Abstract: An apparatus and process for casting metals wherein the molten metal is contained and formed into a desired shape by the application of an electromagnetic field produced by a multi-turn inductor. The pitch or spacing of individual turns of the inductor is controlled to provide accurately varied electromagnetic pressure. The process includes the step of varying the distance between turns and/or the height of the individual turns to control the electromagnetic forces and balance the metallostatic pressure within the molten metal being cast.

Abstract: An apparatus and process for casting metals wherein the molten metal is contained and formed into a desired shape by the application of an electromagnetic field produced by a multi-turn inductor. The pitch or spacing of individual turns of the inductor is controlled to provide accurately varied electromagnetic pressure. The process includes the step of varying the distance between turns and/or the height of the individual turns to control the electromagnetic forces and balance the metallostatic pressure within the molten metal being cast.

Abstract: An apparatus and process electromagnetically forms feed ribbon or rod material into a desired thin strip shape. Inductors contain and form the material in molten form into the desired shape. There are at least an upstream and downstream inductor for applying the magnetic field to the molten material. Both the upstream and downstream inductors may be jointly used to contain and form the molten material into the thin strip shape. An alternating current is applied to the inductors to generate the magnetic field. This magnetic field defines a containment zone for the molten material and a gap between the molten material and the inductors. The current is applied to the inductors so that the gap remains substantially constant. The feed material has an upstream and a downstream liquid-solid interface adjacent the upstream and downstream inductors, respectively, which define the molten material head and solid material portions of the material.

Abstract: A process for continuously treating a ferrous or non-ferrous alloy melt is disclosed. The melt is transferred through a plurality of interconnected zones. The carbon content of the melt is lowered in a first treatment zone. Then, the residual oxygen content of the melt is lowered in a second treatment zone by adding a deoxidizing agent to the melt. Active sulfide forming agents are added to the melt in the third treatment zone to lower the sulfur content of the deoxidized melt. The dissolved gas content of the desulfurized melt is lowered by flushing the melt with a gas in a fourth treatment zone. Next, the remaining particulates and films are removed from the melt by filtering the degassed melt in a fifth treatment zone.

Abstract: A multi-strand apparatus and process is provided for casting molten materials into ingots of desired shape. The apparatus comprises a plurality of devices for receiving and electromagnetically forming the molten material into desired shape. Each of the receiving and forming devices includes an inductor for applying a magnetic force field to the molten material. The inductor in operation is spaced from the molten material by a gap extending from the surface of the molten material to the opposing surface of the inductor. An alternating current applying device sends current to its associated inductor to generate the magnetic force field. Circuitry associated with each of the inductors senses variations in their respective gaps. The improvement comprises a pulse width modulating circuit associated with said gap variation sensing circuitry being connected to the alternating current applying device for controlling the application of alternating current to the inductor.

Abstract: An apparatus and process for casting metals wherein the molten metal is contained and formed into a desired shape by the application of an electromagnetic field established by an inductor. The height of the liquid metal head, the location of the liquid-solid interface at the periphery of the forming ingot, and/or variations in the values of these parameters is displayed during the casting run by a system which monitors the in-phase component of the voltage across the inductor to determine variations in the total equivalent series resistance of the electromagnetic casting system as seen by the inductor.

Abstract: A process and apparatus is described for slurry casting an ingot having a non-dendritic structure across substantially its entire cross section. The casting mold has a first chamber for extracting heat from the molten material. The amount of heat extracted from the molten material and the cooling rate of the molten material is controlled to initiate growth of primary phase particles and to form a semi-solid slurry having a desired fraction solid. The mold also has a second chamber for casting the slurry into an ingot. Adjacent the exit portion of the first chamber and the inlet portion of the second chamber, a transition member is provided for delivering the slurry to the casting chamber and for preventing the ingot shell from extending back into the first chamber.

Abstract: An apparatus and process for electromagnetically forming a material into a desired thin strip shape. The apparatus comprises a first portion for electromagnetically containing and forming the material in molten form into a cross-sectional shape substantially the same as the desired thin strip shape. A second portion receives the molten material in the thin strip shape from the first portion. In addition, the second portion reduces the distortion in the cross-sectional shape due to surface tension. The second portion includes a device for providing an electromagnetic field having a reduced strength as compared to the strength of an electromagnetic field in the first portion. The electromagnetic field may be reduced in strength by providing an inductor having hollow inner surfaces facing the molten material so as to form substantially straight vertical surfaces in the molten material.

Abstract: An apparatus and process for casting metals wherein the molten metal is contained and formed into a desired shape by the application of an electromagnetic field. The apparatus includes an inductor and a non-magnetic shield. Changes in the location or the location of the top surface of the molten metal head are continuously displayed during the casting run by monitoring electrical parameters of the electromagnetic casting system including at least one electrical parameter of the non-magnetic shield.

Abstract: A process and apparatus having improved efficiency for forming a semi-solid alloy slurry. A molten metal in a containing device is mixed electromagnetically by a moving, non-zero magnetic field provided over substantially all of a solidification zone within the containing device. The magnetic field causes the shearing of dendrites formed in the solidification zone at a desired shearing rate. The magnetic field is generated by a device supplied with current at a desired line frequency. By operating within a defined range of line frequencies, a desired shear rate for attaining a desired cast structure at reduced levels of power consumption and current can be achieved.

Abstract: An electromagnetic casting process and apparatus utilizing an active transformer-driven copper shield. The shield is actively driven with a voltage out of phase with the voltage in the containment inductor with the result that a bucking current is produced in the shield which is out of phase with the current induced in the shield by the inductor. An active transformer-driven duplex variable impedance shield is also disclosed.

Abstract: A method and apparatus for electromagnetic casting of metal and alloy ingots of desired shape having portions of small radius of curvature. A modified shield is provided which provides for a reduction of the electromagnetic field intensity at the corners of the forming ingot by increasing local screening of the field at the corners. Increased local screening at the corners is achieved by locally increasing shield depth, by providing for deeper displacement of the shield, by changing the shield section, or by changing the shield orientation. Also disclosed is a modified inductor which is shaped so as to be located at a greater distance from the portions of small radius of curvature of the ingots than from portions of the ingots adjacent to the portions of small radius of curvature. The modified shield may be combined with the modified inductor and/or with a coolant manifold to simultaneously modify and control coolant application elevation such that the elevation is a minimum at the corners of the ingot.

Abstract: An apparatus and a method for forming a semi-solid thixotropic slurry. The apparatus includes a duplex mold arrangement for postponing solidification within the mold until the molten metal is within a magnetic field for providing magnetohydrodynamic stirring. The duplex mold includes a first portion of low thermal conductivity and a second portion of high conductivity.

Abstract: A mold for use in an apparatus and process utilizing an electromagnetic field to stir a molten metal or metal alloy comprises a plurality of laminations of thermally and electrically conductive material separated by electrically insulating material. The electrically insulating material is oriented to minimize at least some of the flow path lengths of currents induced in the mold whereby magnetic induction loses caused by the mold are substantially reduced and the stirring efficiency is enhanced.

Abstract: A multi-strand process is provided for casting molten materials into ingots of desired shape. The process uses two inductors for receiving the molten material and applying the first and second electromagnetic force fields to form the molten material into the ingots. The inductors are located adjacent each other so that the first and second force fields interact with each other. A first device is associated with one of the inductors for applying a first alternating current at a first desired frequency to an associated inductor to generate the first magnetic force field. A second device is associated with the other of the inductors for applying a second alternating current at a second desired frequency to generate the second magnetic force field. The second frequency is set to a desired value in relation to the first frequency in order to control the first and second resulting containment currents circulating in the molten material.

Abstract: A multi-strand apparatus and process for casting molten material into at least two ingots of desired shape. Structure is provided for receiving and electromagnetically forming the molten material into ingots of desired shape. Each of the receiving and forming structures includes an inductor for applying an electromagnetic force field to the molten material. When the inductor is in operation, it is spaced from the molten material by a gap extending from the surface of the molten material to the opposing surface of the inductor. The improvement comprises a device for distributing a common alternating current to the inductors to generate the magnetic fields. A device is provided for minimizing variations in the gaps during operation of the casting apparatus.

Abstract: A process and apparatus for continuously and semi-continuously casting molten metals and alloys. Control of the initial stages of solidification is carried out through application of a thermal insulating layer on the coolant side of a casting mold wall. The layer modifies the heat flux characteristics of the mold along a selected length thereof.

Abstract: A multi-strand apparatus and process for casting molten material into ingots of desired shape. A plurality of structures are provided for receiving and electromagnetically forming the molten material into the desired shape. Each receiving and forming structure includes an inductor for applying a magnetic force field to the molten material. When the inductor is in operation, it is spaced from the molten material by a gap extending from the surface of the molten material to the opposing surface of the inductor. Structure is provided for distributing a current in the inductor to generate the magnetic field. The improvement comprises a device arranged below the inductor for modifying the current distribution in the inductor to minimize the variations in the gap.

Abstract: A continuous lubrication casting mold for use in a process of continuously casting molten metals and alloys wherein a parting and/or lubricating agent reservoir is provided in the mold body. The agent is continuously applied over the inner surface of the mold after being introduced through passages within or through the mold section. The lubricant passages may be an intrinsic characteristic of the mold material or may be provided in the form of feed holes through the mold section. The ability to transmit lubricant through to the internal surface of the mold can be varied within the length of the casting mold to provide for variable lubricant transfer rates to different parts of the casting surface.

Abstract: A process and apparatus for forming a semi-solid thixotropic alloy slurry and preferably a rheocasting therefrom. Molten metal in a mold is cooled under controlled conditions while it is mixed under the influence of a moving magnetic field. A non-zero, magnetic field is provided across the full cross section of the mold and over the entire solidification zone. This results in a magnetomotive stirring force of sufficient magnitude to provide mixing of the molten metal to form the slurry. Preferably, a two pole induction motor stator is used to generate the magnetic field.