Abstract: A one-piece, composite open-bottom casting mold with integral withdrawal section is fabricated by thermal spraying of materials compatible with and used for the continuous casting of shaped products of reactive metals and alloys such as, for example, titanium and its alloys or for the gas atomization thereof.

Abstract: In a dip forming process the core material to be coated is introduced directly into a source block of coating material eliminating the need for a bushing entrance component. The process containment vessel or crucible is heated so that only a portion of the coating material becomes molten, leaving a solid portion of material as the entrance port of, and seal around, the core material. The crucible can contain molten and solid metals and is especially useful when coating core material with reactive metals. The source block of coating material has been machined to include a close tolerance hole of a size and shape to closely fit the core material. The core material moves first through the solid portion of the source block of coating material where the close tolerance hole has been machined, then through a solid/molten interface, and finally through the molten phase where the diameter of the core material is increased.

Abstract: A process for removing copper in a recoverable form from a copper/solid ferrous scrap metal mix is disclosed. The process begins by placing a copper/solid ferrous scrap metal mix into a reactor vessel. The atmosphere within the reactor vessel is purged with an inert gas or oxidizing while the reactor vessel is heated in the area of the copper/solid ferrous scrap metal mix to raise the temperature within the reactor vessel to a selected elevated temperature. Air is introduced into the reactor vessel and thereafter hydrogen chloride is introduced into the reactor vessel to obtain a desired air-hydrogen chloride mix. The air-hydrogen chloride mix is operable to form an oxidizing and chloridizing atmosphere which provides a protective oxide coating on the surface of the solid ferrous scrap metal in the mix and simultaneously oxidizes/chloridizes the copper in the mix to convert the copper to a copper monochloride gas for transport away from the solid ferrous scrap metal.