Utilizing Continuously Advancing Surface Patents (Class 164/463)
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Publication number: 20090266504Abstract: The method of producing thin cast strip by continuous casting having a side dam assembly. The side dam assembly includes a side dam having opposite outer surfaces, one surface contacting molten metal and the opposite outer surface having fastening portions capable of attaching the side dam to a side dam holder, to hold the side dam in place during casting without exposed portions of the side dam holder extending substantially beyond the opposite outer surface toward the outer surface for contacting molten metal.Type: ApplicationFiled: July 2, 2009Publication date: October 29, 2009Applicant: NUCOR CORPORATIONInventors: Brian E. Bowman, Alan J. Deno, Gordon D. Emmert
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Publication number: 20090266503Abstract: The object of the invention is to improve the quality of cast hot strips. The object is achieved in terms of the method by a method for producing hot metallic strips, in particular of lightweight structural steel, wherein a melt is charged in the presence of inert gas by means of a runner onto a circulating casting belt of a horizontal strip casting facility, solidifies to form a pre-strip with a thickness of between 6 and 20 mm and, after thorough solidification, the pre-strip undergoes a hot rolling process. The invention is characterized in that the heat transfer and the contact (surface area, time) between the strand solidified to form a pre-strip and the casting belt is reduced, and by a device for carrying out the method.Type: ApplicationFiled: November 22, 2006Publication date: October 29, 2009Applicant: Salzgitter Flachstahl GmbHInventors: Karl-Heinz Spitzer, Hellfried Eichholz, Rune Schmidt-Jurgensen, Markus Schaperkotter
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Publication number: 20090236068Abstract: An apparatus and method for continuously casting thin steel strip include a pair of counter-rotatable casting rolls mounted in a roll cassette capable of being transferred from a set up station to a casting position through a transfer station, where at the set up station the casting rolls mounted in the roll cassette are capable of being prepared for casting, at the transfer station casting rolls are capable of being exchanged, and in the casting position the casting rolls are operational, and a guide positioned capable of moving the casting rolls mounted in the roll cassette between the set up station and the casting position through the transfer station. The guide may move the casting rolls mounted in the roll cassette from the set up station to the casting position through the transfer station at substantially the same elevation. A scrap receptacle positioned beneath the casting position movable in either direction to a discharge stations.Type: ApplicationFiled: March 19, 2008Publication date: September 24, 2009Applicant: NUCOR CORPORATIONInventors: Jay Jon Ondrovic, Eric Fulbright, Katsumi Nakayama
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Patent number: 7588071Abstract: Methods and apparatuses for the continuous casting of solid foam structures with varying bubble density from bulk solidifying amorphous alloys are provided. Continuously cast solid foam structures having bubble densities in the range of from 50 percent up to 95% by volume are also provided.Type: GrantFiled: April 14, 2004Date of Patent: September 15, 2009Assignee: Liquidmetal Technologies, Inc.Inventor: James Kang
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Patent number: 7575040Abstract: A process and apparatus for continuous casting of amorphous alloy sheets having large sheet thickness using bulk solidifying amorphous alloys are provided. Thick continuous amorphous alloy sheets made of bulk solidifying amorphous alloys are also provided.Type: GrantFiled: April 14, 2004Date of Patent: August 18, 2009Assignee: Liquidmetal Technologies, Inc.Inventor: William L. Johnson
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Patent number: 7571757Abstract: Disclosed is a rare earth magnet in the R—T—B (rare earth element-transition metal-boron) system that is made from an improved composition and properties of main phase alloy in the R—T—B system containing Pr and a boundary alloy. Disclosed also is a manufacturing method of the rare earth magnet alloy flake by a strip casting method with improved rotating rollers such that the alloy flake has a specified fine surface roughness and has a small and regulated amount of fine R-rich phase regions. Consequently, the alloy flake for the rare earth magnet does not containing ?-Fe and has a homogeneous morphology so that the rare earth magnet formed by sintering or bonding the alloy flakes exhibits excellent magnetic properties.Type: GrantFiled: July 12, 2007Date of Patent: August 11, 2009Assignee: Showa Denko K.K.Inventor: Shiro Sasaki
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Publication number: 20090165897Abstract: Substantially austenitic steel having high strength and good formability for cold rolling including (in weight percent): 0.05 to 1.0% C; 11.0 to 14.9% Mn; 1.0 to 5.0% Al; O to 2.5% Ni the remainder being iron and unavoidable impurities, wherein the microstructure includes at least 75% in volume of austenite, and wherein (Ni+Mn) is from 11.0 to 15.9%.Type: ApplicationFiled: February 1, 2006Publication date: July 2, 2009Applicant: Corus Staal BVInventor: Calum McEwan
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Publication number: 20090159235Abstract: A method of producing thin cast strip by continuous casting having a two-piece side dam assembly. The side dam assembly includes a side dam having an upper portion positioned adjacent to a lower portion. The upper and lower side dam portions each have opposite outer surfaces, one surface capable of contacting molten metal and the opposite outer surface having at least one fastening portion capable of attaching the side dam portions to a corresponding side dam holder, in order to hold the side dam portions in place during casting without exposed portions of the side dam holders extending substantially beyond the opposite outer surfaces toward the outer surfaces capable of contacting molten metal, and without the side dam holders preventing the upper side dam portion from being properly positioned adjacent to the lower side dam portion.Type: ApplicationFiled: February 3, 2009Publication date: June 25, 2009Applicant: NUCOR CORPORATIONInventor: Mike Schueren
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Patent number: 7550047Abstract: 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: GrantFiled: December 18, 2002Date of Patent: June 23, 2009Assignee: Hitachi Metals, Ltd.Inventors: Hiroyuki Tomizawa, Yuji Kaneko
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Publication number: 20090126896Abstract: A thin cast strip is formed having at least one microstructure selected from the group consisting of polygonal ferrite, acicular ferrite, Widmanstatten, bainite and martinsite, a surface roughness of less than 1.5 microns Ra and a scale thickness of less than about 10 microns by applying a mixture of water and oil on the work rolls of the hot rolling mill, passing the thin cast strip at a temperature of less than 1100° C. through the hot rolling mill while the mixture of oil and water is applied to the work rolls, and shrouding the thin cast strip from the casting rolls through the hot rolling mill in an atmosphere of less than 5% oxygen to form the thin cast strip.Type: ApplicationFiled: November 17, 2008Publication date: May 21, 2009Applicant: Nucor CorporationInventors: Walter N. Blejde, Jay Jon Ondrovic
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Publication number: 20090090484Abstract: A method for operating a two-roll casting machine for casting molten metal into cast strip, which machine has two casting rolls which are each rotatively driven in opposite directions about an axis of rotation and between them delimit a casting gap on its longitudinal sides, with side plates that can be placed on the casting rolls, which side plates seal the casting gap on its narrow sides in the casting operation, bridging the casting gap with a refractory material, wherein the side plates are moved during the casting operation in a direction which is aligned parallel to the direction of conveying in which the cast strip leaves the casting gap. With such a method the formation of grooves distorting the casting result and the casting operation can be suppressed with increased certainty and the service life of the side plates can be increased, compared to the prior art.Type: ApplicationFiled: November 20, 2006Publication date: April 9, 2009Applicant: ThyssenKrupp Nirosta GmbHInventors: Andre d'Hone, Rene Leenen
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Publication number: 20090056905Abstract: A device and a method for casting of strips from a metal melt includes the use of two casting rollers, which delimit between them a casting gap at their longitudinal sides, and two side plates, which, arranged opposite one another, are held in contact at face sides of the casting rollers, allocated to narrow sides in each case of the casting gap. With the device and method, metallic strips can be reliably produced which have high dimensional stability even in the area of their strip edges, in that the risk of a gathering of solidified melt at the side plates in casting operation is reduced to a minimum. This is achieved by providing at least one heating device for the heating of the casting rollers in at least those sections of their face sides at which the side plate, allocated to the face side in each case, is in contact.Type: ApplicationFiled: August 29, 2008Publication date: March 5, 2009Applicant: ThyssenKrupp Nirosta GmbHInventors: Andre d'Hone, Roland Sellger
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Publication number: 20090020259Abstract: The invention relates to a continuous casting plant (1), in particular for the continuous casting of thin slabs, which has a vertically oriented strand guide (3) arranged below a mould (2), wherein means (4, 5) for driving the cast strand (6) and for bending the same into the horizontal (H) are arranged below the strand guide (3). In order to be able to extend the strand guide without any drawbacks, the invention provides for a means (4) for exclusively driving the cast strand (6) to be arranged below the bottom end of the strand guide (3) and for a means (5) for exclusively bending the cast strand (6) to be arranged below the driving means (4). The invention also relates to a method of operating a continuous casting plant.Type: ApplicationFiled: March 8, 2007Publication date: January 22, 2009Inventors: Jorg Bausch, Bernd Leifeld, Jurgen Muller
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Publication number: 20080271873Abstract: A method of controlling in a twin roll strip caster the thickness of as-cast strip by determining and operating at a target depth of the casting pool and a target speed of the casting rolls. The as-cast strip may be cast to a customer-specified thickness or may be subsequently rolled to a customer-specified thickness.Type: ApplicationFiled: July 10, 2008Publication date: November 6, 2008Applicant: NUCOR CORPORATIONInventors: Walter N. BLEJDE, Rama Ballav MAHAPATRA
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Publication number: 20080264599Abstract: A metal strip casting apparatus and a method of casting continuous metal strip includes assembling a pair of counter-rotatable casting rolls having casting surfaces positioned laterally forming a nip between for casting, and delivering molten metal through a delivery nozzle disposed above the nip capable to form a casting pool supported on the casting rolls. The delivery nozzle comprises segments each having elongate nozzle body with longitudinally extending side walls, end walls and a bottom part to form an inner trough, a nozzle insert disposed above bottom portions of the inner trough of each segment and supported relative to the nozzle body through which incoming molten metal may be delivered to the inner trough of each segment of the delivery nozzle, and the elongate nozzle body of each segment having passageways in fluid communication with the inner trough and outlet openings capable of discharging molten metal from the nozzle body outwardly into the casting pool.Type: ApplicationFiled: June 2, 2008Publication date: October 30, 2008Applicant: NUCOR CORPORATIONInventors: Walter N. Blejde, Mike Schueren, David J. Sosinsky, Brian D. White, Mark Schlichting
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Patent number: 7442262Abstract: Disclosed is a rare earth magnet in the R-T-B (rare earth element-transition metal-boron) system that is made from an improved composition and properties of main phase alloy in the R-T-B system containing Pr and a boundary alloy. Disclosed also is a manufacturing method of the rare earth magnet alloy flake by a strip casting method with improved rotating rollers such that the alloy flake has a specified fine surface roughness and has a small and regulated amount of fine R-rich phase regions. Consequently, the alloy flake for the rare earth magnet does not containing ?-Fe and has a homogeneous morphology so that the rare earth magnet formed by sintering or bonding the alloy flakes exhibits excellent magnetic properties.Type: GrantFiled: December 18, 2002Date of Patent: October 28, 2008Assignee: Showa Denko K.K.Inventor: Shiro Sasaki
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Patent number: 7431070Abstract: One object of the present invention is to provide a rare earth magnet alloy ingot, which has improved magnetic properties. In order to achieve the object, the present invention provides a rare earth magnet alloy ingot, wherein the rare earth magnet alloy ingot comprises an R-T-B type magnet alloy (R represents at least one element selected from among rare earth elements, including Y; and T represents a substance predominantly comprising Fe, with a portion of Fe atoms being optionally substituted by Co, Ni, Cu, Al, Ga, Cr, and Mn) containing at least one element selected from among Nd, Pr, and Dy in a total amount of 11.8 to 16.5% by atom and B in an amount of 5.6 to 9.1% by atom; and wherein as determined in an as-cast state of the alloy ingot, R-rich phase that measures 100 ?m or more is substantially absent on a cross section.Type: GrantFiled: January 12, 2006Date of Patent: October 7, 2008Assignee: Showa Denko K.K.Inventors: Hiroshi Hasegawa, Masahide Utsunomiya, Tadanao Ito
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Publication number: 20080173424Abstract: A method of and apparatus for casting metal strip involving assembling a pair of casting rolls laterally disposed to form a nip between them, assembling an elongated metal delivery nozzle extending along and above the nip between the casting rolls, with at least one segment having opposing side walls and end walls, an inner trough extending longitudinally within between side walls and forming passages between the side walls and the inner trough and communicating with side outlets adjacent bottom portions, introducing molten metal through the elongate metal delivery nozzle to form a casting pool of molten metal supported on the casting rolls above the nip, such that molten metal is caused to flow into the inner trough of the delivery nozzle, from the inner trough through the passages between the inner trough and sidewalls, and from the passages through the side outlets in a substantially lateral direction into the casting pool, and counter rotating the casting rolls to deliver cast strip downwardly from the niType: ApplicationFiled: January 14, 2008Publication date: July 24, 2008Applicant: NUCOR CORPORATIONInventors: W. Kent Cooper, James Leacock McIntosh, Peter Woodberry, Rama B. Mahapatra, Malcolm McDonald
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Patent number: 7306025Abstract: A method for controlling and manipulating solidification of a molten material includes generating a gradient pattern on at least a portion of a substrate and depositing the molten material on at least a portion of the substrate with the gradient pattern.Type: GrantFiled: March 31, 2006Date of Patent: December 11, 2007Assignee: Cornell Research Foundation, Inc.Inventor: Paul H. Steen
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Patent number: 7279053Abstract: The present invention provides a rare earth magnet superior in magnetic properties and thermal stability. In an aspect of the present invention, a production method of an alloy thin ribbon for a rare earth magnet includes a step to obtain a quenched thin ribbon by feeding a molten alloy containing praseodymium (Pr), iron (Fe), cobalt (Co), titanium (Ti), boron (B), and silicon (Si) on a rotating roll and a step to apply heat treatment to the quenched thin ribbon at a heating rate within a range of 100° to 150° C./min to crystallize the quenched thin ribbon.Type: GrantFiled: August 22, 2005Date of Patent: October 9, 2007Assignees: Nissan Motor Co., Ltd., Horoshi YamamotoInventors: Munekatsu Shimada, Takae Ono, legal representative, Tetsurou Tayu, Makoto Kano, Hiroshi Yamamoto, Hideaki Ono, deceased
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Patent number: 7258751Abstract: In a rare earth magnet, an added heavy rare earth element RH such as Dy is effectively used without any waste, so as to effectively improve the coercive force. First, a molten alloy of a material alloy for an R-T-Q rare earth magnet (R is a rare earth element, T is a transition metal element, and Q is at least one element selected from the group consisting of B, C, N, Al, Si, and P), the rare earth element R containing at least one kind of element RL selected from the group consisting of Nd and Pr and at least one kind of element RH selected from the group consisting of Dy Tb, and Ho is prepared. The molten alloy is quenched, so as to produce a solidified alloy. Thereafter, a thermal treatment in which the rapidly solidified alloy is held in a temperature range of 400° C. or higher and lower than 800° C. for a period of not shorter than 5 minutes nor longer than 12 hours is performed.Type: GrantFiled: June 19, 2002Date of Patent: August 21, 2007Assignee: Neomax Co., Ltd.Inventors: Hiroyuki Tomizawa, Yuji Kaneko
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Patent number: 7160398Abstract: A melt of an alloy, represented (Fe1-mTm)100-x-y-zQxRyMz, where T is Co and/or Ni, Q is B and/or C, R is at least one rare-earth element, M is selected from Al, Si, Ti, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb; 10 at %?x?35 at %; 2 at %?y?10 at %; 0 at %?z?10 at %; and 0?m?0.5, is prepared. Next, the melt is brought into contact with, and rapidly cooled and solidified by, the surface of a rotating chill roller. The melt is teemed onto a guide member, of which the guide surface defines a tilt angle with a horizontal plane, runs down on the guide surface, and then is fed through at least one tubular hole onto a contact area on the surface of the chill roller.Type: GrantFiled: June 27, 2003Date of Patent: January 9, 2007Assignee: Neomax Co., Ltd.Inventor: Hirokazu Kanekiyo
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Patent number: 7144463Abstract: The present invention relates to highly quenchable Fe-based rare earth magnetic materials that are made by rapid solidification process and exhibit good magnetic properties and thermal stability. More specifically, the invention relates to isotropic Nd—Fe—B type magnetic materials made from a rapid solidification process with a lower optimal wheel speed and a broader optimal wheel speed window than those used in producing conventional magnetic materials. The materials exhibit remanence (Br) and intrinsic coercivity (Hci) values of between 7.0 to 8.5 kG and 6.5 to 9.9 kOe, respectively, at room temperature. The invention also relates to process of making the materials and to bonded magnets made from the magnetic materials, which are suitable for direct replacement of anisotropic sintered ferrites in many applications.Type: GrantFiled: September 6, 2005Date of Patent: December 5, 2006Assignee: Magnequench, Inc.Inventors: Zhongmin Chen, Benjamin R. Smith, Bao-Min Ma, James W. Herchenroeder
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Patent number: 7138017Abstract: A method of making an alloy powder for an R—Fe—B-type rare earth magnet includes the steps of preparing a material alloy that is to be used for forming the R—Fe—B-type rare earth magnet and that has a chilled structure that constitutes about 2 volume percent to about 20 volume percent of the material alloy, coarsely pulverizing the material alloy for the R—Fe—B-type rare earth magnet by utilizing a hydrogen occlusion phenomenon to obtain a coarsely pulverized powder, finely pulverizing the coarsely pulverized powder and removing at least some of fine powder particles having particle sizes of about 1.0 ?m or less from the finely pulverized powder, thereby reducing the volume fraction of the fine powder particles with the particle sizes of about 1.0 ?m or less, and covering the surface of remaining ones of the powder particles with a lubricant after the step of removing has been performed.Type: GrantFiled: August 21, 2003Date of Patent: November 21, 2006Assignee: Neomax Co., Ltd.Inventors: Yuji Kaneko, Junichiro Baba, Katsuya Taniguchi
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Patent number: 7082986Abstract: A system and method for controlling and manipulating solidification of a molten material includes a substrate on which the molten material is deposited and a writing system that generates a gradient pattern on at least a portion of the substrate on which the molten material is deposited.Type: GrantFiled: February 8, 2002Date of Patent: August 1, 2006Assignee: Cornell Research Foundation, Inc.Inventor: Paul H. Steen
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Patent number: 7022252Abstract: The permanent magnetic alloy of the present invention comprises an R—Fe—B alloy wherein R is at least one element selected from rare earth elements including Y. The R—Fe—B alloy has a composition mainly comprising Fe, substantially containing no N, and containing 4 at. % or more of B. The permanent magnetic alloy substantially comprises a TbCu7 hard magnetic phase (main phase) and a fine crystal having an average crystal grain size of less than 5 nm and/or an amorphous phase, and has high magnetic properties.Type: GrantFiled: November 8, 2002Date of Patent: April 4, 2006Assignee: Hitachi Metals, Ltd.Inventors: Mitsuaki Mochizuki, Michihisa Shimizu, Tsunehiro Kawata, Masao Murakawa
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Patent number: 7017645Abstract: A process and apparatus for thermoplastic casting of a suitable glass forming alloy is provided. The method and apparatus comprising thermoplastically casting the alloy in either a continuous or batch process by maintaining the alloy at a temperature in a thermoplastic zone, which is below a temperature, Tnose, (where, the resistance to crystallization is minimum) and above the glass transition temperature, Tg, during the shaping or moulding step, followed by a quenching step where the item is cooled to the ambient temperature. A product formed according to the thermoplastic casting process is also provided.Type: GrantFiled: January 31, 2003Date of Patent: March 28, 2006Assignee: Liquidmetal TechnologiesInventors: William L. Johnson, Choongnyun Kim, Atakan Peker
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Patent number: 7004228Abstract: To make a raw alloy, consisting mostly of amorphous structure, highly productively and at a reduced cost for a nanocomposite magnet, a molten alloy represented by Fe100-x-y-zRxQyMz (where R is at least one element selected from Pr, Nd, Dy and Tb; Q is B and/or C; M is at least one element selected from Co, Al, Si, Ti, V, Cr, Mn, Ni, Cu, Ga, Zr, Nb, Mo, Ag, Pt, Au and Pb; and 1 at %?x<6 at %, 15 at %?y?30 at % and 0 at %?z?7 at %) is prepared. This molten alloy is rapidly cooled by a strip casting process in which the alloy is fed onto a chill roller, rotating at a peripheral velocity of 3 m/s to less than 20 m/s, at a feeding rate per unit contact width of 0.2 kg/min/cm to 5.2 kg/min/cm. In this manner, an alloy including at least 60 volume percent of amorphous phase can be obtained.Type: GrantFiled: September 25, 2001Date of Patent: February 28, 2006Assignees: Santoku Corporation, Neomax Co., Ltd.Inventors: Ryo Murakami, Hirokazu Kanekiyo, Satoshi Hirosawa
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Patent number: 6916385Abstract: Disclosed herein is a method of manufacturing a magnetic material which can provide a bonded magnet having excellent magnetic properties and having excellent reliability. A melt spinning apparatus 1 is provided with a tube 2 having a nozzle 3 at the bottom thereof, a coil 4 for heating the tube and a cooling roll 5 having a circumferential surface 53 in which gas expelling grooves 54 are formed. A melt spun ribbon 8 is formed by injecting the molten alloy 6 from the nozzle 6 so as to be collided with the circumferential surface 53 of the cooling roll 5, so that the molten alloy 6 is cooled and then solidified. In this process, gas is likely to enter between a puddle 7 of the molten alloy 6 and the circumferential surface 53, but such gas is expelled by means of the gas expelling grooves 54.Type: GrantFiled: April 12, 2001Date of Patent: July 12, 2005Assignee: Seiko Epson CorporationInventors: Akira Arai, Hiroshi Kato
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Patent number: 6864793Abstract: A magnetic marker comprises a magnetically switchable wire and a magnetic casing that covers the magnetically switchable wire. The magnetically switchable wire is formed of a magnetic material that undergoes occurrence of sharp magnetic inversion when an alternating field of intensity higher than its coercive force is applied to it. The magnetic casing is formed of a magnetically hard or semihard magnetic material and can apply a bias magnetic field to the magnetically switchable wire to prevent magnetic inversion of the magnetically switchable wire. Heat-treated portions and high-coercivity regions, which are not heat-treated, are formed alternately in the longitudinal direction on the magnetic casing. The heat-treated portions are given magnetic properties different from magnetic properties essential to the magnetic casing by heat treatment such as annealing.Type: GrantFiled: March 14, 2002Date of Patent: March 8, 2005Assignee: NHK Spring Co., Ltd.Inventors: Yoshiki Ono, Tatsuya Kurihara, Shigemi Sato, Sumikazu Oki
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Patent number: 6830633Abstract: A magnetic material manufacturing method, a ribbon-shaped magnetic material manufactured by the method, a powdered magnetic material formed from the ribbon-shaped magnetic material and a bonded magnet manufactured using the powdered magnet material are disclosed. The method and the magnetic materials can provide magnets having excellent magnetic properties and reliability. A melt spinning apparatus 1 is provided with a tube 2 having a nozzle 3 at the bottom thereof, a coil 4 for heating the tube and a cooling roll 5 having a circumferential surface 53 on which dimple correcting means is provided. A melt spun ribbon 8 is formed by injecting the molten alloy 6 from the nozzle 3 so as to be collided with the circumferential surface 53 of the cooling roll 5 in an inert gas atmosphere (ambient gas) such as helium gas, so that the molten alloy 6 is cooled and then solidified.Type: GrantFiled: May 30, 2001Date of Patent: December 14, 2004Assignee: Seiko Epson CorporationInventors: Akira Arai, Hiroshi Kato
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Patent number: 6800145Abstract: A Nd—Fe—B type rare earth magnet alloy is provided with hard magnetic phases each of which has a size equal to or less than 80 nm, soft magnetic phases each of which has a size equal to or less than 80 nm, with the hard and soft magnetic phases being present in a mixed structure, and partly anisotropic regions wherein axes of easy magnetization of the hard magnetic phases are aligned in one direction and each having a size equal to or greater than 0.1 &mgr;m. Such a magnet alloy is obtained using a strip casting method or ultra cooling method and serves as material for an anisotropic exchange spring magnet to be applied to a motor.Type: GrantFiled: May 17, 2002Date of Patent: October 5, 2004Assignee: Nissan Motor Co., Ltd.Inventors: Munekatsu Shimada, Hideaki Ono
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Patent number: 6796365Abstract: Method provides ceramic fibers with a matrix that includes aluminum.Type: GrantFiled: December 8, 2003Date of Patent: September 28, 2004Assignee: 3M Innovative Properties CompanyInventors: Colin McCullough, Doug E. Johnson
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Publication number: 20040185290Abstract: Method provides ceramic fibers with a matrix that includes aluminum.Type: ApplicationFiled: December 8, 2003Publication date: September 23, 2004Applicant: 3M Innovative Properties CompanyInventors: Colin McCullough, Dough E. Johnson
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Patent number: 6793742Abstract: An alloy powder for bonded rare earth magnets is prepared by melting an alloy consisting essentially of 20-30 wt % of Sm or a mixture of rare earth elements (inclusive of Y) containing at least 50 wt % of Sm, 10-45 wt % of Fe, 1-10 wt % of Cu, 0.5-5 wt % of Zr, and the balance of Co, quenching the melt by a strip casting technique, to form a rare earth alloy strip containing at least 20% by volume of equiaxed crystals with a grain size of 1-200 &mgr;m and having a gage of 0.05-3 mm, and heat treating the strip in a non-oxidizing atmosphere at 1000-1300° C. for 0.5-20 hours, followed by aging treatment and grinding.Type: GrantFiled: May 21, 2002Date of Patent: September 21, 2004Assignee: Shin-Etsu Chemical Co., Ltd.Inventors: Kazuaki Sakaki, Koji Sato, Takahiro Hashimoto, Takehisa Minowa
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Patent number: 6773517Abstract: A rare-earth alloy ingot is produced by melting an alloy composed of 20-30 wt % of a rare-earth constituent which is Sm alone or at least 50 wt % Sm in combination with at least one other rare-earth element, 10-45 wt % of Fe, 1-10 wt % of Cu and 0.5-5 wt % of Zr, with the balance being Co, and quenching the molten alloy in a strip casting process. The strip-cast alloy ingot has a content of 1-200 &mgr;m size equiaxed crystal grains of at least 20 vol % and a thickness of 0.05-3 mm. Rare-earth sintered magnets made from such alloys exhibit excellent magnetic properties and can be manufactured under a broad optimal temperature range during sintering and solution treatment.Type: GrantFiled: September 10, 2001Date of Patent: August 10, 2004Assignee: Shin-Etsu Chemical Co, Ltd.Inventors: Kazuaki Sakaki, Koji Sato, Takahiro Hashimoto, Hajime Nakamura, Takehisa Minowa
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Publication number: 20040112566Abstract: A copper- nickel-silicon quench substrate rapidly solidifies molten alloy into microcrystalline or amorphous strip. The substrate is composed of a thermally conducting alloy. It has a two-phase microstructure with copper rich regions surrounded by a network of nickel silicide phases. The microstructure is substantially homogeneous. Casting of strip is accomplished with minimal surface degradation as a finction of casting time. The quantity of material cast during each run is improved without the toxicity encountered with copper-beryllium substrates.Type: ApplicationFiled: May 17, 2002Publication date: June 17, 2004Inventors: Shinya Myojin, Richard L. Bye, Nicholas J. Decristofaro, Jeng S. Lin, David W. Millure, Joseph G. Cox, Dale R. Walls, Gary B.A. Schuster
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Patent number: 6749700Abstract: An amorphous alloy ribbon free from embrittlement and crystallization and having excellent surface conditions and shape in edge portions is produced by (a) preparing an alloy melt having a composition comprising 13 atomic % or less of B and 15 atomic % or less of at least one selected from the group consisting of transition elements of Groups 4A, 5A and 6A, the balance being substantially Fe; (b) ejecting the alloy melt at a temperature from the melting point of the alloy +50° C. to the melting point of the alloy +250° C. through a nozzle onto the cooling roll rotating at a peripheral speed of 35 m/second or less, a distance between a tip end of the nozzle and the cooling roll being 200 &mgr;m or less; (c) starting to supply a gas based on CO2 to the alloy melt after the surface temperature of the cooling roll has become substantially constant; and (d) grinding the cooling roll while supplying the gas based on CO2.Type: GrantFiled: February 13, 2002Date of Patent: June 15, 2004Assignee: Hitachi Metals Ltd.Inventors: Jun Sunakawa, Yoshio Bizen, Michihiro Nagao
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Patent number: 6695929Abstract: A melt of an iron-based rare earth material alloy, represented by (Fe1-mTm)100-x-y-zQxRyMz, is prepared, wherein T is Co and/or Ni; Q is B and/or C; R is selected from Y (yttrium) and the rare earth elements; M is selected from Al, Si, Ti, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb; 10≦x≦30 at %; 2%≦y<10 at %; 0≦z≦10 at % and 0≦m≦0.5. The melt is fed onto a guide to form a flow of the melt thereon and move the melt onto a melt/chill roller contact region, where the melt is rapidly cooled by the chill roller to make a rapidly solidified alloy. An oxygen concentration of the melt yet to be fed onto the guide is controlled at about 3,000 ppm or less in mass percentage.Type: GrantFiled: August 5, 2002Date of Patent: February 24, 2004Assignee: Sumitomo Special Co., Ltd.Inventors: Hirokazu Kanekiyo, Satoshi Hirosawa
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Patent number: 6668907Abstract: The invention relates to novel casting wheels for the rapid solidification technique which are produced by centrifugal casting. The wheels are made of an alloy with a non-equiaxial granular structure, wherein the grains are elongated and their longitudinal axis lies substantially perpendicular to the casting-wheel surface.Type: GrantFiled: January 17, 2002Date of Patent: December 30, 2003Assignee: Vacuumschmelze GmbHInventors: Dieter Nuetzel, Ewald Grote, Giselher Herzer
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Patent number: 6663729Abstract: An aluminum alloy foil is formed from an alloy containing about 1.2 to 1.7% by weight Fe and about 0.35 to 0.80% by weight Si, with the balance aluminum and incidental impurities. The alloy is continuously strip cast to form a strip having a thickness less than about 25 mm, which is then cold rolled to interanneal gauge and interannealed at a temperature of at least 400° C. The interannealed strip is cold rolled and further annealed to form the final foil product, having excellent rollability combined with high strength of the final foil.Type: GrantFiled: February 13, 2001Date of Patent: December 16, 2003Assignee: Alcan International LimitedInventors: Iljoon Jin, Kevin Gatenby, Christopher Gabryel, Toshiya Anami, Takahiko Watai, Ichiro Okamoto
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Publication number: 20030207144Abstract: A soft magnetic alloy fiber has a width of 10 &mgr;m or more to less than 500 &mgr;m, a thickness of 2 &mgr;m or more to less than 20 &mgr;m, and a Curie temperature of −50° C. or higher.Type: ApplicationFiled: May 29, 2003Publication date: November 6, 2003Applicant: Kabushiki Kaisha ToshibaInventors: Takao Sawa, Katsutoshi Nakagawa, Hisashi Takahashi, Teruo Murakami, Masao Obama
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Publication number: 20030205353Abstract: A soft magnetic alloy fiber has a width of 10 &mgr;m or more to less than 500 &mgr;m, a thickness of 2 &mgr;m or more to less than 20 &mgr;m, and a Curie temperature of −50° C. or higher.Type: ApplicationFiled: May 29, 2003Publication date: November 6, 2003Applicant: Kabushiki Kaisha ToshibaInventors: Takao Sawa, Katsutoshi Nakagawa, Hisashi Takahashi, Teruo Murakami, Masao Obama
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Patent number: 6626228Abstract: A system and method for repairing turbine components. The system includes means for obtaining a rapidly solidified material having a means of forming a rapidly solidified repair material and a means for melting the rapidly solidified repair material at a repair site located in a region of the turbine component. The means for obtaining the rapidly solidified material include melt spinning, planar flow, and melt extraction systems. Means for melting the rapidly solidified repair material include a welding torch, an electron beam, a laser beam, a welding torch, a TIG welder, and a plasma torch.Type: GrantFiled: September 29, 2000Date of Patent: September 30, 2003Assignee: General Electric CompanyInventors: Bernard Patrick Bewlay, Peter George Frischmann
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Patent number: 6622777Abstract: The apparatus and a method are used to produce metal fiber, which can increase production efficiency of metal fiber using a metal plate and simplify manufacturing equipments and includes a controlling device. The method for producing metal fiber includes steps of: making a frame in a vacuum condition by removing the air; vertically inserting an end of a metal plate between two induction coils arranged horizontally at an interval in the inside of the frame and heating and melting the end of the metal plate with heat generated by the induction coils; gradually moving the metal plate downwardly and bringing the end of the metal plate into contact with blades of a rotary disk, the rotary disk being horizontally mounted at a lower portion of the induction coils in the inside of the frame and rotating in a high speed; and solidifying metal fiber separated by the blades of the rotary disk.Type: GrantFiled: August 22, 2002Date of Patent: September 23, 2003Inventor: Yang-Za Park
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Publication number: 20030159795Abstract: Disclosed are a method and an apparatus for producing a uranium foil with fine crystalline granules by forming the foil by the gravitational dropping of molten uranium or uranium alloy and rapidly cooling the foil by the contact with cooling rolls, and a foil produced thereby. In accordance with the present invention, a high-purity and high-quality uranium foil with an isotropic structure and fine crystalline granules is easily produced via a simple process without requiring hot rolling and heat treatment processes. The surface of the foil is prevented from oxidizing and residual stress is not imparted to the foil. The productivity and the economic efficiency of the foil are improved.Type: ApplicationFiled: March 24, 2003Publication date: August 28, 2003Applicant: Korea Atomic Energy Research InstituteInventors: Chang-Kyu Kim, Ki-Hwan Kim, Seok-Jin Oh, Se-Jung Jang, Eung-Soo Kim
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Publication number: 20030155097Abstract: The invention relates to a method for homogenizing a molten metal film, more particularly a steel film, by means of thin strip casting. According to the invention, the melt applied to a rotating strip is of a similar thickness to and possesses the same qualities wherever possible as the width of the strip. In order to homogenize the width of the strip, forces possessing a component perpendicular to the direction of conveyance of the strip are introduced, whereby homogenization of the profile of the molten metal film occurs.Type: ApplicationFiled: February 20, 2003Publication date: August 21, 2003Applicant: SMS Demag AG, Salzgitter AGInventors: Joachim Kroos, Karl-Heinz Spitzer, Ulrich Urlau
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Publication number: 20030150590Abstract: A system and method for controlling and manipulating solidification of a molten material includes a substrate on which the molten material is deposited and a writing system that generates a gradient pattern on at least a portion of the substrate on which the molten material is deposited.Type: ApplicationFiled: February 8, 2002Publication date: August 14, 2003Applicant: Cornell Research Foundation, Inc.Inventor: Paul H. Steen
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Patent number: 6604570Abstract: An apparatus and method for continuously manufacturing metal filaments in mass production. In accordance with the present invention, molten metal is hung in a state freely depending from the tip of a metal bar by its surface tension without using any vessel. The metal filament manufacturing apparatus includes an induction coil upwardly bent in the form of a nose shape at regions thereof where metal filaments are discharged while being soared up, respectively, so as to prevent the molten metal of each of the metal bars from being affected by the induction coil during soaring of the metal filaments. The apparatus also includes wiping assembly for removing residual metal materials left on a spinning disk.Type: GrantFiled: May 10, 2002Date of Patent: August 12, 2003Assignee: Fiber Tech Co., Ltd.Inventors: Chang-Hwan Suk, Deck-Yui Lee, Man-Ho Park
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Patent number: RE39656Abstract: The apparatus and a method are used to produce metal fiber, which can increase production efficiency of metal fiber using a metal plate and simplify manufacturing equipments and includes a controlling device. The method for producing metal fiber includes steps of: making a frame in a vacuum condition by removing the air; vertically inserting an end of a metal plate between the two induction coils arranged horizontally at an interval in the inside of the frame and heating and melting the end of the metal plate with heat generated by the induction coils; gradually moving the metal plate downwardly and bringing the end of the metal plate into contact with blades of a rotary disk, the rotary disk being horizontally mounted at a lower portion of the induction coils in the inside of the frame and rotating in a high speed; and solidifying metal fiber separated by the blades of the rotary disk.Type: GrantFiled: May 21, 2004Date of Patent: May 29, 2007Inventor: Yang-Za Park