Aluminum Company of America

Alcoa Inc.

Gregory J Hildeman

Men Glenn Chu

Subodh K Das

Robert E Sanders, Jr

Que-Tsang Fang

Perry A Foster, Jr

Edmond S Miksch

Roberto J Rioja

Robert L Kozarek

David D Leon

Leo A Vivola

John C Kuli, Jr

Arshad Hafeez

David J Brownhill

Linda C Labarre

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

An aluminum alloy containing dispersoid-forming elements selected from the group consisting of Zr, Mn, Cr, V, Hf, Ti, Nb, Y, Sc and combinations thereof. The improved alloy comprises the dispersoid-forming elements partially in solid solution above the saturation limit and partialy in a form of aluminide particles having an average particle size of less than 1 micron.

Aluminum products containing supersaturated levels of dispersoids

A process of reducing macrosegregation in the casting of a metal alloy ingot is disclosed. The process includes introducing a molten metal alloy into a casting mold cavity, cooling the molten metal alloy to form a solid zone, a liquid-solid mushy zone overlying the solid zone, a liquid zone overlying the liquid-solid mushy zone and a melt surface on the liquid zone, employing during the cooling at least one substantially static magnetic field having at least two planes of symmetry which intersect on the longitudinal axis of the ingot, generating the magnetic field by at least one coil means having an inner region through which the metal alloy passes, energizing the coil means by a substantially static electrical current wherein the current follows a path defined by the coil means and passes around at least one of the molten metal alloy and the zones, improving the strength and uniformity of the magnetic field by at least one ferromagnetic flux path, and dampening convection flows of the molten metal alloy which cause macrosegregation by means of the magnetic field. An associated apparatus suitable for casting metal alloys and an improved ingot having a refined equiaxed grain structure and a reduced pore size are provided.

Process for ingot casting employing a magnetic field for reducing

A process of reducing macrosegregation in the casting of a metal alloy ingot is disclosed. The process includes introducing a molten metal alloy into a casting mold cavity, cooling the molten metal alloy to form a solid zone, a liquid-solid mushy zone overlying the solid zone, a liquid zone overlying the liquid-solid mushy zone and a melt surface on the liquid zone, employing during the cooling at least one substantially static magnetic field having at least two planes of symmetry which intersect on the longitudinal axis of the ingot, generating the magnetic field by at least one coil means having an inner region through which the metal alloy passes, energizing the coil means by a substantially static electrical current wherein the current follows a path defined by the coil means and passes around at least one of the molten metal alloy and the zones, and dampening convection flows of the molten metal alloy which cause macrosegregation by means of the magnetic field. An associated apparatus suitable for casting metal alloys and an improved ingot having a refined equiaxed grain structure and a reduced pore size are provided.

Loose metal particles, or a consolidated metal particle composition, of an aluminum alloy consisting essentially of about 5 to 13% zinc, 1 to 3.5% magnesium, 0.5 to 3.0% copper, with iron being present up to 0.5%, with silicon being present up to 0.4%, plus nickel or cobalt or both being present in an amount effective essentially to place the iron in the incoherent dispersoid Al.sub.9 (Fe,M).sub.2, M being nickel or cobalt or both, M being present up to 0.75%, plus means being present for forming coherent dispersoids, said means being present up to 1%, balance aluminum.

Al-Zn-Mg-Cu powder metallurgy alloy

Aluminum alloy atomized powder containing 4 to 15% iron and 1 to 12% cerium or other rare earth metal, when properly compacted and shaped into a useful article, exhibits very high strength at relatively high temperatures. The iron content exceeds the cerium or rare earth metal content, and the powder may contain refractory elements such as W, Mo and others. The powder is produced by atomizing alloyed molten aluminum, preferably in a nonoxidizing atmosphere, and is compacted to a density approaching 100% under controlled conditions including controlled temperature conditions. The alloy may be subsequently shaped by conventional forging, extruding or rolling processes.

Aluminum powder alloy product for high temperature application

Aluminum alloy atomized or other powder is compacted and shaped into a useful article including heating the compact rapidly by induction heating techniques. Such rapid induction heating results in improved strength or toughness properties without substantial penalty in elongation, thereby rendering the product so produced more useful in high strength applications. The product so produced may be subsequently shaped by forging, extruding or rolling processes.

Method for producing aluminum powder alloy products having improved

An improved electrolytic cell is provided for production of a metal such as aluminum by electrolysis of a compound of the metal in a solvent or bath such as molten salt. Electrolysis is carried out by passing a current from an anode to a cathode between which the solvent bath is situated. The cathode comprises a base cathode and cathode extension surfaces comprising graphite and at least 90% refractory hard metal such as titanium diboride. The cathode extension surfaces are produced from a mixture comprising at least 90% refractory hard metal and a carbonaceous binder with little or substantially no particulate carbonaceous material and graphitizing said mixture above 2350.degree. C. to graphitize the carbonaceous material therein to exhibit the graphitic structure.

Composite cathode

Aluminum alloy atomized powder containing 4 to 12% iron and 1 to 7% cerium or other rare earth metal, when properly compacted and shaped into a useful article, exhibits very high strength at relatively high temperatures. The iron content exceeds the cerium or rare earth metal content, and the powder may contain refractory elements such as W, Mo and others. The powder is produced by atomizing alloyed molten aluminum, preferably in a nonoxidizing atmosphere, and is compacted to a density approaching 100% under controlled conditions including controlled temperature conditions. The alloy may be subsequently shaped by conventional forging, extruding or rolling processes.

A metal such as aluminum is produced by electrolysis of a compound of the metal in a solvent or bath such as molten salt. Electrolysis is carried out by passing a current from an anode to a cathode between which the solvent bath is situated. The cathode is composed of a composite comprising graphite and a refractory hard metal such as titanium diboride. The properties and performance of the composite cathode are improved through careful manufacturing controls and selectivity with respect to electrode configuration and cell operating conditions.

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Murrysville, PA, United States of America

Gregory J Hildeman