Abstract: An apparatus for conducting ultrasonic waves to and from a body of a molten material. The apparatus includes a buffer rod for transmitting ultrasonic waves to the molten metal, a second buffer rod for receiving ultrasonic waves from the molten metal, piezoelectric elements associated with each buffer rod, and cooling mechanisms for protecting the piezoelectric elements by maintaining the buffer rods at a prescribed rate of thermal equilibrium with the molten metal. The cooling mechanisms are configured so as to facilitate regulation of the air flow about the apparatus.

Abstract: The flow rate of molten aluminum through a trough is measured by damming off the trough and diverting the flow through the measuring tube of a magnetic flow meter having a diameter, and located at a level in the trough to create a head of molten aluminum sufficient to produce a flow through the tube which is within the operating range of the meter. The apparatus includes a pair of spaced apart dam members forming a cavity therebetween which is transversed by the measuring tube. The magnet of the flow meter is located in the cavity preferably in a housing through which cooling air is circulated. The electrodes are made of an electrically conductive material which is resistant to corrosion by the molten aluminum, preferably, titanium diboride. Spring biased tapered connections seal the measuring tube with the dam members which have peripheral seals to keep molten aluminum out of the cavity.

Abstract: A known "spark cup process" may be operated without the spark cup if the violent fluctuations in the melt surface with which the electric arc is struck are accommodated so as to allow the electric arc to be maintained substantially continuously. Controlling the dynamic profile of the melt surface without a spark cup allows continuous operation of the electric arc which generates enough plasma to permit addition of as much as 1000 lb/hr of a spray of superheated feed material to a flowing stream of melt which assimilates the feed material.

Abstract: Apparatus for commutating an electrical current to an electrically conductive rod of an alloying element during the feed thereof to a body of molten metal for purposes of changing the alloy composition of the metal. The apparatus includes a power supply capable of providing electrical current in amounts sufficient to melt a free end of the rod of alloying material into the molten metal, and a pair of parallel adjacent shafts of substantial cross-section. A pair of commutation wheels are mounted respectfully on said shafts for rotatably engaging the rod between the wheels and for conducting current to the rod. Means are provided for forcing the wheels against the rod to provide intimate electrical and physical contact between the rod and wheels. A plurality of stationary brushes are disposed to physically engage each of said shafts along the length thereof for supplying current to the shafts from the power supply, and from the shafts to the wheels engaging the rod.

Abstract: A continuous salt-based process is provided for melting and reclaiming aluminum from aluminum scrap containing impurities including heating a molten salt in a heat bay, mixing the heated salt with aluminum scrap or skim in a charge bay to form a molten charge mixture, separating aluminum from impurities in the charge bay by coalescing aluminum to form a molten aluminum metal pad, chlorinating a portion of the charge mixture from the charge bay to form a chlorinated salt mixture and metal chlorides, removing metal chlorides from the salt mixture, and feeding the salt mixture back to the heat bay. In one aspect, the chlorinating step of the present invention includes introducing carbon monoxide or, preferably, solid carbon to control oxide concentration. The process further comprises adding fluorides and removing metal chlorides from the salt to maintain a preferred salt composition.

Abstract: A method for adding alloying material to a molten metal media, such as molten aluminum, is disclosed. The method includes converting the alloying material into a spray of superheated alloy material and directing the spray into the molten metal media at a depth below the media's surface to enhance dissolution and dispersion of the alloying material in the molten media.

Abstract: A value for controlling the flow of molten metal which includes a tubular conduit through which the metal flows and apparatus for applying a force against the exterior of the conduit to vary the size of the cross-sectional area of the opening through the conduit and thereby control the volume of metal flowing through the conduit.

Abstract: A method of more accurately measuring the true surface temperature of metal alloy objects without contacting the same. The surfaces of the objects have unknown emissivities that change and that are less than unity. The method includes the step of providing objects having surfaces that radiate infrared energy. The radiated energy is measured at two wavelengths, and a first measurement is provided that is a function of the ratio of the energies at the two wavelengths. The radiated energy is also measured at a single, narrow band wavelength, and a second measurement is provided that is a function of the radiated energy. The two measurements are then electrically combined to provide measurements of radiated energy and thus temperature measurements that are or at least are closer to the true temperature than either of the first or second measurements.

Abstract: An arc welding torch terminates in a gas cup open at one end through which an electrode projects. Inert gas is introduced under pressure at the other end of the gas cup and flows past and through a gas diffuser disposed in said gas cup. The diffuser is spaced from the inner wall of the gas cup, and a portion of the gas flows axially parallel to the central axis of the gas cup. The diffuser has a set of passageways to form and direct columns of gas in an outward direction, and another set of passageways to form and direct columns of gas in an inward direction. The diffuser is axially and angularly adjustable to vary the pattern of gas discharge with relation to the arc and to control the contour of the weld bead.BACKGROUND OF THE INVENTIONThe present invention relates to inert-gas arc welding, and more particularly, to a method and apparatus for applying a shielding gas in the welding operation.

Abstract: A welding method including the steps of feeding a consumable electrode of at least 1/8 -inch diameter at a constant speed toward a parent metal to be welded, while maintaining, with electrical power at an amperage-voltage characteristic having a slope of 0 to 2 amperes/volt, a direct current arc between the consumable electrode and parent metal, and while maintaining a shielding gas flow at the arc and on molten metal, wherein the electrical power is connected between the consumable electrode and the parent metal in reverse polarity, wherein the speed of the consumable electrode toward the parent metal to be welded is controlled within plus or minus 1/2% of the desired speed, and wherein the power source providing the electrical power has a dynamic regulated output current of plus or minus 5%.