Abstract: 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.

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).

Abstract: An apparatus and method of uniformly heating, rheologically softening, and thermoplastically forming magnetic metallic glasses rapidly into a net shape using a rapid capacitor discharge forming (RCDF) tool are provided. The RCDF method utilizes the discharge of electrical energy stored in a capacitor to uniformly and rapidly heat a sample or charge of metallic glass alloy to a predetermined “process temperature” between the glass transition temperature of the amorphous material and the equilibrium melting point of the alloy in a time scale of several milliseconds or less. Once the sample is uniformly heated such that the entire sample block has a sufficiently low process viscosity it may be shaped into high quality amorphous bulk articles via any number of techniques including, for example, injection molding, dynamic forging, stamp forging, sheet forming, and blow molding in a time frame of less than 1 second.

Abstract: 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.

Abstract: 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.

Abstract: An apparatus and method of uniformly heating, rheologically softening, and thermoplastically forming magnetic metallic glasses rapidly into a net shape using a rapid capacitor discharge forming (RCDF) tool are provided. The RCDF method utilizes the discharge of electrical energy stored in a capacitor to uniformly and rapidly heat a sample or charge of metallic glass alloy to a predetermined “process temperature” between the glass transition temperature of the amorphous material and the equilibrium melting point of the alloy in a time scale of several milliseconds or less. Once the sample is uniformly heated such that the entire sample block has a sufficiently low process viscosity it may be shaped into high quality amorphous bulk articles via any number of techniques including, for example, injection molding, dynamic forging, stamp forging, sheet forming, and blow molding in a time frame of less than 1 second.

Abstract: An arc melting furnace apparatus is provided which reduces an operation burden on a worker and shortens working hours. An arc melting furnace apparatus 1 includes a housing 2 having formed therein a melting chamber 2a, a hearth 4 provided within the melting chamber 2a and having a recessed portion 4a, and a heating mechanism 10 for heating and melting a metal material supplied into the recessed portion 4 to generate an alloy ingot. The apparatus comprises a turning member 23 rotatably supported on a supporting member 21 standing within the melting chamber 2a, a perimeter edge of the turning member 23 rotating and moving along the inner surface of the recessed portion 4a to lift the alloy ingot generated in the recessed portion 4a above the hearth 4 and turn it over, and a resilient turn-over assisting member 24 provided above an upper end of the recessed portion 4a.

Abstract: An arc melting furnace apparatus is provided which reduces an operation burden on a worker and shortens working hours. An arc melting furnace apparatus 1 includes a housing 2 having formed therein a melting chamber 2a, a hearth 4 provided within the melting chamber 2a and having a recessed portion 4a, and a heating mechanism 10 for heating and melting a metal material supplied into the recessed portion 4 to generate an alloy ingot. The apparatus comprises a turning member 23 rotatably supported on a supporting member 21 standing within the melting chamber 2a, a perimeter edge of the turning member 23 rotating and moving along the inner surface of the recessed portion 4a to lift the alloy ingot generated in the recessed portion 4a above the hearth 4 and turn it over, and a resilient turn-over assisting member 24 provided above an upper end of the recessed portion 4a.

Abstract: A system for making a material having domains with insulated boundaries is provided. The system includes a droplet spray subsystem configured to create molten alloy droplets and direct the molten alloy droplets to a surface, a spray subsystem configured to direct a spray of an agent at deposited droplets on the surface. The agent creates insulation layers on the deposited droplets such that the droplets form a material having domains with insulated boundaries on the surface.

Abstract: The invention relates to metallurgy and, more specifically, to iron-and-steel producing plants. The metallurgical complex is provided with three production platforms arranged one above the other. The middle platform is capable of rotating about a central axis and is provided with three identical lined containers situated in three positions at an angle of 120° to each other. The top platform is provided with means for melting metal and means for processing the melt capable of rising and lowering and installed on two adjacent lined containers to form steelmaking arc furnace positions and a melt processing unit position, respectively. The casting station is mounted on the bottom platform in the immediate vicinity of the lined container disposed in the third position.

Abstract: A nucleated casting apparatus including an atomizing nozzle configured to produce a droplet spray of a metallic material, a mold configured to receive the droplet spray and form a preform therein, and a gas injector which can limit, and possibly prevent, overspray from accumulating on the mold. The gas injector can be configured to produce a gas flow which can impinge on the droplet spray to redirect at least a portion of the droplet spray away from a side wall of the mold. In various embodiments, the droplet spray may be directed by the atomizing nozzle in a generally downward direction and the gas flow may be directed in a generally upward direction such that the gas flow circumscribes the perimeter of the mold.

Abstract: 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.

Abstract: A system and method for producing a metallic ingot using, for example, a VAR furnace, includes a primary crucible receiving a melted metal from a source of metal and collecting the melted metal to for a pool of melted metal, the primary crucible including an overflow lip, a secondary crucible receiving the melted metal from the overflow lip of the primary crucible, the secondary crucible being smaller than and electrically isolated from the primary crucible, and a withdrawal device withdrawing the molten metal, solidified by cooling, from the secondary crucible in the form of solidified ingots, wherein the solidified ingots have a smaller diameter than a diameter of the source of metal. A cutting device periodically cuts the withdrawn solidified ingots as they are withdrawn from the secondary crucible.

Abstract: A seal for a continuous casting furnace having a melting chamber with a mold therein for producing a metal cast includes a passage between the melting chamber and external atmosphere. As the cast moves through the passage, the cast outer surface and the passage inner surface define therebetween a reservoir for containing liquid glass or other molten material to prevent the external atmosphere from entering the melting chamber. Particulate material fed into the reservoir is melted by heat from the cast to form the molten material. The molten material coats the cast as it moves through the passage and solidifies to form a coating to protect the hot cast from reacting with the external atmosphere. Preferably, the mold has an inner surface with a cross-sectional shape to define a cross-sectional shape of the cast outer surface whereby these cross-sectional shapes are substantially the same as a cross-sectional shape of the passage inner surface.

Abstract: 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).

Abstract: 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.

Abstract: A molten steel of a special steel or the like including a high-alloy steel is poured in a mold whose bottom portion is closed with a dummy head of a lift table. As the lift table is vertically moved down at a given casting speed, a casting whose lower end is supported by the dummy head is continuously pulled out from the bottom portion of the mold. As a pair of movable molds that constitute the mold are relatively moved away from each other in synchronism with the downward movement of the lift table, both widthwise side surfaces of the casting are provided with required tapering.

Abstract: A method and apparatus for alternating pouring into molds, casts or refining hearths from a common hearth in a 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. The main hearth alternatively pours into a first ingot making line while the other line is prepared, and vice versa allowing for continuous melting.

Abstract: A method and apparatus for optimizing melting of titanium for processing into ingots or end products. The apparatus provides a main hearth, a plurality of optional refining hearths, and a plurality of casting molds or direct molds whereby direct arc electrodes melt the titanium in the main hearth while plasma torches melt the titanium in the refining chambers and/or adjacent the molds. Each of the direct arc electrodes and plasma torches is extendable and retractable into the melting environment and moveable in a circular pivoting or side to side linear motion.

Abstract: The invention invention provides an apparatus (10) and a method for reducing the volume of risers, and for the possibility of reducing shrinkage blowhole and porosity in shaped gravity casting. The invention provides an apparatus (10) for producing metal flow/stir in the liquid metal (31), the apparatus (10) comprising at least one electrode (16) for forming a continuously-moving plasma arc (34) over the upper surface of selected riser(s) (12) in metallic casting being cast, a stand (26) for suspending said plasma arc electrode (16) over the upper surface of said risers (12) during the casting process, a second electrode (28) attachable to the liquid metal (31) or the metal being used for casting and a power supply (36) for completion of an electric circuit including said plasma arc (34); and control means (38) connected between said apparatus (10) and said power supply (36).

Abstract: 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.

Abstract: 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.

Abstract: A locking assembly and a process for electrode or ingot formation that include a stub, a locking member, and a support member. The locking member removably extends through the support member and at least a portion of the stub. Molten material is introduced over the support member and the stub to form the electrode. The electrode and integrated stub may be incorporated into an electrode assembly, including a yoke, a fastening member, a shoe, and a conducting tube.

Abstract: 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.

Abstract: Metal is cast by melting it in a crucible over a hole too small to enable gravity to make the molten metal pass through the hole and with a diameter to length ratio greater than one, after which increased pressure is applied to the metal to drive it through the hole into a mold.

Abstract: 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.

Abstract: Metal is cast by melting it in a crucible over a hole too small to enable gravity to make the molten metal pass through the hole, after which increased pressure is applied to the metal to drive it through the hole into a mold.

Abstract: A method for casting dental metals with a casting apparatus including a melting chamber in which there are located an arc electrode above and a crucible formed of an electrically conductive material positioned below the arc electrode, and a mold chamber divided from the melting chamber by a partition wall having a through-hole at a position below the crucible and housing a mold box receiving a mold provided with an extending open vent positioned below the through-hole, the melting chamber communicating hermetically with the mold chamber through the mold, which is characterized by positioning a dental metal ingot on the crucible, vacuumizing the melting and mold chambers, feeding a small amount of an inert gas into the melting chamber at such a pressure as to induce arc discharge all over the upper surface of the ingot, thereby melting the ingot placed on the crucible by arc discharge from the arc electrode, pouring the thus obtained molten metal into the mold through its inlet, and immediately feeding an addi

Abstract: A method for casting dental metals with a casting apparatus including a hermetically sealed casting chamber in which an arc electrode is located above, a crucible made of an electrically conductive material is positioned below the arc electrode, and a mold provided with a closed vent is disposed below the crucible, the method including by positioning a dental metal ingot on the crucible, evacuating the casting chamber to vacuum, feeding a small amount of an inert gas at such a pressure as to induce arc discharge all over the upper surface of the ingot, thereby melting the ingot placed on the crucible by arc discharge from the arc electrode, pouring the thus obtained molten metal into a mold through its inlet, and immediately feeding an additional amount of the inert gas into the casting chamber to increase its internal pressure to a level suitable for casting. Also the additional amount of the inert gas is rapidly fed into the casting chamber through a gas tank in the vicinity of the casting chamber.

Abstract: The bottom of a solid metal charge melts to fill a form below the charge. During melting, usually, the metal that enters the form remains continuous with an unused solid part of the charge. After cooling, the formed metal is removed together with the unused part of the charge--and usually with the form too. They are separated later or in a different operation, and another charge is positioned immediately for melting into another form, so the useful duty cycle is very high. A preferred form of the invention uses an upper melting chamber and a lower forming chamber, separated by a horizontal wall but communicating by an aperture through the wall. The charge and form are placed against the wall from below to block the aperture. The charge preferably extends up through the aperture into or toward the melting chamber, where an arc electrode or other heater melts the top of the charge, particularly near its center.

Abstract: An apparatus for preparing metallic radioactive waste material for storage is disclosed. The radioactive waste material is placed in a radiation shielded enclosure. The waste material is then melted with a plasma torch and cast into a plurality of successive horizontal layers in a mold to form a radioactive ingot in the shape of a spent nuclear fuel rod storage canister. The apparatus comprises a radiation shielded enclosure having an opening adapted for receiving a conventional transfer cask within which radioactive waste material is transferred to the apparatus. A plasma torch is mounted within the enclosure. A mold is also received within the enclosure for receiving the melted waste material and cooling it to form an ingot. The enclosure is preferably constructed in at least two parts to enable easy transport of the apparatus from one nuclear site to another.

Abstract: A paint or coating composition which contains only pure Ziroconium containing compounds, and a small amount of NH.sub.4 (OH).sub.2 and acid is applied to the vertical walls of a vacuum arc furnace Copper crucible to form a stable, substantially uniform, coating thereon. The Zirconium coating composition of the present invention is free of Aluminum and Aluminum compounds and consists essentially of Zirconium Oxide suspended in a water-based Zirconyl Nitrate gel, to which small amounts of base and acid have been sequentially added. This coating eliminates the introduction of spurious impurities into the surface of the zirconium ingot formed during vacuum are melting of a zirconium compact.

Abstract: In an injection method of a die casting machine of the invention, an inner portion of a billet, excluding peripheral and bottom portions thereof, is melted in advance. The billet with the molten inner portion is supplied into an injection sleeve. The injection sleeve is then externally heated to melt the entire portion of the billet. The molten metal is injected into a die cavity.

Abstract: Metal material is melted by moving the magnetic flux of electromagnets virtually perpendicular to an arc column to apply Lorentz force to the arc column and the metal material so that the arc column can move over the metal material surface. The movement direction and speed of the arc column are determined by detecting the arc voltage of the arc column. Feed back control is performed by comparing the obtained detection data with preset data so that optimum control is performed, and the molten metal is poured into a casting mold.

Abstract: Method and apparatus for joining lead battery parts (e.g., plate lugs, intercell connectors, terminals, etc.) together via a low resistance electrical coupling wherein substantially oxide-free, arc-melted, superheated molten lead is cast into a cavity between the parts. The parts are shielded from the arc while being bathed in a non-oxidizing atmosphere which is preferably formed from an ionizable, non-oxidizing gas heated by the lead-melting arc and spewed onto the parts along with the molten lead to provide additional heat thereto.

Abstract: Apparatus for melting, casting and discharging a metal in a chamber. The apparatus includes a hopper outside of the furnace for delivering metal to a crucible inside of the furnace. The crucible pivots to pour molten metal into a mold which also pivots to pour solidified metal into a bin. The crucible, mold and bin are in a unitary chamber. Also provided is an improved electrode, crucible and mold.

Abstract: Improved casting of titanum or alloy of titanium is obtained by using a crucible and a mold made of high-purity magnesium oxide and/or zirconium oxide. It is also possible for only the interior portion of the crucible to be made of such high-purity material, or for the mold to be made of copper or an alloy of copper. The mold and crucible can be used in a centrifugal-type casting machine or a compression-type casting machine. In either machine, discharge vents must be provided in the mold to connect the casting chamber with the outer atmosphere. An argon electric arc generated between a pivotable, tiltable cathode and an anode may be used for melting the titanium in the crucible. A high-frequency electric current can also be used to melt the titanium. By using the above apparatus, it is possible to obtain castings which are dimensionally accurate and do not have an external layer of fragile metal oxide or rough cavities.

Abstract: An arc furnace and investment casting apparatus includes a copper base with an integrally formed crucible having a passage therethrough. A vacuum chamber is positioned on the top of the copper crucible with a non-consumable cathode projecting into the chamber to effect melting of metal placed in the crucible. A vacuum chamber is also suspended beneath the crucible for support of a mold to receive molten metal flowing through the passage.

Abstract: The raw material in a raw material feeding apparatus of a melting cast installation is supplied, through a guide cylinder vertically mounted inside a furnace wall, towards a melting pot of a casting apparatus. A plurality of plasma arc torches, for heating the raw material, are positioned on the upper rotatable half of said furnace wall and are radially arranged around the axis of said guide cylinder with front ends thereof directed individually towards said melting pot. The raw material feeding apparatus may consist of a rotatable cylindrical drum laid substantially horizontally and a helical compartment wall to define a raw material path inside said cylindrical drum. A cylindrical limiter may be vertically mounted, inside said guide cylinder, for vertical movement so as to form an adjustable annular path for raw material between said limiter and the internal surface of said guide cylinder.

Abstract: A method of producing sound metal castings, particularly of reactive metals, by striking an electrical arc in a gap defined by adjacent end faces of opposed elongate electrodes, wherein the electrodes are mounted for rotation about longitudinal axes that are parallel and offset with respect to each other, realizing substantially complete overlapping of the adjacent end faces during rotation of the electrodes to cause uniform depletion of same, and wherein the metal droplets derived at the gap are maintained in a fully molten condition until they have been cast into an adjacent mold.

Abstract: Electric arc apparatus and an associated method are provided. Pairs of aligned cooperating coils are positioned on opposed sides of a crucible. In a preferred embodiment, three such pairs which overlap each other are employed so as to sequentially generate magnetic fields so as to provide a uniform magnetic field which will rotate the arc between the electrode and the crucible interior in a first direction. The arc rotation may be reversed. It is preferred that the maximum magnetic field created by each pair of coils be out of time phase with respect to the other coil's magnetic field. This apparatus and the associated method serve to resist undesired irregularities in the ingot exterior surface which irregularities would require subsequent treatment and result in loss of metal.

Abstract: An arc furnace and investment casting apparatus includes a copper base with an integrally formed crucible having a passage therethrough. A vacuum chamber is positioned on the top of the copper crucible with a non-consumable cathode projecting into the chamber to effect melting of metal placed in the crucible. A vacuum chamber is also suspended beneath the crucible for support of a mold to receive molten metal flowing through the passage.

Abstract: A method for casting material melted by arc discharge and an arc melting apparatus useful with a precision casting machine, the invention is practiced by initiation of an arc discharge at an arc current lower than the steady state current normally used for arc melting, thereby to prevent starting shock. Current level is subsequently increased in a rapid and regular manner to a steady state current for melting in a stable manner the material which is to be cast. The apparatus of the invention includes a small and compact arc power source provided with apparatus for controlling the arc current which is applied to the material to be melted. When utilized with a precision casting apparatus, the invention improves the manufacture of artificial teeth, accessories, industrial mechanical parts and the like.