Abstract: An apparatus and method for filtering molten metal (M), such as aluminum or an aluminum alloy includes at least one ceramic foam filter or any other type of filtration media such as porous tube or alumina balls disposed in a receptacle (12) for the molten metal (M). A vibrator vibrates at least one of the filter, the receptacle (12) or the metal and may be used to induce priming, filtering and/or drainage of the filter. The vibrator may be retrofitted to an existing filter system and may be adjustable in frequency and amplitude. The vibration may be continuous over a given period or produced in a single shock.

Abstract: A mechanical component that includes a core substrate and a nano-crystalline coating on at least a portion of the core substrate. The core substrate defines a resonance damping cavity. The resonance damping cavity is configured to damp a vibration in the component at a selected frequency.

Abstract: An apparatus and method for filtering molten metal (M), such as aluminum or an aluminum alloy includes at least one ceramic foam filter or any other type of filtration media such as porous tube or alumina balls disposed in a receptacle (12) for the molten metal (M). A vibrator vibrates at least one of the filter, the receptacle (12) or the metal and may be used to induce priming, filtering and/or drainage of the filter. The vibrator may be retrofitted to an existing filter system and may be adjustable in frequency and amplitude. The vibration may be continuous over a given period or produced in a single shock.

Abstract: Apparatus and a method of handling a molten metal processing by-product are provided in which the by-product is placed in a container unit and put in the apparatus, the apparatus including an element having a first position outside of the container and a second position in which at least a part of the element is in the container so as to compress the by-product and exclude oxygen from it. The element also serves to transfer heat from the contents of the container unit to the element and so provide cooling. The element can then be returned to the first position, the container unit be removed and placed at a cooling location for final cooling.

Abstract: A filter which is particularly suitable for filtration of molten metal, and method of making the filter, is described. The filter comprises a ceramic core comprising a primary component selected from the group consisting of alumina and magnesium oxide. A coating is on the ceramic core wherein the coating is selected from the group consisting of BN and Y2O3.

Abstract: A method for filtering molten aluminum and aluminum alloys. The method includes providing a reticulated foam wherein oxygen is introduced to an interior of the reticulated foam. Molten aluminum or aluminum alloy is passed through the reticulated foam wherein oxygen is maintained at a partial pressure of at least 2.51×10?35 atm during filtration.

Abstract: An improved filter is described which is particularly suitable for filtering molten metal. The filter has a porous open celled ceramic foam body with voids separated by struts wherein a portion of the struts are densified with glass.

Abstract: An aluminum alloy sheet for a lithographic printing plate which has excellent ink stain resistance, with a local defect in a photosensitive layer after long-term storage being hard to occur, and excellent the pit uniformity after a roughening and a manufacturing method thereof are provided. An aluminum alloy sheet for a lithographic printing plate containing a predetermined content of Fe, Si, Cu and Ti as well as one type or more selected from B and C, and composed of remaining Al and inevitable impurities, in which a concentration of an aluminum carbide present in the aluminum alloy sheet is not more than 8 ppm, an area occupancy of aggregation substances present on the aluminum alloy sheet surface after the roughening treatment with respect to an arbitrary circle with a radius 5 ?m in the aluminum alloy sheet surface is less than 10%. In a case where the area occupancy is not less than 10%, the aggregation substances are present at a rate of 1 to 2 pieces/50 cm2.

Abstract: A method for filtering molten aluminum and aluminum alloys. The method includes providing a reticulated foam wherein oxygen is introduced to an interior of the reticulated foam. Molten aluminum or aluminum alloy is passed through said reticulated foam wherein oxygen is maintained at a partial pressure of at least 2.51×10?35 atm during filtration.

Abstract: Method for purifying molten metal having a specific density and including one or more foreign elements to be removed, by (a) cooling the molten metal to a eutectic temperature to simultaneously form purified metal crystals and crystals including at least one foreign element, and (b) separating at least some of the purified metal crystals from the crystals including at least one foreign element by adjusting the molten metal specific density within a range delimited by a lower value being specific density of the purified metal crystals and an upper limit being specific density of the crystals including the at least one foreign element. The molten metal specific density is adjusted to this range by addition of a metal to alter the molten metal specific density and maintained within this range during separation. The method is advantageously applicable for purification of aluminium melts from recycle aluminium and aluminium scraps.

Abstract: The present invention provides for a refractory aggregate composition comprising an improved calcium aluminate clinker having the formula CnAx wherein C is calcium oxide and A is aluminum oxide, wherein n is an integer from about 1 to about 12, wherein x is an integer from about 1 to about 24, and wherein said clinker has from zero to less than about fifty weight percent C12A7. Analogs, derivatives and hydrates of the improved calcium aluminate clinker are provided. A refractory composition and a sprayable refractory composition are disclosed comprising the improved calcium aluminate clinker. A method for improving the insulating character and/or penetration resistance of a liner in contact with molten aluminum in an aluminum manufacturing process or during aluminum transport is provided.

Abstract: A method for the separation of a dispersion of molten aluminium and solid inclusions formed from a melt of aluminium containing one or more foreign chemical elements. Molten aluminium surrounding the solid inclusions is at least essentially replaced by a molten salt.

Abstract: A method of handling liquid non-ferrous metals after smelting. The liquid metal is in contact with a solid refractory material, and in the absence of electrical currents passing through the liquid-metal-contacting surfaces. The solid material is Ti3SiC2. The liquid non-ferrous material can be aluminum or an aluminum alloy, magnesium or a magnesium alloy, or other non-ferrous materials as to which the Ti3SiC2 material is stable.

Abstract: A hollow partition wall is employed to feed carbon material to an underflow of a carbothermic reduction furnace used to make aluminum. The partition wall divides a low temperature reaction zone where aluminum oxide is reacted with carbon to form aluminum carbide and a high temperature reaction zone where the aluminum carbide and remaining aluminum oxide are reacted to form aluminum and carbon monoxide.

Abstract: The melter furnace includes a heating chamber (16), a pump chamber (18), a degassing chamber (20), and a filter chamber (22). The pump chamber (18) is located adjacent the heating chamber (16) and houses a molten metal pump (30). The degassing chamber (20) is located adjacent and in fluid communication with the pump chamber (18), and houses a degassing mechanism (36). The filter chamber (22) is located adjacent and in fluid communication with the degassing chamber (20). The filter chamber (22) includes a molten metal filter (38). The melter furnace (12) is used to supply molten metal to an externally located holder furnace (14), which then recirculates molten metal back to the melter furnace (12).

Abstract: A method for filtering molten aluminum containing suspended particles using an improved filtration media, the method comprising the steps of providing a source of molten aluminum and providing media having a coating thereon, the coating having a softening point at molten aluminum temperatures to provide adhesive properties and bonding of suspended particles in the molten aluminum thereto. The filtration media is contacted with molten aluminum and suspended particles are adhesively bonded thereto to provide molten aluminum having suspended particles removed therefrom.

Abstract: Methods for reducing inclusion content of sputter targets and targets so produced are disclosed. Inclusions (93) may be reduced by adding a small amount of Si to the molten Al or molten Al alloy followed by filtering of the molten metals through a filter medium (175). Targets having substantially no inclusions (93) therein of greater than about 400 &mgr;m are especially useful in the sputtering of large flat panel displays and result, upon sputtering, in a reduction in the amount of macrmparticles sputtered onto the substrate.

Abstract: A device for an in-line filtering (10) of a liquid metal, by using only a single installation, to obtain a very good filtering of any liquid metal whatever its melting point. The device comprising a treating chamber (11) made of refractory material and having an inlet (12) for supplying the metal liquid to be filtered, an element for cleaning (16) the metal, and an element for degassing (17) the cleaned metal. The degassed metal is then injected, under pressure via an injection pump (18), into a porous filtering element (19) and injected liquid flows tangentially to a filtering surface of the filtering element (19) for filtering the metal while simultaneously cleaning the filtering surface. Under the effect of the applied pressure, a portion of the degassed metal passes through the filtering element (19), which is enclosed by a chamber (20), and the filtered liquid is evacuated through an output port (21) provided in the treating chamber (11).

Abstract: The present invention relates to a process for carbothermic production of aluminum where molten bath aluminum carbide and aluminum oxide are produced in a low temperature compartment (2), and continuously flow into a high temperature compartment (3) where the aluminum carbide is reacted with alumina to produce a top aluminum layer (31), where the aluminum layer (31) forms a layer on the top of a molten slag layer and is tapped from the high temperature compartment (3) at outlet (5), and where off-gases from the two compartments are treated in reactors fed by one or more columns (9, 19). According to the invention the low temperature compartment (2) and the high temperature compartment (3) are located in a common reaction vessel (1) where the low temperature compartment is separated from the high temperature compartment by an underflow partition wall (4).

Abstract: A filter cartridge for a molten metal filtering system is provided with a modular construction in which the filter elements are adapted to be removably mounted to an end plate. The filter elements may be removed separately from the filter and replaced with new filter elements without removing the entire cartridge assembly. According to another aspect of the invention, the filter elements are provided with an elliptical cross-section.

Abstract: There is provided a method and apparatus for removing liquid salts from liquid metal utilizing at least one porous substrate which is wettable by liquid salts and is not wettable by liquid metal. The porous substrate is inserted into a container having a quantity of liquid metal which is contaminated with an amount of liquid salt. The salt contaminated liquid metal contacts the substrate so that the liquid salt is absorbed into the porous substrate. The salt wetted porous substrate is then removed from the container.

Abstract: The present invention is concerned with a system for the filtration of molten material. The system is particularly useful for removing MgO impurities present in molten magnesium chloride electrolyte. The invention also comprises a method for removing solid particles from molten materials. Preferred molten materials include magnesium, aluminum, magnesium chloride electrolyte and aluminum electrolyte. The concentration of solid remaining in the molten material is less than 0.05 wt %.

Abstract: A method of refining a melt of aluminum scrap material which comprises metallic aluminum and impurities including iron, in order to obtain a target iron level. The method includes the steps of determining the initial amounts in the melt of Mn, Fe and Si, adding a quantity of Mn to the melt so as to obtain in the melt, after refining of the melt a ratio of Mn in the melt to a desired target level of Fe. Thereafter, the method includes the steps of homogenizing the melt by heating, cooling the melt and maintaining it at a super-eutectic holding temperature so that solid intermetallic compounds form and finally separating the solid intermetallic compounds from the melt.

Abstract: An apparatus and method for filtering molten metal are disclosed. The apparatus utilizes a continuous filtering medium that is serially indexed into the metal filtering area. The apparatus may be used to filter ferrous and non-ferrous metals, and provides significant cost and time savings. In one embodiment the apparatus allows automatic indexing of a new filter for each shot or pour on high production casting machines. In another embodiment the apparatus is adapted to filter large amounts of metal up to 5,000 pounds or more.

Abstract: An apparatus and method for filtering molten metal are disclosed. The apparatus utilizes a continuous filtering medium that is serially indexed into the metal filtering area. The apparatus may be used to filter ferrous and non-ferrous metals, and provides significant cost and time savings. In one embodiment the apparatus allows automatic indexing of a new filter for each shot or pour on high production casting machines. In another embodiment the apparatus is adapted to filter large amounts of metal up to 5,000 pounds or more.

Abstract: Molten metal containing suspended liquid and solid particles is passed preferably generally upwardly through a porous media so constructed and arranged such that the movement of the molten metal therethrough renders the suspended liquid particles gravity separable. The gravity separable liquid particles rise upwardly or settle downwardly so as to be removable from said molten metal for subsequent removal therefrom. An associated apparatus is also provided.

Abstract: A filter for molten metal comprises a series of at least two refractory material plates in contact with each other at their periphery and defining between them one or more cavities. Each plate comprises a series of holes through which the molten metal passes and by which the molten metal is filtered. The cavities are at least in part filled with a filter material resistant to the temperature of the molten metal to be filtered and providing additional filtering of the metal. The filter material is based on fibers resistant to the temperature of the molten metal. The filter is used to filter molten metals.

Abstract: Molten metal containing suspended liquid particles is passed preferably generally upwardly through a porous media so constructed and arranged such that the movement of the molten metal therethrough renders the suspended liquid particles gravity separable. The gravity separable liquid particles rise upwardly or settle downwardly so as to be removable from said molten metal for subsequent removal therefrom. An associated apparatus is also provided.

Abstract: Particles or inclusions are removed from a molten alloy by contacting the molten alloy with a material selected from the group consisting of aluminium silicate, magnesium silicate, zirconium oxide or a mixture of alumina-calcia and alumina-magnesia.

Abstract: An apparatus for filtering molten material, such as a molten metal-ceramic particle mixture, includes a porous cloth filter located so that the mixture must pass through the cloth filter, and a mechanical filter shaker that prevents the accumulation of filtered solids on the porous cloth filter. Where a further degree of filtration is required, there is a second filter located so that material leaving the porous cloth filter passes through the second filter after it passes through the porous cloth filter, and a mechanism that prevents an accumulation of filtered solids on the second filter. The second filter is desirably a porous media filter.

Abstract: A method and a particle absorber for separating off entrained particles from a stream of molten metal are proposed. The particle absorber has a multiplicity of surfaces within the metal stream produced by means of mechanical separation. This separation leads to a change in the velocity of the flowing metal and to a change in the surface tension. The entrained non-metallic particles are pushed out of the metal stream into the surface regions and blocked there on the separation surfaces. The proposed method and the particle absorber show a good separation effect and, furthermore, are an inexpensive alternative to conventional systems.

Abstract: Filters for filtering molten light metals comprise a reticular foam having a composition comprising graphite, wollastonite, silica and an alkali phosphate glass. The filters have a low hardness and can readily be machined accurately from large pieces of the filter material. In a preferred embodiment the exterior surfaces of the large pieces of filter are coated with a composition comprising graphite and a binder prior to firing and then machined.

Abstract: An ion exchange membrane reinforced with a multiaxial, preferably triaxial, yarn system and an electrolysis process using the membrane in its highly-fluorinated cation exchange form.

Abstract: A molten metal filter includes a refractory plate having an opening therethrough. A refractory filter element is attached to the refractory plate and projects therefrom, the exterior surfaces of the filter element generally defining a rectangular prism. The filter element is hollow so as to define an interior cavity. The filter element includes an opening in that portion of the filter element that is attached to the refractory plate, the opening surrounding the opening in the refractory plate such that fluid communication is established between the cavity and the opening in the refractory plate. In the preferred embodiment, a plurality of filter elements are provided, which filter elements are connected to the refractory plate such that adjacent sides of the filter elements are oriented vertically and are disposed generally parallel to each other.

Abstract: A method of treating molten aluminum containing a suspension of finely divided salt particles remaining after filtering molten aluminum is disclosed. The method comprises providing a body of molten aluminum containing the suspension of molten salt particles entrained therein and passing the molten aluminum into a medium substantially unwettable by the molten salt particles. The particles of salt are collected on the medium and permitted to agglomerate so as to be removed to the surface of the molten aluminum by gravity.

Abstract: A filter system for removing solid impurities from molten metal is described comprising a housing containing vertically disposed rigid coarse filter facing the incoming flow of molten metal and capable of removing solids having a particle size of at least 10 microns and a rigid fine filter mounted vertically behind the coarse filter and capable of removing solids having a particle size as small as 1 micron. The apparatus further includes a heater for maintaining the temperature of the molten metal and a sparger mounted adjacent the front face of one filter to provide an intermittent gas flow over the face of the filter to dislodge solids on the filter as filter cake. In a preferred embodiment, the rigid filters are nested cylinders, and the molten metal is directed to the center of the smaller coarse filter cylinder from which it then flows through the coarse filter outward to and through the fine filter cylinder and then from the fine filter out of the filter housing.

Abstract: The process for purifying a metal melt operates with an active gas introduced into the lower region thereof and consisting of an inert carrier gas and an active, gaseous halogen which are introduced under control into a vessel with the stagnant or flowing metal melt.The active, gaseous halogen is generated at a controlled rate in at least one gas evolution cell and introduced into the carrier gas. The active gas mixture is passed directly into the metal melt. The gas feed line of the halogen does not have any control element.The gas evolution cell for generating the halogen is preferably an exchangeable electrolysis cell, gas being produced only when the electrolysis current is switched on, which follows a nominal curve proportionally to the current intensity.

Abstract: Ceramic bodies suitable for use in the filtration of molten metal are formed by immersing a porous organic substrate material in an aqueous thixotropic slurry containing yttria, zirconia and alumina; expelling excess slurry; drying the impregnated material; and heating to an elevated temperature to burn off the organic material and sinter the ceramic materials. The resulting zirconia-alumina ceramic bodies have from about 5-80% of the zirconia in a monoclinic phase and the remainder of the zirconia essentially in a stabilized cubic phase due to the yttria. The ceramic bodies thus produced have excellent strength, density, and thermal shock resistance properties.

Abstract: A filter for use in the filtration of molten metals comprises a ceramic foam having a gasket made from fibrous material surrounding its peripheral surface and a metallic foil, such as aluminum foil, fixed to the gasket, for example by means of an adhesive, around the outer peripheral surface of the gasket.

Abstract: The present invention relates to an improved molten metal filtration system. The system comprises at least one filtration assembly positioned within a filter chamber intermediate a molten metal inlet and a molten metal outlet and a dam wall positioned intermediate each filtration assembly and each molten metal outlet. Each dam wall prevents the initial molten metal used to prime the filter(s) in each filtration assembly from proceeding directly to the outlet. Instead, the dam wall collects the initial molten metal and forms it into a pool of heated molten metal. This pool has been found to reduce the amount of heat loss during the filtration process. A process for using the filtration system of the present invention is also described.