Systems and methods for making aluminum alloy products are described including those that decrease the tendency for hot tearing or shrinkage porosity to occur during casting by introducing forced convection during the casting process. The forced convection may result in formation of high circularity grains during the solidification process, thereby increasing the permeability of the liquid aluminum alloy and decreasing the tendency for hot tearing or shrinkage porosity to occur.

A method of producing a continuously cast metal rod capable of producing a high-quality continuously cast material is provided. In the method of producing a continuously cast metal rod, a cooling liquid is supplied to each of outer peripheral surfaces of a plurality of ingots extracted from a plurality of molds in parallel to cool each of the plurality of ingots. In a predetermined ingot, the number of adjacent ingots is the number of other ingots arranged around the predetermined so as to face the predetermined ingot, and an ingot small in the number of adjacent ingots is cooled with weak cooling in which the degree of cooling by the cooling liquid is reduced with respect to an ingot large in the number of adjacent ingots.

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.

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.

Disclosed is a continuous casting ingot mold for metals, of the type made of an assembly of metal plates mounted against cooling devices configured to allow cooling of the metal plates by the circulation of a liquid coolant. Said ingot mold comprises an optical fiber with a diameter greater than 1.6 mm, having a plurality of fiber Bragg grating filters and extending in a wall of at least one of said plates in a direction that is not parallel to the axis of casting of the ingot mold.

Disclosed is a continuous casting ingot mold for metals, of the type made of an assembly of metal plates mounted against cooling devices configured to allow cooling of the metal plates by the circulation of a liquid coolant. Said ingot mold comprises an optical fiber with a diameter greater than 1.6 mm, having a plurality of fiber Bragg grating filters and extending in a wall of at least one of said plates in a direction that is not parallel to the axis of casting of the ingot mold.

This manufacturing method for a slab is a method for manufacturing a slab by a continuous casting equipment including a twin-drum type continuous casting apparatus, a cooling apparatus, an in-line mill, and a coiling apparatus. The method includes calculating a friction coefficient from measured values of a rolling load and a forward slip when the slab is rolled, by use of a rolling analysis model, and controlling a lubrication condition during rolling of the slab so that the friction coefficient falls within a predetermined range, wherein, when the friction coefficient is calculated from the measured values of the rolling load and the forward slip by use of an Orowan theory and a deformation resistance model formula based on a Shida's approximate formula as the rolling analysis model, the predetermined range is 0.15 or more and 0.25 or less.

This manufacturing method for a slab is a method for manufacturing a slab by a continuous casting equipment including a twin-drum type continuous casting apparatus, a cooling apparatus, an in-line mill, and a coiling apparatus. The method includes calculating a friction coefficient from measured values of a rolling load and a forward slip when the slab is rolled, by use of a rolling analysis model, and controlling a lubrication condition during rolling of the slab so that the friction coefficient falls within a predetermined range, wherein, when the friction coefficient is calculated from the measured values of the rolling load and the forward slip by use of an Orowan theory and a deformation resistance model formula based on a Shida's approximate formula as the rolling analysis model, the predetermined range is 0.15 or more and 0.25 or less.

An apparatus and a system including a casting pit; a mold including a reservoir and a cavity; a coolant feed operable to introduce a coolant to a periphery of a metal emerging from the mold cavity; an array of water vapor exhaust ports about at least the top periphery of the casting pit; a mechanism to introduce an inert fluid into the coolant feed. A method for a direct chill casting including, after detecting a bleed out, exhausting generated gas from the casting pit at a flow volume rate that is enhanced relative to a flow volume rate prior to detecting bleed out or run out; introducing an inert gas into the casting pit; and introducing an inert fluid into a coolant feed to the casting mold.

An apparatus and a system including a casting pit; a mold including a reservoir and a cavity; a coolant feed operable to introduce a coolant to a periphery of a metal emerging from the mold cavity; an array of water vapor exhaust ports about at least the top periphery of the casting pit; a mechanism to introduce an inert fluid into the coolant feed. A method for a direct chill casting including, after detecting a bleed out, exhausting generated gas from the casting pit at a flow volume rate that is enhanced relative to a flow volume rate prior to detecting bleed out or run out; introducing an inert gas into the casting pit; and introducing an inert fluid into a coolant feed to the casting mold.