Utilizing Continuously Advancing Surface Patents (Class 164/463)
  • Patent number: 4782884
    Abstract: A number of individual silicon carbide filaments are assembled to form a tape. The tape is passed across a drum in a low pressure plasma deposition apparatus where the surface of the drum is formed of a polished and cooled refractory metal. The tape is sprayed with a plasma spray of the titanium base alloy metal to form a sheet of such metal on the tape and on the surface of the drum. The deposited sheet including the silicon carbide reinforcement tape is removed from the drum surface by peeling. The peeled product is a composite of titanium base sheet metal which is impregnated with the filaments of silicon carbide, i.e. a metal impregnated tape.
    Type: Grant
    Filed: February 4, 1987
    Date of Patent: November 8, 1988
    Assignee: General Electric Company
    Inventor: Paul A. Siemers
  • Patent number: 4771820
    Abstract: Strip casting apparatus including a molten-metal-holding container and a nozzle to deposit molten metal onto a moving chill drum to directly cast continuous metallic strip. The nozzle body includes a slot bounded between a back and a front lip. The slot width exceeds about 20 times the gap distance between the nozzle and the chill drum surface. Preferably, the slot width exceeds 0.5 inch. This method of strip casting minimizes pressure drop, insuring better metal-to-chill-drum contact which promotes heat transfer and results in a better quality metallic strip.
    Type: Grant
    Filed: November 30, 1987
    Date of Patent: September 20, 1988
    Assignee: Westinghouse Electric Corp.
    Inventors: Robert S. Williams, Donald F. Baker
  • Patent number: 4770738
    Abstract: A method of preparing a thin film of a semiconductor material on a substrate, in which charged microdroplets of the semiconductor material or a constituent thereof are generated by electrohydrodynamic (EHD) extraction of the droplets from a meniscus forced at an elongate tip of a nozzle containing the material in a molten state, the EHD extraction occurring under the influcence of a high electric field produced by an extractor electrode adjacent the tip of the nozzle. The microdroplets are then accelerated away from the elongate tip of the nozzle to form a two-dimensional ribbon-like beam or blanket of the charged microdroplets. The two-dimensional beam is directed onto the trailing edge of a target carried on a moving substrate such that a film of the semiconductor material is formed on the substrate by deposition of the microdroplets on the trailing edge of the moving target.
    Type: Grant
    Filed: October 14, 1986
    Date of Patent: September 13, 1988
    Assignee: The BOC Group plc
    Inventor: Jean J. A. Robillard
  • Patent number: 4768458
    Abstract: A method of manufacturing an amorphous metal sheet or ribbon which comprises extruding a molten metal from an orifice of a nozzle and directing the extruded molten metal onto a moving chill surface to rapidly cool and solidify the metal thereby forming said sheet or ribbon; said orifice being a rectangular slit defined by side walls and a front lip and a back lip arranged in front and behind the slit in the direction of movement of the chill surface below said nozzle; said chill surface moving a speed of 10 m/sec to 50 m/sec and being spaced from the front lip by a gap length of from 100 .mu.m to 600 .mu.m and the width W.sub.F of the front lip measured in the direction of movement of the chill surface being represented by the relationship W.sub.F .ltoreq.W, wherein W represent the width the slot in the nozzle.
    Type: Grant
    Filed: October 15, 1987
    Date of Patent: September 6, 1988
    Assignee: Hitachi, Metals Inc.
    Inventors: Shunsuke Arakawa, Yoshizo Sawada
  • Patent number: 4766947
    Abstract: A method and apparatus for producing a rapidly solidified microcrystalline metallic tape. The method provides for molten metal to be continuously poured through a nozzle onto surfaces of cooling members to form a rapidly solidified metallic tape and then coiling the tape on a reel. According to this method, the metallic tape is secondarily cooled and rolled before the coiling. The apparatus includes a device for cutting out a non-steadly portion of the metallic tape, a device for measuring tape thickness, a secondary cooling member, and a device for controlling the tension of the metallic tape.
    Type: Grant
    Filed: January 30, 1987
    Date of Patent: August 30, 1988
    Assignee: Kawasaki Steel Corporation
    Inventors: Kiyoshi Shibuya, Fumio Kogiku, Michiharu Ozawa
  • Patent number: 4763718
    Abstract: Net shape or near net shape metal rod or wire 3 is rapidly solidified. Molten metal 7 is delivered to a semi-cylindrical casting channel 2 in a chill block 1 from a tundish 4 through a critically-designed metering system comprising a drain 6, an orifice formed of the casting channel 2 and a complementary volume control channel 5, and a barrier 8 which directs molten metal to the volume-control orifice.
    Type: Grant
    Filed: March 20, 1986
    Date of Patent: August 16, 1988
    Assignee: Battelle Development Corporation
    Inventor: Robert E. Maringer
  • Patent number: 4762653
    Abstract: The invention relates to the preparation of especially metallic or semi-metallic bands or sheets, particularly with a microcrystalline or amorphous structure.According to this process, an electrically conductive molten material is made to flow from a tank through a nozzle, to form a strip of substantially rectangular cross-section, which is subsequently solidified. According to the invention, the form of the strip of liquid material is stabilized, after it has been shaped and before solidification, as a result of a mechanical surface effect induced by an alternating magnetic field.
    Type: Grant
    Filed: October 30, 1986
    Date of Patent: August 9, 1988
    Assignee: Union Siderurgique du nord et de l'Est de la France (USINOR)
    Inventors: Claude Senillou, Remy de Framond, Marcel Garnier, Ali R. Yavari, Jean-Charles Joud
  • Patent number: 4756788
    Abstract: The present invention provides a method and apparatus for taking up and winding a strip of material which is advancing at a selected velocity from a moving casting surface. Generally stated, the apparatus includes a take-up web supply mechanism for supplying a flexible, take-up web, and a winding mechanism, which has a reel for taking up and concentrically winding the strip and take-up web thereon in a laminated configuration. A connection mechanism connects the take-up web to the reel, and a reel drive mechanism rotates the reel to provide a peripheral velocity at a winding surface on the reel that substantially matches the velocity of the advancing strip. A directing mechanism directs the advancing strip onto the take-up web for transport to a winder nip region between the take-up web and the winding surface of the reel means to initiate winding.
    Type: Grant
    Filed: November 12, 1986
    Date of Patent: July 12, 1988
    Assignee: Allied-Signal Inc.
    Inventors: John R. Bedell, Naim S. Hemmat, Paul Jeges
  • Patent number: 4754804
    Abstract: A rapidly solidified metallic tape is produced by continuously pouring molten metal into a casting space defined among a pair of cooling members and a pair of keep members each disposed close to side edge faces of the cooling rolls to rapidly solidify it. In this method, a solidification shell of molten metal produced on the keep member is continuously moved in a direction opposite to the pouring direction to eliminate to exterior from the system. In the apparatus for practicing the method, the keep member comprises a fixed side plate, a side roll rotatably arranged along a guide groove formed in the central and lower portion of the side plate, a driving means for the rotation of the side roll in a direction opposite to the pouring direction and a means for removing solidification shell from the surface of the side plate.
    Type: Grant
    Filed: October 13, 1987
    Date of Patent: July 5, 1988
    Assignee: Kawasaki Steel Corporation
    Inventors: Masao Yukumoto, Michiharu Ozawa
  • Patent number: 4751957
    Abstract: An improved melt drag metal strip casting apparatus and process in which molten metal is delivered from a supply thereof into contact with a cooled casting surface driven at a predetermined linear rate to quench and withdraw a continuous strip of metal from the molten metal supply. An air knife is employed to direct an elongated narrow jet of gas into contact with the top surface of the strip and with the molten metal supply as the strip is withdrawn to impart the desired shape and finish to the top surface of the strip and to control the amount of liquid metal adhering to the top surface as it is withdrawn to thereby control the thickness of the strip.
    Type: Grant
    Filed: March 11, 1986
    Date of Patent: June 21, 1988
    Assignee: National Aluminum Corporation
    Inventor: Charles F. Vaught
  • Patent number: 4749024
    Abstract: Metal strip 3 may be cast directly from molten metal in an open tundish 2 onto a chill roll 1. Strip thickness is controlled by contouring the tundish lip 14 with an offset 10 near the casting wheel. This can be used remedially to offset the natural tendency for the strip to be thicker near the edges, which is undesirable for cold rolling, or it may be used creatively to produce contoured strip.
    Type: Grant
    Filed: September 28, 1987
    Date of Patent: June 7, 1988
    Assignee: Battelle Development Corporation
    Inventors: Edwin S. Bartlett, Richard A. Wood
  • Patent number: 4743317
    Abstract: The invention provides an aluminum based alloy consisting essentially of the formula Al.sub.bal Fe.sub.a X.sub.b, wherein X is at least one element selected from the group consisting of Zn, Co, Ni, Cr, Mo, V, Zr, Ti, Y, Si and Ce, "a" ranges from about 7-15 wt %, "b" ranges from about 1.5-10 wt % and the balance is aluminum. The alloy has a predominately microeutectic microstructure.The invention also provides a method and apparatus for forming rapidly solidified metal, such as the metal alloys of the invention, within an ambient atmosphere. Generally stated, the apparatus includes a moving casting surface which has a quenching region for solidifying molten metal thereon. A reservoir holds molten metal and has orifice means for depositing a stream of molten metal onto the casting surface quenching region. A heating mechanism heats the molten metal contained within the reservoir, and a gas source provides a non-reactive gas atmosphere at the quenching region to minimize oxidation of the deposited metal.
    Type: Grant
    Filed: July 19, 1984
    Date of Patent: May 10, 1988
    Assignee: Allied Corporation
    Inventors: David J. Skinner, Paul A. Chipko, Kenji Okazaki
  • Patent number: 4735252
    Abstract: An apparatus for manufacturing solidified metallic forms from levitated molten metal including a levitation conduit having an interior surface for accommodating the metal to be levitated, and a device for introducing the metal to the levitation conduit. Induction coils induce a moving magnetic field in the levitation conduit to levitate the metal upwardly through the conduit, and to maintain the outer surface of the levitated metal while molten out of pressured contact with the interior surface of the levitation conduit. The molten metal output is provided to a chamber in which a device re-forms the molten metal output and solidifies it.
    Type: Grant
    Filed: January 16, 1986
    Date of Patent: April 5, 1988
    Assignee: Nuclear Metals, Inc.
    Inventor: Peter R. Roberts
  • Patent number: 4725962
    Abstract: A method and apparatus for maintaining a constant ejection pressure in a melt spinning process for converting a molten metal into a metal foil of a uniform thickness. The backpressure exerted against inert gas being injected into the bottom of a crucible containing molten metal is monitored. Any negative rate change in the backpressure is noted and the gas overpressure in the crucible is then increased to return the back-pressure to its original value. In another embodiment the gas flow rate of the inert gas is monitored. Any positive rate change in the flow rate is noted and the gas overpressure is then increased to return the flow rate of the gas back to normal. This maintains a constant ejection pressure of molten metal passing through the orifice of the crucible producing foil with a uniform thickness.
    Type: Grant
    Filed: April 17, 1986
    Date of Patent: February 16, 1988
    Assignee: GTE Laboratories Incorporated
    Inventors: Shih-Chen Hsu, Ralph P. Adler
  • Patent number: 4721154
    Abstract: During the melt spinning process for producing metal foils having an amorphous structure, molten metal is cast through a slot-like nozzle onto a surface or wall which is rapidly moved past the nozzle. A particularly rapid quenching and cooling rate of the solidifying melt is achieved by providing cooling support elements which are supplied with a cooling pressure medium, on one side of the moved surface or wall and which aide is located opposite to or remote from the nozzle. Advantageously, the surface or wall is constructed as a thin-walled cylindrical shell or tube which is elastically deformable to some extent. In its shell interior, there are provided a number of rows of cooling support elements which may be controlled by thickness sensors and temperature profile sensors. There is thus rendered possible, the continuous production of amorphous metal foils.
    Type: Grant
    Filed: March 11, 1987
    Date of Patent: January 26, 1988
    Assignee: Sulzer-Escher Wyss AG
    Inventors: Alfred Christ, Rolf Lehmann, Hans-Wlater Schlaepfer
  • Patent number: 4719963
    Abstract: The invention relates to a process and apparatus for the casting of metal strands, more particularly in the form of strips. The molten metal emerging from a slotted die 2 is applied to the cooling surface of a cooling member 1 which is moved past the slotted die 2. Allowing for the law of solidification, at the start of casting the strip outlet side die lip is gradually increased from a minimum distance from the cooling surface to the required final distance in such a way that the free gap between the wedge-shaped developing solidification front of the cast strip 7 and the die lip 5 remains small enough to prevent the molten metal from flowing out through the gap in an uncontrolled manner. The end face edge of the slotted die 2 can be borne via one or more gas cushions on the cooling surface and the free surface of the cast strand.
    Type: Grant
    Filed: June 12, 1986
    Date of Patent: January 19, 1988
    Assignee: Sundwiger Eisenhutte Maschinenfabrik Grah & Co.
    Inventors: Horst Schenk, Peter Dziura
  • Patent number: 4719964
    Abstract: In the method for producing a round metal wire from a melt by using a cooling substrate, the cooling substrate is provided with a groove and melt streams are ejected toward the groove and successively impinge upon a wire while it is in an unsolidified state.
    Type: Grant
    Filed: November 29, 1984
    Date of Patent: January 19, 1988
    Assignee: Nippon Steel Corporation
    Inventors: Takashi Sato, Tsutomu Ozawa, Toshio Yamada
  • Patent number: 4719962
    Abstract: The metal substrate (4) is covered with a coating (6) consisting of another metal or alloy having a thickness of 4 to 50 .mu.m, by deposition of molten metal or alloy (5) through a nozzle (2), this melting point [sic] being lower than that of the substrate metal. This coating comprises, at the interface with the substrate, a layer of intermetallic compound with a thickness of between 0.5 and 4 .mu.m not exceeding 40% of the total thickness, the remainder consisting of the initial metal or alloy used for the coating, in a proportion of between 97% and 99.5% by weight.
    Type: Grant
    Filed: November 3, 1986
    Date of Patent: January 19, 1988
    Assignee: Battelle Memorial Institute
    Inventors: Georges Haour, Dag F. Richter, Peter Boswell, Willy Wagnieres
  • Patent number: 4715428
    Abstract: A method is provided for directly casting molten metal from a U-shaped structure of the exit end of a casting vessel onto a moving casting surface to form a continuous strip of crystalline material. The method includes radiantly cooling the molten metal in a zone defined above the molten metal, across the width of the U-shaped structure and adjacent the casting surface. The method also includes providing a non-oxidizing atmosphere in the zone.
    Type: Grant
    Filed: June 18, 1986
    Date of Patent: December 29, 1987
    Assignee: Allegheny Ludlum Corporation
    Inventors: Robert H. Johns, John D. Nauman
  • Patent number: 4715905
    Abstract: Fe alloy containing Si more than 4.0 wt % is produced by a thin plate casting process. The producing condition depends upon rapid solidification of Fe alloy from a molten condition at cooling rate of more than 1.degree. C./sen to less than 10.sup.5 .degree. C./sec.The obtained thin cast plates are subjected to a hot rolling of more than 30% at the temperature range of 600.degree. to 800.degree. C., and to the cold rolling to a determined thickness, followed pickling. By the above mentioned conditions, operations of the industrial scale may be practiced without cracks on the surface in the cold rolling excellent magnetic characteristics may be provided by passing the annealing after the cold rolling.
    Type: Grant
    Filed: February 10, 1986
    Date of Patent: December 29, 1987
    Assignee: Nippon Kokan Kabushiki Kaisha
    Inventors: Kazuhide Nakaoka, Yoshikazu Takada, Junichi Inagaki, Akira Hiura
  • Patent number: 4712603
    Abstract: A nickel based high melting point, homogeneous, ductile brazing foil composition consists essentially of about 17 to 20 atom percent chromium, about 4 to 10 atom percent boron, about 10 to 16 atom percent silicon, the balance being nickel and incidental impurities. The composition is such that the total of nickel and chromium ranges from about 74 to 84 atom percent.
    Type: Grant
    Filed: November 17, 1986
    Date of Patent: December 15, 1987
    Assignee: Allied Corporation
    Inventors: Debasis Bose, Alfred Freilich
  • Patent number: 4709743
    Abstract: In casting thin metal strip or foil by dynamic casting in which molten metal is teemed from a crucible 13 onto a moving belt or wheel, the invention provides an outlet orifice control assembly arranged to define a slot of controlled width through which the metal flows from the crucible outlet 20. The assembly comprises opposed shut-off plates 28,29 extending between edge strips 26,27, and underlying these are opposed slot plates 32,33 extending between second edge strips 30,31 with opposed support strips 34,35 extending beneath the strips 30,31 and supporting the edges of the slot plates 32,33. The sets of plates are aligned and arranged so that one plate 29 and 33 is movable relative to the other respective plate 28 and 32 between closed and open positions for controlled flow of metal through a sized slot defined between the slot plates 32,33.
    Type: Grant
    Filed: January 15, 1987
    Date of Patent: December 1, 1987
    Assignees: Inco Enginered Products Ltd., The General Electric Company plc
    Inventors: Anthony G. Law, Michael J. Fleetwood
  • Patent number: 4708194
    Abstract: The present invention discloses an improved rapid solidification casting system which employs one or more metal conditioning brushes. The casting surface is cleaned by the brushes and the pressure on the brushes is adjusted so as to deposit a layer of the brush metal onto the casting surface, the casting surface so conditioned increases the quality of the resulting cast material.
    Type: Grant
    Filed: July 27, 1981
    Date of Patent: November 24, 1987
    Assignee: Allied Corporation
    Inventor: Walter R. Mohn
  • Patent number: 4705095
    Abstract: An improved heat extracting chill block roll and method for use in the continuous casting of ribbon-like metal sheet directly from the melt by means of rapid solidification techniques. The resulting product is considerably thicker and more uniform than previously possible by such techniques. A textured chill surface is formed on the roll by multi-sided protrusions having intermediate valleys between the protrusions. This provides a plurality of discontinuous surfaces on the sides of the protrusions. The preferred surface texture is that formed by a conventional knurling tool.
    Type: Grant
    Filed: January 9, 1986
    Date of Patent: November 10, 1987
    Assignee: Ribbon Technology Corporation
    Inventor: Thomas A. Gaspar
  • Patent number: 4703550
    Abstract: A torque sensor has a magnetic foil which is wound and attached to a rotating shaft in strip form at an angle to the shaft axis of rotation, the magnetic strip being mechanically stressed dependent upon the torque acting on the shaft, and generating voltages in two secondary windings surrounding the magnetic strips. The voltages will be different due to different forces acting on the two strips, this being a measure of the torque acting on the shaft. The strips are formed from stamped segments cut obliquely from an amorphous tape which is cast with a profiled cross-machine cross section having regions of varying thickness. Such a tape can be manufactured using a nozzle having a correspondingly shaped orifice opening through which molten amorphous alloy is discharged onto a moving cooling surface.
    Type: Grant
    Filed: March 10, 1986
    Date of Patent: November 3, 1987
    Assignee: Vacuumschmelze GmbH
    Inventors: Hans-Rainer Hilzinger, Hans-Joachim Nilius, Michael Friedrichs
  • Patent number: 4702302
    Abstract: A method of making Ag, Au or Cu thin alloy wire comprises a first step of melting alloy containing Be with 0.001 through 1% by weight, a second step of jetting the melted alloy into a thin wire configuration through a small opening and a third step of curing the jetted alloy of a wire configuration in a fluid so that a thin alloy wire having about 0.01 through 0.2 mm diameter with simple processes and high yield.
    Type: Grant
    Filed: August 20, 1986
    Date of Patent: October 27, 1987
    Assignee: Sumitomo Electric Industries Ltd.
    Inventor: Kazuo Sawada
  • Patent number: 4678720
    Abstract: A silver-copper-titanium brazing alloy foil was produced by a rapid solidification processing method(s). The composition ranged from 10 to 50 weight percent copper, 0.1 to 9.5 weight percent titanium and the balance silver. Since the method provides high cooling rates, at least 10000.degree. C. per second, unique alloy structures and properties were obtained. This resulting foil can be used in the as cast form, it can be rolled down to a thinner dimension having also a more uniform surface finish, or it can be punched into preforms.
    Type: Grant
    Filed: August 11, 1986
    Date of Patent: July 7, 1987
    Assignee: GTE Laboratories Incorporated
    Inventors: Shih C. Hsu, Ramas V. Raman
  • Patent number: 4678719
    Abstract: A method is provided for directly casting molten metal from of the exit end of a casting vessel onto a moving casting surface to form a continuous strip of crystalline metal. The surface tension of the molten metal flowing from the exit forms the top, edge and bottom surfaces of the strip being cast to provide good strip surface quality, edges and structure. An apparatus is also provided including a casting vessel having a molten metal receiving end and an exit end from which a fully developed uniform flow of molten metal leaves through a U-shaped structure onto a moving casting surface. A direct cast strip product is also provided.
    Type: Grant
    Filed: June 18, 1986
    Date of Patent: July 7, 1987
    Assignee: Allegheny Ludlum Corporation
    Inventors: Robert H. Johns, John D. Nauman
  • Patent number: 4676298
    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 low density atmosphere to a depletion region located adjacent to and upstream of the quenching region. The quench surface is heated to a temperature that substantially prevents precipitation of condensed or solidified constituents from the low density atmosphere onto the depletion region.
    Type: Grant
    Filed: September 30, 1985
    Date of Patent: June 30, 1987
    Assignee: Allied Corporation
    Inventor: Howard H. Liebermann
  • Patent number: 4670096
    Abstract: In the production of a semi-conductor foil by solidification of a liquid semi-conductor on a horizontal support, the improvement which comprises positioning a molding body on the horizontal support, supplying the liquid semi-conductor to the molding body, and effecting relative movement between the molding body and support in a direction parallel to the support. Thereby fault-free silicon foils can readily be produced.
    Type: Grant
    Filed: May 6, 1985
    Date of Patent: June 2, 1987
    Assignee: Bayer Aktiengesellschaft
    Inventors: Ingo Schwirtlich, Peter Woditsch
  • Patent number: 4664176
    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 heats a gas to lower the density thereof and to produce a low-density atmosphere. The gas is supplied to a depletion region located adjacent to and upstream of the quenching region to provide the low density atmosphere within the depletion region.
    Type: Grant
    Filed: August 20, 1985
    Date of Patent: May 12, 1987
    Assignee: Allied Corporation
    Inventor: Howard H. Liebermann
  • Patent number: 4660622
    Abstract: Apparatus and process for the manufacturing of microcrystalline metallic materials in band form, wherein the chemical compositing for the cooling roller given in ranges within which the upper surface roughness is reduced, the geometry is improved, the presence of microcracks is eliminated or reduced and the ductibility of the band is increased.
    Type: Grant
    Filed: February 14, 1985
    Date of Patent: April 28, 1987
    Assignee: VEB Rohrkombinat, Stahl und Walzwerk, Riesa
    Inventors: Harald Reutler, Wolfgang Loser, Heinz Muhlbach, Gerhard Richter, Gunter Stephani
  • Patent number: 4658885
    Abstract: A method of producing a mark onto a continuously cast metallic strip is disclosed comprising the steps of providing a continuous surface upon which metal strip is cast from a molten metal holding tundish having a nozzle disposed less than about 0.120 inch from the casting surface. The casting surface is cooled and is moved past the nozzle at a rate of about 200 to 10,000 linear surface feet per minute. This method includes providing an impression in the continuous casting surface corresponding to the mark to be produced onto the continuously cast metal strip. Molten metal is continuously fed through the nozzle onto the moving continuous casting surface to produce continuously cast strip thereon, and the cast strip is continuously removed from the casting surface.
    Type: Grant
    Filed: May 9, 1980
    Date of Patent: April 21, 1987
    Assignee: Battelle Development Corporation
    Inventor: Robert E. Maringer
  • Patent number: 4650618
    Abstract: Juxtaposed nozzle openings apply the same or different melts to the surface of a moving cooler surface for producing thin metal strips or foils with a considerable width. The nozzle openings can be staggered in the direction of movement of the cooler surface and apply different materials to produce a metal strip with juxtaposed and sharply defined regions with different characteristics. Amorphous or mixed amorphous/-crystalline, or solely crystalline material structures can also be produced. Alternatively, different cooling capacities on different cooler surface areas and different structuring of different cooler surface areas permit the melt to solidify on the cooler surface such that the strips or foils obtained have adjacent regions with different metallic and/or geometrical structures. By geometrical configuration of the cooler surface, foils with a structured surface or with shape-limited individual regions can be used for mass production of small parts from sheet or strip material.
    Type: Grant
    Filed: November 10, 1983
    Date of Patent: March 17, 1987
    Assignee: Concast Standard AG
    Inventors: Wilfried Heinemann, Thomas Gabriel, Peter Reimann, Hans-Ulrich Kunzi, Hans-Joachim Guntherodt
  • Patent number: 4649984
    Abstract: An apparatus for casting metal strip includes a nozzle having an orifice for depositing a stream of molten metal onto a casting region of a moving chill surface. A conditioning shoe is located generally upstream from the nozzle in a direction opposite to the direction of chill surface movement to delimit a conditioning chamber. The conditioning chamber communicates directly with the nozzle orifice and borders at least three sidelines of the chill surface casting portion. A shield for minimizing an intrusion of ambient atmosphere into the conditioning chamber and for deflecting an entrained gas boundary layer carried along by the chill surface is cooperatively connected to the conditioning shoe. Gas control provides a selected, low density atmosphere, such as a partial vacuum, within the conditioning chamber.
    Type: Grant
    Filed: June 17, 1986
    Date of Patent: March 17, 1987
    Assignee: Allied Corporation
    Inventors: John R. Bedell, Naim S. Hemmat, Paul Jeges
  • Patent number: 4650130
    Abstract: A system is described for the production of rapidly solidified powder. The system contains elements for casting rapidly solidified ribbon, an in-line knife mill or a hammer mill for fracturing the rapidly solidified ribbon into shard, and either an in-line fluid energy mill, or an in-line centrifugal mill for reducing the shard to powder. The system can effectively reduce ribbon to powder in an in-line operation, and produce a powder with a particle size of -35 mesh.
    Type: Grant
    Filed: January 4, 1982
    Date of Patent: March 17, 1987
    Assignee: Allied Corporation
    Inventors: Robert E. Hathaway, Edward M. Norin
  • Patent number: 4648437
    Abstract: A method for producing a metallic strip is disclosed. A metallic melt containing above about 20% by weight of iron is formed into a strip so that fine iron particles are distributed throughout. The strip may be rolled to elongate the iron particles.
    Type: Grant
    Filed: December 16, 1985
    Date of Patent: March 10, 1987
    Assignee: Olin Corporation
    Inventors: Michael J. Pryor, Michael L. Santella
  • Patent number: 4646812
    Abstract: A process for casting metallic strips thicker than from melt-drag processes but thinner than the inherent normal thickness of a cast melt is disclosed. The disclosed process casts molten metal, without decanting or accelerating the molten stream, onto a channel-shaped chill surface. After casting, the molten strip acquires a high thermal gradient. Following thermal shrinkage of the underside the molten top layer is squeegeed using a chill roll to uniformly distribute and crystallize the top surface.
    Type: Grant
    Filed: September 20, 1985
    Date of Patent: March 3, 1987
    Assignee: Battelle Development Corporation
    Inventor: Robert E. Maringer
  • Patent number: 4617982
    Abstract: Material is supplied from a pressure hopper made to have an inert gas atmosphere to each of a plurality of melting furnaces one after another in a predetermined amount each time. The interior atmosphere of each melting furnace is replaced by an inert gas, and the material is melted in the melting furnace by heating. The resulting molten metal is supplied from one of the melting furnaces after another to a discharge container having a discharge nozzle and made to have an inert gas atmosphere, and is continuously discharged from the discharge nozzle against a rapid quenching device.
    Type: Grant
    Filed: July 11, 1984
    Date of Patent: October 21, 1986
    Assignee: Unitika Ltd.
    Inventors: Akira Tanimura, Hisayasu Tsubata, Shoji Tamamura
  • Patent number: 4617983
    Abstract: Molten metal 23 is streamed as a jet 25 from a nozzle 17 toward a cooling liquid layer 24 formed by the centrifugal force of a rotary drum 1 in rotation. The jet 25 is quenched and solidified to form a metal filament. The front end portion of the metal filament rides on a pickup 13a. The pickup 13a rotates synchronously with the rotary drum 1 and, during this synchronous rotation, it is displaced radially inwardly of the rotary drum. The front end portion of the metal filament is attracted by magnetic force to a magnet roller 19 from the pickup 13a. A following portion of the metal filament are wound and held on the magnet roller 19 in rotation. Subsequently, the magnet roller 19 moves toward a winder located outside the drum 1 to deliver the metal filament to the winder so that the metal filament is wound on the winder directly from the rotating drum.
    Type: Grant
    Filed: May 16, 1985
    Date of Patent: October 21, 1986
    Assignee: Unitika Ltd.
    Inventors: Hisayasu Tsubata, Shoji Tamamura, Akira Tanimura
  • Patent number: 4617981
    Abstract: A method for continuously casting strip material onto a casting surface moving past a nozzle in a molten metal holding tundish is disclosed comprising the steps of pouring molten metal into the tundish at a rate sufficient to establish a metallostatic head pressure of at least one-quarter pound per square inch at the nozzle within one second after pouring is initiated, and pouring additional molten metal into the tundish at a rate sufficient to maintain a substantially constant operating pressure at the nozzle throughout the casting operation. A tundish for holding molten metal to be cast into strip material onto a casting surface moving past a nozzle in the tundish, is also disclosed comprising a front wall having an inside surface, a rear wall having an inside surface and sidewalls enclosing a molten metal holding area defined between the inside surfaces of the front and rear walls.
    Type: Grant
    Filed: May 9, 1980
    Date of Patent: October 21, 1986
    Assignee: Battelle Development Corporation
    Inventor: Robert E. Maringer
  • Patent number: 4614222
    Abstract: Apparatus and method for continuous casting of amorphous or polycrystalline metal strip from a melt. The molten metal is delivered from a reservoir (2) to a moving chill surface, preferably a cylindrical roll (1) through an orifice (3) in the reservoir (2). The gap between the reservoir (2) and the chill surface (1) is not fixed as in prior methods but is variable due to a resilient bias on the reservoir toward the chill surface. A pivot (10) and counterweight (11) are convenient apparatus for resiliently biasing the reservoir. The small portion of the reservoir (2) therefore rides lightly upon the molten metal film delivered to the chill surface or upon the solidified metal strip. The variable gap allows better control over the process and better quality surfaces on the metal strip.
    Type: Grant
    Filed: May 16, 1984
    Date of Patent: September 30, 1986
    Assignee: Battelle Development Corporation
    Inventor: Robert E. Maringer
  • Patent number: 4614220
    Abstract: A process and apparatus for continuously casting a castable material to a thickness of 10 to 40 mils. A molten material is first spread onto a spreading roller to a uniform thickness and then transferred to a quenching roller whereon the material is cooled until dimensionally stable. The apparatus may be employed to continuously cast thin sheet, platelets, wire, etc. The materials castable by this process and apparatus include metals, alloys, glasses, thermoplastic materials and metalloids.
    Type: Grant
    Filed: November 16, 1984
    Date of Patent: September 30, 1986
    Assignee: The United States of America as represented by the Secretary of the Air Force
    Inventor: Steven J. Savage
  • Patent number: 4607683
    Abstract: A thin metal wire having a circular cross section is produced by a method which comprises spouting molten metal through a spinning nozzle and bringing the resultant flow of molten metal into contact with a layer of liquid cooling medium formed on a grooved conveyor belt in motion thereby quenching and solidifying the flow of molten metal. This method is capable of continuously producing a thin metal wire of high quality economically on a commercial scale. It is highly effective in directly producing a thin metal wire having an amorphous, non-equilibrium crystalline, or microcrystalline structure.
    Type: Grant
    Filed: March 3, 1983
    Date of Patent: August 26, 1986
    Assignee: Unitika Ltd.
    Inventors: Tatsuo Hamashima, Hisayasu Tsubata, Michiaki Hagiwara
  • Patent number: 4601326
    Abstract: A casting assembly for controllably depositing an elongated, thin cast ribbon on a substrate includes a means for magnetically retaining the ribbon on the substrate. A relatively thin spacer leaf is secured in contacting relationship with the substrate to separate the substrate and the magnets. The spacer is flexible and resilient both in the direction of substrate movement and across the width of the substrate to accommodate irregularities in the surface and movement of the substrate, reducing belt wear and power requirements and improving smoothness of substrate movement.
    Type: Grant
    Filed: May 20, 1985
    Date of Patent: July 22, 1986
    Assignee: Electric Power Research Institute, Inc.
    Inventor: Christian J. Zingler
  • Patent number: 4600048
    Abstract: A thin metal strip excellent in both shape and quality is produced by a continuous casting process which comprises the steps of jetting a molten metal through a nozzle onto the surface of a moving chill body maintained at a pertinent temperature range by irradiating a high density energy at a place positioned at the rear of the nozzle, and subjecting the molten metal to quenching so as to effect solidification.
    Type: Grant
    Filed: August 12, 1985
    Date of Patent: July 15, 1986
    Assignee: Nippon Steel Corporation
    Inventors: Takashi Sato, Tsutomu Ozawa, Katsuhiro Minamida
  • Patent number: 4596207
    Abstract: A method of forming, by melt-spinning techniques, a laminated ribbon structure consisting, for example, of a semiconductor disposed on a metal ribbon substrate. The substrate may be 10-50 .mu.m thick and the semiconductor may be 10-50 .mu.m thick, for example; typically the ribbon width is about one millimeter to several centimeters.
    Type: Grant
    Filed: October 24, 1984
    Date of Patent: June 24, 1986
    Assignee: Massachusetts Institute of Technology
    Inventors: August F. Witt, Ramaswamy V. Raman
  • Patent number: 4592411
    Abstract: A method and apparatus for continuously casting a filament within a region of preselected vacuum and passing the filament to ambient region of higher pressure include a rotating casting wheel which has an annular peripheral quench surface. A guide housing encloses the casting wheel to separate the wheel from the ambient region and to delimit a guide region which is adapted to pass the filament therethrough to an exit region communicating into the ambient region. An extrusion housing delimits an extrusion chamber which communicates with the guide housing and has a portion of the quench surface disposed therein. An extrusion mechanism located in the extrusion chamber extrudes molten metal onto the quench surface to form the filament, and an extrusion vacuum mechanism provides a preselected vacuum in the extrusion chamber. A fluid jet mechanism disposed in the guide housing reduces the pressure in the extrusion chamber and directs the filament through the guide region.
    Type: Grant
    Filed: May 3, 1984
    Date of Patent: June 3, 1986
    Assignee: Allied Corporation
    Inventors: John R. Bedell, Howard H. Liebermann
  • Patent number: 4590988
    Abstract: In a method of manufacturing amorphous metal ribbons by ejecting molten metal through a nozzle attached to a tundish onto a rapidly moving cooling body, the molten metal is suppled to the tundish by first pouring the molten metal from a ladle into an intermediate vessel and then by supplying the molten metal from the intermediate vessel to the tundish through a gas-lift pump. An apparatus for supplying molten metal to a tundish comprises an intermediate vessel adjacent to the tundish and a gas-lift pump to supply the molten metal from the intermediate vessel to the tundish. The molten metal is poured from a ladle into the intermediate vessel. The gas-lift pump has a pump proper that is placed over the intermediate vessel and tundish so that its inlet and outlet open in the intermediate vessel and tundish, respectively. Bubbles are suppled into the pump proper through its inlet.
    Type: Grant
    Filed: September 18, 1984
    Date of Patent: May 27, 1986
    Assignee: Nippon Steel Corporation
    Inventors: Hiromi Fukuoka, Keisuke Asano, Hideo Ide
  • Patent number: 4589471
    Abstract: A method of melt extraction of titanium alloys is provided. The alloys are those containing a high concentration of titanium and a significant amount of an alloying element selected from the group consisting of molybdenum, tantalum and columbium. Surprisingly, the extraction process is rendered feasible when the surface of the extracting mechanism is of molybdenum.
    Type: Grant
    Filed: October 29, 1984
    Date of Patent: May 20, 1986
    Assignee: General Electric Company
    Inventors: Francis X. Gigliotti, Jr., Lee C. Perocchi, Peter G. Frischmann