Metal founding – Process – Shaping liquid metal against a forming surface
Patent
1984-09-06
1986-10-14
Godici, Nicholas P.
Metal founding
Process
Shaping liquid metal against a forming surface
164271, B22D 2704
Patent
active
046166904
DESCRIPTION:
BRIEF SUMMARY
The present invention concerns a process and apparatus for moulding ingots of ferro-alloys by chill casting in a cooled copper mould.
When ferro-alloys are used as additive or treatment elements in ferrous alloys or metals in the molten state, they are used in the form of crushed blocks with a unit weight which may be from some tens of grams to a few kilograms. That is the case in particular with alloys based on iron and silicon, which are used as additives for example for the production of silicon killed steels and as deoxidising agents for steels in general.
It is known that, irrespective of the type of crusher used, the operation of crushing the ferro-silicon produces a relatively substantial quantity of fines (from 10 to 15% of the metal used), and the subsequent use thereof gives rise to technical and economic problems which as yet have not been fully solved. The same also applies in regard to other types of ferro-alloys.
French patent FR-A-No. 1 538 948 (corresponding to U.S. Pat. No. 3 604 494) to METALLGESELLSCHAFT A.G. and SUDDEUTSCHE KALKSTICKSTOFFWERKE A.G. proposed casting pre-alloys of the ferro-silico-magnesium type in cases made of thin sheet metal, which are previously filled to about two thirds or three quarters with crushed blocks of the same alloy or an alloy of slightly different composition, providing for very rapid cooling and thus preventing the sheet metal case from melting.
It is also known for alloys of the ferro-silico-magnesium family to be cast by sand moulding in order to produce inoculating agents for cast irons, in the form of shaped portions which are introduced into cavities in the runners (that process being referred to as "inoculation in-mould").
However, the various processes referred to above are not suited nor can they be rendered suitable to economic and massive production of blocks from an electric furnace having a continuous production per hour of several tonnes, for example a furnace for producing ferro-silicon containing 75% of Si, with an output of 16 MW, which produces about 2 T/h of alloy.
The present invention therefore concerns a process which permits the moulding of ferro-alloy blocks of a predetermined shape and weight, by casting in a cooled copper mould of the liquid metal issuing from the production furnace either directly or by being transferred by way of a ladle or any intermediate vessel.
This process is characterised by the following repetitive steps: copper mould halves, one at least of which comprises a plurality of impressions of the ingots to be moulded, said impressions communicating with each other by way of ducts and opening in the upper part of the mould by way of at least one ingate, heat exchange fluid, filled, 200.degree. C. and preferably 300.degree. C. below its solidus temperature, and mould.
The invention also concerns an apparatus for carrying out the process comprising: which comprises a plurality of impressions of the ingots to be moulded, said impressions communicating with each other by means of ducts and opening in the upper part by way of an ingate, fluid, each other.
The apparatus may also comprise cooled means for introducing the liquid ferro-alloy into the ingate.
The invention is particularly suitable for the production of moulded blocks of ferro-silicon which have a silicon content of higher than 15% and preferably between 40 and 90%, the balance being iron and, as appropriate, secondary additive elements such as Al, Ba, Ca, Mn, Ti and Zr.
FIGS. 1 to 5 illustrate the manner of performing the invention:
FIG. 1 is a view in vertical section of an ingot mould for carrying out the invention,
FIG. 2 is a view in horizontal section taken along line A--A in FIG. 1,
FIG. 3 is an industrial ingot mould comprising four elements, the opening and closing movements of which are controlled by jacks, and
FIGS. 4 and 5 show two alternative embodiments in which the mould halves are asymmetric.
Hereinafter, the term "ingot mould" will be used to denote the subject-matter of the present invention, it being appreciated that that term denotes
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Demange Michel
Septier Louis
Godici Nicholas P.
Reid G. M.
Societe Francaise d'Electrometallurgie-SOFREM
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