Abstract: A method including providing a quantity of metal, the quantity of metal being contaminated by a contaminant including a quantity of carbon; configuring a vacuum induction furnace to operate according to a set of operating parameters, the set of operating parameters being selected based on characteristics of the contaminant, the set of operating parameters including at least one of a pressure, an atmosphere composition, a pour temperature, or a hold time; charging the vacuum induction furnace with the quantity of metal; and operating the vacuum induction furnace to melt the quantity of metal in accordance with the set of operating parameters, whereby at least some of the contaminant is removed from the quantity of metal so as to provide an output metal having a concentration of carbon that is less than or equal to a concentration of carbon in the metal as cast.

Abstract: An apparatus and process for formation of a multicomponent metal alloy ingot or product in which granulated metal feedstock, under a high pressure inert environment, is introduced onto a rotating platen or previously deposited layer on the rotating platen. As the granulated feedstock is deposited on the platen, the platen is rotated such that a segment of the platen having the feedstock thereon passes through an energy generator field such as a melting laser beam or eddy current induction melting field. As it passes it is melted to form an arcuate segment of melt. The melt is then rotated out from under the energy beam and cooled into a solid state of the desired alloy as a next contiguous segment of feedstock is introduced and the process repeated until a layer is formed. The platen may then be indexed lower and a new layer is formed in the same manner.

Abstract: A system for two stage casting of a metal alloy is disclosed that dispenses multiple feedstock metals into an arc melting crucible via a pressurized inert gas or metal vapor chamber to lower the volatilization rate of metals in an arc melting crucible at a rate proportional to the composition of the final desired alloy. The melt from the melting crucible enters a second stage cold wall crucible through a passage, where the melt cools and solidifies. A casting piston is used to slowly and progressively withdraw the solidified alloy from the cold wall crucible as it cools.

Abstract: A method and apparatus for casting molten metal in an opaque container and for determining the level of the metal within the container. This is accomplished by locating a strain sensing transducer over the container and metal, and sending a current pulse from the transducer along a wire located in the tube connected to the transducer and extending toward the vessel and molten metal. A permanent magnet is located on a stem connected to a float within the container, the float being effective to rest and float on the upper level of the molten metal within the container. A current pulse is sent along the wire from the transducer, which pulse produces a magnetic field, and which field interacts with a magnetic field of the permanent magnet. The interaction of the two fields exerts a strain on the tube, which strain is sensed by the transducer.