Abstract: Disclosed is an improved electric heater assembly suitable for heating molten metal, the electric heater assembly having a sleeve comprised of a closed end suitable for immersing in the molten metal. The sleeve is fabricated from a composite material comprised of titanium alloy and having an outside surface to be exposed to the molten metal coated with a refractory resistant to attack by the molten metal; and an electric heater located in the sleeve in heat transfer relationship therewith.

Abstract: The assembly is designed for transferring molten metal from a molten metal reservoir to a mold for casting molten metal. The assembly comprises a casting nozzle having an electrically conductive top wall and bottom wall and two side walls joined to the top wall and the bottom wall to form a passage therebetween for flowing molten metal from the reservoir to the mold, the top wall having a first outside surface and the bottom wall having a second outside surface. An inductive heater is positioned on at least one of the first surface and the second surface, the inductive heater positioned to heat the top wall and bottom wall. A layer of insulation is provided between the inductive heater and the first and second surfaces. A magnetic shield is provided to partially surround the inductive heater, the shield positioned to direct magnetic flux into the nozzle.

Abstract: A method of treating a body of molten metal to produce high levels of shear forces in the body. The method comprises providing a body of molten metal; inductively moving molten metal in the body in one direction at outer regions thereof and in an opposite direction in inner regions of the body. An impeller is provided on a shaft projecting into the inner regions of the body; and the impeller is rotated in the inner region of the body to oppose the direction of the molten metal in the inner regions, thereby generating the high levels of shear forces in the molten metal in the inner regions.

Abstract: A method of liberating or producing chlorine from hexachloroethane, the method comprising the steps of providing a body comprised of solid hexachloroethane and heating the body to a temperature sufficient to cause the solid hexachloroethane to produce hexachloroethane vapors. Thereafter, the hexachloroethane vapors are exposed to a heated surface and the hexachloroethane vapor decomposed utilizing heat from the heated surface to liberate chlorine from the hexachloroethane vapor.

Abstract: An improved method for processing a body of molten metal using an impeller and a rotatable container, the method including increasing shear forces in the body of molten aluminum and reducing vortex formation, the method comprising the steps of providing a body of molten metal in a container and projecting an impeller on a shaft into the body. The impeller is rotated in one direction and the container and the body of molten metal is rotated counter or in a direction opposite of rotating the impeller, the container and the impeller being rotated at a rate which minimizes vortex formation and which maximizes shear forces in the body for purposes of improved processing.

Abstract: An improved method for dispersing high levels of fluxing gas in a body of molten aluminum using an impeller or disperser to disperse the fluxing gas in the body of molten aluminum, the method producing increased shear forces in the body of molten aluminum and reducing vortex formation. The method comprises the steps of providing a body of molten aluminum and a disperser in the body. A fluxing gas is added to the body at the rate of 1 to greater than 200 SCF/hour and dispersed by rotating the disperser in one direction and thereafter reversing the direction of rotation to a counter direction. The direction of rotation is reversed periodically to substantially reduce formation of a vortex and to provide increased shear forces in the body for purposes of improving dispersion of the fluxing gas in the molten aluminum.

Abstract: An improved method for treating a body of molten aluminum using an impeller suitable for dispersing fluxing gas or solid particles in the body of molten aluminum. The method produces increased shear forces in the body of molten aluminum and reduces vortex formation. The method comprises providing a body of molten aluminum and projecting an impeller on a shaft into the body, the impeller comprising a rectangular-shaped body having a first rectangular-shaped face and a second rectangular-shaped face disposed substantially opposite the first face, the faces substantially parallel to the shaft and defined by a length L and a height H wherein the length L is greater than the height H.

Abstract: An improved thermocouple assembly suitable for measuring the temperature of molten metal, the thermocouple assembly having a sleeve comprised of a closed end suitable for immersing in the molten metal. The sleeve is fabricated from a composite material comprised of titanium alloy and having an outside surface to be exposed to the molten metal coated with a refractory resistant to attack by the molten metal; and a thermocouple located in the sleeve in heat transfer relationship therewith.

Abstract: A method for removing a surface layer from a solidified body of metal at an elevated temperature to remove surface defects therefrom. The method comprises providing a solidified body having a surface wherein the body can have a temperature greater than 200.degree. F. and below the solidus temperature of the metal. The metal surface is contacted with an abrasive material having a particle size in the range of 6 to 300 grit (U.S. Sieve Series). The abrasive material is applied at a flux sufficient to remove a surface layer from the body, the layer having a thickness in the range of 10 to 300 .mu.m to provide a surface substantially free of said surface defects.

Abstract: Disclosed is an improved casting tip for a nozzle of a continuous caster, the tip designed for transferring molten metal from a molten metal reservoir to a continuously advancing mold as formed, for example, by twin belts, rolls or block casters for casting molten metal into solid form. The casting tip is comprised of a top wall, a bottom wall oppositely disposed from top wall, a first side wall, and a second side wall oppositely disposed from the first side wall, the first and second side walls joined to the top and bottom walls to form a passage therebetween having an entrance and an exit. The passage has a top wall inside surface having a first portion that first converges towards the bottom wall starting at the entrance and has a second portion that diverges from the bottom wall to the exit, the top wall first portion having a length less than the top wall second portion length.

Abstract: Disclosed is a composite material for handling molten metal, the material having a tensile strength of greater than 30 ksi and being resistant to attack by the molten metal. The composite comprises a base layer of titanium base alloy having bonded thereto a protective refractory coating resistant to attack by the molten metal.

Abstract: Disclosed is an improved method for oxygenation of liquid waste. The method comprises drawing a low pressure stream of liquid waste from a liquid waste tank and introducing an oxygen-containing gas thereto to provide a mixture of liquid waste and gas. Thereafter, the mixture is pumped into a high pressure stream wherein the pressure is maintained in the range of 50 to 1000 psig to obtain an oxygen enriched dispersion. The oxygen enriched dispersion is then discharged into the holding tank.

Abstract: There is provided an improved method for dispersing a treatment media in a body of molten metal using an impeller to disperse the media in the body of molten metal, the method producing increased shear forces in the body of molten metal and reducing vortex formation. The method comprises the steps of providing a body of molten metal and an impeller on a shaft in the body. A treatment media is added to the body and dispersed by rotating said impeller in one direction and thereafter reversing the direction of rotation of the impeller to a counter direction. The direction of rotation of the impeller is reversed periodically to substantially reduce formation of a vortex around the shaft of the impeller and to provide increased shear forces in the body for purposes of improving treatment of the molten metal by improved dispersion of the media therein.

Abstract: Disclosed is an improved method for dispersing a treatment media in a body of molten metal using an impeller, nozzles, and other mixing means to disperse the media in the body of molten metal, the method producing increased shear forces in the body of molten metal and preferably reducing vortex formation. In one embodiment, the method comprises the steps of providing a body of molten metal and an impeller on a shaft in the body. A treatment media is added to the body and dispersed by rotating said impeller in one direction and thereafter reversing the direction of rotation of the impeller to a counter direction. The direction of rotation of the impeller is reversed periodically to substantially reduce formation of a vortex around the shaft of the impeller and to provide increased shear forces in the body for purposes of improving treatment of the molten metal by improved dispersion of the media therein.

Abstract: Disclosed is an improved casting tip for a nozzle of a continuous caster, the tip designed for transferring molten metal from a molten metal reservoir to a continuously advancing mold as formed, for example, by twin belts, rolls or block casters for casting molten metal into solid form. The casting tip is comprised of a top wall, a bottom wall oppositely disposed from the top wall, a first side wall, and a second side wall oppositely disposed from the first side wall, the first and second side walls joined to the top and bottom walls to form a passage therebetween having an entrance and an exit. The passage has a top wall inside surface having a first portion that first converges towards the bottom wall starting at the entrance and has a second portion that diverges from the bottom wall to the exit, the top wall first portion having a length less than the top wall second portion length.

Abstract: A method for pressurizing a gas using a liquid. The method comprises providing a liquid pump; providing a liquid for introducing to the liquid pump; introducing a gas to the liquid prior to the liquid entering the liquid pump; pumping the liquid and the gas through the liquid pump to provide a compressed mixture of the liquid and gas having an increased pressure; thereafter separating the gas from the liquid while both liquid and gas are under pressure; reducing the pressure of the liquid after the separation; and recirculating the liquid back to the liquid pump.

Abstract: Disclosed is a method of casting solidified aluminum comprising providing a body of molten aluminum; providing means for casting solidified aluminum from said molten aluminum and providing a nozzle comprised of titanium adapted to flow molten aluminum into said means for casting said solidified aluminum. The nozzle is electrically preheated before introducing molten aluminum thereto and casting solified aluminum therefrom.

Abstract: Disclosed is an improved casting tip for a continuous caster, the tip designed for transferring molten metal from a molten reservoir to a continuously advancing mold for casting the molten metal, the tip comprising a top wall, a bottom wall and two side walls joined to the top wall and bottom wall to form a passage therebetween having inside surfaces exposed to molten metal passing from the reservoir to the mold, the tip fabricated from a composite material comprised of a base layer of a titanium alloy and a refractory layer bonded to the base layer, the refractory layer resistant to attack by the molten metal.

Abstract: Disclosed is a method and apparatus of treating molten metal for reducing the amount of gaseous or volatile material contained therein. The method comprises providing a body of molten metal and contacting the molten metal with a porous member having a porous surface resistant to penetration with the molten metal. The porous member is subjected to reduced pressure to impose a reduced pressure zone on the molten metal contacting the porous surface thereby removing the gaseous material from the molten metal through the porous member.

Abstract: Disclosed is an improved flux comprising 32 to 61 wt. % sodium chloride, 2 to 15 wt. % magnesium chloride, 2 to 12 wt. % carbon, the remainder potassium chloride.