Abstract: Novel and advantageous metal laminates particularly useful in making coins comprising a copper core and a cladding metallurgically bonded thereto of a copper base alloy containing from 2 to 3.5% aluminum, from 1 to 2.5% silicon and the balance essentially copper. Disclosure also teaches a method of preparing copper laminates by providing a copper core in strip form in the hard temper and a copper alloy cladding fully annealed in strip form, wherein the components are rolled together in a single pass with a reduction of from 50 to 75% to provide the metallurgically bonded laminate.

Abstract: A rapid and effective surface cleaning process for copper alloys, particularly copper alloys containing aluminum and other metals tending to form surface coatings of refractory oxides during annealing treatments, consists of treating such alloys or articles fabricated thereof for a short time in a hot aqueous solution of an alkali hydroxide, rinsing with water, and then immersing for a short time in a hot aqueous solution of ferric sulfate, or other ferric salt of a mineral acid, followed by rinsing with water.

Abstract: An apparatus and process is provided for electromagnetically casting molten material into a desired shape. A containment zone is established. The containment zone has a first section for electromagnetically containing the molten material and a second section downstream and communicating with the first section for forming the molten material into the desired shape. The improvement comprises a heat extraction device for directing a cooling medium into the containment zone whereby the cooling medium passes the molten material in the second section to rapidly solidify the molten material prior to passing the molten material in the first section to lower the temperature in the contained molten material to minimize superheating. A second embodiment of the invention includes a secondary cooling device associated with the heat extraction device for directing a cooling medium against the solidified material.

Abstract: A process for recrystallization of thin strip material includes a device for electromagnetically melting the thin strip material to provide a molten surface layer and a substantially solid core. Apparatus provides relative movement between the thin strip and the device for electromagnetically melting. Also, an apparatus resolidifies the molten surface layer to provide a preferred crystal structure in the thin strip material.

Abstract: A process and apparatus for casting a material into a desired thin strip shape. Molten material is formed into the thin strip shape by an electromagnetic containing and forming process. In a first portion the molten material is shaped into the desired thin strip shape and in a second portion upstream of and communicating with the first portion the molten material is electromagnetically contained in a sump. The sump at a top surface thereof has a substantially larger cross-sectional area as compared to a cross-sectional area of the thin strip shape.

Abstract: A rolling mill apparatus and process comprise a plurality of rolls defining a plurality of roll bites defining a gap spacing between adjacent rolls. A fixed gap spacing is employed for at least one roll bite. A floating gap spacing is provided for at least one other roll bite. It is thereby possible to control in a desired manner the amount of thickness reduction at a desired roll bite in a pass through the mill.

Abstract: Novel and advantageous metal laminates particularly useful in making coins comprising a copper core and a cladding metallurgically bonded thereto of a copper base alloy containing from 2 to 3.5% aluminum, from 1 to 2.5% silicon and the balance essentially copper. Disclosure also teaches a method of preparing copper laminates by providing a copper core in strip form in the hard temper and a copper alloy cladding fully annealed in strip form, wherein the components are rolled together in a single pass with a reduction of from 50 to 75% to provide the metallurgically bonded laminate.

Abstract: A process and apparatus for producing a copper metal or alloy wherein a first material is added to a molten metal, consisting essentially of copper preferably in a furnace. After the first material is added, the molten metal is passed through a filtration device to remove particulate matter from the molten metal and/or reduce the oxygen content of the molten metal. After filtration, a second material is added to the molten metal.

Abstract: A disposable bed filter for removing particulate matter and/or reducing oxygen in a poured metal melt is located within a trough. The bed filter preferably comprises discrete layers of bed media located in a trough between entry and exit baffle plates. The layers of bed media include a layer of coarse media and a layer of fine media. The trough is preferably provided with a closeable lid to permit removal of the bed media and to compensate for buoyancy of the bed media if present. In its preferred use, the bed filter forms part of a process for making a metal alloy wherein the bed filter simultaneously reduces the oxygen content of the melt and filters particulate matter from the melt.

Abstract: A process and apparatus for reforming an improved strip (12) of material from a starting strip (16) of material. An electromagnetic device (18) maintains a floating molten zone (20) of the material in the starting strip (16) of the material and also forms the floating zone into the improved strip (12). The apparatus is provided with a susceptor device (80) arranged adjacent to the starting strip and operatively associated with the electromagnetic device (18) for initially heating the starting strip to be sufficiently conductive so that the starting strip can be directly heated by the electromagnetic device. Further, a control device (67) provides relative movement between the susceptor device (80) and the electromagnetic device by positioning the susceptor device in and out of the field of the electromagnetic device.

Abstract: The system comprises a plurality of on-line cleaning tanks, through which continuous metal strip is passed, and a plurality of storage tanks, each containing a different cleaning solution. Different combinations of cleaning solutions are transferred to the on-line tanks from the storage tanks by selecting a particular combination or sequence of cleaning solutions in accordance with the type or composition of metal or metal alloy comprising the strip and automatically feeding the cleaning solutions to the on-line tanks in accordance with the sequence selected. The on-line tanks and storage tanks are interconnected by a network of conduits, pumps and valves which are automatically conditioned by a control element to operate in response to the selection of a particular cleaning sequence. Upon completion of a cleaning operation, each of the solutions is returned to its corresponding storage tank.

Abstract: A method and apparatus for electromagnetic casting of metal and alloy ingots of desired shape having portions of small radius of curvature. A modified shield is provided which provides for a reduction of the electromagnetic field intensity at the corners of the forming ingot by increasing local screening of the field at the corners. Increased local screening at the corners is achieved by locally increasing shield depth, by providing for deeper displacement of the shield, by changing the shield section, or by changing the shield orientation. Also disclosed is a modified inductor which is shaped so as to be located at a greater distance from the portions of small radius of curvature of the ingots than from portions of the ingots adjacent to the portions of small radius of curvature. The modified shield may be combined with the modified inductor and/or with a coolant manifold to simultaneously modify and control coolant application elevation such that the elevation is a minimum at the corners of the ingot.

Abstract: A method and apparatus are disclosed for steering and treating continuously running strip material. The strip material is directed by a steering assembly having a steering roll mounted to a yoke. The strip material is passed over a portion of the roll surface and is steered by pivoting the yoke so that the roll axis is caused to rotate or tilt in a plane transverse to the plane formed by the running strip material.

Abstract: An electromagnetic casting process and apparatus utilizing an active transformer-driven copper shield. The shield is actively driven with a voltage out of phase with the voltage in the containment inductor with the result that a bucking current is produced in the shield which is out of phase with the current induced in the shield by the inductor. An active transformer-driven duplex variable impedance shield is also disclosed.

Abstract: Copper or copper alloy sheet or foil displaying improved forming and working properties is prepared by the provision over its surface of a thin coating containing a copper salt of an organophosphonic acid, and subsequently, an outer film of lubricant strongly retained by the coating is applied. To form the coating, the sheet or foil is immersed for a short time in an aqueous solution containing a phosphonic acid, rinsed and dried, the treatment being combined with or preceded by oxidation of the sheet surface, and the lubricant film is applied prior to forming operations, preferably as the final step in the production of the cupreous sheet.

Abstract: The disclosure teaches a high strength, high conductivity copper base alloy and method for obtaining same. The composition consists essentially of defined amounts of magnesium, phosphorus and a transition element selected from the group consisting of iron, cobalt, nickel and mixtures thereof with the balance essentially copper.

Abstract: An apparatus for casting metals wherein the molten metal is contained and formed into a desired shape by the application of an electromagnetic field. A control system is utilized to minimize variations in the gap between the molten metal and an inductor which applies the magnetic field. The gap or an electrical parameter related thereto is sensed and used to control the current to the inductor.

Abstract: A continuous lubrication casting mold for use in a process of continuously casting molten metals and alloys wherein a parting and/or lubricating agent reservoir is provided in the mold body. The agent is continuously applied over the inner surface of the mold after being introduced through passages within or through the mold section. The lubricant passages may be an intrinsic characteristic of the mold material or may be provided in the form of feed holes through the mold section. The ability to transmit lubricant through to the internal surface of the mold can be varied within the length of the casting mold to provide for variable lubricant transfer rates to different parts of the casting surface.

Abstract: A process is disclosed for joining narrow width thin gage metal or alloy strip end to end to form an elongated coil. The trailing end of a first strip segment and the leading end of a second strip segment are cut so as to match when placed in a butting relationship and to establish a joint between the strips. A preselected gap is established between the butting ends and a braze material is inserted in the gap. After heating to braze the strip segments together, the brazed joint is hammered to reduce the joint geometry to that of the parent metal strip segments.