Abstract: A seal for a continuous casting furnace having a melting chamber with a mold therein for producing a metal cast includes a passage between the melting chamber and external atmosphere. As the cast moves through the passage, the cast outer surface and the passage inner surface define therebetween a reservoir for containing liquid glass or other molten material to prevent the external atmosphere from entering the melting chamber. Particulate material fed into the reservoir is melted by heat from the cast to form the molten material. The molten material coats the cast as it moves through the passage and solidifies to form a coating to protect the hot cast from reacting with the external atmosphere. Preferably, the mold has an inner surface with a cross-sectional shape to define a cross-sectional shape of the cast outer surface whereby these cross-sectional shapes are substantially the same as a cross-sectional shape of the passage inner surface.

Abstract: A seal for a continuous casting furnace having a melting chamber with a mold therein for producing a metal cast includes a passage between the melting chamber and external atmosphere. As the cast moves through the passage, the cast outer surface and the passage inner surface define therebetween a reservoir for containing liquid glass or other molten material to prevent the external atmosphere from entering the melting chamber. Particulate material fed into the reservoir is melted by heat from the cast to form the molten material. The molten material coats the cast as it moves through the passage and solidifies to form a coating to protect the hot cast from reacting with the external atmosphere. Preferably, the mold has an inner surface with a cross-sectional shape to define a cross-sectional shape of the cast outer surface whereby these cross-sectional shapes are substantially the same as a cross-sectional shape of the passage inner surface.

Abstract: A continuous casting furnace for producing metal ingots includes a molten seal which prevents external atmosphere from entering the melting chamber. A startup sealing assembly allows an initial seal to be formed to prevent external atmosphere from entering the melting chamber prior to the formation of the molten seal.

Abstract: A seal for a continuous casting furnace having a melting chamber with a mold therein for producing a metal cast includes a passage between the melting chamber and external atmosphere. As the cast moves through the passage, the cast outer surface and the passage inner surface define therebetween a reservoir for containing liquid glass or other molten material to prevent the external atmosphere from entering the melting chamber. Particulate material fed into the reservoir is melted by heat from the cast to form the molten material. The molten material coats the cast as it moves through the passage and solidifies to form a coating to protect the hot cast from reacting with the external atmosphere. Preferably, the mold has an inner surface with a cross-sectional shape to define a cross-sectional shape of the cast outer surface whereby these cross-sectional shapes are substantially the same as a cross-sectional shape of the passage inner surface.

Abstract: A seal for a continuous casting furnace having a melting chamber with a mold therein for producing a metal cast includes a passage between the melting chamber and external atmosphere. As the cast moves through the passage, the cast outer surface and the passage inner surface define therebetween a reservoir for containing liquid glass or other molten material to prevent the external atmosphere from entering the melting chamber. Particulate material fed into the reservoir is melted by heat from the cast to form the molten material. The molten material coats the cast as it moves through the passage and solidifies to form a coating to protect the hot cast from reacting with the external atmosphere. Preferably, the mold has an inner surface with a cross-sectional shape to define a cross-sectional shape of the cast outer surface whereby these cross-sectional shapes are substantially the same as a cross-sectional shape of the passage inner surface.

Abstract: A continuous casting furnace includes a temperature control mechanism for controlling the temperature of a metal cast as it exits a continuous casting mold in order to provide improved characteristics of the metal cast. The temperature control mechanism includes a temperature sensor for sensing the temperature of the metal cast, and a heat source and cooling device for respectively heating and cooling the metal cast in light of the temperature of the metal cast. A control unit determines if the temperature of the metal cast is within a predetermined range and controls the heat source and cooling device accordingly. The heat source may double as a cooling device or the cooling device may be separate from the heat source.

Abstract: A seal for a continuous casting furnace having a melting chamber with a mold therein for producing a metal cast includes a passage between the melting chamber and external atmosphere. As the cast moves through the passage, the cast outer surface and the passage inner surface define therebetween a reservoir for containing liquid glass or other molten material to prevent the external atmosphere from entering the melting chamber. Particulate material fed into the reservoir is melted by heat from the cast to form the molten material. The molten material coats the cast as it moves through the passage and solidifies to form a coating to protect the hot cast from reacting with the external atmosphere. Preferably, the mold has an inner surface with a cross-sectional shape to define a cross-sectional shape of the cast outer surface whereby these cross-sectional shapes are substantially the same as a cross-sectional shape of the passage inner surface.

Abstract: A seal for a continuous casting furnace having a melting chamber with a mold therein for producing a metal cast includes a passage between the melting chamber and external atmosphere. As the cast moves through the passage, the cast outer surface and the passage inner surface define therebetween a reservoir for containing liquid glass or other molten material to prevent the external atmosphere from entering the melting chamber. Particulate material fed into the reservoir is melted by heat from the cast to form the molten material. The molten material coats the cast as it moves through the passage and solidifies to form a coating to protect the hot cast from reacting with the external atmosphere. Preferably, the mold has an inner surface with a cross-sectional shape to define a cross-sectional shape of the cast outer surface whereby these cross-sectional shapes are substantially the same as a cross-sectional shape of the passage inner surface.

Abstract: A casting furnace for preheating and melting solid feed material includes a melting chamber with a melting hearth therein and a feed chamber in fluid communication with the melting chamber for conveying the solid material into the melting chamber. A heat source melts the feed material within the melting hearth and produces surplus heat used to preheat the solid feed material. Preferably, gas is heated by the heat source and moved into the feed chamber to preheat the feed material while it is conveyed toward the melting hearth. The heated gas is recycled back into the melting chamber to be re-heated therein and reused to preheat additional feed material in the feed chamber. Where the heat source in the melting chamber includes a plasma torch, the gas is recycled via the plasma torch, which ionizes the gas to create a plasma plume for melting the solid material.

Abstract: A method of manufacturing titanium electrodes in a vacuum arc remelting furnace as well as a reusable header for use in the remelting process is disclosed. An electrode may be attached to the reusable header and remelted in the furnace a number of times until a final ingot of the desired metallurgical quality is produced. The header and electrode are provided with a complimentarily shaped interlocking recess and projection to secure them together. The electrode may alternatively be integrally formed with a starter stub that includes a recess or projection that interlocks with a complimentarily shaped projection or recess on the header. At least a section of the header is made of the same metal as the electrode to be melted to reduce contamination of the ingot being formed in the furnace. Alternatively the starter stub is made from the same metal as the electrode.

Abstract: A method for hearthless processing of a solid metallic material consisting essentially of titanium or other metal or alloy thereof which includes providing a solid metal block having a processing surface and a base surface and consisting essentially of titanium or a metal, forming a pool of molten metal on the processing surface of the solid metal block provided in step, adding the metallic material to be processed to the pool of molten metal formed in step, and melting the metallic material to be processed, and removing metallic material melted in step from the pool of molten metal.

Abstract: An improved process for successful and homogeneous incorporation of ruthenium and iridium into titanium and titanium alloy melts, ingots, and castings via traditional melting processes (e.g., VAR and cold-hearth) has been developed. This result is achieved through the use of low-melting point Ti-Ru or Ti—Ir binary master alloys within the general composition range of ≦45 wt. % Ru and with a preferred composition of Ti-(15-40 wt. % Ru), or within the general composition range of ≦61 wt. % Ir and with a preferred composition of TI-(20-58 wt. % Ir). Primary features are its lower melting point than pure titanium, lower density than pure Ru and Ir metals, and the ability to be readily processed into granular or powder forms.

Abstract: A cost effective process is provided for the production of a clad reactive metal plate composite that contains a complete metallurgical bond between a reactive metal or metal alloy backer plate and the cladding layer which is employed in the present invention as the cladding plate. The full metallurgical bond is achieved in the present invention by maintaining a small gap between the cladding plate and the backer plate in the composite assembly. The small gap, which optionally may contain a evacuation nipple, may be obtained by placing shims composed of the backer plate material between the backer plate and the cladding plate in the composite assembly prior to sealing and hot working the assembly. Also, provided is a highly corrosion resistant clad reactive metal plate composite which comprises a reactive metal or metal alloy cladding layer that is completely bonded to a reactive metal or metal alloy backer plate through a metallurgical bond.

Abstract: The invention relates to a process for improving the aging response and uniformity in a beta titanium alloy comprising the steps of:(a) cold working said beta titanium alloy to at least about 5% so that a reasonable degree of recrystallization can be obtained during subsequent solution treatment;(b) pre-aging said cold worked alloy at about 900.degree. to about 1300.degree. F. for a time in excess of about 5 minutes to obtain a pre-aged alloy;(c) solution treating said pre-aged alloy at a time and temperature to achieve a reasonable degree of recrystallization of said pre-aged alloy above the beta transus; and(d) aging said solution treated alloy at temperature and times to achieve a pre-aged, solution treated and aged beta titanium alloy substantially in a state of metallurgical equilibrium.

Abstract: The present invention relates to a low cost process for providing equivalent or superior ballistic resistance performance compared to standard Ti-6Al-4V alloys. The present inventions process involves increasing the oxygen content of Ti-6Al-4V beyond the conventional limit of 0.20% maximum reported for prior art compounds and subsequently thereafter heating the oxygen rich titanium alloy at temperatures within the beta phase field for further processing.Additionally, the present invention provides a novel Ti-6Al-4V alloy composition which exhibits improved tensile and yield strength properties. Titanium compositions of the present invention exhibit improved ballistic properties compared to titanium compositions previously disclosed in the art. The novel Ti-6Al-4V composition of the present invention is obtained by modifying the alloy composition limits to 5.5 to 6.75% Al, 3.5 to 4.5% V, 0.20 to 0.30% O.sub.2, <0.50% Fe and 0.

Abstract: The present invention relates to a process in which a metal or metal alloy is thermal spray coated onto a base alloy material prior to hot working. More specifically, the invention relates to the use of plasma coating of titanium over a titanium alloy plate for improved hot workability. This combination allows the crack-sensitive base alloy to be rolled with a minimum of surface and edge cracks. In addition, by using a plasma sprayed titanium coating there is a reduction in the roll force required to reduce the material during the hot working process.

Abstract: The invention relates to a process for the removal of oxides and/or oxygen which are formed on the surface of the casting during the investment casting process to levels that are comparable to those found within the bulk of the metal casting thus reducing the inherent hardness of the surfaces of the casting. More specifically, the invention relates to a process for removing oxide layers from titanium casting using an alkaline earth deoxidizing agent.

Abstract: The invention relates to a process for improving the aging response and uniformity in a beta titanium alloy comprising the steps of:(a) cold working said beta titanium alloy to at least about 5% so that a reasonable degree of recrystallization can be obtained during subsequent solution treatment;(b) pre-aging said cold worked alloy at about 900.degree. to about 1300.degree. F. for a time in excess of about 5 minutes to obtain a pre-aged alloy;(c) solution treating said pre-aged alloy at a time and temperature to achieve a reasonable degree of recrystallization of said pre-aged alloy above the beta transus; and(d) aging said solution treated alloy at temperature and times to achieve a pre-aged, solution treated and aged beta titanium alloy substantially in a state of metallurgical equilibrium.

Abstract: A process for the deoxidation of a refractory metal containing minor concentrations of oxygen is disclosed. In this process the refractory metal is contacted with a metallic deoxidant in a dry, inert atmosphere. The metallic deoxidant and the refractory metal are heated to at least liquefy the metallic deoxidant and at least partially deoxidize the refractory metal. The refractory metal is thereafter cooled and contaminants on its surface are removed.