Abstract: A process for applying a metal coating 11 to a metal strip substrate 2 by preheating the casting surface in a non-oxidizing atmosphere and maintaining a casting surface temperature T.sub.s below the solidus temperature of the metal coating material, passing the casting surface through a melt pool 9 of the metal coating material at a pool temperature at least 25.degree. C. in excess of its melting temperature to deposit a melt layer 21 at a casting temperature T.sub.c, and simultaneously rapidly cooling the metal strip substrate from the back surface to solidify the melt layer to an adherent solid coating, wherein the surface temperature T.sub.s is less than about 20 percent (in .degree.K.) below the casting temperature T.sub.c.The process is particularly useful when coating metal strip with an alloy of limited solubility metals.

Abstract: A recirculating fiber filter (1) and method is provided for removing particulates from moving fluid streams. High aspect ratio fibers (2) are used which readily nest with each other to form the high voidage fiber filter bed. In the method, fibers are continuously removed from the bottom of the bed regenerated to remove particulates and recycled back to the top of the bed and distributed thereon. Dirty fluid is passed from the top to the bottom of the filter. Dendrites of the particulate impurity appear to buildup in a thin section (A) at the top of the filter and provide the primary mechanism for further particulate entrapment. Recirculation of fibers offers a continuously fresh volume of fibers at the top for capture of particulates.

Abstract: Continuous production of metal fiber is provided by delivering molten metal at low pressure to a multi-edged, rotating casting drum. The metal is delivered through a wide orifice in a tundish frontwall in close proximity to the casting edges. The flow to the orifice is controlled by means of a constrictive channel upstream of the orifice communicating with the source of molten metal.

Abstract: Metal strip may be directly cast by deposit of a melt layer onto a chill surface. Quality of both the upper and lower surfaces of strip case in this manner may be substantially improved according to the invention by casting on a chill roll having fine, circumferential, surface grooving of a particular geometry.

Abstract: A more uniform cooling system for direct strip forming processes on chilled drums wherein the drum 1 is hollow and is partially filled with a coolant pool 6. A central tube 7 provides coolant spray 8 to the portions of the drum interior when not covered with the coolant pool. Patterned cooling for thickness control is practiced by changing the heat conduction through the drum wall at selected locations.

Abstract: Net shape or near net shape metal rod or wire 3 is rapidly solidified. Molten metal 7 is delivered to a semi-cylindrical casting channel 2 in a chill block 1 from a tundish 4 through a critically-designed metering system comprising a drain 6, an orifice formed of the casting channel 2 and a complementary volume control channel 5, and a barrier 8 which directs molten metal to the volume-control orifice.

Abstract: A method of producing a mark onto a continuously cast metallic strip is disclosed comprising the steps of providing a continuous surface upon which metal strip is cast from a molten metal holding tundish having a nozzle disposed less than about 0.120 inch from the casting surface. The casting surface is cooled and is moved past the nozzle at a rate of about 200 to 10,000 linear surface feet per minute. This method includes providing an impression in the continuous casting surface corresponding to the mark to be produced onto the continuously cast metal strip. Molten metal is continuously fed through the nozzle onto the moving continuous casting surface to produce continuously cast strip thereon, and the cast strip is continuously removed from the casting surface.

Abstract: A process for casting metallic strips thicker than from melt-drag processes but thinner than the inherent normal thickness of a cast melt is disclosed. The disclosed process casts molten metal, without decanting or accelerating the molten stream, onto a channel-shaped chill surface. After casting, the molten strip acquires a high thermal gradient. Following thermal shrinkage of the underside the molten top layer is squeegeed using a chill roll to uniformly distribute and crystallize the top surface.

Abstract: A method for continuously casting strip material onto a casting surface moving past a nozzle in a molten metal holding tundish is disclosed comprising the steps of pouring molten metal into the tundish at a rate sufficient to establish a metallostatic head pressure of at least one-quarter pound per square inch at the nozzle within one second after pouring is initiated, and pouring additional molten metal into the tundish at a rate sufficient to maintain a substantially constant operating pressure at the nozzle throughout the casting operation. A tundish for holding molten metal to be cast into strip material onto a casting surface moving past a nozzle in the tundish, is also disclosed comprising a front wall having an inside surface, a rear wall having an inside surface and sidewalls enclosing a molten metal holding area defined between the inside surfaces of the front and rear walls.

Abstract: Apparatus and method for continuous casting of amorphous or polycrystalline metal strip from a melt. The molten metal is delivered from a reservoir (2) to a moving chill surface, preferably a cylindrical roll (1) through an orifice (3) in the reservoir (2). The gap between the reservoir (2) and the chill surface (1) is not fixed as in prior methods but is variable due to a resilient bias on the reservoir toward the chill surface. A pivot (10) and counterweight (11) are convenient apparatus for resiliently biasing the reservoir. The small portion of the reservoir (2) therefore rides lightly upon the molten metal film delivered to the chill surface or upon the solidified metal strip. The variable gap allows better control over the process and better quality surfaces on the metal strip.

Abstract: An apparatus for continuously casting strip material onto a casting surface includes a tundish for receiving and holding molten metal having a nozzle therein. The nozzle comprises an orifice passage defined between a first inside surface and a second inside surface, wherein at least a portion of at least one inside surface comprises an insert disposed against the tundish. A nozzle gap of at least 0.010 inch is maintained, an outer portion of the insert is able to be disposed to within 0.120 inch of the casting surface, and at least a portion of the outside surface of the tundish at the orifice of the nozzle is able to be disposed to within at least about 0.020 inch of the casting surface.

Abstract: An apparatus for continuously casting metallic strip material includes a tundish, and a nozzle comprising a curvilinear element, with an orifice passage in the element having substantially uniform cross-sectional dimensions throughout the longitudinal extent thereof. Disposed outside the nozzle is a cooled casting surface movable past the nozzle in a direction substantially perpendicular to the longitudinal axis of the orifice passage. First and second inside surfaces of the element define the orifice passage through which molten metal is fed to the casting surface.

Abstract: Normally solid materials, e.g. metals or metal alloys, are provided as solid particulates, and preferably as fine spherical to almost spherical, as well as fiber-like, particulates, including solid particulates of a metallic glassy structure, by contacting a molten stream of the material, which at a temperature within 25 percent of its equilibrium melting point .degree.K. has a surface tension of 10 to 2500 dynes/cm. and a viscosity of 0.001 to 1 poise, preferably from 10.degree. C. to 100.degree. C. above its melting point, with a rapidly moving wall of a centrifugally disposed rotating liquid quench fluid, e.g. water or an oil, etc., in a manner adapted to disrupt the stream with breaking of the stream into molten globules or particles and to quench rapidly those globules or particles into the solid particulates. The produced solid particulates subsequently are separated from the liquid quench fluid and classified to find utility for example in powder metallurgical applications.

Abstract: A method for producing "dogbone" filament fibers having nodules at each end comprising rotating a heat extracting disk having an edge tapering to a narrow peripheral surface and having the peripheral surface notched at intervals with each notch comprising a leading edge, connected to a trailing flat surface, the trailing flat surface supporting an expanded land on the peripheral edge; introducing the rotating disk into the surface of a pool of molten material to form a film of the material on the edge; and removing heat from the film and at least partially solidifying the film on the edge. By the method, the segmented filament fiber products which are produced have a nodule formed on the leading end, a nodule formed on the trailing end, and continuous fiber inbetween, with the general appearance of a dogbone.

Abstract: A method for producing metal flake of small length-to-width ratio or small length-to-thickness ratio directly from a pool or like source of molten metal or molten inorganic compound, or from an unconfined drop of molten metal or an unconfined drop of molten inorganic compound having a surface tension and viscosity similar to that of molten metal, consisting of forming such products by the application of a rotating, generally circular serrated edge, heat-extracting disk-like member to the surface of the pool of molten material so as to form the material into discrete flake particles by extracting the flake particles from the supply of molten material; and controlling the final shape of the product by the physical shape of the member, the temperature and material composition of the melt, as well as the velocity of the member in contact with the melt.

Abstract: A method for producing flake particles by projecting a continuing stream of molten material upon the surface of a rotating generally circular, heat extracting drum, having a serrated edge with each serration comprising a radial surface and an angularly disposed connecting surface from the base of one radial surface to the peripheral extremity of the adjacent radial surface; and rotating the heat extracting drum at a speed relative to the size and shape of the serrations and relative to the rate of molten material projection to form a discrete flake particle on each angularly disposed surface; followed by removing each particle from the surface after each particle is at least partially solidified; and cooling the particles in a surrounding atmosphere.

Abstract: A method for producing metal flake of small length-to-width ratio or small length-to-thickness ratio directly from a pool or like source of molten metal or molten inorganic compound, or from an unconfined drop of molten metal or an unconfined drop of molten inorganic compound having a surface tension and viscosity similar to that of molten metal, consisting of forming such products by the application of a rotating, generally circular serrated edge, heat-extracting disk-like member to the surface of the pool of molten material so as to form the material into discrete flake particles by extracting the flake particles from the supply of molten material; and controlling the final shape of the product by the physical shape of the member, the temperature and material composition of the melt, as well as the velocity of the member in contact with the melt.

Abstract: Polycrystalline titanium-based alloys having a high specific strength are formed by the rapid solidification of a melt composition containing about 80 weight percent titanium and specific amounts of aluminum, vanadium, iron and copper. In the form of filaments the alloys are particularly useful as reinforcing agents in composite structures while in the form of powders the alloys are eminently suitable for use in the fabrication of structural components by the application of powder metallurgy technology.

Abstract: The invention comprises methods and apparatus for forming filamentary material directly from a pendant drop of molten material, and provides for a significant improvement in the quench rate. A typical method of making filamentary material according to the invention, comprises the steps of: (a) heating a solid material, typically, a metal or metal alloy, so as to form a pendant molten drop of the material which is at a temperature within 25 percent of its equilibrium melting point in .degree.K, said molten material having a surface tension of 10 to 2500 dynes/cm. and a viscosity of 0.001 to 1.

Abstract: A continuous casting process is disclosed wherein a plurality of endless flexible belts converge and travel proximate to each other in a common vertical direction to define a travelling mold cavity between the belt faces. Bar shaped products are cast if molten material is poured into the top of a downward moving cavity. Tube shaped products are cast by injection of molten material into the bottom of an upwardly moving cavity.