Abstract: A hot dip coating system comprises a bath of molten coating metal contained in a vessel having a strip passage opening located below the top surface of the bath. A metal strip is directed along a path extending through the strip passage opening and through the bath of molten coating metal, to coat the strip. An electromagnet is employed to prevent the escape of the bulk of the molten coating metal from the bath through the strip passage opening while permitting the strip to move along its path. Expedients are provided to reduce leakage of molten coating metal through the strip passage opening.

Abstract: Two steel members are resistance welded using a filler therebetween in the form of either an insert or a metallized layer on the inner surface of one steel member. The steel members have respective compositions at least one of which comprises at least one alloying element having a concentration which contributes substantially to solidification cracking extensive enough to produce an unacceptable weld fracture. The filler has a composition which, during welding, melts and mixes with molten metal from the steel members, at the welding location, and dilutes the concentration there of one or more of the alloying elements which contribute substantially to solidification cracking. This reduces substantially the contribution, to solidification cracking, of each alloying element which has been so diluted. The cumulative dilution of these alloying elements is sufficient to produce an acceptable weld fracture.

Abstract: A hot dip coating system comprises a bath of molten coating metal contained in a vessel having a strip passage opening located below the top surface of the bath. A metal strip is directed along a path extending through the strip passage opening and through the bath of molten coating metal, to coat the strip. A plug composed of solidified coating metal surrounds the strip downstream of the strip passage opening and is substantially stationary relative to the moving strip. The plug prevents escape of molten coating metal from the bath through the strip passage opening while permitting the strip to move along its path. Expedients are provided to chill the coating metal downstream of the strip passage opening to form and maintain the plug and to heat that part of the molten metal coating bath which is immediately downstream of the plug.

Abstract: An improved strengthening or reinforcing member, and in particular an automotive vehicle door reinforcing beam, constructed from ultra high strength steel is disclosed. The door reinforcing beam has a substantially trapezoidal shaped cross-sectional geometry and optionally can include an additional reinforcement extending over a central portion of the beam. In an alternative embodiment, a rounded outboard flange portion can be substituted for a generally flat outboard flange portion. The door reinforcing beam exhibits a substantial improvement in load carrying capability for a given mass, as compared to door reinforcing beams having other cross-sectional geometries, such as hat-shaped cross-sectional geometries.

Abstract: A method for producing strip cast, austenitic stainless steel strip comprises providing a strip cast strip having an initial microstructure including a detrimental amount of delta ferrite and a detrimental amount of dendritic structure is provided. The strip may have a composition comprising the following ingredients: 0.4 wt. % max. carbon, 5-38 wt. % nickel, and 15-28 wt. % chromium. The strip is subjected to a cold rolling step prior to any annealing step. Upon subsequent annealing, (a) the amount of delta ferrite in the strip is reduced to substantially below the detrimental amount of delta ferrite that was in the strip prior to cold rolling and (b) the amount of dendritic structure in the strip is reduced to below the detrimental amount of dendritic structure that was in the strip prior to cold rolling. By employing the method of the present invention, an austenitic stainless steel strip having a high quality surface is produced.

Abstract: A solid lubricant application procedure is combined in-line with a steel strip processing method which comprises processing steps upstream and downstream of the lubricant application procedure. The latter comprises applying the lubricant material in molten form or as a solution and may include temperature adjusting steps both upstream and downstream of the lubricant material-applying step. The space for incorporating the lubricant application procedure into the steel strip processing line is limited. The strip speed in the lubricant application procedure is synchronized with the strip speed normally attained in the steel strip processing method in the absence of an in-line lubricant application procedure. The steps of the lubricant application procedure are constrained to accommodate the space limits and strip speed synchronization requirement imposed on the lubricant application procedure when it is combined in-line with the steel strip processing method.

Abstract: A hot dip coating apparatus and method for coating a continuous steel strip, wire, or like continuous member with zinc, aluminum, tin, lead, or alloys of each. A molten coating bath is contained in a vessel having a bottom opening upwardly through which the steel member is directed. Magnetic containment devices located below the vessel's bottom opening prevent the escape of molten metal from the vessel through the opening. There are no guide rolls, or other rolls that act on the continuous steel member, in the bath.

Abstract: An electromagnetic dam is employed to confine a vertically disposed pool of molten metal at the open end of the space between two counter-rotating, casting rolls in a continuous strip caster. The dam comprises three magnetic flux conductors each having a pair of spaced-part surfaces adjacent to and facing in the direction of the pool of molten metal. Two such surfaces of a first flux conductor define a relatively wide air gap adjacent the top part of the molten metal pool; two such surfaces of a second flux conductor define a relatively narrow air gap adjacent the bottom part of the pool, at the nip between the casting rolls; and two pool-facing surfaces of a third magnetic flux conductor are disposed between the spaced-apart surfaces of the first flux conductor in the wide air gap.

Abstract: A solid lubricant application procedure is combined in-line with a steel strip processing method which comprises processing steps upstream and downstream of the lubricant application procedure. The latter comprises applying the lubricant material in molten form or as a solution and may include temperature adjusting steps both upstream and downstream of the lubricant material-applying step. The space for incorporating the lubricant application procedure into the steel strip processing line is limited. The strip speed in the lubricant application procedure is synchronized with the strip speed normally attained in the steel strip processing method in the absence of an in-line lubricant application procedure. The steps of the lubricant application procedure are constrained to accommodate the space limits and strip speed synchronization requirement imposed on the lubricant application procedure when it is combined in-line with the steel strip processing method.

Abstract: A solid lubricant application procedure is combined in-line with a steel strip processing method which comprises processing steps upstream and downstream of the lubricant application procedure. The latter comprises applying the lubricant material in molten form or as a solution and may include temperature adjusting steps both upstream and downstream of the lubricant material-applying step. The space for incorporating the lubricant application procedure into the steel strip processing line is limited. The strip speed in the lubricant application procedure is synchronized with the strip speed normally attained in the steel strip processing method in the absence of an in-line lubricant application procedure. The steps of the lubricant application procedure are constrained to accommodate the space limits and strip speed synchronization requirement imposed on the lubricant application procedure when it is combined in-line with the steel strip processing method.

Abstract: An automobile body panel has an outer contour-defining component and an inner structural component. The inner structural component comprises a front member, a rear member, a plurality of side members, a central region defined by the front, rear, and side members, and at least one internal member disposed in the central region, and may also include at least one cross member disposed in the central region. The side members and each internal member have a substantially closed cross-sectional geometry. The outer component is secured to the inner structural component at the periphery of the panel. In addition, the outer component is substantially continuously adhesively bonded to each internal member, to flanges of the front and rear members, to each cross member and to the upper surface of each side member. The resulting panel is light-weight, has a high degree of rigidity, is capable of absorbing crash energy in frontal impact, and is resistant to puckering and oil canning.

Abstract: A strip casting apparatus comprises a pair of counter-rotating casting rolls having a vertically extending, arcuately tapering gap therebetween for containing a pool of molten metal. The gap has an open end near which is an electromagnetic dam for preventing the escape of molten metal through that open end. Various expedients are provided for improving the operation and efficiency of the dam. In one embodiment, projections of magnetic material extend from the dam in mutually overlapping relation with peripheral lips on the casting rolls. In another embodiment, the dam has a confining coil with a front surface (a) facing the open end of the gap and (b) having an arcuately tapering contour conforming to the contour of the gap.

Abstract: A method of processing steel strip such that the steel strip can be temper rolled at the increased speeds and better surface texture control of prior art dry lubricants, yet the steel strip can be temper rolled with less frequent replacement of temper mill working rolls. Further, the resulting steel strip has increased stretchability and can be temper rolled to achieve sufficient reduction of YPE at lower working roll pressures and/or lower strip tension, previously only effective when the steel strip was lubricated with a wet lubricant film. Enhanced corrosion resistance is another advantage of this process.

Abstract: A billet of steel has a composition comprising small amounts of hardenability agents. The billet is hot rolled into a continuous bar, in two hot rolling stages with an intervening cooling step employing a turbulent cooling liquid. After the second hot rolling stage, the bar is gathered into a succession of closely overlaying loops and moved along a roller conveyor where the overlapping loops are cooled by air blowers, after which the bar is coiled. The resulting hot rolled bar has a microstincture consisting essentially of bainite in fine-sized packets reflecting an average austenitic grain size, before the gathering and cooling steps, of 8-11 ASTM. A threaded fastener in its final form can be produced from the hot rolled bar by a cold deforming operation without a heat treating operation before or after cold deforming. The threaded fastener is undistorted and contains residual compressive stresses.

Abstract: A method for degassing molten steel comprises the use of a lift gas which includes carbon dioxide. The inventive method includes providing a reaction zone isolated from the ambient atmosphere, and providing a bath of molten steel, at least a portion of which is located in the reaction zone. The pressure is reduced in the reaction zone to a sub-atmospheric pressure. A gas comprising carbon dioxide is supplied to the bath of molten steel in order to vertically circulate the molten steel. The method also preferably includes (a) supplying carbon dioxide, e.g., with a tuyere, to the reaction zone and (b) supplying carbon dioxide to the bath of molten steel, e.g., by gas bubbling or stirring. An apparatus for performing the method steps is also disclosed.

Abstract: A method for degassing molten steel comprises the use of a lift gas which includes carbon dioxide. The inventive method includes providing a reaction zone isolated from the ambient atmosphere, and providing a bath of molten steel, at least a portion of which is located in the reaction zone. The pressure is reduced in the reaction zone to a sub-atmospheric pressure. A gas comprising carbon dioxide is supplied to the bath of molten steel in order to vertically circulate the molten steel. The method also preferably includes (a) supplying carbon dioxide, e.g., with a tuyere, to the reaction zone and (b) supplying carbon dioxide to the bath of molten steel, e.g., by gas bubbling or stirring. An apparatus for performing the method steps is also disclosed.

Abstract: An electromagnetic confining apparatus prevents the escape of molten metal through the open end of a vertically extending gap between two horizontally extending members, such as two counter-rotating rolls of a continuous strip caster. The molten metal is located between the two members. The apparatus includes a vertically disposed coil through which flows a time-varying electric current to generate a first horizontal magnetic field adjacent the open end of the gap. A time-varying conduction current is directed through the pool of molten metal adjacent the open end of the gap, in a vertical direction opposite that of the current flow in the adjacent portion of the coil. The flow of conduction current through the molten metal pool generates a second horizontal magnetic field adjacent the open end of the gap and which augments the first horizontal magnetic field to provide a repulsive body pressure which urges the pool of molten metal inwardly away from the open end of the gap.

Abstract: A magnetic confining method and apparatus in accordance with the present invention generates, adjacent the open side of the roller gap, a primary vertical magnetic field (a) resulting from direct current (D.C.) or alternating current (A.C.) flowing through a coil surrounding a core of a primary electromagnet or (b) resulting from an induced horizontal current flowing through roller shafts, roller sleeves and the edge of the molten metal. There are one or more additional vertical magnetic fields, that serve to concentrate and/or shape the primary magnetic field, and the vertical fields combine to provide electromagnetic forces sufficient for containment of the molten metal in the vertical gap between the rollers. Both the primary vertical field and one or more additional or secondary vertical magnetic fields extend through the open side of the gap to the molten metal in the gap.

Abstract: A non-magnetic material having a relatively high electrical resistance, such as austenitic stainless steel, is used for the material of construction of the mold utilized in a conventional continuous casting apparatus, or in a rheocasting apparatus or in a continuous strip casting apparatus.

Abstract: A strip casting apparatus comprises a pair of counter-rotating casting rolls having a vertically extending, arcuately tapering gap therebetween for containing a pool of molten metal. The gap has an open end near which is an electromagnetic dam for preventing the escape of molten metal through that open end. Various expedients are provided for improving the operation and efficiency of the dam. In one embodiment, projections of magnetic material extend from the dam in mutually overlapping relation with peripheral lips on the casting rolls. In another embodiment, the dam has a confining coil with a front surface (a) facing the open end of the gap and (b) having an arcuately tapering contour conforming to the contour of the gap.