US 20080083524A1

(19) United States

(12) Patent Application Publication (10) Pub. No.: US 2008/0083524 A1
Sulzer et al. (43) Pub. Date: Apr. 10, 2008

(54) METHOD OF AND MOLTEN METAL Publication Classi?cation

FEEDER FOR CONTINUOUS CASTING
(51) Int. Cl.
(76) Inventors: John Sulzer, Ontario (CA); Willard B22D 11/06 (2006-01)
Mark Truman Gallerneault, Ontario 322D 1”00 (200601)
(CA) B22D 41/00 (2006.01)
(52) U.S. Cl. ......................... .. 164/462; 164/429; 222/591
Correspondence Address:
Richard s. Milner (57) ABSTRACT
Cooper & Dunham _ The invention provides a feeder for delivery of molten metal
1185 Avenue of the Amel‘lcas into a mold formed between confronting casting surfaces of
New YOI‘k, NY 10036 (Us) a continuous casting machine. The feeder comprises a
projecting noZZle tip having at least a loWer Wall provided
(21) Appl- NO-I 11/884,572 With a molten metal-contacting inner surface, a generally ?at
_ outer surface and an end surface at an outer extremity of the
(22) PCT Flledt Feb- 24, 2006 tip extending between the inner and outer surface. The inner
surface is generally ?at and preferably slopes toWards the
(86) PCT NO.I PCT/CA06/00267 outer surface considered in a direction moving toWards the
extremity of the tip at an angle of slope of no more than 8
§ 371(c)(1), degrees. The end surface is generally ?at and extends from
(2), (4) Date: Nov. 21, 2007 the inner surface to the outer surface at an acute angle of less
than 88°, e. g. in the range of 15 to 80 degrees, relative to the
inner surface in a direction aWay from the extremity of the
(30) Foreign Application Priority Data tip. The feeder casts a metal sheet article having reduced
surface defects caused by rupture of the metal oxide during
Feb. 25, 2005 (US) ........................................ .. 11/066625 casting.

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Patent Application Publication Apr. 10, 2008 Sheet 4 0f 5 US 2008/0083524 A1
Patent Application Publication Apr. 10, 2008 Sheet 5 0f 5 US 2008/0083524 A1

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US 2008/0083524 A1
METHOD OF AND MOLTEN METAL FEEDER
FOR CONTINUOUS CASTING
TECHNICAL FIELD
[0001] This invention relates to the continuous casting of
molten metals, preferably aluminum and aluminum alloys.
More particularly, the invention relates to a method of
introducing the molten metal into the casting cavity of a
continuous caster and the design of a metal feeder used for
this purpose.
BACKGROUND ART
[0002] Continuous casting of metals has been carried out
for many years, eg by using a tWin belt caster, tWin roll
caster or rotating block caster. Continuous casters of this
kind usually have a horizontal, or slightly doWnWardly
sloping, casting cavity formed betWeen tWo confronting and
continuously rotating casting surfaces. The molten metal is
introduced into one end of the casting cavity and it is cooled
and solidi?ed as it is draWn through the casting cavity by the
rotating casting surfaces. A cast ingot, slab or strip of
solidi?ed metal emerges from the casting cavity at the
opposite end.
[0003] Molten metal is introduced into the casting cavity
by some form of molten metal feeder that introduces a
stream of molten metal betWeen the casting surfaces. The
feeder may be in the form of an open topped trough, in
Which molten metal is directed by means of an open spout
or channel into the casting cavity (referred to as “pool
feeding”), or more preferably by means of a noZZle Which
encloses and con?nes the molten metal until it emerges from
a tip at the extreme end of the noZZle.
[0004] As-cast ingots produced by both DC (direct chill)
and continuous strip casters produce metal slabs or strips
having surface defects of various kinds. In DC casting such
surface defects are often removed by means of “scalping”
(i.e. removing a thin surface layer from the cast article).
HoWever, in continuous strip casting, scalping may not be
practical or economical and it is desirable to provide an
article at the outset having a minimum of surface defects.
[0005] Surface defects may be produced by a variety of
mechanisms, including reaction With the refractory materials
of the metal delivery system and localiZed cooling non
uniformities, and many improvements have been made to
reduce the siZe and number of such defects.
[0006] Another common mechanism involves entrainment
of surface oxides that form “cold shuts”. Such defects arise
from the inevitable surface oxides that form on the meniscus
surface of the molten metal Where it exits the metal feeder
to contact the moving casting surface. As the meniscus is
dragged along by the moving casting surface, the oxide ?lm
becomes strained and breaks, causing relatively large and
visible surface defects of an irregular nature. This not only
affects the appearance of the cast article, but also can
introduce structural Weaknesses that cause rollability prob
lems. The defects are particularly critical in surface critical
applications such as foil stock, can stock and automotive
sheet, and can limit the speed of casting.
[0007] There are various prior references disclosing feeder
design and methods of metal introduction into a continuous
casting cavity, eg US. Pat. No. 5,636,681 Which issued on
Apr. 10, 2008
Jun. 10, 1997, and US. Pat. No. 6,725,904 Which issued on
Apr. 27, 2004. These patents disclose feeder designs that are
intended to produce non-turbulent metal ?oW into the cast
ing cavity.
[0008] European Patent No. EP 0 962 271 B1, Which Was
granted on Dec. 17, 2003 to HaZeleft Strip-Casting Corpo
ration (inventor Valerie G. Kagan) discloses a belt casting
apparatus With a metal delivery device that “pours” the
metal onto a belt. The tip of the delivery device is spaced a
distance aWay from the surface of the belt and it terminates
at an end surface disposed at right angles to the metal
contacting inner surface of the delivery device.
[0009] US. Pat. No. 4,648,438 Which issued on Mar. 10,
1987 to HaZelett Strip-Casting Corporation (inventor Robert
W. HaZelett, et al.) discloses a belt caster and metal delivery
device in Which the end of the tip is “squared” and is
arranged at right angles to the casting surface.
[0010] The folloWing are examples of strip casters having
tips in Which the interior of the tip is tapered in the direction
of the tip:
[0011] US. Pat. No. 3,774,670 Which issused on Nov. 27,
1973 to ProliZenZ AG (inventor Ivan Gyongyos); US. Pat.
No. 5,660,757 Which issued on Aug. 26, 1997 to Hunter
Engineering Co., Inc. (inventor Denis M. Smith); and US.
Pat. No. 6,173,755 Which issued on Jan. 16, 2001 to Alu
minum Company of America (inventor Nai-Yi Li, et al.).
DISCLOSURE OF THE INVENTION
[0012] An object of the present invention is to improve the
continuous casting of molten metal, especially molten alu
minum and its alloys, particularly With a vieW to reducing
surface defects of the cast article and more particularly to
reduce the incidence of oxide incorporation into the cast
surface.
[0013] According to one aspect of the present invention,
there is provided a feeder for delivery of molten metal into
a mold formed betWeen confronting casting surfaces of a
continuous casting machine. The feeder comprises a noZZle
having a projecting tip including at least one Wall provided
With a molten-metal-contacting inner surface, an outer sur
face, and an end surface at an outer extremity of the tip
extending betWeen the inner and outer surfaces. The inner
surface and the end surface interconnect at a line and form
an included angle of less than 88°, and the Wall of the noZZle
has a thickness adjacent to the line in the range of 0.5 to 3
mm.
[0014] According to another embodiment, there is pro
vided a continuous casting machine comprising a pair of
endless casting surfaces confronting each other across a
casting cavity, means for moving the casting surfaces in the
same direction at the same speed, and a feeder for introduc
ing molten metal into the casting cavity at one end of the
cavity. The feeder comprises a noZZle having a projecting tip
including at least one Wall provided With a molten-metal
contacting inner surface, an outer surface, and an end
surface at an outer extremity of the tip extending betWeen
the inner and outer surfaces. The inner surface and the end
surface interconnect at a line and form an included angle of
less than 88 degrees. The Wall has a thickness adjacent to the
line in the range of 0.5 to 3 mm, and the line is positioned
US 2008/0083524 A1
during casting at a spacing from an adjacent casting surface
Within the range of 0.5 to 3 mm.
[0015] According to yet another embodiment of the inven
tion, there is provided a process of continuous strip casting
a molten metal to form a cast metal strip article. The process
comprises feeding a molten metal Which develops an oxide
layer When in contact With air from a noZZle having a
projecting noZZle tip onto at least one moving casting
surface such that the metal forms a meniscus having a
surface coating of metal oxide betWeen an extremity of the
tip and the casting surface. The metal is fed from a tip having
a Wall provided With an inner surface and an end surface that
interconnect at a line and form an included angle of less than
88 degrees. The Wall has a thickness adjacent to the line in
the range of 0.5 to 3 mm. The tip is positioned during casting
such that the spacing of the line from an adjacent casting
surface is Within the range of 0.5 to 3 mm.
[0016] The present invention is concerned With obtaining
a continuously cast strip article of good surface quality. As
the inventors obtained improvements in surface quality by
making general improvements to the casting technique and
apparatus, they noticed the presence of periodic surface
striations extending across the cast article at right angles to
the direction of casting. The inventors found that these
striations Were due, at least in part, to oscillations of the
meniscus formed betWeen the casting tip and the casting
surface. When casting reactive metals, such as aluminum,
the meniscus is coated With a layer of metal oxide and the
oscillation of the meniscus can cause this to break. The
underlying metal thus exposed rapidly groWs a neW layer of
oxide upon reaction With air, but the break forms a visible
defect in the surface of the cast product as the oxide layer is
draWn onto the casting surface. It is theorized that meniscus
oscillations are inherent in continuous casters, at least in belt
casters used for casting aluminum and its alloys, as Well as
other reactive metals, and that they cannot be entirely
eliminated. The inventors therefore took another approach,
i.e. of increasing the uniformity of the oscillations to pro
duce a cast article having small, regularly spaced striations
that do not manifest themselves as surface defects because
of their regular and ?ne appearance. In particular, it Was
found that an oscillation of the meniscus of at least 50 Hertz,
eg in the range of 50 to 200 HerZ, Was required to impart
an acceptable appearance to the cast product.
[0017] The meniscus tends to oscillate at right angles to its
surface, i.e. it tends to become more rounded and then less
rounded in the region extending from the noZZle to the
casting surface With each such cycle representing one oscil
lation.
[0018] The inventors found that the frequency of the
meniscus oscillations can be affected by various parameters,
eg the application of external forces, such as pneumatic
pressure in the small gap betWeen the noZZle and the casting
belt, and the application of a varying magnetic ?eld in the
area of the meniscus. HoWever, the inventors found that the
most effective Way to increase the frequency of oscillation is
by improving the design and placement of the noZZle used
for injecting the molten metal onto the casting surface.
[0019] With regard to the design of the casting noZZle, the
conventional noZZle employs a pair of projecting Walls that
de?ne a molten metal channel betWeen confronting inner
metal-contacting surfaces. The channel has an exit at the tip
Apr. 10, 2008
of the noZZle Where the projecting Walls terminate at a ?at
end surface that extends at right angles to the inner metal
contacting surfaces. The Walls also have outer surfaces that
in use extend along the casting surfaces With a small gap.
Using this type of noZZle, it Was noticed that not only Was
the frequency of oscillation of the meniscus sloW and erratic,
but the oscillations bring the metal into contact With the end
surfaces of the noZZle Walls, causing oxide Whiskers to form
and build up, thereby causing further sticking and interfer
ence With the oscillations. The inventors found that this
effect could be minimiZed or eliminated by “cutting-back”
the end surface by a feW degrees or more. This means that
the end surface is caused to slope in a rearWard direction
from the line of contact With the inner metal-contacting
surface to form an included angle (the angle Within the
material of the noZZle Wall) of less than 88 degrees, more
preferably 85 degrees or less, even more preferably 80
degrees or less, and most preferably 75 degrees or less. The
minimum angle is preferably 15 degrees, because a smaller
angle may be currently impractical for constructing the
noZZle (although the desirable effect would still be apparent
if the constructional limitations could be overcome). Amore
desirable loWer limit for the cut-back angle is 30 degrees. An
even more preferred loWer limit is 45 degrees. Most pref
erably, the end surface of the noZZle Wall is ?at along its full
length, i.e. from the intersections With the inner and outer
Walls, and from side to side across the noZZle. This has the
advantage of making the striations more regular, particularly
across the Width of the casting cavity.
[0020] The line of contact mentioned above (the apex of
the included angle) forms a so-called “take-off point” for the
meniscus, i.e. the point at Which the molten metal loses
contact With the noZZle and is brie?y supported by surface
tension before contacting the casting surface. It is necessary
to provide such a line (i.e. an abrupt change of direction
Where generally planar surfaces meet at an acute angle).
Without limitation as to the theory of operation of the
invention, it appears that the line and the acute angle at this
position ?xes the point of metal departure from the tip so
that it does not Wander onto the end face of the noZZle Wall.
Oscillations of the metal instead appear to be localiZed at the
take-olf line Where they break the oxide layer on a regular
and frequent basis as the metal leaves the tip, thereby
causing regular and ?ne striations in the ?nal product.
[0021] Again Without limitation as to theory, it seems that
the amplitude of the meniscus oscillations increases With
casting speed (i.e. the speed of the casting belt). A greater
amplitude of the oscillations increases the risk of meniscus
“Wander” onto the end face of the noZZle, so the “cut-back”
angle may desirably be decreased as the casting speed
increases (i.e. the angle of the end surface With the inner
surface should desirably be made smaller, e.g. Within the
range of 15 to 80 degrees). For fast casting, the angle should
preferably be made no larger than 75 degrees, and 70
degrees or even 65 degrees is a more preferred upper limit.
[0022] Ideally, the meniscus should be caused to oscillate
at a frequency of 50 herZ to about 200 HerZ at least for
aluminum and aluminum alloys. The range of frequencies
depends on physical properties of the metal, e.g. density,
viscosity and surface tension, but only for signi?cant
changes in these properties. The variation among aluminum
alloys is quite minor, but a change of base metal (e.g.
US 2008/0083524 A1
aluminum to copper) may produce signi?cant changes that
affect the oscillations more noticeably.
[0023] In the present invention, it is found that the spacing
betWeen the “take-off point” and the casting surface should
be quite speci?c. If it becomes too large, it is dif?cult or
impossible to maintain a stable meniscus as it may “Wander”
onto the end Wall of the tip and the metal may run back under
the tip of the noZZle. The How characteristics change to
become more like pouring a liquid rather than casting at
speed. However, the spacing should be large enough to
alloW a meniscus to form betWeen the take-off point and the
casting surface. The minimum distance is controlled by
restrictions placed on the tip by methods of construction and
the need for the tip to be spaced slightly from the casting
surface. The preferred spacing (take-off line to casting
surface) is about 1 mm+0.5 mm. HoWever, the invention is
effective With normal noZZle Wall thicknesses (usually about
1 mm or 1/32 inch) and a spacing up to about 3 mm.
[0024] The metal can be fed into a closed noZZle or to an
open-topped noZZle from a conventional head box or
tundish. The present invention may be used With both types
of noZZle, but a closed noZZle is preferred.
[0025] When the noZZle is of the closed type, the tWo Walls
forming the noZZle may be ?at and parallel throughout their
length, or they may be “?ared” or “divergent” at the end, i.e.
With the Walls adjacent to the metal delivery end bending
outWardly at an angle of usually no greater than about 8
degrees. This alloWs the Walls to converge toWards the
casting surfaces by a small angle at the extreme end of the
tip.
[0026] The present invention may be used With both
horiZontal and vertical continuous casting machines, e.g.
tWin-belt casters, revolving block casters and even tWin-roll
casters (tWin-roll casters are preferably operated at high
speed When the invention is employed).
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a side vieW, partly in cross-section, of a
tWin-belt caster (Without metal feed apparatus) of a type
With Which the present invention may be employed;
[0028] FIG. 2 is a cross-section of a metal feeder and
adjacent parts of a tWin-belt caster of a type With Which the
present invention may be employed;
[0029] FIG. 3 is a cross-section of a part of a prior art
noZZle and an adjacent casting belt and molten metal ?oW,
shoWing the development of a metal meniscus;
[0030] FIG. 4 is a vieW similar to FIG. 3, but shoWing a
part of a noZZle in accordance With the present invention;
[0031] FIG. 5 is a top plan vieW ofa test device used in the
Example described beloW;
[0032] FIG. 6 is a cross-sectional vieW of the test device
of FIG. 5;
[0033] FIGS. 7A, 7B, 7C, and 7D shoW cross-sections of
tips used in the Example 1 described beloW;
[0034] FIG. 8 shoWs a macrophotograph of the surface of
an aluminum alloy strip cast With a prior art noZZle having
an angle betWeen inner surface and end surface of 93
degrees;
Apr. 10, 2008
[0035] FIG. 9 shoWs a macrophotograph of the surface of
an aluminum alloy strip cast With a noZZle in accordance
With the present invention having an angle betWeen inner
surface and end surface of 88 degrees;
[0036] FIG. 10 shoWs a macrophotograph of the surface of
an aluminum alloy strip cast With a noZZle in accordance
With the present invention having an angle betWeen inner
surface and end surface of 78 degrees;
[0037] FIG. 11 shoWs a macrophotograph of the surface of
an aluminum alloy strip cast With a noZZle in accordance
With the present invention having an angle betWeen inner
surface and end surface of 48 degrees; and
[0038] FIG. 12 shoWs a macrophotograph of the surface of
an aluminum alloy strip cast With a noZZle in accordance
With the present invention having an angle betWeen inner
surface and end surface of 33 degrees.
BEST MODES FOR CARRYING OUT THE
INVENTION
[0039] As noted above, continuous casting of metals to
form strip articles (often referred to as sheets, plates, slabs,
ingots, billets, layers, etc.) has been carried out for many
years and in many different types of continuous casting
machines. For example, a tWin-belt caster is disclosed in
detail in US. Pat. No. 4,061,177 Which issued on Dec. 6,
1977 to Alcan Research and Development Limited (inventor
Olivo Giuseppe Sivilotti), and casting machines of this kind
(as Well as others) are suitable for carrying out the present
invention. The disclosure of this patent is incorporated
herein by reference, and a brief and simpli?ed description is
provided beloW.
[0040] The illustrated tWin belt caster 10 has upper and
loWer endless rotating metal belts 12 and 14 arranged so that
closely spaced moving confronting casting surfaces 16, 18
of the belts are disposed essentially parallel to each other
through a region Where they de?ne a casting cavity (casting
mold) 20 from a cavity entrance 21 to a cavity exit 22. The
belts are guided as they rotate through suitable oval or
otherWise looped return paths betWeen the entrance and the
exit of the casting cavity. The upper belt 12 passes around a
cylindrical driving roll 24 and then travels along an upper
path Where it may be further supported, if desired, by roWs
of idler rollers or the like (not shoWn), and then around a
semi-cylindrical bearing 25. The loWer belt folloWs an
essentially identical but mirror image path including a drive
roll 26 and a semi-cylindrical bearing 27 similar to the
bearing located immediately above. Molten metal is intro
duced into the casting cavity by a feeder 30 (not shoWn in
FIG. 1, but illustrated in FIG. 2) incorporating a noZZle 32
having a projecting tip 34 provided With a molten metal
outlet 35 at the outer extremity (extreme end) 36 of the tip.
Hence, molten metal enters the apparatus from the feeder 30
in the direction shoWn by arroW A (FIG. 1), the metal
solidi?es Within the casting cavity 20 and a cast strip article
emerges from the apparatus at the exit of the casting cavity
in the direction of arroW B as shoWn. The reverse (inner)
surfaces 17, 19 of the casting belt are generally cooled by
means of jets of cooling water, eg as shoWn at 23.
[0041] FIG. 2 shoWs an enlargement of the end of the
caster adjacent to the entrance 21 of the casting cavity 20.
The belts 12 and 14 are shoWn in dash-dot lines. As
US 2008/0083524 A1
previously noted, the apparatus is provided With a molten
metal feeder 30 Which may be of the type disclosed, for
example, in US. Pat. No. 5,636,681 issued on Jun. 10, 1997
to Alcan International Limited (the disclosure of Which is
incorporated herein by reference). The feeder 30 comprises
top and bottom noZZle mounts 38 Which hold metal delivery
noZZle 32 in place so that its tip 34 projects betWeen the tWo
moving belts 12 and 14 of the belt caster. The mounts 38 are
bolted to the caster structure (not shoWn) and support the
noZZle 32 such that an upstream opening 40 can mate With
a similar opening in a tundish or feed-box (not shoWn) used
to feed the caster With molten metal. A resilient refractory
seal (also not shoWn) is used betWeen upstream faces 41 of
the noZZle and the tundish or feed-box. The noZZle 32 is
fabricated from refractory materials, for example as
described in US. Pat. No. 5,636,681, and the tip 34 has a
slightly divergent shape as shoWn. Spacers 46, in the form
or Wire mesh or metal strips, are provided betWeen the outer
surfaces of the noZZle and the adjacent casting belts to
maintain a ?xed and controlled spacing betWeen the noZZle
and belts. The noZZle includes refractory Walls 53 that have
inner molten-metal-contacting surfaces 55 confronting each
other across a molten-metal-conveying channel 50 leading
from the upstream opening to the metal outlet 35. The Walls
have end surfaces 56 that interconnect With the inner sur
faces 55 at lines 65. The Walls also have outer surfaces 54
that confront the casting belts 12 and 14.
[0042] The present invention is primarily concerned With
the delivery of molten metal into the casting cavity in the
region of the noZZle tip 34. This is explained in more detail
With reference to FIGS. 3 and 4.
[0043] FIG. 3 shoWs a conventional noZZle tip 34 in Which
only the loWer Wall 53 of the tip is shoWn adjacent the loWer
casting belt 14. The upper Wall of the tip and the upper
casting belt can be visualiZed as mirror images of the loWer
parts. The illustrated tip has an outer surface 54 extending
generally parallel to the surface of the adjacent casting belt
14, a molten-metal-contacting inner surface 55, and a nar
roW end surface 56 that is disposed at right angles to the
inner surface 55 of the tip (as indicated by the small
rectangle). In the delivery and casting of molten metals, a
meniscus 58 (i.e. an unsupported metal surface) bridges the
gap betWeen the noZZle tip 34 and the adjacent casting belt
14. For reactive metals (i.e. metals that spontaneously form
an oxide layer When in contact With air) such as aluminum
and its alloys, the meniscus is covered by an oxide layer 60.
As the belt 14 moves through the casting cavity, the oxide
layer 60 is draWn along by the belt by friction and is subject
to stress in the region of the meniscus. It is found that the
oxide layer on the meniscus Will periodically rupture and the
exposed metal Will instantly form a neW layer of oxide. The
resulting oxide breakage and re-groWth causes surface
defects in the cast article. The inventors of the present
invention have found that the effect of the inevitable oxide
rupture on surface quality can be reduced or minimized by
ensuring that the oxide membrane ruptures frequently and in
a controlled manner rather than randomly.
[0044] In particular, the inventors have found that by
causing the meniscus to freely oscillate at a controllable
frequency of at least 50 HZ, the effect of oxide layer ruptures
is controlled and reduced. It has been found that a noZZle tip
designed and used in accordance With the present invention,
eg as shoWn in FIG. 4, Will alloW such regular oscillations
Apr. 10, 2008
and oxide rupture to occur. In this tip, angle 0t (referred to
as the “cut-back angle” and also as the “included angle”)
betWeen the inner surface 55 and the end surface 56 is an
acute angle less than 88°, preferably betWeen 15 and 85
degrees, more preferably betWeen 15 and 80°, more prefer
ably betWeen 30 and 80 degrees, and even more preferably
betWeen 30 to 75°. When such an angle is employed, the
meniscus 58 is free to oscillate, and, absent any outside
in?uences, takes on a “natural” frequency determined by the
physical properties of the molten metal, the contact friction
betWeen the molten metal and the moving substrate (casting
belt) and the spacing of the tip to belt distance (spacing “S”
shoWn in FIG. 4). The use of the acute cut-back angle 0t, in
combination With a precisely de?ned spacing S of tip to belt,
means that the geometry of the meniscus is reliably con
trolled betWeen the casting surface 61 of the casting belt 12
and the line of intersection 65 (referred to as the “take-off
point” or “take-off line”) betWeen the inner surface 55 and
the end surface 56 of the noZZle tip, so that the frequency of
oscillation is stable. The use of the acute cut-back angle 0t
ensures that the ?nal point of contact betWeen the molten
metal and the noZZle is con?ned to a ?xed position on the tip,
namely the line of intersection 65. At this point, the molten
metal surface transfers from a supported condition (sup
ported by the noZZle) to an unsupported condition (in the
form of a meniscus) and the oxide ?lm on the metal surface
is repetitively ruptured along this line as the meniscus
oscillates. The oxide rupture has the same regular frequency
as the frequency of oscillation and takes place in small and
regular breaks, thus creating regular and minimal defects on
the metal surface.
[0045] If the cut-back angle 0t is not acute (eg if it is 90
degrees as in a conventional noZZle tip), the meniscus 58 can
touch the end surface 56 of the tip during oscillation.
[0046] This rapidly forms oxide Whiskers on the end
surface of the tip and this in turn causes adherence of the
meniscus to the end surface 56 beloW the line of intersection
65. This adhesion is variable and prevents regular and free
oscillations of the meniscus from occurring. The breaks in
the oxide layer are consequently irregular and delayed and
the resulting surface defects are larger.
[0047] The amplitude of the meniscus oscillations appears
to be someWhat casting speed related, i.e. larger amplitudes
are encountered at higher casting speeds. As larger ampli
tudes can result in the meniscus being more di?icult to ?x on
the noZZle, it is desirable to reduce the angle 0t at higher
casting speeds and an angle no larger than 75 degrees is
usually desirable for high casting speeds. On the other hand,
if the cut back angle is less than 15 degrees, it becomes
dif?cult to construct a noZZle tip having the requisite stilf
ness and strength properties.
[0048] The spacing S (Which is the distance betWeen the
“take-off point”65 and the casting surface 61 of the casting
belt at the point Where the meniscus contacts the surface)
affects the performance of the casting process. For most
alloys and casting operations, the spacing S should be in the
range of 0.5 to 3.0 mm. The spacing S includes the thickness
of the loWer Wall 53 at the tip, and so this thickness must
necessarily also be Within the range of 0.5 to 3.0 mm. The
most preferred distance for spacing S is 110.5 mm. This can
be achieved, for example, by making the sideWall 53 from
an alumina-silicate ?berboard (e.g. Fiberfrax®) having a
US 2008/0083524 A1
thickness of 1 mm at the tip that is slightly compressed With
a rigidizer. As the material is slightly compressed and
changes in thickness slightly during use due to thermal
expansion, the spacing S can be maintained at about 1 mm
With a slight gap forms betWeen the sideWall 53 and the
casting surface. The indicated material has su?icient
strength and rigidity despite its narroW thickness, and desir
ably it also relatively loW thermal conductivity.
[0049] The invention is illustrated in further detail With
reference to the following Examples, Which are not intended
to be limiting of the scope of the invention.
EXAMPLE 1
[0050] The effects of different feeder tip angles Were
investigated on a single mold plane (Water cooled) utilizing
an open-topped box With a sliding bottom, to simulate the
metal ?oW conditions from a stationary feeder tip onto a
moving Water cooled belt. The apparatus employed is shoWn
schematically in FIG. 5 (plan vieW) and FIG. 6 (vertical
longitudinal cross-section).
[0051] The metal Was poured into a box 70 and a bottom
plate 71 Was pulled horizontally at predetermined speeds
and molten metal temperatures, alloWing the metal 75 to
How from an end 72 of the moving bottom plate onto a sheet
steel mold 73, Where it solidi?ed progressively toWards the
moving bottom plate. The moving bottom plate (forming a
thin slide) Was made of the same material as the feeder tips
used for continuous casting, and the right hand end Was
changed in geometry as shoWn in FIGS. 7A to 7D to study
the effects of such changes on the solidi?ed metal, such as
meniscus break lines and other ingot surface defects. The
speed of extracting the bottom plate Was varied to simulate
different metal ?oW rates and conditions of the tip to the
mold surface. The geometry of FIG. 7A corresponds to the
present invention, having a cut back angle of 75 degrees.
FIG. 7B has a cut back angle of 120 degrees, i.e. outside the
present invention. FIG. 7C has a compound surface but the
angle at the inner comer (“take off point”) is 120 degrees.
The second angle does not affect the meniscus because it
does not form a take-off point. FIG. 7D has a curved outer
surface and there is as a result no clear inner corner or “take
off point”. All conditions in FIGS. 7B, 7C, and 7D resulted
in undesirable oxide breaks at the solidi?cation juncture, but
the conditions of FIG. 7A, an undercut tip angle of 75°
angle, gave good results. For the same design as in FIG. 7A,
the undercut angle Was changed to 60 and 30°, all With good
results, attained by the sharp upper edge shoWn in FIG. 7A.
EXAMPLE 2
[0052] A series of casts Were performed in a pilot scale
belt caster using metal delivery nozzles having various
cut-back angles. Casts Were made on copper belts using
aluminum alloy AA5754 cast 10 mm thick cast at a speed of
8 to 10 meters/minute.
[0053] The surface of the as cast strip Was observed and
photographed. The results are shoWn in FIGS. 8 to 12 and
are summarized in Table 1 beloW.
Apr. 10, 2008
TABLE 1
Cut back angle Figure Number Observation
93 degrees 8 Severe oxide banding or folds
irregularly spaced about 30 mm
apart
88 degrees 9 Oxide banding or folds irregularly
spaced about 30 mm apart
78 degrees 10 Regular ?ne banding about 1 mm
spacing
48 degrees 11 Regular ?ne banding about 1 mm
spacing
33 degrees 12 Regular ?ne banding about 1 mm
spacing
[0054] Cut back angles of 93 and 88 degrees are outside
the range of angles of the invention and the sheet cast using
tips at such angles exhibit unacceptable oxide folds or
banding. A spacing of 30 mm, typical of such bands,
corresponds to a frequency of about 4 to 6 Hz. Cut back
angles less than 88 degrees shoW an absence of such heavy
bands, but display ?ner more regular surface marks With
spacings of about 1 mm, corresponding to a frequency of
over 100 Hz.
1. A feeder for delivery of molten metal into a mold
formed betWeen confronting casting surfaces of a continu
ous casting machine, the feeder comprising:
a nozzle having a projecting tip including at least one Wall
provided With a molten-metal-contacting inner surface,
an outer surface, and an end surface at an outer extrem
ity of the tip extending betWeen the inner and outer
surfaces,
characterized in that the inner surface and the end surface
interconnect at a line and form an included angle of less
than 88°, and said at least one Wall has a thickness
adjacent to said line in the range of 0.5 to 3 mm.
2. A feeder according to claim 1, characterized in that said
included angle is in the range of 15 to 85 degrees.
3. A feeder according to claim 1, characterized in that said
included angle is in the range of 15 to 80 degrees.
4. A feeder according to claim 3, characterized in that said
included angle is in the range of 15 to 75 degrees.
5. A feeder according to claim 3, characterized in that said
included angle is selected from a range of 30 to 70 degrees.
6. A feeder according to claim 1, characterized in that said
thickness is 110.5 mm.
7. A feeder according to claim 3, characterized in that the
tip has tWo of said Walls aligned With each other With said
metal-contacting inner surfaces confronting each other
across a metal-conveying channel.
8. A feeder according to claim 7, characterized in that said
Walls of said tip diverge from each other in a direction
extending toWards said outer extremity.
9. A feeder according to claim 8, characterized in that said
Walls diverge from a longitudinal axis of the tip at an angle
of about 8 degrees.
10. A continuous casting machine, comprising:
a pair of endless casting surfaces confronting each other
across a casting cavity;
a means for moving the casting surfaces in the same
direction at the same speed; and
US 2008/0083524 A1
a feeder for introducing molten metal into said casting
cavity at one end of said cavity;
Wherein said feeder comprises a nozzle having a project
ing tip including at least one Wall provided With a
molten-metal-contacting inner surface, an outer sur
face, and an end surface at an outer extremity of the tip
extending betWeen the inner and outer surfaces,
characterized in that said inner surface and said end
surface interconnect at a line and form an included
angle of less than 88 degrees, said at least one Wall has
a thickness adjacent to said line in the range of 0.5 to
3 mm, and said line is held during casting at a spacing
from an adjacent one of said casting surfaces Within a
range of 0.5 to 3 mm.
11. A casting machine according to claim 10, character
ized in that said included angle is in the range of 15 to 85
degrees.
12. A casting machine according to claim 10, character
ized in that said included angle is in the range of 15 to 80
degrees.
13. A casting machine according to claim 12, character
ized in that said included angle is in the range of 15 to 75
degrees.
14. A casting machine according to claim 12, character
ized in that said included angle is Within the range of 30 to
70 degrees.
15. A casting machine according to claim 10, character
ized in that said spacing is 110.5 mm.
16. A casting machine according to claim 12, character
ized in that the tip has tWo of said Walls aligned With each
other With said metal-contacting inner surfaces confronting
each other across a metal-conveying channel.
Apr. 10, 2008
17. A casting machine according to claim 16, character
ized in that said Walls of said tip diverge from each other in
a direction extending toWards said outer extremity.
18. A casting machine according to claim 17, character
ized in that said Walls diverge from a longitudinal axis of the
tip at an angle of about 8 degrees.
19. A process of continuous strip casting a molten metal
to form a cast metal strip article, Which process comprises
feeding a molten metal, Which develops an oxide layer When
in contact With air, from a nozzle having a projecting nozzle
tip onto at least one moving casting surface such that the
metal forms a meniscus having a surface coating of metal
oxide betWeen an extremity of the tip and the casting
surface, characterized in that said metal is fed from a tip
having an inner surface and an end surface that interconnect
at a line and form an included angle of less than 88 degrees,
said at least one Wall has a thickness adjacent to said line in
the range of 0.5 to 3 mm, and said line during casting is
positioned at a spacing from an adjacent one of said casting
surfaces Within a range of 0.5 to 3 mm.
20. A process according to claim 19, characterized in that
the ?nal contact betWeen the molten metal and the tip is
con?ned to a ?xed position on the tip by providing the tip
With an inner metal-contacting surface and an end surface
that interconnect at a line and have an included angle
selected from a range of 15 to 80 degrees, and causing the
molten metal to flow over said interconnecting line onto said
casting surface.