Dynamic mold shape control for direct chill casting

Abstract

Provided herein is a system, apparatus, and method for continuous casting of metal, and more particularly, to a mechanism for controlling the shape of a direct chill casting mold to dynamically control a profile of an ingot cast from the mold during the casting process. Embodiments may provide an apparatus for casting material including: first and second opposing side walls; first and second end walls extending between the first and second side walls, where the first and second opposing side walls and the first and second opposing end walls form a generally rectangular shaped mold cavity. At least one of the first and second opposing side walls may include two or more contact regions, where each of the two or more contact regions may be configured to be displaced relative to a straight line along the side wall.

1 .- 10 . (canceled) 
     
     
         11 . A direct chill casting mold, the mold comprising:
 a first longitudinally extending side wall;   a first force applying member;   a second longitudinally extending side wall;   a second force applying member;   a first end wall;   a second end wall, wherein a mold cavity is defined between the first longitudinally extending side wall and the second longitudinally extending side wall and between the first end wall and the second end wall;   wherein a first bend is imparted to the first longitudinally extending side wall by the first force applying member, wherein a second bend is imparted to the second longitudinally extending side wall by the second force applying member, and wherein the first bend and the second bend create a width of the mold cavity that varies between the first end wall and the second end wall.   
     
     
         12 . The mold of  claim 11 , further comprising a plurality of cooling orifices along at least the first longitudinally extending side wall and the second longitudinally extending side wall configured to direct cooling fluid to a casting extending from the mold cavity. 
     
     
         13 . The mold of  claim 12 , wherein an angle between the casting and the plurality of cooling orifices is determined based on properties of a material of the casting. 
     
     
         14 . The mold of  claim 11 , further comprising a first set of cooling orifices along at least the first longitudinally extending side wall and the second longitudinally extending side wall, and a second set of cooling orifices along at least the first longitudinally extending side wall and the second longitudinally extending side wall, the first set of cooling orifices and the second set of cooling orifices configured to direct cooling fluid to a casting extending from the mold cavity, wherein the first set of cooling orifices is arranged at a first angle relative to the casting and the second set of cooling orifices is arranged at a second angle relative to the casting. 
     
     
         15 . The mold of  claim 14 , wherein the first angle and the second angle are determined based on properties of a material of the casting. 
     
     
         16 . The mold of  claim 11 , further comprising a graphite liner defining, at least in part, a casting face of the first longitudinally extending side wall. 
     
     
         17 . The mold of  claim 16 , wherein the graphite liner maintains contact with the first longitudinally extending side wall along its length as the bend is imparted to the first longitudinally extending side wall. 
     
     
         18 . The mold of  claim 16 , wherein the graphite liner comprises a casting face and a contact face, wherein the contact face contacts the first longitudinally extending side wall along its length, wherein the graphite liner comprises one or more grooves in the contact face to facilitate bending of the graphite liner in congruence with the first longitudinally extending side wall. 
     
     
         19 . The mold of  claim 18 , wherein the one or more grooves extend transverse to the first longitudinally extending side wall. 
     
     
         20 . A mold wall for a direct chill casting mold, the mold wall comprising:
 a longitudinally extending body extending along a length between a first end and a second end;   a graphite liner secured to a face of the longitudinally extending body between the first end and the second end and defining a casting surface; and   a force receiving member disposed on the longitudinally extending body opposite the graphite liner, wherein a bend is imparted to the longitudinally extending body in response to a force received at the force receiving member, wherein a middle of the longitudinally extending body is displaced by the bend relative to the first end and the second end of the longitudinally extending body.   
     
     
         21 . The mold wall of  claim 20 , further comprising a first set of cooling orifices disposed along the longitudinally extending body and a second set of cooling orifices disposed along the longitudinally extending body, wherein the first set of cooling orifices are configured at a first angle relative to a plane defined by the casting surface, wherein the second set of cooling orifices are configured at a second angle relative to the plane defined by the casting surface, and wherein the first angle is different from the second angle. 
     
     
         22 . The mold wall of  claim 21 , wherein the first angle and the second angle are determined based on properties of a material for which the mold wall is configured to cast. 
     
     
         23 . The mold wall of  claim 20 , wherein the graphite liner maintains contact with the face of the longitudinally extending body along its length as the bend is imparted to the longitudinally extending body. 
     
     
         24 . The mold wall of  claim 23 , wherein the graphite liner comprises a contact face, wherein the contact face contacts the longitudinally extending body along its length, wherein the graphite liner comprises one or more grooves in the contact face to facilitate bending of the graphite liner in congruence with the longitudinally extending body. 
     
     
         25 . The mold wall of  claim 24 , wherein the one or more grooves extend transverse to the longitudinally extending body. 
     
     
         26 . The mold wall of  claim 20 , wherein the force receiving member is a first force receiving member, the mold wall further comprising a second force receiving member disposed at a different position along the length of the longitudinally extending body than the first force receiving member, wherein the longitudinally extending body is displaced by the bend relative to the first and the second end at the first force receiving member a distance different than at the second force receiving member. 
     
     
         27 . The mold wall of  claim 20 , wherein the casting surface of the graphite liner extends between a top of the casting face and a bottom of the casting face, wherein the graphite liner has a first thickness at the top of the casting face and a second thickness at the bottom of the casting face, wherein the first thickness is greater than the second thickness. 
     
     
         28 . The mold wall of  claim 27 , wherein the graphite liner at the bottom of the casting face is supported on a ledge of the longitudinally extending body. 
     
     
         29 . The mold wall of  claim 28 , further comprising lubricating orifices define in the longitudinally extending body positioned above a top of the casting face of the graphite liner. 
     
     
         30 . The mold wall of  claim 29 , wherein a lubricant is provided through the lubricating orifices from a fluid chamber to lubricate the casting surface during casting.