Abstract: In a continuous molten metal casting apparatus of the wheel-band type, wherein an elongated endless metal band partially closes a groove inscribed about the periphery of the rotatable casting wheel, an apparatus to apply and maintain a fixed, determinable tension to the elongated, endless band. The tension apparatus of the present invention permits the use of greatly elongated casting bands, maintaining a tension thereon, even during electrical power or air pressure supply failure, to thus provide improved band life. The tension wheel is rotatably mounted upon a carriage which slides on a pair of bellows-enclosed shafts, the carriage riding on a plurality of ball bushings. A dual-action air cylinder, attached at one end to the carriage and the other to the tension mechanism frame, operatively tensions the band through the wheel and carriage assembly.

Abstract: Improved metallic rod product which substantially reduces die wear in wire drawing operations, and which provides other advantages during manufacturing. The exterior surface of the rod product is intentionally provided with a predetermined rough texture having certain characteristics, rather than the smooth bright surface conventionally imparted to metallic rod product intended for subsequent drawing into wire. Certain textured surface characteristics of the rod product reduce wear on the first few wire drawing dies by entraining lubricant as the rod moves through the dies, and carry the entrained lubricant into the dies, while at the same time avoiding some common wire drawing defects such as flakes and slivers. The textured-surface rod thus reduces frictional wear of the drawing dies, so that less force is required to draw the rod product through the dies and the useful life of the drawing dies is increased.

Abstract: An improved premix gas burner design suitable for use in a metal melting furnace which has long service life, a low degree of maintenance, is easily cleared in case of burner blockage, allows inspection of the combustion chamber or furnace interior and still maintains the desired turndown capabilities of premix gas burners. These results are achieved by providing usual and/or physical access to the interior of the burner through a novel access tunnel and by providing a dual composition refractory combustion chamber.

Abstract: An improved permix gas burner design suitable for use in a metal melting furnace which has a long service life, a low degree of maintenance, is easily cleared in case of burner blockage, allows inspection of the combustion chamber or furnace interior and still maintains the desired turndown capabilities of premix gas burners. These results are achieved by providing visual and/or physical access to the interior of the burner through a novel access tunnel and by providing a dual composition refractory combustion chamber.

Abstract: This invention relates to a method for continuously casting an aluminum-copper and an aluminum-copper-iron alloy having an acceptable electrical conductivity and improved elongation, bendability and tensile strength wherein the method generally comprises the steps of pouring molten aluminum alloy into the groove of a continuous casting mold, cooling the molten aluminum in the casting groove, hot forming the cast bar to form a rod and continuously coiling the rod at a temperature of from about 250.degree. F. to 700.degree. F.

Abstract: A vertical shaft furnace for continuously melting metal materials, such as scrap, copper cathode pieces and the like is disclosed. The furnace comprises an elongated cylindrical melting chamber having an opening in the upper portion thereof for intermittently gravity-charging the furnace with metal pieces, which form a descending metal column in the melting chamber. A plurality of plasma arc generators is mounted in the sidewalls of the melting chamber extending inwardly thereof in a downwardly inclined attitude. The plasma arc torches are arranged in upper and lower vertically spaced planes for respectively preheating and melting the metal charged to the furnace. Protective refractory shrouds are provided which extend inwardly from the inside wall of the melting chamber and at least partly surround the plasma arc torches to substantially prevent damage to the torches by the descending or dropped metal charge.

Abstract: A process for recovering solid scrap thermosetting plastic compounds such as crosslinkable polyethylene compound and the like, by immediately hot-granulating the fresh thermosetting scrap before it has time to fully cure and then reducing the granules to a fine powder. The powdered scrap compound may be reused directly or blended with virgin material, and recompounded into granules for reuse in molding or extrusion processes.

Abstract: An improved cooling method and apparatus for a continuous casting process of the type wherein the mold is a rotatable casting wheel having a peripheral groove with a portion enclosed by an endless band. The improved cooling of the hot cast metal bar is accomplished by injecting a cooling fluid, under pressure, into the shrinkage gap between the hot continuously cast bar and the band portion of the mold after the bar is partially solidified but before it is removed from the wheel portion of the mold.

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: Hot-formed rod is prepared in a rolling mill by removing oxide from the surface of a nascent cast bar while the bar is in a non-oxidizing environment. Oxide is removed from the surface of the bar by means such as wire brushing, for example, with the oxide removing means and the nascent bar being enclosed in a non-oxidizing or reducing environment to improve the removal of existing oxide and to inhibit formation of new oxide on the bar while the bar travels from the oxide-removing means to the rolling mill to be hot-formed. Removal of oxide while the bar is in a non-oxidizing environment enhances the removal of oxide and lessens the unwanted removal of metal underlying the surface oxide.

Abstract: A pouring pot for pouring molten metal into a casting mold of a continuous casting apparatus comprises upper and lower pot sections with the upper pot section having a volume sufficiently larger than the effective volume of the lower pot section so as to maintain the molten metal pressure depth and therefore the pressure head substantially constant despite fluctuations in the total amount of molten metal in the pouring pot to thereby effect discharging of the molten metal at a substantially constant flow rate. The upper pot section has a volume at least 20% greater and preferably 20%-40% greater than the effective volume of the lower pot section. The overall volume of the pouring pot is similar to that of conventional low volume pots now in use so that conventional supporting equipment can be used to support the pouring pot.

Abstract: Apparatus for continuously casting molten metal wherein an endless band is used to form a mold by enclosing a portion of the peripheral groove of the casting wheel of a wheel-band type casting machine. The endless band is guided about the periphery of the casting wheel by a plurality of band support wheels, at least two of which are provided with adjustable band positioning apparatus for maintaining the endless band in proper alignment over the casting wheel during casting. Each band support wheel is rotatably mounted on a shaft and is axially adjustable relative to its respective shaft for positioning the endless band laterally of the casting wheel. Each shaft is also adjustably pivotable about a point intermediate the shaft ends for skewing the band support wheel rotational axis relative to the casting wheel axis to steer the endless band into a substantially centered position over the casting wheel groove.

Abstract: The invention is an improvement in the method for recovering aluminum values from alunite ore by roasting the ore to remove water, reducing the ore by roasting it in a reducing atmosphere to remove sulfate, optionally roasting the reduced ore in an oxidizing atmosphere to convert any sulfides formed in the second roast to oxides, leaching the calcined ore with water as a solvent to remove compounds of sulfur and alkali metals, recovering aluminum values as soluble aluminates from the residue from the leaching step by digesting it with at least one alkali metal hydroxide, removing contaminate silica from the resulting leach solution, and precipitating aluminum hydroxide from the solution, the improvement being the use of a two stage reduction of the dehydrated alunite ore, in which the ore is reduced by sulfur in the first stage, followed by a second stage reduction with another reducing agent such as hydrogen.

Abstract: This disclosure relates to a combined wheel spreader and crack closer adapted to maintain the predetermined draft angle of the casting groove of an open casting wheel while simultaneously working the interior surface thereof to close cracks and smooth out flaws therein during a casting operation. The wheel spreader includes rollers adapted to bear in rolling contact against the interior side walls of the casting groove, and the crack closer includes a roller adapted to bear in rolling contact against the bottom surface of the casting groove.

Abstract: Improved metallic rod product which substantially reduces die wear in wire drawing operations, and which provides other advantages during manufacturing. The exterior surface of the rod product is intentionally provided with a predetermined rough texture having certain characteristics, rather than the smooth bright surface conventionally imparted to metallic rod product intended for subsequent drawing into wire. Certain textured surface characteristics of the rod product reduce wear on the first few wire drawing dies by entraining lubricant as the rod moves through the dies, and carry the entrained lubricant into the dies, while at the same time avoiding some common wire drawing defects such as flakes and slivers. The textured-surface rod thus reduces frictional wear of the drawing dies, so that less force is required to draw the rod product through the dies and the useful life of the drawing dies is increased.

Abstract: A device for continuously stripping the insulation off of electrical wires, particularly solid conductors as opposed to stranded conductors, for the re-cycling thereof in the manufacturing process, including an initial cutting section and a subsequent stripping or insulation removal section. The cutting section utilizes two opposed, interdigitated sets of dual rotary "cutters," each having two juxtaposed cutting edges or blades, only one of which however is used to cut at any one time. One "cutter" is used to form a "V" section to laterally hold the wire in position, while the other opposed cutter has one of its blades located centrally within the "V" section of the other holding "cutter" (note FIG. 4).

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: Metallic tubing is manufactured from galvanized steel strip by forming the strip into tubular shape, welding the edges together and replacing the zinc lost in welding by atomization metallizing the weld zone first with an aluminum alloy containing from more than about 0.30 to about 0.95 weight percent iron and then with zinc.

Abstract: An improvement in the process for the recovery of aluminum from alunite in which potassium hydroxide is recovered from byproduct potassium sulfate by electrodialysis, further improvement being the use of sodium hydroxide from the bleed stream from the Bayer leach for use in the electrodialysis process for recovering potassium hydroxide from potassium sulfate.

Abstract: A method of and apparatus for the immersion treatment of discrete lengths of galvanized conduit to inhibit the formation of "white rust" on the conduit surfaces are disclosed. The conduit is continually conveyed successively through three treatment zones comprising a cleaning bath containing a cleaning agent which removes lubricating oils, greases, dirt and the like from the conduit interior and exterior surfaces, a rinse bath and a coating bath containing a coating agent including chromate ions and a polymeric coating composition. A rotary star wheel-type conveyor is arranged in each treatment zone for transporting the conduits in spaced, substantially parallel relation to each other about an arcuate path through each bath and for inclining the conduit above the bath for a time effective to drain excess liquid from the interior and exterior conduit surfaces. Effective draining of excess liquid prior to entry to another zone minimizes contamination of the various baths and yields a high quality product.