Patents Assigned to Kaiser Aluminum & Chemical Corporation
  • Patent number: 6248189
    Abstract: An aluminum-based alloy useful for driveshaft assemblies and method of manufacturing an extruded tube of such alloy. The alloy includes, in weight %, 0.50 to 0.70% Si, up to 0.30% Fe, 0.20 to 0.40% Cu, up to 0.03% Mn, 0.80 to 1.10% Mg, up to 0.03% Cr, balance Al and impurities. In producing extruded tubing, the alloy is extruded, the extruded billet is water quenched, the quenched tube is drawn in a two-stage drawing operation and the drawn tube is given a precipitation hardening treatment.
    Type: Grant
    Filed: June 4, 1999
    Date of Patent: June 19, 2001
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventors: Thomas J. Shaffer, Joseph E. Diggs
  • Patent number: 6152354
    Abstract: Minor additions of calcium (Ca) to Al--(1% to 14%) Si filler metals result in larger fillets than conventional Al--Si alloys normally used in the NOCOLOK brazing process. This new filler metal can be clad to 2XXX, 3XXX, 6XXX, and 7XXX series alloys and brazed with a fluoride flux. The filler metal contains between 0.005% Ca to 0.3% Ca. The new filler metal could have up to 0.3% Mg and up to 0.3% Li. Additionally, the brazing process can optionally include an aqueous treatment with a fluoride salt to reduce the need for NOCOLOK fluxing.
    Type: Grant
    Filed: April 8, 1998
    Date of Patent: November 28, 2000
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: David L. Childree
  • Patent number: 6139653
    Abstract: Al--Mg--Sc based alloys include additional elements selected from the group comprising Hf, Mn, Zr, Cu and Zn to improve their tensile properties. The alloys are preferably comprised of aluminum and, in wt. %, 1.0-8.0% Mg, 0.05-0.6% Sc, 0.05-0.20% Hf and/or 0.05-0.20% Zr, and 0.5-2.0% Cu and/or 0.5-2.0% Zn. In addition, 0.1-0.8 wt. % Mn may be added to the alloy to improve its strength characteristics further.
    Type: Grant
    Filed: August 12, 1999
    Date of Patent: October 31, 2000
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventors: Micky T. Fernandes, Ralph C. Dorward
  • Patent number: 6132571
    Abstract: An aluminum reduction cell system includes a cell controller to monitor and control an associated aluminum reduction cell. The cell controller measures a cell voltage output from the cell and a bus current signal input to the cell, and computes impedance from the measured cell voltage and current. An anode effect predictor is incorporated into the cell controller to predict when the aluminum reduction cell is about to experience an anode effect. The anode effect predictor applies a higher-order statistical function to the cell impedance data to produce a spectrum representative of the cell's behavior. The statistical function is, for example, a third-order coherence function of the impedance data, which is one order higher than a second-order power spectrum. The coherence function captures correlation or interdependence between the samples that make up the power spectrum.
    Type: Grant
    Filed: April 30, 1998
    Date of Patent: October 17, 2000
    Assignee: Kaiser Aluminum and Chemical Corporation
    Inventor: David G. Bell
  • Patent number: 6102102
    Abstract: A metal strip is continuously cast between a pair of heat conductive endless belts which serve to form a molding zone to solidify molten metal. The endless belts remove heat from the molten metal and are cooled when the belts are not in contact with the molten metal, which minimizes belt distortion.
    Type: Grant
    Filed: February 13, 1997
    Date of Patent: August 15, 2000
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: Donald G. Harrington
  • Patent number: 6063215
    Abstract: A belt for use in the casting of metals and a method for its manufacture in which a metal belt is first subjected to heat treatment, quenching and tempering to improve its strength and decrease its stretchability. Then the belt is treated to introduce surface irregularities to promote uniformity of heat transfer and to allow collection of surface gases and then the belt is subjected to further thermal treatment under controlled conditions to form an oxide layer thereon to minimize adhesion between the belt and the metal deposited thereon.
    Type: Grant
    Filed: May 9, 1997
    Date of Patent: May 16, 2000
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: Donald G. Harrington
  • Patent number: 6059976
    Abstract: The present invention is a process for reclaiming and recycling oil/water mixtures. These mixtures are preferably hot or cold rolling oils for aluminum manufacturing operations. When used, the rolling oils contain organometallic particles and have less constituents than the unused oils. The present process enables the valuable portion of the oil to be reused by passing through an acid wash and a reconstitution process.
    Type: Grant
    Filed: June 22, 1998
    Date of Patent: May 9, 2000
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventors: Al J. Kovolick, Robert A. Dickinson, Michael A. Green
  • Patent number: 6004130
    Abstract: A device for sealing a passageway in a flue from a carbon anode baking furnace, the flue being generally rectangular in shape and comprising a flue top and bottom, a headwall on either end of the flue, two walls, an opening in the flue top, at least one baffle, and a plurality of spacers which are connected to both walls of the flue, the headwall, the two walls and the flue top define a headwall port which permits fluid passage between adjoining flues; the sealing device comprises; an inflatable bladder; a means to deliver air under pressure connected to the inflatable bladder by a seal to prevent air leakage between the means to deliver air under pressure and the inflatable bladder; the inflatable bladder is long enough to extend from the flue top to a headwall and seal off the communication between flues at the headwall port when inflated.
    Type: Grant
    Filed: June 15, 1998
    Date of Patent: December 21, 1999
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: Donald B. Gibson
  • Patent number: 6004409
    Abstract: The present invention is a process to use aluminum alloy scrap to manufacture high quality machinable tooling plate. This is an new use for this scrap which has heretofore been used in lower quality products. The tooling plate thus made has superior properties when machined as it produces smaller chips and/or a limited of spirals from the plate. Large chips and long spirals create problems and a smaller chip greatly facilitates the machining operation.
    Type: Grant
    Filed: January 22, 1998
    Date of Patent: December 21, 1999
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventors: Ralph C. Dorward, Greg F. Fitzpatrick
  • Patent number: 5971258
    Abstract: The present invention provides a method of joining aluminum parts by brazing, comprising the steps of (a) providing a composite sheet having an aluminum core alloy material and a filler alloy cladding, applied to the core alloy material, the cladding including about filler alloy for brazing, which includes about 4 to 18 wt. % silicon, about 0.001 to 0.4 wt. % magnesium, about 0.01 to 0.3 wt. % lithium, not more than about 2 wt. % zinc, not more than about 1.25 wt. % manganese, not more than about 0.30 wt. % iron, not more than about 0.10 wt. % copper, not more than 0.15 wt. % impurities, balance aluminum; (b) contacting an aluminum part with the filler alloy cladding; and (c) brazing the aluminum part and the composite sheet to produce a brazed assembly.
    Type: Grant
    Filed: November 3, 1995
    Date of Patent: October 26, 1999
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventors: Edgar G. Eichhorn, David L. Childree
  • Patent number: 5972230
    Abstract: Fines, that are present in lubricating oil, and their organo-metallic coatings are contacted with aqueous solutions of strong acids to solve the problems of plugged cartridge type filters. The present process employs a washing step whereby, following a filter cycle that is terminated due to a pressure build-up, a hot aqueous solution of a strong acid with a pH of approximately 1.5, is circulated through the plugged filter cartridges until the fines and organo-metallic coatings are solubilized. The acid wash solution is kept separate from the filter feedstock and filtrate by suitable valving, piping and tankage so as not to contaminate it. The filter cartridges may be rinsed prior to reintroduction of the feed stock to begin the next filter cycle.
    Type: Grant
    Filed: June 15, 1998
    Date of Patent: October 26, 1999
    Assignee: Kaiser Aluminum and Chemical Corporation
    Inventors: W. Bruce Ely, Bill G. Poynor
  • Patent number: 5938867
    Abstract: A method of producing an aluminum product comprising providing stock including an aluminum alloy comprising about 4.0 to 4.4 wt. % copper, about 1.25 to 1.5 wt. % magnesium, about 0.35 to 0.5 wt. % manganese, not more than 0.12 wt. % silicon, not more than 0.08 wt. % iron, not more than 0.06 wt. % titanium, the remainder substantially aluminum, incidental elements and impurities; hot working the stock; annealing at 725-875.degree. F.; cold rolling; solution heat treating; cooling; holding for at least 12 hours at room temperature; and cold working from about 4% to 7% thereby producing a product having increased strength and toughness properties.
    Type: Grant
    Filed: March 25, 1997
    Date of Patent: August 17, 1999
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventors: Ralph C. Dorward, Steven D. Kennedy
  • Patent number: 5916385
    Abstract: An essentially lead-free aluminum alloy is provided for extruded screw machine stock. The alloy consists essentially of from about 4.5% to about 6% copper, a maximum of about 0.4% silicon, a maximum of about 0.7% iron, not more than about 0.3% zinc, from about 0.1% to about 1% bismuth, from about 0.1% to about 0.5% tin, balance aluminum and unavoidable impurities. The screw machine stock is prepared by extruding a homogenized billet to the desired shape, then the shape is subjected to a thermomechanical treatment involving at least one heat-treatment and cold working.
    Type: Grant
    Filed: May 7, 1998
    Date of Patent: June 29, 1999
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventors: Norman Leroy Coats, II, Larry Eugene Farrar, Jr.
  • Patent number: 5897720
    Abstract: A product comprising an aluminum base alloy including about 3.8 wt. % copper, about 1.2 wt. % magnesium, about 0.3 to 0.6 wt. % manganese, not more than about 0.15 wt. % silicon, not more than about 0.12 wt. % iron, not more than about 0.1 wt. % titanium, the remainder substantially aluminum, incidental elements and impurities, the product having at least 5% improvement over 2024 alloy in fracture toughness, fatigue crack growth rate, corrosion resistance, and formability properties.
    Type: Grant
    Filed: December 18, 1996
    Date of Patent: April 27, 1999
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: Ralph C. Dorward
  • Patent number: 5894879
    Abstract: A method for manufacturing aluminum alloy sheet including a continuous, in-line sequence of forming a strip of aluminum alloy and rolling the strip to reduce its thickness and to cool the strip sufficiently rapidly that precipitation of alloying elements is substantially minimized.
    Type: Grant
    Filed: August 5, 1997
    Date of Patent: April 20, 1999
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventors: Gavin F. Wyatt-Mair, Edwin James Westerman
  • Patent number: 5888320
    Abstract: A method of producing an aluminum product having high formability high fracture toughness, high strength and improved corrosion resistance, the method comprising: (a) providing stock including an aluminum base alloy consisting essentially of about 0.7 to 1.0 wt. % silicon, not more than about 0.3 wt. % iron, not more than about 0.5 wt. % copper, about 0.8 to 1.1 wt. % magnesium, about 0.3 to 0.4 wt. % manganese, and about 0.5 to 0.8 wt. % zinc, the remainder substantially aluminum, incidental elements and impurities; (b) homogenizing the stock at a temperature ranging from about 950.degree. to 1050.degree. F. for a time period ranging from about 2 to 20 hours; (c) hot rolling at a temperature ranging from about 750.degree. to 950.degree. F. will increase; (d) solution heat treating at a temperature ranging from about 1000.degree. to 1080.degree. F. for a time period ranging from about 5 minutes to one hour; (e) cooling by quenching at a rate of about 1000.degree. F./second to a temperature of 100.degree. F.
    Type: Grant
    Filed: February 21, 1997
    Date of Patent: March 30, 1999
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: Ralph C. Dorward
  • Patent number: 5862582
    Abstract: A method for making hollow workpieces such as beverage containers with a circular die in which an aluminum alloy is strip cast whereby the alloy is solidified rapidly without substantial precipitation. Thereafter, the aluminum alloy is formed into a cup which is drawn and passed through one or more dies to iron the walls of the cup and thereby lengthen the side walls thereof using at least one circular die having a die angle of less than about 6.degree.. It has been found that the use of such small die angles prevents or minimizes galling and tearoffs.
    Type: Grant
    Filed: November 3, 1995
    Date of Patent: January 26, 1999
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: Tyzh-Chiang Sun
  • Patent number: 5820015
    Abstract: A process for improving the fillet-forming capability of brazeable aluminum articles includes providing a brazeable aluminum article, having at least one surface; and contacting the surface with a dilute, aqueous solution of fluoridic compounds, for at least 5 seconds at a temperature ranging from about 150.degree. to 212.degree. F. to produce an oxide-free surface which can be readily brazed with a minimal drip loss.
    Type: Grant
    Filed: April 2, 1996
    Date of Patent: October 13, 1998
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventor: David L. Childree
  • Patent number: 5810952
    Abstract: A process for making an essentially lead-free screw machine stock alloy, comprising the steps of providing a cast aluminum ingot having a composition consisting essentially of about 0.55 to 0.70 wt. % silicon, about 0.15 to 0.45 wt. % iron, about 0.30 to 0.40 wt. % copper, about 0.8 to 0.15 wt. % manganese, about 0.80 to 1.10 wt. % magnesium, about 0.08 to 0.14 wt. % chromium, nor more than about 0.25 wt. % zinc, about 0.007 to 0.07 wt. % titanium, about 0.20 to 0.8 wt. % bismuth, about 0.15 to 0.25 wt. % tin, balance aluminum and unavoidable impurities; homogenizing the alloy at a temperature ranging from about 900.degree. to 1060.degree. F. for a time period of at least 1 hour; cooling to room temperature; cutting the ingot into billets; heating and extruding the billets into a desired shape; and thermomechanically treating the extruded alloy shape.
    Type: Grant
    Filed: October 31, 1996
    Date of Patent: September 22, 1998
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventors: Larry E. Farrar, Jr., Norman LeRoy Coats, II
  • Patent number: 5803994
    Abstract: An essentially lead-free aluminum alloy is provided for extruded screw machine stock. The alloy consists essentially of from about 4.5% to about 6% copper, a maximum of about 0.4% silicon, a maximum of about 0.7% iron, not more than about 0.3% zinc, from about 0.1% to about 1% bismuth, from about 0.2% to about 0.5% tin, balance aluminum and unavoidable impurities. The screw machine stock is prepared by extruding a homogenized billet to the desired shape, then the shape is subjected to a thermomechanical treatment involving at least one heat-treatment and cold working.
    Type: Grant
    Filed: March 19, 1997
    Date of Patent: September 8, 1998
    Assignee: Kaiser Aluminum & Chemical Corporation
    Inventors: Norman Leroy Coats, II, Larry Eugene Farrar, Jr.