Aluminum Company of America

Lawrence W Cisko

James R Fields

Robert C Wallace

C Edward Eckert

Men Glenn Chu

Daniel Bergstrom

Jeffrey M Shoup

Thomas R Hornack

Gerald D Scott

M K Premkumar

Daniel E Hunter

S John Pien

Mohammad A Zaidi

Adam J Sartschev

Blair T Allison

Albert C Wang

Richard A Manzini

William A Graham

Marshall A Klingensmith

John M Urbanic

William G Truckner

James R Anglin

Thomas J Kasun

Joshua C Liu

Thomas J Rodjom

Mark F Warchol

Walter R Reichelt

Ronald Bachowski

Bernard C Turley

Ronald C Wojnar

George C Full

Robert J Martin

Richard C Stiffler

Paul E Ringbloom

Aladar Fricke

Phillip J Pallone

Frank E Savor

Peter J Coppola

Janel M Miller

Jerri F McMichael

Michael M Mohajery

A method of gripping a metal tubular member during a forming operation to resist damage to the gripped ends and reduce scrap, includes providing an outer tool having a recess structured to receive an end of the tubular member, inserting a resilient mandrel into the end of the tubular member and inserting the tubular member end into the recess. A compressive force is applied to the resilient member in a direction aligned generally axially of the tubular member to establish transverse expansion of the resilient member in order to clamp the tubular member end between the mandrel and the outer tool recess. The tube may be stretched beyond the yield point and formed while so clamped, after which the compressive force is removed so as to facilitate withdrawal of the formed tube. In one embodiment, the mandrel may consist of a composite which may have a lower durometer hardness inner portion and higher durometer hardness outer portions. In another embodiment, a substantially rigid mandrel is received within the tube end and an annular resilient sleeve is positioned on the outside of the tube end. The method may be used for a wide variety of purposes including forming structural vehicular members. Associated apparatus is provided.

Method of gripping tubular members during forming operations and

Apparatus and a method for forming an elongated workpiece are provided. In a first embodiment, a press has a ram and movable upper platen to which is secured a first die. Upper guide members are provided on the upper platen for movement of slide members on each responsive to movement of the platen. Lower guide elements, which cooperate in a telescoping manner with upper guide members, are secured to a lower platen. The first die cooperates with a pair of rotatable second die members which are provided with each being rotatable responsive to movement of a slide member. In a preferred embodiment, the upper guide members secured to the platens are in relative sliding contact and links connect the slide members with the rotatable second dies. In a preferred embodiment, the elongated metal workpiece may be formed by bending under the influence of the forces applied to the first die and second die members through the upper platen by the press ram. In a second embodiment, the press first die and associated guide members are not employed and forming is effected by the second die members. Associated methods are provided.

Apparatus for forming elongated metal articles and related method

An apparatus for conducting ultrasonic waves to and from a body of a molten material. The apparatus includes a buffer rod for transmitting ultrasonic waves to the molten metal, a second buffer rod for receiving ultrasonic waves from the molten metal, piezoelectric elements associated with each buffer rod, and cooling mechanisms for protecting the piezoelectric elements by maintaining the buffer rods at a prescribed rate of thermal equilibrium with the molten metal. The cooling mechanisms are configured so as to facilitate regulation of the air flow about the apparatus.

Apparatus and method for ultrasonic particle detection in molten metal

Apparatus for lubricating die and/or workpiece surfaces, the apparatus including a container adapted to capture a predetermined volume of lubricant. At least one nozzle is provided for spraying the volume of lubricant onto the die/workpiece surfaces when the volume is received from the container. A first valve is connected between the nozzle and container, and a reservoir of lubricant and a pump for circulating lubricant through the container and past the first valve at a relatively low pressure is provided, the circulation of lubricant occurring during a portion of a lubricating cycle when no lubricant is sprayed onto the die/workpiece surfaces. A second valve is located between the pump and container for interrupting the flow of lubricant past the first valve, and a blocking valve is located between the container and the reservoir for interrupting the flow of lubricant from the container. A piston is located within the container and an actuator is connected to the piston for moving the same within the container to direct the captured volume of lubricant from the container to the first valve at a pressure sufficient to open the first valve.

Forging die lubricator

A roll for use in a belt caster. The roll has a plurality of axial segments, at least one of which can be adjusted to compensate for transverse distortions in the belt. Generally uniform tension is maintained transversely in the belt so that the belt remains generally planar in the portion that contacts the molten metal that is cast in the belt caster.

Roll for use in a belt caster and an associated method

The die casting machine includes a trough containing a supply of molten metal and a feed tube extending into the supply of molten metal in the trough. A flow of molten metal is maintained in the trough past the feed tube independent of the transfer of molten metal through the feed tube. The die casting machine further includes a filtering system.

Die-casting process and equipment

A vacuum die-casting machine has a bellows forming a sealed enclosure between the rear of the fill chamber and the piston rod. A vacuum is applied to the enclosure during evacuation of the die cavity and charging of the fill chamber with molten metal. As the piston moves forward, an inert gas at about atmospheric pressure is introduced into the enclosure and extends into the feed tube.

Vacuum die-casting machine with apparatus and method for controlling

A squeeze-casting method is taught for manufacturing metal matrix composites which require little or no finishing operations. This method utilizes a combination of techniques, fundamentals of which are found in the investment casting, die casting and metal matrix composite-making arts. The method comprises, forming a wax pattern around the preform and investing the pattern to form a melt-impermeable shell-mold around it. The shell-mold is dewaxed leaving the preform positioned within it. The shell-mold is heated before it is placed in a die cavity of a conventional die caster for high pressure injection of molten metal. Molten metal is poured into the die cavity and pressurized with sufficient pressure and for long enough to impregnate the preform. The metal encapsulates the shell-mold which allows for equilibrated pressures within said die. The pressure is released and the shell-mold is removed from the die cavity before the molten metal in the shell-mold solidifies. When the shell-mold is cooled and the molten metal solidified, the shell-mold is broken and the metal matrix composite removed.

Method of squeeze-casting a complex metal matrix composite in a

A continuous casting machine ('block caster') is provided with chain-wise interlinking of mold block assemblies. Such chain-wise interlinking maintains the mold block assemblies essentially contiguous and is essential to provide operation of a continuous casting machine essentially free of mechanical noise. Each mold block assembly is elastically independently hinged by dual parallel hingepins, spaced-apart in the casting direction (x-axis), as the mold block assembly is carried between opposed, transversely (y-axis) spaced-apart guide rails of each carriage track. The elastic hinge means compensates for variation in block-to-block (centerline) distance caused by kinematic phenomena, including thermally induced variations in the dimensions of individual blocks as a function of their position in each track during operation. Guide rollers guided in generally horizontal guide roller-ways are afforded no measurable tolerance relative to their vertical displacement, when the roller-ways are off-set. Microslitted faces of mold blocks minimizes their distortion due to thermal cycles.

Continuous casting machine with mold block assemblies interlinked by

This invention provides improved casting processes, equipment, and products. The invention is especially advantageous for die casting.

An apparatus for a moving conveyor feeder comprises an hydraulic actuator to alternatively move a shaft in opposite directions. Motion amplification is operationally coupled to the shaft to amplify the amount of motion thereof, and a conveyor feeder is operationally coupled to the motion amplification; whereby a small amount of linear movement imparted to the shaft by the hydraulic actuator results in a much larger linear movement by the conveyor feeder.

Hydraulic-powered apparatus with motion amplification means for moving

Apparatus for removing frozen electrolyte bath from surface portions of an electrode body, the apparatus having crust breakers adapted to penetrate and fracture the crust which breaks into discrete pieces and which separates from the body. The crust breakers are attached to a frame through a linkage system which is adapted to move the breakers along a line of travel substantially adjacent to the salt encrusted surfaces of the body. With application of sufficient power to the crust breakers to penetrate and fracture the crust, substantially all of the crust is removed from the electrode body with minimal generation of dust and noise.

Frozen electrolyte bath removal apparatus

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Irwin, PA, United States of America

Lawrence W Cisko