Olin Corporation

Osprey Metals Limited

Sankaranarayanan Ashok

Harvey P Cheskis

William G Watson

John F Breedis

Derek E Tyler

W Gary Watson

Julius C Fister

Thomas J Melillo

Eugene Shapiro

Jacob Crane

Brian Mravic

Brian Lewis

George J Muench

Charles R Pratt

Bruce M Guenin

Michael A D'Onofrio

George A List

Spray cast copper-manganese-zirconium alloys are disclosed. In one embodiment, the alloy is spray cast in nitrogen and contains from about 1 ppm to about 20 ppm of dissolved nitrogen. In a second embodiment, the alloy contains an addition selected from the group consisting of chromium, titanium, erbium and mixtures thereof. The alloys are useful for sound damping as the combination of zirconium and the addition inhibits degradation of the specific damping capacity of the alloy.

Spray cast copper-manganese-zirconium alloys having reduced porosity

There is disclosed methods for the manufacture of a metal matrix composite having a metal or metal alloy matrix and a uniform dispersion of a second phase. The second phase is either a refractory metal or a nonmetal. An element which reacts with both the matrix and the second phase is added to increase the loathing density of the second phase and to improve adhesion between the components of the composite. When the metal alloy matrix is copper or a copper based alloy, suitable reactive elements include zirconium, titanium, chromium and mixtures thereof.

Spray cast copper composites

There is provided an apparatus and method for the manufacture of metallic articles. A molten metal stream is disrupted, such as by gas atomization, to form a plurality of molten metal droplets. The molten metal droplets pass through a cooling zone having a length sufficient to allow up to about 30 volume percent of each of the droplets to solidify. A mold then receives and completes solidification of the metal droplets. When under about 30 volume percent of the droplets is solid, the droplets retain liquid characteristics and readily flow within the mold.

Vertical casting process

A copper based alloy and method for the manufacture thereof having improved properties. The copper alloy contains iron and zirconium with the iron being present as a uniformly dispersed second phase of the dispersoids. The dispersoids have a mean particle size of from about 0.1 micron to about 1.0 micron. The iron is present in the amount of from about 0.25 to about 5.0% by weight.

Copper-iron-zirconium alloy having improved properties and a method of

A method and apparatus for the casting of metal onto a moving horizontal surface in which the solidification of the casting occurs from the top to the bottom. The surface on which the metal is cast comprises a material having a low thermal conductivity of 10 or less watts/meter.degree. Kelvin. If desired, the casting may be cooled by cooling the top of the casting at a point downstream of the feeding system.

Method and apparatus for the casting of molten metal

A method for the manufacture of a copper based alloy and the alloy produced thereby having improved mechanical properties. An alloy containing a dispersoid ingredient and a precipitating ingredient are spray cast so that during spray casting the dispersoid ingredient forms a second phase as a uniform dispersion of relatively small dispersoids. After solution treating and aging, the solid state precipitating ingredient precipitates as a third phase of a solid state precipitate.

Copper alloys and method of manufacture thereof

A method of casting metal wherein molten metal is deposited on a moving planar substrate to form a strip thereon. The strip is removed from the moving substrate onto an open mesh support prior to the strip becoming completely solidified throughout its thickness. Ideally, the strip is removed as soon as it forms a solidified shell on its bottom which is thick enough not to fracture under the weight of the remaining molten metal. This arrangement overcomes the problem of cooling the bottom surface of the cast metal due to an air gap forming between a solid supporting substrate and the cast metal.

Casting of metal strip

A molten metal gas-atomizing spray-depositing apparatus has an atomizer which employs a pressurized gas flow for atomizing a stream of molten metal into a spray pattern of metal particles being initially hotter than the solidus temperature of the metal. The apparatus also has a substrate system which includes an outer substrate of metallic foil and an inner substrate for supporting the outer substrate. The outer foil substrate is movable relative to the metal particles in the spray pattern thereof and disposed below the atomizer for receiving on a surface of the foil a deposit of the particles in the spray pattern to form a product on the outer foil substrate. The outer foil substrate is of a thickness which is less than a predefined maximum thickness at which the capacity of the foil to absorb heat from the deposit is equal to the latent heat and super heat, if present, of the deposit. The foil thickness precludes reduction in temperature below the solidus temperature, and thereby complete solidification, of the metal particles forming the deposit upon initial contact with the foil surface whereby a reduction of porosity is achieved in the deposit.

Substrate for spray cast strip

A casting system for casting molten metal into a continuous solidified strip. A source of molten metal is fed onto a tundish which is interposed between the source of molten metal and a continuous substrate system preferably in the form of a continuous belt. The tundish directs the molten metal onto the moving belt in a direction toward the upstream end thereof so that it is moving in a direction opposed to the direction of the belt. This method of feeding the melt onto the belt results in less turbulance, a dampening of the molten metal and a spreading of the material across the width of the belt.

Feeding system for belt casting of molten metal

The apparatus and method for spray casting a spray of molten metal on a moving substrate. The leading edge of the spray pattern is deflected away from or into the spray pattern to eliminate the cooler and less dense particles of the leading edge from contacting the substrate. The deflector preferably has a surface of non-wetting material to prevent the build up of material thereon.

Spray casting of molten metal

A method and apparatus for the casting of metals in which a molten stream of metal is atomized into a spray of highly liquid droplets. The droplets are deposited on a moving substrate such as an endless belt provided with side dams. The droplets flow in a direction transverse to the direction of movement of the substrate and are contained by the side dams. The droplets may have an average size of 300 microns and the spray may have a liquid to solid ratio of at least 50%. This arrangement overcomes the problems of splashing and turbulence caused by the relative flow between the melt and the belt in regular belt casting and overcomes porosity problems associated with spray casting.

Belt casting of molten metal

A method of casting a copper based composite which includes a second phase ceramic particles. A copper or copper based alloy containing a eutectic reactive element is spray cast with the ceramic particles being injected into the spray cast stream of material prior to its being deposited onto the moving substrate. The eutectic reactive element diffuses into the ceramic particles and provides a good bond between the copper based matrix and the second phase ceramic particles. The ceramic particles may be selected from the group consisting of oxides, borides, nitrides, carbides and mixtures thereof. The eutectic reactive materials may include zirconium, chromium, titanium, aluminum and magnesium.

Incorporation of ceramic particles into a copper base matrix to form a

Spray cast alloys having reduced porosity and increased ductility are provided as well as a process for the manufacture of the alloys. An effective amount of a reactive metal which reacts with the spray casting atmosphere but not with the desired alloy is dissolved into the alloy prior to spray casting. Preferred reactive metals readily form a nitride which is finely dispersed throughout the spray cast alloy.

Copper alloys with dispersed metal nitrides and method of manufacture

A frangible projectile made from powdered metals comprising a body of either iron and carbon, or of iron and alumina. The powdered metals are compacted, sintered, and cooled.

Frangible projectile

The invention provides a process for the manufacture of copper alloys having improved processability. The alloys are melted and atomized into droplets which are spray cast into a coherent deposit. The spray cast alloys are characterized by a finer dispersion of intermetallic than is possible by conventional casting. The alloys are capable of being cold rolled to a reduction of up to 70%. The spray cast alloys exhibit good electrical conductivity and a high yield strength. They are particularly suited for electrical spring contacts.

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Bethany, CT, United States of America

Sankaranarayanan Ashok