Abstract: There is provided a copper-base alloy useful for coinage that has a golden visual appearance. The material has a transverse electrical conductivity substantially similar to that of copper alloy C713 and when clad to a copper alloy C110 core, a transverse electrical conductivity substantially similar to both sides of a Susan B. Anthony United States dollar coin. The copper-base alloy is a copper-manganese-zinc-nickel alloy.

Abstract: An apparatus and method for monitoring the liquid/solid interface position of an alloy ingot being formed by either direct chill or electromagnetically enhanced direct chill casting systems comprising an inductive sensor wire disposed about the mold wall of the casting system, driving the sensor wire to cause a magnetic flux to penetrate into the ingot, and sensing the change in the impedance or components of the impedance of the system. Monitoring the liquid/solid interface position allows ready adjustment to operating controls, such as, containment/stirring inductors, cooling systems and casting parameters, thereby producing a desirable ingot.

Abstract: A process for electromagnetically casting molten material into a thin strip having a substantially constant thickness. An inductor is provided for electromagnetically shaping the molten material. The material is electromagnetically shaped into a strip having a desired thickness. Variations in the thickness of the molten material are automatically reduced during the shaping step by selecting the frequency of the current applied to the inductor so that the thickness of the strip is about 1.8 to about 2.6 current penetration depth.

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: A bottom block for use in electromagnetic casting of metals wherein the block is constructed of a material having a closely matched electrical resistivity to that of the metal to be cast. The block may be provided with a deeply hollowed out central section so that during startup the end of the down spout supplying molten metal may be positioned a substantial distance below the plane of the top surface of the bottom block.

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: A process is disclosed for reducing the carbon content of a melt of metal or metal alloy, carbon, and at least one strong oxide forming metallic alloying element from an initial value of about 0.1 wt % carbon to a final value of not less than about 0.003 wt % carbon. The process consists of contacting the melt with a reactive oxide of the metallic alloying element and simultaneously stirring the melt with an inert gas.

Abstract: A method and apparatus is disclosed for electromagnetic casting of metal and alloy ingots of rectangular or other desired shape having corners or portions of small radius of curvature. A coolant application system is provided which lessens the severity of the rounding off or radius of the corners of the electromagnetically cast ingots by contouring the coolant application rate and/or elevation so that the rate and/or elevation is a minimum at the corners of the ingot.

Abstract: A process and apparatus for determining the value of parameters which affect emissivity of radiation from a metal load in an electromagnetic casting system. Infrared radiation being emitted from the surface of the load is sensed by an array of fiber optic filaments secured within elements of the electromagnetic casting system. Radiation signals are transmitted by the filaments to a signal processor which enables readout display of electromagnetic casting parameters such as liquid temperature, maximum load temperature, position of the liquid/solid interface, and head position.

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: 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 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 or process for casting metals by electromagnetically forming molten metal into a desired shape by applying a magnetic field to the molten metal. The magnetic field defines a containment zone for the molten metal. The hydrostatic pressure exerted by the molten metal in the containment zone is sensed and in response thereto the flow of molten metal into the containment zone is controlled. This minimizes changes in the hydrostatic pressure.

Abstract: The present invention relates to either a batch or continuous process for decarburization of metals and metal alloys. A shallow melt of metal or metal alloy having a depth of between about 2 in. to about 24 in. is provided. The carbon content of the melt is reduced from its initial value to a range of about 0.3 to 0.1 wt. % carbon. To accomplish this reduction, an oxygen enriched gas is blown onto the surface of the melt at a velocity of about 10 to about 50% of supersonic velocity so as to decarburize the melt without creating any substantial splashing of the melt. At the same time, the melt is stirred by injecting an inert gas below the melt surface. Subsequently, the carbon content of the melt is further reduced from the carbon percentage achieved in the first reduction to a value of not less than about 0.001 wt. % carbon.

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: 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 nonmagnetic shield.