Abstract: An additive for increasing the toughness of thin-wall iron castings is provided. The additive includes amounts of a non-ferrous metal oxide and a metal sulfide in which the non-ferrous metal has an affinity for oxygen less than that of iron, and the metal has an affinity for sulfur less than that of magnesium. The metals contained in the oxides and sulfides are also not alkali, alkali earth or rare earth metals to reduce the incidence of defect formation in the castings. The metal oxide and metal sulfide, when added to a cast iron melt react with magnesium added to the melt as a spheroidizing graphite element to form nucleation sites having a core of magnesium oxide surrounded by magnesium sulfide. These nucleation sites allow for increased nucleation of graphite, whether in vermicular or spheroidal form, such that the cross-section of the thin-wall iron casting is more uniform, thereby decreasing the amount of carbide formed in the casting and increasing the toughness of the casting.

Abstract: The preparation of micron sized droplets of high melting point metals by shearing the metal in the molten state into micron sized droplets while in a carrier in the form of a molten inorganic salt, glass or gas, in the presence of an oxidizing agent to form a thin protective coating on the micron sized particles while in their molten state and then allowing the formed micron sized particles to solidify.

Abstract: Bulk shapes and solid structures of amorphous metals formed of micron sized particles produced by droplet emulsion technique whereby undercooled droplets are solidified in the amorphous state with a stabilizing coating on the surfaces thereof, the shapes and solid structures being formed by dispersing the stabilizing coating and bringing the particles into intimate metal to metal contact for atomic bonding, without raising the temperature to crystallization temperature.

Abstract: The preparation of micron sized spherical particles of metals comprising emulsification of the metal in the molten state in a carrier fluid, preferably in the form of an inert liquid, and reacting the molten metal while in the emulsified state in the fluid to form an insoluble reaction product on the surface which stabilizes metal droplets in the emulsion.

Abstract: The preparation of micron sized spherical particles of metals comprising emulsification of the metal in the molten state in a carrier fluid, preferably in the form of an inert liquid, and reacting the molten metal while in the emulsified state in the fluid to form an insoluble reaction product on the surface which stabilizes metal droplets in the emulsion.