By Arc Discharge Patents (Class 164/495)
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Patent number: 11268166Abstract: A method of producing a metal superalloy may include: providing a charge of metal materials; melting the charge of metal materials in an electric-arc furnace to obtain a first melt of the charge of metal materials; performing Argon Oxygen Decarburization (A.O.D.) treatment on the first melt to obtain a decarburized and refined first melt; solidifying the decarburized and refined first melt to obtain first ingots; melting the first ingots in a Vacuum Induction Degassing and Pouring (V.I.D.P.) furnace to obtain a second melt; solidifying the second melt to obtain second ingots; melting the second ingots in a Vacuum Arc Remelting (V.A.R.) furnace to obtain a third melt; and solidifying the third melt to obtain the metal superalloy. The charge of metal materials may have a weight greater than or equal to forty tons and less than or equal to sixty tons.Type: GrantFiled: January 24, 2019Date of Patent: March 8, 2022Assignee: FORONI S.P.A.Inventors: Andrea Foroni, Luca Foroni
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Patent number: 10086246Abstract: Golf clubs formed from bulk-solidifying amorphous metals (i.e., metallic glasses) having high elastic modulus and fracture toughness, and to methods of forming the same are provided. Among other components, the golf club materials disclosed enable fabrication of flexural membranes or shells used in golf club heads (drivers, fairways, hybrids, irons, wedges and putters) exhibiting enhanced flexural or bending compliance together with the ability to deform plastically and avoid brittle fracture or catastrophic failure when overloaded under bending loads. Further, the high strength of the material and its density, comparable to that of steel, enables the redistribution of mass in the golf club while maintaining a desired overall target mass.Type: GrantFiled: January 29, 2014Date of Patent: October 2, 2018Assignee: GlassiMetal Technology, Inc.Inventors: William L. Johnson, David S. Lee, Marios D. Demetriou, Jong Hyun Na, Glenn Garrett
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Patent number: 9868150Abstract: Systems and methods to fabricate objects including metallic glass-based materials using low-pressure casting techniques are described. In one embodiment, a method of fabricating an object that includes a metallic glass-based material includes: introducing molten alloy into a mold cavity defined by a mold using a low enough pressure such that the molten alloy does not conform to features of the mold cavity that are smaller than 100 ?m; and cooling the molten alloy such that it solidifies, the solid including a metallic glass-based material.Type: GrantFiled: September 19, 2014Date of Patent: January 16, 2018Assignee: California Institute of TechnologyInventors: Douglas C. Hofmann, Andrew Kennett
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Patent number: 9841334Abstract: An electrode joining apparatus for joining a fixed electrode and a free electrode including an electrode holder configured to receive the fixed electrode and a torque device positioned above the electrode holder. The torque device is configured to grip and spin the free electrode to join the free electrode to the fixed electrode. A force sensor is coupled to the torque device. The torque device is configured to apply a force on the force sensor when the torque device engages the free electrode. The force sensor can detect a feedback force signal representative of the force applied by the torque device on the free electrode. The feedback force signal can be used to determine the torque applied to the free electrode by the torque device to help ensure that a proper joint is formed between the free electrode and the fixed electrode.Type: GrantFiled: June 30, 2016Date of Patent: December 12, 2017Assignee: Contractors & Industrial Supply Company, Inc.Inventor: Tom D. Schiller
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Patent number: 9808797Abstract: A resistance furnace provides an improved upper and lower electrode construction with significantly increased coolant flow. The lower electrode has a tip design that significantly lowers the electrode tip temperature during an analysis. The upper and lower electrodes also cooperate with an improved crucible design to significantly reduce the power required to fuse a specimen contained in the crucible. The furnace uniformly heats the floor and lower side walls of a crucible, which lowers the power requirement for specimen fusion and provides higher structural benefits to provide consistent analysis and manufacturing yields. The crucible has a cylindrical body and pedestal base with an annular smoothly curved concave indentation therebetween.Type: GrantFiled: June 18, 2013Date of Patent: November 7, 2017Assignee: Leco CorporationInventors: Joshua N. Wetzel, Gordon C. Ford
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Patent number: 9555472Abstract: An arc melting and tilt casting apparatus having a casing provided with a vacuum chamber for housing a hearth having a melting trough and pouring means, arc-melting electrode means passing through the casing in the chamber, a mold having a melt receiving orifice, vacuum generating means, sealing means for maintaining the vacuum in the chamber and tilting means for tilting the apparatus to cause the melt to flow from the melting trough via the pouring means in the mold through the mold orifice. The hearth and mold are connected together and moveable as a single unit in the vacuum chamber and out from the chamber.Type: GrantFiled: May 11, 2012Date of Patent: January 31, 2017Assignee: Aalto University FoundationInventors: Erno Soinila, Tuomas Pihlajamaki, Sven Bossuyt, Hannu Hanninen
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Patent number: 9434000Abstract: A method and a system for forming a solid casting. A material is fed into a mold having a retractable bottom. A first portion of the material at a first, lower position within the mold is allowed to solidify to thereby form a portion of the casting. The retractable bottom is withdrawn downwards at a withdrawal rate. A second portion of the material at a second, upper position within the mold is maintained in a liquid state by application of heat thereto, using a plasma arc generated by a plasma arc torch. A voltage of the plasma arc is measured, and the withdrawal rate of the retractable bottom is controlled based on the voltage of the plasma arc.Type: GrantFiled: October 15, 2014Date of Patent: September 6, 2016Assignee: RETECH SYSTEMS, LLCInventors: Tony Tesoriere, Robin Lampson
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Publication number: 20150107797Abstract: In an electric arc furnace system for making steel, a method and structure (1) for eliminating teeming hang-ups and ensuring temperature homogeneity in a ladle which teems into an ingot mold by gas purging at all possible steps under both atmospheric and vacuum conditions, and (2) for preventing non-metallic inclusions from appearing in the final product by deflecting the granular material in the teeming ladle well block away from the ingot mold by a heat resistant but combustible deflector just prior to entry of the teeming stream into the ingot mold.Type: ApplicationFiled: October 18, 2013Publication date: April 23, 2015Inventors: John A. Guliana, Guy A. Brada, Christian H. Ericksen, Bruce C. Liimatainen, Algirdas A. Underys
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Publication number: 20150090421Abstract: 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: ApplicationFiled: September 9, 2014Publication date: April 2, 2015Inventors: Theodore A. Waniuk, Joseph Stevick, Sean O'Keeffe, Dermot J. Stratton, Joseph C. Poole, Matthew S. Scott, Christopher D. Prest
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Patent number: 8985191Abstract: The present invention is a method for manufacturing a titanium ingot (30), the method being characterized by comprising: a step of melting a titanium alloy for a predetermined time by cold crucible induction melting (CCIM); a step of supplying molten titanium (6) to a cold hearth (10), and separating high density inclusions (HDIs) (8) by precipitation in the cold hearth (10) while spraying a plasma jet or an electron beam onto the bath surface of the molten titanium (6); and a step of supplying a molten titanium starting material from which the HDIs (8) are separated by precipitation to a mold (20) to obtain the titanium ingot.Type: GrantFiled: October 7, 2014Date of Patent: March 24, 2015Assignee: Kobe Steel, Ltd.Inventors: Daisuke Matsuwaka, Daiki Takahashi, Hitoshi Ishida, Hiroshi Yokoyama
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Publication number: 20140375167Abstract: 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: ApplicationFiled: August 27, 2014Publication date: December 25, 2014Inventors: David W. TEALE, Robert P. BADRAK
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Patent number: 8900345Abstract: A separation membrane including an alloy, the alloy including at least one Group 5 element, and at least one selected from Pt and Ir.Type: GrantFiled: March 18, 2013Date of Patent: December 2, 2014Assignee: Samsung Electronics Co., Ltd.Inventors: Kwang Hee Kim, Hyeon Cheol Park, Byung Ki Ryu, Jae Ho Lee
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Patent number: 8881792Abstract: The present invention is a method for manufacturing a titanium ingot (30), the method being characterized by comprising: a step of melting a titanium alloy for a predetermined time by cold crucible induction melting (CCIM); a step of supplying molten titanium (6) to a cold hearth (10), and separating high density inclusions (HDIs)(8) by precipitation in the cold hearth (10) while spraying a plasma jet or an electron beam onto the bath surface of the molten titanium (6); and a step of supplying a molten titanium starting material from which the HDIs (8) are separated by precipitation to a mold (20) to obtain the titanium ingot.Type: GrantFiled: August 16, 2012Date of Patent: November 11, 2014Assignee: Kobe Steel, Ltd.Inventors: Daisuke Matsuwaka, Daiki Takahashi, Hitoshi Ishida, Hiroshi Yokoyama
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Publication number: 20140326424Abstract: The Present invention provides an arc melting furnace apparatus and a method of controlling arc discharge, in which a melt material having been melted can be stirred efficiently, avoiding labor intensive work. The furnace is provided with a mold 3 having a recess 3a and provided in a melting chamber 2, a non-consumable discharge electrode 5 for heating and melting a melt material accommodated in the recess 3a, a power source unit 10 for supplying electric power to the non-consumable discharge electrode 5, and a control device 11 which controls the power source unit to control output intensity of the arc discharge from the non-consumable discharge electrode. The control device 11 controls output current from the power source unit 10 and its current frequency to vary the output intensity of the arc discharge from the non-consumable discharge electrode 5 and stir a molten metal resulting from heating and melting the melt material.Type: ApplicationFiled: August 9, 2012Publication date: November 6, 2014Applicants: TOHOKU TECHNO ARCH CO., LTD., DIAVAC LIMITEDInventors: Motohiro Kameyama, Yoshiaki Kawai, Yoshihiko Yokoyama, Akihisa Inoue
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Publication number: 20140227125Abstract: Systems and methods in accordance with embodiments of the invention implement bulk metallic glass matrix composites in the fabrication of objects. In one embodiment, a method of fabricating an object including a bulk metallic glass matrix composite includes: forming a bulk metallic glass matrix composite composition into the shape of the object to be fabricated; and developing the bulk metallic glass matrix composite composition to include non-equilibrium inclusions that are softer than the surrounding matrix as measured by one of: the shear modulus, the elastic limit, and the hardness; where the bulk metallic glass matrix composite composition is such that the extent of the presence of the inclusions can be made to vary.Type: ApplicationFiled: February 11, 2014Publication date: August 14, 2014Applicant: California Institute of TechnologyInventor: Douglas C. Hofmann
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Publication number: 20140182416Abstract: A system and method for melting a raw material. The raw material is fed into an electrically conductive vessel. A plasma arc torch melts at least some of the raw material within the vessel to thereby create a molten material. An inductor, physically disposed adjacent the vessel, and electrically disposed in series with the vessel in operation, effects electromagnetic stirring of the molten material by interacting with the current of the plasma arc torch.Type: ApplicationFiled: September 18, 2013Publication date: July 3, 2014Applicant: Retech Systems LLCInventors: Robin A. Lampson, Robert E. Haun, Paul G. Meese, Matthew A. Charles, Edward C. Strout, Todd R. Telfer
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ALUMINUM ALLOY INCLUDING IRON-MANGANESE COMPLETE SOLID SOLUTION AND METHOD OF MANUFACTURING THE SAME
Publication number: 20140170018Abstract: Provided are an aluminum alloy including an iron-manganese complete solid solution and a method of manufacturing the same. According to an embodiment of the present invention, iron-manganese alloy powder is provided. The iron-manganese alloy powder is introduced into an aluminum melt. An aluminum alloy including an iron-manganese complete solid solution is manufactured by die casting the aluminum melt.Type: ApplicationFiled: July 26, 2012Publication date: June 19, 2014Applicant: KOREA AUTOMOTIVE TECHNOLOGY INSTITUTEInventors: Si Young Sung, Beom Suck Han -
Publication number: 20140083645Abstract: 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: ApplicationFiled: September 27, 2012Publication date: March 27, 2014Inventors: Theodore A. Waniuk, Joseph Stevick, Sean O'Keeffe, Dermot J. Stratton, Joseph C. Poole, Matthew S. Scott, Christopher D. Prest
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Patent number: 8668760Abstract: A method for the production of a ?-TiAl base alloy by vacuum arc remelting, which ?-TiAl base alloy solidifies via the ?-phase (?-?-TiAl base alloy), includes the following method steps of forming a basic melting electrode by melting, in at least one vacuum arc remelting step, of a conventional ?-TiAl primary alloy containing a lack of titanium and/or of at least one ?-stabilizing element compared to the ?-?-TiAl base alloy to be produced; allocating an amount of titanium and/or ?-stabilizing element to the basic melting electrode, which amount corresponds to the reduced amount of titanium and/or ?-stabilizing element, in an even distribution across the length and periphery of the basic melting electrode; and adding the allocated amount of titanium and/or ?-stabilizing element to the basic melting electrode so as to form the homogeneous ?-?-TiAl base alloy in a final vacuum arc remelting step.Type: GrantFiled: September 28, 2010Date of Patent: March 11, 2014Assignees: GfE Metalle und Materialien GmbH, TiTAL GmbHInventors: Dipl.-Ing Matthias Achtermann, Willy Fürwitt, Volker Güther, Dipl.-Mineraloge Hans-Peter Nicolai
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Publication number: 20130243660Abstract: A separation membrane including an alloy, the alloy including at least one Group 5 element, and at least one selected from Pt and Ir.Type: ApplicationFiled: March 18, 2013Publication date: September 19, 2013Applicant: SAMSUNG ELECTRONICS CO., LTD.Inventors: Kwang Hee KIM, Hyeon Cheol PARK, Byung Ki RYU, Jae Ho LEE
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Publication number: 20130160967Abstract: Methods for casting a metallic material to form a component are described. The component can be a superalloy-containing turbine part, for example. The general method includes the step of pouring the metallic material, in molten form, into an investment mold; and then rapidly immersing the entire investment mold into a bath that contains a low-melting liquid coolant metal, so as to achieve substantially uniform, multi-directional heat transfer out of the molten material. The molten material that solidifies to form the component is characterized by a fine-grained, equiaxed grain structure. Related embodiments include the use of two ingots that constitute the superalloy material. One ingot includes the oxygen-reactive elements, and is prepared by a vacuum-melting technique. The other ingot includes the remainder of the elements, and can be prepared by a number of techniques, such as air-melting processes.Type: ApplicationFiled: December 23, 2011Publication date: June 27, 2013Applicant: GENERAL ELECTRIC COMPANYInventors: Akane Suzuki, Stephen Joseph Balsone, Andrew John Elliott, Michael Francis Xavier Gigliotti, JR., Shyh-Chin Huang, Roger John Petterson, Stephen Francis Rutkowski, Pazhayannur Ramanathan Subramanian
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Patent number: 8469243Abstract: Provided is a molten metal discharge nozzle capable of suppressing turbulence in a molten metal stream passing through an inner bore thereof, with a simple structure. A cross-sectional shape of a wall surface of the inner bore, taken along an axis of the inner bore, comprises a part or an entirety of a curved line expressed by the following formula: log(r(z))=(1/n)×log((Hc+L)/(Hc+z))+log(r(L)) (1), where: 6?n?1.Type: GrantFiled: June 16, 2010Date of Patent: June 25, 2013Assignee: Krosakiharima CorporationInventors: Arito Mizobe, Hideaki Kawabe, Manabu Kimura
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Publication number: 20130146454Abstract: A method of forming targets for cathodic arc deposition of alloy bond coats for turbine engines components consists of melting a base alloy containing aluminum and other metals, adding grain boundary strengthening alloy additions, and casting the melt to form a cylindrical billet that is subsequently sectioned into puck shaped targets. The grain boundary strengthening additions minimize intergranular fracture of the targets during high current operation of the arc coating process.Type: ApplicationFiled: December 9, 2011Publication date: June 13, 2013Applicant: UNITED TECHNOLOGIES CORPORATIONInventors: Reade R. Clemens, Neil B. Ridgeway
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Publication number: 20120298325Abstract: A combined arc furnace, ladle metallurgical furnace and vacuum degassing system having the flexibility to produce at least non-vacuum arc remelt, vacuum arc remelt, vacuum oxygen decarburized non-vacuum arc remelt, and vacuum oxygen decarburized vacuum arc remelt steels from one off to continuous casting end uses in steady state or randomized order which utilizes only a minimum of energy attributable to preheating hot metal contacting components of the system followed by heat loss reduction of the components and use of a carryover heel in the arc furnace, in which the throughput of the system is limited solely by the melting capacity of the arc furnace.Type: ApplicationFiled: May 27, 2011Publication date: November 29, 2012Inventors: John A. Guliana, Guy A. Brada, Christian H. Ericksen, Bruce C. Liimatainen, Algirdas A. Underys
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Publication number: 20120048430Abstract: A process for manufacturing a turbine engine component comprises the steps of: casting ingots made of a gamma TiAl material using a double vacuum arc remelting casting technique; subjecting the cast ingots to a hot isostatic pressing to close porosity; forming at least one pancake of the gamma TiAl material by isothermally forging the hot isostatic pressed ingots; sectioning each pancake into a plurality of blanks; heat treating the blanks to produce a desired microstructure and mechanical properties; and machining the blanks into finished turbine engine components. A system for performing the process is also disclosed.Type: ApplicationFiled: August 30, 2010Publication date: March 1, 2012Applicant: UNITED TECHNOLOGIES CORPORATIONInventor: Gopal Das
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Publication number: 20110219912Abstract: A method for the production of a ?-TiAl base alloy by vacuum arc remelting, which ?-TiAl base alloy solidifies via the (?-phase (?-?-TiAl base alloy), comprises the following method steps: forming a basic melting electrode by melting, in at least one vacuum arc remelting step, of a conventional ?-TiAl primary alloy containing a lack of titanium and/or of at least one (?-stabilising element compared to the (?-?-TiAl base alloy to be produced; allocating an amount of titanium and/or (?-stabilising element to the basic melting electrode, which amount corresponds to the reduced amount of titanium and/or (?-stabilising element, in an even distribution across the length and periphery of the basic melting electrode; adding the allocated amount of titanium and/or (?-stabilising element to the basic melting electrode so as to form the homogeneous (?-?-TiAl base alloy in a final vacuum arc remelting step.Type: ApplicationFiled: September 28, 2010Publication date: September 15, 2011Inventors: Dipl-Ing Matthias Achtermann, Willy Fürwitt, Volker Güther, Dipl-Mineraloge Hans-Peter Nicolai
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Publication number: 20110100514Abstract: A zirconium-based amorphous alloy includes 10.0 to 15.0 wt % copper, 7.0 to 13.0 wt % nickel, 5.0 to 8.0 wt % niobium, and 2.0 to 5.0 wt % aluminum, with the remainder zirconium and unavoidable impurities. A method for constructing a spectacle frame, comprises forming a nickel-niobium alloy, a weight ratio of the nickel and the niobium of which is being in a range between 7:8 and 13:5, melting the nickel-niobium alloy, mixing the molten the nickel-niobium alloy with 55.0 to 75.0 wt % Zr, 10.0 to 15.0 wt % Cu, and 2.0 to 6.0 wt % Al to form a master alloy, melting the master alloy, and molding the master alloy into a spectacle frame.Type: ApplicationFiled: September 30, 2010Publication date: May 5, 2011Applicants: HONG FU JIN PRECISION INDUSTRY (ShenZhen) CO., LTD., HON HAI PRECISION INDUSTRY CO., LTD.Inventors: QING LIU, YI-MIN JIANG
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Publication number: 20100126309Abstract: The invention describes a method for recovering molybdenum, nickel, cobalt or their mixtures from used or regenerated catalysts in an electric arc furnace containing a heel of liquid cast iron, surmounted with a fluid slag, comprising the following steps: a) adding used or regenerated catalysts into the heel contained in the electric arc furnace, b) adding dosed lime in order to obtain a slag with a CaO to Al2O3ratio comprised between 0.7 and 1.3, c) mixing the heel by injecting gas so as to avoid formation of crusts, d) melting the used or regenerated catalysts in the electric arc furnace in order to obtain a liquid ferro-alloy.Type: ApplicationFiled: March 25, 2008Publication date: May 27, 2010Applicant: PAUL WURTH S.A.Inventors: Jean-Luc Roth, Ludivine Piezanowski
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Publication number: 20080142188Abstract: A method for producing a consumable electrode for remelting and an end face cutter for use in the method in which an ingot made in a consumable electrode arc remelting process is used as a material for the consumable electrode, are characterized in that said ingot can be set so that its centerline axis in a longitudinal direction lies horizontally and an end face of said ingot is machined by milling to be flat, the end face being connected with a stub, the stub holding the consumable electrode. In melting the consumable electrode, the present invention makes it easier to machine the bottom face of ingot that is to be mounted onto the stub or to perform conditioning such as cleaning the surface, which results in cutting man-hours and processing steps required for those operations and improving a product yield, thus enabling it to be widely used as a method for producing an ingot by the VAR process and contributing to the development of the relevant technology.Type: ApplicationFiled: October 26, 2005Publication date: June 19, 2008Inventor: Yuzou Ishigami
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Patent number: 7243701Abstract: An apparatus (10) and a method for reducing inclusions, shrinkage blowholes, porosity and segregation in metal castings during the casting process, and for improving the grain structure, mechanical properties and yield of ingots and other castings. The apparatus (10) comprises: At least one electrode (14) for forming a moving electric arc (16) over the upper surface (18) of a metallic casting (12) being cast and a stand (20) for suspending the electric arc electrode (14) over the upper surface (18) of the metallic casting (12) during or after pouring and a second electrode (24) attachable to a metallic surface (26) of the mold (28) being used for casting, for completion of an electric circuit (30) including the electric arc (16) and electronic controls (32) connected between the apparatus (10) and a power supply (34).Type: GrantFiled: December 12, 2001Date of Patent: July 17, 2007Assignee: Netanya Plasmatec Ltd.Inventors: Pavel Dvoskin, Valery Zlochevsky, Emil Rodjak, Dror Nadam
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Patent number: 7114548Abstract: A method of making an article includes forming a molten material by melting at least a portion of a mass of a metal and an alloy. The method further includes forming the article by solidifying at least a portion of the molten material within a mold, and contacting the article with plasma during formation of the article. A method for making an article also is disclosed wherein a molten material is formed by melting at least a portion of a mass of one of a metal and an alloy, the molten material is collected within a mold, and at least a portion of the molten material is magnetohydrodynamically stirred within the mold.Type: GrantFiled: December 9, 2004Date of Patent: October 3, 2006Assignee: ATI Properties, Inc.Inventor: Robin M. Forbes Jones
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Patent number: 6988529Abstract: The present invention relates to a method and apparatus for preparing a metal or metal-alloy product for a casting process—wherein the product is brought into a partly solidified (semi-solidified) state before casting—in which the product contains crystallization nuclei uniformly distributed throughout its volume. The method involves introducing an amount of a chosen alloy (in pulverized form) and an amount of a chosen melt, which is at a temperature above the liquefaction temperature of the alloy, into a crystallization vessel, which is heated to below the liquefaction temperature of the alloy, and mixing the melt and the alloy together in the crystallization vessel by means of electrical and/or magnetic forces to create the desired product.Type: GrantFiled: March 12, 2003Date of Patent: January 24, 2006Inventor: Evgenij Sterling
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Patent number: 6712875Abstract: A method and apparatus for optimized mixing in a common hearth in a plasma furnace. The apparatus provides a main hearth, a plurality of optional refining hearths, and a plurality of casting molds or direct molds whereby the refining hearths and molds define at least two separate ingot making lines. A feed chute provides raw material to the main hearth, whereby the feed chute is moveable to optimize its position during operation of the main hearth. Most particularly, the feed chute is moveable to provide better mixing, minimize skull build-up, and optimally place it opposite the overflow in use.Type: GrantFiled: September 20, 2002Date of Patent: March 30, 2004Assignee: Lectrotherm, Inc.Inventors: Edward Scott Jackson, David O. Warren
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Patent number: 6659165Abstract: In an apparatus for casting a metal comprise a crucible (2), a casting mold (3) and an electrode rod (10) for an arc discharge are provided in an interior portion of a casting chamber (1) capable of controlling a pressure, a supporting shaft (6) exists in a side of an outflow end portion of the crucible (2) close to a charging port (5) of the casting mold (3), the crucible (2) can be tilted around the supporting shaft (6), a crucible tilting means (7) exists in a side of a non-outflow end portion of the crucible (2), a clearance between a metal and the electrode rod is kept substantially constant after the arc melting of the metal (4) on the crucible (2) is started and the melting of the metal (4) makes progress and until the metal (4) in the melting state drops down due to the tilting of the crucible (2), and the arc discharge is kept during a period that the metal (4) flows and drops down.Type: GrantFiled: July 2, 2002Date of Patent: December 9, 2003Assignee: Nissin Dental Products, Inc.Inventors: Matsuyuki Miyake, Yasuhiko Kuwamura
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Patent number: 6561259Abstract: A method for hearthless processing of a solid metallic material consisting essentially of titanium or other metal or alloy thereof which includes providing a solid metal block having a processing surface and a base surface and consisting essentially of titanium or a metal, forming a pool of molten metal on the processing surface of the solid metal block provided in step, adding the metallic material to be processed to the pool of molten metal formed in step, and melting the metallic material to be processed, and removing metallic material melted in step from the pool of molten metal.Type: GrantFiled: October 19, 2001Date of Patent: May 13, 2003Assignee: RMI Titanium CompanyInventors: Frank P. Spadafora, Kuang-O Yu
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Publication number: 20030010472Abstract: In the case of a process for the production of homogeneous mixtures of alloys, in particular of intermetallic phases of at least two alloy components, by the melting of raw materials in an inductively heated cold wall furnace the following processing steps are applied:Type: ApplicationFiled: June 14, 2002Publication date: January 16, 2003Inventors: Alok Choudhury, Matthias Blum, Stefan Pleier, Georg Jarczyk
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Patent number: 6481088Abstract: A golf club which has a clubface of desired shape comprising an alloy metal is provided. The golf club has excellent strength properties as well as excellent ball hitting properties. The clubface is free from casting defects such as cold shuts, and preferably, free from the crystalline phase formed from crystal nuclei through nonuniform nucleation since the club face is produced in a simple, highly reproducible, one-step process by selectively cooling the molten metal at a temperature above the melting point at a rate higher than the critical cooling rate, and the product comprises a single amorphous phase.Type: GrantFiled: July 9, 1998Date of Patent: November 19, 2002Assignees: Kabushiki Kaisha Makabe Giken, Sumitomo Rubber Industries, Ltd.Inventors: Akihisa Inoue, Eiichi Makabe, Masahide Onuki
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Patent number: 6446705Abstract: An apparatus and associated method for manipulating an electrode comprising a stub, an electrode, and a yoke. The stub is affixed to and protrudes from the electrode, and has a first opening. The yoke is sized to receive at least a portion of the stub, and has a second opening positioned for alignment with the first opening of the stub and receipt of a locking member extending through the first opening and the second opening. The apparatus may include a current conducting tube. The elongated yoke may extend around at least a portion of the stub to be removably pinned thereto. The current conducting tube may extend around the elongated yoke to be in electrical contact with the stub.Type: GrantFiled: June 21, 2001Date of Patent: September 10, 2002Assignee: ATI Properties, Inc.Inventors: Ilia S. Geltser, Mitchell D. Tyson
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Patent number: 6427753Abstract: A process and an apparatus for producing metallic glass which are capable of producing a bulk amorphous alloy of desired shape, in particular, a bulk amorphous alloy of desired final shape are provided. In the present invention, the molten metal at a temperature above the melting point is selectively cooled at a rate higher than the critical cooling rate, and the product comprises single amorphous phase which is free from the crystalline phase formed by the development of crystal nuclei through nonuniform nucleation. The present invention is capable of producing the bulk amorphous alloy which is free from casting defects such as cold shuts and which has excellent strength properties in a simple process at a high reproducibility.Type: GrantFiled: February 10, 1999Date of Patent: August 6, 2002Assignees: Kabushiki Kaisha Makabe GikenInventors: Akihisa Inoue, Eiichi Makabe
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Publication number: 20020017376Abstract: An apparatus and associated method for manipulating an electrode comprising a stub, an electrode, and a yoke. The stub is affixed to and protrudes from the electrode, and has a first opening. The yoke is sized to receive at least a portion of the stub, and has a second opening positioned for alignment with the first opening of the stub and receipt of a locking member extending through the first opening and the second opening. The apparatus may include a current conducting tube. The elongated yoke may extend around at least a portion of the stub to be removably pinned thereto. The current conducting tube may extend around the elongated yoke to be in electrical contact with the stub.Type: ApplicationFiled: June 21, 2001Publication date: February 14, 2002Applicant: ATI Properties, Inc.Inventors: Ilia S. Geltser , Mitchell D. Tyson
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Patent number: 6267170Abstract: A metal mold is composed of a lower mold having a portion for fusing metal material and a cavity portion, and an upper mold working with the lower mold which presses molten metal in the portion for fusing metal material and pours the molten metal into the cavity portion to mold. And, the portion for fusing metal material is composed of a material having a heat conductivity equal to or less than 250 kcal/(m·h·° C.).Type: GrantFiled: December 30, 1999Date of Patent: July 31, 2001Assignees: Sumitomo Rubber Industries, Ltd., Akihisa InoueInventors: Masahide Onuki, Hisashi Kakiuchi, Akihisa Inoue
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Patent number: 6006821Abstract: Specialty metals and alloys are melted in a crucible typically holding no more than about 100 lbs. of the metal and disposed in a furnace the interior of which is filled with a desired, e.g. inert, gas and subjected to a vacuum in the range of about 5% to 32% of atmospheric pressure. For special circumstances, it would be possible to start in the specified pressure range and then increase the melt chamber pressure to atmospheric or above. The vacuum permits the initiation and formation of long electric discharge arcs between the electrode of an immovable plasma torch mounted to the furnace and the inside of the crucible to provide enough space for charging of the crucible with fresh metal laterally through a charge opening in the upright side wall of the furnace and a vacuum chamber operatively connected with the charge opening.Type: GrantFiled: December 16, 1998Date of Patent: December 28, 1999Assignee: Retech Services, Inc.Inventors: Robert E. Haun, Robin A. Lampson
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Patent number: 5741557Abstract: A method for forming a desired pattern of a material of conductive or non-conductive type on a variety of substrates. It is based on the use of a pen which essentially consists of a refractory tip wetted with the material in the molten state. The pen preferably consists of a pointed tungsten tip attached to the top of a V-shaped tungsten heater, forming a heater assembly. The tip and the heater top portion are roughened at the vicinity of the welding point. In turn, the ends of the V-shaped heater are welded to the pins of a 3-lead TO-5 package base. The pen is incorporated in an apparatus adapted to the direct writing technique. To that end, the pen is attached to a supporting device capable of movements in the X, Y and Z directions, while the substrate is placed on an X-Y stage for adequate X, Y and Z relative movements therebetween. The two pins of the pen are connected to a power supply to resistively heat the heater.Type: GrantFiled: May 24, 1995Date of Patent: April 21, 1998Assignee: International Business Machines CorporationInventors: Antoine Corbin, Philippe Demoncy, Jacques Foulu, Pierre Sudraud
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Patent number: 5740854Abstract: This invention provides a glassy metal-suction casting method capable of readily and conveniently producing a large-sized amorphous material with excellent properties as an amorphous material. Such an object of the invention is attained by filling a metal material in a mold cooled with water; melting said metal material by using a high-energy heat source which is capable of rapidly melting said metal material; and introducing the resulting molten metal instantaneously into a vertically extending water-cooled mold provided below said mold by using a difference in gas pressure or gravity to move the metal melt at a high speed and attain a high quenching rate to thereby enable the production of a glassy metal ingot of a large size.Type: GrantFiled: July 14, 1997Date of Patent: April 21, 1998Assignees: Akihisa Inoue, Kabushiki Kaisha Makabe GikenInventors: Akihisa Inoue, Tao Zhang, Eiichi Makabe
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Patent number: 5634514Abstract: The firing and/or casting kiln has a containment casing which internally forms a treatment chamber, a part holder which is movably mounted inside the treatment chamber, an opening for access to the treatment chamber, and a conditioning system for producing a vacuum and introducing inert gas into the treatment chamber.Type: GrantFiled: December 5, 1995Date of Patent: June 3, 1997Assignee: Peacock Limited L.C.Inventor: Alberto Gagliano
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Patent number: 5524705Abstract: A method for casting oxidization-active metal under oxygen-free conditions wherein air is discharged from a melting chamber and a casting chamber while maintaining the condition of the melting chamber pressure P.sub.R >the casting chamber pressure P.sub.C and dry compressed inert gas is then introduced into the melting chamber, directionality is imparted to the atmosphere gas of the melting chamber under the condition of P.sub.R >P.sub.C for replacing and discharging the atmosphere in a mold of the casting chamber with inert gas and establishing a non-oxidizing atmosphere in the melting chamber and the casting chamber, and precision casting is thereafter conducted by melting a fusible casting material and pouring it into the mold in the casting chamber.Type: GrantFiled: April 8, 1994Date of Patent: June 11, 1996Assignee: U-WA Tech CorporationInventors: Norio Matsubara, Shouichirou Miyazaki
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Patent number: 5513693Abstract: A method for casting low specific gravity metal with ultra-fine features using high differential pressure wherein a melting chamber volume V.sub.1 and a casting chamber volume V.sub.2 are defined such that V.sub.1 <V.sub.2, fusible casting material is melted with a melting plate under an inert gas atmosphere, a high differential pressure is established between the melting chamber and the casting chamber by introducing compressed inert gas into the melting chamber simultaneously with pouring the melt into a mold of the casting chamber, and the high differential pressure is held until the cast melt solidifies.Type: GrantFiled: April 8, 1994Date of Patent: May 7, 1996Assignee: U-Wa Tech CorporationInventors: Seijirou Matsuda, Shouichirou Miyazaki
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Patent number: 5311655Abstract: The invention is directed to a Titanium-aluminum base alloy articles are produced from pieces of starting materials by melting thereof in a metallic melting crucible having a rotating electrode or a plasma- or electron beam device and there is then accomplished arc remelting, preferably vacuum-arc remelting following the melting of the pieces of starting materials. Furthermore, the arrangement for the manufacture of the articles formed of titanium-aluminum base alloys comprises a melting apparatus containing a rotating electrode or a plasma- or electron beam device and a vacuum-arc melting apparatus.Type: GrantFiled: October 4, 1991Date of Patent: May 17, 1994Assignee: Bohler Edelstahl GmbHInventors: Heimo Jager, Herbert Puschnik
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Patent number: 5287910Abstract: Titanium based and nickel based castings are made by casting a suitable melt having a relatively low melt superheat into a mold cavity defined by one or more low carbon steel or titanium mold members where the melt solidifies to form the desired casting. The melt super-heat is limited so as not to exceed about 150.degree. F. above the liquidus temperature of the particular melt being cast. For a steel mold, one or more titanium melt inlet-forming members are provided for cooperating with the steel mold members to form an melt ingate that communicates to the mold cavity for supplying the melt thereto in a manner to avoid harmful iron contamination of the melt during casting. The mold body-to-mold cavity volume ratio is controlled between 10:1 to 0.5:1 to minimize casting surface defects and mold wear/damage.Type: GrantFiled: September 11, 1992Date of Patent: February 22, 1994Assignee: Howmet CorporationInventors: Gregory N. Colvin, Leonard L. Ervin, Robert F. Johnson
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Patent number: 5273101Abstract: A method and apparatus for casting a molten metallic material in ingot form are provided wherein the molten metallic material is transported to the ingot mold and an upper surface temperature and temperature distribution of the molten metal pool in the casting mold are measured by an imaging radiometer which is disposed external to an inert gas filled chamber enclosing the ingot mold, and is disposed to view the ingot pool surface through a sight port. At least one plasma arc torch is employed to direct an arc at the ingot pool surface, the intensity of which is selectively modulated and the impingement of the arc is simultaneously selectively positioned in order to maintain a desired preselected mold pool surface temperature and temperature distribution thereby yielding a preselected metallurgical structure in the solidified ingot.Type: GrantFiled: June 5, 1991Date of Patent: December 28, 1993Assignee: General Electric CompanyInventors: Robert D. Lillquist, Gordon B. Hunter, Richard G. Menzies