Aluminum Company of America

Alcoa Inc.

Que-Tsang Fang

Edmond S Miksch

Jen C Lin

Gregory J Hildeman

James R Van Wert

Caroline Wei-Berk

Holger Haddenhorst

Michael J Kinosz

David I Yun

Donald J Clements

Carl E Garesche

Roger C Dickenson

Timothy A Kuhn

Nai-Yi Li

Steven A Jones

An improved Al&mdash;Si&mdash;Mg&mdash;Mn casting alloy that consists essentially of: about 6.0-9.0 wt. % silicon, about 0.2-0.8 wt. % magnesium, about 0.1-1.2 wt. % manganese, less than about 0.15 wt. % iron, less than about 0.3 wt. % titanium and less than about 0.04 wt. % strontium, the balance aluminum. Preferrably, this casting alloy is substantially copper-free, chromium-free and beryllium-free.

Al-Si-Mg-Mn casting alloy and method

A method for preventing oxidation of molten aluminum alloy and magnesium alloy surfaces, the method comprising providing a molten aluminum alloy or magnesium alloy having a molten aluminum or magnesium alloy surface; covering the molten aluminum or magnesium alloy surface with an initial layer of petroleum coke, the initial layer of petroleum coke having an initial layer thickness of about 0.75 inches; oxidizing a portion of the initial layer of petroleum coke to form a working layer of petroleum coke covering the molten metal surface, the working layer of coke having a working layer thickness of about 0.5 inches, and a layer of carbon dioxide immediately adjacent to and contiguous with the working layer of petroleum coke; and adding additional petroleum coke to the working layer of petroleum coke to maintain the working layer thickness at about 0.5 inches.

Petroleum coke melt cover for aluminum and magnesium alloys

An improved casting nozzle for continuous slab casting machines is provided. The nozzle includes a sloped surface which reduces molten metal turbulence during the casting process. The nozzle also includes a resilient, thermal insulation layer which prevents undesired backflow and premature solidification of the molten metal near the nozzle tip. The nozzle may also include a friction reducing layer which prevents excessive wear or fracture of the nozzle as it contacts the casting mold. The casting nozzle is suitable for use with both horizontal and vertical continuous casting machines, and may be used with various types of casting molds including continuous belt or caterpillar molds, and stationary molds. The improved nozzle may be used to cast various metals such as aluminum and aluminum alloys.

Nozzle for continuous slab casting

There is claimed an aluminum alloy composition consisting essentially of: about 12-22 wt % silicon, about 2.5-4.5 wt % nickel, about 0.2-0.6 wt % magnesium, up to about 1.2 wt % manganese, up to about 1.2 wt % iron, and about 0.005-0.015 wt % phosphorus. This alloy composition may further contain up to about 0.25 wt % vanadium, up to about 0.2 wt % zirconium, up to about 0.25 wt % titanium, up to about 2 wt % cerium and/or mischmetal. Because of its high temperature strengths, said alloy is suitable for manufacturing into various cast automotive components, including vehicle disk brake frames and other parts.

Aluminum-silicon alloy for high temperature cast components

Alloy and cast alloy product ideally suited for use as a component in a vehicle frame or subframe, i.e., body-in-white, comprising an alloy consisting of about 2.00 to 5.00 wt. % magnesium, up to approximately 0.30 wt. % silicon, approximately 0.20 to 1.60 wt. % manganese, up to approximately 1.00 wt. % iron, and between about 0.10 to 0.30 wt. %, zirconium, the balance substantially aluminum and incidental elements and impurities. The aluminum/magnesium alloy is typically solidified into ingot derived working stock by continuous casting or semi-continuous casting into a shape suitable for remelt for casting, which shape is typically an ingot billet. Excellent mechanical properties are obtained from a cast product that is not subjected to high temperature heat treating operations subsequent to casting.

Alloy for cast components

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.

Method and apparatus for reducing macrosegregation in the simultaneous casting of a plurality of metal alloy ingots in a continuous or semicontinuous casting operation. Several casting molds are arranged closely together in an array. An outer electromagnetic coil is arranged around the outer periphery of the array of molds and their formed ingots. Preferably, when the circular molds are employed, a solenoid is provided in the central space of the molds. Direct current in the outer coil and in the solenoid create a static magnetic field whose combined effect acts on the liquid pool of the molten metal. The outer coil has straight sides and curved corners. Passive flux return devices are located along the straight sides of the outer coil. If rectangular molds are used, then only the outer electromagnetic coil is arranged around the casting assembly.

Method and apparatus for casting a plurality of closely-spaced ingots in

A method of manufacturing a metal matrix composite material containing high thermal stability polymer fibers, comprising the steps of: (1) providing high thermal stability polymer fibers; (2) providing a liquid-phase metal; (3) mixing the liquid-phase metal and the high thermal stability fibers; and (4) allowing the liquid-phase metal to solidify and form a metal matrix composite.

Production of metal matrix composites reinforced with polymer fibers

Disclosed is a metal matrix composite comprising randomly oriented polymer fibers and a metal alloy surrounding the polymer fiber. The composite is formed by the method of manufacturing comprising the steps of: (1) providing polymer fibers; (2) providing a liquid-phase metal; (3) mixing the liquid-phase metal and the polymer fibers; and (4) allowing the liquid-phase metal to solidify and form a metal matrix composite. In a preferred embodiment, the polymer fibers are liquid crystal polymer fibers.

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.

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Export, PA, United States of America

Que-Tsang Fang