CA1089183A - Method of rebuilding an ingot mold - Google Patents
Method of rebuilding an ingot moldInfo
- Publication number
- CA1089183A CA1089183A CA284,730A CA284730A CA1089183A CA 1089183 A CA1089183 A CA 1089183A CA 284730 A CA284730 A CA 284730A CA 1089183 A CA1089183 A CA 1089183A
- Authority
- CA
- Canada
- Prior art keywords
- compound
- metal
- ingot mold
- eroded area
- eroded
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
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Abstract
ABSTRACT OF THE DISCLOSURE
A method of rebuilding the eroded area of an ingot mold such as used in casting steel ingots places a metal producing exothermic compound in a cleaned eroded area of the ingot mold to be rebuilt, ignites the compound and confines the molten metal produced by the exothermic reaction to the eroded area where it forms a welded bond with the metal of the ingot mold and fills the eroded area. A protective metal coating of a suitable welding rod metal may be deposited by electric arc or flame welding on the metal patch formed of the exothermic material. This invention is distinguishable from other inventions by reason of the steps of cleaning the eroded ares in the ingot mold,placing a metal producing material including an exothermic compound in the cleaned area and igniting the material, confining the material in the eroded area to restore the ingot mold cavity and its original configuration.
A method of rebuilding the eroded area of an ingot mold such as used in casting steel ingots places a metal producing exothermic compound in a cleaned eroded area of the ingot mold to be rebuilt, ignites the compound and confines the molten metal produced by the exothermic reaction to the eroded area where it forms a welded bond with the metal of the ingot mold and fills the eroded area. A protective metal coating of a suitable welding rod metal may be deposited by electric arc or flame welding on the metal patch formed of the exothermic material. This invention is distinguishable from other inventions by reason of the steps of cleaning the eroded ares in the ingot mold,placing a metal producing material including an exothermic compound in the cleaned area and igniting the material, confining the material in the eroded area to restore the ingot mold cavity and its original configuration.
Description
Background of the Inv~ntion 1089i8;~
(1) Field of ~he Invention:
This inven~ion relates to ;ngot molds, either iron or steel and a method and material for rebuilding the same to eliminate eroded areas th~rein,
(1) Field of ~he Invention:
This inven~ion relates to ;ngot molds, either iron or steel and a method and material for rebuilding the same to eliminate eroded areas th~rein,
(2) Description of the Prior Art:
No prior art is known relating to the rebuilding of an eroded aren in an ingot mold. A rebuilt oxygen lance i5 soon in U,S, Patont 3,743,814 of July 3, 1973 to Grant A. Oakes wherein oxygen passageways are formed in a rebuilt metal tip of the oxygen lance and in U.S. Patent 3,589,875 of Jan. 17, 1969 to Grant A. Oakes a bullt up strip mill guide is disclosed wherein grooves in the worn guide are filled up by a welding procedure.
Summary oF the Invention .; A method of rebuilding an ingot mold and a materTal for use in such method comprises the cleaning and heating of the eroded area in an ingot mold placing a suitable quantity of a metal producing exothermic compound in the eroded area ignit;ng it and confining the molten metal produced thereby to said eroded area whereby a weld bonded patch replaces the eroded area and reconditions the ingot mold making it suitable for again receiving mo I te n metal to form an ingot therein. ~-2~ Description of the Drawings ~ ;
Figure 1 is a vertical sect;on through an eroded ingot mold of the big end up type showing an eroded areo therein prepared for reconditioning;
Figure 2 is a vertical section throuah a portion of the ingot mold illustrated :1 in Figure 1 showing an exothermic compound positioned in the eroded area and confined thereto;
Figure 3 is a vertical section through a portion of the ingot mold of Figure 1 showing the recondTtioned in~ot rrK~ld;
28 Figure 4 is a vertical ~ection of a portion of a bTg end down ingot rnold .~ ~, ' , ' .
O ~ .
~, ~
1~89~83 showing an eroded area therein partially prepared for reconditTonlng;
Figure 5 is a vertical sect;on of th~ ingot rnold in Figure 4 showing the positioning of a metal producing exothermic compound therein and conftntng the same to the eroded area; and Figure 6 is a vertical section through a portion of the ingot mold seen in Figures 4 and 5 and showing the reconditioned Tngot mold.
Description of the Preferred Embodiment In the form of the invention chosen for illustration herein, an ingot mold which m~y be either iron or steel is indicated in Figure 1 of the drawings by the numeral 10 and it will be observed that it is a big end up ingot mold wherein a solidified ingot formed therein is removed therefrom in a stripping operation which lifts the ingot formed therein upwardly therefrom. The cavity in the ingat mold 10 is indicated by the numeral 11 and an eroded area 12 may be seen in the bottom of the cavity 11 as occurs from the continual pouring of molten metal into the ingot mold. The eroded area 12 renders the ingot mold incapable of further use as the ingot, upon cooling, becomes locked into the mold and cannot be stripped therefrom. Heretofore such ingot molds 5 ave been scrapped.
Still referring to Figure 1 of the drawings, it will be observed that the cavity 12 has been cleaned so as to be free of scale or other impurities and a plurality of outwardly directed holes 13 have been drilled into ~he remaining metal of the ingot mold 10 from the area of the cavity 12. These holes may extend sub-stantially half way into the remaining metal of the ingot mold 10. The ingot mold .
thus prepared is preferably heated, at least in the area of the cavity 12, to a ;~
temperature which may vary from 10C F. to 400F. or greater and by referring to Figure 2 of the drawings, it will be seen that a mehl producing exothermic com~
pound 14 has been positioned in tho area of the cavTty 12 in the ;ngot mold !~
;gnited and confined therein ~y a mehl member 15 preferably covered with an 28 Insulating member 16. The metal member 15 and the Tnsulating member 16 are ~ . , prefarably of a shape corrcsponding with a destrod shape of the lower end of thecavity I 1 in the lngot mold lO . The mctal producing exothermic compound a-hereinafter described, produces molten metal whlch flows into the holes 13 and fills the area of the cavlty 12 and upon solidifying forms a weld bonded patch filling the former eroded area 12. Upon cooling, the metal member 15 and/or the insulating member I 6 may be removed from the patch formed of the metal pro-ducing exothermic compound 14 and as seen in Figure 3 of the drawings the original and desired shape and area of the cavity I I in the ingot mold I0 has been restored.
St;ll referring to Figure 3 of the draw;ngs, ;t wili be seen that a protective mehllic coating 17 of a desirable welding rod mehl is then deposited by arc or flame welding over the patch formed of the metal producing exothermic compound I4 and feathered into the surfaces defining the cavity Il in the ingot rnold I0.
It will thus be seen that the patch material formed of the metal producing exothermic compound is both mechanically and weld bonded in the ingot mold lO
becawe part of It extends into the holes I 3 to form a mechanical anchor and themolten metal of the metal producing exothermic compound forms a weld bond with the cleaned metal surface of the eroded area I 2 heretofore described. The rebuilt ingot mold may now be repeatedly reused for the casting of steel ingots and has been found to have a longer life than a comparable new cast iron or steel Ingot mold.
Those skilled in the art will observe that steel ingots are frequently cast tn big en~ down ingot molds and by referring to Figures 4, 5 and 6 of the drawings, a portion of such an ingot mold may be seen as indicated by the numeral I 9. Themold 19 has a 6ig end down cavity 20 therein and in use is positioned upon a stool so that molten metal poured thereinto will be confined thereby. Such pouring results in erosion of the lower side wall portions of the ingot mold I 9 and such an eroded area is indicated by the numeral 21 in Figure 4 of the drawings. The eroded area has been prepared for rebuilding by cleaning the same of scale and 28 - th~ Jike and having a plurality of holo- 22 drllled outwardly therefrom into the remaining metal of the Ingot mold 19. The holes are preforably drllled so as to-incline outwardly and downwardly, generally opposTtely to the dlrection of the tngot mold when moved upwardly in a strippTng operation relative to an Tngot cast therein.
The ingot mold 19 may be positioned horizontally on one side or inverted if desired, so that a metal producing exothermic compound 23 may 6e positioned therein qnd retained in the eroded area 21 as illustrated In Figure 5 of the draw;ngs.
The metal producing exothermic compound 23 rnay be held in the cavity area by mehl members 24 positioned and secured to the inner walls of the cavity 20 ofthe mold 19 and a mehl member 25 may be positioned across the normally open bottom of the mold 19 to insure retaining the metal producing exothermic compound 23 in the cavity area. Insulating members 26 may also be used if desired. Ignition of the metal produc;ng exothermic compound will produce molten metal filling thecavity area 21 and rebuilding the Tngot mold 19 in conformity with its original covity size and shape.
By referrTng now to Figure 6 of the drawings, it will be seen that upon coolln~
of the patch material, which is the mehl produced by the metal producing exothermlc compound, the retain;ng members 24, 25 and 26 are removed and a thin protective layer 27 of o suitable metal such as from a welding rod, is depesited by electric arc or flame welding and feathered over the inner surfaces of the ingot mold 19 defining the cavity 20.
A suita61e mehl producing exothermic compound for use Tn the foregoing method may comprise between 16% and 22h metallic aluminum, between 14% and 20%
wollastonite (silicate of calc;um), between 3h and 6% ferro silicon, between 4%and 8% manganese dioxide, between 40% and 60% fine iron scale and between
No prior art is known relating to the rebuilding of an eroded aren in an ingot mold. A rebuilt oxygen lance i5 soon in U,S, Patont 3,743,814 of July 3, 1973 to Grant A. Oakes wherein oxygen passageways are formed in a rebuilt metal tip of the oxygen lance and in U.S. Patent 3,589,875 of Jan. 17, 1969 to Grant A. Oakes a bullt up strip mill guide is disclosed wherein grooves in the worn guide are filled up by a welding procedure.
Summary oF the Invention .; A method of rebuilding an ingot mold and a materTal for use in such method comprises the cleaning and heating of the eroded area in an ingot mold placing a suitable quantity of a metal producing exothermic compound in the eroded area ignit;ng it and confining the molten metal produced thereby to said eroded area whereby a weld bonded patch replaces the eroded area and reconditions the ingot mold making it suitable for again receiving mo I te n metal to form an ingot therein. ~-2~ Description of the Drawings ~ ;
Figure 1 is a vertical sect;on through an eroded ingot mold of the big end up type showing an eroded areo therein prepared for reconditioning;
Figure 2 is a vertical section throuah a portion of the ingot mold illustrated :1 in Figure 1 showing an exothermic compound positioned in the eroded area and confined thereto;
Figure 3 is a vertical section through a portion of the ingot mold of Figure 1 showing the recondTtioned in~ot rrK~ld;
28 Figure 4 is a vertical ~ection of a portion of a bTg end down ingot rnold .~ ~, ' , ' .
O ~ .
~, ~
1~89~83 showing an eroded area therein partially prepared for reconditTonlng;
Figure 5 is a vertical sect;on of th~ ingot rnold in Figure 4 showing the positioning of a metal producing exothermic compound therein and conftntng the same to the eroded area; and Figure 6 is a vertical section through a portion of the ingot mold seen in Figures 4 and 5 and showing the reconditioned Tngot mold.
Description of the Preferred Embodiment In the form of the invention chosen for illustration herein, an ingot mold which m~y be either iron or steel is indicated in Figure 1 of the drawings by the numeral 10 and it will be observed that it is a big end up ingot mold wherein a solidified ingot formed therein is removed therefrom in a stripping operation which lifts the ingot formed therein upwardly therefrom. The cavity in the ingat mold 10 is indicated by the numeral 11 and an eroded area 12 may be seen in the bottom of the cavity 11 as occurs from the continual pouring of molten metal into the ingot mold. The eroded area 12 renders the ingot mold incapable of further use as the ingot, upon cooling, becomes locked into the mold and cannot be stripped therefrom. Heretofore such ingot molds 5 ave been scrapped.
Still referring to Figure 1 of the drawings, it will be observed that the cavity 12 has been cleaned so as to be free of scale or other impurities and a plurality of outwardly directed holes 13 have been drilled into ~he remaining metal of the ingot mold 10 from the area of the cavity 12. These holes may extend sub-stantially half way into the remaining metal of the ingot mold 10. The ingot mold .
thus prepared is preferably heated, at least in the area of the cavity 12, to a ;~
temperature which may vary from 10C F. to 400F. or greater and by referring to Figure 2 of the drawings, it will be seen that a mehl producing exothermic com~
pound 14 has been positioned in tho area of the cavTty 12 in the ;ngot mold !~
;gnited and confined therein ~y a mehl member 15 preferably covered with an 28 Insulating member 16. The metal member 15 and the Tnsulating member 16 are ~ . , prefarably of a shape corrcsponding with a destrod shape of the lower end of thecavity I 1 in the lngot mold lO . The mctal producing exothermic compound a-hereinafter described, produces molten metal whlch flows into the holes 13 and fills the area of the cavlty 12 and upon solidifying forms a weld bonded patch filling the former eroded area 12. Upon cooling, the metal member 15 and/or the insulating member I 6 may be removed from the patch formed of the metal pro-ducing exothermic compound 14 and as seen in Figure 3 of the drawings the original and desired shape and area of the cavity I I in the ingot mold I0 has been restored.
St;ll referring to Figure 3 of the draw;ngs, ;t wili be seen that a protective mehllic coating 17 of a desirable welding rod mehl is then deposited by arc or flame welding over the patch formed of the metal producing exothermic compound I4 and feathered into the surfaces defining the cavity Il in the ingot rnold I0.
It will thus be seen that the patch material formed of the metal producing exothermic compound is both mechanically and weld bonded in the ingot mold lO
becawe part of It extends into the holes I 3 to form a mechanical anchor and themolten metal of the metal producing exothermic compound forms a weld bond with the cleaned metal surface of the eroded area I 2 heretofore described. The rebuilt ingot mold may now be repeatedly reused for the casting of steel ingots and has been found to have a longer life than a comparable new cast iron or steel Ingot mold.
Those skilled in the art will observe that steel ingots are frequently cast tn big en~ down ingot molds and by referring to Figures 4, 5 and 6 of the drawings, a portion of such an ingot mold may be seen as indicated by the numeral I 9. Themold 19 has a 6ig end down cavity 20 therein and in use is positioned upon a stool so that molten metal poured thereinto will be confined thereby. Such pouring results in erosion of the lower side wall portions of the ingot mold I 9 and such an eroded area is indicated by the numeral 21 in Figure 4 of the drawings. The eroded area has been prepared for rebuilding by cleaning the same of scale and 28 - th~ Jike and having a plurality of holo- 22 drllled outwardly therefrom into the remaining metal of the Ingot mold 19. The holes are preforably drllled so as to-incline outwardly and downwardly, generally opposTtely to the dlrection of the tngot mold when moved upwardly in a strippTng operation relative to an Tngot cast therein.
The ingot mold 19 may be positioned horizontally on one side or inverted if desired, so that a metal producing exothermic compound 23 may 6e positioned therein qnd retained in the eroded area 21 as illustrated In Figure 5 of the draw;ngs.
The metal producing exothermic compound 23 rnay be held in the cavity area by mehl members 24 positioned and secured to the inner walls of the cavity 20 ofthe mold 19 and a mehl member 25 may be positioned across the normally open bottom of the mold 19 to insure retaining the metal producing exothermic compound 23 in the cavity area. Insulating members 26 may also be used if desired. Ignition of the metal produc;ng exothermic compound will produce molten metal filling thecavity area 21 and rebuilding the Tngot mold 19 in conformity with its original covity size and shape.
By referrTng now to Figure 6 of the drawings, it will be seen that upon coolln~
of the patch material, which is the mehl produced by the metal producing exothermlc compound, the retain;ng members 24, 25 and 26 are removed and a thin protective layer 27 of o suitable metal such as from a welding rod, is depesited by electric arc or flame welding and feathered over the inner surfaces of the ingot mold 19 defining the cavity 20.
A suita61e mehl producing exothermic compound for use Tn the foregoing method may comprise between 16% and 22h metallic aluminum, between 14% and 20%
wollastonite (silicate of calc;um), between 3h and 6% ferro silicon, between 4%and 8% manganese dioxide, between 40% and 60% fine iron scale and between
3% and 4% graphite. A typical batch may have the following analysTs: Mehllic aluminum -16%, wollastonite - 14%, ferro silicon-3%, man~anese dioxide -4%
fine Tron scale-60% and graphite -3%.
28 ~ An eqwlly suitable batch may compriso the followlng: Metallic aluminum-, . .. . . .
.. ~ . . . . ... .
: . . . . . . -, .
22%, wollastonite - 20%, ferro stlicon - 6%, manganese dioxide 8%, fine iron scale - 40% and graphite 4%.
Those skilled in the art will observe that the compound dis;closed has satisfactory exothermic characteristTcs enabling a hlgh temperature reaction suitable for melting the compound and that the remainTng compound resulting from the exothermTc reaction will have an analysis close to the original analys;s of the inyot mold in which it is being positioned. This is necessary to insure a welded physical bond to the metal of the Jngot mold.
It w;ll thus be seen that a method of rebuilding an ingot mold and a material for use in such method has been disclosed and havlng thus disclosed my invention what I claim 1s:
_7_ ;, :
fine Tron scale-60% and graphite -3%.
28 ~ An eqwlly suitable batch may compriso the followlng: Metallic aluminum-, . .. . . .
.. ~ . . . . ... .
: . . . . . . -, .
22%, wollastonite - 20%, ferro stlicon - 6%, manganese dioxide 8%, fine iron scale - 40% and graphite 4%.
Those skilled in the art will observe that the compound dis;closed has satisfactory exothermic characteristTcs enabling a hlgh temperature reaction suitable for melting the compound and that the remainTng compound resulting from the exothermTc reaction will have an analysis close to the original analys;s of the inyot mold in which it is being positioned. This is necessary to insure a welded physical bond to the metal of the Jngot mold.
It w;ll thus be seen that a method of rebuilding an ingot mold and a material for use in such method has been disclosed and havlng thus disclosed my invention what I claim 1s:
_7_ ;, :
Claims (7)
1. The method of rebuilding an ingot mold having an eroded area in the cavity thereof, said cavity having a known original con-figuration and comprising the steps of cleaning said eroded area, placing a metal producing exothermic compound in said eroded area and igniting said compound so as to produce a molten mass in said eroded area and containing said molten mass in said eroded area so as to reshape said cavity in said mold in accordance with its known original configuration, said metal producing exothermic compound comprising metallic aluminum, wollastonite, ferro silicon, manganese dioxide, fine iron scale and graphite, the fine iron scale and metallic aluminum being present in quantities sufficient to form thermite capable of melting the compound.
2. The method of claim 1 and wherein said ingold mold is heated to a temperature between 100°F. and 400°F. prior to igniting said compound.
3. The method of claim 1 and wherein said compound, after ignition, is confined to said eroded area.
4. The method set forth in claim 1 and wherein a protective metallic coating is deposited on the solidified compound filling said eroded area.
5. The method set forth in claim 4 and wherein said pro-tective metallic coating is welding rod metal deposited by welding.
6. The method of rebuilding an ingot mold set forth in claim 1 and wherein the metal producing exothermic compound comprises between about 16% and 22% metallic aluminum, between about 14% and 20% wollastonite, between about 3% and 6% ferro silicon, between about 4% and 8% manganese dioxide, between about 40% and 60%
fine iron scale and between about 3% and 4% graphite.
fine iron scale and between about 3% and 4% graphite.
7. The method of rebuilding an ingot mold set forth in claim 1 and wherein the metal producing exothermic compound comprises 16% metallic aluminum, 14% wollastonite, 3% ferro silicon, 4%
manganese dioxide, 60% fine iron scale and 3% graphite.
manganese dioxide, 60% fine iron scale and 3% graphite.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA284,730A CA1089183A (en) | 1977-08-15 | 1977-08-15 | Method of rebuilding an ingot mold |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA284,730A CA1089183A (en) | 1977-08-15 | 1977-08-15 | Method of rebuilding an ingot mold |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1089183A true CA1089183A (en) | 1980-11-11 |
Family
ID=4109331
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA284,730A Expired CA1089183A (en) | 1977-08-15 | 1977-08-15 | Method of rebuilding an ingot mold |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1089183A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108188361A (en) * | 2017-12-01 | 2018-06-22 | 重庆材料研究院有限公司 | A kind of method for preventing high temperature alloy from melting adhesion pedestal when pouring into a mould |
-
1977
- 1977-08-15 CA CA284,730A patent/CA1089183A/en not_active Expired
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108188361A (en) * | 2017-12-01 | 2018-06-22 | 重庆材料研究院有限公司 | A kind of method for preventing high temperature alloy from melting adhesion pedestal when pouring into a mould |
| CN108188361B (en) * | 2017-12-01 | 2020-05-01 | 重庆材料研究院有限公司 | Method for preventing base from being fused and adhered during high-temperature alloy pouring |
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