Abstract: A continuous lubrication casting mold for use in a process of continuously casting molten metals and alloys wherein a parting and/or lubricating agent reservoir is provided in the mold body. The agent is continuously applied over the inner surface of the mold after being introduced through passages within or through the mold section. The lubricant passages may be an intrinsic characteristic of the mold material or may be provided in the form of feed holes through the mold section. The ability to transmit lubricant through to the internal surface of the mold can be varied within the length of the casting mold to provide for variable lubricant transfer rates to different parts of the casting surface.

Abstract: A process for electromagnetically containing and forming molten material into a desired thin strip shape. At least two inductors are employed which are powered at respectively different frequencies. The frequency of the current applied to the upstream inductor is substantially lower than the frequency applied to the downstream inductor thereby providing improved efficiency and reduced power consumption.

Abstract: An apparatus and process for operating a rolling mill having at least two rolls rotating at different speeds to produce a continuous strip material having a substantially constant final thickness comprises a mechanism for controlling the magnitude of the compressive force between the rolls in response to the ratio of the incoming strip speed to the outgoing strip speed. A mechanism is provided for comparing the ratio of the strip speeds to a ratio of the roll speeds and for adjusting the compressive force magnitude until the two speed ratios are substantially equal. In this manner, the amount of off-stage strip material produced during mill start-up is reduced and process stability and gage control during steady state operation is enhanced.

Abstract: A duplex rolling process and apparatus for working a metal or alloy subject to the formation of strain induced martensite. The metal or alloy is first worked at an elevated temperature wherein the formation of strain induced martensite is substantially suppressed or eliminated. The metal or alloy is then worked at a lower temperature wherein the formation of strain induced martensite is promoted whereby working is carried out more efficiently.

Abstract: A disposable bed filter for removing particulate matter and/or reducing oxygen in a poured metal melt is located within a trough. The bed filter preferably comprises discrete layers of bed media located in a trough between entry and exit baffle plates. The layers of bed media include a layer of coarse media and a layer of fine media. The trough is preferably provided with a closeable lid to permit removal of the bed media and to compensate for buoyancy of the bed media if present. In its preferred use, the bed filter forms part of a process for making a metal alloy wherein the bed filter simultaneously reduces the oxygen content of the melt and filters particulate matter from the melt.

Abstract: A process and apparatus for casting a material into a desired thin strip shape. Molten material is formed into the thin strip shape by an electromagnetic containing and forming process. In a first portion the molten material is shaped into the desired thin strip shape and in a second portion upstream of and communicating with the first portion the molten material is electromagnetically contained in a sump. The sump at a top surface thereof has a substantially larger cross-sectional area as compared to a cross-sectional area of the thin strip shape.

Abstract: A continuous lubrication casting mold for use in a process of continuously casting molten metals and alloys wherein a parting and/or lubricating agent reservoir is provided in the mold body. The agent is continuously applied over the inner surface of the mold after being introduced through passages within or through the mold section. The lubricant passages may be an intrinsic characteristic of the mold material or may be provided in the form of feed holes through the mold section. The ability to transmit lubricant through to the internal surface of the mold can be varied within the length of the casting mold to provide for variable lubricant transfer rates to different parts of the casting surface.

Abstract: A continuous lubrication casting mold for use in a process of continuously casting molten metals and alloys wherein a parting and/or lubricating agent reservoir is provided in the mold body. The agent is continuously applied over the inner surface of the mold after being introduced through passages within or through the mold section. The lubricant passages may be an intrinsic characteristic of the mold material or may be provided in the form of feed holes through the mold section. The ability to transmit lubricant through to the internal surface of the mold can be varied within the length of the casting mold to provide for variable lubricant transfer rates to different parts of the casting surface.

Abstract: A rapid and effective surface cleaning process for copper alloys, particularly copper alloys containing aluminum and other metals tending to form surface coatings of refractory oxides during annealing treatments, consists of treating such alloys or articles fabricated thereof for a short time in a hot aqueous solution of an alkali hydroxide, rinsing with water, and then immersing for a short time in a hot aqueous solution of ferric sulfate, or other ferric salt of a mineral acid, followed by rinsing with water.

Abstract: An apparatus and process is provided for electromagnetically casting molten material into a desired shape. A containment zone is established. The containment zone has a first section for electromagnetically containing the molten material and a second section downstream and communicating with the first section for forming the molten material into the desired shape. The improvement comprises a heat extraction device for directing a cooling medium into the containment zone whereby the cooling medium passes the molten material in the second section to rapidly solidify the molten material prior to passing the molten material in the first section to lower the temperature in the contained molten material to minimize superheating. A second embodiment of the invention includes a secondary cooling device associated with the heat extraction device for directing a cooling medium against the solidified material.

Abstract: A process and apparatus for casting a material into a desired thin strip shape. Molten material is formed into the thin strip shape by an electromagnetic containing and forming process. In a first portion the molten material is shaped into the desired thin strip shape and in a second portion upstream of and communicating with the first portion the molten material is electromagnetically contained in a sump. The sump at a top surface thereof has a substantially larger cross-sectional area as compared to a cross-sectional area of the thin strip shape.

Abstract: A process and apparatus for producing a copper metal or alloy wherein a first material is added to a molten metal, consisting essentially of copper preferably in a furnace. After the first material is added, the molten metal is passed through a filtration device to remove particulate matter from the molten metal and/or reduce the oxygen content of the molten metal. After filtration, a second material is added to the molten metal.

Abstract: A rolling mill apparatus and process comprise a plurality of rolls defining a plurality of roll bites defining a gap spacing between adjacent rolls. A fixed gap spacing is employed for at least one roll bite. A floating gap spacing is provided for at least one other roll bite. It is thereby possible to control in a desired manner the amount of thickness reduction at a desired roll bite in a pass through the mill.

Abstract: A disposable bed filter for removing particulate matter and/or reducing oxygen in a poured metal melt is located within a trough. The bed filter preferably comprises discrete layers of bed media located in a trough between entry and exit baffle plates. The layers of bed media include a layer of coarse media and a layer of fine media. The trough is preferably provided with a closeable lid to permit removal of the bed media and to compensate for buoyancy of the bed media if present. In its preferred use, the bed filter forms part of a process for making a metal alloy wherein the bed filter simultaneously reduces the oxygen content of the melt and filters particulate matter from the melt.

Abstract: A continuous lubrication casting mold for use in a process of continuously casting molten metals and alloys wherein a parting and/or lubricating agent reservoir is provided in the mold body. The agent is continuously applied over the inner surface of the mold after being introduced through passages within or through the mold section. The lubricant passages may be an intrinsic characteristic of the mold material or may be provided in the form of feed holes through the mold section. The ability to transmit lubricant through to the internal surface of the mold can be varied within the length of the casting mold to provide for variable lubricant transfer rates to different parts of the casting surface.

Abstract: A method for electrochemically removing a tin layer from copper or copper alloy substrates without any attack on the substrate is disclosed which permits the simultaneous recovery of pure tin at high efficiency. The process is carried out by achieving effective complexing of tin ions in solution so that a stannous ion activity of greater than 10.sub.-4 gm ions/l is never achieved while conducting the electrochemical detinning potentiostatically at a potential where anodic corrosion of the copper or copper alloy substrate is not possible.

Abstract: An apparatus and process for rolling metal strip to provide increased percentage reductions in the thickness of the strip per pass and increased total reduction between anneals. A 4-high rolling mill is modified so that it is back-up roll driven such that the back-up rolls have different peripheral speeds in the same ratio as the desired strip reduction. The strip travels through the mill in a serpentine arrangement to provide three reductions per pass. Forward and back tension are applied to the strip during rolling.

Abstract: The invention relates to an improved method for the preparation and delivery of semi-solid thixotropic metal slurries for use in metal forming processes such as the rheocast and thixocast processes. The method includes inducing turbulent motion within the metal during solidification by electromagnetic or electrodynamic techniques under controlled temperature conditions so as to produce a highly fluid semi-solid slurry with a degenerate dendritic structure comprising solid spheroids dispersed in liquid. In the method of the preferred embodiment of the present invention, flow of the thixotropic metal slurry from the vibrating chamber is controlled by electromagnetic techniques and may be continuous or semi-continuous.

Abstract: An aluminum composite is provided having improved resistance to intergranular corrosion, especially a brazed aluminum composite. The composite comprises an aluminum base alloy core clad with a brazing alloy consisting essentially of from 4-14% silicon, from 0.01-2% tin, and the balance essentially aluminum. The additions to the brazing alloy reduce the tendency for the brazing alloy layer to induce intergranular corrosion of the core alloy layer. They also reduce the pitting rate of the brazing alloy layer.

Abstract: An aluminum composite is provided having improved resistance to intergranular corrosion, especially a brazed aluminum composite. The composite comprises an aluminum base alloy core clad with a brazing alloy consisting essentially of from 4-14% silicon, from 0.01-2% of a material selected from the group consisting of indium, gallium and mixtures thereof, and the balance essentially aluminum. The additions to the brazing alloy reduce the tendency for the brazing alloy layer to induce intergranular corrosion of the core alloy layer. They also reduce the pitting rate of the brazing alloy layer.