Abstract: A laminate sandwich structure useful for, inter alia, decking for naval vessels, which includes a core formed of carbon foam having a ratio of compressive strength to density of at least about 7000 psi/g/cc.

Abstract: A sealant useful for sealing the surfaces of carbon foams to provide a surface useful for, inter alia, composite tooling or other high temperature applications or for bonding of carbon foams together to form larger blocks.

Abstract: An electrode joint having first and second complementary elements capable of being joined together to form the joint, wherein one of the threaded elements has at least one slot at least partially along its length; and wherein one of the threaded elements includes a source of a flowable adhesive in fluid communication with the slot.

Abstract: A mixture of carbon-containing fibers, such as mesophase or isotropic pitch fibers, a suitable matrix material, such as a milled pitch is compressed while resistively heating the mixture to form a carbonized composite material. Preferably, the carbonized material has a density of at least about 1.30 g/cm3. Preferably, the composite material is formed in less than ten minutes. This is a significantly shorter time than for conventional processes, which typically take several days and achieve a lower density material. A treating component may be impregnated into the composite. Consequently, carbon/carbon composite materials having final densities of about 1.6–1.8 g/cm3 or higher are readily achieved with one or two infiltration cycles using a pitch or other carbonaceous material to fill voids in the composite and rebaking.

Abstract: An end-face seal for graphite electrode joints, including a seal formed of a plurality of individual elements interlocked to form a unitary whole, and formed of a material having an oxidation rate equal to or less than that of the electrodes.

Abstract: Insulation materials suited to high temperature applications, such as the insulation of furnaces, are formed from a mixture of pitch carbon fibers, such as isotropic pitch carbon fibers, and a binder comprising a solution of sugar in water. The sugar solution is preferably at a concentration of from 20–60% sucrose to yield a low density material having high flexural strength and low thermal conductivity when carbonized to a temperature of about 1800° C.

Abstract: A pin for use in connecting graphite electrodes into a joint, where the pin has at least one male tang having a tang factor, defined as the ratio of male tang length to diameter of the electrode into which hit is to be threaded, of at least about 0.60.

Abstract: A graphite electrode joint, where the male tang has a tang factor, defined as the ratio of male tang length to electrode diameter, of at least about 0.60.

Abstract: A process for preparing graphite articles is presented. In particular, the process includes employing a particulate fraction comprising at least about 35 weight percent coke, coal or combinations thereof having a diameter such that a major fraction of it passes through a 0.25 mm to 25 mm mesh screen. The particulate fraction is mixed with a liquid or solid pitch binder, to form a stock blend; the stock blend is extruded to form a green stock; the green stock is baked to form a carbonized stock; and the carbonized stock is graphitized. The stock blend further comprises one or both of carbon fibers (advantageously added after mixing of the particulate fraction and pitch has begun) and small particle size filler (advantageously added as part of the particulate fraction).

Abstract: An induction furnace capable of operation at temperatures of over 3100° C. has a cooling assembly (60), which is selectively mounted to an upper end of the furnace wall (76). The cooling assembly includes a dome (62), which is actively cooled by cooling water coils (68). During the cool-down portion of a furnace run, cooling initially proceeds naturally, by conduction of heat away from the hot zone through a furnace insulation layer (58). Once the temperature within the furnace hot zone (20) reaches about 1500° C., a lifting mechanism (80), mounted to the dome, raises a cap (16) of the furnace slightly, allowing hot gases from the hot zone to mix with cooler gas in the dome. This speeds up cooling of the hot zone, reducing cool-down times significantly, without the need for encumbering the furnace itself with valves or other complex cooling mechanisms which have to be replaced periodically.

Abstract: A mixture of carbon-containing fibers, such as mesophase or isotropic pitch fibers, a suitable matrix material, such as a milled pitch is compressed while resistively heating the mixture to form a carbonized composite material. Preferably, the carbonized material has a density of at least about 1.30 g/cm3. Preferably, the composite material is formed in less than ten minutes. This is a significantly shorter time than for conventional processes, which typically take several days and achieve a lower density material. A treating component may be impregnated into the composite. Consequently, carbon composite materials having final densities of about 1.6-1.8 g/cm3 or higher are readily achieved with one or two infiltration cycles using a pitch or other carbonaceous material to fill voids in the composite and rebaking.

Abstract: A system is provided for ultrasonic inspection of cylindrical carbon articles, such as electrodes of the type utilized in electric arc steel making furnaces. An inspection station is provided for receiving the electrode in a fixed longitudinal location and for rotating the electrode about the longitudinal axis of the electrode. Master and slave robots are provided, and each carries a pair of transducers arranged to engage the electrode at circumferentially spaced positions about the electrode. Each pair of transducers is carried on a yoke. The inspection station rotates the electrode while the master and slave robots o each carry their associated pair of transducers along approximately one half the length of the electrode.

Abstract: Lay-up mold comprising a contoured metal frame having an overlying conformal coating of polyurethane.

Abstract: A system is provided for recording information relating to the condition of electrodes in an electric arc furnace. An imaging apparatus is provided in a consistent position relative to an imaging station. Periodically, the electrode columns are removed from the furnace and moved to a position such that the electrode column is placed at the imaging station. Then an image of the electrode column is created with the imaging apparatus, and the images are stored in a memory of a computer for subsequent analysis.

Abstract: Carbon fiber bundles may be dispersed into substantially single mono-filaments in pitch by stirring a mixture of fibers and pitch at a temperature at which the pitch has a viscosity of about 0.1 to about 5 poise. The resulting fiber pitch binder contains about 0.5 to about 10.0 wt. % carbon fibers substantially dispersed as substantially single mono-filaments which are randomly oriented which may then be used directly as a binder for producing carbon bodies, for example, graphite electrodes, pinstock or specialty graphite articles. This unique binder using an economical amount of carbon fibers has the capacity to increase the strength and reduce the coefficients of thermal expansion of the resulting carbon products in more than one direction due to the random orientation of the carbon fibers.

Abstract: Insulation materials suited to high temperature applications, such as the insulation of furnaces, are formed from a mixture of pitch carbon fibers, such as isotropic pitch carbon fibers, and a binder comprising a solution of sugar in water. The sugar solution is preferably at a concentration of from 20-60% sucrose to yield a low density material having high flexural strength and low thermal conductivity when carbonized to a temperature of about 1800° C.

Abstract: A composite high temperature insulator (A) includes a planar layer (10) having anisotropic thermal conductivity properties. A second planar layer (12) is formed from a rigid insulation material, such as a carbonized mixture of carbon fibers and a binder. The second layer is coextensive with the first layer and is preferably bonded thereto by a carbonaceous cement (44). When used to insulate a heat source, such as a furnace (50), convective heat is directed back to the source by the reflective surface (16) of the inner, anisotropic layer (10). Heat which enters the anisotropic layer is dissipated evenly through the plane of the layer along a plurality of heat paths defined by a plurality of layers (14) of flexible graphite. Accordingly, heat which reaches the outer, second layer (12) results in fewer hot spots than occur with a conventional rigid insulation material, thereby reducing the total amount of insulation material required to achieve a desired level of thermal insulation.

Abstract: An induction furnace capable of operation at temperatures of over 3100° C. has a cooling assembly (60), which is selectively mounted to an upper end of the furnace wall (76). The cooling assembly includes a dome and a lifting mechanism (80), mounted to the dome, which raises a cap (16) of the furnace slightly, allowing hot gases from the hot zone to mix with cooler gas in the dome.

Abstract: A process for preparing carbon electrodes is presented. In particular, a process for preparing carbon electrodes including the steps of combining calcined coke, a liquid pitch binder and carbon fibers derived from mesophase pitch to form an electrodestock blend; extruding the electrodestock blend to form a green electrodestock; baking the green stock to form a carbonized electrodestock; and graphitizing the carbonized stock by maintaining the carbonized tock at a temperature of at least about 2500.degree. C. for no more than about 18 hours is presented. The electrodes prepared by the inventive process are also presented.

Abstract: A mixture of carbon-containing fibers, such as mesophase or isotropic pitch fibers, and a suitable matrix material, such as a milled pitch, is compressed while resistively heating the mixture to form a carbonized composite material having a density of about 1.5 g/cm3, or higher. The composite material is formed in under ten minutes. This is a significantly shorter time than for conventional processes, which typically take several days and achieve a lower density material. Consequently, carbon/carbon composite materials having final densities of about 1.6-1.8 g/cm3, or higher are readily achieved with one or two infiltration cycles using a pitch or other carbonaceous material to fill voids in the composite and rebaking.