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Molten metal is poured from furnaces into ladles, treated, and transported to casting machines. The ladle sits on a rotating turret and pours metal into a tundish reservoir above molds. Metal drains from the tundish into open copper molds, where it solidifies on the walls and bottom before exiting as a strand. The strand passes through water sprays and rollers for further cooling and solidification before final processing. Near-net-shape beam-blank casting produces beams with fewer rolling passes for lower energy use and costs than conventional bloom casting.
Molten metal is poured from furnaces into ladles, treated, and transported to casting machines. The ladle sits on a rotating turret and pours metal into a tundish reservoir above molds. Metal drains from the tundish into open copper molds, where it solidifies on the walls and bottom before exiting as a strand. The strand passes through water sprays and rollers for further cooling and solidification before final processing. Near-net-shape beam-blank casting produces beams with fewer rolling passes for lower energy use and costs than conventional bloom casting.
Molten metal is poured from furnaces into ladles, treated, and transported to casting machines. The ladle sits on a rotating turret and pours metal into a tundish reservoir above molds. Metal drains from the tundish into open copper molds, where it solidifies on the walls and bottom before exiting as a strand. The strand passes through water sprays and rollers for further cooling and solidification before final processing. Near-net-shape beam-blank casting produces beams with fewer rolling passes for lower energy use and costs than conventional bloom casting.
Molten metal is tapped into the ladle from furnaces.
After undergoing any ladle treatments, such as
alloying and degassing, and arriving at the correct temperature, the ladle is transported to the top of the casting machine. Usually the ladle sits in a slot on a rotating turret at the casting machine. One ladle is in the 'on-cast' position (feeding the casting machine) while the other is made ready in the 'off-cast' position, and is switched to the casting position when the first ladle is empty. From the ladle, the hot metal is transferred via a refractory shroud (pipe) to a holding bath called a tundish. The tundish allows a reservoir of metal to feed the casting machine while ladles are switched, thus acting as a buffer of hot metal, as well as smoothing out flow, regulating metal feed to the molds and cleaning the metal (see below). Metal is drained from the tundish through another shroud into the top of an open-base copper mold. The depth of the mold can range from 0.5 to 2 metres (20 to 79 in), depending on the casting speed and section size. The mold is water-cooled to solidify the hot metal directly in contact with it; this is the primary coolingprocess. It also oscillates vertically (or in a near vertical curved path) to prevent the metal sticking to the mold walls. A lubricant can also be added to the metal in the mold to prevent sticking, and to trap any slag particlesincluding oxide particles or scalethat may be present in the metal and bring them to the top of the pool to form a floating layer of slag. Often, the shroud is set so the hot metal exits it below the surface of the slag layer in the mold and is thus called a submerged entry nozzle (SEN). In some cases, shrouds may not be used between tundish and mold; in this case, interchangeable metering nozzles in the base of the tundish direct the metal into the moulds. Some continuous casting layouts feed several molds from the same tundish. In the mold, a thin shell of metal next to the mold walls solidifies before the middle section, now called a strand, exits the base of the mold into a spray chamber. The bulk of metal within the walls of the strand is still molten. The strand is immediately supported by closely spaced, water-cooled rollers which support the walls of the strand against the ferrostatic pressure (compare hydrostatic pressure) of the still-solidifying liquid within the strand. To increase the rate of solidification, the strand is sprayed with large amounts of water as it passes through the spray-chamber; this is the secondary cooling process. Final solidification of the strand may take place after the strand has exited the spray-chamber.
BEAM-BLANK CASTING REDUCED ENERGY
CONSUMPTION WITH NEAR-NET-SHAPE CASTING Beam-blank casting results in fewer passes in the section mill, reduced energy use and lower production costs. Near-net-shape casting is an energy-saving alternative to conventional bloom casting for the production of beams and sections. The greatest benefits can be derived through the direct coupling of the caster to the rolling mill. The special mold-taper design from Primetals Technologies offers a large operating window with respect to varying casting speeds and different steel grades. High-quality structural beams can be produced with a broad range of product dimensions.
A Practical Workshop Companion for Tin, Sheet Iron, and Copper Plate Workers: Containing Rules for Describing Various Kinds of Patterns used by Tin, Sheet Iron, and Copper Plate Workers, Practical Geometry, Mensuration of Surfaces and Solids, Tables of the Weights of Metals, Lead Pipe, Tables of Areas and Circumferences