Abstract: The present invention provides a method and apparatus for taking up and winding a strip of material which is advancing at a selected velocity from a moving casting surface. Generally stated, the apparatus includes a take-up web supply mechanism for supplying a flexible, take-up web, and a winding mechanism, which has a reel for taking up and concentrically winding the strip and take-up web thereon in a laminated configuration. A connection mechanism connects the take-up web to the reel, and a reel drive mechanism rotates the reel to provide a peripheral velocity at a winding surface on the reel that substantially matches the velocity of the advancing strip. A directing mechanism directs the advancing strip onto the take-up web for transport to a winder nip region between the take-up web and the winding surface of the reel means to initiate winding.

Abstract: An apparatus for casting metal strip includes a nozzle having an orifice for depositing a stream of molten metal onto a casting region of a moving chill surface. A conditioning shoe is located generally upstream from the nozzle in a direction opposite to the direction of chill surface movement to delimit a conditioning chamber. The conditioning chamber communicates directly with the nozzle orifice and borders at least three sidelines of the chill surface casting portion. A shield for minimizing an intrusion of ambient atmosphere into the conditioning chamber and for deflecting an entrained gas boundary layer carried along by the chill surface is cooperatively connected to the conditioning shoe. Gas control provides a selected, low density atmosphere, such as a partial vacuum, within the conditioning chamber.

Abstract: A method is disclosed for the welding of two or more glassy metallic ribbons into a monolithic or composite glassy metallic body. The method includes the step of drawing the ribbons in converging fashion through a nip between two high speed rotating rollers. A heat source is generated with a series of laser beams focused at spaced intervals along the nip between the converging and contacting ribbon surfaces prior to compressing the ribbons together. The welded body is internally cooled at a rate sufficient to retain the ribbons and the weld zone therebetween in a glassy metallic state following welding. The parameters of temperature, ribbon speed, exposure time, laser beam power and ribbon thickness for the process are disclosed. In the preferred embodiment, full width welding in a narrow rectangular area adjacent the line of convergence is generated to provide a monolithic body; whereas, in an alternative embodiment strip/spot welding is provided between the ribbons.

Abstract: The present invention provides a method and apparatus for taking up and winding a strip of material which is advancing at a selected velocity from a moving casting surface. Generally stated, the apparatus includes a take-up web supply mechanism for supplying a flexible, take-up web, and a winding mechanism, which has a reel for taking up and concentrically winding the strip and take-up web thereon in a laminated configuration. A connection mechanism connects the take-up web to the reel, and a reel drive mechanism rotates the reel to provide a peripheral velocity at a winding surface on the reel that substantially matches the velocity of the advancing strip. A directing mechanism directs the advancing strip onto the take-up web for transport to a winder nip region between the take-up web and the winding surface of the reel means to initiate winding.

Abstract: A continuous casting assembly has a pair of contiguously counter-rotating belts for controllably forming a continuous cast metal ribbon. One of the belts is chilled and forms a casting surface for the cast ribbon, while the other belt is intimately positioned to hug the ribbon and improve the quality of the ribbon. The two belts are squeezed together to compress the ribbon by evacuating between the belts and allowing the atmospheric pressure to act on the opposite surfaces of the belts. A sealing box adjacent the lateral edges of the belts includes elongated floating seals and provides the evacuation by connection to a vacuum source. The floating seals are formed of plastic rods and are retained in the sealing box by end wiper seals which also serve to seal against the belts at the ends of the box.

Abstract: A method and apparatus for continuously casting a filament within a region of preselected vacuum and passing the filament to ambient region of higher pressure include a rotating casting wheel which has an annular peripheral quench surface. A guide housing encloses the casting wheel to separate the wheel from the ambient region and to delimit a guide region which is adapted to pass the filament therethrough to an exit region communicating into the ambient region. An extrusion housing delimits an extrusion chamber which communicates with the guide housing and has a portion of the quench surface disposed therein. An extrusion mechanism located in the extrusion chamber extrudes molten metal onto the quench surface to form the filament, and an extrusion vacuum mechanism provides a preselected vacuum in the extrusion chamber. A fluid jet mechanism disposed in the guide housing reduces the pressure in the extrusion chamber and directs the filament through the guide region.

Abstract: A cooling apparatus and related method for a continuous casting apparatus includes a series of spray nozzles for spraying a coolant against one surface of a moving chill substrate. The invention apparatus includes an enclosure having vacuum applied thereto for preventing migration of the sprayed coolant from the surface against which it is sprayed to the surface contacting the molten solidifying material. Any coolant having a tendency to escape along sealed edges of the enclosure is forced back into the enclosure by the pressure gradient. The edges are sealed by elongated plastic rods. Additionally, scrapers are provided for removing remanent coolant from the sprayed surface. The coolant is sprayed at a high velocity to increase its heat transferring efficiency.

Abstract: The invention provides an apparatus and method for continuously casting a filament, such as a glassy metal filament, at high speed within a zone of preselected vacuum. A continuous extrusion mechanism and a rapidly moving quench surface are located within a casting module. A vacuum mechanism provides the preselected vacuum in the module as the filament is cast, and a transport mechanism continuously moves the resultant rapidly advancing filament across the boundary between the vacuum in the casting airlock mechanism substantially preserves the module vacuum as the cast filament is transported across the boundary and a passivator mechanism passivates the quench surface to prevent the filament from adhering thereto.

Abstract: A method and apparatus for forming a cast metal ribbon with a slit along the ribbon length includes the step of or a means for generating a controlled disturbance of the cast ribbon along a defined and localized width. The disturbance may be generated by a highly defined, needle-sized stream of gaseous media into the ribbon prior to complete solidification, or alternatively, a needle-like ceramic stylus. The dynamic pressure of the gaseous media or depth of stylus may be adjusted to completely penetrate the ribbon, severing the ribbon into multiple ribbons in a single casting; or alternatively, to only partially penetrate the ribbon, forming a score line of weakening and producing multiple ribbons readily detachable from each other along adjoining edges.

Abstract: A continuous casting assembly has a pair of counter-rotating belts for controllably forming a continuous elongated cast ribbon. One of the belts is a chilled substrate for receiving molten metal discharged from a dispensing nozzle. The other belt is positioned immediately adjacent the chilled substrate belt and contactable. Both of the belts are moved in a substantially parallel paths at the same predetermined speed with the cast ribbon interposed between the belts. Magnetic forces are used to urge the two belts together in contacting relationship with each other and with the interposed cast ribbon.

Abstract: A continuous casting nozzle has a relatively narrow dispensing slot reinforced against flexing along its length by intermittent supporting structure. The nozzle may be a tubular insert member to be received in a mounting means, such as a support plate and providing the reinforcement. The nozzle may be formed from a hollow tubular member with longitudinally aligned sectors or openings formed in the side wall to provide passage of the molten metal to the dispensing slot. The relatively narrow slot is formed in the side wall opposite the openings. The reinforcement ribs are integrally formed between the openings. The end portions of the nozzle member are plugged to direct the molten metal through the dispensing slot. With the nozzle member inserted into the bore in the mounting plate of the crucible, the nozzle assembly is supported along its entire length. The mounting plate may include reinforcement ribs aligned with the ribs of the nozzle member when fully inserted in the plate.

Abstract: Metal flow control for a continuous casting process is provided by providing a gas back pressure bubble to block the flow of molten metal above the casting nozzle. Pressurized gas is provided to a cap positioned upstream of the nozzle and including a depending skirt that cooperates with a dam. When the gas pressure offsets the head pressure of the molten metal, the flow of molten metal into the nozzle is blocked. By terminating the control pressure, the flow of metal over the dam may be reestablished. The cap including the skirt and the dam form a weir assembly defining a channel along one side or around the periphery of the nozzle. The cap may be supported and fed with gas pressure through a duct from the side, or along the center of the crucible.

Abstract: Improvement in apparatus for making metal filament by depositing a stream of molten metal onto the inner surface of an annular chill roll as it is being rotated includes provision of a rotatably mounted annular chill roll having an inner surface substantially parallel to its axis of rotation, and means for stripping the metal filament from the inner surface of the chill roll and for guiding the stripped metal filament away from the chill roll.

Abstract: An apparatus is provided for planar flow casting of metal ribbon. The apparatus comprises a movable chill surface, a reservoir for holding molten metal and a slotted nozzle whose lips are located close to the chill surface. In operation, molten metal is forced through the nozzle onto the chill surface to form a melt puddle. Rapid cooling of the molten metal results in the formation of a continuous ribbon. The nozzles of this invention provide a planar bottom surface which includes the leading edge of the first lip and the side edges at the bottom of the lips and which is as close or closer to the chill surface than is any other point on the lips. The nozzle reduces air flow around the melt puddle and thereby improves ribbon uniformity.

Abstract: An apparatus is provided for planar flow casting of metal ribbon. The apparatus comprises a movable chill surface, a reservoir for holding molten metal and a slotted nozzle whose lips are located close to the chill surface. In operation, molten metal is forced through the nozzle onto the chill surface to form a melt puddle. Rapid cooling of the molten metal results in the formation of a continuous ribbon. Ribbon contour is controlled through the use of nozzle designs that provide reproducible configuration of the melt puddle and reduce turbulent air flow over the molten metal surface.

Abstract: Foundry sand molds and cores are provided which incorporate glassy metal reinforcing filaments. Molds prepared from the sand composition of this invention provide greater strength before and during metal casting. As the casting solidifies, the temperature of the reinforcing filaments rises, the filaments devitrify and become weak and the mold can be crumbled for easy removal of the casting.

Abstract: Improvement in the method for making metal filament by depositing molten metal onto the peripheral surface of a rotating annular chill roll and separating the solid filament from the chill roll, which involves applying tension to the filament, after it has been separated from the chill roll, along the direction of a tangent to the chill roll past the point at which the filament separates from the chill roll by centrifugal action, to thereby prolong its contact with the chill roll. Apparatus is provided for practice of the method.

Abstract: Improvement in apparatus for making metal filament by depositing a stream of molten metal onto the inner surface of an annular chill roll as it is being rotated includes provision of a rotably mounted annular chill roll having an inner surface substantially parallel to its axis of rotation, and means for stripping the metal filament from the inner surface of the chill roll and for guiding the stripped metal filament away from the chill roll.

Abstract: Improvement in apparatus for making metal filament by depositing molten metal onto the peripheral surface of a rotating annular chill roll includes provision of a stationary housing surrounding the peripheral surface of the chill roll in an arc, covering the segment beginning at the vicinity of the point of deposition of the metal onto the chill roll and terminating at a predetermined point of stripping of the solid filament from the chill roll, and defining a gap between the peripheral surface of the chill roll and the interior of the housing, together with means for introducing a fluid into the gap for passage therethrough in the direction of rotation of the chill roll. In operation, cocurrent passage of the filament and the fluid through the gap effects controlled retention of the filament on the chill roll and fixes the point at which the filament is stripped from the chill roll.

Abstract: A stopper rod tapping assembly for bottom tapping of a crucible to extrude molten metal through a tapping orifice is described. The stopper rod has an interior vent, providing communication of a pressurized inert gas from above the melt to the tapping orifice in the bottom of the crucible. The vent permits flushing of the tapping orifice between tapping runs to prevent buildup of residues in the tapping orifice which would otherwise adversely affect the tapping operation. The assembly is advantageously used in casting filaments from the molten metal.