Method and device for casting metal alloy ingots

Abstract

The invention relates to a method of casting a metal alloy ingot. The method includes providing an on one side open-ended mould having a mould cavity, positioning the open-ended mould such that the mould opening points side-wards or down-wards, providing a casting container with an upwardly positioned aperture, and filling said casting container with molten metal for one casting operation. The method also includes locating the casting container below the mould while the mould opening points side-wards or down-wards, and rotating the mould together with the casting container to a position whereby the mould opening points upwards such that the molten metal is conveyed into the open-ended mould until a desired thickness. Molten metal in the open-ended mould is cooled directionally through its thickness where the solidification front remains substantially monoaxial.

1 . A method of casting a metal alloy ingot, comprising the following steps:
 providing an on one side open-ended mould comprising a plurality of sides and a bottom plate defining a mould cavity, said open-ended mould being pivotable around a horizontal rotational axis between a position so that the mould opening points upwards and a position so that the mould opening points side-wards or down-wards, and wherein the bottom plate of the mould is preferably provided with coolant means;   positioning the open-ended mould such that the mould opening points side-wards or down-wards;   providing a casting container with an upwardly positioned aperture;   filling said casting container with molten metal for one casting operation;   coupling the casting container to the open-ended mould so that the casting container is located below the mould while the mould opening points side-wards or down-wards;   rotating the open-ended mould together with the casting container around the horizontal axis for approximately 45° to 180°, preferably 90° to 180°, from a position whereby the mould opening points side-wards or down-wards to a position whereby the mould opening points upwards such that the molten metal is conveyed into the open-ended mould until a desired thickness;   and whereby the molten metal in the open-ended mould is cooled directionally through its thickness where a solidification front remains substantially monoaxial.   
     
     
         2 . A method according to  claim 1 , wherein the metal alloy is an aluminium alloy, and preferably an aluminium wrought alloy. 
     
     
         3 . A method according to  claim 1 , wherein the open-ended mould consists of four sides positioned upwards from the bottom plate of the mould. 
     
     
         4 . A method according to  claim 1 , wherein at least one of the sides of the mould is provided with temperature control means. 
     
     
         5 . A method according to  claim 1 , wherein the bottom plate of the mould is made from a metal and preferably provided with cooling channels for cooling medium passage. 
     
     
         6 . A method according to  claim 1 , further comprising the step of releasing the casting container from the coupled position and removing the casting container from the mould. 
     
     
         7 . A method according to  claim 1 , wherein a surface of the molten metal in the open-ended mould is heated via an external heat source. 
     
     
         8 . A method according to  claim 1 , wherein at least the conveying of the molten metal from the casting container to the open-ended mould is carried out under a protective gas atmosphere. 
     
     
         9 . A method according to  claim 1 , wherein at least the conveying of the molten metal from the casting container to the open-ended mould is carried out under a protective salt layer. 
     
     
         10 . A casting system comprising an on one side open-ended mould comprising a plurality of sides and a bottom plate defining a mould cavity, said open-ended mould being pivotable mounted around a horizontal rotational axis between a position so that the mould opening points upwards and a position so that the mould opening points side-wards or down-wards, and wherein optionally at least one of the sides of the mould is provided with temperature control means, and wherein the bottom plate of the mould is provided with coolant means; and a casting container with an upwardly positioned aperture pivotable mountable around the horizontal rotational axis.