Abstract: A casting apparatus (10) for direct chill casting metal includes a tundish (12) containing a supply of molten metal, a casting mold (14), and a starter block (44) associated with the casting mold (14). The casting mold (14) is in fluid communication with the tundish (12) through a passage (22) defined in the tundish wall. The casting mold (14) includes a header plate (24), a casting ring (26), and a feed ring (28). The header plate (24) defines an arcuate shaped opening (36) connected to the passage (22). The header plate (24) has an upstream side (38) and a downstream side (40). The casting ring (26) is connected to the downstream side (40) of the header plate (24) and defines a groove (52) proximate to the sidewall (48) of the header plate (24). The feed ring (28) is disposed in the groove.

Abstract: A method of gas fluxing molten aluminum with at least two, relatively small diameter upper and lower rotatable dispersers located in the molten aluminum and mounted on a shaft. Fluxing gas is added to the molten aluminum beneath each of the rotatable dispersers at a substantial rate of gas flow while rotating the dispersers at a substantial rpm in the molten aluminum. The dispersers directly shear gas bubbles that form in the molten aluminum as the fluxing gas is directed into the molten aluminum beneath each of the dispersers. The direct shearing of the gas bubbles maintains a high surface area between the bubbles and molten aluminum to effect efficient removal of impurities in the molten aluminum.

Abstract: A method for adding alloying material to a molten metal media, such as molten aluminum, is disclosed. The method includes converting the alloying material into a spray of superheated alloy material and directing the spray into the molten metal media at a depth below the media's surface to enhance dissolution and dispersion of the alloying material in the molten media.