Abstract: A duplex impedance shield is disclosed which is used to effect improved shape control in the electromagnetic casting of molten metal or alloy. The shield is provided with a primary loop which substantially surrounds the upper portion of an electromagnetic casting station and a secondary loop attached thereto which serves to enlarge the air gap enclosed by the shield thereby increasing the impedance of the shield. The secondary loop of the shield may be provided with shunt means which can be manipulated to vary the inductance and/or the resistance of the shield thereby varying the impedance of the shield.

Abstract: A method and apparatus is disclosed for electromagnetic casting of metal and alloy ingots of desired shape having portions of small radius of curvature. An open-ended container or hot-top having spaced internal baffles is placed before the electromagnetic induction station of the casting apparatus to provide desired metal flow patterns. Also disclosed is a downspout having nozzle portions which provide preferred directionality to supplied molten metal.

Abstract: An improved method and apparatus for degassing molten metal is disclosed in which the molten metal is passed in countercurrent relationship with a fluxing gas which is introduced through a sparger plate provided with a plurality of orifices of controlled size and spacing so as to minimize fluxing gas bubble size while maximizing fluxing gas bubble density thereby optimizing the degassing of the molten metal.

Abstract: The invention relates to an improved method for the preparation and delivery of semi-solid thixotropic metal slurries for use in metal forming processes such as the rheocast and thixocast processes. The method includes inducing turbulent motion within the metal during solidification by electromagnetic or electrodynamic techniques under controlled temperature conditions so as to produce a highly fluid semi-solid slurry with a degenerate dendritic structure comprising solid spheroids dispersed in liquid. In the method of the preferred embodiment of the present invention, flow of the thixotropic metal slurry from the vibrating chamber is controlled by electromagnetic techniques and may be continuous or semi-continuous.

Abstract: An improved method for fabricating a ceramic sparger plate for use in the degassing of molten metal is disclosed in which a castable ceramic is poured into a mold which contains an array of vertically disposed strands which are removed subsequent to the ceramic curing and prior to firing of the ceramic thus leaving the desired pattern of holes through which the fluxing gas is introduced into the molten metal.

Abstract: A method and apparatus for electromagnetic casting of metals and alloys is disclosed wherein anti-parallel inductors are utilized between the main inductor and the ingot being cast to provide for shape control of the ingot.

Abstract: An apparatus for casting metals wherein the molten metal is contained and formed into a desired shape by the application of an electromagnetic field. A control system is utilized to minimize variations in the gap between the molten metal and an inductor which applies the magnetic field. The gap or an electrical parameter related thereto is sensed and used to control the current to the inductor.

Abstract: An improved method for fabricating a ceramic sparger plate for use in the degassing of molten metal is disclosed in which a castable ceramic is poured into a mold which contains an array of vertically disposed strands which are removed subsequent to the ceramic curing and prior to firing of the ceramic thus leaving the desired pattern of holes through which the fluxing gas is introduced into the molten metal.

Abstract: The disclosure teaches an improvement in the degassing and filtration of molten metal, especially aluminum, using an apparatus which employs a pair of sequentially placed, removable filter-type plates and at least one fluxing gas inlet positioned therebetween. The first of said filter-type plates is characterized by a plurality of holes which provide a preferential path through which the fluxing gas flows upwardly through the first of said filter plates in countercurrent contact with the melt. Said plate serves to break up said fluxing gas into a fine dispersion to assure its intimate and extensive contact with the melt. Dissolved gases and non-metallic inclusions are thereby abstracted and removed from said melt.

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. A control system is utilized to minimize variations in the gap between the molten metal and an inductor which applies the magnetic field. The gap or an electrical parameter related thereto is sensed and used to control the current to the inductor.

Abstract: Improvements in the direct chill casting of copper base alloys such as the tin brasses, tin bronzes and those alloys which exhibit a liquidus-solidus temperature separation of at least 50.degree. C. is brought about by utilizing boron nitride particles in the dressing material for the mold walls. These boron nitride particles may also be added to normally used molten metal covering material and utilized as a cover for said alloys in the casting process. The most effective results in casting are obtained when using the boron nitride particles in mold dressing form in conjunction with molten cover form.

Abstract: The disclosure teaches an improvement in the degassing and filtration of molten metal, especially aluminum, using an apparatus which employs a pair of sequentially placed, removable filter-type plates and at least one fluxing gas inlet positioned therebetween. The first of said filter-type plates is characterized by a plurality of holes which provide a preferential path through which the fluxing gas flows upwardly through the first of said filter plates in countercurrent contact with the melt. Said plate serves to break up said fluxing gas into a fine dispersion to assure its intimate and extensive contact with the melt. Dissolved gases and non-metallic inclusions are thereby abstracted and removed from the melt.

Abstract: The disclosure teaches an improved filter-type media which is characterized by a plurality of holes of equal size which are substantially larger than the pore size of the filter-type media thereby providing a preferential path through the filter-type media.

Abstract: A method and apparatus for electromagnetic continuous or semicontinuous casting of metals and alloys. A coolant application system may be adjustably positioned to control the solidification front at the surface of the casting without otherwise influencing the containment process through modification of the magnetic field.

Abstract: A copper base alloy is disclosed which exhibits improved resistance to crack propagation during hot processing as well as good mechanical properties. The alloy comprises from about 4.0 to about 11.0% tin, from about 0.01 to about 0.3% phosphorus, from about 1.0 to about 5.0% of a material selected from the group consisting of iron and a mixture of iron and cobalt, up to about 0.4% chromium, balance essentially copper. The alloy of the present invention possesses a substantially non-dendritic grain structure in the cast condition which contributes to said resistance to crack propagation.

Abstract: A method for adding reactive elements to molten copper or copper base alloys is disclosed. This method prevents unwanted reactions and oxidation by adding the reactive elements to the molten metal in the form of a powder mixture placed within tubing which is compatible with said molten metal. This filled tubing is sealed and drawn down, if desired, to an appropriate size for rapid melting within said molten metal and consequent rapid dissolution of the reactive elements throughout the molten metal.

Abstract: A method of cladding metal plate with a protective layer of copper or copper base alloy is disclosed. The metal plate is contacted with a standing waveform of molten copper or copper base alloy in order to provide the cladding layer. This clad composite material is used to provide corrosion resistance for the metal plate substrate and an inexpensive alternative to solid thick sheets of copper or copper base alloy to deter corrosion.

Abstract: Improved method for melting copper base alloys containing from 2 to 12% aluminum including the steps of covering a molten mass of said copper base alloy with an essentially continuous flux layer of a molten salt consisting essentially of from 10 to 90% by weight of potassium chloride, from 10 to 90% by weight of sodium chloride and less than 5% by weight of other materials, said salt having a melting point of from 660 to 800.degree. C, and adding additional amounts of said alloy through said flux layer.

Abstract: Brazing preforms are disclosed which may take the form of wire, sheet or strip, and which are useful for joining copper, ferrous and nickel base alloys. The preforms of this invention are prepared from an alloy which contains manganese from 22 to 40%, iron from 0.1 to 2%, aluminum from 0.1 to 5%, zinc from 2 to 10%, balance essentially copper. A method of brazing is also disclosed which may be performed with or without a flux, and which is conducted in an inert atmosphere, at a temperature of from about 900.degree. to 1100.degree.C. The brazed products of this invention possess reduced brittleness and improved resistance to corrosion.