Abstract: Nucleated casting systems and methods comprise the addition of powders into a liquidus portion of the casting. The casting system forms a casting comprising a liquidus portion that receives the refined liquid metal and a solidified portion, the casting further comprising a fine-grain, homogeneous microstructure that is essentially oxide- and sulfide-free and segregation defect free. The casting system comprises a source of refined liquid metal, the refined liquid metal having oxides and sulfides refined out of the metal; a solid metal particle addition system that adds solid metal particles to a surface of the liquidus portion of the casting; and a nucleated casting system for forming the casting. The solid metal particle addition system adds solid metal particles that serve as nucleation centers during solidification of the casting.

Abstract: A melt guide includes a base plate having internal cooling channels and a center aperture extending vertically therethrough. A unitary drain bushing is removably mounted in the aperture and is readily replaceable after wear thereof.

Abstract: A casting system with auxiliary cooling onto a liquidus portion of the casting can produce a metal casting that comprises a fine-grain, homogeneous microstructure. The microstructure is essentially oxide- and sulfide-free, segregation defect free, and essentially free of voids caused by air entrapped during solidification of the metal from a liquidus state to a solid state. The casting system with auxiliary cooling onto a liquidus portion of the casting can comprises an electroslag refining system as a source of liquid metal; a nucleated casting system; and at least one cooling system that supplies coolant onto a liquidus portion of the casting. The liquidus portion of the casting is cooled in a manner sufficient to provide a casting microstructure that comprises a fine-grain, homogeneous microstructure that is essentially oxide- and sulfide-free, segregation defect free, and essentially free of voids caused by air entrapped during solidification from a liquidus state to a solid state.

Abstract: An inspection apparatus for water flow testing of cooling passageways in gas turbine buckets provides observable visual determination of whether any blockages were formed during the manufacturing or refurbishing processes. The inspection apparatus includes a manifold block and manifold control valve mounted on a platform and adapted to engage the root end of a turbine bucket and supply fluid therethrough. The turbine bucket is affixed to the platform with a holder. The fluid exiting at the tip of the turbine bucket is visible and any blockages in the passageways will be easily discerned by the absence or paucity of fluid flow at the tip. Fluid is supplied to the manifold block by a pressure regulated fluid supply line with a control valve and a flow meter. An air supply line is also connected to the manifold block to supply air through the passageways to remove residual fluid from the bucket.

Abstract: A consumable electrode feed system for a refining system provides consumable electrodes to a refining system. The consumable electrode feed system comprises a side feed device that feeds consumable electrodes to a refining system in a first direction; a refining feed device that feeds consumable electrodes to a refining system in a second direction, in which the second direction being generally orthogonal to the first direction; and a connection system for connecting fed consumable electrodes to each other. The consumable electrode feed system allows for a predetermined amount of a consumable electrode to be refined in the refining system, and can position another consumable electrode above a previously fed consumable electrode. The connecting system then can connect a fed consumable electrode to a previously fed consumable electrode thus avoiding refining operation.

Abstract: In a method and apparatus for the electroslag refining of metal, the method includes providing a refining vessel to contain an electroslag refining layer floating on a layer of molten refined metal. The refining vessel representing an upper part of a cooled mould comprises a plurality of superimposed sleeves which are electrically insulated from one another. The top sleeve, being the refining vessel, is substantially a non-consumable electrode and has a current lead electrically insulated from the sleeve. The molten electroslag layer is heated by a refining current which is passed from a power source through the mould and slag layer to the metal pool. An unrefined metal is lowered into the vessel into contact with the molten electroslag layer such that its surface is melted and overheated at the point of contact with the slag such that droplets of the metal are formed and these droplets pass down through the slag and are collected in a pool of molten refined metal beneath the slag.

Abstract: A method for controlling electromagnetic flux concentration in a discharge guide tube for a metal refining apparatus is provided. The discharge guide tube comprises a base plate, an extension, a central orifice that extends through the extension from a source of liquid metal to an outlet in the discharge guide tube for directing a stream of metal therethrough, and an interior discharge guide tube flux concentration configuration; an induction heater system that generates an electromagnetic field in the discharge guide tube, the induction heater system being disposed on the extension with a gap defined therebetween, the induction heater system and the discharge guide tube being capable of relative vertical movement and subsequent positions with respect to each other with the gap being essentially constant.

Abstract: A method for assessing quality of a coating process includes providing a facsimile assembly, the facsimile assembly having a fixture holding an audit coupon, and coating the facsimile assembly to form a coating thereon. The assembly is then disassembled, and the coating on the audit coupon is inspected.

Abstract: A bottom pour electroslag refining system refines raw material into refined liquid metal. The bottom pour electroslag refining system comprises an electroslag refining crucible; a slag; a bottom pour structure that comprises an orifice from which refined liquid metal from the electroslag refining crucible can flow as a stream of refined liquid metal; and a current path. The current path is defined in the bottom pour electroslag refining system for applying current to the raw material for melting and refining the raw material. The melted and refined raw material forms a refined liquid metal pool in the electroslag refining crucible. The current that is applied by the current path is sufficient to provide the refined liquid metal in the refined liquid metal pool with a viscosity under which the refined liquid metal can flow through the orifice under its own viscosity.

Abstract: Rare earth alloy compositions, such as the neodymium iron boron (NdFeB) alloy are made by a Reduction-Melting process. The Reduction-Melting process comprises preparing a primary electrode containing at least one compound or metal to be reduced to form a refined metal or metal alloy ingot; placing the electrode in an electroslag refining furnace; passing a current through the electrode into a molten flux or slag to melt the electrode; reducing the metal or compound in the slag while forming an oxide by-product; collecting melted metal or metal alloy droplets falling through the slag; forming an ingot of the metal or metal alloy from the melted droplets; and collecting the solid oxide byproducts in the slag.

Abstract: The flowrate of a stream discharged from a drain in a vessel is measured by imaging the stream, measuring a diameter of the stream image, and calculating the flowrate based on the measured diameter. A video camera may be aimed below the drain for imaging the stream. A computer is joined to the camera for measuring the diameter of the stream and calculating a corresponding flowrate therefor.

Abstract: An article that comprises a fine-grain, homogeneous microstructure is essentially oxide- and sulfide-free and segregation defect free. The article is produced by a process that comprises forming a source of clean refined metal that has oxides and sulfides refined out by electroslag refining; and forming the article by nucleated casting. The invention also sets forth the article made by a system for implementing the clean metal nucleated casting process.

Abstract: A system for controlling the flow rate of the stream from an electroslag refining apparatus is taught. The system includes the introduction of unrefined metal into an electroslag refining process in which the unrefined metal is first melted at the upper surface of the refining slag. The molten metal is refined as it passes through the molten slag. The refined metal is collected in a cold hearth apparatus having a skull of refined metal formed on the surface of the cold hearth for protecting the cold hearth from the leaching action of the refined molten metal. A cold finger bottom pour spout is formed at the bottom of the cold hearth to permit dispensing of molten refined metal from the cold hearth.

Abstract: A consumable electrode is suspended by a stub. The stub includes upper and lower hangers between which is vertically mounted a loadcell for weighing the electrode attached to the lower hanger. An electrical conductor is joined between the upper and lower hangers for carrying electrical current therebetween to power the electrode without damaging the loadcell.

Abstract: A guide tube structure for flux concentration is provided. The discharge guide tube comprises a central orifice that extends from a source of metal to an outlet in the discharge guide tube for directing a stream of melt therethrough; a structure that generates an electromagnetic field in the discharge guide tube; and an interior discharge guide tube flux concentration configuration that is capable of concentrating at least one of heat, electromagnetic field, and electromagnetic flux onto the stream of melt that flows through the central orifice. The electromagnetic field is applied at a substantially constant level.

Abstract: Systems for controlling the superheat of the stream of molten metal from an electroslag refining apparatus is taught. The systems include the introduction of unrefined metal into an electroslag refining process apparatus in which the unrefined metal is first melted at the upper surface of the refining slag. The molten metal is refined as it passes through the molten slag. The refined metal is collected in a cold hearth apparatus having a skull of refined metal formed on the surface of the cold hearth for protecting the cold hearth from the leaching action of the refined molten metal. A cold finger bottom pour spout or exit orifice is formed at the bottom of the cold hearth to permit dispensing of molten refined metal from the cold hearth.

Abstract: A melt guide is provided for enclosing a bottom of an electroslag refining crucible containing a melt of electroslag refined metal. The guide includes an upper plate sized to engage the crucible bottom for attachment thereto, and includes an upper orifice drain therethrough for draining by gravity the melt from the crucible. A lower plate is spaced below the upper plate to define a plenum therebetween, and includes a lower orifice drain therethrough. A downspout extends through the plenum in flow communication between the upper and lower drains, and includes a middle orifice drain. A heater surrounds the downspout for heating the melt drainable therethrough. And, a coolant is circulated through the plenum for cooling the guide.

Abstract: A cold hearth for an electroslag refining crucible includes a floor above which a melt pools. The floor includes a drain for draining the melt by gravity. A plug is deployed inside the drain to block discharge of the melt therethrough, and an actuator is attached to the plug for withdrawing the plug from the drain to permit drainage of the melt upon startup.

Abstract: A method and spray forming system for effectively spraying the inner diameters of intricate objects and makes inner diameter spray forming practical for articles that have various and complicated inner geometries. The spray forming system can include at least one of a rotating mandrel and preform, and atomizer, which is fed with liquid metal, to form a spray. The atomizer is positioned with respect to inner walls of at least one of the rotating mandrel and preform to accurately and fully spray form an inner diameter of an article, even if the article has complicated and irregular inner surfaces.

Abstract: Systems and methods of electroslag refining of metal include the introduction of unrefined metal into an electroslag refining process in which the unrefined metal is first melted at the upper surface of the refining slag. The molten metal is refined as it passes through the molten slag. The refined metal is collected in a cold hearth apparatus having a skull of refined metal formed on the surface of the cold hearth for protecting the cold hearth from the leaching action of the refined molten metal. A cold finger bottom pour spout is formed at the bottom of the cold hearth to permit dispensing of molten refined metal from the cold hearth. The cold finger bottom pour spout comprises a plurality of copper segments having gaps. The gap between the segments is established and maintained by insulation structure and sealing structure positioned in each gap.