Abstract: This manufacturing apparatus for a multi-channel tube having a plurality of parallel channels includes: a crucible; and a die set for forming the multi-channel tube from molten copper supplied from the crucible, the die set including: a hollow portion having an inner surface shaped like the profile of the multi-channel tube; punches which are inserted into the hollow portion from an inlet end of the hollow portion to define a space between the inner surface of the hollow portion and each of the punches; and a feed passage which is disposed between the crucible and the space, and configured to feed the molten copper from the crucible to the space, the molten copper being supplied from the crucible to the space within the die set through the feed passage to solidify as it passes through the hollow portion.

Abstract: In the tube manufacturing industry, five general methodologies for manufacturing tubes are known at this time. The first is under an extrusion of molten metal by means of a press. The second is by means of a rotary lamination system known as “Piercing” or “Mannesmann”. The third is the welded pre-tube that is obtained from a laminated strip. The fourth, known as the “Cast & Roll” system, whereby a pre-tube, obtained directly from the melting, is laminated by a triple roller system. Finally, the innovative manner whereby a continuous vertical casting manufactures pre-tubes continuously, directly from the melt. The four first systems are widely used in the industry to manufacture what is known as a “pre-tube” that usually has a diameter of 60 mm or higher, which we shall name “old pre-tube”. Different processes are applied to that old pre-tube to bring it to smaller diameters and thicknesses finally required by the market.

Abstract: A crankshaft is cast in a mold to define a plurality of pin bearing journals and a plurality of main bearing journals, at least one of each has a hollow section extending therethrough. A single core is positioned within the mold to form all of the hollow sections. The single core may include a cross-section defining an elliptical shape to form hollow sections having an elliptical cross-sectional shape to further reduce the weight of the crankshaft. The hollow sections are each positioned along a path that minimizes stress within the crankshaft. The path may include a non-linear path relative to a longitudinal axis of the crankshaft or a linear path angled relative to the longitudinal axis to bend or direct the hollow sections away from high stress regions of the crankshaft. The non-circular cross section of the core may spiral about its own axis to maximize mass reduction.

Abstract: This manufacturing apparatus for a multi-channel tube having a plurality of parallel channels includes: a crucible; and a die set for forming the multi-channel tube from molten copper supplied from the crucible, the die set including: a hollow portion having an inner surface shaped like the profile of the multi-channel tube; punches which are inserted into the hollow portion from an inlet end of the hollow portion to define a space between the inner surface of the hollow portion and each of the punches; and a feed passage which is disposed between the crucible and the space, and configured to feed the molten copper from the crucible to the space, the molten copper being supplied from the crucible to the space within the die set through the feed passage to solidify as it passes through the hollow portion.

Abstract: Methods and associated apparatus for semi-continuous casting of hollow ingots are described. In one embodiment a method for the semi-continuous casting of a metallic hollow ingot is provided. The method includes providing a mold that includes a mold center having an inner pipe and an outer pipe arranged to form an annular space for a cooling media and an outer mold, circulating a cooling media in the annular space, feeding a source material to the mold, heating the source material to produce a molten material, moving the mold center progressively downward relative to the outer mold, and solidifying the molten material to form a hollow ingot. Embodiments relating to an apparatus for semi-continuous casting of hollow ingots, and products resulting from the semi-continuous casting of hollow ingots are also described.

Abstract: This manufacturing apparatus for a multi-channel tube having a plurality of parallel channels includes: a crucible; and a die set for forming the multi-channel tube from molten copper supplied from the crucible, the die set including: a hollow portion having an inner surface shaped like the profile of the multi-channel tube; punches which are inserted into the hollow portion from an inlet end of the hollow portion to define a space between the inner surface of the hollow portion and each of the punches; and a feed passage which is disposed between the crucible and the space, and configured to feed the molten copper from the crucible to the space, the molten copper being supplied from the crucible to the space within the die set through the feed passage to solidify as it passes through the hollow portion.

Abstract: A method of forming a medical device, the method including the steps of providing a substrate, depositing a metallic layer on the substrate by a vapor deposition process, and removing the metallic layer from the substrate. The metallic layer thus removed is the medical device or serves as a basis for forming the medical device. In another aspect, the present invention includes a medical device formed by the process of the present invention.

Abstract: The present invention is a method for one piece molding of closed shapes which have interior surface features. The method involves the dissociation of the mold for the interior surface of the closed shape which is removed through an opening in the closed shape upon dissociation.

Abstract: A process for producing a tube target for cathode sputtering plants, in which the tube target is formed from a metallic inner tube (target holder) made of a first material with a first melting point of Ts1≧900 K and a metallic outer tube (target) that concentrically surrounds the inner tube and that is made of a second material with a second melting point of Ts2≦800 K. The inside diameter of the outer tube and the outside diameter of the inner tube are proportioned in such a way that the two tubes fit together tightly and are mechanically firmly joined. The outer tube is formed by casting the second material in a molten state in a heated, vertical, A cylindrical permanent mold, which has a heated mandrel that constitutes the inner tube.

Abstract: A process for the production of industrial tubes or section bars from metal, such as copper, copper alloys, special brasses, cupronickel or aluminum bronzes, comprises the following steps: melting the metal material with possible compatible working scraps; obtaining a preform from a casting; roll milling and/or drawing said preform to reduce its section; drawing with one or more concatenated intervention said roll-milled and/or drawn preform, in order to further reduce its section up to the size desired; straightening and possibly submitting to thermal and/or degreasing treatment the dimensionally finished product, and cutting the finished product to measure.

Abstract: A method for production of a cooling plate (50, 80) with integrated coolant ducts (52, 84) for iron and steel making furnaces, in particular blast furnaces, is described. A preform of the cooling plate (50, 80) is continuously cast by a continuous casting mould (10), wherein rod-shaped inserts (28) in the casting duct (20) of the continuous casting mould (10) produce in this preform ducts (52, 84) running in the continuous casting direction, which form coolant ducts in the finished cooling plate.

Abstract: A method for the production of a cast article having a small hole comprises the steps of setting a linear core member in a cavity of a metal mold, injecting a molten metal into the cavity, and drawing out the core member from the resultant cast product to form a small hole. A linear core member having a surface film formed by surface coating or by subjecting to a surface treatment is used so that the surface film is partly or as a whole peeled off the linear core member upon drawing it from the cast product, thereby enabling the core member to be drawn from the inside of the cast product. Alternatively, the linear core member is so constructed as to elastically deform in the drawing direction upon drawing it from the cast product to have a diameter smaller than the original diameter.

Abstract: A device for continuous. casting of workpieces has a melting crucible, a filling device, and a forming tool provided with a temperature control system. The temperature control system of the forming tool is designed so that areas of the workpiece to be manufactured that have a greater wall thickness can be cooled to a greater degree and areas of the workpiece to be manufactured with a lesser wall thickness can be cooled to a lesser degree and/or heated. The solid-liquid interface of the workpiece is located in a plane that is at least approximately perpendicular to the vertical axis of the workpiece.

Abstract: Method of making valve seats by thermally spraying bulk material. The method includes the steps of: (i) preparing a cylindrical polymeric mandrel having an outside dimension not greater than the desired inside dimension of the desired insert, the mandrel having no means to provide for separation of the sprayed material from the mandrel, (ii) thermal spraying separate particles of one or more types of steel or nickel alloys in the presence of a controlled oxidizing medium under conditions that allow firstly, melting of the mandrel and its infiltration into the sprayed material and secondly to form a subsequent polymer free dense metallic bulk composite material (iii) after cooling, machining and cutting into discrete seat shapes for implanting into the final product.

Abstract: A booster equipped carburetor in which the venturi bores in the carburetor have an enhanced drop leg booster therein. The drop leg booster has a venturi orifice and a “bent” channel member. The channel member communicates fuel to the venturi orifice and positions the venturi orifice below a second end of the channel member within a venturi bore of the carburetor. The channel member preferably has smooth sides to assure consistent flow without undue turbulence.

Abstract: A method of manufacturing a metal and polymeric composite article by the following steps. Droplets of spray deposited metal and spray deposited polymeric material are combined to form an article having the polymeric material interspersed within the metal. A carrier or form that shaped to receive the metal and polymeric layers is provided. The carrier may be made either stationary or movable. Layers of spray deposited metal and spray deposited polymeric material are applied atop the carrier. The spray deposited metal is between 90 and 95 percent by volume of the article. The polymeric layers do not completely cover the metal layers. Succeeding spray deposited metal layers contact bond to previous metal layers. The polymeric material between imbedded between the interconnected metal layers.

Abstract: A generally tubular device (e.g., a stent or catheter) for placement in a lumen of a patient's body is made by forming a depressed pattern in an external surface of a mold. The depressed pattern corresponds to a desired shape of the generally tubular device. A material is deposited in the depressed pattern for the material to form the generally tubular device conforming to the depressed pattern. The generally tubular device is separated from the mold.

Abstract: The present invention aims to provide a method of regenerating foundry sand whereby the carbon component adhering to the surface of spent foundry sand and similar substances is combusted efficiently, allowing the foundry sand to be regenerated at low cost. In the present invention, in order to achieve this aim the spent foundry sand with the carbon component adhering to it is placed in a combustion furnace which is connected on one side to a pressure-reducing pump and is open on the other, the pressure-reducing pump is operated to draw air from within the foundry sand and introduce air into it, and the accretion is ignited upwind of the current of air which is being introduced, allowing combustion of the accretion to proceed successively on the downwind side. Foundry sand can thus be recycled at very low cost, simply and reliably because it is allowed to self-combust continuously without any heating or agitation from elsewhere, and because the resin is combusted entirely.

Abstract: A composite part consisting of a metallic matrix and reinforcing fibers is fabricated by the simultaneous winding of the fiber and plasma spraying of the matrix onto a rotating mandrel, wherein an axi-symmetric part is produced with multiple layers of the fibers aligned in the circumferential direction. Single or multiple fiber strands are wound onto a mandrel and simultaneously sprayed with the heated powder matrix material using a thermal spray process. Rotation and translation of the mandrel produces an axi-symmetric composite part. The content of the fiber material in the plasma sprayed matrix is typically up to 40% by volume. The light-weight composite part is produced in a single processing step. The part may be used either directly, or as an insert in other components with or without further densification.

Abstract: An alloy material 4 received in a melting hearth 1 is melted by high-density energy supplied from a heat source 5. The molten alloy is transferred to a forced-cooled die 3 having a cavity 2 defining the profile of a product, and quenched to an amorphous state. The alloy has the composition represented by the general formula of Zr.sub.100-a-b-c A.sub.a B.sub.b C.sub.c (wherein the mark A represents one or more elements selected from Ti, Hf, Al and Ga, the mark B represents one or more elements selected from Fe, Co, Ni and Cu, the mark C represents one or more elements selected from Pd, Pt, Au and Ag, and the marks a-c represent the atomic ratios of respective elements A-C under the conditions of a=5-20, b=15-45, c.ltoreq.10 and a+b+c=30-70. The differential temperature region .DELTA.T (=T.sub.x -T.sub.g) in the supercooled liquid phase of the Zr alloy represented by the difference between the crystallization point T.sub.x and the glass transition point T.sub.g, is preferably 100 K or more.

Abstract: Method and apparatus used for continuous casting of copper alloy rods and tubes for obtaining a fine grain size therein. Liquidus copper alloy material flows from a reservoir area or crucible into a continuous casting die through spaced apart feed slots disposed in the casting die cap, thereby effecting agitation of the liquidus material, which prevents the formation of thermal gradients large enough to produce gross directional solidification of the alloy at the liquid-solid state transition zone. The desired agitation is effected by altering the number, location, size and angle of the feed slots in accordance with formulas provided for that purpose.

Abstract: A process for the continuous manufacture of seamless tube by confining a selected length of metal strip in the form of a tube and with at least two longitudinal abutting edges and completely melting a selected length of such tubular form to form a seamless tube and cooling the formed seamless tube. The cooling is preferably in a controlled atmosphere of nitrogen and the temperature is reduced to about 700.degree. F. before further processing takes place. In a preferred process the material is a single strip of metal formed into a tube with only one longitudinal seam and it is moved continuously through a mould heated by induction heating selectively controlled to cause the tube to preheat to a selected temperature and then be subjected to a temperature bringing the metal to its molten state to form a seamless tube and while the seamless tube is moving it is cooled downstream from the melting zone solidifying the metal and bringing it to a selected temperature before exiting the mould.

Abstract: In a continuous casting a hollow ingot by means of a forcedly cooled tubular mold and a core, gas is introduced around an outer peripheral surface of the core along longitudinal slits to form an annular gap surrounding an inner peripheral surface of hollow metallic molten metal, and gas pressure is applied on said inner peripheral surface of the hollow molten metal. Refractory heat-insulative material, starter bar, is brought into contact with the molten metal poured into said annular space at the casting start, encased in the metal solidified thereon, and withdrawn together with the hollow ingot being withdrawn. By these methods smooth cast skin is formed on the inner peripheral surface of a hollow ingot.

Abstract: The process and apparatus according to the invention relates to the continuous casting of hollow bodies of metals such as aluminium, copper, steels of all types, or other metals or alloys. The process comprises introducing a liquid metal into an annular space between an outer mold and an inner mandrel, the liquid metal being subjected in the vicinity of the mandrel to the action of a movable magnetic field which entrains it in an upward direction. The magnetic field is preferably generated by a magnetic rotor which is disposed in the mandrel. The process is used in particular for producing blanks intended for the production of non-welded pipes and tubes.

Abstract: A method and apparatus utilizing a core is located at a central portion of a molten metal storing portion in a vertical semi-continuous mold. The molten metal is poured into the molten metal storing portion, and casting takes place with the inner diameter of a solidified distal portion of the molten metal being controlled by a distal portion of the core. This approach provides a reliable method for the manufacture of high-quality hollow billets which are free from internal defects.

Abstract: The process and apparatus according to the invention concern continuous casting of hollow bodies of metals such as aluminum, copper, steels of all types, or other metals or alloys. The process comprises introducing the liquid metal into an annular space between an outer mold and an inner mandrel, the liquid metal being subjected in the vicinity of the mandrel to the action of a movable magnetic field which entrains it in an upward direction. The magnetic field is preferably generated by a magnetic rotor which is disposed in the mandrel. The process is used in particular for producing blanks intended for the production of non-welded pipes and tubes.

Abstract: The apparatus comprises an annular water-cooled metallic mold having open upper and lower ends, a core member located in the inner space of the mold to form therebetween an annular casting passage for solidifying therein the molten metal supplied in the casting passage, and a movable supporting base member adapted to initially close the lower end of the casting passage to support the molten metal therein and then to be moved downwardly apart from the lower end as the metal in the casting passage solidifies so as to permit the solidified metal to be pulled out from the casting passage for continuously producing the hollow metallic ingot.

Abstract: A method of making a laminated structure for use in an electrical apparatus. A female mold is produced having an upwardly facing cavity of a shape corresponding to the laminated structure. A layer of a ferrous metal is sprayed onto the bottom surface of the mold and subsequently an electrically insulated layer is applied to the layer of metal. Alternate layers of the ferrous metal and the insulating layer are deposited in the cavity of the mold to provide a laminated structure in which the metal and insulating layers are integrally bonded together. Through use of the method of the invention, a ferrous metal with the most desirable electrical characteristics can be employed.

Abstract: In a continuous vertical ascending casting installation for iron pipes T, graphite elements 3 defining a molten metal feed chimney 28, a die and coaxial core arrangement 13, 14 and an expansion vessel 16 are mounted under a cover 2 of an electric furnace 1. In use these graphite elements are immersed in a bath of molten metal contained in the hearth area 7 of the furnace, to thus enable precise temperature regulation and control. The outer surface of the die 13 is surrounded by a water cooling jacket 18, and the level of molten iron in the hollow cavity 25 of the core 14 is varied by the expansion vessel 16, to provide even finer control of the temperature gradient within the annular casting space. The overall arrangement is thus similar to a double boiler.

Abstract: The process and the device according to the invention relate to the continuous casting of hollow bodies made of metals such as aluminum, copper, steels of all types or other metals or alloys. The process involves introducing the liquid metal into an annular space between an external mold and an internal mandrel, the liquid metal being subjected in the vicinity of the mandrel to the action of a moving magnetic field which drives it upward. This field is created by a magnetic rotor housed in the mandrel comprising a rotating part around which is arranged at least one spiral made of magnetized magnetic material made integral with the rotor by at least one collar. The process is applied, in particular, to the production of blanks intended for the manufacture of seamless tubes.

Abstract: An apparatus is provided for electromagnetically coiling a molten material into a longitudinally extending casting defining a longitudinal axis thereof. The casting has a desired cross section extending perpendicular to the longitudinal axis. At least one portion of the outer peripheral surface of the casting extends transversely of the longitudinal axis and has a small radius of curvature. The apparatus includes an inductor extending transversely about the molten material for providing an electromagnetic containment force field acting on the outer peripheral surface of the molten material to form the desired cross section. The improvement comprises a device for turning the electromagnetic containment force field about the longitudinal axis to cause a corresponding turn of the transverse cross section of the molten material about the longitudinal axis.

Abstract: The vertically ascending casting of a thin-walled metal pipe and integral end fitting from a bath of molten metal is implemented using a housing 12 and a core 14 to mold the end fitting or bell housing and a tubular draw tube 6 to mold the pipe shank. The end fitting E is first formed by forcing the metal to rise in the annular space 16 between the housing and the core, simultaneously forming the initial section of the pipe shank. Once the end fitting has solidified it is extracted upwardly, step by step, while shank sections are simultaneously withdrawn from the metal bath. These sections are also solidified step by step along a tapering front S in the bath until the desired length of pipe T has been obtained.

Abstract: A method of manufacturing a cylindrical billet having a predetermined length useable as raw material for producing a pipe. This method is practiced by way of the steps of drawing a cast slab from a casting mold on a continuous casting stand, spirally winding or cylindrically bending it around a rotating mandrel, joining together both end faces of the wound or bent cast slab to a cylindrical body and cutting it to a predetermined length. Two or more cast slabs may be used for forming the cylindrical body. Two rectangular cast slabs may be used as starting material which are subjected to roll forming and thereafter are cut to the predetermined length. They are then press worked to form a recess having a semi-circular cross-sectional configuration whereby a cylindrical body is constituted by assembly thereof in a superimposed relation.

Abstract: The invention provides an apparatus and process to cast continuously high quality hollow round steel billets or tubes. The hollow round steel billets are produced by a compact, high production casting machine incorporating a rotating hypocycloidal mandrel for inside cooling and deformation of the solidified steel. The outside cooling is by traditional mold and spray cooling. The adjustable rolling movement of the mandrel controls the uniform heat extraction from the inner annulus as well as the deformation and deformation rate of the as-cast steel to increase the ductility. The inside of the hollow round billet so formed is substantially round and the inside surface is smooth to facilitate high quality and further processing to finished pipes in conventional high production machinery.

Abstract: For use in a continuous casting apparatus wherein molten metal flows through a die progressively and is solidified in the die and withdrawn from the die, a die and cooling assembly comprising a tubular die having an external tapered surface which is uniformly tapered radially inwardly in the direction of movement of metal to the die, a cooling sleeve having an internal surface complementary to the external surface of the die and in substantial contact with the external surface of the die and an annular cooling jacket wall surrounding the cooling sleeve and having portions thereof spaced from the sleeve to define a cooling chamber. At least one coolant inlet is provided to the chamber and at least one coolant outlet is provided from the chamber. The inlet and outlet are spaced axially with the outlet being nearest the upper end of the die where the molten metal enters the die and the inlet being nearest the lower end of the die where the solidified metal leaves the die.

Abstract: To produce tubes of reactive metals, a melt (14) is removed from the annu gap (13) of a crucible (10). The temperature of the melt (14) is such as to ensure the formation of the solidus-liquidus zone (33) directly behind the annular gap (13), a planar solidification front (34) being created in a non supported region which is not exposed to the direct influence of a cooling means. In the subsequent region, the oriented solidification of the tube with high temperature gradients is realized, and the tube can be shaped or adjusted free of thermal influences. Only thereafter, the tube (25) is exposed to the action of cooling means (26, 31) to cool it without contact. In such a way, it is possible to produce tubes having a high stability and resistance to temperatures for use in turbines, heat exchangers or the like.

Abstract: The die (6) comprises a thick cylindrical body (7) which is surrounded by a cooling jacket (15) clamped against the pouring basin (2) and in contact with the latter in a plane (P). The body (7) is extended in the casting orifice (4) by a composite head (17) comprising a thin inner annular lip (22), whereof the inner surface extends that of the body (7) and a ring (24) of refractory material fitted between the lip, the body and the casting orifice. The (hot) lip (22) is connected to the body (7) in the plane (P), so that the ring (24) rejoins it also in this plane and that the flow of heat (f.sub.1) passing from the casting orifice to the cooling jacket must skirt around this ring.

Abstract: In the art of continuous vertical casting, an improved cooler assembly surrounds the forming die through which molten metal is poured for forming elongated metallic bar products which may be solid or hollow. The cooler assembly includes a cooling sleeve surrounding the die in continuous intimate contact; and a jacket surrounding the cooling sleeve and spaced therefrom to provide space for receiving a coolant. Along a substantial intermediate length of the cooling sleeve is formed a continuous helical or spiral groove for controlling the flow of coolant from the bottom to the top of the cooler assembly while increasing surface contact of the coolant with the cooling sleeve and the jacket itself. Coolant is introduced into and discharged from the cooler assembly at an oblique angle to initiate helical flow of the coolant about the sleeve and also avoid cold spots and consequently grain and strength imperfections in the bar product being cast.

Abstract: A cap 42 with a lower spherical surface 46 is held against the flared head 38 of a casting core 24 and rests on the spherical upper surface of an annular bed 50 which is fixed above a casting head 12. The bed is coaxial with an enlarged orifice 40 for the passage of the core, and is coaxial with a casting tank 16. Projections 70 are distributed regularly around the periphery of the core and come into contact with the internal wall of a mold 22 near a die opening to center the core in the mold by possibly moving the cap in relation to the bed, before final tightening.