Nosetip design for high-performance continuous casting

Abstract

Described are nosetips for continuous casting of a metal alloy. The nosetip may include a first portion having a first surface parallel to a second surface opposite the first surface. The nosetip may include a second portion having a third surface directed toward an extended first surface. The extended first surface may be in a common plane with the first surface. The nosetip may include a third portion having an arcuate surface connecting the third surface to the extended first surface. The arcuate surface may include a point of curvature at a vertical distance from the extended first surface. The vertical distance may be configured to limit a maximum meniscus height for liquid metal, cast using the nosetip, between the nosetip and a continuous casting surface. Also described are methods of continuous casting a metal alloy at a casting speed of greater than 12 m/min.

What is claimed is: 
     
         1 . A nosetip for continuous casting of a metal alloy, the nosetip comprising:
 a first portion having a first surface parallel to a second surface, the second surface opposite the first surface;   a second portion having a third surface directed toward an extended first surface, the extended first surface in a common plane with the first surface; and   a third portion having an arcuate surface connecting the third surface to the extended first surface.   
     
     
         2 . The nosetip of  claim 1 , wherein the arcuate surface includes a point of curvature. 
     
     
         3 . The nosetip of  claim 2 , wherein the point of curvature is a vertical distance from the extended first surface, the vertical distance configured to limit a maximum meniscus height for liquid metal, cast using the nosetip, between the nosetip and a continuous casting surface. 
     
     
         4 . The nosetip of  claim 2 , wherein the third portion includes a cutback between the point of curvature and the extended first surface. 
     
     
         5 . The nosetip of  claim 1 , wherein the third portion includes a turbulence generating mechanism. 
     
     
         6 . The nosetip of  claim 5 , wherein the turbulence generating mechanism is at least one chosen from a plurality of dimples, a plurality of ribs, a plurality of piers, or a surface roughness greater than a surface roughness of the first surface, the second surface, or the extended first surface. 
     
     
         7 . The nosetip of  claim 1 , wherein the nosetip comprises a refractory material. 
     
     
         8 . A method of continuous casting a metal alloy, the method comprising:
 providing an arcuate nosetip, the arcuate nosetip including:
 a first portion having a first surface parallel to a second surface, the second surface opposite the first surface; 
 a second portion having a third surface directed toward an extended first surface, the extended first surface in a common plane with the first surface; and 
 a third portion having an arcuate surface connecting the third surface to the extended first surface; and 
   flowing liquid metal, through the arcuate nosetip, to a casting cavity to form a cast product.   
     
     
         9 . The method of  claim 8 , wherein a meniscus length of the liquid metal flowing through the arcuate nosetip is at most equal to a distance from a point of curvature to a casting surface partially defining the casting cavity. 
     
     
         10 . The method of  claim 9 , wherein the meniscus length is from 0.5 mm to 2.0 mm. 
     
     
         11 . The method of  claim 8 , wherein the third portion of the arcuate nosetip further comprises a turbulence generating mechanism. 
     
     
         12 . The method of  claim 11 , wherein the turbulence generating mechanism is at least one chosen from a surface roughness, a plurality of dimples, a plurality of ribs, a plurality of piers, and combinations thereof. 
     
     
         13 . The method of  claim 8 , further comprising generating turbulence in the liquid metal at the arcuate surface using a magnetic oscillation technique. 
     
     
         14 . The method of  claim 8 , wherein the nosetip is a refractory material. 
     
     
         15 . The method of  claim 8 , wherein the cast product has a surface roughness of at most 10 μm. 
     
     
         16 . The method of  claim 8 , wherein the cast product has a composition near the surface having a decrease in Fe and Mn at the cast surface as compared with a reference conventionally cast standard. 
     
     
         17 . The method of  claim 16 , wherein the composition is characterized by Glow Discharge Optical Emission Spectroscopy. 
     
     
         18 . The method of  claim 8 , wherein the cast product has an exudate frequency of at most 30 exudates/cm 2 . 
     
     
         19 . The method of  claim 18 , wherein the exudate frequency is determined by 3D image analysis. 
     
     
         20 . The method of  claim 8 , wherein the method provides a casting speed of greater than 12 m/min.