Abstract: A vessel used for containing molten metal, e.g. a trough section for conveying molten metal from one location to another. In some embodiments, the vessel employs refractory liner units of different thermal conductivity to maximize heat penetration into the molten metal from heaters in the gap, but to minimize heat loss at the inlet and outlet of the vessel where the end units contact the housing.

Abstract: A curvilinear metal transfer device with support and compression assemblies that help maintain a constant force on the transfer device's metal outer casing and refractory as the outer casing and refractory expand and contract due to temperature fluctuations. In one embodiment, the support assemblies are configured to apply force to the refractory to keep the refractory in tension with the outer casing to suspend the refractory relative the outer casing. Also disclosed are clamp plates that help hold the refractory in place, and nested lids that cover the curvilinear metal transfer device.

Abstract: A method of casting a metal ingot with a microstructure that facilitates further working, such as hot and cold rolling. The metal is cast in a direct chill casting mold, or the equivalent, that directs a spray of coolant liquid onto the outer surface of the ingot to achieve rapid cooling. The coolant is removed from the surface at a location where the emerging embryonic ingot is still not completely solid, such that the latent heat of solidification and the sensible heat of the molten core raises the temperature of the adjacent solid shell to a convergence temperature that is above a transition temperature for in-situ homogenization of the metal. A further conventional homogenization step is then not required. The invention also relates to the heat-treatment of such ingots prior to hot working.

Abstract: Automated processes that dynamically control rate of delivery of molten metal to a mold during a casting process. Such automated processes can use dynamic metal level variation, control pin pulses and/or oscillation during the mold fill and transient portion of the cast. It has been found that such pulses keep metal flowing in a manner that addresses problems, particularly at the beginning of an ingot cast, associated with metal meniscus contracting and pulling away from the mold on the short faces and corners.

Abstract: Automated processes that dynamically control rate of delivery of molten metal to a mold during a casting process. Such automated processes can use dynamic metal level variation, control pin pulses and/or oscillation during the mold fill and transient portion of the cast. It has been found that such pulses keep metal flowing in a manner that addresses problems, particularly at the beginning of an ingot cast, associated with metal meniscus contracting and pulling away from the mold on the short faces and corners.

Abstract: A method of casting a metal ingot with a microstructure that facilitates further working, such as hot and cold rolling. The metal is cast in a direct chill casting mold, or the equivalent, that directs a spray of coolant liquid onto the outer surface of the ingot to achieve rapid cooling. The coolant is removed from the surface at a location where the emerging embryonic ingot is still not completely solid, such that the latent heat of solidification and the sensible heat of the molten core raises the temperature of the adjacent solid shell to a convergence temperature that is above a transition temperature for in-situ homogenization of the metal. A further conventional homogenization step is then not required. The invention also relates to the heat-treatment of such ingots prior to hot working.

Abstract: Exemplary embodiments of the invention relate to a compressive rod assembly for applying force to a refractory vessel positioned within an outer metal casing. The assembly includes a rigid elongated rod having first and second opposed ends, a threaded bolt adjacent to the first opposed end of the elongated rod, and a compressive structure positioned operationally between the elongated rod and the bolt. Compressive force applied by the bolt to the elongated rod passes through the compressive structure which allows limited longitudinal movements of the elongated rod to be accommodated by the compressive structure without requiring corresponding longitudinal movements of the bolt. Exemplary embodiments also relate to rod structure forming a component of the assembly, and to a metal containment structure having a vessel supported and compressed by at least one such assembly.

Abstract: A composite metal ingot, comprising at least two layers of differing alloy composition, wherein pairs of adjacent layers consisting of a first alloy and a second alloy are formed by applying the second alloy in a molten state to the surface of the first alloy while the surface of the first alloy is at a temperature between solidus and liquidus temperatures of the first alloy to form an interface there between, wherein the second alloy is a high or medium strength heat treatable aluminum alloy, and further wherein one or more alloy components from the second alloy are present within grain boundaries of the first alloy adjacent said interface.

Abstract: The invention relates to a method and apparatus for direct chill casting ingots with in-situ homogenization. Large particles of eutectic material may form in the solid ingot and the metal may exhibit macrosegregation of alloying components, especially when large ingots are cast in this way. This can be alleviated by applying a first liquid coolant to the ingot emerging from the mold, removing the first liquid coolant at a certain distance along the ingot by means of a wiper, and then applying a second liquid coolant to perform a quench at a greater distance along the ingot. The quench raises the level of the molten sump in the ingot, which helps to overcome the indicated problems, without affecting the desired temperature rebound of the ingot shell (usually at least 425° C. (797° F.)) for a time effective to cause in-situ homogenization.

Abstract: Automated processes that dynamically control rate of delivery of molten metal to a mold during a casting process. Such automated processes can use dynamic metal level variation, control pin pulses and/or oscillation during the mold fill and transient portion of the cast. It has been found that such pulses keep metal flowing in a manner that addresses problems, particularly at the beginning of an ingot cast, associated with metal meniscus contracting and pulling away from the mold on the short faces and corners.

Abstract: The invention relates to a method and apparatus for direct chill casting ingots with in-situ homogenization. Large particles of eutectic material may form in the solid ingot and the metal may exhibit macrosegregation of alloying components, especially when large ingots are cast in this way. This can be alleviated by applying a first liquid coolant to the ingot emerging from the mold, removing the first liquid coolant at a certain distance along the ingot by means of a wiper, and then applying a second liquid coolant to perform a quench at a greater distance along the ingot. The quench raises the level of the molten sump in the ingot, which helps to overcome the indicated problems, without affecting the desired temperature rebound of the ingot shell (usually at least 425° C. (797° F.)) for a time effective to cause in-situ homogenization.

Abstract: A vessel used for containing molten metal, e.g. a trough section for conveying molten metal from one location to another. In some embodiments, the vessel employs refractory liner units of different thermal conductivity to maximize heat penetration into the molten metal from heaters in the gap, but to minimize heat loss at the inlet and outlet of the vessel where the end units contact the housing.

Abstract: A vessel used for containing molten metal, e.g. a trough section for conveying molten metal from one location to another. The vessel has a refractory liner made of at least two refractory liner units positioned end to end, with a joint between the units, the units each having an exterior surface and a metal-contacting interior surface. A housing at least partially surrounds the exterior surfaces of the refractory liner units with a gap present between the exterior surfaces and the housing. Molten metal confinement elements, impenetrable by molten metal, are positioned on opposite sides of the joint within the gap, at least below a horizontal level corresponding to a predetermined maximum working height of molten metal held within the vessel in use, to partition the gap into a molten metal confinement region between the elements and at least one other region that may be used to hold equipment such as electrical heaters that may be damaged by contact with molten metal.

Abstract: The invention relates to a method and apparatus for direct chill casting ingots with in-situ homogenization. Large particles of eutectic material may form in the solid ingot and the metal may exhibit macrosegregation of alloying components, especially when large ingots are cast in this way. This can be alleviated by applying a first liquid coolant to the ingot emerging from the mold, removing the first liquid coolant at a certain distance along the ingot by means of a wiper, and then applying a second liquid coolant to perform a quench at a greater distance along the ingot. The quench raises the level of the molten sump in the ingot, which helps to overcome the indicated problems, without affecting the desired temperature rebound of the ingot shell (usually at least 425° C. (797° F.)) for a time effective to cause in-situ homogenization.

Abstract: A method of casting a metal ingot with a microstructure that facilitates further working, such as hot and cold rolling. The metal is cast in a direct chill casting mold, or the equivalent, that directs a spray of coolant liquid onto the outer surface of the ingot to achieve rapid cooling. The coolant is removed from the surface at a location where the emerging embryonic ingot is still not completely solid, such that the latent heat of solidification and the sensible heat of the molten core raises the temperature of the adjacent solid shell to a convergence temperature that is above a transition temperature for in-situ homogenization of the metal. A further conventional homogenization step is then not required. The invention also relates to the heat-treatment of such ingots prior to hot working.

Abstract: An exemplary embodiment of the invention provides a method of direct chill casting a composite metal ingot. The method involves sequentially casting two or more metal layers to form a composite ingot by supplying streams of molten metal to two or more casting chambers within a casting mold of a direct chill casting apparatus. Inlet temperatures of one or more of the streams of molten metal are monitored at a position adjacent to an inlet of a casting chamber fed with the stream, and the inlet temperatures are compared with a predetermined set temperature for the stream to determine if there is any difference. A casting variable that affects molten metal temperatures entering or within the casting chambers (e.g. casting speed) is then adjusted by an amount based on the difference of the compared temperatures to eliminate adverse casting effects caused by the difference of the inlet temperature and the set temperature.

Abstract: A composite metal ingot having two or more lengthwise alloy layers including adjacent first and second layers respectively formed of an aluminum-manganese alloy and an aluminum alloy of a different composition wherein the interface between the first and second layers is in the form of a substantially continuous metallurgical bond characterized by the presence of particles of one or more intermetallic compositions containing manganese from the first layer dispersed within a region of the second layer adjacent the interface, the first and second layers having been formed by applying the alloy for the second layer to a self-supporting surface of the first layer while the self-supporting surface is at a temperature between the solidus and liquidus temperatures of the first layer alloy.

Abstract: A method of casting a metal ingot with a microstructure that facilitates further working, such as hot and cold rolling. The metal is cast in a direct chill casting mold, or the equivalent, that directs a spray of coolant liquid onto the outer surface of the ingot to achieve rapid cooling. The coolant is removed from the surface at a location where the emerging embryonic ingot is still not completely solid, such that the latent heat of solidification and the sensible heat of the molten core raises the temperature of the adjacent solid shell to a convergence temperature that is above a transition temperature for in-situ homogenization of the metal. A further conventional homogenization step is then not required. The invention also relates to the heat-treatment of such ingots prior to hot working.

Abstract: A method and apparatus are described for the casting of a composite metal ingot having two or more separately formed layers of one or more alloys. An open ended annular mould is provided having a divider wall dividing a feed end of the mould into at least two separate feed chambers. For each pair of adjacent feed chambers, a first alloy stream is fed through one of the pair of feed chambers into the mould and a second alloy stream is fed through another of the feed chambers. A self-supporting surface is generated on the surface of the first alloy stream and the second alloy stream is contacted with the first stream. By carefully selecting conditions and positions where the alloy streams meet, a composite metal ingot is formed in which the alloy layers are mutually attached with a substantially continuous metallurgical bond.

Abstract: The invention provides a method of reducing butt curl during DC casting of a metal ingot. The ingot is cast in at least two stages, including an initial casting stage and then a steady-state casting stage carried out at higher casting speed. The emerging ingot is cooled by directing a liquid coolant onto its outer surface. During the first casting stage, the liquid coolant is directed in the form of at least two streams, including a constant first stream in the form of a series of first jets, and an intermittent second stream in the form of a series of second jets. The first and second jets impact the outer surface at locations spaced from each other peripherally and/or longitudinally of the ingot. Both the first and second streams experience film boiling when they contact the ingot. The invention includes apparatus for the method.