Method for continuous casting

Abstract: Disclosed are a method and apparatus for continuous casting capable of casting alloys of different composition concurrently in two kinds or more. The continuous casting of the invention comprises using a multistrand type continuous casting apparatus, disposing a plurality of tundishes (2A,2B) provided with each number of nozzles dividing the number of strands (7B,8B) into two or more at an arbitrary ratio, transfusing each molten metal into the tundishes from separate ladles corresponding to each tundish and feeding to each water-cooled mold (1A,1B,1C,1D) through the nozzles to continuous casting. The mode of dividing the strand number is selected so as to improve a casting yield of expensive alloys and enhance a rate of operation of the apparatus according to a time cycle required for the preparation of molten metal, an amount of charge and a casting speed of each molten metal.

Description: The invention relates to a method for casting alloys, comprising: (a) supplying a first molten metal and a second molten metal to a plurality of ladles; (b) feeding said first molten metal to a first tundish and said second molten metal to a second tundish; (c) continuously and concurrently casting said first and second molten metals through water-cooled molds by feeding said first molten metal from said first tundish and said second molten metal from said second tundish to said water-cooled molds. Furthermore, the invention relates to a method for casting alloys, comprising: (a) supplying a first, second and third molten metal to a plurality of ladles; (b) feeding said first molten metal to a first and second tundish; (c) continuously and concurrently casting said first molten metal through water-cooled molds. More generally the invention relates to improvement of a method for casting continuously a metal or special steel in particular. In a manufacture of special steel, to say nothing of ordinary steel, a molten steel is cast through continuous casting into cast pieces in the majority of cases. Needless to say, since segregation to arise longitudinally of the cast pieces is nothing serious substantially,the continuous casting is really advantageous in securing a high yield of a rolled product to castings. That is, portions of a strand obtained continuously which must be cut off are only some of longitudinal end portions. Accordingly, in the case of steels of a kind, it is advantageous that the strand is cast as jointedly as possible to one strand, which is so called continuous-continuous casting. A continuous casting apparatus used industrially employs multistrand system wherein a water-cooled mold for providing a strand of casting material is provided in plural pieces, and a molten steel transfused from a ladle to a tundish is cast concurrently by the water-cooled molds. The reason is that an efficiency of the continuous casting is enhanced thereby, time from start to end of casting of each ladle can be shortened, and a problem to arise from a temperature drop of the molten metal may be minimized. A proper number of strands varies according to factors such as steel kind, strand sectional size, drawing speed and so forth, coming in 2 to 8 pieces, however, a typical apparatus standardizes 4 strands. In regard to a steel kind for mass production, such multistrand system continuous casting apparatus may preferably be used for casting making the most of an advantage of the continuous casting, and there may be a case where, for example, a molten steel of 80-ton ladle is cast in 4 charges on a 4-strand apparatus, however, a molten steel of 80 tons and one charge only may be cast for special steel with a smoll-lot demand. A deterioration in yield is unavoidable from casting on the 4-strand apparatus. A small lot of a special steel contains generally an expensive alloy component so much in most cases, therefore it is desirable that a high yield be secured for satisfying the requirements of energy saving and resource saving and also for decreasing the costs. On the other hand, the continuous casting apparatus requires a great deal of equipment investment, therefore, it is natural that a constructed apparatus be used preferably at a high rate of operation. A recent large-scale steel foundry employs various types of smelting apparatuses such as convertor, arc furnace, AOD furnace, LF furnace and the like according to a kind of steel to manufacture, and still these are prepared more than one to operation in most cases. Under such circumstances, it is preferable that an operation to harmonize a yield of steel with a rate of operation of the apparatus be realized. Furthermore, methods of the first and second types mentioned in the beginning are known from US-A-3 344 847. Although the technology disclosed in this document offers multi-strand continuous casting, this document, however, does not disclose a solution for concurrent casting of different steels. Finally, "PATENT ABSTRACT OF JAPAN", vol. 10, no. 381 (M-547) describes continuous casting of different kinds of steel into one strand, and is characterized by quick change of tundishes and by an improved manner of using connecting metals at the border of the steels. However, this document does not mention concurrent continuous casting of different steels, which is the object of the present invention. The object of this invention is to provide a method for continuous casting, wherein cast pieces can be manufactured concurrently by sharing strands with reference to alloys of not less than two kinds which are different in composition, of stainless steel and general steel, for example, or by dividing four strands into 2 strands + 2 strands or 3 strands + 1 strand, when necessary in a multistrand type continuous casting apparatus in normal service, and also the four strands can be used collectively, needless to say, when not so necessary. According to a first aspect of the invention, there is provided a method of the first type mentioned in the beginning, which is characterized by (1) said first and second molten metals having different compositions; and (2) continuously and concurrently casting said first and second molten metals through four water-cooled molds by feeding said first molten metal from said first tundish to at least two of said four water-cooled molds and feeding said second molten metal from said second tundish to at least one of said four water-cooled molds. According to a second aspect of the invention, there is provided a method of the second type mentioned in the beginning, which is characterized by: (1) said first, second and third molten metals having different compositions; (2) continuously and concurrently casting said first molten metal through four water-cooled molds by feeding said first molten metal from said first tundish to at least two of said four water-cooled molds; (3) feeding said second molten metal to said first tundish after said first molten metal; (4) continuously casting said second molten metal by feeding said second molten metal from said first tundish to at least two of said four water-cooled molds while concurrently and continuously casting said first molten metal by feeding said first molten metal from said second tundish to at least one of said four water-cooled molds; (5) supplying said third molten metal to said second tundish after said first molten metal; (6) continuously casting said third molten metal by feeding said third molten metal from said second tundish to at least one of said four water-cooled molds while concurrently casting said second molten metal by feeding said second molten metal from said first tundish to at least two of said four water-cooled molds. Thus the present invention provides a continuous casting method capable of casting alloys of different composition concurrently in two kinds or more, comprising using a multistrand type continuous casting apparatus with a plurality of water-cooled molds arrayed theron, disposing a plurality of tundishes provided with each number of nozzles dividing the number of strands into two or more at an arbitrary ratio, transfusing each molten metal into the tundishes from separate ladles corresponding to each tundish and feeding to each water-cooled mold through the nozzles to continuous casting, wherein a mode of dividing the strand number is selected so as to improve a casting yield of expensive alloys and enhance a rate of operation of the apparatus according to a time cycle required for the preparation of molten metal, an amount of charge and a casting speed of each molten metal. The aforementioned methods can be put into practice by a continuous casting apparatus capable of casting alloys of different composition concurrently in two kinds or more, comprising two or more tundishes which are supported on each tundish support means with reference to a multistrand type continuous casting apparatus with a plurality of water-cooled molds arrayed thereon, molten metal ladles on ladle support means correspondingly to each tundish, wherein the plurality of water-cooled molds can be shared into two or more at an arbitrary ratio by the two or more tundishes shifting closely each other on a row of the water-cooled molds, the ladle support means comprises traveling cranes with girders placed in the direction across the row of the water-cooled molds reciprocating along the row of the water-cooled molds, and transfer trucks placed on the girders and reciprocating toward the girders with the ladles theron. DRAWINGS Fig. 1 is a conceptional explanatory drawing exemplifying a continuous casting pattern according to a method of this invention in relation to smelting. Fig. 2 to Fig. 8 are drawings representing a structure of a continuous casting apparatus for realizing the method of this invention. Fig. 2 is a schematic plan view; Fig. 3 is a side view in the direction indicated by an arrow "1" in Fig. 2; Fig. 4 is a side view in the direction indicated by an arrow "2" in Fig. 2. Fig. 5 and Fig. 6 are side views similar to Fig. 4, indicating various ladle change systems for separate examples each. Fig. 7 and Fig. 8 are a plan view and a side view showing a tundish and its support means, respectively. DETAILED EXPLANATION OF PREFERRED EMBODIMENTS In exemplifying a manufacture and continuous casting of special steel by an arc furnace, while varying more or less according to a kind of steel, the time required for smelting is generally 80 minutes or so, however, a continuous casting speed varies greatly according to a quality to require, and thus in the case of materials for which segregation is never desirable like, for example, bearing steel, the speed must be controlled half of a casting speed of ordinary steel and stainless steel other than that. Now, taken up here is such case wherein a continuous casting is carried out from melting an ordinary steel "A" in 4 charges, an ordinary steel "B" in 4 charges, a stainless steel SUS in 4 charges and a bearing steel "C" in 1 charge on 2 units of arc furnaces of a capacity and a 4-strand type continuous casting apparatus under the condition that the ordinary steel and the stainless steel for which a drawing speed can be increased are capable of having 1 charge of molten steel processed through continuous casting half of the time required for smelting, but the bearing steel for which drawing must be retarded requires the time for casting so long as smelting when subjected to continuous casting for period of time double thereof, i.e., in 4 strands. In view of the circumstances that the stainless steel SUS may exert an influence on the next charge with remaining molten steel in the arc furnace from its containing nickel and chromium so much and that an exclusive ancillary equipment is required for the arc furnace from the difference in melting process to the ordinary steel, a melting of the stainless steel must be limited to a specified one unit of arc furnace. On the other hand, from a side of continuous casting, it is desirable that the same kind of steel be cast jointedly in succession so as to keep opposite ends of the strand from being cut off in each occasion. Fig. 1 indicates, in comparison, sequences of the case where the same molten steel is cast into 4 strands all and the case where subjected to continuous casting by 2 strands and 2 strands (1St + 2St/3St + 4St) under the condition given above. As will be apparent from Fig. 1, a time half of smelting is enough for casting an ordinary steel in 4 strands, however, in case a stainless steel is cast jointedly in succession, a casting speed must be decreased in harmony with an efficiency of the one unit of arc furnace, that is, taking time so long as smelting to a continuous casting, and hence, three charges (charges 4, 6, 8) of the ordinary steels "A" and "B" melted in the furnace #2 then cannot be subjected to the continuous casting on the equipment. On the other hand, when subjecting two strands each to a continuous casting as (1St + 2St) for the stainless steel and (3St + 4St) for the ordinary steel, one charge (11) must be removed from the continuous casting while an adjustment for starting the four strands concurrently is mode before casting the bearing steel for which all the four strands become necessary, however, as compared with the case where the same molten steel is subjected to a continuous casting for all the four strands, two charges more is available in this case. The difference will be expanded according as a ratio of the stainless steel is high. The description given above exemplifies only one case, and when using those different in casting speed and in furnace capacity as well in combination, an optimal pattern for melting and continuous casting may be determined by putting this invention into practice. As summarized in Fig. 2 and Fig. 3, the aforementioned continuous casting apparatus capable of using strands in division comprises disposing two tundishes (2A, 2B) on a row of four water-cooled molds (1A, 1B, 1C, 1D), for example, so as to share the water-cooled molds (2 pieces each as illustrated), feeding molten metals from the molten metal ladles correspondingly to each tundish. In the example illustrated therein, molten metals (7a and 8a) different in kind are fed from a ladle (3A) to the tundish (2A) and from another ladle (3D) to the tundish (2B), respectively, the former is subjected to a continuous casting through the water-cooled molds (1A and 1B) and the latter through the water-cooled molds (1C and 1D), thereby obtaining 4 strands (7b x 2 pcs., 8b x 2 pcs.). Ladle support means (4A, 4B) comprises, as illustrated in Fig. 4, transfer trucks (41A, 41B) and traveling cranes (42A, 42B), capable of changing the ladles for molten metals fed to the tundish (2A) from (3A) to (3B) according to movement of the transfer truck (41A), for example, and capable further of carrying the emptied ladle away from over the tundish (2A) or carrying over the other ladle containing a molten metal according to movement of the traveling crane (42A) on rails (43A, 43B). Needless to say, an overhead crane (not illustrated) will be used in this case according to a necessity of ladle operation. Ladle change to the tundish is effected by the two-throw transfer trucks (41A, 41B) as shown in Fig. 2 and Fig. 4, however, various modes may be realized as shown in Fig. 5 and Fig. 6. That is, the ladle is ready for changing through a combination of transfer trucks (41C of Fig. 5 and 41D of Fig. 6) supporting the ladle in one only thereon and the overhead crane. The tundish may be supported on support means (5) shown in Fig. 7 and Fig. 8. The support means (5) is structured such that a support arm (52) on a truck (51) can be adjusted fine for the height by means such as hydraulic cylinder (53) or the like. From moving on a rail (54), the truck (51) is capable of changing the way of sharing the water-cooled molds as, for example, (3 pcs. + 1 pc.) or (4 pcs. + 0 pcs.) from (2 psc. + 2 pcs.) with reference to the 4 strands. From carrying out a continuous casting according to the method of this invention, strands may be divided at an arbitrary ratio according to a necessity of process, and various metals may be cast concurrently in succession on a multistrand type continuous casting apparatus conventional, or existing or by existing design. Thus, wishes for securing a high yield on products in a special steel using expensive alloy components will be met satisfactorily, and a continuous casting apparatus requiring a large amount of equipment investment may be operated at a high rate of operation. As an apparatus for carrying out the aforementioned continuous casting, the apparatus may be realized by applying some modification and increase to an existing multistrand type continuous casting equipment, or a design may be accomplished without adding a radical modification to that of existing design, and hence the equipment may be constructed without a great difference in cost from a conventional equipment.

Claims: A method for casting alloys, comprising: (a) supplying a first molten metal and a second molten metal to a plurality of ladles (3A, 3B, 3C, 3D); (b) feeding said first molten metal to a first tundish (2A) and said second molten metal to a second tundish (2B); (c) continuously and concurrently casting said first and second molten metals through water-cooled molds (1A, 1B, 1C, 1D) by feeding said first molten metal from said first tundish (2A) and said second molten metal from said second tundish (2B) to said water-cooled molds (1A, 1B, 1C, 1D); characterized by (1) said first and second molten metals having different compositions; and (2) continuously and concurrently casting said first and second molten metals through four water-cooled molds (1A, 1B, 1C, 1D) by feeding said first molten metal from said first tundish (2A) to at least two of said four water-cooled molds and feeding said second molten metal from said second tundish (2B) to at least one of said four water-cooled molds. The method according to claim 1, characterized in that a number of said water-cooled molds respectively fed by said first and second tundishes (2A, 2B) is selected based upon time required for preparing said first and second molten metals, an amount of said first and second molten metals supplied to said ladles (3A, 3B, 3C, 3D), and casting speed of said first and second molten metals for increasing yield of said method. The method according to claim 1, characterized in that said first molten metal is an alloy containing expensive alloy element or elements. The method according to claim 1, characterized in that said first molten metal is stainless steel. The method according to claim 1, characterized by further comprising supplying a third molten metal having a composition different from said first and second molten metals to one of said ladles (3A, 3B, 3C, 3D), from which the molten metal being fed to the first tundish (2A) or the second tundish (2B). A method for casting alloys, comprising: (a) supplying a first, second and third molten metal to a plurality of ladles (3A, 3B, 3C, 3D); (b) feeding said first molten metal to a first and second tundish (2A, 2B); (c) continuously and concurrently casting said first molten metal through water-cooled molds (1A, 1B, 1C, 1D); characterized by (1) said first, second and third molten metals having different compositions; (2) continuously and concurrently casting said first molten metal through four water-cooled molds (1A, 1B, 1C, 1D) by feeding said first molten metal from said first tundish (2A) to at least two of said four water-cooled molds (1A, 1B, 1C, 1D); (3) feeding said second molten metal to said first tundish (2A) after said first molten metal; (4) continuously casting said second molten metal by feeding said second molten metal from said first tundish (2A) to at least two of said four water-cooled molds (1A, 1B, 1C, 1D) while concurrently and continuously casting said first molten metal by feeding said first molten metal from said second tundish (2B) to at least one of said four water-cooled molds (1A, 1B, 1C, 1D); (5) supplying said third molten metal to said second tundish (2B) after said first molten metal; (6) continuously casting said third molten metal by feeding said third molten metal from said second tundish (2B) to at least one of said four water-cooled molds (1A, 1B, 1C, 1D) while concurrently casting said second molten metal by feeding said second molten metal from said first tundish (2A) to at least two of said four water-cooled molds (1A, 1B, 1C, 1D). A method according to claim 6, characterized in that the number of said water-cooled molds respectively fed by said first and second tundishes (2A, 2B) is selected based upon the time required for preparing said first, second and third molten metals; amounts of said first, second and third molten metals supplied to said ladles (3A, 3B, 3C, 3D); and casting speed of said first, second and third molten metals for increasing yield of said method. The method according to claim 7, characterized in that a first charge of said first molten metal is initially fed to said first tundish (2A) and then second and third charges of said first molten metal are fed to said second tundish (2B); four charges of said second molten metal are fed to said first tundish (2A) sequentially after said first charge of said first molten metal is continuously cast, and three charges of said third molten metal are fed to said second tundish (2B) sequentially after said third charge of said first molten metal is continuously cast. The method according to claim 8, characterized in that after continuous casting of said second and third molten metal, a fourth molten metal is fed to said first and second tundishes (2A, 2B) and sequentially continuously cast from said second tundish (2B) after continuous casting of said second molten metal is complete.

Inventors: HAYAKAWA SHYZUNORI, INAGAKI YOSHIO, KUMURA SHUZO, MORII KIYOSHI, HAYAKAWA, SHYZUNORI, INAGAKI, YOSHIO, KUMURA, SHUZO, MORII, KIYOSHI, INAGAKI, YOSHIO, 12-2 AZA-TOSENDAI
Applicants: DAIDO STEEL CO LTD, DAIDO TOKUSHUKO KABUSHIKI KAISHA
Application year: 1990
Main classification: B22D11
IPC codes: B22D11