Direct chill casting mold system

Abstract

A direct chill casting mold system includes a mold and at least one coolant bar. The mold defines a casting cavity having a casting axis along which a metal product moves during a casting process. The at least one coolant bar includes a plurality of nozzles, and the at least one coolant bar is configured to dispense a coolant via the plurality of nozzles onto a periphery of the metal product after the metal product has passed through the mold. In various aspects, the at least one coolant bar is movable relative to the casting axis.

1 . A direct chill casting mold system comprising:
 a mold defining a casting cavity comprising a casting axis; and   a coolant bar comprising a plurality of nozzles, wherein the coolant bar is configured to dispense a coolant via the plurality of nozzles onto a periphery of a metal product after the metal product has passed through the mold, and wherein the coolant bar is movable relative to the casting axis.   
     
     
         2 . The direct chill casting mold system of  claim 1 , wherein the coolant bar comprises a coolant bar axis, wherein the plurality of nozzles comprises a first set of nozzles and a second set of nozzles, wherein each nozzle of the first set of nozzles extends at a first non-zero angle relative to the coolant bar axis, and wherein each nozzle of the second set of nozzles extends at a second non-zero angle relative to the coolant bar axis that is different from the first non-zero angle. 
     
     
         3 . The direct chill casting mold system of  claim 1 , wherein the coolant bar is movable between a start position, a transition position, and a run position, wherein:
 in the start position, at least one nozzle of the plurality of nozzles is a first distance from the casting axis;   in the transition position, the at least one nozzle of the plurality of nozzles is a second distance from the casting axis that is less than the first distance; and   in the run position, the at least one nozzle of the plurality of nozzles is a third distance from the casting axis that is less than the second distance.   
     
     
         4 . The direct chill casting mold system of  claim 1 , wherein the mold and the coolant bar are each movable relative to the casting axis in a direction substantially perpendicular to the casting axis. 
     
     
         5 . The direct chill casting mold system of  claim 4 , wherein the coolant bar is a first coolant bar and the plurality of nozzles are a first plurality of nozzles, wherein the direct chill casting mold system further comprises a second coolant bar comprising a second plurality of nozzles, and wherein the second coolant bar is between the mold and the first coolant bar along the casting axis. 
     
     
         6 . The direct chill casting mold system of  claim 5 , wherein the second coolant bar is fixed in the direction substantially perpendicular to the casting axis. 
     
     
         7 . (canceled) 
     
     
         8 . A direct chill casting mold system comprising:
 a mold defining a casting cavity comprising a casting axis; and   a coolant bar comprising a plurality of nozzles, wherein the coolant bar is configured to dispense a coolant via the plurality of nozzles onto a periphery of a metal product after the metal product has passed through the mold, and wherein an angle of at least one nozzle of the plurality of nozzles is adjustable relative to the casting axis.   
     
     
         9 . The direct chill casting mold system of  claim 8 , wherein the mold is internally cooled. 
     
     
         10 . The direct chill casting mold system of  claim 8 , wherein the coolant bar comprises a coolant bar axis, wherein the plurality of nozzles comprises a first set of nozzles and a second set of nozzles, wherein each nozzle of the first set of nozzles extends at a first non-zero angle relative to the coolant bar axis, and wherein each nozzle of the second set of nozzles extends at a second non-zero angle relative to the coolant bar axis that is different from the first non-zero angle. 
     
     
         11 . The direct chill casting mold system of  claim 8 , wherein the coolant bar is pivotable about a pivot axis that is substantially perpendicular to the casting axis such that the angle of the at least one nozzle is adjustable relative to the casting axis. 
     
     
         12 . The direct chill casting mold system of  claim 8 , wherein the mold and the coolant bar are each movable relative to the casting axis in a direction substantially perpendicular to the casting axis such that a dimension of the casting cavity in the direction substantially perpendicular to the casting axis is adjustable. 
     
     
         13 . The direct chill casting mold system of  claim 8 , wherein the mold comprises a plurality of mold sections that are movable relative to each other, and wherein the coolant bar comprises a plurality of coolant bar sections that are movable relative to each other. 
     
     
         14 . The direct chill casting mold system of  claim 8 , wherein the coolant bar is a first coolant bar and the plurality of nozzles are a first plurality of nozzles, wherein the direct chill casting mold system further comprises a second coolant bar comprising a second plurality of nozzles, wherein the second coolant bar is configured to direct the coolant via the second plurality of nozzles onto the periphery of the metal product after the metal product has pass through the mold. 
     
     
         15 . A direct chill casting mold system comprising:
 a mold defining a casting cavity comprising a casting axis;   a first coolant bar downstream from the mold, the first coolant bar comprising a plurality of first nozzles, wherein the first coolant bar is configured to dispense a coolant via the plurality of first nozzles onto a periphery of a metal product after the metal product has passed through the mold; and   a second coolant bar downstream from the mold, the second coolant bar comprising a plurality of second nozzles, wherein the second coolant bar is configured to dispense the coolant via the plurality of second nozzles onto the periphery of the metal product after the metal product has passed through the mold,   wherein the first coolant bar is fixed in a direction substantially perpendicular to the casting axis, and   wherein the second coolant bar is adjustable in the direction substantially perpendicular to the casting axis.   
     
     
         16 . The direct chill casting mold system of  claim 15 , wherein the mold is adjustable in the direction substantially perpendicular to the casting axis such that a dimension of the casting cavity in the direction substantially perpendicular to the casting axis is adjustable. 
     
     
         17 . The direct chill casting mold system of  claim 15 , wherein the first coolant bar is configured to dispense the coolant at a first pressure, wherein the second coolant bar is configured to dispense the coolant at a second pressure that is less than the first pressure, and wherein the first coolant bar is between the mold and the second coolant bar. 
     
     
         18 . The direct chill casting mold system of  claim 15 , wherein the mold is internally cooled. 
     
     
         19 . The direct chill casting mold system of  claim 15 , wherein the plurality of second nozzles comprises a first set of second nozzles and a second set of second nozzles, wherein an angle of each one of the first set of second nozzles relative to the casting axis is different from an angle of each one of the second set of second nozzles relative to the casting axis. 
     
     
         20 . The direct chill casting mold system of  claim 15 , wherein the second coolant bar is movable between a start position, a transition position, and a run position, wherein:
 in the start position, at least one nozzle of the plurality of second nozzles is a first distance from the casting axis;   in the transition position, the at least one nozzle of the plurality of second nozzles is a second distance from the casting axis that is less than the first distance; and   in the run position, the at least one nozzle of the plurality of second nozzles is a third distance from the casting axis that is less than the second distance.   
     
     
         21 . The direct chill casting mold of  claim 1 , wherein the mold is adjustable in the direction substantially perpendicular to the casting axis such that a dimension of the casting cavity in the direction substantially perpendicular to the casting axis is adjustable.