Abstract: A system and method for sensing the position of an ingot within a segmented mold of a vacuum metallurgical system. An inductive sensory system measures the variations in current between a power source and load of an induction heating coil. The system and method is particularly suitable for determining the position of an ingot within a melting system mold where the mold has a relatively reduced or small cross-sectional area.

Abstract: A system and method for sensing the position of an ingot within a segmented mold of a vacuum metallurgical system. An inductive sensory system measures the variations in current between a power source and load of an induction heating coil. The system and method is particularly suitable for determining the position of an ingot within a melting system mold where the mold has a relatively reduced or small cross-sectional area.

Abstract: A puller head mold for receiving molten metal or alloy during the casting of an ingot, the puller head mold having a tapered screw thread structure. The tapered threaded puller head is used to pull and withdraw a cast ingot from a casting furnace, and can be particularly useful for the handling of ingots having a relatively narrow diameter. The tapered threaded puller head profile provides for full release of the tapered threaded puller head from a cast ingot in a fraction of a turn. The size and profile of the cast ingot formed with the tapered threaded puller head is resilient to thermal gradients while cooling.

Abstract: A system and method for melting a raw material. The raw material is fed into an electrically conductive vessel. A plasma arc torch melts at least some of the raw material within the vessel to thereby create a molten material. An inductor, physically disposed adjacent the vessel, and electrically disposed in series with the vessel in operation, effects electromagnetic stirring of the molten material by interacting with the current of the plasma arc torch.

Abstract: A heat shield for a casting furnace (e.g., a directional solidification or single crystal casting furnace) includes a plurality of heat insulating plates (e.g., 6 plates), each with a leading edge. The plurality of heat insulating plates are arranged, for example, in an overlapping layout, such that at least a portion of their leading edges define a discharge opening (e.g., a hexagonal discharge opening in the case of a heat shield with 6 heat insulating plates) circumscribed by the heat insulating plates. The heat insulating plates are moveable in a manner that adjusts (i.e., increases or decreases) the size of the discharge opening. The heat shield also includes a rotatable disk operatively coupled to the heat insulating plates such that when the rotatable disk is rotated in one direction, the heat insulating plates are moved in a manner which decreases the size of the discharge opening.

Abstract: A heat shield for a casting furnace (e.g., a directional solidification or single crystal casting furnace) includes a plurality of heat insulating plates (e.g., 6 plates), each with a leading edge. The plurality of heat insulating plates are arranged, for example, in an overlapping layout, such that at least a portion of their leading edges define a discharge opening (e.g., a hexagonal discharge opening in the case of a heat shield with 6 heat insulating plates) circumscribed by the heat insulating plates. The heat insulating plates are moveable in a manner that adjusts (i.e., increases or decreases) the size of the discharge opening. The heat shield also includes a rotatable disk operatively coupled to the heat insulating plates such that when the rotatable disk is rotated in one direction, the heat insulating plates are moved in a manner which decreases the size of the discharge opening.

Abstract: A plasma arc torch is disclosed which has an elongated electrode with an open front and a nozzle with a plasma discharge opening that is coaxial with the electrode. A mounting arrangement includes a ceramic ring that engages the front end of the electrode and a gas ring which concentrically surrounds the ceramic ring. A forward portion of the gas ring, the forward end of the electrode, and the nozzle define a swirl chamber of the torch, and opposing, spaced-apart concentric cylindrical surfaces of the ceramic ring and the gas ring, respectively, form an annulus which extends rearwardly from the swirl chamber. The ceramic ring closes the aft end of the annulus, and the gas ring houses a plurality of plasma gas injection ports which are located immediately forward of the aft end of the annulus.