Method and apparatus for manufacturing metal bars or ingots

Abstract

Method and apparatus for manufacturing metal bars or ingots. The abstract of the disclosure is submitted herewith as required by 37 C.F.R. §1.72(b). As stated in 37 C.F.R. §1.72(b): A brief abstract of the technical disclosure in the specification must commence on a separate sheet, preferably following the claims, under the heading “Abstract of the Disclosure.” The purpose of the abstract is to enable the Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure. The abstract shall not be used for interpreting the scope of the claims. Therefore, any statements made relating to the abstract are not intended to limit the claims in any manner and should not be interpreted as limiting the claims in any manner.

1 . A method of manufacturing small diameter bars or ingots using a bar mold system; said method comprising the steps of:
 refining molten metal for a first run of small diameter bars or ingots;   transferring said refined molten metal into a ladle;   protecting said refined molten metal from the atmosphere with an insulating ladle cover;   argon-stirring said refined molten metal in said ladle to promote homogeneity, temperature, and cleanliness of said refined molten metal;   protecting said refined molten metal from re-oxidation with an argon shroud and said insulating ladle cover;   bottom-pouring said refined molten metal into a holding tundish while protecting said refined molten metal with said argon shroud;   maintaining temperature control of said refined molten metal with a temperature control device and minimizing re-oxidation in said holding tundish;   monitoring the temperature of said refined molten metal with a probe, which probe is connected to a monitor device;   transferring said refined molten metal into a pouring vessel while protecting said refined molten metal with said argon shroud;   controlling the pouring rate of said refined molten metal with a pouring control arrangement;   minimizing temperature losses with an insulated pouring vessel lid and minimizing argon losses with said insulated pouring vessel lid;   sending a signal from a control device to a plurality of stopper rod nozzle assemblies and alternating said plurality of stopper rod nozzle assemblies between open and closed positions;   metering said refined molten metal from said pouring vessel, through said plurality of stopper rod nozzle assemblies, and into a multi-part bar mold system;   freezing said refined molten metal against the water-cooled side walls of said multi-part bar mold system and the water-cooled bottom of said multi-part bar mold system, upon said refined molten metal entering a cavity of said multi-part bar mold system, and producing a small diameter bar or ingot;   moving said water-cooled side walls, and thereby said small diameter bar or ingot, away from said water-cooled bottom of said multi-part bar mold system and allowing said small diameter bar or ingot to drop onto a collection conveyor;   controlling said moving with said control device;   transporting said small diameter bar or ingot to an identification station;   identifying the heat number and grade of said small diameter bar or ingot at said identification station;   packaging said small diameter bar or ingot into a predetermined shipping container;   weighing said predetermined shipping container;   labeling said predetermined shipping container; and   staging said predetermined shipping container for shipment.   
   
   
       2 . A small diameter bar or ingot manufacturing arrangement for performing the method of manufacturing small diameter bars or ingots using a bar mold system according to  claim 1 ; said small diameter bar or ingot manufacturing arrangement comprising:
 a refining arrangement being configured to refine molten metal for a first run of small diameter bars or ingots;   a transferring arrangement being configured to transfer refined molten metal into a ladle;   an insulating ladle cover being configured to protect refined molten metal from the atmosphere;   an argon-stirring arrangement being configured to argon-stir refined molten metal in said ladle to promote homogeneity, temperature, and cleanliness of the refined molten metal;   said insulating ladle cover and an argon shroud being configured to protect refined molten metal from re-oxidation;   a bottom-pouring arrangement being configured to bottom-pour refined molten metal into a holding tundish while refined molten metal is being protected with said argon shroud;   a temperature control device being configured to maintain temperature control of refined molten metal and to minimize re-oxidation in said holding tundish;   a probe being configured to monitor the temperature of refined molten metal, which probe is connected to a monitor device;   a transferring arrangement being configured to transfer refined molten metal into a pouring vessel while refined molten metal is being protected with said argon shroud;   a pouring control arrangement being configured to control the pouring rate of refined molten metal;   an insulated pouring vessel lid being configured to minimize temperature losses and minimize argon losses;   a control device being configured to send a signal to a plurality of stopper rod nozzle assemblies and alternate said plurality of stopper rod nozzle assemblies between open and closed positions;   a metering arrangement being configured to meter refined molten metal from said pouring vessel, through said plurality of stopper rod nozzle assemblies, and into a multi-part bar mold system;   water-cooled side walls and a water-cooled bottom of said multi-part bar mold system being configured to freeze refined molten metal, upon refined molten metal entering a cavity of said multi-part bar mold system, and produce a small diameter bar or ingot;   a moving arrangement being configured to move said water-cooled side walls, and thereby a small diameter bar or ingot, away from said water-cooled bottom of said multi-part bar mold system and allow the small diameter bar or ingot to drop onto a collection conveyor;   said control device being further configured to control said moving arrangement;   said collection conveyor being configured to transport a small diameter bar or ingot to an identification station;   said identification station being configured to identify the heat number and grade of a small diameter bar or ingot;   a packaging arrangement being configured to package a small diameter bar or ingot into a predetermined shipping container;   a weighing arrangement being configured to weigh a predetermined shipping container;   a labeling arrangement being configured to label a predetermined shipping container; and   a staging arrangement being configured to stage a predetermined shipping container for shipment.   
   
   
       3 . The method of manufacturing small diameter bars or ingots using a bar mold system according to  claim 1 , wherein:
 said water-cooled bottom of said multi-part bar mold system is configured to remain stationary during said steps of metering, freezing, moving, and controlling said moving; and   said method further comprises:
 moving said water-cooled side walls over said stationary water-cooled bottom prior to said step of metering said refined molten metal from said pouring vessel; and 
 moving said water-cooled side walls away from said water-cooled bottom of said multi-part bar mold system after said step of freezing said refined molten metal, thereby creating a bottomless mold. 
   
   
   
       4 . The method of manufacturing small diameter bars or ingots using a bar mold system according to  claim 3 , wherein said method further comprises:
 skimming said refined molten metal in said holding tundish;   sealing said holding tundish to minimize heat losses and argon losses; and   inserting a pyrometer or probe into said refined molten metal and monitoring the temperature of said refined molten metal.   
   
   
       5 . The method of manufacturing small diameter bars or ingots using a bar mold system according to  claim 4 , wherein said holding tundish and said pouring vessel are configured to permit:
 control of the temperature of said refined molten metal;   protection of the homogeneity and cleanliness of said refined molten metal; and   substantially accurate transferring and bottom-pouring of said refined molten metal.   
   
   
       6 . The method of manufacturing small diameter bars or ingots using a bar mold system according to  claim 4 , wherein said holding tundish comprises:
 insulated walls;   an insulated floor;   an induction coil;   a power supply;   an automated control system;   an insulated lid, which insulated lid comprises ports for temperature monitoring and ports for argon backfill flooding;   a spout;   at least one of: screw jacks and electric cylinders; and   at least one of: a plurality of linear positions transducers and a plurality of encoders.   
   
   
       7 . The method of manufacturing small diameter bars or ingots using a bar mold system according to  claim 6 , wherein:
 said pouring vessel comprises:
 insulated walls; 
 a floor; 
 said insulated pouring vessel lid, which insulated pouring vessel lid comprises ports for temperature monitoring and ports for argon backfill flooding; 
 a temperature monitoring arrangement; 
 an emergency run out arrangement; 
 an automated dual stopper rod system with both a plunge and twist arrangement and a nozzle clean out arrangement; 
 stopper rods; 
 a nozzle; 
 a metal level control system; and 
 an automated control system; 
   said multi-part bar mold system further comprises:
 at least one quick-change water-cooled mold size and shape insert; and 
 a motion control system configured to move said water-cooled side walls before and after said step of metering said refined molten metal from said pouring vessel; 
   said insulating ladle cover comprises at least one of: a rice hulls or vermiculite;   said multi-part bar mold system is comprised of one of: Chrome-Zinc Alloy grade #108, C18150, or Alloy grade #101;   said pouring control arrangement comprises at least one of: load cells, a level detection device, measuring rods, a tilting device, a screw jack, and a trunnion; and   said pouring control arrangement further comprises at least one of: an encoder, a linear position transducer, or a similar device, in order to monitor the position of said pouring vessel; and   said method is used for the manufacture of small diameter bars or ingots comprising at least one of: steels, superalloys, nickel base, cobalt base, copper-based grades, and raw material master alloys.   
   
   
       8 . A method of manufacturing small diameter bars or ingots; said method comprising the steps of:
 refining molten metal for a first run of small diameter bars or ingots;   transferring said refined molten metal;   protecting said refined molten metal from the atmosphere;   argon-stirring said refined molten metal to promote homogeneity, temperature, and cleanliness of said refined molten metal;   protecting said refined molten metal from re-oxidation;   bottom-pouring said refined molten metal while protecting said refined molten metal from re-oxidation;   maintaining temperature control of said refined molten metal and minimizing re-oxidation;   monitoring the temperature of said refined molten metal;   transferring said refined molten metal while protecting said refined molten metal;   controlling the pouring rate of said refined molten metal;   minimizing temperature losses and minimizing argon losses;   metering said refined molten metal;   freezing said refined molten metal and producing a small diameter bar or ingot;   moving said small diameter bar or ingot and allowing said small diameter bar or ingot to drop; and   transporting said small diameter bar or ingot.   
   
   
       9 . Means for performing the method of manufacturing small diameter bars or ingots according to  claim 8 ; said means comprising:
 means for refining molten metal for a first run of small diameter bars or ingots;   means for transferring refined molten metal;   means for protecting refined molten metal from the atmosphere;   means for argon-stirring refined molten metal to promote homogeneity, temperature, and cleanliness of the refined molten metal;   means for protecting refined molten metal from re-oxidation;   means for bottom-pouring refined molten metal while protecting the refined molten metal from re-oxidation;   means for maintaining temperature control of refined molten metal and minimizing re-oxidation;   means for monitoring the temperature of refined molten metal;   means for transferring refined molten metal while protecting the refined molten metal;   means for controlling the pouring rate of refined molten metal;   means for minimizing temperature losses and minimizing argon losses;   means for metering refined molten metal;   means for freezing refined molten metal and producing a small diameter bar or ingot;   means for moving a small diameter bar or ingot and allowing the small diameter bar or ingot to drop; and   means for transporting a small diameter bar or ingot.   
   
   
       10 . A small diameter bar or ingot manufacturing arrangement for performing the method of manufacturing small diameter bars or ingots according to  claim 8 ; said small diameter bar or ingot manufacturing arrangement comprising:
 a refining arrangement configured to refine molten metal for a first run of small diameter bars or ingots;   a first transferring arrangement being configured to transfer refined molten metal;   a first protecting arrangement being configured to protect refined molten metal from the atmosphere;   an argon-stirring arrangement being configured to argon-stir refined molten metal to promote homogeneity, temperature, and cleanliness of the refined molten metal;   a second protecting arrangement being configured to protect refined molten metal from re-oxidation;   a bottom-pouring arrangement being configured to bottom-pour refined molten metal while the refined molten metal is being protected from re-oxidation;   a maintaining arrangement being configured to maintain temperature control of refined molten metal and minimize re-oxidation;   a monitoring arrangement being configured to monitor the temperature of refined molten metal;   a second transferring arrangement being configured to transfer refined molten metal while the refined molten metal is being protected;   a controlling arrangement being configured to control the pouring rate of refined molten metal;   a minimizing arrangement being configured to minimize temperature losses and minimize argon losses;   a metering arrangement being configured to meter refined molten metal;   a freezing arrangement being configured to freeze refined molten metal and produce a small diameter bar or ingot;   a moving arrangement being configured to move a small diameter bar or ingot and allow the small diameter bar or ingot to drop; and   a transporting arrangement being configured to transport a small diameter bar or ingot.   
   
   
       11 . The method of manufacturing small diameter bars or ingots using a bar mold system according to  claim 8 , wherein:
 said step of metering further comprises metering said refined molten metal from a pouring vessel, through a plurality of stopper rod nozzle assemblies, and into a multi-part bar mold system;   said multi-part bar mold system comprises water-cooled side walls and a water-cooled bottom;   said method further comprises controlling said moving with a control device;   said step of moving said small diameter bar or ingot and allowing said small diameter bar or ingot to drop further comprises moving said water-cooled sidewalls, and thereby said small diameter bar or ingot, away from said water-cooled bottom of said multi-part bar mold system and allowing said small diameter bar or ingot to drop onto a collection conveyor;   said water-cooled bottom of said multi-part bar mold system is configured to remain stationary during said steps of metering, freezing, moving, and controlling said moving; and   said method further comprises:
 moving said water-cooled side walls over said stationary water-cooled bottom prior to said step of metering said refined molten metal from said pouring vessel; and 
 moving said water-cooled side walls away from said water-cooled bottom of said multi-part bar mold system after said step of freezing said refined molten metal, thereby creating a bottomless mold. 
   
   
   
       12 . The method of manufacturing small diameter bars or ingots using a bar mold system according to  claim 11 , wherein:
 said method of bottom-pouring further comprises bottom-pouring said refined molten metal into a holding tundish while protecting said refined molten metal with a shroud comprising an inert gas;   said method further comprises:
 skimming said refined molten metal in said holding tundish; 
 sealing said holding tundish to minimize heat losses and argon losses; and 
 inserting a pyrometer or probe into said refined molten metal and monitoring the temperature of said refined molten metal. 
   
   
   
       13 . The method of manufacturing small diameter bars or ingots using a bar mold system according to  claim 12 , wherein:
 said step of transferring said refined molten metal while protecting said refined molten metal further comprises transferring said refined molten metal into a pouring vessel while protecting said refined molten metal with said shroud comprising an inert gas;   said holding tundish and said pouring vessel are configured to permit:
 control of the temperature of said refined molten metal; 
 protection of the homogeneity and cleanliness of said refined molten metal; and 
 substantially accurate transferring and bottom-pouring of said refined molten metal. 
   
   
   
       14 . The method of manufacturing small diameter bars or ingots using a bar mold system according to  claim 13 , wherein said holding tundish comprises:
 insulated walls;   an insulated floor;   an induction coil;   a power supply;   an automated control system;   an insulated lid, which insulated lid comprises ports for temperature monitoring and ports for argon backfill flooding;   a spout;   at least one of: screw jacks and electric cylinders; and   at least one of: a plurality of linear positions transducers and a plurality of encoders.   
   
   
       15 . The method of manufacturing small diameter bars or ingots using a bar mold system according to  claim 14 , wherein:
 said pouring vessel comprises:
 insulated walls; 
 a floor; 
 an insulated pouring vessel lid, which insulated pouring vessel lid comprises ports for temperature monitoring and ports for argon backfill flooding; 
 a temperature monitoring arrangement; 
 an emergency run out arrangement; 
 an automated dual stopper rod system with both a plunge and twist arrangement and a nozzle clean out arrangement; 
 stopper rods; 
 a nozzle; 
 a metal level control system; and 
 an automated control system; 
   said multi-part bar mold system further comprises:
 at least one quick-change water-cooled mold size and shape insert; and 
 a motion control system configured to move said water-cooled side walls before and after said step of metering said refined molten metal from said pouring vessel; 
   said step of transferring said refined molten metal further comprises transferring said refined molten metal into a ladle;   said step of protecting said refined molten metal from the atmosphere further comprises protecting said refined molten metal from the atmosphere with an insulating ladle cover   said insulating ladle cover comprises at least one of: a rice hulls or vermiculite;   said multi-part bar mold system is comprised of one of: Chrome-Zinc Alloy grade #108, C18150, or Alloy grade #101;   said step of controlling the pouring rate further comprises controlling the pouring rate of said refined molten metal with a pouring control arrangement;   said pouring control arrangement comprises at least one of: load cells, a level detection device, measuring rods, a tilting device, a screw jack, and a trunnion;   said pouring control arrangement further comprises at least one of: an encoder, a linear position transducer, or a similar device, in order to monitor the position of said pouring vessel;   said method is used for the manufacture of small diameter bars or ingots comprising at least one of: steels, superalloys, nickel base, cobalt base, copper-based grades, and raw material master alloys; and   said shroud comprising an inert gas comprises an argon shroud.   
   
   
       16 . A method for the manufacture of metal bars using a bar mold system comprising: a ladle; a ladle cover; an argon shroud; a holding tundish; a temperature control device; a probe; a monitor device; a pouring vessel comprising two independently operated stopper rod assemblies on the bottom of said pouring vessel; a controller to operate said stopper rod assemblies; a pouring control arrangement; a mold arrangement comprising moveable water-cooled side walls, size and shape inserts, and a water-cooled bottom base plate; a collection conveyor; and an identification station; said method comprising the steps of:
 refining molten metal for a first run of metal bars;   transferring said molten metal into said ladle;   maintaining homogeneity of said molten metal by means of argon stirring;   protecting said molten metal from re-oxidation by use of said argon shroud and said ladle cover;   bottom-pouring said molten metal while said molten metal is surrounded by said argon shroud into said holding tundish;   maintaining temperature control of said molten metal with said temperature control device and minimizing the chance of re-oxidation in said holding tundish;   monitoring the molten metal temperature with said probe that is connected to said monitor device;   transferring said molten metal surrounded by said argon shroud into said pouring vessel;   controlling the pouring rate of said molten metal with said pouring control arrangement;   transferring said molten metal into said mold arrangement;   freezing said molten metal against said moveable water-cooled side walls and said water-cooled bottom base plate of said mold arrangement upon said molten metal entering said mold arrangement;   separating said moveable water-cooled side walls from said water-cooled bottom base plate and allowing the newly formed metal bar to drop onto said collection conveyor;   transporting said newly formed metal bar to said identification station.   
   
   
       17 . The method for the manufacture of metal bars using a bar mold system according to  claim 16 , wherein:
 said water-cooled bottom base plate of said mold arrangement is configured to remain stationary during said steps of transferring said molten metal into said mold arrangement, freezing, and separating; and   said method further comprises:
 moving said moveable water-cooled side walls over said stationary water-cooled bottom base plate prior to said step of transferring said molten metal into said mold arrangement; and 
 moving said moveable water-cooled side walls away from said water-cooled bottom base plate of said mold arrangement after said step of freezing, thereby creating a bottomless mold. 
   
   
   
       18 . The method for the manufacture of metal bars using a bar mold system according to  claim 17 , wherein said method further comprises:
 skimming said molten metal in said holding tundish;   sealing said holding tundish to minimize heat losses and argon losses; and   inserting said probe into said molten metal and monitoring the temperature of refined molten metal.   
   
   
       19 . The method for the manufacture of metal bars using a bar mold system according to  claim 18 , wherein said holding tundish and said pouring vessel are configured to permit:
 control of the temperature of said molten metal;   protection of the homogeneity and cleanliness of said molten metal; and   substantially accurate transferring and bottom-pouring of said refined molten metal.   
   
   
       20 . The method for the manufacture of metal bars using a bar mold system according to  claim 19 , wherein:
 said holding tundish comprises:
 insulated walls; 
 an insulated floor; 
 an induction coil; 
 a power supply; 
 an automated control system; 
 an insulated lid, which insulated lid comprises ports for temperature monitoring and ports for argon backfill flooding; 
 a spout; 
 at least one of: screw jacks and electric cylinders; and 
 and at least one of: a plurality of linear positions transducers and a plurality of encoders; 
   said pouring vessel comprises:
 insulated walls; 
 a floor; 
 an insulated pouring vessel lid, which insulated pouring vessel lid comprises ports for temperature monitoring and ports for argon backfill flooding; 
 a temperature monitoring arrangement; 
 an emergency run out arrangement; 
 an automated dual stopper rod system with both a plunge and twist arrangement and a nozzle clean out arrangement; 
 stopper rods; 
 a nozzle; 
 a metal level control system; and 
 an automated control system; 
   said mold arrangement further comprises:
 at least one quick-change water-cooled mold size and shape insert; and 
 a motion control system configured to move said moveable water-cooled side walls before and after said step of transferring said molten metal into said mold arrangement; 
   said insulating ladle cover comprises at least one of: a rice hulls or vermiculite;   said mold arrangement is comprised of one of: Chrome-Zinc Alloy grade #108, C18150, or Alloy grade #101;   said pouring control arrangement comprises at least one of: load cells, a level detection device, measuring rods, a tilting device, a screw jack, and a trunnion; and   said pouring control arrangement further comprises at least one of: an encoder, a linear position transducer, or a similar device, in order to monitor the position of said pouring vessel; and   said method is used for the manufacture of small diameter bars or ingots comprising at least one of: steels, superalloys, nickel base, cobalt base, copper-based grades, and raw material master alloys.