An unfired, refractory molded body (1), includes a binding agent matrix (2) containing at least one set, permanent binding material and aggregate grains (3) with and/or of biogenic silicic acid, preferably with and/or of rice husk ash, which grains are incorporated into the binding agent matrix (2), for thermal isolation of a molten metal, especially of molten steel, and/or of a metal ingot solidifying from the molten metal, and also the use of the molded body (1) for thermal isolation of a refractory lining, in particular in a multiple-layer brick wall or in a heat-treatment furnace, or as a corrosion barrier, e.g. against alkali attack, or as a fire protection lining or as filter material for hot gases.

An unfired, refractory molded body (1), includes a binding agent matrix (2) containing at least one set, permanent binding material and aggregate grains (3) with and/or of biogenic silicic acid, preferably with and/or of rice husk ash, which grains are incorporated into the binding agent matrix (2), for thermal isolation of a molten metal, especially of molten steel, and/or of a metal ingot solidifying from the molten metal, and also the use of the molded body (1) for thermal isolation of a refractory lining, in particular in a multiple-layer brick wall or in a heat-treatment furnace, or as a corrosion barrier, e.g. against alkali attack, or as a fire protection lining or as filter material for hot gases.

A method for casting a part, that includes the steps of: introducing a mold into a first housing; engaging the first housing with a second housing to define a second chamber; melting an ingot within the furnace; reducing pressure within the second chamber to a first predetermined pressure; pouring at least a portion of the melted ingot into the mold; adding an gas to the second chamber to raise the pressure to a second predetermined pressure; moving the mold such that it is engaged with the means for cooling; and solidifying the liquid metal within the mold.

An apparatus for casting a part that includes a first housing, a second housing, a handling system and a means for cooling. The first housing defines a first chamber. The first chamber is configured to receive a melt heater and a mold heater. The second housing is configured to move between a first position and a second position such that when the second housing is in the first position, the first housing is open such that a mold can be inserted therein and when the second housing is in the second position, the second housing and the first housing define a second chamber. The means for cooling is configured to be positioned within the second chamber.

A method of casting a metal alloy ingot, including the following steps: providing a one side open-ended mould including a plurality of sides and a bottom plate defining a mould cavity with a mould opening, the open-ended mould being pivotable around a horizontal rotational axis between a position so that the mould opening points upwards and a position so that the mould opening points side-wards or down-wards; positioning the open-ended mould such that the mould opening points side-wards or down-wards; providing a casting container with an upwardly positioned aperture; filling the casting container with molten metal for one casting operation; coupling the casting container to the open-ended mould so that the casting container is located below the mould while the mould opening points side-wards or down-wards; rotating the open-ended mould together with the casting container around the horizontal rotational axis for approximately 90 to 180 from a position whereby the mould opening points side-wards or down-wards to a position whereby the mould opening points upwards such that the molten metal is conveyed through the mould opening into the open-ended mould until reaching a desired thickness, whereby the molten metal in the open-ended mould is cooled directionally through its thickness where the solidification front remains substantially monoaxial.

For continuously casting an ingot of titanium or titanium alloy, molten titanium or titanium alloy is poured into a top opening of a bottomless mold with a circular cross-sectional shape, the solidified molten metal in the mold is pulled downward from the mold, a plurality of plasma torches disposed on an upper side of molten metal in the mold such that their centers are located directly vertically above the molten metal in the mold, are operated to generate plasma arcs that heat the molten metal in the mold, and the plasma torches are moved in a horizontal direction above a melt surface of the molten metal in the mold, along a trajectory located directly vertically above the molten metal in the mold, while keeping a mutual distance between the respective plasma torches such that the plasma torches do not interfere with each other.

For continuously casting an ingot of titanium or titanium alloy, molten titanium or titanium alloy is poured into a top opening of a bottomless mold with a circular cross-sectional shape, the solidified molten metal in the mold is pulled downward from the mold, a plurality of plasma torches disposed on an upper side of molten metal in the mold such that their centers are located directly vertically above the molten metal in the mold, are operated to generate plasma arcs that heat the molten metal in the mold, and the plasma torches are moved in a horizontal direction above a melt surface of the molten metal in the mold, along a trajectory located directly vertically above the molten metal in the mold, while keeping a mutual distance between the respective plasma torches such that the plasma torches do not interfere with each other.

A device to generate and direct electric heat 10 for use over risers, drains, pathways and pour cups during solidification in which less than 2% plasma is utilized, comprising an outer shell 20 having one open heat delivery end 25, at least one lip 30 located at the open end 25, one closed end 35, at least one electric heating element 80 affixed within the closed 35 end and refractory material 60 surrounding the electric heating element 80. A method, employing the device 10, to improve the properties of cast alloys which comprises the heating and blanketing of a molten cast surface with an atmosphere of less than 2% plasma during solidification, the atmosphere of less than 2% plasma thereby controlling temperature during the solidification and shielding the molten cast surface from the affects of oxidation.

A device to generate and direct electric heat 10 for use over risers, drains, pathways and pour cups during solidification in which less than 2% plasma is utilized, comprising an outer shell 20 having one open heat delivery end 25, at least one lip 30 located at the open end 25, one closed end 35, at least one electric heating element 80 affixed within the closed 35 end and refractory material 60 surrounding the electric heating element 80. A method, employing the device 10, to improve the properties of cast alloys which comprises the heating and blanketing of a molten cast surface with an atmosphere of less than 2% plasma during solidification, the atmosphere of less than 2% plasma thereby controlling temperature during the solidification and shielding the molten cast surface from the affects of oxidation.

Provided is a device for titanium continuous casting (1) capable, even when continuously casting large diameter titanium ingots or titanium alloy ingots, of suppressing component segregation thereof. The device for titanium continuous casting (1) comprises: a mold (3) having an upper section having a circular upper opening (3a) for pouring in molten metal (6), and a bottom section having a lower opening for continuously drawing ingots (11); and a plurality of plasma torches (4, 5) to heat the molten metal in the mold (3) from the upper opening (3a) side. The plurality of plasma torches (4, 5) are disposed so that the amount of heat input to the molten metal (6) present in the outer circumference enclosing the center of the upper opening (3a) is greater than the amount of heat input to the molten metal (6) present in the center of the upper opening (3a).