Forming A Composite Article Patents (Class 164/461)
  • Patent number: 11697150
    Abstract: A production apparatus for short-process metal composite plate manufacturing, the apparatus including a metal supply device including an uncoiler (1), pinch roll (2), shot blasting machine (3), welding device (4), welding pinch roll (5), induction heating apparatus (6), metal delivery machine (7), two crystallization cooling rolls (8), secondary cooling leveling roll (9), rolling mill pinch roll (10), rolling mill (11), on-line cooling apparatus (12), straightener (13), and at least one of a dividing shear (14) and a recoiling machine (15). Also disclosed is a production method for short-process metal composite plate manufacturing. The apparatus and method combine continuous casting, rolling, and heat-treating means for single material production with continuous and large-scale production of composite plate strips, and production efficiency of composite plates is sharply improved.
    Type: Grant
    Filed: June 24, 2019
    Date of Patent: July 11, 2023
    Assignee: Baoshan Iron & Steel Co., Ltd.
    Inventors: Qingfeng Zhang, Sihai Jiao
  • Patent number: 11185915
    Abstract: A method and apparatus for manufacturing a flexible layer stack, and to a flexible layer stack. Implementations of the present disclosure particularly relate to a method and apparatus for coating flexible substrates with a low melting temperature metal or metal alloy. In one implementation, a method is provided. The method includes delivering a transfer liquid to a quenching surface of a rotating casting drum. The method further includes forming a material layer stack over the rotating casting drum by delivering a molten metal or molten metal alloy toward the quenching surface of the rotating casting drum. The method further includes transferring the material layer stack from the rotating casting drum to a continuous flexible substrate, wherein the quenching surface of the rotating casting drum is cooled to a temperature at which the layers of the material layer stack solidify.
    Type: Grant
    Filed: August 18, 2020
    Date of Patent: November 30, 2021
    Assignee: Applied Materials, Inc.
    Inventor: Subramanya P. Herle
  • Patent number: 10707397
    Abstract: Materials and systems and methods of manufacture thereof that function as thermoelectric materials both in and near a cryogenic temperature range. In particular, the synthesis of heavy fermion materials that exhibit higher ZTs than previously achieved at cryogenic and near-cryogenic temperatures.
    Type: Grant
    Filed: March 13, 2015
    Date of Patent: July 7, 2020
    Assignee: UNIVERSITY OF HOUSTON SYSTEM
    Inventors: Zhifeng Ren, Machhindra Koirala
  • Patent number: 9790599
    Abstract: A composite material can include a carrier material that is coated, at least over part of the surface, with a corrosion protection layer made of an aluminum alloy. The composite material can provide a defined, effective, durable corrosion protection and simultaneously have a high recycling potential. The aluminum alloy of the corrosion protection layer can have the following composition in % by weight: 0.8 ? Mn ? 1.8 Zn ? 0.05 Cu ? 0.05 Si ? 1.0 Cr ? 0.25 Zr ? 0.25 Mg ? 0.10 remainder aluminum and unavoidable impurities, individually a maximum of 0.05% by weight, in total a maximum of 0.15% by weight.
    Type: Grant
    Filed: January 14, 2009
    Date of Patent: October 17, 2017
    Assignee: Hydro Aluminum Deutschland GmbH
    Inventors: Manfred Mrotzek, Raimund Sicking
  • Patent number: 9566643
    Abstract: Method of casting aluminum alloy ingot including lithium, including: preparing at least two molten aluminum based alloys in separate furnaces, first alloy with composition A free from lithium as purposive alloying element, and second alloy with composition B including lithium as purposive alloying element; transferring the first alloy via metal conveying trough from the furnace to a casting station; initiating casting an ingot and casting the first alloy to required length L1 in the casting direction; subsequently transferring the second alloy via metal conveying trough from the furnace to the casting station while simultaneously stopping transfer of the first alloy to the casting station; casting the second alloy from an end surface of the cast first alloy at length L1 to an additional required length L2 in the casting direction; cropping the cast ingot at a bottom thereof at a length greater than of equal to cast length L1.
    Type: Grant
    Filed: March 11, 2014
    Date of Patent: February 14, 2017
    Assignee: ALERIS ROLLED PRODUCTS GERMANY GMBH
    Inventor: Fred Brandt
  • Patent number: 9052242
    Abstract: A cast piece surface temperature measuring device includes: a magnetic field exciting device which applies an AC magnetic field substantially perpendicular to a surface of a cast piece; a magnetic field detecting device which detects the AC magnetic field to detect a magnetic flux varied in response to a surface temperature of the cast piece; and a surface temperature deriving device which derives the surface temperature of the cast piece based on an induced electromotive force obtained by detecting the AC magnetic field by the magnetic field detecting device and a predetermined relation data.
    Type: Grant
    Filed: January 8, 2010
    Date of Patent: June 9, 2015
    Assignee: Nippon Steel & Sumitomo Metal Corporation
    Inventors: Hiroshi Harada, Masanori Yamana, Atsushi Saida, Masaki Nagashima, Tomohiro Konno
  • Patent number: 9050617
    Abstract: A nozzle for applying a liquid adhesive to a web moving continuously in a travel direction has a body having a passage forming an outlet opening generally transversely to the direction immediately adjacent the moving web at a face of the body so that the liquid adhesive flows through the passage and out the outlet end onto the moving web. Structure on the face of the body forms immediately upstream of the outlet a porous region. Air is fed through the structure and out of the face to form between the region and the web an air cushion.
    Type: Grant
    Filed: April 5, 2012
    Date of Patent: June 9, 2015
    Assignee: MONDI GRONAU GMBH
    Inventors: Juergen Weitkamp, Marcus Schoenbeck
  • Patent number: 9004150
    Abstract: A new method for continuous casting of molten metal is provided that allows one to obtain an intermediate product such as slab, billet wire, etc. before subsequent thermomechanical treatment (e.g. lamination or annealing), such that its chemical composition is modified by the addition of elements in order to give it greater mechanical strength.
    Type: Grant
    Filed: June 2, 2011
    Date of Patent: April 14, 2015
    Assignee: Centre de Recherches Metallurgiques ASBL—Centrum Voor Research in de Metallurgie VZW
    Inventors: Paul Naveau, Astrid De Ro
  • Patent number: 8757244
    Abstract: Processes and methods related to producing, processing, and hot working alloy ingots are disclosed. An alloy ingot is formed including an inner ingot core and an outer layer metallurgically bonded to the inner ingot core. The processes and methods are characterized by a reduction in the incidence of surface cracking of the alloy ingot during hot working.
    Type: Grant
    Filed: June 26, 2012
    Date of Patent: June 24, 2014
    Assignee: ATI Properties, Inc.
    Inventor: Ramesh S. Minisandram
  • Patent number: 8673453
    Abstract: Discontinuous diamond particulate containing metal matrix composites of high thermal conductivity and methods for producing these composites are provided. The manufacturing method includes producing a thin reaction formed and diffusion bonded functionally graded interactive SiC surface layer on diamond particles. The interactive surface converted SiC coated diamond particles are then disposed into a mold and between the particles and permitted to rapidly solidify under pressure. The surface conversion interactive SiC coating on the diamond particles achieves minimal interface thermal resistance with the metal matrix which translates into good mechanical strength and stiffness of the composites and facilitates near theoretical thermal conductivity levels to be attained in the composite. Secondary working of the diamond metal composite can be performed for producing thin sheet product.
    Type: Grant
    Filed: October 26, 2011
    Date of Patent: March 18, 2014
    Assignee: Nano Materials International Corporation
    Inventors: Sion M. Pickard, James C. Withers, Raouf O. Loutfy
  • Patent number: 8418748
    Abstract: An exemplary embodiment of the invention provides a method of direct chill casting a composite metal ingot. The method involves sequentially casting two or more metal layers to form a composite ingot by supplying streams of molten metal to two or more casting chambers within a casting mold of a direct chill casting apparatus. Inlet temperatures of one or more of the streams of molten metal are monitored at a position adjacent to an inlet of a casting chamber fed with the stream, and the inlet temperatures are compared with a predetermined set temperature for the stream to determine if there is any difference. A casting variable that affects molten metal temperatures entering or within the casting chambers (e.g. casting speed) is then adjusted by an amount based on the difference of the compared temperatures to eliminate adverse casting effects caused by the difference of the inlet temperature and the set temperature.
    Type: Grant
    Filed: February 9, 2011
    Date of Patent: April 16, 2013
    Assignee: Novelis Inc.
    Inventors: Robert Bruce Wagstaff, Aaron David Sinden, Todd F. Bischoff, Eric Ball, Jeff McDermott
  • Patent number: 8381797
    Abstract: Skin material of a clad material is composed of one or more layers, each layer of the skin materials is made of a metal different from the core material in their component compositions, and at least one layer of the skin material has a cast microstructure, when the skin material is superposed on either of one or both faces of the core material.
    Type: Grant
    Filed: June 15, 2011
    Date of Patent: February 26, 2013
    Assignee: Kobe Steel, Ltd.
    Inventors: Masayuki Takada, Yasuhiro Nishioka, Tomohiro Nishimura, Kenji Tokuda, Toshiki Ueda, Makoto Morishita, Takashi Inaba, Akihiro Tsuruno, Yoshinori Kato, Fumihiro Koshigoe, Masaki Tanigawa, Naoki Sakashita, Kenji Harada, Jitsuto Shikata, Masanori Ikeda
  • Patent number: 8381796
    Abstract: A method of making a functionally graded metal matrix composite (MMC) sheet having a central layer of particulate matter, the particulate matter having a size of at least about 30 microns. The method includes providing a molten metal containing particulate matter to a pair of advancing casting surfaces. Solidifying the molten metal while advancing the molten metal between the advancing casting surfaces to form a first solid outer layer, a second solid outer layer, and a semi-solid central layer having a higher concentration of particulate matter than either of the outer layers. Solidifying the central layer to form a solid metal product including a central layer sandwiched between the outer layers and withdrawing the metal product from between the casting surfaces.
    Type: Grant
    Filed: October 28, 2010
    Date of Patent: February 26, 2013
    Assignee: ALCOA Inc.
    Inventors: David A. Tomes, Jr., Gavin F. Wyatt-Mair, David W. Timmons, Ali Unal
  • Patent number: 8336603
    Abstract: A method and apparatus is disclosed for casting a composite ingot made of metals that are susceptible to surface oxide formation when molten. The method involves co-casting at least two metal layers from at least two molten metal pools formed within a direct chill casting apparatus. During the casting operation, movement of metal oxide formed on the upper surface of at least one of the pools towards an edge of the pool is restrained by an oxide skimmer positioned close to an edge of the pool above an external surface or metal-metal interface of the ingot. The apparatus provides a DC caster with at least one oxide skimmer that operates in this manner.
    Type: Grant
    Filed: May 21, 2009
    Date of Patent: December 25, 2012
    Assignee: Novelis Inc.
    Inventors: Todd F. Bischoff, Randy Womack, Wayne J. Fenton, Robert Bruce Wagstaff, Lawrence G. Hudson
  • Publication number: 20120321909
    Abstract: The invention relates to a multilayered bearing shell (2) comprising a back metal layer (3) as a carrier element for the layer structure and at least one further bearing layer joined to the back metal layer (3), wherein the back metal layer (3) is made from a bronze. The back metal layer (3) contains in addition to copper, which forms the matrix of the bronze, tin in a proportion selected from a range with a lower limit of 1.25 wt. % and an upper limit of 12 wt. %, zinc in a proportion selected from a range with a lower limit of 0.25 wt. % and an upper limit of 6 wt. % and phosphorus in a proportion selected from a range with a lower limit of 0.01 wt. % and an upper limit of 0.5 wt. %.
    Type: Application
    Filed: June 13, 2012
    Publication date: December 20, 2012
    Applicants: MTU FRIEDRICHSHAFEN GMBH, MIBA GLEITLAGER GMBH
    Inventors: Reiner BOESCHEN, Robert MERGEN, Falko LANGBEIN, Ulrich SCHMID
  • Patent number: 8312916
    Abstract: Method and apparatus employing a casting mould including a liquid feed end for supplying the casting mould with molten second alloy and an exit end with an outlet for casting molten second alloy downwardly. While continuously moving the mould and an elongated solid first alloy substrate relative to one another, casting molten second alloy passes downwardly through at least one outlet of the mould onto an upper surface of the substrate at a temperature wherein the substrate locally at least partly remelts beginning at a reference point of a remelting zone and mixes at least partly with molten second alloy to form an alloy pool. After remelting the molten alloy pool continuously cools and solidifies at a location away from the reference point and joins the substrate to form composite ingot including at least two separately formed layers of one or more alloys before discharging from the mould.
    Type: Grant
    Filed: June 3, 2009
    Date of Patent: November 20, 2012
    Assignee: Aleris Aluminum Koblenz GmbH
    Inventors: Joost Christiaan Storm, Andreas Ten Cate, Ingo Günther Kröpfl, Achim Bürger
  • Patent number: 8312915
    Abstract: An apparatus is described for the casting of a composite metal ingot having two or more separately formed layers of one or more alloys. An open ended annular mould is provided having a divider wall dividing a feed end of the mould into at least two separate feed chambers. For each pair of adjacent feed chambers, a first alloy stream is fed through one of the pair of feed chambers into the mould and a second alloy stream is fed through another of the feed chambers. A self-supporting surface is generated on the surface of the first alloy stream and the second alloy stream is contacted with the first stream. By carefully selecting conditions and positions where the alloy streams meet, a composite metal ingot is formed in which the alloy layers are mutually attached with a substantially continuous metallurgical bond.
    Type: Grant
    Filed: September 13, 2010
    Date of Patent: November 20, 2012
    Assignee: Novelis Inc.
    Inventors: Mark Douglas Anderson, Kenneth Takeo Kubo, Todd F. Bischoff, Wayne J. Fenton, Eric W. Reeves, Brent Spendlove, Robert Bruce Wagstaff
  • Patent number: 8302666
    Abstract: A method of continuous casting a beam blank adapted for impact absorption is disclosed. The method includes: introducing molten steel into a continuous casting mold from a tundish through an immersion nozzle to perform non-oxidation casting, wherein the immersion nozzle is disposed at one side of the continuous casting mold forming both side flanges of a beam blank, and the molten steel is introduced into the continuous casting mold through the immersion nozzle. The method is advantageous in that it is possible to produce steel adapted for low-temperature impact absorption, and productivity is improved due to the increase of the number of consecutive heats of continuous casting.
    Type: Grant
    Filed: December 2, 2011
    Date of Patent: November 6, 2012
    Assignee: Hyundai Steel Company
    Inventors: Seangjun Hwang, Jeongjae Kim, Pankeun Kim
  • Patent number: 8230899
    Abstract: Processes and methods related to producing, processing, and hot working alloy ingots are disclosed. An alloy ingot is formed including an inner ingot core and an outer layer metallurgically bonded to the inner ingot core. The processes and methods are characterized by a reduction in the incidence of surface cracking of the alloy ingot during hot working.
    Type: Grant
    Filed: February 5, 2010
    Date of Patent: July 31, 2012
    Assignee: ATI Properties, Inc.
    Inventor: Ramesh S. Minisandram
  • Patent number: 8210237
    Abstract: Equipment for manufacturing skin material of a clad material includes a casting apparatus which melts and mixes a metal for the skin material different from the core material in their component compositions, and casts the skin material; an ingot-cutting apparatus which cuts an ingot for skin material which is cast by the casting apparatus; and a conveying apparatus which conveys the ingot for skin material among each apparatus. The ingot-cutting apparatus is a slicing apparatus which slices the ingot for skin material into a predetermined thickness.
    Type: Grant
    Filed: June 15, 2011
    Date of Patent: July 3, 2012
    Assignee: Kobe Steel, Ltd.
    Inventors: Masayuki Takada, Yasuhiro Nishioka, Tomohiro Nishimura, Kenji Tokuda, Toshiki Ueda, Makoto Morishita, Takashi Inaba, Akihiro Tsuruno, Yoshinori Kato, Fumihiro Koshigoe, Masaki Tanigawa, Naoki Sakashita, Kenji Harada, Jitsuto Shikata, Masanori Ikeda
  • Patent number: 8191609
    Abstract: A method for manufacturing a clad material composed of a core material and one or more skin materials which are superposed on either one or both faces of the core material, includes a clad material preparation process where an ingot for core material is manufactured by dissolving and casting a metal, and an ingot for skin material is manufactured by dissolving and casting a different metal for skin material, without hot rolling. The ingot for skin material is superposed as a skin material at a predetermined position of either one or both faces of the ingot for core material and the superposed material is hot-rolled to manufacture a clad material.
    Type: Grant
    Filed: September 22, 2011
    Date of Patent: June 5, 2012
    Assignee: Kobe Steel, Ltd.
    Inventors: Masayuki Takada, Yasuhiro Nishioka, Tomohiro Nishimura, Kenji Tokuda, Toshiki Ueda, Makoto Morishita, Takashi Inaba, Akihiro Tsuruno, Yoshinori Kato, Fumihiro Koshigoe, Masaki Tanigawa, Naoki Sakashita, Kenji Harada, Jitsuto Shikata, Masanori Ikeda
  • Patent number: 8122940
    Abstract: A method for twin roll casting aluminum clad magnesium by joining one or more sheets of aluminum cladding to molten magnesium during twin roll casting. The method includes feeding aluminum cladding to at least one roll of a pair of rotating rolls, feeding a core of molten magnesium into a continuous casting mold formed by the roll, solidifying the magnesium core by heat extraction to the rolls and through the aluminum cladding, surface treating the aluminum cladding and the magnesium core to prevent inter-diffusion between the aluminum cladding and the magnesium core, bonding the aluminum cladding with the magnesium core and extruding the composite core and aluminum cladding out of the continuous casting mold by a casting load exerted by the rolls.
    Type: Grant
    Filed: July 16, 2008
    Date of Patent: February 28, 2012
    Assignee: Fata Hunter, Inc.
    Inventor: Christopher A. Romanowski
  • Patent number: 8096344
    Abstract: A method and apparatus are disclosed for sequentially direct chill casting a composite ingot made of metals having similar freezing ranges. Poor adhesion between the layers and low reliability of casting are addressed by adjusting the position of secondary cooling (created by applying water streams to the emerging ingot) relative to the upper surfaces of the molten metal pools compared to the conventional positions of first application of the secondary cooling. This can be achieved by moving one or more walls of the mold (when the secondary cooling emanates from the bottom of such walls), or adjusting the height of the molten metal pools within the mold and moving cooled divider walls between the pools. The relative temperatures and conditions of the metals at positions where they meet at the metal interface may therefore be optimized.
    Type: Grant
    Filed: July 30, 2009
    Date of Patent: January 17, 2012
    Assignee: Novelis Inc.
    Inventors: Robert Bruce Wagstaff, Eric W. Reeves, Wayne J. Fenton, Jim Boorman
  • Patent number: 8091612
    Abstract: A method for manufacturing a clad material composed of a core material and one or more skin materials which are superposed on either one or both faces of the core material, includes a clad material preparation process where an ingot for core material is manufactured by melting and casting a metal, and an ingot for skin material is manufactured by melting and casting a different metal for skin material, without hot rolling. The ingot for skin material is superposed as a skin material at a predetermined position of either one or both faces of the ingot for core material and the superposed material is hot-rolled to manufacture a clad material.
    Type: Grant
    Filed: December 7, 2006
    Date of Patent: January 10, 2012
    Assignee: Kobe Steel, Ltd.
    Inventors: Masayuki Takada, Yasuhiro Nishioka, Tomohiro Nishimura, Kenji Tokuda, Toshiki Ueda, Makoto Morishita, Takashi Inaba, Akihiro Tsuruno, Yoshinori Kato, Fumihiro Koshigoe, Masaki Tanigawa, Naoki Sakashita, Kenji Harada, Jitsuto Shikata, Masanori Ikeda
  • Patent number: 7975752
    Abstract: Apparatus and method of co-casting metal ingots in direct-chill casting apparatus. The apparatus and method employs at least one divider (divider member or divider wall) that separates a casting mold into two or more chambers for receiving molten metal that is combined into a single ingot. The divider may be moved, angled and/or flexed during casting to produce ingots that are designed primarily for rolling into thin plate or sheet. The ingot has at least one outer layer that is thicker adjacent to the side (width) edges than in the center, and/or thicker adjacent to the butt or head regions. This compensates for wiping of the outer layer from the ingot core during rolling. Also, the divider may be outwardly bowed outwardly towards one of the mold walls during the casting run.
    Type: Grant
    Filed: February 21, 2008
    Date of Patent: July 12, 2011
    Assignee: Novelis Inc.
    Inventor: Robert Bruce Wagstaff
  • Publication number: 20110146937
    Abstract: Method and apparatus employing a casting mould including a liquid feed end for supplying the casting mould with molten second alloy and an exit end with an outlet for casting molten second alloy downwardly. While continuously moving the mould and an elongated solid first alloy substrate relative to one another casting molten second alloy passes downwardly through at least one outlet of the mould onto an upper surface of the substrate at a temperature wherein the substrate locally at least partly remelts beginning at a reference point of a remelting zone and mixes at least partly with molten second alloy to form an alloy pool. After remelting the molten alloy pool continuously cools and solidifies at a location away from the reference point and joins the substrate to form composite ingot including at least two separately formed layers of one or more alloys before discharging from the mould.
    Type: Application
    Filed: June 3, 2009
    Publication date: June 23, 2011
    Applicant: ALERIS ALUMINUM KOBLENZ GMBH
    Inventors: Joost Christiaan Storm, Andreas Ten cate, Ingo Gunther Kropfl, Achim Burger
  • Patent number: 7938165
    Abstract: A vertical casting process for an intermediate product, including the steps of (a) preparation of at least two aluminum based alloys, particularly a first alloy with composition P and a second alloy with composition T, (b) casting of the first alloy with composition P to a required height HP, and (c) casting of an additional required height HT of the alloy with composition T. The object of this invention is the manufacture of monolithic structural elements with working properties that are variable in at least one direction, and particularly bi-functional or multi-functional structural elements capable of performing at least two functions that are traditionally performed by two different parts.
    Type: Grant
    Filed: December 5, 2006
    Date of Patent: May 10, 2011
    Assignee: Alcan Rhenalu
    Inventors: Philippe Lequeu, Benoit Commet, Armelle Danielou, David Dumont, Olivier Ribaud
  • Publication number: 20110073272
    Abstract: A method of producing an aluminum substrate for a planographic printing plate is provided in which a recycled material including a used planographic printing plate having a planographic printing plate support obtained by treating an aluminum substrate is prepared, a recycled bare metal is obtained from the recycled material, and a new aluminum bare metal and a trace-metal master alloy of necessary amounts are mixed into the recycled bare metal to produce a new aluminum substrate.
    Type: Application
    Filed: September 27, 2010
    Publication date: March 31, 2011
    Applicant: FUJIFILM CORPORATION
    Inventors: Takeshi SERIKAWA, Masakazu OSADA
  • Publication number: 20110042032
    Abstract: The present invention discloses a method of making a functionally graded metal matrix composite (MMC) sheet having a central layer of particulate matter, the particular matter having a size of at least about 30 microns. The method includes providing a molten metal containing particulate matter to a pair of advancing casting surfaces. Solidifying the molten metal while advancing the molten metal between the advancing casting surfaces to form a product comprising a first solid outer layer, a second solid outer layer, and a semi-solid central layer having a higher concentration of particulate matter than either of the outer layers. Solidifying the central layer to form a solid metal product comprised of a central layer sandwiched between the outer layers and withdrawing the metal product from between the casting surfaces.
    Type: Application
    Filed: October 28, 2010
    Publication date: February 24, 2011
    Inventors: David A. Tomes, JR., Gavin F. Wyatt-Mair, David W. Timmons, Ali Unal
  • Patent number: 7892365
    Abstract: A method of making a magnetically anisotropic magnet powder according to the present invention includes the steps of preparing a master alloy by cooling a rare-earth-iron-boron based molten alloy and subjecting the master alloy to an HDDR process. The step of preparing the master alloy includes the step of forming a solidified alloy layer, including a plurality of R2Fe14B-type crystals (where R is at least one element selected from the group consisting of the rare-earth elements and yttrium) in which rare-earth-rich phases are dispersed, by cooling the molten alloy through contact with a cooling member.
    Type: Grant
    Filed: December 5, 2007
    Date of Patent: February 22, 2011
    Assignee: Hitachi Metals, Ltd.
    Inventors: Hiroyuki Tomizawa, Yuji Kaneko
  • Publication number: 20110036530
    Abstract: A process of making a multilayer metallic casting includes steps of simultaneously forming a first layer of a first metallic material and a second layer of a second metallic material using a continuous casting process, and continuously bonding the first and second layers to form a integrally cast multilayer metallic casting. The process may be performed using a twin-roll type continuous casting system having a continuous casting mold that includes a first mold compartment for receiving a molten first metallic material and a second mold compartment for receiving a molten second metallic. The molten first and second types of metallic material are gradually solidified into semi-solid shells and are pressed together by opposed casting rolls, creating a metallurgical bond between the first and second types of metallic material in order to form an integrally cast multilayer metallic casting. The process permits the large scale efficient manufacturing of near net shape multilayer metallic castings.
    Type: Application
    Filed: August 11, 2009
    Publication date: February 17, 2011
    Inventor: James B. Sears, JR.
  • Publication number: 20110036531
    Abstract: A process of making a multilayer metallic casting includes steps of simultaneously forming a first layer of a first metallic material and a second layer of a second metallic material using a high speed continuous casting process, and continuously bonding the first and second layers to form a integrally cast multilayer metallic casting. The process may be performed using a twin-roll type continuous casting system having a continuous casting mold that includes a first mold compartment for receiving a molten first metallic material and a second mold compartment for receiving a molten second metallic. The molten first and second types of metallic material are quickly solidified into semi-solid shells and are pressed together by opposed casting rolls, creating a metallurgical bond between the first and second types of metallic material in order to form an integrally cast multilayer metallic casting. The process permits the high speed efficient manufacturing of near net shape multilayer metallic castings.
    Type: Application
    Filed: November 27, 2009
    Publication date: February 17, 2011
    Inventor: James B. SEARS, JR.
  • Patent number: 7882887
    Abstract: A method and apparatus is disclosed for casting metals in a DC mold to form an ingot or product having at least two layers formed by sequential solidification. The apparatus has at least one cooled divider wall at the entry end portion of the mold to divide the entry end portion into at least two feed chambers. Metal is fed to the chambers to form an inner layer and at least one outer layer. The divider wall has a metal-contacting surface for contacting the metal for the at least one outer layer, the surface being arranged at an angle sloping away from the metal for the outer layer in a downward direction. The angle is larger at the center of the divider wall compared to the angle adjacent to each longitudinal end thereof. The apparatus is suitable for co-casting metals having similar coefficients of contraction to minimize problems of adhesion between the layers of a resulting ingot or rolled products produced therefrom.
    Type: Grant
    Filed: July 29, 2008
    Date of Patent: February 8, 2011
    Assignee: Novelis Inc.
    Inventors: Robert Bruce Wagstaff, Todd F. Bischoff
  • Publication number: 20100288463
    Abstract: An apparatus for manufacturing a molten metal coated steel strip configured to control the amount of a metal coated on surfaces of a steel strip by blowing a gas from gas wiping nozzles to the surfaces of the steel strip continuously drawn from a molten metal, includes molten-metal-reducing members arranged on both sides of the steel strip below the surface of the molten metal in the coating bath to face the steel strip, each of the molten-metal-reducing members having a length equal to or longer than the steel-strip width, and shields arranged between the molten-metal-reducing members each extending along an extension of a corresponding one of the surfaces of the steel strip.
    Type: Application
    Filed: September 30, 2008
    Publication date: November 18, 2010
    Applicant: JFE STEEL CORPORATION
    Inventors: Gentaro Takeda, Hiroyuki Fukuda, Hideyuki Takahashi, Tadashi Nara, Keisuke Ono, Shinji Goto, Nobutomo Inenaga
  • Patent number: 7819170
    Abstract: A method and apparatus are described for the casting of a composite metal ingot having two or more separately formed layers of one or more alloys. An open ended annular mould is provided having a divider wall dividing a feed end of the mould into at least two separate feed chambers. For each pair of adjacent feed chambers, a first alloy stream is fed through one of the pair of feed chambers into the mould and a second alloy stream is fed through another of the feed chambers. A self-supporting surface is generated on the surface of the first alloy stream and the second alloy stream is contacted with the first stream. By carefully selecting conditions and positions where the alloy streams meet, a composite metal ingot is formed in which the alloy layers are mutually attached with a substantially continuous metallurgical bond.
    Type: Grant
    Filed: November 13, 2008
    Date of Patent: October 26, 2010
    Assignee: Novelis Inc.
    Inventors: Mark Douglas Anderson, Kenneth Takeo Kubo, Todd F. Bischoff, Wayne J. Fenton, Eric W. Reeves, Brent Spendlove, Robert Bruce Wagstaff
  • Patent number: 7789124
    Abstract: A method of casting an ingot of a metal having a susceptibility to hot-tearing while avoiding such hot tearing. The method involves co-casting a cladding metal on a surface of a metal core ingot as the ingot is being cast in a DC casting procedure. The cladding layer preferably contacts the core ingot at a position on the ingot surface where the metal of the ingot is incompletely solid, e.g. at a temperature between its solidus temperature and liquidus temperatures. The metal of the core ingot and the metal of the cladding layer are the same and, if they contain grain refiners, the are present in an amount of 0.005% by weight of the metal or less.
    Type: Grant
    Filed: October 5, 2009
    Date of Patent: September 7, 2010
    Assignee: Novelis Inc.
    Inventor: Willard Mark Truman Gallerneault
  • Patent number: 7762310
    Abstract: A method of producing a clad sheet article having superplastic properties, and the resulting clad sheet article. The method involves producing a cladding layer onto at least one rolling face of a core ingot made of a metal having superplastic properties, preferably by co-casting, to form a clad ingot and then rolling said clad ingot to produce a sheet article. The core ingot includes an element that diffuses from an interior of the ingot to a surface at superplastic forming temperatures thereby deteriorating surface properties of the ingot. The cladding layer is provided with an element (dopant) that reacts with the element of the core to reduce the ability of the element to diffuse through the cladding layer.
    Type: Grant
    Filed: April 12, 2007
    Date of Patent: July 27, 2010
    Assignee: Novelis Inc.
    Inventors: Michael J. Bull, David J. Lloyd, Phil Morris, Paul A. Wycliffe, Robert Bruce Wagstaff, Alok K. Gupta, Gijsbertus Langelaan
  • Patent number: 7748434
    Abstract: A method and apparatus for casting metals in a DC mold to form an ingot or product having at least two layers formed by sequential solidification. The apparatus has at least one cooled divider wall at the entry end portion of the mold to divide the entry end portion into at least two feed chambers. Metal is fed to the chambers to form an inner layer and at least one outer layer. The divider wall has a metal-contacting surface for contacting the metal for the at least one outer layer, the surface being arranged at an angle to the vertical sloping away from the metal for the outer layer in a downward direction. The angle increases at positions on the divider wall spaced from a central section of the wall approaching each longitudinal end thereof. The apparatus is suitable for casting a metal having a high coefficient of contraction as an inner layer or core ingot, e.g. a high-Mg or high-Zn aluminum alloy, or metal combinations having a large difference in their coefficients of contraction.
    Type: Grant
    Filed: February 28, 2007
    Date of Patent: July 6, 2010
    Assignee: Novelis Inc.
    Inventor: Robert Bruce Wagstaff
  • Patent number: 7681625
    Abstract: A wet filament winding method and apparatus for producing a consolidated metal matrix composite is described. The methods are directed to winding a softened metal infiltrated fiber bundle and layering the resulting softened metal infiltrated fiber bundle onto a rotating mandrel in a prescribed pattern on the surface of the mandrel to form a consolidated metal matrix composite. Upon cooling, the matrix metal solidifies and the resulting consolidated metal matrix composite may be removed from the mandrel. The consolidated metal matrix composites may be produced in a variety of shapes, such as cylinder, a tapered cylinder, a sphere, an ovoid, a cube, a rectangular solid, a polygonal solid, and panels.
    Type: Grant
    Filed: November 24, 2004
    Date of Patent: March 23, 2010
    Assignee: Touchstone Research Laboratory, Ltd
    Inventors: Brian L. Gordon, Gregg W. Wolfe
  • Publication number: 20100015469
    Abstract: A method for twin roll casting aluminum clad magnesium by joining one or more sheets of aluminum cladding to molten magnesium during twin roll casting.
    Type: Application
    Filed: July 16, 2008
    Publication date: January 21, 2010
    Inventor: Christopher A. Romanowski
  • Patent number: 7617864
    Abstract: A method of casting an ingot of a metal having a susceptibility to hot-tearing while avoiding such hot tearing. The method involves co-casting a cladding metal on a surface of a metal core ingot as the ingot is being cast in a DC casting procedure. The cladding layer preferably contacts the core ingot at a position on the ingot surface where the metal of the ingot is incompletely solid, e.g. at a temperature between its solidus temperature and liquidus temperatures. The metal of the core ingot and the metal of the cladding layer are the same and, if they contain grain refiners, the are present in an amount of 0.005% by weight of the metal or less.
    Type: Grant
    Filed: February 5, 2007
    Date of Patent: November 17, 2009
    Assignee: Novelis Inc.
    Inventor: Willard Mark Truman Gallerneault
  • Patent number: 7591299
    Abstract: A method and apparatus for the production of long lengths of continuous-fiber metal matrix composite prepeg ribbon or tape. The tape or ribbon is produced by bringing together multiple fiber tows into a formed bundle of fibers and infiltrating the bundle with metal using a continuous pultrusion process. Pultrusion is a preferred method of tape or ribbon manufacture since it places the fibers in tension during manufacture and avoids subsequent issues associated with buckling stress.
    Type: Grant
    Filed: November 24, 2004
    Date of Patent: September 22, 2009
    Assignee: Touchstone Research Laboratory, Ltd.
    Inventors: Brian L. Gordon, Gregg W. Wolfe
  • Publication number: 20090159233
    Abstract: To stably manufacture a high-quality molten metal plated steel strip while splashes caused in use of a gas wiping nozzle for controlling the plating amount is prevented. A gas wiping nozzle is used which includes a primary nozzle portion and at least one secondary nozzle portion provided either or both above and below the primary nozzle portion. The secondary nozzle portion jets a gas in a direction tilted from the direction in which the primary nozzle portion jets the gas, and the secondary nozzle portion jets the gas at a lower flow rate than the primary nozzle portion. The gas wiping nozzle has a tip whose lower surface forms an angle of 60° or more with the steel strip. By jetting a gas from the secondary nozzle portion at predetermined conditions, the gas jet can scrape molten metal effectively. By controlling the angle between the lower surface of the gas wiping nozzle and the steel strip, the plating can be scraped more effectively.
    Type: Application
    Filed: April 27, 2007
    Publication date: June 25, 2009
    Inventors: Gentaro Takeda, Hideyuki Takahashi
  • Publication number: 20090056904
    Abstract: A method and apparatus is disclosed for casting metals in a DC mold to form an ingot or product having at least two layers formed by sequential solidification. The apparatus has at least one cooled divider wall at the entry end portion of the mold to divide the entry end portion into at least two feed chambers. Metal is fed to the chambers to form an inner layer and at least one outer layer. The divider wall has a metal-contacting surface for contacting the metal for the at least one outer layer, the surface being arranged at an angle sloping away from the metal for the outer layer in a downward direction. The angle is larger at the center of the divider wall compared to the angle adjacent to each longitudinal end thereof. The apparatus is suitable for co-casting metals having similar coefficients of contraction to minimize problems of adhesion between the layers of a resulting ingot or rolled products produced therefrom.
    Type: Application
    Filed: July 29, 2008
    Publication date: March 5, 2009
    Inventors: Robert Bruce Wagstaff, Todd F. Bischoff
  • Patent number: 7472740
    Abstract: A method and apparatus are described for the casting of a composite metal ingot having two or more separately formed layers of one or more alloys. An open ended annular mould is provided having a divider wall dividing a feed end of the mould into at least two separate feed chambers. For each pair of adjacent feed chambers, a first alloy stream is fed through one of the pair of feed chambers into the mould and a second alloy stream is fed through another of the feed chambers. A self-supporting surface is generated on the surface of the first alloy stream and the second alloy stream is contacted with the first stream. By carefully selecting conditions and positions where the alloy streams meet, a composite metal ingot is formed in which the alloy layers are mutually attached with a substantially continuous metallurgical bond.
    Type: Grant
    Filed: June 23, 2004
    Date of Patent: January 6, 2009
    Assignee: Novelis Inc.
    Inventors: Mark Douglas Anderson, Kenneth Takeo Kubo, Todd F. Bischoff, Wayne J. Fenton, Eric W. Reeves, Brent Spendlove, Robert Bruce Wagstaff
  • Publication number: 20080254309
    Abstract: The present invention discloses a method of making a functionally graded metal matrix composite (MMC) sheet having a central layer of particulate matter. The method includes providing a molten metal containing particulate matter to a pair of advancing casting surfaces. Solidifying the molten metal while advancing the molten metal between the advancing casting surfaces to form a product comprising a first solid outer layer, a second solid outer layer, and a semi-solid central layer having a higher concentration of particulate matter than either of the outer layers. Solidifying the central layer to form a solid metal product comprised of an inner layer sandwiched between the outer layers and withdrawing the metal product from between the casting surfaces. The method yields an MMC having a central layer enriched with particulate matter and sandwiched between metallic outer layers.
    Type: Application
    Filed: April 11, 2007
    Publication date: October 16, 2008
    Applicant: Alcoa Inc.
    Inventors: David A. Tomes, Gavin F. Wyatt-Mair, David W. Timmons, Ali Unal
  • Patent number: 7318267
    Abstract: Arranged are a twin- or single-roll continuous casting machine supplied with molten metal from a tundish arranged above so as to continuously cast a strip with a predetermined width, a trimmer arranged downstream of the continuous casting machine to trim widthwise edges of the strip and a rolling mill arranged downstream of the trimmer.
    Type: Grant
    Filed: July 11, 2003
    Date of Patent: January 15, 2008
    Assignee: Ishikawajima-Harima Heavy Industries Co., Ltd.
    Inventor: Hisashi Honjou
  • Patent number: 7281568
    Abstract: A method is described for producing a stratified composite material, with a melt of a layer material being cast progressively in a forward feed direction onto a strip-like metal carrier which is heated to a treatment temperature required for the bonding with the layer material and is cooled below the melting temperature after the casting via the metal carrier. In order to provide advantageous casting conditions it is proposed that the metal carrier is heated continuously with a temperature profile prior to the casting of the melt of the layer material in the forward feed direction, which temperature profile decreases towards lower temperatures from a maximum temperature below the treatment temperature in the region of a surface layer receiving the melt towards a core layer of the metal carrier, and that the metal carrier is heated in a surface layer by the melt to the treatment temperature upon casting of the melt which is overheated for this purpose.
    Type: Grant
    Filed: June 1, 2005
    Date of Patent: October 16, 2007
    Assignee: Miba Gleitlager GmbH
    Inventors: Robert Mergen, Günther Kutzik
  • Patent number: 7156149
    Abstract: A method is described for producing a stratified composite material, with a layer of sinterable solids particles being applied to a strip-like metal carrier and being sintered with liquid phase by the supply of heat continuously in the forward feed direction. In order to provide simplified production conditions it is proposed that the metal carrier is heated continuously in the forward feed direction with a temperature profile which decreases towards lower temperatures from a maximum temperature above the melting temperature of the solids particles in the region of a surface layer receiving the particle layer towards a core layer of the metal carrier, and that the particle layer is sintered at least in a layer resting on the metal carrier by a heat transmission from the heated metal carrier.
    Type: Grant
    Filed: June 1, 2005
    Date of Patent: January 2, 2007
    Assignee: Miba Gleitlager GmbH
    Inventors: Robert Mergen, Günter Kutzik
  • Patent number: RE45353
    Abstract: A method of making composites of bulk-solidifying amorphous alloys, and articles made thereof, containing at least one type or reinforcement material, wherein the composite material preferably comprises a high volume fraction of reinforcement material and is fully-dense with minimum porosity are provided.
    Type: Grant
    Filed: July 14, 2011
    Date of Patent: January 27, 2015
    Assignee: Crucible Intellectual Property, LLC
    Inventor: Atakan Peker