Hot-top type continuous casting machine for hollow billet

FIELD OF THE INVENTION

The present invention relates to a hot-top type continuous casting machine for hollow billets, which can stably cast hollow billets made of nonferrous metal such as, in particular, aluminum alloy including aluminum, with a high degree of quality, and in addition in particular to an improved core adapted to be used in a mold for casting such hollow billets.

RELATED ART

Metal billets are used as materials for extrusion of a pipe, using a mandrel, which are advantageous since they offer a higher yield for extrusion in comparison with that of solid billets.

In order to produce the above-mentioned hollow billets, there has been used a hot-top type continuous casting machine or a direct chill casting machine.

Among them, as shown in

FIG. 1

, the hot-top type continuous casting machine is adapted to retain, in a molten metal holding part

2

formed of refractory materials, molten metal

3

such as aluminum alloy, which is continuously transferred from a holding furnace (not shown), through a trough

20

, and the thus retained molten metal

3

is then continuously cast into a hollow billet

1

through the intermediary of a casting part

4

located underneath the molten metal holding part

2

and composed of an ring mold

6

and a core

31

. This continuous casting machine in provided with a feeder head, and accordingly, the thus produced hollow billet may have a high degree of interior quality. The ring mold

6

constituting the above-mentioned casting part

4

defines the outer peripheral part of the hollow billet

1

, and the core

31

defines the inner peripheral part of the hollow billet

1

. The core

31

is attached to a support bar

21

located on the upper surface of the molten metal holding part

2

.

The core

31

has conventionally made of aluminum alloy or graphite as disclosed in Japanese Patent Application No. S62-107749.

However, a core made of aluminum alloy has such a structure that water is injected, direct to the inner peripheral surface of a hollow billet from the lower end part of the core, and further, it is high heat conductive. Thus, a solidified shell is formed at the inner surface

5

of the ring billet on a relatively earlier stage, and this solidified shell is then remelted by molten metal in the molten metal holding part

2

. Thus, the molten metal which has been remelted gives rise to an uneven surface, possibly causing leakage of the molten metal.

Meanwhile, Japanese patent Application No. S63-273553 discloses a core made of graphite, silicon nitride or the like. The graphite core has a relative low thermal conductivity so that the position where the formation of a solidified shell is initiated is likely to vary depending upon a casting condition, and accordingly, a hollow billet

1

with a high degree of quality cannot be stably produced. Further, since the outer surface of the graphite core

31

is worn with the time, resulting in ununiform cooling by the core, which would cause a defect in the inner peripheral surface of the hollow billet

1

. Thus, there would be finally resulted a risk of leakage of molten metal.

Thus, there has been proposed a core having an upper part made of a refractory material and a lower part made of metal, and adapted to directly inject cooling water from the lower end part of the core onto the inner peripheral surface of a hollow billet (refer to, for example, Japanese patent No. 1630402).

However, this core is always subjected to such a risk that it is drawn into the hollow billet due to solidification contraction of the hollow part of the hollow billet. Should the core be drawn into the hollow billet, molten metal in the molten metal holding part would attack the above-mentioned injected cooling water thereover, resulting in the risk of occurrence of steam explosion. Thus, this core has not yet been practically used.

SUMMARY OF THE INVENTION

Accordingly, an object of the present invention is to provide a hot-top type continuous casting machine which can stably cast a hollow billet having a high degree of quality, and in particular, to provide an improved core used in an ring mold for casting a hollow billet.

To the end, according to a first aspect of the present invention, there is provided a hot-top type continuous casting machine for casting a hollow billet, comprising: (a) a molten metal holding part into which molten metal is fed; (b) an ring mold arranged being connected to the molten metal holding part; and (c) a core inserted in the ring mold from the top of the later so as to define the inner wall of the hollow billet, and composed of an upper core which is low heat-conductive, and a lower core which is high heat-conductive and which is adapted to be cooled by cooling medium circulated therethrough.

According to a second aspect of the present invention, there is provided a hot-top type continuous casting machine in which the boundary part between the upper and lower cores is set at a heightwise position which is substantially equal to that of the ring mold.

According to a third aspect of the present invention, there is provided a hot-top type continuous casting machine in which both upper and lower cores are gradually tapered from the upper part to the lower part thereof with a predetermined gradient.

According to a fourth aspect of the present invention, there is provided a hot-top type continuous casting machine in which the high heat-conductive core is cooled by coolant circulating therethrough.

According to a fifth aspect of the present invention, there is provided a hot-top type continuous casting machine which is provided with a means for feeding lubrication oil onto the outer surface of the core in the boundary part between the low conductive upper core and the high conductive lower core.

According to a sixth aspect of the present invention, there is provided a hot-top type continuous casting machine in which the above-mentioned lubrication oil is rape seed oil or castor oil.

According to a seventh aspect of the present invention, there is provided a hot-top type continuous casting machine which is used for casting aluminum alloy.

According to an eighth aspect of the present invention, there is provided a core adapted to be used in a hot-top type continuous casting machine for casting a hollow billet, comprising (a) a low heat-conductive upper core and a high heat-conductive lower core; (b) a coolant supply pipe, and a coolant discharge pipe for discharging the coolant, which are extended through the core, (c) the coolant fed from the coolant supply pipe being discharged from the outside from the coolant discharge pipe after cooling the interior of the high heat-conductive core, and (d) means for feeding lubrication oil onto the outer surface of the core, being provided in the boundary part between the upper core and the lower core.

According to a ninth aspect of the present invention, there is provided a core used in a hot-top type continuous casting machine, in which the core is made of a heat-insulation board.

According to a tenth aspect of the present invention, there is provided a core used in a hot-top type continuous casting machine, in which the core is made of either aluminum alloy including AA6061 alloy, or copper alloy including Cu—Cr group alloy.

According to an eleventh aspect of the present invention, there is provided a core used in a hot-top type continuous casting machine, in which the coolant is water.

According to a twelfth aspect of the present invention, there is provided a core used in a hot-top type continuous casting machine, in which the lubrication oil is rape seed oil or castor oil.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1

is a longitudinal sectional view illustrating a conventional hot-top type continuous casting machine;

FIG. 2

is a longitudinal section view illustrating a hot-top type continuous casting machine using a core, for a hollow billet in an embodiment of the present invention;

FIG. 3

is a detailed sectional view illustrating the core according to the present invention;

FIGS.

4

(A) to

4

(C) are views for explaining the height positions of a boundary part between an upper core and a lower core, and an ring mold in the hot-top type continuous casting machine; and

FIG. 5

is a plan view illustrating a configuration of an embodiment in which a plurality of hot-top type continuous casting machines for hollow billets are arranged.

DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

Description will be hereinbelow made of a hot-top type continuous casting machine using a core, for a hollow billet, according to the present invention in specific forms with reference to the drawings.

Referring to

FIG. 2

which is a longitudinal sectional view illustrating an embodiment of a hot-top type continuous casting machine using a core, for a hollow billet, according to the present invention.

The continuous casting machine according to the present invention is basically composed of a molten metal holding part

2

, a mold part

4

and a core

11

. The molten metal holding part

2

is always replenished with molten metal

3

through a trough

20

, and constitutes a hot-top

2

composed of a refractory material.

The mold part

4

is arranged being connected to the hot top

2

, that is, the molten metal holding part

2

, and is formed of an ring mold

6

which is cooled in its interior with coolant. Further, the core

11

is fixed to a support part

21

, and is inserted in the ring mold

6

from thereabove. The core

11

is composed of a low heat-conductive upper core

12

and a high heat-conductive lower core

13

. As mentioned above, the hot-top type continuous casting machine for producing a hollow billet

1

casts the molten metal

2

retained in the molten metal holding part

2

, into the mold part

4

therebelow. The mold part

4

is composed of the ring mold

6

defining the outer peripheral surfaced of the hollow billet

1

and the core

11

defining the inner peripheral part thereof.

The interior of the ring mold

6

is cooled by the coolant

7

which is desirably water, and accordingly, the molten metal

3

is cooled (for primary cooling) at the inner surface of the ring mold

6

so as to solidify. Thus, the outer peripheral surface

8

of the hollow billet is formed. Thereafter, the coolant

7

which has cooled the ring mold

6

and which is usually water, is jetted onto the surface of the billet under the mold through a coolant jet port

9

(for secondary cooling) in order to promote solidification of the molten metal.

The ring mold

2

is usually formed in its inner surface in the vicinity of the top part thereof (about 1 mm from its top surface) with a lubrication oil supply passage

60

, a supply groove

62

for feeding the lubrication oil over the entire periphery of the mold, and a slit

64

for feeding the lubrication oil onto the inner surface of the mold. The lubrication oil such as rape seed oil or castor oil is fed through this slit in order to maintain satisfactory lubrication between the inner surface of the ring mold

6

and a solidified shell.

Referring to

FIG. 3

which shows the core

11

in detail, the core

11

is composed of the upper core

12

made of a low heat-conductive material, and the lower core

13

made of a high heat-conductive material such as aluminum alloy, and the lower core

13

is fed with coolant

27

such as water while the upper core

12

is formed therethough with a coolant passage

14

. The coolant

27

fed from a coolant pipe

15

, flows through the coolant passage

14

so as to cool the interior of the lower core, and thereafter it is discharged through a coolant discharge pipe

16

. Since the coolant

27

is prevented from being directly injected onto the inner surface

5

of the hollow part of the hollow billet

1

, no risk of explosion would be caused even though the solidified shell would be broken so that the molten metal

3

leaks.

Since the lower core

13

is made of a high heat-conductive material such as aluminum alloy, and is formed therein with the coolant passage

14

through which the coolant

27

flows to cool the lower core

13

, the solidified shell is formed at the inner peripheral surface

5

of the hollow part of the hollow billet

1

, having a thickness with which the shell cannot be melted again. Further, since the core

11

is tapered so that its diameter is decreased down ward, the solidified shell is prevented from being broken by a friction force between itself and the core. Thus, the inner peripheral surface

5

of the hollow part of the hollow billet

1

can be formed with a high degree of surface quality.

According to the present invention, the upper core

12

is made of a low heat-conductive material such as graphite or a refractory material. As to the refractory material, Marinite (trade name: manufactured by Jones Manbill Co.,), Lumiboard (trade name; manufactured by Nitias Co.,) or Recepal (trade name: manufactured by Nitias Co.,) may be suitably used. These materials are in general so-called as heat-insulation boards having a thermal conductivity of less than 0.2 Kcal/m·hr·deg.C.

The lower core

13

is made of a high heat-conductive aluminum alloy material such as AA6061 alloy or Cu—Cr group alloy. As to coolants

7

,

27

fed through the ring mold

6

and the lower core

11

, any coolant such as water or air may be used.

A lubrication oil feeder is provided in a boundary part

18

between the upper core

12

and the lower core

13

. This lubricant oil feeder is composed of a supply pipe

180

for feeding lubrication oil from the outside, a high heat-conductive upper ring

182

having a slit passage

184

opened to the outer peripheral surface of the core, and a groove

186

for circumferentially distributing the lubrication oil. The lubrication oil is fed onto the outer surface of the lower core

13

through the slit passage

184

. When the lubrication oil is fed, satisfactory lubrication can be held between the outer surface of the lower core

13

and inner peripheral surface

5

of the hollow part of the billet, and accordingly, the inner peripheral surface

5

of the hollow part of the billet which is excellent can be stably formed.

The core used for a continuous casting machine for a hollow billet, is composed of the upper core

12

made of a refractory material so as to prevent the molten metal

3

from being solidified, and the lower core

13

made of a metal material and cooled by the coolant circulated therein so as to cause the molten metal to be at once solidified in this lower core

13

in order to form a solidified shell having a thickness which is enough for preventing the shell from being remelted. Thus, the height of the boundary part

18

between the upper core

12

and the lower core

13

should be set with respect to the height of the ring mold

16

.

That is, as shown in FIG.

4

(A), if the heightwise positions of the boundary part

18

and the ring mold

6

are substantially aligned with each other, the surface of the molten metal

3

makes contact with the outer surface of the lower core

13

so that a thick solidified shell is stably formed, and accordingly, the solidified shell would be never remelted, thereby it is possible to obtain an inner surface of the hollow part with extremely high surface quality. It is noted that substantially the same height between the boundary part

18

and the ring mold

6

means that the heightwise position H of the boundary part

18

falls in a heightwise range h of the ring mold

6

.

Meanwhile, as shown in FIG.

4

(B), the heightwise position H of the boundary part

18

is above the heightwise range h of the ring mold

6

, a solidified shell which is initially formed, is remelted by heat from the molten metal in the molten metal holding part

2

so as cause unevenness in the inner peripheral surface

5

of the hollow part, that is, no smooth surface can be obtained.

As shown in FIG.

4

(C), if the heightwise position H of the boundary part

18

is located below the heightwise range h of the ring mold part

6

, the molten metal

3

is solidified at the outer surface of the upper core

2

so as to form a fragile solidified shell, defect is caused on the inner peripheral surface of the hollow part. Thus, it is impossible to obtain a smooth inner surface.

According to the present invention, the casting conditions, including the descending speed of the hollow billet, the volume of cooling water, a temperature of the molten metal also affect upon the quality of the billet, and accordingly, it is necessary to appropriately carry out control for every metal to be cast. Usually, there should be set the descending speed of a hollow billet in a range of 40 to 80 mm/min, the volume of cooling water for the ring mold

6

in a range of 100 to 200 l/min, the volume of cooling water for the lower core in a range of 30 to 60 l/min, and the temperature of molten aluminum alloy in a range of 670 to 750 deg.C.

According to the present invention, technical effects and advantage similar to those as mentioned above can be also obtained even though the invention is applied to a hot-top type continuous casting machine for producing several hollow billets, as shown in

FIG. 5

, in which molten metal

3

fed from a holding furnace (which is not shown) is fed into several molten metal holding parts

3

through a molten metal pool

19

and a channel

20

, and several billets are cast from mold parts below the molten metal holding parts

2

.

EXAMPLES

Explanation will be hereinbelow detailed in the form of reference examples.

Example 1

Three hollow billets having an outer diameter of 410 mm, an inner diameter of 165 mm and a length of 3 m and made of JIS3003 group aluminum alloy (AA3003) were produced with the use of the hot-top type continuous casting machine for hollow billets, as shown in FIG.

2

.

The molten metal holding part

2

and the channel

20

were formed of a heat insulating material manufactured by Recepal Co., and the ring mold

6

having a circular ring shape, in the mold part, was formed of a copper alloy pipe having an inner diameter of 420 mm and a height of 90 mm. As to the core

11

, the upper core

12

was made of a heat insulating material manufactured by Recepal Co., and the lower core

13

was made of JIS6061 aluminum alloy (AA6061), and an upper ring

182

having lubrication oil passages opened to the outer peripheral surface of the core was provided in the boundary part

18

, the core having an overall length of 400 mm and being tapered (tapering angle of 3 deg.) so as to decrease its diameter downward.

The core

11

was located in the center part of the circular ring mold

6

while the boundary part

18

was located at the center of the heightwise range h of the ring mold

6

(Refer to FIG.

3

(A)).

As to casting conditions:

Temperature of Molten Metal in Molten Metal Holding Part 2 (molten metal holding temperature): 730 deg.C.

Descending Speed of Hollow Billet 1: 45 mm/min

Volume of Cooling Water for Ring Mold 6: 170 l/min

Volume of Cooling Water for Lower Core 13: 30 l/min

Example 2

A multiple billet casting machine as shown in

FIG. 5

was used to continuously casting six hollow billets having an outer diameter of 410 mm, an inner diameter of 165 mm, a length of 3 m and made of JIS5052 Alloy (AA5052) simultaneously. With the repetitions of such casting by three times, eighteenth hollow billets were obtained.

As to casting conditions:

Temperature for Holding Molten Metal: 690 deg.C

Descending Speed of Hollow billet: 55 mm/min

Volume of Cooling Water for Ring Mold: 170 l/min

Volume of Cooling Water for Lower Core: 30 l/min.

The other conditions were set to those stated in Reference Example 1.

Example 3

A multiple billet casting machines as shown in

FIG. 5

were used to continuously casting six hollow billets having an outer diameter of 410 mm, an inner diameter of 165 mm, a length of 3 m and made of JIS6N01 Alloy, simultaneously. With the repetitions of such casting by three times, eighteenth hollow billets were obtained.

As to casting conditions:

Temperature for Holding Molten Metal: 710 deg.C

Descending Speed of Hollow billet: 45 mm/min

Volume of Cooling Water for Ring Mold: 170 l/min

Volume of Cooling Water for Lower Core: 30 l/min.

The other conditions were set to those stated in Reference Example 1.

Example 4

Hollow billets were cast in the method explained in the reference example 1, except that the boundary part

18

was set above (refer to

FIG. 2

) and below (refer to

FIG. 2

) the height range h of the ring mold by 10 mm.

Quality of the inner peripheral surfaces of the hollow parts of the hollow billets obtained in the embodiments 1 to 4 were examined. Results obtained through the examination are shown in Table 1.

TABLE 1

Molten

*Volume

Metal

of

Cast

Holding

Descending

Cooling

Quality Of

Casting

Height Of

Alloy

Temp.

Speed

Water

Inner Surface of

Conditions

No

Boundary

(JIS)

(° C.)

(mm/min)

(l/min)

Hollow Part

Results

1

Within

3003

730

45

200

Extremely

of

Range h

Satisfactory

Casting

FIG. 3(A)

2

Within

5052

690

55

200

Extremely

Range h

Satisfactory

FIG. 3(A)

3

Within

6N01

710

45

200

Extremely

Range h

Satisfactory

FIG. 3(A)

4

10 mm

3003

730

45

200

Almost

above h

Satisfactory

FIG. 3(B)

5

10 mm

3003

730

45

200

Almost

below h

Satisfactory

FIG. 3(C)

Note:

*Consisting of 170 l/min for the ring mold and 30/min for the lower core.

It is clear from Table 1 that any of the qualities of the inner peripheral surfaces of the hollow parts in the reference examples of the present invention 1 to 3 extremely satisfactory.

However, in reference example No. 4, concavities and convexities were found on the inner peripheral surface of the hollow part since the height H of the boundary part was above the height range h of the ring mold by 10 mm. Further, in the reference example 5, a small number of fine cracks were found in the inner peripheral surface of the hollow part of the boundary part since the height H of the boundary was below the height range h of the ring mold by 10 mm. However, all of them was practically usable.

The above-mentioned reference examples exhibit that there would be no practical problems even though the height H of the boundary part is deviated from the height range h of the ring mold by about 10 mm. It is noted that the quality of the outer peripheral surface of every hollow billet was satisfactory.

As mentioned above, according to the present invention, the core consists of the upper core made of a low heat-conductive material and the lower core made of a high heat-conductive material and cooled by the coolant circulated through the interior of the lower core, and accordingly, a solidified shell can be formed having a thickness with which it cannot be remelted when it is made into contact with the lower core. Thus the quality of the inner peripheral surface of the hollow part becomes satisfactory. Further, since the coolant is directly jetted onto the inner peripheral surface of the hollow part, and accordingly, no explosion is caused even though the molten metal internally leaks. With the provision of the lubrication oil feeder in the boundary part, the lubrication oil is fed onto the outer surface of the core, and accordingly, the quality of the inner surface of the hollow part can be further enhanced. Thus, the hot-top type continuous casting method for a hollow billet according to the present invention with the use of the above-mentioned core can stably produce hollow billets having a high degree of quality. The quality of hollow billets can be further enhanced by setting the height of the boundary between the upper core and the lower core to be equal to that of the ring mold. Thereby the invention is possible to provide industrially remarkable industrial advantages.

EXPLANATION TO REFERENCE NUMERAL

1

. Hollow Billet

2

. Molten Metal Holding Part

3

. Molten Metal

4

. Casting Part

5

. Inner peripheral surface of Hollow Part of Hollow Billet

6

. Ring Mold

7

. Coolant Circulated through Ring Mold

8

. Outer Peripheral Surface of Hollow Billet

9

. Coolant Jet Port in Ring Mold

11

. Core according to the Present Invention

12

. Upper Core,

13

. Lower Core

14

. Coolant Passage

15

. Coolant Introduction Pipe

16

. Coolant Discharge Pipe

18

. Boundary Part between Upper Core and Lower Core

19

. Molten Metal Sump

20

. Trough

21

. Support Bar

27

. Coolant through Lower Core

31

. Conventional Core,

60

. Supply Passage for Lubrication Oil

62

. Groove for Feeding Lubrication Oil over Entire Periphery of Mold

64

. Slit for Feeding Lubrication Oil

180

. Lubrication Oil Supply Pipe

182

. Lubrication Oil Distributing Groove

184

. Slit Passge

Number	Name	Date	Kind
4437508	Pryor et al.	Mar 1984	A
4531569	Fritscher	Jul 1985	A
4546816	Schwarz	Oct 1985	A
4875519	Ishii et al.	Oct 1989	A
5052469	Yanagimoto et al.	Oct 1991	A

Number	Date	Country
62089549	Apr 1987	JP
1630402	Jan 1989	JP
S62-107749	May 1997	JP

Hot-top type continuous casting machine for hollow billet

Information

Patent Number

Date Filed

Date Issued

Inventors

Original Assignees

Examiners

Agents

CPC

US Classifications

Field of Search

US

International Classifications

Term Extension

Abstract

Description

Claims

US Referenced Citations (5)

Foreign Referenced Citations (3)