Abstract: An apparatus is set forth wherein powder is produced by melting metal in a melting furnace and then directing it onto an atomizer rotor or cup. The atomizer cup is positioned to receive molten metal at the center thereof and is rotated by any means desired. The cup comprises an outer metal cup fixed to the top of a rotating shaft, with an inner cup mounted in the center thereof and spaced therefrom by an outwardly extending flange at the top. A low conductivity thermal insulation is provided between the cups, and the inner cup is coated with a ceramic such as by plasma or flame spray. The inner cup is tapered inwardly as it extends from its bottom to the top edge to provide an annular pool of molten metal around the inner surface permitting the liquid metal to attain the peripheral speed fo the spinning cup as it moves from the center of the cup to the top edge.A heater is provided to preheat the cup and during operation to aid in keeping the cup surface above the melting point of the liquid metal.

Abstract: A method for producing flake particles by projecting a continuing stream of molten material upon the surface of a rotating generally circular, heat extracting drum, having a serrated edge with each serration comprising a radial surface and an angularly disposed connecting surface from the base of one radial surface to the peripheral extremity of the adjacent radial surface; and rotating the heat extracting drum at a speed relative to the size and shape of the serrations and relative to the rate of molten material projection to form a discrete flake particle on each angularly disposed surface; followed by removing each particle from the surface after each particle is at least partially solidified; and cooling the particles in a surrounding atmosphere.

Abstract: A method of forming fibers from a flowable thermoplastic forming material wherein the fiber forming material is fed onto an outer surface of a spinning element which tapers inwardly to a terminal point and sweeping the fiber forming material with a flow of heated fluid along the surface of the spinning element and spinning the fiber forming material from the terminal point into congealed fibers under the continued influence of the sweeping fluid, cooling the uncongealed fibers to form a uniform suspension in the sweeping fluid and collecting the congealed fibers.

Abstract: A rotary liquid metal atomizer is positioned to receive a stream of molten metal on the top thereof. The atomizer is formed as a hollow disc means having a concave top surface and mounted for rotation at high R. P. M.'s on the top of a hollow drive shaft. A circular coolant baffle is located in the hollow disc means, for cooling fluid to flow around, and is mounted on the top of an inlet cooling tube located within the drive shaft. Cooling fluid is directed through the inlet cooling tube to the top of the water baffle where it flows through a hole in the center thereof and around the space between the baffle and the interior of the hollow disc means and down between the inlet cooling tube and drive shaft. The top of the disc means over the coolant baffle is formed of copper. A metal rim is placed around the upper outer periphery of the copper disc forming a recessed center portion. A ceramic coating is placed in the recessed portion with its outer edge against the inside of the rim.

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 method of spinning fibres from a liquid, particularly a liquid urea formaldehyde resin, which comprises the step of supplying the liquid to at least one rotating annular reservoir having an outwardly extending upper and/or lower weir, and causing the liquid to flow outwardly over the said weir(s) and to be spun outwardly therefrom in the form of fibres by centrifugal force.

Abstract: Nonmetallic inclusions and like contaminants are removed from a metal charge by melting the charge to form a molten pool on which the inclusion contaminants float and directing an electron beam onto a preselected first portion of the pool surface, said selective beam impingement causing the floating contaminants to segregate to other portion not subjected to beam impingement. Removal of molten metal from the impinged surface portion while the inclusion contaminants are confined elsewhere on the pool surface provides a clean molten metal product. Apparatus for use with the process is also disclosed. The invention finds special application in the master melting or remelting of metals and alloys for conversion to ingot shapes or high purity molten metal for powder making, investment casting, forging and the like.

Abstract: A rotary liquid metal atomizer is positioned to receive a stream of molten metal on the top thereof. The atomizer is formed as a hollow disc means having a concave top surface and mounted for rotation at high R. P. M.'s on the top of a hollow drive shaft. A circular coolant baffle is located in the hollow disc means, for cooling fluid to flow around, and is mounted on the top of an inlet cooling tube located within the drive shaft. Cooling fluid is directed through the inlet cooling tube to the top of the water baffle where it flows through a hole in the center thereof and around the space between the baffle and the interior of the hollow disc means and down between the inlet cooling tube and drive shaft. The top of the disc means over the coolant baffle is formed of copper. A metal rim is placed around the upper outer periphery of the copper disc forming a recessed center portion. A ceramic coating is placed in the recessed portion with its outer edge against the inside of the rim.

Abstract: A method for producing metal flake of small length-to-width ratio or small length-to-thickness ratio directly from a pool or like source of molten metal or molten inorganic compound, or from an unconfined drop of molten metal or an unconfined drop of molten inorganic compound having a surface tension and viscosity similar to that of molten metal, consisting of forming such products by the application of a rotating, generally circular serrated edge, heat-extracting disk-like member to the surface of the pool of molten material so as to form the material into discrete flake particles by extracting the flake particles from the supply of molten material; and controlling the final shape of the product by the physical shape of the member, the temperature and material composition of the melt, as well as the velocity of the member in contact with the melt.

Abstract: Molten sulfur is fed at a controlled flow rate into a spinning vessel located in an enclosure. A ring of sulfur ejecting nozzles each have an inlet communicating with a conduit that extends tangentially from the periphery of the vessel interior and an outlet communicating with the air in the enclosure. As the sulfur is ejected from the nozzles, it is atomized. The atomized sulfur is further cooled to form solid particles before appreciable agglomeration takes place by fans on both sides of the ring of nozzles into which cooling water is ejected and evaporated. Each nozzle has a deflector at its outlet, and adjustable protrusions that interrupt the flow at the nozzle outlet to control the particle size. The solid particles are removed from the enclosure, thoroughly mixed with a substantial quantity of air, and then separated from the air by a cyclone centrifugal separator.

Abstract: A rotary liquid metal atomizer is positioned to receive a stream of molten metal on the top thereof. The atomizer is formed as a hollow disc means having a concave top surface and mounted for rotation at high RPM's on the top of a hollow drive shaft. A circular coolant baffle is located in the hollow disc means having radial passageways on the top and bottom thereof and connected at the outer periphery for cooling fluid to flow around, and is mounted on the top of an inlet cooling tube located within the drive shaft. Cooling fluid is directed through the inlet cooling tube to the top of the water baffle wherein it flows through a hole in the center thereof and through the passageways between the baffle and the interior of the hollow disc means and down between the inlet cooling tube and drive shaft. A pin fixes the baffle to the disc means. The top of the disc means over the coolant baffle is formed of copper.

Abstract: Apparatus and method are disclosed for forming encapsulated material. Centrifugal force developed by a rotating nozzle having a plurality of radial orifices is used for extruding material to be encapsulated. The nozzle is mounted for rotation about a generally vertical axis and is provided with a circumferential outside surface near its bottom inclined upwardly away from the axis of the nozzle which, when partially submerged in a liquid during rotation, impels a sheet or spray of the liquid along the circumferential surface and shears off successive leading tips of extruded material to form capsules.

Abstract: Expanded slag, especially blast-furnace slag of Thomas melts is made by passing the slag along a trough in which water is fed into a layer of the molten slag. The slag is then permitted to cascade downwardly along an inclined surface which is wetted with water and finally is dispersed by a rotating disintegration drum and curtain of finely divided water. The expanded slag has a lower density, a more complete expansion characteristic and a greater uniformity than conventionally produced expanded slags.

Abstract: An apparatus for producing mineral fibers by low pressure air fiberization having a housing defining a substantially toroidal air chamber formed of a forward vertical wall and having a substantially circular central opening, an annular slot provided around the central opening, and an air inlet provided at a portion of the chamber. A cup-form spinner is mounted on a substantially horizontally oriented shaft arranged to be rotated. The spinner is mounted in front of the forward wall of the plenum and with the open end facing the forward wall. A duct is provided to direct molten slag into the spinning cup which ejects molten slag into an air stream emitted from the annular slot of the chamber, thereby producing mineral fiber of excellent quality.

Abstract: A shot producing machine includes a rotatable vessel containing molten metal, the rotation of such vessel throwing the molten metal therefrom in the form of spherical droplets. The spherical droplets are caused to pass through a liquid spray whereby they are solidified into pellets, and thereafter fall to the bottom of a receiving vessel for collection.

Abstract: System for suppression of pollution in fiber attenuating operations, especially in mineral fiber insulation blanket production. The system disclosed provides gas blast attenuation of the attenuable material in a fiber forming chamber and for recirculation of attenuating gases and for discharge of a portion of the gases by means of a controllable blower. The operation of the blower is regulated by a pressure sensor responsive to the pressure in the forming section.

Abstract: An apparatus is set forth wherein powder is produced by melting metal in a melting furnace where it is then poured into a tundish which directs the molten metal onto a spinning disc means. The tundish is located at the center of a nozzle plate which contains a plurality of annular nozzle means for directing a coolant flow downwardly around the spinning disc means at different radial positions. Controls are provided for controlling atmosphere in said apparatus. Further, controls are provided to control the speed of the disc means and the mass flow of the cooling fluid through each of the nozzle means.

Abstract: The lower portions of the guard rings of a row of rotary fiberizing units are surrounded by an elongate rectangular noise suppressor having front and rear panels extending lengthwise of the row and transverse end panels connecting the front and rear panels. The panels have impervious sheet steel at their outer surfaces, but are provided with screens of expanded steel at their inner surfaces and are filled with a sound deadening material. Between each pair of adjacent fiberizing units a panel-like expanded steel basket full of sound deadening material is suspended immediately below the guard rings and connected to the front and rear panels. The front panel is segmented into removable doors enabling the fiberizer units to be moved out of the noise suppressor for inspection or repair.

Abstract: The centrifugal pelletizer proposed in the present invention is applicable for producing pellets from a molten metal, such as magnesium or aluminium. The pelletizer comprises a hollow drive shaft, which is enclosed in a housing and rotates in bearings, and a hollow transmission shaft accommodated in the hollow drive shaft so as to define an annular gap between it and said drive shaft. The bottom end of the transmission shaft is rigidly coupled to the drive shaft. In addition, the transmission shaft features a frictional coupling with the drive shaft provided in the bottom portion thereof. In such a centrifugal pelletizer any contact of the molten metal with the drive shaft is fully obviated, which provides for favorable conditions for operation of both said shaft and the bearings in which it rotates.

Abstract: Particles of perfectly spherical shape are produced within a vacuum-tight furnace chamber of small size by means of a movably mounted screen for stopping the particles discharged from a molten zone of an ingot which is driven in rotation at high speed. The rigid screen is formed of material having high thermal conductivity and is provided with a consumable coating on the surface which is struck by the particles. The coating is capable of producing a vapor atmosphere around the point of impact so as to modify the interfacial surface tension of the particles on the screen by means of a localized process of calefaction.

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 apparatus for making beads and a bead product are provided in the form of a member rotatable about a generally vertical axis having an outer peripheral edge adapted to discharge molten material in the form of pellets as the member rotates, means for creating heat on said member sufficient to maintain a molten layer of material being discharged on the walls of said member and fluid cooling means receiving discharged pellets which may be glassy generally spherical particles as solids or having frothy uniform voids surrounded by a glassy smooth surface or having integral crystalline elements.

Abstract: The plant for producing metallic pellets from a salt-added magnesium or alloys thereof comprises a metal-melting furnace, a centrifugal pelletizer with a perforated bowl and a cylindrical pellet-collecting chamber. A hopper is provided in said cylindrical chamber to divide the latter into two concentric zones open from below, of which one zone is adapted for collecting salvage resulting from the pellet formation process, while the other zone is for pellet collection. Provision of said zones makes it possible to considerably reduce the content of salts in magnesium pellets or in those of alloys thereof, as a great proportion of the salts get into the hopper and is withdrawn from the chamber as process waste, whereas the magnesium pellets settle down in the other zone and are then forwarded for further processing.

Abstract: By controlling the design and operational parameters in accordance with particular relationships fibers having an average diameter of 7 microns or less can be formed by passing molten material through orifices in a peripheral wall of a rotor without using conventional hot gas blast attenuation externally of the rotor. The primary fibers are broken into finite lengths to produce staple fiber by a plurality of relatively cool and relatively low pressure air streams which are circumferentially spaced about the rotor and which flow in a direction transverse to the direction of travel of the primary fibers as they exit the orifices in the rotor. The rotors utilized in the perferred embodiment of the present invention have a peripheral wall with at least 40,000 orifices having diameters of about 18 mils or less.

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: A centrifugal extruder is provided with a friction generating element within a hollow rotor of the extruder. The material to be extruded is heated by shear generated by differential rotation between the extruder rotor and a shear generating element. Heat plastification is obtained adjacent the periphery of the rotor and a very short heat history is added to material treated in the apparatus.

Abstract: Cellulose ester fibrillar material is produced by forming a cellulose ester dope, pumping the dope to an extrusion orifice, extruding the dope through the orifice into a region of shear and high draw in a precipitation bath containing a non-solvent for said cellulose ester maintained at an elevated temperature. The fibrillar material is preferably subjected to further treatment to reduce the particle size and set the structure by expanding voids and expelling residual solvent. Paper having a high degree of opacity is produced by incorporating the cellulose ester material to obtain light weight paper.

Abstract: In the manufacture of metal and alloy powders in the form of small diameter spheres whose shape and diameter must be maintained within narrow limits, a substantially cylindrical solid electrode of the material from which the powder is to be made is rotated at high speed about its longitudinal axis and one end of the electrode is heated to fusion point, the molten material being sprayed therefrom under centrifugal forces in the form of small diameter spheres, wherein fusion of the one end of the electrode is obtained by means which produce a local fusion zone on the end surface of the electrode and means for causing the local fusion zone to move along a spiral path on the end surface of the electrode as the electrode rotates.

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: An improved method for spraying molten material in order to obtain solidified grains or prills. Molten material, such as NPK-fertilizer is fed into a symetrical rotating reservoir which rotates about a vertical axis and whose upright walls are provided with apertures for spraying. The interior of the rotating reservoir accommodates a member provided with blades, which member rotates at a speed different from that of the reservoir. The sprayed molten material cools while falling to form solid round prills. The blades inside the reservoir rotate at a speed at least 1.5 times greater than the speed of rotation for the reservoir.

Abstract: High purity metallic powder is made from high purity metallic rod by positioning the rod above a horizontally oriented, cooled and rotating electrode. An electric potential is applied between the rod and the electrode so that the electrode end porixmate the disc is progressively melted down. Molten droplets are thrown off the disc by centrifugal forces onto a cooled, rotating, concave shield which intercepts the trajectory of the droplets. As the droplets contact the cooled shield they solidify and are deflected into a collector. The melting and cooling operations are performed in a controlled atmosphere, e.g., in a vacuum.

Abstract: Apparatus is disclosed for molding foamed thermoplastic articles characterized by a cellular core and a substantially non-cellular integral peripheral shell comprising:A. extruder means adapted to flux a thermoplastic material;B. Disperser means connected to said extruder means for producing a dispersion of fluid blowing agent in the fluxed thermoplastic material comprising a cylindrical barrel having therein at least one ratatable disc dispersion unit with an alternating spaced series of perforated-solid rotating discs; said perforated disc, providing a high shear mixing zone, having outer edge surfaces in close rotating clearance with the inner walls of said barrel; the outer edge surface of said rotating disc being spaced from the inner walls of said barrel to form an intense shear mixing zone; and wherein said blowing agent is dispersed when passed through the apertures of said perforated disc and is intimately dispersed throughout the thermoplastic material when passed through said intense shear zone;C.