Provided is an online cooperative control method for soft reduction and heavy reduction in bloom continuous casting. A quantitative relationship of a theoretical ultimate reduction amount to a reduction position is accurately determined according to an offline three-dimensional solidification and heat transfer model for a continuous casting bloom and a three-dimensional reduction model for a continuous casting bloom under thermo-mechanical coupling; a thermal state of a continuous casting bloom, soft reduction and heavy reduction zones, and a total reduction amount are calculated in real time with an online three-dimensional solidification and heat transfer calculation model for a continuous casting bloom; actual reduction amounts of the rollers for soft reduction and heavy reduction are calculated and distributed online based on a real-time equivalent central solid fraction and a theoretical ultimate reduction amount of each reduction roller. Online cooperative control of soft reduction and heavy reduction in bloom continuous casting is realized.

Systems and associated methods are provided for controlling the shape of an ingot head during formation. At the end of a cast, prior to forming the ingot head, chill bars or other cooling structure may be lowered into an ingot mold and define a reduced casting footprint for forming the ingot head. Supplemental molten metal may be fed into the reduced casting footprint, and the chill bars may be moved laterally towards the center of the ingot, further reducing the casting footprint. As additional molten metal fills the reduced mold footprint, the ingot may be lowered relative to the chill bars to further increase the height of the ingot head. Additional molten metal may be added until the desired shape of the ingot head is formed.

Systems and associated methods are provided for controlling the shape of an ingot head during formation. At the end of a cast, prior to forming the ingot head, chill bars or other cooling structure may be lowered into an ingot mold and define a reduced casting footprint for forming the ingot head. Supplemental molten metal may be fed into the reduced casting footprint, and the chill bars may be moved laterally towards the center of the ingot, further reducing the casting footprint. As additional molten metal fills the reduced mold footprint, the ingot may be lowered relative to the chill bars to further increase the height of the ingot head. Additional molten metal may be added until the desired shape of the ingot head is formed.

A monitoring device (6) records variables that are characteristic of operating parameters of a continuous casting mold (1) for casting a metal strand (2). The monitoring device (6) records at least some of the characteristic variables by independently performing measurements during the casting of the metal strand (2). The monitoring device (6) forms groups (G1, G2) of operating parameters and independently tests whether the operating parameters of the respective group (G1, G2) satisfy a respective predetermined stability criterion. The monitoring device (6) accepts the operating parameters into a database (12). The monitoring device (6) determines those data records (11) contained in the database (12) that coincide in their input variables with the basic operating parameters and determines admissible operating parameter ranges for supplementary operating parameters. The monitoring device (6) independently tests whether the supplementary operating parameters lie within the admissible operating parameter ranges.

A processing system and method for processing a cast raw casting has a spray system for cooling the raw casting. The spray system has at least one nozzle device for at least temporally, locally, or quantitatively variable application of a free-flowing medium to at least one section of the raw casting. The processing system also has a temperature measuring device for measuring the temperature on at least one section of the raw casting and a monitoring device for controlling and adjusting the nozzle device as a function of the measured temperature.

A processing system and method for processing a cast raw casting has a spray system for cooling the raw casting. The spray system has at least one nozzle device for at least temporally, locally, or quantitatively variable application of a free-flowing medium to at least one section of the raw casting. The processing system also has a temperature measuring device for measuring the temperature on at least one section of the raw casting and a monitoring device for controlling and adjusting the nozzle device as a function of the measured temperature.

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.

Provided is a method that includes ejecting an FeSiB-based molten alloy containing iron (Fe), boron (B), and silicon (Si) as essential components from a tapping nozzle to a surface of a cooling roll and rotating the cooling roll at a surface speed of 15 m/sec or more and 50 m/sec or less to rapidly cool the FeSiB-based molten alloy on the surface of the cooling roll to manufacture an alloy ribbon, the tapping nozzle includes a single slit formed to have a width of 0.6 mm or more and less than 2.0 mm, the cooling roll has a curvature of 810.sup.4 or more and less than 210.sup.3, and the method includes passing cooling water in an amount of 0.3 m.sup.3/min or more and less than 20 m.sup.3/min at 5 C. or more and less than 60 C. through the cooling roll to manufacture a rapidly solidified alloy ribbon having an average thickness of 30 m or more and less than 55 m.

A monitoring and control system is for a strand guide roll assembly of a continuous casting machine which includes a plurality of rolls spaced apart generally along a path of travel of a strand from an input end located adjacent to a mold to an output end. The system includes a plurality of sensors each coupled with a separate one of the rolls so as to be spaced apart generally along the travel path, each sensor senses magnitude of a load on the coupled roll. A logic circuit is coupled with each sensor so as to receive input from the sensors corresponding to load magnitude. The logic circuit is configured to determine from the sensor input a general position on the travel path at which the strand substantially solidifies, preferably by calculating a difference between loads on adjacent rolls and determining when the difference is less than a predetermined value.