Abstract: A molten metal gas-atomizing spray-depositing apparatus has an atomizer which employs a pressurized gas flow for atomizing a stream of molten metal into a spray pattern of metal particles and for producing a flow of the particles in the pattern thereof along with the pressurized gas flow in a generally downward direction. The apparatus also has a substrate, such as composed of stainless steel, disposed in spaced relation below the atomizer with at least an upper surface layer of a glass thereon, being thermally softenable over a broad predetermined temperature range. The pressurized gas flow impinges on the glass surface layer of the substrate which receives a deposit of the particles in the spray pattern to form a product thereon.

Abstract: A die set includes a punch for stamping a cavity in a work piece to produce a flat base surface and sidewalls which are perpendicular to the base surface. A forming bushing applies a deformation stress perpendicular to the stress applied by the punch to direct metal flow. In one embodiment, the impact surface of the punch contains piercing points to increase the depth of penetration of the punch.

Abstract: A molten metal gas-atomizing spray-depositing apparatus has an atomizer employing a pressurized gas flow for atomizing a stream of molten metal into a divergent spray pattern of metal particles and producing a flow of the particles in the pattern thereof along with the gas flow in a generally downward direction. The apparatus also includes a substrate movable continuously along an endless path and having an area thereon disposed below the atomizer for receiving a deposit of the particles in the spray pattern to form a product on the substrate being substantially uniform in thickness. The endless path of the substrate is generally elongated in the downward direction and thus extends parallel to the general downward direction of gas flow such that any particle overspray past the deposit-receiving area is carried by the gas flow downward past the substrate, substantially avoiding entrainment of the particle overspray in the product being formed on the substrate.

Abstract: A molten metal spray-depositing apparatus employs a magnetic field-generating nozzle for atomizing a molten metal stream into a spray of metal particles. The magnetic driving field generated by the magnetic atomizing nozzle generates eddy currents which produce an induced field in the metal stream opposing the driving field and creating a torque which causes the stream to break up upon exiting the driving field. The nozzle has one of two configurations for generating one of two generic magnetic field geometries. In one configuration the nozzle utilizes a pair of spaced magnetic poles, such as provided by Helmholtz coils, for generating a transverse magnetic field geometry across the stream. In the other configuration the nozzle employs a solenoid coil for generating a solenoidal magnetic field geometry parallel to the stream.

Abstract: A molten metal gas-atomizing spray-depositing apparatus has an atomizer which employs a pressurized gas flow for atomizing a stream of molten metal into a spray pattern of semi-solid metal particles. The apparatus also has a movable non-preheated substrate composed of a material having a predetermined thermal conductivity of about one or less (W/M-K) being disposed below the atomizeer. The substrate receives thereon a deposit of the particles in the spray pattern. The pressurized gas flow also impinges thereon for cooling the deposit on the substrate to form a product thereon. The predetermined thermal conductivity of the substrate of one or less precludes extraction of heat by the substrate from, and thus solidification of, the deposit upon initial contact with the substrate whereby a reduction of porosity is achieved in the deposit.

Abstract: A gas-atomizing system for spray casting a spray of molten metal on a moving substrate in which the gas atomizing device is in the form of an annulus having a central opening therethrough through which the molten metal to be atomized flows. The annulus is provided with a plenum chamber which communicates with elongated openings on the bottom surface of the annulus. The manifold and outlets are so arranged that a divergent conical spray pattern is produced having a central axis inclined with respect to the vertical axis of the molten metal stream in a direction downstream of the moving substrate upon which the spray material is deposited.

Abstract: An apparatus and process for continuous horizontal casting of an ingot from molten metal. The apparatus comprises a mold for effecting rapid solidification of the molten metal into the ingot. A feed nozzle supplies the molten metal to the mold. Transition structure is disposed between the mold and the feed nozzle for solidifying the molten metal in the transition structure to prevent freeze back in the feed nozzle.

Abstract: The present invention relates to a technique for forming silicon carbide coated porous filters for use in filtering molten metal, especially copper and copper alloy melts. The technique comprises preparing a silicon carbide containing slurry having a viscosity in the range of about 1 to about 50, preferably from about 5 to about 30, centipoise and impregnating a rigid porous substrate material with the slurry. In a preferred embodiment, the slurry contains mono-aluminum phosphate as a binding agent, ethylene glycol as a wetting agent, powdered silicon carbide having a maximum settling rate of about 0.1 mm./min. and the balance essentially water. After draining of the excess slurry, the coating substrate material is heated to substantially prevent foaming of the coating during firing and fired to bond the silicon carbide coating to the substrate material.

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: The present invention relates to a technique for forming silicon carbide coated porous filters for use in filtering molten metal, especially copper and copper alloy melts. The technique comprises preparing a silicon carbide containing slurry having a viscosity in the range of about 1 to about 50, preferably from about 5 to about 30, centipoise and impregnating a rigid porous substrate material with the slurry. In a preferred embodiment, the slurry contains mono-aluminum phosphate as a binding agent, ethylene glycol as a wetting agent, powdered silicon carbide having a maximum settling rate of about 0.1 mm./min. and the balance essentially water. After draining of the excess slurry, the coated substrate material is heated to substantially prevent foaming of the coating during firing and fired to bond the silicon carbide coating to the substrate material.

Abstract: A copper or copper alloy material having a reduced number of defects is formed by removing impurities from the material while in a molten state with a member having exposed silicon carbide particles. The member may be a bed filter formed from bed media having exposed silicon carbide particles, a porous body formed from a slurry containing silicon carbide, a porous body having at least one melt contacting surface coated with a silicon carbide material, and/or a lining having at least one melt contacting surface coated with a silicon carbide material.

Abstract: A copper or copper alloy material having a reduced number of defects is formed by removing impurities from the material while in a molten state with a member having exposed silicon carbide particles. The member may be a bed filter formed from bed media having exposed silicon carbide particles, a porous body formed from a slurry containing silicon carbide, a porous body having at least one melt contacting surface coated with a silicon carbide material, and/or a lining having at least one melt contacting surface coated with a silicon carbide material.

Abstract: A copper or copper alloy material having a reduced number of stringer defects is formed by removing iron-containing components from the material with a member having exposed silicon carbide particles while the material is in a molten state. The member may be a bed filter formed from bed media having exposed silicon carbide particles, a porous body formed from a slurry containing silicon carbide, a porous body having at least one melt contacting surface coated with a silicon carbide material, and/or a furnace or passageway lining having at least one melt contacting surface coated with a silicon carbide material.

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: A process and apparatus for producing a copper metal or alloy wherein a first material is added to a molten metal, consisting essentially of copper preferably in a furnace. After the first material is added, the molten metal is passed through a filtration device to remove particulate matter from the molten metal and/or reduce the oxygen content of the molten metal. After filtration, a second material is added to the molten metal.

Abstract: Copper base alloys having improved rupture properties and improved hot rolling performance consisting of from 2 to 9.5% aluminum, preferably also from 0.001 to 3.0% silicon, a grain refining element, preferably cobalt in an amount from 0.001 to 5.0%, from 0.001 to 0.5% of a material selected from the group consisting of a material of the lanthanide series of the Periodic Table and mixtures thereof, and the balance essentially copper.

Abstract: The present invention comprises an improved process for the preparation of aluminum base alloys containing magnesium and silicon in wrought form, and particularly as tread plate which includes the steps of casting, homogenizing, hot rolling within a critical temperature and time range and cooling at a rate greater than a critical rate and before a critical delay time after said hot rolling step. The resulting product can be artificially aged without the need for a separate solution heat treatment and possesses improved tensile properties, surface appearance and corrosion resistance.

Abstract: An improved copper base alloy having good high temperature properties, such as hot rollability, creep strength and stress rupture life. The alloy contains from about 2 to 9.5% aluminum, from about 0.001 to 3% silicon, and a grain refining element selected from the group consisting of iron from about 0.001 to 5%, chromium from about 0.001 to 1%, zirconium from about 0.001 to 1%, cobalt from about 0.001 to 5% and mixtures thereof. In addition, the alloy contains titanium in an amount from about 0.2 to 1%.