Ultrasonic grain refining and degassing procedures and systems for metal casting

• US 10,639,707 B2
• Filed: 09/09/2016
• Issued: 05/05/2020
• Est. Priority Date: 09/10/2015
• Status: Active Grant

• Current Assignee: Southwire Company
• Original Assignee: Southwire Company
• Inventors: Gill, Kevin Scott, Powell, Michael Caleb, Rundquist, Victor Frederic, Manchiraju, Venkata Kiran, Guffey, Roland Earl
• Primary Examiner(s): Kerns, Kevin P
• Application Number:
  US15/337,645
• Publication Number:
  US 20170252799A1
• Time in Patent Office: 1,334 Days
• Field of Search: 164416, 164478
• CPC Class Codes: B22D 11/0611 formed by a single casting wheel, e.g. for casting amorphous metal strips or wires
• CPC Class Codes: B22D 11/0651 Casting wheels B22D11/0682 takes precedence
• CPC Class Codes: B22D 11/114 by using agitating or vibrating means B22D11/117 takes precedence
• CPC Class Codes: B22D 11/12 Accessories for subsequent treating or working cast stock in situ rolling immediately subsequent to continuous casting B21B1/46, B21B13/22
• CPC Class Codes: B22D 11/124 for cooling
• CPC Class Codes: B22D 11/144 with a rotating mould
• CPC Class Codes: B22D 21/007 with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
• CPC Class Codes: B22D 27/20 Measures not previously mentioned for influencing the grain structure or texture; Selection of compositions therefor
• CPC Class Codes: C22B 9/026 by acoustic waves, e.g. supersonic waves
• CPC Class Codes: C22C 1/026 Alloys based on aluminium
• CPC Class Codes: C22F 3/02 by solidifying a melt controlled by supersonic waves or electric or magnetic fields

Abstract

A molten metal processing device including an assembly mounted on the casting wheel, including at least one vibrational energy source which supplies vibrational energy to molten metal cast in the casting wheel while the molten metal in the casting wheel is cooled, and a support device holding the vibrational energy source. An associated method for forming a metal product which provides molten metal into a containment structure included as a part of a casting mill, cools the molten metal in the containment structure, and couples vibrational energy into the molten metal in the containment structure.

Claims

1. A molten metal processing device comprising:

a source of molten metal;

a casting wheel for reception of the molten metal;

an assembly mounted on the casting wheel, including,

at least one vibrational energy source which supplies vibrational energy through an intervening liquid medium to molten metal cast in the casting wheel while the molten metal in the casting wheel is cooled, and

a support device holding said at least one vibrational energy source, the support device including a housing comprising a cooling channel for transport of the cooling medium therethrough,

wherein the at least one vibrational energy source comprises an ultrasonic wave probe inserted in the cooling channel.

2. The device of claim 1, wherein the cooling channel includes said cooling medium comprising at least one of water, gas, liquid metal, and engine oils.

3. The device of claim 1, wherein the at least one vibrational energy source comprises at least one ultrasonic transducer.

4. The device of claim 1, wherein the at least one vibrational energy source comprises at least one mechanically-driven vibrator.

5. The device of claim 4, wherein the mechanically-driven vibrator is configured to provide vibrational energy in a range of frequencies up to 10 KHz.

6. The device of claim 1, wherein the casting wheel includes a band confining the molten metal in a channel of the casting wheel.

7. The device of claim 1, wherein the assembly is positioned above the casting wheel and has passages in the housing for a band confining the molten metal in a channel of the casting wheel to pass therethrough.

8. The device of claim 7, wherein

the housing has a cooling channel for transport of a cooling medium therethrough, and

said band is guided along the housing to permit the cooling medium from the cooling channel to flow along a side of the band opposite the molten metal.

9. The device of claim 1, further comprising an ultrasonic degasser upstream of the casting wheel, the ultrasonic degasser including an ultrasonic probe configured to be inserted into the molten metal.

10. The device of claim 1, wherein the molten metal comprises aluminum.

11. A molten metal processing device, comprising:

a casting wheel that includes a band for confining molten metal in a channel of the casting wheel,

an assembly mounted on the casting wheel band, including,

at least one vibrational energy source configured to supply vibrational energy to molten metal cast in the casting wheel through an intervening liquid medium in contact with the casting wheel band while the molten metal in the casting wheel is cooled, and

a support device holding said at least one vibrational energy source,

wherein a tip of the at least one vibrational energy source is located less than 2 cm from the band.

12. The device of claim 11, wherein the at least one vibrational energy source comprises at least one ultrasonic transducer.

13. The device of claim 11, wherein the at least one vibrational energy source comprises at least one mechanically-driven vibrator.

14. The device of claim 13, wherein the at least one mechanically-driven vibrator is configured to provide vibrational energy in a range of frequencies up to 10 KHz.

15. The device of claim 13, wherein the at least one mechanically-driven vibrator is configured to provide vibrational energy in a range of frequencies from 5 kHz to 400 KHz.

16. The device of claim 11, wherein the intervening liquid medium is contained in a cooling channel and the at least one vibrational energy source comprises an ultrasonic probe disposed in the cooling channel.

17. The device of claim 11, wherein the tip of the at least one vibrational energy source is located less than 5 mm from the band.

18. A molten metal processing device, comprising:

a casting wheel that includes a containment structure for confining molten metal,

an assembly mounted on the casting wheel, the assembly including,

at least one vibrational energy source configured to supply vibrational energy to molten metal cast in the casting wheel through an intervening liquid medium in contact with the containment structure,

a support device holding said at least one vibrational energy source, and

an ultrasonic degasser upstream of the casting wheel, the ultrasonic degasser including an ultrasonic probe configured to be inserted into the molten metal.

19. The device of claim 18, wherein the at least one vibrational energy source comprises at least one ultrasonic transducer.

20. The device of claim 18, wherein the at least one vibrational energy source comprises an ultrasonic probe configured to be in direct contact with the liquid medium and not in direct contact with the containment structure.