A method and apparatus for continuous Near Net Shape casting of a liquid metal (10) into a metal strip are described. The method comprises transferring the liquid metal in a velocity adjusted manner from a headbox (50) a chilled substrate (36), via a meniscus gap (69). The headbox (50) comprising a slot nozzle (68) defined in a bottom portion (66) for the headbox (50) above (36) onto the chilled substrate. The slot nozzle (68) defining a smooth elongated cavity with a slot width (67) and the slot length (65) of the metal strip (34). It has been surprisingly found that the generation of some turbulence at the outlet of the apparatus described herein promotes stable Near Net Shape Continuous Casting. The present method and apparatus increase the level of turbulence in the liquid metal of the outlet nozzle upstream of the chilled substrate (36) to minimize premature metal freezing. In a particularly preferred embodiment the slot nozzle is adjustable.

A continuous casting device having multi-stage convergence control is disclosed. Cooling surfaces of the continuous casting device can be articulated in stages, providing individual convergence control to longitudinally spaced-apart regions of the casting cavity. In a proximal region, during which the molten metal exhibits solidification shrinkage, a first convergence profile can be used to optimally account for the solidification shrinkage. In a subsequent distal region, a second convergence profile can be used, such as to provide optimal control of exit temperature of the continuously cast article. Multi-stage convergence control can be achieved through individually articulatable cooling pads or other supports positioned opposite the cooling surfaces from the casting cavity to displace the cooling surfaces and thereby adjust the convergence profile of the casting cavity. Actuation of the individually articulatable cooling pads can effect different convergence profiles along the length of the continuous casting device.

A cooling pad for a belt casting system includes a first nozzle arrangement and a second nozzle arrangement. In some embodiments, the first nozzle arrangement includes an elongated nozzle assembly that includes a base defining a receiving area, a first insert positionable within the receiving area, and a second insert positionable within the receiving area. The first insert and the base together define a first elongated dispensing slot. The second insert is adjustable relative to the first insert, and the second insert and the base together define a second elongated dispensing slot. In various embodiments, the second nozzle arrangement includes a plurality of multi-position nozzles, each movable between a base position and an offset position such that the heat transfer rate may be locally controlled across the cooling cavity.

A cooling pad for a belt casting system includes a first nozzle arrangement and a second nozzle arrangement. In some embodiments, the first nozzle arrangement includes an elongated nozzle assembly that includes a base defining a receiving area, a first insert positionable within the receiving area, and a second insert positionable within the receiving area. The first insert and the base together define a first elongated dispensing slot. The second insert is adjustable relative to the first insert, and the second insert and the base together define a second elongated dispensing slot. In various embodiments, the second nozzle arrangement includes a plurality of multi-position nozzles, each movable between a base position and an offset position such that the heat transfer rate may be locally controlled across the cooling cavity.

The mould contains a casting wheel, on the outer surface of which an open channel is made, a continuous tape adjacent to the casting wheel from its outer surface in such a way as to close the specified open channel, as well as a cooling system able of adjustable supply of coolant to the casting wheel and the continuous tape at least on the outer surface, on the inner surface and on both side surfaces of the wheel, in which the ratio of the coolant flow on the inner surface of the wheel to the coolant flow on the outer surface of the wheel is 1.9-3.0, and the ratio of the total coolant flow on the side surfaces of the casting wheel to the coolant flow on the inner surface of the casting wheel is 1.3-1.7.