Abstract: A system for controlling a flow may be provided. The system may comprise a first flow controller and a gas density meter. The gas density meter may be in fluid communication with the first flow controller. The gas density meter may be configured to calculate a gas density for a first gas flowing through the gas density meter. In addition, the gas density meter may be configured to output a first signal configured to cause the first flow controller to alter a first flow rate of the first gas flowing through the first flow controller. Furthermore, the gas density meter may be configured to output a density signal going to the second controller.

Abstract: A mold for creating metal ingots, a hottop sideboard and a system and method of manufacturing metal ingots utilizing the same. A hottop sideboard utilizes a layer of a rigid refractory material integrally connected to a layer a flexible refractory material that is compressed between the rigid layer and the sidewalls of the mold during use. The mold for creating metal ingots comprises: a main body having a floor and sidewalls that form a cavity for receiving a molten metal; a plurality of sideboards connected to the sidewalls and forming a perimeter about the cavity in a spaced relation from the floor, the sideboards comprising a first layer of a rigid refractory material and a second layer of a flexible refractory material, the first layer and the second layer being connected to one another; and the sideboards are secured to the sidewalls so that the second layer is compressed between the first layer and the sidewall.

Abstract: A device to generate and direct electric heat 10 for use over risers, drains, pathways and pour cups during solidification in which less than 2% plasma is utilized, comprising an outer shell 20 having one open heat delivery end 25, at least one lip 30 located at the open end 25, one closed end 35, at least one electric heating element 80 affixed within the closed 35 end and refractory material 60 surrounding the electric heating element 80. A method, employing said device 10, to improve the properties of cast alloys which comprises the heating and blanketing of a molten cast surface with an atmosphere of less than 2% plasma during solidification, said atmosphere of less than 2% plasma thereby controlling temperature during the solidification and shielding the molten cast surface from the affects of oxidation.

Abstract: A method of casting metal articles includes providing a plurality of interconnected support sections. Article mold sections are positioned on the support sections. After article mold cavities, have been filled with a molten metal which is at a first temperature, the support sections and a body of a second molten metal are moved relative to each other while the body of a second molten metal is at a temperature which is less than the first temperature. Space extending between side surfaces of the support sections and between side portions of the article mold sections is filled with the second molten metal during movement between the support sections and the body of a second molten metal. A layer of insulating material may be provided above the body of a second molten metal. A baffle may be provided between a container holding the body of a second molten metal and a furnace assembly.

Abstract: A method and apparatus for the production of a casting comprises: —pouring molten material into a mould for forming the casting; —allowing the molten material to solidify; —removing the mould at least in part from the resulting solidified casting; and —locating the solidified casting in a chamber (10) that completely surrounds and facilitates a controlled rate of cooling of the casting.

Abstract: A method of casting metal articles includes providing a plurality of interconnected support sections. Article mold sections are positioned on the support sections. After article mold cavities have been filled with a molten metal which is at a first temperature, the support sections and a body of a second molten metal are moved relative to each other while the body of a second molten metal is at a temperature which is less than the first temperature. Space extending between side surfaces of the support sections and between side portions of the article mold sections is filled with the second molten metal during movement between the support sections and the body of a second molten metal. A layer of insulating material may be provided above the body of a second molten metal. A baffle may be provided between a container holding the body of a second molten metal and a furnace assembly.

Abstract: A method for preventing oxidation of molten aluminum alloy and magnesium alloy surfaces, the method comprising providing a molten aluminum alloy or magnesium alloy having a molten aluminum or magnesium alloy surface; covering the molten aluminum or magnesium alloy surface with an initial layer of petroleum coke, the initial layer of petroleum coke having an initial layer thickness of about 0.75 inches; oxidizing a portion of the initial layer of petroleum coke to form a working layer of petroleum coke covering the molten metal surface, the working layer of coke having a working layer thickness of about 0.5 inches, and a layer of carbon dioxide immediately adjacent to and contiguous with the working layer of petroleum coke; and adding additional petroleum coke to the working layer of petroleum coke to maintain the working layer thickness at about 0.5 inches.

Abstract: A device is made available for producing monocrystals, for example large-diameter gallium arsenide monocrystals, that has a cylindrical heating appliance with a floor heater (2) and a cover heater (3). The heating surfaces of the floor and the cover heater are considerably larger than the cross-sectional area of the monocrystal to be produced. In addition, an insulator (6) is planned for the reaction space that is designed to prevent a radial heat flow and the guarantee a strictly axial heat flow over the complete height of the reaction space between the cover heater (3) and the floor heater (2).

Abstract: A method to minimize oxidation of metal during melting processes is provided, the method comprising placing solid phase metal into a furnace environ-ment, transforming the solid-phase metal into molten metal phase having a molten metal surface, and creating a barrier between the surface and the environment. Also provided is a method for isolating the surface of molten metal from its environment, the method comprising confining the molten metal to a controlled atmos-phere, and imposing a floating substrate between the surface and the atmosphere.

Abstract: Method and investment shell mold for casting comprising introducing molten metallic material into an investment shell mold to fill a mold cavity and provide an upper surface of the molten metallic material above the mold cavity. An initially closed, destructible region of the mold then is broken to provide an entry opening through which exothermic material is placed on the upper surface of the molten metallic material to provide a source of molten metallic material to accommodate shrinkage of a casting as it solidifies in the mold cavity.

Abstract: Fully dense long ingots are produced by the bottom pouring method and apparatus of the present invention. A solidification sequence is achieved which is conducive to eliminating solidification shrinkage and piping. The set-up of the bottom poured ingot molds facilitates a solidification sequence starting from the top and then down the ingot mold and then up the down pour pipe.

Abstract: Casting aluminum-lithium based alloys under a salt cover involves forming a molten aluminum-lithium alloy, transferring the molten aluminum-lithium alloy to a casting station, and direct chill casting the aluminum-lithium alloy, wherein a protective molten salt cover comprising a mixture of lithium chloride and potassium chloride is maintained over the aluminum-lithium alloy during the casting process. Formation of the molten aluminum-lithium alloy includes alloying of lithium with aluminum by adding lithium to the salt-covered molten aluminum in a melting vessel. The molten salt may be added to the ingot head during casting. A preferred salt mixture includes 35 to 90 mole % LiCl and 10 to 65 mole % KCl.

Abstract: The invention relates to a coolant of aluminium dross, which used in separating and recovering metallic aluminium involved in the dross which is formed when aluminium and aluminium alloys are molten. The coolant consists of 4-60% by weight of a crabonaceous material wherein the particles whose size is 2-7 mm in diameter are not less than 50% by weight, and 4-60% by weight of at least one of obsidian, perlite, vermiculite and natural pumice whose particle size is 2-7 mm in diameter. Alternately, the coolant consists of 20-50% by weight of the carbonaceous material wherein the particles whose size 2-7 mm in diameter are not less than 50% by weight, 20-50% by weight of at least of obsidian, perlite, vermiculite and natural pumice whose particle size is 2-7 mm in diameter, and not more than 30% by weight of at least one of SiC or metal oxides such as of Al, Si Zr, Cr and Zn. Preferably, said carbonaceous material is at least one of coke and charcoal.

Abstract: Methods are known for producing a body from a material susceptible to thermal cracking, in particular from an alloy, by casting a melt of the material in a mold with thermally insulated side walls and a bottom of material with good thermal conducting properties and cooling the melt in the casting mold, where the solid-liquid interface forming as the border between the melt and the already solidified material essentially extends parallel to the bottom and, in the course of the solidification of the melt, moves from the bottom in the direction of the exposed surface of the melt.

Abstract: An asbestos-free insulating material suitable for use as a header in molten metal casting. The material is made from a dry mixture comprising lime, siliceous component, delaminated vermiculite or spodumene or lithium aluminate or mixtures thereof, and optionally, wollastonite and organic fiber. The dry mixture is mixed with water to form a slurry, shaped, heated in the presence of steam, and dried to remove free water.

Abstract: Spherical graphite cast iron utilized to prepare a lapping tool is manufactured by casting a molten composition into a mold cavity, and by chilling one side of the resulting casting thereby causing unidirectional solidification, the one side being used as the operating surface of the lapping tool. The molten composition consists essentially of 3.0-3.8 wt. % of carbon, 2.0-2.9 wt. % of silicon, 0.3-0.9 wt. % of manganese, less than 0.05 wt. % of phosphorus, less than 0.03 wt. % of sulfur, 0.2-1.0 wt. % of nickel, 0-0.8 wt. % of copper, 0.05-0.5 wt. % of molybdenum, 0.03-0.09 wt. % of magnesium and the balance of iron. The lapping tool made of this casting has a percentage of sphericity of higher than 80%, graphite particle diameter of less than 100 microns, a density of graphite particles of larger than 70/mm.sup.2, and a Vickers hardness of larger than 200.

Abstract: A ferromagnetic amorphous metal strip insulated with a coating of glass that is about 0.001 to about 0.02 mils thick.

Abstract: A mold additive for use in continuous casting, which includes a base material having a chemical composition of CaO--BaO--SiO.sub.2 --F system, and contains 2-15% by weight in total of at least one carbonate of alkali and alkaline earth metals, 2-30% by weight in total of at least one fluoride of alkali and alkaline earth metals and 0.2-10% by weight of carbon, and, if necessary, 2-10% by weight in total of at least one oxide of Fe, Mn and Ni, and has a solidification temperature of not more than 900.degree. C. and a viscosity at 1,300.degree. C. of not more than 3 poises. The base material has a weight ratio of (CaO+BaO)/SiO.sub.2 of 0.6-2.5 and contains not less than 2% by weight of BaO and 2-15% by weight of F.

Abstract: A casting powder for use in ingot steel production through bottom pour process is provided. The powder combines the crucial properties of existing bottom pour fluxes and hot topping compounds into a single, easily dispensed mixture. The present invention provides a significant simplifying and savings over present methods while producing steel with fewer impurities.

Abstract: A process of using a thermally insulating board, made of a homogeneous mixture of expanded perlite particles and cellulosic and/or mineral and/or ceramic fibers, bonded together, comprising placing on the surface of a molten steel mass, in direct contact with the surface, so as to cover substantially all the surface. According to a preferred embodiment, the board consists of 51 to 80% by weight of expanded perlite particles, 15 to 39% by weight of cellulosic and/or mineral fibers and 5 to 10% by weight of binder.

Abstract: A mold additive for use in the continuous casting is disclosed, which comprises a base material for slag having a chemical composition of CaO--SiO.sub.2 --Al.sub.2 O.sub.3 system, a flux and a carbonaceous aggregate. The mold additive contains 0.5-2.0% by weight of carbon black and 1-4% by weight of activated carbon with an average particle size of not more than 10 .mu.m as the carbonaceous aggregate, and has a bulk density of not more than 0.9 g/cm.sup.3.

Abstract: The exposed surface of a molten metal, ferrous or non-ferrous in a ladle is covered by an expanding insulating ladle covering compound that is capable of absorbing and removing non-metallic inclusions in a predictable volume. The compound includes burnt lime in amounts between 56% and 60% by weight, aluminum dross, including Al.sub.2 O.sub.3 in amounts between 22% and 30% by weight, fluorspar in amounts between 7% and 9% by weight, and acid treated graphite in amounts between 1% and 4% by weight.

Abstract: The granular insulation product is intended more particularly for the insulation, protection or processing of metal baths during their manufacture or transport. The product comprises a solid phase having a certain mineral matter content and an organic binder comprising cellulose-based pulp, and preferably paper pulp. The granulation is carried out under conditions such that the granules being formed experience no appreciable compression likely to break the structure of the solid phase containing the mineral matter.

Abstract: A simple method of producing a rim-stabilized steel ingot without requiring the use of special equipment wherein a rimming-type steel is teemed into an ingot mold and thereafter allowed to rim for a suitable period of time, and then adding a particulate mixture of aluminum and an exothermic material to the top of the molten metal so that the exothermic mixture will ignite, melting and superheating the aluminum content which is driven into the molten steel at the ingot core.

Abstract: A hot top consists of a number of sheets of insulating fibrous material. The principally vertical walls of the hot top consist of a number of sheets located close to and joined to one another. When the hot top is placed in an ingot mould, these sheets cover the upper part of the ingot mould walls. The hot top has an upper confinement consisting of one or more sheets of insulating fibrous material which cover the opening formed by the vertical sheets. One or more containers holding additives used in casting are arranged in the space under the confinement. In one preferred embodiment, the walls of the hot top, the upper confinement of the hot top and the hot top containers holding additives form a single unit matched to the dimensions of the ingot mould, so that in a preferred embodiment, the unit is assembled before the hot top is inserted into the ingot mould.

Abstract: The present invention relates to a method of and a device for effecting electroslag remelting processes.While effecting an electroslag remelting process by the proposed method an electrode is dipped into a slag bath. Electric current is passed through the electrode and slag bath, heating the slag to a melting point of said electrode. Upon establishing the molten slag bath and a metal pool said electrode is shielded by lowering on the surface of the molten slag bath a disc with an opening for the passage of said electrode so that the disc will float in the slag without coming in contact with the metal pool. A device for effecting electroslag remelting processes, comprising a baseplate mounting a means for effecting an electro slag remelting process accommodating a slag bath and an electrode that is dipped thereinto and is encompassed with a protective shield made as a disc of material whose specific density is lower than that of the slag of said slag bath.

Abstract: A process for providing a thermal insulating cover of discrete particles for a container of fluids involves forming a plurality of hollow interior, discrete, ceramic particles, firing the particles at a temperature of at least 350.degree. C and then covering the heated liquid with at least a 1/8 inch thick layer of the fired particles. A potentially improved ceramic thermal insulating particle is also described and contains a hollow interior with a plurality of partitions.

Abstract: A flux powder for use in the continuous casting of steels, particularly aluminum killed steels in the form of a mechanical mixture of components and has the following chemical analysis by weight % :- silicon dioxide 20 - 60, calcium oxide source 20 - 60, calcium fluoride 3 - 20, alkali metal carbonate 3 - 20, carbon source 4 - 20 and aluminum oxide 0 - 10. At least the inorganic components of the mixture are substantially pure, whereby the properties of the powder may be made substantially uniform and reproducible. The components preferably have a uniform grain size and calcium carbonate is disclosed as a calcium oxide source and natural graphite is a preferred carbon source.

Abstract: In direct pouring of molten metal for an ingot-making process, hollow long bodies made from self-fluxing heat-resistant sheets are used as a splash-preventive pipe. The self-fluxing heat-resistant sheet is composed of one or more inorganic fibers having fixed softening and fusion temperatures, binders and silicate fillers. The fusion rate and temperature of the sheet are selected in accordance with the teeming rate and temperature to insure that the body end is fused and consumed while being submerged in a given depth below the molten metal surface in a mold.

Abstract: A process of manufacturing killed steel ingots of superior quality by forming the sound hot top portion and reducing the concentration of nonmetallic inclusion in the mushy zone of ingot bottom, characterized by arranging on the molten steel surface immediately after the pouring of the molten steel into a mold, a board-like molded heat-retaining material in which lining of a layer consisting of easily-flammable material is made to an exothermic, diabatic layer consisting of crushed flat charcoal, a refractory material expansible by heating and a binder.

Abstract: A process for casting an ingot from a molten metal by bottom pouring molten metal into an ingot mould is described in which there is located in the ingot mould a bonded flux composition comprising one or more fluxing agents, together with a bonded refractory composition comprising particulate refractory material and fibrous material, the bonded refractory composition being positioned in relation to the bonded flux composition to protect the latter from the initial upsurge of molten metal when pouring commences. The bonded flux composition and the bonded refractory composition can be formed together as a laminate, or the bonded flux composition can be formed with an insert of the bonded refractory composition. Alternatively, the bonded flux composition can be placed on the base of the ingot mould while the bonded refractory composition is placed as a striker pad in a recessed basin in the bottom plate of the mould.

Abstract: A process for casting steel ingots, wherein the steel from a ladle is cast under vacuum through the lid of a container which can be evacuated, into a mould, and wherein covering powder or anti-piping compound, respectively, is evenly applied upon the surface of the molten steel in the mould while the vacuum is maintained.

Abstract: The surface quality of ingots may be improved by bottom-pouring molten metal into an ingot mould wherein there is located in the ingot mould, prior to the commencement of pouring, a multi-layered board having a first layer which is a preformed slab comprising an anti-piping composition including an exothermic material and a second layer adjacent the first layer which is a preformed slab comprising a fluxing agent, a fibrous material and a binder, the second layer having a central cavity therein filled with a preformed refractory slab comprising a refractory material, a fibrous material and a binder, the slabs being arranged such that the refractory slab is enclosed within the board, and the board being located in the mould with the first layer uppermost. The board acts as both a mould additive and as an anti-piping compound.

Abstract: A method of casting quiet steel in a mold according to which prior to the casting of casting powder with a bulk weight of from 250 to 705 gr/liter and in a quantity of from 1 to 3 kg/ton of steel is introduced into the mold at a distance of from 5 to 50 cm from the base of the mold, and in which when the liquid steel level reaches the desired height the slag layer is instantaneously and completely covered with water whereby the entire slag layer solidifies and lifts itself off the steel level so that the latter is contacted by the water.

Abstract: An insulating composition useful for riser sleeves, hot tops, ladle liners, and the like articles for use in casting of molten ferrous metal is described. The composition comprises 30% to 50% refractory fiber, 1% to 35% granular silicon carbide, inorganic binder, organic binder, and refractory filler. Molten steel at temperatures on the order of 3,000.degree. F can be readily handled by the articles of this composition. They also afford superior heat insulating properties and in the form of riser sleeves allow molten metal in a riser to remain molten for a longer period before solidification.

Abstract: A process of producing steel ingots having a steel composition at the skin hich differs from that at the heart comprises tapping incompletely killed steel from a tapping ladle into an ingot mould, adding a deoxidizing agent to the steel in the mould, intensively mixing the steel for a period in minutes equal to at least half the height of the ingot in meters and decanting the inclusions in the steel, both the intensive mixing and decant taking place during the basaltic crystallization phase.

Abstract: A process for reducing the degree of oxidation of a metal obtained by a production or purification operation wherein the metal is converted to the vapor state and then condensed to the liquid form in a vessel the lower part of which forms a crucible or pot in which it solidifes and in which a fusible flux is added to the metal in the crucible with a view to reducing the degree of oxidation, whereby the flux is added after previously being melted and the molten flux caused to penetrate into the void formed by contraction between the ingot and the inner wall of the crucible or pot.

Abstract: A method of casting an ingot which comprises locating in an ingot mould a vertical tube of fibrous heat-insulating material of melting point less than the casting temperature of the metal of the ingot, and teeming molten metal into the mould.

Abstract: A mould flux which comprises at least 30% by weight of a mixture comprising:I. wollastonite;Ii. at least one low melting fluxing agent.

Abstract: The surface quality of bottom poured ingots can be improved by placing on the mould floor, prior to pouring, a bonded composition of one or more fluxing agents and expandable graphite.

Abstract: There is disclosed a material and method for preventing heat loss from molten metal, one side of this material being impregnated with heat insulating refractory or exothermic material. The impregnated side has a porosity of less than about 50 AFS units and contains a binder.