Dr. Dmitri Kopeliovich
Horizontal continuous casting methods are used for manufacturing Aluminum based bearing materials.
The alloys are cast in form of continuous strips (either cut-to-length or coiled). The aluminum casting is then cold rolled and backed with a steel strip in order to obtain bi-metal structure.
In this continuous casting method the mold surface is sprinkled by water streams.
This type of cooling is very effective due to elimination of air gap between the graphite mold surface and the coolers.
The process is terminated after casting 3-4 ton of aluminum based bearing alloys for replacing the graphite mold.
Benefits of casting in short water-cooled mold:
Disadvantages of casting in short water-cooled mold:
Graphite mold is cooled by water-cooled copper blocks. Cooling rate in this method is relatively low due to the air gap between the Graphite mold surface and the surfaces of the copper coolers. Molds of this type are longer than directly water-cooled graphite molds. The enter tip of the graphite mold is prominent into the holding vessel space and submerged into the melt.
Benefits of casting in submerged graphite mold:
Disadvantages of casting in submerged graphite mold:
Twin-belt casting relates to the continuous casting methods using traveling "endless" molds (rolls, belts, wheels). The method is characterized by zero relative movement between the mold (two belts) and casting surfaces.
Twin-belt casters are used for manufacturing cast strips of Aluminum based bearing materials.
In twin-belt casting process a melt is fed through a ceramic nozzle into the gap between two rotating endless thin belts held in tension.
The belts are supported and chilled by two water-cooled copper plate. The melt cools down and solidifies between the belts.
The cast strip is pulled out by a withdrawal unit synchronized with the drive of the belts.
Benefits of twin-belt casting:
Disadvantages of twin-belt casting:
Twin-roll casting relates to the continuous casting methods using traveling "endless" molds (rolls, belts, wheels). The method is characterized by zero relative movement between the mold (two rolls) and casting surfaces.
Twin-roll casters are used for manufacturing cast strips of Aluminum based bearing materials.
In twin-roll casting process a melt is fed through a ceramic nozzle into the gap between two rotating water-cooled rolls. The melt cools down and solidifies between the rolls. Additionally the solid strip exerts hot rolling with the thickness reduction of about 5-20%.
Sticking between the roll and the solidified strip is prevented by means of a parting agent applied to the roll surface. The agent contains Graphite or magnesium hydroxide.
Twin-roll casting process provides extremely high cooling rate up to 1000ºF/s (550ºC/s).
Benefits of twin-roll casting:
Disadvantages of twin-roll casting: