Abstract: A method and apparatus is disclosed for rapidly solidifying and cooling molten metal oxides, by continuous casting, which according to the invention, comprises: feeding the molten metal oxides into the convergent space formed between two cylinders mounted for rotation about horizontal axes and rotated in opposite directions, i.e., counter-rotating, at a substantially equal peripheral speed, the distance between their axes being equal to the sum of the radius of each cylinder plus at least about one millimeter; cooling the walls of the cylinders to enable solidification of the molten material; controlling the rotary speed of the cylinders so that the molten metal oxide is not completely solidified until it reaches a point beyond a plane passing through the axes of rotation of the cylinders, and retrieving a solidified metal oxide product from the divergent space formed between the cylinders. The method is particularly suited to the production of fine grain abrasives of a corundum or courndum-zirconia base.

Abstract: A system is provided for forming small accurately-spherical objects. Preformed largely-spherical objects (18) are supported at the opening of a conduit (16) on the update of hot gas emitted from the opening, so the object is in a molten state. The conduit is suddenly jerked away at a downward incline, to allow the molten object to drop in free fall, so that surface tension forms a precise sphere. The conduit portion that has the opening, lies in a moderate-vacuum chamber 40, and the falling sphere passes through the chamber and through a briefly-opened valve (30) into a tall drop tower (32) that contains a lower pressure, to allow the sphere to cool without deformation caused by falling through air.

Abstract: A core/sheath vibrating system is utilized to produce core droplets within the sheath, which in turn form into microparticles through phase separation. The flow momentum is first arrested by means of an inclined surface, and the combination is thence deposited, in a continuous, helical channel extending from one end to the other of the inside of a hollow, rotating drum. Rotation of the drum moves the forming microspheres through the channel. At the exit end of the drum, the sheath fluid which carries suspended microspheres, may be filtered, and the microspheres collected and utilized.

Abstract: A system is described for forming hollow spheres containing pressured gas, which includes a cylinder device (14) containing a molten solid material (20) and having a first nozzle (18) at its end, and a second gas nozzle (24) lying slightly upstream from the tip of the first nozzle and connected to a source (26) that applies pressured filler gas that is to fill the hollow spheres. High pressure is applied to the molten metal, as by moving a piston (22) within the cylinder device, to force the molten material out of the first nozzle and the same time pressured gas fills the center of the extruded hollow liquid pipe that breaks into hollow spheres (12a). The environment (54) outside the nozzles contains gas at a high pressure such as 100 atmospheres, the gas is supplied to the gas nozzle (24) at a slightly higher pressure such as 101 atmospheres, and the pressure applied to the molten material (20) is at a still higher pressure such as 110 atmospheres.

Abstract: Light emitting diodes (LED) are used in conjunction with phototransistors determine the liquid-solid state of a 0.030-0.040 inch film of trinitrotoluene (TNT). Liquid TNT is collected on the surface of a rotating drum, and is subsequently cooled to a solid film and removed by a "flaking" knife. The emitted beam from the LED is absorbed when the TNT is in the solid state and transmitted to and reflected from the drum surface when the TNT is in the liquid state. The relative intensity of the reflected beam is a measure of the state of the TNT.

Abstract: An apparatus for making metallic glass powder is disclosed. A jet of a molten glass forming metal alloy is impinged under an acute angle against the inner surface of a rotating cylindrical chill body, whereon it is atomized into a stream of droplets of molten alloy, which again impinge on the chill surface to be rapidly quenched into metallic glass powder.

Abstract: A method of forming hollow glass spheres S shaped by the effects of surface tension acting on bubbles of glass in its molten state; the method is characterized by the steps of establishing a downwardly flowing stream of air accelerated at a one-G rate of acceleration through a drop tower 10, introducing into the stream of air free-falling bubbles B of molten glass, and freezing the bubbles in the stream as they are accelerated at a one-G rate of acceleration.

Abstract: Uniform particles are produced by introducing a laminar stream of a core liquid into a laminar flowing body of an immiscible sheath liquid. The core liquid or the sheath liquid, or both liquids, can contain one or more materials dispersed (dissolved or suspended) in them from which the uniform particles are formed. The two liquids and the dispersed material are expelled from a nozzle to form a liquid jet. The liquid jet is disturbed at a uniform, periodic rate to form liquid droplets which contain a uniform amount of the core liquid, the sheath liquid and the dispersed material. The droplets are collected and held in a catch liquid until the core and the sheath liquid in each droplet have diffused into the catch liquid leaving the uniform particles formed from the dispersed materials. There can be more than one sheath liquid which can also contain one or more materials dispersed in it.

Abstract: A device for the production of a non-woven product from a fluid dielectric substance, comprising a first electrode, means for leading this electrode along a closed path, driving means to move this electrode along this path, coating means for coating this electrode with the said substance opposite a first portion of the said path, a second electrode whose surface is relatively extensive with regard to the first electrode, located opposite a second portion of the said path, an electrostatic generator connected to one of the said electrodes to establish a potential difference between them so as to create an electrostatic field capable of acting on the said substance to form a plurality of fibers in the direction of the said second electrode, characterized in that it comprises two endless transport bands mounted respectively around guide means defining two closed parallel trajectories passing near the coating means and the said second electrode, these bands being connected to the said driving means so as to move

Abstract: An apparatus is disclosed for producing solid materials in form of microspheres or spherules for a number of applications, such as nuclear fuel, catalyst, fluid beds for fluidization and other like applications. An inert gas shield is provided to surround the droplets of liquid from which the microspheres shall be originated so as to prevent a premature reaction of such droplets with the reaction gas. Provision is made for renewing the braking foam placed over the liquid reactive bath and the reactive gas is supplied in the form of a blade-like stream so as to improve the contact time and intensity between the droplets and the reactive gas.

Abstract: Apparatus for the extrusion of a flowable mass onto a conveyor, comprises first and second cylindrical containers. The first container is disposed for rotation about a longitudinal axis and includes first passages for depositing the flowable mass. The second container includes a wall portion which contains a plurality of second passages. The wall portion is disposed against the first container, the latter rotating relative to the second container so that the first and second passages are periodically aligned to enable the flowable mass to be deposited onto the conveyor. The first and second containers define a gap therebetween which creates a negative pressure to suck-in excess mass from the outer periphery of the apparatus. A spatula is provided to push the mass into the gap.

Abstract: Hollow spheres with precisely concentric inner and outer spherical surfaces are formed by applying vibrations to a nonconcentric hollow sphere while it is at an elevated temperature at which it is fluid or plastic, the vibrations producing internal flows which cause the inner and outer surfaces to become precisely concentric. Concentric spheres can be mass produced by extruding a material such as glass or metal while injecting a stream of gas into the center of the extrusion to form a gas-filled tube. Vibrations are applied to the extruded tube to help break it up into individual bodies of a desired uniform size, the bodies tending to form spherical inner and outer surfaces by reason of surface tension, and the continuing application of vibrations causing these surfaces to become concentric.

Abstract: An apparatus for making shot is disclosed, in which a container (3) for molten metal is provided with holes (17) which allow molten metal to pass onto a chute (10), there being a torch or torch holder (11) so disposed that in use heat can be directed directly onto metal within the container. Metal shot can be produced efficiently by the apparatus, and the size of the shot can be varied by regulating the temperature.

Abstract: Amorphous or microcrystalline alloy powder is prepared by the rapid quenching of ultrafine metallic spheroids generated from the molten metal state. The molten metal droplets are formed when an intense electric field (10.sup.5 V/cm) is applied to the surface of liquid metal held in a suitable container. The interactions between the intense electric field and liquid surface tension disrupts the metal surface, resulting in a beam of positively charged droplets. The liquid metal spheres generated by this electrohydrodynamic process are subsequently cooled by radiative heat transfer. Rapid cooling of the droplets may be accomplished by heat transfer to a low pressure gas by free molecular heat conductivity. Quenching rates exceeding 10.sup.6 .degree.K./sec are possible using this technique. Thin film coatings are prepared by electrohydrodynamically spraying a beam of charged droplets against a target (substrate). The target can be electrically controlled to effect the charged particles impact.

Abstract: Apparatus for making miniature capsules having a capsule-forming orifice defined by the open ends of two coaxial conduits. The inner conduit defines a central opening in the orifice and the outer conduit defines an annulus circumferentially of the central opening. Filter-content material for the individual capsules is extruded as a stream through the central opening and a settable coating liquid material is extruded as a thin film sleeve circumferentially of the filler-content material stream. The film sleeve and the stream of filler-content material pass through a cooling liquid which is flowed through a fixed nozzle downstream of the extruding orifice. The nozzle has an inlet section with converging inner surfaces and a uniform diameter downstream of the inlet section. The cooling fluid, the film sleeve and filler-content stream therein all pass through the nozzle.

Abstract: A process is provided for making a prilled product from a molten substance wherein steam or heated gas is passed through the nozzle which produces the prilled product prior to the introduction of the molten substance through the nozzle at the beginning of the process.

Abstract: Substantially pure, free flowing, sodium amalgam particles of predetermined composition and controlled particle size are prepared for use as vaporizable fill for high pressure discharge lamp devices, whereby accurately measurable quantities of the sodium amalgam may be introduced into the lamp devices. A process for producing the substantially pure amalgam particles of accurately controlled size includes heating a mixture of sodium and mercury to form a melt, passing the melt through a vibrating discharge nozzle and subjecting the droplets so formed to an inert cooling fluid maintained at a temperature below the solidification point of the amalgam. An apparatus for producing the amalgam particles comprises a vessel to contain an alkali metal amalgam melt, a vibrating discharge nozzle adapted to form the melt into uniformly sized droplets, and a column of inert cooling fluid maintained at a low temperature at which the melt droplets are solidified.

Abstract: Apparatus for pelletizing liquid and viscous products. A body of the liquid or viscous material is enclosed within a chamber having discharge orifices or nozzles at the bottom of the body of liquid. There is a body of gas above the liquid which is subjected alternately to increased and decreased gas pressures so that the pressure on the body of liquid is first above and then below atmospheric pressure. That causes the product to be discharged from the orifices in droplets. The droplets are then solidified to form pellets. A predetermined liquid level is maintained within the chamber. The changes in gas pressure are produced by operating a valve which connects the body of gas in the chamber alternately to a suction line and supply line for gas under pressure.

Abstract: A nozzle pre-heating device is provided for use in a tower for prilling molten substances. The device comprises a pre-heating chamber which is open only at the upper portion thereof for pre-heating a prilling nozzle and is closed at the bottom to shield the nozzle from the cooling effects of upper flowing gas in the prilling tower. The device is provided with means for moving either the nozzle or the pre-heating device from proximity to one another when the pre-heating device is not in use, thereby permitting free flow of the molten substance from the nozzle during normal operation of the prilling tower.

Abstract: An improved prilling tower is provided for the prilling of molten substances wherein a receiver equipped with an exhaust conduit is positioned below the nozzle during pre-heating of the nozzle prior to normal operation, after the end of a normal operating cycle or when the nozzle is replaced during operation of the prilling tower. Means are provided for moving either the receiver or the nozzle in a horizontal direction so that the nozzle is out of proximity with the receiver during normal operation of the prilling tower. More than one nozzle or more than one receiver can be employed in a prilling tower to provide for continuous operation of the prilling tower during replacement or cleaning of the nozzles.

Abstract: Centrifugal spinning apparatus is provided for the manufacture of fibrils from hot viscous hydrocarbon solutions of olefin polymers having an intrinsic viscosity of at least 3.5. The apparatus consists of an impeller which rotates at high speed in a cylindrical cavity having a discharge port. The impeller has a plurality of blades whose narrow dimensions lie substantially in the plane of the impeller's rotation and whose tips come in close proximity to the inner peripheral surface of the cylindrical cavity. The blades are arranged in at least two substantially-identical sets. Within each set, the blades are offset substantially equidistant from one another, both in the rotational plane of the impeller and in the plane transverse thereto. Two inlet ports are provided in the peripheral surface of the cylindrical cavity to feed liquids to the cylindrical cavity, each of which port is narrow in a plane transverse to the plane of the impeller's rotation and extends over substantially the entire peripheral surface.

Abstract: A system and method is provided for forming semiconductor tear-drop shaped bodies having minimal grain boundaries. Semiconductor material is melted in a capillary tube at the top of a tower, and forced under gas pressure through a nozzle. Separate semiconductor bodies are formed. They are passed through a free fall path over which a predetermined temperature gradient controls solidification of the bodies. The resultant bodies are tear-drop semiconductor bodies of near uniform size with minimal grain boundaries.

Abstract: The stability of a flash fibrillation process for converting thermoplastics materials into fibrils by flash extruding a hot pressurized dispersion of thermoplastics material in liquid through an orifice is improved by inserting a pressure-responsive valve in the orifice which ensures the dispersion is at a specified minimum pressure before it is extruded through the orifice. The minimum pressure should be sufficient to ensure the liquid does not volatilize prior to its extrusion through the outlet.

Abstract: Method and apparatus for producing small hollow spheres of glass, metal or plastic, wherein the sphere material is mixed with or contains as part of the composition a blowing agent which decomposes at high temperature (T.gtoreq.600.degree. C.). As the temperature is quickly raised, the blowing agent decomposes and the resulting gas expands from within, thus forming a hollow sphere of controllable thickness. The thus produced hollow spheres (20 to 10.sup.3 .mu.m) have a variety of application, and are particularly useful in the fabrication of targets for laser implosion such as neutron sources, laser fusion physics studies, and laser initiated fusion power plants.

Abstract: A fluidizing tank for granular refractory material has a porous bottom wall that is displaceable downwardly from a bottom edge of the tank in order to define a gap through which contaminating precipitated particles can fall from the tank, preferably aided by a downward slope of the porous wall. A receptacle housing the tank contains a vibratory sieve for separating the particles from the material falling from the tank so that the sieved material may be returned to the tank, preferably directly by mechanical or suction transfer from the bottom of the receptacle.

Abstract: Finely divided sulfur particles in a liquid suspension are agglomerated by adding molten sulfur to the suspension and agitating the mixture to transform the particles into agglomerates wherein the finely divided sulfur particles are held together by the previously molten, now solidified sulfur, acting as a binder agent.

Abstract: A process is provided for the manufacture of fibrils of short length by suddenly releasing the pressure acting on a two-phase liquid mixture of molten polymer and solvent and which is at a high pressure and a high temperature. The two-phase liquid mixture is ejected through a pressure release orifice so as to vaporize the solvent instantaneously and solidify the polymer, and the flow path of the two-phase liquid mixture is perturbed at the instant when it enters the pressure release orifice.Spinnerets are provided which have a perturbation chamber containing a supply orifice and a pressure release orifice.

Abstract: Spherical particulates containing inorganic material are produced by forming a slurry of particles in an aqueous solution of a gellable organic binder, introducing droplets of the slurry into a two-phase liquid containing an upper hydrophobic phase for forming and maintaining the droplets in spherical form, and a lower ionic phase containing divalent or trivalent metal cations for promoting gellation of the organic binder, thereby converting the slurry droplets into substantially self-supporting spheres of particles dispersed in the gelled binder. Upon separation from the two-phase liquid and one or more optional heat treatments to remove the binder, to convert precursors into the desired final inorganic form, or to strengthen or densify the spheres, such spheres are useful, for example, as starting materials for single crystal growth from a melt.

Abstract: An agglomerating unit having a rotatable, conical, downwardly, narrowing section on the interior surface of which moistened powder is deposited. Close to said interior surface a stationary scraper is mounted. When the conical section is rotated the powder is dislodged from said surface by the scraper. A very efficient removal of powder is obtained whereby the risk of biological or chemical deterioration of the powder is reduced.

Abstract: The disclosure embraces a method of and apparatus for distributing linear groups of fibers onto a moving collector which include engaging and advancing groups of fibers by rotating pull wheels, disengaging the groups of fibers from the pull wheels by oscillating and rotating members associated with the pull wheels, oscillating the members by cam-actuated systems of linkage to control disengagement of the groups of fibers from the pull wheels and effect distribution of the groups of fibers on the collector, and applying pressure on the linkage systems opposing the operation of the systems to substantially eliminate lost motion in the linkage systems and thereby promote oscillatory motion accuracy of the fiber disengaging members whereby the collected body of fibers is endowed with substantially uniform characteristics.

Abstract: An apparatus and method for providing a stream of molten metal from a metallic ingot wherein a quantity of the molten metal from the melted ingot is maintained at an established level within the chamber of the apparatus. It is further heated to an established temperature to then facilitate passage of the molten material through the apparatus's orifice.

Abstract: Process and apparatus for forming essentially spherical solid pellets directly from a melt, and particularly solid metal pellets such as iron and lead. The melt from a column of a preset height is directed through one or more orifices in a way to form a jet which experiences an upwardly directed trajectory path and which under the influence of vibratory action breaks up to form pellets of a predetermined diameter. Adjustments of the column height and/or vibration frequency are used to control pellet diameter. The pellets may be formed and solidified in a controlled atmosphere; and in the case of iron pellets, the carbon content of the pellets may be adjusted, to attain a desired degree of hardness, either before or after pellet formation. Iron pellets thus formed are particularly suitable as substitutes for lead pellets in ammunition.

Abstract: An improved apparatus is set forth wherein powder is produced by melting metal in a crucible where it is then poured into a tundish which directs the molten metal onto a spinning disc means. A nozzle plate has a central opening through which the metal is directed from the tundish to the disc means. An efficient annular nozzle means directs a cooling fluid around the disc means. The crucible has means for tilting it which keeps the molten metal entering the tundish properly as the metal is poured therefrom.

Abstract: Solid waste material is disposed of and a portion thereof converted into valuable refractory prills by use of a reactor having a substantially vertical pyrolysis chamber, a refuse charging inlet and a combustible gas outlet in the upper region thereof and a molten refractory material outlet in the lower region thereof. The molten refractory material withdrawn from the chamber is prilled to form ceramic beads. Gas-feed means charges an oxygen-rich gas into the chamber under pressure at a plurality of vertically spaced points along the length thereof so as to produce combustion of the waste organic components and generate heat. The charge is controlled to maintain a plurality of different temperature zones along the length of the chamber so as to effect incomplete combustion of the waste organic component and form a combustible gas and an organic-free molten refractory material.

Abstract: Metal fibers are produced in a magnetic field by generating magnetic flux lines which extend normal to a planar supporting surface located in an enclosed space. Metallic substances are fed into the enclosed space for travel lengthwise of the flux lines and normal to the supporting surface. The space is heated to a decomposition temperature at which the substances undergo thermal decomposition and liberate metal atoms which agglomerate under the influence of the flux lines on the supporting surface and form thereon metal fibers which project from the supporting surface in direction normal thereto. The supporting surface is then moved in the direction of travel of the incoming metallic substances past a fiber transporting device, and when it has moved to a position downstream of the fiber transporting device, the fiber transporting device engages the fibers and effects their further transportation.

Abstract: An expanded granular material, particularly intended as a lightweight aggregate for concrete, is produced by melting a finely ground fusible silico-aluminous material, such as fly ash, in the presence of a controlled atmosphere intended to inhibit the liberation of gases coming from the silico-aluminous material, and then forming the melt into drops and cooling under conditions to permit gases to escape from the material thereby causing is expansion.

Abstract: A method for making granules from sprayed molten material falling through a tower in which a substantial amount of the rising cooling gas stream is withdrawn from the tower at a level below the top of the tower and is discharged to atmosphere. Only the remaining gas stream requires treatment to remove dust and other pollutants, resulting in a considerably lower energy consumption at the same environmental pollution compared with other processes and installations known.

Abstract: An electric arc which is struck between an electrode and the surface of a pool of molten material rotates under the influence of a magnetic field to thereby free liquid particles from the surface of the pool. The particles produced are quenched in an adjacent inert atmosphere or solidified in a vacuum and become powder. This powder is then collected conveniently.