Alcoa Inc.

Aluminum Company of America

Michael J Kinosz

Thomas N Meyer

Marshall A Klingensmith

Nicolas Bigler

Rick A Borns

Guy Arnaud

Jan H Van Linden

Que-Tsang Fang

James R Fields

Moustapha Mbaye

Joseph R Herrick

Jamal Righi

David R Trudel

Andreas Kaleja

F Donald Kuhns, Jr

Alan P Mitchell

An apparatus for transferring molten metal from a melting furnace to a casting furnace is provided. A sensing and control system for the transfer of molten metal from a transfer furnace to a casting furnace is also described. The combination of the transfer apparatus with the sensing and control system provides for the introduction of reduced oxide molten metal into a casting furnace.

Overflow transfer furnace and control system for reduced oxide production in a casting furnace

The melter furnace includes a heating chamber ( ), a pump chamber ( ), a degassing chamber ( ), and a filter chamber ( ). The pump chamber ( ) is located adjacent the heating chamber ( ) and houses a molten metal pump ( ). The degassing chamber ( ) is located adjacent and in fluid communication with the pump chamber ( ), and houses a degassing mechanism ( ). The filter chamber ( ) is located adjacent and in fluid communication with the degassing chamber ( ). The filter chamber ( ) includes a molten metal filter ( ). The melter furnace ( ) is used to supply molten metal to an externally located holder furnace ( ), which then recirculates molten metal back to the melter furnace ( ).

Recirculating molten metal supply system and method

The filtering molten metal injector system includes a holder furnace, a casting mold supported above the holder furnace, and at least one molten metal injector supported from a bottom side of the casting mold. The holder furnace contains a supply of molten metal. The mold defines a mold cavity for receiving the molten metal from the holder furnace. The molten metal injector projects into the holder furnace. The molten metal injector includes a cylinder defining a piston cavity housing a reciprocating piston for pumping the molten metal upward from the holder furnace to the mold cavity. The cylinder and piston are at least partially submerged in the molten metal when the holder furnace contains the molten metal. The cylinder or the piston includes a molten metal intake for receiving the molten metal into the piston cavity when the holder furnace contains molten metal. A conduit connects the piston cavity to the mold cavity. A molten metal filter is located in the conduit for filtering the molten metal passing through the conduit during the reciprocating movement of the piston. The molten metal intake may be a valve connected to the cylinder, a gap formed between the piston and an open end of the cylinder, an aperture defined in the sidewall of the cylinder, or a ball check valve incorporated into the piston. A second molten metal filter preferably covers the molten metal intake to the injector.

Filtering molten metal injector system and method

Disclosed is a molten metal injector system including a holder furnace, a casting mold supported above the holder furnace, and a molten metal injector supported from a bottom side of the mold. The holder furnace contains a supply of molten metal having a metal oxide film surface. The bottom side of the mold faces the holder furnace. The mold defines a mold cavity for receiving the molten metal from the holder furnace. The injector projects into the holder furnace and is in fluid communication with the mold cavity. The injector includes a piston positioned within a piston cavity defined by a cylinder for pumping the molten metal upward from the holder furnace and injecting the molten metal into the mold cavity under pressure. The piston and cylinder are at least partially submerged in the molten metal when the holder furnace contains the molten metal. The cylinder further includes a molten metal intake for receiving the molten metal into the piston cavity. The molten metal intake is located below the metal oxide film surface of the molten metal when the holder furnace contains the molten metal. A method of injecting molten metal into a mold cavity of a casting mold is also disclosed.

Molten metal injector system and method

A bottom heated holder furnace ( ) for containing a supply of molten metal includes a storage vessel ( ) having sidewalls ( ) and a bottom wall ( ) defining a molten metal receiving chamber ( ). A furnace insulating layer ( ) lines the molten metal receiving chamber ( ). A thermally conductive heat exchanger block ( ) is located at the bottom of the molten metal receiving chamber ( ) for heating the supply of molten metal. The heat exchanger block ( ) includes a bottom face ( ), side faces ( ), and a top face ( ). The heat exchanger block ( ) includes a plurality of electrical heaters ( ) extending therein and projecting outward from at least one of the faces of the heat exchanger block ( ), and further extending through the furnace insulating layer ( ) and one of the sidewalls ( ) of the storage vessel ( ) for connection to a source of electrical power. A sealing layer ( ) covers the bottom face ( ) and side faces ( ) of the heat exchanger block ( ) such that the heat exchanger block ( ) is substantially separated from contact with the furnace insulating layer ( ).

Molten metal holder furnace and casting system incorporating the molten metal holder furnace

A molten metal treatment furnace ( ) with metal treatment and level control includes a heating chamber ( ) for containing and heating a supply of molten metal ( ), a pump ( ) connected to the heating chamber ( ), a molten metal treatment chamber ( ) located at the outlet of the pump ( ), and a dosing chamber ( ) located downstream and in fluid communication with the molten metal treatment chamber ( ). A trough ( ) is connected to the dosing chamber ( ) for supplying the molten metal ( ) to a downstream process. A molten metal level sensor ( ) is located in the dosing chamber ( ). The pump ( ) is a variable speed pump having a pump inlet ( ) connected to the heating chamber ( ) and configured to pump the molten metal ( ) through the furnace ( ) during operation. The molten metal level sensor ( ) is connected to the pump ( ) for providing a pump speed control signal to the pump ( ). The molten metal level sensor ( ) is configured to monitor the level of the molten metal ( ) in the dosing chamber ( ) and maintain a preset level of the molten metal ( ) in the dosing chamber ( ) by controlling the speed of the pump ( ) with the pump speed control signal.

Molten metal treatment furnace with level control and method

A dosing furnace ( ) with metal treatment and level control includes a holding chamber ( ) for containing a supply of molten metal ( ), a pump ( ) connected to the holding chamber ( ), a molten metal treatment chamber ( ) located at an outlet ( ) of the pump ( ), and a dosing chamber ( ) located downstream and in fluid communication with the molten metal treatment chamber ( ). A molten metal level sensor ( ) is located in the dosing chamber ( ). The pump ( ) is a variable speed pump having a pump inlet ( ) connected to the holding chamber ( ) and configured to pump the molten metal ( ) through the dosing furnace ( ) during operation. The molten metal level sensor ( ) is connected to the pump ( ) for providing a pump speed control signal to the pump ( ). The molten metal level sensor ( ) is configured to monitor the level of the molten metal ( ) in the dosing chamber ( ) and maintain a preset level of the molten metal ( ) in the dosing chamber ( ) by controlling the speed of the pump ( ) with the pump speed control signal.

Molten metal dosing furnace with metal treatment and level control and method

A bottom heated holder furnace ( ) for containing a supply of molten metal includes a storage vessel ( ) having sidewalls ( ) and a bottom wall ( ) defining a molten metal receiving chamber ( ). A furnace insulating layer ( ) lines the molten metal receiving chamber ( ). A thermally conductive heat exchanger block ( ) is located at the bottom of the molten metal receiving chamber ( ) for heating the supply of molten metal. The heat exchanger block ( ) includes a bottom face ( ), side faces ( ), and a top face ( ). The heat exchanger block ( ) includes a plurality of electrical heaters ( ) extending therein and projecting outward from at least one of the faces of the heat exchanger block ( ), and further extending through the furnace insulating layer ( ) and one of the sidewalls ( ) of the storage vessel ( ) for connection to a source of electrical power. A sealing layer ( ) covers the bottom face ( ) and side faces ( ) of the heat exchanger block ( ) such that the heat exchanger block ( ) is substantially separated from contact with the furnace insulating layer ( ). A gas pressurization valve ( ) is in fluid communication with the molten metal receiving chamber ( ) and the interior of the heat exchanger block ( ) for pressurizing the interior of the holder furnace ( ).

Pressurized molten metal holder furnace

An apparatus and method of casting a melt into an ingot possessing a fine grain structure. The apparatus comprises (1) a casting mold for holding a reservoir of melt; (2) a partition means located in the melt for dividing the melt into a melt supply reservoir located on a first side of the partition means and a solidification reservoir on a second side of the partition means, the partition means having a communication means for permitting melt to flow from the melt supply reservoir to the solidification reservoir, the partition preventing turbulence from the solidification reservoir to be transferred to the surface of the melt; and (3) means for stirring the portion of the melt located in the solidification reservoir. The means for stirring provides nuclei for grain refinement of the ingot.

Fine grain casting by mechanical stirring

An injection apparatus for introducing fluid material, such as a reactive element to a molten metal bath while resisting undesired oxidation. The injection apparatus consists of a body assembly having a chamber defined therein, and inlet and outlet passageways communicating with the chamber which cooperate to define a passageway therethrough. The lower end of the outlet extends below the surface of the molten metal bath. Purging gas is introduced through a gas inlet and provide a substantially purged atmosphere throughout the molten metal passageway. The atmosphere in the passageway is purged in order that the fluid material can be safely introduced into the molten bath. The injection apparatus is readily assembled and disassembled by means of a unique clamping device employed with the body assembly.

Injection apparatus for introduction of a fluid material into a molten

A system for melting metal scrap in a molten melting media comprises a housing having an upper portion wherein the melting media and scrap are brought together to initiate melting. The housing also has a lower portion in which a volute is located. An impeller, having a central hub, a circumferential band surrounding the hub, and canted vanes projecting radially from the hub to the band, is positioned in the lower portion of the housing to cooperate with the volute so that upon rotation of the impeller, metal scrap and melting media are moved downwardly and out of the housing.

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Apollo, PA, United States of America

Michael J Kinosz