Electroslag Remelting Type Apparatus Patents (Class 164/515)
  • Patent number: 11066272
    Abstract: An assembly and method for deploying, retrieving, and storing a cable having a minimum bend radius onto a drum. The assembly may comprise a frame, a rotatable drum carried by the frame, a levelwind carried by the frame, and a powertrain. The levelwind may comprise a rail spanning at least the width of the drum, and a traversable carriage carried by the rail. The levelwind may also comprise a cable guide carried by the carriage, where the cable guide comprises an elongated chute having contoured walls. The contoured walls of the chute include no bends having a radius less than the minimum bend radius of the cable. The powertrain may be operatively connected to rotate the drum about the drum axis and traverse the carriage along the rail. In some examples, the contoured walls of the chute are coated with a supplmentary coating.
    Type: Grant
    Filed: April 23, 2019
    Date of Patent: July 20, 2021
    Assignee: ROLLS-ROYCE CANADA LIMITED
    Inventors: Terry Sharpe, Bob Millett, Graham Knowles
  • Patent number: 10144057
    Abstract: A method for manufacturing a forged steel roll comprises: casting, by the ESR method, a steel ingot which contains, by mass %, C: 0.3% or more, Si: 0.2% or more, Cr: 2.0-13.0% and Mo: 0.2% or more, and further contains Bi at 10-100 ppm by mass; and forging the steel ingot to manufacture the roll. According to this method, since freckle defects can be sealed near the center of the steel ingot, the roll can be stably used over a long period of time.
    Type: Grant
    Filed: February 1, 2013
    Date of Patent: December 4, 2018
    Assignee: NIPPON STEEL & SUMITOMO METAL CORPORATION
    Inventors: Hirofumi Onishi, Akihiro Yamanaka, Hideo Mizukami, Tomoaki Sera, Hideyoshi Yamaguchi
  • Patent number: 9770781
    Abstract: A process for growing a substrate (24) as a melt pool (28) solidifies beneath a molten slag layer (30). An energy beam (36) is used to melt a powder (32) or a hollow feed wire (42) with a powdered alloy core (44) under the slag layer. The slag layer is at least partially transparent (37) to the energy beam, and it may be partially optically absorbent or translucent to the energy beam to absorb enough energy to remain molten. As with a conventional ESW process, the slag layer insulates the molten material and shields it from reaction with air. A composition of the powder may be changed across a solidification axis (A) of the resulting component (60) to provide a functionally graded directionally solidified product.
    Type: Grant
    Filed: December 31, 2013
    Date of Patent: September 26, 2017
    Assignee: SIEMENS ENERGY, INC.
    Inventors: Gerald J. Bruck, Ahmed Kamel
  • Patent number: 8662142
    Abstract: A method and a device for remelting metal in an electric furnace includes forming a slag bath to form molten material electrodes. The molten metal of the material electrodes solidifies in block form in a crucible apparatus as a result of cooling in such a way that a block growth forms from a block base using a progressing solidification process, wherein the block base is heated by applying energy directly to the block base to influence the cooling process.
    Type: Grant
    Filed: June 11, 2010
    Date of Patent: March 4, 2014
    Assignee: Ald Vacuum Technologies GmbH
    Inventors: Ulrich Biebricher, Michael Protzmann, Gerhard Brückmann
  • Publication number: 20120168110
    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.
    Type: Application
    Filed: March 15, 2012
    Publication date: July 5, 2012
    Applicant: ATI PROPERTIES, INC.
    Inventors: Robin M. Forbes Jones, Sterry A. Shaffer
  • Publication number: 20100247946
    Abstract: Methods and associated apparatus for semi-continuous casting of hollow ingots are described. In one embodiment a method for the semi-continuous casting of a metallic hollow ingot is provided. The method includes providing a mold comprising a mold center having an inner pipe and an outer pipe arranged to form an annular space for a cooling media and an outer mold, circulating a cooling media in the annular space, feeding a source material to the mold, heating the source material to produce a molten material, moving the mold center progressively downward relative to the outer mold, and solidifying the molten material to form a hollow ingot. Embodiments relating to an apparatus for semi-continuous casting of hollow ingots, and products resulting from the semi-continuous casting of hollow ingots are also described.
    Type: Application
    Filed: March 24, 2010
    Publication date: September 30, 2010
    Applicant: TITANIUM METALS CORPORATION
    Inventors: Alan BLACKBURN, Richard ROTH, Andrew PURSE, David MAY
  • Publication number: 20080115909
    Abstract: The energy consumption during electroslag remelting is determined to a considerable extent by the heat losses of a slag bath on the wall of a water-cooled ingot mould. A process and an ingot mould suitable for carrying it out wherein these heat losses may be avoided for the most part.
    Type: Application
    Filed: November 14, 2007
    Publication date: May 22, 2008
    Applicant: INTECO SPECIAL MELTING TECHNOLOGIES GMBH
    Inventors: Wolfgang Holzgruber, Harald Holzgruber
  • Patent number: 6904955
    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.
    Type: Grant
    Filed: September 20, 2002
    Date of Patent: June 14, 2005
    Assignee: Lectrotherm, Inc.
    Inventors: Edward Scott Jackson, David O. Warren
  • Patent number: 6868896
    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.
    Type: Grant
    Filed: September 20, 2002
    Date of Patent: March 22, 2005
    Inventors: Edward Scott Jackson, David O. Warren
  • Patent number: 6540012
    Abstract: In an electroslag remelting point with a mold (4) for forming an ingot from the remelted material of at least one consumable electrode (33), with a body (6) having at least one vertically driven electrode rod (15) for advancing a respective consumable electrode (33), and with a hood (19) which is disposed above the mold (4) and has at least one opening (18) which is concentric with the respective electrode axis (A), a pot-shaped boiler (20) is provided which accommodates the mould (4) and can be joined to the hood (19) to form a chamber (34) which is closed all round, completely encompasses the mould (4, 28) and can be connected via pipelines (22, 23) to a vacuum pump and/or a gas source, so that the chamber (34) can be evacuated or filled with an inert gas.
    Type: Grant
    Filed: May 8, 2000
    Date of Patent: April 1, 2003
    Assignee: ALD Vacuum Technologies AG
    Inventors: Harald Scholz, Arno Niebling, Ulrich Biebricher
  • Patent number: 6273973
    Abstract: A process for producing a steel includes subjecting at least a portion of a melt of the steel to electroslag remelting and, in a subsequent step, heating the steel to a temperature at least as great as the lowest temperature at which all carbides that can form in the remelted steel will dissolve and no greater than the nil ductility temperature of the of the remelted steel, and maintaining the temperature for a period of time sufficient to dissolve primary and clustered carbide particles in the remelted steel greater than 15 micrometers in length. A novel martensitic stainless steel also is disclosed including 0.65 to 0.70 carbon; 0 to 0.025 phosphorus; 0 to 0.020 sulfur; 0.20 to 0.50 silicon; at least one of greater than 0.0004 boron and greater than 0.03 nitrogen; 0.45 to 0.75 manganese; 12.7 to 13.7 chromium; and 0 to 0.50 nickel.
    Type: Grant
    Filed: December 2, 1999
    Date of Patent: August 14, 2001
    Assignee: ATI Properties, Inc.
    Inventors: Thomas R. Parayil, David S. Bergstrom, Raymond A. Painter
  • 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: 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
  • Patent number: 4966222
    Abstract: The method consists in that molten metal and slag are obtained in a reservoir and then are poured into a mold and kept there till crystallization of the metal takes place and a shaped casting is produced. Prior to the process of pouring, the mold is moved towards the reservoir so that their upper end faces adjoin each other to form a closed integrated unit, which is turned in a vertical plane to transfer the metal and slag into the mold. The joint of the mold with the reservoir in the process of pouring is tightened by providing a time delay for this process from the moment of covering the joint with a slag layer till the moment of solidification of this layer. In the device for producing the castings, the mold and reservoir are provided with individual drives rotating them in a vertical plane, the drives moving the mold to form a closed integrated unit with the reservoir and rotating this unit in the process of pouring the molten metal and slag into the mold.
    Type: Grant
    Filed: October 5, 1989
    Date of Patent: October 30, 1990
    Inventors: Boris E. Paton, Boris I. Medovar, Jury V. Orlovsky, Vitaly V. Lupan, Vladimir Y. Maidannik, Grigory B. Schupak, Jury Y. Chernyavsky, Alexei G. Bogachenko, Alexandr N. Kozhushko
  • Patent number: 4850573
    Abstract: Method of and apparatus for providing agitation of the melt in the induction melting of metals. A medium frequency melting power supply (12) of an induction furnace or crucible (10) acts in conjunction with a modulating circuit incorporating a wave form generator (14) whereby modulation at a predetermined amplitude and frequency is applied to the furnace power frequency during at least part of the melt processing cycle to cause agitation of the melt to a predetermined extent independently of the selected overall power input.
    Type: Grant
    Filed: January 15, 1988
    Date of Patent: July 25, 1989
    Assignee: Inductotherm Europe Limited
    Inventor: John H. Simcock
  • Patent number: 4815521
    Abstract: A method of producing a composite steel body shaft by using at least one cooling metal mold having a cavity of a diameter and a steel body having another cavity of another diameter both of which cavities are coaxially disposed to define a through-hole in which the remelting and solidifying of electrode is effected to provide a shaft portion connected to the hollow body. At a contact position defined by both the metal mold and the hollow steel body at which contact position the diameter of the through-hole is reduced step-wise, a space is provided so that the diameter of the through hole is reduced gradually without the step-wise reduction of diameter of the through hole so as to prevent the confining of slag from occurring at the contact position.
    Type: Grant
    Filed: October 23, 1987
    Date of Patent: March 28, 1989
    Assignee: Hitachi, Ltd.
    Inventors: Takaaki Sakai, Mitsuru Kuragano
  • Patent number: 4612649
    Abstract: A process for refining metal in a crucible containing a layer of molten slag, wherein molten metal passes downwardly through the slag and resolidifies as an ingot thereunder. The slag is kept molten by passing electrical current through the slag layer and between a first electrode and a second electrode. The second electrode has liquid or gas cooling means as an integral part thereof. Current is passed between the first electrode and the second electrode through at least one electrically conductive member interposed between the slag and the second electrode. The electrically conductive member has a melting temperature above the melting temperature and below the bulk temperature of the slag. A portion of the surface of the electrically conductive member that is in contact with the slag has a temperature above the freezing temperature of the slag.
    Type: Grant
    Filed: November 10, 1983
    Date of Patent: September 16, 1986
    Assignee: Cabot Corporation
    Inventors: Arthur H. Griebel, III, Richard A. Foster
  • Patent number: 4578794
    Abstract: The metallurgical vessel comprises a continuous wall and a bottom plate and such vessel constitutes a mold for electrically remelting an electrode by resistance heating of an electrically conductive slag bath. The metallurgical vessel further comprises solenoids for generating an electromagnetic field which is controlled by control means operatively connected to a reference signal generator and to magnetic measuring means like Hall generators preferably arranged tangentially relative to the vessel.
    Type: Grant
    Filed: May 14, 1984
    Date of Patent: March 25, 1986
    Assignee: Vereinigte Edestahlwerke Aktiengesellschaft (VEW)
    Inventor: Walter Cadek
  • Patent number: 4418741
    Abstract: A method of controlling relative movement between an ingot and a mold consists of monitoring the level of the metal pool in the mold by measuring the voltage between the ingot and a mold section disposed above the metal pool, in contact with the bath of molten slag and insulated electrically from the ingot and from the ingot-forming mold section; comparing an instantaneous value of said voltage with a predetermined value and varying the relative speed of the ingot and the mold depending on a signal proportional to the difference between the instantaneous and the predetermined values of said voltage so that the predetermined level of the metal pool is restored.
    Type: Grant
    Filed: November 26, 1979
    Date of Patent: December 6, 1983
    Inventors: Oleg P. Bondarenko, Igor A. Genis, Vitaly M. Baglai, Boris B. Fedorovsky, Boris I. Medovar, Grigory A. Timashov, Vasily I. Us, Georgy S. Pavlichenko, Igor G. Sidorenko
  • Patent number: 4326580
    Abstract: A method of fabricating a structural member such as a wicket gate for water turbines by electro slag forming comprises the steps of mounting a water-cooled metal mold on a part of a previously formed structural member, such as a stem; melting electrodes inserted in the water-cooled metal mold to form the other part of the structural member such as a vane portion of the wicket gate on the previously formed structural member. The previously formed structural member has a concave portion which is exposed in the water-cooled metal mold and the water-cooled metal mold is mounted so as to contact with the previously formed structural member at the lower portion than the top of the concave portion. The previously formed structural member is melted gradually from the central portion of the concave to the outer periphery and then such a portion as the vane portion is formed by molten metal of the electrode.
    Type: Grant
    Filed: October 16, 1979
    Date of Patent: April 27, 1982
    Assignee: Hitachi, Ltd.
    Inventors: Takeshi Wada, Tetsuo Okuni
  • Patent number: 4305451
    Abstract: An electroslag remelting and surfacing apparatus having a cooled mould comprising a plurality of superimposed sleeves which are electrically insulated from one another. The top sleeve of the mould, being substantially a non-consumable electrode, has a current lead and a lining of electrically conducting material. If provided with a radial electrically insulating layer, it may also serve as a single-coil inductor adapted to impart a rotary motion to the slag pool.
    Type: Grant
    Filed: September 4, 1979
    Date of Patent: December 15, 1981
    Inventors: Georgy V. Ksendzyk, Isidor I. Frumin, Vladimir S. Shirin
  • Patent number: 4284123
    Abstract: In a method of and apparatus for producing ingots of unalloyed and alloyed steels having an improved primary crystallization, reduced ingot segregation and a reduced content of non-metallic inclusions, molten steel is poured into a mould, a slag mixture is supplied onto said steel, energy is supplied to the slag mixture while the steel is solidifying in the mould, and the upper rim zone of the molten steel bordering on the slag mixture is cooled.
    Type: Grant
    Filed: February 21, 1979
    Date of Patent: August 18, 1981
    Assignee: Vereinigte Edelstahlwerke Aktiengesellschaft (VEW)
    Inventors: Erwin Plockinger, Gert Kuhnelt, Peter Machner