ULTRA-THIN SLAB OR THICK-STRIP CASTING

• Main Author: SEARS, JR. JAMES B
• Format: Patent
• Language: English
• Published: 19.09.2013
• Subjects: CASTING; CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES; PERFORMING OPERATIONS; POWDER METALLURGY; TRANSPORTING

A system of twin-roll casting an ultra-thin slab or thick-strip of metal with a liquid core still present inside the hollow shell of the casting as it exits the nip of the opposing counter rotating casting rolls. The wide sides of the cast shell are formed against a recessed casting surface on each roll and the narrow end walls of the shell are formed against the tapered ends of the recessed area so one half of the narrow end wall is formed on each roll and the two halves are joined together at the nip to form the full perimeter of the metal casting. A liquid-cooled copper mold liner provides continued support to each of the four sides of the casting below the twin-rolls and contact with those chilled copper mold liners continues to remove heat from the liquid core of the casting enabling the shell to continue growing in thickness. As the casting exits the mold it will be of adequate thickness to pass through opposing pairs of support rolls below the mold without bulging where water sprays can provide the additional cooling needed for final and complete solidification. A variation of this system uses one or more separating dams to cast different metals or different alloys of the same metal to integrally cast a dual-layer or multi-layer ultra-thin slab or thick strip of metal with a thin metal layer on one or both of the wide and narrow end casting surfaces.