Abstract: A process for producing a liquid-solid composition comprising heating a liquefiable material sufficiently to form a liquid phase with solid dendritic particles therein without completely liquefying the material and subjecting said liquid-solid material to a shearing action sufficient to break at least a portion of the dendritic structures. The process includes injection molding, forging or die casting the material produced by the process.

Abstract: A process for forming a liquid-solid composition from a material which, when frozen from its liquid state without agitation, forms a dendritic structure. A material having a non-thioxotropic-type structure, in a solid form, is fed into an extruder. The material is heated to a temperature above its liquidus temperature. It is then cooled to a temperature less than its liquidus temperature and greater than its solidus temperature, while being subjected to sufficient shearing action to break at least a portion of the dendritic structures as they form. Thereafter, the material is fed out of the extruder.

Abstract: An apparatus and process for producing shaped metal parts of a semi-solid metal slurry. The metal slurry is introduced as a preform slug or ingot to a prechamber which is subjected to sufficient pressure to force a portion of the semi-solid metal slurry from the prechamber to a metal part shaping die cavity. The completed metal part, together with the portion of metal which remained in the prechamber during part formation, is removed and the metal which remained in the prechamber is detached from the final metal part.

Abstract: A process and apparatus for continuously casting a castable material to a thickness of 10 to 40 mils. A molten material is first spread onto a spreading roller to a uniform thickness and then transferred to a quenching roller whereon the material is cooled until dimensionally stable. The apparatus may be employed to continuously cast thin sheet, platelets, wire, etc. The materials castable by this process and apparatus include metals, alloys, glasses, thermoplastic materials and metalloids.

Abstract: A method is described for continuously casting an ingot of a metal alloy of a type having a substantial liquidus-solidus temperature range to produce internal microstructure of a desired fineness. Molten alloy is flowed along an electron beam heated skulled hearth while controlling the electron beam to maintain a solids content in the alloy on the hearth of between about 15% and about 40%. The alloy is poured from the hearth into the top of a continuous casting mold at a rate which produces a thixotropic region at the upper end of the fully solidified alloy in the mold. The ingot produced is characterized by a macrostructure in excess of one millimeter average grain dimensions with a non-uniform shape, orientation, and distribution, and is characterized by a microstructure of the order of fifty micron cell spacing of dendritic crystallites comprising the microstructure.

Abstract: A molten metal treatment apparatus comprising a passage of predetermined size and length for receiving superheated molten metal from a source thereof, and for supplying the molten metal for subsequent casting; a gas inlet and a control valve for controlling the velocity of the molten metal through the passage by exposing the molten metal to a source of pressurized gas; a cooling jacket at least partially surrounding the passage for controlling the temperature of the molten metal within the passage between predetermined upper and lower limits for forming a thin solidified shell having a molten metal core within the passage; the combination of the velocity of molten metal and the temperature of the molten metal within the passage for allowing dendrites to grow into the molten core from the solidified shell, and for breaking off portions of the dendrites and entraining them in the molten metal thereby producing a solids content within the molten metal for subsequent casting.

Abstract: A solid titanium alloy comprises Ti+Co+Cu+ optionally other elements. The titanium is from 95 to 40 wt. %. The liquidus is below 1300.degree. C. and the structure is of small equiaxed high-melting grains surrounded by at least 10 vol. % of low-melting material. This structure is achieved by vigorously agitating the alloy between its liquidus and solidus so as to break up dendrites, and thereby permits the alloy to be subsequently thixocast.

Abstract: A process for preparing a slurry structured metal composition comprising degenerate dendritic solid particles contained within a lower melting matrix composition, the process comprising vigorously agitating at a given shear rate molten metal as it is solidified. Greatly improved processing efficiencies result if the shear and solidification rates are adjusted so that the ratio of the shear rate to the solidification rate is maintained at a value ranging from 2.times.10.sup.3 to 8.times.10.sup.3.

Abstract: First a reinforcing material mass is formed from a quantity of reinforcing material by binding it together with inorganic binder, and then this reinforcing material mass is compounded with matrix metal to form a composite material mass. Then the composite material mass is heated up so that the proportion of the matrix metal thereof which is in the liquid phase is at least 40%, and while still hot it is subjected to a plastic processing process to form the composite material object.

Abstract: A process and apparatus for forming a thin-walled, elongated member having superior strength properties from an age hardenable copper base alloy is described herein. A slug or billet of a slurry cast, age hardenable copper base alloy is formed into a semi-solid slurry having about 10% to about 30% of the alloy in a liquid phase. The semi-solid slurry is then thixoforged to form the thin-walled, elongated member. Thereafter, the member is age hardened to provide a product having desired strength properties. The process and apparatus of the instant invention may be utilized to form cartridge casings.

Abstract: A process and apparatus for providing metal material having an improved structure for forming into a desired article is disclosed herein. The improved structure is obtained by slurry casting a material into a continuous member and then hot working the slurry cast material. Upon reheating to a semi-solid state, the hot worked, slurry cast material will exhibit finer particles and fewer eutectic melting rosettes than would be exhibited by the slurry as-cast material in an unworked and heated condition. The hot working of the slurry cast material produces an article having a deformed structure exhibiting directionality.

Abstract: Equipment (3) for centrifugal casting from a crucible (5) into a mold (8) is modified by the addition of agitation means (19) movable relative to the crucible (5) and a heating furnace (30) which is movable relative to the mold (8) in order to heat the latter, before casting, to a temperature close to that of the alloy in the thixotropic state.

Abstract: A process and apparatus for forming a thin-walled, elongated member having superior strength properties from an age hardenable copper base alloy is described herein. A slug or billet of a slurry cast, age hardenable copper base alloy is formed into a semi-solid slurry having about 10% to about 30% of the alloy in a liquid phase. The semi-solid slurry is then thixoforged to form the thin-walled, elongated member. Thereafter, the member is age hardened to provide a product having desired strength properties. The process and apparatus of the instant invention may be utilized to form cartridge casings.

Abstract: A process and apparatus for the continuous production of shaped aluminum alloy-particulate composites. The process comprises metering at a substantially constant ratio a particulate solid molten aluminum alloy containing at least 0.10% by weight of magnesium into a mixing station while continuously vigorously agitating to produce a homogeneous mixture, simultaneously discharging from the mixing station a homogeneous mixture of molten aluminum alloy and particulate solid, transferring the mixture to a forming station and shaping and solidifying the composite.

Abstract: A pair of compressible, hinged opposing arms enclose a bladder chamber, which in turn is coupled to the catheter. As the arms are compressed together, successive pivot fulcra close, in turn first pinching and closing, and then opening the bladder to create negative differential pressure against the catheter, and promoting flashback.

Abstract: A process and apparatus for continuously and semi-continuously casting molten metals and alloys. Control of the initial stages of solidification is carried out through application of a thermal insulating layer on the coolant side of a casting mold wall. The layer modifies the heat flux characteristics of the mold along a selected length thereof.

Abstract: In a method for forming shaped articles from molten metallic material the melt is caused to flow from a holding vessel therefor through a refractory duct having at least one static thermally-conducting element extending transversely within the duct so dimensioned and located to both cool and stir by shear the melt flowing therethrough. The melt is cooled to a temperature within its freezing range, if it is an alloy, or at its freezing point, if it is a metal, and is stirred to precipitate a solid phase as fragmented dendrites. The cooled and stirred metal outflow from the duct is cast into shaped articles. The invention has one specific application in producing the precipitating solid phase as non-degenerate micro-crystalline particles.

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

Abstract: A homogeneous mixture of liquid-solid metal is shaped by passing the composition from an agitation zone onto a surface moving relative to the exit of the agitation zone. A portion of the composition contacting the moving surface is solidified and the entire composition then is formed.

Abstract: Die castings are made from metal compositions that are fully liquid or as a preferred embodiment contain between about 10 and 85 weight percent degenerate dendrites. The composition is injected into the cavity of a die at a mean die temperature which is as near to ambient temperature as possible and usually less than about 400.degree. F. The die is formed of a material having a thermal diffusivity of at least about 0.5 cm.sup.2 /sec. The castings are ejected and the die surface is sprayed with a liquid to bring the die surface temperature back to the mean die temperature or below in the shortest possible time. The time between injection and ejection is less than about 1 minute and the time between ejection and spraying is less than about 30 seconds.

Abstract: Apparatus for and method of die casting a part with a particulate inert filler material (e.g., sand) substantially uniformly dispersed through the casting thereby to decrease the amount of metal required to die cast the part.