Abstract: A method for producing an alloy in atomized form, wherein the alloy includes between about 10% to about 100% of a silicon based alloy, including obtaining a base silicon-iron alloy mixture and an atomization unit having an atomization chamber and a plurality of nozzles, injecting an atomizing fluid into the atomization chamber via the plurality of nozzles, introducing the base silicon-iron alloy mixture into the atomization chamber such that the atomizing fluid impinges on the base silicon-iron alloy mixture to produce the alloy in atomized form, cooling the alloy in atomized form using a pool of water so as to produce a cooled alloy product, retrieving the cooled alloy product and drying the cooled alloy product to produce the alloy in atomized form.

Abstract: Metallurgically treated metal castings are produced using a consumable plug assembly made of a meltable material which is placed in a reaction chamber in an open treating basin and above a passage to a molding cavity. The consumable plug assembly has physical and chemical characteristics which maintain the plugged relationship for a preselected retaining period. All of a treating material is placed on the plug in the reaction chamber prior to metal pouring so as to react directly with the poured metal in a non-dynamic way.

Abstract: A method of desulfurizing iron in an induction furnace is disclosed. High purity magnesium, carried in a lance controlled cartridge, is plunged into the lower zone of a molten metal pool of an induction furnace; the cartridge is held submerged for a period of 30-200 seconds. The molten metal column above the submerged cartridge must be at least 2.5 feet, preferably 6-7 feet. The molten metal temperature at the time of cartridge plunging is limited to 2400.degree. F. or less. Magnesium recovery will be at least 70%, which is better than other prior art methods by a factor of 1.4.

Abstract: A method of desulfurizing iron in an induction furnace is disclosed. High purity magnesium, carried in a lance controlled cartridge, is plunged into the lower zone of a molten metal pool of an induction furnace; the cartridge is held submerged for a period of 30-200 seconds. The molten metal column above the submerged cartridge must be at least 2.5 feet, preferably 6-7 feet. The molten metal temperature at the time of cartridge plunging is limited to 2400.degree. F. or less. Magnesium recovery will be at least 70%, which is better than other prior art methods by a factor of 1.4.

Abstract: An improved catalyst is disclosed for making spheroidal graphite cast iron, the catalyst being in the form of a solid impervious and brittle block but severed from a sheet stock having a predetermined grid pattern of perforations or notches along at least one surface of said sheet stock. The block is substantially devoid of segregation and oxide interiorally thereof; the thickness of said block is increased over that capable of being produced by the prior art in the as-cast condition and yet devoid of segregation. The method of making such block comprises casting the molten catalyst into shallow closed pans, the cover for said pans carrying a pattern of ribs or projections, the cover and pan cooperating to define a selected configuration for an as-cast sheet stock. The resulting cast product can be manually or automatically broken along any desired module, defined by said grid pattern, to suit a variety of in plant casting applications particularly utilizing in-the-mold nodularizing treatment.

Abstract: A method and apparatus is disclosed for conditioning a charge of molten cast iron, which would normally solidify with a flake graphite structure, to produce partial or total spheroidal graphite cast iron. In addition, the method and apparatus can be used to further condition a partially conditioned cast iron to yield a partial or fully spheroidal graphite cast iron. A recess is provided in the metal flow system (within or without the mold system) leading to the casting cavity or cavities. The recess has a shape and cross-section (taken in directions normal to the direction of flow of the molten charge) such that the spheroidizing agent dissolves uniformly when the molten iron flows over it to achieve unprecedented homogeneity. A dense solid unitary block of spheroidizing or nodularizing agent, substantially devoid of MgO interiorly thereof, is typically snugly fitted in said recess and mates with the side walls and bottom of said recess.

Abstract: A method of making a more economical and reliable treating agent for use in late metal treatment when pouring metal castings. The treating agent is defined as an essentially homogeneous solid cast block preferably containing alloying ingredients to nodulize or inoculant ferrous metal. Each block is designed to present a generally uniform reaction surface to molten metal to be treated. This is obtained by casting the block to a shape which snugly fits a prepared basin in the mold gating system over which the molten metal to be treated must flow, or to cast the block in an annular configuration through which the molten metal must flow. The latter block has contoured inner surfaces which maintain a generally constant reactive surface as the block is consumed. These blocks are preferably prepared by simultaneously casting a large number in closely nested relation.