Having Continuously Advancing Shaping Surface Patents (Class 164/479)
  • Patent number: 11062817
    Abstract: The present invention relates to core shell liquid metal encapsulates comprising and processes of making and using such encapsulates and networks. The shell(s) of such encapsulates employ a palette of materials having widely varied band structures and/or the desired spin pairing and/or bond polarization. Such encapsulates can be designed to respond to one or more stimuli of choice, including but not limited to electromagnetic, thermal, mechanical, photonic, and/or magnetic and are environmentally robust.
    Type: Grant
    Filed: July 10, 2020
    Date of Patent: July 13, 2021
    Assignee: United States of America as represented by the Secretary of the Air Force
    Inventors: Christopher E. Tabor, Zachary J. Farrell, Nicholas J. Morris, Megan A Creighton
  • Patent number: 10350675
    Abstract: A machine for manufacturing continuous bars of nonferrous metal by continuous casting includes a movable casting shell, composed of segments arranged in succession, each one having a portion defined, with a bottom and flanks, of the casting shell, and open on the sides directed toward the contiguous segments. The contiguous segments are movable along a closed path that has a substantially rectilinear portion at the casting region. Along the portion, the segments are substantially aligned and define a portion of the casting shell, with bottom and flanks, which is continuous, substantially rectilinear and closed, for at least one portion of the path downstream of the casting region, by a closure component.
    Type: Grant
    Filed: February 8, 2017
    Date of Patent: July 16, 2019
    Inventor: Giulio Properzi
  • Patent number: 8915291
    Abstract: Plant for forming grids for electric battery plates, which comprises a grid forming machine with continuous casting provided with a rotary drum, and a sliding block mounted fixed and slideably sealingly coupled with the external surface of the rotary drum and provided with means for distributing molten lead, in order to insert the molten lead within grooves provided on the external peripheral surface of the rotary drum during the rotation of the latter. The plant is also provided with an ultrasound generator placed to intercept a feed duct for the molten lead, connected to the distribution means and provided with at least one tip immersed in the pressurized flow of molten lead that moves through the aforesaid feed duct in order to transmit the waves produced by the ultrasound generator to the molten lead flow.
    Type: Grant
    Filed: May 19, 2013
    Date of Patent: December 23, 2014
    Assignee: Sovema S.p.A.
    Inventor: Pietro Farina
  • Patent number: 8820393
    Abstract: Embodiments herein relate to a method for forming a bulk solidifying amorphous alloy sheets have different surface finish including a “fire” polish surface like that of a float glass. In one embodiment, a first molten metal alloy is poured on a second molten metal of higher density in a float chamber to form a sheet of the first molten that floats on the second molten metal and cooled to form a bulk solidifying amorphous alloy sheet. In another embodiment, a molten metal is poured on a conveyor conveying the sheet of the first molten metal on a conveyor and cooled to form a bulk solidifying amorphous alloy sheet. The cooling rate such that a time-temperature profile during the cooling does not traverse through a region bounding a crystalline region of the metal alloy in a time-temperature-transformation (TTT) diagram.
    Type: Grant
    Filed: July 11, 2013
    Date of Patent: September 2, 2014
    Assignee: Apple Inc.
    Inventors: Christopher D Prest, Joseph C. Poole, Joseph Stevick, Theodore Andrew Waniuk, Quoc Tran Pham
  • Patent number: 8701745
    Abstract: A method of continuously casting a lead alloy strip includes continuously supplying molten lead alloy to a tundish having a lip insert and containing a pool of molten lead alloy. The molten lead alloy is continuously supplied to the pool from a bath maintained at a temperature in the range of 575° to 750° F. The surface level of the molten alloy in the lip insert is controlled to produce a strip of desired thickness. The temperature of the lead alloy in the lip insert is controlled in a range of about 640° to 750° F. An abraded casting surface is moved upwardly through the pool for depositing the lead alloy thereon. The abraded casting surface is cooled to a temperature in the range of about 100° to 210° F. to solidify a strip of lead alloy, and the lead alloy strip is stripped from the abraded casting surface.
    Type: Grant
    Filed: November 5, 2010
    Date of Patent: April 22, 2014
    Assignee: Mitek Holdings, Inc.
    Inventors: Jeffrey A. Rossi, Theodore J. Seymour
  • Patent number: 8695685
    Abstract: A method and a device for producing steel strips by belt casting, wherein a molten metal is output from a feed vessel onto a circulating casting belt of a horizontal belt casting system under protective gas by a gutter and a siphon-like outlet area designed as a casting nozzle. At least one plasma jet, which renders the area of action inert and heats the area of action, influences the outlet-side area of the casting nozzle and the molten metal exiting therefrom at least during the casting process. For this purpose, at least one plasma torch, which produces a plasma jet and is directed at the outlet area of the casting nozzle in a direction opposite the casting direction, is provided.
    Type: Grant
    Filed: May 7, 2010
    Date of Patent: April 15, 2014
    Assignee: SMS Siemag Aktiengesellschaft
    Inventors: Hellfried Eichholz, Jochen Wans, Karl-Heinz Spitzer, Hans-Jürgen Hecken
  • Publication number: 20130233506
    Abstract: A molten metal mold and bottom block system, including apparatus and method embodiments, which may include a mold cavity framework with a first side, a second side opposite the first side, a third side, and a fourth side opposite the third side, each side including an inner surface and the inner surfaces defining a mold cavity, and wherein one or more of the sides are movably mounted relative to the second side, and are controllably moved during the casting. This system may also include embodiments wherein the castpart produced has a tapered form at one or both of the castpart ends. Aspects of this invention may be considered to be a castpart shrinkage management system or a castpart form or profile control system due to the advantage of increased controls of castpart form during the casting process.
    Type: Application
    Filed: March 9, 2012
    Publication date: September 12, 2013
    Inventors: Michael K. Anderson, Craig Shaber, Steve Anderson, Brett Thielman, Mike Komicki
  • Patent number: 8485245
    Abstract: Embodiments herein relate to a method for forming a bulk solidifying amorphous alloy sheets have different surface finish including a “fire” polish surface like that of a float glass. In one embodiment, a first molten metal alloy is poured on a second molten metal of higher density in a float chamber to form a sheet of the first molten that floats on the second molten metal and cooled to form a bulk solidifying amorphous alloy sheet. In another embodiment, a molten metal is poured on a conveyor conveying the sheet of the first molten metal on a conveyor and cooled to form a bulk solidifying amorphous alloy sheet. The cooling rate such that a time-temperature profile during the cooling does not traverse through a region bounding a crystalline region of the metal alloy in a time-temperature-transformation (TTT) diagram.
    Type: Grant
    Filed: May 16, 2012
    Date of Patent: July 16, 2013
    Assignee: Crucible Intellectual Property, LLC
    Inventors: Christopher D. Prest, Joseph C. Poole, Joseph Stevick, Theodore Andrew Waniuk, Quoc Tran Pham
  • Patent number: 8322399
    Abstract: Continuous casting machine for forming a lead alloy strip of large thickness; which comprises a cooled rotating drum (4) having an annular seat (8) formed on the periphery thereof and a vat (10) for containing a molten lead bath, which is sealingly engaged on the peripheral surface (7) of the rotating drum (4). The machine (1) also comprises a fixed shoe (11) extending, from the vat (10), along an arc (25) around the rotating drum (4) and having an arc shape suitable for sealing engagement, in a sliding relationship, on the shoulders (90) of the annular seat (8). Heating means (26) are provided, these consisting of a plurality of torches acting on the shoe (11) along at least an initial section thereof (25) which extends from the vat (10), for heating to a temperature higher than the melting temperature of the lead alloy the free surface of the lead inside the annular seat (8).
    Type: Grant
    Filed: August 3, 2010
    Date of Patent: December 4, 2012
    Assignee: Sovema S.p.A.
    Inventor: Pietro Farina
  • Patent number: 8316916
    Abstract: A method for producing a pipe, a carrier element being coated by means of a thermal spraying method, the material of the pipe formed later being selected as the coating material, and the coating forming the pipe being detached from the carrier element, the spraying angle, at which the coating material is sprayed onto the carrier element, being selected such that a low level of adhesion of the coating on the carrier element is achieved.
    Type: Grant
    Filed: October 26, 2011
    Date of Patent: November 27, 2012
    Assignee: Linde Aktiengesellschaft
    Inventors: Peter Heinrich, Peter Richter, Helmut Höll, Erik Bahr
  • Patent number: 8272426
    Abstract: An apparatus for casting near-net-shape, rectangular metal strands includes a horizontally circulating metal conveyor belt (7) with a cooled bottom a melt feeder (3?) for casting the metal onto the conveyor belt(7), and an arrangement for feeding the solidified pre-strip under mechanical tension to a driver (16). A cooled pressure device (11, 12, 13) is arranged above the cast product (4) in a region of the deflection roller (8) of the metal conveyor belt (7) which is located downstream in a casting direction, for applying an adjustable pressure from above to the cast product (4) solidifying into the pre-strip (5); and immediately behind the metal conveyor belt (7) a cooling device (17, 19, 19?)for cooling the bottom of the pre-strip (5) over its entire width.
    Type: Grant
    Filed: August 1, 2008
    Date of Patent: September 25, 2012
    Assignee: SMS Siemag AG
    Inventors: Jörg Bausch, Hans Jürgen Hecken
  • Patent number: 8261812
    Abstract: A method of casting near-net-shape, rectangular metal strands includes providing a horizontally circulating metal conveyor belt (7) with a cooled bottom and a melt feeder (3?) for casting the metal melt onto the conveyor belt (7), smooth/pinch rollers (14) for feeding the solidified pre-strip under mechanical tension to a driver (16), a pressure device (11, 12, 13) arranged above the cast product (4) in a region of the deflection roller (8) of the metal conveyor belt (7) which is located downstream in a casting direction, for applying an adjustable pressure from above to the cast product (4) solidifying into the pre-strip (5). Immediately behind the metal conveyor belt (7) and upstream of the pinch rollers, a cooling device (17, 19, 19?) is provided for cooling the bottom of the pre-strip (5) after the pre-strip leaves the conveyor belt.
    Type: Grant
    Filed: May 4, 2011
    Date of Patent: September 11, 2012
    Assignee: SMS Siemag Aktiengesellschaft
    Inventors: Jörg Bausch, Hans Jürgen Hecken
  • Publication number: 20120103555
    Abstract: A system of twin-roll casting an ultra-thin slab or thick-strip of metal with a liquid core still present inside the hollow shell of the casting as it exits the nip of the opposing counter rotating casting rolls. The wide sides of the cast shell are formed against a recessed casting surface on each roll and the narrow end walls of the shell are formed against the tapered ends of the recessed area so one half of the narrow end wall is formed on each roll and the two halves are joined together at the nip to form the full perimeter of the metal casting. A liquid-cooled copper mold liner provides continued support to each of the four sides of the casting below the twin-rolls and contact with those chilled copper mold liners continues to remove heat from the liquid core of the casting enabling the shell to continue growing in thickness.
    Type: Application
    Filed: July 20, 2011
    Publication date: May 3, 2012
    Inventor: James B. Sears, JR.
  • Patent number: 8096345
    Abstract: A method and apparatus are provided for producing an amorphous ribbon by ejecting and rapidly solidifying molten alloy on a circumferential surface of a rapidly rotating cooling roll, wherein the cooling roll is polished online during amorphous ribbon production. When the circumferential surface of the cooling roll after peeling off the ribbon is polished using a polishing member, the circumferential surface of the cooling roll is polished continuously or intermittently across its lateral direction while differentiating the polishing mode in accordance with the surface properties.
    Type: Grant
    Filed: April 16, 2008
    Date of Patent: January 17, 2012
    Assignee: Nippon Steel Corporation
    Inventors: Shigekatsu Ozaki, Takeshi Imai
  • Patent number: 7984748
    Abstract: An apparatus for continuously casting thin strip includes a caster having a pair of casting rolls having a nip there between capable of delivering cast strip downwardly from the nip and an first enclosure capable of forming a protective atmosphere into which the strip can be formed in loop to extend over a plurality of rollers into pinch rolls with the strip having a strain of less than 0.4%, which may be provided by a plurality of rollers at entry of the strip into the pinch rolls to carry the strip into the pinch rolls, with at least a first entry roller having a diameter between 200 and 650 millimeters and being below a majority of other rollers.
    Type: Grant
    Filed: July 3, 2008
    Date of Patent: July 26, 2011
    Assignee: Nucor Corporation
    Inventors: Andrew Edward Dixon, Gary McQuillis, Rama Ballav Mahapatra, Leigh Wolley
  • Patent number: 7938167
    Abstract: A method for operating a two-roll casting machine for casting molten metal into cast strip, which machine has two casting rolls which are each rotatively driven in opposite directions about an axis of rotation and between them delimit a casting gap on its longitudinal sides, with side plates that can be placed on the casting rolls, which side plates seal the casting gap on its narrow sides in the casting operation, bridging the casting gap with a refractory material, wherein the side plates are moved during the casting operation in a direction which is aligned parallel to the direction of conveying in which the cast strip leaves the casting gap. With such a method the formation of grooves distorting the casting result and the casting operation can be suppressed with increased certainty and the service life of the side plates can be increased, compared to the prior art.
    Type: Grant
    Filed: November 20, 2006
    Date of Patent: May 10, 2011
    Assignee: ThyssenKrupp Nirosta GmbH
    Inventors: André d'Hone, René Leenen
  • Patent number: 7905272
    Abstract: A method for producing wide strips of copper is performed by pouring a molten liquid into a revolving wide strip mold via a distribution container and a pour nozzle. A surface of the molten metal in the distribution container is maintained at a constant level above the place where the pour nozzle is fixed in the distribution container in the range of 75 mm to 90 mm with respect to the level of the bath surface of the mold. The molten metal is guided by an ascending channel from the distribution container to the pour nozzle and is distributed within the pour nozzle symmetrically over a width corresponding to the width of the strip. Within the pour nozzle, the molten metal is guided through first and second flow restrictors and is separated into numerous small individual flows in a vertical direction over the entire strip width of the mold.
    Type: Grant
    Filed: December 8, 2007
    Date of Patent: March 15, 2011
    Assignee: MKM Mansfelder Kupfer und Messing GmbH
    Inventors: Michael Albrecht, Joachim Dauterstedt, Hans-Jürgen Schütt, Michael Starke
  • Patent number: 7823623
    Abstract: A twin-belt casting machine for casting metal strip. The machine is provided with a casting cavity which includes an upstream fixed casting region, in which the belts are in fixed convergent paths in contact with the cast slab, and an adjacent downstream portion in which the belts are adjustable between alignment with the fixed convergent paths and non-alignment therewith (being less convergent or divergent). When the adjustable portions of the paths are moved outwardly relative to the fixed convergent paths, the belts separate from the cast slab at differing predetermined points within the casting cavity. By adjusting the downstream portion of the casting cavity in this manner, the casting machine can operate at essentially constant throughput for a wide range of alloys while ensuring that the cast slab exiting the caster has a temperature within a predetermined range suitable for further rolling to produce sheet product.
    Type: Grant
    Filed: March 15, 2007
    Date of Patent: November 2, 2010
    Assignee: Novelis Inc.
    Inventors: John Fitzsimon, Ronald Roger Desrosiers, Willard Mark Truman Gallerneault, Kevin Michael Gatenby
  • Patent number: 7806165
    Abstract: In a method for making hot strips, a workable lightweight construction steel is used which in particular can easily be deep-drawn cold and includes the main elements Si, Al and Mn, with high tensile strength and good TRIP and/or TWIP characteristics. The mass % are as follows for C 0.04 to <1.0, Al 0.05 to <4.0, SI 0.05 to ?6.0; Mn 9.0 to ?30.0, the remainder being iron with the common incidental steel elements. The melt is cast in a horizontal strip casting unit, close to the final dimensions at calm flow and without bending to form a pre-strip in the range between 6 and 15 mm, and subsequently is fed for further processing.
    Type: Grant
    Filed: December 22, 2004
    Date of Patent: October 5, 2010
    Assignees: Salzgitter Flachstahl GmbH, Max-Planck-Institut Für Eisenforschung GmbH
    Inventors: Joachim Kroos, Karl-Heinz Spitzer, Georg Frommeyer, Volker Flaxa, Udo Brüx, Klaus Brockmeier
  • Publication number: 20100236748
    Abstract: The invention relates to a casting device (1) having a casting ladle (2), a distribution device (4), and a horizontally moveable transport belt (5) having side boundaries (13, 14), wherein liquid metal, preferably steel, can flow out of the casting ladle (2) onto the distribution device (4), and from there can be applied to the horizontal transport belt (5), the side boundaries (13, 14) of the horizontal transport belt (5) being adjustable across the width of the horizontal transport belt. The invention further relates to a corresponding method.
    Type: Application
    Filed: August 15, 2008
    Publication date: September 23, 2010
    Applicant: SMS DEMAG AG
    Inventors: Joerg Bausch, Jochen Wans
  • Patent number: 7614441
    Abstract: The present casting machine and the underlying caterpillar-mold casting method distinguish themselves by the fact that the blocks (4) forming the mold circulate caterpillar-like around one of the casting caterpillars (2;3) and are subdivided in the lateral direction into individual elements that are held together, the elements, which rest on a transport means, being held on the transport means at least over a part of the circumference of the caterpillar by means of stationary magnets.
    Type: Grant
    Filed: January 14, 2004
    Date of Patent: November 10, 2009
    Assignee: Lamec AG
    Inventors: Wilhelm Friedrich Lauener, Martin Lauener
  • Patent number: 7503377
    Abstract: A method and apparatus for continuous casting of metal strip, the apparatus having (i) a first endless belt supported and moved on the surfaces of a first entry pulley and a first exit pulley and (ii) a second endless belt supported and moved on the surfaces of a second entry pulley and a second exit pulley, with an entry nip defined between the first and second entry pulleys and an exit nip defined between the first and second exit pulleys. Opposing surfaces of the first and second belts progressively diverge from each other in the direction of movement thereof. The apparatus may include a cooled roll in place of the first pulley and first belt with a nip defined between the cooled roll and the second entry pulley.
    Type: Grant
    Filed: June 23, 2006
    Date of Patent: March 17, 2009
    Assignee: Alcoa Inc.
    Inventors: Gavin F. Wyatt-Mair, Ali Unal
  • Publication number: 20090056907
    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: Application
    Filed: October 27, 2008
    Publication date: March 5, 2009
    Applicant: SUMITOMO ELECTRIC INDUSTRIES, LTD.
    Inventors: Taichiro Nishikawa, Yoshihiro Nakai
  • Patent number: 7451804
    Abstract: A method and apparatus for preparing and delivering various types of carbon and microalloy steel, free of oxygen with abundance of nuclei, when cast producing ultra fine grain steel free of internal defeats with excellent quality. A horizontal sealed table caster has a chamber, containing a suitable atmosphere for casting, with a tube connecting to a tundish so as to allow a liquid to flow into the chamber. The liquid metal is captured on a cooling belt along the bottom of the chamber and is maintained as a specific width and depth. The cooling belt serves as a heat sink causing the liquid metal to solidify from the bottom up, allowing inclusions to migrate to the surface of the steel. A layer of liquid metal is maintained on top of the solidifying steel until the solidification reaches the surface. The belt moves the solid metal toward the exit of the chamber.
    Type: Grant
    Filed: November 22, 2006
    Date of Patent: November 18, 2008
    Inventor: Oren V. Peterson
  • 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: 7089993
    Abstract: A method and apparatus for continuous casting of metal strip, the apparatus having (i) a first endless belt supported and moved on the surfaces of a first entry pulley and a first exit pulley and (ii) a second endless belt supported and moved on the surfaces of a second entry pulley and a second exit pulley, with an entry nip defined between the first and second entry pulleys and an exit nip defined between the first and second exit pulleys. Opposing surfaces of the first and second belts progressively diverge from each other in the direction of movement thereof. The apparatus may include a cooled roll in place of the first pulley and first belt with a nip defined between the cooled roll and the second entry pulley.
    Type: Grant
    Filed: March 11, 2005
    Date of Patent: August 15, 2006
    Assignee: Alcoa Inc.
    Inventors: Gavin F. Wyatt-Mair, Ali Unal
  • Patent number: 7059384
    Abstract: Disclosed is a method and apparatus for continuously casting a metal strip. A casting pool of molten metal is formed, and a metal strip is solidified onto a casting surface. The temperature of the casting surface is maintained above a predetermined critical value. By maintaining the surface temperature above the predetermined critical value, either the heat transfer uniformity or the heat transfer capacity or both are improved.
    Type: Grant
    Filed: June 14, 2002
    Date of Patent: June 13, 2006
    Assignee: National Research Council of Canada
    Inventors: Dominique Bouchard, Jean-Paul Nadeau, Francois Hamel, Daniel Simard, Serge F. Turcotte
  • Patent number: 6945311
    Abstract: In a method for vertical continuous casting of a steel band, a strand (11) of a parallelogram-like cross section is cast at first in a revolving chill-mold (2) and is thereafter transferred from said initial cross section with completely solidified longitudinal edges (10) and liquid core into a band (1) with plane-parallel cross section, this occurring in such a way that an already solidified shell (9) of the strand (11) which becomes increasingly thicker by cooling is increasingly compressed in the casting direction in a forming device (4) without upsetting deformation of the completely solidified longitudinal edges (10). In order to provide advantageous conditions it is proposed that after the compression into a band (1) the strand (11) with a still liquid core (16) is guided during the complete solidification of the core merely in a forming gap with a constant width corresponding to the thickness of the completely solidified longitudinal edges (10) and is calibrated in this process.
    Type: Grant
    Filed: May 7, 2002
    Date of Patent: September 20, 2005
    Inventor: Anton Hulek
  • Patent number: 6942013
    Abstract: In twin roll casting of steel strip, molten steel is introduced into the nip between parallel casting rolls to create a casting pool supported on casting surfaces of the rolls and the rolls are rotated to deliver solidified strip downwardly from the nip. Casting surfaces are textured by a random pattern of discrete projections at least some of which include peaks having a surface distribution of between 5 and 200 projections per mm2 and an average height of at least 10 microns. The random texture may be produced by grit blasting the casting surfaces on a substrate covered by a protective coating. Alternatively the texture may be produced by chemical deposition or electrodeposition of a coating onto a substrate to form the casting surfaces.
    Type: Grant
    Filed: June 5, 2002
    Date of Patent: September 13, 2005
    Inventors: Lazar Strezov, Kannappar Mukunthan
  • 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: 6880617
    Abstract: A method and apparatus for continuous casting of metal strip, the apparatus having (i) a first endless belt supported and moved on the surfaces of a first entry pulley and a first exit pulley and (ii) a second endless belt supported and moved on the surfaces of a second entry pulley and a second exit pulley, with an entry nip defined between the first and second entry pulleys and an exit nip defined between the first and second exit pulleys. Opposing surfaces of the first and second belts progressively diverge from each other in the direction of movement thereof. The apparatus may include a cooled roll in place of the first pulley and first belt with a nip defined between the cooled roll and the second entry pulley.
    Type: Grant
    Filed: February 28, 2003
    Date of Patent: April 19, 2005
    Assignee: Alcon Inc.
    Inventors: Gavin F. Wyatt-Mair, Ali Unal
  • 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: 6800145
    Abstract: A Nd—Fe—B type rare earth magnet alloy is provided with hard magnetic phases each of which has a size equal to or less than 80 nm, soft magnetic phases each of which has a size equal to or less than 80 nm, with the hard and soft magnetic phases being present in a mixed structure, and partly anisotropic regions wherein axes of easy magnetization of the hard magnetic phases are aligned in one direction and each having a size equal to or greater than 0.1 &mgr;m. Such a magnet alloy is obtained using a strip casting method or ultra cooling method and serves as material for an anisotropic exchange spring magnet to be applied to a motor.
    Type: Grant
    Filed: May 17, 2002
    Date of Patent: October 5, 2004
    Assignee: Nissan Motor Co., Ltd.
    Inventors: Munekatsu Shimada, Hideaki Ono
  • Publication number: 20040188057
    Abstract: In a method for vertical continuous casting of a steel band, a strand (11) of a parallelogram-like cross section is cast at first in a revolving chill-mold (2) and is thereafter transferred from said initial cross section with completely solidified longitudinal edges (10) and liquid core into a band (1) with plane-parallel cross section, this occurring in such a way that an already solidified shell (9) of the strand (11) which becomes increasingly thicker by cooling is increasingly compressed in the casting direction in a forming device (4) without upsetting deformation of the completely solidified longitudinal edges (10). In order to provide advantageous conditions it is proposed that after the compression into a band (1) the strand (11) with a still liquid core (16) is guided during the complete solidification of the core merely in a forming gap with a constant width corresponding to the thickness of the completely solidified longitudinal edges (10) and is calibrated in this process.
    Type: Application
    Filed: May 17, 2004
    Publication date: September 30, 2004
    Inventor: Anton Hulek
  • Publication number: 20040168789
    Abstract: A method and apparatus for continuous casting of metal strip, the apparatus having (i) a first endless belt supported and moved on the surfaces of a first entry pulley and a first exit pulley and (ii) a second endless belt supported and moved on the surfaces of a second entry pulley and a second exit pulley, with an entry nip defined between the first and second entry pulleys and an exit nip defined between the first and second exit pulleys. Opposing surfaces of the first and second belts progressively diverge from each other in the direction of movement thereof. The apparatus may include a cooled roll in place of the first pulley and first belt with a nip defined between the cooled roll and the second entry pulley.
    Type: Application
    Filed: February 28, 2003
    Publication date: September 2, 2004
    Inventors: Gavin F. Wyatt-Mair, Ali Unal
  • 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: 20030205356
    Abstract: A continuous chain caster has upper and lower mold assemblies comprising endless belts and chains traveling at synchronized speeds. The mold assemblies meet to form a mold channel which is filled with molten metal from a headbox and feed tip. As the molten metal passes through the mold channel, the metal solidifies into the shape of the mold channel. Each belt is positioned outside the corresponding chain so that the smooth surface of the belt defines the surface of the mold channel thereby preventing the formation of fins between mold blocks which make up the chain, protecting the chain blocks, and neutralizing deformations in the chain blocks. The upper and lower blocks of the chains have protrusions at opposite ends which engage the opposing blocks to form the sides of the mold channel. By sliding the chains relative to each other, the width of the mold channel is adjustable.
    Type: Application
    Filed: April 9, 2003
    Publication date: November 6, 2003
    Inventors: Curt Braun, Christopher A. Romanowski, Bobby Bruce Speed, Pieter F. Post
  • Patent number: 6622773
    Abstract: Methods and apparatus for forming a plurality of uniformly sized solder balls utilize a stencil having a plurality of holes of uniform volume disposed on a substrate. Solder is disposed in the holes of the stencil on the substrate. Typically, the solder is in the form of solder paste which is distributed into the holes using a squeegee. While within the holes of the stencil on the substrate, the solder is melted to form solder balls. The stencil may then be removed to leave the solder balls on the substrate, or the solder balls may be removed while the stencil remains on the substrate.
    Type: Grant
    Filed: January 15, 2003
    Date of Patent: September 23, 2003
    Assignee: Micron Technology, Inc.
    Inventor: Warren M. Farnworth
  • Patent number: 6585033
    Abstract: The invention provides a process for producing vanadium alloy foil suitable as a membrane in a hydrogen-refining unit. A vanadium alloy comprising 5 to 25% by weight of at least one selected from the group consisting of Ni, Co, Mo, Fe and Ag, 0.01 to 5% by weight of at least one selected from the group consisting of Ti, Zr and Y, and the balance being V is used. A melt of the vanadium alloy is prepared by use of a crucible 1 having slit 3 in the bottom, a roll 2 comprising a cylinder whose central axis is arranged to be parallel to the slit is rotated, the melt is jetted from the slit 3 to the roll surface 5, the melt is jetted from the slit 3 is rapidly cooled, and the vanadium alloy solidified on the roll surface 5 is continuously exfolitated from the roll surface 5 to obtain the foil.
    Type: Grant
    Filed: February 19, 2002
    Date of Patent: July 1, 2003
    Assignee: Fukuda Metal Foil & Powder Co., Ltd.
    Inventors: Motonori Nishida, Akira Takagi, Toshiki Ohnishi, Osamu Kajita
  • Patent number: 6585032
    Abstract: A strip casting plant with side limits arranged closely adjacent to a carrying belt. The side limits, and preferably the supply device for molten metal, are capable of vibrating and are connected to a device for producing vibrations. The adhesion of solidified material can thus be prevented.
    Type: Grant
    Filed: November 5, 2001
    Date of Patent: July 1, 2003
    Assignee: Mannesmann AG
    Inventors: Klaus Schwerdtfeger, Karl-Heinz Spitzer, Paul Freier, Thomas Von Hinrichs, Wolfgang Reichelt, Ulrich Urlau, Ewald Feuerstacke, Joachim Kroos, Michael Brühl
  • Publication number: 20030102105
    Abstract: An apparatus for producing ingots of nonferrous metals, comprising a continuous casting machine provided with a moving casting shell composed of a plurality of segments arranged in succession, each segment having a portion, with bottom and side walls, of the casting shell formed therein and being open on the sides directed toward the contiguous segments. The segments are movable along a closed path that has at least one substantially straight portion at the casting region. The segments, along the at least one portion of path, are substantially aligned and form a casting shell that is continuous and substantially straight and is closed, along at least one portion of path downstream of the casting region, by closure means at its side that is arranged opposite with respect to the bottom.
    Type: Application
    Filed: November 18, 2002
    Publication date: June 5, 2003
    Inventor: Giulio Properzi
  • Publication number: 20030000675
    Abstract: The invention describes a process for producing a spatially shaped carrier layer (3) which is of foil-like design from hard brittle material.
    Type: Application
    Filed: June 18, 2002
    Publication date: January 2, 2003
    Inventors: Reinhard Fried, Alkan Goecmen
  • Patent number: 6497271
    Abstract: The invention relates to a pig casting machine comprising at least one endless conveyor belt (2), on which pig casting molds (3) are fixed, for conveying pig casting molds from a casting station (4) to a pig removal station and vice versa, wherein each pig casting mold is filled with molten metal as it passes through the casting station with the mold cavity facing upwards, in addition to a device for cooling the pig casting molds before, during and/or after casting, wherein the pig casting molds are embodied having a thin wall. According to the invention, in order to increase output and to be able to cast heavy metals in such a pig casting machine, the pig casting molds (3, 112, 207) are designed to receive molten metal at a melting temperature above 1,000° C.
    Type: Grant
    Filed: April 27, 2001
    Date of Patent: December 24, 2002
    Assignee: SMS Schloemann-Siemag Aktiengesellschaft
    Inventors: Peter Heinrich, Volker Hille, Ursula Kallenborn-Weber, Fritz-Peter Pleschiutschnigg, Manfred Albedyhl, Hartmut Hille
  • Patent number: 6450242
    Abstract: A method and a belt casting device for producing thin billets, in particular composed of steel, has an endless belt to which liquid metal is supplied via a feed device which has a casting channel and is connected to a metallurgical vessel. In this case, the feed device is in the form of a casting channel which has a first casting channel part in the form of a restriction channel part, and which has a second casting channel part whose opening faces the endless belt and whose size corresponds to the cross-sectional area of the finished product. The feed device is connected to a container to which liquid melt can be fed from a metallurgical vessel. Measurement elements are provided, which can be used to detect the level of the liquid melt in the container and/or the thickness of the billet located on the endless belt. Furthermore, the measured values are connected via a measurement and control element to an actuator which is connected to an element for adjusting the outlet rate from the metallurgical vessel.
    Type: Grant
    Filed: September 7, 1999
    Date of Patent: September 17, 2002
    Assignee: Mannesmann AG
    Inventors: Joachim Kroos, Hans-Jürgen Schemeit, Karl-Heinz Spitzer, Ulrich Urlau
  • Patent number: 6446703
    Abstract: The present invention includes a method and apparatus for enhancing the quality of cast metal being cast in a continuous casting process. In particular, the method and apparatus of the present invention combines temperature and quality control sensing to achieve closed-loop control of the cooling of molten metal in a continuous caster.
    Type: Grant
    Filed: May 12, 2000
    Date of Patent: September 10, 2002
    Assignee: Nichols Aluminum-Golden, Inc.
    Inventors: Rudolf Roder, Marcel Witschi
  • Patent number: 6386266
    Abstract: A substrate system for receiving a deposit of sprayed metal droplets including a movable outer substrate on which the sprayed metal droplets are deposited. The substrate system also includes an inner substrate disposed adjacent the outer substrate where the sprayed metal droplets are deposited on the outer substrate. The inner substrate includes zones of differing thermal conductivity to resist substrate layer porosity and to resist formation of large grains and coarse constituent particles in a bulk layer of the metal droplets which have accumulated on the outer substrate. A spray forming apparatus and associated method of spray forming a molten metal to form a metal product using the substrate system of the invention is also provided.
    Type: Grant
    Filed: July 7, 2000
    Date of Patent: May 14, 2002
    Assignee: Alcoa Inc.
    Inventors: Men G. Chu, William P. Chernicoff
  • Patent number: 6363997
    Abstract: A method and a device for the casting of rectangular billets from metal, in particular from steel, close to final dimensions, and for the subsequent inline rolling out of the billet, with a material supply vessel, via the outlet nozzle of which the liquid metal is deposited onto the upper strand of a conveyor belt, on which it solidifies and is transferred to a roll stand for forming, characterized by the following steps: a) before the start of casting aa) the point at which the liquid metal is deposited onto the conveyor belt is predetermined approximately, ab) the conveying speed of the conveyor belt is set as a function of the desired rolling thickness and rolling speed of the roll stand, b) during casting ba) the position of thorough solidification of the metal billet located on the conveyor belt is detected, bb) the temperature of the rolling stock is detected in the region of the roll stand, and bc) the position of thorough solidification and the temperature of the rolling stock are used as contr
    Type: Grant
    Filed: January 11, 2001
    Date of Patent: April 2, 2002
    Assignee: SMS Demag AG
    Inventor: Ulrich Urlau
  • Patent number: 6357637
    Abstract: A method and a casting nozzle for starting the casting of a metal strip close its final dimensions. The method includes leading a melt via a melt-feed vessel into a pouring chamber of a siphon vessel. The melt from the pouring chamber is led onto a cooled transport belt via casting nozzle and a main chamber of the siphon vessel which can be put under vacuum. The pouring chamber and the main chamber of the siphon vessel are filled with the melt up to a top of the siphon. Before the melt flows over the top of the siphon a vacuum is induced in the main chamber by actuating a vacuum device connected to the main chamber. After the melt has flowed over the top of the siphon the melt stream is led through the casting nozzle so that the nozzle cross-section closes in the manner of a plug. The vacuum is increased depending on position of the plug in the casting nozzle until there is in the melt stream a hydraulic connection between the steam inlet and the stream outlet.
    Type: Grant
    Filed: July 25, 2000
    Date of Patent: March 19, 2002
    Assignee: SMS Demag AG
    Inventors: Ulrich Urlau, Joachim Kroos, Reinhard Scholz, Karl-Heinz Spitzer
  • Patent number: RE38555
    Abstract: A continuous chain caster has upper and lower mold assemblies comprising endless belts and chains traveling at synchronized speeds. The mold assemblies meet to form a mold channel which is filled with molten metal from a headbox and feed tip. As the molten metal passes through the mold channel, the metal solidifies into the shape of the mold channel. Each belt is positioned outside the corresponding chain so that the smooth surface of the belt defines the surface of the mold channel thereby preventing the formation of fins between mold blocks which make up the chain, protecting the chain blocks, and neutralizing deformations in the chain blocks. The upper and lower blocks of the chains have protrusions at opposite ends which engage the opposing blocks to form the sides of the mold channel. By sliding the chains relative to each other, the width of the mold channel is adjustable.
    Type: Grant
    Filed: September 25, 2001
    Date of Patent: July 13, 2004
    Assignees: Hunter Douglas Industries, B.V., Fata Hunter, Inc.
    Inventors: Curt Braun, Christopher A. Romanowski, Bobby Bruce Speed, Pieter F. Post
  • Patent number: RE45414
    Abstract: A process and apparatus for continuous casting of amorphous alloy sheets having large sheet thickness using bulk solidifying amorphous alloys are provided. Thick continuous amorphous alloy sheets made of bulk solidifying amorphous alloys are also provided.
    Type: Grant
    Filed: August 29, 2012
    Date of Patent: March 17, 2015
    Assignee: Crucible Intellectual Property, LLC
    Inventor: William L. Johnson