Abstract: A method for making an equiaxed investment casting. The method utilizes an ultrasonic generator to send an ultrasonic pulse into molten metal in an investment casting mold. The investment casting mold is positioned within a working zone of furnace having low output induction coils for generating a convection current in molten metal. The ultrasonic pulse separates dendrites growing from the face of the mold inward into the molten metal. Instead, equiaxed grains can nucleate within the molten metal. In addition, the ultrasonic pulse and the low output induction coils circulate the molten metal as solute is rejected from solidifying equiaxed grains. The mixing reduces the effects of segregation in the solidifying alloy and assists in nucleating equiaxed grains.

Abstract: Nanomaterials are incorporated within a material, such as within a metal-based material. As may be implemented in accordance with various embodiments, nanomaterials are introduced to a metal-based material in a liquid state, and the metal-based material and nanomaterials are cooled from the liquid state to a viscous state. The metal-based material is stirred in the viscous state to disperse the nanomaterials therein, and the metal-based material is used in the viscous state to maintain dispersion of the nanomaterials as the metal-based material cools.

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.

Abstract: Provided are an indium target capable of achieving a high deposition rate while suppressing the occurrence of arcing, and a method for manufacturing the indium target. In the process of solidification at the time of melting and casting an indium ingot, ultrasonic vibration is applied to molten indium liquid which is at least in a state immediately before solidification, and thereby, coarsening of the grain size is suppressed. Thus, an indium target is provided An indium target in which an overall average grain size is 10 mm or less; for the grains observed from a cross-section parallel to a thickness direction, a ratio of an average grain size in a direction parallel to the thickness direction with respect to an average grain size in a direction perpendicular to the thickness direction is 0.7 to 1.1; and pores with a pore size of 50 ?m or greater exists at a density of 1 pore/cm3 or less.

Abstract: An aluminum alloy which is excellent in high temperature strength and heat conductivity by adjusting the composition to one keeping down the drop in high temperature strength and making the Mn content as small as possible to reduce the formation of a solid solution in the aluminum, which aluminum alloy having a composition of ingredients which contains Si: 12 to 16 mass %, N: 0.1 to 2.5 mass %, Cu: 3 to 5 mass %, Mg: 0.3 to 1.2 mass %, Fe: 0.3 to 1.5 mass %, and P: 0.004 to 0.02 mass % and furthermore 0 to 0.1 mass % of Mn and further contains, as necessary, at least one of V: 0.01 to 0.1 mass %, Zr: 0.01 to 0.6 mass %, Cr: 0.01 to 0.2 mass %, and Ti: 0.01 to 0.2 mass %. Also described is a method for producing the aluminum alloy melt.

Abstract: The invention is related to the foundry practice. According to this invention, the method for making castings by directed solidification from a selected point of the melt toward the periphery of the casting comprises forming a casting in a mold having thermodynamic characteristics that allow uniform volume cooling of the melt to be effected to a temperature at which natural solidification processes are completed. To improve the structural isotropy of the casting formed, the cooling is effected at a rate not exceeding 0.5° C./sec. The casting is formed in a nonuniform field of force. The nonuniform field of force is set up by ultrasonic waves focused on a selected point of the melt to form therein a localized elevated pressure zone and to direct the solidification front from the zone toward the periphery of the casting. The nonuniform field of force is sustained in the mold until the cooling casting reaches a temperature at which the natural melt solidification processes are completed as the melt cools.

Abstract: Apparatus assemblies and methods for melting and injection molding an article from a meltable metal that is sensitive to heating by radio frequency (RF) induction. An exemplary apparatus includes a mold including a cavity having a shape of an article to be molded, a delivery chute including a channel for delivering a solid metal billet from a proximal end of the delivery chute to a distal end which is adjacent to the mold, and an RF induction heating coil that surrounds the cavity of the mold and the distal end of the delivery chute. Advantageously, the portion of the mold defining the cavity and at least the distal end of the delivery chute (i.e., those portions surrounded by the RF coil) are formed of materials that are substantially insensitive to heating by RF induction so that the metal billet is melted and molded at approximately the same time.

Abstract: The invention is related to the foundry practice. According to this invention, the method for making castings by directed solidification from a selected point of the melt toward the periphery of the casting comprises forming a casting in a mold having thermodynamic characteristics that allow uniform volume cooling of the melt to be effected to a temperature at which natural solidification processes are completed. To improve the structural isotropy of the casting formed, the cooling is effected at a rate not exceeding 0.5° C./sec. The casting is formed in a nonuniform field of force. The nonuniform field of force is set up by ultrasonic waves focused on a selected point of the melt to form therein a localized elevated pressure zone and to direct the solidification front from the zone toward the periphery of the casting. The nonuniform field of force is sustained in the mold until the cooling casting reaches a temperature at which the natural melt solidification processes are completed as the melt cools.

Abstract: A method of forming a material includes the steps of: vibrating a molten material at an ultrasonic frequency while cooling the material to a semi-solid state to form non-dendritic grains therein; forming the semi-solid material into a desired shape; and cooling the material to a solid state. The method makes semi-solid castings directly from molten materials (usually a metal), produces grain size usually in the range of smaller than 50 ?m, and can be easily retrofitted into existing conventional forming machine.

Abstract: Disclosed is a method for dislodging a mold from a casting formed within the mold. The mold may be removed from the casting by scoring the mold and applying a force sufficient to cause the mold to fracture and break into pieces. Additionally, the mold may be fractured by either explosive charges placed in the mold pack or by high energy pulsations directed at the mold. Once the mold is fractured and broken into various pieces it may then be dislodged from the casting.

Abstract: Disclosed is a method for dislodging a mold from a casting formed within the mold. The mold may be removed from the casting by scoring the mold and applying a force sufficient to cause the mold to fracture and break into pieces. Additionally, the mold may be fractured by either explosive charges placed in the mold pack or by high energy pulsations directed at the mold. Once the mold is fractured and broken into various pieces it may then be dislodged from the casting.

Abstract: Method of making articles comprising polycrystalline &agr;-Al2O3 fibers within a matrix of aluminum, or an alloy of aluminum and up to about 2% copper.

Abstract: Metal matrix composite wires that include at least one tow comprising a plurality of substantially continuous, longitudinally positioned fibers in a metal matrix. The fibers are selected from the group of ceramic fibers carbon fibers, and mixtures thereof. The wires have certain specified characteristics such as roundness values, roundness uniformity values, and/or diameter uniformity values.

Abstract: Metal matrix composite wires that include a plurality of substantially continuous, longitudinally positioned fibers in a metal matrix. The wire exhibits zero breaks over a length of at least 300 meters when tested according to a specified test.

Abstract: A casting process for producing a metal matrix composite comprising a first phase or a matrix of a metal or metal alloy and a second phase of particles dispersed in the matrix, comprising the steps of: preparing a melt of the metal or metal alloy in a vessel; feeding the particles to the melt; applying ultrasonic vibration to the melt while electromagnetically stirring the melt; and then causing solidification of the melt. The process preferably further comprises the step of applying ultrasonic vibration to the melt while electromagnetically stirring the melt during the solidification of the melt.

Abstract: 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.

Abstract: A method and apparatus for the accurate formation of a three-dimensional article comprises providing a first quantity and a second quantity of substantially uniform size droplets of a desired material wherein each droplet has a positive or negative charge. Each quantity of droplets is focused or aligned into a narrow stream by passing the droplets through or adjacent an alignment means which repels each droplet toward an axis extending through the alignment means. The droplets are deposited in a predetermined pattern at a predetermined rate onto a target to form the three-dimensional article without a mold of the shape of the three-dimensional article. The droplets of the first quantity and the second quantity are supplied at different distances, whereby the droplets of the first quantity bond to each other and the droplets of the second quantity do not bond to each other or to the first quantity of droplets.

Abstract: The invention relates to an apparatus for pulverizing at least a jet of a quid or solid material in a standing ultrasonic field which is generated between at least a pair of ultrasonic devices. To increase the pulverizing capacity a plurality of pulverizing fluid jets and in addition supplementary fluid jets, for example a gas is introduced through separate nozzles at each nodal pressure area of the standing ultrasonic wave. In addition the pulverizing capacity is further increased by providing special horn shapes of the ultrasonic devices.

Abstract: On spray-forming metals onto a substrate from which the sprayed coating is to be detached, unwanted adhesion may occur, even to a smooth substrate. Conversely, if the coating is meant to adhere, it may accidentially delaminate, even from a roughened substrate.By vibrating the substrate, marginally adherent splats will be encouraged to detach themselves while, on the other hand, well adherent splats will not be affected.

Abstract: The invention relates to a method of and a device for simultaneously generating heat energy and oscillation energy. In the method heat is generated by induction heating and oscillations are created by means of at least piezoelectric elements. Previously a resonance circuit formed by a series connection of an inductive component and a capacitive, piezoelectric component has been used for the generation of oscillations only. A disadvantage of this kind of circuit has been that the circuit is difficult to control on account of the narrow resonance region of the piezoelectric element. This advantage is avoided in the solution according to the invention in such manner that one and the same resonance circuit formed by a series connection of an inductive and capacitive element generates both heat energy and oscillation energy.

Abstract: A method for continuous casting of light-alloy ingots, consisting in pouring a melt, acting upon the melt with ultrasound using at least one radiator to purify the melt and to refine the structure of the solidifying ingot, the radiation being applied uniformly throughout the cross-section of the melt in an intensity of 2 to 60 W/cm.sup.2 depending on the cross-sectional area of the solidifying ingot, the radiator being immersed into the melt to a depth equal to between 1/12 and 1/4 of the sound wavelength in the material of the melt and the melt temperature being maintained by 60.degree. to 150.degree. C. above the liquidus temperature of the melt, and subsequently withdrawing the ingot.

Abstract: In melting aluminum containing impurities which form a eutectic with the aluminum and solidifying the molten aluminum by cooling, the aluminum is purified by breaking down dendrites extending from the liquid-solid interface into the liquid phase to release impurities from between the dendrites or between the branches of the dendrites, and dispersing the released impurities in the entire body of the liquid phase.

Abstract: The invention relates to a method and apparatus for obtaining an ingot wherein elastic oscillations are directed on metal being crystallized over a broad frequency range and at high intensity in the form of powerful pulses generated by a high-voltage spark discharge in liquid. One form of the apparatus of the invention comprises a discharge chamber filled with liquid in contact with a mould or with melt. The discharge chamber is provided with a system of electrodes connected to a pulse current generator. Upon feeding high-voltage current pulses to the electrodes, high pressure, impulse flows, cavitation and surge waves are built-up in the liquid resulting in the appearance of elastic oscillations acting on the molten metal.