Abstract: Methods for creating a cast component, along with the resulting cast components, are provided. The method may include heating a mold having a cavity therein; supplying a first molten metal material into the cavity of the mold such that the first molten metal material is directed to a first portion of the cavity of the mold; supplying a second molten metal material into the cavity of the mold such that the second molten metal material is directed to a second portion of the cavity of the mold, wherein the first molten metal material is compositionally different than the second molten metal material; and thereafter, allowing the first molten metal material and the second molten metal material to form the cast component.

Abstract: A process for the manufacture of metal products includes the steps of providing a mold including a first portion made of an aggregate and a binder, delivering a molten metal into the mold, removing a first portion of the mold with a fluid and solidifying at least one targeted portion of the molten metal which will form the metal product with the fluid. A flow of fluid to the mold is stopped for a period of time. Subsequently, a remaining portion of the molten metal is solidified to form the metal product. The at least one targeted portion of the metal product has better mechanical properties than does a remaining portion of the metal product. A unitary, one-piece aluminum alloy component with differing mechanical properties is also disclosed.

Abstract: A method of manufacturing an Fe-based amorphous alloy ribbon includes forming a coated film of a molten alloy on a peripheral surface of a chill roll that has been subjected to polishing using a polishing brush roll, cooling the coated film on the peripheral surface, and then winding the Fe-based amorphous alloy ribbon, which has been peeled off by a peeling means, on a wind-up roll, to obtain a wound body of an Fe-based amorphous alloy ribbon. The polishing brush roll includes a roll axis member and a polishing brush that is equipped with a plurality of brush bristles and satisfies the following condition (1) and condition (2) while rotating axially in a reverse direction to the chill roll. Condition (1): Free length of brush bristles is more than 30 mm but no more than 50 mm. Condition (2): Density of brush bristles at the brush bristle tip is more than 0.30 bristles/mm2 but no more than 0.60 bristles/mm2.

Abstract: In a casting device, when a mold varied in outer size depending on a position passes through a heat shielding portion between a heating chamber and a cooling chamber, a flexible portion of a heat shielding body is bent to fit the outer size of the mold.

Abstract: A process for the manufacture of metal products includes the steps of providing a mold including a first portion made of an aggregate and a binder, delivering a molten metal into the mold, removing a first portion of the mold with a fluid and solidifying at least one targeted portion of the molten metal which will form the metal product with the fluid. A flow of fluid to the mold is stopped for a period of time. Subsequently, a remaining portion of the molten metal is solidified to form the metal product. The at least one targeted portion of the metal product has better mechanical properties than does a remaining portion of the metal product. A unitary, one-piece aluminum alloy component with differing mechanical properties is also disclosed.

Abstract: The present invention provides a superelastic alloy formed by addition of Fe or Co to an Au—Cu—Al alloy, including: Cu of 12.5% by mass or more and 16.5% by mass or less; Al of 3.0% by mass or more and 5.5% by mass or less; Fe or Co of 0.01% by mass or more and 2.0% by mass or less; and a balance Au, and a difference between Al content and Cu content (Cu—Al) is 12% by mass or less. The superelastic alloy according to the present invention has superelastic property while being Ni-free, excellent X-ray imaging property, processability, and strength property, and is suitable for a medical field.

Abstract: The present invention aims at providing a thermoelectric conversion module with low toxicity, which exhibits conversion efficiency equivalent to that of BiTe. The thermoelectric conversion module of the present invention employs a full Heusler alloy as the material for forming the P-type thermoelectric conversion unit and the N-type thermoelectric conversion unit. The material for forming the N-type thermoelectric conversion unit contains at least any one of Fe, Ti, and Si and Sn.

Abstract: A casting mold for casting a piston for an internal combustion engine may include a mold body having a surface texture in a region corresponding to a subsequent internal surface of a piston skirt. The surface texture may be defined by a plurality of grooves. The plurality of grooves may have the following dimension: a depth of 0.2 mm<t<0.5 mm, a width of 0.02 mm<b<0.05 mm, and at least two groove walls which are inclined outwardly at 0°<?<10°.

Abstract: An example cooling system for a mold assembly includes a quench plate that defines one or more discharge ports and one or more recuperation ports. A fluid is circulated from the one or more discharge ports to the one or more recuperation ports to cool the mold assembly. A blocking ring is positioned on the quench plate and defines a central aperture for receiving a bottom of the mold assembly. An insulation enclosure having an interior for receiving the mold assembly is positioned on the blocking ring. The blocking ring prevents vapor generated by the fluid contacting the bottom of the mold assembly from migrating into the interior of the insulation enclosure.

Abstract: The present invention relates to a process of forming copper anodes (6) in a casting wheel (I) from the stage in which the copper is in liquid molten state (5) in a dumping chute (3) and is transferred to a ladle (4) until the anode (6) of solid copper is transformed into an anode (6) and is discharged from a mold (2) located in said casting wheel (I) wherein said process prevents the liquid molten copper (5) from being adhered to the edge of the ladle (4) and in the interstice (14) generated between the surfaces of the ejector rod (13) and the passing through bore (12) located on the mold (2) comprising the stages of: pouring the molten liquid copper from a distributing dumping chute (3) towards a ladle (4); (b) connecting the metallic components of the ladle (4) to the ground in order to produce positive charge (17); (c) spraying towards the edge (lip) of the ladle (4) an air jet (19) with dry dusting release agent (20) which is expelled by a nozzle (21) charging the particles of said dry dusting (20) with

Abstract: In general, in various embodiments, the present disclosure is directed systems and methods for producing a porous surface from a solid piece of polymer. In particular, the present disclosure is directed to systems that include a track assembly, mold assembly, press assembly, and methods for using the same for producing a porous surface from a solid piece of polymer. In some embodiments, the present systems and methods are directed to processing a polymer at a temperature below a melting point of the polymer to produce a solid piece of polymer with an integrated a porous surface.

Abstract: A method to produce cast pieces with optimum mechanical properties having through-openings with minimal outlay in terms of equipment. A casting mold in which at least one casting core is used. A through-channel leading through the through-opening of the cast piece is formed by burning the binder in the molding material out of the casting core representing the through-opening by means of the heat input into the casting mold when pouring the molten metal into the casting mold, or by mechanically destroying, at least in part, the respective casting core representing the through-opening and the regions of the casting mold arranged in the extension of the casting core.

Abstract: A method to produce cast pieces with optimum mechanical properties having through-openings with minimal outlay in terms of equipment. A casting mould in which at least one casting core is used. A through-channel leading through the through-opening of the cast piece is formed by burning the binder in the moulding material out of the casting core representing the through-opening by means of the heat input into the casting mould when pouring the molten metal into the casting mould, or by mechanically destroying, at least in part, the respective casting core representing the through-opening and the regions of the casting mould arranged in the extension of the casting core.

Abstract: An article includes a first portion having a first grain pattern and a second portion having a second grain pattern different from the first grain pattern. The article is a cast article such as a turbine engine blade.

Abstract: A damper for a gas turbine engine is provided. The damper comprises a first portion, a second portion, and a surface. The second portion angularly extends from the first portion to define an interior corner therebetween. The surface bounds the first portion, the second portion, and the interior corner. The damper further comprises a grain composition containing columnar grains and equiaxed grains. The equiaxed grains are disposed adjacent to the surface such that a volume of the columnar grains is less than a volume of the equiaxed grains in the grain composition.

Abstract: Devices may be in contact with molten metals such as copper, for example. The devices may include, but are not limited to, a die used for producing articles made from the molten metal, a sensor for determining an amount of a dissolved gas in the molten metal, or an ultrasonic device for reducing gas content (e.g., hydrogen) in the molten metal. Niobium may be used as a protective barrier for the devices when they are exposed to the molten metals.

Abstract: A method includes providing a mold including a molten casting material, moving the mold in a first direction, and guiding a solidification interface across the mold in a second direction in response to the moving the mold. The second direction is deviated from the first direction, and the solidification interface includes a transition to a negative heat transfer region. The mold moves in the first direction at a constant speed, and the mold includes heat transfer features such that a solidification time of the molten casting material at the conditions of the solidification interface is approximately constant as a function of the second direction.

Abstract: An alloy for R-T-B-based rare earth sintered magnets which contains R which is a rare earth element; T which is a transition metal essentially containing Fe; a metallic element M containing one or more metals selected from Al, Ga and Cu; B and inevitable impurities, in which R accounts for 13 at % to 15 at %, B accounts for 4.5 at % to 6.2 at %, M accounts for 0.1 at % to 2.4 at %, T accounts for balance, a proportion of Dy in all rare earth elements is in a range of 0 at % to 65 at %, and the following Formula 1 is satisfied, 0.0049Dy+0.34?B/TRE?0.0049Dy+0.36??Formula 1 wherein Dy represents a concentration (at %) of a Dy element, B represents a concentration (at %) of a boron element, and TRE represents a concentration (at %) of all the rare earth elements.

Abstract: Provided are raw material alloy flakes for a rare earth sintered magnet and a method for producing the same. The alloy flakes have a roll-cooled face, and (1) contain at least one R selected from rare earth metal elements including Y, B, and the balance M including iron, at a particular ratio; (2) as observed in a micrograph at a magnification of 100× of its roll-cooled face, have not less than 5 crystals each of which is a dendrite grown radially from a point of crystal nucleation, and crosses a line segment corresponding to 880 ?m; and (3) as observed in a micrograph at a magnification of 200× of its section taken generally perpendicularly to its roll-cooled face, have an average distance between R-rich phases of not less than 1 ?m and less than 10 ?m.

Abstract: A casting method and apparatus are provided for casting a near-net shape article, such as for example a gas turbine engine blade or vane having a variable cross-section along its length. A molten metallic melt is provided in a heated mold having an article-shaped mold cavity with a shape corresponding to that of the article to be cast. The melt-containing mold and mold heating furnace are relatively moved to withdraw the melt-containing mold from the furnace through an active cooling zone where cooling gas is directed against the exterior of the mold to actively extract heat. At least one of the mold withdrawal rate, the cooling gas mass flow rate, and mold temperature are adjusted at the active cooling zone as the melt-containing mold is withdrawn through the active cooling zone to produce an equiaxed grain microstructure along at least a part of the length of the article.

Abstract: A casting, mold and method for producing a casting are disclosed. The casting may have an area of small thermal mass and an area of large thermal mass. The method may comprise providing a casting having a work product and an appendage engaged to, and suspended over, the work product between the area of small thermal mass and the area of large thermal mass, and controllably cooling the work product using the appendage.

Abstract: A method and a device for remelting metal in an electric furnace includes forming a slag bath to form molten material electrodes. The molten metal of the material electrodes solidifies in block form in a crucible apparatus as a result of cooling in such a way that a block growth forms from a block base using a progressing solidification process, wherein the block base is heated by applying energy directly to the block base to influence the cooling process.

Abstract: There is provided a machine for forming metal bars particularly suitable for melting and the subsequent continuous solidification of precious metal such as gold, silver, precious alloys, as well as other pure metals or different alloys, in the form of powder, grits or swarf of various sizes, for producing ingots having weights varying from 50 g to 50 kg. The machine having six operating stations arranged in succession.

Abstract: A spheroidal graphite cast iron alloy comprises, in % by weight, in addition to addition elements, the following elements: Ni between 3.5% and 7%, Cu between 0.5% and 3%, Mo between 0.15% and 1%, the remainder being iron and inevitable impurities. The spheroidal graphite cast iron alloy may be used in manufacturing a part such as cogwheels and gear rims. The method of manufacturing the part may comprise casting a rough casting blank, notably into a mold, and letting the rough casting blank cool in the mold, thus obtaining the part.

Abstract: Some embodiments provide methods and systems for casting articles. One example of a method includes providing and positioning a thermal blanket within a mold cavity and then introducing a molten material into the mold cavity and into contact with the thermal blanket. The method allows the molten material to remain in a molten state during a dwell time that extends from the introduction of the molten material at least until the mold cavity is filled. In another example, a method of using a thermal blanket includes keeping a molten material in a molten state during a dwell time extending from first introduction of the molten material until pressurization. Systems including a variety of mold types, one or more thermal blankets, and in some cases preforms and/or inserts are also provided. Also described is a novel thermal blanket and method of manufacturing the same.

Abstract: The present invention relates to the field of casting blank manufacturing, in particular to a method for enhancing the self-feeding ability of a heavy section casting blank, which can solve the problems of poor centre quality, surface crack and high rejection rate of the heavy section casting blanks in the prior art.

Abstract: A wrought aluminium material with improved damage tolerance while preserving the high strength of the material is disclosed. Furthermore, a cast aluminium material of a precipitation hardenable aluminium alloy is disclosed, the material comprising grains having two distinct zones with a first centre zone enriched in elements capable of reacting peritectically with aluminium and a second zone, surrounding the first zone, enriched in elements capable of reacting eutectically with aluminium.

Abstract: A piston ring exhibiting particles capable of wear resistance on its shoulder is produced by producing a melt of the base materials of a metal material, adding ceramic particles to the melt, pouring the melt into a prefabricated mould and cooling the melt. During cooling, the mould is aligned such that the ceramic particles gather on at least one of the piston ring shoulders.

Abstract: The present invention provides an Ni-based intermetallic compound alloy having excellent hardness. The present invention provides an Ni-based dual multi-phase intermetallic compound alloy comprising Ni as a main component, and 5 to 12 atomic % of Al, 11 to 17 atomic % of V and 1 to 5 atomic % of Re, and having a dual multi-phase microstructure including a primary precipitate L12 phase and a (L12+D022) eutectoid microstructure.

Abstract: The invention relates to a steel plate, the chemical composition of which comprises, the contents being expressed by weight: 0.010%?C?0.20%, 0.06%?Mn?3%, Si?1.5%, 0.005%?Al?1.5%, S?0.030%, P?0.040%, 2.5%?Ti?7.2%, (0.45×Ti)?0.35%?B?(0.45×Ti)+0.70%, and optionally one or more elements chosen from: Ni?1%, Mo?1%, Cr?3%, Nb?0.1%, V?0.1%, the balance of the composition consisting of iron and inevitable impurities resulting from the smelting.

Abstract: In an aspect the disclosure relates to an alloy comprising, by weight, about 0.15% to about 1.00% zinc, 0% to about 0.20% gallium, and the balance aluminum and incidental elements and impurities, wherein the alloy has a corrosion potential from about ?0.85 V to about ?0.73 V relative to a saturated calomel electrode.

Abstract: The present invention discloses a method of strip casting an aluminum alloy from immiscible liquids that yields a highly uniform structure of fine second phase particles. The results of the present invention are achieved by using a known casting process to cast the alloy into a thin strip at high speeds. In the method of the present invention, the casting speed is preferably in the region of about 50-300 feet per minute (fpm) and the thickness of the strip preferably smaller than 0.08-0.25 inches. Under these conditions, favorable results are achieved when droplets of the immiscible liquid phase nucleate in the liquid ahead of the solidification front established in the casting process. The droplets of the immiscible phase are engulfed by the rapidly moving freeze front into the space between the Secondary Dendrite Arms (SDA).

Abstract: An aluminium-copper alloy comprising substantially insoluble particles which occupy the interdendritic regions of the alloy, provided with free titanium in quantity sufficient to result in a refinement of the grain structure in the cast alloy.

Abstract: A method and apparatus for the production of a casting that includes pouring molten material into a mold for forming the casting, allowing the molten material to solidify, removing the mold at least in part from the resulting solidified casting, and locating the solidified casting in a chamber that completely surrounds and facilitates a controlled rate of cooling of the casting.

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 copper alloy wrought material, containing 1.5 to 7.0 mass % of Ni, 0.3 to 2.3 mass % of Si, 0.02 to 1.0 mass % of S, and optionally at least one selected from the group consisting of Sn, Mn, Co, Zr, Ti, Fe, Cr, Al, P, and Zn in a total amount of 0.05 to 2.0 mass %, with the balance being Cu and unavoidable impurities, wherein sulfide particles, which contribute to machinability, are dispersed therein, in which an average diameter of the sulfide particles is 0.1 to 10 ?m, and in which an area ratio of the sulfide particles is 0.1 to 10%, and wherein the copper alloy wrought material has a tensile strength of 500 MPa or greater and an electrical conductivity of 25% IACS or higher.

Abstract: A process for making a composite material and the composite materials having thermoelectric properties.

Abstract: The invention concerns an aluminum-based master alloy for manganese alloying of metal alloys and a method for producing thereof, and use thereof for production of the metal alloys. The master alloy is aluminum and manganese (Al—Mn) alloy in form of splatters, which contains the following components in mass %: Mn 77-93, other components in total 0-5, Al—the rest. The method for producing the master alloy is characterized in that the temperature for adding the manganese to the liquid metal is in the range from 660 to 1600° C., and the cooling rate of the alloy during casting is in the range of 50-1500° C./sec for obtaining splatters of the master alloy. Thickness of splatters is in the range of 1-10 mm. The master alloys AlMn80 and AlMn90 are designed to be used for manganese alloying of metal alloys, whereas the temperature for adding the master alloy in the liquid metal is in the range from 600 to 850° C.

Abstract: The present invention relates to single-phase solid solution magnesium alloys suitable for the applications as cast or wrought. These alloys are prepared by multi-microalloying with rare earth elements (including gadolinium, yttrium, dysprosium, samarium, lanthanum, cerium, neodymium and praseodymium). Each alloy contains 0.5 to less than 5 wt. % rare earth elements with a content of 0.05-2.0% by weight. The total amount of rare earth elements is controlled below 5% by weight in order for economical considerations. The amount of grain refiner calcium or zirconium is in the range of 0.05-0.6% by weight. These alloys can be prepared by die casting, permanent casting, chill casting, semi-solid processes, continuous casting and continuous twin roll casting.

Abstract: An exemplary embodiment provides a method of eliminating a shrinkage cavity in a metal ingot cast by direct chill casting. The method involves casting an upright ingot having an upper surface at an intended height. Upon completion of the casting, the lower tip of the spout is maintained below the molten metal near the center of the upper surface. The metal flow through the spout is terminated and a partial shrinkage cavity is allowed to form as metal of the ingot shrinks and contracts. Before the partial cavity exposes the lower tip of the spout, the cavity is preferably over-filled with molten metal, while avoiding spillage of molten metal, and then the flow of metal through the spout is terminated. These steps are repeated until no further contraction of the metal causes any part of the upper surface to contract below the intended ingot height.

Abstract: A process for manufacturing a single-crystal turbomachine nozzle guide vane including an airfoil between two platforms is disclosed. The process includes pouring molten metal into a shell mold followed by directional solidification from a single crystal provided by a single-crystal grain provider device placed in the mold and having a predetermined orientation coinciding with the vertical. The volumes of the mold forming the platforms are oriented in a plane parallel to the vertical direction of the single crystal. The single-crystal grain providing device emerges in a grain duct forming a connection between the device and the lower ends of the platforms. The grain duct is shaped to present two branches for feeding the platforms and a web-shaped volume extending between the feed branches, the platforms and a lower edge of the airfoil. The upper edge of the volume forming the airfoil is inclined to the horizontal direction.

Abstract: A method produces a cast component of an internal combustion engine with a cast-in pipe. Expendable molds and a permanent pattern, or permanent molds are used in the method. A solid core mold is mounted in a split outer mold. To solve the problem of the pipe changing its position during the casting of the component, a separate pipe holder is integrated into the outer mold or the core mold. The pipe is inserted into a retaining section of the pipe holder that is configured in such a manner that it locally surrounds the outer circumference of the pipe at least in part and with little play so that the pipe can expand in the axial direction during casting but is secured against displacements in radial directions caused by buoyancy forces of the liquid casting material. Subsequently the component is cast.

Abstract: A process for producing a rare earth alloy comprises heating a raw material alloy to be a molten alloy, and quench-solidifying the molten alloy, wherein the raw material alloy is compounded so as to have a composition represented by the formula: REx(Co1-yMy)4Sb12 (wherein RE is at least either one member of La and Ce, M is at least one member selected from the group consisting of Ti, Zr, Sn, Cu, Zn, Mn and Pb, 0<x?1, and 0<y<1).

Abstract: A lead-free copper alloy includes, in combination by weight, about 10.0% to about 20.0% bismuth, about 0.05% to about 0.3% phosphorous, about 2.2% to about 10.0% tin, up to about 5.0% antimony, and up to about 0.02% boron, the balance essentially copper and incidental elements and impurities. The alloy contains no more than about 0.05 wt. % or 0.10 wt. % lead.

Abstract: A method of casting metal articles includes providing a plurality of interconnected support sections. Article mold sections are positioned on the support sections. After article mold cavities, have been filled with a molten metal which is at a first temperature, the support sections and a body of a second molten metal are moved relative to each other while the body of a second molten metal is at a temperature which is less than the first temperature. Space extending between side surfaces of the support sections and between side portions of the article mold sections is filled with the second molten metal during movement between the support sections and the body of a second molten metal. A layer of insulating material may be provided above the body of a second molten metal. A baffle may be provided between a container holding the body of a second molten metal and a furnace assembly.

Abstract: A method of mitigating against thermal contraction induced cracking during casting of a super Ni alloy, the method comprising: pouring liquid alloy into a mould such that liquid alloy is present in a feeder of said mould; and inducing an electrical current in alloy in said feeder to reduce a rate of cooling of alloy in said feeder.

Abstract: A process for producing a rare earth alloy comprising: heating a raw material alloy in an inert atmosphere to be a molten alloy, and then quench-solidifying the molten alloy, wherein the raw material alloy is compounded so as to have a composition represented by the formula: REx(Fe1-yMy)4Sb12 (wherein RE is at least either one member of La and Ce, M is at least one member selected from the group consisting of Ti, Zr, Sn and Pb, 0<x?1, 0.01?y?0.15, and the lower limit of y is more than impurity).

Abstract: A first method for producing a half Heuslar alloy includes quench-solidifying a molten alloy at a cooling rate of 1×102 to 1×103° C./sec to produce a half Heuslar alloy having a ratio of strongest peak of the half Heuslar phase of 90% or more in an as-cast state, the alloy having the formula: ABC (wherein A and B each is at least one member selected from Fe, Co, Ni, Ti, V, Cr, Zr, Hf, Nb, Mo, Ta and W, and C is at least one member selected from Al, Ga, In, Si, Ge and Sn). A second method is one in which the half Hueslar alloy has the formula: Ti1-xAxNi1-yBySn1-zCz (wherein each of A and B is at least one member selected from Co, Ni, Ti, V, Cr, Zr, Hf, Nb, Mo, Ta and W, C is at least one selected from Al, Ga, In, Si, Ge and Sn).

Abstract: The invention is related to the foundry practice. According to this invention, the method for making castings by directed solidification from a selected point of the melt toward the periphery of the casting comprises forming a casting in a mold having thermodynamic characteristics that allow uniform volume cooling of the melt to be effected to a temperature at which natural solidification processes are completed. To improve the structural isotropy of the casting formed, the cooling is effected at a rate not exceeding 0.5° C./sec. The casting is formed in a nonuniform field of force. The nonuniform field of force is set up by ultrasonic waves focused on a selected point of the melt to form therein a localized elevated pressure zone and to direct the solidification front from the zone toward the periphery of the casting. The nonuniform field of force is sustained in the mold until the cooling casting reaches a temperature at which the natural melt solidification processes are completed as the melt cools.

Abstract: To cast one or more metal articles, a mold structure is positioned on a support with an anchor extending upward from the support into the mold structure. The mold structure and anchor are interconnected by a retainer which extends through a portion of the mold structure into the anchor. When the mold structure is immersed in a cooling bath, force is transmitted between the mold structure and anchor to retain the mold structure against movement relative to the support.