Abstract: Methods and apparatus for producing composite-coated rigid flat-rolled sheet metal substrate in which thermoplastic polymeric materials are selected and combined for dual-layer molten-film extrusion presenting a first-contacting tie-layer and an externally-located finish-layer which are simultaneously extruded for a single substrate surface at-a-time; in which tie-layer selection includes an ethylene-glycol modified PET, requiring a substrate-surface temperature between 230° F. and 300° F.

Abstract: A heat treatment or heat soak furnace for use in both galvannealing and galvanizing processes including a heating apparatus configured to supply heat and remove heat. The heating apparatus may draw hot air from the exhaust of a direct fire strip annealing furnace, gas burners or electric heat exchangers as necessary. The furnace also may include a plurality of cooling mechanisms in order to ensure heat is removed and the temperature within the furnace regulated. In addition, the furnace may include baffles configured to allow portions of the interior of the furnace to be separated into different temperature zones.

Abstract: Processes and apparatus for manufacturing an engineered-composite combining rigid flat-rolled sheet metal continuous-strip and selected polypropylene thermoplastics, which are formulated into dual polymeric coating layers for extrusion deposition, as distinct layers, on a single surface at a time, of continuous-strip, traveling in-line at ambient temperature. Steps for forming a uniform thickness of polymeric layers across strip width, and attraction to an activated metallic surface which provides enhanced adhesion. Solidification of the polymeric layers is augmented by strip temperature during continuous-in-line travel; final dual-surface finishing provides for complete bonding of the polymeric layers on both metallic surfaces.

Abstract: Method steps and apparatus combinations for continuous in-line polymeric coating of rigid corrosion-protected flat-rolled sheet metal continuous-strip substrate utilizing a thermoplastic polymeric material having adhesive characteristics, capable of molten thin-film extrusion for chemical-bonding with an activated-surface of the flat-rolled sheet metal substrate, and substantially-simultaneously bonding with a solid-film polymeric material, establishing a work-product embodiment with multiple-polymer-layers traveling with the single activated surface; and, on which the solid polymeric film is selected to provide strength, hardness and other desired surface mechanical properties which also provide for external surface coloration, design, weather-proofing, and fabricating capabilities. A second embodiment provides dual-surface multiple-polymeric layer coating carried on by activating and polymeric coating one surface, at a time, of rigid corrosion-protected flat-rolled sheet metal continuous strip substrate.

Abstract: A method of coating of steel products such as plate and sheet using an aluminum-zinc coating alloy includes modifying the coating bath with a particulate compound constituent in effective amounts to control the spangle facet size of the coated product, improve tension bend rust stain performance, and improve coated product paintability. Constituents include borides such as titanium boride and aluminum borides, carbides such as titanium carbide, and aluminides such as titanium aluminide. The method produces a coated steel product that does not require temper rolling for painting.

Abstract: A method for measuring and displaying the flatness of a rolled steel sheet is disclosed that includes the steps of measuring tension in the sheet at a plurality of locations on the surface of the sheet and determining a plurality of tension ranges into which the sensed tension level can fall. A color is associated with each of the tension ranges, and a representation of the sheet is produced that is made up of a plurality of regions, each region having a color corresponding to tension range into which the tension sensed at the corresponding location on the surface of the sheet falls. A device for carrying out this method is also disclosed.

Abstract: A process is provided for making a composite work article suitable for fabricating rigid sheet metal can components. A steel sheet having first and second surfaces is pre-treated to enhance reception and retention of a multi-layer polymer coating on the pre-treated first surface. The multi-layer polymer coating is melt extruded on the pre-treated first surface and beyond opposite lateral edges of the work article to establish overhang portions, then solidified. The multi-layer polymeric coating has a tie polymeric layer contacting the pre-treated first surface, and a finish-surface polymeric layer.

Abstract: The present invention is directed to a method of refining spangle facet size in a hot-dip coated product by applying grain-refining particles to the surface of a steel substrate before immersion into the hot-dip coating bath, to an intermediate coated steel sheet, and to a finish coated steel sheet having a different coating spangle facet size on opposite surfaces.

Abstract: Engineered composite coated flat-rolled steel strip is produced in continuous line operations, in which flat-rolled steel strip, free of surface iron oxide, having a metallic corrosion-protective coating, is polymer coated in continuous-line operations in which a plurality of adherent thin-film layers of polymeric material are deposited on a strip surface. In a dual-surface polymeric coating embodiment, each surface is separately-pretreated for surface adhesion, solidified, and polymeric overhang is removed. Finish processing re-melts the polymer coating and rapidly cools that coating through glass-transition temperature to establish amorphous characteristics in the polymeric coating materials. An anhydride-modified polypropylene, first contacts the strip, an intermediate layer can include about fifteen to twenty five percent, by weight, polybutylene with the balance polypropylene; an outer surface polymeric layer includes about five to ten percent, by weight, polybutylene with the balance polypropylene.

Abstract: A method of coating of steel products such as plate and sheet using an aluminum-zinc coating alloy includes modifying the coating bath with a particulate compound constituent in effective amounts to control the spangle facet size of the coated product, improve tension bend rust stain performance, and improve coated product paintability. Constituents include borides such as titanium boride and aluminum borides, carbides such as titanium carbide, andaluminides such as titanium aluminide. The method produces a coated steel product does not require temper rolling for painting.

Abstract: The present invention provides a water treatment apparatus and method for reducing toxicity in zinc containing acid stormwater runoff, the apparatus comprising a first filter layer of high calcium material a last filter layer comprising a drainpipe arrangement embedded within an aggregate; and at least one intermediate filter layer comprising a wood mulch material positioned between the first filter layer and said last filter layer.

Abstract: A method for measuring and displaying the flatness of a rolled steel sheet is disclosed that includes the steps of measuring tension in the sheet at a plurality of locations on the surface of the sheet and determining a plurality of tension ranges into which the sensed tension level can fall. A color is associated with each of the tension ranges, and a representation of the sheet is produced that is made up of a plurality of regions, each region having a color corresponding to tension range into which the tension sensed at the corresponding location on the surface of the sheet falls. A device for carrying out this method is also disclosed.

Abstract: The present invention provides an improved submerged entry nozzle (SEN) for use in a continuous casting machine. The SEN includes a connection end adapted to attach to a slide gate mechanism, a discharge end including a bifurcated port, a tapered bore extending between the connection end and the discharge end, and a flow control structure positioned within the discharge end. The flow control structure includes divergent flow control surfaces extending downward along opposite sides of a contiguous edge, each downwardly extending divergent flow control surface flaring in an outward direction toward a respective perimeter defining an outside edge of the bifurcated port and communicating therewith.

Abstract: A high strength dual phase cold rolled steel having controlled amounts of carbon, manganese, and molybdenum is used as a starting material in a hot-dip zinc coating process to manufacture a high strength dual phase cold rolled steel having a conventional galvanized or galvannealed coating applied to at least one surface thereof, the zinc coated steel product having a uniform coating of zinc in spite of the high manganese content of the steel.

Abstract: A system for monitoring coal flow through a coal delivery tube in a blast furnace fuel injection system is disclosed, which system automatically actuates a purge cycle for clearing accumulations of coal from a coal lance when a temperature drop indicative of an imminent blockage is detected. A method of controlling the purge system is also disclosed.

Abstract: The present invention is directed a method for adjusting the height of a lance with respect to a bath surface of any selected heat manufactured in a metallurgical vessel during a continuing series of heats.

Abstract: A structural section for use in frame construction where the section includes a horizontal segment and a pair of spaced apart legs. Each leg has a first end portion attached to the horizontal segment, a second end portion opposite the horizontal segment, and a flange that extends inward from the second end portion toward the centerline of the structural section. Each leg further includes a longitudinal surface located between the first end portion and the second end portion. The longitudinal surface is positioned inboard of the flange so that the distance between opposed flanges that extend along each leg of the structural section is greater than the distance between opposed longitudinal surfaces that extend along each leg of the structural section.

Abstract: A high strength dual phase cold rolled steel having controlled amounts of carbon, manganese, and molybdenum is used as a starting material in a hot-dip zinc coating process to manufacture a high strength dual phase cold rolled steel having a conventional galvanized or galvannealed coating applied to at least one surface thereof, the zinc coated steel product having a uniform coating of zinc in spite of the high manganese content of the steel.

Abstract: A method of coating of steel products such as plate and sheet using an aluminum-zinc coating alloy includes modifying the coating bath with a particulate compound constituent in effective amounts to control the spangle facet size of the coated product, improve tension bend rust stain performance, and improve coated product paintability. Constituents include borides such as titanium boride and aluminum borides, carbides such as titanium carbide, and aluminides such as titanium aluminide. The method produces a coated steel product that does not require temper rolling for painting.

Abstract: The invention is directed to a dynamic control system that maintains an inert gas feed at a constant target gas flow rate sufficient to prevent or reduce alumina or alloy plugging within a slide gate discharge opening. The dynamic control system includes a gas feed line extending between an inert gas supply and the slide gate discharge passageway, a gas flow regulator, a pressure gauge; and a gas feed flow control that detects an amount of incoming inert gas lost through leaks in the system and adjusts the gas flow regulator in response to the detected amount of incoming gas flow loss so that the adjusted incoming gas feed continues to deliver the target inert gas flow rate to the discharge passageway.