Olin Corporation

International Telephone and Telegraph Corporation

Alumax, Inc.

Osprey Metals Limited

Wieland-werke Ag Metallwerke

W Gary Watson

Harvey P Cheskis

John F Breedis

Derek E Tyler

Eugene Shapiro

Sankaranarayanan Ashok

Ronald N Caron

Brian Mravic

Stanley Shapiro

Ashok Sankaranarayanan

Kenneth P Young

Dennis R Brauer

Michael A D'Onofrio

Richard P Vierod

Thomas J Melillo

William L Brenneman

Charles R Pratt

Carl L Deppisch

Melillo Thomas J

Dieter Stock

Carlos J Rivera

There is provided a tin brass alloy having a grain structure that is refined by the addition of controlled amounts of both zinc and iron. Direct chill cast alloys containing from 1% to 4%, by weight of tin, from 0.8% to 4% of iron, from an amount effective to enhance iron initiated grain refinement to 35% of zinc and the remainder copper and inevitable impurities are readily hot worked. The zinc addition further increases the strength of the alloy and improves the bend formability in the 'good way', perpendicular to the longitudinal axis of a rolled strip. Certain of the grain refined brass alloys are useful as semisolid forming feedstock.

Iron modified tin brass

There is provided a phosphor bronze alloy having a grain structure that is refined by the addition of a controlled amount of iron. Direct chill cast alloys containing from 1.5% to 2.5%, by weight tin, from 1.65% to 2.65% iron, from 0.03% to 0.35% phosphorous and the remainder copper and inevitable impurities have an as-cast average crystalline grain size of less than 100 microns and are readily hot worked. When the iron content is too low, the average crystalline grain size increases and the alloy cracks during hot working. When the iron content is too high, iron stringers form, detrimentally impacting both the appearance and properties of a wrought strip.

Iron modified phosphor-bronze

A rotationally symmetrical preform (1) is made by atomizing molten metal by means of a gas jet in a nozzle and by deposition of the droplets on a suitable substrate, wherein at least two independent nozzles (2,3) are arranged so that their droplet streams (4,5) overlap and are directed onto a substrate (6) of circular cross-section, and wherein insoluble particles are injected either into the first or into the second droplet stream (4 or 5) or wherein different types of particles are injected into the first and the second droplet stream (4,5).

Rotationally symmetrical article with properties varying over the

A method of casting metal material wherein metallic metal is deposited on a foil moving underneath the feeding means for the molten metal and is supported on a supporting substrate. The foil is formed with side edges before receiving a deposit of molten metal to contain the flow of molten metal thereon in a direction transverse to the direction of movement of the foil.

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

The spray casting of metal wherein an atomized spray of metal droplets is caused to be deposited upon a moving metallic foil substrate. The metallic foil substrate is maintained under tension as it passes in a position to receive the deposit such that thermal distortion is eliminated without causing tensile failure. In the second embodiment, the leading edge of the spray is positioned such that it does not contact the foil whereby the low mass density thereof does not contribute to deposit helping to eliminate bottom porosity.

Production of spray cast strip

A method of casting metal wherein the molten metal is deposited on a moving planar substrate formed from an insulating refractory material. The deposited liquid metal is maintained as a liquid until the turbulence induced by the pouring of the metal onto the substrate is minimized.

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 molten metal gas-atomizing spray-depositing apparatus has an atomizer for atomizing a stream of molten metal into metal particles in a divergent spray pattern thereof being of higher temperature at a center region of the pattern than at an outer peripheral region thereof. A substrate is continuously movable along an endless path and has an area thereon disposed below the atomizer for receiving a deposit of the particles in the spray pattern to form a product on the substrate being substantially uniform in thickness. The deposit-receiving substrate area has consecutively arranged upstream, intermediate and downstream portions upon which respective inner, intermediate and outer cross-sectional portions of the metal deposit are layered one upon the next to form the product. The substrate area is oriented in inclined configuration in one form and in concave configuration in another form relative to a vertical axis of the divergent spray pattern such that particles in the spray pattern travel through at least as great a distance (and preferably a greater distance) to reach the intermediate portion of substrate area as particles in the spray pattern travel to reach the upstream portion thereof.

Substrate orientation in a gas-atomizing spray-depositing apparatus

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 semi-solid metal particles and producing a flow of the particles along with the gas flow in a generally downward direction. The apparatus also has a substrate disposed below the atomizer for impingement on the substrate of the gas flow at a steady state temperature resulting from heat transfer by the metal particles to the gas flow and for receiving a deposit of the particles in the spray pattern to form a product thereon. The substrate is composed of a material having a thermal conductivity primarily correlated with the steady state temperature of the gas flow so as to limit heat transfer from the deposit to the substrate and provide a sufficient fraction of liquid in the initial deposit to feed the interstices between the particles and provide an interface for subsequent deposits, resulting in a reduction of porosity and improvements of flatness of the deposit.

Thermal conductivity of substrate material correlated with atomizing

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 and for producing a flow of the particles in the pattern thereof along with the pressurized gas flow in a generally downward direction. The apparatus also has a substrate, such as composed of stainless steel, disposed in spaced relation below the atomizer with at least an upper surface layer of a glass thereon, being thermally softenable over a broad predetermined temperature range. The pressurized gas flow impinges on the glass surface layer of the substrate which receives a deposit of the particles in the spray pattern to form a product thereon. The use of a glass which will soften over a broad predetermined temperature range but still retain a viscosity of sufficient strength to prevent it from being blown away by a pressurized atomizing gas flow and thereby maintain its capability to function as a substrate results in a reduction of porosity and an improvement of flatness of the deposit bottom surface located in contact with the glass substrate surface.

Substrate for use in spray-deposited 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 semi-solid metal particles. The apparatus also has a movable non-preheated substrate composed of a material having a predetermined thermal conductivity of about one or less (W/M-K) being disposed below the atomizeer. The substrate receives thereon a deposit of the particles in the spray pattern. The pressurized gas flow also impinges thereon for cooling the deposit on the substrate to form a product thereon. The predetermined thermal conductivity of the substrate of one or less precludes extraction of heat by the substrate from, and thus solidification of, the deposit upon initial contact with the substrate whereby a reduction of porosity is achieved in the deposit.

Non-preheated low thermal conductivity substrate for use in

A process and apparatus is described for slurry casting an ingot having a non-dendritic structure across substantially its entire cross section. The casting mold has a first chamber for extracting heat from the molten material. The amount of heat extracted from the molten material and the cooling rate of the molten material is controlled to initiate growth of primary phase particles and to form a semi-solid slurry having a desired fraction solid. The mold also has a second chamber for casting the slurry into an ingot. Adjacent the exit portion of the first chamber and the inlet portion of the second chamber, a transition member is provided for delivering the slurry to the casting chamber and for preventing the ingot shell from extending back into the first chamber.

Process and apparatus for continuous slurry casting

The disclosure teaches a high strength, high conductivity copper base alloy and method for obtaining same. The composition consists essentially of defined amounts of magnesium, phosphorus and a transition element selected from the group consisting of iron, cobalt, nickel and mixtures thereof with the balance essentially copper.

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Cheshire, CT, United States of America

W Gary Watson