Abstract: A process and apparatus are disclosed for removing inclusions and inclusion clusters from a molten metal or alloy stream prior to casting. In the process, the molten metal is passed through a flotation box having a primary chamber and a secondary chamber located within the primary chamber. The primary chamber is provided with entry and exit portions, one on each side of the secondary chamber so that the stream of molten metal or alloy is directed to flow into the primary chamber, flowing beneath the secondary chamber and out the exit portion. Inclusions and inclusion clusters float to the surface of the molten metal or alloy in the secondary chamber prior to the exiting of the molten metal or alloy stream from the primary chamber through the exit portion for supply to a casting station.

Abstract: A tool for forming electrical interconnections between the terminal ends of storage cell plate lugs. This tool is particularly suited to forming such welds between the terminal ends of plate lugs which project through a cell case wall.

Abstract: Amorphous metal tapes are produced by expressing a metallic melt in a supply container through at least one nozzle opening onto a moving surface of a cooling body positioned in relatively close proximity to the nozzle opening. The nozzle opening is 1.5 through 6 mm wide, as measured in the direction of motion of the cooling body surface, which is positioned at a distance of about 0.005 through 0.6 times the width of the nozzle opening from such opening and is moved at a velocity of at least 5 meters per second past such nozzle opening.

Abstract: An apparatus and method for producing ingot mold caps is provided in which a shaped opening in a chill element is lined with a pre-formed refractory/ceramic fiber pad and metal is cast in the lined opening around a cored lift engaging means.

Abstract: A method of pouring molten steel into a container having a bottom made of material subject to damage by the falling stream includes providing a light weight tin free steel mat made from a plurality of thin sheets each having closely spaced holes therein over most of its area and the sheets being arranged in a plurality of layers arranged to define a honeycombed spongelike structure of considerable thickness having a plurality of discontinuous voids. Substantially flat individual thin sheets are arranged on the top and bottom of the spongelike structure to form an assembly with the top and bottom sheets being made from tin free steel. None of the discontinuous voids extend from the top sheet to the bottom sheet. The mat is lowered into the container and positioned on the bottom after which the molten steel is poured onto the mat which protects the bottom while it melts and is absorbed into the molten steel.

Abstract: An elongated dummy bar has one end secured to a closure plug arranged within an open ended, continuous casting mold for supporting the plug within the mold and for endwise movement for removing the plug from the mold and guiding it along a curved path away from the mold. Molten metal cast in the mold forms a continuous cast strand whose lead end joins to the closure plug so that endwise movement of the bar and plug guides the cast strand along the curved path. The bar is formed of parallel rows, of rigid links which are arranged end to end. Pivot pins transversely extend across all the rows between the adjacent ends of the links. The pins are pivotally journalled within opposing sockets formed in the facing ends of adjacent links in each row. Flexible cables are arranged between and parallel to the rows of links and pass through openings extending diametrically through the pins.

Abstract: The invention is an apparatus for removing a dummy bar from a casting line and reintroducing the dummy bar into the mold. The apparatus comprises a handling system for moving a basket from an end station where the dummy bar is separated from a continuous casting to a position above the mold of the casting installation. The system includes a lifting frame capable of holding the basket, a raising device having one end attached to the lifting frame for vertically raising the lifting frame, a travel frame supporting and end of a raising device opposite to the one end, the travel frame having vertical runways capable of receiving and guiding the raised lifting frame, and a horizontal pathway supporting the travel frame for movement to and from the position above the mold.

Abstract: This invention relates to an improved ingot mold. The only alteration in design involves the outside surface of the ingot mold. The invention involves recesses cast or cut into the outside surface of ingot molds for the specific purpose of accommodating steel reinforcement bands. These recesses allow air spaces to exist between the mold surface and the steel reinforcement bands for the purpose of reducing thermal conduction and to bridge any irregularities in the iron mold surface. They can further allow the band to be applied in such a way that the band does not extend beyond the furthest outside surface of the ingot mold exterior wall. The benefit of this is that the steel band is protected from any abuse that may occur as a result of handling the mold. The further benefit is achieved of protecting the band from molten steel that may splash from the top of the mold during teeming (pouring) or transportation.

Abstract: A dummy bar head for a continuous casting installation, particularly for casting steel, containing a dovetail-shaped coupling portion which can be decoupled by carrying out a relative movement between the dummy bar head and the cast strand. The relative movement is undertaken in a direction approximately transverse to the strand withdrawal direction. To ensure a disturbance-free starting of the continuous casting operation, with high casting speeds, the dovetail-shaped coupling portion comprises a raised or protruding dovetail-shaped body. The dovetail-shaped body or body member essentially contains a trapezoidal-shaped surface area. A boundary surface of the raised body has aligned therewith a boundary surface of the dummy bar head which is arranged in the strand withdrawal direction and as to the remaining three boundary surfaces at least two oppositely situated ones thereof contain undercut portions.

Abstract: An apparatus useful for the production of wide amorphous or polycrystalline metal foils of substantially uniform thickness by the double roller chill quenching method comprises a fixed roller member and a spring-loaded movable roller member mounted on a set of mounting rails. The movable roller member is maintained at a selectably adjustable minimum spacing from the fixed roller member and is free to move away from this position of minimum spacing to accommodate forces tending to displace the rollers from one another. A spring urges the movable roller toward the fixed roller and provides for selectable adjustment of the restoring force urging the rollers together.

Abstract: Production of boron-containing steel slabs free from surface defects by continuous casting, particularly prevention of the slab surface crackings by cooling the slab with a specific cooling rate through the temperature range from the melting point to 900.degree. C. so as to prevent boron-containing compounds such as BN from precipitating along the austenite grain boundary. Great advantage over the conventional art is that boron-containing molten steels which could not be continuously cast can be successfully continuously cast into slabs free from surface defects.

Abstract: A foundry core or mold machine utilizes a horizontally extending frame pivoted at one end which fixedly supports one box half or cope and movably supports the other box half or drag. A power actuator pivots the frame to clamp the box halves closed against a blow head or gassing head which may be shuttled thereabove. The drag box half is mounted on a cradle on the frame for movement toward and away from the cope or fixed box half and for pivoting movement to bring the box to a core or mold discharge or an inspection or disassembly position when the box halves are not clamped against the blow head or gassing head. Each box half includes a machine actuated stripping mechanism to insure removal of the core or mold both from the cope and drag with the latter then placing the core on a discharge conveyor. The conveyor may be of the flat belt type canted slightly to present a flat surface to receive the core or mold.

Abstract: A mold forming tool for use in the manufacture of casting molds by compression of loose mold forming material by a process in which the final compacting is achieved by pressing, for the casting of cast pieces having undercuts, the tool having an elastically deformable portion in the region of the undercuts, and the elastically deformable portion being made of a material which is deformable, thus creating the undercut pattern, solely under the influence of the pressure exerted on the mold forming material during the final compacting.

Abstract: Apparatus and method for injecting molten lead from a reservoir into a die mold cavity formed about an aperture in the wall of a plastic battery for casting lead-alloy battery terminal connectors. Batteries are positioned adjacent the molten lead reservoir of the apparatus and mold portions move together to hold the battery containers in a clamp-like action. Molten lead is die cast under pressure into the mold cavity in which a stainless steel threaded nut is positioned. The lead is forced through a heated chamber into a portion of the mold which may be water cooled. The mold is designed to allow venting of gases, thereby eliminating porosity; and the apparatus is designed to provide casting which is free of jagged projections in the sprue hole.

Abstract: A centrifugal casting high in an easily oxidized element achieved by casting a high melting point metal on to an easily oxidized metal of lower melting point. The desirable distribution of the oxidizable element through the cross section of a casting is achieved relying on the basic effect of centrifugal separation.

Abstract: In order to support a steel strand fabricated during a continuous strand casting method, and whose liquid core is agitated or stirred with the aid of an electromagnetic stirrer installed near the strand surface, the stirrer together with guide rolls is oscillatingly moved during the casting operation in the lengthwise direction of the cast strand.

Abstract: Disclosed is a core for producing halves of cambered hollow articles, such as bonded turbine blades. The core has opposing flanges which differ in thickness, since the opposing contour surfaces are rotated relative to one another, compared to the relationship of the contour surfaces in the interior of the hollow article being produced. Thus, the core is made thicker and more sound in the area of high camber where it is otherwise prone to be thin.

Abstract: An apparatus is set forth for the continuous production of highly cooled metal splats. Melted metal is poured onto a spinning atomization disc means whereby liquid metal droplets leave the disc means in a horizontal plane. An annular cooling gas jet flowing normal to the particle plane around the disc deflects the heavier liquid droplets to a conical splat plate which is fixed to rotate with said disc, where the droplets splat and cool, and are ejected by centrifugal force. An annular space is located between said conical splat plate and said rotary atomization means for permitting the gas and other solidified particles to pass downwardly to a shield which directs the particles to a collection area.

Abstract: A process and apparatus for casting a material into a desired thin strip shape. Molten material is formed into the thin strip shape by an electromagnetic containing and forming process. In a first portion the molten material is shaped into the desired thin strip shape and in a second portion upstream of and communicating with the first portion the molten material is electromagnetically contained in a sump. The sump at a top surface thereof has a substantially larger cross-sectional area as compared to a cross-sectional area of the thin strip shape.

Abstract: A finished ceramic airfoil is provided having within it a lining of thermal insulation and a fusible core having the desired contour of the metal core of the turbine blade. A casting mold is provided around the airfoil. The fusible core is melted and removed, leaving a cavity in the airfoil surrounded by the insulation lining. The cavity is filled with molten metal which is allowed to solidify to form the metal core of the turbine blade.