Induction Coil Means Patents (Class 164/513)
  • Patent number: 11141780
    Abstract: A method of casting a metal alloy ingot, including the following steps: providing a one side open-ended mould including a plurality of sides and a bottom plate defining a mould cavity with a mould opening, the open-ended mould being pivotable around a horizontal rotational axis between a position so that the mould opening points upwards and a position so that the mould opening points side-wards or down-wards; positioning the open-ended mould such that the mould opening points side-wards or down-wards; providing a casting container with an upwardly positioned aperture; filling the casting container with molten metal for one casting operation; coupling the casting container to the open-ended mould so that the casting container is located below the mould while the mould opening points side-wards or down-wards; rotating the open-ended mould together with the casting container around the horizontal rotational axis for approximately 90° to 180° from a position whereby the mould opening points side-wards or down-war
    Type: Grant
    Filed: October 10, 2016
    Date of Patent: October 12, 2021
    Assignee: Aleris Rolled Products Germany GmbH
    Inventors: Philippe Meyer, Johannes Morscheiser
  • Patent number: 9248531
    Abstract: A portion of a work-hardened essentially tubular work piece such as a metallic firearm cartridge case is annealed by contact with solid or granular tooling material which has been heated to a temperature approximately that of the appropriate annealing temperature, thereby reducing the possibility of overheating the work piece, and also thereby permitting the annealing of only that portion of the work piece contacted or in close proximity to the point(s) of contact.
    Type: Grant
    Filed: April 29, 2014
    Date of Patent: February 2, 2016
    Assignee: VISTA OUTDOOR OPERATIONS LLC
    Inventor: James Eveland
  • Publication number: 20150144292
    Abstract: Disclosed is an apparatus comprising at least one gate and a vessel, the gate being configured to move between a first position to restrict entry into an ejection path of the vessel and contain a material in a meltable form within the vessel during melting of the material, and a second position to allow movement of the material in a molten form through the ejection path. The gate can move linearly or rotate between its first and second positions, for example. The apparatus is configured to melt the material and the at least one gate is configured to allow the apparatus to be maintained under vacuum during the melting of the material. Melting can be performed using an induction source. The apparatus may also include a mold configured to receive molten material and for molding a molded part, such as a bulk amorphous alloy part.
    Type: Application
    Filed: October 14, 2011
    Publication date: May 28, 2015
    Applicant: Crucible Intellectual Property, LLC
    Inventors: Quoc Tran Pham, Michael Deming, Theodore A. Waniuk, Sean O'Keeffe
  • Publication number: 20150147227
    Abstract: An induction furnace comprising a upper furnace vessel; an induction coil positioned below the upper furnace vessel; and a melt-containing vessel positioned inside the induction coil and communicably connected to the upper furnace vessel, wherein the positioning of the melt-containing vessel inside the induction coil defines a gap between an outside surface of the melt-containing vessel and an inside surface of the induction coil. A system for direct-chill casting comprising at least one an induction furnace; at least one in-line filter operable to remove impurities in molten metal; at least one gas source coupled to a feed port associated with the gas; and at least one device for solidifying metal by casting. A method of cooling an induction furnace comprising introducing a gas into a gap between an induction coil and a melt-containing vessel positioned inside the induction coil; and circulating the gas through the gap.
    Type: Application
    Filed: November 18, 2014
    Publication date: May 28, 2015
    Inventor: Ravindra V. Tilak
  • Publication number: 20150107730
    Abstract: Embodiments herein relate to a process for semi-continuous or continuous production of a solid object from a molten metal, with the potential of being a cleaner and less expensive alternative to complicated split mold processes currently used. The embodiments can be used to perform multiple melt/pour cycles without breaking vacuum, with the system only opened to remove the solid object via an air lock, e.g., a separate chamber or load lock, which will be periodically opened to remove feedstock without breaking the vacuum of the process chamber. Embodiments also relate to an apparatus for semi-continuous or continuous production of a solid object from a molten metal.
    Type: Application
    Filed: January 23, 2012
    Publication date: April 23, 2015
    Inventors: Quoc Tran Pham, Sean Timothy O'Keeffe, Theodore A. Waniuk
  • Patent number: 9004151
    Abstract: Disclosed is a vessel for melting and casting meltable materials. The vessel may be a surface temperature regulated vessel for providing a substantially non-wetting interface with the molten materials. In one embodiment, the vessel may include one or more temperature regulating channels configured to flow a fluid therein for regulating a surface temperature of the vessel such that molten materials are substantially non-wetting at the interface with the vessel. Disclosed also includes systems and methods for melting and casting meltable materials using the vessel.
    Type: Grant
    Filed: September 27, 2012
    Date of Patent: April 14, 2015
    Assignee: Apple Inc.
    Inventors: Theodore A. Waniuk, Joseph Stevick, Sean Timothy O'Keeffe, Dermot J. Stratton, Joseph C. Poole, Matthew S. Scott, Christopher D. Prest
  • Publication number: 20150013932
    Abstract: Various embodiments provide an apparatus and methods for containing the molten materials within a melt zone during melting. The apparatus may include a vessel configured to receive a material for melting therein and an induction coil with unevenly spaced turns along its length. Induction coil can have a series of turns acting as a first (e.g., load) induction coil and a series of turns acting as a second (e.g., containment) induction coil. The material in the vessel can be heated and contained by the separated turns of the induction coil. A plunger can also assist in containing material during melting. Once the desired temperature is achieved and maintained for the molten material, operation of the induction coil can be stopped and the molten material can be ejected from the vessel into a mold using the plunger.
    Type: Application
    Filed: July 11, 2013
    Publication date: January 15, 2015
    Inventors: Adam A. VERREAULT, Sean T. O'KEEFFE, Joseph W. STEVICK, Brennan D. YAHATA
  • Publication number: 20140352907
    Abstract: A die casting apparatus (100) for amorphous alloy comprises a stationary die (1) and a movable die (2); a sealed cabin (4) difining a sealing chamber (40); a protecting gas supplying device connected with the sealed cabin (4) for supplying the protecting gas into the sealing chamber (40); a melting device (5) for receiving and melting amorphous alloy; a feed sleeve (6) having a molten material inlet (60), with a plunger (7) positioned therein for injecting the molted amorphous alloy from the melting device (5) into a die chamber via the molten material inlet (60); a driving device (8) connected with the plunger (7) for driving the plunger (7) in the feed sleeve (6); and a gas purifying device (10) communicated with the sealed cabin (4) for purifying the gas from the sealed cabin (4).
    Type: Application
    Filed: December 13, 2012
    Publication date: December 4, 2014
    Inventor: Faliang Zhang
  • Publication number: 20140290901
    Abstract: Disclosed is an apparatus for loading one or more alloy ingots into a molding machine. The apparatus includes a holder configured to hold a plurality of the alloy ingots and dispense one or more of the alloy ingots into a melt zone of the molding machine through an opening in a mold of the machine. The holder is moved in a perpendicular direction with respect to an axis along a center of the opening in the mold between a first position in line with the opening in the mold to dispense one or more of the alloy ingots and a second position away from the opening in the mold. The apparatus can carry ingots of amorphous alloy material so that when the machine melts and molds the material, it forms a bulk amorphous alloy containing part.
    Type: Application
    Filed: November 11, 2011
    Publication date: October 2, 2014
    Applicant: Crucible Intellectual Property, LLC
    Inventor: Joseph W. Stevick
  • Publication number: 20140262109
    Abstract: Disclosed herein is a device comprising: vacuum chamber; a stage configured to receive BMG in a molten state or a BMG feedstock, configured to spin, and located in the vacuum chamber; a heater configured to melt the BMG feedstock or to keep BMG in a molten state molten; wherein the stage comprises one or more conduits therein and the conduits are configured to accommodate a cooling fluid. Also disclosed herein is a method of forming a solid BMG sheet, the method comprising: disposing BMG in a molten state onto a stage; spreading the BMG in a molten state into a sheet of BMG in a molten state by spinning the stage; cooling the sheet of BMG in a molten state to form a solid BMG sheet.
    Type: Application
    Filed: March 14, 2013
    Publication date: September 18, 2014
    Applicant: Crucible Intellectual Property, LLC
    Inventor: Joseph W. Stevick
  • Publication number: 20140262110
    Abstract: BMG may be squeeze cast in a squeeze cast machine. The squeeze cast machine may have a vacuum chamber, a transfer sleeve entirely located inside the vacuum chamber, and a plunger inside the transfer sleeve. The transfer sleeve may be configured to receive BMG feedstock from outside the vacuum chamber. The vacuum chamber may prevent contamination of a BMG in a molten state. The plunger may push a BMG in a molten state into a mold.
    Type: Application
    Filed: March 14, 2013
    Publication date: September 18, 2014
    Applicant: Crucible Intellectual Property, LLC.
    Inventor: Joseph W. Stevick
  • Publication number: 20140251572
    Abstract: A method and apparatus for vacuum or air casting a molten superalloy, or other metal or alloy, containing an oxygen-reactive alloying element to form a cast part involves introducing the molten metallic material (melt) into a preheated mold having a melt reservoir, such as for example a mold pour cup, and gating for feeding the melt to one or more mold cavities. An induction coil disposed locally adjacent to the mold pour cup is energized in a manner to locally heat excess melt left in the melt reservoir to maintain it molten as the melt solidifies under vacuum or in air in the mold cavity to avoid shrinkage defects in the cast part.
    Type: Application
    Filed: March 7, 2013
    Publication date: September 11, 2014
    Applicant: Howmet Corporation
    Inventors: Russell G. Vogt, Christopher R. Hanslits
  • Patent number: 8813813
    Abstract: Described herein is a method of melting a bulk metallic glass (BMG) feedstock, comprising: feeding the BMG feedstock into a crucible; melting a first portion of the BMG feedstock to form molten BMG, while maintaining a second portion of the BMG feedstock solid; wherein the second portion and the crucible hold the molten BMG.
    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: 20140127032
    Abstract: A casting method and apparatus are provided for casting a near-net shape article, such as for example a gas turbine engine blade or vane having a variable cross-section along its length. A molten metallic melt is provided in a heated mold having an article-shaped mold cavity with a shape corresponding to that of the article to be cast. The melt-containing mold and mold heating furnace are relatively moved to withdraw the melt-containing mold from the furnace through an active cooling zone where cooling gas is directed against the exterior of the mold to actively extract heat. At least one of the mold withdrawal rate, the cooling gas mass flow rate, and mold temperature are adjusted at the active cooling zone as the melt-containing mold is withdrawn through the active cooling zone to produce an equiaxed grain microstructure along at least a part of the length of the article.
    Type: Application
    Filed: October 17, 2013
    Publication date: May 8, 2014
    Inventor: Rajeev Naik
  • Publication number: 20140102661
    Abstract: Various embodiments provide apparatus and methods for melting materials and for containing the molten materials within melt zone during melting. Exemplary apparatus may include a vessel configured to receive a material for melting therein; a load induction coil positioned adjacent to the vessel to melt the material therein; and a containment induction coil positioned in line with the load induction coil. The material in the vessel can be heated by operating the load induction coil at a first RF frequency to form a molten material. The containment induction coil can be operated at a second RF frequency to contain the molten material within the load induction coil. Once the desired temperature is achieved and maintained for the molten material, operation of the containment induction coil can be stopped and the molten material can be ejected from the vessel into a mold through an ejection path.
    Type: Application
    Filed: October 15, 2012
    Publication date: April 17, 2014
    Inventors: Theodore A. WANIUK, Joseph STEVICK, Sean O'KEEFFE, Dermot J. STRATTON, Joseph C. POOLE, Matthew S. SCOTT, Christopher D. PREST
  • Publication number: 20140090799
    Abstract: Various embodiments provide apparatus and methods for injection molding. In one embodiment, a constraining plunger may be configured in-line with an injection plunger to transfer a molten material from a melt zone and into a mold. The constraining and injection plungers are configured to constrain the molten material there-between while moving. The constrained molten material can be controlled to have an optimum surface area to volume ratio to provide minimized heat loss during the injection molding process. The system can be configured in a longitudinal direction (e.g., horizontally) for movement between the melt zone and mold along a longitudinal axis. A molded bulk amorphous object can be ejected from the mold.
    Type: Application
    Filed: September 28, 2012
    Publication date: April 3, 2014
    Inventors: Theodore A. Waniuk, Joseph Stevick, Sean O' Keeffe, Dermot J. Stratton, Joseph C. Poole, Matthew S. Scott, Christopher D. Prest
  • Publication number: 20130294901
    Abstract: A method of component forming according to an exemplary aspect of the present disclosure includes, among other things, positioning a metal powder in a mold cavity, melting the metal powder within the mold cavity, and cooling the melted metal powder to form a component.
    Type: Application
    Filed: May 1, 2012
    Publication date: November 7, 2013
    Inventors: Sergey Mironets, Wendell V. Twelves, Agnes Klucha
  • Publication number: 20130156637
    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.
    Type: Application
    Filed: December 20, 2011
    Publication date: June 20, 2013
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Junyoung PARK, Jason Robert PAROLINI, Ibrahim UCOK
  • Publication number: 20130118704
    Abstract: A casting system, mold, and method are disclosed for electromagnetically stirring sand castings. In an embodiment, the casting mold includes a mold body having a cavity therein, and a passageway fluidly connecting the cavity with an exterior of the mold body. The passageway allows for introduction of a molten metal into the cavity. The mold body further includes at least one induction coil embedded in a cope of the mold body; and at least one induction coil embedded in a drag of the mold body. The induction coils are configured to generate an electromagnetic field for stirring a molten metal casting while it solidifies inside the mold.
    Type: Application
    Filed: November 10, 2011
    Publication date: May 16, 2013
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Junyoung Park, Jason Robert Parolini, Jon Conrad Schaeffer
  • Publication number: 20120247705
    Abstract: A casting apparatus is presented. The casting apparatus includes a first chamber and a second chamber. The first chamber includes a crucible and a sealed discharge outlet. The second chamber includes a casting mold for casting a plurality of filaments of a superalloy composition. The second chamber further includes a discharge inlet aligned with the sealed discharge outlet of the first chamber. The casting apparatus further includes a first port for applying a positive pressure to the first chamber and a second port for applying a vacuum to the second chamber. The sealed discharge outlet includes a hermetic seal comprising a material having a melting temperature equal to or greater than a melting temperature of the superalloy composition.
    Type: Application
    Filed: January 27, 2012
    Publication date: October 4, 2012
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Laurent Cretegny, Bernard Patrick Bewlay
  • Publication number: 20120048497
    Abstract: The method for reducing interstitial elements in alloy castings which comprises the following steps: pouring the alloy for the formation of a casting; and allowing said alloy to cool. According to the method, at least a peripheral region of the casting is heated, so that the flux of interstitial elements is caused towards the at least one peripheral region. The method is achieved where most of the interstitial elements concentrate in at least one region in the surface region of the casting. At later stages these elements can be easily eliminated from the respective regions by means of a thermal surface treatment or surface machining of the casting.
    Type: Application
    Filed: August 22, 2011
    Publication date: March 1, 2012
    Inventor: Daniel Gaude Fugarolas
  • Publication number: 20120037334
    Abstract: The invention relates to a method and to a device for carrying out this method, during which the shell molds are filled with a melt, a clocked manner, the respectively required amount of melt being currently provided at the same time. The casting process ensues by marrying the crucible which is filled with a melt with a shell mold so that the crucible and shell mold form a common cavity and this arrangement is subsequently titled 180° C. so that the melt falls into the shell mold.
    Type: Application
    Filed: October 25, 2011
    Publication date: February 16, 2012
    Inventor: Pavel SESERKO
  • Patent number: 7967057
    Abstract: There is described a method for producing ultrahigh-purity Fe-base, Ni-base, and Co-base alloying materials to achieve impurity levels of (C+O+N+S+P)<100 ppm, and Ca<10 ppm, in the form of a large ingot, using a refining flux while forcibly cooling the crucible. A refining flux selected from the group consisting of metal elements of the Groups IA, IIA, and IIIA of the Periodic Table, oxides thereof, halides thereof, and mixtures thereof, is added to the molten metal during primary melting and the molten metal is held in contact with the refining flux for at least 5 minutes before tapping. Thereafter, the molten metal is caused to undergo solidification inside a mold, thereby producing a primary ingot.
    Type: Grant
    Filed: November 21, 2006
    Date of Patent: June 28, 2011
    Assignee: Kobe Steel, Ltd.
    Inventors: Kazutaka Kunii, Tatsuhiko Kusamichi, Jumpei Nakayama, Kiyoshi Kiuchi
  • Publication number: 20110139394
    Abstract: The introduction of spray formed metals into critical applications in the aircraft engine and power generation industries has been hampered by the possibility of erosion of oxide particles from a crucible lining or pouring nozzle in conventional spray forming equipment. These oxide particles may become inclusions that limit low-cycle fatigue life of parts. Use of a cold-walled induction guide (CIG) with an electrical insulation layer between copper CIG elements and the liquid metal offers a means of delivering ceramic-free alloys to a spray system with improved efficiency. CIG design options facilitated by a new oven-brazed fabrication technique resolve induction coil environmental isolation issues, correct thermal strain tolerance problems, facilitate dual frequency induction designs, allow improved electrical coupling efficiency and thermal efficiency, result in improved melt flow initiation, and facilitate disassembly without damage from the solidified melt.
    Type: Application
    Filed: December 16, 2009
    Publication date: June 16, 2011
    Inventors: William T. Carter, Russell S. Miller, Howard R. Hart, JR.
  • Publication number: 20100186923
    Abstract: Apparatus for preparing alloy sheet, comprising a container for melted alloy liquid positioned in an inductive heating coil; a liquid flow stabilization outfit comprising a barrel container with open bottom and a base board arranged below the open bottom, and the barrel container's upper part being positioned below the mouth of the container for melted alloy liquid; a quenching wheel positioned below the melted alloy liquid flown from the liquid flow stabilization outfit's base board, which carries the melted alloy liquid and spins it into strips, so as to make the strips become alloy sheets after collision; a transferring outfit positioned below the wheel for further cooling and transferring of the alloy sheets, characterized in that the quenching wheel is equipped with a means for differentiating cooling rate for various alloy sheets.
    Type: Application
    Filed: May 28, 2008
    Publication date: July 29, 2010
    Inventors: Boping Hu, Yizhong Wang, Xiaolei Rao, Jingdong Jia
  • Publication number: 20100147484
    Abstract: The invention pertains to a method for manufacturing a metal strip (1) by means of continuous casting and rolling, wherein a thin slab (3) is initially cast in a casting machine (2) and this thin slab is subsequently rolled in at least one rolling train (4, 5) by utilizing the primary heat of the casting process, wherein a continuous manufacture of the metal strip (1) (continuous rolling) can be realized in a first operating mode by directly coupling the casting machine (2) to the at least one rolling train (4, 5), and wherein a discontinuous manufacture of the metal strip (1) (batch rolling) can be realized in a second operating mode by decoupling the casting machine (2) from the at least one rolling train (4, 5).
    Type: Application
    Filed: August 21, 2008
    Publication date: June 17, 2010
    Inventors: Dieter Rosenthal, Stephan Kraemer, Christoph Klein, Juergen Seidel, Wolfgang-Dietmar Hackenberg
  • Publication number: 20090321037
    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.
    Type: Application
    Filed: June 19, 2009
    Publication date: December 31, 2009
    Applicant: Ultradent Products, Inc.
    Inventors: Paul E. Lewis, Dan E. Fischer
  • Publication number: 20090321038
    Abstract: The invention concerns an apparatus for centrifugal casting under vacuum, said apparatus comprising: a rotor (1) having a shaft (2) extending in an essentially vertical direction therefrom and being rotatable around an axis (A) defined by the shaft (2), the rotor (1) having at least one fixing means for releaseably fixing at least one mold (9) in a first radial distance from the axis (A), and a means for accommodating at least one crucible (6, 7, 23) being associated with the mold (9) so that an outlet opening (8) of the crucible (7, 23) is arranged opposite an inlet opening of the mold (9), the rotor (1) further comprising a gas-tight housing (1, 10) in which the mold (9) and the crucible (7, 23) are accommodated, a vacuum source to create a vacuum in the housing (1, 10), a heating device for melting a metal, the metal being taken up in the gas-tight housing (1, 10) within in the crucible (7, 23), a drive device (13) for driving the shaft (2) in order to rotate the rotor (1), and an auxiliary acceleration d
    Type: Application
    Filed: October 22, 2007
    Publication date: December 31, 2009
    Applicant: Manfred RENKEL
    Inventor: Manfred Renkel
  • Publication number: 20090050284
    Abstract: The invention relates to a method and to a device for sing out this method, during which the shell molds (3) are filled with a melt (11) in a clocked manner, the respectively required amount of melt being currently provided at the same time. The casting process ensues by marrying the crucible (6), which is filled with a melt (11), with a shell mold (3) so that the crucible (6) and shell mold (3) form a common cavity (10), and this arrangement is subsequently tilted 180°, so that the melt (11) falls into the shell mold (3).
    Type: Application
    Filed: April 6, 2006
    Publication date: February 26, 2009
    Inventor: Pavel Seserko
  • Publication number: 20080314547
    Abstract: The invention concerns a casting apparatus which includes a crucible support and induction heating means (14, 16, 18) arranged to receive and support a crucible (10) containing material which is to be melted and poured from an outlet (38). The outlet is positioned on a vertical axis (40). The support and induction heating means also operates to apply induction heating to the material to melt it in the crucible. There is also a translation mechanism which tilts the crucible while the crucible is still supported and while heat is continuously applied to it. This mechanism operates in such a way that during tilting, the outlet of the crucible is maintained on the vertical axis so that the molten material pours from the outlet on the vertical axis. In the embodiments described, the crucible is simultaneously moved vertically towards the mould into which the melt pours.
    Type: Application
    Filed: May 17, 2005
    Publication date: December 25, 2008
    Inventors: Irshad Khan, Wessel Marthinus Cronje
  • 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
  • Publication number: 20080179034
    Abstract: One non-limiting embodiment of an apparatus for forming an alloy powder or preform includes a melting assembly, an atomizing assembly, and a collector. The melting assembly produces at least one of a stream of a molten alloy and a series of droplets of a molten alloy, and may be substantially free from ceramic in regions contacted by the molten alloy. The atomizing assembly generates electrons and impinges the electrons on molten alloy from the melting assembly, thereby producing molten alloy particles.
    Type: Application
    Filed: March 21, 2008
    Publication date: July 31, 2008
    Applicant: ATI Properties, Inc.
    Inventors: Robin M. Forbes Jones, Richard L. Kennedy
  • Patent number: 7246649
    Abstract: A diecast machine comprises: a sleeve extending in the vertical direction; a plunger moving upward in the vertical direction inside the sleeve; a mold disposed above an upper side of the sleeve; a case member constituted of a nonconductive member, which covers at least a lower end of the sleeve and forms a closed space including the lower end of the sleeve; a communicating pipe connecting the inside of the closed space to the outside of the closed space; and high-frequency induction coil configured to heat metal material disposed on the plunger from the outside of the case member and melt the metal material.
    Type: Grant
    Filed: June 23, 2005
    Date of Patent: July 24, 2007
    Assignees: NGK Insulators, Ltd., Tohoku University
    Inventors: Naokuni Muramatsu, Akihisa Inoue, Hisamichi Kimura
  • Patent number: 7000678
    Abstract: Disclosed is an electromagnetic continuous casting apparatus for a material having a low electric conductivity. The casting apparatus includes a crucible having a vertical axis. The crucible comprises an upper hot crucible and a lower cold crucible. The crucible is surrounded with an induction coil. The hot crucible is formed of a non-metallic material having a high electric conductivity and is not water-cooled. The cold crucible has a cooling structure and is formed of a metallic material having a high thermal conductivity and a high electric conductivity.
    Type: Grant
    Filed: April 11, 2005
    Date of Patent: February 21, 2006
    Assignee: Korea Institute of Industrial Technology
    Inventors: Byoung Moon Mon, Sang Mok Lee, Je Sik Shin
  • Patent number: 6994835
    Abstract: The present invention reduces temperature gradient in the direction of the radius of solidified ingots of silicon immediately after solidification, which has serious influences on the quality as a solar cell and improves the quality. Silicon raw materials are melted inside a bottomless crucible combined with an induction coil by electromagnetic induction heating. The silicon melt formed inside the bottomless crucible is allowed to descend and solidified ingots of silicon are manufactured continuously. Plasma heating by a transferred plasma arc torch is also used for melting the silicon raw materials. The plasma arc torch is moved for scanning along the inner surface of the bottomless crucible in the horizontal direction. A plasma electrode on the solidified ingot side to generate transferred plasma arc is allowed to contact the surface of the solidified ingot at positions where the temperature of the solidified ingot becomes 500 to 900° C.
    Type: Grant
    Filed: December 28, 2000
    Date of Patent: February 7, 2006
    Assignee: Sumitomo Mitsubishi Silicon Corporation
    Inventors: Kenichi Sasatani, Naritoshi Kimura, Masakazu Ohnishi
  • Patent number: 6910521
    Abstract: A molten metal feed apparatus which can feed molten metal into a casting apparatus by opening a vessel and which is free from leakage of the molten metal from the opening/closing part of the vessel, provided with a holding vessel having an opening at its bottom and holding a metal material, a lid for closing the opening, a drive means for making the lid move with respect to the holding vessel to open or close the opening, and an induction heating coil for heating the metal material by induction of a current to the metal material in the holding vessel and generating a magnetic field applying to the molten metal a force preventing leakage of the molten metal in the holding vessel from between the opening and the lid.
    Type: Grant
    Filed: April 25, 2003
    Date of Patent: June 28, 2005
    Assignee: Toshiba Kikai Kabushiki Kaisha
    Inventors: Hiroshi Nanto, Akira Hirahara
  • Patent number: 6695035
    Abstract: To restrict to a low level a temperature gradient of an ingot immediately after solidification in a bottomless crucible in a electromagnetic induction casting method using an electrically conductive bottomless crucible. An upper section and a lower section of an electrically conductive bottomless crucible to be disposed inside an induction coil are configured as a water-cooled section and a non-water-cooled section. Both the water-cooled section and the non-water-cooled section are divided by vertical slits into a plurality of portions in a circumferential direction. Rapid cooling with water in the lower section of the crucible is restricted.
    Type: Grant
    Filed: September 26, 2001
    Date of Patent: February 24, 2004
    Assignee: Sumitomo Mitsubishi Silicon Corporation
    Inventors: Naritoshi Kimura, Kenichi Sasatani, Kyojiro Kaneko
  • Publication number: 20030205358
    Abstract: To restrict to a low level a temperature gradient of an ingot immediately after solidification in a bottomless crucible in a electromagnetic induction casting method using an electrically conductive bottomless crucible. An upper section and a lower section of an electrically conductive bottomless crucible to be disposed inside an induction coil are configured as a water-cooled section and a non-water-cooled section. Both the water-cooled section and the non-water-cooled section are divided by vertical slits into a plurality of portions in a circumferential direction. Rapid cooling with water in the lower section of the crucible is restricted.
    Type: Application
    Filed: September 26, 2001
    Publication date: November 6, 2003
    Inventors: Naritoshi Kimura, Kenichi Sasatani, Kyojiro Kaneko
  • Patent number: 6604570
    Abstract: An apparatus and method for continuously manufacturing metal filaments in mass production. In accordance with the present invention, molten metal is hung in a state freely depending from the tip of a metal bar by its surface tension without using any vessel. The metal filament manufacturing apparatus includes an induction coil upwardly bent in the form of a nose shape at regions thereof where metal filaments are discharged while being soared up, respectively, so as to prevent the molten metal of each of the metal bars from being affected by the induction coil during soaring of the metal filaments. The apparatus also includes wiping assembly for removing residual metal materials left on a spinning disk.
    Type: Grant
    Filed: May 10, 2002
    Date of Patent: August 12, 2003
    Assignee: Fiber Tech Co., Ltd.
    Inventors: Chang-Hwan Suk, Deck-Yui Lee, Man-Ho Park
  • Patent number: 6523598
    Abstract: The vacuum induction melting system is designed to be operated in a continuous or semi-continuous manner for extended periods of time for increased efficiency, and makes it possible to easily and quickly remove the induction furnace from the melt chamber when it becomes necessary to replace and rebuild the furnace. The melting system includes a melt chamber which forms an airtight enclosure, with an induction furnace located within the melt chamber. A charging chamber is communicatively connected to the melt chamber adjacent its upper end. The charging chamber includes a door providing access to the interior of the charging chamber so that a charge of raw materials can be placed therein. An isolation valve is located between the melt chamber and the charging chamber and is movable between open and closed positions.
    Type: Grant
    Filed: January 9, 2002
    Date of Patent: February 25, 2003
    Assignee: ATI Properties, Inc.
    Inventor: Sterry A. Shaffer
  • Patent number: 6474404
    Abstract: The invention relates to a method for controlling the temperature of a melt (10), preferably of a steel melt, in a distributing vessel (11), whereby the temperature of the melt is measured, the measured result is compared with a predetermined temperature range in the form of specified values, and as much heat is supplied or withdrawn from the melt such that the temperature remains inside said range. In order to control the melt temperature, a fireproof shaped part (20) which is closed on both sides and which is provided for accommodating a liquid cooled induction coil (1) is immersed in the melt (10). The transmission of heat is carried out by means of thermal conduction out of the wall of the shaped part (20) which is coupled to the induced electromagnetic field and/or by means of a direct coupling to the liquid melt (10).
    Type: Grant
    Filed: October 15, 2001
    Date of Patent: November 5, 2002
    Assignees: SMS Schloemann-Siemag Aktiengesellschaft, Didier Werke AG
    Inventors: Horst Grothe, Markus Reifferscheid, Raimund Brückner, Karl Heinz Schmitt
  • Patent number: 6435260
    Abstract: Hot-chamber diecasting machines for processing magnesium melts include a casting vessel, an inductive heating system, and an additional ring inductor in an area of the neck of the casting vessel in order to achieve a heating also in this area. The ring inductor is formed of a one-piece tube made of an elastic material which is open at one point and can be bent open by the extent of the diameter of the neck of the casting vessel and can be pushed laterally onto the casting vessel, and through which air can also flow for the cooling.
    Type: Grant
    Filed: October 21, 1999
    Date of Patent: August 20, 2002
    Assignee: Oskar Frech GmbH & Co.
    Inventors: Roland Fink, Ulrich Schraegle
  • Patent number: 6360810
    Abstract: A vacuum induction melting system includes a melt chamber which forms an airtight enclosure, with an induction furnace located within the melt chamber. A mold tunnel is connected to the melt chamber adjacent its lower end, with the mold tunnel including a pour opening which communicates with the melt chamber and through which molten metal poured from the furnace can enter the mold tunnel. A mold carriage is positioned within the mold tunnel for receiving and carrying one or more molds adapted for receiving molten metal. An isolation valve is located between the melt chamber and the mold tunnel for isolating the mold tunnel from the melt chamber to allow for removing the mold carriage from the mold tunnel for loading or unloading of molds thereon. A mold transport assembly is provided for moving the mold carriage from a pouring position within the mold tunnel to a loading position located outside of the mold tunnel.
    Type: Grant
    Filed: February 23, 1999
    Date of Patent: March 26, 2002
    Assignee: ATI Properties, Inc.
    Inventor: Sterry A. Shaffer
  • Patent number: 6077474
    Abstract: An apparatus and method of forming balls includes a metering device 2, a melting device 14 and a cooling device 20. The metering device 14 stamps a desired volume of solid material in the form of a slug 12 which passes through the melting device 14 where it is caused to levitate and transform state from a solid to a molten liquid. The molten liquid material 13 is released from the melting device 14 and descends through the cooling device 20 where it transforms state once again from a molten material to a solid material while maintaining a ball shape. A forming gas is passed over the molten material 13 in a direction opposite to the falling molten material 13. The balls 15 are finally cooled in a cooling bath 32.
    Type: Grant
    Filed: May 27, 1997
    Date of Patent: June 20, 2000
    Assignee: The Whitaker Corporation
    Inventors: Dimitry Grabbe, Iosif Korsunksy
  • Patent number: 6072166
    Abstract: In a method of operating an inductor of a tapping device of a melt vessel, the inductor couples inductively during a working phase with an electrically conductive shaped component and is cooled by means of a fluid. The inductor is electrically decoupled and cooled by means of a fluid in another working phase.
    Type: Grant
    Filed: June 30, 1999
    Date of Patent: June 6, 2000
    Assignee: Didier-Werke AG
    Inventors: Raimund Bruckner, Daniel Grimm, Steve Lee
  • Patent number: 6059015
    Abstract: A method for directional solidification (DS) of a molten material, and an apparatus therefor. The method generally entails the use of a container having a base and peripheral wall that define an interior of the container, an induction coil for heating the contents of the container and generating an electromagnetic field, and means for controllably separating the container from the heating means and the electromagnetic field, such as by withdrawing the container from the heating means and electromagnetic field. Using such an apparatus, a material is heated within the container to yield a melt that is substantially prevented from contacting the wall of the container as a result of being at least partially levitated by the electromagnetic field. The container is then separated, e.g.
    Type: Grant
    Filed: June 26, 1997
    Date of Patent: May 9, 2000
    Assignee: General Electric Company
    Inventors: Bernard Patrick Bewlay, Dennis Joseph Dalpe
  • Patent number: 6051822
    Abstract: In a method of operating an inductor of a tapping device of a melt vessel, the inductor couples inductively during a working phase with an electrically conductive shaped component and is cooled by means of a fluid. The inductor is electrically decoupled and cooled by means of a fluid in another working phase.
    Type: Grant
    Filed: August 28, 1996
    Date of Patent: April 18, 2000
    Assignee: Didier-Werke AG
    Inventors: Raimund Bruckner, Daniel Grimm, Steve Lee
  • Patent number: 5992503
    Abstract: Systems and methods of electroslag refining of metal include the introduction of unrefined metal into an electroslag refining process in which the unrefined metal is first melted at the upper surface of the refining slag. The molten metal is refined as it passes through the molten slag. The refined metal is collected in a cold hearth apparatus having a skull of refined metal formed on the surface of the cold hearth for protecting the cold hearth from the leaching action of the refined molten metal. A cold finger bottom pour spout is formed at the bottom of the cold hearth to permit dispensing of molten refined metal from the cold hearth. The cold finger bottom pour spout comprises a plurality of copper segments having gaps. The gap between the segments is established and maintained by insulation structure and sealing structure positioned in each gap.
    Type: Grant
    Filed: October 23, 1997
    Date of Patent: November 30, 1999
    Assignee: General Electric Company
    Inventors: Bruce Alan Knudsen, Robert John Zabala, Mark Gilbert Benz, William Thomas Carter, Jr.
  • Patent number: 5872352
    Abstract: A heating machine for heating an ingot of a metal such as a magnesium alloy. The heating machine has a heating chamber equipped with a RF induction coil capable of swinging about a horizontally axis. The coil is placed horizontally, and the metal ingot is fed into the coil from an introduction chamber by a pushrod. Stoppers prevent the ingot from falling from the RF induction coil when it is switched from its horizontal posture to its vertical posture. The coil is wound on a cylindrical member. A rotatable hollow shaft is firmly mounted to the holder in a perpendicular relation to a substantially axially central portion of the cylindrical member. A part of the coil is inserted in the hollow shaft via an insulating material. The rotatable hollow shaft is swung by a swinging mechanism. The induction heating coil is wound on a ceramic holder. A metal ingot is inserted in the holder with a given clearance.
    Type: Grant
    Filed: March 21, 1996
    Date of Patent: February 16, 1999
    Assignee: Honda Ginken Kogyo Kabushiki Kaisha
    Inventors: Hiromitsu Suganuma, Kazuya Sakamoto, Atsushi Suzuki, Masayoshi Kai, Shinji Kazama, Nobumasa Hamazoe
  • Patent number: 5810066
    Abstract: A system and method of electroslag refining of metal is taught. The system and method includes the introduction of unrefined metal into an electroslag refining process in which the unrefined metal is first melted at the upper surface of the refining slag. The molten metal is refined as it passes through the molten slag. The refined metal is collected in a cold hearth apparatus having a skull of refined metal formed on the surface of the cold hearth for protecting the cold hearth from the leaching action of the refined molten metal. A cold finger bottom pour spout is formed at the bottom of the cold hearth to permit dispensing of molten refined metal from the cold hearth. The dimensions of the cold finger apparatus pour spout are controlled by positioning a retaining means around the outer surface of the pour spout thereby controlling the flow rate of molten metal through the cold finger apparatus.
    Type: Grant
    Filed: December 21, 1995
    Date of Patent: September 22, 1998
    Assignee: General Electric Company
    Inventors: Bruce Alan Knudsen, Robert John Zabala, Mark Gilbert Benz, William Thomas Carter, Jr., Paul Leonard Dupree