Claims:
1. A top cover assembly (100) for a mould (108) of a slab caster, the assembly (100) comprising:
a metallic base plate (101) positioned on the mould (108) covering a top surface of the mould (108), wherein the metallic base plate (101) is defined with a cavity (103) to allow flow of molten metal into the mould (108); and
a ceramic plate (104), removably positioned on the metallic base plate (101) covering at least a portion of a top surface of the metallic base plate (101), wherein the ceramic plate (104) comprises a conduit (106) co-operating with the cavity (103) defined in the metallic base plate (101);
wherein, the ceramic plate (104) eliminates sticking of molten metal to the metallic base plate (101) during casting process.

2. The assembly (100) as claimed in claim 1, wherein the ceramic plate (104) comprises a head portion (105) defined with a hole (109), and the conduit (106) extends along a periphery of the hole (109).

3. The assembly (100) as claimed in claim 1, wherein the conduit (106) defines an extension of the hole defined in the head portion (105) and protrudes into the mould (108).

4. The assembly (100) as claimed in claim 2, wherein the hole (109) is defined at a substantially central portion of the head portion (105).

5. The assembly (100) as claimed in claim 1, wherein shape of the cavity (109) defined in the metallic base plate (101) confirms the shape of the conduit (106) of the ceramic plate (104).

6. The assembly (100) as claimed in claim 1, wherein shape of the cavity (103) defined in the metallic base plate (101) and the shape of the conduit (106) of the ceramic plate (104), is at least one of cylindrical, rectangular and circular.

7. The assembly (100) as claimed in claim 1, wherein the ceramic plate (104) comprises a holding portion (107), to position the ceramic plate (104).

8. The assembly (100) as claimed in claim 1, wherein the metallic base plate (101) is made of steel.

9. The assembly (100) as claimed in claim 1, wherein the metallic base plate (101) provides structural stability to the mould (108) of the slab caster.

10. The assembly (100) as claimed in claim 1, wherein the ceramic plate (104) eliminates hanger formation during casting process.
, Description:TECHNICAL FIELD
The present disclosure generally relates to a field of metallurgy. Particularly, but not exclusively the disclosure relates to a mould of a slab caster used for a continuous casting process. Further, embodiments of the disclosure disclose a top cover assembly for the mould of the slab caster.
BACKGROUND
Continuous casting is a metallurgical process involving continuous casting of a slab by supplying a liquid metal, also referred to as a molten metal, into a mould of a slab caster. The molten metal flowing into the mould may be allowed to be solidified into a semi-finished billet. The continuous casting process is a critical link, especially in steel manufacturing, where a steel slab of desired length comes out as an end result. In the continuous casting process, liquid steel is continuously tapped into a mould, and the mould may be rectangular or cylindrical in shape. The walls of the mould may be cooled by continuous supply of a coolant such as water, and an inner surface of each of the wall may be coated with a lubricating medium. When the liquid steel is tapped into the mould, the liquid steel that comes in contact with the lubricating medium of the mould solidifies to form a solid shell/layer, while rest of the liquid steel may remain in liquid or semi-liquid state, thus forming a steel slab. The steel slab may be continuously extracted from the mould and may be directly subject to one or more secondary metallurgical manufacturing operations.
Generally, the mould of the slab caster includes a plate, which covers a top portion of the mould, to provide structural stability to the mould during the continuous casting process. The plate is defined with a cavity, which may allow flow of molten metal into the mould during continuous casting process. During continuous casting process, i.e. while tapping molten metal into the mould, the molten metal may stick on to the surface of the metal plate, due to which metal spatters accumulate on the surface of metal plate and inner surfaces of the cavity in the plate. This accumulation of the metal spatters may lead to hanger formation and, ultimately lead to hanger breakouts, which affects the end product. Hence, frequent cleaning of the accumulated metal spatters on the surface of the plate is a predominant task, as formation of hangers in the mould may weaken the shell of the casted steel slab or may form an underdeveloped shell. Due to the underdevelopment or weakening of the shell, the casted steel slab may not be able to sustain ferro static pressure, thereby resulting in breakout of liquid steel in the steel slab. Such breakouts may cause extreme loss of time, money and resources during the casting. However, due to harsh and hazardous operating environments during the continuous casting process, the operators may not perform frequent cleaning of the metal spatters accumulated on the surface of the plate. Also, as cleaning of the accumulated metal spatters may consume more time, this leads to increase in the down time of the casting process.
The present disclosure is directed to overcome one or more limitations stated above or any other limitation associated with the conventional arts.
The information disclosed in this background of the disclosure section is only for enhancement of understanding of the general background of the disclosure and should not be taken as an acknowledgement or any form of suggestion that this information forms prior art already known to a person skilled in the art.
SUMMARY
One or more shortcomings of the prior art may be overcome, and additional advantages may be provided through the present disclosure. Additional features and advantages may be realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
In one on-limiting embodiment of the present disclosure, a top cover assembly for a mould of a slab caster is disclosed. The assembly includes a metallic base plate, which is positioned on the mould to cover a top surface of the mould, and the metallic base plate is defined with a cavity to allow flow of molten metal into the mould. Further, the assembly comprises a ceramic plate, which is removably positioned on the metallic base plate covering at least a portion of a top surface of the metallic base plate. The ceramic plate comprises a conduit co-operating with the cavity defined in the metallic base plate. The ceramic plate eliminates sticking of the molten metal to the metallic base plate during casting process.
In an embodiment, the ceramic plate comprises a head portion. The head portion is defined with a hole, and the conduit extends along a periphery of the hole defined in the head portion. The conduit defines an extension of the hole defined in the head portion and protrudes into the mould.
In an embodiment, the hole is at a substantially central portion of the head portion.
In an embodiment, shape of the cavity defined in the metallic base plate confirms with the shape of the conduit of the ceramic base plate. The shape of the cavity defined in the metallic base plate and the shape of the conduit of the ceramic plate, is at least one of cylindrical, rectangular and circular.
In an embodiment, the ceramic plate comprises a holding portion, to position the ceramic plate over the metallic base plate.
In an embodiment, the metallic base plate is made of steel, and provides structural stability to the mould of the slab caster.
In an embodiment, the ceramic plate eliminates hanger formation during casting process.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE ACCOMPANYING DIAGRAMS

The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, serve to explain the disclosed principles. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of the assembly in accordance with embodiments of the present subject matter are now described, by way of example only, and with reference to the accompanying figures, in which:

Figure. 1 illustrates a schematic exploded view of a top cover assembly for a mould of a slab caster, in accordance with some embodiments of the present disclosure.

Figure. 2 illustrates a schematic assembled view of the top cover assembly mounted on the mould of the slab caster, in accordance with some embodiments of the present disclosure.

Figure. 3 illustrates a perspective of a ceramic plate, in accordance with an embodiment of the present disclosure.

Figure. 4 illustrates a sectional view of the top cover assembly mounted on the mould, in accordance with some embodiments of the present disclosure.

It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative assemblies embodying the principles of the present subject matter. Similarly, it will be appreciated that any flow charts, flow diagrams, state transition diagrams, pseudo code, and the like represent various processes which may be substantially represented in computer readable medium and executed by a computer or processor, whether or not such computer or processor is explicitly shown.

DETAILED DESCRIPTION

In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however that it is not intended to limit the disclosure to the forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the scope of the disclosure.
The terms “comprises”, “comprising”, “includes” or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, device or method that includes a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device or method. In other words, one or more elements in an assembly proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the assembly
Embodiments of the present disclosure disclose a top cover assembly for a mould of a slab caster. The top cover assembly is configured to eliminate hanger formation during continuous casting process.

Conventional moulds of the slab caster include a metal plate, which is positioned on the mould to cover a top surface of the mould. The metal plate is defined with a cavity, which is configured to allow flow of molten metal into the mould. During, continuous casting process i.e. while tapping molten metal into the mould, the molten metal may stick or adhere on to the surface of the plate and within the internal surfaces of the cavity, due to metal to metal affinity, and as a result of which, metal spatters accumulates on the top surface and on the inner surfaces of the cavity of the metal plate. Such accumulation of the metal spatters may result in hanger or sticker formation. Hence, frequent cleaning/scrapping of the accumulated metal spatters on the top surface and inner surfaces of the cavity of the metal plate is a predominant task, as formation of hangers in the mould may weaken the shell of the casted steel slab or may form an underdeveloped shell. However, due to harsh operating environments during the continuous casting process, the operators may not be able to perform frequent cleaning of the metal spatters accumulated on the metal plate. Thus, this may lead to hanger formation and, ultimately lead to hanger breakouts, which is an undesired phenomenon in the continuous casting process. Further, casting process should be shut to perform cleaning of the metal spatters, which result in production loss. Accordingly, the present disclosure discloses the top cover assembly for the mould of the slab caster, which may eliminate hanger formation on the metal plate and to reduce down time, in case of hanger formation in the continuous casting process.

The top cover assembly of the present disclosure may include a metallic base plate, which may be positioned on the mould, covering a top surface of the mould. The metallic base plate may be defined with a cavity to allow flow of molten metal into the mould, during continuous casting process. The metallic base plate may provide structural stability to the mould. Further, the top cover assembly may include a ceramic plate, which may be positioned over the metallic base plate on a top surface of the metallic base plate. In an embodiment, the ceramic plate may include a head portion, which may be defined with a hole. Further, the ceramic plate may include a conduit which extends outwardly from the head portion, such that the conduit extends the hole defined in the head portion outwardly to a desired length. Upon positioning of the ceramic plate on the metallic base plate, the head portion of the ceramic plate may reside on the top surface of the metallic base plate, and the conduit may co-operate and protrude through the cavity of the metallic base plate and into the mould. Thus, the ceramic plate may cover the top surface of the metallic base plate and inner surfaces of the cavity defined of the metallic base plate. This may help in mitigating contact of the molten metal with the metallic base plate and, hence prevents sticking or adherence of the molten metal onto the metallic base plate, and thus eliminating hanger formation, during continuous casting process.

In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.

Figures. 1 and 2 illustrates an exploded and a assembled perspective views of a top cover assembly (100) respectively, and the top cover assembly (100) which may be positioned on a mould (108) of a slab caster, to cover a top surface (TS) of the mould (100). The mould (108) may be configured to receive molten metal for casting the into desired shape and configuration. In an embodiment, the mould (108) may be associated with a plurality of cooling systems (not shown in figures), for cooling walls of the mould (108) in order to cool the molten metal flowing through molten metal for solidification, during continuous casting process. In an illustrated embodiment, the mould (108) may be of a rectangular configuration, and the same should not be considered as a limitation as the mould (108) may include any geometrical configuration such as but not limiting to cylindrical, square, octagonal and the like, based on the required of the casted product. As an example, the mould (108) may be made of material having high thermal conductivity, such as but not limiting to copper.

As apparent from Figures. 1 and 2, the mould (108) may include a top cover assembly (100), which may be configured to cover the top surface (TS) of the mould (108). The top cover assembly (100) may include a metallic base plate (101). The metallic base plate (101) may be positioned on the mould (108) and may be configured to cover the top surface (TS) of the mould (108). In an embodiment, the metallic base plate (101) may impart structural stability to the mould (108) during continuous casting process, i.e. the metallic base plate (101) may provide structural stability to the mould (108) by absorbing the thermal stresses and forces generated during the continuous casting process. As seen in Figure. 1, the metallic base plate (101) may be defined with a cavity (109) to allow flow of molten metal from a ladle or tundish [not shown in figures] into the mould (108). In an embodiment, the metallic base plate (101) may be positioned on the mould (108) by at least one of mechanical joining process such as fastening, press fit, and the like or by thermal joining process such as but not limiting to welding, brazing and the like. In an illustrated embodiment, the metallic base plate (101) may be of a square configuration, and the same may not be construed as a limitation, as the metallic base plate (101) may include any geometrical shapes such as circular, rectangular and the like. As an example, the metallic base plate (101) may be made of material such as but not limiting to steel. Further, as apparent from figures. 1 and 2, the top cover assembly (100) may further include a ceramic plate (104). The ceramic plate (104) may be removably positioned on the metallic base plate (101) and may be configured to cover at least a portion of a top surface of the metallic base plate (101).

Turning now to Figure. 3, which illustrates a perspective view of the ceramic plate (104). The ceramic plate (104) may include a head portion (105), which may be defined with a hole (109). In an embodiment, the hole (109) may be defined at a substantially central portion of the head portion (105). Further, the ceramic plate (104) may include a conduit (106), which extends away from the head portion (105) i.e. the conduit (106) may extend outwardly or downwardly from the head portion (105). In an embodiment, the conduit (106) may extend along a periphery of the hole (109) defined in the head portion (105) and may define an extension of the hole (109) of the head portion (105). In other words, the conduit (106) extends from the hole (109) defined in the head portion (105) for a certain length away from the head portion (105). Additionally, the ceramic plate (104) may include one or more holding portions (107) for handling the ceramic plate (104) such as lifting or moving the ceramic plate (104) from the top surface of the metallic base plate (101). As an example, the holding portions may be a metallic rod, rigidly fixed to the ceramic plate (104). In the illustrated embodiment, shape of the ceramic plate (104) and the hole (109) defined in the ceramic plate (104) is defined in a square configuration, and the same should not be considered as a limitation, as the shape of the ceramic plate (104) and the hole (109) defined in the ceramic plate (104) may vary from rectangular, cylindrical, circular and the like.
In an embodiment, the shape of the cavity (103) defined in the metallic base plate (101) and shape of the hole (109) defined in the ceramic plate (104) may confirm to each other. Further, dimension of the cavity (103) of the metallic base plate (101) may be larger than the dimension of the hole (109) and the conduit (106) of the ceramic plate (104), such that the cavity (103) provides sufficient clearance for the conduit (106) to protrude through the cavity (103), during placing of the ceramic plate (104) on the metallic base plate (101).
Turning back to Figure. 2 and referring to Figure. 4, upon positioning the ceramic plate (104) on the top surface of the metallic base plate (101), the head portion (105) of the ceramic plate (104) may reside on the top surface of the metallic base plate (101), thus covering the top surface of the metallic base plate (101). Further, the conduit (106) extending from the head portion (105) may co-operate with the cavity (103) of the metallic base plate (101) and protrudes into the mould (108) via the cavity (103) of the metallic base plate (101). This may facilitate in aligning the hole (109) of the ceramic plate (104) and the cavity (103) of the metallic base plate (101), to facilitate flow of molten metal into the mould (108). In an embodiment, the conduit (106) protruding into the mould (108) via the cavity (103) of the metallic base plate (101), may cover inner surfaces of the cavity (109) of the metallic base plate (101). Thus, the ceramic plate (104) may facilitate in covering the top surface and inner surfaces of the cavity (103) of the metallic base plate (101).
In an embodiment, the ceramic plate (104) covering the metallic base plate (101) of the mould (108), may help in mitigating accumulation of the metal spatters on the top surface of the metallic base plate (101). Further, the ceramic plate (104) may help in mitigating accumulation of the metal spatters in vicinity and on the surfaces of the cavity (109) defined in the metallic base plate (101), as the ceramic plate (104) prevents metal to metal contact [i.e. contact of the molten metal with the metallic base plate (101)] and, thus eliminates hanger formation, during continuous casting process.
In an embodiment, the ceramic plate (104) may possess high thermal resistivity and may not be adhesive to the molten metal tapped into the mould (108). Thus, less or no metal spatters accumulate on the surface of the ceramic plate (104), which facilitates in eliminating hanger formation during continuous casting process.
In an embodiment, upon accumulation of the metal spatters on the surface and within the conduit (106) of the ceramic plate (104), the ceramic plate (104) may be replaced with a new ceramic plate (104), instantaneously, which may reduce the downtime of the casting process.
In an embodiment, the ceramic plate (104) may eliminate the operators from working in vicinity of the liquid steel for longer periods, frequent cleaning of the metallic base plate (101) to remove the accumulated metal spatters.
EQUIVALENTS

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."

While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
Referral numerals

Reference Number Description
100 Top cover assembly
101 Metallic base plate
103 Cavity defined in the metallic base plate
104 Ceramic plate
105 Head portion of the ceramic plate
106 Conduit
107 Holding portion
108 Mould
109 Hole defined in the ceramic plate
TS Top surface