Abstract: Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal or vertical direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting.

Abstract: Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal or vertical direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting.

Abstract: Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal or vertical direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting.

Abstract: Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal or vertical direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting.

Abstract: Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal or vertical direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting.

Abstract: Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casing, and low stresses throughout the casting.

Abstract: Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting.

Abstract: Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal or vertical direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting.

Abstract: Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting.

Abstract: A DC casting mold for casting molten metal alloy comprising a cooled tubular body that has a thermally insulated insert attached to its top surface. The thermally insulated insert has a bottom portion with a beveled sidewall, which forms an angle with the horizontal melt surface layer of the molten metal and creates an eddy. The eddy causes a substantial number of oxides that are formed during the casting process to remain in the bottom sidewall portion of the thermally insulated insert of the mold, thereby substantially reducing the number of ingot surface imperfections that promote ingot cracking. In addition, the eddy promotes break-up of the oxides into smaller pieces as the oxides flow toward the cooled inner walls of the cooled tubular body, thereby having limited surface area for growth of oxide folds. A method of casting molten metal alloys with improved surface quality is also disclosed.

Abstract: A DC casting mold for casting molten metal alloy comprising a cooled tubular body that has a thermally insulated insert attached to its top surface. The thermally insulated insert has a bottom portion with a beveled sidewall, which forms an angle with the horizontal melt surface layer of the molten metal and creates an eddy. The eddy causes a substantial number of oxides that are formed during the casting process to remain in the bottom sidewall portion of the thermally insulated insert of the mold, thereby substantially reducing the number of ingot surface imperfections that promote ingot cracking. In addition, the eddy promotes break-up of the oxides into smaller pieces as the oxides flow toward the cooled inner walls of the cooled tubular body, thereby having limited surface area for growth of oxide folds. A method of casting molten metal alloys with improved surface quality is also disclosed.

Abstract: In an oxidation inhibiting lubricant composition suitable for use in the manufacture of aluminum alloys comprising lubricant base selected from the group consisting of solid lubricants, liquid lubricants, grease lubricants, emulsion lubricants, and dispersion lubricants, the improvement wherein the lubricant composition further comprises: an effective amount of a fluorine-containing passivating compound.

Abstract: A mold for casting metal ingot sows having an aspect ratio of at least 4:1. The mold comprises a bottom wall from which a side wall extends upwardly and outwardly and from which heat transfer structure extends downwardly for transferring heat away from the bottom wall.