Horizontal single belt casting of ferrous and non-ferrous metals

水平单带铸造（HSBC）工艺是一种新的选择，可用于近净形铸造钢和铝带材的薄板制造业务。它提供了无摩擦，无约束凝固的水平板坯或带材的合金，其次是在线轧制到最终的规格板。在我们的Stinson实验室，麦吉尔金属加工中心的熔化和铸造设备已经被重新安置，一个中试规模的汇丰连铸机正在成功地生产AA 6111铝合金带材。现在，它正在升级，以铸造新等级的高强度，高韧性钢（HSHD）。这些都是在全球范围内进行深入研究的。由于这些新牌号的HSHD钢代表了钢铁制造商的新时代，其强度至少是常规钢的两倍，在失效前具有更大的延展性（~+65-100%），因此它们可以用作轻型汽车的较薄截面，和/或显著增强关键部件。我们将在汇丰机器上并行工作，在这两种金属上，将我们在铸造铝合金方面获得的专业知识扩展到同等的钢合金系统。我们将继续我们的温度-时间测量，模拟第一个20-30毫秒的液体金属和合金与冷却子表面的初始接触。这就决定了带钢的底面质量.同样，我们打算确定各种气体气氛对薄带上表面质量的影响，并测量HSHD钢、5XXX和6XXX系列铝合金的各种性能和特征。为了优化水冷带上的熔体铸造，以0.5-1.5 m/s的速度移动，我们打算对各种液态金属输送系统进行数学建模，使用计算流体动力学，并比较预测对我们的实验铸造工作。为了提高获得理想铸坯组织和性能所需的金属等速送料，我们将探索设计电磁制动的可能性，以确保所有液态金属以带速移动。最后，我们打算开发一个完全预测模型的汇丰系统的铝和钢熔体，可用于设计目的，并按比例放大。

The Horizontal Single Belt Casting (HSBC) process is a new option available for the Near-Net Shape Castingof steel and aluminium strips for sheet making operations. It provides for the friction-free, unconstrainedsolidification of a horizontal slab or strip of alloy, followed by in-line rolling down to final gauge sheet. At ourStinson Laboratories where the McGill Metals Processing Centre melting and casting equipment have beenre-located, a pilot-scale HSBC caster is successfully producing AA6111 aluminium alloy strips. It is now beingupgraded to cast new grades of High Strength, High Ductility Steels (HSHD). These are being intensivelyresearched, globally. As these new grades of HSHD steels represent a new era for steelmakers, being at leasttwice the strength of regular steels, with much greater ductility prior to failure (~+65-100%), they can be usedas thinner sections to lightweight cars, and/or to significantly strengthen critical components. We will work inparallel on the HSBC machine on these two metals, extending our expertise gained in casting aluminum alloys,to equivalent steel alloy systems. We will continue with our temperature-time measurements, modelling thefirst 20-30 milleseconds of initial contact of liquid metals and alloys with a cooling sub-surface. Thisdetermines the bottom surface quality of the strip. Similarly, we intend to determine the effects of variousgaseous atmospheres on the surface quality of the upper surface of thin strips being formed, and to measure thevarious properties and characteristics of the HSHD steels, 5XXX, and 6XXX series Al alloys being produced.To optimize the melt casting on a water cooled belt, moving at 0.5-1.5 m/s, we intend to mathematically modelvarious liquid metal delivery systems, using computational fluid dynamics, and to compare predictions againstour experimental casting work. To enhance the iso-kinetic feeding of metal that is needed for obtaining anideal cast slab structure and properties, we will explore the possibility of designing electromagnetic braking toensure that all the liquid metal moves at the belt speed. Finally, we intend to develop a fully predictive modelof the HSBC system for aluminum and steel melts, that can be used for design purposes, and scale-up.