Casting continuous

A typical m el ter iastalled in a medium sized brass foundry contains 4500 kg of brass and its inductor is rated 500 kilowatts. Brass is an alloy containing copper and zinc. Zinc vaporizes at temperatures weU below the melting temperature of the alloy. The channel iaductor furnace s low bath temperature and relatively cool melt surface result in low metal loss and reduced environmental concerns. Large dmm furnaces have found use in brass and copper continuous casting installations. 

Three bulk polymerization processes are commercially important for the production of methacrylate polymers batch cell casting, continuous casting, and continuous bulk polymerization. Approximately half the worldwide production of bulk polymerized methacrylates is in the form of molding and extmsion compounds, a quarter is in the form of cell cast sheets, and a quarter is in the form of continuous cast sheets. 

Synthetic Marble. Synthetic marble-like resin products are prepared by casting or molding a highly filled monomer mixture or monomer—polymer symp. When only one smooth surface is required, a continuous casting process using only one endless stainless steel belt can be used (52,53). Typically on the order of 60 wt % inorganic filler is used. The inorganic fillers, such as aluminum hydroxide, calcium carbonate, etc, are selected on the basis of cost, and such properties as the translucence, chemical and water resistance, and ease of subsequent fabrication (54,55). 

High purity 50% ferrosihcon containing <0.1% Al and C is used for production of stainless steel and corded wire for tires, where residual aluminum can cause harm fill alumina-type inclusions. These are also useflil in continuous cast heats, where control of aluminum is necessary. High purity grades of 50 and 75% ferrosihcon containing low levels of aluminum, calcium, and titanium are used for sihcon additions to grain-oriented electrical steels, where low residual aluminum content contributes to the attainment of desired electrical properties, eg, significant reduction of eddy currents. 

High purity 75% ferrosihcon containing low aluminum and calcium can be used in continuously cast heats where nozzle blockage is a problem. In iron melting, this ahoy is desirable to minimize buildup on refractory faces in the furnace or on stopper rods or nozzles. Low aluminum ferroshicons can also help reduce hydrogen pin holes in castings poured in green-sand molds. 

Although the continuous casting of steel appears deceptively simple in principle, many difficulties are inherent to the process. When molten steel comes into contact with a water-cooled mold, a thin soHd skin forms on the wall (Eig. 10). However, because of the physical characteristics of steel, and because thermal contraction causes the skin to separate from the mold wall shortly after solidification, the rate of heat abstraction from the casting is low enough that molten steel persists within the interior of the section for some distance below the bottom of the mold. The thickness of the skin increases because the action of the water sprays as the casting moves downward and, eventually, the whole section solidifies. 

Eig. 10. Schematic representation of the process of cooling of steel (H) during continuous casting. The tundish is a buffer between the ladle and the mold. 

Production. World production of raw steel, largely continuously cast, is shown in Table 6. U.S. production has approached 9.0 x 10 t/yi") over 90% of which is continuously cast. The amount melted in electric furnaces approached 40% and in 1995 was stiU increasing. 

Development in Dadle Steelmaking and Continuous Casting, Canadian Institute of Mining, Metallurgy and Petroleum, Montreal, Quebec, Canada, 1990. 

ISS Continuous Casting Series, Vols. 1—7, Iron and Steel Society, Warrendale, Pa., 1983—1995. 

Alumina—graphite refractories, almost all continuous casting ware, have come into much greater use as continuous casting has spread in steelmaking. These refractories are used in shrouds that conduct the molten metal from the ladle to the tundish, in the subentry tubes that take the metal from the tundish to the mold, in isostatically pressed stopper rods, and in shroud tubes for slab and bloom casters. The alumina—graphite compositions are used in these products because of the thermal-shock resistance and corrosion resistance they impart to the product. 

Tape can be cast on a stainless steel table or belt, glass plate, or a Mylar, Teflon, or ceUulose acetate film carrier. The tape should adhere to the carrier sufficiently to prevent curling, but should be easily removable. In a continuous casting process, the tape is dried by air flowing 1—2 m/min counter to the casting direction. A typical dry green tape contains approximately 35 vol % organics, 50% ceramic powder, and 15% porosity. 

The end product is either cast as anodes for electrolytic refining or, rarely, as ingots for sale as fire-refined copper. A horizontal casting wheel with 12—32 horizontal molds is normally used for anode casing. Using continuous casting machines, the copper is cast as a continuous strip to be cut to the required anode shape (28). 

In the past, wire bar, cake, billets, and a variety of semifinished products were cast in horizontal casting wheels. These have largely been replaced by continuous casting (Fig. 9). 

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