Abstract: This invention provides an improved method and apparatus for controlling the flow of molten metal alloys and, in particular, to a method to finely control the delivery rate of liquid aluminum alloys and the liquid fraction of semi-solid aluminum alloys. The apparatus and method described herein provide for the pumping of liquid metal alloys in a precise and controlled manner. By controlling the heat flow through a section of the pump piston, the pump chamber, the porous liner of the pump chamber and the metal alloy charge, the present invention provides a means to deliver liquid metal alloys at high pressure through one or more exit ports.

Abstract: A method including providing a quantity of metal, the quantity of metal being contaminated by a contaminant including a quantity of carbon; configuring a vacuum induction furnace to operate according to a set of operating parameters, the set of operating parameters being selected based on characteristics of the contaminant, the set of operating parameters including at least one of a pressure, an atmosphere composition, a pour temperature, or a hold time; charging the vacuum induction furnace with the quantity of metal; and operating the vacuum induction furnace to melt the quantity of metal in accordance with the set of operating parameters, whereby at least some of the contaminant is removed from the quantity of metal so as to provide an output metal having a concentration of carbon that is less than or equal to a concentration of carbon in the metal as cast.

Abstract: Various methods are disclosed for additively manufacturing a feedstock material to create an AM preform, wherein the AM preform is configured with a body having an internal passage defined therein, wherein the internal passage further includes at least one of a void and a channel; inserting a filler material into the internal passage of the AM preform; closing the AM preform with an enclosure component such that the filler material is retained within the internal passage of the AM preform; and deforming the AM preform to a sufficient amount to create a product having an internal passage therein, wherein the product is configured with wrought properties for that material via the deforming step.

Abstract: An apparatus and process for formation of a multicomponent metal alloy ingot or product in which granulated metal feedstock, under a high pressure inert environment, is introduced onto a rotating platen or previously deposited layer on the rotating platen. As the granulated feedstock is deposited on the platen, the platen is rotated such that a segment of the platen having the feedstock thereon passes through an energy generator field such as a melting laser beam or eddy current induction melting field. As it passes it is melted to form an arcuate segment of melt. The melt is then rotated out from under the energy beam and cooled into a solid state of the desired alloy as a next contiguous segment of feedstock is introduced and the process repeated until a layer is formed. The platen may then be indexed lower and a new layer is formed in the same manner.

Abstract: A system for two stage casting of a metal alloy is disclosed that dispenses multiple feedstock metals into an arc melting crucible via a pressurized inert gas or metal vapor chamber to lower the volatilization rate of metals in an arc melting crucible at a rate proportional to the composition of the final desired alloy. The melt from the melting crucible enters a second stage cold wall crucible through a passage, where the melt cools and solidifies. A casting piston is used to slowly and progressively withdraw the solidified alloy from the cold wall crucible as it cools.

Abstract: Wires for use in electron beam or plasma arc additive manufacturing of titanium alloys are disclosed. The wires have a first portion comprising a first material, and a second portion comprising a second material. The combination of the first and second materials results in a titanium alloy product of the appropriate composition.

Abstract: The present disclosure relates to new metal powders, wires and other physical forms for use in additive manufacturing, welding and cladding, and multi-component alloy products made from such metal powders, wires and forms via additive manufacturing, welding and cladding. The composition(s) and/or physical properties of the metal powders, wires or forms may be tailored. In turn, additive manufacturing, welding and cladding may be used to produce a tailored multi-component alloy product.

Abstract: Various methods are disclosed for additively manufacturing a feedstock material to create an AM preform, wherein the AM preform is configured with a body having an internal passage defined therein, wherein the internal passage further includes at least one of a void and a channel; inserting a filler material into the internal passage of the AM preform; closing the AM preform with an enclosure component such that the filler material is retained within the internal passage of the AM preform; and deforming the AM preform to a sufficient amount to create a product having an internal passage therein, wherein the product is configured with wrought properties for that material via the deforming step.

Abstract: Composite products and methods of making the same are provided.

Abstract: This invention discloses a molten metal supply system that can supply molten metal to a downstream process at a constant pressure and molten metal flow rate. The molten metal supply system includes a molten metal supply source, a plurality of injectors, and a plurality of check valves.

Abstract: This invention discloses a molten metal supply system that can supply molten metal to a downstream process at a constant pressure and molten metal flow rate. The molten metal supply system includes a molten metal supply source, a plurality of injectors, and a plurality of check valves.

Abstract: A method of artificially aging an aluminum alloy product to achieve a property in the product having the steps of aging the product to achieve the property by heating the product over an aging period, the aging period including a time period where the product is in an underaged state, and terminating the heating when the property is achieved according to a mathematical formula. The property is calculated as a function of time and product temperature measured over the aging period. Calculation of the property includes integration of the thermal effects on the product over the entire aging period including during the time period of underaged product state.

Abstract: A molten metal supply system (90) includes a plurality of injectors (100) each having an injector housing (102) and a reciprocating piston (104). A molten metal supply source (132) is in fluid communication with the housing (102) of each of the injectors (100). The piston (104) is movable through a first stroke allowing molten metal (134) to be received into the housing (102) from the molten metal supply source (132), and a second stroke for displacing the molten metal (134) from the housing (102). A pressurized gas supply source (144) is in fluid communication with the housing (102) of each of the injectors (100) through respective gas control valves (146). The molten metal supply system (90) is in fluid communication with an outlet manifold (140) having a plurality of outlet dies (404), which may be used to form continuous metal articles including rods, bars, ingots, and continuous plate.

Abstract: A molten metal supply system (90) includes a plurality of injectors (100) each having an injector housing (102) and a reciprocating piston (104). A molten metal supply source (132) is in fluid communication with the housing (102) of each of the injectors (100). The piston (104) is movable through a first stroke allowing molten metal (134) to be received into the housing (102) from the molten metal supply source (132), and a second stroke for displacing the molten metal (134) from the housing (102). A pressurized gas supply source (144) is in fluid communication with the housing (102) of each of the injectors (100) through respective gas control valves (146). The molten metal supply system (90) is in fluid communication with an outlet manifold (140) having a plurality of outlet dies (404), which may be used to form continuous metal articles including rods, bars, ingots, and continuous plate.

Abstract: A molten metal supply system (90) includes a plurality of injectors (100) each having an injector housing (102) and a reciprocating piston (104). A molten metal supply source (132) is in fluid communication with the housing (102) of each of the injectors (100). The piston (104) is movable through a first stroke allowing molten metal (134) to be received into the housing (102) from the molten metal supply source (132), and a second stroke for displacing the molten metal (134) from the housing (102). A pressurized gas supply source (144) is in fluid communication with the housing (102) of each of the injectors (100) through respective gas control valves (146). The injectors (100) each include an intake/injection port (138) in the form of a dual action valve (500) adapted to admit and dispense molten metal from the injectors (100).

Abstract: A method of artificially aging an aluminum alloy product to achieve a property in the product having the steps of aging the product to achieve the property by heating the product over an aging period, the aging period including a time period where the product is in an underaged state, and terminating the heating when the property is achieved according to a mathematical formula. The property is calculated as a function of time and product temperature measured over the aging period. Calculation of the property includes integration of the thermal effects on the product over the entire aging period including during the time period of underaged product state.

Abstract: A molten metal supply system (90) includes a plurality of injectors (100) each having an injector housing (102) and a reciprocating piston (104). A molten metal supply source (132) is in fluid communication with the housing (102) of each of the injectors (100). The piston (104) is movable through a return stroke allowing molten metal (134) to be received into the housing (102) from the molten metal supply source (132), and a displacement stroke for displacing the molten metal (134) from the housing (102). A pressurized gas supply source (144) is in fluid communication with the housing (102) of each of the injectors (100) through respective gas control valves (146). The gas supply source (144) is used to pressurize a space formed between the molten metal (134) and the piston (104) during the return stroke of the piston (104) of each of the injectors (100).

Abstract: A molten metal supply system (90) includes a plurality of injectors (100) each having an injector housing (102) and a reciprocating piston (104). A molten metal supply source (132) is in fluid communication with the housing (102) of each of the injectors (100). The piston (104) is movable through a first stroke allowing molten metal (134) to be received into the housing (102) from the molten metal supply source (132), and a second stroke for displacing the molten metal (134) from the housing (102). A pressurized gas supply source (144) is in fluid communication with the housing (102) of each of the injectors (100) through respective gas control valves (146). The molten metal supply system (90) is in fluid communication with an outlet manifold (140) having a plurality of outlet dies (404), which may be used to form continuous metal articles including rods, bars, ingots, and continuous plate.

Abstract: An injector (100) for a molten metal supply system includes an injector housing (102) configured to contain molten metal. A molten metal supply source (132) is in fluid communication with the housing (102). A piston (104) extends into the housing (102). The piston (102) is movable through a return stroke allowing molten metal (134) to be received into the housing (102) from the molten metal supply source (132), and a displacement stroke for displacing the molten metal (134) from the housing (102). A gas supply source (144) is in fluid communication with the housing (102) through a gas control valve (146). The gas supply source (144) is used to pressurize a space (148) formed between the molten metal (134) and the piston (104) during the return stroke of the piston (104) such that when the piston (104) moves through the displacement stroke a compressed gas filled space is formed.

Abstract: A molten metal supply system (90) includes a plurality of injectors (100) each having an injector housing (102) and a reciprocating piston (104). A molten metal supply source (132) is in fluid communication with the housing (102) of each of the injectors (100). The piston (104) is movable through a first stroke allowing molten metal (134) to be received into the housing (102) from the molten metal supply source (132), and a second stroke for displacing the molten metal (134) from the housing (102). A pressurized gas supply source (144) is in fluid communication with the housing (102) of each of the injectors (100) through respective gas control valves (146). The injectors (100) each include an intake/injection port (138) in the form of a dual action valve (500) adapted to admit and dispense molten metal from the injectors (100).