Molten metal-containing vessel and methods of producing same

• US 20110139797A1
• Filed: 12/08/2010
• Published: 06/16/2011
• Est. Priority Date: 12/10/2009
• Status: Active Grant

• Current Assignee: Novelis Incorporated (Hindalco Industries Limited)
• Original Assignee: Novelis Incorporated (Hindalco Industries Limited)
• Inventors: Reeves, Eric W., Bruski, Richard Scott, Boorman, James E.
• Granted Patent: US 9,498,821 B2
• Time in Patent Office: Days
• US Class Current: 220/668
• CPC Class Codes: B22D 11/103 Distributing the molten metal, e.g. using runners, floats, distributors
• CPC Class Codes: B22D 35/04 into moulds, e.g. base plates, runners
• CPC Class Codes: B28B 1/08 by vibrating or jolting of moulding sand B22C15/10; of concrete in general E04G21/063
• CPC Class Codes: B28B 1/14 by simple casting, the material being neither forcibly fed nor positively compacted for molten material B28B1/54
• CPC Class Codes: B28B 23/02 wherein the elements are reinforcing members B28B23/0006 takes precedence
• CPC Class Codes: C04B 2235/3873 Silicon nitrides, e.g. silicon carbonitride, silicon oxynitride
• CPC Class Codes: C04B 2235/5216 Inorganic
• CPC Class Codes: C04B 2235/5252 having a specific pre-form
• CPC Class Codes: C04B 2235/5256 Two-dimensional, e.g. woven structures
• CPC Class Codes: C04B 2235/5264 characterised by the diameter of the fibers
• CPC Class Codes: C04B 2235/6027 Slip casting
• CPC Class Codes: C04B 2235/616 Liquid infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 2235/9676 against molten metals such as steel or aluminium
• CPC Class Codes: C04B 35/117 Composites
• CPC Class Codes: C04B 35/18 rich in aluminium oxide
• CPC Class Codes: C04B 35/565 based on silicon carbide
• CPC Class Codes: C04B 35/62218 obtaining ceramic films, e.g. by using temporary supports
• CPC Class Codes: C04B 35/62625 Wet mixtures
• CPC Class Codes: C04B 35/6316 Binders based on silicon compounds
• CPC Class Codes: C04B 35/76 Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C21B 7/14 : Discharging devices, e.g. for slag
• CPC Class Codes: C21C 5/5247 : processing a moving metal stream while exposed to an electromagnetic field, e.g. in an electromagnetic counter current channel
• CPC Class Codes: F27D 3/14 : Charging or discharging liquid or molten material
• CPC Class Codes: Y02P 10/20 : Recycling

Abstract

Exemplary embodiments of the invention provide a vessel for containing or conveying molten metal therein. At least part of the outer surface of the vessel incorporates a web of metal wires embedded in the surface, the wires being mutually overlaid with openings formed therebetween. The refractory material penetrates into the openings. The web may comprise woven metal wires or non-woven wires or both. The web imparts resistance to cracking (or containment of cracks, once formed) and/or resistance to molten metal leakage if cracks develop. The invention also provides metal containment structures containing such vessels, and methods of producing the same.

Claims

1. A vessel for molten metal, the vessel comprising a body of refractory material having a cavity for containing or conveying molten metal, and an outer surface having a web of metal wires embedded therein, said wires being overlaid with respect to each other with openings formed between said wires into which openings said refractory material penetrates.

2. The vessel of claim 1, wherein said body has a horizontal level above which an upper surface of molten metal contained in or conveyed through the cavity does not extend during normal use of the vessel, and wherein said reinforcement is embedded in at least all parts of said outer surface at and below said horizontal level.

3. The vessel of claim 1, wherein said web of metal wires comprises a woven matrix of said metal wires.

4. The vessel of claim 1, wherein said web of metal wires comprises a non-woven matrix of said metal wires.

5. The vessel of claim 1, wherein the web of metal wires comprises at least two overlying web sections joined to each other.

6. The vessel of claim 5, wherein one of the overlying web sections comprises a woven matrix of said metal wires and another of said web sections comprises a non-woven matrix of said metal wires.

7. The vessel of claim 6, wherein said non-woven matrix is positioned closer to said surface than said woven matrix.

8. The vessel of claim 6, wherein said woven matrix is positioned closer to said surface than said non-woven matrix.

9. The vessel of claim 6, wherein the woven matrix of said wires has openings with an average width greater than an average width of openings in the non-woven matrix.

10. The vessel of claim 9, wherein the average width of the openings in the woven matrix is in the range of 0.5 to 10 mm.

11. The vessel of claim 9, wherein the average width of the openings in the woven matrix is in a range of 1 to 10 mm.

12. The vessel of claim 9, wherein the average width of the openings in the non-woven matrix is in a range of 50 μ

m to 10 mm.

13. The vessel of claim 9, wherein the average width of the openings in the non-woven matrix is in a range of 50 μ

m to 150 μ

m.

14. The vessel of claim 9, wherein the average width of the openings in the non-woven matrix is about 100 μ

m.

15. The vessel of claim 1, wherein said metal wires are made from a metal which resists attack by molten metal conveyed by the trough section.

16. The vessel of claim 1, wherein said metal wires are made from a metal selected from the group consisting of stainless steel, titanium, Ni—

Cr based alloys and Fe—

Cr—

Al based alloys.

17. The vessel of claim 1, wherein the vessel is an elongated trough or trough section with said cavity forming a channel extending from one longitudinal end of said body to another end thereof.

18. The vessel of claim 17, wherein said body has an upper surface and said channel is open at said upper surface of the body.

19. The vessel of claim 17, wherein the body of the vessel completely encloses the channel except at said longitudinal ends.

20. The vessel of claim 1, wherein said vessel is an article selected from the group consisting of an elongated metal-conveying trough, a container for a molten metal filter, a container for a molten metal degasser, and a crucible.

21. A molten metal containment structure comprising a vessel according to claim 1, and a metal casing at least partially surrounding the vessel.

22. A method of making a reinforced refractory vessel or vessel section, comprising:

providing a mold having an intended shape of the vessel or vessel section;

creating a slurry of a castable refractory material capable of forming a cast refractory body;

lining at least one internal surface of the mold with a web of metal wires, said wires being overlaid with openings formed therebetween;

introducing the slurry into the mold while causing said slurry to penetrate said openings;

allowing said slurry to set to form a vessel or vessel section incorporating said web at an outer surface thereof; and

removing the vessel or vessel section from the mold.

23. The method of claim 22, wherein said mold is vibrated before said slurry sets to facilitate penetration of slurry into the openings of the web.

24. The method of claim 22, wherein said mold is pressurized before said slurry sets to facilitate penetration of slurry into the openings of the web.

25. The method of claim 22, wherein said mold is vibrated and pressurized before said slurry sets to facilitate penetration of slurry into the openings of the web.

26. A method of of making a reinforced refractory vessel, comprising:

providing a vessel made of a refractory material and having an external surface, and adhering a web to the external surface, wherein the web comprises metal wires having openings therebetween, and wherein the web is adhered to the external surface by means of a refractory adhesive that is infiltrated into the web through said openings.