Abstract: A heat extracting substrate is moved along a melt front formed at the edge of the surface of a molten material so that a layer of molten material is deposited on the substrate, cooled and removed from the substrate to form ribbon, filaments, fiber of film directly from the molten material. The edge may be formed by providing an upper edge upon a portion of the wall of a receptacle lower than the top of the receptacle. The molten material may be overflowed over this relatively horizontal edge and against the moving substrate surface.

Abstract: An improved method for forming steel fibers from a process of the type in which the fiber is drawn directly from a pool of molten metals. The improvement revolves around the discovery of an alloy starting material which substantially reduces processing steps and equipment and produces a fiber with improved ductility and strength characteristics. The addition of controlled amounts of copper to a typical low carbon steel alloy provides a wider latitude in the necessary cooling steps to greatly facilitate the control of the ductility and strength of the final product through the use of low cost processing techniques.