Method and Apparatus for Semi-Continuous Casting of Hollow Ingots and Products Resulting Therefrom

Abstract

Methods and associated apparatus for semi-continuous casting of hollow ingots are described. In one embodiment a method for the semi-continuous casting of a metallic hollow ingot is provided. The method includes providing a mold comprising a mold center having an inner pipe and an outer pipe arranged to form an annular space for a cooling media and an outer mold, circulating a cooling media in the annular space, feeding a source material to the mold, heating the source material to produce a molten material, moving the mold center progressively downward relative to the outer mold, and solidifying the molten material to form a hollow ingot. Embodiments relating to an apparatus for semi-continuous casting of hollow ingots, and products resulting from the semi-continuous casting of hollow ingots are also described.

What is claimed is: 
     
         1 . A metallic hollow ingot product comprising:
 a metallic hollow ingot; and   a pipe intimately connected to the metallic hollow ingot at an inner surface of the metallic hollow ingot.   
     
     
         2 . The metallic hollow ingot of  claim 1 , wherein the pipe is selected from the group consisting of steel, copper, and ceramics. 
     
     
         3 . The metallic hollow ingot of  claim 1 , wherein the metallic hollow ingot is selected from the group consisting of titanium, zirconium, niobium, tantalum, hafnium, nickel, and alloys thereof. 
     
     
         4 . The metallic hollow ingot of  claim 1 , wherein the ingot has an outside diameter greater than about 18 inches, an inside diameter less than about 8.5 inches, and a length greater than 55 inches. 
     
     
         5 . The metallic hollow ingot of  claim 1 , wherein the ingot has an outside diameter greater than about 23 inches, an inside diameter less than about 10.75 inches, and a length greater than 65 inches. 
     
     
         6 . The metallic hollow ingot of  claim 1 , wherein the ingot has an outside diameter greater than about 25 inches, an inside diameter less than about 13.375 inches, and a length greater than 70 inches. 
     
     
         7 . The metallic hollow ingot of  claim 3 , wherein the ingot has an outside diameter greater than about 18 inches, an inside diameter less than about 8.5 inches, and a length greater than 55 inches. 
     
     
         8 . The metallic hollow ingot of  claim 3 , wherein the ingot has an outside diameter greater than about 23 inches, an inside diameter less than about 10.75 inches, and a length greater than 65 inches. 
     
     
         9 . The metallic hollow ingot of  claim 3 , wherein the ingot has an outside diameter greater than about 25 inches, an inside diameter less than about 13.375 inches, and a length greater than 70 inches. 
     
     
         10 . A metallic hollow ingot product comprising:
 a metallic hollow ingot; and   an outer casting pipe intimately connected to the metallic hollow ingot at an inner surface of the metallic hollow ingot, wherein the metallic hollow ingot is produced by a semi-continuously casting method comprising:   providing a mold having a mold cavity formed between:
 a mold center having an inner pipe and an outer casting pipe arranged to form an annular space for a cooling medium; and 
 an outer mold; 
   circulating a cooling medium in the annular space;   feeding a source material into the mold cavity;   heating the source material to produce a molten material;   moving the mold center progressively downward relative to the outer mold; and   solidifying the molten material around the outer casting pipe to form the hollow ingot.   
     
     
         11 . The metallic hollow ingot of  claim 10 , wherein the outer casting pipe is selected from the group consisting of steel, copper, and ceramics. 
     
     
         12 . The metallic hollow ingot of  claim 10 , wherein the source material is selected from the group consisting of titanium, zirconium, niobium, tantalum, hafnium, nickel, and alloys thereof. 
     
     
         13 . The metallic hollow ingot of  claim 10 , wherein the ingot has an outside diameter greater than about 18 inches, an inside diameter less than about 8.5 inches, and a length greater than 55 inches. 
     
     
         14 . The metallic hollow ingot of  claim 10 , wherein the ingot has an outside diameter greater than about 23 inches, an inside diameter less than about 10.75 inches, and a length greater than 65 inches. 
     
     
         15 . The metallic hollow ingot of  claim 10 , wherein the ingot has an outside diameter greater than about 25 inches, an inside diameter less than about 13.375 inches, and a length greater than 70 inches. 
     
     
         16 . The metallic hollow ingot of  claim 12 , wherein the ingot has an outside diameter greater than about 18 inches, an inside diameter less than about 8.5 inches, and a length greater than 55 inches. 
     
     
         17 . The metallic hollow ingot of  claim 12 , wherein the ingot has an outside diameter greater than about 23 inches, an inside diameter less than about 10.75 inches, and a length greater than 65 inches. 
     
     
         18 . The metallic hollow ingot of  claim 12 , wherein the ingot has an outside diameter greater than about 25 inches, an inside diameter less than about 13.375 inches, and a length greater than 70 inches.