BRPI0815268B1 - CAST OF CAST METAL, AND METHOD FOR CASTING METAL WITH VERTICAL DIRECT COOLING - Google Patents

Abstract

cast metal mold and method for vertical direct cooling cast metal casting is a cast metal lower block mold system which includes embodiments of the apparatus and method which may include a mold cavity structure with a first side, a second side opposite the first side, a third side, and a fourth side opposite the third side, wherein each side includes an inner surface, and the inner surfaces define a mold cavity, and wherein one or most of the sides are movably mounted relative to the second side, and are controllably moved during casting. This system may also include embodiments in which the produced cast part has a tapered shape at one or both ends of the cast part. Aspects of the present invention may be considered as a cast part shrink management system or a cast shape shape or profile control system due to the advantage of increased cast part shape controls during the casting process.

Description

CAST METAL MOLD, AND CAST METHOD FOR CAST METAL WITH DIRECT VERTICAL COOLING

TECHNICAL FIELD [001] The present invention relates to an automated variable size mold system and bottom sill brick, which results in a desired tapering or casting configuration.

BACKGROUND OF THE INVENTION [002] Metal ingots, billets and other castings can be formed by a casting process using a vertically oriented mold located above a large casting well below the floor level of the metal casting facility , although the present invention can also be used in horizontal molds. The bottom component of the vertical casting mold is a starting block. When the casting process begins, the starting blocks are in their highest position and in the molds. As the molten metal is poured into the hole or mold cavity and cooled (typically by water), the starting block is slowly lowered at a predetermined speed by a hydraulic cylinder or another device. As the starting block is lowered, metal or solidified aluminum emerges from the bottom of the mold and ingots, round bars or billets of iron or steel of various geometries are formed, which can also be named here invention as castings.

[003] Although the invention applies to metal casting in general, including, without limitation, aluminum, bronze, lead, zinc, magnesium, copper,

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2/66 steel, etc., the examples provided and the preferred embodiments described can refer to aluminum and, therefore, the term aluminum or molten metal can be used until the end for consistency, even if the invention applies more generally to metals.

[004] Although there are numerous ways to obtain and configure a vertical casting arrangement, Figure 1 illustrates an example. In Figure 1, the vertical casting of aluminum generally occurs below the elevation level of the factory floor in a casting well. Directly below the casting well, floor 101a is a pneumatic box 103, in which hydraulic cylinder drum 102 is placed for the hydraulic cylinder.

[005] As shown in Figure 1, the components of the lower portion of a typical vertical aluminum caster apparatus, shown inside a caster pit 101 and a pneumatic box 103, include a hydraulic cylinder drum 102, a piston 106, a mounting base casing 105, an upper plate 107 and a bottom sill brick 108 (also referred to as the starting head or starting block base), all shown at elevations below the floor 104 of the casting facility.

[006] The casing of the mounting base 105 is mounted on the floor 101a of the casting pit 101, below which is the pneumatic box 103. The pneumatic box 103 is defined by its side walls 103b and its floor 103a.

[007] A typical ingot holder table assembly 110 is also shown in Figure 1, which can be tilted as shown by hydraulic cylinder 111 which

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3/66 pushes the tilt arm 110a of the hatch table in such a way that it rotates around point 112 and thereby enlarges and rotates the main caster structure assembly, as shown in Figure 1. There are also ingot holder table that allows the ingot holder table assemblies to be moved to and from the caster position above the caster pit.

[008] Figure 1 additionally shows the upper plate 107 and the base of the starting block 108 that partially descend to the casting well 101 with the casting 113 (which can be an ingot or a billet being partially formed). The casting 113 is at the base of the starting block 108, which may include a starting head or a bottom sill brick, which usually (but not always) is at the base of the starting block 108, which is known in the state of technique and therefore does not need to be shown or described in more detail. Although the term starting block is used for item 108, it should be noted that the terms bottom threshold brick and starting head are also used in industry to refer to item 108, the bottom threshold brick is typically used when an ingot is being cast, and the starting head when a billet is being cast.

[009] Although the base of the starting block 108 in Figure 1 shows only a starting block 108 and a support, there are typically several of each mounted on each base of the starting block, which simultaneously shape billets, tapers or special configurations , or ingots as the starting block is lowered during the casting process.

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4/66 [010] When the hydraulic fluid is introduced into the hydraulic cylinder at a sufficient pressure, the piston 106 and, consequently, the starting block 108, are raised to the desired start elevation level for the casting process, which it is when the starting blocks are inside the set of the ingot holder table 110.

[011] The lowering of the starting block 108 is carried out by withdrawing the hydraulic fluid from the cylinder at a predetermined ratio, thereby lowering the piston 106 and, consequently, the starting block at a predetermined and controlled ratio. The mold is cooled in a controllable manner during the process to assist in the solidification of the emerging billets or billets, typically using a water cooling device.

[012] There are numerous molding and casting technologies that adapt to the ingot holder tables and none in particular is required to practice the various embodiments of the present invention, since they are known for elements skilled in the art.

[013] The upper side of the typical ingot holder table operatively connects, or interacts, with the metal distribution system. The typical ingot molding table also operatively connects to the molds it houses.

[014] When the metal is melted using a continuous vertical casting mold, the molten metal is cooled in the mold and emerges continuously from the lower end of the mold while the starting block base is lowered. The billet, billet or other emerging configuration must be sufficiently solidified

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5/66 in such a way as to maintain your desired profile, bottleneck or other desired configuration. There is a gap between the emerging solidified metal and the permeable ring wall. Below this, there is also a mold air cavity between the emerging solidified metal and the lower part of the mold and related equipment.

[015] Once the casting is complete, the casting, an ingot in this case, is removed from the bottom sill brick. Figure 1A illustrates an exemplary lower configuration of the block with a melt 113 being removed from the bottom sill brick 108 after casting. Figure 1A illustrates a bottom sill brick 108 with a particular shape or configuration in the internal cavity that receives the initial flow of the molten metal during the casting process, and the outer perimeter of the melt 113 once solidified takes on that shape.

[016] Figure 1A illustrates the inclined portions 115 and 116 and the notched portion 119 in the casting 113. The inclined portions 115 and 116 generally correspond to the lower notches 117 and 114 of the block in shape and configuration, and with some related variation usually to contraction or other factors of casting. The protrusion of the bottom brick 118 corresponds in shape and configuration to the groove of the castings 119, as can be seen in Figure 1A. The inclined portions 115 and 116 in the prior art ingots were at different angles, such as thirty degrees, forty five degrees and sixty degrees.

[017] Figure 1B is a sectional view

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6/66 transverse elevation of a wall of the mold 142 of the technique

previous with the surface in caster 142a, the piece fused 141, the structure of mold 143, the chamber with soda net 149, the zone of impact of the soda

liquid 146 where the liquid refrigerant (typically water) beats and cools the melt 141. The embodiments of the present invention can be applied to the prior art of all types, including the mold configuration illustrated in Figure 1B.

[018] In conventional casting and direct cooling casting processes for ingot rolling, a ingot undergoes a substantial transformation process during rolling. The ingot can be laminated to a plate, it can accumulate aluminum sheets and other products of different dimensions and thicknesses by a process that sends the ingot through a series of rolls repeatedly, with the rolls being moved closer sequentially. This laminating equipment can be called a laminating cage.

[019] One of the problems associated with this process is that a portion of the lamination ingot is wasted due to a phenomenon sometimes referred to as an alligator tail. The alligator tail occurs during the lamination process when the metal in the main body of the ingot is laminated and pushed over the end of the ingot on the head and on the sides of the base. When the ingot is observed in this condition from the side view, the head and base resemble an alligator's mouth, hence the origin of the term alligator tail. The alligator tail is illustrated in Figure 9. During the lamination process, the ends of the ingots that

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7/66 showing the alligator tail are cut off, thereby resulting in a substantial amount of residual aluminum that must be reheated and re-melted, in addition to the expense of this procedure.

[020] In some prior art, it has been shown that by producing an angle with a tapered head and base, the alligator's tail can be reduced or eliminated.

[021] An objective of some realizations of the present invention is to present an automated mold casting system with calculated and variable dimensions and a bottom sill brick that provides tapered parts and other configurations of the castings.

[022] An objective of some embodiments of the present invention is to present an automated mold casting system with calculated and variable dimensions that reduces the losses of the end cut.

[023] Other objectives, characteristics and advantages of the present invention will be evident from the specification, the claims and the attached drawings that form part of it. In achieving the objectives of the present invention, it should be understood that its essential features are susceptible to changes in the design and structural arrangement, with only one practical and preferred embodiment being illustrated in the attached drawings, as required.

BRIEF DESCRIPTION OF THE DRAWINGS [024] The preferred embodiments of the invention are described below with reference to the following attached drawings.

[025] Figure 1 is an elevation view of a

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8/66 vertical caster pit, pneumatic box and prior art metal caster;

[026] Figure 1A is an elevation view of a particularly formed prior art sill bottom brick and the corresponding cast removed from it;

[027] Figure 1B is a cross-sectional elevation view of a mold wall or a casting surface of the prior art that cools and interfaces with a casting;

[028] Figure 2 is a schematic cross-sectional top view of a fixed cast ingot typical of the prior art; when [029] Figure 3 is a schematic elevation representation of the lower portion of a casting that expands in a horizontal direction during the casting process;

[030] Figure 4 is a schematic top cross-sectional view of an embodiment of a perimeter wall of the mold, illustrating the potential directions of movement of the side walls;

[031] Figure 5 is a top view of an embodiment of a mold casting system contemplated by the present invention, in which two of the perimeter walls are mobile;

[032] Figure 6 is a top view of an embodiment of a mold casting system contemplated by the present invention, in which two of the end perimeter walls are movable;

[033] Figure 7 is an elevation view

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9/66 representative of an example of an ingot that can be produced as a product of the embodiments of the present invention, illustrating the tapering in the upper and lower portions of the ingot;

[034] Figure 8 is an elevation view of a typical cast piece ingot, with some contraction and associated cracks, shown in the corners;

[035] Figure 9 is an elevation view of the ends of an ingot such as that shown in Figure 8, after rolling operations and generally illustrating the alligator tail;

[036] The figure 10 is an representation schematic of an achievement in one system mold in variable dimension automated and in brick background in threshold, where the sill bottom brick is wider of

that the starting position or the width of the movable walls;

[037] The figure 11 is an representation schematic of a realization in one system of mold variable dimension automated and in brick background of threshold, where the movable walls of mold allow the

sill bottom brick is started within the movable walls of the mold;

[038] The figure 12 is an representation schematic of a realization in one system in mold in variable dimension automated and in brick in bottom in

sill, partly in the casting process as the bottom sill brick is being lowered;

[039] The figure 13 is an representation schematic of a realization in one system in mold in variable dimension automated and in brick in bottom in

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10/66 sill, advancing in the casting process and illustrates how the cast can be shaped dimensionally wider than the sill bottom brick;

[040] The figure 14 is an representation schematic of a realization in one system of mold variable dimension automated and in brick background of sill, even more advanced in proces casting machine Figure 13; [041] The figure 15 is an representation schematic of a realization in one system of mold variable dimension automated and in brick background of sill illustrating the capacity From aspects of this invention to affect the profile i or the part configuration

top of the casting at the end of the mold;

[042] The figure 16 is an representation schematic of a realization in one system in mold in variable dimension automated and in brick in bottom in

sill, illustrating a part cast partially in the casting process in which the present invention provides a different dimension and taper or configuration on one side of the cast compared to the other side;

[043] Figure 17 is a schematic representation of an aspect of an automated variable dimension mold system and bottom sill brick contemplated by the present invention, illustrating a bottom sill brick in a different way configured with the approximate width the opening of the mold;

[044] The figure 18 is an representation schematic of a realization in one system in mold in variable dimension automated and in brick in bottom in

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11/66 sill, illustrating another aspect of the present invention, wherein a liquid coolant is used within the bottom sill brick to obtain more desirable cooling of the molten metal in relation to the bottom sill brick;

[045]

The Figure is a schematic representation of an implementation of an automated variable-size mold system of bottom sill brick, illustrating another aspect of the invention in which movement of the mold side walls is not linear;

[046]

A schematic representation of an embodiment of an automated variable-size mold system of bottom sill brick is shown, illustrating an aspect of the invention similar to that shown in Figure 19, in which only one of the mold walls is moved at a mold angle to provide dissimilarity with respect to the other wall of a different dimension and / or configuration on one side of the casting compared to the other side;

[047]

A schematic representation of an automated variable dimensioned representation of a sill bottom brick mold system is shown, illustrating a mold wall formed or configured in a different way;

[048]

Figure 22 is a schematic representation of another aspect of the invention with a sill bottom brick configured in a different way and which only needs to have full height side walls on two sides, where said aspect can use the mold walls as part or all of the perimeter wall on two other sides;

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12/66 [049] Figure 23 is a schematic representation of the realization of an automated variable size mold system and bottom sill brick illustrated in Figure 22, which shows the end of the bottom sill brick and the absence of sill bottom brick end walls;

[050] Figure 24 is a schematic representation of an embodiment of the mold starting block configuration possible for some aspects of the present invention and which can be used in the embodiments of the present invention of the perimeter wall only on two sides;

[051] Figure 25 is a schematic representation of an implementation of an automated variable size mold system and bottom sill brick, illustrating another aspect of the present invention, in which a liquid refrigerant system is used within the sill bottom to obtain more desirable cooling of the molten metal compared to the sill bottom brick;

[052] Figure 26 is a schematic representation of another aspect of the invention, which includes an upper cover of the casting which is being lowered over the upper part of the molten metal in the upper part of the casting;

[053] Figure 27 is a schematic representation of the realization of the invention illustrated in Figure 26, where the top cover was placed on the top of the cast, thereby causing the molten metal to assume the contour or configuration of the side of the cover higher;

[054] Figure 28A is a representation

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13/66 schematic of the embodiment of the aspect of the invention illustrated in Figures 26 and 27, leaving the lower part of the mold cavity with a particular formed upper lid;

[055] Figure 28B is a schematic representation of the realization of the aspect of the invention illustrated in Figures 26 and 27, leaving the bottom of the mold cavity with the top cover formed in a different way;

[056] Figure 28C is a schematic representation of the realization of the aspect of the invention illustrated in Figures 26 and 27, leaving the bottom of the mold cavity with yet another top cover formed in a different way;

[057] Figure 29 is a schematic representation of yet another aspect of the invention, in which any electromagnetic field is used to form the upper part of the casting at the end of the casting process;

[058]

Figure 30 is a schematic representation in elevation of the exemplary movements that can be made by the movable mold walls contemplated in the embodiments of the present invention;

[059] Figure 31 is an elevation view of a

profile of the casting or of a configuration that can be produced as or part of the casting system described by aspects of the present invention;

[060] Figure 32 is detail 32 of Figure 31; [061] Figure 33 is a flowchart of blocks of

an embodiment of a process that can be used in the embodiments of the present invention;

[062] Figure 34 is an elevation view of

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14/66 another aspect of the present invention, illustrating another drawing of an ingot that can be produced as part of the present invention;

[063] Figure 35 is a schematic diagram of an embodiment of a control system that can be used to control the movement of the side wall of the mold when practicing the aspects of the present invention;

[064] Figure 36 is a schematic elevation representation of a configuration of the mold walls or casting surfaces that can be used in some aspects of the present invention, illustrating an upper and lower beveled surface area on each mold wall;

[065] Figure 37A is a schematic elevation representation of a configuration of the mold walls or casting surfaces that can be used in some aspects of the present invention, illustrating two upper chamfered surface areas and two lower chamfered surfaces on each wall. the mold;

[066] Figure 37B is a schematic elevation representation of a configuration of the mold walls or casting surfaces that can be used in some aspects of the present invention, illustrating an upper and lower beveled surface area on each mold wall, with each beveled area combined with a curved or arched surface area;

[067] Figure 37C is a schematic elevation representation of a configuration of the mold walls or casting surfaces that can be

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15/66 used in some aspects of the present invention, illustrating a curved or arched surface area of the top and bottom on each mold wall;

[068]

The figure

7D is a schematic elevation representation of a configuration of the mold walls or casting surfaces that can be used in some aspects of the present invention, illustrating an upper and lower bevelled surface area on each mold wall, the area of which upper chamfered surface has dissimilar angle dimensions from the lower chamfered surface area;

[069]

Figure

37E is a schematic elevation representation of a configuration of the mold walls or casting surfaces that can be used in some aspects of the present invention, illustrating an upper chamfered surface area combined with a curved or arched lower surface area on each wall the mold;

[070]

Figure 38A is a schematic elevation representation of a configuration of the mold walls or the casting surface, which can be the initial stage of casting in an embodiment of the invention, where the level of molten metal is initially in the middle portion 623a of the mold walls;

[071] Figure 38B is a schematic elevation representation of a configuration of the mold walls or the casting surface, which can be a second stage of casting in an embodiment of the invention, in which the level of molten metal has been raised from the one shown in Figure 38A in such a way that it is in the

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16/66 upper portion 623b of the mold walls;

[072] Figure 38C is a schematic elevation representation of a configuration of the mold walls or the casting surface, which can be a third stage or constant state of casting in an embodiment of the invention, in which the level of molten metal is in the middle portion 623a of the mold walls;

[073] Figure 38D is a schematic elevation representation of a configuration of the mold walls or the casting surface, which can be a third stage or constant state of casting in an embodiment of the invention, in which the level of molten metal is in the lower portion 623c of the mold walls;

[074] Figure 39 is a schematic elevation of a configuration of the mold walls or casting surfaces in an embodiment of the invention, illustrating the upper portion of the casting being formed in a taper at a predetermined angle;

[075] Figure 40 is a schematic elevation representation of a configuration of the mold walls or casting surfaces in an embodiment of the invention, illustrating why the level of molten metal needs to be maintained in the lower portion of the mold walls to prevent the frozen metal prevents additional internal movement of the mold walls from creating the upper taper;

[076] Figure 41 is a schematic elevation representation of a configuration of the mold walls or casting surfaces in an embodiment of the invention, illustrating an upper portion with a surface

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Chamfered 17/66 forming a tapered portion of the bottom of the casting in combination with the bottom sill brick; and [077] Figure 42 is a schematic elevation representation of a mold and sill bottom brick configuration that illustrates another feature of some embodiments of the present invention, in which the mold walls can be moved outward to accommodate the expansion of the bottom sill brick at initiation.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [078] Many of the fixing, connecting, manufacturing and other devices and components used in the present invention are widely known and used in the field of the described invention, and their exact nature or type is not necessary for an understanding and use of the invention by an element skilled in the art or science; therefore, they will not be discussed in significant detail. In addition, the various components shown or described in the present invention for any specific patent application of the present invention can be varied or changed as provided by the present invention, and the practice of a specific patent application or a specific realization of any element it may already be widely known or used in the state of the art or by elements skilled in the art or science; therefore, each of them will not be discussed in significant detail.

[079] The terms one, one and o, a, os, as, as used in the claims in the present invention, are used in accordance with the practice of drafting the long-standing claim and not in a limiting manner. Unless specifically stated in the

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18/66 of the present invention, the terms one, one and o, a, os, as are not limited to one of such elements, but preferably mean at least one.

[080] It should be understood that the present invention applies and can be used with respect to various types of casting and casting technologies and configurations, including, but not limited to, mass casting technology and conventional casting technology. The mold, therefore, must receive the molten metal from a molten metal source, whatever the particular type of source. The mold cavities in the mold must therefore be oriented in the receiving position of molten or molten metal in relation to the molten metal source.

[081] Aspects of the present invention control the dimensions of the head and base of the ingots through an automated variable-size mold system and bottom sill brick. In some embodiments of the present invention, for example, the two sides of the lamination face of the mold move in and out relative to each other, thereby providing a taper of the ingot. The sill bottom brick can be narrower in thickness than the nominal billet thickness and at the beginning of the billet, and the sides of the mold can be positioned inward towards the center of the billet and adjacent to the sides of the bottom billet brick. threshold. At the beginning of the casting, the sides of the mold are gradually moved outward to a ratio that forms the desired dimensions at the base of the ingot, resulting in any of a number of different desired shapes, depending on the

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19/66 application. Once the dimensions of the ingot reach the desired nominal thickness of the ingot for lamination, the walls of the mold are kept constant in position. Then, at the end of the casting, the walls of the mold are gradually moved inward until the head of the ingot (the upper portion) reaches the desired dimensions, when the mold must be finished. It will be appreciated by those skilled in the art that the upper portion of the billet is sometimes called the head of the billet and the lower portion of the billet is sometimes called the base of the billet, since the billet is in the vertical billet position.

[082] Aspects of the present invention also contemplate a process that can be used in some embodiments of the present invention that include controlling the mold variables such as controlling the metal level, the casting speed and the reason the sides of the mold are moved.

[083] During casting, there may be three phases that are considered for the control to produce a more desirable casting, namely the initial casting, the constant-state casting and the final casting, where the constant-state casting is that between the initial casting and the final casting. Different control parameters can be desired for each of these casting stages, and more stages can be introduced to divide any or more of these into sub-stages, depending on the desired results of the casting.

[084] The shape of the mold face can also play a role in the process in some of the

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The present invention. For example, at the beginning of the casting, when the mold walls are moved out of the center of the ingot, the metal level can be kept above a certain level in relation to the mold or the mold walls. Then, near the end of the mold, when the sides of the mold are brought back inwards towards the center of the ingot, the metal level can be lowered to a lower level between certain points that are within a certain range between the walls of the mold , with a specific angle of the mold walls. The angle of the mold walls can also be dependent on the casting speed of the reason the mold walls are moved. This can also be done, where the mold design is such that the angle between the points on the mold wall is essentially equal to the angle of the desired casting.

[085]

Ingot castings can come in any of a number of different lengths, widths and configurations, generally ranging from fifteen feet to twenty-five feet in length. The cross-sectional dimensions of a twenty-foot long ingot may, for example, be thirty inches by seventy-two inches or, alternatively, may be twenty inches by sixty inches.

[086] It is also believed that a deeper sill bottom brick can help to reduce or eliminate liquidations and bleeds from the melt so that the melt can support its own shape for as long as the sill bottom brick emerges below the walls of the mold. Generally, the prior art includes configurations where the bottom sill brick was wider than the

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21/66 mold cavity and could not be extended into the mold cavity. Aspects of the present invention, on the other hand, allow the bottom sill brick to be introduced into the mold cavity, which allows more time for the molten metal to remain and cool inside the bottom sill brick before the additional weight of the additional casting is placed on this starting metal, which allows a lower part of the solidified cast to better support the shape of the ingot as a whole through solidification. In other aspects of the invention, external or internal cooling within the bottom sill brick can assist this support.

[087] There is a secondary benefit of coupling the block through the mold and this is because the spacing between the chute and the block is maintained in normal industry standards. Another benefit is the prevention of massive oxidation, which is made possible by the movable mold walls that seal or reduce the mold to the opening sufficiently to prevent bleeding when the block passes through the mold and the metal rollers on the edge of the starting block that comes into contact with the mold.

[088] It will be appreciated by those skilled in the art that the term sill bottom brick can also be called starting head, false block, ingot tray cover or starting block, all used in a generic way in the industry to name them general components.

[089] While others recognize the problem and try to taper or configure the castings or mold ingots in more desirable ways, this was done

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22/66 by machining or cutting the melt after it is melted and solidified, which is a more expensive and time-consuming procedure that still results in an undesirable amount of metal that must be undone, melted again and then melted again. Others have also tried to taper the casting (s) through the caster as starting heads with angles greater than thirty degrees, which affects only the lower portion of the casting. The present invention, on the other hand, allows the formation or configuration of the castings at the upper and lower ends during the casting process, without the need to machine the cast piece afterwards.

[090] Figure 1 is an elevation view of a typical prior art vertical casting well, the pneumatic box and the metal casting machine and is described in more detail above.

[091] Figure 2 is a schematic cross-sectional top view of a perimeter wall of the typical prior art fixed or static cast mold 120, including the outer surface 123, the inner perimeter wall surface 122, the cavity of the mold 124 and a plurality of lubricant application openings 121.

[092] Figure 3 is a schematic representation in elevation of the lower portion of a thickness of the casting 126 in a horizontal direction during the casting process. Figure 3 shows the walls of the mold 125, the opening of the mold 129, the casting 126, with the downward arrows 128 showing the downward movement

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23/66 of the cast. Starting block 127 is shown and the swelling distance from base 130 is shown to illustrate the thickest portion at the bottom of the casting 126. Generally, the lower portion may be thicker because there may be more contraction in the middle portion of the piece fused and less contraction in the lower portion.

[093] The bottom portion of the cast is sometimes called the base or base portion of the cast and tends to be thicker, which is sometimes called swelling of the base. The illustration of the swelling of the base can be exaggerated in Figure 3 for illustrative purposes, and the specific amount of swelling depends on numerous parameters in the casting process, which are generally known to those skilled in the art. It will be appreciated by those skilled in the art that a significant amount of time and money is spent to remove swelling from the base of the cast, requiring the metal to be sent to scrap and requiring substantial expense in the process.

[094] Figure 4 is a schematic top cross-sectional view of an embodiment of a perimeter wall 140 of an aspect of a casting system contemplated by the present invention, illustrating the potential directions of movement of the mold wall or side walls. of the mold. Figure 4 illustrates the side walls of the mold 141, the end walls of the mold 142, with the arrows 144 indicating the potential movement of the side walls 141 and the arrows 145 indicating the potential movement of the end walls 142.

[095] Figure 5 is a top view of a

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24/66 realization of a casting system of the mold 160 contemplated by the present invention, in which two of the rigid walls of the perimeter, a first side and a second side, are movable. Figure 5 shows the inner surface 163 of the mold side walls and the inner surfaces 164 of the perimeter wall with the mold cavity 162 in the center. Structure 161 can be any of a number of different structures 162 in general.

[096] It will be appreciated by those skilled in the art that the shape or configuration of the casting can be manipulated by adjusting one or more of the parameters in combination with the movable walls, mold parameters such as the casting speed, the casting duration , the level of the metal, the vertical height of the castings, the rate of movement of the mold walls in or out, depending on the circumstances, as well as other casting parameters. In addition, it will be appreciated that aspects of the casting system described by the present invention can create any one of a number of different shapes and configurations of castings, including substantially linear, arched, convex sides and concave head and base sections, from such that any slice is generally rectangular in shape. Due to the number of objectives and potential variables for a given caster, no set of parameters is desired for the present invention, but, instead, the present invention features an additional caster control system with additional parameters, to work towards the optimization of the resulting castings.

[097] It will be appreciated that the movement of

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25/66 mold walls can be mechanically realized in any of a number of different ways, such as by motors that cause movement. A motor operatively connected to a first side wall of a mold structure can be, for example, controlled by an auxiliary driver, which can be controlled by a programmable logic controller (PLC), which can be controlled or configured via a machine interface with man (HMI). It is observed that other types of actuators and mechanical controls can be used within what is contemplated by the present invention.

[098] Figure 6 is a top view of an embodiment of a mold casting system 160 contemplated by the present invention, in which two of the walls of the end perimeter, a third side and a fourth side, are movable. Figure 6 illustrates structure 161, the inner surface 164 of the end wall, the inner surface 163 of the side walls, the mold cavity 162, in which the end walls are moved to the positions shown by the hidden lines identified as the surface internal 164 of the end walls of the perimeter wall.

[099] A Figure 7 is a view in elevation representative of a example on one ingot 201 what Can be produced as a product of achievements gives gift

invention, illustrating the tapering in the upper and lower portions of the ingot 201. Figure 7 illustrates a potential resulting shape or configuration of a casting 200, width 202, height 203, with arrow 204 representing the linear distance to the arcuate portion of the cast

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26/66

01, which can also be an angular portion. Figure 7 shows an upper portion 201a, a medium portion 20lb and a lower or bottom portion 201c, of the melt 201. It is noted that, with the embodiments of the present invention, the shape of the upper, middle or lower portions can be melted as desired in a controlled manner, and the upper portion 201a may be configured and angled differently from the lower portion 201c, including by means of a different method or apparatus. For example, the lower portion may be formed by a particularly shaped internal cavity of the bottom sill brick, as illustrated in Figure 1, the upper portion 201a being configurable using the embodiments of the present invention that use, for example, movable walls.

[0100] Figure 7 also illustrates the angle 199 on the casting surface of the casting. Although angle 199 can be any angle within the scope of the present invention, in some embodiments, it is preferable that angle 199 is between twenty-one degrees and twenty-nine degrees, such as twenty-six degrees. Although numerous factors can affect the preferred angle 199 for a casting 201 to be laminated later, in some applications of the present invention, twenty-six degrees may be preferred. Figure 7 also illustrates how a cast can be treated differently in different sections or portions, and Figure 7 shows, in particular, three portions, an upper portion 201a, a middle portion 201b and a lower portion 201c. For the management and control of the casting, it will be appreciated by the elements versed in the technique that the casting 201 can be theoretically divided

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27/66 in any of a number of different portions in order to obtain the desired resulting cast, without any being required in particular for the practice of the invention.

[0101] Although previous attempts to affect the shape of the ingots have been shown in addition to this method (that is, the post-ingot trimming of the casting, the molding of the bottom sill brick), the present invention has the advantage of being able forming the desired casting as desired, such as by tapering the upper and lower portions of the casting.

[0102] Figure 8 is an elevation view of a typical cast part ingot, with some contraction and swelling of the base. Figure 8 illustrates the casting 210, the corners 211, with the thickness of the casting 212.

[0103] Figure 9 is an elevation view of the ends of an ingot 210 such as those shown in Figure 8, after having been laminated and generally illustrating the alligator's tail. Figure 9 illustrates the width 217 of the casting, the alligator tail 216 and 215 at the opposite ends of the casting 210. It is generally known to those skilled in the art that the alligator tail is a harmful and undesirable result of lamination.

[0104] Figure 10 is a schematic elevation representation of an embodiment of an automated variable-size mold system and bottom brick 230, where bottom brick 235 is wider than the position or the initial width of the movable walls. Figure 10 illustrates the chute 231, the movable walls 233 and 234, the starting block 235, and the molten metal 237 applied by the chute 231 through the metal flow 232. The

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28/66 starting block 235, in this aspect of the invention, is at a width 238 with the moving cylinder 236 which provides the lowering of the casting during casting. Arrows 240 and 241 illustrate the respective movement of the mold walls 233 and 234, respectively.

[0105] Figure 11 is a schematic elevation representation of an implementation of an automated variable-size mold system and bottom sill brick 250, where the movable mold walls allow the bottom sill brick 256 to be started between the movable walls of the mold 254 and 255. Figure 11 illustrates the chute 251, the molten metal 252 being applied to the starting block 256 and is shown as 253 accumulating within the starting block 256. The starting block 256 has an approximate thickness 259 and the arrows 257 reflect the downward movement of the cylinder 258 and the starting block 256. The walls of the mold 254 and 255 are shown and the present invention contemplates that the walls of the mold 254 and 255 are moved outward during the casting process. Figure 11 further illustrates how, in some embodiments of the invention, the internal angles 239 within a bottom sill brick 256 can be used to obtain a particular shape at the bottom of the ingot. This type of formation combined with other aspects of the present invention can be used to obtain a casting that is formed in the upper and lower portions without the need to cut or later machine for this to be done.

[0106] It will be appreciated by the elements versed in the technique that it is generally more desirable to reduce the leakage drop, which is at a distance from the chute to the position where the metal

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Melted 29/66 lands or is deposited on or on the bottom sill brick. It will be evident to those skilled in the art that compare the leakage drop in Figure 10 to that in Figure 11, the benefits that can be obtained in aspects of the present invention by allowing the bottom sill brick to be raised above the mold cavity and between the movable walls of the mold, such as the movable walls of the mold 254 and 255.

[0107] The figure 12 is an representation schematic of a realization in one system in mold in variable dimension automated and in brick in bottom in

threshold 250, partly in the casting process while threshold bottom brick 256 is being lowered. Figure 12 shows the first movable wall 254, which moves as indicated by arrows 261, the second movable wall 255, as reflected by arrows 262. The system 250 shown in Figure 12 additionally shows the molten metal 252 of channel 251, and the accumulated metal 253 with arrows 261 and 262 reflecting the respective movements of the mold walls 254 and 255.

[0108] The figure 13 is an representation schematic of a realization in one system mold in variable dimension automated and in brick background in threshold 250, advancing in the process casting in

compared to Figure 12 and illustrating how the casting 253 can be fused dimensionally wider than the sill bottom brick 256. Figure 13 illustrates the first movable wall 254 and the second movable wall 255, as indicated by arrows 261 and 262, respectively. System 250 includes chute 251, molten metal 253, block of

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30/66 starting 256 and starting cylinder 258. Some dimensions are shown in the Figure, namely the width 267 of starting block 267, with cylinder 258, where starting block 256 has a dimension of width 256 , while the ingot 253 was cast in the outer dimension greater than the outer dimension of the starting block 256 in the same direction. The distance 264 represents the additional dimension on that side of the ingot 253 by which the ingot 253 exceeds the dimension of the starting block 256, and the distance 265 represents the additional dimension on the opposite side of the ingot 253 by means of the

which the ingot exceeds the size of the starting block 256. [0109] The figure 14 is an representation schematic of a realization in one system mold in variable dimension automated and in brick background in

threshold 250, further advancing the casting process of Figure 13, with the casting 253 being further formed. Since similar numerical references represent similar items and components of Figure 13, each one will not be identified and discussed further with respect to Figure 14, since they are sufficiently identified and discussed with respect to Figure 13.

[0110] The figure 15 is an representation schematic of a realization in one system in mold in variable dimension automated and in brick in bottom in

sill 250, illustrating the end portion of the mold and showing the ability of aspects of the present invention to affect the shape or configuration of the upper part of the casting 253. Arrows 261 illustrate how the mold walls 254 and 255 can be moved to inside in the final part of the

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31/66 casting process to affect the shape and configuration of the corner of the casting 253. It will be appreciated by those skilled in the art that any of a number of different shapes and configurations can be programmed in such a system to obtain the profile and the desired shape of the melt 253, without any in particular being required for the practice of the present invention. In fact, a feature of some aspects of the invention is the ability to produce any of a number of different shapes of the castings 253 for the specific application. Since similar numerical references represent similar items and components of Figure 13, each one will not be identified and discussed further with respect to Figure 15, since they are sufficiently identified and discussed with respect to Figure 13.

[0111] The figure 16 is an representation schematic of a realization in one system in mold in variable dimension automated and in brick in bottom in

threshold 250, illustrating a casting 253 partially in the casting process in which the present invention provides a different size and shape on one side of the casting compared to the other side. Figure 16 illustrates how aspects of the present invention can be used to create asymmetric castings 253 if desired, with one side being provided with different dimensions when compared to the opposite side. Figure 16 shows a different distance from the center of the casting 253 represented by the arrow 265 compared to the arrow 264 on the opposite side of the casting 253. It will be appreciated by those skilled in the art that the ability to produce asymmetric parts does not

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32/66 is limited to dimensions, as shown in Figure 16, but can also be used to produce different shapes and configurations on one side of the casting 253 against the other side of the casting 253. Since similar numerical references represent items and similar components of Figure 13, none of them will be identified and discussed further with respect to Figure 16, since they are sufficiently identified and discussed with respect to Figure 13.

[0112] Figure 16 also illustrates how, in some embodiments of the invention, the angle of the upper surface 254a of the mold wall 254 can correspond to the corresponding angle 253a in the lower portion of the resulting cast and similarly the angle of the upper surface 255a of the wall of the mold 255 corresponds to the corresponding angle 253b in the lower portion of the resulting cast. In practice, the angles 253a and 253b can be one degree or more different from the corresponding angle in the upper portions 254a and 255a of the mold walls 254 and 255.

[0113] Figure 17 is a schematic representation of an aspect of an automated variable dimension mold system and bottom sill brick contemplated by the present invention, illustrating a bottom sill brick in a differently configured way 269 that is an approximate width of the mold opening.

[0114] Figure 17 further shows another aspect of the invention, illustrating grooves 269a vertically oriented around bottom sill brick 269. These grooves 269a can provide a conduit and surface area through which liquid refrigerant can be

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33/66 passed to help further and cool the bottom sill brick 269 and the molten metal contained therein. Another cooling device is shown and described in relation to Figure 18 below.

[0115] Figure 17 further illustrates another configuration of block 269 in which the sloping sides 270 can be provided in the bottom sill brick 269 to form the bottom portion of a resulting melt to create the desired shape for further lamination of the part cast 269. This aspect can be used in combination with other aspects to create the desired shape or configuration of the cast parts in the upper and lower portions, all within the scope of the present invention. For example, the lower portion of the casting shown in Figure 34 can be produced using a bottom sill brick 269 such as that shown in Figure 17. Since similar numerical references represent similar items and components in Figure 13, none of them will be identified and discussed further in relation to Figure 17, since they are sufficiently identified and discussed with respect to Figure 13.

[0116] Figure 18 is a schematic representation of another aspect of an automated variable size mold and bottom brick, illustrating a liquid refrigerant system used within the bottom brick 292 to obtain the most desirable cooling of the molten metal 291 in relation to the bottom brick 292. Figure 18 shows the cooling system of the bottom brick 292 in which cylinder 258 is

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34/66 used to house the cooling system 294, where the cooling system can comprise the cooling duct 293 operatively connected to the components of the cooling system 294 to provide sufficient cooling to solidify the molten metal comprising the part cast 291 during the initial part of the casting. Those skilled in the art will appreciate that any of a number of different types of cooling systems, components of the cooling system and positions for the cooling system, can be used within the scope of the present invention, without any of them in particular it is required for the practice of the present invention. Since similar numerical references represent similar items and components of Figure 13, none of them will be identified and discussed further with respect to Figure 18, since they are sufficiently identified and discussed with respect to Figure 13.

[0117] Figure 19 is a schematic representation of an embodiment of an automated variable size mold system and bottom sill brick contemplated by the present invention, illustrating an aspect of the invention in which the movement of the mold side walls 300 and 301 is not necessarily linear as in the previous figures, but is preferably rotated or moved alternately outward and inward to affect the shape of the casting according to arrows 302 and 303. The mold wall 300 can be, for example, moved downward toward angle 305 and the mold wall 301 can be moved angularly downward toward angle 306 to obtain

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35/66 the desired shape of the casting as the bottom sill brick 294 is lowered during casting. It will be appreciated by those skilled in the art that the specific external shape of the mold walls 300 and 301 can be configured for specific applications and different shapes and corners can be used to achieve different configurations of the resulting cast. Figure 19 further illustrates the chute 251, the cylinder 258 and the bottom sill brick 294. In addition, it is noted that the rotating assembly of the mold walls 300 and 301 may be in a cam configuration or another configuration to obtain the desired result of the cast, all within what is

contemplated by the present invention. is an representation [0118] Figure 20 schematic of a realization of one system mold in variable dimension automated and in brick background in contemplated sill for this invention, illustrating one aspect of the invention similar to that shown in Figure 19, in

that only one of the mold walls is moved at a dissimilar angle from the other mold wall to provide a different dimension and / or shape on one side of the melt compared to the other side. The angle 305 in Figure 20 is a different angle or dissimilar to the angle 306 on the opposite wall of the mold, to provide the asymmetric configuration of the mold or to provide a different shape on one side of the casting 293 compared to the other side of the casting 293 Since similar numerical references represent similar items and components of Figure 19, none of them will be identified and discussed further with respect to Figure 20, since they are sufficiently identified and

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discussed with respect to Figure 19. is an representation [0119] The Figure 21 schematic of an achievement in one system in mold in automated variable dimension and in brick in bottom in

threshold 320 contemplated by the present invention, illustrating the mold walls in a different way formed or configured 322 and 323. The rail 321 applies the molten metal, the mold walls 322 and 323 can be independently moved as indicated by arrows 324 and 325 This system 320 shows a molten metal 329 that becomes part of the molten part 327, a molten metal surface 330 and a more solidified surface 328. The mold walls 322 and 323 have more chamfered ends instead of the ends

rounded arrows and arrows 332 and 333 illustrate the exit portion from the walls of mold 322 and 323 during the process in casting and measure what The piece cast 327 is solidified. [0120] The figure 21 illustrates additionally one additional aspect of this invention in that the walls of

mold 322 and 323 can be moved up or down linearly or in some other pattern, as indicated by arrows 324a and 325a. This particular vertical movement will allow some flexibility in controlling the distance from the trough 321 to the surface of the molten metal 330, as well as the position of specific mold wall geometries at the metal level. Due to other molten metal equipment and application systems, it is more difficult to move the 321 rail in many situations. Although Figure 21 illustrates that the angle of the upper and lower portions of the mold walls 322 and 323 can be at twenty-seven degrees, that angle

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37/66 can be any one of a number of different angles, with none in particular being required for the practice of the invention.

[0121] Figure 22 is a schematic representation of another aspect of the invention with a sill bottom brick in a differently configured way and where the sill bottom brick only needs to have only full side walls on two sides, being that said aspect may use the mold walls as part of or instead of the side wall on two other sides. Figure 22 shows the first movable wall of the mold 356, the second movable wall of the mold 357, which respectively move according to arrows 358 and 359, the bottom sill brick 354 with the inner surface of the bottom sill brick 354a and the side walls 354b and 354c. Figure 22 also shows the chute 351 at the original height 352 and lowered at a distance 353 from the lower surface 354a of the bottom brick 354. The side walls 354b and 354c are at a height 355, all within the scope of this aspect of the system. 350. It will be appreciated that, instead of moving the chute vertically, the mold or the walls of the mold can also be moved vertically in relation to the chute to perform the desired casting, all within the scope of the present invention.

[0122] It will be appreciated by those skilled in the art that the mold or chute 351 can be moved up and down to obtain different desired results during casting. The height of the gutter can be one of the parameters of the casting which can be adjusted or balanced to achieve the desired results. Per

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For example, as shown in the schematic diagram in Figure 30, the level of molten metal is preferably at or near the top of the mold walls just before the mold walls are moved out to obtain a different shape and configuration . This will provide some cushioning, so that as the mold walls are moved outwards, they do not create a bleeding or leakage situation with the molten metal contained between the respective mold walls. On the other hand, just before the mold walls are moved closer together, it should be preferable to have the lowest level of molten metal on the mold wall, so that it rises only above towards the top of the mold wall and not more than that during the internal movement of the mold walls in the process.

[0123] Figure 23 is a schematic representation of the realization of an automated variable dimension mold system and bottom brick 350 illustrated in Figure 22, showing the end of the bottom brick 354 and the absence of the walls of end of the sill bottom brick. Figure 23 also shows the rail 351 at height 352, the mold wall 356 and the mold wall 357, with arrows 358 and arrows 359 indicating, respectively, the movement of the two mold walls. The inner surface 354a of the sill bottom brick 354 is also shown.

[0124] Figure 24 is a schematic representation of an aspect or possible embodiment of a mold starting block configuration for some aspects of the present invention and which can be used in

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39/66 realizations of the present invention of the perimeter wall on two sides only. Figure 24 shows the bottom sill brick 354 with the bottom surface 354a, side walls 354b and 354c.

[0125] Figure 25 is a schematic representation of another possible embodiment of an automated variable size mold system and bottom sill brick 380, illustrating another aspect of the present invention in which a liquid refrigerant system is used within the brick bottom bottom 382 to obtain more desirable cooling of the molten metal in relation to bottom bottom brick 382. Figure 25 shows the rail 381, the first movable wall of the mold 385 shown as movable by the arrow 386, the second wall movable of mold 387 shown as movable by arrow 388, where arrows 389 indicate the downward movement or lowering of starting block 382 during the casting process. The inner surface 391 has a depth 390 that receives the molten metal from the channel 381.

[0126] Those skilled in the art will appreciate that any of a number of different types of cooling systems and cooling system components can be used to provide cooling for the 382 bottom brick. The 383 cooling system with a refrigerant duct 384 is an example of how liquid refrigerant is distributed through the bottom sill brick and provides the cooling for better solidification of the molten metal deposited on the bottom sill brick 382 by channel 381. Another example of a way to obtain additional cooling to a brick

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40/66 sill bottom is illustrated in Figure 17, in which cooling channels or grooves are provided in the sill bottom brick to receive the liquid coolant that is used mainly in the solidified molten metal.

[0127] Figure 26 is a schematic representation of another aspect 400 of the invention, which includes a lid from the top of the casting 406 that is being lowered (as indicated by the arrows 407) to the top of the molten metal at the top of the casting 405. Figure 26 additionally shows the first wall of the mold 403, the second wall of the mold 404, the trough 401, where the arrow 402 indicates that the trough 401 can be moved up and out after the pouring of the molten metal ceases. Alternatively, as shown by arrows 415a and 416a in Figure 27, this movement can also be performed by the vertical movement of the walls of the mold 403 and 404 as shown, which towards the end of the mold would be descending. Aspects of the present invention provide the tapering or molding of the upper end of the ingot or cast 405.

[0128] Figure 27 is a schematic representation of aspect 400 of the invention illustrated in Figure 26, where the top cover 406 was placed on top of the melt 405, which in this way causes the molten metal to take the form inside the top cover 406 and, in this example, form a radius at the corners, as indicated by items 412 and 413. Arrows 407 indicate that downward pressure or movement can be applied over the top cover 406 to prevent the molten metal between the top cover 406 and the walls of the mold 403 and 404. The

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41/66 arrows 415a and 416a illustrate how the mold walls 403 and 404 can be moved vertically (although the movement need not be limited vertically to linear motion), during the casting process, in order to obtain more desirable clearances with the trough 401 or other reasons for casting control. Figure 27 further illustrates how the mold walls in the aspects of the present invention can be moved vertically and horizontally with the horizontal movement of the mold walls which are indicated by arrows 415b and 416b, as shown.

[0129] Figure 28A is a schematic representation of aspect 400 of the invention illustrated in Figures 26 and 27, as the casting 405 is exiting the bottom of the mold cavity. The mold cavity is generally the area between the first mold wall 403 and the second mold wall 404. Figure 28A also shows the rail 401, arrows 415a and 416a show the downward movement of the mold walls 403 and 404, the cover 406 of the upper part of the casting in the solidified casting 405. Arrows 414 indicate the general movement of the upper cover 406 with the casting 405. It is also noted that, alternatively, the upper cover 406 can be held on or in relation to the mold walls 403 and 404 when filling at the end of the casting to create the upper form without movement of the gutter, in which case the upper part could be cooled by liquid or air and by the cold caused by a refractory material or a metal in several realizations of the invention. Figure 28A further illustrates how the mold walls in the aspects of the present invention

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42/66 can be moved vertically and horizontally with the horizontal movement of the mold walls indicated by arrows 415b and 416b, as shown.

[0130] Figure 28B is the same schematic representation of aspect 400 of the invention as in Figure 28A, where only the top cover 406 has a different configuration to obtain a top portion formed differently from Figure 28B of the casting 405c. Figure 28B illustrates an upper cover in which the sides are angled and the middle portion is notched, as illustrated by the notch angles 406c. Figure 28B further illustrates how the mold walls in aspects of the present invention can be moved vertically and horizontally with the horizontal movement of the mold walls indicated by arrows 415b and 416b, as shown.

[0131] Similarly, Figure 28C is the same schematic representation of aspect 400 of the invention as in Figure 28A and Figure 28B, only where the top cover 406 has a different configuration to obtain a differently formed top portion that includes tapered side angles and which consequently results in side angles in the upper portion of the cast 405a. Figure 28C further illustrates how the mold walls in aspects of the present invention can be moved vertically and horizontally with the horizontal movement of the mold walls indicated by arrows 415b and 416b, as shown.

[0132] The ability to move the walls of the mold 403 and 404 in the direction indicated by arrows 415a and 416a (usually vertical) provides an enhanced ability to use a top cover 406 to configure the portion

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43/66 upper part of the casting 405a, along and in combination with the mold walls 403 and 404 which are movable in the horizontal direction (as shown in other figures).

[0133] Figure 29 is a schematic representation of yet another aspect 430 of the invention in which an electromagnetic field (represented by arrows 443 and 444) is used to form the upper part of the casting 433 at the end of the casting process. Figure 29 shows the trough 431, movable according to arrow 432 in an upward direction, and the upper surface 446 of the casting 433 being formed through a magnetic force or a magnetic field at, on or near the upper surface 446 A magnetic device 436 and 437 can be moved towards or away from the upper surface 446 of the casting 433 in order to obtain the desired shape of the upper portion of the casting 433. The mold walls 434 and 435 are shown immediately below the magnetic devices 436 and 437, although they may be adjacent or even below the mold walls 434 and 435, all within the scope of the present invention. There is a type of casting called Electromagnetic Casting, in which the acronym is EMC, which can also be used to provide the formation or tapering of the upper part of the casting towards the end of the casting, as shown in a

example in Figure 29. 30 is an representation [0134] The figure schematic of one aspect 450 gives gift invention, illustrating the exemplifying movements what can be

executed by the movable walls of the mold 451 and 452, as contemplated in some aspects of the present invention. The figure

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44/66 shows variable distances between mold walls 451 and 452 to illustrate their movement. It will be appreciated by the elements versed in the technique, and it is shown in other figures, that the movement does not need to be symmetrical, but can preferably be programmed to obtain other results that may be desired in the asymmetric modeling of the castings. The hidden lines 451a and 452a show a second position of the mold walls 451 and 452, and the hidden lines 451b and 452b show additional possible movement positions of the mold walls, along with any intermediate position between them.

[0135] Figure 30 also serves to illustrate how the casting parameters such as the control of the level of molten metal between levels 457 and 458, for example, can be used in combination with aspects of the present invention. For example, when the mold walls are spaced as indicated by arrow 455, the level of molten metal 457 may be preferable if the mold walls are subsequently moved outward, as indicated by arrows 456 and 457. On the other hand, if the mold walls 451 and 452 are spaced at a distance indicated by the arrow 453 and the process will have the joint movement of the mold walls 451 and 452, then the level of molten metal 458 may be more desirable to allow reduction in the area of the mold cavity and should naturally cause the molten metal level 458 to rise as the mold walls 451 and 452 move. This can also serve to prevent attachment to the ingot or cast, as the mold cavity is reduced. It would be preferable if the level of molten metal 458 did not rise

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45/66 above the mold walls as the mold walls are moved inward, as will be appreciated by those skilled in the art.

[0136] Figure 30 also illustrates how a molten metal mold in the embodiments of the present invention can be used to melt castings of different sizes, such as the casting of a twenty-one-inch ingot in a first casting and an ingot of nineteen inches in a second leak. Since previous molds are generally dedicated to one size, the embodiments of the present invention offer more flexibility in a manufacturing facility and reduce the change in molds that would then need to be made to cast castings of different widths. In these embodiments, the distance 455 must represent a first casting with a first thickness, the distance 454 should represent a second casting with a second thickness and the distance 453 should represent a third casting with a third thickness. It is noted that there are a number of different thicknesses or widths that can be cast into castings within the scope of the present invention.

[0137] Figure 31 is an elevation view of a shape of the casting that can be produced as the system or as part of the casting system described by aspects of the present invention. The casting 480 shown in Figure 31 has an overall length or height 484 and the chamfered corners on the upper portion of the casting are shown additionally in detail 32, and the angular edges on the lower portion are shown chamfered at angle 479. The distance from 485 straight edge on the workpiece side

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46/66 cast and the distance from the straight edge 482 at the bottom can be determined based on the desired resulting shape and the lamination that will occur later on the cast. The width 481 and the chamfered widths 483 and 486 of the casting are also illustrated in Figure 31. It will be appreciated by those skilled in the art that aspects of this process can produce symmetrical or asymmetric castings of different dimensions; for example, distance 483 may differ from distance 486.

[0138] Figure 32 is detail 32 of Figure 31, and illustrates the casting 480, the chamfer width 490, the chamfer height 491, with the angles 492 and 493 providing the chamfer parameters. It will be appreciated that these parameters can be changed, depending on other casting parameters, the metal composition, the lamination that must be performed on the casting 480, as well as by many other factors in the casting or in the casting application, all within than is contemplated by the present invention.

[0139] Figure 33 is a block flow chart 500 of an embodiment of a process that can be used in the embodiments of the present invention. Figure 33 illustrates the start of casting 501 with an initial mold speed 502. At some point, the casting speed is typically high or increased, intermediate casting 503 producing the desired results, and a first speed can be used for the taper or other feature of the cast.

Although it may not be necessary, a second intermediate casting speed increase

504 can be used and generally a

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47/66 increase in the final casting speed 505 will be used before the end 506 of the casting process. Depending on the objectives of the tapering and others of the casting, as well as other parameters of the casting, the casting speed can be varied in order to obtain the desired results.

[0140] Figure 34 is an elevation view of another aspect of the present invention, illustrating another form of a 520 ingot that can be produced as part of the present invention. Figure 34 shows the surface of the tapered top portion 521, the side wall 520a, radius 523 and the surface of the tapered bottom portion 522. A significant advantage and characteristic of aspects of the present invention is the ability to produce any of a series different configurations and shapes of the casting during the casting process instead of through machining or another process after casting the casting.

These features significant cost savings after solidified machining or handling, as well as reheating and advantages and

da da

will allow in expenses piece of the mold scrap and

residue from the post-casting process.

[0141]

It is also noted that, although the achievements shown in the

Figures showing a first side, a second side, a third side and a fourth side, there may be embodiments of the present invention in which the sides are configured in such a way that two, three, four or more sides define the structure of the mold with the internal surfaces of said sides defining the mold cavity, all within the scope of the present invention.

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48/66 [0142] It will also be appreciated by those skilled in the art that with the provision of a movable mold wall in the present invention, other benefits will be received, such as the ability to correct the mold process to reduce swelling of the base and position the molds in relation to the rails and to correct the mold spacing. Those skilled in the art will appreciate that this allows the cast to be obtained more quickly and efficiently. The prior art recognizes the problem with swelling of the base and the advantages that would be obtained if the problem of swelling of the base was resolved. Previous attempts have attempted to increase the speed of the casting to reduce swelling of the base; however, aspects of the present invention allow for a resulting parallel profile due to the ability to move the mold walls, which allows the part to be cast to be cast more quickly with less swelling of the base or without increased swelling of the base.

[0143] The embodiments of the present invention also allow the casting speed to be optimized. The casting speed in a vertical casting arrangement is the speed at which the bottom sill brick is lowered into the casting pit while the molten metal solidifies. There has traditionally been a conflict of choice between casting speed and casting quality because, although you want to mold more quickly from a production point of view, faster casting speeds generally result in more shrinkage and an external surface or concave lamination surface during state casting

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49/66 constant. If the casting speed is too slow in a given application, an undesirable amount of swelling of the base tends to result. The achievements of the present invention can, therefore, allow a better contraction to be managed or controlled to result in a more desirable shape of the casting when casting at a casting speed which should result in excessive contraction but for the use of the present invention. . A more desirable shape of the cast in some applications is a cast with roughly parallel sides in the middle portion of the cast, which generally provides a more desirable lamination surface. The achievements of the present invention offer improved contraction management and control in vertical molten metal casting systems.

[0144] The realizations of the present invention that relate to the contraction management can include a method to optimize the rolling surfaces of a cast piece produced during the continuous casting of the molten metal. In such an embodiment, a correlation can be sketched or predicted for a given predetermined casting speed for a specific casting, and that contraction of a certain amount in different positions along the casting must occur. The present invention then allows the relative movement of the mold walls (or the first side and / or the second side) to oppose the contraction, thereby providing a contraction control or management system.

[0145] Figure 35 is a schematic diagram of an implementation of a 570 control system that can be

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50/66 used to control the movement of the mold sidewall when practicing aspects of the present invention. Figure 35 illustrates the machine interface with man (HMI) 571, the programmable logic controller (PLC) 572 connected in an operational manner and controlled or driven by HMI 571, with the first motor 575 being propelled and controlled by the first motor auxiliary 574, which is shown operationally connected and controlled by PLC 572, the second motor 577 propelled and controlled by the second auxiliary motor 576, which is shown operationally connected and controlled by PLC 572, the third motor 579 propelled and controlled by third auxiliary motor 578, which is shown operationally connected and controlled by PLC 572 and the fourth motor propelled and controlled by fourth auxiliary motor 580, which is shown operationally connected and controlled by PLC 572. It is observed that this is a number exemplifier of components such as motors, auxiliary motors, PLC and HMI, and no number is required for the practice of the present invention. the or any particular provision of a group of like components to another.

[0146] Figure 35 further illustrates how each of the engines can control one or more molds, without any particular number of controlled molds being required for the practice of the present invention. Figure 35 illustrates the first engine 575 controlling two molds, the second engine 577 controlling a mold, the third engine 579 controlling two molds and the X engine (which can represent the total number of engines) controlling a mold.

[0147] Figure 36 is a schematic representation in elevation of a 600 configuration of the walls

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51/66 of the mold or casting surfaces that can be used in some aspects of the present invention, illustrating an upper casting surface 602b, which can also be referred to as an upper portion 602b of the casting surface, a middle portion 602a of the surface caster area and a lower beveled surface area which is the lower portion 602c of the caster surface. Figure 36 illustrates the casting 327, the liquid refrigerant stream 605, the mold walls 601, the channel 321, the bevel angle 603 for the upper portion 6 02b and the angle 064 for the chamfer in a lower portion 602c of the casting surface. The level of molten metal is shown in the middle portion 602a of the casting surface.

[0148] Figures 37A to 37E show a series of different configurations, angles and other geometries for the upper, middle and lower portions of the casting surface on the mold walls showing various applications of the embodiments of the present invention. It will be appreciated that no particular configuration is required for the practice of the invention, but that any one of a number of different configurations can be used to optimize different embodiments based on different casting parameters.

[0149] Figure 37A is a schematic elevation representation of a 610 configuration of the mold walls 611 with the casting surfaces that can be used in some aspects of the present invention. Figure 37A illustrates such a configuration that includes two upper caster surface areas 612a and 612b, two lower caster surface areas 612d and 612e and the portion

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52/66 average caster surface 612c, for each mold wall 611. The first upper caster surface area 612a is at angle 614 relative to the vertical, the second upper caster surface area 612b is at angle 613 relative to to the vertical, the first lower caster surface area 612e is at angle 614 with respect to the vertical and the second lower caster surface area 612d is at angle 613 with respect to the vertical. Figure 37A also shows the casting 327, the rail 321 and the mold walls 611.

[0150] Figure 37B is a schematic elevation representation of a configuration 700 of the mold walls 731 with the casting surfaces that can be used in some aspects of the present invention, illustrating an upper portion and a lower portion that include a linear caster 731b and an arched or curved caster surface 731c, a middle portion 731a of the caster surface and a lower portion of the caster surface that includes the linear caster surface 731d and the arcuate caster surface 731e. Figure 37B also shows the casting 327, the rail 321 and the mold walls 731.

[0151] Figure 37C is a schematic elevation representation of a 740 configuration of the mold walls 741 with the casting surfaces that can be used in some aspects of the present invention, illustrating an upper portion 742b of the casting surface, a portion of the lower curved or arched caster surface 742c and a middle portion of the caster surface 742a. Figure 37C also shows the

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53/66 casting 327, rail 321 and mold walls 741.

[0152] Figure 37D is a schematic elevation representation of a 750 configuration of the mold walls 751 with the casting surfaces that can be used in some aspects of the present invention. Figure 37D illustrates an upper caster surface area 752b at an angle 753 to the vertical or from the middle caster surface area which, in this case, because it is linear, an average caster surface area 752a and a lower caster surface area 752c at angle 755 to the vertical. In Figure 37D, angle 753 is different from angle 755 and the length 754 of the chamfered area in the upper portion is different from the length 756 in the lower portion of the chamfered area. It should be noted that the desired casting can preferably be configured using different configurations for the casting surface, and dissimilar configurations in the angles and lengths from the upper portion of the casting surface to the lower portion of the casting surface, all within what is contemplated. by some aspects of the present invention. Figure 37D also shows the casting 327, the rail 321 and the mold walls 751.

[0153] Figure 37E is a schematic elevation representation of a 760 configuration of the mold walls 761 with the casting surfaces that can be used in some aspects of the present invention, illustrating a combination casting surface that includes a middle portion 162a , an upper portion 762b at an angle 763 to the vertical, a curved or arched lower portion 762c with an internal radius 764. Figure 37E also

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54/66 shows the casting 327, the rail 321 and the mold walls 761.

[0154] Figures 38A to 38D are a series of schematic representations in elevation of a 620 configuration of mold walls 621 with the casting surfaces and illustrate sequentially a method in which the embodiments of the present invention can be used in casting, with reference particularly at the level of molten metal and the casting surface in relation to the level of molten metal during the casting process. The casting surfaces illustrated in Figures 38A to 38D include the middle portion 623a, the upper portion 623b at the angle 625 of the vertical, the lower portion 623c at the angle 626 of the vertical, the molten part 327, and the molten metal channel 321. Figures 38A to 38D further illustrate an aspect of the present invention in which the mold walls 621, or more particularly the casting surface, can be moved vertically upwards or downwards in order to more effectively control the level of molten metal in relation to the casting surface and the portion of the casting surface where it is desired, at this stage of casting, to have the level of molten metal. In order to avoid repetition and new exposure of each component in relation to each of Figures 38A to 38D, they will not be repeated for each Figure. The arrow 622 shows the vertical movement of the mold walls 621 which causes the vertical movement of the casting surfaces and the arrows 622a show how the casting surface or the mold walls 621 can be moved horizontally with respect to the casting.

[0155] Figure 38A therefore illustrates a level

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55/66 molten metal in the middle portion 623a of the casting surface during the initial phase or initiation in which the starting block is being filled and is still located at least partially in 20, and the casting surfaces.

[0156] Figure 38B therefore illustrates a level of molten metal in the upper portion 623b of the casting surface during the next stage when the lower portion of the casting is being formed outside the dimension shown in Figure 38B. Although it can be indicated here that the level of molten metal is increased, this is relative, and refers to the casting service, so that the level of molten metal can be increased or can rise in relation to the casting surface if the walls of the mold 621 are moved up and / or down to perform the relative movement.

[0157] Figure 38C thus illustrates a level of molten metal again in the middle portion 623a of the casting surface, which is a preferred position during casting, when it is indicated as constant state casting.

[0158] Figure 38D therefore illustrates a level of molten metal in the lower portion 623c of the casting surface during the final stage when the upper portion of the casting 327 is configured as desired, such as when placing a taper in exactly the same approximate angle 626 at which a lower portion 623c is configured. It is important that the level of molten metal remains below the point where the middle portion 623a of the casting surface intersects the lower portion 623c of the casting surface.

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56/66 caster. This is a preferred position for the level of molten metal during the last casting phase to obtain a tapered upper part in the casting 327. The resulting tapering angle in the casting will be approximately equal to the 626 angle, allowing for tolerances and contractions.

[0159] Figure 39 is a schematic elevation representation of a 640 configuration of the mold walls 641 with the casting surfaces in an embodiment of the invention, illustrating a casting surface with an upper portion 642b, a middle portion 642a and a portion lower 642c to angle 648 in relation to the vertical. Figure 39 illustrates the casting 327 being formed in its upper portion with a taper at a predetermined angle 648. Figure 39 further illustrates the molten metal channel 321, the solidification point 647, the liquid refrigerant 644, and the surface of the molten metal 645.

[0160] Figure 40 is a schematic elevation representation of a 620 configuration of the mold walls with the middle portion 642a and the lower portion 642c of the casting surfaces in an embodiment of the invention. Figure 40 illustrates how the mold walls can be moved horizontally, as represented by arrow 651. The solidification points 647 show where solidification is taking place and there is a freezing area 650 that will generally occur if the molten metal level 645 is not below the corner between the two casting surfaces shown at or near the 647 freezing point. If the solidification occurs as a freeze 650, then the walls

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57/66 of the mold and the casting surface cannot be moved further in because the solidified metal 650 or frozen must prevent internal movement of the mold walls or the casting surface 642a. That is why, in most embodiments of the present invention, during that casting phase, it is preferable to maintain the level of molten metal 645 at or below the freezing point 647.

[0161] Figure 41 is a schematic elevation representation of a 660 configuration of the mold walls 641 or the casting surfaces in an embodiment of the invention, illustrating the casting surfaces including an upper portion 642c, which can be called a beveled surface , forming a lower portion of the tapered casting 655 in combination with the bottom sill brick 657. In this stage of the casting, the movable metal is deposited through the channel 321, and the level of molten metal 645 is maintained in the upper portion 642c, at an angle of 654 to the vertical. Figure 41 shows how a lower portion of a casting can be formed in combination by the configuration of the internal cavity of a sill bottom brick 657 combined with the aspects of the present invention provided by the movable casting surfaces and an angular casting surface for preferred results.

[0162] Figure 42 is a schematic elevation representation of a sill bottom mold and brick configuration 350 that illustrates another feature of some embodiments of the present invention, in which the mold walls 357 can be moved outwardly to accommodate the expansion of the sill bottom brick 354 in

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58/66 initiation. It is desirable to have a gap without gap between the bottom sill brick 354 and the mold walls 356 and 357. However, since the prior art mold walls are not movable to accommodate the natural expansion of the brick. metallic sill bottom 354, it would be difficult to maintain the desired tolerances between the mold walls 356 and 357 and the sides of the bottom block 354, which would likely leave the mold false because the sill bottom brick 354 would become enlarged and would get stuck inside of the mold cavity between the mold walls 356 and 357. The second identification of the sill bottom brick 354 that is in 354 CE shows the sill bottom brick in its heat expanded condition, and arrows 358 and 359 show how the mold walls 356 and 357 can be moved so that the same slot without gap between the mold walls and the sill bottom brick, but the sill bottom brick meets the expansion sets that stay am stuck between the walls of the mold. In this case, the height of the bottom sill brick 355 is measured from the bottom surface 354a and top of the walls of the bottom sill brick 354b and 354c. Arrows 358a and 358b show how the mold walls 356 and 357 can be moved vertically.

[0163] As will be appreciated by those skilled in the art, there are numerous embodiments of the present invention, and variations of the elements and components that can be used, all within the scope of the present invention.

[0164] An embodiment of the present invention, for example, a molten metal mold, is provided, which

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59/66 comprises: a mold cavity structure that includes a first side, a second side opposite the first side, a third side and a fourth side opposite the third side, each side including an inner surface and the inner surfaces define a mold cavity; and where the first side is movably mounted relative to the second side.

[0165] Other achievements of that described in the preceding paragraph may include: an additional molten metal mold, in which the second side is movably mounted in relation to the first side; an additional molten metal mold in which the first side moves linearly with respect to the second side; an additional molten metal mold on which the first side is rotatably mounted; and / or an additional molten metal mold the pivoting movement of the first side in relation to the mold cavity structure alters the defined mold cavity. In additional aspects, the movement of the first side and the second side can be asynchronous.

[0166] In another embodiment, a vertical molten metal mold casting system can be provided, which comprises: a mold cavity structure that includes a first side, a second side opposite the first side, a third side and a fourth side opposite the third side, each side including an inner surface and the inner surfaces defining a mold cavity; wherein the first side and the second side are movably mounted relative to each other; and a bottom sill brick configured to fit within the mold cavity when initiating the mold casting system.

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60/66 [0167] Other achievements of that described in the preceding paragraph may include: an additional vertical molten metal mold casting system in which the first side and the second side move linearly with each other; an additional vertical molten metal mold casting system in which the first side and the second side are rotatably mounted for movement relative to each other; a vertical molten metal mold casting system in which the bottom sill brick includes two side walls and in which in addition the third and fourth side of the mold cavity structure combined with the two side walls of the bottom brick sill define the mold cavity at initiation; a vertical molten metal mold casting system in which the bottom sill brick includes an internal cooling apparatus; and / or an additional vertical molten metal mold casting system in which the bottom sill brick is configured for vertical movement within the mold cavity during initiation to control a chute at a distance from the bottom sill brick during the initial casting.

[0168] In another embodiment of the invention, a method for direct cold vertical molten metal casting is provided, which comprises: the provision of a mold cavity structure with a first side and a second side opposite the first side, a third side and a fourth side opposite the third side, where the inner surfaces of the first side, the second side, the third side and the fourth side define a mold cavity arranged to receive the molten metal; the provision of a bottom brick

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61/66 vertically mobile sill configured in relation to the mold cavity to contain the molten metal that enters the mold cavity upon initiation; the provision of the molten metal in the mold cavity; moving the bottom sill brick down at a predetermined rate; and moving the first side and the second side of the mold cavity structure in relation to each other during casting and thereby to varying the dimensions of a resulting cast during casting.

[0169] Other achievements of that described in the preceding paragraph may include: a method for direct cold vertical molten metal casting where additionally the first side and the second side are moved linearly in relation to each other; a method for direct cold vertical molten metal casting where additionally the first side and the second side are moved asymmetrically in relation to each other; a method for direct cold vertical molten metal casting where additionally the first side and the second side are pivotally mounted relative to the mold cavity structure in such a way that the pivoting movement of the first side and the second side changes the defined mold cavity; and / or a method for direct cold vertical molten metal casting where additionally the movement of the first side and the second side are at the same approximate rate.

[0170] Other achievements of that described in the preceding second paragraph may include: a method for direct cold vertical molten metal casting in which additionally the movement of the first and second sides

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62/66 side of the mold cavity structure in relation to each other during the casting further comprises the movement of the first side and the second side apart from each other in an anterior portion of the casting after initiation, to provide an increasing cross section of the cast piece from its lower portion; and / or a method for direct cold vertical molten metal casting, in which the movement of the first side and the second side of the mold cavity structure in relation to each other during the casting further comprises: the movement of the first side and the second side towards each other at an end portion of the casting to provide a decreasing cross section of the casting in its upper portion. These embodiments in which the movement of the first and second sides of the mold cavity structure in relation to each other during casting can additionally comprise: the movement of the first side and the second side towards each other in an end portion of the casting to provide a decreasing cross section of the casting in its upper portion. The increasing cross section of the casting from its lower portion provides a taper in the lower portion of the casting which can, for example, be at an angle in the range of 22 degrees to 29 degrees; and / or the increasing cross section of the casting from its upper portion provides a taper in the upper portion of the casting which can be at an angle in the range of 22 degrees to 29 degrees.

[0171] In other realizations of the method for direct cold vertical molten metal casting as indicated above, the movement of the first side and the

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63/66 second side of the mold cavity structure in relation to each other during casting, produces a cast with a larger cross section in a medium portion than the bottom sill brick; and / or produces a casting with a larger cross section in its middle portion than in its lower and upper portion.

[0172] However, in another embodiment of the invention, a molten metal mold is provided, which comprises: a structure of the mold cavity including a first side, a second side opposite the first side and spaced from the first side by a variable distance , a third side and a fourth side opposite the third side, each side including an inner surface and the inner surfaces define a mold cavity; and wherein the mold cavity structure is alternatively configurable for molding a first melt with a first thickness and for molding a second melt with a second thickness.

[0173] However, in another embodiment of the invention, a method for the direct cold vertical molten metal casting comprises: the provision of a mold cavity structure with a first side and a second side opposite the first side and spaced from the first side by a variable distance, a third side and a fourth side opposite the third side, where the internal surfaces of the first side, the second side, the third side and the fourth side define a mold cavity arranged to receive the molten metal; the provision of a vertically movable sill bottom brick configured in relation to the mold cavity to contain the molten metal that enters the mold cavity upon initiation; the provision of the molten metal in the

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64/66 mold cavity; casting a first cast of a first thickness; and moving the first side and the second side of the mold cavity structure in relation to each other; and casting a second casting of a second thickness different from the first thickness.

[0174] However, in another embodiment of the invention, a molten metal mold can be provided, which comprises: a mold structure; a mold operatively connected to the mold structure, the mold comprising: a first side movably mounted in relation to the mold structure; a second side opposite the first side and movably mounted on the mold structure; a third side; a fourth side opposite the third side; wherein each side includes an inner surface and the inner surfaces define a mold cavity; a first motor operatively connected to the first side and configured to move the first side in relation to the mold structure; a second motor operatively connected to the second side and configured to move the second side in relation to the mold structure; and a programmable logic controller operatively connected to and which controls the first motor and the second motor for controlling the predetermined movement of the first side and the second side of the mold.

[0175] Other achievements of that described in the preceding paragraph may include: a molten metal mold in which in addition the first engine and the second engine are auxiliary engines; and / or a molten metal mold that further comprises an interface with the

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65/66 user operatively linked to the programmable logic controller.

[0176] In another embodiment of the method, a method of optimizing the rolling surfaces of a casting produced during the continuous casting of the molten metal can be provided, which comprises: the provision of a mold cavity structure with a first side and a second side opposite the first side, a third side and a fourth side opposite the third side, where the inner surfaces of the first side, the second side, the third side and the fourth side define a mold cavity arranged to receive the molten metal; the provision of a vertically movable sill bottom brick configured in relation to the mold cavity to contain the molten metal that enters the mold cavity upon initiation; the provision of molten metal in the mold cavity; moving the bottom sill brick down at a predetermined speed of the mold; and moving the first side and the second side of the mold cavity structure in a predetermined manner with respect to each other during casting to optimize the configuration of the casting for later operations. A possible additional embodiment to this can be one in which the movement of the first side and the second side of the mold cavity displaces at least substantially the predicted contraction during the casting at the predetermined speed of the mold.

[0177] In accordance with the statute, the invention has been described in more or less specific language with regard to structural and methodical characteristics. It should be understood, however, that the

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The invention is not limited to the specific characteristics shown and described, since the devices described in the present invention comprise the preferred forms of practice of the invention. The invention is therefore claimed in some of its forms or modifications within the appropriate scope of the appended claims interpreted appropriately in accordance with the doctrine of equivalents.

Claims (28)

1. CAST METAL MOLD, characterized by comprising: a mold cavity structure (161) that includes a first side (164), a second side opposite the first side (164), a third side (163), and a fourth side opposite the third side (163), wherein each side includes an inner surface and the inner surfaces define a mold cavity (162), wherein the first and second sides are movably mounted relative to each other; wherein the inner surfaces of the first side and second side have a lower portion with a linear or arched surface that tilts vertically and outwardly; and a controller that controls the movement of the first side of the mold cavity structure, so that the movement of the first side is related to maintaining a level of molten metal from the related upper surface in the lower portion of the first side and still controls the movement of the first side of the mold cavity structure, wherein said controller is a programmable controller (572) operatively connected to control predetermined movement of the first side and the second side to provide a taper (521) in an upper portion (201a) of a part emerging cast (201). 2. TEMPLATE according to claim 1, characterized in that the first side moves linearly with respect to the second side. 3. TEMPLATE according to claim 1, characterized in that the first side is mounted on a pivot. Petition 870170084823, of 11/03/2017, p. 8/16 2/6 4. TEMPLATE according to claim 1, characterized by the pivot movement of the first side in relation to the mold cavity structure (161) changing the defined mold cavity (162). 5. TEMPLATE according to claim 1, characterized in that the movement of the first side and the second side is asynchronous. 6. TEMPLATE according to claim 1, further characterized in that the first side and the second side are movably mounted relative to each other; and a lower block (235) configured to fit into the mold cavity (162) at the start of the mold casting system. 7. TEMPLATE according to claim 6, characterized in that the first side and the second side move linearly with respect to each other. 8. TEMPLATE according to claim 6, characterized in that the first side and the second side are pivoted to move from one to the other. 9. TEMPLATE according to claim 6, characterized in that the lower block (235) includes two side walls and in which the third side and the fourth side of the mold cavity structure (161) are combined with the two side walls of the block bottom (235) to define the mold cavity (162) at startup. 10. TEMPLATE according to claim 6, characterized in that the lower block (382) includes an internal cooling device. 11. TEMPLATE according to claim 6, characterized in that the lower block (235) is configured to Petition 870170084823, of 11/03/2017, p. 9/16 3/6 vertical movement inside the mold cavity (162) during initialization to control a distance from the chute to the lower block during casting at startup. 12. TEMPLATE according to claim 1, further characterized in that the mold cavity structure (161) is alternatively configurable to melt a first melt with a first thickness and melt a second melt with a second thickness. 13. TEMPLATE according to claim 1, further characterized by: a first motor operatively connected to the first side and configured to move the first side in relation to the mold structure (161); a second motor operatively connected to the second side and configured to move the second side in relation to the mold structure (161); and a programmable logic controller (572) operatively connected and which controls the first motor and the second motor to control the predetermined movement of the first side and the second side of the mold. 14. TEMPLATE according to claim 13, characterized in that the first motor and the second motor are servo motors. 15. TEMPLATE according to claim 13, characterized in that it additionally comprises a human user interface operatively connected to the programmable logic controller (572). 16. METHOD FOR CASTING OF CAST METAL WITH DIRECT VERTICAL COOLING, characterized by comprising: the provision of a cavity structure (161) Petition 870170084823, of 11/03/2017, p. 10/16 4/6 mold with a first side and a second side opposite the first side, a third side each including an inner surface and a fourth side opposite the third side, where the inner surfaces of the first side, the second side, the third side and fourth side define a mold cavity (162) arranged to receive the molten metal; the provision of a vertically movable lower block (235) configured in relation to the mold cavity (162) to contain the molten metal that enters the mold cavity (162) with the initialization; the provision of molten metal to the mold cavity (162); moving the lower block (235) downwards at a predetermined rate; and the displacement of the first side and the second side of the mold cavity structure (161) relative to each other during casting, thereby varying the dimensions of a resulting cast (201) during casting, providing a taper (521 ) in an upper portion (201a) of an emerging casting (201). 17. METHOD, according to claim 16, characterized in that the first side and the second side are moved linearly with respect to each other. 18. METHOD, according to claim 16, characterized in that the first side and the second side are moved asymmetrically in relation to each other. 19. METHOD, according to claim 16, characterized in that the first side and the second side are pivoted in relation to the mold cavity structure (161) in such a way that the pivot movement of the first side Petition 870170084823, of 11/03/2017, p. 11/16 5/6 and the second side changes the defined mold cavity (162). 20. METHOD, according to claim 16, characterized by the movements of the first side and the second side occurring at the same approximate ratio. 21. METHOD according to claim 16, characterized by the movement of the first side and the second side of the mold cavity structure (161) in relation to each other during the casting, further comprising: the displacement of the first side and the second side away from each other in an initial part of the casting after initialization, to obtain an increasing cross section of the casting (201) from its bottom. 22. METHOD according to claim 16, characterized by the movement of the first side and the second side of the mold cavity structure (161) in relation to each other during the casting, further comprising: O displacement of first side and of second side approaching one from the other in a final part of caster to get an decreased cross section gives casting (201) in its upper part (201a). 23. METHOD according to claim 21, characterized by the movement of the first side and the second side of the mold cavity structure (161) in relation to the other during the casting, further comprising: O displacement of first side and of second side approaching one from the other in a final part of caster to get an decreased cross section gives casting (201) in its upper part (201a). 24. METHOD, according to claim 21, Petition 870170084823, of 11/03/2017, p. 12/16 6/6 characterized by the increasing cross section of the casting (201) from its lower part providing a taper (522) in the lower part of the casting (201) at an angle in the range of 22 degrees to 29 degrees. 25. METHOD according to claim 22, characterized by the increasing cross section of the casting (201) from its upper part (201a) provides a taper (521) in the upper part (201a) of the casting (201) to an angle in the range of 22 degrees to 29 degrees. 26. METHOD, according to claim 16, characterized by the movement of the first side and the second side of the mold cavity structure (161) in relation to the other during the casting process to produce a casting (201) with a cross section in one median part larger than the lower block (235). 27. METHOD, according to claim 16, characterized by the movement of the first side and the second side of the mold cavity structure (161) in relation to the other during the casting to produce a casting (201) with a cross section in its greater median part than in its inferior part and its superior part (201a). 28. METHOD, according to claim 16, characterized in that it additionally comprises the steps of: casting a first cast of a first thickness; displacing the first side and the second side of the mold cavity structure (161) with respect to the other; and casting a second casting of a second thickness different from the first thickness.