Abstract: A casting device includes a covered crucible having a top opening and a bottom orifice, a lid covering the top opening, a stopper rod sealing the bottom orifice, and a reusable mold having at least one chamber, a top end of the chamber being open to and positioned below the bottom orifice and a vacuum tap into the chamber being below the top end of the chamber. A casting method includes charging a crucible with a solid material and covering the crucible, heating the crucible, melting the material, evacuating a chamber of a mold to less than 1 atm absolute through a vacuum tap into the chamber, draining the melted material into the evacuated chamber, solidifying the material in the chamber, and removing the solidified material from the chamber without damaging the chamber.

Abstract: Processes and methods related to producing, processing, and hot working alloy ingots are disclosed. An alloy ingot is formed including an inner ingot core and an outer layer metallurgically bonded to the inner ingot core. The processes and methods are characterized by a reduction in the incidence of surface cracking of the alloy ingot during hot working.

Abstract: Disclosed is a method for producing alloy ingot including: a step of: charging alloy starting material into a cold crucible in a cold-crucible induction melter, and forming melt pool of the alloy starting material by induction heating in inert gas atmosphere; a step of continuing the induction heating and adding first refining agent to the melt pool, and then reducing the content of at least phosphorus from among impurity elements present in the melt pool; and a step of forming alloy ingot by solidifying the melt, the phosphorus content of which has been reduced. The first refining agent is mixture of metallic Ca and flux, where the flux contains CaF2 and at least one of CaO and CaCl2. The weight proportion of the sum of CaO and CaCl2 with respect to CaF2 ranges from 5 to 30 wt % and the weight proportion of metallic Ca with respect to the melt pool is 0.4 wt % or greater.

Abstract: A system and process for reclaiming nickel and cadmium from a feed source such as Ni—Cd batteries. The feed source is shredded to produce feed particles, screened to size the particles, magnetically separated to remove non-metallic materials, and induction heated to generate nickel and cadmium products.

Abstract: A process produces a 3-dimensional component (16) by selective laser melting (SLM), in which the component (16) is formed on a foundation with a surface, e.g., a platform (10) or a support, which in particular is a component of the same type which has already been produced previously, by successively melting layers of a first metal powder to form a sequence of stacked layers. The process is substantially simplified and made more flexible by virtue of the fact that the separation of the finished component (16) from the surface of the platform (10) or the support thereof is simplified by providing a separating layer (11) between the component (16) and the platform (10) or the support, this separating layer making it possible to separate the finished component (16) from the platform (10) or the support without damaging the finished component (16).

Abstract: A rolling method in a rolling line, to obtain strip with a thickness varying from 0.7 mm to 20 mm, for steel which can be cast in the form of thin slabs with a thickness from 30 mm to 140 mm, the line includes a continuous casting device; a tunnel furnace for maintenance/equalization and possible heating; a rolling train having a roughing train and a finishing train; a rapid heating unit, with elements able to be selectively activated, interposed between the roughing train and the finishing train. For each lay-out of the rolling line, the position of the rapid heating unit which defines the number of stands which form the roughing train, disposed upstream of the unit, and the number of stands which form the finishing train, disposed downstream of the unit, is calculated as a function of the product of the thickness and speed of the thin slab.

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: Processes and methods related to producing, processing, and hot working alloy ingots are disclosed. An alloy ingot is formed including an inner ingot core and an outer layer metallurgically bonded to the inner ingot core. The processes and methods are characterized by a reduction in the incidence of surface cracking of the alloy ingot during hot working.

Abstract: There is described a method for producing ultrahigh-purity Fe-base, Ni-base, and Co-base alloying materials to achieve impurity levels of (C+O+N+S+P)<100 ppm, and Ca<10 ppm, in the form of a large ingot, using a refining flux while forcibly cooling the crucible. A refining flux selected from the group consisting of metal elements of the Groups IA, IIA, and IIIA of the Periodic Table, oxides thereof, halides thereof, and mixtures thereof, is added to the molten metal during primary melting and the molten metal is held in contact with the refining flux for at least 5 minutes before tapping. Thereafter, the molten metal is caused to undergo solidification inside a mold, thereby producing a primary ingot.

Abstract: Provided are an aluminum alloy having high toughness and high electric conductivity, an aluminum alloy wire, an aluminum alloy stranded wire, a covered electric wire, a wire harness, and a process for production of an aluminum alloy wire. The aluminum alloy wire contains by mass 0.2 to 1.0% of Mg, 0.1 to 1.0% of Si, and 0.1 to 0.5% of Cu with the balance being Al and impurities and satisfies the relationship: 0.8?Mg/Si mass ratio?2.7. The Al alloy wire exhibits an electric conductivity of 58% IACS or above and an elongation of 10% or above. The Al alloy wire is produced via successive steps of casting, rolling, wire drawing, and softening treatment. Since the Al alloy wire has been subjected to softening treatment, the wire is excellent in toughnesses such as elongation and impact resistance, so that when used in a wire harness, the wire is inhibited from being broken in the neighborhood of a terminal in mounting the wire harness.

Abstract: A method for producing a wide steel strip using thin slab continuous casting and rolling by the following steps a) casting a molten steel into a thin slab having a thickness of between 50 and 90 mm; b) cutting; c) soaking; d) heating by electromagnetic induction; e) descaling; f) rolling; g) cooling with laminar flow; and h) coiling. The method can effectively control the solution and precipitation of carbon, nitrogen, and sulfide in steel with a low cost. The process is easy and flexible, and steel can be produced in a wide range of categories. Further provided is a system for producing a wide steel strip with thin slab continuous casting and rolling.

Abstract: A zirconium-based amorphous alloy includes 10.0 to 15.0 wt % copper, 7.0 to 13.0 wt % nickel, 5.0 to 8.0 wt % niobium, and 2.0 to 5.0 wt % aluminum, with the remainder zirconium and unavoidable impurities. A method for constructing a spectacle frame, comprises forming a nickel-niobium alloy, a weight ratio of the nickel and the niobium of which is being in a range between 7:8 and 13:5, melting the nickel-niobium alloy, mixing the molten the nickel-niobium alloy with 55.0 to 75.0 wt % Zr, 10.0 to 15.0 wt % Cu, and 2.0 to 6.0 wt % Al to form a master alloy, melting the master alloy, and molding the master alloy into a spectacle frame.

Abstract: Methods for centrifugally casting a highly reactive titanium metal involving providing a cold wall induction crucible having a plurality of induction coils and a removable bottom plate, using a power source to heat a titanium metal charge in the induction crucible to obtain a molten metal, preheating a secondary crucible and placing the preheated secondary crucible into a centrifugal casting machine, positioning the centrifugal casting machine having the secondary crucible beneath the induction crucible, withdrawing the bottom plate of the induction crucible and turning off the power source to the induction crucible to allow the molten metal to fall from the induction crucible into the secondary crucible, and accelerating the secondary crucible to centrifugally force the molten metal into a casting mold to produce a cast component.

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 lithium-containing alloy material is described. The process supplies a light alloy material applicable to the design of lightweight structural components. The process includes first melting alloy materials at a required ratio into a homogeneous alloy melt, then pouring the alloy melt into a ladle protected with an inert gas and pre-filled with a lithium material, where the lithium material is vigorously flushed and mixed with a hot stream of the alloy melt, and diffused into the alloy melt, and then after uniformly mixing, pouring the lithium-containing alloy melt into a mold to form an ingot and produce a lithium alloy. The process solves the fundamental problems of both contamination and uncontrolled component caused by longtime overheat in traditional melting techniques, and is a novel, safe, economic, and efficient manufacture process.

Abstract: The invention refers to a process for forming a steel component, incorporating the steps of—providing a blank having substantially the volume of the component to be formed,—heating the blank to a semi solid state with a specific liquid fraction,—forming the blank with a forging technique to a component of near net shape dimensions,—subjecting the formed, near net shape component, to a normalization combined with a hardening,—subjecting the normalized and hardened near net shape component to machining to give the component net shape.

Abstract: The invention relates to a method for producing a metal strip (1) by continuous casting and rolling. According to said method, a thin slab (3) is initially cast into a casting machine (2), which is subsequently rolled in at least one rolling train (4, 5) using primary heat from the casting cycle. According to the invention, in order to improve the functionality of the continuous casting and rolling installation, the cast thin slab (3) is passed between the casting machine (2) and the at least one rolling train (4, 5) and at least one holding oven (6) as well as at least one induction oven (7). The holding oven (6) and the induction oven (7) are activated or deactivated according to a selected mode of operation, that is, a first mode of operation for the continuous production of the metal strip (1) and a second mode of operation for the discontinuous production of the metal strip (1). The invention further relates to a device for producing a metal strip by continuous casting and rolling.

Abstract: The invention concerns a production of precision castings by centrifugal casting, comprising the following steps: a) providing a centrifugal casting device having a rotor (1) being rotatable around an axis (A), and at least one crucible (8) being accommodated in the rotor (1) and at least one mold (4) being associated with said crucible (8) and being accommodated in a first radial distance (r1) from the axis (A), b) creating a metal melt (15) within the crucible (8), c) rotating the rotor (1) and thereby forcing the melt (15) by means of centrifugal forces from the crucible (8) into the mold (4), d) exerting a pressure on the melt (15) being forced into the mold (4) until the temperature of the solidifying melt (15) has reached a predetermined cooling-temperature in a range of 1300° to 800° C., wherein the pressure corresponds to the centrifugal force acting on the melt (15) at the moment when the mold (4) is completely filled times a factor of 1.0 to 5.

Abstract: The invention relates to a high-hardness palladium alloy for manufacturing semi-finished products to be used in goldsmith's art or jewels to be obtained by the lost wax casting method, which comprises, in the following concentrations, expressed in thousandths by weight (‰): palladium from 948 to 990‰; copper from 0.0 to 50‰; indium from 0.0 to 50‰; gallium from 1 to 48‰; aluminium from 0.8 to 49.5‰; ruthenium from 0.0 to 50‰; rhenium from 0.0 to 50‰; silicon from 0.1 to 1.2‰; platinum from 0.0 to 40‰; nickel from 0.0 to 50‰; iridium from 0.0 to 40‰. In the manufacturing process of the above alloy, the component elements of said alloy are placed in a crucible, respectively made of zirconia, boron nitride or other ceramic material, and are melted using the induction method and using a protective atmosphere, respectively of argon, nitrogen or other inert gas.

Abstract: A casting device includes a covered crucible having a top opening and a bottom orifice, a lid covering the top opening, a stopper rod sealing the bottom orifice, and a reusable mold having at least one chamber, a top end of the chamber being open to and positioned below the bottom orifice and a vacuum tap into the chamber being below the top end of the chamber. A casting method includes charging a crucible with a solid material and covering the crucible, heating the crucible, melting the material, evacuating a chamber of a mold to less than 1 atm absolute through a vacuum tap into the chamber, draining the melted material into the evacuated chamber, solidifying the material in the chamber, and removing the solidified material from the chamber without damaging the chamber.

Abstract: The invention concerns a method for production of a turbine blades by centrifugal casting, the turbine blade having a leading edge portion with a first thickness and a flowing-off edge portion with a second thickness being smaller than the first thickness, comprising the following steps: a) providing a centrifugal casting device having a rotor (1) being rotatable around an axis (A), and at least one crucible (8) being accommodated in the rotor (1), the crucible having at least one outlet opening, b) providing a mold (4) having an extended cavity (20) for forming the turbine blade, c) arranging the mold (4) at a radially outward position with respect to the crucible (8), so that an inlet opening (5) of the mold (4) is arranged vis-a-vis with an outlet opening (9) of the crucible (8), and further arranging the mold (4) so that a mold leading edge (21) is directed in a direction against the rotational direction of the rotor (1), d) rotating the rotor (1) and thereby forcing a metal melt (15) by means of centrif

Abstract: Method for inductive heating of a material located in a channel, the material having a melting range between a solidus temperature and a liquidus temperature. The method includes providing an internal inductive heating assembly in the material in the channel, and supplying a signal to the assembly to generate a magnetic flux in at least one of the assembly and material. The magnetic flux generates inductive heating of the assembly and/or the material and a physical agitation which lowers the solidus temperature of the material to a reduced solidus temperature.

Abstract: There is provided an induction-melting apparatus capable of exhibiting high refining performance without inflicting damage to a crucible even if a halide-compound base refining flux is used upon induction-melting of an ultrahigh-purity high melting-point metal, having a melting point reaching 1500° C., and a method for induction-melting using the same. There is also provided a melting method for enabling production of ultrahigh-purity Fe-base, Ni-base, and Co-base alloying materials, each having an impurity level of (C+O+N+S+P)<100 ppm, and Ca<10 ppm, and in the form of a large ingot. Further, with the induction-melting apparatus, a plurality of tubular segments are disposed so as to be cylindrical in shape, a gap in a range of 1.

Abstract: An integrated process control installation is provided for electric induction metal melting furnaces with variable furnace states. The integrated process control installation can include supporting charge delivery and slag removal installations, and furnace process operations for process control of melting metal in the furnaces. The variable furnace states, supporting installations, and furnace process operations are controlled by a supporting processing installation, while a robotic apparatus performs the furnace process operations.

Abstract: The present invention relates to a method of production of functionally graded materials based on an incremental melting and solidification process. Its operation principle can be described as follows: the materials (metal elements, alloys or ceramics) are melt by the induction heating in the mould, and the continual granules, powders or wire, or even liquid materials, of another metal alloys are fed to the mould. The heating zone is limited to a small part of the mould. The incremental melting and solidification process proceeds from the bottom to the top of the mould by changing the relative position between the mould and the heating apparatus. Usage of this method ensures the obtainment of components with no particular alloy composition, but with a gradual changing of the chemical composition along the casting.

Abstract: The invention relates to a high-hardness palladium alloy for manufacturing semi-finished products to be used in goldsmith's art or jewels to be obtained by the lost wax casting method, which comprises, in the following concentrations, expressed in thousandths by weight (%) palladium from 948 to 990%; copper from 0.0 a 50%; indium from 0.0 to 50%; gallium from 1 to 48%; aluminium from 0.8 to 49.5%; ruthenium from 0.0 to 50%; rhenium from 0.0 to 50%; silicon from 0.1 to 1.2%; platinum from 0.0 to 40%; nickel from 0.0 to 50%; iridium from 0.0 to 40%. In the manufacturing process of the above alloy, the component elements of said alloy are placed in a crucible, respectively made of zirconia, boron nitride or other ceramic material, and are melted using the induction method and using a protective atmosphere, respectively of argon, nitrogen or other inert gas.

Abstract: A diecast machine comprises: a sleeve extending in the vertical direction; a plunger moving upward in the vertical direction inside the sleeve; a mold disposed above an upper side of the sleeve; a case member constituted of a nonconductive member, which covers at least a lower end of the sleeve and forms a closed space including the lower end of the sleeve; a communicating pipe connecting the inside of the closed space to the outside of the closed space; and high-frequency induction coil configured to heat metal material disposed on the plunger from the outside of the case member and melt the metal material.

Abstract: To restrict to a low level a temperature gradient of an ingot immediately after solidification in a bottomless crucible in a electromagnetic induction casting method using an electrically conductive bottomless crucible. An upper section and a lower section of an electrically conductive bottomless crucible to be disposed inside an induction coil are configured as a water-cooled section and a non-water-cooled section. Both the water-cooled section and the non-water-cooled section are divided by vertical slits into a plurality of portions in a circumferential direction. Rapid cooling with water in the lower section of the crucible is restricted.

Abstract: The invention relates to a crucible induction furnace for producing cast parts consisting of aluminum and magnesium alloys, especially particle-reinforced alloys. According to the invention, the material being melted is directly, inductively heated and stirred in an electrically non-conductive, refractory lining or crucible.

Abstract: A composite material is rapidly melted by furnishing a pre-wetted composite material in the form of granules, placing the granules into an induction coil, and powering the induction heater to melt the metal matrix portion of the granules to form a molten mixture. High power inputs to the induction coil may be used, so that the granules are rapidly heated to their melting point and to temperatures above the melting point, from which the molten mixture may be cast. Because of the rapid heating, otherwise-reactive composite materials may be prepared by melting in air.

Abstract: An apparatus and method of forming balls includes a metering device 2, a melting device 14 and a cooling device 20. The metering device 14 stamps a desired volume of solid material in the form of a slug 12 which passes through the melting device 14 where it is caused to levitate and transform state from a solid to a molten liquid. The molten liquid material 13 is released from the melting device 14 and descends through the cooling device 20 where it transforms state once again from a molten material to a solid material while maintaining a ball shape. A forming gas is passed over the molten material 13 in a direction opposite to the falling molten material 13. The balls 15 are finally cooled in a cooling bath 32.

Abstract: A method for directional solidification (DS) of a molten material, and an apparatus therefor. The method generally entails the use of a container having a base and peripheral wall that define an interior of the container, an induction coil for heating the contents of the container and generating an electromagnetic field, and means for controllably separating the container from the heating means and the electromagnetic field, such as by withdrawing the container from the heating means and electromagnetic field. Using such an apparatus, a material is heated within the container to yield a melt that is substantially prevented from contacting the wall of the container as a result of being at least partially levitated by the electromagnetic field. The container is then separated, e.g.

Abstract: Solid and liquid phases coexist in a semi-molten casting material. A plurality of composite-solid phases having liquid and solid phase regions and a plurality of single-solid phases exist as the solid phases in a mixed state in an outer layer portion of the semi-molten casting material. If the sectional area of the solid phase region is represented by A, and the sectional area of the solid phase region is represented by B in one of the composite-solid phases, the liquid phase enclosure rate P of the composite-solid phase is defined as being represented by P={B/(A+B)}.times.100 (%). The liquid phase enclosure rate P of the single-solid phase is equal to 0 (%). When two groups are selected from a class of the solid phases, for example, by first and second straight lines so as to include a plurality of the solid phases, average values M.sub.1 and M.sub.2 of liquid phase enclosure rates of, for example, six solid phases in each of the first and second groups are represented by M.sub.1 =(P.sub.1 +P.sub.2 - - - +P.

Abstract: A refractory guide member and a method for heating the refractory guide member by use of an inductor, where at least one collateral electromagnetic field located in a region spaced apart from the inductor is generated by the inductor. The mold part is made of an electrically conductive layer with several insulating interrupting slots for the controlled deflection of eddy currents from a main field generated by the inductor into a region spaced apart from the inductor.

Abstract: Disclosed is a levitation melting method comprising applying a high-frequency current to a high frequency induction coil wound around a melting crucible to induction-heat a material introduced to the melting crucible; and erecting the resulting molten metal to be in no contact with the inner wall surface of the melting crucible with the bottom of the material being maintained in the solidified state; wherein a power input P of a high-frequency power source to the high-frequency induction coil, an inner radius R at the bottom of the crucible and super heat .DELTA.T of the molten metal satisfy the relationship of P/R2=.DELTA.T.multidot.(0.0008 to 0.002), as well as, a melting and casting method for casting the molten metal prepared by the levitation melting method described above into a mold using a snout suspended above the melting crucible such that the lower end of the snout may be submerged in the molten metal.

Abstract: Metal is melted in an induction-heated crucible (13) on which a mold (10) with a downward-facing filling opening (26) is located in the melting position. After melting the metal, the crucible (13) and the mold (10) are jointly rotated about a horizontal axis (A--A) into a tilting position in which the molten material flows from the crucible (13) into the mold (10). In order to melt reactive metals, melting is done in a crucible (13) that is surrounded by a vacuum, this crucible being surrounded by an induction coil (15) outside of the vacuum. The mold (10) is located in a vacuum-sealed casting chamber (6) which is evacuated together with the crucible (13) prior to melting and casting is carried out by a joint tilting of the crucible (13), casting chamber (6) and mold (10) by at least 180 degrees while the vacuum is maintained.

Abstract: A system and method of electroslag refining of metal is taught. The system and method includes the introduction of unrefined metal into an electroslag refining process in which the unrefined metal is first melted at the upper surface of the refining slag. The molten metal is refined as it passes through the molten slag. The refined metal is collected in a cold hearth apparatus having a skull of refined metal formed on the surface of the cold hearth for protecting the cold hearth from the leaching action of the refined molten metal. A cold finger bottom pour spout is formed at the bottom of the cold hearth to permit dispensing of molten refined metal from the cold hearth. The dimensions of the cold finger apparatus pour spout are controlled by positioning a retaining means around the outer surface of the pour spout thereby controlling the flow rate of molten metal through the cold finger apparatus.

Abstract: Methods for controlling the superheat of the stream of molten metal from an electroslag refining apparatus is taught. The methods include the introduction of unrefined metal into an electroslag refining process apparatus in which the unrefined metal is first melted at the upper surface of the refining slag. The molten metal is refined as it passes through the molten slag. The refined metal is collected in a cold hearth apparatus having a skull of refined metal formed on the surface of the cold hearth for protecting the cold hearth from the leaching action of the refined molten metal. A cold finger bottom pour spout or exit orifice is formed at the bottom of the cold hearth to permit dispensing of molten refined metal from the cold hearth.

Abstract: A levitation melting method and device through which a material having various configurations can be melted through efficient induction heating. First, a starting material(WB), whose outer diameter has been adapted to the inner diameter of a crucible(13), is inserted in crucible(13). The crucible(13) is shielded with argon gas, thereby starting the melting of the material(WB) to molten metal(WM). Subsequently, a suction tube(33) of a mold(31) is inserted into the molten metal(WM) for drawing a part of molten metal(WM) up into the mold(31) for casting. After part of the molten metal(WM) is drawn up, a sliding cover(15) is slid such that a material holder(19) is positioned right above the crucible(13). By opening a sliding plate(35) of the material holder(19), material pieces(WS) are inserted from the material holder(19) into the molten metal(WM) left in the crucible(13).

Abstract: Molten metal melted in a levitation melting furnace is cast through a suction pipe immersed therein from above into a mold having a gas permeability in a double-structure mold chamber arranged directly above the melting furnace. The metal is levitation-melted in an inert atmosphere under atmospheric pressure. An outer mold chamber of the double-structure mold chamber is joined to the levitation melting furnace. Pressure in the outer mold chamber and in an inner mold chamber of the double-structure mold chamber and in an upper space in the levitation melting furnace is reduced to below atmospheric pressure. The suction pipe arranged in the inner mold chamber and communicating with the mold therein is immersed into the molten metal. The molten metal is cast into the mold under an increased pressure by blowing an inert gas into the upper space in the melting furnace. The inner mold chamber is raised, thereby pulling out the suction pipe from the molten metal.

Abstract: A process and a device for coating the surface of strip material, especially non-ferrous metal and steel strip, with a metal coating, wherein the material is conducted without reversal of direction through a container holding the molten coating material. The container has a passage duct below the level of the melting bath, in which induction currents are induced by an electromagnetic travelling field and produce, in interaction with the electromagnetic travelling field, an electromagnetic force for restraining the coating material. In order to stabilize the melt in the passage duct as well as in the container, and in order to attain, to a large extent, a counterbalance between hydrostatic and electromagnetic forces, a constant direct or alternating current field is directed opposite to the travelling field in the area near the container, damping the movement in the coating material.

Abstract: A die casting method and a die casting machine of the invention is provided. The method comprises the steps of forming a casting sleeve comprising an inner cylinder and an outer cylinder, having a conductor material, and disposing an induction coil on the outer periphery of the outer cylinder. The conductor material may be in the form of a plurality of conductors uncontinuously disposed about the cylinder or it may be in the form of a single conducting material having a plurality of slits. A material to be cast in the casting sleeve may be heated, maintained a constant temperature and stirred by electromagnetic induction. The material may be substantially separated from the wall face of the casting sleeve by an electromagnetic force generated between the conductor and the material and the temperature drop of the material may be suppressed.

Abstract: An ingot having a predetermined amount of electrolytic copper and a small percentage of boron copper alloy is rapidly heated to about 2,100.degree. F. in a clay graphite crucible by induction coils surrounding the crucible. The crucible and the entire amount of molten copper are automatically transferred to a cavity defined within a shot cylinder above a vertically movable shot piston of a vertical die casting press. A shuttle moves a lower end ring mold and a stack of connected rotor laminations into a position above the shot cylinder, and the press moves an upper end ring mold downwardly to clamp the stack between the molds and against the cylinder. The molten copper is rapidly injected upwardly through gates within the lower mold and into end ring cavities within the molds and also through connecting aligned bar slots within the stack of laminations with a shot pressure of about 2250 psi.

Abstract: A method for the electroslag refining of metal is provided. The method involves providing a refining vessel to contain an electroslag refining layer floating on a layer of molten refined metal. An ingot of unrefined metal is lowered into the vessel into contact with the molten electroslag layer. A refining current is passed through the slag layer to the ingot to cause surface melting at the interface between the ingot and the electroslag layer. As the ingot is surface melted at its point of contact with the slag, droplets of the unrefined metal are formed and these droplets pass down through the slag and are collected in a body of molten refined metal beneath the slag. The refined metal is held within a cold hearth. At the bottom of the cold hearth, a cold finger orifice is provided to permit the withdrawal of refined metal from the cold hearth apparatus. The refined metal passes from the cold finger orifice as a stream and is processed into a sound metal structure having desired grain structure.

Abstract: The present invention involves a method and apparatus for making an intermetallic casting (e.g. a titanium, nickel, iron, etc. aluminide casting) wherein a charge of a solid first metal protected from air as required is disposed in a vessel, and a charge of a second metal that reacts exothermically with the first metal is melted in another vessel. The molten second metal is introduced to the vessel containing the charge of the first metal so as to contact the first metal. The first and second metals are heated in the vessel to exothermically react them and form a melt for gravity or countergravity casting into a mold. The exothermic reaction between the first and second metals releases substantial heat that reduces the time needed to obtain a melt ready for casting into a mold. In particular, the exothermic reaction between the first and second metals, in effect, reduces the residence time of the intermetallic melt in the vessel.

Abstract: Titanium based and nickel based castings are made by casting a suitable melt having a relatively low melt superheat into a mold cavity defined by one or more low carbon steel or titanium mold members where the melt solidifies to form the desired casting. The melt super-heat is limited so as not to exceed about 150.degree. F. above the liquidus temperature of the particular melt being cast. For a steel mold, one or more titanium melt inlet-forming members are provided for cooperating with the steel mold members to form an melt ingate that communicates to the mold cavity for supplying the melt thereto in a manner to avoid harmful iron contamination of the melt during casting. The mold body-to-mold cavity volume ratio is controlled between 10:1 to 0.5:1 to minimize casting surface defects and mold wear/damage.

Abstract: Apparatus for inductively melting a quantity of metal without a container includes a first induction coil having a plurality of turns defining a volume for receiving a quantity of metal, the first induction coil being adapted to exert a force on the metal, a second induction coil having a plurality of turns at substantially right angles to the turns of the first induction coil, the second induction coil, being disposed within said volume coaxial with the first induction coil. Both the first and second induction coils have connectors thereon for connecting the coils to at least one power supply for energizing the first and second induction coils. A support is provided for supporting the metal from below, and has an opening through it. The support includes a raised segmented rim around substantially its entire periphery. The support is maintained at a preselected temperature. In an alternate embodiment, structure is also provided for imparting rotational motion to the support.

Abstract: A method for metallurgically bonding cast-in-place cylinder liners 12 to a cylinder block 38 includes first coating the outer surface of the liners 12 with a low melting point molten metal material 14 and allowing it to solidify. The coated liners 12 are then positioned within a cylinder block casting mold 22 and molten cylinder block metal introduced into the mold 22. At a time prior to the cylinder block metal contacting and surrounding the coated liners 12, induction heating coils 28 are activated to premelt the coating material 14. The molten cylinder block metal then contacts and mixes with the molten coating metal 14 to form a metallurgical bond between the liners 12 and cylinder block 38 upon solidification.

Abstract: Precision casting of titanium or titanium alloy includes establishing molten metal by induction heating in an assembly formed with water cooled copper segments disposed circlewise on the inside of an induction coil in a state insulated from each other and casting the molten metal into a permeable mold by vacuum casting. The precision casting method uses apparatus including an induction coil, an assembly formed with the aforementioned copper segments, an arrangement for feeding a base metal from the under side thereof and a permeable mold into which the molten base metal in the assembly is transferred by vacuum casting. It is possible to obtain precision castings of metal having high melting points and high actvitiy such as titanium, titanium alloy or the like.

Abstract: A permanent mold for mold-casting reactive metals and metal alloys (FIG. 1) includes a multiple of radially disposed, plate-like segments 3, 3', 3", . . . which enclose the workpiece 12 and are preferably made of cooled metallic material and which form together the permanent mold including a top inlet opening 14 and a bottom opening 15 for withdrawing the working piece; in order to close the withdrawal opening 15, a closing plate 9 is provided which is composed of a multiple of ring segments 13, 13', 13", . . . and the permanent mold 5 is enclosed by a magnetic coil 6 so as to generate an electromagnetic field.