Abstract: An apparatus for continuously casting metallic strip material includes a tundish, and a nozzle comprising a slotted element, with the slot 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 slot. The slot is defined between first and second lips of the nozzle which have inside surfaces facing one another at least at an inner portion of the slot. The facing inside surfaces diverge from one another at an outer portion of the slot. The first and second lips are further provided with bottom surfaces facing the casting surface at a standoff distance less than 0.120 inch.

Abstract: An apparatus for rapid solidification casting of molten high temperature and/or reactive metallic alloys has a heat extraction crucible for containing the alloy in liquid form. A nozzle forms an integral part of the crucible and allows for ejection of a stream of molten metal. The heat extracting crucible and nozzle are protected from the molten alloy by a shell of the alloy which has solidified and prevents reaction between the molten metal and the heat extracting crucible.

Abstract: A silicon ribbon growth wheel having a thermal resistance zone between an outer silicon contacting surface and an inner cooling fluid contacting surface to control rate of heat flow from the outer to inner surfaces. In a preferred form the thermal resistance zone is defined by a row of holes through the wheel near the outer surface with said holes isolated from the cooling fluid. A method for controlling the heat flow is also diclosed.

Abstract: A silicon ribbon growth wheel having an internal cooling fluid contacting surface modified to provide a lateral temperature profile on the wheel surface of lower temperature near the wheel edges. In a preferred form the inner surface is provided with grooves near the wheel edges to increase heat conduction to the cooling fluid at the wheel edges. A method for surface temperature profiling the growth wheel is also disclosed. A method for surface temperature profiling the growth wheel is also disclosed.

Abstract: A continuous casting nozzle has a relatively narrow dispensing slot reinforced against flexing along its length by intermittent supporting structure. The nozzle may be a tubular insert member to be received in a mounting means, such as a support plate and providing the reinforcement. The nozzle may be formed from a hollow tubular member with longitudinally aligned sectors or openings formed in the side wall to provide passage of the molten metal to the dispensing slot. The relatively narrow slot is formed in the side wall opposite the openings. The reinforcement ribs are integrally formed between the openings. The end portions of the nozzle member are plugged to direct the molten metal through the dispensing slot. With the nozzle member inserted into the bore in the mounting plate of the crucible, the nozzle assembly is supported along its entire length. The mounting plate may include reinforcement ribs aligned with the ribs of the nozzle member when fully inserted in the plate.

Abstract: An improved apparatus and process is provided for producing solid metal strip from a molten source using a rapidly moving quench surface. The improvement comprises an auxiliary, liquid-cooled chill roll for contacting the solid strip and urging it against the quench surface. The invention permits high quench rates and improved strip surface smoothness to be achieved and finds particular advantage in the casting of metallic glass alloys.

Abstract: Apparatus is provided for controlling the extrusion of molten metal from a tundish through a nozzle onto a rotating quenching surface in the high speed continuous casting of glassy metal alloy continuous filaments. An inverted pressure bell is disposed in the tundish containing molten metal. A controller, in response to the sensing of the liquid level outside the pressure bell, regulates the gas pressure inside the pressure bell to maintain a constant liquid level outside the pressure bell as molten metal flows from the tundish through the nozzle and therefore to maintain a substantially constant pressure at the nozzle inlet. As the quantity of the molten metal in the tundish is depleted, the controller, in response to the sensing of the gas pressure inside the pressure bell, causes molten metal to be supplied to the tundish as a low liquid level limit is approached in the pressure bell.

Abstract: An apparatus for producing thin metal sheet by applying molten metal onto the peripheral surface of a rotary drum through a molten metal applying nozzle, and allowing the molten metal to be cooled and solidified on the peripheral surface of the drum. The molten metal applying nozzle is so disposed in relation to the rotary drum that the molten metal is applied upwardly to the peripheral surface of the rotary drum and that the direction of application of the molten metal intersects the peripheral surface of the rotary drum. This arrangement permits an easy setting of the nozzle in relation to the drum, as well as control of application of the molten metal, to make it possible to produce thin metal sheets of a large variety of thickness and high qualities, at an increased precision and production efficiency.

Abstract: A modular apparatus is provided for depositing molten metal onto a movable chill surface to form continuous strip. The apparatus includes a crucible, consisting of a receptacle, sealed at one end to a base, and a heater for maintaining metal in the molten state in the receptacle. A simple nozzle conveys the molten metal from the crucible into contact with the chill surface. The individual elements of the apparatus may be replaced without replacing the remaining elements, and the nozzle may be replaced while a charge of molten metal is in the crucible.

Abstract: A method for producing serrated ribbon or shard is described. Metal is cast onto a grooved chill surface where the grooves are at an inclination of between about 25.degree. to 70.degree. with respect to the direction of motion of the chill surface.

Abstract: A non-contact, optical method is provided for controlling a gap between a crucible orifice and a rapidly moving chill surface during casting of metal strip. The method comprises setting a desired value for the gap; measuring the gap by continually scanning it with a light beam; generating a deviation signal that indicates whether there is a difference between the measured and desired values; and using the deviation signal to adjust the crucible position so as to minimize the difference. In a preferred embodiment, the light beam is provided by a laser.

Abstract: An apparatus for continuously casting strip material is disclosed comprising a tundish having an internal cavity for receiving and holding molten metal and an orifice passage through which the molten metal is delivered from the cavity to a casting surface located within about 0.120 inch of the orifice passage and movable past the orifice passage at a speed of from 200 to 10,000 linear surface feet per minute. The tundish has at least one molten metal resistant upper block and at least one molten metal resistant lower block vertically aligned and secured sufficiently to prevent molten metal in the cavity from passing through the interface of the secured blocks. The orifice passage has a substantially uniform width dimension, of at least about 0.010 inch, throughout the longitudinal extent thereof.

Abstract: Amorphous metal tapes are produced by expressing a metallic melt in a supply container through at least one nozzle opening onto a moving surface of a cooling body positioned in relatively close proximity to the nozzle opening. The nozzle opening is 1.5 through 6 mm wide, as measured in the direction of motion of the cooling body surface, which is positioned at a distance of about 0.005 through 0.6 times the width of the nozzle opening from such opening and is moved at a velocity of at least 5 meters per second past such nozzle opening.

Abstract: An apparatus useful for the production of wide amorphous or polycrystalline metal foils of substantially uniform thickness by the double roller chill quenching method comprises a fixed roller member and a spring-loaded movable roller member mounted on a set of mounting rails. The movable roller member is maintained at a selectably adjustable minimum spacing from the fixed roller member and is free to move away from this position of minimum spacing to accommodate forces tending to displace the rollers from one another. A spring urges the movable roller toward the fixed roller and provides for selectable adjustment of the restoring force urging the rollers together.

Abstract: Metallic ribbon having cutout patterns therein is fabricated in continuous helical form by directing a melt stream or jet onto a rapidly moving patterned substrate surface.

Abstract: Metallic ribbon is provided in continuous helical form. The ribbon may be nested and/or manufactured with a continuous pattern of predetermined geometry in the inner and/or the outer edge as well as in the interior of the ribbon.

Abstract: An improved nozzle is disclosed for a strip casting apparatus wherein molten metal is delivered to a casting surface located within about 0.120 inch of the nozzle, and is movable past the nozzle at a speed of from 200 to 10,000 linear surface feet per minute. The improved nozzle comprises a pair of spaced orifice lips substantially parallel to and facing one another, with the spacing being substantially uniform throughout the majority of the longitudinal extent of the nozzle. The peripheral end portions of the orifice lips continuously diverge outwardly from one another for a length of less than about three times the substantially uniform spacing between lips, and for a height of less than about two times the substantially uniform spacing between lips.

Abstract: A method of forming filaments, particularly continuous strips, sheets or the like, by rotating a chill wheel against a meniscus of molten material formed about the periphery of an elongate orifice through which the molten material is fed under uniform fluid pressure along the longitudinal axis of the orifice. Filaments of different widths, thicknesses and composite structures are extracted by utilizing single or plural chill wheels in conjunction with plural orifices.

Abstract: In a process and installation for the manufacture of a metal wire from a jet of molten metal, the jet of metal which is in the course of solidification is supported by cooling fluid displaced by two cylinders rotating in opposite directions with a tangential velocity such that the wire is supported in stable equilibrium in the plane of vertical symmetry of the two cylinders above the level defined by the plane perpendicular to the plane of symmetry and passing through the axes of rotation of the two cylinders, the space between the two cylinders being between about 0.15% and 3% of their common radius and their peripheral speed being between about 4 and 120 m/sec.

Abstract: A casting wheel cooling apparatus and method for rapid quenching of molten metal is provided. The cooling apparatus provides a multiplicity of axial conduits around the periphery of the wheel, close to the chill surface. In operation, molten metal deposits on the chill surface of the rapidly rotating casting wheel. The molten metal cools and solidifies, transferring heat to the casting wheel. By flowing coolant, preferably water, through the conduits at a sufficient rate, the heat transfer is generally radial. The molten metal cools uniformly across its width and the resulting metallic strip has substantially uniform properties.

Abstract: An apparatus for producing a metal ribbon has a rotary roll. Molten metal is poured from a heated nozzle onto the outer peripheral surface of the roll to form a solidified metal ribbon on the roll surface. To facilitate easy separation of the metal ribbon from the roll surface, a jet of a non-oxidizing gas is directed to the point of separation of the ribbon from the roll surface. The roll surface just upstream of the metal-pouring nozzle is enclosed by a cover the inside of which is evacuated to assure intimate contact of the poured metal with the roll surface and thus improve cooling of the poured metal. A heater is provided in the cover to heat the roll surface just upstream of the metal-pouring nozzle for thereby removing dew droplets and ambient gases from the roll surface whereby the formation of depressions or recesses in the roll-containing ribbon surface is prevented.

Abstract: A method and device for the manufacture of metal bands, particularly of an amorphous metal alloy is provided. The liquid alloy is deposited on a cooling body having a rapidly moving surface, upon which solidification into a metal band occurs. Concurrent with the cooling body surface movement, the cooling body and the melt stream are moved relative to one another at right angles to the direction of the melt stream. This additional movement allows utilization of the entire cooling body surface and not merely that in the plane of the melt stream.

Abstract: An apparatus is provided for planar flow casting of metal ribbon. The apparatus comprises a movable chill surface, a reservoir for holding molten metal and a slotted nozzle whose lips are located close to the chill surface. In operation, molten metal is forced through the nozzle onto the chill surface to form a melt puddle. Rapid cooling of the molten metal results in the formation of a continuous ribbon. The nozzles of this invention provide a planar bottom surface which includes the leading edge of the first lip and the side edges at the bottom of the lips and which is as close or closer to the chill surface than is any other point on the lips. The nozzle reduces air flow around the melt puddle and thereby improves ribbon uniformity.

Abstract: Defined shapes of thin metallic sheet are continuously formed by forcing molten metal onto the surface of a moving chill body under pressure through a slotted nozzle located in close proximity to the surface of the chill body. The surface of the chill body whereon the shaped parts are formed is provided with raised or lowered domains corresponding in outline to that of the desired defined shape. As the metal is cast, as a thin sheet against the chill surface, discontinuities arise in the sheet at the walls of the raised or lowered domains defining the desired shape so that sheet product of defined shape is obtained, as if punched out from a continuous strip of the metal.

Abstract: Metallic ribbon is fabricated in continuous helical form by directing a melt stream or jet onto a rapidly moving substrate surface. The axis of the crucible along which the melt stream or jet is cast is defined by an inverted cone with apex at the point of crucible axis intersection with the substrate surface.

Abstract: An apparatus is provided for planar flow casting of metal ribbon. The apparatus comprises a movable chill surface, a reservoir for holding molten metal and a slotted nozzle whose lips are located close to the chill surface. In operation, molten metal is forced through the nozzle onto the chill surface to form a melt puddle. Rapid cooling of the molten metal results in the formation of a continuous ribbon. Ribbon contour is controlled through the use of nozzle designs that provide reproducible configuration of the melt puddle and reduce turbulent air flow over the molten metal surface.

Abstract: A high silicon steel strip having excellent magnetic properties and good workability, and having a composition consisting of 4-10% by weight of silicon and the remainder being substantially iron and incidental impurities is produced by cooling super rapidly the high silicon steel melt on a cooling substrate to form a thin strip having micro-structure comprising very fine crystal grains having substantially no ordered lattice.

Abstract: A bearing gas sleeve coaxial with the melt ejection crucible is provided in an apparatus for making glassy alloy ribbons to provide a confluent bearing gas flow which minimizes dynamic fluctuations in the molten alloy puddle from which metallic ribbon is formed during chill block melt-spinning. The bearing gas flow causes an improved quench rate and melt puddle stabilization which results in reduced upper ribbon surface texture and improved edge definition.

Abstract: The invention relates to an improvement of a manufacturing process for making a filament directly from a molten material. The process consists of the ejection of a liquid filament which solidifies in air by making a rotating disc touch the surface of a liquid. The improvement consists in the stabilization of the meniscus which appears upon the wheel near the surface of the liquid and thereby fixing the point where the filament leaves the wheel in order to obtain a constant cross section of the filament. The meniscus is stabilized by the interposition of a body: a rod or a convex piece of a material which does not react with the melt.

Abstract: An improvement is provided in a method for the continuous casting of glassy metal alloy filaments wherein molten alloy is extruded from a pressurized crucible through an extrusion orifice onto a rotating quench surface. The invention provides a boric oxide seal for the extrusion orifice that prevents oxidation of the molten alloy prior to initiation of extrusion. At initiation of extrusion, the seal is conveniently expelled from the orifice with the leading surge of the extruded molten alloy.

Abstract: An improved method for forming steel fibers from a process of the type in which the fiber is drawn directly from a pool of molten metals. The improvement revolves around the discovery of an alloy starting material which substantially reduces processing steps and equipment and produces a fiber with improved ductility and strength characteristics. The addition of controlled amounts of copper to a typical low carbon steel alloy provides a wider latitude in the necessary cooling steps to greatly facilitate the control of the ductility and strength of the final product through the use of low cost processing techniques.

Abstract: A method of manufacturing a thin ribbon of magnetic material having a high permeability and excellent flexibility and workability comprising the combination of steps ofmelting a magnetic material consisting of essentially of by weight 4-7% of aluminum, 8-11% of silicon and the remainder substantially iron and inevitable impurities at a temperature of between a melting point and a temperature not exceeding 300.degree. C. from the melting point, and necessary subingredient of less than 7%,ejecting thus obtained melt under a pressure of 0.01-1.5 atm. through a nozzle onto a moving or rotating cooling substrate,cooling super-rapidly the melt on the rotating surface of said cooling substrate at a cooling rate of 10.sup.3 -10.sup.6 .degree. C./sec so as to have a high initial permeability of more than 10.sup.4, a low coercive force of less than 0.

Abstract: Structurally defined continuous metal strips are formed by forcing molten metal onto the surface of a moving chill body under pressure through a slotted nozzle located in close proximity to the surface of the chill body. The surface of the chill body (chill surface) whereon casting of the strips takes place has a contoured surface, i.e. it is provided with structurally defined protruberances and/or indentations, which are faithfully replicated by the formed strip, the thickness of the strip being substantially uniform throughout, regardless of whether it replicates a level area of the chill surface or a raised or indented area.

Abstract: A method of manufacturing an amorphous alloy in which a molten mixture of raw materials making up the amorphous alloy is first prepared, and then introduced between a pair of oppositely rotating rolls where the molten material is rolled and quenched into a film. The conditions under which the rolling and quenching occur are carried out under the following conditions: ##EQU1## where: Y is the roll pressure per unit width of the film in metric tons per centimeter,C.sub.o is a constant determined by Young's modulus and the thermal conductivity of the material of the rolls,A is the rotational speed of the rolls in r.p.m.,R is the diameter of the rolls in centimeters,X is the thickness of the film in microns,T.sub.cry is the crystallization temperature of the amorphous alloy in .degree.C.,T is the temperature of the rolls in .degree.C., and where ##EQU2## where the rolls have the diameters of R.sub.1 and R.sub.2 centimeters, respectively.

Abstract: Improvement in apparatus for making metal filament by depositing molten metal onto the flat peripheral surface of a rotating annular chill roll includes provision of an elastomeric flexible belt supported by at least three guide wheels, carried in frictional engagement with said surface for urging the filament into prolonged contact with said surface.

Abstract: Improvement in the method for making metal filament by depositing molten metal onto the peripheral surface of a rotating annular chill roll and separating the solid filament from the chill roll, which involves applying tension to the filament, after it has been separated from the chill roll, along the direction of a tangent to the chill roll past the point at which the filament separates from the chill roll by centrifugal action, to thereby prolong its contact with the chill roll. Apparatus is provided for practice of the method.

Abstract: Improvement in apparatus for making metal filament by depositing a stream of molten metal onto the inner surface of an annular chill roll as it is being rotated includes provision of a rotably mounted annular chill roll having an inner surface substantially parallel to its axis of rotation, and means for stripping the metal filament from the inner surface of the chill roll and for guiding the stripped metal filament away from the chill roll.

Abstract: Installation for manufacturing wire by projecting a jet of electrically conductive metallic liquid through a die into a cooling medium, comprising a crucible equipped with a heating device, a die and an enclosure containing a gas under pressure, an enclosure containing a cooling medium and a wire-receiving device is improved by providing the installation with a thermally and electrically conductive immobile hot piece arranged in such a manner as to debouch into the section of a crucible passageway which is wetted by the metallic liquid, occupies that section and is in contact with a cooling element and with one of the poles of a source of electric current, while an electrically conductive cold piece is connected to the other pole of the source of electric current and assures electrical contact with the jet or the wire.

Abstract: A critical gas boundary layer Reynolds number has been defined to indicate processing conditions under which wide glassy alloy ribbons result when processing under various gaseous atmospheres and pressures and casting onto a moving substrate at an impingement angle .alpha..

Abstract: A method and apparatus for producing filamentary articles from an open bath of molten material. A quench wheel having a peripheral chill surface is rotated upon the surface of a portion of the bath provided with a baffle that defines a puddle of molten material free from fluid turbulence, thereby permitting high production rates and precise control of product configuration.

Abstract: There is described an improved apparatus for producing filaments from a high melting point material by forming a pendant drop at the end of the material and engaging the drop with a rotating heat extracting member (e.g. copper disc). The improvement to the apparatus comprises a pair of heating components to heat the material to a temperature immediately below its melting point and thereafter heat only the end of the material to the melting point. The result is a vibration free pendant drop suspended from the rod's end. A method for making the filament is also described.

Abstract: Liquid amorphous metal alloy is manufactured into shaped laminations ready for assembly in an inductive component in one process. The rotating chill surface to which the melt is delivered has high thermal conductivity metal in a pattern corresponding to the shaped lamination and is surrounded by thermally insulating material. Melt coming in contact with the high thermal conductivity metal becomes amorphous and that contacting the thermally insulating areas cools more slowly and becomes crystalline. The brittle crystalline scrap is broken away from the strip of laminations and is collected and recycled to the melt.

Abstract: Metal filament forming apparatus including a casting crucible having a tapping orifice and a casting nozzle for ejecting molten metal from the crucible are described. The casting nozzle is characterized by having an externally replaceable orifice member. The casting nozzle comprises three parts: (1) a nozzle body providing a conduit for the molten metal in association with the tapping orifice; (2) a replaceable orifice member positioned at the lower end of the nozzle body; and (3) retaining means for holding the replaceable orifice member in sealing engagement with the nozzle body. The crucible is preferably provided with a stopper rod to permit discontinuation of metal flow through the nozzle, while holding molten metal in the crucible.

Abstract: Metal alloy filaments having improved surface characteristics and enhanced mechanical properties are extracted from a source of molten metal alloy using a quenching wheel in a partial vacuum.

Abstract: An improved cooling fluid for an apparatus for the manufacture of a wire by projecting a jet of liquid metal or metal alloy through a nozzle into a cooling enclosure containing the cooling fluid is characterized by the fact that the cooling fluid consists of a mixture of a gas and steam, the gas and the steam being compatible with the jet, the gas furthermore being at a temperature below the condensation point of the steam, so as to transform at least a part of the steam into liquid droplets.

Abstract: A process for the manufacture of filiform reinforcement elements of steel in the form of ribbons is improved by projecting a jet of liquid steel onto a cylinder rotating in a cooling medium and imparting a relative reciprocating movement parallel to the axis of rotation of the cylinder between the jet of liquid steel and the cylinder in order to undulate the ribbon in the direction parallel to the axis of rotation of the cylinder.

Abstract: An improved apparatus and method for making solid filamentary elements from a pendant drop of a high melting point material (e.g. hafnium, zirconium). The improvement constitutes providing a protective layer in the form of a thin film on the circumferential edge of the casting wheel prior to engagement of the drop and release of the elements. The layer material serves to reduce heat flow from the drop material to the wheel as well as prohibit bonding of the drop material thereto. The preferred layer materials are aluminum, carbon (e.g. graphite), boron nitride, and borosilicate glass.

Abstract: An installation for the manufacture of wire by projecting a jet of liquid metal or metal alloy into a cooling fluid and having a crucible for containing the liquid metal or metal alloy and provided with at least one nozzle, means for exerting a pressure on the liquid metal or metal alloy sufficient to project it in the form of a jet through the nozzle into the cooling fluid, and a cooling enclosure for containing the cooling fluid and arranged at the outlet of the nozzle, is characterized by the fact that the cooling enclosure comprises, in the portion thereof adjacent to the nozzle, means for imparting to the cooling fluid a flow which is substantially transverse to the jet, at least over a length approximately equal to the length of the jet.

Abstract: A reactive cooling medium for apparatus for the manufacture of wire by projecting a jet of liquid steel which contains silicon and manganese through a nozzle into a cooling enclosure containing the reactive cooling medium is characterized by the fact that the reactive cooling medium is a gaseous mixture having an oxidizing power with respect to the steel, at least in the zone adjacent to the orifice of the nozzle, such that the oxidation product of the steel is silica at the thermochemical equilibrium corresponding to the temperature prevailing near the orifice of the nozzle.