Abstract: A preform useful in forming fiber reinforced cementitious composites is disclosed. The preform consists of a free-standing network of metal fibers. In one embodiment, the preform has a shape which bounds a substantial non-interstitial volume devoid of fibers such as a ladle lip ring or an I-beam. The amount of fibers in the preform ranges from about 1 to 10 percent by volume.

Abstract: Described herein is a method for reinforcing a cement block structure having a plurality of vertical cavities therein comprising:providing an access to at least one vertical cavity in the cement block structure large enough to insert a fiber reinforcing element;inserting a fiber reinforcing element through the access such that the element fills the cavity;introducing a slurry of cementitious material into the cavity through the access so that the slurry of cementitious material fills the cavity and infiltrates and encapsulates the fiber reinforcing element; andcuring the cementitious material.

Abstract: Molten metal dispensed upon the surface of an adjacent rotating drum produces a ribbon of solidified metal which separates from the drum while the drum is rotating. To prevent ripples from forming in the surface of the ribbon, a casting surface on the periphery of the rotating drum includes structure to minimize the ratio of transverse heat flow rate from the casting surface to radial heat flow rate.

Abstract: A method for manufacturing a reinforced cementitious structural member having a predetermined shape and size includes providing a mold having a cavity which corresponds to the shape and size of the member, placing at last one permeable fibrous mat into the cavity, introducing a slurry of cementitious material into the cavity so that the slurry of cementitious material fills the cavity and infiltrates and encapsulates the fibrous mat, curing the reinforced cementitious material, and separating the cured reinforced cementitious structural member from the mold.

Abstract: An apparatus and method for forming round wire from non-round wire has: a heat extracting drum having a semi-circular channel formed in and entirely around its outer circumferential surface; a feed device for directing a precursor wire into the channel; and a heater for melting the precursor wire in the channel. The wire is typically flat and is stood up on edge, perpendicular to the surface of the drum, melted with the heater, solidified and removed. The surface tension and wetting characteristics of the liquid metal cause it to "bead up", forming a near round wire when solidified.

Abstract: A melt overflow apparatus for controlling various elements in response to incremental changes in parameters which affect the linear density of a continuous metal fiber mat or metal strip being produced is described. The net width of fibers being cast against a rotating, cylindrical casting wheel is measured by an infrared detector. A similar infrared detector is used to measure the net width of a metal strip being formed against a casting wheel. The weight of a portion of the strip or fiber mat is also measured. The weight and net width values are relayed to a control system which then controls various elements used in producing the metal product. These devices include electric motors driving both the casting wheel and a conveyer means for transporting the fiber mat or strip. A ceramic plunging body driven into a pool of molten metal to overflow onto the casting wheel can also be controlled.

Abstract: A two part, integrated melt overflow pouring apparatus including a hearth which contains molten material, and a spout which is stationary with respect to, and transfers the liquid to, a rotating, heat extracting substrate such as a drum. A hinging body such as a cylinder connects the hearth and the spout and allows the hearth to rotate with respect to the spout. A channel is formed in the cylinder and an equal width channel is formed in the spout. The floor of the channel in the hinging body is at a 45.degree. angle with horizontal initially and rotates when the hinging body rotates. The hearth is rotated about the axis of the hinging body, the molten material flows out of the hearth through the channel in the hinging body, through the channel in the spout and solidifies against the drum.

Abstract: The invention relates to a method and apparatus for controlling the temperatures of a plurality of zones of a casting hearth or vessel. The invention also relates to a method for controlling the thickness of the solidified skull of castable material in the casting hearth or vessel. By the present invention, the efficiency of the skull casting process can be significantly improved by reducing the thickness of the skull and thereby increasing the amount of castable material which can remain molten and pourable.

Abstract: The flow control of molten material in a tundish is improved by the design of a perpendicular turn in the path of flow of the molten material as the flow leaves an intermediate section of the tundish or casting receptacle and overflows transversely an exit lip to thereby contact a heat-extracting substrate. The perpendicular turn in the flow achieves improved control of the molten material's velocity profile, cooling rate, and depth and flow uniformity of the molten material in the casting receptacle. The essentially perpendicular turn in the path of the molten material from the intermediate section causes the molten material to approach the exit lip in a transverse direction unlike conventional laminar or direct delivery molten flow. The transverse flow relative to the direction of the exit overflow toward the casting or cooling surface facilitates improved mixing of the molten material, improved control of the depth gradient, and improved control of the velocity into the exit lip.

Abstract: The flow control of molten alloy material in a tundish is improved by the design of a perpendicular turn in the path of flow of the molten alloy material as the flow leaves an intermediate section of the tundish or casting receptacle and overflows transversely an exit lip to thereby contact a heat-extracting substrate. The perpendicular turn in the flow achieves improved control of the molten alloy material's velocity profile, cooling rate, and depth and flow uniformity of the molten alloy material in the casting receptacle. The essentially perpendicular turn in the path of the molten alloy material from the intermediate section causes the molten alloy material to approach the exit lip in a transverse direction unlike conventional laminar or direct delivery molten flow.

Abstract: The invention is directed to an apparatus and method for controlling the overflow of molten material from a receptacle for the purpose of achieving more uniform casting of the molten material. The apparatus and method utilize a force detector able to detect the change in the buoyant force exerted on a submersible body lowered into a molten material. A differentiating means, a control means, and a drive means are responsive to the force detector, whereby a constant rate of change of buoyant force is translated into a uniform rate of overflow of molten material delivered to a heat extracting substrate for solidification.

Abstract: A heat extracting substrate is moved along a melt front formed at the edge of the surface of a molten material so that a layer of molten material is deposited on the substrate, cooled and removed from the substrate to form ribbon, filaments, fiber or film directly from the molten material. The edge may be formed by providing an upper edge upon a portion of the wall of a receptacle lower than the top of the receptacle. The molten material may be overflowed over this relatively horizontal edge and against the moving substrate surface.

Abstract: This invention relates to an apparatus for producing filament, fiber, ribbon or film from a molten material, comprising a preferably heat extracting crucible which contains a pool of molten material at a selected horizontal level in the pool. The crucible has an opening extending from above the free surface level to a bottom edge of the opening, the bottom edge being sufficiently below the free surface level so that the molten material cannot form and hold a meniscus by surface tension between the edge and the level of the free surface and further comprises a heat extracting substrate laterally disposed with respect to the crucible and which rotates about an axis of rotation. The substrate is positioned adjacent the edge of the opening which confines the molten material and prevents it from overflowing downwardly out of the crucible.

Abstract: A method for the production of a unitary or laminated film or sheet of finely controlled thickness from a molten material utilizes spaced, first and second parallel rolls rotating in opposite directions to form a kissing zone between the rolls. The method moves the surface of a cooling rotating roll past a region of contact with a molten material to form a rapidly solidifying layer of material thereon, which then is passed into the kissing zone, wherein the solidified layer is either pressed to form a unitary film or is fused by contacting another solidified layer.

Abstract: A heat extracting substrate is moved along a melt front formed at the edge of the surface of a molten material so that a layer of molten material is deposited on the substrate, cooled and removed from the substrate to form ribbon, filaments, fiber of film directly from the molten material. The edge may be formed by providing an upper edge upon a portion of the wall of a receptacle lower than the top of the receptacle. The molten material may be overflowed over this relatively horizontal edge and against the moving substrate surface.

Abstract: An improved heat extracting chill block roll and method for use in the continuous casting of ribbon-like metal sheet directly from the melt by means of rapid solidification techniques. The resulting product is considerably thicker and more uniform than previously possible by such techniques. A textured chill surface is formed on the roll by multi-sided protrusions having intermediate valleys between the protrusions. This provides a plurality of discontinuous surfaces on the sides of the protrusions. The preferred surface texture is that formed by a conventional knurling tool.

Abstract: An improved method for forming steel fibers from a process of the type in which the fiber is drawn directly from a pool of molten metals. The improvement revolves around the discovery of an alloy starting material which substantially reduces processing steps and equipment and produces a fiber with improved ductility and strength characteristics. The addition of controlled amounts of copper to a typical low carbon steel alloy provides a wider latitude in the necessary cooling steps to greatly facilitate the control of the ductility and strength of the final product through the use of low cost processing techniques.

Abstract: A heat extracting substrate is moved along a melt front formed at the edge of the surface of a molten material so that a layer of molten material is deposited on the substrate, cooled and removed from the substrate to form ribbon, filaments, fiber of film directly from the molten material. The edge may be formed by providing an upper edge upon a portion of the wall of a receptacle lower than the top of the receptacle. The molten material may be overflowed over this relatively horizontal edge and against the moving substrate surface.