Abstract: A process and apparatus for forming a thin-walled, elongated member having superior strength properties from an age hardenable copper base alloy is described herein. A slug or billet of a slurry cast, age hardenable copper base alloy is formed into a semi-solid slurry having about 10% to about 30% of the alloy in a liquid phase. The semi-solid slurry is then thixoforged to form the thin-walled, elongated member. Thereafter, the member is age hardened to provide a product having desired strength properties. The process and apparatus of the instant invention may be utilized to form cartridge casings.

Abstract: An apparatus is provided for electromagnetically coiling a molten material into a longitudinally extending casting defining a longitudinal axis thereof. The casting has a desired cross section extending perpendicular to the longitudinal axis. At least one portion of the outer peripheral surface of the casting extends transversely of the longitudinal axis and has a small radius of curvature. The apparatus includes an inductor extending transversely about the molten material for providing an electromagnetic containment force field acting on the outer peripheral surface of the molten material to form the desired cross section. The improvement comprises a device for turning the electromagnetic containment force field about the longitudinal axis to cause a corresponding turn of the transverse cross section of the molten material about the longitudinal axis.

Abstract: A mold for use in an apparatus and process utilizing an electromagnetic field to stir a molten metal or metal alloy comprises a plurality of laminations of thermally and electrically conductive material separated by electrically insulating material. The electrically insulating material is oriented to minimize at least some of the flow path lengths of currents induced in the mold whereby magnetic induction losses caused by the mold are substantially reduced and the stirring efficiency is enhanced.

Abstract: A process and apparatus for forming a thin-walled, elongated member having superior strength properties from an age hardenable copper base alloy consisting essentially of about 3% to about 20% nickel, about 5% to about 10% aluminum, and the balance essentially copper, is described herein. A slug or billet of a slurry cast, age hardenable copper base alloy is formed into a semi-solid slurry having about 5% to about 40% of the alloy in a liquid phase. The semi-solid slurry is then thixoforged to form the thin-walled, elongated member. Thereafter, the member is age hardened to provide a product having desired strength properties. The process and apparatus of the instant invention may be utilized to form cartridge casings.

Abstract: A flux concentrator is disclosed for generating a strong magnetic field. An inductor is provided for generating a primary magnetic field which is weaker than the strong magnetic field. A concentrator body has a hollow interior for receiving material to be acted upon by the strong magnetic field. The body is located within the primary magnetic field and shields the primary magnetic field from the hollow interior. A flux concentrator device is positioned within the hollow interior and has a slot extending therethrough. The flux concentrator device is coupled to the primary field for generating the strong magnetic field within the slot. Structure is provided to vary the size of the slot while the strong magnetic field is being generated in the slot.

Abstract: A process and apparatus for forming a thin-walled, elongated member having superior strength properties from an age hardenable copper base alloy is described herein. A slug or billet of a slurry cast, age hardenable copper base alloy is formed into a semi-solid slurry having about 10% to about 30% of the alloy in a liquid phase. The semi-solid slurry is then thixoforged to form the thin-walled, elongated member. Thereafter, the member is age hardened to provide a product having desired strength properties. The process and apparatus of the instant invention may be utilized to form cartridge casings.

Abstract: A process and apparatus for controlling the position of a cast ingot is provided so that unwanted distortions of the casting are substantially avoided. The instant process and apparatus also permit substantially uniform heat transfer about the casting periphery. A control system for maintaining the casting within a mold so that the casting outer periphery is substantially uniformly spaced from the mold inner wall comprises a casting supporting mechanism adjacent the mold exit and non-thermal position detectors.

Abstract: A flux concentrator is disclosed for generating a strong magnetic field. An inductor is provided for generating a primary magnetic field which is weaker than the strong magnetic field. A concentrator body has a hollow interior for receiving material to be acted upon by the strong magnetic field. The body is located within the primary magnetic field and shields the primary magnetic field from the hollow interior. A flux concentrator device is positioned within the hollow interior and has a slot extending therethrough. The flux concentrator device is coupled to the primary field for generating the strong magnetic field within the slot. Structure is provided to vary the size of the slot while the strong magnetic field is being generated in the slot.

Abstract: A process and apparatus for forming a thin-walled, elongated member having superior strength properties from an age hardenable copper base alloy is described herein. A slug or billet of a slurry cast, age hardenable copper base alloy is formed into a semi-solid slurry having about 10% to about 30% of the alloy in a liquid phase. The semi-solid slurry is then thixoforged to form the thin-walled, elongated member. Thereafter, the member is age hardened to provide a product having desired strength properties. The process and apparatus of the instant invention may be utilized to form cartridge casings.

Abstract: A process and apparatus having improved efficiency for forming a semi-solid alloy slurry. A molten metal in a containing device is mixed electromagnetically by a moving, non-zero magnetic field provided over substantially all of a solidification zone within the containing device. The magnetic field causes the shearing of dendrites formed in the solidification zone at a desired shearing rate. The magnetic field is generated by a device supplied with current at a desired line frequency. By operating within a defined range of line frequencies, a desired shear rate for attaining a desired cast structure at reduced levels of power consumption and current can be achieved.

Abstract: An apparatus and a method for forming a semi-solid thixotropic slurry. The apparatus includes a duplex mold arrangement for postponing solidification within the mold until the molten metal is within a magnetic field for providing magnetohydrodynamic stirring. The duplex mold includes a first portion of low thermal conductivity and a second portion of high conductivity.

Abstract: A mold for use in an apparatus and process utilizing an electromagnetic field to stir a molten metal or metal alloy comprises a plurality of laminations of thermally and electrically conductive material separated by electrically insulating material. The electrically insulating material is oriented to minimize at least some of the flow path lengths of currents induced in the mold whereby magnetic induction loses caused by the mold are substantially reduced and the stirring efficiency is enhanced.

Abstract: A process and apparatus for continuously and semi-continuously casting molten metals and alloys. Control of the initial stages of solidification is carried out through application of a thermal insulating layer on the coolant side of a casting mold wall. The layer modifies the heat flux characteristics of the mold along a selected length thereof.

Abstract: A process and apparatus for forming a semi-solid thixotropic alloy slurry and preferably a rheocasting therefrom. Molten metal in a mold is cooled under controlled conditions while it is mixed under the influence of a moving magnetic field. A non-zero, magnetic field is provided across the full cross section of the mold and over the entire solidification zone. This results in a magnetomotive stirring force of sufficient magnitude to provide mixing of the molten metal to form the slurry. Preferably, a two pole induction motor stator is used to generate the magnetic field.

Abstract: An improved method and apparatus for degassing molten metal is disclosed in which the molten metal is passed in countercurrent relationship with a fluxing gas which is introduced through a sparger plate provided with a plurality of orifices of controlled size and spacing so as to minimize fluxing gas bubble size while maximizing fluxing gas bubble density thereby optimizing the degassing of the molten metal.

Abstract: The disclosure teaches an improvement in the degassing and filtration of molten metal, especially aluminum, using an apparatus which employs a pair of sequentially placed, removable filter-type plates and at least one fluxing gas inlet positioned therebetween. The first of said filter-type plates is characterized by a plurality of holes which provide a preferential path through which the fluxing gas flows upwardly through the first of said filter plates in counter-current contact with the melt. Said plate serves to break up said fluxing gas into a fine dispersion to assure its intimate and extensive contact with the melt. Dissolved gases and non-metallic inclusions are thereby abstracted and removed from the melt.

Abstract: An improved method and apparatus for degassing molten metal is disclosed in which the molten metal is passed in countercurrent relationship with a fluxing gas which is introduced through a sparger plate provided with a plurality of orifices of controlled size and spacing so as to minimize fluxing gas bubble size while maximizing fluxing gas bubble density thereby optimizing the degassing of the molten metal.

Abstract: An improved method for fabricating a ceramic sparger plate for use in the degassing of molten metal is disclosed in which a castable ceramic is poured into a mold which contains an array of vertically disposed strands which are removed subsequent to the ceramic curing and prior to firing of the ceramic thus leaving the desired pattern of holes through which the fluxing gas is introduced into the molten metal.

Abstract: An improved method for fabricating a ceramic sparger plate for use in the degassing of molten metal is disclosed in which a castable ceramic is poured into a mold which contains an array of vertically disposed strands which are removed subsequent to the ceramic curing and prior to firing of the ceramic thus leaving the desired pattern of holes through which the fluxing gas is introduced into the molten metal.

Abstract: The disclosure teaches an improvement in the degassing and filtration of molten metal, especially aluminum, using an apparatus which employs a pair of sequentially placed, removable filter-type plates and at least one fluxing gas inlet positioned therebetween. The first of said filter-type plates is characterized by a plurality of holes which provide a preferential path through which the fluxing gas flows upwardly through the first of said filter plates in countercurrent contact with the melt. Said plate serves to break up said fluxing gas into a fine dispersion to assure its intimate and extensive contact with the melt. Dissolved gases and non-metallic inclusions are thereby abstracted and removed from said melt.