Abstract: A system for wirelessly obtaining a measurement of a characteristic of a molten metal is disclosed. The system includes a contact block configured to be operatively coupled to a first end of a substantially hollow lance holder. The contact block is detachably and electrically coupled to and receives analog signals from a measurement sensor. The contact block converts the received analog signals into ultrasonic signals and transmits the ultrasonic signals through the hollow of the lance holder. A receiver block is configured to be operatively coupled to a second end of the lance holder. The second end is opposite the first end of the lance holder. The receiver block receives the ultrasonic signals from the contact block and converts the received ultrasonic signals into a digital voltage signal.

Abstract: A thermocouple system is disclosed. The thermocouple system includes a thermocouple having a positive lead and a negative lead. A positive wire is connected at a first end to the positive lead at a first junction and at a second end to a second junction. A negative wire is connected at a first end to the negative lead at a third junction and at second end to a fourth junction. The second and fourth junctions constitute a reference junction. At least one of a thermal conductivity and a gauge of at least one of the positive wire and the negative wire are selected to govern the respective flows of heat from the first junction toward the reference junction and the flow of heat from the third junction toward the reference junction to be of such quantities that the difference in the heat flows is less than a predetermined amount.

Abstract: A system for wirelessly obtaining a measurement of a characteristic of a molten metal is disclosed. The system includes a contact block configured to be operatively coupled to a first end of a substantially hollow lance holder. The contact block is detachably and electrically coupled to and receives analog signals from a measurement sensor. The contact block converts the received analog signals into ultrasonic signals and transmits the ultrasonic signals through the hollow of the lance holder. A receiver block is configured to be operatively coupled to a second end of the lance holder. The second end is opposite the first end of the lance holder. The receiver block receives the ultrasonic signals from the contact block and converts the received ultrasonic signals into a digital voltage signal.

Abstract: A thermocouple system is disclosed. The thermocouple system includes a thermocouple having a positive lead and a negative lead. A positive wire is connected at a first end to the positive lead at a first junction and at a second end to a second junction. A negative wire is connected at a first end to the negative lead at a third junction and at second end to a fourth junction. The second and fourth junctions constitute a reference junction. At least one of a thermal conductivity and a gauge of at least one of the positive wire and the negative wire are selected to govern the respective flows of heat from the first junction toward the reference junction and the flow of heat from the third junction toward the reference junction to be of such quantities that the difference in the heat flows is less than a predetermined amount.

Abstract: A probe to measure particulates suspended in molten metal includes an inner tube forming a receiving chamber. The tube includes an orifice permitting molten metal to flow into the chamber. A gas passageway extends out of the tube for connection to a vacuum source. A first electrode including a first member extends into the chamber. A second electrode surrounds a portion of the tube. The first and second electrodes connect to a measurement device for measuring changes in the electrical potential produced by particulates passing through the orifice. A liquidus depressing material within the chamber lowers the liquidus temperature of the molten metal and permits a longer period for measuring particulates therein. A second member is connected to the gas passageway at a first end of the second member. A chill block spaced from the liquidus depressing material is attached to a second end of the second member.

Abstract: A probe to measure particulates suspended in molten metal includes an inner tube forming a receiving chamber. The tube includes an orifice permitting molten metal to flow into the chamber. A gas passageway extends out of the tube for connection to a vacuum source. A first electrode including a first member extends into the chamber. A second electrode surrounds a portion of the tube. The first and second electrodes connect to a measurement device for measuring changes in the electrical potential produced by particulates passing through the orifice. A liquidus depressing material within the chamber lowers the liquidus temperature of the molten metal and permits a longer period for measuring particulates therein. A second member is connected to the gas passageway at a first end of the second member. A chill block spaced from the liquidus depressing material is attached to a second end of the second member.

Abstract: A probe for measuring particulates in molten metal includes an inner metal receiving chamber, with an orifice to permit metal to flow into the chamber. A first electrode extends into the chamber and a second electrode surrounds at least a portion of the chamber. The electrodes are connected to a measurement device for measuring changes in the electrical potential produced by the passage of particulates entrained in the molten metal passing through the orifice. An outer sheath of heat resistant material surrounds the second electrode and a gas passageway extends out of the inner tube for creating a pressure differential within the chamber for facilitating the flow of molten metal through the orifice. A liquidus depressing material is in the chamber to lower the liquidus temperature of the molten metal and permit a longer time period for detecting and measuring particulates in the molten metal.

Abstract: A probe for insertion into molten metal to detect and measure particulates suspended therein includes an inner tube of an electrically insulated material forming a metal receiving chamber, the tube having an orifice to permit molten metal to flow into the chamber. A first electrode extends into the chamber for engaging metal within the chamber and a second electrode surrounds at least a portion of the inner tube for engaging molten metal outside of the chamber. The electrodes may be connected to a measurement device for establishing a current path through the electrodes and passing through the orifice for measuring changes in the electrical potential produced by the passage of particulates entrained in the molten metal passing through the orifice.

Abstract: An improved method of ultrasonically welding together two conductors having differing lateral dimensions comprising selecting a welding capture fixture having lateral sides spaced apart by a distance substantially equal to the lateral dimension of a first conductor having the greatest lateral dimension. The first conductor is placed in the selected fixture so that the first conductor is proximate to or substantially engages both lateral sides of the fixture. The second conductor is formed so that at least a first portion extends laterally beyond a second portion. The second conductor is placed into the select fixture so that the first portion is proximate to or substantially engages one of the lateral sides of the fixture and the second portion is proximate to or substantially engages the other lateral side of the fixture with both portions substantially engaging the first conductor.

Abstract: A method and apparatus for introducing an additive material into a metallurgical sample. In a preferred embodiment, the method and apparatus of the present invention comprises introducing a stabilizer, for example, tellurium and/or bismuth, into a metallurgical sample of cast iron or blast furnace hot metal to induce white solidification comprising a probe having a generally enclosed sample cavity and a conduit extending from the cavity for receiving a flow of molten metal for collection in the cavity. A distribution member proximate the conduit is employed for inserting a predetermined quantity of the additive material at a predetermined rate into the molten metal flowing through the conduit so that the additive material is homogeneously distributed throughout the molten metal within the sample cavity.