Abstract: A titanium alloy may be characterized by a good oxidation resistance, high strength and creep resistance at elevated temperatures up to 750° C., and good cold/hot forming ability, good superplastic forming performance, and good weldability. The alloy may contain, in weight percent, aluminum 4.5 to 7.5, tin 2.0 to 8.0, niobium 1.5 to 6.5, molybdenum 0.1 to 2.5, silicon 0.1 to 0.6, oxygen up to 0.20, carbon up to 0.10, and balance titanium with incidental impurities.

Abstract: A method is provided of non-destructively inspecting titanium alloy articles in the as-cast condition using ultrasonic waves to detect internal flaws, comprising modification of grain structure in the as-solidified ingot structure by the addition of trace boron to various titanium alloys. The ability to ultrasonically inspect as-cast billets combined with improved hot workability provided by trace boron enhancement permits an economical method of manufacture of titanium alloy articles destined for high performance applications.

Abstract: A titanium alloy may be characterized by a good oxidation resistance, high strength and creep resistance at elevated temperatures up to 750° C., and good cold/hot forming ability, good superplastic forming performance, and good weldability. The alloy may contain, in weight percent, aluminum 4.5 to 7.5, tin 2.0 to 8.0, niobium 1.5 to 6.5, molybdenum 0.1 to 2.5, silicon 0.1 to 0.6, oxygen up to 0.20, carbon up to 0.10, and balance titanium with incidental impurities.

Abstract: A method is provided of non-destructively inspecting titanium alloy articles in the as-cast condition using ultrasonic waves to detect internal flaws, comprising modification of grain structure in the as-solidified ingot structure by the addition of trace boron to various titanium alloys. The ability to ultrasonically inspect as-cast billets combined with improved hot workability provided by trace boron enhancement permits an economical method of manufacture of titanium alloy articles destined for high performance applications.

Abstract: A method and apparatus are provided to cast a metal ingot using a continuous casting mold so that the ingot is essentially free of gas pockets which otherwise would result from gas bubbles being entrapped in the mushy zone and solid portion of the ingot during formation, wherein such bubbles may be caused by pouring molten metal into a molten liquid portion of the forming ingot and by impingement of a plasma plume of a plasma torch on the upper surface of the molten liquid portion.

Abstract: A continuous casting furnace is configured for efficiently continuously casting ingots, including titanium alloy ingots. The furnace is configured with an internal cutter for cutting an ingot within the furnace interior chamber. The furnace typically includes a first interior chamber in which a continuous casting mold is disposed and a withdrawal chamber which is separable from the first interior chamber to facilitate withdrawal of finished ingots therefrom while casting continues within the first chamber.

Abstract: A hot stretch wrap forming die typically includes a rigid backing section, a series of spaced ribs extending forward from the backing section, and an elongated face sheet secured to the ribs forward of the backing section with a convex forward-facing die face. The ribs elastically deflect during thermal expansion of the face sheet when a heated metal bar is forced against the die face so that the metal bar transfers heat to the face sheet. The die typically includes stiff ribs secured to the backing section and the face sheet which provide substantially fixed points for the face sheet during its thermal expansion. The face sheet may include several face sheet segments which together from the die face. The face sheet may also include contour plates which form respective portions of the die face and which may be used to adjust the specific contour of the die face.

Abstract: A continuous casting furnace is configured for efficiently continuously casting ingots, including titanium alloy ingots. The furnace is configured with an internal cutter for cutting an ingot within the furnace interior chamber. The furnace typically includes a first interior chamber in which a continuous casting mold is disposed and a withdrawal chamber which is separable from the first interior chamber to facilitate withdrawal of finished ingots therefrom while casting continues within the first chamber.

Abstract: A continuous casting furnace is configured for efficiently continuously casting ingots, including titanium alloy ingots. The furnace is configured with an internal cutter for cutting an ingot within the furnace interior chamber. The furnace typically includes a first interior chamber in which a continuous casting mold is disposed and a withdrawal chamber which is separable from the first interior chamber to facilitate withdrawal of finished ingots therefrom while casting continues within the first chamber.

Abstract: A hot stretch wrap forming die typically includes a rigid backing section, a series of spaced ribs extending forward from the backing section, and an elongated face sheet secured to the ribs forward of the backing section with a convex forward-facing die face. The ribs elastically deflect during thermal expansion of the face sheet when a heated metal bar is forced against the die face so that the metal bar transfers heat to the face sheet. The die typically includes stiff ribs secured to the backing section and the face sheet which provide substantially fixed points for the face sheet during its thermal expansion. The face sheet may include several face sheet segments which together from the die face. The face sheet may also include contour plates which form respective portions of the die face and which may be used to adjust the specific contour of the die face.

Abstract: A hot stretch wrap forming die typically includes a rigid backing section, a series of spaced ribs extending forward from the backing section, and an elongated face sheet secured to the ribs forward of the backing section with a convex forward-facing die face. The ribs elastically deflect during thermal expansion of the face sheet when a heated metal bar is forced against the die face so that the metal bar transfers heat to the face sheet. The die typically includes stiff ribs secured to the backing section and the face sheet which provide substantially fixed points for the face sheet during its thermal expansion. The face sheet may include several face sheet segments which together from the die face. The face sheet may also include contour plates which form respective portions of the die face and which may be used to adjust the specific contour of the die face.

Abstract: A titanium alloy contains niobium from 8 to 18% by weight; zirconium from 2 to 15% by weight; tin from 0 to 8% by weight; yttrium from 0.0 to 0.3% by weight, and a balance essentially titanium. The titanium alloy has a low Young's modulus, high yield strength, excellent cold bending properties, and good cold stamping and forming performance.

Abstract: A casting furnace for manufacturing a metal casting comprises an interior chamber and a secondary chamber through which the metal casting passes from the interior chamber into external atmosphere. A seal along the secondary chamber surrounds and seals against the metal casting to separate the interior chamber from the external atmosphere in a manner which allows for an extended period of continuous casting. A force producing mechanism may force the seal against the metal casting. Multiple seals may be used sequentially to increase the duration of the sealing capability and the continuous casting process. Inert gas sensors may detect loss of inert gas from the interior chamber.

Abstract: A casting furnace for manufacturing a metal casting comprises an interior chamber and a secondary chamber through which the metal casting passes from the interior chamber into external atmosphere. A seal along the secondary chamber surrounds and seals against the metal casting to separate the interior chamber from the external atmosphere in a manner which allows for an extended period of continuous casting. A force producing mechanism typically forces the seal against the metal casting. Multiple seals may be used sequentially to increase the duration of the sealing capability and the continuous casting process.

Abstract: A hot stretch wrap forming die typically includes a rigid backing section, a series of spaced ribs extending forward from the backing section, and an elongated face sheet secured to the ribs forward of the backing section with a convex forward-facing die face. The ribs elastically deflect during thermal expansion of the face sheet when a heated metal bar is forced against the die face so that the metal bar transfers heat to the face sheet. The die typically includes stiff ribs secured to the backing section and the face sheet which provide substantially fixed points for the face sheet during its thermal expansion. The face sheet may include several face sheet segments which together from the die face. The face sheet may also include contour plates which form respective portions of the die face and which may be used to adjust the specific contour of the die face.

Abstract: A casting furnace for manufacturing a metal casting comprises an interior chamber and a secondary chamber through which the metal casting passes from the interior chamber into external atmosphere. A seal along the secondary chamber surrounds and seals against the metal casting to separate the interior chamber from the external atmosphere in a manner which allows for an extended period of continuous casting. A force producing mechanism typically forces the seal against the metal casting. Multiple seals may be used sequentially to increase the duration of the sealing capability and the continuous casting process.

Abstract: A hot stretch wrap forming die typically includes a rigid backing section, a series of spaced ribs extending forward from the backing section, and an elongated face sheet secured to the ribs forward of the backing section with a convex forward-facing die face. The ribs elastically deflect during thermal expansion of the face sheet when a heated metal bar is forced against the die face so that the metal bar transfers heat to the face sheet. The die typically includes stiff ribs secured to the backing section and the face sheet which provide substantially fixed points for the face sheet during its thermal expansion. The face sheet may include several face sheet segments which together form the die face. The face sheet may also include contour plates which form respective portions of the die face and which may be used to adjust the specific contour of the die face.

Abstract: A casting furnace for manufacturing a metal casting comprises an interior chamber and a secondary chamber through which the metal casting passes from the interior chamber into external atmosphere. A seal along the secondary chamber surrounds and seals against the metal casting to separate the interior chamber from the external atmosphere in a manner which allows for an extended period of continuous casting. A force producing mechanism typically forces the seal against the metal casting. Multiple seals may be used sequentially to increase the duration of the sealing capability and the continuous casting process.

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 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.