Abstract: Disclosed is an improved system for annealing strand of the type comprising at least two sheaves across which the strand passes and becomes electrically annealed, the improvement comprising a first flange member, a second flange member concentric with the first flange member and adjacent thereto, and an annealing band positioned between the first and second flange members and forming the bottom of a sheave groove, further provided that the annealing band is adapted to center strand being annealed to prevent contact between the strand and either of the flange members thereby providing a renewable, strand centering annealer sheave adapted for long life.

Abstract: Disclosed is a method and apparatus for continuously lubricating cable during continuous dry curing of cable insulation to reduce friction between the cable insulation and the dry curing apparatus, thereby eliminating cable oscillation and vibration to increase product quality and the speed of production.

Abstract: A method of continuously casting a molten metal in a casting means to obtain a solidified cast bar at a hot-forming temperature, passing the cast metal at a hot-forming temperature from the casting means to a hot-forming means, and hot forming the cast bar into a wrought product by a two-stage reduction of its cross-sectional area while it is still at a hot-forming temperature, including, in the first stage, the step of forming a shell of finely distributed recrystallized grains in the surface layers of the cast bar by compressive forging affecting at least the surface layer of the cross section of the bar in its as-cast condition prior to the second stage in which substantial reduction of its cross-sectional area by rolling deformation forms the desired wrought product.

Abstract: A hydrometallurgical process is provided for separative treatment of zinc-bearing metallurgical flue dust containing significant amounts of lead, chlorine, and iron. The process is especially suited for extraction of zinc sulfate from blast furnace white dust resulting in the smelting of secondary copper. According to the process, the flue dust is leached in sulfuric acid solution for substantially complete dissolution of soluble constituents, notably zinc, leaving insoluble residue consisting principally of lead oxide. At completion of leaching, pH is selectively adjusted corresponding to the desired extent of subsequent chloride removal. Second, the loaded leach solution is treated for chloride removal wherein chloride ion concentration is substantially and selectively reduced by precipitation of cuprous chloride, cuprous ions being provided by pH regulated reduction of cupric ions.

Abstract: An improvement in wheel-band type continuous metal casting machines wherein a stationary corner filling device is used in combination with the usual moving mold members, such as the wheel and band, to modify the mold geometry so as to prevent corner cracking of the cast bar due to the uneven solidification stresses present in conventionally molded shapes having sharp or square edges, especially useful in modifying the usual trapezoidal cross sections of prior art molds for the casting of steel alloys.

Abstract: An improved apparatus for collecting, storing, transporting and dumping cropped (cut) sections of continuously cast bar. The present invention is embodied in a dumpable crop bar container generally comprising a yoke and rear stanchion assembly surrounding and pivotally attached to a receptacle and front stanchion assembly by an axle and sleeve assembly. A conventional forklift is used to transport the present invention and to discharge collected crop bar from it. The forklift pushes the front stanchions against a stationary curb, forcing them to pivot inward and upward on the axle which cause the receptacle rigidly affixed thereto to pivot upward and outward. The base of the receptacle pivots to almost vertical and all of the crop bar is dumped out. As the fork lift backs away from the stationary curb, the weight of the receptacle and front stanchion assembly returns it to its original position.

Abstract: Disclosed is an apparatus for guiding various sizes of elongated objects such as wire, cable or rod through a predetermined path in such a manner that the longitudinal axis of said elongated object conforms to the longitudinal axis of said predetermined path, said apparatus being quickly adjustable by automatic and manual means.

Abstract: Disclosed herein is a method and an apparatus for improving the efficiency of conventional vertical shaft metal melting and refining furnaces by novel refractory arrangements to form a multiple level hearth which will support pieces of metal that have reached the hearth without being melted. With this invention there is even and complete distribution and diffusion of heat around and through these unmelted pieces of metal to effect their rapid melting. Thus unmelted pieces of metal cannot block burners or clog tapping outlets of vertical shaft furnaces, and undue restriction to the flow of molten metal in and from these furnaces is substantially avoided.

Abstract: Disclosed is apparatus for treating the components of a gaseous fuel mixture, to obtain a predetermined mass ratio of the gaseous components, for use in a metallurgical melting furnace. Two streams of gaseous fuel components are temperature equalized in a heat exchanger, pressure equalized by pressure balancing regulators, and mixed together by a mixing valve which controls only the volume flow rates of the two streams. The resulting gaseous fuel mixture has a predetermined oxygen to fuel mass ratio, which is easily maintained near stoichiometric composition and which when combusted, supplies a hot gaseous blast of predetermined composition. When air and a liquified fuel such as liquid propane are the fuel components, the liquified fuel is vaporized and optionally diluted with dry air prior to heat equalizing, pressure equalizing, and mixing. When a gaseous fuel such as natural gas is one of the fuel components, no vaporization or dilution is required.

Abstract: This disclosure relates to a method and apparatus for manufacturing an aluminum alloy electrical conductor which promote the formation of a wire having a fine, stable subgrain structure of small cell size in the aluminum matrix and a fine dispersion of stable, insoluble intermetallic phase particles. The subgrain structure is improved by closely controlling the thermomechanical processing, particularly the casting rate, deformation parameters and annealing characteristics. After casting, the cast product is substantially immediately hot-formed in a rolling mill wherein the first deformation is more than 30% such that a substantially well defined subgrain structure will be formed in the aluminum matrix, thereby maximizing a refinement of the subgrain structure by permitting breaking-up thereof in each of the subsequent deformations in the rolling mill. After cold-working, without preliminary or intermediate anneals, the product is finally annealed at a temperature not exceeding approximately 700.degree. F.

Abstract: Improved aluminum alloy electrical conductors and method for making same are disclosed. The alloy contains from about 0.55 to about 0.65 weight percent nickel, the remainder aluminum with associated trace elements including no more than 0.15 weight percent iron, no more than 0.001 weight percent magnesium and no more than 0.05 weight percent copper.

Abstract: An improvement in wheel-band type continuous metal casting machines wherein a corner filling device or material is used in combination with the mold members such as the wheel and band to modify the mold geometry so as to prevent corner cracking due to the solidification stresses present in conventional mold shapes having sharp or square edges, especially useful in modifying the usual trapezoidal cross sections of prior art molds. Ablative, conductive, or insulating materials, selected in accordance with the desired change in solidification pattern, may be introduced into the mold either separate from, or attached to the moving mold members such as the endless band or the casting wheel.

Abstract: Disclosed is a method of treating the components of a gaseous fuel mixture to obtain a predetermined mass ratio of the gaseous components for use in metallurgical melting furnace. Two streams of gaseous fuel components are temperature equalized in a heat exchanger, pressure equalized by pressure balancing regulators, and mixed together by a mixing valve which controls only the volume flow rates of the two streams. The resulting gaseous fuel mixture has a predetermined oxygen to fuel mass ratio, which is easily maintained near stoichiometric composition and which when combusted, supplies a hot gaseous blast of predetermined composition. When air and a liquified fuel such as liquid propane are the fuel components, the liquified fuel is vaporized prior to heat equalizing, pressure equalizing, and mixing. When a gaseous fuel such as natural gas is one of the fuel components, no vaporization or dilution is required.

Abstract: A rotary casting machine with an improved translatable band comprising a rigid frame with a rotary casting wheel having a peripheral groove mounted on the frame, the band and the wheel being relatively moveable to move "damaged" surface areas of the band out of contact with the wheel and present "new" surface areas for molding purposes. An endless band frictionally engages a portion of the wheel, the band having a width greater than the width of the casting wheel. Guide rollers on the frame orient the band properly on the frame and into cooperation with the groove of the casting wheel so as to form a mold. A power source drives the casting wheel and the frictionally engaged endless band. A spout is provided for the addition of molten metal to the groove and band mold. A pusher is provided to adjustably translate the band laterally across the peripheral groove of the casting wheel.

Abstract: A method of and apparatus for hot-rolling non-ferrous metal bar in a plural stage rolling mill are disclosed. Each stage of the rolling mill is provided with a plurality of work rolls which have a predetermined hardness and toughness depending on their intended use in the rolling mill to improve the uniformity of the useful life of the rolls among the various stages of the mill. A method of heat treating the work rolls and an improved forged steel work roll are also disclosed. The steel used to make the rolls is a forged chromium-molybdenum alloy steel having a chromium content in the range of 4.0 to 6.0 percent. The heat treatment process provides the working surfaces of the rolls with a dense, tightly-adhering oxide layer to protect the rolls from the high temperatures and pressures encountered during the hot-rolling operation.

Abstract: An aluminum alloy electrical conductor having an electrical conductivity of at least fifty-seven percent (57%) based on the International Annealed Copper Standard and unexpected properties of increased bendability, creep resistance, fatigue resistance and thermal stability at a minimum standard elongation, when compared to conventional aluminum alloy conductors of the same tensile strength is described. The aluminum alloy conductors are produced by the addition of from about 0.10 weight percent to about 1.00 weight percent copper and up to about 0.10 weight percent iron to an alloy mass containing from about 98.70 weight percent to about 99.90 weight percent aluminum, and trace quantities of conventional impurities normally found within a commercial aluminum alloy.

Abstract: This disclosure relates to a method and apparatus for manufacturing zinc coated steel tubing from zinc coated steel strip. The zinc lost by volatilization during welding of the seam is replaced in a two-stage metallizing process. In the first stage an aluminum alloy is spray atomized onto the tubing. The alloy contains from 0.45 to 0.95 weight percent iron, no more than 0.10 weight percent silicon, and the remainder aluminum with associated trace elements. Thereafter, in the second stage, zinc is spray atomized over the aluminum alloy-coated substrate.

Abstract: A system for continuously quench-pickling cast rod from a continuous casting machine wherein molten metal is poured into a mold of a casting device and cooled and solidified into a continuous solid bar, the bar is elongated and reduced in its cross-sectional area to form continuous rod, and the rod is arranged in a coil. The surface of the hot rod from the rolling mill is contacted with a pickling fluid, such as a citric acid solution, after the rod leaves the rolling mill and before the rod is arranged in a coil, to simultaneously quench and pickle the rod.

Abstract: An improved method of continuously manufacturing a hot-formed, heat treatable aluminum base alloy product comprising casting a molten aluminum base alloy metal, cooling a cast metal during casting at a rate at which solidification shrinkage will not occur, hot-forming cast metal to form a rod at a temperature above the temperature level at which the alloy metals will precipitate to the grain boundaries of the aluminum base metal, heating the rod to a solutionizing temperature after hot forming and subsequently reducing the metal temperature from the solutionizing temperature of the metal to a temperature at which no substantial immediate precipitation occurs within a time interval before which any substantial precipitation occurs.

Abstract: An aluminum alloy wire having an electrical conductivity of at least sixty-one percent (61%) based on the International Annealed Copper Standard and unexpected properties of increased ultimate elongation, bendability and fatigue resistance when compared to conventional aluminum alloy wire of the same tensile strength. The aluminum alloy wire contains substantially evenly distributed iron aluminate inclusions in a concentration produced by the addition of more than about 0.30 weight percent iron to an alloy mass containing less than about 99.70 weight percent aluminum, no more than 0.15 weight percent silicon, and trace quantities of conventional impurities normally found within a commercial aluminum alloy. The substantially evenly distributed iron aluminate inclusions are obtained by continuously casting an alloy consisting essentially of less than about 99.70 weight percent aluminum, more than 0.30 weight percent iron, no more than 0.