The United States of America As Represented by the Secretary of

Ronald R Jordan

Paul C Turner

Jeffrey S Hansen

Ralph H Nafziger

Gary L Hundley

A method of casting metal using evaporative pattern casting process patterns in combination with a fixture for creating and maintaining a desired configuration in flexible patterns. A pattern is constructed and gently bent to the curvature of a suitable fixture. String or thin wire, which burns off during casting, is used to tie the pattern to the fixture. The fixture with pattern is dipped in a commercially available refractory wash to prevent metal adherence and sticking to the fixture. When the refractory wash is dry, the fixture and pattern are placed in a flask, and sand is added and compacted by vibration. The pattern remains in position, restrained by the fixture. Metal that is poured directly into the pattern replaces the pattern exactly but does not contact or weld to the fixture due to the protective refractory layer. When solid, the casting is easily separated from the fixture. The fixture can be cleaned for reuse in conventional casting cleaning equipment.

Fixture for forming evaporative pattern (EPC) process patterns

A conventional electric arc furnace is provided with an outlet in a sidewall of the furnace, the inner and outer ends of which are positioned such that the outer end of the outlet is higher than the inner end of the outlet. The outer end of the outlet communicates directly with a graphite electrode having a hollow interior leading from the sidewall of the electric arc furnace to an electroslag furnace positioned below the electric arc furnace. After an initial charge of ore in the electric arc furnace is brought to the molten state with the slag floating on top of the molten metal, the level of molten metal is maintained above the inner end of the slanted outlet and caused to flow through the slanted outlet and hollow graphite electrode to the electroslag furnace. In the electroslag furnace, the molten metal solidifies on a movable base plate positioned at the bottom of the furnace which is slowly withdrawn out of the bottom of the electroslag furnace, thereby continuously forming the desired steel ingot.

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Albany, OR, United States of America

Ronald R Jordan