Abstract: A molten metal conveyor having a receptor plate in contact with molten metal during transport of the molten metal. The receptor plate extends from an entrance where molten metal enters onto the receptor plate to an exit where molten metal exits the receptor plate. The molten metal conveyor has at least one vibrational energy source which supplies vibrational energy directly to the receptor plate in contact with molten metal. A corresponding method for forming a metal product includes providing molten metal onto a molten conveyor; cooling the molten metal by control of a cooling medium flowing through a cooling passage in the or attached to the conveyor; and coupling vibrational energy directly into a receptor plate in contact with the molten metal on the conveyor.

Abstract: A method and apparatus for direct chill casting of metals and metal alloys which includes application of vibrational energy to the molten material in an open-ended mold and at the outlet of the mold are provided. In an aspect, the method is directed to the production of cast aluminum alloys.

Abstract: A molten metal processing device including an assembly mounted on the casting wheel, including at least one vibrational energy source which supplies vibrational energy to molten metal cast in the casting wheel while the molten metal in the casting wheel is cooled, and a support device holding the vibrational energy source. An associated method for forming a metal product which provides molten metal into a containment structure included as a part of a casting mill, cools the molten metal in the containment structure, and couples vibrational energy into the molten metal in the containment structure.

Abstract: A molten metal processing device including an assembly mounted on the casting wheel, including at least one vibrational energy source which supplies vibrational energy to molten metal cast in the casting wheel while the molten metal in the casting wheel is cooled, and a support device holding the vibrational energy source. An associated method for forming a metal product which provides molten metal into a containment structure included as a part of a casting mill, cools the molten metal in the containment structure, and couples vibrational energy into the molten metal in the containment structure.

Abstract: Methods for removing sludge and/or impurities from a molten metal are disclosed herein, as well as sludge removal devices and systems for use in the methods. Sludge removal devices that can reduce the downstream deposition of sludge in certain process components through upstream deposition and subsequent removal from the molten metal are also disclosed.

Abstract: An energy coupling device for coupling energy into molten metal. The energy coupling device includes a cavitation source which supplies energy through a cooling medium and through a receptor in contact with the molten metal. The cavitation source includes a probe disposed in a cooling channel. The probe has at least one injection port for injection of a cooling medium between a bottom of the probe and the receptor. The probe under operation produces cavitations in the cooling medium. The cavitations are directed through the cooling medium to the receptor.

Abstract: A molten metal processing device including an assembly mounted on the casting wheel, including at least one vibrational energy source which supplies vibrational energy to molten metal cast in the casting wheel while the molten metal in the casting wheel is cooled, and a support device holding the vibrational energy source. An associated method for forming a metal product which provides molten metal into a containment structure included as a part of a casting mill, cools the molten metal in the containment structure, and couples vibrational energy into the molten metal in the containment structure.

Abstract: A molten metal processing device including an assembly mounted on the casting wheel, including at least one vibrational energy source which supplies vibrational energy to molten metal cast in the casting wheel while the molten metal in the casting wheel is cooled, and a support device holding the vibrational energy source. An associated method for forming a metal product which provides molten metal into a containment structure included as a part of a casting mill, cools the molten metal in the containment structure, and couples vibrational energy into the molten metal in the containment structure.

Abstract: A molten metal processing device including an assembly mounted on the casting wheel, including at least one vibrational energy source which supplies vibrational energy to molten metal cast in the casting wheel while the molten metal in the casting wheel is cooled, and a support device holding the vibrational energy source. An associated method for forming a metal product which provides molten metal into a containment structure included as a part of a casting mill, cools the molten metal in the containment structure, and couples vibrational energy into the molten metal in the containment structure.