METHOD AND DEVICE FOR PRODUCING A CONTINUOUS STRIP-SHAPED COMPOSITE MATERIAL

Abstract

A device and a method for producing a continuous strip-shaped composite material. For this purpose, a base material, which is produced using at least one casting machine as a continuous strand, in particular made of steel, and providing at least one cladding material, which is unwound in the form of at least one metal strip by a coil unwinding unit are provided. Subsequently, a slab which has formed by solidification from the strand produced by the casting machine and the metal strip unwound by the coil unwinding unit, in the hot state are brought together, wherein the materials, which are moved in the direction toward one another, formed from the slab and the unwound metal strip are hot rolled, so that a single continuous strip-shaped composite material is thus produced by roll cladding. The base material is continuously cast in the vertical direction in the casting direction.

Claims

1-18. (canceled)

19. A method for producing a continuous strip-shaped composite material, comprising the following steps: (i) providing a base material, which is produced using at least one casting machine as a continuous strand, in particular made of steel, and providing at least one cladding material, which is unwound in the form of at least one metal strip by a coil unwinding unit, (ii) bringing together a slab which has formed by solidification from the strand produced by the casting machine and the metal strip unwound by the coil unwinding unit, and (iii) hot rolling the materials, which are moved in the direction toward one another, formed from the slab, which is formed by solidification from the strand produced using the casting machine, and the at least one metal strip unwound by the coil unwinding unit, so that a single continuous strip-shaped composite material, which consists of the base material and the at least one cladding material, is thus produced by roll cladding, wherein the base material is vertically continuously cast in the casting machine and exits through an opening of a mold of the casting machine into a strand guiding system having cooling, the coil unwinding unit is accommodated in a heatable chamber and the metal strip wound thereon is thus heated, before step (ii) and/or during step (ii), the slab formed by solidification from the strand produced using the casting machine and/or the metal strip unwound by the coil unwinding unit is/are heated by means of an induction heater, so that the slab and the metal strip are brought together in step (ii) in the hot state at a temperature which is greater than the recrystallization temperature of the base material and the cladding material, before step (ii), the slab formed by solidification from the strand produced using the casting machine is descaled and the metal strip unwound by the coil unwinding unit is cleaned, preferably descaled, before step (iii), a surface temperature of at least one material partner formed from the slab formed by solidification from the strand produced using the casting machine and/or the metal strip unwound by the coil unwinding unit is increased on a side which is opposite to the respective other material partner, by means of an induction heater.

20. The method as claimed in claim 19, wherein before step (ii), a speed of at least one material partner formed from the slab formed by solidification from the strand produced using the casting machine and the metal strip unwound by the coil unwinding unit is controlled, preferably regulated, preferably the slab is guided through a compensation rolling stand, using which the speed of the slab can be controlled, preferably regulated.

21. The method as claimed in claim 19, wherein before step (ii) and/or during step (ii) and/or before step (iii), the slab formed by solidification from the strand produced using the casting machine and/or the metal strip unwound by the coil unwinding unit are laterally guided to thus align the slab and the metal strip laterally in relation to one another, preferably at least one lateral influencing unit in the form of a guide ruler is provided for the lateral guiding, which is moved by an actuator in the direction of the band center, in particular using a predetermined force.

22. The method as claimed in claim 19, wherein before step (ii) and/or during step (ii) and/or before step (iii), the slab formed by solidification from the strand produced using the casting machine and/or the metal strip unwound by the coil unwinding unit is/are guided in a protective gas atmosphere.

23. The method as claimed in claim 19, wherein, following step (iii), a material condition of the produced single continuous strip-shaped composite material is detected, in particular by x-rays and/or ultrasound, preferably in that a process signal is generated by a control unit on the basis of the detected material condition, and is used to form a control loop for the method.

24. The method as claimed in claim 19, wherein this method is carried out automatically as a function of at least one predetermined process variable, preferably this process variable is selected from the group formed from in particular the casting speed of the casting machine, a change of the liquid-core reduction of the strand produced using the casting machine, the speed of the slab formed by solidification from the strand produced using the casting machine and/or the metal strip unwound by the coil unwinding unit present before step (ii), a temperature difference of the slab and the metal strip before step (ii) and/or before step (iii), a respective speed of the work rollers of the roll-cladding unit, and/or a thickness reduction achieved in step (iii) of the produced single continuous strip-shaped composite material.

25. The method as claimed in claim 19, wherein in step (iii), the cladding material is applied to opposing sides of the slab formed by solidification from the strand produced using the casting machine, wherein the cladding material consists of the same material and is unwound by separate coil unwinding units in each case.

26. The method as claimed in claim 19, wherein the base material and the at least one cladding material can each consist of different material qualities, preferably in step (i) a further cladding material in the form of a metal strip is unwound by a further coil unwinding unit, wherein the subsequent steps (ii) and (iii) are carried out using a total of three plies, which are formed by the slab formed by solidification from the strand produced using the casting machine and the two metal strips unwound by the respective coil unwinding units.

27. The method as claimed in claim 26, wherein the cladding materials of which the two metal strips unwound by the respective coil unwinding units consist are each formed from different materials, wherein these metal strips are either applied to opposing sides of the slab formed by solidification from the strand produced using the casting machine or to the same side of this slab.

28. The method as claimed in claim 19, wherein at least one intermediate layer in solid, liquid, or powdered form is introduced between the material partners to be brought together, which passivates or activates the surfaces of the material partners opposite to one another.

29. A device for producing a continuous strip-shaped composite material, comprising: at least one casting machine, using which a continuous strand is produced, in particular from steel, which is used as a base material, at least one coil unwinding unit, using which a metal strip is provided, which is used as a cladding material, at least one rolling stand in the form of a roll-cladding unit, which is arranged in line with the casting machine and with the coil unwinding unit and downstream from each of them, wherein the casting machine has a mold having walls, between which the base material can be poured in from above as liquid metal and exits downward through an opening into a strand guiding system having cooling, the at least one coil unwinding unit is positioned inside a heatable chamber and has a quick-change unit, by means of which a replacement of coils is possible, wherein the quick-change unit comprises a welding unit, to weld successive metal strips to one another in step (i) of a method as claimed in claim 19, between the casting machine and the coil unwinding unit, on the one hand, and the roll-cladding unit, on the other hand, a bringing-together unit is arranged, by means of which a slab formed by solidification from the strand produced using the casting machine and the metal strip unwound by the coil unwinding unit can be moved in the direction toward one another in the hot state, upstream of the bringing-together unit and/or as a part thereof, at least one heating unit is provided, wherein the slab formed by solidification from the strand produced using the casting machine and the metal strip unwound by the coil unwinding unit are guided through this heating unit, at least one cleaning unit, preferably a descaling unit, by means of which the slab formed by solidification from the strand produced using the casting machine and/or the metal strip unwound by the coil unwinding unit can be cleaned, preferably can be descaled, is arranged between the casting machine and the coil unwinding unit, on the one hand, and the bringing-together unit, on the other hand, at least one temperature influencing unit is provided between the bringing-together unit and a roll-cladding unit arranged directly downstream thereof, by means of which the surface temperature of at least one material partner formed from the slab formed by solidification from the strand produced using the casting machine and/or the metal strip unwound by the coil unwinding unit can be influenced on one side which is opposite to the respective other material partner, so that an arrangement of material partners formed from the slab formed by solidification from the strand produced using the casting machine and the metal strip unwound by the coil unwinding unit can be hot rolled in the roll-cladding unit, and thus a single continuous strip-shaped composite material, which consists of the base material and the at least one cladding material, results by roll cladding.

30. The device as claimed in claim 29, wherein at least one compensation rolling stand is provided, which is arranged in line between the casting machine and the bringing-together unit.

31. The device as claimed in claim 29, wherein the heating unit functions according to the principle of an induction heater, furthermore a separate heating unit is preferably provided in each case for the slab formed by solidification from the strand produced using the casting machine and the metal strip unwound by the coil unwinding unit.

32. The device as claimed in claim 29, wherein at least one lateral influencing unit is provided, which is arranged upstream of the bringing-together unit and/or as a part thereof and/or upstream of the roll-cladding unit, wherein the slab formed by solidification from the strand produced using the casting machine and/or the metal strip unwound by the coil unwinding unit can be brought into contact on the lateral edges thereof with the lateral influencing unit to be laterally aligned in relation to one another, preferably the lateral influencing unit is designed in the form of a guide ruler, which is movable in particular using a predetermined force in the direction of the strip center.

33. The device as claimed in claim 29, wherein a protective gas unit, which is provided as part of the bringing-together unit and/or as part of a roll-cladding unit arranged downstream directly adjoining the bringing-together unit, wherein the slab formed by solidification from the strand produced using the casting machine and/or the metal strip unwound by the coil unwinding unit is/are guided inside this protective gas unit in a protective gas atmosphere.

34. The device as claimed in claim 29, wherein a measuring unit, by a material condition of the produced single continuous strip-shaped composite material is detectable, in particular by x-rays and/or ultrasound, is provided downstream of the roll-cladding unit.

35. The device as claimed in claim 29, wherein the at least one coil unwinding unit has a plurality of unwinding modules, which can be moved in succession into an unwinding position, preferably this coil unwinding unit comprises a welding unit, to weld successive metal strips to one another in step (i).

36. The device as claimed in claim 29, wherein at least one second coil unwinding unit is provided, by means of which a continuous metal strip is provided, which is used as a further cladding material.

Description

[0039] Exemplary embodiments of the invention are described in detail hereafter on the basis of a schematic simplified drawing.

[0040] In the figures:

[0041] FIG. 1 shows a schematic side view of a device according to the invention, in which at least two casting machines are used,

[0042] FIG. 2 shows a schematic side view of a modification of a bringing-together unit, which can be part of the device of FIG. 1,

[0043] FIGS. 3a, 3b shows side views of work rollers of a roll-cladding unit which is part of the device of FIG. 1, and

[0044] FIG. 4 shows a schematic simplified enlarged view of a modified coil unwinding unit, which can be part of the device of FIG. 1.

[0045] Preferred embodiments of a device 10 according to the invention and components thereof are explained hereafter with reference to FIGS. 1 to 4, wherein this device 10 is used for producing a metal strip in the form of a continuous strip-shaped composite material 11. Identical features in the drawings are each provided with identical reference signs. It is to be especially noted here that the drawing is solely shown in simplified form and in particular is not to scale.

[0046] FIG. 1 shows a schematic simplified side view of the device 10 according to a first embodiment.

[0047] The device 10 comprises a casting machine 12, using which a continuous strand 13 is produced, in particular from steel, which is used as a base material. The device 10 furthermore comprises a coil unwinding unit 14, using which a metal strip 15 is provided, which is used as a cladding material and can be suitably unwound by this coil unwinding unit 14. A slab 16 formed by solidification from the strand 13, which slab is subsequently guided jointly with the unwound metal strip 15 through a bringing-together unit 26, which is arranged upstream of the casting machine 12 and the coil unwinding unit 14, and in this way are moved in the direction toward one another. The device 10 furthermore comprises at least one rolling stand in the form of a roll-cladding unit 18.1, which is arranged directly adjoining the bringing-together unit 26 and therefore downstream thereof. The function of this roll-cladding unit 18.1 is also explained separately hereafter.

[0048] The bringing-together unit 26 is used for the purpose of moving the slab 16 and the unwound metal strip 15 in the direction toward one another. In the embodiment shown in FIG. 1, it can be provided that the slab 16 and the unwound metal strip 15 already come into contact with one another inside the bringing-together unit 26. According to an alternative embodiment of the bringing-together unit 26, which is shown schematically simplified in the side view according to FIG. 2 and can also be used for the device of FIG. 1, it is provided that the slab 16 and the unwound metal strip 15 do not contact inside this bringing-together unit 26, but rather only outside and downstream thereof, when they run into the roll-cladding unit 18.1 positioned directly adjoining thereon.

[0049] In FIG. 2, a transportation direction, in which the produced continuous strip-shaped composite material 11 is transported or moved (from left to right in the plane of the drawing), is indicated with the arrow T. With respect to the illustrations of FIG. 1, it is apparent that the composite material 11 is moved therein in the same direction, namely from left to right (viewed in the plane of the drawing).

[0050] The device 10 has a compensation rolling stand 28, which is arranged in line between the casting machine 12 and the bringing-together unit 26. The slab 16, which is formed by solidification from the strand 13 produced using the first casting machine 12, is guided through the compensation rolling stand 28. In this way it is possible to control, preferably to regulate, a speed of the slab 16 in the direction of the bringing-together unit 26 by means of the compensation rolling stand 28. In the same manner, the speed at which the unwound metal strip 15 is transported in the direction of the bringing-together unit 26 can be controlled, preferably regulated, by the associated coil unwinding unit 14. It is advantageous in this context if the modulation of the compensation rolling stand 28 and the coil unwinding unit 14 is adapted to one another by means of a preferably shared control unit, so that the slab 16 and the unwound metal strip 15 enter the bringing-together unit 26 at the same speed.

[0051] The device 10 comprises a first heating unit 30 (cf. FIG. 1), which is arranged in line between the casting machine 12 and the bringing-together unit 26, and a second heating unit 31, which is arranged in line between the coil unwinding unit 14 and the bringing-together unit 26. The side view of FIG. 1 illustrates that the slab 16 is guided through the first heating unit 30. In the same manner, the unwound metal strip 15 is guided through the second heating unit 31. In this way, the slab 16 and the metal strip 15 are heated according to the principle of through heating, wherein possible temperature differences, which can occur as a result of a transportation route of differing length between the slab 16, which has formed by solidification from the strand 13 produced using the casting machine 12, and the metal strip 15, which has been unwound by the coil unwinding unit 14, are adapted. In this case, it can also be advantageous to keep the temperatures of the material partners intentionally different, for example, in the case of different materials, material qualities, or material thicknesses. As a result thereof, the slab 16 and the metal strip 15 preferably enter the bringing-together unit 26 at a predetermined temperature.

[0052] The device 10 has lateral influencing units, which are each arranged upstream of the bringing-together unit 26 and in line with the first casting machine 12 or with the coil unwinding unit 14, respectively. These lateral influencing units are only symbolically indicated in the illustration of FIG. 2 by the reference sign 32 and can be formed, for example, by guide rulers. The slab 16 and the metal strip 15 are accordingly laterally guided by these guide rulers and are thus aligned in relation to one another. It is particularly to be noted at this point that these lateral influencing units 32 can also be arranged inside the bringing-together unit 26 and can thus be formed as a part of this bringing-together unit 26.

[0053] The above-mentioned roll-cladding unit 18.1 is used for the purpose of carrying out hot rolling for the slab 16 and the metal strip 15 and thus producing a continuous strip-shaped composite material 11 therefrom by means of roll cladding. The side view of FIG. 3a shows in schematically simplified form a two-layer roll welding of two material partners, which can consist, for example, of the slabs 16 and the metal strip 15, when they come into contact with the work rollers A1, A2 of the roll-cladding unit 18.1 and are guided through between these work rollers A1, A2. It is apparent from the side view of FIG. 3a that a composite is formed from the slab 16 and the metal strip 15 when they enter the roll-cladding unit 18.1 jointly, which is then hot rolled or roll clad by the work rollers A1, A2 of the roll-cladding unit.

[0054] Adjoining the roll-cladding unit 18.1 or downstream thereof, further rolling stands and/or roll-cladding units can be provided, using which hot rolling is carried out for the strip-shaped composite material 11. It is indicated in FIG. 1 by the reference sign 18.i that at least one further roll-cladding unit or multiple such rolling stands can be arranged in the rolling train 19 downstream of the roll-cladding unit 18.1. Furthermore, further rolling stands can be provided in the rolling train 19 adjoining the roll-cladding units 18.i.

[0055] The device 10 comprisesas shown in the illustration in FIG. 2a cleaning unit in the form of a descaling unit 34, which is arranged upstream of the bringing-together unit 26. The slab 16 and the metal strip 15 are suitably descaled by this descaling unit 34, which is advantageous in particular if at least one of these two material partners, or both, (each) consist/consists of steel or a steel alloy. Furthermore, the side view of FIG. 2 illustrates that the device 10 comprises a protective gas unit 36, which is integrated into the bringing-together unit 26. The protective gas unit 36 is merely symbolized in simplified form by dashed lines in the illustration of FIG. 2. The slab 16 and the metal strip 15, before they are bonded to one another by means of hot rolling or roll cladding, are guided through the protective gas unit 36, which effectively prevents the formation of fresh scale on the opposing surfaces of these material partners. The bonding of the slab 16 and the unwound metal strip 15 by means of the hot rolling in step (iii) can furthermore be improved in that a surface temperature of at least one of these material partners is influenced on the respective opposing sides thereof, preferably increased. For this purpose, a temperature influencing unit 38, which is shown in symbolically simplified form in the illustration of FIG. 2, is arranged directly upstream of the roll-cladding unit 18.1.

[0056] The device 10 can also comprise a rolling train 19, using which the produced continuous strip-shaped composite material 11 can be rolled out to lesser thicknesses.

[0057] The device furthermore comprises at least one measuring unit 40, using which the material condition of the continuous strip-shaped composite material 11, which has been produced by means of hot rolling by the roll-cladding unit 18.1, can be detected. The measuring unit 40 is arranged, for example, behind or downstream of the roll-cladding unit 18.1, and preferably functions according to the principle of x-rays and/or ultrasound. For this purpose, it can be provided that associated sensors of the measuring unit 40 are arranged above and/or below the continuous strip-shaped composite material 11, so that an upper side and/or a lower side of the metal strip in the form of this composite material 11 can be examined therewith with respect to its material condition and/or surface quality.

[0058] In the embodiment of FIG. 1, the casting machine 12 is designed in the form of a vertical continuous-casting unit. In this case, the casting machine 12 has a mold 20 having walls. The base material is poured in from above as liquid metal between the walls of the mold 20. The mold 20 has an opening at its lower side. The liquid metal can accordingly exit through this opening into a strand guiding system 24, which is equipped with cooling.

[0059] Severing units 42, for example, in the form of flame cutting units, pendulum shears, drum shears, or the like, are arranged at various points along the process line of the device 10. These severing units 42 enable cutting out and/or discharge of unusable material. Additionally or alternatively, a discontinuous rolling mode of individual strips and/or an emergency mode using only the casting machine 12 can be implemented with use of these severing units 42. The severing can also be performed with the goal of improving the following process steps and/or producing the lengths of the final product produced in this plant. In this regard, it is to be noted that the positions of the respective severing units 42 shown in FIG. 1 are only to be understood as examples.

[0060] At least one reel 44 is provided at the end of the rolling train 19 to wind the produced continuous strip-shaped composite material 11 into a coil. A plurality of such reels 44 can expediently also be provided, having corresponding units (not shown) for switching over between the individual reels 44. Additionally and/or alternatively, at least one shelf or the like can be provided at the end of the rolling train 19, to remove plates or heavy plates therefrom.

[0061] The embodiment of FIG. 1 can be modified in that a further or second coil unwinding unit (not shown) is provided, using which a further continuous metal strip is provided, which is also used as a cladding material. This further coil unwinding unit can also be arranged in line with the roll-cladding unit 18.1. It is accordingly possible to carry out above-explained steps (ii) and (iii) of the method according to the invention using a total of three plies, which are formed from the slab 16 formed by solidification from the strand 13 produced using the casting machine 12 and the two metal strips unwound by the respective coil unwinding units. Roll cladding of a total of three plies between the work rollers A1 and A2 of the roll-cladding unit 18.1 is illustrated in schematically simplified form in the side view of FIG. 3b. In this case, the slab 16 is used as a base material, wherein the metal strips 15 and 46 are used as the cladding material, which are each clad on opposing sides of the slabs 16. In this regard, it is to be noted that different material qualities and/or steel qualities can be used for each of the base material (in the form of the slab 16), on the one hand, and for the cladding material (in the form of the metal strips 15, 46), on the other hand. The cladding material used for the metal strips 15, 46 can consist of the same material. Furthermore, it is to be noted thatnotwithstanding the illustration in FIG. 3bthe two metal strips 15, 46 can also be applied or clad on the same side of the slab 16.

[0062] A further modification of the device 10 according to FIG. 1 can be performed in such a manner that the coil unwinding unit 14 is accommodated in a heatable chamber 48. This is shown in simplified form in the illustration of FIG. 4. It is ensured by such an accommodation of the coil unwinding unit 14 in the heatable chamber 48 that metal strip 15 unwound thereby already has a predetermined temperature, with respect to bringing together with the slab 16 and the subsequent hot rolling to form a single continuous strip-shaped composite material 11. The heating of the coil unwinding unit 14 or the metal strip 15 unwound thereby in the heatable chamber 48 can also be carried out in a protective gas atmosphere.

[0063] The method according to the invention for producing the continuous strip-shaped composite material 11 can be carried out using the above-explained embodiments of the device 10 according to the invention. This method can be carried out automatically, and preferably in a regulated manner, as a function of at least one of the process variables mentioned at the outset.

LIST OF REFERENCE SIGNS

[0064] 10 device [0065] 11 continuous strip-shaped composite material [0066] 12 casting machine [0067] 13 continuous strand (produced by the casting machine 12) [0068] 14 coil unwinding unit [0069] 15 metal strip (which is unwound by the coil unwinding unit 14) [0070] 16 slab (formed from the strand 13) [0071] 18.1 roll-cladding unit [0072] 18.i (further) roll-cladding unit(s) [0073] 19 rolling train [0074] 20 mold [0075] 24 strand guiding system [0076] 26 bringing-together unit [0077] 28 compensation rolling stand [0078] 30 first heating unit (for example, induction heater) [0079] 31 second heating unit (for example, induction heater) [0080] 32 lateral influencing unit (for example, guide ruler) [0081] 34 cleaning unit (for example, descaling unit) [0082] 36 protective gas unit [0083] 38 temperature influencing unit [0084] 40 measuring unit [0085] 42 severing unit (for example, drum shears) [0086] 44 reel [0087] 46 (further) metal strip [0088] 48 heatable chamber (for accommodating at least one coil unwinding unit 14) [0089] A1, A2 work rollers (of the roll-cladding unit 18.1) [0090] T transportation direction (for the strip-shaped composite material 11)