With Inert Or Reducing Gaseous Atmosphere Patents (Class 164/475)
  • Patent number: 10571194
    Abstract: Apparatus to heat and transfer mainly metal materials to a melting furnace (12), the apparatus comprising a transporter device (13) configured to move the materials continuously to the melting furnace (12), and at least an induction heating unit (28) associated with the transporter device (13) and configured to heat by electromagnetic induction the materials moved in the transporter device (13), keeping them in a solid state.
    Type: Grant
    Filed: January 29, 2015
    Date of Patent: February 25, 2020
    Assignees: DANIELI & C. OFFICINE MECCANICHE SPA, DANIELI AUTOMATION SPA
    Inventors: Antonello Mordeglia, Stefano Morsut, Andrea Codutti, Fabio Guastini
  • Patent number: 9381571
    Abstract: A casting system and method. The casting system can include an energy source and a hearth, which can have a tapered cavity. The tapered cavity can have a first end portion and a second end portion, and the tapered cavity can narrow between the first and second end portions. Further, the tapered cavity can have an inlet at the first end portion that defines an inlet capacity, and one or more outlets at the second end portion that define an outlet capacity. Where the cavity has a single outlet, the outlet capacity can be less than the inlet capacity. Where the cavity has multiple outlets, the combined outlet capacity can match the inlet capacity. Further, the cross-sectional area of the tapered cavity near the inlet can be similar to the cross-sectional area of the inlet.
    Type: Grant
    Filed: December 7, 2015
    Date of Patent: July 5, 2016
    Assignee: ATI PROPERTIES, INC.
    Inventors: Evan H. Copland, Matthew J. Arnold, Ramesh S. Minisandram
  • Patent number: 8875777
    Abstract: A method of continuously casting steel strip includes steps of providing rails positioned beneath a casting position and extending in opposite directions there from to discharge stations, supporting first and second scrap receptacles movable along the rails, engaging a seal between the first scrap receptacle and an enclosure enabling support of a protective atmosphere beneath a pair of casting rolls, disengaging the seal between the first scrap receptacle and the enclosure and moving the first scrap receptacle along the rails in a direction away from the second scrap receptacle to a discharge station, and moving the second scrap receptacle into the casting position and sealingly engaging the second scrap receptacle and the enclosure.
    Type: Grant
    Filed: March 13, 2013
    Date of Patent: November 4, 2014
    Assignee: Nucor Corporation
    Inventors: Jay Jon Ondrovic, Eric Fulbright, Katsumi Nakayama
  • Patent number: 8869875
    Abstract: An aluminum alloy for producing an aluminum strip for lithographic print plate carriers, a method for producing an aluminum alloy for lithographic print plate carriers, in which, during the production of the aluminum alloy, after the electrolysis of the aluminum oxide, the liquid aluminum, up to the casting of the aluminum alloy, is supplied to a plurality of purification steps, as well as an aluminum strip for lithographic print plate carriers and a corresponding use of the aluminum strip for lithographic print plate carriers include a carbide content of less than 10 ppm, and preferably less than 1 ppm. As a result, the aluminum alloy, the method for producing the aluminum alloy, the aluminum strip, and corresponding use of the aluminum strip for lithographic print plate carriers described herein allow for the use of virtually gas-tight coatings.
    Type: Grant
    Filed: March 19, 2012
    Date of Patent: October 28, 2014
    Assignee: Hydro Aluminium Deutschland GmbH
    Inventors: Bernhard Kernig, Werner Droste, Henk-Jan Brinkman
  • Patent number: 8857332
    Abstract: The invention relates to an aluminum alloy strip for the production of printing plate carriers comprising water-based coatings, wherein the aluminum alloy strip has a thickness of at most 0.5 mm. The object is to propose an aluminum alloy strip for the production of printing plate carriers comprising at least one water-based coating so that punctiform coating faults are prevented. The object is achieved for an aluminum alloy strip in that the aluminum alloy strip, in a longitudinal polished section prepared using water as a lubricant, has etch figures with a cubic etching, of which the longitudinal extent is at most 15 mm.
    Type: Grant
    Filed: August 29, 2013
    Date of Patent: October 14, 2014
    Assignee: Hydro Aluminium Rolled Products GmbH
    Inventors: Stefan Knabben, Bernhard Kernig, Jochen Hasenclever, Gerd Steinhoff, Werner Droste, Katrin Kuhnke
  • Patent number: 8733425
    Abstract: A casting device for producing semiconductor material foil includes a casting frame and a substrate band. The casting frame is arranged for holding a molten semiconductor material and includes sidewalls of which an exit sidewall is located at an output position for the semiconductor material foil. The exit side wall is provided with an exit slit. The casting device further includes a local force exerting means to exert at the location of the exit slit a locally enlarged external force on the molten semiconductor material to enlarge an outer pressure on the molten material at the exit slit.
    Type: Grant
    Filed: February 8, 2011
    Date of Patent: May 27, 2014
    Assignee: RGS Development B.V. Petten
    Inventors: Axel Georg Schoenecker, Eric De Jager, Eelko Gelbert Hoek, Pierre-Yves Pichon
  • Patent number: 8689856
    Abstract: A continuous casting furnace is configured for efficiently continuously casting ingots, including titanium alloy ingots. The furnace is configured with an internal cutter for cutting an ingot within the furnace interior chamber. The furnace typically includes a first interior chamber in which a continuous casting mold is disposed and a withdrawal chamber which is separable from the first interior chamber to facilitate withdrawal of finished ingots therefrom while casting continues within the first chamber.
    Type: Grant
    Filed: March 5, 2013
    Date of Patent: April 8, 2014
    Assignee: RTI International Metals, Inc.
    Inventors: Michael P. Jacques, Kuang-O Yu
  • Patent number: 8631853
    Abstract: An apparatus and method for continuously casting thin steel strip include a pair of counter-rotatable casting rolls in a roll cassette laterally positioned to form a nip there between through which thin cast strip can be cast, adapted to support a casting pool of molten metal on the casting surfaces, an enclosure to support a protective atmosphere immediately beneath the casting rolls in the casting position, and an upper cover positioned below the casting rolls to move between a closed position covering the upper portion of the enclosure maintaining the protective atmosphere in the enclosure in the closed position and a retracted position enabling cast strip to be cast into the enclosure. A scrap receptacle positioned beneath the casting position movable in either direction to a discharge stations. Further, a movable tundish adapted to be transferred from a heating station to the casting position.
    Type: Grant
    Filed: December 2, 2011
    Date of Patent: January 21, 2014
    Assignee: Nucor Corporation
    Inventors: Jay Jon Ondrovic, Eric Fulbright, Katsumi Nakayama
  • Patent number: 8365808
    Abstract: Steam exhaust ports are located around a perimeter of a direct chill casting pit, at various locations from below the top of the pit to the pit bottom to rapidly remove steam from the casting pit with addition of dry excess air. Gas introduction ports are also located around a perimeter of the casting pit and configured to introduce an inert gas into the casting pit interior.
    Type: Grant
    Filed: May 17, 2012
    Date of Patent: February 5, 2013
    Assignee: Almex USA, Inc.
    Inventors: Ravindra V. Tilak, Rodney W. Wirtz, Ronald M. Streigle
  • Patent number: 8302657
    Abstract: A casting process for an aluminum alloy containing at least about 0.1% of Mg and/or at least about 0.1% of Li in which a liquid surface of the alloy is put into contact with a dried gas including at least about 2% of oxygen by volume and with a water partial pressure lower than about 150 Pa throughout most of the solidification process is described. The process makes it possible to cast most oxidable aluminum alloys, in particular aluminum alloys containing magnesium and/or lithium, without using additives such as beryllium and/or calcium and without using expensive devices and/or gases, to obtain cast ingots generally free from surface defects and pollution, in complete safety.
    Type: Grant
    Filed: February 16, 2010
    Date of Patent: November 6, 2012
    Assignee: Constellium France
    Inventors: Guillaume Bes, Robert Rey-Flandrin, Olivier Ribaud, Stephane Vernede
  • Publication number: 20120222831
    Abstract: A method of continuously casting steel including steps of forming a casting pool of molten steel comprising a carbon content of less than 0.5% by weight on casting surfaces of a pair of internally cooled casting rolls having a nip formed between them, counter rotating the casting surfaces of the casting rolls toward each other to produce a cast steel strip moving downwardly away from the nip between the casting rolls, guiding the cast strip through a first enclosure adjacent the casting rolls as the strip moves away from the casting rolls, the first enclosure having a reducing atmosphere containing carbon monoxide and optionally hydrogen of at least 0.1%, establishing the reducing atmosphere in the first enclosure to control ingress of atmospheric air so as to maintain said atmosphere with a CO to CO2 ratio of at least 1.5 during steady state operation.
    Type: Application
    Filed: March 4, 2011
    Publication date: September 6, 2012
    Applicant: NUCOR CORPORATION
    Inventors: Dhiren Panda, Leigh Wooley, Neal Ross, Gary McQuillis, James D. Edwards
  • Publication number: 20120195788
    Abstract: An aluminum alloy for producing an aluminum strip for lithographic print plate carriers, a method for producing an aluminum alloy for lithographic print plate carriers, in which, during the production of the aluminum alloy, after the electrolysis of the aluminum oxide, the liquid aluminum, up to the casting of the aluminum alloy, is supplied to a plurality of purification steps, as well as an aluminum strip for lithographic print plate carriers and a corresponding use of the aluminum strip for lithographic print plate carriers include a carbide content of less than 10 ppm, and preferably less than 1 ppm. As a result, the aluminum alloy, the method for producing the aluminum alloy, the aluminum strip, and corresponding use of the aluminum strip for lithographic print plate carriers described herein allow for the use of virtually gas-tight coatings.
    Type: Application
    Filed: March 19, 2012
    Publication date: August 2, 2012
    Applicant: HYDRO ALUMINIUM DEUTSCHLAND GMBH
    Inventors: Bernhard Kernig, Werner Droste, Henk-Jan Brinkman
  • Patent number: 8191607
    Abstract: A continuous casting machine injecting molten mold flux into a mold includes: melt-surface covers covering the upper side of the mold; gas aspirators provided below the melt-surface covers for inhaling the gas in an upper space of the mold; and purge gas injectors provided below the melt-surface covers for injecting purge gas into the upper space of the mold.
    Type: Grant
    Filed: June 22, 2007
    Date of Patent: June 5, 2012
    Assignee: Posco
    Inventors: Jung Wook Cho, Sang Pil Lee, Jae Suk Hong, Soon Kyu Lee
  • Publication number: 20120073780
    Abstract: An apparatus and method for continuously casting thin steel strip include a pair of counter-rotatable casting rolls in a roll cassette laterally positioned to form a nip there between through which thin cast strip can be cast, adapted to support a casting pool of molten metal on the casting surfaces, an enclosure to support a protective atmosphere immediately beneath the casting rolls in the casting position, and an upper cover positioned below the casting rolls to move between a closed position covering the upper portion of the enclosure maintaining the protective atmosphere in the enclosure in the closed position and a retracted position enabling cast strip to be cast into the enclosure. A scrap receptacle positioned beneath the casting position movable in either direction to a discharge stations. Further, a movable tundish adapted to be transferred from a heating station to the casting position.
    Type: Application
    Filed: December 2, 2011
    Publication date: March 29, 2012
    Applicant: NUCOR CORPORATION
    Inventors: Jay Jon Ondrovic, Eric Fulbright, Katsumi Nakayama
  • Patent number: 8141617
    Abstract: A continuous casting furnace for producing metal ingots includes a molten seal which prevents external atmosphere from entering the melting chamber. A startup sealing assembly allows an initial seal to be formed to prevent external atmosphere from entering the melting chamber prior to the formation of the molten seal.
    Type: Grant
    Filed: October 13, 2011
    Date of Patent: March 27, 2012
    Assignee: RTI International Metals, Inc.
    Inventors: Michael P. Jacques, Kuang-O Yu
  • Publication number: 20120024492
    Abstract: A continuous casting furnace for producing metal ingots includes a molten seal which prevents external atmosphere from entering the melting chamber. A startup sealing assembly allows an initial seal to be formed to prevent external atmosphere from entering the melting chamber prior to the formation of the molten seal.
    Type: Application
    Filed: October 13, 2011
    Publication date: February 2, 2012
    Applicant: RTI INTERNATIONAL METALS, INC.
    Inventors: MICHAEL P. JACQUES, KUANG-O YU
  • Patent number: 8069904
    Abstract: In a method for producing hot strips from a deformable lightweight steel which includes as main elements Fe, Mn, Si and Al, melt is cast close to its final dimension in a horizontal continuous strip casting installation under a protective gas to form a pre-strip between 6 and 20 mm, and the temperature of the pre-strip is adjusted after complete solidification and before the beginning of a hot-rolling process. The pre-strip is passed through a device under a protective gas for homogenization in concert with a selective maintenance of the temperature, cooling or heating, and subsequently subjected to a hot-rolling process having at least one pass with a total degree of deformation of at least 50%, and is then reeled as a hot strip following the cooling process. The hot-rolling process is executed in-line or in decoupled manner depending on the ratio of casting speed to rolling speed.
    Type: Grant
    Filed: December 14, 2005
    Date of Patent: December 6, 2011
    Assignee: SMS Siemag AG
    Inventors: Karl-Heinz Spitzer, Hellfried Eichholz, Markus Schäperkötter, Guido Bormann
  • Patent number: 8056776
    Abstract: The invention generally relates to a refractory pouring tube for pouring a molten metal from one metallurgical vessel to another metallurgical vessel. The invention as well relates to a corresponding assembly, comprising such a pouring tube.
    Type: Grant
    Filed: July 8, 2006
    Date of Patent: November 15, 2011
    Assignee: Refractory Intellectual Property GmbH & Co. KG
    Inventors: Stephen Lee, Ian Proudfoot, David Bloomfield
  • Patent number: 7926548
    Abstract: A continuous casting furnace for producing metal ingots includes a molten seal which prevents external atmosphere from entering the melting chamber. A startup sealing assembly allows an initial seal to be formed to prevent external atmosphere from entering the melting chamber prior to the formation of the molten seal.
    Type: Grant
    Filed: September 10, 2008
    Date of Patent: April 19, 2011
    Assignee: RTI International Metals, Inc.
    Inventors: Michael P. Jacques, Kuang-O Yu
  • Patent number: 7891407
    Abstract: A method of and apparatus for continuous casting of thin cast strip including removing oxides from the casting surface of each casting roll by contacting the casting surface of each casting roll with a rotating brush between the nip and the casting area, determining the temperature in segments along the casting roll surfaces or across the cast strip adjacent the nip, and delivering gas adjacent the casting surface between the rotating cleaning brush and the casting area regulated in segments corresponding to the determined temperature in the segment to control the quality of the strip produced. The gas delivery adjacent the casting surface between the rotating brush and the casting area may be done in at least five segments along the casting roll, and the temperature determination step may be done in a continuum such as by a scanning pyrometer. The temperature determination of the cast strip may be done between 0.2 and 1 meter from the nip.
    Type: Grant
    Filed: November 26, 2007
    Date of Patent: February 22, 2011
    Assignee: Nucor Corporation
    Inventors: Mark Schlichting, Walter Blejde, Eugene Pretorius
  • Patent number: 7841380
    Abstract: A magnesium alloy material such as a magnesium alloy cast material or a magnesium alloy rolled material, excellent in mechanical characteristics and surface precision, a producing method capable of stably producing such material, a magnesium alloy formed article utilizing the rolled material, and a producing method therefor. The magnesium material producing method includes a melting step of melting a magnesium alloy in a melting furnace to obtain a molten metal, a transfer step of transferring the molten metal from the melting furnace to a molten metal reservoir, and a casting step of supplying a movable mold with the molten metal from the molten metal reservoir, through a pouring gate, and solidifying the molten metal to continuously produce a cast material. Parts are formed by a low-oxygen material having an oxygen content of 20 mass % or less. The cast material is given a thickness of from 0.1 to 10 mm.
    Type: Grant
    Filed: June 28, 2005
    Date of Patent: November 30, 2010
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Masatada Numano, Yoshihiro Nakai, Toshiya Ikeda, Taichiro Nishikawa
  • Patent number: 7628952
    Abstract: Molten steel is conducted by a tubular shroud interconnecting a slide gate at a bottom tap hole of a ladle with the molten steel in an underlying tundish of a continuous caster. The flow path is confirmed to be isolated from contaminants in atmospheric air by applying a source of partial vacuum to the internal cavity of tubular shroud to allow prevailing atmospheric pressure acting on molten steel in a tundish to push molten steel upwardly in the internal cavity of the tubular shroud. A measure of the partial vacuum in the cavity of the shroud is used to assess the integrity of the gas tight seal. Before and after the integrity of the gas tight seal is determined, a three way valve is used to apply an inert gas to the volume in the cavity of the shroud.
    Type: Grant
    Filed: April 5, 2007
    Date of Patent: December 8, 2009
    Assignee: SMS Demag, Inc.
    Inventor: Albert J. Klimas
  • Patent number: 7617863
    Abstract: A continuous casting furnace includes a temperature control mechanism for controlling the temperature of a metal casting as it exits a continuous casting mold in order to provide improved characteristics of the metal casting. The temperature control mechanism includes a temperature sensor for sensing the temperature of the metal casting, and a heat source and cooling device for respectively heating and cooling the metal casting in light of the temperature of the metal casting. A control unit determines if the temperature of the metal casting is within a predetermined range and controls the heat source and cooling device accordingly. The heat source may double as a cooling device or the cooling device may be separate from the heat source.
    Type: Grant
    Filed: August 11, 2006
    Date of Patent: November 17, 2009
    Assignee: RTI International Metals, Inc.
    Inventors: Kuang-O Yu, Frank P. Spadafora, Michael P. Jacques
  • Publication number: 20090008059
    Abstract: A continuous casting furnace for producing metal ingots includes a molten seal which prevents external atmosphere from entering the melting chamber. A startup sealing assembly allows an initial seal to be formed to prevent external atmosphere from entering the melting chamber prior to the formation of the molten seal.
    Type: Application
    Filed: September 10, 2008
    Publication date: January 8, 2009
    Applicant: RMI Titanium Company dba RTI Niles
    Inventors: Michael P. Jacques, Kuang-O Yu
  • Publication number: 20080311423
    Abstract: The invention is to provide a magnesium alloy material such as a magnesium alloy cast material or a magnesium alloy rolled material, excellent in mechanical characteristics and surface precision, a producing method capable of stably producing such material, a magnesium alloy formed article utilizing the rolled material, and a producing method therefor. The invention provides a producing method for a magnesium alloy material, including a melting step of melting a magnesium alloy in a melting furnace to obtain a molten metal, a transfer step of transferring the molten metal from the melting furnace to a molten metal reservoir, and a casting step of supplying a movable mold with the molten metal from the molten metal reservoir, through a pouring gate, and solidifying the molten metal to continuously produce a cast material. In a process from the melting step to the casting step, parts contacted by the molten metal are formed by a low-oxygen material having an oxygen content of 20 mass % or less.
    Type: Application
    Filed: June 28, 2005
    Publication date: December 18, 2008
    Inventors: Masatada Numano, Yoshihiro Nakai, Toshiya Ikeda, Taichiro Nishikawa
  • Publication number: 20080264525
    Abstract: A high copper low alloy steel sheet less than 5 mm is made by preparing a molten melt producing an as-cast low alloy steel comprising by weight, 0.02 % to 0.3% carbon, 0.10% to 1.5% manganese, 0.01% to 0.5% silicon, greater than 0.01 % and less than or equal 0.15% phosphorus, less than 0.05% aluminum, more than 0.20% copper, less than 0.03 % tin, less than 0.10 % nickel, total oxygen level at least 70 ppm and usually less than 250 ppm, free oxygen content 20 to 70 ppm, the remainder iron and impurities, solidifying the melt into sheet less than 10 mm thickness in a non-oxidizing atmosphere to below 1080° C. Copper content may be between 0.2% and 2.0% by weight. The steel may have a corrosion index (I) of at least 6.0 in accordance with ASTM G101 where: I=26.01 (% Cu)+3.88 (% Ni)+1.20 (% Cr)+1.49 (% Si)+17.28 (% P)?7.29 (% Cu)(% Ni)?9.10 (% Ni)(% P)?33.39 (% Cu)2. The steel may be produced by twin roll casting, and may be less than 2 mm thickness.
    Type: Application
    Filed: October 23, 2007
    Publication date: October 30, 2008
    Applicant: NUCOR CORPORATION
    Inventor: Mary E. ALWIN
  • Publication number: 20080105399
    Abstract: The invention relates to a method for producing a cast steel strip of preferably hot crack-sensitive or hot-brittle steel quality by means of a strip casting plant and to a strip casting plant for carrying out this method. In this case, steel melt is conducted into a melt space formed by two casting rolls and two sideplates, slab shells are formed in the melt space on cooled surface areas of the casting rolls and are brought together in the strip forming cross section between the casting rolls to form an at least partly solidified steel strip, the cast steel strip is then guided along the surface area of one of the two casting rolls from a vertical casting direction into an essentially horizontal transport direction, and the cast steel strip is supplied essentially horizontally on a transport device to a strip winding device and is wound there into a coil.
    Type: Application
    Filed: September 20, 2005
    Publication date: May 8, 2008
    Inventors: Gerald Hohenbichler, Gerald Eckerstorfer, Michael Zahedi
  • Patent number: 7160398
    Abstract: A melt of an alloy, represented (Fe1-mTm)100-x-y-zQxRyMz, where T is Co and/or Ni, Q is B and/or C, R is at least one rare-earth element, M is selected from Al, Si, Ti, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb; 10 at %?x?35 at %; 2 at %?y?10 at %; 0 at %?z?10 at %; and 0?m?0.5, is prepared. Next, the melt is brought into contact with, and rapidly cooled and solidified by, the surface of a rotating chill roller. The melt is teemed onto a guide member, of which the guide surface defines a tilt angle with a horizontal plane, runs down on the guide surface, and then is fed through at least one tubular hole onto a contact area on the surface of the chill roller.
    Type: Grant
    Filed: June 27, 2003
    Date of Patent: January 9, 2007
    Assignee: Neomax Co., Ltd.
    Inventor: Hirokazu Kanekiyo
  • Patent number: 7077186
    Abstract: A mold for horizontal casting of molten metal comprising a mold body forming an open-ended mold cavity having an inlet end and an outlet end. An annular permeable wall member is mounted in the mold body adjacent the inlet end of the mold cavity with an inner face thereof forming an interior face of the mold. A refractory transition plate is mounted at the inlet end of the mold cavity, this transition plate providing a mold inlet opening having a cross-section less than that of the mold cavity. This provides an annular shoulder at the inlet end of the cavity. Means are provided for feeding molten aluminum through the inlet opening. Separate conduits are also provided for feeding a gas into the shoulder and via the permeable wall means for providing a layer of gas between the metal and the inner face of the mold. A gas that is more reactive with molten aluminum is fed into the shoulder and a less reactive gas is fed via the permeable wall.
    Type: Grant
    Filed: December 11, 2003
    Date of Patent: July 18, 2006
    Assignee: Novelis Inc.
    Inventors: Wade Lee Bowles, Jack Hamby, Alexander J. Fischer, David A. Salee
  • Patent number: 6920912
    Abstract: Roll caster (11) produces thin steel strip (12) formed on casting surfaces (22A) of casting roll (22) that passes through first enclosure (37) adjacent casting roll surfaces (22A) and, optionally, thereafter second enclosure (61). Enclosure (37) and/or enclosure (61) may be fitted with spray nozzles (71,72) and/or (67, 68) operable to spray fine water mist adjacent strip (12) to produce hydrogen gas in enclosure (37) while tending to avoid liquid water contact with steel strip (12) and casting surfaces (22A). If hydrogen gas is produced only in enclosure (61), the two enclosures (37, 61) are interconnected so that gas can flow from enclosure (61) to enclosure (37). Enclosure (37) and, if present, enclosure (61) are sealed to maintain positive pressure and oxygen levels less than the surrounding atmosphere, and with the presence of hydrogen gas, reduce formation of scale on the strip in enclosure (37) and, if present, enclosure (61).
    Type: Grant
    Filed: April 11, 2003
    Date of Patent: July 26, 2005
    Assignee: Nucor Corporation
    Inventors: Walter N. Blejde, Andrew Glutz
  • Patent number: 6904954
    Abstract: In manufacturing a magnesium alloy, continuous casting is performed using a movable mold. A magnesium alloy to be processed by presswork, forging, and the like can be efficiently provided.
    Type: Grant
    Filed: April 1, 2002
    Date of Patent: June 14, 2005
    Assignee: Sumitomo Electric Industries, Ltd.
    Inventors: Taichiro Nishikawa, Yoshihiro Nakai
  • Patent number: 6890392
    Abstract: A method of making a material alloy for an iron-based rare earth magnet includes the step of forming a melt of an alloy with a composition of (Fe1-mTm)100-x-y-z-n(B1-pCp)xRyTi2Mn. T is Co and/or Ni; R is at least one element selected from Y (yttrium) and the rare earth elements; and M is at least one element selected from Al, Si, V, Cr, Mn, Ni, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb, wherein the following inequalities are satisfied: 10<x?25 at %, *6?y<10 at %, 0.5?z?12 at %, 0?m?0.5, 0?n?10 at % and 0?p?0.25. Next, the melt is fed onto a shoot with a guide surface tilted at about 1 degree to about 80 degrees with respect to a horizontal plane, thereby moving the melt onto a melt/roller contact region. The melt is then rapidly cooled using a chill roller to make a rapidly solidified alloy including an R2Fe14B phase.
    Type: Grant
    Filed: August 19, 2002
    Date of Patent: May 10, 2005
    Assignee: Neomax Co., Ltd.
    Inventors: Hirokazu Kanekiyo, Toshio Miyoshi, Satoshi Hirosawa
  • Patent number: 6860317
    Abstract: Disclosed are a method and an apparatus for producing a uranium foil with fine crystalline granules by forming the foil by the gravitational dropping of molten uranium or uranium alloy and rapidly cooling the foil by the contact with cooling rolls, and a foil produced thereby. In accordance with the present invention, a high-purity and high-quality uranium foil with an isotropic structure and fine crystalline granules is easily produced via a simple process without requiring hot rolling and heat treatment processes. The surface of the foil is prevented from oxidizing and residual stress is not imparted to the foil. The productivity and the economic efficiency of the foil are improved.
    Type: Grant
    Filed: March 24, 2003
    Date of Patent: March 1, 2005
    Assignee: Korea Atomic Energy Research Institute
    Inventors: Chang-Kyu Kim, Ki-Hwan Kim, Seok-Jin Oh, Se-Jung Jang, Eung-Soo Kim
  • Patent number: 6776218
    Abstract: A twin roll caster (11) produces thin steel strip (12) which passes through a first enclosure (37) to a pinch roll stand (14) including pinch rolls (50) through which the strip passes into a second enclosure (61). The strip passes horizontally through enclosure (61) to an in-line hot rolling mill (16) which closes the exit end of enclosure (61) and hot rolls the strip as it exits that enclosure. Enclosures (37) and (61) are sealed against ingress of atmospheric air and both maintain oxygen levels less than the surrounding atmosphere to reduce formation of scale on the strip. The second chamber (61) is fitted with water spray nozzles (67, 68) operable to spray fine mist of water droplets onto the upper face of the strip as it passes through that enclosure thereby to generate steam producing a superatmospheric pressure within the enclosure preventing ingress of atmospheric air.
    Type: Grant
    Filed: April 12, 2002
    Date of Patent: August 17, 2004
    Assignee: Castrip LLP
    Inventors: Andrew Glutz, Graham Minter
  • Patent number: 6695929
    Abstract: A melt of an iron-based rare earth material alloy, represented by (Fe1-mTm)100-x-y-zQxRyMz, is prepared, wherein T is Co and/or Ni; Q is B and/or C; R is selected from Y (yttrium) and the rare earth elements; M is selected from Al, Si, Ti, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb; 10≦x≦30 at %; 2%≦y<10 at %; 0≦z≦10 at % and 0≦m≦0.5. The melt is fed onto a guide to form a flow of the melt thereon and move the melt onto a melt/chill roller contact region, where the melt is rapidly cooled by the chill roller to make a rapidly solidified alloy. An oxygen concentration of the melt yet to be fed onto the guide is controlled at about 3,000 ppm or less in mass percentage.
    Type: Grant
    Filed: August 5, 2002
    Date of Patent: February 24, 2004
    Assignee: Sumitomo Special Co., Ltd.
    Inventors: Hirokazu Kanekiyo, Satoshi Hirosawa
  • Publication number: 20030234096
    Abstract: Disclosed are a method and an apparatus for continuously casting a uranium rod so that impurities generated in melting the metallic substance reduced from nuclear spent fuel are easily removed, the molten metal is easily degassed, the oxidation of uranium is prevented, and the molten metal does not remain in a crucible, thereby completely removing the noxious gas, improving the safety of work, allowing the workers to be close to the apparatus, reducing the consumption rate of the inert gas, completely preventing the oxidation of uranium, and being remotely controlled.
    Type: Application
    Filed: November 18, 2002
    Publication date: December 25, 2003
    Inventors: Yoon-Sang Lee, Chang-Kyu Kim, Ki-Hwan Kim, Se-Jung Jang, Young-Joon Shin, Seong-Won Park
  • Patent number: 6622778
    Abstract: A method for the direct production, from molten metal, of scale-free thin metal strip. Hot thin metal strip exiting a continuous caster system is directed to a reducing chamber wherein a reducing gas reduces strip surface oxides while the cast metal strip is at an elevated temperature from retained heat from the molten metal. A cooling unit following the reducing chamber is used to cool the strip to a temperature below about 150° C. prior to exposing the strip to an oxidizing atmosphere. In various embodiments of the invention, strip thickness is reduced with use of hot and cold rolling mills and the scale-free surface of the strip is coated with protective coatings.
    Type: Grant
    Filed: July 12, 2000
    Date of Patent: September 23, 2003
    Assignee: Danieli Technology, Inc.
    Inventor: Stephen L. Feldbauer
  • Patent number: 6581674
    Abstract: Disclosed is a method and apparatus for making a molten film of metal, steel, in particular a steel film, more uniform, by strip casting, in which the molten material which is applied to a revolving belt is to have a thickness and properties which are as uniform as possible across the width of the strip. To make the strip more uniform over its width, forces are introduced into the metal film with a component which is perpendicular to the direction in which the strip is conveyed, which forces make the profile of the molten film of metal more uniform.
    Type: Grant
    Filed: November 28, 2000
    Date of Patent: June 24, 2003
    Assignees: SMS Demag AG, Salzgitter AG
    Inventors: Joachim Kroos, Karl-Heinz Spitzer, Ulrich Urlau
  • Patent number: 6575225
    Abstract: A process for continuously casting a thin metal strip controls has jets directed at casting rollers using sensor feedback. Sensor feedback can be taken directly from the rollers, or can be determined indirectly by sensing a condition of the thin metal strip. Surface conditions are controlled over a longitudinal extent of the rollers through locally controlled gas jets. The feedback control of the roller surfaces provides a more uniform casting surface and a more consistent output from the casting surface.
    Type: Grant
    Filed: September 20, 2000
    Date of Patent: June 10, 2003
    Assignees: Voest-Alpine Industrieanlagenbau GmbH, Acciai Speciali Terni S.p.A.
    Inventors: Gerald Hohenbichler, Gerald Eckerstorfer
  • Patent number: 6524408
    Abstract: To produce sheet steel components optimised for loading, a steel strip is cast between two cooled rolls with a variable nip and the thickness of the steel strip is changed by changing the time of contact between the strand shells and the rolls or by changing the cooling intensity of the rolls on the molten steel cast into the gusset formed by the rolls, thereby changing the thickness of the steel strip. Such a strip has a homogeneous structure and can subsequently be given a special quality by hot or cold rolling for its particular purpose of use.
    Type: Grant
    Filed: June 18, 2001
    Date of Patent: February 25, 2003
    Assignee: Thyssen Krupp Stahl AG
    Inventors: Wilhelm Schmitz, Dieter Senk, Ulrich Albrecht-Früh, Reiner Kopp
  • Patent number: 6500230
    Abstract: The invention relates to a process for protecting a non-ferrous liquid metal from oxidation and from firing in a machine processing this metal or its alloys, consisting of disposing a gaseous mixture containing carbon dioxide at the surface of the non-ferrous metal. According to this process, the gaseous mixture is prepared by adding to the carbon dioxide an oxidising gas, argon and xenon only, this gaseous mixture having properties ensuring protection from the ambient atmosphere, and the proportion of carbon dioxide in this gaseous mixture ranging from 50% to 90% by volume.
    Type: Grant
    Filed: October 3, 2000
    Date of Patent: December 31, 2002
    Assignee: Brochot S.A.
    Inventors: Michel Pescheux, Michel L. Rhodon
  • Patent number: 6491089
    Abstract: A process for manufacturing carbon-steel strip having a thickness of less than or equal to 10 mm directly from liquid steel, by casting said liquid steel between the lateral surfaces, made of copper or copper alloy, of two internally cooled rotating horizontal rolls.
    Type: Grant
    Filed: March 20, 2000
    Date of Patent: December 10, 2002
    Assignee: Sollac
    Inventors: François Poirier, Françoise Commarieu, Christian Marchionni, Patrice Vicente, Michel Faral, Jacques Selaries
  • Patent number: 6453984
    Abstract: An apparatus and method for casting metal strip includes 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 includes a plurality of independently controllable gas nozzles to supply a reducing gas to multiple zones of a depletion region located adjacent to and upstream from the quenching region. The gas flow profile can be controlled in each zone independently of controlling the gas flow in other zones. The reducing gas reacts exothermically to lower the density to provide a low density reducing atmosphere within the depletion and substantially prevent formation of gas pockets in the strip.
    Type: Grant
    Filed: March 13, 2001
    Date of Patent: September 24, 2002
    Assignee: Honeywell International Inc.
    Inventors: Howard H. Liebermann, Stephen D. Albert, Phillip L. Roberts, David W. Palm, Shinya Myojin
  • Publication number: 20020129923
    Abstract: An apparatus and method for casting metal strip includes 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 includes a plurality of independently controllable gas nozzles to supply a reducing gas to multiple zones of a depletion region located adjacent to and upstream from the quenching region. The gas flow profile can be controlled in each zone independently of controlling the gas flow in other zones. The reducing gas reacts exothermically to lower the density to provide a low density reducing atmosphere within the depletion and substantially prevent formation of gas pockets in the strip.
    Type: Application
    Filed: March 13, 2001
    Publication date: September 19, 2002
    Inventors: Howard H. Liebermann, Stephen D. Albert, Phillip L. Roberts, David W. Palm, Shinya Myojin
  • Patent number: 6443220
    Abstract: In a method of preventing contact of oxygen with a metal melt, metal melt flows into a casting chamber bounded by walls (1, 2, 13) and leaves this chamber as a stream. In order to completely prevent contact of oxygen with a metal melt and thus reoxidation, oxygen attempting to enter via any gaps (18) between the walls (1, 2, 13) and/or adhering to the walls (1, 2) is reacted to form a compound which is not injurious to the metal melt (20).
    Type: Grant
    Filed: August 13, 1999
    Date of Patent: September 3, 2002
    Assignees: Voest-Alpine Industrieanlagenbau GmbH, Acciai Speciali Terni S.p.A.
    Inventors: Gerald Hohenbichler, Stefano Pellissetti, Romeo Capotosti, Riccardo Tonelli
  • Patent number: 6427752
    Abstract: A casting system with auxiliary cooling onto a liquidus portion of the casting can produce a metal casting that comprises a fine-grain, homogeneous microstructure. The microstructure is essentially oxide- and sulfide-free, segregation defect free, and essentially free of voids caused by air entrapped during solidification of the metal from a liquidus state to a solid state. The casting system with auxiliary cooling onto a liquidus portion of the casting can comprises an electroslag refining system as a source of liquid metal; a nucleated casting system; and at least one cooling system that supplies coolant onto a liquidus portion of the casting. The liquidus portion of the casting is cooled in a manner sufficient to provide a casting microstructure that comprises a fine-grain, homogeneous microstructure that is essentially oxide- and sulfide-free, segregation defect free, and essentially free of voids caused by air entrapped during solidification from a liquidus state to a solid state.
    Type: Grant
    Filed: February 3, 2000
    Date of Patent: August 6, 2002
    Assignee: General Electric Company
    Inventors: William Thomas Carter, Jr., Mark Gilbert Benz, Robert John Zabala, Bruce Alan Knudsen
  • Publication number: 20020036073
    Abstract: Continuous strip casting device comprises a pair of parallel casting rolls onto which molten metal is supplied by metal supply means. Casting rolls are enclosed by a casting chamber into which hot strip is delivered downwardly from the casting rolls. Strip passes downwardly into a cooling chamber where it can either fall into a moveable scrap box at the bottom of chamber or be guided by operation of moveable apron through an exit door from chamber into a heat exchange chamber provided with heaters. A pair of seal rolls are moveable in a seal chamber to form a seal between chambers and are provided with respective gas inlets to admit oxidation inhibiting gas into those chambers. Scrap box is moveable into and out of the bottom of chamber via a scrap box exchange chamber fitted with an airtight door.
    Type: Application
    Filed: August 8, 2001
    Publication date: March 28, 2002
    Inventors: Osamu Takeuchi, Heiji Kato, Toshiro Matsushita
  • Publication number: 20020017374
    Abstract: A method and apparatus for the direct production, from molten metal, of scale-free thin metal strip. Hot thin metal strip exiting a continuous caster system is directed to a reducing chamber wherein a reducing gas reduces strip surface oxides while the cast metal strip is at an elevated temperature from retained heat from the molten metal. A cooling unit following the reducing chamber is used to cool the strip to a temperature below about 150° C. prior to exposing the strip to an oxidizing atmosphere. In various embodiments of the invention, strip thickness is reduced with use of hot and cold rolling mills and the scale-free surface of the strip is coated with protective coatings.
    Type: Application
    Filed: August 21, 2001
    Publication date: February 14, 2002
    Applicant: Danieli Technology, Inc.
    Inventor: Stephen L. Feldbauer
  • Patent number: 6287391
    Abstract: A method for manufacturing a permanent magnet by fabricating rapidly cooled alloy thin strip of amorphous composition which has good tenacity, simple working properties and an average thickness of 10 &mgr;m˜200 &mgr;m, from a molten alloy of a specific composition containing 6 at % or less of rare-earth element and 15 at %˜30 at % of boron, by means of specific rapid cooling conditions, and then subjecting this rapidly cooled alloy thin strip, after cutting or punching to a prescribed shape, to crystallization heat treatment such that the average crystal grain size thereof becomes 10 nm˜50 nm, and by layering together two or more of these thin permanent magnets and bonding and uniting the layered thin strips by means of an inorganic adhesive material or a resin, it is possible readily to provide a high-performance layered permanent magnet having a desired thickness and a prescribed shape, without using a method involving crushing and bonded magnet forming processes and without needing to car
    Type: Grant
    Filed: February 24, 1999
    Date of Patent: September 11, 2001
    Assignee: Sumitomo Special Metals Co., Ltd.
    Inventors: Hirokazu Kanekiyo, Satoshi Hirosawa
  • Patent number: 6269862
    Abstract: A method for preparing a mould lubricant for use in direct chill casting of reactive metals, including magnesium, magnesium alloys, aluminum, and aluminum alloys, proceeds through combining a casting lubricant and a gaseous oxidation-inhibiting agent in a vessel external from the mold under vacuum conditions. The casting lubricant is selected from a variety of casting oils and casting greases. The gaseous oxidation-inhibiting agent is selected from a variety of inert gases, including sulfur hexafluoride (SF6).
    Type: Grant
    Filed: August 19, 1999
    Date of Patent: August 7, 2001
    Assignee: Cast Centre Pty Ltd.
    Inventors: Cheryl Richards, Stephen Ronald Peck, Phillip Wilmott Baker