Abstract: A high speed twin roll casting process is described in which molten metal is fed through a feeding nose into a convergent cavity formed between the walls of two rotating rolls with a meniscus of hot metal extending from the feeding nose tip in a casting zone and the metal strip formed in the casting zone is reduced in a rolling zone. According to the novel feature, the tendency of the metal strip to stick to the rolls is significantly inhibited by shrouding the hot metal meniscus with an oxygen enriched atmosphere. Also when the metal is an Al--Mg alloy, the sticking is greatly inhibited by adding to the alloy a small amount of at least one alloying element selected from nickel, lead, indium and bismuth.

Abstract: A stream of overheated metal melt is applied from a container through a pouring nozzle as a closed jet, or in such a way as to be split up into drops by a gaseous medium, at a pouring point, to the inner surface of a strip coil or composite body also rotating in a mold body. Thus, an initially liquid metal film is produced to which a liquid coolant, preferably a low-temperature liquefied gas such as argon or nitrogen, is applied from a cooling nozzle at a cooling point which is offset in the direction of rotation relative to the pouring point. The coolant dissipates a substantial portion of the excess and melt heat of the metal film, mostly due to vaporization of the liquid coolant. Depending on the residual heat which it still has after the cooling operation, the metal film either remains isolated from the innermost metal layer applied beforehand, so that a strip coil develops, or melts with the metal layer so that a rotationally symmetrical composite body forms.

Abstract: A quench substrate for rapid solidification of molten alloy into strip has a microcrystalline or amorphous structure. The substrate is composed of a thermally conducting alloy and the structure is substantially homogeneous. The substrate is a thermal conducting material such as copper or a copper alloy, and has a constituent grain size uniformity greater than 1 .mu.m and less than 1,000 .mu.m in size.

Abstract: Apparatus and method of producing a thin metal ribbon by pouring a molten metal onto the surface of a quench roll rotating at a high speed so as to rapidly cool and solidify the metal to form the ribbon, separating the ribbon from the quench roll and conveying the same to a take-up device. A compressed gas is blown tangent to the quench roll to separate the ribbon from the quench roll. The separated ribbon is sucked and caught by a suction conveyor which runs at a velocity greater than the speed of production of the thin meal ribbon thereby imparting tension to the ribbon.

Abstract: The subject of the invention is a process for the continuous casting of very small-diameter wires directly from liquid metal, according to which said liquid metal is made to flow out of a heated and pressurized container made of refractory material, forming a jet of liquid. metal having a diameter equal to or slightly greater than that of the wire to be cast, and said jet is made to solidify by making it penetrate into a layer of moving cooling liquid deposited on the internal wall of a drum rotating about a horizontal axis, wherein said container is fed, continuously or intermittently, with solid metal without interrupting casting and wherein said solid metal is melted inside said container.The subject of the invention is also a device for the continuous casting of very small-diameter wires directly from liquid metal, allowing this process to be implemented.

Abstract: A continuous thin metal strip formed by quenching on a single quenching roll is separated from the quenching roll and conveyed along a fly path to a coiling system directly or via pinch rolls. The path along which the thin metal strip flies is stabilized by a jet of a fluid jetted from a slit and biased to flow along a convex curved surface, whereby the time until the strip is taken up or nipped by the pinch rolls is shortened.

Abstract: In producing a metal material having a single-phase texture of an amorphous phase, a supercooled liquid having an amorphous composition is first prepared in a melting manner within a large-diameter pipe portion of a quartz pipe. Then, the supercooled liquid is converted into another form by allowing it to flow into a small-diameter pipe portion. The form conversion causes the temperature of the supercooled liquid to rise, so that the temperature of the supercooled liquid is uniformalized by this temperature-increase effect, thereby inhibiting the production of non-uniform crystal nuclei. Thereafter, the quartz pipe with the supercooled liquid contained therein is placed into a water bath, where the supercooled liquid is cooled by water and solidified.

Abstract: A process and device for producing a wire (12) made of amorphous metal alloy having an iron base by producing a jet (7) of molten alloy (4) through the orifice (60) of a die (6), and introducing this jet (7) into a cooling liquid (9) urged by centrifugal force against the inner wall of a rotary drum. The crucible (2) containing the alloy (4) and the die (6) are made using different materials and are joined by a joint (25) the material of which differs from those of the crucible (2) and of the die (6). Furthermore, means (3) are employed for heating the alloy (4) both in the crucible (2) and in the die (6) and an inert or reducing gas is delivered directly in contact with the jet (7) as it leaves the die (6). Wire (12) obtained with this process or this device, this wire being employed, for example, for reinforcing pneumatic tires.

Abstract: Disclosed are an amorphous iron based alloy having excellent magnetic characteristics as well as bendability and a method of manufacturing the amorphous iron based alloy. The amorphous iron based alloy has a mean centerline Ra surface roughness of about 0.8 .mu.m or less and the formula Fe.sub.X B.sub.Y Si.sub.Z Mn.sub.a in approximate proportions wherein:75.ltoreq.X.ltoreq.82 at %7.ltoreq.Y.ltoreq.15 at %,7.ltoreq.Z.ltoreq.17 at %, and0.2.ltoreq.a.ltoreq.0.5 at %.The method of manufacturing the amorphous iron based alloy comprises quenching and solidifying a molten alloy having the formula Fe.sub.X B.sub.Y Si.sub.Z Mn.sub.a in approximate proportions wherein:75.ltoreq.X.ltoreq.82 at %7.ltoreq.Y.ltoreq.15 at %,7.ltoreq.Z.ltoreq.17 at %, and0.2.ltoreq.a.ltoreq.0.5 at %, andeffecting the quenching and solidifying steps in a Co.sub.2 atmosphere containing H.sub.2 in an amount of about 1-4% by volume.

Abstract: A method and apparatus for manufacturing a thin amorphous metal strip. Molten metal is injected onto a single cooling roll rotating at high speed. A gas flow impeding wall is disposed adjacent to the surface of a cooling roll and extends across the body of the cooling roll. The wall is located upstream of the molten metal injection nozzle. CO.sub.2 gas is jetted along one surface of the gas insulating wall which faces the molten metal injection nozzle and toward the surface of the cooling roll. An atmosphere rich in CO.sub.2 gas is maintained adjacent the roll surface just upstream of the molten metal injection nozzle.

Abstract: A master alloy for magnet production, which contains as main ingredients R representing at least one element selected from rare-earth elements including Y, T representing Fe or Fe and Co, and B, and includes columnar crystal grains substantially made up of R.sub.2 T.sub.14 B, and crystal grain boundaries composed primarily of R-enriched phases having an R content higher than that of R.sub.2 T.sub.14 B, said columnar crystal grains having a mean diameter lying in the range of 3 to 50 .mu.m. The master alloy is formed into a sintered magnet through pulverization, compacting and sintering steps. The dispersion of the R-enriched phases in the master alloy is so well-enough that the R-enriched phases can also be well dispersed in the resulting sintered magnet. In addition, the master alloy is so easily pulverized that the incorporation of oxygen at the time of pulverization can be reduced.

Abstract: An apparatus for melting and rapid solidification casting of metal alloys has a crucible for molding a metal charge. The crucible has side walls, a top and a bottom having an orifice therein. Collectively, the side walls, top and bottom define an interior of the crucible. A portion of the dimensions of the side walls of the side walls and bottom is divided by longitudinal slits into at least two segments. A nozzle is disposed partially within the crucible and extends through the orifice. The nozzle has a first end in communication with the interior of tune crucible. A second end of the nozzle has a nozzle orifice therein for defining a stream of molten metal alloy. A cooling mechanism cools the top, side walls and bottom of the crucible. The apparatus has mechanisms for inducing alternating electrical currents within the metal charge and within the nozzle, and for establishing and maintaining pressure within the interior of the crucible.

Abstract: A roll for use in a roll caster. The roll has a heat exchanger core and an outer generally cylindrical shell surrounding the core, the core and the shell defining an enclosed space. A working fluid is contained in the enclosed space. When molten metal is cast onto the shell, the working fluid in proximity to the outer shell changes from a liquid to a vapor. Due to the rotation of the roll, the liquid phase of the working fluid forces the vapor in proximity with the outer cylindrical shell to return to the area adjacent to the core. At this area, the vapor phase is condensed into a liquid which is then subsequently delivered radially to the outer cylindrical shell. In this way, the working fluid constantly changes from vapor to liquid and back to vapor again and acts to continuously remove heat from the molten metal cast onto the outer cylindrical shell. A single roll caster, a twin roll caster, and a melt spinning apparatus as well as an associated method are also disclosed.

Abstract: A method and device (1) for the continuous production of a thread (12) by extrusion of a molten material into a cooling liquid (9) applied by centrifuging against the inner wall (10) of a drum (11). The inner wall (10) of the drum (11) comprises a lateral surface (102) which progressively approaches the axis of rotation of the drum (11) in the direction towards the outside (E) of the drum (11). Means (23, 24) are used which make it possible to displace the thread (12) along said surface (102) so that the thread (12) emerges from the drum (11) under the action of the centrifugal force. Threads (12) obtained by this method and this device, these threads being, for instance, amorphous metal threads used to reinforce automobile tires.

Abstract: An alloy ingot for permanent magnet consists essentially of rare earth metal and iron and optionally boron. The two-component alloy ingot contains 90 vol % or more of crystals having a crystal grain size along a short axis of 0.1 to 100 .mu.m and that along a long axis of 0.1 to 100 .mu.m. The three-component alloy ingot contains 90 vol % or more of crystals having a crystal grain size along a short axis of 0.1 to 50 .mu.m and that along a long axis of 0.1 to 100 .mu.m. The alloy ingot is produced by solidifying the molten alloy uniformly at a cooling rate of 10.degree. to 1000.degree. C./sec. at a sub-cooling degree of 10.degree. to 500.degree. C. A permanent magnet and anisotropic powders are produced from the alloy ingot.

Abstract: According to the present invention, in the PFC (planar flow casting) method, He gas at room temperature is blown onto the surface of a cooling roll at a flow rate of 0.1 to 5 liters/min.multidot.cm.sup.2 through a He gas blow nozzle provided upstream of a molten alloy (a puddle) ejected through a molten alloy ejection nozzle onto the surface of the cooling roll at a distance from the ejection nozzle, the distance from the surface of the cooling roll and an angle of inclination of the nozzle within respectively specified ranges, thereby forming a He gas atmosphere around the puddle, and a thin strip is dragged out of said puddle. This enables a thin amorphous alloy strip having a very small thickness and a smooth surface free from significant uneven portions and pores to be easily produced at a low cost without use of any vessel for regulating the atmosphere or an apparatus for heating the blown gas.

Abstract: The method for forming rings of uniform thickness from an active brazing alloy by melt-spinning the liquid alloy has the following steps: The alloy is liquefied in a crucible having a lateral opening whose height is approximately equal to the width of the ring material; the liquid alloy is forced out of the crucible onto the side surface of a metal drum of high thermal conductivity at a radial distance from the drum center approximately equal to the ring diameter, said metal drum rotating at a high circumferential velocity at a distance from the crucible approximately equal to the ring thickness; after an,,,approximately quarter to three-quarter turn of the active brazing alloy solidified on the metal drum into ring material, the latter is lifted off the metal drum by a mechanical deflector or a gas stream blown onto it in a direction opposite to the direction of rotation of the metal drum, and guided past the crucible; the ring helix being formed is guided around a lateral, coaxial extension of the metal dru

Abstract: A method and apparatus for trimming edge scrap from continuously cast metal strip includes an edge trimming device in combination with a drag casting apparatus for producing aluminum or aluminum alloy cast strip. The edge trimming device includes a tool which marks the casting surface of the casting wheel to disruption the solidification rate during casting of the molten aluminum. Disruption of the solidification rate forms a longitudinal split in the strip being cast resulting in formation of a high quality cast strip product acceptable for further processing and edge trim scrap. The edge trim scrap may be recovered and recycled for further use. The edge trimming device includes adjustable features to permit varying the location of the longitudinal split along the width of the strip being cast in response to casting parameters such as excess gauge variation, surface defects or changing of the cast strip width prior to or during the continuous casting operation.

Abstract: A method is disclosed for producing an extremely thin soft magnetic alloy strip, in which a molten alloy is ejected through a nozzle onto the surface of a rotating cooling member and rapidly quenched. The length of the short side of the rectangular nozzle, the distance between the nozzle and the rotating cooling member, peripheral speed of the rotating cooling member, ejecting pressure of the molten alloy, and atmosphere pressure of ejecting are specified.

Abstract: A method for the electroslag refining of metal is provided. The method involves providing a refining vessel to contain an electroslag refining layer floating on a layer of molten refined metal. An ingot of unrefined metal is lowered into the vessel into contact with the molten electroslag layer. A refining current is passed through the slag layer to the ingot to cause surface melting at the interface between the ingot and the electroslag layer. As the ingot is surface melted at its point of contact with the slag, droplets of the unrefined metal are formed and these droplets pass down through the slag and are collected in a body of molten refined metal beneath the slag. The refined metal is held within a cold hearth. At the bottom of the cold hearth, a cold finger orifice is provided to permit the withdrawal of refined metal from the cold hearth apparatus. The refined metal passes from the cold finger orifice as a stream and is processed into a sound metal structure having desired grain structure.

Abstract: A method of producing amorphous alloy thin strip suitable for use in commercial frequency band transformers utilizes a high-quality molten steel suitable for electromagnetic silicon steel plates but containing insufficient silicon and boron. The molten steel is divided when tapped out of a converter or after a vacuum degasifying steel making process, and silicon and boron are added with heating to create the desired composition. The molten steel is formed into thin amorphous alloy strip by quenching.

Abstract: A melt of Nd-Fe-B alloy is injected in an inert gas atmosphere through a nozzle against a chill roll or a pair of chill rolls rotating relative to the nozzle for contacting the melt with the circumference of the chill roll or rolls, thereby quenching the melt. The chill roll has a low heat conductivity surface layer around a base or has a predetermined surface roughness on its circumference. The contact time of the melt with the chill roll can be increased by blowing an inert gas flow. Further the melt is quenched in an inert gas atmosphere of up to 1 Torr. A wind shield is disposed in proximity to the chill roll circumference for preventing a wind of the ambient gas induced by rotation of the chill roll from reaching a paddle of the melt. With these means, there is obtained a permanent magnet material having a grain diameter with a reduced variation.

Abstract: An iron base amorphous alloy strip having a sheet thickness of from 50 to 150 .mu.m and a sheet width of at least 20 mm. The strip is produced by a single-roll cooling process and has a fracture strain of 0.01 or more.

Abstract: Silicon wafers useful in solar cells or wafers of metal are produced by a process for producing wafers of predetermined dimensions by the sheet drawing process in which a melt of the wafer material is crystallized on a substrate wherein the substrate surface is modified by changing the wetting behavior of the substrate toward the melt.

Abstract: A process for improving the surface condition and thickness regularity of a thin metal strip cast on a rotating wheel by injection of a molten metal having a free surface forming a meniscus in contact with the wheel. The process comprises detecting undulations or variations in thickness of the strip of at least 10 .mu.m, forming a gas cushion above the free surface utilizing a porous body disposed facing the free surface, and adjusting the pressure of the gas cushion, the location of the porous body or both to control the variations or undulations.

Abstract: A molten metal gas-atomizing spray-depositing apparatus has an atomizer which employs a pressurized gas flow for atomizing a stream of molten metal into a spray pattern of metal particles being initially hotter than the solidus temperature of the metal. The apparatus also has a substrate system which includes an outer substrate of metallic foil and an inner substrate for supporting the outer substrate. The outer foil substrate is movable relative to the metal particles in the spray pattern thereof and disposed below the atomizer for receiving on a surface of the foil a deposit of the particles in the spray pattern to form a product on the outer foil substrate. The outer foil substrate is of a thickness which is less than a predefined maximum thickness at which the capacity of the foil to absorb heat from the deposit is equal to the latent heat and super heat, if present, of the deposit.

Abstract: An apparatus and method for forming round wire from non-round wire has: a heat extracting drum having a semi-circular channel formed in and entirely around its outer circumferential surface; a feed device for directing a precursor wire into the channel; and a heater for melting the precursor wire in the channel. The wire is typically flat and is stood up on edge, perpendicular to the surface of the drum, melted with the heater, solidified and removed. The surface tension and wetting characteristics of the liquid metal cause it to "bead up", forming a near round wire when solidified.

Abstract: A gaseous atmosphere having a predetermined composition is formed near an injected molten metal flow and an injection nozzle of the atmospheric gas so as to manufacture a thin metal strip exhibiting excellent surface property. A thin strip manufacturing apparatus includes an injection nozzle 1 for injecting a molten metal onto a cooling roll 2, an atmospheric gas injection nozzle 3 for injecting an atmosphere having a predetermined composition, a sensor 5 for measuring the concentration of the atmospheric gas, a control device 6 for adjusting a flow rate of the atmospheric gas on the basis of the output of the sensor 5, a cover 4 for maintaining the concentration of the atmospheric gas, and a heating device for preventing cooling of the injection nozzle 1.

Abstract: Bulk rapidly solidified magnetic materials having a density of greater than 90%, a thickness of at least 250 microns, and preferably a low oxygen content, are produced by a liquid dynamic compaction process which, depending upon the chosen operating conditions, can yield materials ranging from crystalline to partially crystalline to amorphous. The materials so produced are directly useful, i.e. without having to be reduced to a powder and consolidated into a shape, to produce permanent magnets.

Abstract: Soft magnetic alloy comprising Fe, a vitrifying element (Si and B), and Cu, and containing a crystalline phase shows a low magnetic permeability of up to 3,000 at 100 kHz. Magnetic cores formed therefrom have low permeability, a wide unsaturation region, and iso.permeability without forming a gap and find application in choke coils and transformers.

Abstract: A method of guiding and transferring a rapidly quenched metallic tape includes steps of peeling the rapidly quenched metallic tape produced by solidification through rapid quenching on a circumferential surface of a single cooling roll rotating at a high speed, introducing the metallic tape into a cylindrical transfer guide to a pinch roll unit arranged at a terminal end of the transfer guide to catch the metallic tape by the pinch roll unit, and moving the pinch roll unit to a winder for the metal tape. The metallic tape is fed in the transfer guide substantially without being in contact with the transfer guide.

Abstract: The hard magnetic properties, including intrinsic coercivity, remanence and energy product of rapidly quenched, rare earth-transition metal alloys has been substantially increased by the addition of suitable amounts of the element boron. The preferred rare earth constituent elements are neodymium and praseodymium, and the preferred transition metal element is iron.

Abstract: Magnetically hard compositions having high values of coercivity, remanence and energy product contain rare earth elements, transition metal elements and boron in suitable proportions. The preferred rare earth elements are neodymium and praseodymium, and the preferred transition metal element is iron. The magnetic alloys have characteristic very finely crystalline microstructures.

Abstract: An Fe-base soft magnetic alloy having the composition represented by the general formula:(Fe.sub.1-a M.sub.a).sub.100-x-y-z-.alpha.-.beta.-.gamma. Cu.sub.x Si.sub.y B.sub.z M'.sub..alpha. M".sub..beta. X.sub..gamma.wherein M is Co and/or Ni, M' is at least one element selected from the group consisting of Nb, W, Ta, Zr, Hf, Ti and Mo, M" is at least one element selected from the group consisting of V, Cr, Mn, Al, elements in the platinum group, Sc, Y, rare earth elements, Au, Zn, Sn and Re, X is at least one element selected from the group consisting of C, Ge, P, Ga, Sb, In, Be and As, and a, x, y, z, .alpha., .beta. and .gamma. respectively satisfy 0.ltoreq.a.ltoreq.0.5, 0.1.ltoreq.x.ltoreq.3, 0.ltoreq.y.ltoreq.30, 0.ltoreq.z.ltoreq.25, 5.ltoreq.y+z.ltoreq.30, 0.1.ltoreq..alpha..ltoreq.30, .beta..ltoreq.10 and .gamma..ltoreq.10, at least 50% of the alloy structure being fine crystalline particles having an average particle size 1000 .ANG. or less.

Abstract: The invention relates to a method for starting a device for the continuous casting of molten metal, particularly steel, on a cooled roll (1) rotating about its horizontal axis. An adjacent container (4) contains the metal to be cast and has a front wall (5) whose free upper edge (11) is lowered in order to permit the exit of the metal to be cast, and which is swept by the cooled surface of the roll (1). According to the invention, casting is started with a relatively large lead angle (A) and, when casting has started, the container is displaced by pivoting about a horizontal axis, which can be the axis of rotation of the roll, so as to reduce the lead angle in order to arrive at a nominal working position (4') in which the container is held stationary.

Abstract: Disclosed is a method for forming a high magnetic parameter ferromagnetic material. The material has a distribution of magnetic parameters as solidified, and is separated into a first fraction having relatively high magnetic parameters and a second fraction having relatively low magnetic parameters. The method comprises applying a magnetic field to the materials, the magnetic field being high enough to magnetize the low magnetic parameter fraction, but low enough to avoid substantially magnetization of the high parameter fraction. Thereafter the fractions of material are magnetically separated.

Abstract: Spray cast alloys having reduced porosity and increased ductility are provided as well as a process for the manufacture of the alloys. An effective amount of a reactive metal which reacts with the spray casting atmosphere but not with the desired alloy is dissolved into the alloy prior to spray casting. Preferred reactive metals readily form a nitride which is finely dispersed throughout the spray cast alloy.

Abstract: An apparatus and method for monitoring and maintaining a predetermined width in the gap between a casting nozzle and a casting wheel, wherein the gap is monitored by means of at least one pneumatic gap sensor. The pneumatic gap sensor is mounted on the casting nozzle in proximity to the casting surface and is connected by means of a tube to a regulator and a transducer. The regulator provides a flow of gas through a restictor to the pneumatic gap sensor, and the transducer translates the changes in the gas pressure caused by the proximity of the casting wheel to the pneumatic gap sensor outlet into a signal intelligible to a control device. The relative positions of the casting nozzle and casting wheel can thereby be selectively adjusted to continually maintain a predetermined distance between their adjacent surfaces. The apparatus and method enables accurate monitoring of the actual casting gap in a simple and reliable manner resistant to the extreme temperatures and otherwise hostile casting environment.

Abstract: In continuously casting thin metal products such as sheets or strips, molten metal is introduced into the gap between a rotating cooled main cylinder and a counterrotating roller spaced from the cylinder to form a gap corresponding to the thickness of the desired product. The metal, in cooling, forms solidifying skins on the respective rollers. The peripheral speed of the roller exceeds that of the cylinder by 2 to 20%. The resulting product is substantially free of the surface defects characteristic of prior art processes.

Abstract: A process for applying a metal coating 11 to a metal strip substrate 2 by preheating the casting surface in a non-oxidizing atmosphere and maintaining a casting surface temperature T.sub.s below the solidus temperature of the metal coating material, passing the casting surface through a melt pool 9 of the metal coating material at a pool temperature at least 25.degree. C. in excess of its melting temperature to deposit a melt layer 21 at a casting temperature T.sub.c, and simultaneously rapidly cooling the metal strip substrate from the back surface to solidify the melt layer to an adherent solid coating, wherein the surface temperature T.sub.s is less than about 20 percent (in .degree.K.) below the casting temperature T.sub.c.The process is particularly useful when coating metal strip with an alloy of limited solubility metals.

Abstract: The pool to be filamented is liquefied by heating in a crucible. A disk having an edge immersed in the molten pool rotates at high velocity and drives the pool outwards in the form of a ribbon which breaks up into pieces forming the required particles. The portion of the pool in contact with the disk is constantly replenished and, owing to the use of heating means, has sufficient fluidity to satisfy the conditions for extraction, the molten pool being continuously moved horizontally with respect to the disk.

Abstract: Casting nozzles will provide improved flow conditions with the parameters controlled according to the present invention. The gap relationships between the nozzle slot and exit orifice must be controlled in combination with converging exit passageway to provide a smooth flow without shearing and turbulence in the stream. The nozzle lips are also rounded to improve flow and increase refractory life of the lips of the nozzle. The tundish walls are tapered to provide improve flow for supplying the melt to the nozzle. The nozzle is located about 45.degree. below top dead center for optimum conditions.

Abstract: The continuous casting of metal strip using the melt overflow process is improved by controlling the weir conditions in the nozzle to provide a more uniform flow of molten metal across the width of the nozzle and reducing the tendency for freezing of metal along the interface with refractory surfaces. A weir design having a sloped rear wall and tapered sidewalls and critical gap controls beneath the weir has resulted in the drastic reduction in edge tearing and a significant improvement in strip uniformity. The floor of the container vessel is preferably sloped and the gap between the nozzle and the rotating substrate is critically controlled. The resulting flow patterns observed with the improved casting process have reduced thermal gradients in the bath, contained surface slag and eliminated undesirable solidification near the discharge area by increasing the flow rates at those points.

Abstract: The present invention is directed to an improved process and apparatus for strip casting. The combination of a planar flow casting nozzle positioned back from the top dead center position with an attached nozzle extension, provides an increased level of casting control and quality. The nozzle extension provides a means of containing the molten pool above the rotating substrate to increase the control of molten metal at the edges of the strip and increase the range of coating thicknesses which may be produced. The level of molten metal in the containment means is regulated to be above the level of melt supplying the casting nozzle which produces a condition of planar drag flow with the casting substrate prior to solidification.

Abstract: The present invention provides a method of making a sheet material adapted to make bonded electrical connections to an array of closely-spaced conductive terminal pads. The method comprises the steps of providing a thin, flexible, insulating substrate, and squirting a plurality of fine molten strands onto the substrate to form metal strands. The metal strands individually have a cross-section with an area of about 100 to 100,000 .mu.m.sup.2 and the cross-section having a flat section and an arcuate portion. An adhesive or conductive adhesive may be coated over the metal strands, or the adhesive may be provided on the substrate and the conductors imbedded into the adhesive by pressure or heat-sinking the conductors into the adhesive layer.

Abstract: Magnetically hard compositions having high values of coercivity, remanence and energy product contain rare earth elements, transition metal elements and boron in suitable proportions. The preferred rare earth elements are neodymium and praseodymium, and the preferred transition metal element is iron. The magnetic alloys have characteristic very finely crystalline microstructures.

Abstract: A magnetic material melt is solidified by cooling the material from two opposing surfaces while deforming the material by applying compressive pressure to the two opposing surfaces. Twin roller quenching is a preferred method for producing the flakes. The flakes exhibit strong texture normal to their surface, that is, there is a high degree of alignment of the magnetically easy axes of the crystals within the polycrystalline flake. The strong crystal orientation appears to result both from directional solidification in a thermal gradient and uniaxial deformation of the solid phase in the twin rollers. Magnetization studies on individual flakes show intrinsic coercivities of 14 kOe and a nearly 50% higher remanance for field normal to the flake surface than in the flake plane. Splat quenching is another suitable technique for carrying out the invention.

Abstract: The present invention concerns a process for producing a grain-oriented electrical steel sheet by means of a rapid quench-solidification process, for example, a continuous casting by a twin roll strip caster. The feature of the present invention resides in quenching to solidify molten steels into a thin cast sheet of 0.7 to 3.0 mm thickness, at a cooling rate of greater than 50.degree. C./sec. in the central portion along the direction of thickness of the thin cast sheet, cooling the sheet at a cooling rate of greater than 10.degree. C./sec. in a temperature range between 1300.degree. to 900.degree. C. and then applying cold rolling for once or twice or more annealing the thin cast steel for a period between 30 seconds and 30 minutes in a temperature range between 950.degree. and 1,200.degree. C. and subsequently including intermediate annealing under a final cold rolling reduction rate of not less than 80%.

Abstract: An apparatus and method for casting metal strip include a moving chill body that has a quench surface. A nozzle mechanism deposits a stream of molten metal on a quenching region of the quench surface to form the strip. The nozzle mechanism has an exit portion with a nozzle orifice. A depletion mechanism supplies a reducing gas to a depletion region located adjacent to and upstream from the quenching region. The reducing gas reacts exothermically to lower the density provide a low density reducing atmosphere within the depletion and substantially prevent formation of gas pockets in the strip.

Abstract: A method of preparing alloy of a transition metal and lanthanide comprising the steps of alloying a transition metal, boron, at least one lower-weight lanthanide having none or few stable compounds with iron, optionally one or more higher-weight lanthanides, a glass former, and optionally the pseudo lanthanide, yttrium; forming an amorphous or nearly amorphous metastable microstructure in the alloy; and heating the amorphous alloy to form a polycrystalline, multiphase, fine-grain single-domain structure.