Novelis, Inc.

Jason D Hymas

Eric W Reeves

John Steven Tingey

Robert Bruce Wagstaff

Todd F Bischoff

James E Boorman

John Robert Buster McCallum

Aaron David Sinden

Phillip Wilson

Randy Womack

Brent Opdendries

Systems and associated methods are provided for controlling the shape of an ingot head during formation. At the end of a cast, prior to forming the ingot head, chill bars or other cooling structure may be lowered into an ingot mold and define a reduced casting footprint for forming the ingot head. Supplemental molten metal may be fed into the reduced casting footprint, and the chill bars may be moved laterally towards the center of the ingot, further reducing the casting footprint. As additional molten metal fills the reduced mold footprint, the ingot may be lowered relative to the chill bars to further increase the height of the ingot head. Additional molten metal may be added until the desired shape of the ingot head is formed.

Method of controlling the shape of an ingot head

Exemplary embodiments of the invention relate to a compressive rod assembly for applying force to a refractory vessel positioned within an outer metal casing. The assembly includes a rigid elongated rod having first and second opposed ends, a threaded bolt adjacent to the first opposed end of the elongated rod, and a compressive structure positioned operationally between the elongated rod and the bolt. Compressive force applied by the bolt to the elongated rod passes through the compressive structure which allows limited longitudinal movements of the elongated rod to be accommodated by the compressive structure without requiring corresponding longitudinal movements of the bolt. Exemplary embodiments also relate to rod structure forming a component of the assembly, and to a metal containment structure having a vessel supported and compressed by at least one such assembly.

Compressive rod assembly for molten metal containment structure

Exemplary embodiments of the invention provide a molten metal containment structure including a refractory molten metal containment vessel having an external surface, and a metal casing for the vessel having an internal surface at least partially surrounding the external surface of the vessel at a distance therefrom forming a spacing between the vessel and the casing. The spacing includes an unobstructed upwardly extending gap that is vented to the exterior of the structure by upper and lower openings in the casing. A layer of insulating material is preferably positioned in the spacing between the internal surface of the casing and the external surface of the vessel, with the layer of insulating material being narrower than the spacing at least at upwardly extending sides of the casing, thereby forming the unobstructed gap. The vessel may be a metal conveying trough, a housing for a metal filter, a container for a metal degasser unit, a crucible, or the like.

Molten metal containment structure having flow through ventilation

Exemplary embodiments of the invention relate to a flow control apparatus for control of molten metal flow through a trough. The apparatus includes a flow control element (e.g. a movable dam or flow restrictor) movable between an operating position and an inactive position. A guide element provides an elongated track having a first part extending generally parallel to the longitudinal axis of the flow control element. One or more track followers are retained by the guide element and are movable along the track. An elongated arm is attached at one end to the flow control element and to the track follower at an opposite end. An actuator operably connects to the track follower to move the track follower along the track. The track causes the flow control element to move away from the operating position with a straight (non-pivoting) motion, but preferably causes the flow control element to pivot as it approaches the inactive position. The flow control apparatus may be combined with a connector unit for connecting sections of a metal-conveying trough or the like, or may be used directly with such trough or trough sections.

Flow control apparatus for molten metal

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Fairfield, WA, United States of America

Jason D Hymas