Abstract: Preferred embodiments of the present invention include methods that allow for casting alloys, and preferentially casting wrought alloys to circumvent problems such as, for example, hot tearing. Preferred embodiments of the present invention provide for alloys having predominantly spherical primary ?-aluminum grains in their microstructure (i.e., substantially free of dendrites) formed by mixing two liquids of differing compositions that are held at predetermined temperatures, such that when mixed they produce a predetermined alloy composition at a predetermined temperature that is inclined to solidify with a predominantly spherical grain structure that minimizes the alloy's tendency towards hot tearing.

Abstract: A method for the refining of primary aluminum in hypoeutectic alloys by mixing a titanium based grain refiner into a solid/semi-solid hypoeutectic slurry is described. The method provides control of the morphology, size, and distribution of primary Al in a hypoeutectic Al—Si casting by mixing a hypoeutectic Al—Si liquid with titanium boron alloys. The invention enables grain refining techniques for SSM casting of hypoeutectic Al—Si alloys.

Abstract: A method for the refining of primary silicon in hypereutectic alloys by mixing at least two hypereutectic alloys into a solid/semi-solid hypereutectic slurry is described. The method provides control of the morphology, size, and distribution of primary Si in a hypereutectic Al—Si casting by mixing a hypereutectic Al—Si liquid with solid hypereutectic Al—Si particles. The invention enables SSM processing of hypereutectic Al—Si alloys.

Abstract: A method for the refining of primary aluminum in hypoeutectic alloys by mixing at least two hypoeutectic alloys into a solid/semi-solid hypoeutectic slurry is described. The method provides control of the morphology, size, and distribution of primary Al in a hypoeutectic Al—Si casting by mixing a hypoeutectic Al—Si liquid with solid hypoeutectic Al—Si particles to impart desirable mechanical properties. The invention enables SSM molding of hypoeutiectic alloys without the need for secondary processing steps associated with other rheocasting processes.

Abstract: Preferred embodiments of the present invention include methods that allow for casting alloys, and preferentially casting wrought alloys to circumvent problems such as, for example, hot tearing. Preferred embodiments of the present invention provide for alloys having predominantly spherical primary ?-aluminum grains in their microstructure (i.e., substantially free of dendrites) formed by mixing two liquids of differing compositions that are held at predetermined temperatures, such that when mixed they produce a predetermined alloy composition at a predetermined temperature that is inclined to solidify with a predominantly spherical grain structure that minimizes the alloy's tendency towards hot tearing.

Abstract: A method for the refining of primary aluminum in hypoeutectic alloys by mixing at least two hypoeutectic alloys into a solid/semi-solid hypoeutectic slurry is described. The method provides control of the morphology, size, and distribution of primary Al in a hypoeutectic Al—Si casting by mixing a hypoeutectic Al—Si liquid with solid hypoeutectic Al—Si particles to impart desirable mechanical properties. The invention enables SSM molding of hypoeutiectic alloys without the need for secondary processing steps associated with other rheocasting processes.

Abstract: A method for the refining of primary aluminum in hypoeutectic alloys by mixing a titanium based grain refiner into a solid/semi-solid hypoeutectic slurry is described. The method provides control of the morphology, size, and distribution of primary Al in a hypoeutectic Al-Si casting by mixing a hypoeutectic Al-Si liquid with titanium boron alloys. The invention enables grain refining techniques for SSM casting of hypoeutectic Al-Si alloys.

Abstract: A method for the refining of primary silicon in hypereutectic alloys by mixing at least two hypereutectic alloys into a solid/semi-solid hypereutectic slurry is described. The method provides control of the morphology, size, and distribution of primary Si in a hypereutectic Al—Si casting by mixing a hypereutectic Al—Si liquid with solid hypereutectic Al—Si particles. The invention enables SSM processing of hypereutectic Al—Si alloys.

Abstract: A method for the refining of primary aluminum in hypoeutectic alloys by mixing at least two hypoeutectic alloys into a solid/semi-solid hypoeutectic slurry is described. The method provides control of the morphology, size, and distribution of primary Al in a hypoeutectic Al—Si casting by mixing a hypoeutectic Al—Si liquid with solid hypoeutectic Al—Si particles to impart desirable mechanical properties. The invention enables SSM molding of hypoeutiectic alloys without the need for secondary processing steps associated with other rheocasting processes.

Abstract: Described herein are alloys substantially free of dendrites. A method includes forming an alloy substantially free of dendrites. A superheated alloy is cooled to form a nucleated alloy. The temperature of the nucleated alloy is controlled to prevent the nuclei from melting. The nucleated alloy is mixed to distribute the nuclei throughout the alloy. The nucleated alloy is cooled with nuclei distributed throughout.

Abstract: A method for the refining of primary silicon in hypereutectic alloys by mixing a hypereutectic alloy and a solid/semi-solid hypoeutectic alloy is described. The method provides control of the morphology, size, and distribution of primary Si in a hypereutectic Al—Si casting by mixing a hypoeutectic Al—Si liquid with one that is hypereutectic to impart desirable mechanical properties.

Abstract: The present invention relates to systems of methods of detecting and measuring inclusions in liquid metals. More particularly, non-metallic inclusions having a conductivity level different from the liquid metal melt are forced to migrate and are collected on a measurement surface using electromagnetic Lorentz forces. The inclusions and their concentrations are detected at the measurement surface using either an electrostatic detection system or an optical detection system.

Abstract: The present invention relates to systems of methods of detecting and measuring inclusions in liquid metals. More particularly, non-metallic inclusions having a conductivity level different from the liquid metal melt are forced to migrate and are collected on a measurement surface using electromagnetic Lorentz forces. The inclusions and their concentrations are detected at the measurement surface using either an electrostatic detection system or an optical detection system.

Abstract: The present invention relates to systems of methods of detecting and measuring inclusions in liquid metals. More particularly, non-metallic inclusions having a conductivity level different from the liquid metal melt are forced to migrate and are collected on a measurement surface using electromagnetic Lorentz forces. The inclusions and their concentrations are detected at the measurement surface using either an electrostatic detection system or an optical detection system.

Abstract: Molten metal containing suspended liquid particles is passed preferably generally upwardly through a porous media so constructed and arranged such that the movement of the molten metal therethrough renders the suspended liquid particles gravity separable. The gravity separable liquid particles rise upwardly or settle downwardly so as to be removable from said molten metal for subsequent removal therefrom. An associated apparatus is also provided.

Abstract: A method of treating molten aluminum containing a suspension of finely divided salt particles remaining after filtering molten aluminum is disclosed. The method comprises providing a body of molten aluminum containing the suspension of molten salt particles entrained therein and passing the molten aluminum into a medium substantially unwettable by the molten salt particles. The particles of salt are collected on the medium and permitted to agglomerate so as to be removed to the surface of the molten aluminum by gravity.

Abstract: A filter system for removing solid impurities from molten metal is described comprising a housing containing vertically disposed rigid coarse filter facing the incoming flow of molten metal and capable of removing solids having a particle size of at least 10 microns and a rigid fine filter mounted vertically behind the coarse filter and capable of removing solids having a particle size as small as 1 micron. The apparatus further includes a heater for maintaining the temperature of the molten metal and a sparger mounted adjacent the front face of one filter to provide an intermittent gas flow over the face of the filter to dislodge solids on the filter as filter cake. In a preferred embodiment, the rigid filters are nested cylinders, and the molten metal is directed to the center of the smaller coarse filter cylinder from which it then flows through the coarse filter outward to and through the fine filter cylinder and then from the fine filter out of the filter housing.