Abstract: Disclosed is a flux injector assembly and method for refining a molten material, wherein at least a portion of the material is aluminum, as it flows through a trough. A dispensing rod having a hollow body and a dispensing rim is configured to allow a flux and/or inert gas to travel through the hollow body and be injected into the molten material through the dispensing rim as the molten material flows through the trough. A baffle plate is configured to be positioned within the molten material in the associated trough to allow the molten material to flow passed the baffle plate. The elongated dispensing rod is positioned at a downstream location relative to the baffle plate. The rate of flow of molten material is increased as it passes the dispensing rim of the elongated dispensing rod to inject and mix the flux within the molten aluminum alloy.

Abstract: A heating element includes a filament that conducts electricity. In some embodiments, the filament is encapsulated in a silicon nitride cover. The heating element provides a heating zone located relatively closer to the tip of the heating element and relatively further from a connection where electrical leads connect to the filament.

Abstract: A method of producing nano-metal powder by providing a process metal to be processed. Selecting a metal halide identical to the process metal. Placing the process metal and selected metal halide in a controlled environment so that vapor from the selected metal halide can contact and react with the process metal. Heating the selected metal halide to a selected temperature to achieve vaporization of the selected metal halide at a desired vapor pressure, wherein the selected temperature controls the evaporation rate of the selected metal halide and the rate the nano-metal powder is formed. Heating the process metal to a temperature below the melting point of the process metal. Providing contact between the vapor of the selected metal halide and the process metal to form the nano-metal powder and reform the selected metal halide.

Abstract: The present invention relates to an apparatus and method for purifying materials using a fractional solidification. Devices and methods shown provide control over a temperature gradient and cooling rate during fractional solidification, which results in a material of higher purity. The apparatus and methods of the present invention can be used to make silicon material for use in solar applications such as solar cells.

Abstract: The disclosure provides a method and apparatus for inerting the surface of a metal charge in an induction furnace. The process generally involves use of a porous plug positioned near the surface of the metal charge. Argon (or other blanket gases) is flushed through the porous plug to back fill the volume of the induction furnace above the metal charge with an inert gas.

Abstract: An “in-line” device to continuously remove dissolved gasses from liquid metal is described. The device described herein may contain an apparatus to create a partial vacuum, one or more ultrasonic vibrators below the surface of the liquid metal to evolve gas bubbles within the metal, and a high-frequency vibrating metal plate which the fluid must pass over at a low depth. The device may be used to create high quality metals, including aluminum and aluminum alloy for a number of demanding applications such as pharmaceutical, semiconductor, foil, and aerospace applications including Aluminum-Lithium alloys.

Abstract: A flux injector apparatus and method adapted to distribute a predetermined amount of flux to an associated pool of molten aluminum. The flux injector apparatus includes a pressurized tank adapted to store and feed the flux under pressure. A feed mechanism operative to discharge a predetermined amount of flux to an outlet and a controller for monitoring and operating the apparatus. The feed mechanism includes a housing having an inner wall defining a cavity with an inlet and an outlet. A feed wheel is positioned within the cavity and operative to receive a predetermined amount of flux from the inlet, translate the flux within the cavity and discharge the predetermined amount of flux through the outlet of the pressurized tank.

Abstract: A device and method for removing impurities in aluminum melt. The device comprises an upper furnace body, a lower furnace body, an intermediate partition plate, a crucible, heating elements and a charging opening. The intermediate partition plate is mounted between the upper furnace body and the lower furnace body. The upper furnace body, a mixing chamber and the heating element are above the intermediate partition plate. The crucible is amounted in the lower furnace body. The heating element is provided around the lower furnace body. The lower furnace body is provided with the charging opening and a pipeline. The upper furnace body is provided with an inlet valve and an exhaust valve. The mixing chamber and the crucible are connected by a jet pipe passing through the intermediate partition plate. A ceramic seal pad is used for sealing between the mixing chamber and the jet pipe.

Abstract: A process for producing particle-reinforced composite materials through utilization of an in situ reaction to produce a uniform dispersion of a fine particulate reinforcement phase. The process includes forming a melt of a first material, and then introducing particles of a second material into the melt and subjecting the melt to high-intensity acoustic vibration. A chemical reaction initiates between the first and second materials to produce reaction products in the melt. The reaction products comprise a solid particulate phase, and the high-intensity acoustic vibration fragments and/or separates the reaction products into solid particles that are dispersed in the melt and are smaller than the particles of the second material. Also encompassed are particle-reinforced composite materials produced by such a process.

Abstract: A method to introduce ceramic particles into liquid metal through the polymeric precursor route by cross-linking organic precursor into a hard polymer, which is added to the liquid melt for in-situ pyrolysis of the organic into the ceramic phase. The starting material, the organic, for the above process can be in the form of a liquid or a solid. If it is a solid it is usually dissolved into a solvent to create a liquid form. The organic is then cross linked either directly by a thermal process, by adding a catalyst, or by the well known sol-gel process into a hard polymer. It is this hard polymer which is then pyrolyzed into a high temperature ceramic material by the process outlined above.

Abstract: The present disclosure provides an aluminum (Al) alloy, for general casting, and a technique for producing the same. The Al alloy includes Al, Si in the range of 5 to 13 wt %, Ti in the range of 2 to 7 wt % and B in the range of 1 to 3 wt %. According to the disclosure, a TiB2 compound may be formed in the Al alloy, where the ratio of Ti:B may range from 2 to 2.5 wt %. The Al alloy of the disclosure has improved elasticity, and is suitable for general casting processes such as, for example, high pressure casting process.

Abstract: Provided are a method and an apparatus for melting an aluminum powder, which are capable of melting the aluminum powder with a high yield and allow the melted aluminum to be reused for a variety of applications. The method for melting the aluminum powder includes the steps of: preparing a mixture (M) including an aluminum powder (A) and a fluoride-based flux (F) by previously mixing the aluminum powder (A) and the fluoride-based flux (F); and melting the mixture (M) in molten aluminum (L).

Abstract: The present invention relates to new compositions of matter, particularly metals and alloys, and methods of making such compositions. The new compositions of matter exhibit long-range ordering and unique electronic character.

Abstract: The present invention relates magnesium-aluminum based alloys having a small grain size and to a method of their production. The alloys are particularly useful in casting applications. The alloys comprise a grain refiner, the grain refiner having the chemical formula: Mg100-x-y-zAlxCyRz wherein R is an element selected from the group consisting of silicon, calcium, strontium or a rare earth element, x is from 10 to 60 At. %, y is from 5 to 50 At. %, and z is from 0 to 20 At. %, provided that x+y+z is less than 100 At. %.

Abstract: Methods for degassing and for removing impurities from molten metals are disclosed. These methods can include operating an ultrasonic device in a molten metal bath, and adding a purging gas into the molten metal bath through the tip of the ultrasonic device.

Abstract: A method for the purification of a metal selected from the group consisting of aluminum and aluminum alloys, wherein said metal is in a liquid phase and is contacted with a salt flux consisting of a selected tertiary mixture of NaCl, KCl, and MgCl2.

Abstract: The present disclosure provides a method for making aluminum-based composite material. The method includes the following steps. First, a aluminum-based material in semi-solid state is provided. Second, at least one nanoscale reinforcement is added into the aluminum-based material in semi-solid state to obtain a mixture in semi-solid state. Third, the mixture in semi-solid state is heated to a mixture in liquid state. Fourth, the mixture in liquid state is ultrasonically processed. Fifth, the mixture in liquid state is cooled to obtain the aluminum-based composite material.

Abstract: The present invention relates to new compositions of matter, particularly metals and alloys, and methods of making such compositions. The new compositions of matter exhibit long-range ordering and unique electronic character.

Abstract: The invention relates to a method for processing aluminum in a furnace consisting in introducing an aluminum-containing material and possibly one or several types of salt into the furnace, melting said material by heating with the aid of at least one burner supplied with a combustive material and fuel in such a way that a molten aluminum possibly covered with a slag containing, in particular alumina and at least one salt is produced and in measuring a carbon monoxide and/or hydrogen concentration in the furnace atmosphere or in a smoke at the exit of the furnace. Oxygen content in the combustive material supplying at least one burner is greater than 10% by volume, preferably greater than 21% by volume.

Abstract: Methods for treating aluminum in a furnace. An aluminum charge is introduced into a furnace and melted with heat from at least one burner. The burner is supplied with at least one oxidizer and at least one fuel. The oxidizer is made up of at least 10% oxygen by volume. The concentration of a first gas is measured in the furnace atmosphere or in a flue gas exiting the furnace. The oxidation of the molten aluminum is then reduced by holding the flow rate of the oxidizer steady while varying the flow rate of the fuel, according to the concentration of a second gas in the furnace or in the flue gas exiting the furnace. The concentration of the second gas is determined by comparing the measured species concentration and the intrinsic concentration which would be present absent the aluminum charge.

Abstract: A method of forming a hypoeutectic aluminium silicon alloy including the steps of: forming an aluminium melt including greater than zero and less than about 12 wt % silicon, adding 20-3000 ppm of a eutectic modifying element selected from the group consisting of strontium, sodium, antimony, barium, calcium, yttrium, lithium, potassium, ytterbium, europium and mischmetal; and either adding nucleant particles and/or causing nucleant particles to be formed in the melt, the nucleant particles being selected from the group of TiSix, MnCx, AlP, AlBx and CrBx wherein x is an integer of 1 or 2.

Abstract: A process and a device for melting aluminum where solid aluminum is melted in a furnace to form aluminum melt pool. The temperature and carbon monoxide (CO) concentration of the flue gas generated in the melting process is detected and examined for variations. Using this variation information, it is determined if aluminum oxides have formed on the surface of the aluminum melt pool and if they have, the melting process is regulated accordingly.

Abstract: An apparatus for separating molten aluminium from a mixture of molten aluminium and aluminium dross includes a table for supporting an insulated crucible containing the mixture of molten aluminium and aluminium dross. A rotatable frame supports a plurality of tines which can be lowered into the mixture in the crucible for stirring the mixture. Vibration means are provided enabling simultaneous vibration of the crucible and stirring of the mixture. The tines cuts through the dross in a shearing action gently rolling the dross, mixing and tumbling it and causing the droplets of aluminium to coalesce. The aluminium droplets and particles in the dross coalesce to form larger droplets and gradually sink to the base of the crucible. A screening means is disposed to substantially surround the crucible when it is supported by the table, which includes a door to both allow and prevent access to the crucible.

Abstract: A process is described for treating molten metal with a particulate treating agent. A melt of a metal, e.g. aluminum, is provided in a treatment vessel such as a ladle and a mixing impeller is positioned substantially below the surface of the molten metal. The impeller comprises a plate with a series of spaced blades extending from the surface of the plate. This impeller is adapted to provide high shear mixing with minimum vortex. While rotating the impeller on a substantially vertical axis, particulate treating agent is fed by way of an injection tube below the surface of the molten metal and into the region between the axis and periphery of the impeller. This causes a high shearing action in the region of the blades whereby the treating agent is quickly broken down into finely divided droplets that are at least partially molten and which are circulated within the molten metal.

Abstract: A container for molten metal which uses heat of solidification for heating the molten metal and method of heating body of molten aluminum.

Abstract: A continuous vacuum refining method of molten metals, wherein impurities in the molten metal are eliminated by evaporation by stirring the molten metal (1) in the molten liquid stirring part B in the evacuated and pre-heated vacuum chamber, the molten liquid is transferred from the stirring part B to the tapping part C in the chamber through connecting holes, the molten liquid is continuously guided into the vessel in the refined molten liquid recovery chambers (10a), (10b) through the recovery passageways (8a), (8b) connected to the tapping part C, the recovery chamber being evacuated and connected with the passageway, and the refined molten liquid (9) is recovered after returning the pressure to the atmospheric pressure, wherein the molten liquid is discharged using plural passageways and plural recovery chambers connected with the respective passageways with alternating the recovery chamber. An apparatus employed for this method.

Abstract: A container for molten metal which uses heat of solidification for heating the molten metal.

Abstract: A method of heating molten aluminum in a container utilizing gas stirring means.

Abstract: A container for molten metal which uses heat of solidification for heating the molten metal.

Abstract: A shaft for use with molten aluminum using an impeller mounted on the shaft comprising a protective refractory sleeve resistant to attack by molten aluminum, the protective sleeve employing a reinforcing media and mounted on the shaft to extend above and below the molten aluminum surface when the shaft is in use.

Abstract: A continuous vacuum refining method of molten metals, wherein impurities in the molten metal are eliminated by evaporation by stirring the molten metal (1) in the molten liquid stirring part B in the evacuated and pre-heated vacuum chamber, the molten liquid is transferred from the stirring part B to the tapping part C in the chamber through connecting holes, the molten liquid is continuously guided into the vessel in the refined molten liquid recovery chambers (10a), (10b) through the recovery passageways (8a), (8b) connected to the tapping part C, the recovery chamber being evacuated and connected with the passageway, and the refined molten liquid (9) is recovered after returning the pressure to the atmospheric pressure, wherein the molten liquid is discharged using plural passageways and plural recovery chambers connected with the respective passageways with alternating the recovery chamber. An apparatus employed for this method.

Abstract: A method of coating of steel products such as plate and sheet using an aluminum-zinc coating alloy includes modifying the coating bath with a particulate compound constituent in effective amounts to decrease the spangle facet size of the coated product, improve tension bend rust stain performance, improve coated surface appearance when brushed, and coated product paintability. Constituents include borides such as titanium boride and aluminum borides, carbides such as titanium carbide, and aluminides such as titanium aluminide. The method produces a coated steel product that does not require temper rolling for painting.

Abstract: A shaft for use in a method for treating molten aluminum using an impeller mounted on the shaft comprising a protective refractory sleeve resistant to attack by molten aluminum, the protective sleeve mounted on the shaft by casting to extend above and below the molten aluminum surface when the shaft is in use.

Abstract: A method of heating a body of molten metal passing through a treatment bay. The method comprises providing a body of molten metal in a treatment bay and providing a baffle heater in the treatment bay to contact the molten metal. The baffle heater is comprised of a member fabricated from a material substantially inert to the molten metal, the member containing at least one heating element receptacle. An electric heating element is positioned in the receptacle for heating the member, the element protected from the molten metal by the material constituting the member.

Abstract: A shaft for use in a method for treating molten aluminum using an impeller mounted on the shaft comprising a protective refractory sleeve resistant to attack by molten aluminum, the protective sleeve mounted on the shaft by casting to extend above and below the molten aluminum surface when the shaft is in use.

Abstract: A method and apparatus are provided for mixing nonmetallic reinforcing particles into a molten metal or metal alloy for the production of stir-cast metal matrix composite (MMC) materials under atmospheric or near-atmospheric pressure. In a preferred embodiment, the particles are introduced into the matrix under the surface of the matrix by feeding the particles through the inner passage of a rotatable hollow impeller tube positioned in the matrix. The impeller tube is terminated at its lower end by an impeller head. The impeller head includes one or more teeth and is positioned proximate to an impeller base. The particles enter the matrix through a shear region which exists in and around the volume between the impeller base and the impeller head. The rotating impeller and the high shear force thereby created wet the particles in the composite matrix and effect homogenization of the composite matrix.

Abstract: An injector for injecting gas into a molten metal. The injector has a rotor that is rotatable about an axis of rotation, the rotor having a cylindrical projection-free side surface, a bottom surface, and a cavity for receiving molten metal located centrally of the rotor with respect to the axis of rotation. The rotor is provided with a plurality of openings in the side surface spaced around the rotor for ejecting molten metal and gas from the rotor upon rotation of the rotor about the axis of rotation. At least one opening in the bottom surface communicates with the cavity permitting entry of molten metal into the cavity, and a plurality of passages disposed in the rotor interconnect the cavity and the openings in the side surface. A gas passageway introduces gas into molten metal present within the rotor but lacks direct communication with the cavity, and is provided with at least one outlet opening into at least one of the plurality of passages to ensure regular and even gas distribution.

Abstract: An improved method for processing a body of molten metal using an impeller and a rotatable container, the method including increasing shear forces in the body of molten aluminum and reducing vortex formation, the method comprising the steps of providing a body of molten metal in a container and projecting an impeller on a shaft into the body. The impeller is rotated in one direction and the container and the body of molten metal is rotated counter or in a direction opposite of rotating the impeller, the container and the impeller being rotated at a rate which minimizes vortex formation and which maximizes shear forces in the body for purposes of improved processing.

Abstract: An improved method for treating a body of molten aluminum using an impeller suitable for dispersing fluxing gas or solid particles in the body of molten aluminum. The method produces increased shear forces in the body of molten aluminum and reduces vortex formation. The method comprises providing a body of molten aluminum and projecting an impeller on a shaft into the body, the impeller comprising a rectangular-shaped body having a first rectangular-shaped face and a second rectangular-shaped face disposed substantially opposite the first face, the faces substantially parallel to the shaft and defined by a length L and a height H wherein the length L is greater than the height H.

Abstract: A process for obtaining aluminum of purity above 99.998%. A liquid aluminum raw material is subjected to a fractional crystallization to obtain prepurified aluminum crystals in a yield of between 50 and 80% and a liquid aluminum portion of lesser purity. The prepurified aluminum crystals are subjected to a three-layer electrolysis process in which the uppermost layer comprises a cathodic purified aluminum layer. The aluminum of purity above 99.998% is removed from the uppermost layer at a yield of above 90%, the aluminum having a total rare earth content of less than 100 ppb and a total content of U+Th of less than 20 ppb.

Abstract: A substantially lithium-free aluminum base alloy product having improved combinations of elongation and fracture toughness in an aged condition, the aluminum alloy product comprising at least 0.5 wt. % magnesium; 0.01 to 1 ppm Na; 0.01 to 1 ppm K; less than 0.1 ppm Rb; and less than 0.1 ppm Cs, the remainder comprising aluminum, the amount of Na, K, Rb and Cs measured by GDMS, the product in an aged condition having a grain boundary region substantially free of liquid phase eutectics comprised of Na and K that form embrittlement phases at room temperature; and an increase in fracture toughness compared to an aluminum magnesium alloy having greater amounts of Na, K, Rb and Cs.

Abstract: Disclosed is an improved method for dispersing a treatment media in a body of molten metal using an impeller, nozzles, and other mixing means to disperse the media in the body of molten metal, the method producing increased shear forces in the body of molten metal and preferably reducing vortex formation. In one embodiment, the method comprises the steps of providing a body of molten metal and an impeller on a shaft in the body. A treatment media is added to the body and dispersed by rotating said impeller in one direction and thereafter reversing the direction of rotation of the impeller to a counter direction. The direction of rotation of the impeller is reversed periodically to substantially reduce formation of a vortex around the shaft of the impeller and to provide increased shear forces in the body for purposes of improving treatment of the molten metal by improved dispersion of the media therein.

Abstract: There is provided an improved method for dispersing a treatment media in a body of molten metal using an impeller to disperse the media in the body of molten metal, the method producing increased shear forces in the body of molten metal and reducing vortex formation. The method comprises the steps of providing a body of molten metal and an impeller on a shaft in the body. A treatment media is added to the body and dispersed by rotating said impeller in one direction and thereafter reversing the direction of rotation of the impeller to a counter direction. The direction of rotation of the impeller is reversed periodically to substantially reduce formation of a vortex around the shaft of the impeller and to provide increased shear forces in the body for purposes of improving treatment of the molten metal by improved dispersion of the media therein.

Abstract: Disclosed is a method and apparatus of treating molten metal for reducing the amount of gaseous or volatile material contained therein. The method comprises providing a body of molten metal and contacting the molten metal with a porous member having a porous surface resistant to penetration with the molten metal. The porous member is subjected to reduced pressure to impose a reduced pressure zone on the molten metal contacting the porous surface thereby removing the gaseous material from the molten metal through the porous member.

Abstract: There is provided an improved method for dispersing a treatment media in a body of molten metal using an impeller to disperse the media in the body of molten metal, the method producing increased shear forces in the body of molten metal and reducing vortex formation. The method comprises the steps of providing a body of molten metal and an impeller on a shaft in the body. A treatment media is added to the body and dispersed by rotating said impeller in one direction and thereafter reversing the direction of rotation of the impeller to a counter direction. The direction of rotation of the impeller is reversed periodically to substantially reduce formation of a vortex around the shaft of the impeller and to provide increased shear forces in the body for purposes of improving treatment of the molten metal by improved dispersion of the media therein.

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: The invention relates to a process and apparatus for manufacturing low-gas and pore-free aluminum casting alloys by vacuum degasification and densification of the melt. Contact between the aluminum melt and the atmospheric humidity of the alloying process, from refining to continuous casting of the cast bars, is kept extremely short, so that effective vacuum degasification, and a high cooling rate, can prevent the formation of gas pores. After the metal melt is alloyed in a smelting furnace, the melt is fed through a system of gutters directly to at least one vacuum furnace. Refining components are added in the vacuum furnace and heating is conducted to provide the pouring temperature required for continuous casting.

Abstract: The toughness of Al-Li, Al-Mg and Mg-Li alloys is increased by a melting and refining process designed to reduce the concentration of alkali metal impurities below specified levels. The hydrogen and chlorine gas constituents are also significantly reduced.

Abstract: A method for the preparation of a mixture of at least one reactive element or an alloy thereof and a liquid metal melt, including introducing the reactive element or alloy thereof, in a liquid state and under pressure, within, i.e. below the surface of, the metal melt, is provided. An apparatus to facilitate the method above is also provided. The apparatus includes a crucible, an immersion pipe that passes into the crucible, an accommodating vessel for storing the reactive element or alloy thereof and a pressure unit.

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.