Abstract: A permanent magnet for an MRI scanner is made by removing extraneous elements from an ore containing rare earth elements to leave elements Pr and Nd therein, and then selectively stripping therefrom a portion of the element Nd as a byproduct to leave an ore residuum including both elements Pr and Nd therein. The residuum is alloyed with a transition metal to form an alloy therewith. The alloy is then formed into a rare earth permanent magnet configured for use in the MRI scanner.

Abstract: A method of making a permanent magnet body is provided. The method includes providing a first precursor body comprising a plurality of blocks and magnetizing the first precursor body to form a first permanent magnet body. A recoil magnetization pulse may be applied to the permanent magnet body after the magnetization. The precursor body may be heated during magnetization. A power supply containing a battery may be used to energize a pulsed magnet used to magnetize the precursor body.

Abstract: Nucleated casting systems and methods comprise the addition of powders into a liquidus portion of the casting. The casting system forms a casting comprising a liquidus portion that receives the refined liquid metal and a solidified portion, the casting further comprising a fine-grain, homogeneous microstructure that is essentially oxide- and sulfide-free and segregation defect free. The casting system comprises a source of refined liquid metal, the refined liquid metal having oxides and sulfides refined out of the metal; a solid metal particle addition system that adds solid metal particles to a surface of the liquidus portion of the casting; and a nucleated casting system for forming the casting. The solid metal particle addition system adds solid metal particles that serve as nucleation centers during solidification of the casting.

Abstract: A melt guide includes a base plate having internal cooling channels and a center aperture extending vertically therethrough. A unitary drain bushing is removably mounted in the aperture and is readily replaceable after wear thereof.

Abstract: An improved X-ray tube target comprises a refractory metal target substrate and a refractory metal focal track applied to the target substrate by a tape casting process. The X-ray tube target comprises a refractory metal target substrate and a refractory metal focal track formed on the target substrate to form a focal track/target substrate interface plane that varies less than about ±0.13 mm.

Abstract: A casting system with auxiliary cooling onto a liquidus portion of the casting can produce a metal casting that comprises a fine-grain, homogeneous microstructure. The microstructure is essentially oxide- and sulfide-free, segregation defect free, and essentially free of voids caused by air entrapped during solidification of the metal from a liquidus state to a solid state. The casting system with auxiliary cooling onto a liquidus portion of the casting can comprises an electroslag refining system as a source of liquid metal; a nucleated casting system; and at least one cooling system that supplies coolant onto a liquidus portion of the casting. The liquidus portion of the casting is cooled in a manner sufficient to provide a casting microstructure that comprises a fine-grain, homogeneous microstructure that is essentially oxide- and sulfide-free, segregation defect free, and essentially free of voids caused by air entrapped during solidification from a liquidus state to a solid state.

Abstract: An X-ray tube anode comprises a graphite ring, a target substrate applied onto the graphite ring and a target focal track applied onto the target substrate. The target focal track comprises a first refractory metal and the target substrate comprises a second refractory metal and at least one layer of a material that is characterized by characterized by a coefficient of thermal expansion (CTE) that is the same as the CTE of the target focal track or is intermediate between the CTE of the target focal track and the CTE of the substrate.

Abstract: A permanent magnet for an MRI scanner is made by removing extraneous elements from an ore containing rare earth elements to leave elements Pr and Nd therein, and then selectively stripping therefrom a portion of the element Nd as a byproduct to leave an ore residuum including both elements Pr and Nd therein. The residuum is alloyed with a transition metal to form an alloy therewith. The alloy is then formed into a rare earth permanent magnet configured for use in the MRI scanner.

Abstract: A permanent magnet for an MRI scanner is made by removing extraneous elements from an ore containing rare earth elements to leave elements Pr and Nd therein, and then selectively stripping therefrom a portion of the element Nd as a byproduct to leave an ore residuum including both elements Pr and Nd therein. The residuum is alloyed with a transition metal to form an alloy therewith. The alloy is then formed into a rare earth permanent magnet configured for use in the MRI scanner.

Abstract: A consumable electrode feed system for a refining system provides consumable electrodes to a refining system. The consumable electrode feed system comprises a side feed device that feeds consumable electrodes to a refining system in a first direction; a refining feed device that feeds consumable electrodes to a refining system in a second direction, in which the second direction being generally orthogonal to the first direction; and a connection system for connecting fed consumable electrodes to each other. The consumable electrode feed system allows for a predetermined amount of a consumable electrode to be refined in the refining system, and can position another consumable electrode above a previously fed consumable electrode. The connecting system then can connect a fed consumable electrode to a previously fed consumable electrode thus avoiding refining operation.

Abstract: In a method and apparatus for the electroslag refining of metal, the method includes providing a refining vessel to contain an electroslag refining layer floating on a layer of molten refined metal. The refining vessel representing an upper part of a cooled mould comprises a plurality of superimposed sleeves which are electrically insulated from one another. The top sleeve, being the refining vessel, is substantially a non-consumable electrode and has a current lead electrically insulated from the sleeve. The molten electroslag layer is heated by a refining current which is passed from a power source through the mould and slag layer to the metal pool. An unrefined metal is lowered into the vessel into contact with the molten electroslag layer such that its surface is melted and overheated at the point of contact with the slag such that droplets of the metal are formed and these droplets pass down through the slag and are collected in a pool of molten refined metal beneath the slag.

Abstract: A tin alloy bath with controlled iron content is used for coating a niobium-base substrate with tin in a manufacturing process for triniobium tin superconductor. One hundred twenty-five parts per million by weight or less of iron is used in tin alloy baths to increase the reaction kinetics of the formation of the superconductor material.

Abstract: A method for controlling electromagnetic flux concentration in a discharge guide tube for a metal refining apparatus is provided. The discharge guide tube comprises a base plate, an extension, a central orifice that extends through the extension from a source of liquid metal to an outlet in the discharge guide tube for directing a stream of metal therethrough, and an interior discharge guide tube flux concentration configuration; an induction heater system that generates an electromagnetic field in the discharge guide tube, the induction heater system being disposed on the extension with a gap defined therebetween, the induction heater system and the discharge guide tube being capable of relative vertical movement and subsequent positions with respect to each other with the gap being essentially constant.

Abstract: A bottom pour electroslag refining system refines raw material into refined liquid metal. The bottom pour electroslag refining system comprises an electroslag refining crucible; a slag; a bottom pour structure that comprises an orifice from which refined liquid metal from the electroslag refining crucible can flow as a stream of refined liquid metal; and a current path. The current path is defined in the bottom pour electroslag refining system for applying current to the raw material for melting and refining the raw material. The melted and refined raw material forms a refined liquid metal pool in the electroslag refining crucible. The current that is applied by the current path is sufficient to provide the refined liquid metal in the refined liquid metal pool with a viscosity under which the refined liquid metal can flow through the orifice under its own viscosity.

Abstract: An X-ray tube anode comprises a graphite ring, a target substrate applied onto the graphite ring and a target focal track applied onto the target substrate. The target focal track comprises a first refractory metal and the target substrate comprises a second refractory metal and at least one layer of a material that is characterized by characterized by a coefficient of thermal expansion (CTE) that is the same as the CTE of the target focal track or is intermediate between the CTE of the target focal track and the CTE of the substrate.

Abstract: Rare earth alloy compositions, such as the neodymium iron boron (NdFeB) alloy are made by a Reduction-Melting process. The Reduction-Melting process comprises preparing a primary electrode containing at least one compound or metal to be reduced to form a refined metal or metal alloy ingot; placing the electrode in an electroslag refining furnace; passing a current through the electrode into a molten flux or slag to melt the electrode; reducing the metal or compound in the slag while forming an oxide by-product; collecting melted metal or metal alloy droplets falling through the slag; forming an ingot of the metal or metal alloy from the melted droplets; and collecting the solid oxide byproducts in the slag.

Abstract: An improved X-ray tube target comprises a refractory metal target substrate and a refractory metal focal track applied to the target substrate by a tape casting process. The X-ray tube target comprises a refractory metal target substrate and a refractory metal focal track formed on the target substrate to form a focal track/target substrate interface plane that varies less than about ±0.13 mm.

Abstract: A VAR process is conducted in an apparatus characterized by a crucible wall that provides a stable shelf anchor. The VAR apparatus includes a furnace chamber, a consumable electrode formed of a material to be remelted within the furnace chamber and a crucible within the furnace chamber. The crucible has a wall that forms a vessel to collect melt material from the consumable electrode. At least part of the wall is textured to provide area for mechanical stabilization of the shelf as the underside of the shelf melts and the upperside of the shelf forms. In a vacuum arc remelting process, a consumable electrode is loaded into a furnace chamber above a cooled crucible having a textured wall that forms a vessel to collect melt material from the consumable electrode. The process includes striking a direct electric current between the electrode and a bottom of the crucible to cause melting of material from a tip of the electrode. Melt material is collected from the tip in the crucible.

Abstract: An improved X-ray tube target comprises a refractory metal target substrate and a refractory metal focal track applied to the target substrate by a tape casting process. The X-ray tube target comprises a refractory metal target substrate and a refractory metal focal track formed on the target substrate to form a focal track/target substrate interface plane that varies less than about ±0.13 mm.

Abstract: The flowrate of a stream discharged from a drain in a vessel is measured by imaging the stream, measuring a diameter of the stream image, and calculating the flowrate based on the measured diameter. A video camera may be aimed below the drain for imaging the stream. A computer is joined to the camera for measuring the diameter of the stream and calculating a corresponding flowrate therefor.