TWO WHEEL MELT OVERFLOW PROCESS AND APPARATUS

Abstract: A unitary or laminated film or sheet of finely controlled thickness is produced by utilizing spaced, first and second parallel rolls rotating in opposite directions to form a kissing zone between the rolls. The method comprises: contacting a molten material (12) overflowing from a molten material receptacle (10) onto the rotating first roll (20) and cooling thereon to form an at least partially solidified first film, the first roll rotating around a lower circumferential axis (22) than the second roll; positioning the second roll (28) either 1) completely above the molten material in the receptacle or 2) partially immersed therein, the partially immersed second roll forming and cooling a second, at least partially solidified film thereon; pressing the first film on the first roll with either 1) the second roll surface or 2) the second film on the second roll, in the kissing zone (36) to form a substantially solidified film product; and removing the solidified film product.

Description: TITLE: TWO WHEEL MELT OVERFLOW PROCESS AND APPARATUS Technical Field This invention relates to a process and accompanyin apparatus for producing film or sheet of finely controlle thickness and microstructure, and more particularly relate to a process and apparatus for producing a wide variety o such materials directly from a molten material, such a metals, polymers and ceramics. The process initially move the surface of a cooling, rotating roll past a region o contact with the molten material to form a rapidl solidifying layer of the material thereon, then cools th layer and passes it into a kissing region where it contact a second, oppositely rotating upper roll which may contain chilled, solidifying layer. The resultant pressing forms unitary or fused product film or sheet which is removed fro the apparatus. Background Art The prior art discloses a variety of methods an apparatus which can produce solid material directly from source of molten material. Many of these prior art system are for the fabrication of metal products and use some typ of fixed, rigid, noncontrollable forming orifice t stabilize the dimensions of the product. Additionally, th prior art utilizes a wide variety of two wheel systems tha form a kissing zone as they rotate in opposite directions. With respect to two wheel systems which form a finishe product, the Bessemer Patent, 49,053, discloses the basi concept behind a majority of the systems that are currentl utilized. Bessemer manufactures sheets, plates and the lik directly from fluid malleable iron or steel by utilizing pair of rolls, with their axes in a horizontal, paralle position to form a kissing zone. The molten metal is poure into this kissing zone, or thin space between the rolls, which are constantly moving during the flow of the meta between them. The cool surfaces of the rolls rapidl solidify the metal and the pressure of the rolls forms metal product. However, as one would expect from such a early setup, there are many difficulties present in th « system of Bessemer, particularly with respect to thei utilization of a fixed sized crucible. U.S. Patent No. 1,756,196 to Hopkins, et al. disclose a method of making metal sheets wherein the method teach solidifying on a first roll and then rolling with a seco roll to produce a finished product. U.S. Patent No. 2,171,132 to Simons discloses a proces of producing film products from molten materials in which pair of relatively cool, rotating cylindrical members eac have a portion of their surface submerged in the heate material. A suction process is utilized to suck the molte material in between the grooves on the wheel's oute surfaces. U.S. Patent No. 993,904 to Strange discloses forerunner of a melt overflow system which is related t that used in the invention. U.S. Patent No. 4,224,978 to Klein discloses forming metal strip product in a continuous casting proces featuring two rolls and a kissing zone in which aluminum i discharged between the rolls by means of a nozzle having particular structure; the process and apparatus are sub stantially different than those of the present invention. U.S. Patent No. 4,274,471 to Minoura, et al. disclose a process for the continuous casting of metals into sheets wires, bars and the like. The process comprises a rol system with the main roll cooled from an inner portion and plurality of sub-rolls, the sub-rolls being provided alon the outer periphery surface of the main roll by holding given gap against the main roll, supplying a molten meta into the gap formed by the main roll and the sub-rolls whil rotating the main roll and the sub-rolls mutually in direction carrying with the molten metal, allowing th molten metal to solidify when the molten metal passe through the gap between the main roll and the sub-rolls an taking out the solidified metal continuously from the rol system. U.S. Patent No. 4,518,029 to Shibuya, et al. disclose a double roll type method and apparatus for producing a thi metallic sheet by pouring a molten metal of a desire composition into a kissing region between two cooling roll rotating in opposite directions, and rapidly cooling an solidifying the molten metal while it passes through th kissing region. U. S. Patent No. 4,705,905 discloses a textured surfac which is suitable for usage as a cooling roll. In page 45, Fig. 3 of the rticle, "Latest Development and Operating Results of the High Speed Strip Coatin Machine at SMS Schloemann-Siemag AG, W. Germany" b Friedrich-Marten et al., a two wheel strip caster is se forth. It is known to utilize resiliently mounted springs o rotating wheels to control the resulting pressure exerte onto a sheet or film. Accordingly, it 'is an object of the present inventio to provide a process and accompanying apparatus which ca produce a uniform, high quality film or sheet product carefully controlled thinness, smoothness and microstructu by freezing material on one or both rolls followed b pressing the rolls to form either a unitary or a fuse product. It is another object of the invention to make a wid variety of film and sheet products by utilizing a single flexible process and accompanying apparatus setup which ca monitor the roll pressure in a roll kissing zone, be free o the problems involving metal orifices, have excellen control of the frozen film thickness and microstructure an be suitable for the utilization of textured rolls to make product of desired characteristics. Upon further study of the specification and appende claims, further objects and advantages of this inventio will become apparent to those skilled in the art. Brief Disclosure Of Invention In a method aspect, this invention relates to a metho for the production of a film or sheet of finely controlle thickness and microstructure from a molten material whic utilizes spaced, first and second parallel rolls rotating i opposite directions to form a kissing zone between th rolls, the method comprising; contacting a molten film o predetermined thickness overflowing from a molten materia receptacle onto the first roll and cooling thereon to for an at least partially solidified first film, the first rol rotating around a lower circumferential axis than the secon roll; positioning the second roll either 1) completely abov the molten material and the receptacle or 2) partiall immersed therein, the partially immersed second roll formin and cooling a second, at least partially solidified fil thereon; pressing the first film on the first roll wit either 1) the second roll surface or 2) the second film o the second roll, in the kissing zone to form a substan tially solidified film product; removing the solidified fil product. In an apparatus aspect the invention relates to a apparatus for producing a film or sheet of finely controlle thickness and microstructure from a molten material, th apparatus comprising: (a) a receptacle for containing a poo of molten material, the receptacle including a wall portio having an upper generally horizontal edge relatively lowe than the top of said receptacle and over which molte material may be overflowed; (b) a movably mounted, hea extracting, generally cylindrical first roll spaced a fixe distance from the edge so as to be contacted by th overflowing molten material at the level of the uppe surface of the molten material; (c) a movably mounted generally cylindrical second roll adaptable for rotating i the opposite direction to the first roll along an axi parallel thereto but positioned above the axis of the firs roll, whereby the distance between the outer surfaces of t first and second rolls form a kissing zone and at least o roll has means for controlling the applied pressure to film or sheet within the kissing zone; (d) means f rotating the first and second roll in opposite direction substantially the same surface speed to each other. Brief Description Of Drawings Figs. 1-3 are simplified diagrams of three respecti embodiments of the invention, each having a differe position of the upper rotating roll in relationship to t surface of the molten material present in the tundish. Fig. 4 is a close-up section of molten and froz material flowing into the kissing zone between the t rolls. Fig. 5 sets forth a cross sectional view of a fi product produced by at least partially freezing material each roll surface and fusing the two films together. Fig. 6 is a cross sectional side view of a tundi illustrating the inner molten material containing structur Fig. 7 describes a roll suitable for molten materi contacting that contains a plurality of patterns on t outer contacting surface. In describing the preferred embodiment which illustrated in the drawings, specific terminology will resorted to for the sake of clarity. However, it is n intended that the invention be limited to the specific term so selected and it is to be understood that each specifi term includes all technical equivalents which operate in similar manner to accomplish a similar purpose. Detailed Description Fig. 1 illustrates a receptacle, or tundish 10 which i heated in a conventional manner and contains a pool o molten material 12 which can be supplied by a variety o methods, such as from furnace 14. However, instead of th walls of receptacle 10 everywhere extending above the uppe surface 16 of the molten material 12, a portion of th receptacle wall is absent in the region above a generall horizontal edge 18 which is formed at the top of a portio of the wall of the receptacle 10. A particularly suitabl receptacle for depositing thin, molten substrates o rotating surfaces and the like is set forth in copendin application Serial No. 819,474, filed January 16, 1986, th disclosure of which is Incorporated by Reference. Edge 18 is lower than the top of the other walls of th receptacle so that the molten material level may be rais sufficiently to overflow over the edge 18 and onto peripheral surface of a lower cylindrical heat extractin substrate, i.e., a rotating wheel or roll 20 which i rotated about its pivot axis 22. The cooling roll 20 i spaced a fixed distance from the edge 18 and is preferabl vertically and horizontally adjustable relative to the ed during periods of non apparatus operation so as to perm the spacing from the edge to be controllably varied and al to permit adjustment of the angular position about the ro 20 at which the molten material melt or film 24 contacts t surface 26 of roll 20. A conventional means such as an electrical motor an connecting drive means (both not shown) are provided fo driving the surface 26 of the roll 20 past the region of it contact with the melt 16. In most applications it is drive at a surface speed in the range of 0.1 to 15.0 meters/sec. Above the first roll 20 is positioned a second rotatin substrate, i.e., roll 28, the respective axes of rotation o the rolls being parallel while their rotational motion is i opposite direction. Upper roll 28 is attached to resilient spring means 30 positioned on an immovabl substrate 32. This enables the resulting pressure in th "kissing zone", i.e. the area wherein the two roll surface 26 and 34 are positioned nearest to one another and throug which the molten and partially solidified film or film which must be pressed to form a product film or sheet pas through, to be carefully maintained within a predetermine range. Although not essential, it is greatly preferred to hav the upper roll spring pressure controlled and a hydrauli system or the like can also be used in place of a sprin system. In the embodiment set forth in Figure 1, upper rol surface 34 does not come in contact with a molten meta chilled film or melt frozen on the lower roll 20 until th melt enters into kissing region 36, wherein the upper rol presses the melt with a desired controlled pressure t produce a smooth, high quality film product of desire thickness, smoothness and microstructure. Additionally roll 20 is cooled in a manner known to one skilled in th art. By utilization of a resilient spring mount on uppe roll 28, the kissing pressure is controlled so the proces can produce a smooth, consistent, high quality and, i desired, very thin film product. The films and fiber produced can be very thin, in part because melt overflo technology permits very thin, high quality products to b formed. As can be seen in Figs. 2 and 3 an advantage of th invention is that small variations in the basic apparatu setup enable a wide variety and great amount of flexibilit in the types of products which can be produced. Bot embodiments feature a repositioning of the upper roll 28 i relationship to the surface 16 of the bath of molte material. In Fig. 2, as well as Figs. 1 and 3, the mel overflow system produces a thin melt film 38 which in thi particular embodiment is deposited almost in the immediat kissing region 36 between wheels 20 and 28. Upper wheel 2 is positioned so that the upper wheel surface 34 almo touches the surface 16 of the molten material in t receptacle 10. Fig.! 3 retains the basic geometric relationship of the two rolls, i.e., the axis of the spri controlled roll is above the melt deposited cooling roll 2 However, roll 28 is now immersed in the pool of molt metal, thus both lower and upper rolls form films 38 and 4 respectively, of chilled material on their respecti surfaces, which are pressed into a fused film 24. It shou be noted that although upper roll 28 is cooled in Fig. 3 as to produce a frozen film on its surface, in oth embodiments, such as that of Fig. 1, the upper roll does n have to be chilled and thus functions as a cold formi roll. Thus, in the broadest embodiment, the invention c utilize either one or two cooling surfaces to form a varie of resultant products; it is preferred to utilize bo wheels as chilling surfaces. Also, the precise degree chilling on each wheel does not have to be constant,but c instead by varied so as to change the characteristics of t product to be formed. As one skilled in the art can easily understand, t wide variety of apparatus embodiments which can be obtain from variations in the respective axial positions of the t rolls, the differing cooling rates and diameters each rol can have, and also the differing dimensions of the kissi zone can all be made by minor changes which enable t production of significantly different products. Thus thi relatively simple system gives a great deal of flexibilit regarding type of product formed in its operation. Also, certain embodiments of the invention enable the material t pass into the kissing region either in molten form, or as a at least partially frozen film with either one or both roll being cooling agents. In Fig. 4 is set forth a close-up of an embodimen similar to Figs. 1 and 2, wherein it is seen that the mel overflow contacts the lower cooling substrate 26 to form solid film 38; also, some molten material enters into th kissing region 36 wherein it is pressed to form a fil product 24. The particular dimensions of kissing region 36 must b carefully controlled in order to produce a desired product as one skilled in the art will quickly realize. Fo example, unless the spacing in this region is just the su of the thickness of the two solidified layers frozen on eac roll, the resultant product film will feature centerlin segregation. That is, e.g., if the rolls are too far apart a molten material, i.e. liquid, will be present in betwee the two solidified films and the resulting section of th product will possess a different alloy composition than tha exhibited by the solid compositions. Such a resultin product thus lacks the consistent homogeneity required in product film, since it cannot form a fused film in whic fusion zones that have a substantially homogeneo composition are found along the line where the two chill segments fuse together.' Fig. 5 sets forth a simplified outline of a cro section of a product film formed from an operation such seen in Figs. 3 or 4. In these embodiments, the proce forms at least partially chilled films on each roll surfa and then fuses the two films together in the kissing zone form the product 100. The cross sectional view indicat that in areas 102 and 104, which correspond to t completely chilled portions of the films formed on the upp and lower rolls, respectively, dendrites are seen to ha formed. Thus, the product 100 exhibits a cross section which rigid, solidified grain structures are found on bo surfaces, while the middle section 106 lacks such a gra structure and instead is a fusion zone which exhibits substantially homogeneous composition throughout. Also, t various thicknesses of sections 102, 104 and 106 can carefully controlled by controlling the thickness of mel which is frozen and which is kept in molten form on eac roll before fusion together in the kissing zone. Thus, a one skilled in the art can readily understand, the product formed by the process of the invention can be very carefull fabricated and their structure and properties very carefull controlled. A particular advantage of melt overflow is the abilit to very accurately control the depth of metal deposited o frozen on a substrate. This is because the molten metal i kept in a large receptacle whose height can be more easil and carefully controlled than can the smaller kissing zone associated with the Bessemer process, in which it is ver difficult to constantly control the resulting height o metal in the kissing zone. Additionally, orifice containin systems have a similar problem maintaining constant flo through a small orifice, due to such problems as meta freezing. Thus, constant molten material flow is much mor difficult to control than in the melt overflow system. Fig. 6 sets forth a cross section of a molten materia containing receptacle, i.e. tundish, 50 particularl suitable for usage in the invention. One can see that b carefully forming volume variations inside the tundish wit changing heights 52, 54 and 56 the amount of materia overflowing the lower edge 58 can be carefully and easil controlled by the skilled operator. Fig. 7 illustrates a surface containing patterns whic may be ridges, contours, or the like and can be formed o either one or both of the roll surfaces used in th invention. It is preferred to so texture only the first o bottom roll, although the second roll can also be s constructed. The circular, concentric ridges are positione around a cylinder and form a roll suitable for use i pressing and if desired, cooling the formed product. B utilizing such indentations in one or both of the rotati rolls a wide variety of products can be made. Also, t grooves enable films of greater thickness to be utilized the fabricated products, which may be desirable in certa instances. In any event, one skilled in the art can utili a wide variety of different ridge, grooves, helic structures and the like texturing to produce a desir product, in similar fashion as in Serial No. 819,474. The characteristics of the products produced by t invention is also influenced by other parameters as well by the particular method of fabrication. For example, it preferred to closely control the level in the molt material containing receptacle by utilization of a plunge such as those which are known in the art. Also, t pressure head or hydrostatic pressure of the overflow molten material is dependent upon the height of the surfa of the molten material above the overflow edge. Oth variables include the position of each rotating roll, described earlier, the particular molten material utiliz to form a product, and the like. While certain preferred embodiments of the prese invention have been disclosed in detail, it is to understood that various modifications may be adopted withou departing from the spirit of the invention or scope of th following claims.

Claims: CLAIMS 1. A method for the production of a film or sheet o finely controlled thickness and microstructure from a molte material which utilizes spaced, first and second paralle rolls rotating in opposite directions to form a kissing zon between the rolls, the method comprising: contacting a molten material overflowing from molten material receptacle onto the rotating first roll an cooling thereon to form an at least partially solidifie first film of predetermined thickness; rotating the second roll around a highe circumferential axis than the first roll; pressing the first film on the first roll with th second roll in the kissing zone to form a substantiall solidified film product; removing the solidified film product. 2. A process according to claim 1 wherein the seco roll applies a controlled kissing pressure adapted substantially range within a predetermined value. 3. A process according to claim 1, further comprisi positioning the second roll completely above the molte material, the second roll surface being substantially fre of molten or solidified molten material as it approaches th kissing zone. 4. A process according to claim 1, further comprisin partially immersing the second roll in the molten materia in the receptacle and forming and cooling a second, at leas partially solidified film thereon; the formed film on th second roll then pressing the first film on the first rol to form a fused film product. 5. A process according to claim 4 wherein the kissin region between the cooling rolls is of a magnitude enablin the formed film product to have a fusion zone exhibiting substantially homogeneous composition. 6. A process according to claim 1 wherein the meta entering into the kissing zone is at least partially molten 7. A process according to claim 1 wherein at leas one of the first and second rolls utilizes a plurality o patterns on the roll surface which are simultaneousl migrated laterally of the direction of movement to produce desired, thicker film. 8. A process according to claim 7 wherein only th first roll utilizes a plurality of patterns to contact th film. 9. A process according to claim 1 wherein the surfac speed of the rolls is about 0.1 to 15.0 meters/sec. 10. A film product made according to the process o claim 3. 11. A film product made according to the process o claim 4 or 5. 12. Apparatus for producing a film or sheet of finel controlled thickness and microstructure from a molte material, the apparatus comprising: (a) a receptacle for containing a pool of molten material, the receptacle including a wall portion having an upper generally horizontal edge relatively lower than the top of said receptacle and over which molten material may be overflowed; (b) a movably mounted, heat extracting, substantially cylindrical first roll spaced a fixed distance from the edge so as to be contacted by the overflowing molten material at the level of the upper surface of the molten material; (c) a movably mounted, generally cylindrical second roll adaptable for rotating in the opposite direction to the first roll along an axis parallel thereto but positioned above the axis of the first roll, whereby the distance between the outer surfaces of the first and second rolls form a kissing zone and at least one roll has means for controlling the applied pressure to a film or sheet within the kissing zone; and (d) means for rotating the first and second roll in opposite rotation at substantially the same surface speed to each other. 13. Apparatus according to claim 12 wherein the firs roll is vertically and horizontally adjustable relative t the edge during non operation. 14. Apparatus according to claim 12 wherein the secon roll is vertically and horizontally adjustable to the uppe surface of the molten material and/or the first roll. 15. Apparatus according to claim 12 wherein at leas one of the first or ≤econd rolls features a plurality o protruding patterns. 16. Apparatus according to claim 12 wherein th receptacle for containing the pool of molten materia further comprises a plunger adaptable for controlling th level of molten material therein and flowing over the edge. 17. Apparatus according to claim 12 wherein th controlled pressure in the kissing zone is regulated by resilient spring mounted on the second roll. 18. Apparatus according to claim 12 wherein the firs and second rolls are cooling rolls. 19. Apparatus according to claim 12 wherein the roll rotate at about 0.1 to 15.0 meters/sec.

Inventors: HACKMAN LLOYD E, HACKMAN, LLOYD, E.
Applicants: RIBBON TECHNOLOGY CORP, RIBBON TECHNOLOGY CORPORATION
Application year: 1989
Main classification: B22D11
IPC codes: B22D11