Alcoa Inc.

Aluminum Company of America

David D Leon

Robert L Kozarek

Ho Yu

Adel B Mansour

Norman Chigier

Roberto J Rioja

Men Glenn Chu

Gregory J Hildeman

William D Straub

Richard C Stiffler

Herbert J Lause

Larry D Tanis

Allen M Hummel

Douglas L Bruce

Joern E Fischer

Francis J Glogowski

Kristen L Parks

A cooling mechanism for a casting apparatus having a mold that includes sides, a bottom, and a top defining a cavity. The cooling mechanism allows for simultaneous injection of liquid and gas onto a cast ingot therefore providing a lower minimum operation liquid flow rate, while maintaining a fairly constant coolant impingement location on the ingot surface. As a result, heat is extracted from the metal ingot at a much lower rate allowing the ingot to experience superior startup butt curl control, which substantially reduces the number of localized stresses that can lead to cracking of the ingot. Reducing the number of cracks in the ingot substantially reduces the number of wasted ingots, therefore improving efficiency and reducing costs. A method of casting is also disclosed.

Gas enhanced controlled cooling ingot mold

There is claimed a method for depositing fluid material from a linear nozzle in a substantially uniform manner across and along a surface. The method includes directing gaseous medium through said nozzle to provide a gaseous stream at the nozzle exit that entrains fluid material supplied to the nozzle, said gaseous stream being provided with a velocity profile across the nozzle width that compensates for the gaseous medium's tendency to assume an axisymmetric configuration after leaving the nozzle and before reaching the surface. There is also claimed a nozzle divided into respective side-by-side zones, or preferably chambers, through which a gaseous stream can be delivered in various velocity profiles across the width of said nozzle to compensate for the tendency of this gaseous medium to assume an axisymmetric configuration.

Linear nozzle with tailored gas plumes

A method and apparatus is provided for producing a porous metal. The method broadly includes the steps of first, providing a molten metal and second, introducing a gas into said molten metal. The method then includes spray casting the molten metal containing the gas onto a surface thereby producing the porous metal. The method further provides for controlling the amount and size of the porosity contained within the porous metal by controlling the parameters at which the gas is introduced into the molten metal, as well as, controlling the parameters surrounding the spray casting of the molten metal. Additionally, the method also provides for producing a porous metal having either an isolated or interconnected pore structure. The present invention also provides for a porous metal product, as well as a porous aluminum alloy product, made by the described method. The apparatus includes a means for containing the molten metal wherein the containing means has a discharge end. A means for introducing a gas into the containing means is also provided. The apparatus further includes molten metal discharge means positioned adjacent the discharge end of the containing means for atomizing the molten metal that is discharged from the discharge end into metal droplets, and a substrate on which the metal droplets are deposited in order to form the porous metal.

Method and apparatus for producing a porous metal via spray casting

Linear nozzle with tailored gas plumes and method

Microwave frequencies in the range of 0.5 GHz to 10 GHz are used to weld thermoplastic substrates by interposing a carrier strip. The strip is formed of a polymer carrier which is miscible in the substrates. Electrically conductive submicron carbon black susceptor particles are chosen with specified properties such that they generate enough heat within a specified time to produce a weld in which the heat generated is confined to the weld zone. The resulting weld is such that the welded assembly has essentially the same dimensions as the clamped assembly. Glass fiber reinforced substrates are welded without breaking glass fibers in the weld zone. Lap strength of welded substrates is greater than that of substrates joined by prior art methods, whether by welding or adhesive bonding. Articles microwave welded in accordance with the invention are useful for manufacturing and repairing vehicle components such as automobile bumpers and dashboards and other structural parts of automobiles, aircraft, and spacecraft.

Method of welding thermoplastic substrates with microwave frequencies

A method and apparatus for continuously monitoring the cooling capacity of a liquid coolant containing gas bubbles. The apparatus includes a measuring means for measuring the number density of the bubbles to infer the heat transfer characteristics of the liquid coolant, a control means for varying the amount of gas in the liquid coolant so that the number density is within a predetermined range and an electro-acoustic transducer in fluid contact with the liquid coolant capable of generating waves of sufficient intensity to cause cavitation in the liquid coolant in the area of the measuring means. In a preferred embodiment the electro-acoustic transducer is an ultrasonic horn.

Method and apparatus for controlling the heat transfer of liquid coolant

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Murrysville, PA, United States of America

David D Leon