# Patent

## Title
Continuous casting method

## Abstract

In a continuous casting device 100 for casting a stainless steel billet 3c, a long nozzle 2 extending into a tundish 101 is provided at a ladle 1. A molten stainless steel 3 is poured through the long nozzle 2 into the tundish 101, and a spout 2a of the long nozzle 2 is immersed into the poured molten stainless steel 3. During pouring, an argon gas 4a is supplied around the molten stainless steel 3 in the tundish 101. Further, continuous casting is performed, in which, while immersing the spout 2a of the long nozzle 2 into the molten stainless steel 3 in the tundish 101, the molten stainless steel 3 is poured from the ladle 1 into the tundish 101 and poured from the tundish 101 into a casting mold 105. During casting, a nitrogen gas 4b is supplied instead of the argon gas 4a around the molten stainless steel 3 inside the tundish 101.

## Background
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a 35 U.S.C. §371 National Phase Entry Application from PCT/JP2013/072722, filed on Aug. 26, 2013, and designating the United States, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
This invention relates to a continuous casting method.
BACKGROUND ART
In the process for manufacturing stainless steel, which is a kind of metal, molten iron is produced by melting raw materials in an electric furnace, molten steel is obtained by subjecting the produced molten iron to refining including decarburization for instance performed to remove carbon, which degrades properties of the stainless steel, in a converter and a vacuum degassing device, and the molten steel is thereafter continuously cast to solidify to form a plate-shaped slab for instance. In the refining process, the final composition of the molten steel is adjusted.
In the continuous casting process, molten steel is poured from a ladle into a tundish and then poured from the tundish into a casting mold for continuous casting to cast. In this process, an inert gas which barely reacts with the molten steel is supplied as a seal gas around the molten steel transferred from the ladle to the casting mold to shield the molten steel surface from the atmosphere in order to prevent the molten steel with the finally adjusted composition from reacting with nitrogen and oxygen contained in the atmosphere, such reactions increasing the content of nitrogen and causing oxidation.
For example, PTL 1 discloses a method for manufacturing a continuously cast slab by using an argon gas as the inert gas.
CITATION LIST
Patent Literature
[PTL 1]
Japanese Patent Application Publication No. H4-284945
SUMMARY OF INVENTION
Technical Problem
However, the usage of the argon gas as the seal gas as in the manufacturing method of PTL 1 causes a problem. That is, the argon gas taken into the molten steel remains therein in the form of bubbles. As a result, bubble defects, that is, surface defects easily appear on the surface of the continuously cast slab due to the argon gas. Further, when such surface defects appear on the continuously cast slab, another problem appears. That is, the surface needs to be ground to ensure the required quality, increasing the cost.
The present invention has been created to resolve the above-described problems, and it is an objective of the invention to provide a continuous casting method in which an increase in nitrogen content during casting of a slab (solid metal) is suppressed and surface defects are reduced.
Solution to Problem
In order to resolve the above-described problems, the present invention provides a continuous casting method for casting a solid metal by pouring a molten metal in a ladle into a tundish disposed therebelow and continuously pouring the molten metal in the tundish into a casting mold, the continuous casting method including: a long nozzle installation step for providing at the ladle a long nozzle extending into the tundish as a pouring nozzle for pouring into the tundish the molten metal in the ladle; a pouring step for pouring the molten metal into the tundish through the long nozzle and immersing a spout of the long nozzle into the molten metal in the tundish; a first seal gas supply step for supplying an inert gas as a seal gas around the molten metal in the tundish in the pouring step; a casting step for pouring the molten metal into the tundish through the long nozzle, while immersing the spout of the long nozzle into the molten metal in the tundish, and pouring into the casting mold the molten metal in the tundish; and a second seal gas supply step for supplying a nitrogen gas, instead of the inert gas, as a seal gas around the molten metal in the tundish in the casting step.
Advantageous Effects of Invention
With the continuous casting method in accordance with the present invention, it is possible to suppress an increase in nitrogen content and reduce surface defects when a solid metal is cast.



BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic diagram illustrating the configuration of a continuous casting device which is used in the continuous casting method according to Embodiment 1 of the present invention.
FIG. 2 is a schematic diagram illustrating the state of a tundish in the continuous casting method according to Embodiment 1 of the present invention.
FIG. 3 is a schematic diagram illustrating the state of a tundish in the continuous casting method according to Embodiment 2 of the present invention.
FIG. 4 illustrates a comparison of the number of bubbles generated in the stainless steel billet in Example 3 and Comparative Example 3.
FIG. 5 illustrates a comparison of the number of bubbles generated in the stainless steel billet in Example 4 and Comparative Example 4.
FIG. 6 illustrates a comparison of the number of bubbles generated in the stainless steel billet in Comparative Example 3 and when a long nozzle is used in Comparative Example 3.



DESCRIPTION OF EMBODIMENTS
Embodiment 1
The continuous casting method according to Embodiment 1 of the invention will be explained hereinbelow with reference to the appended drawings. In the below-described embodiment, a method for continuously casting stainless steel is explained.
Stainless steel is manufactured by implementing a melting process, a primary refining process, a secondary refining process and a casting process in the order of description.
In the melting process, scrap or alloys serving as starting materials for stainless steel production are melted in an electric furnace to produce molten iron, and the produced molten iron is transferred into a converter. In the primary refining process, crude decarburization is performed to remove carbon contained in the melt by blowing oxygen into the molten iron in the converter, thereby producing a molten stainless steel and a slag including carbon oxides and impurities. Further, in the primary refining process, the components of the molten stainless steel are analyzed and crude adjustment of components is implemented by charging alloys for bringing the steel composition close to the target composition. The molten stainless steel produced in the primary refining process is tapped into a ladle and transferred to the secondary refining process.
In the secondary refining process, the molten stainless steel is introduced, together with the ladle, into a vacuum degassing device, and finishing decarburization treatment is performed. A pure molten stainless steel is produced as a result of the finishing decarburization treatment of the molten stainless steel. Further, in the secondary refining process, the components of the molten stainless steel are analyzed and final adjustment of components is implemented by charging alloys for bringing the steel composition closer to the target composition.
In the casting process, as depicted in FIG. 1, the ladle 1 is taken out from the vacuum degassing device and set to a continuous casting device (CC) 100. Molten stainless steel 3 which is the molten metal in the ladle 1 is poured into the continuous casting device 100 and cast, for example, into a slab-shaped stainless steel billet 3c as a solid metal with a casting mold 105 provided in the continuous casting device 100. The cast stainless billet 3c is hot rolled or cold rolled in the subsequent rolling process (not illustrated in the figures) to obtain a hot-rolled steel strip or cold-rolled steel strip.
The configuration of the continuous casting device (CC) 100 will be explained hereinbelow in greater detail.
The continuous casting device 100 has a tundish 101 which is a container for temporarily receiving the molten stainless steel 3 transferred from the ladle 1 and transferring the molten stainless steel to the casting mold 105. The tundish 101 has a main body 101b which is open at the top, an upper lid 101c that closes the open top of the main body 101b and shields the main body from the outside, and an immersion nozzle 101d extending from the bottom of the main body 101b. In the tundish 101, a closed inner space 101a is formed by the main body 101b and the upper lid 101c inside thereof. The immersion nozzle 101d is opened into the interior 101a at the inlet port 101e from the bottom of the main body 101b. 
Further, the ladle 1 is set above the tundish 101, and a long nozzle 2 is connected to the bottom of the ladle 1. The long nozzle 2 is a pouring nozzle for a tundish, which extends into the interior 101a through the upper lid 101c of the tundish 101. A spout 2a at the lower tip of the long nozzle 2 opens in the interior 101a. Sealing is performed and gas tightness is ensured between the through portion of the long nozzle 2 in the upper lid 101c and the upper lid 101c. 
A plurality of gas supply nozzles 102 are provided in the upper lid 101c of the tundish 101. The gas supply nozzles 102 are connected to a gas supply source (not depicted in the figures) and deliver a predetermined gas from the top downward into the interior 101a of the tundish 101. The long nozzle 2 is configured such that the predetermined gas is also supplied into the long nozzle 2.
A powder nozzle 103 is provided in the upper lid 101c of the tundish 101, which is for charging a tundish powder (referred to hereinbelow as “TD powder”) 5 (see FIG. 3) into the interior 101a of the tundish 101. The powder nozzle 103 is connected to a TD powder supply source (not depicted in the figure) and delivers the TD powder 5 from the top downward into the interior 101a of the tundish 101. The TD powder 5 is constituted by a synthetic slag agent, and the surface of the molten stainless steel 3 is covered thereby, the following effects for instance are produced on the molten stainless steel 3: the surface of the molten stainless steel 3 is prevented from oxidizing, the temperature of the molten stainless steel 3 is maintained, and inclusions contained in the molten stainless steel 3 are dissolved and absorbed. In Embodiment 1, the powder nozzle 103 and the TD powder 5 are not used.
A rod-shaped stopper 104 movable in the vertical direction is provided above the immersion nozzle 101d. The stopper 104 extends from the interior 101a of the tundish 101 to the outside through the upper lid 101c of the tundish 101.
Where the stopper 104 is moved downward, the tip thereof can close the inlet port 101e of the immersion nozzle 101d. Further, the stopper is also configured such that where the stopper is pulled upward from a position in which the inlet port 101e is closed, the molten stainless steel 3 inside the tundish 101 flows into the immersion nozzle 101d and the flow rate of the molten stainless steel 3 can be controlled by adjusting the opening area of the inlet port 101e according to the amount of pull-up. Further, sealing is performed and gas tightness is ensured between the through portion of the stopper 104 in the upper lid 101c and the upper lid 101c. 
The tip 101f of the immersion nozzle 101d in the bottom portion of the tundish 101 extends into a through hole 105a of the casting mold 105, which is located therebelow, and opens sidewise.
The through hole 105a of the casting mold 105 has a rectangular cross section and passes through the casting mold 105 in the vertical direction. The through hole 105a is configured such that the inner wall surface thereof is water cooled by a primary cooling mechanism (not depicted in the figure). As a result, the molten stainless steel 3 inside is cooled and solidified and a slab 3b of a predetermined cross section is formed.
A plurality of rolls 106 for pulling downward and transferring the slab 3b formed by the casting mold 105 is provided apart from each other below the through hole 105a of the casting mold 105. A secondary cooling mechanism (not depicted in the figure) for cooling the slab 3b by spraying water is provided between the rolls 106.
The operation of the continuous casting device 100 in Embodiment 1 will be explained hereinbelow.
Referring to FIG. 1 together with FIG. 2, in the continuous casting device 100, the ladle 1 containing inside thereof the molten stainless steel 3 which has been secondarily refined is disposed above the tundish 101. Further, the long nozzle 2 is mounted on the bottom of the ladle 1, and the tip of the long nozzle having the spout 2a extends into the interior 101a of the tundish 101. In this configuration, the stopper 104 closes the inlet port 101e of the immersion nozzle 101d. 
In the below-described embodiment, a case is explained in which two ladles 1 are used successively and the casting is performed continuously, without stopping, when the ladles 1 are replaced. In other words, in the below-described embodiment, two charges of molten stainless steel which have been manufactured in an electric furnace in the melting process are cast continuously.
Then, inert gas, an argon (Ar) gas 4a, is injected as a seal gas 4 from the gas supply nozzle 102 into the interior 101a of the tundish 101, and the argon gas 4a is also supplied into the long nozzle 2. As a result, any air which is present in the interior 101a of the tundish 101 and the long nozzle 2 that includes impurities is pushed out of the tundish 101 to the outside, and the interior 101a and the long nozzle 2 are filled with the argon gas 4a. In other words, the region from the ladle 1 through the interior 101a of the tundish 101 and to the casting mold 105 is filled with the argon gas 4a. 
A valve (not depicted in the figure) which is provided at the long nozzle 2 is then opened, and the molten stainless steel 3 in the ladle 1 flows down under gravity inside the long nozzle 2 and then flows into the interior 101a of the tundish 101. In other words, the interior of the tundish 101 is in the state illustrated by a process A in FIG. 2.
In this case, the molten stainless steel 3 which has flown in is sealed on the periphery thereof with the argon gas 4a filling the interior 101a and is not in contact with air. As a result, nitrogen (N2) which is contained in air and can be dissolved in the molten stainless steel 3 is prevented from dissolving in the molten stainless steel 3 and increasing the concentration of nitrogen component therein. Further, the molten stainless steel 3 which has flown down from the spout 2a of the long nozzle 2 hits the surface 3a of the molten stainless steel 3 inside the tundish 101. As a result, the argon gas 4a is dragged in and mixed, albeit in a small amount, with the molten stainless steel 3. However, since the argon gas 4a is inactive, it neither reacts with the molten stainless steel 3 nor dissolves therein.
The surface 3a of the molten stainless steel 3 in the interior 101a of the tundish 101 is raised by the inflowing molten stainless steel 3. Where the rising surface 3a reaches the vicinity of the spout 2a of the long nozzle 2, the intensity with which the molten stainless steel 3 flowing down from the spout 2a hits the surface 3a decreases and the amount of the surrounding gas which is dragged in also decreases. Therefore, a nitrogen gas 4b is injected from the gas supply nozzle 102 into the interior 101a of the tundish 101 instead of the argon gas 4a. As a result, the argon gas 4a inside the interior 101a of the tundish 101 is pushed out to the outside, and the zone between the molten stainless steel 3 and the upper lid 101c of the tundish 101 is filled with the nitrogen gas 4b. 
Where the rising surface 3a causes the spout 2a of the long nozzle 2 to dip into the molten stainless steel 3 and the depth of the molten stainless steel 3 in the interior 101a of the tundish 101 becomes a predetermined depth D, the stopper 104 rises, the molten stainless steel 3 in the interior 101a flows into the through hole 105a of the casting mold 105 through the interior of the immersion nozzle 101d, and casting is started. At the same time, the molten stainless steel 3 inside the ladle 1 is continuously poured through the long nozzle 2 into the interior 101a of the tundish 101 and new molten stainless steel 3 is supplied. The interior of the tundish 101 at this time is in a state as illustrated by process B in FIG. 2.
When the molten stainless steel 3 in the interior 101a has the predetermined depth D, it is preferred that the long nozzle 2 penetrate into the molten stainless steel 3 such that the spout 2a is at a depth of about 100 mm to 150 mm from the surface 3a of the molten stainless steel 3. Where the long nozzle 2 penetrates to a depth larger than that indicated hereinabove, it is difficult for the molten stainless steel 3 to flow out from the spout 2a of the long nozzle 2 due to the resistance produced by the internal pressure of the molten stainless steel 3 remaining in the interior 101a. Meanwhile, where the long nozzle 2 penetrates to a depth less than that indicated hereinabove, when the surface 3a of the molten stainless steel 3, which is controlled such as to be maintained in the vicinity of a predetermined position during casting, changes and the spout 2a is exposed, the molten stainless steel 3 which has been poured out hits the surface 3a and nitrogen gas 4b can be dragged in and mixed with the steel.
The molten stainless steel 3 which has flowed into the through hole 105a of the casting mold 105 is cooled by the primary cooling mechanism (not depicted in the figure) in the process of flowing through the through hole 105a, the steel on the inner wall surface side of the through hole 105a is solidified, and a solidified shell 3ba is formed. The formed solidified shell 3ba is pushed downward to the outside of the casting mold 105 by the solidified shell 3ba which is newly formed in an upper part of the through hole 105a. A mold powder is supplied from a tip 101f side of the immersion nozzle 101d to the inner wall surface of the through hole 105a. The mold powder acts to induce slag melting on the surface of the molten stainless steel 3, prevent the oxidation of the surface of the molten stainless steel 3 inside the through hole 105a, ensure lubrication between the casting mold 105 and the solidified shell 3ba, and maintain the temperature of the surface of the molten stainless steel 3 inside the through hole 105a. 
The slab 3b is formed by the solidified shell 3ba which has been pushed out and the non-solidified molten stainless steel 3 inside thereof, and the slab 3b is grasped from both sides by rolls 106 and pulled further downward and out. In the process of being transferred between the rolls 106, the slab 3b which has been pulled out is cooled by water spraying with the secondary cooling mechanism (not depicted in the figure), and the molten stainless steel 3 inside thereof is completely solidified. As a result, by forming a new slab 3b inside the casting mold 105, while pulling out the slab 3b from the casting mold 105 with the rolls 106, it is possible to form the slab 3b which is continuous over the entire extension direction of the rolls 106 from the casting mold 105. The slab 3b is fed out to the outside of the rolls 106 from the end section of the rolls 106, and the fed-out slab 3b is cut to form a slab-shaped stainless billet 3c. 
The casting rate at which the slab 3b is cast is controlled by adjusting the opening area of the inlet port 101e of the immersion nozzle 101d with the stopper 104. Furthermore, the inflow rate of the molten stainless steel 3 from the ladle 1 through the long nozzle 2 is adjusted such as to be equal to the outflow rate of the molten stainless steel 3 from the inlet port 101e. As a result, the surface 3a of the molten stainless steel 3 in the interior 101a of the tundish 101 is controlled such as to maintain a substantially constant position in the vertical direction in a state in which the depth of the molten stainless steel 3 remains close to the predetermined depth D. At this time, the spout 2a at the distal end of the long nozzle 2 is immersed in the molten stainless steel 3. Further, the casting state in which the vertical position of the surface 3a of the molten stainless steel 3 in the interior 101a is maintained substantially constant, while the spout 2a of the long nozzle 2 is immersed in the molten stainless steel 3 in the interior 101a of the tundish 101, as mentioned hereinabove, is called a stationary state.
Therefore, as long as the casting is performed in the stationary state, the molten stainless steel 3 flowing in from the long nozzle 2 does not hit the surface 3a, and therefore the nitrogen gas 4b is not dragged into the molten stainless steel 3 and the state of gentle contact of the molten stainless steel 3 with the surface 3a is maintained. As a result, although the nitrogen gas 4b is soluble in the molten stainless steel 3, the penetration thereof into the molten stainless steel 3 in the stationary state is suppressed.
Where no molten stainless steel 3 remains inside the ladle 1, the long nozzle 2 is detached and the ladle is replaced with another ladle 1 containing the molten stainless steel 3. The replacement ladle 1 is installed at the tundish 101, and the long nozzle 2 is connected. The casting operation is continuously performed also during the replacement of the ladle 1. As a result, the surface 3a of the molten stainless steel 3 in the interior 101a of the tundish 101 is lowered. The supply of the nitrogen gas 4b into the interior 101a of the tundish 101 is also continued during the replacement of the ladle 1. The interior of the tundish 101 at this time is in the state such as illustrated by process C in FIG. 2.
During the replacement of the ladle 1, the opening area of the inlet port 101e of the immersion nozzle 101d is adjusted with the stopper 104 and the flow rate of the molten stainless steel 3, that is, the casting rate, is controlled such that the surface 3a of the molten stainless steel 3 in the interior 101a of the tundish 101 does not fall below the spout 2a of the long nozzle 2. As a result of continuously casting the molten stainless steel 3 of the two ladles 1 in the above-described manner, the quality of a seam in the continuous slab 3b which is formed by the molten stainless steel 3 of the two ladles 1 can be maintained at a level identical to that of the slab 3b cast in the stationary state. In other words, as will be described hereinbelow, the change in quality of the slab 3b in the initial period of casting which occurs each time the ladle 1 is replaced can be reduced. As a result, the disposal or processing of the zone with changed quality becomes unnecessary and the cost can be reduced. Further, by continuously casting the molten stainless steel 3 of two ladles 1, it is possible to omit a step for storing the molten stainless steel 3 in the tundish 101 to start the casting, as compared with the case in which the casting is ended for each single ladle 1. As a result, the operation efficiency is increased, and therefore the cost can be reduced.
Further, where the casting advances and no molten stainless steel 3 remains in the replacement ladle 1, the surface 3a of the molten stainless steel 3 in the interior 101a of the tundish 101 falls below the spout 2a of the long nozzle 2, but since there is no new downward flow of the molten stainless steel 3, the surface is not disturbed by hits of falling steel and is in contact with the nitrogen gas 4b. Therefore, admixture of the nitrogen gas 4b due to dissolution thereof in the molten stainless steel 3 is reduced until the end of the casting at which time no molten stainless steel 3 remains in the tundish 101. The interior of the tundish 101 at this time is in a state such as illustrated by process D in FIG. 2.
Even before the spout 2a of the long nozzle 2 is immersed into the molten stainless steel 3 in the interior 101a of the tundish 101, the admixture of the air and argon gas 4a caused by dragging into the molten stainless steel 3 is reduced because the distance between the spout 2a and the surface 3a of the molten stainless steel 3 on the bottom or in the interior 101a of the main body 101b of the tundish 101 is small, and also because the surface 3a is hit by molten stainless steel 3 only for a limited amount of time until the spout 2a is immersed.
Where the nitrogen gas 4b is used as the seal gas when the surface 3a is hit by molten stainless steel 3, the nitrogen gas 4b can be excessively dissolved in the molten stainless steel 3 and this component can make the steel unsuitable as a product. In other words, it may be necessary to dispose of the entire stainless steel billet 3c which has been cast from the molten stainless steel 3 remaining in the interior 101a of the tundish 101 until the spout 2a of the long nozzle 2 is immersed. However, by using argon gas 4a, components of the molten stainless steel 3 within prescribed ranges can be obtained, without causing significant changes thereof.
Therefore, prescribed compositions can be obtained for the stainless steel billet 3c in the initial period of casting which is affected by a very small amount of air or argon gas 4a that has been admixed with the molten stainless steel 3 over a short period of time until the spout 2a of the long nozzle 2 is immersed into the molten stainless steel 3 in the interior 101a of the tundish 101. As a result, the stainless steel billet 3c can be used as a product once the surface thereof is ground in order to remove bubbles generated by the admixed argon gas 4a. Further, stainless steel billet 3c which has been cast over a period of time other than the abovementioned initial period of casting, this period of time making up the major part of the casting interval of time from the start to the end of casting, is not affected by the air or argon gas 4a admixed before the immersion of the spout 2a of the long nozzle 2. Furthermore, the admixture of the nitrogen gas 4b during casting is also reduced. Therefore, in a stainless steel billet 3c which is cast over the major part of the above-mentioned casting interval of time, increases in nitrogen content from the state after the secondary refining is suppressed and the occurrence of surface defects caused by bubbles created by the dissolution of a small amount of admixed nitrogen gas 4b in the molten stainless steel is greatly suppressed. Thus, the billet can be used, as is, as a product.
Therefore, as a result of using argon gas 4a as the seal gas before the casting is started, it is possible to suppress changes in the composition of the molten stainless steel 3 before the casting, and by the nitrogen gas 4b as the seal gas during casting and pouring the molten stainless steel 3 in the ladle 1 through the long nozzle 2 immersed by the spout 2a thereof into the molten stainless steel 3 in the tundish 101, it is possible to suppress the generation of bubbles in the stainless steel billet 3c after the casting and suppress increases in the nitrogen content from the state after the secondary refining.
Embodiment 2
In the continuous casting method according to Embodiment 2 of the invention, the TD powder 5 is sprayed to cover the surface 3a of the molten stainless steel 3 in the tundish 101 in the continuous casting method according to Embodiment 1.
In the continuous casting method according to Embodiment 2, the continuous casting device 100 is used similarly to that in Embodiment 1. Therefore, the explanation of the configuration of the continuous casting device 100 is herein omitted.
The operation of the continuous casting device 100 in Embodiment 2 will be explained with reference to FIG. 1 and FIG. 3.
In the continuous casting device 100, in the tundish 101 in which the ladle 1 is set and the long nozzle 2 is mounted on the ladle 1, the argon gas 4a is supplied from the gas supply nozzle 102, or the like, into the interior 101a and the long nozzle 2 to fill them with the argon gas 4a in a state in which the inlet port 101e of the immersion nozzle 101d is closed by the stopper 104, in the same manner as in Embodiment 1. Then, the molten stainless steel 3 is poured from the ladle 1 into the interior 101a of the tundish 101 through the long nozzle 2. In other words, the interior of the tundish 101 at this time is in the state illustrated by process A in FIG. 3.
Where the surface 3a of the molten stainless steel 3 rising because of the inflow of the molten stainless steel 3 becomes close to the spout 2a of the long nozzle 2 in the interior 101a of the tundish 101, the intensity at which the molten stainless steel 3 flowing down from the spout 2a hits the surface 3a decreases and the dragging of gas into the steel caused by the hitting is also reduced. Accordingly, the TD powder 5 is sprayed from the powder nozzle 103 toward the surface 3a of the molten stainless steel 3 in the interior 101a. The TD powder 5 is sprayed such as to cover the entire surface 3a of the molten stainless steel 3.
After the TD powder 5 has been sprayed, instead of the argon gas 4a the nitrogen gas 4b is injected from the gas supply nozzle 102. As a result, in the interior 101a of the tundish 101, the argon gas 4a is pushed to the outside, and the region between the TD powder 5 and the upper lid 101c of the tundish 101 is filled with the nitrogen gas 4b. 
The TD powder 5 which has been deposited as a layer on the surface 3a of the molten stainless steel 3 prevents the surface 3a of the molten stainless steel 3 from contact with the nitrogen gas 4b and suppresses the dissolution of the nitrogen gas 4b in the molten stainless steel 3.
Further, where the surface 3a of the molten stainless steel 3 rises and the depth thereof becomes the predetermined depth D in the interior 101a of the tundish 101 into which the molten stainless steel 3 is poured, the stopper 104 is lifted. As a result, the molten stainless steel 3 in the interior 101a flows into the casting mold 105 and the casting is started.
During casting, in the tundish 101, the amount of molten stainless steel 3 flowing out from the immersion nozzle 101d and the amount of molten stainless steel 3 flowing in through the long nozzle 2 are adjusted such that the depth of the molten stainless steel 3 in the interior 101a is maintained close to the predetermined depth D and the surface 3a assumes a substantially constant position, while the spout 2a of the long nozzle 2 remains immersed in the molten stainless steel 3 in the interior 101a of the tundish 101.
As a result, at the surface 3a of the molten stainless steel 3 covered by the TD powder 5, the deposited TD powder 5 is prevented from being disturbed by the molten stainless steel 3 which is poured in, whereby the surface 3a is prevented from being exposed and coming into direct contact with the nitrogen gas 4b. Therefore, the TD powder 5 continuously shields the surface 3a of the molten stainless steel 3 from the nitrogen gas 4b as long as the casting is performed in the stationary state.
At this time, the interior of the tundish 101 is in the state illustrated by process B in FIG. 3.
Further, where no molten stainless steel 3 remains in the ladle 1, the operations of detaching the long nozzle 2, replacing the ladle 1 with the other ladle 1 containing molten stainless steel 3, and connecting the long nozzle 2 to the replacement ladle 1 are sequentially performed while continuing the casting and maintaining the surface 3a of the molten stainless steel 3 in the interior 101a of the tundish 101 above the spout 2a of the long nozzle 2, in the same manner as in Embodiment 1. At this time, the interior of the tundish 101 is in the state illustrated by process C in FIG. 3.
Where the casting further advances and no molten stainless steel 3 remains in the replacement ladle 1, the surface 3a of the molten stainless steel 3 in the interior 101a of the tundish 101 is lowered below the spout 2a of the long nozzle 2. In this case, the TD powder 5 on the surface 3a of the molten stainless steel 3 fills the zone where the long nozzle 2 served as a through hole, and covers the entire surface 3a, and continuously prevents direct contact between the surface 3a of the molten stainless steel 3 and the nitrogen gas 4b. At this time, the interior of the tundish 101 is in the state illustrated by process D in FIG. 3.
Then, the molten stainless steel 3 in the interior 101a of the tundish 101 flows into the casting mold 105 in a state in which the entire surface 3a is covered with the TD powder 5 until the end of the casting, and the TD powder 5 continuously prevents contact between the surface 3a of the molten stainless steel 3 and the nitrogen gas 4b. 
Therefore, in the tundish 101, the molten stainless steel 3 in the interior 101a is covered with the TD powder 5, and the molten stainless steel 3 in the ladle 1 is poured into the molten stainless steel 3 in the interior 101a through the long nozzle 2 which is immersed by the spout 2a thereof into the molten stainless steel 3 in the interior 101a in the stationary state of the casting after the TD powder 5 has been sprayed and until the subsequent end of the casting. As a result, the molten stainless steel 3 does not come into direct contact with the nitrogen gas 4b, and the nitrogen gas 4b is practically unmixed with the molten stainless steel 3.
Further, in the stainless steel billet 3c which is cast in the initial period of casting that is affected by a very small amount of air or argon gas 4a mixed with the molten stainless steel 3 over a short period of time until the TD powder 5 is sprayed, the required composition can be obtained and the billet can be used as a product, if surface grinding is performed, in the same manner as in Embodiment 1. In addition, the stainless steel billet 3c cast over a period that takes most of the casting time from the start to the end of casting, this period being other than the abovementioned initial period of casting, is not affected by the air and argon gas 4a admixed before the TD powder 5 is sprayed, and also practically no nitrogen gas 4b is admixed during the casting. Therefore, in the stainless steel billet 3c which is cast over most of the abovementioned casting time, the nitrogen content practically does not increase from that after the secondary refining, and the occurrence of surface defects caused by bubbling of the admixed gas such as the nitrogen gas 4b is greatly suppressed, and the billet can be directly used as a product even in the case of a stainless steel of a low-nitrogen steel grade.
Therefore, changes in the composition of the molten stainless steel 3 before the casting which are caused by using argon gas 4a as a seal gas before the casting is started are suppressed. Furthermore, as a result of using nitrogen gas 4b as the seal gas, pouring the molten stainless steel 3 through the long nozzle 2 immersed by the spout 2a thereof into the molten stainless steel 3 in the tundish 101, and preventing the direct contact of the molten stainless steel 3 and the nitrogen gas 4b by covering the surface 3a of the molten stainless steel 3 in the tundish 101 with TD powder 5 during the casting, it is possible to suppress the occurrence of bubbles in the cast stainless steel billet 3c and also to suppress the increase in the nitrogen content from that after the second refining to a degree higher than that in Embodiment 1.
Further, other features and operations relating to the continuous casting device 100 using the continuous casting method according to Embodiment 2 of the invention are the same as in Embodiment 1, and the explanation thereof is, therefore, omitted.
EXAMPLES
Explained hereinbelow are examples in which stainless steel billets were cast by using the continuous casting methods according to Embodiments 1 and 2.
The evaluation of properties was performed with respect to Examples 1 to 4 in which slabs, which are stainless steel billets, were cast by using the continuous casting methods of Embodiments 1 and 2 with respect to SUS430, a ferritic single-phase stainless steel (chemical composition (19Cr-0.5Cu—Nb-LCN)), and SUS316L, and Comparative Examples 1 and 2 in which slabs of stainless steel SUS430 were cast by using a short nozzle as a pouring nozzle and argon gas or nitrogen gas as a seal gas. The detection results described hereinbelow were obtained by sampling from the slabs cast in the stationary state, excluding the initial period of casting, in the examples, and by sampling from the slabs cast within the same period as the sampling period of the examples from the beginning of casting in the comparative examples.
Table 1 shows the steel grades, types and supply flow rates of the seal gas, types of pouring nozzles, and whether or not a TD powder was used with respect to the examples and comparative examples. The short nozzle, as referred to in Table 1, has a length such that when the short nozzle is mounted instead of the long nozzle 2 on the ladle 1 in the configuration depicted in FIG. 1, the distal end at the lower side thereof is at an approximately the same height as the lower surface of the upper lid 101c of the tundish 101.










TABLE 1









Seal gas
Type of













Steel grade
Type
Supply flow rate
pouring nozzle
TD powder
















Example 1
SUS430
N2
100 Nm3/h
Long nozzle
Not used


Example 2
SUS430
N2
100 Nm3/h
Long nozzle
Used


Example 3
Ferritic single-
N2
100 Nm3/h
Long nozzle
Used



phase stainless



steel


Example 4
SUS316L
N2
100 Nm3/h
Long nozzle
Used


Comparative
SUS430
Ar
100 Nm3/h
Short nozzle
Not used


Example 1


Comparative
SUS430
N2
100 Nm3/h
Short nozzle
Not used


Example 2









In Example 1, a stainless steel slab of SUS430 was cast using the continuous casting method of Embodiment 1.
In Example 2, a stainless steel slab of SUS430 was cast using the continuous casting method of Embodiment 2.
In Example 3, a stainless steel slab of a ferritic single-phase stainless steel (chemical composition (19Cr-0.5Cu—Nb-LCN)), which is a low-nitrogen steel, was cast using the continuous casting method of Embodiment 2.
In Example 4, a stainless steel slab of SUS316L (austenitic low-nitrogen steel), which is a low-nitrogen steel, was cast using the continuous casting method of Embodiment 2.
In Comparative Example 1, a stainless steel slab of SUS430 was cast using the short nozzle instead of the long nozzle 2 and using an argon (Ar) gas instead of the nitrogen gas as the seal gas in the continuous casting method of Embodiment 1.
In Comparative Example 2, a stainless steel slab of SUS430 was cast using the short nozzle instead of the long nozzle 2 in the continuous casting method of Embodiment 1.
Table 2 shows the results relating to an N pickup, which is the pickup amount of nitrogen (N) in the slabs cast in Examples 1 to 4 and Comparative Examples 1 and 2. The N pickups measured in a plurality of slabs cast in Examples 1 to 4 and Comparative Examples 1 and 2 are summarized in Table 2. The N pickup is the increase in the nitrogen component contained in the cast slab with respect to the nitrogen component in the molten stainless steel 3 in the ladle 1 after the final adjustment of composition in the secondary refining process, this increase being the mass of the nitrogen component newly introduced in the molten stainless steel in the casting process. The N pickup is represented as a mass concentration in ppm units.







TABLE 2




















In Comparative Example 1, argon gas, rather than nitrogen gas, was used as the seal gas. As a result, the N pickup was within a range of 0 ppm to 20 ppm, and the average value thereof was as low as 8 ppm.
In Comparative Example 2, the short nozzle was used. As a result, the molten stainless steel poured into the tundish 101 hit the surface of the molten stainless steel in the tundish 101 and a large amount of the surrounding nitrogen gas was dragged in. As a consequence, the N pickup was 50 ppm, and the average value thereof also rose to 50 ppm.
In Example 1, the spout 2a of the long nozzle 2 was immersed in the stainless steel in the stationary state of casting. As a result, the molten stainless steel which was poured in was prevented from hitting the surface of the molten stainless steel in the tundish 101 and the nitrogen gas was in contact only with the smooth surface of the molten stainless steel. Therefore, the N pickup decreased to about the same level as in Comparative Example 1. More specifically, the N pickup in Example 1 was within a range of 0 ppm to 20 ppm, and the average value thereof was as low as 10 ppm.
In Examples 2 to 4, in addition to using the long nozzle 2, the molten stainless steel in the tundish 101 was shielded from the nitrogen gas by the TD powder in the stationary state of casting. For this reason, the N pickup was substantially lower than in Comparative Example 1 and Example 1. More specifically, the N pickup in Example 2 was within a range of −10 ppm to 0 ppm, and the average value thereof was very low and equal to −4 ppm. In other words, the content of nitrogen in the slab was lower than that in the molten stainless steel after the secondary refining. This is apparently because the TD powder had absorbed the nitrogen component contained in the molten stainless steel. The N pickup in Example 3 was also within a range of −10 ppm to 0 ppm, and the average value thereof was very low and equal to −9 ppm. Further, the N pickup in Example 4 was also within a range of −10 ppm to 0 ppm, and the average value thereof was very low and equal to −7 ppm.
Where argon gas, which is an inert gas, is contained in the molten stainless steel, it mostly remains as bubbles in the cast slab, without dissolving in the molten stainless steel, but nitrogen which is soluble in the molten stainless steel mostly dissolves in the molten stainless steel. Therefore, in the examples in which nitrogen gas was used as the seal gas, practically no nitrogen gas was detected as bubbles in the slab. In other words, in Examples 1 to 4 and Comparative Example 2, practically no bubbles were confirmed to be present in the slabs, whereas in Comparative Example 1, a large number of bubbles were confirmed to be present as surface defects in the slab.
For example, in FIG. 4, the number of bubbles with a diameter of 0.4 mm or more which appeared in the slabs was compared between Example 3 and Comparative Example 3 (steel grade: ferritic single-phase stainless steel [chemical composition: 19Cr-0.5Cu—Nb-LCN], seal gas: Ar, seal gas supply flow rate: 60 Nm3/h, pouring nozzle: short nozzle). Depicted in FIG. 4 are the numbers of bubbles per 10,000 mm2 (a 100 mm×100 mm region) at 6 measurement points obtained by dividing a region from the center to the end in the width direction of the slab surface into equal segments, the division being made from the center toward the end.
As depicted in FIG. 4, in Example 3, the number of bubbles was 0 over the entire region, and in Comparative Example 3, the bubbles were confirmed to be present over substantially the entire region, with 0 to 14 bubbles being confirmed at each measurement point.
Further, in FIG. 5, the number of bubbles with a diameter of 0.4 mm or more which appeared in the slabs was compared between Example 4 and Comparative Example 4 (steel grade: SUS316L (austenitic low-nitrogen steel), seal gas: Ar, seal gas supply flow rate: 60 Nm3/h, pouring nozzle: short nozzle). Depicted in FIG. 5 are the numbers of bubbles per 10,000 mm2 (a 100 mm×100 mm region) at 5 measurement points obtained by dividing a region from the center to the end in the width direction of the slab surface into equal segments, the division being made from the center toward the end.
As depicted in FIG. 5, in Example 4, the number of bubbles was 0 over the entire region, and in Comparative Example 4, the bubbles were confirmed to be present over substantially the entire region, with 5 to 35 bubbles being confirmed at each measurement point.
Incidentally, in FIG. 6, the number of bubbles with a diameter of 0.4 mm or more which appeared in the slab in the aforementioned Comparative Example 3 is compared with the number of bubbles with a diameter of 0.4 mm or more which appeared in the slab cast in the stationary state, with the exception of the initial period, when the long nozzle 2 was used instead of the short nozzle in Comparative Example 3. Depicted in FIG. 6 are the numbers of bubbles per 10,000 mm2 (a 100 mm×100 mm region) at 6 measurement points obtained by dividing a region from the center to the end in the width direction of the slab surface into equal segments, the division being made from the center toward the end.
As depicted in FIG. 6, when the long nozzle 2 was used, the number of bubbles decreased with respect to that in Comparative Example 3, but 3 to 7 bubbles were confirmed to be present over the entire region, and the bubble reduction effect such as demonstrated in Examples 1 to 4 could not be confirmed.
Therefore, in Example 1 using the continuous casting method of Embodiment 1, the N pickup in the casting process can be suppressed to about the same level as in Comparative Example 1, in which nitrogen gas was not used as the seal gas, while suppressing the bubble defects in the slab almost to zero. Therefore, the continuous casting method of Embodiment 1 can be effectively used instead of the conventional casting method using argon gas as the seal gas for the production of stainless steel with a low nitrogen content in which the content of nitrogen component is 400 ppm or less.
Further, in Examples 2 to 4 using the continuous casting method of Embodiment 2, while suppressing the bubble defects in the slab almost to zero, the N pickup in the casting process can be suppressed to below that in Comparative Example 1, in which nitrogen gas was not used as the seal gas, and can effectively be zero. Therefore, the continuous casting method of Embodiment 2 can be effectively used for the production of stainless steels of a low-nitrogen steel grade and this method demonstrates an effect of reducing the bubble defects.
Therefore, by using nitrogen gas as the seal gas in the stationary state of casting, it is possible to suppress the occurrence of bubbles in the cast stainless steel billet. Further, by using the long nozzle 2 immersed by the spout 2a thereof into the molten stainless steel in the tundish 101 in the stationary state of casting, it is possible to reduce the N pickup. In addition, by covering the surface of the molten stainless steel in the tundish 101 with TD powder in the stationary state of casting, it is possible to reduce the N pickup close to 0.
In addition to the abovementioned steel grades, the present invention was also applied to SUS409L, SUS444, SUS445J1, and SUS304L, and the possibility of obtaining the N pickup reduction effect and bubble reduction effect such as demonstrated in Examples 1 to 4 was confirmed.
Further, the continuous casting methods according to Embodiments 1 and 2 were applied to the production of stainless steel, but they may be also applied to the production of other metals.
The control in the tundish 101 in the continuous casting methods according to Embodiments 1 and 2 is applied to continuous casting, but it may be also applied to other casting methods.
REFERENCE SYMBOLS
1 ladle, 2 long nozzle, 2a spout, 3 molten stainless steel (molten metal), 3c stainless steel billet (solid metal), 4 seal gas, 4a argon gas (inert gas), 4b nitrogen gas, 5 tundish powder, 100 continuous casting device, 101 tundish, 105 casting mold.

## Claims

1. A continuous casting method for casting a solid metal by pouring a molten metal in a ladle into a tundish disposed therebelow and continuously pouring the molten metal in the tundish into a casting mold, the continuous casting method comprising:
a long nozzle installation step for providing in the ladle a long nozzle extending into the tundish as a pouring nozzle for pouring into the tundish the molten metal in the ladle;
a pouring step for pouring the molten metal into the tundish through the long nozzle and immersing a spout of the long nozzle into the molten metal in the tundish;
a first seal gas supply step for supplying an inert gas as a seal gas around the molten metal in the tundish in the pouring step;
a casting step for pouring the molten metal into the tundish through the long nozzle, while immersing the spout of the long nozzle into the molten metal in the tundish, and pouring into the casting mold the molten metal in the tundish;
a second seal gas supply step for supplying a nitrogen gas, instead of the inert gas, as a seal gas around the molten metal in the tundish in the casting step; and
a spraying step for spraying a tundish powder so as to cover a surface of the molten metal in the tundish between the pouring step and the casting step and prior to the second seal gas supply step.

2. The continuous casting method of claim 1, wherein the inert gas of the first seal gas supply step is argon.

3. The continuous casting method of claim 2, wherein in the casting step, the molten metal in a plurality of ladles is continuously cast, while sequentially replacing the plurality of the ladles, and the ladles are replaced while immersing the spout of the long nozzle into the molten metal in the tundish.

4. The continuous casting method of claim 2, wherein in the casting step the spout of the long nozzle is inserted to a depth of 100 mm to 150 mm into the molten metal in the tundish.

5. The continuous casting method of claim 2, wherein the solid metal which is to be cast is a stainless steel with a concentration of contained nitrogen of 400 ppm or less.

6. The continuous casting method of claim 1, wherein in the casting step, the molten metal in a plurality of ladles is continuously cast, while sequentially replacing the plurality of the ladles, and the ladles are replaced while immersing the spout of the long nozzle into the molten metal in the tundish.

7. The continuous casting method of claim 6, wherein in the casting step the spout of the long nozzle is inserted to a depth of 100 mm to 150 mm into the molten metal in the tundish.

8. The continuous casting method of claim 6, wherein the solid metal which is to be cast is a stainless steel with a concentration of contained nitrogen of 400 ppm or less.

9. The continuous casting method claim 1, wherein in the casting step the spout of the long nozzle is inserted to a depth of 100 mm to 150 mm into the molten metal in the tundish.

10. The continuous casting method of claim 9, wherein the solid metal which is to be cast is a stainless steel with a concentration of contained nitrogen of 400 ppm or less.

11. The continuous casting method of claim 1, wherein the solid metal which is to be cast is a stainless steel with a concentration of contained nitrogen of 400 ppm or less.