 B1

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 US 6,491,087 B1
1 2
DIRECT CHILL CASTING MOLD SYSTEM and a coolant box coupled to the mold body. The casting
mold further may include a coolant ring having a regulation
BACKGROUND OF THE INVENTION Surface where the coolant ring may be coupled to the coolant
1. Field of the Invention box So as to bring the regulation Surface and the direction
Surface together to form a nozzle. The casting mold further
The invention includes the metal founding process of may include a mold Starting head.
continuously and Semi-continuously Shaping liquid metal
against a forming Surface. More particularly, the invention BRIEF DESCRIPTION OF THE DRAWINGS
includes direct chill casting of a billet by applying liquid
coolant directly to the billet product. FIG. 1 illustrates DC casting mold system 100 of the
2. Background Information invention;
Founding includes making objects by introducing molten FIG. 2 is a detailed view of mold system 102 taken
material into a mold where the material Solidifies as heat is generally off of line 2 of FIG. 1;
removed from the material. Slip or continuous casting may FIG. 3A illustrates heat absorbing ring 120 and direction
be a process whereby molten metal is Solidified by gravity 15 Surface 122 as machined from the material of coolant box
feeding the molten metal through a heat absorbing ring. A 116;
Starting head, having a base mounted to a hydraulic ram, FIG. 3B illustrates regulation surface 164 as machined
forms an unattached bottom to the heat absorbing ring. The from the material of coolant box 116;
heat absorbing ring and the Starting head comprise the basic FIG. 3C illustrates an embodiment where each of mold
elements of a slip mold. body 110 and coolant ring 118 may be adjusted;
When the molten metal fills the mold and begins to FIG. 3D sets out method 300 for producing billet 132 of
Solidify, the Starting head may be lowered at a controlled the invention;
rate. Solidified metal may exit the heat absorbing ring to
form a billet. Residing above the billet and within the heat FIG. 4 illustrates DC casting mold 400 of the invention;
absorbing ring may be a Solidified metal Shell that Serves to 25 FIG. 5 illustrates an isometric view of baffle ring 430;
stabilize the moving billet between the heat absorbing ring FIG. 6 illustrates an isometric view of ceramic header
and the starting head. Within the Sump of this shell may be 440;
replenishing molten metal. AS molten metal is passed into FIG. 7 illustrates DC casting mold system 700 of the
the shell Sump and through the heat absorbing ring, the billet invention;
may grow in length. FIG. 8 is an isometric top view of mold table 702 of FIG.
Abillet (or ingot) may be viewed as an elongated mass of 7;
metal that is cast in a Standard shape by a billet Supplier for FIG. 9 is an isometric bottom view of mold table 702
convenient storage or shipment. The billet may take on the containing casting mold 400 of FIG. 4; and
cylindrical croSS Sectional shape of the heat absorbing ring
and may be made of aluminum or aluminum alloy. Even 35 FIG. 10 illustrates billets 1000 produced by the invention.
though the heat absorbing ring may be less than two inches DETAILED DESCRIPTION OF THE
in height, a billet may be twenty feet long and have a INVENTION
diameter from three inches to thirty six inches. Manufac
turers further process cylindrical billets by thermomechani An embodiment includes a casting mold. The casting
cally forging, extruding, rolling, Scalping, or drawing a billet 40 mold may include a mold body having a direction Surface
to produce marketable products Such as curtain rods for and a coolant box coupled to the mold body. The casting
indoors, engine mounts, aircraft landing gear, sheet metal for mold further may include a coolant ring having a regulation
ships, and I-beams for buildings. Surface where the coolant ring may be coupled to the coolant
To better control the heat transfer cooling process of the box So as to bring the regulation Surface and the direction
billet, water may be applied directly to the surface of the 45 Surface together to form a nozzle particularly Such that the
Solid metal as the Solid metal exits the heat absorbing ring. nozzle opening, jet turbulence and the angle of coolant
Thus, as the Starting head lowers, water jets built into the impingement can be changed quickly, conveniently and
mold may spray water onto the billet to cool the Surface and inexpensively. The casting mold further may include a mold
further solidify the metal. This continuous direct chill (DC) Starting head.
casting process, invented in 1942 by W. T. Ennor (U.S. Pat. 50
I. DC Casting Mold and Mold System
No. 2,301,027), produces a fine-grained metal structure with
minimum Segregation. High production rates may be FIG. 1 illustrates DC casting mold system 100 of the
achieved in the casthouse when multiple DC casting molds invention. Included with DC casting mold system 100 may
are used simultaneously in a mold table. be mold system 102, auxiliary system 200, and control
Although Some advancements in this area have been made 55 system 250. Each of mold system 102, auxiliary system 200,
since 1942, there still exists a need in the industry for a direct and control system 250 may be subsystems that work
chill casting mold System package that produces an opti together to form DC casting mold system 100. Mold system
mized metallurgical Structure of the cast product with desir 102 may be viewed as including a DC casting mold.
able Surface finish. In comparison to conventional industry A. Mold System 102
mold System packages, this direct chill casting mold System 60 Included with mold system 102 may be mold body 110,
package should be safer to operate, easier to use and mold starting head 112, feeder tube 114, coolant box 116,
maintain, should maximize the casting productivity, and be and coolant ring 118.
leSS expensive to manufacture and operate. FIG. 2 is a detailed view of mold system 102 taken
SUMMARY OF THE INVENTION
generally off of line 2 of FIG. 1. As seen in FIG. 2, mold
65 body 110 may include heat absorbing ring 120 at the inner
An embodiment includes a casting mold. The casting most interior surface of mold body 110. The horizontal
mold may include a mold body having a direction Surface cross-section of heat absorbing ring 120 may be defined by
 US 6,491,087 B1
3 4
any Symmetrical or asymmetrical shape used in the extru friction reducing element may be included between billet
Sion arts or the direct chill casting arts. For example, the surface 133 of billet shell 140 and heat absorbing ring 120.
horizontal or X-cross-section of heat absorbing ring 120 For example, lubricant 142 may be introduced into gap 144
may be defined by a circular shape, a Square shape, a Star of FIG. 2 through lubrication channel 146 as a friction
shape, an Oval shape, or a rectangular shape. Since the reducing element. AS noted in more detail below, lubricant
preferred shape of a billet is a that of a cylinder, in one 142 may be a liquid, Such as oil, or a gas, Such as one of the
embodiment, heat absorbing ring 120 is defined by a circular inert gases, or a mixture of gases, or a combination thereof.
shape. Examples of asymmetrical shapes include rectangular Mold body 110 may include an aluminum alloy, a copper
form with rounded corners for slab (rolling) ingot, flat beryllium alloy, or a graphite based material. The aluminum
shaped form with concave edges for thin Strip casting, and alloy may be aluminum alloy AA6061 or aluminum alloy
a truncated “T” shaped form for remelt ingot casting. Ingots, AA5052. The material for mold body 110 may exhibit
Slabs, and material that may be cast in a Standard shape thermal Stability and inertneSS towards molten materials to
object also may be produced by the invention. be cast. Moreover, he material for mold body 110 may
provide sufficient heat conductivity and provide the ability
Mold body 110 may also include direction surface 122, to hold close dimensional tolerances during both machining
internal threads 124, external threads 126, and lip 128. 15 and extreme temperature conditions that may be encoun
Direction surface 122 may serve to direct the flow of coolant tered in casting.
curtain 130 (FIG. 1) against billet surface 133 of billet 132 In an alternate embodiment, mold body 110 and coolant
at a desired angle 134 (FIG. 2). Angle 134 may be in the box 116 are a single element. For example, FIG. 3A illus
range of 60 degrees () to 85. In one embodiment, angle 134 trates heat absorbing ring 120 and direction Surface 122 as
may be in the range of 60 to 75. Angle 134 may be in machined from the material of coolant box 116. Where
reference to a horizontal plane. In another embodiment, coolant box 116 includes absorbing ring 120 and direction
angle 134 is in the range of 67 to 72. surface 122, and where heat absorbing ring 120 and direc
As seen in FIG. 2, feeder tube 114 may be installed into tion surface 122 define mold body 110, internal threads 124,
mold body 110 from the top such that gravity may aid in external threads 126, lip 128, and gasket 138 of FIG.1 may
securing feeder tube 114 to mold body 110. Internal threads 25 not be required as part of mold system 102. Where internal
124 may be used to further secure feeder tube 114 to mold threads 124 may not be required as part of mold system 102,
body 110 as well as provide a Surface against which gasket feeder tube 114 may be omitted as shown in FIG. 3A Such
136 may be compressed. Gasket 136 may be any of a wide that absorbing ring 120 may directly receive a Supply of
variety of Seals or packings used between matched machine molten material 152 for processing into billet 132. Lubri
parts to prevent the escape of a fluid, Such molten metal. The cation channel 146 may be eliminated. For example, lubri
material of gasket 136 may have thermal stability at tem cation channel 146 may be eliminated where the friction
peratures up to 2100 degrees Fahrenheit, may be chemically coefficient between heat absorbing ring 120 and molten
non-wetting to molten materials to be cast, may be able to material head 154 is low enough to pass molten material
Seal any and all internal porosity upon applying through heat absorbing ring 120.
compression, may be of material having low heat conduc 35 As seen in FIG. 1, mold system 102 may also include
tivity and may be of material having low thermal coefficient mold starting head 112. Mold starting head 112 may include
of expansion or contraction in the temperature range of base 148 and hydraulic ram 150. Mold starting head 112
minus forty to twenty one hundred degrees Fahrenheit. may serve as an unattached bottom to heat absorbing ring
Gasket 136 may include ceramic KaowoolTM type of com 120. Hydraulic ram 150 may be coupled to a platen.
pressible blanket made and marketed by Thermal Ceramics, 40 Included with mold system 102 also may be feeder tube
Inc., of Augusta, Ga. Gasket 136 may also include Fiber 114 as coupled to mold body 110. Feeder tube 114 may work
fraxTMJ970 type of compressible ceramic paper made and to deliver molten material 152 as molten material head 154
marketed by Unifrax, Inc. of Niagara Falls, N.Y. to a first opening in heat absorbing ring 120. Molten material
Mold body 110 may be installed into coolant box 116 head 154 may provide a positive pressure head to drive billet
from the top Such that gravity may aid in Securing mold body 45 132 past heat absorbing ring 120.
110 to coolant box 116. External threads 126 may be used to It may be undesirable to have molten material 152 cooling
further secure mold body 110 to the internal threads of prior to reaching heat absorbing ring 120. Thus, feeder tube
coolant box 116. As best seen in FIG. 1, lip 128 may extend 114 may work to adiabatically deliver molten material head
radially outward from a point above external threads 124 so 154 to heat absorbing ring 120. To accomplish this delivery
as to provide a Surface against which gasket (138) may be 50 with minimal heat loss, feeder tube 114 may be made from
compressed. any of various hard, brittle, heat-resistant and corrosion
Gasket 138 may be any of a wide variety of seals or resistant materials.
packings used between matched machine parts to prevent The material included with feeder tube 114 may exhibit
the escape of a fluid, Such quench water. Gasket 138 may low heat conductivity, low coefficient of volumetric
include VitonTM, Buna, or silicon materials. 55 expansion, high resistance to thermal fatigue, Strength at
Gasket 138 may be in the shape of an “O’ring. Depending high temperature, and a chemically non-wetting behavior to
on the extension of lip 128 (which in-turn may depend on the the molten materials to be cast. In one embodiment, feeder
overall diameter of billet 132), the cross section of gasket tube 114 includes a nonmetallic mineral, Such as clay. In
138 may vary. The cross section of gasket 138 may be round another embodiment, feeder tube 114 may include a ceramic
shaped or oval shape or rectangular with rounded corners. 60 material. The ceramic material may be based on a pure
The compressibility of this gasket 138 may provide sealing Sigma Alumina and Kaoline composition. The ceramic
over a range of 0.005 to 0.250 inches separation of the material may include aluminum Silicate. In another
mating surfaces between which gasket 138 is placed. The embodiment, the ceramic material offeeder tube 114 may be
croSS Section of a Seat adjacent to gasket 138 may permit made by vacuum forming a slurry of Silicon-di-Oxide with
Static as well as dynamic Sealing action. 65 Suitable high temperature bonding agents added to the Slurry.
Since billet 132 of FIG. 1 may be formed by passing The resulting Slurry Subsequently may be sintered to achieve
molten material 152 through heat absorbing ring 120, a cohesiveness and Strength.
 US 6,491,087 B1
S 6
Also included with mold system 102 may be coolant box that characterizes conventional coolant flow in DC casting
116. To contain and channel coolant 134, coolant box 116 molds So as to provide better heat transfer characteristics.
may include cavity 156 and coolant inlet 158 placed in fluid To regulate the fluid volume and force of coolant curtain
communication with cavity 156. As noted above, mold body 130 and direction of coolant curtain 130, an embodiment of
110 may be coupled to coolant box 116 through external the invention includes the ability to adjust nozzle height 172
threads 126. Coolant box 116 may include primer coated and, in turn, the angle at which coolant curtain 130 impacts
1020 Steel or stainless steel such as type SS 316. In one billet 132.
embodiment, coolant box 116 includes aluminum alloy Radially extending outward from lip 160 of coolant ring
AA5052 or AA6061-T651 stress relieved plate stock. The 118 may be gear teeth 178. To mate with gear teeth 178,
materials included with coolant box 116 may be machinable another item that may be included as part of mold System
to very close tolerances Such as plus or minus two thousands 102 may be coolant ring gear 180. Coolant ring gear 180
of an inch and may be able to hold the tolerances over a long may be located so as to mesh with gear teeth 178 and permit
period of time, Such as Several years. rotation of coolant ring 118. Rotation of coolant ring 118, in
Another item that may be included as part of mold System turn, may permit adjustments to the shape and Volume of
102 may be coolant ring 118. Included with coolant ring 118 15 coolant 134 exiting nozzle 176. Additional frictional reduc
may be lip 160, external threads 162, and regulation surface ing elements, Such as bearings and grease, may be added to
164. As best seen in FIG. 1, lip 160 may extend radially mold system 102 to make it easier to rotate coolant ring 118.
outward from a point below external threads 162 so as to In a DC casting mold, heat transfer from a billet may be
provide a Surface against which gasket 138 may be com a function of coolant Velocity, thickness of coolant film,
pressed. External threads 162 may be used to Secure coolant Volume of coolant, angle of impingement, and the Reynolds
ring 118 to the internal threads of coolant box 116. number of the coolant flow as the coolant impacts the
As seen in FIG. 2, with coolant ring 118 installed into Surface of a billet. ASSuming the other variables maintain
coolant box 116, regulation surface 164 of coolant ring 118 themselves, the higher the coolant Velocity up to a threshold,
may meet direction Surface 122 of mold body 110 at angle the higher the heat transfer. Although an increase in the
168 to define internal nozzle region 166 and nozzle opening 25 coolant pressure would increase the coolant Velocity, coolant
170. Angle 168 may be in the range of 0° to 90° since pump capacity generally is fixed. The ability to adjust the
coolant 134 ejects from nozzle 176 more along direction shape and volume of coolant 134 exiting nozzle 176 may
Surface 122. In one embodiment, angle 168 is in the range present the ability to adjust at least one of the coolant
of 4 to 12. In another embodiment, angle 168 is 6. Nozzle Velocity, the film thickness, and the angle of impingement.
opening 170 may be defined by the average croSS Sectional Thus, the ability to adjust the shape and Volume of coolant
distance between the lowest Y-point on direction surface 122 134 exiting nozzle 176 may provide the almost instanta
in a first X-Y plane and the adjacent, lowest Y-point on neous ability to change the heat transfer characteristics of a
regulation Surface 164 in the first X-Y plane. The average DC casting mold.
croSS Sectional distance of nozzle opening 170 may be in the In operation, as coolant ring gear 180 is rotated in one
range of 0.050 inches to 0.150 inches. In one embodiment, 35 direction, coolant ring 118 rotates in the direction of arrow
the average croSS Sectional distance of nozzle opening 170 A of FIG. 1 so as to decrease nozzle height 172 of FIG. 2.
is in the range of 0.075 inches to 0.108 inches. Decreasing nozzle height 172 may decrease the nozzle
Nozzle opening 170 also may be defined by nozzle height opening 170. ASSuming a constant pressure, the Volume of
172 and nozzle distance 174. Nozzle height 172 may be coolant 134 exiting nozzle 176 decreases to give more of a
defined by the Y-distance between the lowest Y-point on 40 knife edge to coolant curtain 130. Moreover, decreasing
direction Surface 122 in a first X-Y plane and the adjacent, nozzle height 172 may move the center of nozzle opening
lowest Y-point on regulation surface 164 in the first X-Y 170 towards billet Surface 133 So as to decrease nozzle
plane. Nozzle distance 174 may be defined as the extent of distance 174 and increase the angle at which coolant curtain
Space in the X direction between the center of nozzle 130 impacts billet 132 as coolant 134 is pulled towards
opening 170 and billet surface 133. 45 coolant ring 118. Rotating coolant ring gear 180 in the
Nozzle height 172 may be in the range of plus or minus opposite direction may rotate coolant ring 118 in the direc
0.200 inches. In one embodiment, nozzle height 172 is in the tion of arrow B of FIG. 1.
range of Zero inches to 0.100 inches. In another In an alternate embodiment, coolant ring 118 and coolant
embodiment, nozzle height 172 is a multiple of 0.010, box 116 are a single element. For example, FIG. 3B illus
irrespective of the units used. In a further embodiment, 50 trates regulation Surface 164 as machined from the material
nozzle height 172 is zero inches. Where nozzle height 172 of coolant box 116. Where coolant box 116 includes regu
is Zero inches, regulation Surface 164 does not overhang lation surface 164, lip 160, external threads 162, and gasket
direction Surface 122. Where there is no overhang, regula 138 may not be required as part of mold system 102.
tion Surface 164 may not encourage the bottom half of a As shown in FIG. 3B, mold body 110 may be adjusted up
coolant column from nozzle 176 to diverge from the upper 55 or down through coolant ring gear 181 coupled to teeth
half of that Same coolant column as discussed below. disposed about lip 182 to vary nozzle opening 170.
Nozzle distance 174 may be in the range of 0.06 inches to In another alternative embodiment, each of mold body
0.36 inches. In another embodiment, nozzle distance 174 is 110 and coolant ring 118 may be adjusted to vary the cross
a multiple of at least one of 0.001 and 0.006, irrespective of section of nozzle opening 170 in at least one of the X, Y, and
the units used. In a further embodiment, nozzle distance 174 60 Z direction as well as adjusted to vary a mean X-diameter of
is one of 0.090 inches and 0.106 inches. nozzle opening 170. FIG. 3C illustrates an embodiment
Internal nozzle region 166 may work with nozzle opening where each of mold body 110 and coolant ring 118 may be
170 as nozzle 176 to regulate and direct a flow of fluid (such adjusted. Here, each of mold body 110 and coolant ring 118
as coolant 134) from nozzle 176 as coolant curtain 130. may be adjusted to vary the position of nozzle opening 170.
Coolant curtain 130 may be an uninterrupted, laminar flow 65 To provide a greater molten material head 154 in this
of coolant disposed about billet surface 133. The laminar embodiment, feeder tube 114 may be engaged by threads to
flow of coolant curtain 130 may lack the intermittent spaces the inside surface of mold body 110 and can be remotely
 US 6,491,087 B1
7 8
move up or down through a mesh engagement between gear lubricants may be graphite ring inserts, graphite powder and
190 and teeth disposed about feeder tube 114. Where feeder molybdenum-di-Sulphide powder.
tube 114 is fragile, a toothed annulus ring may be used about C. Control System 250
feeder tube 114 to engage gear 190. Included with DC casting mold system 100 of FIG.1 may
In an alternate embodiment, the adjustment of at least one be control system 250. Control system 250 may include
of mold body 110 and coolant ring 118 may be in at least one computer server 252 and communication lines 254. Com
of the Y-direction, the X-direction, a pitch direction, a roll puter Server 252 may be any device that computes, espe
direction, a yaw direction, and a polar direction. cially a programmable electronic machine that performs
B. Auxiliary System 200 high-speed mathematical or logical operations or that
Included with DC casting mold system 100 of FIG.1 may assembles, Stores, correlates, or otherwise processes infor
be auxiliary system 200. Auxiliary system 200 may include
hydraulic box 202, hydraulic box 204, coolant supply box mation. Communication lines 254 may serve to Send com
206, material box 208, and lubricant box 210. Hydraulic box munication Signals between computer Server 252 and
202 may be coupled to coolant ring gear 180 to control the hydraulic box 202, hydraulic box 204, coolant supply box
movement of coolant ring gear 180 and thus control coolant 206, material box 208, and lubricant box 210. The commu
curtain 130. Hydraulic box 204 may be coupled to mold 15 nication signals may be sent through at least one of wire
starting head 112 through hydraulic ram 150 such as through cables and wireleSS cables.
a platen to control the movement of mold Starting head 112. Control system 250 also may include computer clients
Hydraulic box 202 and hydraulic box 204 may be a single 256 coupled to computer server 252 through network 258.
power box that operates by a fluid, especially water or air, Network 258 may be any system of computers intercon
under pressure. nected by communication channels, Such as telephone wires,
Coolant Supply box 206 may be coupled to coolant inlet cables, and radio waves, in order to share information. In
158 so as to supply coolant 134 as a quench fluid to coolant one embodiment, network 258 is the Internet. The Internet
box 116. In one embodiment, coolant 134 is a liquid. The may be any global information System that may be logically
liquid may be water, or water mixed with glycol (for linked together by a globally unique address Space based on
example, 3% to 25% glycol by volume). 25 an Internet Protocol (IP) or its subsequent extensions/
Material box 208 may contain material 214 that is to be follow-ons and may be able to Support communications
processed into billet 132. Material box 208 may be coupled using the Transmission Control Protocol/Internet Protocol
to the interior of feeder tube 114 to provide a supply of (TCP/IP) suite or its subsequent extensions/follow-ons, and/
molten material 152 for processing into billet 132. Material or other IP-compatible protocols. In one embodiment, the
214 may be any material capable of being changed from a Internet may provide, use or make accessible, either publicly
Solid to a liquid State by application of at least one of heat or privately, high level Services layered on the communica
and preSSure. tions and related infrastructure. In another embodiment,
In one embodiment, material 214 is a metal. The metal network 258 is a plurality of telephone connection.
may include aluminum, aluminum alloys, magnesium, mag D. Operation
nesium alloys, copper, copper alloys, Lithium, Lithium 35 A first method of molding an object such as billet 132 may
alloys, or noble metals and their alloys. In another include presenting a mold body having a direction Surface,
embodiment, material 214 is a plastic. The plastic may a coolant box, and a coolant ring having a regulation Surface.
include a thermoplastic resin, including polystyrene or poly The next step may be to form a nozzle in a manner that
ethylene. In another embodiment, the material may include provides an ability to adjust a nozzle opening by disposing
glass. The glass may include colored glass. In another 40 the regulation Surface adjacent to the direction Surface. This
embodiment, the material may include a two phase mixture. may be done by coupling the coolant box between the
The two phase mixture may include a metal-matrix com coolant ring and the mold body. The nozzle may be adjusted
posite. The metal-matrix composite may include one of to change the nozzle opening. The adjustment may be Static
metal and ceramic particles, and metal and amorphous glass or dynamic.
particles. In another embodiment, the material may include 45 The method may further include passing coolant through
a thixotropic slurry in Semi-Solid condition. the nozzle to form a coolant curtain and hardening molten
Lubricant box 210 may be coupled to lubrication channel material by passing the molten material though the mold
146 of FIG. 2 to deliver a friction reducing element to gap body and the coolant ring and contacting the molten material
144. Lubricant 142 may be a liquid, Such as oil, a gas, Such with a mold Starting head.
an one of the inert gases, a Solid State material, or a 50 The hardened material may then be passed through the
combination thereof. coolant curtain by lowering the mold Starting head. If
The lubricants may exhibit physical compatibility and desired, the nozzle may be readjusted as the hardened
chemical compatibility with the material to be cast (Such as material passes through the coolant curtain. In one
material 214) and with the cooling media employed. The embodiment, adjusting the nozzle includes at least one of
factors of lubricant physical compatibility may include flash 55 rotating a gear and adding a shim, wherein the gear is in
point, Specific gravity, Specific heat, Surface tension, and rotation contact with at least one of the coolant ring and the
fluidity of the lubricant. The factors of lubricant chemical mold body and wherein the shim is disposed between at least
compatibility may include Surface reactivity, decomposition one of the coolant box and the mold body and the coolant
products, reversibility of chemical reaction, Separability of ring and the coolant box.
the lubricant from the cooling media, and environmental 60 FIG. 3D sets out method 300 for producing billet 132 of
consideration of disposition of the spent lubricant A pre the invention. As step 302, mold starting head 112 of FIG.
ferred liquid lubricant may include biodegradable vegetable 1 may be position adjacent to heat absorbing ring 120 Such
oils. Such as peanut oil and caster oil. Synthetic mineral oils that there is a gap between mold Starting head 112 and heat
also may be employed. Moreover, synthetic oils with addi absorbing ring 120. At step 304, coolant ring 118 may be
tions of alpha olefins may be used. 65 adjusted to obtain the desired nozzle opening 170. Adjust
Gaseous lubricants may be mixture of inert gases applied ment may be by activating coolant ring gear 180 or by
with or without further mixture with air. The Solid state inserting/removing Shims as discussed below. At Step 306,
 US 6,491,087 B1
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coolant supply box 206 may be activated to force coolant forces in the water Stream and the increase in distance the
134 through nozzle opening 170 (FIG. 2) as coolant curtain bottom half of the coolant column must travel before
130. At step 308, material box 208 may be activated to impinging billet surface 133. This lessens the steam bubble
deliver molten material 152 to the inside of feeder tube 114. Shearing properties of the coolant column Such that more
This may form molten material head 154. At step 310, steam bubbles remain on billet Surface 133. With more
molten material head 154, Such as that at the Surface along steam bubbles remaining on billet surface 133, the heat
the perimeter may harden to form shell 140 on contacting transfer from billet 132 is reduced. Thus, to minimize
mold starting head 112 and heat absorbing ring 120 due to impingement Velocity gradient over the Vertical profile of a
the Significant temperature differential between molten coolant column, nozzle height 172 of FIG. 2 preferably is
material head 154 and the two elements of mold starting Zero inches for certain materials.
head 112 and heat absorbing ring 120. Where casting materials that are highly quench Sensitive,
MetalloStatic pressure may vary over the depth of a a delayed heat extraction along billet surface 133 may be
column liquid material and may be expressed as the density preferable. For these applications, the presence of a Velocity
of the material times the gravitational constant time the gradient over the vertical profile of a coolant column may be
height of the liquid column. The phase transformation from 15 desirable and, accordingly, nozzle height 172 of FIG.2 may
molten material head 154 to shell 140 may occur when be other than Zero inches.
material head 154 either solidifies or partially solidifies such Shearing steam bubbles from billet surface 133 promotes
that the phased changed material exhibits enough Strength heat transfer by freeing up areas of billet surface 133 to
(for example, thickness) to withstand the metallostatic pres come into contact with coolant 134. The value chosen for
Sure of the material head 154. As molten material head 154 angle 134 of FIG.2 may promote shearing of steam bubbles
hardens, base 148 may be lowered at step 312 in the from billet surface 133. Heat transfer may also occur over a
direction of arrow C into the path of coolant curtain 130 by span of twelve inches beyond the point coolant 134
activating hydraulic box 204. To provide a more uniform impinges Surface 133. In addition to promoting Steam
billet 132, base 148 may be rotated as it is lowered where the bubble shearing, the value chosen for angle 134 may work
croSS Section of heat absorbing ring 120 permits. 25 to minimize the quantity of coolant 134 that bounces from
AS base 148 is lowered into the path of coolant curtain billet surface 133. Experiments have shown that the pre
130 at step 312, coolant 134 may impact billet 132 at surface ferred range for angle 134 is 60 to 75 as noted above.
133 to further draw away heat at step 314. Over time, base As coolant 134 from coolant curtain 130 impacts billet
148 further may be lowered at step 316 until the desired 132, water sheet 186 of FIG. 1 may cascade down billet
length of billet 132 is obtained. Surface 133. In one embodiment, water sheet 186 cascades
It takes time for the entire X-cross section of molten down billet surface 133 at six feet per second. Water sheet
material 152 to solidify. Thus, as the material furthest from 186 may cascade down billet surface 133 of billet 132 and
the Y-centerline of billet 132 cools, billet shell 140 may into sink 188. To make a twenty foot long billet, base 148
form. The formation of billet shell 140 may create Sump 182. may be lowered over approximately ninety minutes. At
Sump 182 and billet shell 140 may meet at liquidus surface 35 Some point during this time, billet 132 may be lowered into
184. A cross section of liquidus Surface 184 may be defined Sink 188.
by a concave parabola. The properties of this concave Bubbles remaining on billet surface 133 may turn into
parabola may be based on the meniscus formed at the top free rising steam. Bubbles sheared free from billet surface
end of billet 132 due to the movement of base 148 as molten 133 may be carried into sink 188 by water sheet 186, where
material 152 cools. 40 they do not turn into free rising steam. Thus, sink 188 may
Coolant 134 from coolant curtain 130 at approximately 30 help control the formation of Steam as well as provide a
to 120 degrees Fahrenheit (F) may impact billet surface reservoir from which to recycle coolant 134. Sink 188 may
133, where billet surface 133 may be at approximately 900 be eight to ten feet deep.
F. Due to the large temperature differential (-830 F), Controlling coolant curtain 130 may also help control the
coolant 134 may evaporate into its vapor phase where 45 formation of Steam. If too much Steam is being generated or
coolant 134 is a liquid. For example, where coolant 134 is billet 132 is not cooling properly, coolant ring 118 may be
water, the water may vaporize into minute Steam bubbles adjusted during the movement of base 148 to obtain the
that adhere to billet Surface 133. desired nozzle opening 170 by activating coolant ring gear
AS noted above, when a first measure of water impacts 180 so as to carry more steam bubbles into sink 188.
billet 132, minute steam bubbles form on billet Surface 133. 50 FIG. 4 illustrates DC casting mold 400 of the invention.
Principally, the minute steam bubbles are formed by the Included with DC casting mold 400 may be mold body 410,
upper half of a coolant column from nozzle 176. When the mold starting head 412, feeder tube 414, coolant box 416,
Subsequent, Second measure of water impacts billet 132, the and coolant ring 418. As seen in FIG. 4, mold body 410 may
Second measure of water shears the minute Steam bubbles include heat absorbing ring 420 at an inner most interior
from billet Surface 133 and forms its own minute steam 55 surface of mold body 410. Heat absorbing ring 420 may
bubbles. Principally, the minute steam bubbles are sheared include porous ring 422 and mold tang 424.
from billet surface 133 by the lower half of a coolant column Molten material 152 of the invention may move as it
from nozzle 176. Solidifies. Thus, porous ring 422 may function to admit the
Where nozzle height 172 of FIG. 2 is greater than Zero passage of fluid through pores or interstices within the
inches, the additional Surface adhesion between coolant 134 60 material of porous ring 422 to provide a friction reducing
and the overhang of regulation Surface 164 may encourage Surface between porous ring 422 and a billet shell, Such as
the bottom half of the coolant column from nozzle 176 to billet shell 140. This fluid, whether liquid, gas, or a combi
diverge from the upper half of that Same coolant column. nation thereof, may provide a friction reducing Surface
Where the bottom half of the coolant column diverges from between molten material and porous ring 422 to allow
the upper half of that same coolant column, the billet 65 molten material to pass through porous ring 422.
impingement velocity of the bottom half of the coolant To admit the passage of fluid through pores or interstices
column decreases due to at least one of the internal shearing within the material of porous ring 422, porous ring 422 may
 US 6,491,087 B1
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include a crystallized allotrope of carbon. In another water impinges the billet Y-surface. However, the vertical
embodiment, porous ring 422 includes graphite. In another span of a heat absorbing ring must be beyond a minimum
embodiment, porous ring 422 includes Silicon carbide. length to prevent molten material from bleeding out the
The horizontal cross-section of porous ring 422 may be bottom of the heat absorbing ring.
defined by any Symmetrical or asymmetrical shape used in Recall that mold tang 424 of FIG. 4 may server as the
the extrusion arts or the direct chill casting arts. For lower part of casing 426 and function to provide Structural
example, the horizontal cross-section of porous ring 422 support billet 132 in addition to drawing away heat from
may be defined by a circular shape, a Square shape, a Star molten material head 154. The longer the vertical span of a
shape, an Oval shape, or a rectangular shape. Since the mold tang, the further from the top X-Surface of the billet
preferred shape of a billet is a that of a cylinder, in one that coolant water impinges the billet Y-Surface.
embodiment, porous ring 422 is defined by a circular shape. Conventionally, industry Standard for heat absorbing rings
Mold tang 424 of FIG. 4 may server as the lower part of includes a one inch high graphite ring and a 5/8 inch high
casing 426 and function to provide Structural Support to mold tang to present a 1-ys inches vertical Span of an
industry Standard heat absorbing ring.
billet 132 in addition to drawing away some heat from Sump A Surprising result of the coolant curtain of the invention
182 of molten material head 154. 15 is that the efficiency of this coolant curtain permits the
The heat drawn from the molten material head within a vertical span of heat absorbing ring 420 to be as low as 78
Sump by the porous ring principally forms a billet Shell. inches. This reduction in the height of heat absorbing ring
After the billet shell is formed, molten material continues to 420 may represent a 25% improvement over conventional
harden near the porous ring and become part of the billet industry Standards. The low vertical span of heat absorbing
shell. On hardening, the material shrinks away from the ring 420 may significantly reduce the Sump depth while at
porous ring. After shrinking away from the porous ring, the the Same time may achieve an improvement in the metal
heat and the outward radial preSSure from the molten mate lurgical Structure of the cast material.
rial in the Sump softens the billet shell and pushes the Metallurgical Structure may be viewed as a collective
material towards the porous ring. AS this Soften material term that may describe the following attributes of the cast
moves towards the porous ring, the material re-hardens. On 25 material. The metallurgical Structure may be Superior if the
re-hardening, the material shrinks away from the porous ring attributes include at least one of the following: (i) finer
to experience the heat and the outward radial preSSure from interdendritic spacing; (ii) minimum Sub-Surface liquation;
the molten material in the Sump. This cycle repeats itself, the (iii) minimum microSegregation within the grain; (iv) mini
effect of which defines a SubSurface liquation band adjacent mum macroSegregation from the Surface to the axis of the
to the Y-surface of the billet. The subsurface liquation band billet, (v) finer grain size, (vi) absence of Shrinkage porosity;
is characterized by an undesirable SubSurface Solidification and (vi) avoidance of undesirable precipitation of eutectic
Segregation. and peritectic primary phases. Moreover, by hitting metal
It is desirable to minimize the SubSurface liquation band. much earlier With coolant, casting Speed may be increased.
The SubSurface liquation band may be a function of at least Achieving higher casting Speed may maximize productivity
one of the outward radial pressure from the molten material 35 for each eight man-hour shift employing the embodiments of
in the Sump, the Solidification temperature range of the the invention.
material, the distance between the point of cooling media In one embodiment, the vertical height of heat absorbing
impingement and the point of first contact of the molten ring 420 is less than 1-5/8 inches. In one embodiment, the
material meniscus on ring 422, the impingement Velocity of Vertical height of heat absorbing ring 420 is in the range of
the cooling media, the value by which the molten material 40 7s inches and 1-ys inches. In another embodiment, the
temperature is higher than its normal melting point, and the Vertical height of porous ring 422 is in the range of ys inches
rate at which the ram 150 is lowered. The outward radial to 7s inches and the vertical height of mold tang 424 is in the
preSSure from the molten material in the Sump may be a range of 2/8 inches to 9/8 inches.
function of the depth of the Sump. AS the Sump depth In another embodiment, the vertical height of porous ring
decreases, the outward radial pressure from the liquid mol 45 422 is one of ys inches, /8 inches, and % inches and the
ten material may decrease. A decrease in outward radial vertical height of mold tang 424 is one of 2/8 inches, ys
preSSure from the molten material desirably may decrease inches, and V8 inches.
the subsurface liquation band. Thus, it may be desirable to Coolant box 416 may include baffle ring 430 as a static
minimize the Sump depth. In a practical environment of device that regulates the flow of coolant. FIG. 5 illustrates an
continuous casting, it may not be possible to change quickly 50 isometric view of baffle ring 430. As shown in FIG. 4, baffle
the material feed level inside the feeder tube 114 and the ring 430 may be slip fit or compression fit within coolant box
material temperature Since these variables may have high 416 and retained in the Y-direction by coolant ring 418 and
inertia, where the high inertia may be due in part to the mold casing 426. Since baffle ring 430 may be placed within
variables being maintained by the continuous Supply of coolant box 416 without the need to machine baffle ring
molten material from a material melting furnace. 55 retaining lips within the material of coolant box 416, the
One technique to minimize the Sump depth is to impinge manufacturing costs of and waste material from this embodi
the billet Y-surface with coolant as close as possible to the ment of the invention are dramatically reduced in compari
top, X-surface of the billet. In other words, the closer to the Son with conventional DC casting molds.
top X-Surface of the billet that the coolant water impinges In addition to porous ring 422 and mold tang 424, mold
the billet Y-surface, the shallower the Sump depth. 60 body 410 may also include mold casing 426 and retaining
The X-Surface of the billet where the coolant water ring 428. Within mold casing 426 of FIG. 4 installed into
impinges the billet Y-Surface may be a function of at least the baffle ring 430 from the top, retaining ring 428 and gravity
Vertical span of a heat absorbing ring. The longer the Vertical may be used to secure mold casing 426 to coolant box 416
span of a heat absorbing ring, the further from the top as shown. Gaskets 432 may be used as indicated to prevent
X-Surface of the billet that coolant water impinges the billet 65 the escape of a fluid, Such molten metal or coolant. Mold
Y-surface. The shorter the vertical span of a heat absorbing casing 426 may include direction surface 434 and threaded
ring, the closer to the top X-Surface of the billet that coolant holes 436.
 US 6,491,087 B1
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Also included with DC casting mold 400 may be mold include aluminum foil, thin gage Stainless Steel sheet, or any
starting head 412. Mold starting head 412 is similar to mold gasket material.
starting head 112 of FIG. 1. Mold starting head 412 may An embodiment of the invention may include a set of
include a base and a threaded cavity into which a hydraulic Shims, where the quantity of the Set may range from one to
ram may be Secured. Moreover, mold Starting head 412 may one-hundred. An embodiment of the invention may include
Serve as an unattached bottom to heat absorbing ring 420. a set of ten Shims as part of a tooling package that includes
Feeder tube 414 may include ceramic ring 438. Ceramic a DC casting mold of the invention. Each shim in the set of
ring 438 may be installed into mold casing 426 from the top ten Shims may be defined by a thickness within the range of
So that gravity aids in Sealing ceramic ring 438 to mold 0.001 to 0.01 inches, where the thickness of each shim is
casing 426. unique within the Set of ten Shims. An alternate Set of ten
A mold table may include two or more molds that are fed shims may be defined by a thickness of 0.01 inches, where
molten material from the same horizontal fluid flow chan each shim is 0.01 thick.
nels. Where coolant box 416 is part of a mold table, it may Different alloys have different heat transfer characteris
be important to provide an intermediate connection between tics. For example, there are about Sixty aluminum alloys,
a horizontal fluid flow channel of the mold table and the inlet 15 each having a different heat transfer characteristic. Conven
to mold body 410. Thus, feeder tube 414 may further include tional practice requires employing a different tooling pack
ceramic header 440. Ceramic header 440 may include age for each alloy to be cast or employing a uniquely
header opening 442. FIG. 6 illustrates an isometric view of researched and exhaustive combination of ram Speed, cool
ceramic header 440. ant Volume & pressure, material temperature, casting Start
To secure ceramic header 440 to ceramic ring 438 and up Sequence, etc. for each alloy. However, each shim of the
Secure ceramic ring 438 to mold casing 426, an embodiment invention may provide the ability to change the heat transfer
of the invention may provide tubular supports 465 disposed characteristics of the mold such that different alloys may be
about hold down bolts 441 and below header retaining ring cast with the same tooling package using the pre-Set casting
444. With header retaining ring 444 disposed on the top practice steps. The ability to cast different alloys with the
surface of ceramic header 440, hold down bolts 441 may be 25 Same tooling package of the invention and with the identical
placed through openings in header retaining ring 444 and in casting practice is in Stark contrast to the conventional
tubular supports 465 and secured into threaded holes 436 of practice of employing either a different tooling package or a
mold casing 426. Tubular supports 465 may work to prevent new Set of practice Steps for each alloy to be cast.
the use of excessive torque while assembling DC casting FIG. 7 illustrates DC casting mold system 700 of the
mold 400. In turn, this may work towards retaining a fragile invention. Included within DC casting mold system 700 may
integrity of ceramic ring 438 over a longer duration as may be mold table 702 having DC casting molds 400. DC casting
b measured in years. molds 400 may also be DC casting molds included with
Ceramic gasket paper 446 may be used as indicated to mold System 102. Also included with DC casting mold
prevent leakage of molten material from feeder tube 414. system 700 may be various control systems and auxiliary
Colloidal graphite filling, Such as filling 447, may be used 35 Systems as noted above.
where needed to further act as a gasket and prevent leakage FIG. 8 is an isometric top view of mold table 702 of FIG.
of molten material, to impart the Surface lubricating property 7. As seen, Supply channel 704 of mold table 702 provide a
to otherwise rough surface of ceramic ring 438, and to fill in path for molten material to reach each header opening 442.
corners So that crevices do not exist in the travel path of Since a billet may be formed by passing through heat
molten material, Such as molten material 152. 40 absorbing ring 420 of FIG. 4, a friction reducing element
Another item that may be included as part of DC casting may be included between the billet surface and heat absorb
mold 400 may be coolant ring 418. Included with coolant ing ring 420 to aid in this passage. In one embodiment of the
ring 418 may be lip 450 and regulation surface 452. As best invention, lubricant is introduced to the outer diameter Side
seen in FIG. 4, lip 450 may extend radially outward to of porous ring 422 through lubricant supply channel 454.
provide a surface through which coolant ring 418 may be 45 Lubricant supply channel 454 may be flexible and may be
Secured to coolant box 416. In one embodiment, coolant ring coupled to mold casing 426 through coolant ring 418 Such
418 is secured to coolant box 416 by a series of bolts from that lubricant supply channel 454 does not interfere with the
the bottom side of coolant box 416. In another embodiment, coolant curtain. This may be achieved by routing lubricant
coolant ring 418 is secured to coolant box 416 by a series of supply channel 454 from the bottom of coolant box 416,
latches, each of which may include a bar that fits over a hook 50 between the interior of coolant ring 418 and the exterior of
and is Secured by depressing on a lever coupled to the bar. the coolant curtain, and Securing lubricant Supply channel
In another embodiment, coolant ring 438 may be engaged by 454 to mold casing 426. A shaft end of lubricant supply
threads to the inside surface of baffle ring 430 and can be channel 454 may be secured to mold casing 426 by thread
remotely made to move up or down with a gear mechanism. engagement or a ball and detent engagement.
With coolant ring 418 installed into coolant box 416, 55 In conventional DC casting molds, where the mold is
regulation surface 452 of coolant ring 418 may meet direc fitted from the top of the mold table, the lubricant supply
tion Surface 424 of mold casing 426 at an angle to define an channel is routed from the top of the mold table as well.
internal nozzle region and a nozzle opening. The angle, Routing lubricant Supply channel 454 from the bottom of
nozzle region, and nozzle opening may be similar to angle coolant box 416 between the interior of coolant ring 418 and
168, internal nozzle region 166, and nozzle opening 170 of 60 the exterior of the coolant curtain allows more DC casting
FIG. 2. molds per unit mold table area and eliminates the need for
To regulate the fluid volume and force of the coolant Seals between the baffle ring and the lubricant Supply chan
curtain and direction of the coolant curtain, nozzle opening nel. Eliminating the need for seals between the baffle ring
170 of this embodiment may be modified by disposing or and the lubricant Supply channel works towards minimizing
removing shims between lip 450 and coolant box 416. A 65 the chances of lubricant mixing with coolant water.
Shim may be viewed as a thin, often tapered piece of material FIG. 9 is an isometric bottom view of mold table 702 of
used to adjust Something to fit as desired. The Shims may FIG. 7. Coolant ring 418 and lubricant supply channel 454
 US 6,491,087 B1
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of FIG. 4 may be seen in this view. FIG. 10 illustrates billets In operation, the height of the porous lubrication ring was
1000 produced by the invention. Billets 1000 may be narrow held constant at 0.81 inches and height of the mold tang was
or may have a large diameter. For example, billets may held constant at 0.66 inches thus the total height of the
twenty feet long and have a diameter of twenty Six inches. heat-absorbing ring was kept at 0.147". The angle of the
Standard six foot man 1002 provides a reference as to the direction Surface with respect to the horizontal plane was
large scale of billets 1000 shown at twenty feet long and kept fixed at 62.5 degrees. The total supply volume of the
have a diameter of four inches. coolant was kept constant at 720 gallons per minute at the
II. Examples Supply pressure of nine pounds per Square inch down Stream
of the in-line coolant filter. The coolant temperature on the
Although heat transfer from hot materials to flowing 1O Supply Side was maintained in the range of 75 degrees +/-
cooling media has been researched for over a century and five degrees F. The molten metal temperature was main
heat transfer in direct chill casting for over half a century, no tained in the wider range of 1250 to 1350 degrees F.
researcher has put together a dynamic model of heat transfer Addition of 0.003% Titanium (in line) was made to molten
in direct chill casting without making certain assumptions
and accepting many approximations. A holistic approach has metal for grain refinement. Peanut oil was used as lubricat
been lacking. Partly, this has been due to the fact that the rate 15 ing medium and its Supply was regulated at 0.005 cubic
of heat transfer abruptly jumps by one to two magnitudes of inches per mold at an interval of every 20 seconds. In the
change in the nucleate boiling Zone. first Set of trials, the nozzle opening was kept constant at
When ordinary water is used as coolant, the temperature 0.93 inches and nozzle height of Zero inches.
range in which nucleate boiling takes place is 330 F. to 390 In production, more than a dozen castings were carried
F. Particularly, in the case of direct chill casting of aluminum out in each billet size in alloy AA 6063 (Aluminum Asso
alloy as practiced with recycled water as cooling media, the ciation (AA) Specification). Billet lengths ranged from 225
initial Surface temperature of the aluminum presented to the to 240 inches and the total average weight of each cast was
stream of water may be in the range of 1100 F. to 1200 F. about 21,000 pounds.
As water at room temperature (or within +/-50 F. from Example 1 Observations: In observation, the castings
room temperature) encounters a 1200 F. Surface, a variety 25 could be conducted without encountering any problem
of reactions take place at the interface. ESSentially, these related to dimensional stability of the mold system. The
reactions are both physical and chemical in natural. mold System remained rigid and showed excellent resistance
Using the laws of thermodynamics and the Simultaneous to thermal fatigue resulting from Start and completion of the
conduction and convection heat-mass transfer equations, casting cycle. No leakage was observed in the molten metal,
researchers have formulated various heat transfer models in coolant media or lubrication line flow paths over repeated
general. However, these models are not Sufficient for pre uses of the mold package. No Steam was observed in the
dicting the casting behavior and the metallurgical Structure immediate vicinity of water impingement location on the
of the cast material. One reason for this may be that the billet and downstream of that point under the mold table or
temperature distribution is constantly changing on the cast above the mold table. The Surface of the billet was Smooth
material Surface and the true “steady State' temperature 35 and qualifying for the required industry Standard Set for
distribution is a pattern of changing conditions oscillating direct extrusion application. The metallurgical Structure of
within a certain interval. These changing conditions may be the billet exhibited 75 microns as grain size and around 42
dictated by (a) casting variables Such as speed, water microns as cell size (interdendritic spacing) at the center of
Volume, mold geometry, metal temperature, and alloy spe the billet. The sub-surface liquation band varied in depth
cific physics, and (b) extraneous factors Such as start up 40 ranging from 0.015 to 0.060 inches with average close to
conditions, mold fill rate, rate of change of feed material 0.030 inches. The casting speeds that could be attained
temperature, heat transfer through ceramic feeder tube, without inducing cracking, tearing or bleed out were 4.5"/
oxidation of molten material and Several other parameters minute (min) for 8" dia, 5"/min for 7" dia and 5.5"/min for
Such as atmospheric temperature, and humidity, each of 6" dia.
which lie outside the Scope of the equations used to build the 45 B. Example 2
model. Accordingly, experimentation is a chief way to Set Up: Conditions mentioned in example 1 were main
develop and test direct chill casting mold Systems. Below are tained except recycled water was used as cooling media. The
experiments that accompany the invention. recycled water typically had the following chemistry:
A. Example 1 i) Total dissolved solids of 1,200 milligrams per liter (as
Set Up: Tooling for a billet mold system was manufac 50 compound to 250 milligrams for city water);
tured per the above embodiments to cast aluminum alloy ii) Total Suspended Solids which generated about two
billets using city water as cooling media. The tooling was pounds per Square inch (psi) pressure difference across
built to cast (i) 6 inch (") diameter billets in a mold table the in-line filter during the course of the casting (mesh
having a thirty mold capacity, (ii) 7" diameter billet in a opening 0.064 inches); and
mold table having a twenty four mold capacity, (iii) and 8" 55 iii) Total oil and grease content of 60 milligrams per liter.
diameter billet in a mold table having an eighteen mold Example 2 Observations: In observation, as a result of
capacity. In each of the above three situations, the mold body using recycled water, no deleterious effect was observed on
that provided a directing Surface was fitted from the top side the functioning of the mold System. No change was required
of the coolant box. Moreover, a water ring (coolant ring) in the casting practice of the billets, the Same thresholds of
having a regulation Surface was attached from the underside 60 casting Speeds could be maintained with recycled water as
of the coolant box. A lubrication shaft was run through the with direct city water. The metallurgical structure of the
coolant ring and the coolant box. The Set up did not include billet did not indicate any difference from that observed in
a provision of Steam exhaust duct in the DC casting pit. The example 1.
total manufacturing cost of the tooling as described above C. Example 3
ranged around U.S.S180,000+/-U.S.S30,000. This cost 65 Set Up: From example 2, the nozzle opening was nar
included the cost of the mold table of which the coolant box rowed to 0.79 inches and nozzle height was changed from
is an integral part. Zero to 0.01 inches. All other parameters remained the same
 US 6,491,087 B1
17 18
as Set out in example 2. Twenty one castings were made in and Semi-continuous casting of those materials that Show
billet size of 8" diameter. The lengths of the billets varied Susceptibility to hot-cracking, cold-cracking, Surface
from 120 inches to 236 inches. tearing, and bleeding. Typically these materials exhibit fol
Example 3 Observations: In observation, the overall func lowing properties: (i) high Solidification shrinkage (i.e. the
tioning of the mold system improved. This was evidenced by Shrinkage which the material undergoes as its State changes
the ability to cast the metal at higher casting Speeds without from that of liquid to Solid), (ii) larger Solidification tem
affecting the metallurgical Structure, the Surface of the cast perature range (i.e. the temperature range from the emer
product or the Overall castability of the alloy. The casting gence of the first particle of Solid to the disappearance of the
Speeds in excess of 5.25 inches per minute were registered last droplet of the liquid from the Sump), and (iii)lower
for 8" diameter billet. This represents an improvement in the internal heat conductivity than external (i.e. at Surface) heat
transfer coefficient.
overall productivity in excess of 16%. This significant
increase in the casting Speed is attributed to having achieved Due to the reduction of the number of parts in the
a Superior Surface heat transfer coefficient resulting from embodiments, the cost per unit is dramatically lower than
changing nozzle opening and nozzle height. Which in turn conventional DC casting mold and mold System. For
changed the area of nucleant boiling region, provided higher 15 example, a conventional thirty Strand DC casting mold for
impingement Velocity and Simultaneously maintained shear seven inch diameter billets may cost U.S.S300,000. A DC
ing currents within the coolant curtain which assisted in casting mold for Seven inch diameter billets employing the
faster removal of the steam bubbles from the Surface of the invention may cost U.S.S210,000, a savings of U.S.S90,000.
billet. The reduction in the number of parts in the embodiments
D. Example 4 corresponds to less parts that wear and need to be replaced.
Set Up: Identical conditions were maintained as given in This may work towards reducing the cost of the Spare parts
example 3 except the material chemistry was changed to and those parts that may be consumed in use (for example,
alloy AA 2024 (Aluminum Association (AA) Specification). the consumables). Additionally, with lesser parts there is a
Alloy AA 2024 material, containing copper and magnesium, lesser chance of molten metal or coolant leakage due to the
has higher Susceptibility for cracking due to its larger 25 reduced number and Surface area of mating Surfaces. This
Solidification temperature range and due to the fact that it results in a much lower probability of uncontrolled metal to
undergoes higher Solidification shrinkage than alloy AA coolant reactions, Some of which are known to turn explo
6063. Sive in nature.
Example 4 Observation: In observation, based on the The DC casting mold and mold system embodiments of
Sump data and heat transfer curves, the practice could be the invention provide additional advantage S.
easily developed for casting this material with the afore Conventionally, interrupted flows of coolant and turbulent
mentioned embodiments of the present invention. The met flows of coolant promote free rising Steam generation by
allurgical structure of the cast alloy AA 2024 qualified all failing to shear minute steam bubbles from the surface of the
requirements pertaining to the Specifications to manufacture billet. However, the mold water ring geometry embodiments
extrusions and forgings for a wide range of end use appli 35 may control the generation of Steam in a casting Station
cations. through nozzle opening 170 of FIG. 2, angle 134, and nozzle
E. Example 5 height 172, particularly where nozzle height 172 is zero
Set Up: All the conditions were maintained Same as in inches. Since coolant curtain 130 may be an uninterrupted,
example 3 except the angle of the direction Surface of the laminar flow of coolant disposed about billet surface 133,
impinging coolant with respect to the horizontal plane was 40 free rising Steam generation further is minimized by the
changed from 62.5 degrees to 72 degrees. invention. Controlling the generation of Steam maximizes
Example 5 Observation: in observation, the casting Speed the visibility of the product being manufactured and thus
of 5.64 inches per minute was repeatedly achieved for increases operator and equipment Safety. Further, controlling
casting of 8" diameter AA 6063 alloy billet. These casting the generation of free rising Steam may eliminate the need to
Speeds are well beyond the conventional Direct Chill casting 45 employ an expensive Steam Suction blower System.
industry Standards and provide Significant bottom line When coolant in a DC casting operations is recycled as is
advantages to the billet manufacturer. the typical practice, the recycled coolant builds up a great
amount of foreign particles. These foreign particles tend to
III. Advantages choke the cooling passages. Moreover, if the quality of the
The DC casting mold and mold system embodiments of 50 cooling media is not good then deposits or Sediments can
the invention provide an enormous advantage in that they crystallize on the back Side of the mold (for example, on
produce a Superior metallurgical Structure, are easily direction surface 434 in FIG. 4). If these deposits are not
assembled, easy to repair/maintain, increase casting produc removed periodically, the deposits will reduce the heat
tivity and most importantly permit immediate in-situ adjust conductivity of the mold. An example is, if recycled water
ments to effectively control heat transfer. This also helps to 55 having a high water hardneSS is used as a cooling media,
reduce research time and expense associated in making then Calcium and Magnesium deposits very commonly form
newer alloys. The highly simplified tooling of the embodi on the back side of the mold.
ments may be assembled from the top of the mold table so Conventionally, maintenance Such as inspection and
as to take advantage of gravity in Sealing the mold from cleaning of the cooling passages of a DC casting mold is a
coolant water leakage. Moreover, the lubricant Supply chan 60 routine chore that is done after the completion of each
nel may be routed from the bottom of the mold table and casting. Besides cleaning a mold, the mere inspection of the
through the coolant ring. cooling passages of a conventional mold is in itself a
The dynamically adjustable cooling capability of a DC cumbersome and lengthy task. The entire mold with all of its
casting mold of the aforementioned embodiments provides Seals has to be taken apart. This takes significant time away
the ability to effectively manage the castability of the 65 from the time that may be used for billet production.
material until the Steady-state casting conditions are In comparison to conventional DC casting molds and
attained. This ability is critically required in the continuous mold Systems, the maintenance access to the coolant chan
 US 6,491,087 B1
19 20
nels of the invention is very accessible in that, on removing a heat absorbing ring, wherein Said absorbing ring com
a coolant ring located underneath a mold of the invention, a prises a porous ring having a height, wherein the height
worker may easily clean out the passages in the coolant of Said porous ring is in the range of ys inches to 78
channels. Experiments have shown that one DC casting inches, and
mold of the invention may be cleaned and placed back in 5 a lubrication Supply routed from the underside of the
Service within three minutes. This maintenance time of the coolant ring, through an interior of the coolant ring, and
invention is in Stark contrast with the twenty minute main coupled to the mold casing.
tenance time of one conventional DC casting mold. Thus, 2. The direct chill casting mold of claim 1, the heat
the exceptional maintenance aspects of the invention reduce absorbing ring being defined by a span that is less than 1%
the total casting turn-around time, thereby further adding to inches.
the productivity. 3. The direct chill casting mold of claim 2, wherein the
The heat transfer Surfaces of the heat absorbing ring of span is in the range of 78 inches and 1/8 inches.
4. The direct chill casting mold of claim 1, the heat
conventional DC casting mold Systems are So inaccessible absorbing ring further comprising a mold tang having a
that maintenance workers often over look clearing off cal height, wherein the height of Said mold tang is in the range
cium buildup on the heat transfer Surfaces. However, a 15 of 2/8 inches to % inches.
maintenance worker located underneath mold table 702 as 5. The direct chill casting mold of claim 1, wherein the
seen in FIG. 9 may clear off calcium buildup on the heat direction Surface is defined by an angle, wherein the angle
transfer Surfaces of the heat absorbing ring of the invention is in the range of 60° to 85.
without removing any components of the invention. The 6. The direct chill casting mold of claim 5, wherein the
ease with which the coolant channels of the invention may angle is in the range of 60 to 75 and is in reference to a
be maintained relaxes the Stringent filtration requirements horizontal plane.
for the coolant employed in conventional DC casting mold 7. The direct chill casting mold of claim 5, wherein the
Systems. angle is in the range of 67 to 72.
The user friendly, cheaper, and Simple embodiments of 8. The direct chill casting mold of claim 1, the mold body
the invention translate into a longer life DC casting mold. 25 further comprising a mold casing comprising a mold tang, a
Since different alloys may be cast with the same tooling retaining ring, and a porous ring coupled to the mold casing
package of the invention, the invention has a broader appli at a location that is adjacent to the mold tang, wherein the
retaining ring couples the mold casing to the means for
cation in the billet production industry than conventional DC holding coolant.
casting molds. Moreover, the refined embodiments permit 9. The direct chill casting mold of claim 1, wherein the
more DC casting molds per unit area in mold table 702 than means for holding coolant is part of a mold table.
conventional DC casting mold designs. This may provide a 10. The direct chill casting mold of claim 1, further
more aggressive management control over billet production. comprising:
The environmentally friendly, DC casting mold and mold a baffle ring configured to fit within the means for holding
System embodiments of the invention provide advantages in 35
coolant and retained by the mold body and the coolant
casting Speed leading to productivity improvement, SubSur ring.
face liquation band minimization leading to metallurgical 11. The direct chill casting mold of claim 1, the regulation
improvement, fabrication ease, assembly ease, and alloy Surface being defined by an angle, wherein the angle is in the
Versatility leading to quality and productivity improvement, range of 0° to 90°.
fewer number of parts leading to economical value, 12. The direct chill casting mold of claim 11, wherein the
cleanability leading to maintenance improvement, and 40 angle is in the range of 4 to 12.
safety improvement. Thus, the embodiments of the inven 13. The direct chill casting mold of claim 12, wherein the
tion renders a DC casting mold package having a great angle is 6.
number of improvements for the operator to use from which 14. The direct chill casting mold of claim 1, wherein the
the billet production plant may benefit. nozzle includes an nozzle opening, wherein the nozzle
45 opening is adjustable.
The exemplary embodiments described herein are pro 15. The direct chill casting mold of claim 14, wherein the
Vided merely to illustrate the principles of the invention and nozzle opening is in the range of 0.050 inches to 0.150
should not be construed as limiting the Scope of the Subject inches.
matter of the terms of the claimed invention. The principles 16. The direct chill casting mold of claim 15, wherein the
of the invention may be applied toward a wide range of 50 nozzle opening is in the range of 0.070 inches to 0.108
Systems to achieve the advantages described herein and to inches.
achieve other advantages or to Satisfy other objectives, as 17. The direct chill casting mold of claim 1, wherein the
well.
What is claimed is: nozzle includes a nozzle height, wherein the nozzle height is
adjustable.
1. A direct chill casting mold, comprising: 55 18. The direct chill casting mold of claim 17, wherein the
a mold body comprising a direction Surface; nozzle height is in the range of plus or minus 0.200 inches
a means for holding coolant coupled to the underside of relative to a position in which the nozzle height is Zero.
the mold body; 19. The direct chill casting mold of claim 18, wherein the
a coolant ring comprising a regulation Surface, the coolant nozzle height is in the range of Zero inches to 0.100 inches
ring coupled to the underside of the means for holding 60 relative to a position in which the nozzle height is Zero.
coolant So as to bring the regulation Surface and the 20. The direct chill casting mold of claim 1, wherein the
direction Surface adjacent to one another to form a nozzle height is adjustable in increments of 0.01 inches.
nozzle, the direction Surface having a position relative 21. The direct chill casting mold of claim 20, wherein the
to a position of the regulation Surface, wherein at least nozzle height is Zero inches.
one of the position of the direction Surface and the 65 22. The direct chill casting mold of claim 1, wherein the
position of the regulation Surface is adjustable nozzle includes a nozzle distance, wherein the nozzle dis
a mold Starting head; tance is adjustable.
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21 22
23. The direct chill casting mold of claim 22, wherein the a feeder tube coupled to the mold body.
nozzle distance is in the range of 0.06 inches to 0.36 inches. 29. The direct chill casting mold of claim 28, further
24. The direct chill casting mold of claim 1, wherein the comprising:
nozzle distance is a multiple of at least one of 0.0010 and an auxiliary System having at least one hydraulic box, a
0.0060, irrespective of the units used. coolant Supply box, a material box, and lubricant box;
25. The direct chill casting mold of claim 24, wherein the and
nozzle distance is 0.090 inches. a control System having a computer Server in communi
26. The direct chill casting mold of claim 1, further cation with the auxiliary System.
comprising: 30. The direct chill casting mold of claim 29 further
at least one Shim disposed between at least one of the 1O comprising:
means for holding coolant and the mold body and the at least one computer client adapted to be coupled to the
coolant ring and the means for holding coolant. computer Server through a network.
27. The direct chill casting mold of claim 1, further 31. The direct chill casting mold of claim 30 wherein the
comprising: network is the Internet.
15
at least one gear in rotational contact with at least one of 32. The direct chill casting mold of claim 1, wherein the
the mold body and the coolant ring. means for holding coolant comprises a coolant box.
28. The direct chill casting mold of claim 1, further
comprising: k k k k k