Alcoa Inc.

Aluminum Company of America

Aloca Inc.

Men Glenn Chu

Siba P Ray

Ho Yu

Alvaro Giron

Jeffrey J Shaw

C Edward Eckert

Ralph R Sawtell

Lawrence W Cisko

Thomas R Hornack

Gregory J Hildeman

James R Fields

Gerald D Scott

M K Premkumar

Mohammad A Zaidi

Richard A Manzini

William P Chernicoff

Ken Kallaher

Roberto J Rioja

Robert L Kozarek

Marshall A Klingensmith

William G Truckner

David D Leon

Thomas J Kasun

Thomas J Rodjom

Hasso Weiland

Robert C Wallace

Ronald E Boylstein

George C Full

Kenneth Joseph Kallaher

Jerri F McMichael

Janel M Miller

William A Casada

Kenneth Kallaher

In some embodiments, the instant invention provides methods for making reinforced composites and reinforced composite products. In one embodiment, a method includes adding (a) a carrier including a salt and (b) a plurality of substantially inert sub-micron sized particles into a molten metal to form a mixture; and forming a reinforced composite from the mixture, the reinforced composite including a non-particulate metal portion having the substantially inert sub-micron sized particles therein.

Methods of making a reinforced composite and reinforced composite products

System and method of producing multi-layered aluminum alloy products are disclosed. A multi-layered aluminum alloy product may be formed by first heating a first aluminum alloy to a first temperature where the first temperature is at least about 5&#xb0; C. lower than the eutectic temperature of the first aluminum alloy, second heating a second aluminum alloy to a second temperature where the second temperature is at least about 5&#xb0; C. higher than the liquidus temperature of the second aluminum alloy, and coupling the second aluminum alloy to the first aluminum alloy to produce a multi-layered aluminum alloy product.

System and method of producing multi-layered alloy products

Molten metal of a first composition is fed into a mold cavity, via a first control apparatus, wherein the control apparatus is open, wherein the feeding includes at least flowing out of a first feed chamber. The first control apparatus is closed. A second control apparatus is opened. Molten metal of a second composition is fed into the mold cavity, via the second control apparatus, wherein at least a portion of the metal of the first composition in the mold cavity is sufficiently molten so that an initial feed of molten metal of the second composition mixes with the molten metal of the first composition in the mold cavity, wherein the feeding includes at least flowing out of a second feed chamber, wherein the second composition is different from the first composition. An ingot is removed from the mold cavity, wherein the ingot as a top section, a middle section, and a bottom section, wherein the bottom section is composed of metal of the first composition, wherein the top section is composed of metal of the second composition, wherein the middle section is composed of a mixture of metal of the first composition and the second composition.

Method of producing ingot with variable composition using planar solidification

Molten metal of a first composition flows out of a first chamber via an open first control apparatus into a mold cavity. The first control apparatus is closed. A second control apparatus is opened. Molten metal of a second composition, different from the first composition, flows out of a second feed chamber via the second control apparatus into the mold cavity. At least a portion of the first composition metal in the mold cavity is sufficiently molten that an initial feed of the second composition molten metal mixes with the first composition molten metal in the mold cavity. An ingot is removed from the mold cavity, the ingot having top, middle, and bottom sections, the bottom section composed of metal of the first composition, the top section composed of metal of the second composition, and the middle section composed of a mixture of metal of the first and second compositions.

Method for producing ingot with variable composition using planar solidification

Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal or vertical direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting. A multiple layer ingot product is also provided comprising a base alloy layer and at least a first additional alloy layer, the two layers having different alloy compositions, where the first additional alloy layer is bonded directly to the base alloy layer by applying the first additional alloy in the molten state to the surface of the base alloy while the surface temperature of the base alloy is lower than the liquidus temperature and greater than eutectic temperature of the base alloy &#x2212;50 degrees Celsuis.

Method of unidirectional solidification of castings and associated apparatus

Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting.

A DC casting mold for casting molten metal alloy comprising a cooled tubular body that has a thermally insulated insert attached to its top surface. The thermally insulated insert has a bottom portion with a beveled sidewall, which forms an angle with the horizontal melt surface layer of the molten metal and creates an eddy. The eddy causes a substantial number of oxides that are formed during the casting process to remain in the bottom sidewall portion of the thermally insulated insert of the mold, thereby substantially reducing the number of ingot surface imperfections that promote ingot cracking. In addition, the eddy promotes break-up of the oxides into smaller pieces as the oxides flow toward the cooled inner walls of the cooled tubular body, thereby having limited surface area for growth of oxide folds. A method of casting molten metal alloys with improved surface quality is also disclosed.

Controlled fluid flow mold and molten metal casting method for improved surface

A novel product composed of a ceramic phase particle dispersoid in metal, including uniformly distributed, finely sized carbide phase particles formed in situ in a molten metal and a novel method for producing such a ceramic phase particle dispersoid in metal are disclosed. A salt-based liquid state reaction involving a liquid metal/alloy containing a liquid Ti, B, Si, Sc, Hf, Nb, Ta, Zr, Mo, Al (when the molten metal matrix is not aluminum), or V and a halide salt containing carbon particles forms a uniform distribution of finely sized ceramic phase particles formed and dispersed in-situ in the metal matrix. The ceramic dispersoid in metal product of the present invention includes at least about 50 volume percent of a matrix metal of aluminum; and up to about 50 volume percent of a uniform distribution of finely sized ceramic phase particles formed and dispersed in-situ in the aluminum metal matrix, wherein the finely sized ceramic phase particles have an average particle diameter of less than about 2.5 microns, and wherein the uniform distribution consists of a substantially cluster-free distribution of no more than two particles attached to one another at a magnification of 500&#xd7;.

Aluminum alloy product refinement and applications of aluminum alloy product refinement

A novel method for producing a ceramic phase particle dispersoid in metal and a novel product composed thereof. The method includes (a) providing a molten composition consisting essentially of molten aluminum alloy containing molten metal selected form the group consisting of Zr, V and combinations thereof; (b) providing a chloride salt containing fine carbon particles; and (c) reacting the chloride salt containing fine carbon particles in the molten aluminum metal liquid with the molten metal liquid to form a uniform distribution of finely sized carbide particles formed and dispersed in-situ in an aluminum alloy matrix.

Metal product containing ceramic dispersoids form in-situ

A novel product composed of a ceramic phase particle dispersoid in metal, including uniformly distributed, finely sized carbide phase particles formed in situ in a molten metal and a novel method for producing such a ceramic phase particle dispersoid in metal are disclosed. A salt-based liquid state reaction involving a liquid metal/alloy containing a liquid Ti, B, Si, Sc, Hf, Nb, Ta, Zr, Mo, Al (when the molten metal matrix is not aluminum), or V and a halide salt containing carbon particles forms a uniform distribution of finely sized ceramic phase particles formed and dispersed in-situ in the metal matrix. The ceramic dispersoid in metal product of the present invention includes at least about 50 volume percent of a matrix metal of aluminum; and up to about 50 volume percent of a uniform distribution of finely sized ceramic phase particles formed and dispersed in-situ in the aluminum metal matrix, wherein the finely sized ceramic phase particles have an average particle diameter of less than about 2.5 microns, and wherein the uniform distribution consists of a substantially cluster-free distribution of no more than two particles attached to one another at a magnification of 500&times;.

Uniformly dispersed, finely sized ceramic particles in metals and alloys

A substrate system for receiving a deposit of sprayed metal droplets including a movable outer substrate on which the sprayed metal droplets are deposited. The substrate system also includes an inner substrate disposed adjacent the outer substrate where the sprayed metal droplets are deposited on the outer substrate. The inner substrate includes zones of differing thermal conductivity to resist substrate layer porosity and to resist formation of large grains and coarse constituent particles in a bulk layer of the metal droplets which have accumulated on the outer substrate. A spray forming apparatus and associated method of spray forming a molten metal to form a metal product using the substrate system of the invention is also provided.

Substrate system for spray forming

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.

Growing community of inventors

Export, PA, United States of America

Men Glenn Chu