Allied Chemical Corporation

Allied Corporation

Robert W Smith

John R Bedell

Sheldon Kavesh

Naim S Hemmat

Seymour Draizen

Howard Horst Liebermann

Ralph R Saunders

Noel Y Rothmayer

The invention provides an apparatus and method for continuously casting a filament, such as a glassy metal filament, at high speed within a zone of preselected vacuum. A continuous extrusion mechanism and a rapidly moving quench surface are located within a casting module. A vacuum mechanism provides the preselected vacuum in the module as the filament is cast, and a transport mechanism continuously moves the resultant rapidly advancing filament across the boundary between the vacuum in the casting airlock mechanism substantially preserves the module vacuum as the cast filament is transported across the boundary and a passivator mechanism passivates the quench surface to prevent the filament from adhering thereto.

Continuous vacuum casting and extraction device

A modular apparatus is provided for depositing molten metal onto a movable chill surface to form continuous strip. The apparatus includes a crucible, consisting of a receptacle, sealed at one end to a base, and a heater for maintaining metal in the molten state in the receptacle. A simple nozzle conveys the molten metal from the crucible into contact with the chill surface. The individual elements of the apparatus may be replaced without replacing the remaining elements, and the nozzle may be replaced while a charge of molten metal is in the crucible.

Modular apparatus for casting metal strip

An apparatus is provided for planar flow casting of metal ribbon. The apparatus comprises a movable chill surface, a reservoir for holding molten metal and a slotted nozzle whose lips are located close to the chill surface. In operation, molten metal is forced through the nozzle onto the chill surface to form a melt puddle. Rapid cooling of the molten metal results in the formation of a continuous ribbon. The nozzles of this invention provide a planar bottom surface which includes the leading edge of the first lip and the side edges at the bottom of the lips and which is as close or closer to the chill surface than is any other point on the lips. The nozzle reduces air flow around the melt puddle and thereby improves ribbon uniformity.

Nozzle geometry for planar flow casting of metal ribbon

An apparatus is provided for planar flow casting of metal ribbon. The apparatus comprises a movable chill surface, a reservoir for holding molten metal and a slotted nozzle whose lips are located close to the chill surface. In operation, molten metal is forced through the nozzle onto the chill surface to form a melt puddle. Rapid cooling of the molten metal results in the formation of a continuous ribbon. Ribbon contour is controlled through the use of nozzle designs that provide reproducible configuration of the melt puddle and reduce turbulent air flow over the molten metal surface.

Contour control for planar flow casting of metal ribbon

Metal filament forming apparatus including a casting crucible having a tapping orifice and a casting nozzle for ejecting molten metal from the crucible are described. The casting nozzle is characterized by having an externally replaceable orifice member. The casting nozzle comprises three parts: (1) a nozzle body providing a conduit for the molten metal in association with the tapping orifice; (2) a replaceable orifice member positioned at the lower end of the nozzle body; and (3) retaining means for holding the replaceable orifice member in sealing engagement with the nozzle body. The crucible is preferably provided with a stopper rod to permit discontinuation of metal flow through the nozzle, while holding molten metal in the crucible.

Externally replaceable metal casting nozzle

Improvement in apparatus for making metal filament by depositing molten metal onto the peripheral surface of a rotating annular chill roll includes provision of a stationary housing surrounding the peripheral surface of the chill roll in an arc, covering the segment beginning at the vicinity of the point of deposition of the metal onto the chill roll and terminating at a predetermined point of stripping of the solid filament from the chill roll, and defining a gap between the peripheral surface of the chill roll and the interior of the housing, together with means for introducing a fluid into the gap for passage therethrough in the direction of rotation of the chill roll. In operation, cocurrent passage of the filament and the fluid through the gap effects controlled retention of the filament on the chill roll and fixes the point at which the filament is stripped from the chill roll.

Chill roll casting of continuous filament

A stopper rod tapping assembly for bottom tapping of a crucible to extrude molten metal through a tapping orifice is described. The stopper rod has an interior vent, providing communication of a pressurized inert gas from above the melt to the tapping orifice in the bottom of the crucible. The vent permits flushing of the tapping orifice between tapping runs to prevent buildup of residues in the tapping orifice which would otherwise adversely affect the tapping operation. The assembly is advantageously used in casting filaments from the molten metal.

Growing community of inventors

Long Valley, NJ, United States of America

Robert W Smith