Continuous casting apparatus and method

Abstract

A conveyor furnace system is provided that includes a housing, a conveyor, a vacuum device, and at least one heating element. The housing may have a first end and a second end. The conveyor may be configured to transit one or more component molds from the first end to the second end. The vacuum device may be configured to selectively produce a below atmospheric pressure within the housing. The at least one heating element may be disposed in the housing, and has a first end disposed adjacent the first end of the housing and a second end adjacent the second end of the housing. The at least one heating element is configured to provide a vertically tapered heating exposure in a direction from the first end of the housing to the second end of the housing.

What is claimed is: 
     
         1 . A conveyor furnace system, comprising:
 a housing having a first end and a second end, the second end opposite the first end;   a conveyor configured to transit one or more component molds from the first end to the second end, each component mold having a base end and a top end and a height extending therebetween;   a vacuum device configured to selectively produce a below atmospheric pressure within the housing; and   a plurality of heating elements disposed in the housing, the plurality of heating elements is arranged within the housing so that the one or more component molds transiting through the housing are subjected to a progressively different heating exposure in a direction from the first end to the second end during operation of the system.   
     
     
         2 . The system of  claim 1 , wherein the housing includes a loading station and an intermediate station, and the conveyor is configured to transit the one or more component molds from the loading station and into the intermediate station, and the plurality of heating elements are disposed in the intermediate station. 
     
     
         3 . The system of  claim 2 , wherein the housing includes an unloading station, and the loading station is disposed at the first end of the housing, and the unloading station is disposed at the second end of the housing, and the intermediate station is disposed between the first end and the second end. 
     
     
         4 . The system of  claim 3 , wherein the loading station, the intermediate station, and the unloading station are linearly arranged. 
     
     
         5 . The system of  claim 3 , wherein the loading station, the intermediate station, and the unloading station are non-linearly arranged. 
     
     
         6 . The system of  claim 5 , wherein the vacuum device is configured to selectively produce a below atmospheric pressure within the loading station, the unloading station, and the intermediate station, all independent from one another. 
     
     
         7 . The system of  claim 1 , wherein the housing includes at least one station configured for loading and unloading component molds. 
     
     
         8 . The system of  claim 7 , wherein the housing includes an intermediate station that extends arcuately from the at least one station, and the first end of the housing is disposed at the at least one station and the second end of the housing is disposed at the at least one station. 
     
     
         9 . The system of  claim 1 , wherein the progressively different heating exposure continuously changes in the direction from the first end to the second end during operation of the system. 
     
     
         10 . The system of  claim 9 , wherein the progressively different heating exposure continuously decreases in the direction from the first end to the second end during operation of the system. 
     
     
         11 . The system of  claim 1 , wherein the progressively different heating exposure changes in a stepped configuration in the direction from the first end to the second end during operation of the system. 
     
     
         12 . The system of  claim 11 , wherein the stepped configuration includes a plurality of steps, with each downstream step having a decreased heating exposure. 
     
     
         13 . The system of  claim 1 , further comprising a plurality of cooling elements, and the plurality of cooling elements is arranged within the housing relative to the plurality of heating elements so that the one or more component molds transiting through the housing are subjected to a progressively different heating exposure in a direction from the first end to the second end during operation of the system. 
     
     
         14 . A conveyor furnace system, comprising:
 a housing having a first end and a second end, the second end opposite the first end;   a conveyor configured to transit one or more component molds from the first end to the second end, each component mold having a base end and a top end and a height extending therebetween;   a vacuum device configured to selectively produce a below atmospheric pressure within the housing; and   at least one heating element disposed in the housing, the at least one heating element has a first end disposed adjacent the first end of the housing and a second end adjacent the second end of the housing, wherein the at least one heating element is configured to provide a vertically tapered heating exposure in a direction from the first end of the housing to the second end of the housing.   
     
     
         15 . The system of  claim 14 , wherein the first end of the heating element has a first vertical heating exposure portion, and the second end of the heating element having a second vertical heating exposure portion, and the first vertical heating exposure portion is greater than the second vertical heating exposure portion. 
     
     
         16 . The system of  claim 15 , wherein the first vertical heating exposure portion and the second vertical heating exposure portion both extend from adjacent a ceiling of the housing. 
     
     
         17 . A method of producing a directionally solidified component, comprising:
 heating a component mold within a conveyor furnace system to a predetermined temperature, the conveyor furnace system having a housing with a first lengthwise end and an opposite second lengthwise end, and the component mold having a top vertical end and a bottom vertical end;   transferring a charge of molten metal into the heated component mold;   transiting the heated component mold containing the charge of molten metal within the housing from the first lengthwise end to the second lengthwise end; and   exposing the heated component mold containing the charge of molten metal to a vertically tapered heating exposure in a direction from the first lengthwise end of the housing to the second lengthwise end of the housing.   
     
     
         18 . The method of  claim 17 , further comprising selectively creating an environment within the housing that is below atmospheric pressure. 
     
     
         19 . The method of  claim 18 , wherein the housing includes a loading station disposed at the first lengthwise end of the housing and an unloading station disposed at the second lengthwise end of the housing, and an intermediate station disposed between the loading station and the unloading station;
 the method further comprising loading the component mold into the loading station prior to heating the component mold to the predetermined temperature, transiting the component mold from the loading station, through the intermediate station, and into the unloading station, and unloading the component mold from the unloading station.   
     
     
         20 . The method of  claim 19 , further comprising selectively creating an environment within the loading station that is below atmospheric pressure prior to transiting the component mold from the loading station, through the intermediate station, and into the unloading station.