Abstract: A method of producing aluminum in an electrolytic cell containing alumina dissolved in an electrolyte, the method comprising the steps of providing a molten salt electrolyte at a temperature of less than 900° C. having alumina dissolved therein in an electrolytic cell having a liner for containing the electrolyte, the liner having a bottom and walls extending upwardly from said bottom. A plurality of non-consumable Cu—Ni—Fe anodes and cathodes are disposed in a vertical direction in the electrolyte, the cathodes having a plate configuration and the anodes having a flat configuration to compliment the cathodes. The anodes contain apertures therethrough to permit flow of electrolyte through the apertures to provide alumina-enriched electrolyte between the anodes and the cathodes. Electrical current is passed through the anodes and through the electrolyte to the cathodes, depositing aluminum at the cathodes and producing gas at the anodes.

Abstract: A method of producing aluminum in a low temperature electrolytic cell containing alumina dissolved in an electrolyte. The method comprises the steps of providing a molten electrolyte having alumina dissolved therein in an electrolytic cell containing the electrolyte. A non-consumable anode and cathode is disposed in the electrolyte, the anode comprised of Cu—Ni—Fe alloys having single metallurgical phase. Electric current is passed from the anode, through the electrolyte to the cathode thereby depositing aluminum on the cathode, and molten aluminum is collected from the cathode.

Abstract: An improved Si—Cu—Mg—Al base alloy suitable for forming in the semi-solid condition into members such as vehicular members having improved properties.

Abstract: A method of producing aluminum in a low temperature electrolytic cell containing alumina dissolved in an electrolyte. The method comprises the steps of providing a molten electrolyte having alumina dissolved therein in an electrolytic cell containing the electrolyte. A non-consumable anode and cathode is disposed in the electrolyte, the anode comprised of Cu—Ni—Fe alloys containing 0.1 to 5 wt. % carbon and incidental elements and impurities. Electric current is passed from the anode, through the electrolyte to the cathode thereby depositing aluminum on the cathode, and molten aluminum is collected from the cathode.

Abstract: A method of producing aluminum in an electrolytic cell containing alumina dissolved in an electrolyte, the method comprising the steps of providing a molten salt electrolyte at a temperature of less than 900° C. having alumina dissolved therein in an electrolytic cell having a liner for containing the electrolyte, the liner having a bottom and walls extending upwardly from said bottom. A plurality of non-consumable Cu—Ni—Fe anodes and cathodes are disposed in a vertical direction in the electrolyte, the cathodes having a plate configuration and the anodes having a flat configuration to compliment the cathodes. The anodes contain apertures therethrough to permit flow of electrolyte through the apertures to provide alumina-enriched electrolyte between the anodes and the cathodes. Electrical current is passed through the anodes and through the electrolyte to the cathodes, depositing aluminum at the cathodes and producing gas at the anodes.

Abstract: A method of producing aluminum in a low temperature electrolytic cell containing alumina dissolved in an electrolyte. The method comprises the steps of providing a molten electrolyte having alumina dissolved therein in an electrolytic cell containing the electrolyte. A non-consumable anode and cathode is disposed in the electrolyte, the anode comprised of Cu—Ni—Fe alloys having single metallurgical phase. Electric current is passed from the anode, through the electrolyte to the cathode thereby depositing aluminum on the cathode, and molten aluminum is collected from the cathode.

Abstract: An improved Si—Cu—Mg—Al base alloy suitable for forming in the semi-solid condition into members such as vehicular members having improved properties.

Abstract: A method of producing aluminum in a low temperature electrolytic cell containing alumina dissolved in an electrolyte. The method comprises the steps of providing a molten electrolyte having alumina dissolved therein in an electrolytic cell containing the electrolyte. A non-consumable anode and cathode is disposed in the electrolyte, the anode comprised of Cu—Ni—Fe alloys containing 0.1 to 5 wt. % carbon and incidental elements and impurities. Electric current is passed from the anode, through the electrolyte to the cathode thereby depositing aluminum on the cathode, and molten aluminum is collected from the cathode.

Abstract: A method for forming a remateable cracked aluminum base alloy connecting rod using a semi-solid aluminum alloy processing to produce a connecting rod having a globular microstructure contained in a lower melting eutectic with improved properties.

Abstract: A method for forming a remateable cracked aluminum base alloy connecting rod using a semi-solid aluminum alloy processing to produce a connecting rod having a globular microstructure contained in a lower melting eutectic with improved properties.

Abstract: A billet of an aluminum alloy for thermally transforming from a dendritic microstructure to a globular structure and for forming in a semi-solid condition into a shaped aluminum alloy article; the billet having a dendritic microstructure having a grain size in the range of 20 to 250 .mu.m provided by a solidification rate in the range of 5.degree. to 100.degree. C./sec between liquidus and solidus temperatures when the aluminum alloy is cast into billet; the billet having a dendritic microstructure thermally transformable to the globular structure or non-dendritic structure by heat applied to the billet at a heat-up rate greater than 30.degree. C. per minute to a superheated temperature of 3.degree. to 50.degree. C. above solidus temperature of the aluminum alloy; the billet in the globular structure or non-dendritic structure and in the semi-solid condition having the ability to be formed into the shaped aluminum article.

Abstract: Disclosed is an improved aluminum base alloy comprising an improved aluminum base alloy comprising 0.2 to 2 wt. % Si, 0.3 to 1.7 wt. % Mg, 0 to 1.2 wt. % Cu, 0 to 1.1 wt. % Mn, 0.01 to 0.4 wt. % Cr, and at least one of the elements selected from the group consisting of 0.01 to 0.3 wt. % V, 0.001 to 0.1 wt. % Be and 0.01 to 0.1 wt. % Sr, the remainder comprising aluminum, incidental elements and impurities. Also disclosed are methods of casting and thermomechanical processing of the alloy.

Abstract: A process for casting, thermally transforming and semi-solid forming an aluminum base alloy into an article, the process comprising the steps of: casting a molten body of aluminum base alloy comprising 2 to 7 wt. % Si, 0.3 to 1.7 wt. % Mg, 0.3 to 3 wt. % Cu, 0.05 to 0.4 wt. % Fe, and at least one of the group consisting of 0.01 to 1 wt. % Mn, 0.01 to 0.35 wt. % Cr, max. 0.2 wt. % Ti, max. 0.3 wt. % V to provide a solidified body, the molten aluminum base alloy being solidified at a rate between liquidus and solidus temperatures of the aluminum base alloy to provide a solidified body having a dendritic microstructure. Thereafter, heat is applied to the solidified body to bring the body to a superheated temperature of 3.degree. to 50.degree. C. above the solidus temperature of the aluminum base alloy while maintaining the body in a solid shape and effecting thermal transformation of the body having the dendritic structure when the body is heated to above the solidus temperature.

Abstract: A process for casting, thermally transforming and semi-solid forming an aluminum base alloy into an article, the process comprising the steps of: casting a molten body of aluminum base alloy comprising 2 to 5 wt. % Si, 0.3 to 1.7 wt. % Mg, 0.3 to 1.2 wt. % Cu, 0.05 to 0.4 wt. % Fe, and at least one of the group consisting of 0.01 to 1 wt. % Mn, 0.01 to 0.35 wt. % Cr, max. 0.2 wt. % Ti, max. 0.3 wt. % V to provide a solidified body, the molten aluminum base alloy being solidified at a rate between liquidus and solidus temperatures of the aluminum base alloy to provide a solidified body having a dendritic microstructure. Thereafter, heat is applied to the solidified body to bring the body to a superheated temperature of 3.degree. to 50.degree. C. above the solidus temperature of the aluminum base alloy while maintaining the body in a solid shape and effecting thermal transformation of the body having the dendritic structure when the body is heated to above the solidus temperature.

Abstract: Disclosed is an improved aluminum base alloy comprising an improved aluminum base alloy comprising 0.2 to 2 wt. % Si, 0.3 to 1.7 wt. % Mg, 0 to 1.2 wt. % Cu, 0 to 1.1 wt. % Mn, 0.01 to 0.4 wt. % Cr, and at least one of the elements selected from the group consisting of 0.01 to 0.3 wt. % V, 0.001 to 0.1 wt. % Be and 0.01 to 0.1 wt. % Sr, the remainder comprising aluminum, incidental elements and impurities. Also disclosed are methods of casting and thermomechanical processing of the alloy.

Abstract: A process for casting, thermally transforming and semi-solid forming an aluminum base alloy into an article, the process comprising the steps of: casting a molten body of aluminum base alloy to provide a solidified body, the molten aluminum base alloy being solidified at a rate between liquidus and solidus temperatures of the aluminum base alloy in a range of 5.degree. to 100.degree. C./sec. to provide an entire solidified body having a denditic microstructure. Thereafter, heat is applied to the solidified body to bring the body to a superheated temperature of 3.degree. to 50.degree. C. above the solidus temperature of the aluminum base alloy while maintaining a body in a solid shape and effecting thermal transformation of the body having the dendritic structure when the entire body is uniformly heated to the superheated temperature. The body having a non-dendritic structure is formed in a semi-solid condition into the article.