Abstract: A mold for casting metal ingot sows having an aspect ratio of at least 4:1. The mold comprises a bottom wall from which a side wall extends upwardly and outwardly and from which heat transfer structure extends downwardly for transferring heat away from the bottom wall.

Abstract: Continuously-cast lithium-containing alloy ingots are produced by a direct chill process including cooling the alloy to form a continuous ingot having a solid shell and further cooling the ingot by direct chill with an organic coolant. The organic coolant in one aspect includes a modified hydrocarbon fluid, e.g., ethylene glycol, having less than a predetermined moisture content. The method includes recirculating coolant while controlling moisture content. An ingot formed by the present invention provides small dendrite arm spacing in a relatively large size ingot. Aircraft plate or sheet is produced from the ingot of the present invention.

Abstract: Disclosed is an aluminum-lithium alloy containing a predetermined amount of lanthanides which provides the alloy with an improved combination of strength and fracture toughness relative to a baseline alloy not containing lanthanides but otherwise having the alloy's composition.

Abstract: A method for continuously casting lithium-containing alloys by a direct chill process includes cooling the alloy to form a continuous ingot having a solid shell and further cooling the ingot by direct chill with an organic coolant. The organic coolant in one aspect includes a modified hydrocarbon fluid, e.g., ethylene glycol, having less than a predetermined moisture content. The method includes recirculating coolant while controlling moisture content. An ingot formed by the present invention provides small dendrite arm spacing in a relatively large size ingot.

Abstract: A method for continuously casting lithium-containing alloys by a direct chill process includes cooling the alloy to form a continuous ingot having a solid shell and further cooling the ingot by direct chill with an organic coolant. The organic coolant in one aspect includes a modified hydrocarbon fluid, e.g., ethylene glycol, having less than a predetermined moisture content. The method includes recirculating coolant while controlling moisture content. An ingot formed by the present invention provides small dendrite arm spacing in a relatively large size ingot.

Abstract: A process is disclosed for the continuous casting of a lithium-containing alloy including casting the alloy through a mold and applying alpha-olefin oligomer to the mold. In one aspect, the process includes a lubricant containing alpha-olefin oligomer, preferably having a viscosity in the range of about 1-3 cs at 450.degree. F. In another aspect, the process includes a lubricant containing less than the varnish-film forming amount of fatty ester, fatty acid, or fatty alcohol.

Abstract: A method for continuously casting lithium-containing alloys by a direct chill process includes cooling the alloy to form a continuous ingot having a solid shell and further cooling the ingot by direct chill with an organic coolant. The organic coolant in one aspect includes a modified hydrocarbon fluid, e.g., ethylene glycol, having less than a predetermined moisture content. The method includes recirculating coolant while controlling moisture content. An ingot formed by the disclosed method provides small dendrite arm spacing in a relatively large size ingot.

Abstract: The present invention involves a process for continuously casting a lithium-containing alloy by direct chill with a direct chill coolant and providing a moisture barrier liquid having a flash point higher than about 400.degree. F. to reduce water absorption in the coolant. The process in one aspect includes applying the moisture barrier liquid as a mold parting composition containing less than a varnish-film forming amount of fatty esters, fatty acids, or fatty alcohols. The process is particularly useful in the direct chill casting of aluminum-lithium alloy by direct chill with ethylene glycol coolant.

Abstract: A lubricating process is disclosed for continuously casting molten metal through a mold or header including applying a parting lubricant containing alpha-olefin oligomer to the mold or header. In one aspect, the process includes applying a parting lubricant containing alpha-olefin oligomer and fatty ester.

Abstract: A method for continuously casting lithium-containing alloys by a direct chill process includes cooling the alloy to form a continuous ingot having a solid shell, further cooling the ingot by direct chill with an organic coolant, and inhibiting fire by adding non-aqueous fire retardant liquid to the coolant.

Abstract: A method for continuously casting lithium-containing alloys by a direct chill process includes cooling the alloy to form a continuous ingot having a solid shell, further cooling the ingot by direct chill with an organic coolant, and inhibiting fire by covering the coolant with fire retardant atmosphere.

Abstract: A continuous process for forming aluminum-lithium alloys is disclosed which comprises continuously monitoring the ingot casting rate and continuously adding a measured and controlled amount of molten lithium beneath the surface of a molten aluminum stream as it flows toward an ingot casting station. The amount of molten lithium to be added is based on the ingot casting rate, the ingot size and the lithium content of the alloy being cast.