Consarc Corporation

Amg Idealcast Solar Corporation

Consarc Composition

Raymond J Roberts

Graham A Keough

Robert L Danley

Nathan G Stoddard

Roger F Clark

Mark Wilmerton

James A Cliber

Jesse I Gerber

Graham A Keogh

Mark A Wilmerton

A metalloid such as silicon in the form of a preheated solid electrode is purified by a CEVAR purification process by producing an ingot with controlled heating and cool down after the preheated electrode is melted in a CEVAR furnace system using a short CEVAR open-bottomed crucible.

Purification of a metalloid by consumable electrode vacuum arc remelt process

This invention relates to a system and a method of use for large ceramic member support and manipulation at elevated temperatures in non-oxidizing atmospheres, such as using carbon-carbon composite materials for producing high purity silicon in the manufacture of solar modules. The high temperature apparatus of this invention includes one or more support ribs, one or more cross braces in combination with the one or more support ribs, and a shaped support liner positionable upon the one or more support ribs and the one or more cross braces.

High temperature support apparatus and method of use for casting materials

Apparatus and method are provided for damping the induced fluid flow, particularly in the region of the base plate, in an electrically conductive material that is heated and melted in a cold crucible induction furnace. Damping is accomplished by establishing a dc magnetic field such that flow of the electrically conductive liquid metal in that dc magnetic field would induce eddy currents in the liquid metal which would generate forces that tend to oppose the flow. The dc magnetic field may be established by dc current flow in the ac induction coil that induces current in the material, dc current flow in a separate dc coil, or coils, constructed to prevent excessive induced losses, by discrete magnets, or a combination of any of the three prior methods.

Cold crucible induction furnace with eddy current damping

Apparatus and method are provided for damping the induced fluid flow, particularly in the region of the base plate, in an electrically conductive material that is heated and melted in a cold crucible induction furnace. Damping is accomplished by establishing a dc magnetic field such that flow of the electrically conductive liquid metal in that dc magnetic field would induce eddy currents in the liquid metal which would generate forces that tend to oppose the flow. The dc magnetic field may be established by dc current flow in the ac induction coil that induces current in the material, dc current flow in a separate dc coil, or coils, constructed to prevent excessive induced losses, by discrete magnets, or a combination of any of the three prior methods. The dc magnetic field may also be established by dc current flow in one or more dc coils disposed around a magnetic pole piece located below the base of the furnace. One end of the magnetic pole piece is located adjacent to the bottom of the crucible base, so that the pole piece concentrates the dc field into the lower portion of the molten electrically conductive material.

An increased diameter wire is formed by drawing a feed wire through a cooled nozzle located in a cooled crucible, and through a liquid metal bath contained within the crucible. Liquid metal freezes onto the feed wire as it passes through the bath, thereby increasing the diameter of the feed wire to form an increased diameter wire product. The invention is particularly suited to forming a wire from a metal composition that would undesirably react with refractory apparatus.

Formation of metal wire

A power activated assembly is disclosed that provides rapid and simultaneous disconnection and reconnection of water cooled power connectors to and from an induction furnace of a melting assembly which is tiltable about the axis of its trunnion. The power activated assembly carries extensions that have respective female connectors on the end and which have flexible conductors connected for supplying electrical power and cooling water to the induction furnace. The housing is positioned concentric with the trunnion so as to allow its female connectors to mate with corresponding male connectors of the assembly when the housing is axially moved toward and along the trunnion axis in response to motion control means such as a power activated device. The male connectors are distributed on the assembly about and inside the circumference of the trunnion. In one embodiment, the male and female connectors have flow control means such as shut-off valves which allow the water to flow from the coolant supply source to the vacuum furnace when the connectors are engaged and terminates such flow when the connectors are disengaged. The power activated assembly of the present invention reduces the time needed to remove the crucible of the assembly or to exchange the introduction furnace of the assembly.

Vacuum induction melting assembly having simultaneously activated

A process and apparatus for electro-slag remelting including a cooling medium directed towards the electrode surface adjacent its entry into the slag layer. The cooling medium retards the melting of the electrode periphery within the slage so as to form a concave surface at the electrode tip, such that the molten metal from the electrode tip moves from the center of the electrode toward the outer periphery. The remelting of the electrode in this manner resulting in a shallower molten metal pool below the slag layer and a higher current density in the slag. The invention further redistributes the heat generated in the slag layer from the center towards the outer edge of the molten metal pool progressively formed within the mould and results in an improved smoothness on the surface of the ingot.

Method and apparatus for adjusting electrode isotherms within

A method and apparatus for controlling electrode drive speed in a consumable electrode furnace. The electrode drive speed is regulated at a base speed computed from measured changes in physical characteristics of the electrode or ingot, such as changes in weight, as the melt proceeds. The base speed also takes into consideration the known geometry of the electrode, the furnace mold or crucible, the density of the ingot material, and the speed of movement of the bottom of the ingot if any. This base speed is increased or decreased by a trim speed determined from measurement of an electrical phenomenon associated with the consumable electrode process, which electrical phenomenon has a relatively long term value related to the distance between the bottom surface of the electrode and the top surface of the ingot.

Method and apparatus for controlling electrode drive speed in a

An electroslag remelting furnace with a power connection at the base and a coaxial conductor to eliminate the deleterious effects of magnetic fields upon the pool of molten metal. The furnace may have a vertically moveable crucible, and also a top supported inner mold to form a hollow ingot, for containing the molten portions of the metal as the ingot is formed. The upper portions of the annulus between an inner and outer mold can be greater in width than the width of the lower portion of the annulus to permit increased spacing between the electrodes and the walls of the molds or to permit the use of electrodes of a larger diameter than the width of the lower portion of the annulus.

Electroslag remelting furnace with improved power connection

A melt rate control system for consumable electrode remelting uses a closed loop control system to control electrical power and hence the electrode melt rate. The control equation is purposely adjusted to cause the melt rate to initially exceed the steady state melt rate in a controlled manner to take advantage of the higher permissible melt rate at the bottom of an ingot. Initially, the melting current is held at a steady level sufficiently high to cause the melt rate to exceed the steady state melt rate. The initial current is then reduced in a controlled manner to bring the melt rate to the steady state condition. The length of time and amount of excessive melt rate is matched to the higher permissible melt rate at the bottom of an ingot.

Automatic melt rate control system for consumable electrode remelting

A method and apparatus for casting a plurality of ingots by forming a pool of molten metal in a main mold section which is in direct, open communication with a plurality of ingot mold sections by flowing the molten metal from the pool into the ingot mold sections. An electrode and a conductor establish an electrical current path, through the molten metal pool, which does not enter the ingot mold sections, and the cast ingots are electrically isolated at their lower ends.

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Moorestown, NJ, United States of America

Raymond J Roberts