An aluminum power transmission rail product comprises a profile main component made from molten aluminum onto which a stainless steel cap has been co-cast. Preferably, this main component has a locking feature such as a down-turn on at least one edge of the stainless steel cap. The rail product is preferably cast on a casting unit selected from the group consisting of a horizontal caster, a horizontal DC caster, an MDC caster and a semi-solid casting unit.

A method of manufacturing an aluminum power transmission rail product with a metallurgically bonded stainless steel cap comprises providing molten aluminum in a tundish; providing a roll formed stainless steel wear cap; pretreating and preheating the stainless steel cap, then introducing that cap into the tundish; co-casting the aluminum and cap through one or more dies; and tensioning the stainless steel cap at an exit of the casting die and rapidly cooling the same. An aluminum-stainless composite product is also disclosed.

Continuous casting apparatus, comprising a mold and a crystallizer for the continuous casting of a metal product. The mold is provided with primary cooling means using a cooling fluid and associated with the walls of the crystallizer. A plurality of cooling members is installed downstream of the mold to perform a secondary cooling of the product, said cooling members comprising a plurality of delivery nozzles configured to deliver a liquid for cooling the product.

A mold for semi-continuous casting of metal strands from liquid metal, comprising a mold body provided with at least one mold cavity. The at least one mold cavity comprises a liquid metal inlet defined by a nozzle plate; an insert defining a perimeter wall intended to be in contact with the metal leaving said liquid metal inlet; a mold outlet; a plurality of spray nozzles for spraying cooling fluid onto the metal strand, the spray nozzles being preferably provided in the insert. The mold body is provided with a channel for cooling fluid. The insert is removable and is made from a metallic material. The mold is useful for casting aluminium strands.

A continuous casting method and apparatus are described that generate alpha-phase Al(Fe,Mn)Si intermetallic particles on the surface of an aluminum alloy strip to facilitate the manufacture of beverage cans. The alpha phase particle size is generated so that subsequent rolling will ensure the particles will provide galling-free operation in the ironing stages of the can body making process. The control of alpha-particle size upon the surface layers of the strip ensures galling-free operation.

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

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