Abstract: One embodiment provides a method of melting, comprising: providing a mixture of alloy elements that are at least partially crystalline; and heating the mixture in a container to a temperature above a melting temperature of the alloy elements to form an alloy, wherein the container comprises silica, and wherein the mixture comprising Zr and is free of Ti and Be.

Abstract: Disclosed herein is a bulk metallic glasses (BMG) comprising 0.0001 wt % to 0.7 wt % of Be, 0.0001 wt % to 0.2 wt % of Be, or 0.06 wt % to 0.08 wt % of Be. Be may have the effect of reducing a liquidus temperature of the BMG relative to melting temperatures of individual alloying elements of the BMG.

Abstract: A method for reducing impurities in magnesium comprises: combining a zirconium-containing material with a molten low-impurity magnesium including no more than 1.0 weight percent of total impurities in a vessel to provide a mixture; holding the mixture in a molten state for a period of time sufficient to allow at least a portion of the zirconium-containing material to react with at least a portion of the impurities and form intermetallic compounds; and separating at least a portion of the molten magnesium in the mixture from at least a portion of the intermetallic compounds to provide a purified magnesium including greater than 1000 ppm zirconium. A purified magnesium including at least 1000 ppm zirconium and methods for producing zirconium metal using magnesium reductant also are disclosed.

Abstract: Crucible compositions and methods of using the crucible compositions to melt titanium and titanium alloys. More specifically, crucible compositions having intrinsic facecoats that are effective for melting titanium and titanium alloys for use in casting titanium-containing articles. Further embodiments are titanium-containing articles made from the titanium and titanium alloys melted in the crucible compositions. Another embodiment is a crucible curing device and methods of use thereof.

Abstract: The present invention provides a method for the Industrial production of a titanium salt TP, said method comprising the steps of: i. Precipitation of titanic acid from a solution comprising titanium salt TP1; ii. Production of a titanium containing product TP2 from a medium comprising of said titanic acid and an acid; and iii. Thermal conversion of titanium containing product TP3 to a titanium salt TP at temperature higher than 170° C.

Abstract: A compound represented by General Formula (1) below, where R denotes a C1-C10 hydrocarbon group, Z denotes any one of a sulfide group, a sulfinyl group and a sulfonyl group, and n denotes an integer of 4 to 8 is described. A method for extracting metals and a metal recovery method using a metal extractant comprising the compound represented by General Formula (1) are also described.

Abstract: Provided herein are materials that can achieve up to 14% hydrogen absorption by weight in ambient conditions, which is a marked improvement over the hydrogen absorption values found in the prior art. Further provided are experimental conditions necessary to produce these materials. In order to produce the hydrogen storage material, a transition metal (or Lithium) is vaporized in a pi bond gas in conditions that permit only a few bonding collisions to occur between the vaporized transition metal atoms and pi bond gas molecules before the resulting bonded material is collected.

Abstract: Disclosed is a deoxidation apparatus for preparing low-oxygen titanium powders. The deoxidation apparatus includes a lower container having an open upper portion and storing an deoxidizer representing an oxygen degree higher than an oxygen degree of titanium and a melting temperature lower than a melting temperature of titanium, and an upper container coupled with the lower container on the lower container and storing titanium base powders. The upper container is provided at a lower surface thereof with a sieve, and allows the deoxidizer, which is evaporated due to heating, to make contact with the titanium base powders so that the titanium base powders are deoxidized.

Abstract: Process for melting scrap metal in a furnace comprising the steps of feeding a charge of solid scrap metal to the furnace, supplying fuel and an oxygen-rich oxidant to the furnace and combusting the fuel with the oxidant to generate heat inside the furnace, melting the charge of solid scrap metal in the furnace by means of the heat, withdrawing the molten metal from the furnace. Following the step of feeding the charge of solid scrap metal to the furnace, the fuel is combusted with the oxidant so as to generate one or more visible flames in the furnace above the charge and before the step of withdrawing the molten metal from the furnace, the fuel is combusted with the oxidant so as to generate flameless combustion in the furnace above the molten metal.

Abstract: A process for recovering metal from a process material comprising the metal and a component that is more volatile than the metal, which process comprises: transporting the process material in a retort provided in a furnace, the retort being operated under vacuum and at a temperature sufficient to cause sublimation of the component from the process material thereby producing purified metal; depositing the component that has been sublimed on a cool surface; removing purified metal from the retort; and removing deposited component from the cool surface.

Abstract: One embodiment provides a method of melting, comprising: providing a mixture of alloy elements that are at least partially crystalline; and heating the mixture in a container to a temperature above a melting temperature of the alloy elements to form an alloy, wherein the container comprises silica, and wherein the mixture comprising Zr and is free of Ti and Be.

Abstract: The invention provides a method for preparing sponge titanium from sodium fluotitanate by aluminothermic reduction, comprising the following steps: a reaction step: aluminum and zinc are mixed under a vacuum state, and sodium fluotitanate is then added into the mixture for reaction; a separation step: the product resulting from the complete reaction stands still and is then introduced with inert gas, and NaF and AlF3 in upper-layer liquid phase are extracted; and a distillation step: Zn in the remaining product Zn—Ti is distilled out under a vacuum state, wherein the mass ratio of the aluminum to the zinc is 1:2 to 1:10.

Abstract: The present invention provides a preparation method of a metal matrix composite. The method comprises the following steps of: 1) pulverizing a solid carbon material to a micrometer size; 2) plastic deforming a metal matrix powder and dispersing the pulverized nanometer-sized carbon material into the metal matrix powder during the plastic deformation; 3) integrating the metal/carbon nano-material composite powder obtained in step 2) by using a hot forming process; and 4) heat treating the integrated bulk material at a predetermined temperature to form a composite having a metal-carbon nanophase, a metal-carbon nanoband formed by growth of the metal-carbon nanophase, or a metal-carbon nano-network structure formed by self-coupling of the metal-carbon nanoband.

Abstract: A simple, compact burner achieves a more optimal melting of a solid charge followed by performance of combustion under distributed combustion conditions. The burner achieves this by fluidically bending the flame towards the solid charge during a melting phase with an actuating jet of oxidant, redirecting the flame in a direction away from the charge, and staging injection of oxidant among primary and secondary portions during a distributed combustion phase.

Abstract: A process for producing titanium metal sponge from an exothermic reaction between titanium tetrachloride vapor and molten magnesium vapor, and reclaiming reactive metals from by-products of the exothermic reaction.

Abstract: The present invention provides a method for the Industrial production of a titanium salt TP, said method comprising the steps of: i. Precipitation of titanic acid from a solution comprising titanium salt TP1; ii. Production of a titanium containing product TP2 from a medium comprising of said titanic acid and an acid; and iii. Thermal conversion of titanium containing product TP3 to a titanium salt TP at temperature higher than 17O° C.

Abstract: Provided herein are materials that can achieve up to 14% hydrogen absorption by weight in ambient conditions, which is a marked improvement over the hydrogen absorption values found in the prior art. Further provided are experimental conditions necessary to produce these materials. In order to produce the hydrogen storage material, a transition metal (or Lithium) is vaporized in a pi bond gas in conditions that permit only a few bonding collisions to occur between the vaporized transition metal atoms and pi bond gas molecules before the resulting bonded material is collected.

Abstract: A process for producing Ti, comprising a reduction step of reacting TiCl4 with Ca in a CaCl2-containing molten salt having the Ca dissolved therein to thereby form Ti particles, a separation step of separating the Ti particles formed in said molten salt from said molten salt and an electrolysis step of electrolyzing the molten salt so as to increase the Ca concentration, wherein the molten salt increased in Ca concentration in the electrolysis step is introduced into a regulating cell to thereby render the Ca concentration of the molten salt constant and thereafter the molten salt is used for the reduction of TiCl4 in the reduction step. In the present invention, the Ca concentration of the molten salt to be fed to the corresponding reduction vessel can be inhibited from fluctuating and, at the same time, can maintain high concentration levels. Further, a large volume of the molten salt can be treated continuously.

Abstract: A method of manufacturing high purity hafnium is provided and includes the steps of making aqueous solution of chloride of hafnium, thereafter removing zirconium therefrom via solvent extraction, performing neutralization treatment to obtain hafnium oxide, further performing chlorination to obtain hafnium chloride, obtaining hafnium sponge via reducing said hafnium chloride, and performing electron beam melting to the hafnium sponge in order to obtain a hafnium ingot, as well as a high purity hafnium material obtained thereby and a target and thin film formed from such material. The present invention relates to a high purity hafnium material with reduced zirconium content contained in the hafnium, a target and thin film formed from such material, and the manufacturing method thereof, and provides efficient and stable manufacturing technology, a high purity hafnium material obtained according to such manufacturing technology, and a target and high purity hafnium thin film formed from such material.

Abstract: A method and apparatus for optimized mixing in a common hearth in a plasma furnace. The apparatus provides a main hearth, a plurality of optional refining hearths, and a plurality of casting molds or direct molds whereby the refining hearths and molds define at least two separate ingot making lines. A feed chute provides raw material to the main hearth, whereby the feed chute is moveable to optimize its position during operation of the main hearth. Most particularly, the feed chute is moveable to provide better mixing, minimize skull build-up, and optimally place it opposite the overflow in use.

Abstract: An improved process for successful and homogeneous incorporation of ruthenium and iridium into titanium and titanium alloy melts, ingots, and castings via traditional melting processes (e.g., VAR and cold-hearth) has been developed. This result is achieved through the use of low-melting point Ti-Ru or Ti-Ir binary master alloys within the general composition range of ≦45 wt. % Ru and with a preferred composition of Ti-(15-40 wt. % Ru), or within the general composition range of ≦61 wt. % Ir and with a preferred composition of TI-(20-58 wt. % Ir). Primary features are its lower melting point than pure titanium, lower density than pure Ru and Ir metals, and the ability to be readily processed into granular or powder forms.

Abstract: A high power density alkaline electrochemical capacitor cell includes a pair of titanium nitride powder electrodes fabricated by subjecting titanium hydride powder to a controlled flow of ammonia vapor. A porous separating membrane for containing an electrolyte is attached to a first surface of the pair of powder electrodes. A conductive termination is attached to the second side of each of the powder electrodes. The electrodes have a high surface area and are electrochemically stable in strong alkaline electrolyte. The capacitor cell can be hermetically sealed and is capable of long-term cyclical operation over a wide range of operating temperatures (−55° C. to +100° C.) while providing high-density energy storage.

Abstract: A titanium dioxide compound was isolated from a rare type of naturally occurring ore. Processes for efficiently isolating and obtaining these TiO2 compounds, as well as methods for using them have been developed. These TiO2 compounds may be used directly in applications such as paper, plastics and paints without being subjected to the chloride or sulfate processes. Also they made be used as a feedstock for the chloride or sulfate processes. In order to obtain these TiO2 compounds, one may grind or pulverize the naturally occurring ore, disperse it in a solution or suspension, and process it by selective flocculation or aqueous biphasic extraction.

Abstract: A process is provided for the production of titania rich slag from ilmenite. The ilmenite is fed together with carbonaceous reductant, and in the absence of fluxes, to the molten bath of a DC arc furnace. The molten bath of the furnace forms the anode and one or more electrodes in the roof of the furnace forms the cathode. A frozen lining is established and maintained between the refractory lining of the furnace and the molten bath and the process includes means to control the thickness of the frozen lining as well as the whole smelting process.

Abstract: A method of magnetically-controllable, electroslag melting of titanium and titanium-based alloys is provided that includes the effect of an external radial magnetic field on the metallurgical melt. The field forms at least two adjoining melting layers which are rotated horizontally in opposite directions, and causes intralayer and meridional toroidal rotation of the melt. The uniform hydrodynamic structure of the melt over the total length of the ingot is stabilized by changing the melting voltage. The external radial magnetic field and the use of a fluoride-chloride flux improves the refinement of metal (by reducing harmful inclusions), condenses the metal structure, and provides high chemical and physical homogeneity of the metal ingot.

Abstract: A plasma cold hearth melting process which provides an ingot of improved properties and including a plasma cold hearth melting furnace operated inside an air-tight chamber containing an inert gas, such as helium, at subatmospheric pressure levels. Raw material metals for a desired titanium or titanium alloy composition are supplied to a melting hearth located inside the chamber and heated by a plasma torch which utilizes an inert gas. The plasma torch melts the raw material metal thereby forming a molten pool of metal that is directed to at least one refining hearth. Plasma torches located in the refining hearths maintain the composition in a molten state as it passes through the cold hearth furnace to allow impurities present in the composition to be refined therefrom. After passing through the refining hearths, the molten pool of metal is poured into an ingot mold while still under subatmospheric inert gas pressure. The molten material is then allowed to cool and solidify into an ingot.

Abstract: Method and apparatus for melting reactive metallic materials, such as for example titanium base alloys and other reactive alloys, by selective and sequential induction heating of a plurality of solid alloy charge components segregated in a refractory melting vessel in a manner to effect rapid top-to-bottom melting that avoids harmful reaction of the melt with refractory melting vessel material and contamination of the melt.

Abstract: An improved high-modulus, low-cost, castable, weldable titanium alloy and a process for making such an alloy is provided. In general, titanium is alloyed with about 0.75 weight percent iron and about 8 weight percent aluminum to result in an alloy with a modulus of over 21.times.10.sup.6 psi. This modulus is above the modulus for conventional castable titanium alloys, such as the commercially-available castable titanium alloy containing 6 weight percent aluminum and 4 weight percent vanadium.Applications for this alloy include golf club heads, which can be fabricated by casting a golf club head body from the above alloy and welding a sole plate onto the cast golf club head body. This provides a golf club head with superior energy transfer characteristics for hitting a golf ball.

Abstract: The charge well of a metal melting furnace is provided with an internal cavity having a circular cross section when viewed from the top, preferably a cavity of cylindrical or conical configuration, and with a peripheral exit port located tangentially with respect to said cavity at a lower level thereof for exit of molten metal into the main chamber of the furnace. An inert gas bubble-actuated molten metal pump brings molten metal from a hotter section of the furnace, advantageously directly from the main chamber, and has its exit port located tangentially to the periphery of the cavity at an upper level thereof, thereby creating vortical flow of molten metal within the charge well for the more rapid and efficient melting of metal chips and scraps into the molten metal therein and for circulation of hotter molten metal throughout the furnace.

Abstract: Purification of tantalum by plasma arc melting. The level of oxygen and carbon impurities in tantalum was reduced by plasma arc melting the tantalum using a flowing plasma gas generated from a gas mixture of helium and hydrogen. The flowing plasma gases of the present invention were found to be superior to other known flowing plasma gases used for this purpose.

Abstract: A method for the recovery of valuable materials from titanium grinding swarf is provided comprising the steps of sieving the accumulated titanium grinding swarf to remove unwanted coarse trash and grinding wheel fragments, pelletizing, and smelting in an electric arc furnace to produce ferrotitanium and/or high titanium slag.

Abstract: A process for facilitating the removal of impurities e.g. radionuclides, such as uranium and thorium, and/or one or more of their radionuclide daughters, from titaniferous material includes contacting the titaniferous material with one or more reagents at an elevated temperature selected to enhance the accessibility of at least one of the radionuclide daughters in the titaniferous material. The reagent(s) may be a glass forming reagent and is selected to form a phase at the elevated temperature which disperses onto the surfaces of the titaniferous material and incorporates the radionuclides and one or more radionuclide daughter. The titaniferous material may be, e.g., ilmenite, reduced ilmenite, altered ilmenite or synthetic rutile.

Abstract: A method for the recovery of valuable materials from titanium grinding swarf is provided comprising the steps of sieving the accumulated titanium grinding swarf to remove unwanted coarse trash and grinding wheel fragments, pelletizing, and smelting in an electric arc furnace to produce ferrotitanium and/or high titanium slag.

Abstract: The present invention provides a method for producing high-purity titanium from titanium sponge obtained by the Kroll process in which a core of the cylindrical lump of titanium sponge obtained with a weight less than 20-30% of that of the cylindrical lump is separated by cutting off from the lump a bottom portion, a top portion and a peripheral portion, and the core is cut by a press into grains of specific size, which are melted into ingot or refined by reaction with iodine. The high-purity titanium thus produced contains less than 300 ppm of oxygen and less than 10 ppm each of iron, nickel, chromium, aluminum and silicon, the balance being titanium and inevitable impurities; or less than 200 ppm of oxygen and less than 1 ppm each of iron, nickel, chromium, aluminum and silicon, the balance being titanium and inevitable impurities. Thus the invention provides titanium materials of very high purity suitable for thin film deposition as wiring of LSIs from titanium sponge obtained by the Kroll process.

Abstract: A process for facilitating the removal of impurities e.g. radionuclides, such as uranium and thorium, and/or one or more of their radionuclide daughters, from titaniferous material includes contacting the titaniferous material with one or more reagents at an elevated temperature selected to enhance the accessibility of at least one of the radionuclide daughters in the titaniferous material. The reagent(s) may be a glass forming reagent and is selected to form a phase at the elevated temperature which disperses onto the surfaces of the titaniferous material and incorporates the radionuclides and one or more radionuclide daughters. The titaniferous material may be, e.g., ilmenite, reduced ilmenite, altered ilmenite or synthetic rutile.

Abstract: A process for the preparation of lead-zirconium-titanium (PZT) film and powder compositions. The process comprises the steps of providing an electrodeposition bath, providing soluble salts of lead, zirconium and titanium metals to this bath, electrically energizing the bath to thereby direct ions of each respective metal to a substrate electrode and cause formation of metallic particles as a recoverable film of PZT powder on the electrode, and also recovering the resultant film as a powder. Recovery of the PZT powder can be accomplished by continually energizing the bath to thereby cause powder initially deposited on the substrate-electrode to drop therefrom into the bath from which it is subsequently removed. A second recovery alternative comprises energizing the bath for a period of time sufficient to cause PZT powder deposition on the substrate-electrode only, from which it is subsequently recovered.

Abstract: A sputtering target for forming a thin film consisting of high-purity titanium, in which the content of alkali metal is 0.1 ppm or less, the content of radio active elements is 1 ppb or less, and the oxygen content is 100 ppm or less, and, further, the balance of the elements is Ti, is produced by a fused salt electrolysis, in which the members of the electrolytic cell being in contact with the fused salt consist of Ni.

Abstract: The thermal neutron capture cross-section of zirconium may be altered by altering its natural isotope distribution through a steady state chromatographic separation of these isotopes using an anion exchange resin as the stationary phase of the chromatographic column. Zirconium is dissolved in a very strong acid which causes the formation of a zirconium anion, such as the ZrOCl.sub.4.sup.-2 anion formed in six normal hydrochloric acid, and eluted off the column with a weaker acid. Distinct elution volumes representative of each isotope are collected. In a preferred embodiment, the process also separates the zirconium from hafnium and the other impurities normally present in the product obtained by chlorinating zircon sand and utilizes a continuous annular chromatograph.

Abstract: A process is disclosed for recovering high purity refractory product metal such as titanium, hafnium, zirconium, vanadium, niobium or their alloys from the regulus of a reduction reaction mixture of a by-product metal halide, excess reducing metal and product metal, which process includes feeding crushed regulus material into a furnace, heating the regulus at temperatures to melt then remove by vaporizing the metal halide and excess reducing metal, and melting the product metal before recovering it from the furnance pool obviating the steps of vacuum distillation or leaching in the recovering step.

Abstract: A simple, low cost continuous process for separating and purifying zirconium and hafnium which eliminates liquid waste and facilitates the management of RCRA and LLW wastes is provided. An aqueous zirconium and hafnium--containing feed solution is prepared and fed to a continuously rotating annular chromatograph containing a bed of acid exchange resin. An acid eluant, such as hydrochloric acid, nitric acid, phosphoric acid or the like, is fed through the acid exchange bed while chromatograph is rotating, which separates the feed into substantially pure zirconium and hafnium fractions and into RCRA and LLW waste fractions. The zirconium and hafnium are processed further into nuclear quality zirconium and hafnium metals. The acid eluant is recycled for reuse in the chromatograph, and the RCRA and LLW waste fractions are disposed of in solid form.

Abstract: The isotopes of zirconium can be partially or completely separated by loading an aqueous solution of an ionic compound of zirconium onto a cationic exchange resin with pentavalent phosphorus derived active groups which serves as the stationary phase of a chromatograph, eluting the compound with an aqueous acid and collecting distinct elution volumes representative of each isotope. In a preferred embodiment, the eluant is a strong mineral acid, such as hydrochloric acid and the chromatograph is of a type, such as a continuous annular chromatograph, that it can be operated in a continuous, steady state manner.

Abstract: The isotopes of zirconium can be partially or completely separated by loading an aqueous solution of an ionic compound of zirconium onto a cationic exchange resin which serves as the stationary phase of a chromatograph, eluting the compound with an aqueous acid and collecting distinct elution volumes representative of each isotope. In a preferred embodiment, the eluant is a strong mineral acid, such as hydrochloric acid and the chromatograph is of a type, such as a continuous annular chromatograph that it can be operated in a continuous, steady state manner.

Abstract: A process for hardening sponge refractory metal and making it more susceptible to crushing by the addition of oxygen and/or nitrogen gas to either the reduction stage of the production of the metal from a tetrachloride thereof with magnesium, or to the treatment of a regulus of such metal following vacuum distillation thereof.

Abstract: A vacuum distillation furnace and method for removing unreacted magnesium metal and magnesium chloride from a sponge refractory metal, such as zirconium, utilizes a vertically arranged series of mutually isolated distillation vessels in respective furnace sections for continuous or semi-continuous vacuum distillation of the sponge metal following formation thereof by usual reduction procedures.

Abstract: A continuous method is provided for purifying and recovering transition metals such as neodymium and zirconium that become reactive at temperatures above about 500.degree. C. that comprises the steps of contacting the metal ore with an appropriate fluorinating agent such as an alkaline earth metal fluosilicate to form a fluometallic compound, and reducing the fluometallic compound with a suitable alkaline earth or alkali metal compound under molten conditions, such as provided in an induction slag metal furnace. The method of the invention is advantageous in that it is simpler and less expensive than methods used previously to recover pure metals, and it may be employed with a wide range of transition metals that were reactive with enclosures used in the prior art methods and were hard to obtain in uncontaminated form.

Abstract: A sponge refractory metal product, especially a zirconium metal sponge, that retains a residual quantity of magnesium chloride following subjection to an initial, conventional, distillation cycle is reprocessed by the addition of virgin magnesium in amount normally within the range of about 20% to about 60% of the weight of such sponge metal product and by passing it through re-distillation, including the steps of melting the added virgin magnesium and the sponge metal to open the otherwise closed pores thereof, lowering furnace temperature to solidify the molten magnesium, raising the temperature to vaporize and remove from the furnace the magnesium metal, and again raising the temperature to vaporize and remove from the furnace the initially entrapped magnesium chloride. Thereafter, it is preferable that the temperature be again raised to sinter together any loose particles of the sponge metal. It is believed that a eutectic of the sponge metal is formed during the process.

Abstract: Continuous process for preparing titanium comprising fluorinating titanium ore, and reducing the formed alkaline earth fluotitanate with an alkaline earth metal in an induction slag reactor.

Abstract: The bottom of a solid metal charge melts to fill a form below the charge. During melting, usually, the metal that enters the form remains continuous with an unused solid part of the charge. After cooling, the formed metal is removed together with the unused part of the charge--and usually with the form too. They are separated later or in a different operation, and another charge is positioned immediately for melting into another form, so the useful duty cycle is very high. A preferred form of the invention uses an upper melting chamber and a lower forming chamber, separated by a horizontal wall but communicating by an aperture through the wall. The charge and form are placed against the wall from below to block the aperture. The charge preferably extends up through the aperture into or toward the melting chamber, where an arc electrode or other heater melts the top of the charge, particularly near its center.