Abstract: The products of this invention are produced in an elongated casting vessel disposed in upright position to receive liquid metal for solidification within an electromagnetic field generating means disposed around the vessel along a portion of its length. The electromagnetic field generating means produces an upward lifting effect on liquid metal in the vessel together with a containment effect wherein the liquid metal is continuously urged upwardly into contact with the lower end of the solidifying product and maintained in a pressureless contact condition with respect to the walls of the casting vessel. In this way, voids and flaws are avoided and fully dense homogeneous products of uniform, small grain cross section result without wear on the casting vessel. The novel products of the invention are long metal bodies which are fully dense and of substantially uniform, fine grain cross section and constant composition throughout in each instance.

Abstract: The method of this invention is practiced within an elongated casting vessel disposed in upright position to receive liquid metal for solidification together with means for delivering liquid metal into the lower portion of the vessel. Heat exchange means are associated with the vessel for cooling and solidifying the liquid metal therein and means are provided for removing solidified metal from the upper portion of the vessel. Electromagnetic field generating means are disposed around the vessel along a portion of its length which includes a plurality of electromagnetic coils for connection to successive phases of a polyphase electric current source to produce both an upward lifting effect on liquid metal in the vessel and a containment field effect. By "lifting effect" is meant that liquid metal is continuously urged upwardly into contact with the lower end of the solidifying product. In this way, voids and flaws are avoided and fully dense homogeneous products of uniform, small grain cross section result.

Abstract: The new apparatus of this invention comprises an elongated casting vessel disposed in upright position to receive liquid metal for solidification, means for delivering liquid metal into the lower portion of that vessel, heat exchange means associated with the vessel for cooling and solidifying the liquid metal therein, means for removing solidified metal from the upper portion of the vessel, and electromagnetic field generating means disposed around the vessel along a portion of its length. The field generating means includes a plurality of electromagnetic coils for connection to successive phases of a polyphase electric current source to produce a combined electromagnetic upward levitating field effect and a containment field effect on liquid and metal in the vessel. By "levitating effect" is meant that liquid metal is continuously suspended in space and urged upwardly into contact with the lower end of the solidifying product. In this way, voids and flaws are avoided.

Abstract: Apparatus for producing dense homogeneous metal cast in long lengths by introducing liquid metal into the lower portion of a casting vessel in the presence of an elongated upwardly-traveling alternating electromagnetic levitation field that provides a levitation ratio of from 75% to 200% of the weight per unit length of the liquid metal. The apparatus provides cooling for solidifying the metal while moving upwardly through the field, and a withdrawal mechanism for removing solidified metal product from the upper portion of the field. The electromagnetic field producing means is designed to establish an alternating electromagnetic field having a frequency at or near a value F=36.rho./D.sup.2 where F is the frequency in kilohertz, .rho. is the resistivity of the liquid metal column in micro-ohm-centimeters and D is the average diameter of the solidified metal rod product in millimeters.

Abstract: Dense homogeneous metal is cast in long lengths by introducing liquid metal into the lower portion of a casting vessel in the presence of an elongated upwardly-traveling alternating electromagnetic levitation field that provides a levitation ratio of from 75% to 200% of the weight per unit length of the liquid metal, solidifying the metal while moving upwardly through the field, and removing solidified metal product from the upper portion of the field. The frequency of the alternating electromagnetic field is established at or near a value F=(36.rho./D.sup.2) where F is the frequency in kilohertz, .rho. is the resistivity of the liquid metal column in micro-ohm-centimeters and D is the diameter of the solidified metal rod product in millimeters.

Abstract: An electromagnetic levitation casting apparatus having an improved levitation coil assembly employing flux concentration devices, is provided. The improved levitation coil assembly comprises a plurality of slotted annular slugs surrounding a tubular casting vessel within which a liquid metal column is to be levitated and solidified by cooling pursuant to the General Electric Levitation Casting (GELEC (.RTM.)) process. Each of the slotted annular slugs is inductively coupled to a respective electromagnetic field producing coil having a large number of turns surrounding the slug. Each slotted annular slug serves to concentrate the magnetic field produced by its associated primary mutli-turn coil to substantially the interior cross sectional area of the tubular casting vessel it surrounds and functions as a current step-up transformer.