Swiss Aluminium Ltd.

Olin Corporation

James E Dore

John C Yarwood

Robert K Preuss

Jerry W Brockmeyer

Leonard S Aubrey

Derek E Tyler

David W Dickinson

Abid A Khan

Clifford N Soble

An improved ceramic foam filter for use in filtering molten metal prepared from a ceramic slurry containing silicon carbide and a colloidal silica binder. The filter has a solids content of at least 50% silicon carbide and at least 3% of silica.

Ceramic foam filter

Ceramic foam filter and process for preparing same

A molten metal pouring cup is provided communicating with a transfer means for transferring molten metal from the pouring cup to a casting station. Vent means is provided on the pouring cup at the interface between the pouring cup and the transfer means to permit release of entrapped gas downstream of the pouring cup.

Vented pouring cup for molten metal casting

The disclosure teaches an improvement in the filtration of molten metal especially aluminum using a removable vertically disposed filter plate and at least one fluxing gas inlet positioned in such a manner so as to introduce fluxing gas into the filter plate. The filter plate is provided with a bevelled peripheral surface mating with a like bevelled surface in a filter chamber so that the filter plate can be conveniently inserted in the chamber and removed therefrom. Fluxing gas is provided to the melt through the inlet and flows through the filter plate so as to assure extensive contact with the melt. Dissolved gases and non-metallic inclusions are thereby abstracted and removed from the melt.

Filtering and inline degassing of molten metal

An improved method for the filtration of molten metal for use in the production of castings is disclosed in which a ladling crucible provided with a ceramic foam filter is inserted into a furnace crucible which is filled with molten metal so that the molten metal passes through the filter into the ladling crucible cavity so that oxide films and other impurities are removed prior to ladling.

Method for the filtration of molten metal in a crucible type furnace

An improved apparatus for the filtration of molten metal for use in the production of castings is disclosed in which a ladling crucible provided with a ceramic foam filter is employed in a furnace type crucible to remove impurities.

Apparatus for the filtration of molten metal in a crucible type furnace

A method for adding reactive elements to molten copper or copper base alloys is disclosed. This method prevents unwanted reactions and oxidation by adding the reactive elements to the molten metal in the form of a powder mixture placed within tubing which is compatible with said molten metal. This filled tubing is sealed and drawn down, if desired, to an appropriate size for rapid melting within said molten metal and consequent rapid dissolution of the reactive elements throughout the molten metal.

Addition of reactive elements in powder wire form to copper base alloys

The disclosure teaches an improvement in the filtration of molten metal, especially aluminum, using a removable filter plate. The filter plate is provided with a bevelled peripheral surface mating with a like bevelled surface in a filter chamber so that the filter plate can be conveniently inserted in the chamber and removed therefrom.

Filtering of molten metal

Ceramic foams possessing controlled permeability and uniformity are prepared by a combined rolling operation of impregnating an open-celled organic polymer foam material possessing a predetermined permeability and resilience with a fluid aqueous slurry of a thixotropic ceramic composition and immediate passage through at least two controlled roll gaps, wherein the rolls are preset to effect a temporary compression ranging from about 50 to 90% for the first pass and 70 to 90% for the second pass. The resulting material is thereby uniformly impregnated with the required amount of slurry, and is then dried and heated to remove the organic foam component. The foams prepared in accordance with the present invention are useful as filters for molten metals, especially aluminum and its alloys.

Method of preparation of ceramic foam

The disclosure teaches an improvement in the degassing and filtration of molten metal, especially aluminum, using an apparatus which employs a pair of sequentially placed, removable filter-type plates and at least one fluxing gas inlet positioned therebetween. Fluxing gas is provided to the melt through the inlet and flows upward through the first of said plates into counter-current contact with the melt. Said plate serves to break up said fluxing gas into a fine dispersion to assure its intimate and extensive contact with the melt. Dissolved gases and non-metallic inclusions are thereby abstracted and removed from the melt.

Method for in-line degassing and filtration of molten metal

Improved method for melting copper base alloys containing from 2 to 12% aluminum including the steps of covering a molten mass of said copper base alloy with an essentially continuous flux layer of a molten salt consisting essentially of from 10 to 90% by weight of potassium chloride, from 10 to 90% by weight of sodium chloride and less than 5% by weight of other materials, said salt having a melting point of from 660 to 800.degree. C, and adding additional amounts of said alloy through said flux layer.

Method of melting copper alloys with a flux

Apparatus and method for in-line degassing and filtration of molten metal

Ceramic foams possessing controlled permeability and uniformity are prepared by the impregnation of an open-celled organic polymer foam material possessing a predetermined permeability and resilience with a aqueous slurry of a thixotropic ceramic composition while shearing said slurry an amount sufficient to maximize said impregnation, and expelling excess slurry from said material by conducting at least two passes of said material through preset rollers to effect a temporary compression ranging from about 50 to 90% for the first pass and 70 to 90% for the second pass. The resulting material is then dried and heated to remove the organic foam component. The foams prepared in accordance with the present invention are useful as filters for molten aluminum.

Growing community of inventors

Ballwin, MO, United States of America

James E Dore