Alcan International Limited

Novelis, Inc.

Ronald Roger Desrosiers

John Fitzsimon

Olivo G Sivilotti

Kevin Michael Gatenby

John Sulzer

Willard Mark Truman Gallerneault

Andr&eacute; Larouche

Iljoon Jin

Simon Barker

Simon William Barker

Willard Mark Gallerneault

Andre Larouche

A twin-belt casting machine for casting metal strip. The machine is provided with a casting cavity which includes an upstream fixed casting region, in which the belts are in fixed convergent paths in contact with the cast slab, and an adjacent downstream portion in which the belts are adjustable between alignment with the fixed convergent paths and non-alignment therewith (being less convergent or divergent). When the adjustable portions of the paths are moved outwardly relative to the fixed convergent paths, the belts separate from the cast slab at differing predetermined points within the casting cavity. By adjusting the downstream portion of the casting cavity in this manner, the casting machine can operate at essentially constant throughput for a wide range of alloys while ensuring that the cast slab exiting the caster has a temperature within a predetermined range suitable for further rolling to produce sheet product.

Belt casting machine having adjustable contact length with cast metal slab

A continuous belt casting apparatus is provided with a casting cavity, and at least one flexible metal belt having an elongated casting surface passing through and at least partially defining the casting cavity. A motor is provided for rotating the metal belt in the longitudinal direction of the casting surface whereby the casting surface passes through the casting cavity in the longitudinal direction. A molten metal supply device delivers molten metal continuously to the casting cavity, so that molten metal supplied to the casting cavity is solidified and removed as a continuous strip ingot from the casting cavity by rotation of the belt. The casting surface is provided with a plurality of grooves oriented in substantially the same direction. The invention also relates to a casting belt for such an apparatus and a method of casting using the apparatus.

Surface texturing of casting belts of continuous casting machines

A casting belt for using in a single-belt or twin-belt casting apparatus is disclosed. The casting belt is made of aluminum alloy such as an alloy from the AA5XXX and AA6XXX systems, preferably having a thickness in the range of 1 to 2 mm. The aluminum casting belt of the invention is suitable for casting non-ferrous and light metals such as aluminum, magnesium, copper, zinc and their alloys, especially aluminum alloys such as Al&#x2014;Mg, Al&#x2014;Mg&#x2014;Si, Al&#x2014;Fe&#x2014;Si and Al&#x2014;Fe&#x2014;Mn&#x2014;Si alloy systems. A belt casting machine and process using the aluminum casting belt of the invention are also disclosed.

Belt casting of non-ferrous and light metals and apparatus therefor

A process of casting a molten metal to form a cast metal strip ingot while controlling heat flux from the cast metal. The process comprises continuously supplying molten metal to a casting cavity formed between a pair of moving continuous casting surfaces that withdraw heat from the molten metal to cause metal solidification, and continuously withdrawing a resulting cast strip ingot from the casting cavity. A gas (e.g. air) containing water vapour substantially without liquid water (i.e. a moist gas) is supplied to the inlet of the casting cavity in a region containing the meniscus formed where the molten metal first contacts the casting surfaces. The moist gas has the effect of adjusting the heat withdrawal by the casting surfaces to minimize surface defects in the cast strip ingot and to avoid undesired distortion of the casting cavity. Furthermore, in those cases where a parting agent is applied to the casting surfaces, the amount of parting agent applied to the casting surfaces may be reduced. The invention also relates to equipment provided for the delivery and dewpoint control of the moist gas.

Control of heat flux in continuous metal casters

Process and apparatus for continuous casting of metal strip in which a layer of liquid parting agent, and any solid detritus contained therein, is completely removed from a casting surface of a rotating belt after contact with the metal, and in which a new layer of liquid parting agent is applied to the casting surface thereafter and prior to renewed contact with the molten metal. The removal of used parting agent and the application of fresh helps to present the formation of surface blemishes and defects on the cast metal strip product. Such blemishes and defects can also be minimized by using an injector having a flexible tip used to inject the molten metal onto the casting surface and preferably one or more spacers to create a gap between the tip and the casting surface itself. The spacer is preferably a screen of wire strands orientated to minimize disruption of the new layer of liquid parting agent applied to the casting surface. By avoiding disruption of the new layer of liquid parting agent, surface blemishes on the cast product are minimized. The invention also relates to the molten metal injector having a flexible tip and optionally provided with spacer elements.

Injector for casting metal strip

A layer of liquid parting agent, and any solid detritus contained therein, is completely removed from a casting surface of a rotating belt after contact with molten metal. A new layer of liquid parting agent is applied to the casting surface thereafter and prior to renewed contact with the molten metal. The removal of used parting agent and the application of fresh helps to prevent the formation of surface blemishes and defects on the cast metal strip product. Such blemishes and defects can also be minimized by using an injector having a flexible tip used to inject the molten metal onto the casting surface and preferably one or more spacers to create a gap between the tip and the casting surface itself. The spacer is preferably a screen of wire strands orientated to minimize disruption of the new layer of liquid parting agent applied to the casting surface. By avoiding disruption of the new layer of liquid parting agent, surface blemishes on the cast product are minimized.

Growing community of inventors

Kingston, Canada

Ronald Roger Desrosiers