Abstract: A cast aluminum alloy and tooling fixture fabricated therefrom is provided which can be produced in thicknesses up to 32.0 inches; and which has equiaxed grains, an ultimate tensile strength above 30,000 psi after annealing, is dimensionally stable, and is free from porosity. The alloy has a nominal composition of 3.0% copper, 2.2% zinc, 0.7% nickel, 1.0% magnesium, 1.2% iron, 0.3% manganese, and balance aluminum. The alloy is direct water chill cast followed by a stress relieving anneal.

Abstract: The present invention provides a method for processing environmentally undesirable materials including petroleum coke and the sulfur and heavy metals contained therein and agglomerated waste dust from an electric arc furnace and the zinc, cadmium, lead and iron oxides contained therein and of providing fuel and a charging material for a process of making molten iron or steel preproducts and reduction gas in a melter gasifier. Metallized arc furnace waste dust material from a reduction furnace is introduced into the melter gasifier. The petroleum coke, oxygen and metallized waste dust material are reacted to produce reduction gas and molten iron from the iron oxides in the waste dust material. The molten iron contains the metals freed from combustion of the petroleum coke. The reduction gas is removed from the melter gasifier for use in the reduction furnace to produce an top off gas containing vapors of zinc, cadmium and lead.

Abstract: Molten metal containing suspended liquid particles is passed preferably generally upwardly through a porous media so constructed and arranged such that the movement of the molten metal therethrough renders the suspended liquid particles gravity separable. The gravity separable liquid particles rise upwardly or settle downwardly so as to be removable from said molten metal for subsequent removal therefrom. An associated apparatus is also provided.

Abstract: The proposed method is characterized in that the liquid bath is constituted by the melt of low carbon steel and molten slag. Oxidation and reducing zones are created through which, along a closed path on the surface of the molten low-carbon steel, is circulated the molten slag, into which are blown powder slag materials which are melted with the heat of a fuel oxygen torch immersed into the melt. The melting is carried out in a melting reservoir shaped as a closed annular chamber (1) provided with partitions (11) hermetically dividing the gas space above the molten slag into oxidation (6) and reducing (7) zones.

Abstract: Particles or inclusions are removed from a molten alloy by contacting the molten alloy with a material selected from the group consisting of aluminium silicate, magnesium silicate, zirconium oxide or a mixture of alumina-calcia and alumina-magnesia.

Abstract: A method for producing a cast aluminum vehicle wheel uses a high intensity electric infrared heating system to heat treat the wheel. The infrared heating system is an indexing-type system which includes a plurality of individual heating stations. A first group of heating stations effects solution heat treating of the wheel, while a second group effects artificial aging. The infrared system enables the solution heat treating and aging to be completed in less than 15 minutes.

Abstract: In a process for the treatment of electric arc furnace (EAF) dust, the dust is first subjected to atmospheric leaching with a ferric chloride solution and thereafter subjected to treatment in an autoclave at an elevated temperature and pressure for conversion of low temperature stable goethite (FeO.OH) to a filterable crystalline hematite (Fe.sub.2 O.sub.3) in an acidic chloride solution. Zinc is recovered from the solution by solvent extraction using a solvating extractant followed by stripping and zinc recovery by electrolysis of zinc chloride solution. Lead is separated from the solution by cooling to precipitate lead chloride.

Abstract: Fuel and combustion gas are supplied to the blast pipes and tuyeres of a blast furnace through injection lances which have an inner tube and an outer tube. The inner tube is generally used to carry the fuel, while the space formed between the inner and outer tubes is used to carry the combustion gas. Such a lance can have a heat resistant tip which has a bore for forming an extension of the inner fuel supply tube, and which also has a number of helical channels disposed about the bore for forming an extension of the space between the tubes. It is advantageous to have more than one such lance in each blast pipe and to have the lances extend obliquely into the hot blast channel that is formed by the blast pipe and the tuyere.

Abstract: A process and apparatus are described for manufacturing particle stabilized foamed metal slabs. A foam is first formed in a foaming chamber by heating a composite of a metal matrix and finely divided solid stabilizer particles above the solidus temperature of the metal matrix and discharging gas bubbles into the molten metal composite below the surface thereof to thereby form a stabilized liquid foam on the surface of the molten metal composite. The stabilized liquid foam is continuously drawn off the surface of the molten metal composite and is solidified into a shaped foam product while being continuously drawn off.

Abstract: A method and apparatus is provided for temporarily retaining slag and nonmetallic particles in a tundish while molten metal is being transferred through the tundish to other desired vessels. In particular, a meltable dam is placed into an opening between the chambers in a tundish, and the meltable dam retains an accumulation of molten metal in the pour chamber of the tundish with the slag and nonmetallic particles floating on top of that level such that the slag and nonmetallic particles are above the opening between the chambers of the tundish. The dam then completely melts and allows the transfer of molten metal through the opening. The slag and nonmetallic particles are retained in the pour chamber, however, because the molten metal being transferred into the pour chamber maintains the level in that chamber above the opening until almost all of the metal has been transferred into and through the chamber.

Abstract: A method of smelting aluminum from aluminum ore wherein the powdered ore is mixed with a flux containing substantial amounts of borax, sodium bicarbonate and a copper compound, preferably copper sulphate. The mixture is placed in a suitable vessel, preferably with a rounded bottom, that can withstand high temperatures and that has an outlet hole in the bottom. The mixture of powdered ore and flux is heated to a temperature sufficient to melt the mixture and thereby produce a molten material containing aluminum. The molten material is allowed to flow out of the outlet hole and to cool outside by means of air cooling which results in the aluminum separating out. Preferably, the flux comprises about one third borax, one third sodium bicarbonate and about one third copper sulphate. A suitable ore for this method is nepheline syenite.

Abstract: Apparatus for supplying a molten metal (5) in a metallurgical vessel (3) with a gas and fine-grain solid materials comprising a water-cooled first lance (117) for the supply of the gas and a second lance (119) for the supply of the solid materials. The supply of the solid materials is effected in such a way that, after leaving the outlet opening of the second lance (119), the materials are deflected by the gas (127) issuing from the outlet opening of the first lance (117), and are fed with said gas to the molten metal (5). The lances are inserted through the side wall of the vessel (3).

Abstract: Flowable molybdenum metal powder of controlled particle size distribution is produced by stage-wise reduction wherein, in a first stage, molybdenum trioxide feed is preferably introduced at depth in a fluid bed of molybdenum dioxide and is reduced in an atmosphere containing at least 50% hydrogen, by volume, at a temperature between 560.degree. and 620.degree. C. and the product molybdenum dioxide is then reduced to molybdenum metal in a second stage fluid bed at a temperature between 1025.degree. C. and 1075.degree. C. in an atmosphere containing at least 50% hydrogen employed in amount of at least 2.75 times stoichiometric while controlling the off-gas dewpoint to be at least 21.degree. C. and controlling the off-gas hydrogen:water vapor ratio so as not to exceed 24:1 and removing the product spheroidal molybdenum metal particles from the bottom of the bed to prevent collapse of the bed.

Abstract: Hood assembly for pneumatic process metallurgical vessel, such as BOF, which includes removeable spray cooled sub-assemblies at predetermined locations in the hood assembly.

Abstract: A method for treating gases and solids in a fluid bed, the fluid bed reactor substantially comprising, regarded downstream, a mixing chamber, a riser pipe and a cyclone with a solids return pipe to the mixing chamber, the gases being introduced into the mixing chamber at a gas rate immediately before the inlet port of the mixing chamber of more than 35 m/sec.

Abstract: The invention relates to a process and apparatus for manufacturing low-gas and pore-free aluminum casting alloys by vacuum degasification and densification of the melt. Contact between the aluminum melt and the atmospheric humidity of the alloying process, from refining to continuous casting of the cast bars, is kept extremely short, so that effective vacuum degasification, and a high cooling rate, can prevent the formation of gas pores. After the metal melt is alloyed in a smelting furnace, the melt is fed through a system of gutters directly to at least one vacuum furnace. Refining components are added in the vacuum furnace and heating is conducted to provide the pouring temperature required for continuous casting.

Abstract: A hafnium alloy consisting essentially of hafnium and containing Sn by 0.1-1.5 weight %, O by 0.03-0.2 weight %, Fe by 0.01-0.15 weight %, Zr by 0.02-2.0 weight %, and (1) Cr by 0.01-0.15 weight %, and Ni by less than 0.10 weight %, (2) Cr by 0.01-0.15 weight %, Ni by less than 0.10 weight %, and Mo by 0.01-0.2 weight %, (3) Nb by 0.2-1.0 weight %, or (4) Nb by 0.2-1.0 weight %, and Mo by 0.01-0.2 weight % has high neutron-absorbing capacity, high resistance to uniform and nodular corrosion, high tensile and creep strength, and good wear resistance, and is suited to be used as neutron absorber for nuclear power reactors.

Abstract: Mixed gas of nonoxidizing gas and oxygen is blown into molten chrome steel in a vessel. The molten chrome steel is stirred by the gas and is decarbonized by the oxygen in the gas while being stirred. After the carbon potential in the molten chrome steel has been lowered, the pressure inside the vessel is reduced and the nonoxidizing gas alone is blown as the gas. Bubbles of the gas blown into the molten chrome steel become large on account of reduced pressure and exhibit sufficient stirring function. Consequently, the molten chrome steel is effectively stirred and the decarbonizing reaction is prompted.

Abstract: This invention relates to the melting of scrap metal containing steel in an electric arc furnace using whole scrap rubber tires as an additional source of heat. Also, scrap rubber may be pylarized to form combustibles which are fed into the electric arc furnace for combustion.

Abstract: A method of producing an electrical conductor is described. The electrical conductor is made of an oxygen-free copper material having an oxygen content of not more than 50 ppm, wherein copper crystals constituting the copper material are giant crystals. These giant copper crystals are formed by heating the copper material in an inert atmosphere maintained at a temperature exceeding 800.degree. C., but below the melting point of copper for at least 15 minutes.