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.

Abstract: An improved process for treating a body of molten metal is disclosed wherein a rotating impeller is used to disperse treatment media in the body. The process comprises the steps of providing a body of molten metal to be treated, the body having an upper region and a lower region, and providing an impeller on a shaft in said body. Treatment media is added to the body and the impeller is rotated to disperse the treatment media in the body. During the process of treating the body, the impeller is moved periodically between the lower portion and the upper portion of the molten metal body to reduce vorticity therein and to improve dispersion of the treatment media.

Abstract: Disclosed is an improved ladle suitable for transferring molten metal from a molten metal body. The ladle is fabricated from a titanium alloy and coated with a refractory resistant to attack by the molten metal. The titanium alloy and refractory coating have coefficients of thermal expansion that permit the ladle to be cycled in and out of the molten metal without spalling of the refractory coating from the titanium alloy.

Abstract: The die casting machine includes a trough containing a supply of molten metal and a feed tube extending into the supply of molten metal in the trough. A flow of molten metal is maintained in the trough past the feed tube independent of the transfer of molten metal through the feed tube. The die casting machine further includes a filtering system.

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: There is disclosed a method of treating a solution, e.g., an alkaline or acidic solution, containing heavy metals ions therein. With respect to alkaline solutions, the method includes providing a body of the solution; contacting the body with a material such as carbon dioxide to change the pH, e.g., to lower the pH to a pH in the range of 9 to 10.5; then treating the solution to further change the pH and cause precipitation of hydroxides, including chromium hydroxide; and separating the hydroxide precipitates from the solution to provide a substantially neutral solution having a reduced amount of chromium ions, for example, contained therein.

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.

Abstract: This invention provides improved casting processes, equipment, and products. The invention is especially advantageous for die casting.

Abstract: A system for in-line alloying of a molten metal stream comprises: means for controlling mass flow rate of the stream; means for adding alloying material to the stream at an adjustable rate; means for determining chemical composition of the stream downstream from the material adding means, preferably at timed intervals; and means for adjusting the rate at which alloying material is added to the stream based on mass flow rate and the extent to which the determined stream composition differs from a desired composition. A method for conducting in-line alloying and analysis of a continuous metal stream is also disclosed.