To Electrically Heat Work Material Patents (Class 164/492)
  • Patent number: 11511488
    Abstract: A device produces three-dimensional objects layer by layer in a powder bed fusion process. The device includes a building space, at least one energy source, a building area with a building space platform and a building space container laterally confining the building space platform. The building space platform has an upper side, facing a powder, and an underside, facing away from the powder. The upper side of the building space platform includes a material with a thermal conductivity of at least 20 W/(m·K) and the underside of the building space platform includes a material with a thermal conductivity of a maximum of 0.5 W/(m·K). The contact surface of the upper side of the building space platform with respect to the powder or with respect to the cooling medium is raised by at least 20% in comparison with the planar surface of a building space platform.
    Type: Grant
    Filed: December 17, 2018
    Date of Patent: November 29, 2022
    Assignee: Evonik Operations GmbH
    Inventors: Maik Grebe, Wolfgang Diekmann, Sigrid Hessel, Maximilian Gruhn
  • Patent number: 11426797
    Abstract: The disclosure relates to a powder and a method for generating a component by a powder-bed-based additive manufacturing method, such as laser melting. The powder includes particles having a core and a shell. The particles have an alloy composition of the component. The concentration of higher-melting alloy elements is greater in the shell and the concentration of lower-melting alloy elements is greater in the core, wherein the surface of the particles is higher in comparison with particles with a constant alloy composition. This advantageously prevents the particles from caking together in the powder bed during the production of the component, and so the powder bed may also be subjected to high preheating temperatures of up to 1000° C.
    Type: Grant
    Filed: August 30, 2017
    Date of Patent: August 30, 2022
    Assignee: Siemens Energy Global GmbH & Co. KG
    Inventors: Christian Brunhuber, Martin Schäfer
  • Patent number: 10828722
    Abstract: This relates to a method of manufacturing a metallic component by additive layer manufacturing. The method comprises the step of providing a layer of granular metallic material. The layer of the granular metallic material is melted by a laser beam or electron beam which applies a defined scanning strategy, which is defined in such a way that a first region of the layer is melted before a second region of the layer such that during the subsequent solidification, residual stresses emerge in the first and the second region. These residual stresses act as integrated crack stoppers of the metallic component.
    Type: Grant
    Filed: January 6, 2016
    Date of Patent: November 10, 2020
    Assignee: Airbus Operations GmbH
    Inventor: Tom Shearn
  • Patent number: 10792906
    Abstract: A method of additive manufacturing metal components includes selecting a first component to be formed in a layer-by-layer process, and providing at least a second component to be formed in the same layer-by layer process. The components being selected such that the stresses created in the components during additive manufacturing are substantially balanced. The method further includes separating the components after completion of the layer-by-layer process.
    Type: Grant
    Filed: March 18, 2016
    Date of Patent: October 6, 2020
    Assignee: SIEMENS AKTIENGESELLCHAFT
    Inventor: Trevor Illston
  • Patent number: 10252366
    Abstract: In a method for producing a piston (10) for an internal combustion engine, a melt treatment is performed at least in regions in particular in the region of a combustion chamber depression (14), the depth of said melt treatment being varied in the circumferential direction.
    Type: Grant
    Filed: July 10, 2013
    Date of Patent: April 9, 2019
    Assignee: Federal-Mogul Nurnberg GmbH
    Inventors: Klaus Lades, Wolfram Cromme
  • Patent number: 10118226
    Abstract: A method of fabricating a part by additive fabrication, in particular by melting or sintering particles of powder by means of a high energy beam. The method includes supplying a digital model of a part to be fabricated; orienting the model relative to a construction direction for constructing the part; modifying the model by adding a sacrificial balancing fraction configured so as to balance the residual stresses that appear in the part while it is being fabricated; making a rough part layer by layer using an additive fabrication technique on the basis of the model as modified in this way, the layers being stacked in the construction direction; and using a material-removal method to eliminate the sacrificial portion from the rough part as results from the sacrificial balancing fraction of the model, thereby obtaining the part that is to be fabricated.
    Type: Grant
    Filed: April 1, 2014
    Date of Patent: November 6, 2018
    Assignee: SAFRAN AIRCRAFT ENGINES
    Inventor: Cyrille Baudimont
  • Patent number: 9027632
    Abstract: A method for producing a metal part, the part including, in particular, a first set of elements having a small thickness, and a second set of elements having a large thickness, the method including: forming a peripheral portion of the elements of the second set of elements by selectively melting a powder by scanning the surface of the powder layer with a laser beam or with an electron beam; using the peripheral portion of the elements of the second set of elements as a mould by carrying out an operation of filling an inner area defined by the peripheral portion with liquid metal; cooling the metal part to solidify the inner area defined by the peripheral portion and filled with metal.
    Type: Grant
    Filed: October 24, 2012
    Date of Patent: May 12, 2015
    Assignee: SNECMA
    Inventors: Thomas Vilaro, Sebastien Rix, Cyrille Baudimont
  • Publication number: 20150090421
    Abstract: Exemplary embodiments described herein related to methods and systems for casting metal alloys into articles such as BMG articles. In one embodiment, processes involved for storing, pre-treating, alloying, melting, injecting, molding, etc. can be combined as desired and conducted in different chambers. During these processes, each chamber can be independently, separately controlled to have desired chamber environment, e.g., under vacuum, in an inert gas environment, or open to the surrounding environment. Due to the flexible, independent control of each chamber, the casting cycle time can be reduced and the production throughput can be increased. Contaminations of the molten materials and thus the final products are reduced or eliminated.
    Type: Application
    Filed: September 9, 2014
    Publication date: April 2, 2015
    Inventors: Theodore A. Waniuk, Joseph Stevick, Sean O'Keeffe, Dermot J. Stratton, Joseph C. Poole, Matthew S. Scott, Christopher D. Prest
  • Patent number: 8991474
    Abstract: Various embodiments provide systems and methods for casting amorphous alloys. Exemplary casting system may include an insertable and rotatable vessel configured in a non-movable induction heating structure for melting amorphous alloys to form molten materials in the vessel. While the molten materials remain heated, the vessel may be rotated to pour the molten materials into a casting device for casting them into articles.
    Type: Grant
    Filed: July 7, 2014
    Date of Patent: March 31, 2015
    Assignee: Apple, Inc.
    Inventors: Theodore A. Waniuk, Joseph Stevick, Sean O'Keeffe, Dermot J. Stratton, Joseph C. Poole, Matthew S. Scott, Christopher D. Prest
  • Publication number: 20150034266
    Abstract: A method of building or repair of a hollow superalloy component (20, 61) by forming an opening (38, 62) in a wall (28) of the component; filling a cavity (22B, 64) behind the opening with a fugitive support material (34, 52, 54, 68) to support a filler powder (36) across the opening; traversing an energy beam (42) across the filler powder to form a deposit (44) that spans and closes the opening; in which the deposit is fused to the edges (32, 62) of the opening. The filler powder includes at least metal, and may further include flux. The support material may include filler powder, a solid (54), a foam (52) insert, a flux powder (34) and/or other ceramic powder (68). Supporting powder may have a mesh size smaller than that of the filler powder.
    Type: Application
    Filed: July 14, 2014
    Publication date: February 5, 2015
    Inventors: Gerald J. Bruck, Ahmed Kamel
  • Publication number: 20140375167
    Abstract: Embodiments of the present invention provide methods for manufacturing an even-wall rotor or stator that do not suffer from drawbacks of the prior art. Even-wall rotors or stators produced according to those methods are also provided. In one embodiment, a method for manufacturing a rotor or stator for use in a mud motor is provided. The method includes providing a vacuum chamber; providing a metal electrode at least partially disposed in the vacuum chamber; providing a mold disposed in the vacuum chamber; and melting a portion of the electrode with a direct current arc, the molten metal flowing into the mold ring.
    Type: Application
    Filed: August 27, 2014
    Publication date: December 25, 2014
    Inventors: David W. TEALE, Robert P. BADRAK
  • Patent number: 8915290
    Abstract: The invention relates to a diecasting die (7) and a diecasting method for sprueless diecasting, in particular in a diecasting hot-runner system (1), wherein the diecasting die (7) is provided in a feeding region (8) for forming a plug of solidified molten material (22) that interrupts a flow of the molten material and can be completely remelted. The problem addressed by the present invention is therefore that of providing a diecasting die and a diecasting method according to the preamble of the invention that are suitable for different molten materials, in which a heating acts directly on the molten material with high power and largely without delay, a cooling is not required and the injection-molding method can be carried out at a high operating machine speed and under feeding conditions that can be monitored and reproduced well. The problem is solved by the feeding region (8) comprising direct resistance heating that produces a melting heat and is in direct thermal contact with the molten material (22).
    Type: Grant
    Filed: November 16, 2011
    Date of Patent: December 23, 2014
    Assignee: Ferrofacta GmbH
    Inventor: Walter Müller
  • Publication number: 20140335373
    Abstract: Joining process, joined article, and process of fabricating a joined article are disclosed. The joining process includes providing a consumable electrode comprising a first material and a second material, melting the consumable electrode by a current-induced melting or remelting, and re-solidifying the first material and the second material to form a dissimilar ingot having a first region being a re-solidification of the first material and a second region being a re-solidification of the second material. The joined article includes the first region and the second region; the dissimilar ingot at least partially defines the joined article. The process of fabricating includes providing the dissimilar ingot, positioning the dissimilar ingot within a die, and applying force from the die to compress the dissimilar ingot, thereby forming the joined article.
    Type: Application
    Filed: May 8, 2013
    Publication date: November 13, 2014
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Yan CUI, Srikanth Chandrudu KOTTILINGAM, John R. WOOD, Dechao LIN
  • Publication number: 20140262124
    Abstract: A method for producing a metal part, the part including, in particular, a first set of elements having a small thickness, and a second set of elements having a large thickness, the method including: forming a peripheral portion of the elements of the second set of elements by selectively melting a powder by scanning the surface of the powder layer with a laser beam or with an electron beam; using the peripheral portion of the elements of the second set of elements as a mould by carrying out an operation of filling an inner area defined by the peripheral portion with liquid metal; cooling the metal part to solidify the inner area defined by the peripheral portion and filled with metal.
    Type: Application
    Filed: October 24, 2012
    Publication date: September 18, 2014
    Applicant: SNECMA
    Inventors: Thomas Vilaro, Sebastien Rix, Cyrille Baudimont
  • Patent number: 8813817
    Abstract: Various embodiments provide systems and methods for casting amorphous alloys. Exemplary casting system may include an insertable and rotatable vessel configured in a non-movable induction heating structure for melting amorphous alloys to form molten materials in the vessel. While the molten materials remain heated, the vessel may be rotated to pour the molten materials into a casting device for casting them into articles.
    Type: Grant
    Filed: September 28, 2012
    Date of Patent: August 26, 2014
    Assignee: Apple Inc.
    Inventors: Theodore A. Waniuk, Joseph Stevick, Sean O'Keeffe, Dermot J. Stratton, Joseph C. Poole, Matthew S. Scott, Christopher D. Prest
  • Publication number: 20140231266
    Abstract: The present invention relates to the fabrication of complicated electronic and/or mechanical structures and devices and components using homogeneous or heterogeneous 3D additive build processes. In particular the invention relates to selective metallization processes including electroless and/or electrolytic metallization.
    Type: Application
    Filed: July 13, 2012
    Publication date: August 21, 2014
    Applicant: Nuvotronics, LLC
    Inventors: David W. Sherrer, Dara L. Cardwell
  • Publication number: 20140230605
    Abstract: A method of processing a metallic material includes introducing an electrically conductive metallic material comprising at least one of a metal and a metallic alloy into a furnace chamber maintained at a low pressure relative to atmospheric pressure. A first electron field having a first area of coverage is generated using at least a first ion plasma electron emitter, and the material within the furnace chamber is subjected to the first electron field to heat the material to a temperature above a melting temperature of the material. A second electron field having a second area of coverage smaller than the first area of coverage is generated using a second ion plasma electron emitter. At least one of any solid condensate within the furnace chamber, any solidified portions of the electrically conductive metallic material, and regions of a solidifying ingot to the second electron field, is subjected to the second electron field, using a steering system.
    Type: Application
    Filed: April 24, 2014
    Publication date: August 21, 2014
    Applicant: ATI PROPERTIES, INC.
    Inventor: Robin M. Forbes Jones
  • Publication number: 20140219860
    Abstract: A process for producing formed parts made of an aluminum alloy, including the steps of exposing the aluminum alloy to high shearing forces in a mixing and kneading machine, feeding the liquid aluminum alloy to the working space at one end of the housing and, at the other end of the housing, removing from the working space the liquid aluminum alloy now formed as a partially solid aluminum alloy with a predefined solids content, and processing the partially solid aluminum alloy with the predefined solids content into formed parts, wherein the solids content of the aluminum alloy in the working space is set to the predefined solids content by cooling and heating the working space in a targeted manner. The mixing and kneading machine includes a housing with a working space, a worm shaft including kneading blades and axial passage openings, and kneading projections.
    Type: Application
    Filed: August 8, 2012
    Publication date: August 7, 2014
    Applicant: Rheinfelden Alloys GmbH & Co. KG
    Inventor: Rudiger Franke
  • Patent number: 8752613
    Abstract: The present invention relates to the field of magnesium and magnesium alloy processing, and discloses the use of aluminum-zirconium-titanium-carbon (Al—Zr—Ti—C) intermediate alloy in wrought processing of magnesium and magnesium alloys, wherein the aluminum-zirconium-titanium-carbon intermediate alloy has a chemical composition of: 0.01% to 10% Zr, 0.01% to 10% Ti, 0.01% to 0.3% C, and Al in balance, based on weight percentage; the wrought processing is plastic molding; and the use is to refine the grains of magnesium or magnesium alloys. The present invention further discloses the method for using the aluminum-zirconium-titanium-carbon (Al—Zr—Ti—C) intermediate alloy in casting and rolling magnesium and magnesium alloys. The present invention provides an aluminum-zirconium-titanium-carbon (Al—Zr—Ti—C) intermediate alloy and the use thereof in the plastic wrought processing of magnesium or magnesium alloys as a grain refiner.
    Type: Grant
    Filed: July 18, 2011
    Date of Patent: June 17, 2014
    Assignee: Shenzhen Sunxing Light Alloys Materials Co., Ltd.
    Inventors: Xuemin Chen, Qingdong Ye, Yueming Yu, Jianguo Li
  • Patent number: 8746324
    Abstract: The present invention relates to the field of magnesium and magnesium alloy processing, and discloses a use of aluminum-zirconium-carbon (Al—Zr—C) intermediate alloy in wrought processing of magnesium and magnesium alloys, wherein the aluminum-zirconium-carbon intermediate alloy has a chemical composition of: 0.01% to 10% Zr, 0.01% to 0.3% C, and Al in balance, based on weight percentage; the wrought processing is plastic molding; and the use is to refine the grains of magnesium or magnesium alloys. The present invention further discloses the method for using the aluminum-zirconium-carbon (Al—Zr—C) intermediate alloy in casting and rolling magnesium and magnesium alloys. The present invention provides an aluminum-zirconium-carbon (Al—Zr—C) intermediate alloy and the use thereof in the plastic wrought processing of magnesium or magnesium alloys as a grain refiner.
    Type: Grant
    Filed: April 22, 2011
    Date of Patent: June 10, 2014
    Assignee: Shenzhen Sunxing Light Alloys Materials Co., Ltd.
    Inventors: Xuemin Chen, Qingdong Ye, Yueming Yu, Jianguo Li
  • Publication number: 20140083645
    Abstract: Exemplary embodiments described herein relate to methods and systems for casting metal alloys into articles such as BMG articles. In one embodiment, processes involved for storing, pre-treating, alloying, melting, injecting, molding, etc. can be combined as desired and conducted in different chambers. During these processes, each chamber can be independently, separately controlled to have desired chamber environment, e.g., under vacuum, in an inert gas environment, or open to the surrounding environment. Due to the flexible, independent control of each chamber, the casting cycle time can be reduced and the production throughput can be increased. Contaminations of the molten materials and thus the final products are reduced or eliminated.
    Type: Application
    Filed: September 27, 2012
    Publication date: March 27, 2014
    Inventors: Theodore A. Waniuk, Joseph Stevick, Sean O'Keeffe, Dermot J. Stratton, Joseph C. Poole, Matthew S. Scott, Christopher D. Prest
  • Patent number: 8662142
    Abstract: A method and a device for remelting metal in an electric furnace includes forming a slag bath to form molten material electrodes. The molten metal of the material electrodes solidifies in block form in a crucible apparatus as a result of cooling in such a way that a block growth forms from a block base using a progressing solidification process, wherein the block base is heated by applying energy directly to the block base to influence the cooling process.
    Type: Grant
    Filed: June 11, 2010
    Date of Patent: March 4, 2014
    Assignee: Ald Vacuum Technologies GmbH
    Inventors: Ulrich Biebricher, Michael Protzmann, Gerhard Brückmann
  • Patent number: 8610027
    Abstract: A process produces a 3-dimensional component (16) by selective laser melting (SLM), in which the component (16) is formed on a foundation with a surface, e.g., a platform (10) or a support, which in particular is a component of the same type which has already been produced previously, by successively melting layers of a first metal powder to form a sequence of stacked layers. The process is substantially simplified and made more flexible by virtue of the fact that the separation of the finished component (16) from the surface of the platform (10) or the support thereof is simplified by providing a separating layer (11) between the component (16) and the platform (10) or the support, this separating layer making it possible to separate the finished component (16) from the platform (10) or the support without damaging the finished component (16).
    Type: Grant
    Filed: January 20, 2011
    Date of Patent: December 17, 2013
    Assignee: Alstom Technology Ltd
    Inventors: Simone Hövel, Alexander Stankowski, Lukas Rickenbacher
  • Publication number: 20130312928
    Abstract: The invention concerns a method for manufacturing at least one thin-walled structure (1,11,13,17,18), whereby this structure is built layer by layer by applying successive powder layers extending substantially horizontally and by moving an energy beam over each of these powder layers according to a predetermined pattern so as to make said powder melt and subsequently make it solidify or sinter, such that successive layers connected to each other of said thin-walled structure (1,11, 13,17,18) are formed which extend according to a horizontal cross section of this thin-walled structure (1, 11,13,17,18).
    Type: Application
    Filed: February 6, 2012
    Publication date: November 28, 2013
    Applicant: LAYERWISE N.V.
    Inventors: Peter Mercelis, Jonas Van Vaerenbergh, Wilfried Van Der Perre
  • Publication number: 20130309121
    Abstract: Described herein are methods of constructing a part using BMG layer by layer. In one embodiment, a layer of BMG powder is deposited to selected positions and then fused to a layer below by suitable methods such as laser heating or electron beam heating. The deposition and fusing are then repeated as need to construct the part layer by layer. One or more layers of non-BMG can be used as needed. In one embodiment, layers of BMG can be cut from one or more sheets of BMG to desired shapes, stacked and fused to form the part.
    Type: Application
    Filed: May 16, 2012
    Publication date: November 21, 2013
    Applicants: Crucible Intellectual Property LLC, Apple Inc.
    Inventors: Christopher D. Prest, Joseph C. Poole, Joseph Stevick, Theodore Andrew Waniuk, Quoc Tran Pham
  • Publication number: 20130263977
    Abstract: A method for manufacturing a component or coupon made of a high temperature superalloy based on Ni, Co, Fe or combinations thereof includes forming the component or coupon using a powder-based additive manufacturing process. The manufacturing process includes completely melting the powder followed by solidifying the powder. The formed component or coupon is subjected to a heat treatment so as to optimize specific material properties. The heat treatment takes place at higher temperatures compared to cast components or coupons.
    Type: Application
    Filed: October 31, 2012
    Publication date: October 10, 2013
    Applicant: ALSTOM TECHNOLOGY LTD
    Inventor: ALSTOM Technology Ltd
  • Publication number: 20130233507
    Abstract: The invention relates to a diecasting die (7) and a diecasting method for sprueless diecasting, in particular in a diecasting hot-runner system (1), wherein the diecasting die (7) is provided in a feeding region (8) for forming a plug of solidified molten material (22) that interrupts a flow of the molten material and can be completely remelted. The problem addressed by the present invention is therefore that of providing a diecasting die and a diecasting method according to the preamble of the invention that are suitable for different molten materials, in which a heating acts directly on the molten material with high power and largely without delay, a cooling is not required and the injection-moulding method can be carried out at a high operating machine speed and under feeding conditions that can be monitored and reproduced well. The problem is solved by the feeding region (8) comprising direct resistance heating that produces a melting heat and is in direct thermal contact with the molten material (22).
    Type: Application
    Filed: November 16, 2011
    Publication date: September 12, 2013
    Inventor: Walter Müller
  • Publication number: 20130228302
    Abstract: A process for producing a crack-free and dense three-dimensional article of a gamma-prime precipitation-strengthened nickel-base superalloy, with more than 6 wt. % of [2 Al (wt. %)+Ti (wt. %)], which involves: (a) preparing a powder layer of a gamma-prime precipitation-strengthened nickel-based alloy material, with uniform thickness on a SLM apparatus substrate plate, or on a previously processed powder layer; (b) melting the prepared powder layer by scanning with a focused laser beam an article cross section area according to a three-dimensional sliced model with calculated cross sections, stored in the SLM control unit; (c) lowering the substrate plate by one layer thickness; and (d) repeating (a) to (c) until reaching a final cross section according to the three-dimensional sliced model, wherein, for (b), the laser power, focus diameter of the focal spot, and scan speed of the focused laser beam are adjusted to obtain heat dissipation welding.
    Type: Application
    Filed: November 2, 2012
    Publication date: September 5, 2013
    Applicant: ALSTOM TECHNOLOGY LTD
    Inventors: Lukas Emanuel Rickenbacher, Adriaan Bernardus Spierings
  • Publication number: 20130139964
    Abstract: A mirror or mirror assembly fabricated by molding, pressing, assembling, or depositing one or more bulk metal glass (BMG), bulk metal glass composite (BMGMC), or amorphous metal (AM) parts and where the optical surface and backing of the mirror can be fabricated without machining or polishing by utilizing the unique molding capabilities of this class of materials.
    Type: Application
    Filed: November 16, 2012
    Publication date: June 6, 2013
    Applicant: California Institute of Technology
    Inventor: California Institute of Technology
  • Publication number: 20120255701
    Abstract: Certain embodiments of a melting and casting apparatus comprising includes a melting hearth; a refining hearth fluidly communicating with the melting hearth; a receiving receptacle fluidly communicating with the refining hearth, the receiving receptacle including a first outflow region defining a first molten material pathway, and a second outflow region defining a second molten material pathway; and at least one melting power source oriented to direct energy toward the receiving receptacle and regulate a direction of flow of molten material along the first molten material pathway and the second molten material pathway. Methods for casting a metallic material also are disclosed.
    Type: Application
    Filed: April 7, 2011
    Publication date: October 11, 2012
    Applicant: ATI Properties, Inc.
    Inventors: Travis R. Moxley, Lanh G. Dinh, Timothy F. Soran, Edmund J. Haas, Douglas P. Austin, Matthew J. Arnold, Eric R. Martin
  • Publication number: 20120241054
    Abstract: In various embodiments, metallic products are formed by alloying niobium with at least one of yttrium, aluminum, hafnium, titanium, zirconium, thorium, lanthanum, or cerium and processing the alloy.
    Type: Application
    Filed: May 3, 2012
    Publication date: September 27, 2012
    Inventor: Paul R. Aimone
  • Publication number: 20120160443
    Abstract: A material addition process is described that includes coupling a plate to a gas turbine engine component and adding material to the plate. In one embodiment the gas turbine engine component can be processed by removing a portion that is damaged, such as a portion that includes a crack. A material can be deposited on the plate and built up in layers to replace the removed portion. The material can be layered upon the plate such that its thickness through the layers is smaller than a reach of the layers in a direction of the layer. The plate can be removed in whole or in part after a material has been added. In one form the material can be added by direct laser deposition. In one embodiment a metal powder is fused using a laser. Excess buildup can be removed to reveal a net shape article.
    Type: Application
    Filed: December 26, 2011
    Publication date: June 28, 2012
    Inventor: Quinlan Yee Shuck
  • Publication number: 20120138258
    Abstract: A method for manufacturing an engine component includes forming the component by deposition of powder, which is melted by a heat source, in subsequent Layers to form the component into a desired shape, the component having an outer surface, and re-melting at least part of the outer surface.
    Type: Application
    Filed: April 24, 2009
    Publication date: June 7, 2012
    Applicant: VOLVO AERO CORPORATION
    Inventors: Peter Jonsson, Dzevad Imamovic, Börje Nordin, Per Thorin
  • Publication number: 20120132385
    Abstract: The invention relates to a method and a device for remelting metal in an electric furnace, wherein material electrodes are melted on by forming a slag bath, and the melted-on metal of the material electrodes solidifies in block form in a crucible apparatus (10) as a result of cooling in such a way that a block growth forms from a block base by means of a progressing solidification process, wherein the block base is heated to influence the cooling process, wherein the block base is heated by applying energy directly to the block base.
    Type: Application
    Filed: June 11, 2010
    Publication date: May 31, 2012
    Inventors: Ulrich Biebricher, Michael Protzmann, Gerhard Bruckmann
  • Publication number: 20120090805
    Abstract: Systems, apparatus, methods, and articles of manufacture that provide for a thermistor furnace, such as for melting, casting, and/or smelting loads (e.g., precious metals, other metals such as titanium, and/or thermoset plastics), are provided. In some embodiments, the thermistor furnace may comprise a vacuum spin casting apparatus capable of utilizing various types and configurations of molds, such as graphite and/or plaster molds.
    Type: Application
    Filed: October 18, 2011
    Publication date: April 19, 2012
    Inventors: Stanislaw P. Uzialko, Brenda J. Prince
  • Publication number: 20120043050
    Abstract: The present invention relates to the field of magnesium and magnesium alloy processing, and discloses a use of aluminum-zirconium-carbon (Al—Zr—C) intermediate alloy in wrought processing of magnesium and magnesium alloys, wherein the aluminum-zirconium-carbon intermediate alloy has a chemical composition of: 0.01% to 10% Zr, 0.01% to 0.3% C, and Al in balance, based on weight percentage; the wrought processing is plastic molding; and the use is to refine the grains of magnesium or magnesium alloys. The present invention further discloses the method for using the aluminum-zirconium-carbon (Al—Zr—C) intermediate alloy in casting and rolling magnesium and magnesium alloys. The present invention provides an aluminum-zirconium-carbon (Al—Zr—C) intermediate alloy and the use thereof in the plastic wrought processing of magnesium or magnesium alloys as a grain refiner.
    Type: Application
    Filed: April 22, 2011
    Publication date: February 23, 2012
    Applicant: Sun Xing Chemical & Metallurgical Materials (Shenzhen) Co., Ltd.
    Inventors: Xuemin Chen, Qingdong Ye, Yueming Yu, Jianguo Li
  • Publication number: 20120037332
    Abstract: The present invention relates to the field of magnesium and magnesium alloy processing, and discloses the use of aluminum-zirconium-titanium-carbon (Al—Zr—Ti—C) intermediate alloy in wrought processing of magnesium and magnesium alloys, wherein the aluminum-zirconium-titanium-carbon intermediate alloy has a chemical composition of: 0.01% to 10% Zr, 0.01% to 10% Ti, 0.01% to 0.3% C, and Al in balance, based on weight percentage; the wrought processing is plastic molding; and the use is to refine the grains of magnesium or magnesium alloys. The present invention further discloses the method for using the aluminum-zirconium-titanium-carbon (Al—Zr—Ti—C) intermediate alloy in casting and rolling magnesium and magnesium alloys. The present invention provides an aluminum-zirconium-titanium-carbon (Al—Zr—Ti—C) intermediate alloy and the use thereof in the plastic wrought processing of magnesium or magnesium alloys as a grain refiner.
    Type: Application
    Filed: July 18, 2011
    Publication date: February 16, 2012
    Applicant: Sun Xing Chemical & Metallurigical Materials (Shenzhen) CO., Ltd.
    Inventors: Xuemin Chen, Qingdong Ye, Yueming Yu, Jianguo Li
  • Publication number: 20120018115
    Abstract: A process produces a 3-dimensional component (16) by selective laser melting (SLM), in which the component (16) is formed on a foundation with a surface, e.g., a platform (10) or a support, which in particular is a component of the same type which has already been produced previously, by successively melting layers of a first metal powder to form a sequence of stacked layers. The process is substantially simplified and made more flexible by virtue of the fact that the separation of the finished component (16) from the surface of the platform (10) or the support thereof is simplified by providing a separating layer (11) between the component (16) and the platform (10) or the support, this separating layer making it possible to separate the finished component (16) from the platform (10) or the support without damaging the finished component (16).
    Type: Application
    Filed: January 20, 2011
    Publication date: January 26, 2012
    Inventors: SIMONE HÖVEL, ALEXANDER STANKOWSKI, LUKAS RICKENBACHER
  • Publication number: 20110214830
    Abstract: To produce hollow ingots, at least two consumable electrodes having a diameter of at least 1.0 times the wall thickness of the hollow ingots are melted in a short, water-cooled mold that is flared particularly in a T-shape in the area of the consumable electrodes, wherein the inner wall of the hollow ingot is formed by a mandrel with a conicity of at least 1.5% that is installed in the mold from above, and the level of the liquid heel is maintained below the T-shaped flaring of the mold.
    Type: Application
    Filed: March 2, 2011
    Publication date: September 8, 2011
    Applicant: INTECO SPECIAL MELTING TECHNOLOGIES GMBH
    Inventors: Harald HOLZGRUBER, Michael BREITLER, Bertram OFNER
  • Patent number: 8002014
    Abstract: Method such as can be used, for example, for producing molded articles from metallic glasses. Method and apparatus are provided in which a good mold filling during casting is achieved in addition to high cooling rates. The method includes introducing a metal-containing melt into an electrically conducting casting mold, the metal-containing melt and the mold being connected in an electrically conducting manner to the outputs of the same voltage source during the introduction into a casting mold, so that a preset current flows through the boundary interface between the melt and the mold. Apparatus is also provided in which there is an electrically conducting connection to a voltage source between a metal-containing melt and an electrically conducting mold for the melt.
    Type: Grant
    Filed: July 28, 2006
    Date of Patent: August 23, 2011
    Assignee: Leibniz-Institut fuer Festkoerper-und Werkstofforschung Dresden E.V.
    Inventors: Stefan Roth, Ludwig Schultz
  • Publication number: 20110041708
    Abstract: Cookware in the form of a grill plate, griddle plate, waffle iron, panini press or the like is made from a cast composite including a graphite core plate encapsulated within a cast metal shell of aluminum or stainless steel, and a method for manufacturing same.
    Type: Application
    Filed: August 19, 2010
    Publication date: February 24, 2011
    Applicant: ALL-CLAD METALCRAFTERS LLC
    Inventor: William A. Groll
  • Publication number: 20100200189
    Abstract: A method for making a turbine airfoil includes providing a mold core and an outer shell which cooperatively define a cavity in the shape of a hollow airfoil having an outer wall, a root, and a tip. A tip portion of the core extends completely through the portion of the cavity defining the tip of the airfoil. The core is restrained to prevent movement between the core and outer shell. Molten metal is introduced into the cavity and solidified to form an airfoil having at least one outer wall which defines an open tip and a hollow interior. A metallic tip cap is formed on the outer wall which substantially closes off the open tip. The tip cap may be formed by packing the airfoil with metallic powder; and laser sintering the exposed powder so as to form a tip cap which is metallurgically bonded to the outer wall.
    Type: Application
    Filed: February 12, 2009
    Publication date: August 12, 2010
    Applicant: General Electric Company
    Inventors: Huan Qi, Magdi Azer, Prabhjot Singh, Todd Jay Rockstroh, Sudhir K. Tewari, Joseph Giancarlo Sabato, Donald Brett Desander, Mark Douglas Gledhill
  • Patent number: 7754027
    Abstract: A method for manufacturing a sputtering target includes the steps of: providing a highly pure matrix material containing a magnetic metal, and a highly pure precious metal ingot material; cleaning the surfaces of the matrix material and the precious metal ingot; vacuum melting the matrix material and the precious metal ingot to obtain a molten alloy; pouring the molten alloy in a mold having a cooling system while maintaining a surface of the molten alloy at a molten state by arc heating until the pouring is finished, thereby forming the molten alloy into a cast blank; hot working the cast blank; and annealing the cast blank after the hot working.
    Type: Grant
    Filed: August 27, 2007
    Date of Patent: July 13, 2010
    Assignee: China Steel Corporation
    Inventors: Rong-Zhi Chen, Jye-Long Lee, In-Ting Hong, Jui-Tung Chang, Pa-Tsui Sze
  • Publication number: 20100044003
    Abstract: A method and apparatus involve positioning an insert within a cavity of a mold, heating an insert wall within the cavity of the mold, and casting a molten metal into the cavity adjacent the insert. A surface of the insert absorbs heat from the molten metal to melt and fuse to the molten metal.
    Type: Application
    Filed: August 24, 2009
    Publication date: February 25, 2010
    Inventor: Mark A. Baumgarten
  • Publication number: 20100021338
    Abstract: An iron-based high-temperature alloy is disclosed which contains the following chemical composition: 20% by weight Cr; 5 to 6% by weight Al; 4% by weight Ta; 4% by weight Mo; 3 to 4% by weight Re; 0.2% by weight Zr; 0.05% by weight B; 0.1% by weight Y; 0.1% by weight Hf; 0 to 0.05% by weight C; and remainder Fe and unavoidable impurities. The alloy can be produced at low cost and can possess outstanding oxidation resistance and good mechanical properties at temperatures up to 1200° C.
    Type: Application
    Filed: July 24, 2009
    Publication date: January 28, 2010
    Applicant: ALSTOM Technology Ltd
    Inventors: Mohamed NAZMY, Andreas KÜNZLER, Giuseppe BANDIERA, Hanspeter ZINN
  • Publication number: 20090165988
    Abstract: A method for making a turbine airfoil includes: (a) providing a mold having: (i) a core; (ii) an outer shell surrounding the core such that the core and the outer shell cooperatively define a cavity in the shape of an airfoil having at least one outer wall; and (iii) a core support extending from the core to the outer shell through a portion of the cavity that defines the at least one sidewall; (b) introducing molten metal alloy into the cavity and surrounding the core support; (c) solidifying the alloy to form an airfoil casting having at least one outer wall which has at least one core support opening passing therethrough; (d) removing the mold so as to expose the airfoil; and (e) sealing the at least one core support opening in the airfoil with a metal alloy metallurgically bonded to the at least one outer wall.
    Type: Application
    Filed: December 31, 2007
    Publication date: July 2, 2009
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Todd Jay Rockstroh, Sudhir K. Tewari, Joseph Giancarlo Sabato, Donald Brett Desander, David Henry Abbott, Mark Douglas Gledhill
  • Publication number: 20080295991
    Abstract: The invention relates to the field of materials sciences and relates to a method such as can be used, for example, for producing molded articles from metallic glasses. The object of the present invention lies in disclosing a method and an apparatus in which a good mold filling during casting is achieved in addition to high cooling rates. The object is attained by a method in which a metal-containing melt is introduced into an electrically conducting casting mold, the metal-containing melt and the mold being connected in an electrically conducting manner to the outputs of the same voltage source during the introduction into a casting mold, so that a preset current flows through the boundary interface between the melt and the mold. The object is furthermore attained through an apparatus in which there is an electrically conducting connection to a voltage source between a metal-containing melt and an electrically conducting mold for the melt.
    Type: Application
    Filed: July 28, 2006
    Publication date: December 4, 2008
    Applicant: LEIBNZ-INSTITU FUER FESTKOERPE-UND WERKSTOFFORSCHU E.V. HELMHOLTZSTRASSE 20
    Inventors: Stefan Roth, Ludwig Schultz
  • Patent number: 7111665
    Abstract: In a lubricant composition suitable for use in the manufacture of aluminum alloys comprising a lubricant base, the improvement wherein the lubricant composition further comprises: an effective amount of water, surfactant, and a high viscosity organic material having a low vapor pressure. It is believed that this mixture provides a method for uniformly distributing the surface oxide at the meniscus for casting applications and increasing meniscus stability. Uniform distribution of the oxide and increased stability at the meniscus reduces vertical fold formation that can lead to cracks in the aluminum ingot. In addition, the mixture promotes uniform heat transfer around the mold. Uniform heat transfer around the mold allows the solidifying aluminum alloy to stay in contact with the mold longer and form stronger ingot shells. A process for continuous or semi-continuous casting of aluminum alloys via the use of this lubricant composition is also disclosed.
    Type: Grant
    Filed: August 4, 2005
    Date of Patent: September 26, 2006
    Assignee: Alcon Inc.
    Inventors: Patricia A. Stewart, James R. Anglin, Ray T. Richter, Larry F. Wieserman, Brian C. Reynolds, Dean K. Vinnedge, Jim M. Hart
  • Patent number: 6820679
    Abstract: The invention relates to a method according to which a metal (13) is re-shaped by a primary forming process. The aim of the invention is to improve such a method so that heat can be relatively easily added to the part and so that the addition can be varied as regards space and time. To this end, a voltage is applied to parts of the primary forming device between which the metal is disposed during the insertion process and/or during the primary forming process and/or during a subsequent treatment in the primary form after the primary forming process so that a closed circuit is produced and heat energy is supplied to the metal by the closed circuit.
    Type: Grant
    Filed: September 12, 2002
    Date of Patent: November 23, 2004
    Assignee: DRM Druckguss GmbH
    Inventor: Peter Lutze
  • Patent number: 6598662
    Abstract: An apparatus for supplying molten steel and a continuous casting method therewith are described. The apparatus is equipped with a tundish 1 having an upper nozzle 2 at the bottom, a flow control mechanism 3 disposed below the upper nozzle 2, an immersion nozzle 4 formed by a refractory material having a good electrical conductivity, one electrode 5 disposed in the inner space of the tundish 1, the other electrode 6 disposed in the immersion nozzle 4, and a power supply 7 connected to the electrodes 5 and 6. In the method, the molten steel is supplied into a mold in the state of supplying an electric current between the inner surface of the immersion nozzle 4 and the molten steel 8 passing through the inside thereof by utilizing the apparatus for supplying molten steel. The deposition of the Al oxide or the like in the molten steel onto the inner surface of the immersion nozzle and others can be prevented, and thereby the generation of the surface defects in the products can also be prevented.
    Type: Grant
    Filed: August 13, 2002
    Date of Patent: July 29, 2003
    Assignee: Sumitomo Metal Industries, Ltd.
    Inventors: Toru Kato, Norihiro Nishida, Masashi Hara, Masayuki Kawamoto, Toshihiko Murakami