Abstract: Steam exhaust ports are located around a perimeter of a direct chill casting pit, at various locations from below the top of the pit to the pit bottom to rapidly remove steam from the casting pit with addition of dry excess air. Gas introduction ports are also located around a perimeter of the casting pit and configured to introduce an inert gas into the casting pit interior.

Abstract: An induction furnace comprising a upper furnace vessel; an induction coil positioned below the upper furnace vessel; and a melt-containing vessel positioned inside the induction coil and communicably connected to the upper furnace vessel, wherein the positioning of the melt-containing vessel inside the induction coil defines a gap between an outside surface of the melt-containing vessel and an inside surface of the induction coil. A system for direct-chill casting comprising at least one an induction furnace; at least one in-line filter operable to remove impurities in molten metal; at least one gas source coupled to a feed port associated with the gas; and at least one device for solidifying metal by casting. A method of cooling an induction furnace comprising introducing a gas into a gap between an induction coil and a melt-containing vessel positioned inside the induction coil; and circulating the gas through the gap.

Abstract: An apparatus and a system including a casting pit; a mold including a reservoir and a cavity; a coolant feed operable to introduce a coolant to a periphery of a metal emerging from the mold cavity; an array of water vapor exhaust ports about at least the top periphery of the casting pit; a mechanism to introduce an inert fluid into the coolant feed. A method for a direct chill casting including, after detecting a bleed out, exhausting generated gas from the casting pit at a flow volume rate that is enhanced relative to a flow volume rate prior to detecting bleed out or run out; introducing an inert gas into the casting pit; and introducing an inert fluid into a coolant feed to the casting mold.

Abstract: A process in direct chill casting wherein molten metal is introduced into a casting mold and cooled by impingement of a liquid coolant on solidifying metal in a casting pit including a movable platen and an occurrence of a bleed-out or run-out is detected the process including exhausting generated gas from the casting pit; and introducing an inert gas into the casting pit, the inert gas having a density less than a density of air; reducing any flow of the liquid coolant.

Abstract: An apparatus and a system including a casting pit; a mold including a reservoir and a cavity; a coolant feed operable to introduce a coolant to a periphery of a metal emerging from the mold cavity; an array of water vapor exhaust ports about at least the top periphery of the casting pit; a mechanism to introduce an inert fluid into the coolant feed. A method for a direct chill casting including, after detecting a bleed out, exhausting generated gas from the casting pit at a flow volume rate that is enhanced relative to a flow volume rate prior to detecting bleed out or run out; introducing an inert gas into the casting pit; and introducing an inert fluid into a coolant feed to the casting mold.

Abstract: An induction furnace comprising a upper furnace vessel; an induction coil positioned below the upper furnace vessel; and a melt-containing vessel positioned inside the induction coil and communicably connected to the upper furnace vessel, wherein the positioning of the melt-containing vessel inside the induction coil defines a gap between an outside surface of the melt-containing vessel and an inside surface of the induction coil. A system for direct-chill casting comprising at least one an induction furnace; at least one in-line filter operable to remove impurities in molten metal; at least one gas source coupled to a feed port associated with the gas; and at least one device for solidifying metal by casting. A method of cooling an induction furnace comprising introducing a gas into a gap between an induction coil and a melt-containing vessel positioned inside the induction coil; and circulating the gas through the gap.

Abstract: A process in direct chill casting wherein molten metal is introduced into a casting mold and cooled by impingement of a liquid coolant on solidifying metal in a casting pit including a movable platen and an occurrence of a bleed-out or run-out is detected the process including exhausting generated gas from the casting pit; and introducing an inert gas into the casting pit, the inert gas having a density less than a density of air; reducing any flow of the liquid coolant.

Abstract: Steam exhaust ports are located around a perimeter of a direct chill casting pit, at various locations from below the top of the pit to the pit bottom to rapidly remove steam from the casting pit with addition of dry excess air. Gas introduction ports are also located around a perimeter of the casting pit and configured to introduce an inert gas into the casting pit interior.

Abstract: A system comprising at least one furnace including a melt containing vessel; an intermediate casting product station coupled to the at least one furnace and operable to receive a molten metal from the at least one furnace, the intermediate casting product station including a casting pit, at least one moveable platen disposed in the casting pit, an array of exhaust ports about at least a top periphery of the casting pit, and an array of gas introduction ports about at least the top periphery of the casting pit; and an inert gas source operable to supply an inert gas to the array of gas introduction ports.

Abstract: An apparatus and a system including a casting pit; a mold including a reservoir and a cavity; a coolant feed operable to introduce a coolant to a periphery of a metal emerging from the mold cavity; an array of water vapor exhaust ports about at least the top periphery of the casting pit; a mechanism to introduce an inert fluid into the coolant feed. A method for a direct chill casting including, after detecting a bleed out, exhausting generated gas from the casting pit at a flow volume rate that is enhanced relative to a flow volume rate prior to detecting bleed out or run out; introducing an inert gas into the casting pit; and introducing an inert fluid into a coolant feed to the casting mold.

Abstract: An “in-line” device to continuously remove dissolved gasses from liquid metal is described. The device described herein may contain an apparatus to create a partial vacuum, one or more ultrasonic vibrators below the surface of the liquid metal to evolve gas bubbles within the metal, and a high-frequency vibrating metal plate which the fluid must pass over at a low depth. The device may be used to create high quality metals, including aluminum and aluminum alloy for a number of demanding applications such as pharmaceutical, semiconductor, foil, and aerospace applications including Aluminum-Lithium alloys.

Abstract: A system comprising at least one furnace including a melt containing vessel; an intermediate casting product station coupled to the at least one furnace and operable to receive a molten metal from the at least one furnace, the intermediate casting product station including a casting pit, at least one moveable platen disposed in the casting pit, an array of exhaust ports about at least a top periphery of the casting pit, and an array of gas introduction ports about at least the top periphery of the casting pit; and an inert gas source operable to supply an inert gas to the array of gas introduction ports.

Abstract: Steam exhaust ports are located around a perimeter of a direct chill casting pit, at various locations from below the top of the pit to the pit bottom to rapidly remove steam from the casting pit with addition of dry excess air. Gas introduction ports are also located around a perimeter of the casting pit and configured to introduce an inert gas into the casting pit interior.

Abstract: An “in-line” device to continuously remove dissolved gasses from liquid metal is described. The device described herein may contain an apparatus to create a partial vacuum, one or more ultrasonic vibrators below the surface of the liquid metal to evolve gas bubbles within the metal, and a high-frequency vibrating metal plate which the fluid must pass over at a low depth. The device may be used to create high quality metals, including aluminum and aluminum alloy for a number of demanding applications such as pharmaceutical, semiconductor, foil, and aerospace applications including Aluminum-Lithium alloys.

Abstract: Direct chill casting that allows for the continuous or serial introduction of an inert fluid into the coolant stream during casting while allowing for stoppage of the coolant flow and introduction of only inert fluid as the coolant in the event of a “bleed out” or “run out”.

Abstract: Steam exhaust ports are located around a perimeter of a direct chill casting pit, at various locations from below the top of the pit to the pit bottom to rapidly remove steam from the casting pit with addition of dry excess air. Gas introduction ports are also located around a perimeter of the casting pit and configured to introduce an inert gas into the casting pit interior.