Westinghouse Electric Corporation

Alcoa Inc.

Other

Thomas N Meyer

Maurice G Fey

Michael J Kinosz

Charles B Wolf

Francis J Harvey, Ii

Nicolas Bigler

Guy Arnaud

Robert A Frosch

Robert Tracy Elms

John A Wafer

Alan B Shimp

Ronald W Crookston

David F Ciliberti

Ronald W Gunkel

Michael G Down

Srinath Viswanathan

Moustapha Mbaye

William H Reed

Raymond F Taylor, Jr

Paul P Koren

Joachim V Heberlein

Jamal Righi

Joseph W George

Larry L Podey

F Donald Kuhns, Jr

John E Heidrich

John H Fatum

David R Trudel

A wind turbine having two blades is rotated by omnidirectional gas motion. A generator is connected by a shaft to the wind turbine for generating electrical power by the rotation of the wind turbine. A method of extracting energy from moving gas comprises rotating a wind turbine having two blades by omnidirectional gas motion. The method includes connecting a generator by a shaft to the wind turbine and generating electrical power by the rotation of the wind turbine.

Wind turbine having two hemispherical blades

The casting apparatus ( ) includes a holding vessel ( ) for containing a supply of molten metal ( ) and a casting mold ( ) located above the holding vessel ( ) and having a casting cavity ( ). A molten metal injector ( ) extends into the holding vessel ( ) and is at least partially immersed in the molten metal ( ) in the holding vessel ( ). The molten metal injector ( ) is in fluid communication with the casting cavity ( ). The molten metal injector ( ) has an injector body ( ) defining an inlet opening ( ) for receiving molten metal into the injector body ( ). A gas pressurization source ( ) is in fluid communication with the injector body ( ) for cyclically pressurizing the injector body ( ) and inducing molten metal to flow from the injector body ( ) to the casting cavity ( ). An inlet valve ( ) is located in the inlet opening ( ) in the injector body ( ) for filling molten metal into the injector body ( ). The inlet valve ( ) is configured to prevent outflow of molten metal from the injector body ( ) during pressurization and permit inflow of molten metal into the injector body ( ) after pressurization. The inlet valve ( ) has an inlet valve actuator ( ) located above the surface of the supply of molten metal ( ) and is operatively connected to the inlet valve ( ) for operating the inlet valve ( ) between open and closed positions.

Casting apparatus including a gas driven molten metal injector and method

The melter furnace includes a heating chamber ( ), a pump chamber ( ), a degassing chamber ( ), and a filter chamber ( ). The pump chamber ( ) is located adjacent the heating chamber ( ) and houses a molten metal pump ( ). The degassing chamber ( ) is located adjacent and in fluid communication with the pump chamber ( ), and houses a degassing mechanism ( ). The filter chamber ( ) is located adjacent and in fluid communication with the degassing chamber ( ). The filter chamber ( ) includes a molten metal filter ( ). The melter furnace ( ) is used to supply molten metal to an externally located holder furnace ( ), which then recirculates molten metal back to the melter furnace ( ).

Recirculating molten metal supply system and method

The filtering molten metal injector system includes a holder furnace, a casting mold supported above the holder furnace, and at least one molten metal injector supported from a bottom side of the casting mold. The holder furnace contains a supply of molten metal. The mold defines a mold cavity for receiving the molten metal from the holder furnace. The molten metal injector projects into the holder furnace. The molten metal injector includes a cylinder defining a piston cavity housing a reciprocating piston for pumping the molten metal upward from the holder furnace to the mold cavity. The cylinder and piston are at least partially submerged in the molten metal when the holder furnace contains the molten metal. The cylinder or the piston includes a molten metal intake for receiving the molten metal into the piston cavity when the holder furnace contains molten metal. A conduit connects the piston cavity to the mold cavity. A molten metal filter is located in the conduit for filtering the molten metal passing through the conduit during the reciprocating movement of the piston. The molten metal intake may be a valve connected to the cylinder, a gap formed between the piston and an open end of the cylinder, an aperture defined in the sidewall of the cylinder, or a ball check valve incorporated into the piston. A second molten metal filter preferably covers the molten metal intake to the injector.

Filtering molten metal injector system and method

Disclosed is a molten metal injector system including a holder furnace, a casting mold supported above the holder furnace, and a molten metal injector supported from a bottom side of the mold. The holder furnace contains a supply of molten metal having a metal oxide film surface. The bottom side of the mold faces the holder furnace. The mold defines a mold cavity for receiving the molten metal from the holder furnace. The injector projects into the holder furnace and is in fluid communication with the mold cavity. The injector includes a piston positioned within a piston cavity defined by a cylinder for pumping the molten metal upward from the holder furnace and injecting the molten metal into the mold cavity under pressure. The piston and cylinder are at least partially submerged in the molten metal when the holder furnace contains the molten metal. The cylinder further includes a molten metal intake for receiving the molten metal into the piston cavity. The molten metal intake is located below the metal oxide film surface of the molten metal when the holder furnace contains the molten metal. A method of injecting molten metal into a mold cavity of a casting mold is also disclosed.

Molten metal injector system and method

A bottom heated holder furnace ( ) for containing a supply of molten metal includes a storage vessel ( ) having sidewalls ( ) and a bottom wall ( ) defining a molten metal receiving chamber ( ). A furnace insulating layer ( ) lines the molten metal receiving chamber ( ). A thermally conductive heat exchanger block ( ) is located at the bottom of the molten metal receiving chamber ( ) for heating the supply of molten metal. The heat exchanger block ( ) includes a bottom face ( ), side faces ( ), and a top face ( ). The heat exchanger block ( ) includes a plurality of electrical heaters ( ) extending therein and projecting outward from at least one of the faces of the heat exchanger block ( ), and further extending through the furnace insulating layer ( ) and one of the sidewalls ( ) of the storage vessel ( ) for connection to a source of electrical power. A sealing layer ( ) covers the bottom face ( ) and side faces ( ) of the heat exchanger block ( ) such that the heat exchanger block ( ) is substantially separated from contact with the furnace insulating layer ( ).

Molten metal holder furnace and casting system incorporating the molten metal holder furnace

A method of joining an aluminum cast member to an aluminum component. The method includes the steps of coating a surface of an aluminum component with flux comprising cesium fluoride, placing the flux coated component in a mold, filling the mold with molten aluminum alloy, and allowing the molten aluminum alloy to solidify thereby joining a cast member to the aluminum component. The flux preferably includes aluminum fluoride and alumina. A particularly preferred flux includes about 60 wt. % CsF, about 30 wt. % AlF , and about 10 wt. % Al O .

Fluxing agent for metal cast joining

A compound cast product is formed in a casting mold ( ) having a mold cavity ( ) sized and shaped to form the cast product. A plurality of injectors ( ) is supported from a bottom side ( ) of the casting mold ( ). The injectors ( ) are in fluid communication with the mold cavity ( ) through the bottom side ( ) of the casting mold ( ). A molten material holder furnace ( ) is located beneath the casting mold ( ). The holder furnace ( ) defines molten material receiving chambers ( ) configured to separately contain supplies of two different molten materials ( ). The holder furnace ( ) is positioned such that the injectors ( ) extend downward into the receiving chamber ( ). The receiving chamber ( ) is separated into at least two different flow circuits ( ). A first molten material ( ) is received in a first flow circuit ( ), and a second molten material ( ) is received into a second flow circuit ( ). The first and second molten materials ( ) are injected into the mold cavity ( ) by the injectors ( ) acting against the force of gravity. The injectors ( ) are positioned such that the first and second molten materials ( ) are injected into different areas of the mold cavity ( ). The molten materials ( ) are allowed to solidify and the resulting compound cast product is removed from the mold cavity ( ).

Compound cast product and method for producing a compound cast product

A bottom heated holder furnace ( ) for containing a supply of molten metal includes a storage vessel ( ) having sidewalls ( ) and a bottom wall ( ) defining a molten metal receiving chamber ( ). A furnace insulating layer ( ) lines the molten metal receiving chamber ( ). A thermally conductive heat exchanger block ( ) is located at the bottom of the molten metal receiving chamber ( ) for heating the supply of molten metal. The heat exchanger block ( ) includes a bottom face ( ), side faces ( ), and a top face ( ). The heat exchanger block ( ) includes a plurality of electrical heaters ( ) extending therein and projecting outward from at least one of the faces of the heat exchanger block ( ), and further extending through the furnace insulating layer ( ) and one of the sidewalls ( ) of the storage vessel ( ) for connection to a source of electrical power. A sealing layer ( ) covers the bottom face ( ) and side faces ( ) of the heat exchanger block ( ) such that the heat exchanger block ( ) is substantially separated from contact with the furnace insulating layer ( ). A gas pressurization valve ( ) is in fluid communication with the molten metal receiving chamber ( ) and the interior of the heat exchanger block ( ) for pressurizing the interior of the holder furnace ( ).

Pressurized molten metal holder furnace

This invention relates to an electric arc heater process and apparatus for the essentially complete decomposition of hazardous materials including polychlorinated biphenyls. Finely divided liquid or gaseous hazardous material is injected into a primary gas stream which has been superheated in an electric arc heater. The mixture is directed into a primary reactor for complete decomposition with dwell times in the reactor being in the order of 0.05 to 0.15 seconds. The decomposition products are neutralized with the gases being released to atmosphere and any remaining particulates being collected for ultimate disposal. Large solid hazardous material is first shredded then heated in a roaster or rotary kiln to vaporize the primary gas stream. A soaking reactor is provided where increased dwell times are required for the decomposition of thermally stable compounds which may be formed in the primary reactor. When these compounds are absent the soaking reactor can be by-passed.

Electric arc heater process and apparatus for the decomposition of

An apparatus and process for the reduction in a plasma stream of a feed material including a comminuted metal oxide, a slag former and a reductant utilizing an enclosed horizontal reactor having a reduction chamber and a filter chamber therein separated by an either common partition having a plurality of holes therethrough or a refractory lined passageway. Coke filter media in the filter chamber act to filter out entrained molten metal contained in the plasma stream with the partition or passageway preventing entry of the coke from the filter chamber into the metal bath contained in the reduction chamber thereby limiting the amount of carbon entering the metal produced. Unreduced metal oxide is provided in the slag layer of the metal bath to maintain the stoichiometric ratio between the metal and reductant in the reduction chamber. In alternate embodiments of the invention, the reactor is provided with a sloped floor or with a rocker mechanism to control the residence time of the metal with the coke thus limiting the amount of carbon entering the metal product. The exhausted plasma stream can be recycled for preheating and prereducing the incoming feed material.

Apparatus and process for reduction of metal oxides

A method of preheating a ladle addition to a melt contained in an enclosed or covered ladle without significant loss of melt temperature. A gas stream is heated in a non-transferred arc electric arc heater to a temperature in excess of that of the melt. The ladle addition is introduced into the heated gas stream in the arc heater downstream of the arc heater wherein its temperature is increased to be about equal to or greater than the melt temperature. The heated gas stream and the entrained ladle addition is then introduced into the ladle. As the gas stream impinges on the melt, the ladle addition separates out and combines with the melt with the resulting off-gas being exhausted from the ladle. The off-gas can be recycled to the arc heater for reuse.

Hot injection ladle metallurgy

A high power non-transferred electric arc heater utilizing interelectrode segments which create a stepped arc chamber intermediate two hollow, substantially cylindrical, axially spaced electrodes. Gas to be heated is admitted upstream of the arc chamber and between adjacent segments. Gas is used to form a cold boundary layer about the expanding core of arc-heater gas. Additional secondary gas inlets adjacent the electrode provide fluid dynamic means for arc positioning on the electrode segments. Gas pressures of less than or in the range of about 1 atmosphere to about 50 atmospheres are used with power levels of about 10 MW being possible. The stepped arc chamber facilitates arc transfer to the downstream electrodes and allows a larger diameter for the arc heated gas while the boundary layer of gas maintaining comparable spacing along the length of the arc-heated gas and the surface of the arc chamber reducing the rate of heat transfer from the arc heated gas to the segments of the arc heater. In an alternate embodiment, field coils are provided around the interelectrode segments and electrodes for the magnetic rotation of the arc within the arc chamber. In a further embodiment, a resistor is interconnected between each interelectrode segment and the electrode segment that is connected as the cathode. These resistors assist in arc initiation and reduce the possibility of strikeover to the interelectrode segments during operation. Multiple electrode segments connected as anode or cathodes can also be provided.

High power arc heater

A melting furnace or cupola utilizing electric arc heaters to provide an arc-heated air stream to melt loose metal chips as well as larger pieces of metal scrap. In one embodiment, the arc-heated gas stream and metal chips are directed into a melting segment with the melted chips and gas stream passing therefrom into the furnace through a tuyere. In another embodiment an electric arc heater serves as a tuyere for the furnace with the metal chips being fed into the arc-heated stream at the outlet of the arc heater. The chips and arc-heated air stream immediately enter the furnace wherein melting of the metal chips occurs. With either embodiment, recycling of the gases in the furnace and metal chip preheat can be provided.

Electric arc fired cupola for remelting of metal chips

A method for producing a metal by reduction of a metal halide characterized by the steps of feeding into a plasma such as the arc heated stream of an arc heater, a quantity of a reducing metal such as an alkali or alkaline earth metal, feeding into the plasma a quantity of a metal halide, maintaining the temperature of the reaction chamber wall higher than the vapor point of the alkali metal chloride formed or alkaline earth metal chloride formed but lower than the melting point of the elemental metal, co-products formed being an elemental metal and a gaseous salt, projecting the co-products into the reaction chamber to cause the metal to deposit on the interior wall of the collection chamber, removing the gaseous salt, heating the metal deposited on the interior of the reaction chamber with the arc heated stream thereby causing the elemental metal to fall gravitationally or be blown into an associated receptacle in the form of solidified globules and/or crystals and/or granules and/or large diameter powders.

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Murrysville, PA, United States of America

Thomas N Meyer