Abstract: This invention discloses a metal product that is suitable for a forming process. By anodizing an oxide layer onto at least one surface of the metal product, the total amount of lubricant that is applied onto the metal product prior to being formed is reduced or eliminated. This invention also discloses a method of generating such an oxide layer onto the metal product.

Abstract: A method for producing an aluminum foam product wherein reactive gas producing particles are introduced into an aluminum alloy melt under controlled conditions and subjected to agitation to induce the production of foam-stabilizing by-products, and, under certain conditions, the production of gases used to produce the molten metal foam itself. Foam products produced through this method have intrinsically formed metal oxides and other solid particles dispersed therein and are devoid of the large extrinsically added stabilizing ceramic additions traditionally used in the production of aluminum foams. The invention claims a rapid, single step method for producing an inoculated, foamable melt using low cost precursor materials.

Abstract: A spacer member in a furnace including an aluminum tube containing a ceramic material. The ceramic material provides high compressive strength and the composite product resists high temperature creep.

Abstract: In a lubricant composition suitable for use in the manufacture of aluminum alloys comprising lubricant base selected from the group consisting of solid lubricants, liquid lubricants, grease lubricants, emulsion lubricants, and dispersion lubricants, the improvement wherein the lubricant composition further comprises: an effective amount of water and surfactant or water and a compound comprising phosphates, borates, fluorides, and silicates. It is believed that mixing oil with water and surfactant or one of these compounds provides a method for uniformly distributing the surface oxide at the meniscus for casting applications, thereby reducing vertical fold formation that lead to cracks in aluminum ingots. In addition, the mixture promotes uniform heat transfer around the mold allowing the solidifying aluminum alloy to stay in contact with the mold longer and form stronger ingot shells.

Abstract: A spacer member for supporting a metallic alloy product during heat treatment comprising a ceramic core and a tubular housing is disclosed. The tubular housing, which encloses the ceramic core, comprises a bore, a wall portion, and two end portions. In order to resist deformation during usage, the tubular housing is made from high temperature steel, a high temperature steel alloy, or cold rolled steel. The wall portion has at least two substantially flat surfaces having corner edges that have a radius of at least ? inch and ends that are tapered at least ¼ inch. In addition, the flat surfaces also have a coating that reduces the sticking of a metallic alloy product. The end portions each have at least one aperture to allow the inside to adjust itself to ambient atmospheric pressure. A method of making a spacer member is also disclosed.

Abstract: Method of producing sintered nickel ferrite powder having steps of mixing the particles of iron oxide and nickel oxide with an alkali metal borate mineralizer, compacting the mixture to produce green compact and heating the compact at temperatures less than about 1400° C. Resulting product which may be in the form of a non-consumable electrode for electrolysis of alumina, exhibits satisfactory mechanical properties and electrical properties with enhanced chemical stability while being produced at significantly lower sintering temperatures than previously employed.

Abstract: In an oxidation inhibiting lubricant composition suitable for use in the manufacture of aluminum alloys comprising lubricant base selected from the group consisting of solid lubricants, liquid lubricants, grease lubricants, emulsion lubricants, and dispersion lubricants, the improvement wherein the lubricant composition further comprises: an effective amount of a fluorine-containing passivating compound.

Abstract: A method of producing aluminum castings which includes the steps of casting a molten alloy, contacting the surface of the molten alloy with a humidified atmosphere and solidifying the alloy. The method is particularly suited for aluminum-magnesium alloys such as AA 5XXX and 7XXX series alloys. In addition to reducing the thickness of the surface oxide layer formed during casting, the method also provides improved surface quality of cast products and reduces subsequent remedial re-work or scalping. An improved aluminum-magnesium cast alloy product is also disclosed.