Apparatus and method for producing high purity copper-based alloys

Abstract

In one aspect, a method of making a high purity copper-based alloy includes providing a feedstock in a melting furnace and melting the feedstock. The method further includes bubbling an inert gas into the molten copper-based alloy to form a high purity copper-based alloy. Various aspects also relate to an apparatus for making a high purity copper-based alloy and a method of making an apparatus for making a high purity copper-based alloy.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 362,509, filed on April 5, 2022, and U.S. Provisional Patent Application No. 63 / 387,076, filed on December 12, 2022. The entire contents of each of these two applications are incorporated herein by reference. Technical Field

[0003] The disclosed technology relates generally to apparatus and methods for making copper-based alloys, and more particularly to apparatus for making high-purity copper-based alloys with reduced impurities. Background Art

[0004] Copper can be alloyed with various elements to have various useful properties, including, for example, high toughness, high ductility, high thermal conductivity, high electrical conductivity, and high corrosion resistance. Due to these properties, copper-based alloys have found many applications. For example, some copper-based alloys have found use in electrical components, accessories, locks, door handles, etc. Other copper-based alloys have found use in construction, springs, connectors, terminals, etc. Some uses of copper-based alloys require improved mechanical and chemical properties. . Summary of the invention

[0005] To summarize the present disclosure and the advantages it obtains over the prior art, certain objects and advantages of the present disclosure are described herein. Not all of these objects or advantages may be achieved in any particular embodiment. Thus, for example, those skilled in the art will recognize that the present invention may be implemented or realized in a manner that realizes or optimizes one advantage or a group of advantages taught herein without necessarily realizing other objects or advantages that may be taught or mentioned herein.

[0006] All these embodiments are intended to fall within the scope of the invention disclosed herein. These and other embodiments will become apparent to those skilled in the art through the following detailed description of preferred embodiments with reference to the accompanying drawings, and the present invention is not limited to any particular one or more preferred embodiments disclosed.

[0007] In one aspect, an apparatus for making a copper-based alloy includes a closed melting furnace configured to: form a molten copper-based alloy in a closed inert environment, the molten copper-based alloy including at least 50% copper by weight; and bubble an inert gas through the molten copper-based alloy. The apparatus also includes a transfer ladle configured to: receive the molten copper-based alloy from the melting furnace in a closed inert environment; and transfer the molten copper-based alloy to a shot pit or one or more molds configured to solidify the molten copper-based alloy.

[0008] In another aspect, an apparatus for making a molten copper-based alloy includes a closed melting furnace configured to: form a molten copper-based alloy in a closed inert environment, the molten copper-based alloy including at least 50% copper by weight; and bubble an inert gas through the molten copper-based alloy. The apparatus also includes a transfer ladle configured to: receive the molten copper-based alloy from the melting furnace through a speed control element; and transfer the molten copper-based alloy to a pellet-shaped depression or one or more molds configured to solidify the molten copper-based alloy.

[0009] In a further aspect, a method of making a molten copper-based alloy includes providing a plurality of feed blocks having a combination composition in a melting furnace, the combination composition being configured to form a molten copper-based alloy, the molten copper-based alloy including at least 50% copper by weight. The method also includes: bubbling an inert gas through gaps between the feed blocks before heating; and heating the feed blocks while bubbling the inert gas through the feed blocks, thereby melting the feed blocks to form the molten copper-based alloy. The method also includes bubbling the inert gas through the molten copper-based alloy. The method also includes transferring the molten copper-based alloy to a transfer ladle.

[0010] In another aspect, a method of manufacturing a copper-based alloy includes providing a plurality of feed blocks having a combination composition in a melting furnace, the combination composition being configured to form a molten copper-based alloy, the molten copper-based alloy including at least 50% copper by weight. The method also includes heating the feed blocks to form the molten copper-based alloy. The method also includes bubbling an inert gas through the molten copper-based alloy. The method also includes transferring the molten copper-based alloy to a transfer ladle. One or more of heating the feed blocks, bubbling the inert gas, and transferring the molten copper-based alloy is performed at least in part in a closed inert environment, the closed inert environment being configured to substantially exclude external ambient air from mixing with the closed inert environment.

[0011] In another aspect, a method of manufacturing a copper-based alloy includes providing a plurality of feed blocks having a combination composition in a melting furnace, the combination composition being configured to form a molten copper-based alloy, the molten copper-based alloy including at least 50% copper by weight. The method also includes heating the feed blocks to form the molten copper-based alloy. The method also includes bubbling an inert gas through the molten copper-based alloy. The method also includes transferring the molten copper-based alloy to a transfer ladle, wherein the transferring includes limiting the velocity of the molten copper-based alloy transferred from the melting furnace to the transfer ladle to less than 100 inches / second.

[0012] In another aspect, an apparatus for producing a molten copper-based alloy includes a melting furnace configured to form a molten copper-based alloy comprising at least 50% copper by weight. The melting furnace includes a diffusion liner comprising an aluminum silicate ceramic having a porous structure suitable for bubbling an inert gas through the molten copper-based alloy.

[0013] In another aspect, an apparatus for making a molten copper-based alloy includes a melting furnace configured to form a molten copper-based alloy comprising at least 50% copper by weight. The melting furnace includes a diffusion liner that substantially covers the bottom inner surface of the melting furnace and has a porous structure suitable for bubbling an inert gas into the molten copper-based alloy.

[0014] In another aspect, an apparatus for manufacturing a copper-based alloy includes a melting furnace configured to form a molten copper-based alloy comprising at least 50% copper by weight. The melting furnace includes a diffusion liner having a porous structure. The diffusion liner is formed on at least two different inner surfaces of the melting furnace, so that the diffusion liner is suitable for bubbling an inert gas into the molten copper-based alloy from the at least two different inner surfaces.

[0015] In another aspect, a method of manufacturing an apparatus for making a copper-based alloy includes providing a melting furnace chamber configured to form a molten copper-based alloy, the molten copper-based alloy including at least 50% copper by weight. The method also includes forming a diffusion liner on an inner surface of the melting furnace chamber, the diffusion liner including an aluminum silicate ceramic material having a porous structure suitable for bubbling an inert gas through the molten copper-based alloy.

[0016] In another aspect, a method of manufacturing an apparatus for making a copper-based alloy includes providing a melting furnace chamber configured to form a molten copper-based alloy comprising at least 50% copper by weight. The method also includes forming a diffusion liner that substantially covers the bottom inner surface of the melting furnace and has a porous structure suitable for bubbling an inert gas into the molten copper-based alloy.

[0017] In another aspect, a method of manufacturing an apparatus for making a copper-based alloy includes providing a melting furnace chamber configured to form a molten copper-based alloy comprising at least 50% copper by weight. The method also includes forming a diffusion liner having a porous structure on at least two different inner surfaces of the melting furnace, such that the diffusion liner is suitable for bubbling an inert gas from the at least two different inner surfaces into the molten copper-based alloy.

[0018] In another aspect, a method of manufacturing an apparatus for making an alloy includes providing a melting furnace chamber and arranging a compacted powder layer on an inner surface of the melting furnace chamber. The compacted powder includes a mixture of silicon dioxide and aluminum oxide. The method also includes: sintering the compacted powder in the melting furnace to form a diffusion lining on the inner surface. The diffusion lining includes an aluminum silicate ceramic material having a porous structure suitable for bubbling an inert gas therethrough.

[0019] In another aspect, a method of manufacturing an apparatus for making an alloy includes providing a melting furnace chamber and arranging a compacted powder layer on an inner surface of the melting furnace chamber. The method also includes: selectively sintering a surface portion of the compacted powder to form a diffusion liner on the inner surface, the diffusion liner including a sintered ceramic layer and an unsintered ceramic layer.

[0020] In another aspect, a method of manufacturing an apparatus for making an alloy includes providing a melting furnace chamber and arranging a compacted powder layer on an inner surface of the melting furnace chamber. The method also includes: using heat from the heated material arranged in the melting furnace chamber to sinter the compacted powder to form a diffusion lining on the inner surface.

[0021] In another aspect, a method of manufacturing a copper-based alloy includes providing a feedstock in a melting furnace, the feedstock having a composition configured to form a molten copper-based alloy, the molten copper-based alloy having at least 50% copper by weight; and heating the feedstock to melt the feedstock to form a molten copper-based alloy. The method also includes bubbling an inert gas into the molten copper-based alloy using a diffusion liner formed on an inner surface of the melting furnace chamber. The diffusion liner includes an aluminum silicate ceramic material having a porous structure suitable for bubbling an inert gas through the molten copper-based alloy.

[0022] In another aspect, a method for manufacturing a copper-based alloy includes: providing a feedstock in a melting furnace, the feedstock having a composition configured to form a molten copper-based alloy, the molten copper-based alloy having at least 50% copper by weight; and heating the feedstock to melt the feedstock to form a molten copper-based alloy. The method also includes using a diffusion liner formed in the melting furnace chamber to bubble an inert gas through the molten copper-based alloy. The diffusion liner generally covers the bottom inner surface of the melting furnace and has a porous structure suitable for bubbling an inert gas into the molten copper-based alloy.

[0023] In another aspect, a method for manufacturing a copper-based alloy includes: providing a feedstock in a melting furnace, the feedstock having a composition configured to form a molten copper-based alloy, the molten copper-based alloy having at least 50% copper by weight; and heating the feedstock to melt the feedstock to form a molten copper-based alloy. The method also includes using a diffusion liner having a porous structure to bubble an inert gas through the molten copper-based alloy. The diffusion liner is formed on at least two different inner surfaces of the melting furnace, so that the diffusion liner is suitable for bubbling the inert gas into the molten copper-based alloy from the at least two different inner surfaces. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 is a schematic diagram of an apparatus for producing a copper-based alloy having a low impurity content, according to some embodiments.

[0025] Figure 1A is a schematic side view of a closed configuration of a melting furnace for producing copper-based alloys according to some embodiments.

[0026] Figure 1B is a schematic side view of an open configuration of a melting furnace for producing high purity copper-based alloys according to some embodiments.

[0027] Figure 2 is a schematic diagram of an apparatus for manufacturing a copper-based alloy having a low impurity content according to some other embodiments.

[0028] Figure 3A is a schematic diagram of an apparatus for manufacturing a copper-based alloy having a low impurity content according to some other embodiments.

[0029] Figure 3B According to some other embodiments, a method for producing a copper-based alloy having a low impurity content is provided. Figure 3A Detailed perspective view of the portion of the device including the transfer wheel shown in FIG.

[0030] Figure 3CAccording to some other embodiments, a method for producing a copper-based alloy having a low impurity content is provided. Figure 3A Detailed side view of the part of the device including the transfer wheel shown in FIG.

[0031] Figure 4A A schematic cross-sectional view of a diffuser according to an embodiment is shown.

[0032] Figure 4B is a photograph of a diffuser according to an embodiment.

[0033] Figure 4C is a photograph of a diffuser installed at the bottom of a melting furnace according to an embodiment.

[0034] Figure 5 A method of manufacturing a copper-based alloy having a low impurity content according to an embodiment is shown.

[0035] Fig. 6A is a schematic side view of a melting furnace including a diffusion liner for producing high purity copper-based alloys according to some embodiments.

[0036] Figure 6B is a schematic side view of a melting furnace including a diffusion liner for producing a high purity copper-based alloy according to some other embodiments.

[0037] Figure 6C is used for Fig. 6A and Figure 6B A cross-sectional view of a diffusion lining of a melting furnace is shown in FIG.

[0038] Fig. 7A Methods of forming a diffusion liner in a furnace for melting a high purity copper-based alloy are shown according to various embodiments.

[0039] Figure 7B is a schematic side view of a melting furnace, the melting furnace being in accordance with Fig. 7A The method shown in is at a stage in which a diffusion liner is formed for use in the manufacture of a high purity copper-based alloy.

[0040] Figure 7C is a schematic side view of a melting furnace, the melting furnace being in accordance with Fig. 7A The method shown in is a further stage in which a diffusion liner is formed for the manufacture of a high purity copper-based alloy.

[0041] Fig.7D is a schematic side view of a melting furnace, the melting furnace being in accordance with Fig. 7A The method shown in is a further stage in which a diffusion liner is formed for the manufacture of a high purity copper-based alloy.

[0042] Fig. 7E is a schematic side view of a melting furnace, the melting furnace being in accordance with Fig. 7A The method shown in is a further stage in which a diffusion liner is formed for the manufacture of a high purity copper-based alloy.

[0043] Figure 7F is a schematic side view of a melting furnace, the melting furnace being in accordance with Fig. 7A The method shown in is a further stage in which a diffusion liner is formed for the manufacture of a high purity copper-based alloy.

[0044] Figure 8 A method of manufacturing a copper-based alloy having a low impurity content using a diffusion liner according to an embodiment is shown. DETAILED DESCRIPTION

[0045] The present disclosure may be understood by reference to the following detailed description. It should be noted that for clarity of illustration, certain elements in the various drawings may not be drawn to scale, may be shown in a schematic or conceptual manner, or may not completely correspond to certain physical configurations of the embodiments.

[0046] Various impurities in copper-based alloys can reduce the favorable properties of the copper-based alloys. The presence of various unwanted impurities in various parts formed by copper-based alloys may be due to the presence of these impurities in the feed material, such as copper-based chips, such as copper-based alloy scrap. For example, various impurities in copper-based chips or copper-based alloy scrap used as feed material can have a negative impact on the mechanical and chemical properties of cast copper-based parts, and may cause high failure rates during fixture casting and shortened life expectancy of parts, which in turn leads to higher replacement costs. This increased failure rate may lead to increased production costs of copper-based parts, such as copper-based fixtures, such as water fixtures. Therefore, improved equipment and methods are needed to reduce the impurity content in copper feed materials, thereby limiting the incorporation of impurities into the final product. Therefore, a technology for manufacturing copper-based alloys with low impurity levels, such as copper-based ingots or copper-based shots, is needed to improve mechanical properties, while the technology can also reduce costs, improve casting efficiency, and simultaneously increase component life.

[0047] The inventors have found that oxygen and oxygen-related defects may be particularly harmful to copper-based alloys. Oxygen-related defects include, for example, oxygen-containing voids or cavities and oxides that are confined in copper-based alloys. Without being bound by any theory, the formation of such oxygen-containing voids or cavities may be caused by a relatively large amount of oxygen dissolved in the molten copper-based alloy. For example, when the molten copper-based alloy is cooled to solidification, the solubility of oxygen in the copper-based alloy decreases, resulting in the nucleation of oxygen-containing voids or cavities in the copper-based alloy. The voids or cavities that are not released into the atmosphere are confined to the solidified copper-based alloy, resulting in voids and pores, which in turn may result in reduced mechanical properties such as yield strength and toughness. In particular, oxygen-containing voids or cavities can serve as stress concentration centers, thereby becoming the starting point for rupture. Other oxygen-related impurities may include oxygen compounds, such as copper oxide, which can be precipitated in the copper-based alloy, thereby reducing the mechanical properties of the copper-based alloy.

[0048] The inventors have discovered that in order to effectively reduce oxygen and oxygen-related impurities in copper-based alloys, the oxygen content should be reduced from the copper-based alloy starting from the melting process and in the molten state. In addition, after forming the molten copper-based alloy with reduced oxygen content, the introduction or reintroduction of oxygen and oxygen-related impurities into the molten copper-based alloy should be prevented before solidification. Therefore, in order to improve the mechanical properties of the copper-based alloy, for example, by reducing the oxygen content of the copper-based alloy, the disclosed embodiments relate to the following apparatus and methods: the apparatus and methods are used to reduce the oxygen content starting from the melting process and in the molten copper-based alloy, and maintain the low oxygen content through the solidification process including transfer to the mold. According to various embodiments, an apparatus for manufacturing copper-based ingots or copper-based shots includes a closed melting furnace, which is configured to: form a molten copper-based alloy in a closed inert environment; and bubble an inert gas through the molten copper-based alloy. The apparatus also includes a transfer ladle configured to receive molten copper-based alloy from a melting furnace in a closed inert environment and to transfer the molten copper-based alloy to one or more molds, such as an ingot mold or a component mold, which is configured to solidify the molten copper-based alloy into, for example, a copper-based ingot or a copper-based component. The transfer ladle may be configured to receive the molten copper-based alloy from the melting furnace through a speed control element. The transfer ladle may also be configured to transfer the molten copper-based alloy into a pellet-shaped recess, which is configured to solidify the molten copper-based alloy into a pellet. Depending on the tolerance of the amount of oxygen and oxygen-related impurities in the solidified copper alloy, the transfer ladle may be closed or unclosed. As described herein, bubbling an inert gas through the molten alloy may be referred to as sparging. A furnace according to the present disclosure may provide a reduced impurity content in a copper-based alloy and a component made thereof, such as an ingot, a pellet, or a component such as a fixture, which may be attributed to the molten copper-based alloy in the furnace, as described herein. Certain mechanical properties of copper, including tensile strength and ductility, can be improved by reducing the amount of oxygen and oxygen-related impurities in copper-based alloys and parts made therefrom, particularly by blasting to reduce the amount of oxygen or oxygen-related impurities.

[0049] According to various embodiments, the injection furnace includes a melting furnace configured to melt a copper-based feedstock. The melting furnace is configured to flow an inert gas through the feedstock material before melting and during heating; and to bubble the inert gas through the molten alloy in the melting furnace, for example, by a diffuser. The melting furnace can be in an inert gas environment. As configured, bubbling the inert gas through the molten copper-based alloy can entrain unwanted impurities and remove these unwanted impurities from the molten copper-based alloy. Unwanted impurities may include, but are not limited to, for example, oxygen or oxygen-related impurities. As described herein, oxygen or oxygen-related impurities include combined and uncombined oxygen, such as atomic oxygen (O), molecular oxygen (O2, O3), and any compound formed with or by oxygen, including but not limited to water, metal and non-metal hydroxides, metal and non-metal oxyhydrides, and metal and non-alloy oxides. Unwanted oxygen-related impurities, such as oxides, may form a slag layer or island on the top of the molten copper-based alloy after being entrained by the inert gas. The slag layer may be removed from the melt, thereby removing oxide impurities from the molten alloy.

[0050] The inventor has found that the jet furnace so constructed effectively removes impurities including oxygen and oxygen-related impurities from the molten copper-based alloy. As described herein, although impurity removal can be described in the context of removing oxygen-related impurities, it is understood that the embodiments are not limited thereto, and other impurities can be removed in a similar manner. Without being limited by any theory, the jet removes impurities, such as oxygen, from the molten alloy according to Henry's law, which states that, under equilibrium conditions, the concentration of a gas in a liquid is proportional to the partial pressure of the gas in contact with the liquid. According to Henry's law, since the inert bubbles initially do not contain oxygen, when the inert bubbles pass through the molten alloy, the oxygen dissolved in the molten alloy is removed from the molten alloy and forms a gas mixture with the inert gas before escaping from the alloy into the surrounding environment. In addition, oxide particles and other oxygen-related impurities can be removed by electrostatic forces. Without being limited by any theory, when small inert bubbles travel through the molten alloy, small oxide particles and oxygen-related impurities can be attached to the inert bubbles via electrostatic forces. Removing oxygen or oxygen-related impurities by bubbling an inert gas may be preferred over methods that rely on chemical reactions between reactive elements, such as reducing gases, and oxygen or oxygen-related impurities in molten copper-based alloys. Strong reducing gases may not be suitable for certain manufacturing facilities because they may pose greater risks to workers and require enhanced safety precautions. In addition, while some elements, such as Zr, are used as deoxidizers, it may be necessary to reduce the amount used during processing, for example to reduce manufacturing costs. The inventors have found that removing and suppressing impurities, including oxygen and oxygen-related impurities, from molten alloys as described herein according to embodiments is related to improving the mechanical properties of cast copper-based alloys, ingots, or copper-based shots.

[0051] The inventors have also found that when a molten alloy having a low impurity content, such as a low oxygen content, is formed in this way, impurities including oxygen and oxygen-related impurities should be prevented from being reintroduced into the molten alloy. To this end, in some embodiments, the melting furnace is closed and arranged under an inert gas environment. The controlled environment can effectively prevent or reduce the reintroduction of oxygen or oxygen-related impurities into the metal alloy. However, embodiments are not limited thereto, and the melting furnace can be open to the surrounding environment in the case where some reintroduction of oxygen or oxygen-related impurities can be allowed, or in the case where the inert gas can be flushed through the system at a sufficiently high flow rate to substantially inhibit the mixing of external air with the inert environment inside the melting furnace.

[0052] The inventors have also discovered that the velocity of the molten copper-based alloy should be carefully controlled when transferring the molten alloy from the furnace to the transfer ladle to reduce any excessive turbulence, which may also result in the introduction of impurities such as oxygen or oxygen-related impurities back into the molten alloy, including any slag that may have formed at the surface of the molten alloy. Therefore, according to some embodiments, a velocity control device, such as a ramp or launder, connects the molten furnace to the transfer ladle. The velocity control device is configured to transfer the copper-based alloy to the transfer ladle without excessive turbulence and entrainment of atmospheric gases, including oxygen or other oxygen-related impurities including oxides that may be present in the system.

[0053] The inventors have also found that in order to further reduce or effectively prevent the reintroduction of impurities including oxygen or oxygen-related impurities into the molten alloy, the transfer pipeline between the melting furnace and the transfer ladle and optionally the transfer pipeline between the transfer ladle and the mold can be at least partially enclosed and arranged in an inert environment. Therefore, in some embodiments, the transfer ladle is at least partially encapsulated and configured to receive the molten copper-based alloy from the speed control device. In some embodiments, the transfer ladle and the speed control device can be enclosed in an inert environment common to the melting furnace. In some embodiments, the transfer ladle is configured to transfer, such as spray or pour the molten copper-based alloy into a mold such as an ingot mold or a component mold. The sprayed molten copper-based alloy can be cooled and hardened into a sprayed copper-based alloy in solid form after being poured into the mold.

[0054] System and method for producing high purity copper-based alloys using inert gases

[0055] Figure 1 FIG. 3 shows a furnace system according to the present disclosure, which is configured for manufacturing a copper-based alloy having a low impurity content, including oxygen or oxygen-related impurity content. Figure 1A and Figure 1B Two different configurations of a melting furnace of a furnace system for producing copper-based alloys according to some embodiments are shown. Figure 5 The use according to the embodiment is shown Figure 1 A method for manufacturing a copper-based alloy by using a furnace system in the furnace system shown in FIG. Figure 1 , Figure 2 Each of the furnace systems 100, 200 and 300 shown in FIG. 3, respectively, includes a melting furnace that can be in a closed configuration ( Figure 1A ) or open configuration ( Figure 1B ). Melting furnace 108A ( Figure 1A )、108B( Figure 1BEach of the furnace systems 100, 200, and 300 is configured to: form a molten copper-based alloy comprising at least 50% copper by weight; flow an inert gas through the feed material prior to melting and during heating; and bubble the inert gas through the molten copper-based alloy. Each of the furnace systems 100, 200, and 300 also includes a transfer ladle configured to receive the molten copper-based alloy from the melting furnace and transfer the molten copper-based alloy to a pellet-shaped depression or one or more molds configured to solidify the molten copper-based alloy.

[0056] Any of the furnace systems 100, 200, and 300 may be used to perform Figure 5 The method 500 of manufacturing a copper-based alloy includes providing 504 a plurality of feed blocks in a melting furnace, the feed blocks having a combination composition configured to form a molten copper-based alloy including at least 50% copper by weight. The method 500 also includes flowing 508 an inert gas stream through gaps between the feed blocks and heating 512 the feed blocks while flowing the inert gas through between the feed blocks, thereby melting the feed blocks to form a molten copper-based alloy. The method 500 also includes bubbling 516 the inert gas through the molten copper-based alloy. The method 500 also includes transferring 520 the molten copper-based alloy to a transfer ladle. Hereinafter, Figure 1 , Figure 2 and details of the furnace systems 100, 200 and 300 shown in FIG. 3 and Figure 5 The method 500 shown in FIG.

[0057] Figure 1 1 is a spray furnace system 100 for manufacturing a copper-based alloy, such as an ingot, a pellet, or a copper-based component, according to one embodiment. The spray furnace system 100 includes a melting furnace 108, which can be configured as a closed melting furnace 108A ( Figure 1A ) or open melting furnace 108B ( Figure 1B As disclosed herein, references to melting furnace 108 will be understood to apply to melting furnace 108A ( Figure 1A )、Melting furnace 108B( Figure 1B ) or both.

[0058] The melting furnace 108 is connected to the gas supply device 102 via the gas pipeline 104 and the diffuser 106. Figure 1A and Figure 1B, the melting furnace 108 is enclosed by a chamber wall 134. The melting furnace 108 includes refractory linings 130A, 130B, which include suitable refractory materials at least at the inner surfaces of the refractory linings 130A, 130B. The refractory lining 130A lines the bottom inner surface of the melting furnace 108, while the refractory lining 130B lines the side wall surface of the melting furnace 108. When the melting furnace 108 is a closed melting furnace 108A, the melting furnace 108A further includes a cover 130. Figure 1 As shown in FIG. 1 , the melting furnace 108 includes an opening for transferring the molten copper-based alloy 110. For example, in Figure 1 1 , the opening is arranged in an upper portion of the melting furnace 108. The opening can be connected to a passage, for example, to a velocity control element 114. The diffuser 106 is configured to bubble an inert gas through a molten copper-based alloy 110 formed in the melting furnace 108. The diffuser 106 has a surface area that covers a portion of a cross-sectional area of ​​the molten copper-based alloy 110 formed in the melting furnace 108, thereby removing impurities in a bubble path through the cross-sectional area. The melting furnace 108 is configured to produce the molten copper-based alloy 110 from a copper-based feed material. As the inert gas flows through the diffuser 106, the inert gas forms bubbles 112 that pass through the molten copper-based alloy 110. The bubbles 112 pass through the molten copper-based alloy 110 and entrain impurities including oxygen and oxygen-related impurities from the molten copper-based alloy 110.

[0059] After impurities are removed from the melting furnace 108, the molten copper-based alloy 110 is transferred through an opening formed through a side wall 134 of the melting furnace 108, such as Figure 1 As shown in (for clarity in Figure 1A and Figure 1B 108). For example, the molten copper-based alloy 110 can be transferred by tilting the melting furnace to pour the copper-based alloy 110 out of the melting furnace 108. In the configuration shown, the molten copper-based alloy 110 is transferred from the melting furnace 108 to the transfer ladle 116 via the first speed control element 114 at a controlled speed. As described herein, the speed can be controlled using structures such as an inclined ramp or a flow trough that utilizes gravity. In some embodiments, the transfer ladle 116 includes one or more ejectors 124. After the molten copper-based alloy 110 is transferred to the transfer ladle 116, the molten copper-based alloy 110 is transferred to one or more ingot molds 118, for example, the molten copper-based alloy 110 is poured or ejected into one or more ingot molds 118 through the ejector 124. The molten copper-based alloy 110 solidifies in the mold 118 to form a solidified copper-based alloy ingot. The mold 118 can be moved via a conveyor belt 120, wherein the mold 118 can be further processed, such as cooled, before being collected.

[0060] Still refer to Figure 1 In some embodiments, mold 118 can be any suitable mold, including ingot molds and fixture molds. In some embodiments, mold 118 can be a mold for a final part, such as a fixture mold. In some embodiments, the fixture mold can be a mold for any suitable water fixture, such as a faucet, a valve, or a pipe.

[0061] Still refer to Figure 1 In some embodiments, the mold 118 can be replaced by hardware suitable for producing metal pellets. For example, some pellet production methods include passing the molten copper-based alloy through a screen, such as a stainless steel screen, and passing the molten copper-based alloy into a fluid, such as water, in which the molten copper-based alloy is quenched and solidified into metal pellets. In some other pellet production methods, air or other suitable gas is passed through the molten copper-based alloy and the molten copper-based alloy is quenched in a fluid, such as water. Although two exemplary methods of suitable pellet production methods are described, it is understood that other known pellet production methods are also within the scope of the present disclosure.

[0062] Still refer to Figure 1 , a gas supply system supplies an inert gas to the melting furnace. In some embodiments, the inert gas may include, for example, argon (Ar) or any other inert gas. In some other embodiments, the inert gas includes nitrogen (N2). In some embodiments, the inert gas is any inert gas or combination of suitable inert gases. In some embodiments, the inert gas may be substantially or substantially free of reactive gases, including reducing or oxidizing gases, such as hydrogen. In these embodiments, the inert gas is free of reactive gases, such as hydrogen, except for impurity levels of reactive gases, such as hydrogen.

[0063] Still refer to Figure 1, the gas supply system is configured to purge or begin flowing an inert gas through the feed material prior to substantially melting the feed. The inventors have discovered that it is important to reduce the presence of ambient oxygen and / or moisture in the melting furnace 108 not only during melting the feed, but also before forming the molten alloy 110, such as before and during heating. Otherwise, unnecessary oxidation of the feed due to ambient oxygen and / or moisture may be accelerated at elevated temperatures during heating prior to forming the molten alloy 110. The oxide so formed on the surface of the feed, which may be relatively stable at the temperature of the molten alloy 110, may remain in the form of an oxide or release oxygen into the molten alloy 110, resulting in oxygen and oxygen-related impurities in the molten alloy 110, which may have a deleterious effect on the mechanical properties of the resulting ingot or pellet. In addition, the inventors have discovered that oxides may also be formed by surface-absorbed oxygen or moisture, which may be effectively removed by flowing an inert gas through the feed. Thus, prior to substantially heating the feedstock and throughout melting, an inert gas is purged through the feedstock in the furnace 108. In some embodiments, flowing the inert gas includes flowing at a sufficient flow rate such that the feedstock is substantially surrounded by the flowing inert gas prior to and during melting.

[0064] As described above, the melting furnace 108 may be a closed configuration (108A, Figure 1A ) or open configuration (108B, Figure 1B ). Reference Figure 1A In the closed configuration of the melting furnace 108A, a lid 130 or similar device can be used to close the furnace 108A. In the closed configuration, the surface of the feedstock and the molten alloy 110 can be placed in a substantially inert environment. As disclosed herein, a substantially inert environment refers to an environment in which the ambient air is substantially reduced above the molten alloy 110, such as less than 50%, 40%, 30%, 20%, 10%, or a value within a range defined by any of these values ​​relative to a normal environment. It is understood that although Figure 1A The closed configuration shown in FIG. 1 , such as using a cover 130, is an effective way to place the surface of the molten alloy 110 in a substantially inert environment, but the embodiments are not limited thereto. For example, the inventors have found that without the cover 130, in the melting furnace 108B ( Figure 1B ), a substantially inert environment can still be achieved by increasing the inert gas flow rate to suppress the presence of ambient air. At a sufficiently high flow or purge rate of the inert gas, the surfaces of the feedstock and molten alloy 110 can be in a substantially inert gas environment even in the absence of a cover or a cover that partially encloses the interior volume of the furnace 108.

[0065] In some embodiments, the inert gas may be purged or flowed through the feed material for, for example, 5 minutes, 10 minutes, 30 minutes, 60 minutes, or more before substantially melting the feed material, and then substantial heating may be initiated to induce melting. During the purging period, before inducing melting of the feed material, the melting furnace 108 may be heated to a relatively low temperature (e.g., 200° C.) well below the melting temperature, which is sufficient to accelerate the removal of moisture but insufficient to substantially oxidize the feed material.

[0066] As described herein, a closed system and its components refer to an arrangement in which the closed ejector furnace system 100 or its subcomponents are physically sealed or isolated from the external environment at least part of the time during the operation of the closed ejector furnace system 100 or its subcomponents. For example, during the loading of a feedstock that may include a plurality of feedstock blocks, the space occupied by the feedstock will decrease as the feedstock blocks melt. Therefore, during the loading process of the melting furnace 108, the chamber cover (when present) may be opened one or more times before the molten alloy 110 reaches the filling line of the melting furnace 108 (the filling line represents the liquid level of the fully loaded melting furnace 108). According to an embodiment, an inert gas may flow into the melting furnace and flow through the molten alloy 110 during the entire filling process until the molten alloy 110 reaches the filling line, which may include multiple cycles of adding solid feedstock blocks to the pool of the melting furnace 110. It will be appreciated that even when the chamber cover is opened during the addition of feedstock to fill the furnace 108, the inert gas may flow into the furnace 108 and through the additional feedstock, thereby reducing or substantially preventing oxidation of the additional feedstock. However, when the furnace 108 is fully loaded, the system 100 including at least the gas supply 102, the gas line 104, the furnace 108, the first speed control element 114, and the transfer ladle 116 may be closed or sealed from the external environment, at least temporarily, while being purged with the inert gas from the gas supply 102 to inhibit the introduction of oxygen into the system 100. Thus, in the method 500 ( Figure 5 ), one or more of flowing 508 the inert gas, heating 512 the feed block, and bubbling 516 the inert gas through the molten copper-based alloy is at least partially performed in a closed inert environment that is configured to substantially exclude outside air from mixing with the closed inert environment. Figure 1In the illustrated configuration, the transfer of the molten alloy 110 through the first velocity control element 114 to the transfer ladle 116 may also be at least partially performed in a closed inert environment that is configured to substantially exclude external air from mixing with the closed inert environment. The sealing for isolating the relevant portions of the closed injection furnace system 100 from the external air may be performed using, for example, one or more valves disposed in the injection furnace system 100, for example, disposed between the melting furnace 108 and the transfer ladle 116 and / or disposed between the transfer ladle 116 and the outside world. For example, the injector 124 may include a valve or other closing mechanism that is used to isolate the transfer ladle 116 from the melting furnace 108 before being opened to inject the molten alloy therethrough.

[0067] The feedstock may be present in various forms, including one or more alloy blocks and / or elemental metal blocks. The feedstock blocks may have the same composition or may not have the same composition. However, these pieces have the following combined composition: the combined composition is configured to form a molten copper-based alloy having a target composition of the alloy to be formed and including at least 50% copper by weight. Depending on the size of the feedstock block, the inventors have also found that the amount or flow rate of the inert gas that effectively inhibits oxidation of the feedstock before melting as described above may be different. The amount or flow rate of the inert gas may depend on the relative amount of open space between the feedstock blocks or the permeability of the copper-based alloy feedstock material that forms the raw material to produce the molten alloy 110, etc. A relatively large amount of open space or a relatively high permeability that may exist when the feedstock includes a relatively large feedstock block may have a relatively small amount of alloy surface area exposed to the inert gas. For example, in some embodiments, the feedstock material may include the following feedstock block: the feedstock block has a relatively large size and a correspondingly high amount of open space or a correspondingly high permeability. For feedstocks having high permeability, a relatively high inert gas flow rate, such as greater than or about 5 liters / minute, may be suitable for removing various impurities including oxygen and oxygen-related impurities from the feedstock. In some embodiments, the feedstock material may include a feedstock block having a relatively small size and a correspondingly small amount of open space or a relatively low permeability. For example, the feedstock may be a relatively small copper-based alloy cutting (e.g., copper-based scrap). For feedstocks having low permeability, a relatively low inert gas flow rate, such as an inert gas flow rate of less than about 5 liters / minute, may be suitable for removing impurities including oxygen and oxygen-related impurities from the scrap. The inert gas flow rate prior to melting described herein may have any value that is the same or different relative to the inert gas flow rate during the inert gas bubbling through the molten alloy 110 as described below (these values ​​are not repeated herein for brevity).

[0068] The inventors have found that in order to effectively remove impurities including oxygen and oxygen-related impurities from the molten aluminum 110 as described above, specific combinations of various process parameters may be effective. In particular, the inventors have found that the size, density and velocity distribution of the bubbles 112 traveling through the molten alloy 110 may be related to the effectiveness of the impurity removal process. When the size, density per unit volume and velocity of the bubbles 112 are too small or too low, the bubbles may be too slow or ineffective in removing oxygen or oxygen-related impurities. In other aspects, when the size, density and velocity of the bubbles 112 are too large or too high, as the bubbles rise and burst at the surface of the molten alloy 110, the bubbles may form a large amount of turbulence. The inventors have found that this turbulence can not only make any removal of oxygen or oxygen-related impurities ineffective when the amount is large, but can even increase the content of oxygen or oxygen-related impurities. Therefore, the inventors have found that it may be crucial to control the size, density and velocity distribution of the inert bubbles. The size, density, and velocity distribution of the bubbles may be optimized based on various factors, including: the viscosity of the molten alloy 110; the flow rate of the inert gas through the molten alloy 110; the cross-sectional flow area of ​​the molten alloy 110 through which the inert gas flows; the porosity of the diffuser 106; and the volume of the molten alloy 110 that is defined by the size of the furnace 108, among others. It will be appreciated that these parameters may be interdependent. For example, the flow rate of the inert gas and the cross-sectional flow area through the diffuser determine the flow rate of the inert gas. Furthermore, certain values ​​of flow parameters, such as flow rate, may be particularly relevant when there is a proportional relationship with the total volume of the molten alloy 110.

[0069] The viscosity of the molten alloy 110 depends on the composition and temperature of the molten alloy 110. For a given composition of the various compositions of the molten alloy 110 described herein, including a molten copper-based alloy composition containing at least 50% by weight copper, the viscosity can be controlled by controlling the temperature of the molten alloy 110 above the melting temperature, such as the liquidus temperature. For this reason and others, the inventors have discovered that when the molten alloy 110 is heated to a temperature of 100° C. to 400° C. above the liquidus temperature of the alloy, the methods described herein can be effective in removing impurities, including oxygen and oxygen-related impurities, from the molten alloy 110. According to various embodiments, the temperature to which the molten alloy 110 is heated is greater than 50° C., 100° C., 150° C., 200° C., 250° C., 300° C., 350° C., 400° C., 450° C., or any temperature within a range bounded by any of these values.

[0070] As discussed above, the inventors have discovered that the flow rate of the inert gas during bubbling should be optimized so that the size, density, and velocity distribution of the inert bubbles are effective in reducing various impurities, including oxygen and oxygen-related impurities, while not creating excessive turbulence, which can have negative effects. Figure 1A ) or in an open configuration ( Figure 1B ), the optimized flow rate is different. According to various embodiments, when the melting furnace 108A ( Figure 1A ) is in a closed configuration, the inert gas is bubbled into the melting furnace 108A at a flow rate greater than 10 liters / minute, 9 liters / minute, 8 liters / minute, 7 liters / minute, 6 liters / minute, 5 liters / minute, 4 liters / minute, 3 liters / minute, 2 liters / minute, 1 liter / minute, or greater than any value within a range limited by these values, such as 1 liter / minute to 10 liters / minute or 2 liters / minute to 6 liters / minute, etc., for example, about 4 liters / minute. According to various embodiments, when the melting furnace 108B ( Figure 1B ) is in the open configuration, the inert gas is bubbled into the melting furnace 108B at a higher flow rate than in the closed configuration. For example, the flow rate in the open configuration can be greater than 13 liters / minute, 12 liters / minute, 11 liters / minute, 10 liters / minute, 9 liters / minute, 8 liters / minute, 7 liters / minute, 6 liters / minute, 5 liters / minute, 4 liters / minute, or greater than any value within a range defined by these values, such as 4 liters / minute to 13 liters / minute or 5 liters / minute to 9 liters / minute, for example, about 7 liters / minute. When the configurations of the closed melting furnace 108A and the open melting furnace 108B are otherwise the same, the optimized flow rate of the inert gas in the open melting furnace configuration 108A is 2 liters / minute, 3 liters / minute, 4 liters / minute, or a value within a range defined by any of these values, relative to the closed melting furnace 108A.

[0071] To further control the size, density and velocity distribution of the inert gas bubbles, the inert gas flows into the melting furnace through a diffuser 106 having a limited diffuser area to control the flow rate. According to various embodiments, the inert gas is diffused through the diffuser 106 having a diameter d ( Figure 1A ), the diameter d is greater than 5cm, 10cm, 15cm, 20cm, 25cm, 30cm, 35cm, 40cm, 45cm, 50cm, or greater than a value in the range defined by any of these values.

[0072] The size, density and velocity distribution of the inert bubbles can also be controlled by the pores of the diffuser 106. The pore size of the diffuser 106 should be controlled so that the bubbles have a suitable size, density and distribution while preventing the molten liquid alloy from penetrating. The diffuser 106 can have an average pore size greater than 20 μm, 30 μm, 40 μm, 50 μm, 60 μm, 70 μm, 80 μm, 90 μm, 100 μm, or a value greater than the range defined by any of these values. In addition, the diffuser 106 has a porosity defined as the ratio of void space to total macroscopic volume greater than 10%, 15%, 20%, 25%, 30%, 35%, or a value greater than the range defined by any of these values.

[0073] In the illustrated embodiment, the diffuser 106 is disposed at the bottom surface of the melting furnace. However, the embodiment is not limited thereto, and the diffuser 106 may be formed at other surface positions including the side surface.

[0074] Figure 4A and Figure 4B A schematic cross-sectional view and a photograph are shown, respectively, of a diffuser according to an embodiment that meets the criteria described herein. Figure 4C is a photograph of a diffuser installed at the bottom of the melting furnace 108 according to an embodiment. Figure 4A As shown in FIG. 4 , diffuser 400 includes a gas inlet 404 through which an inert gas is introduced and a container 408 for holding a diffuser material or medium 412. The diffuser material or medium 412 is shown to include a porous refractory ceramic material. Figure 4B 4 is a photograph of an example of a diffuser 400 having a diffuser material or medium formed primarily of porous alumina and silica. The diffuser material or medium 412 includes alumina in an amount of 50 mol% (mole percent) to 80 mol%, 55 mol% to 75 mol%, 60 mol% to 70 mol%, or a mol% in a range defined by any of these values, such as 65 mol%. The diffuser material or medium 412 also includes silica in an amount of 10 mol% to 35 mol%, 15 mol% to 30 mol%, 20 mol% to 25 mol%, or a mol% in a range defined by any of these values, such as 24 mol%. The diffuser material or medium may have the following Fig. 6A and Figure 6B The various properties and structures of the diffuser liner described in the description. For example, the diffuser material 412 has a porosity of 27.6% and a porosity of 2.45 g / cm 3 The diffuser material or liner 412 may also have a density of Fig. 6A and Figure 6B Described double layer structure.

[0075] Still refer to FIG. 4A to FIG. 4C According to an embodiment, the inert gas is passed through a diffusion material or medium 412 ( Figure 4A ) is bubbled into the melting furnace 108 at a flow rate as described above, for example, 1 liter / minute to 10 liters / minute, the diffusion material or medium 412 has a diameter of 5 cm to 50 cm in the furnace, and the furnace has the ability to melt the following amount of alloy: the amount is greater than 1000 pounds (lbs), 2000 pounds, 5000 pounds, 10,000 pounds, 20,000 pounds, 50,000 pounds, 100,000 pounds, or a value within the range defined by any of these values. For example, in a 4000 pound furnace or in a furnace having the ability to melt an amount of alloy of about 4000 pounds, the inert gas is bubbled into the melting furnace at a flow rate between 1 liter / minute and 10 liters / minute.

[0076] Return to reference Figure 1A and Figure 1B In addition to the capacity of the melting furnace 108A, 108B, the furnace may also have a volume defined by an area, such as a cylindrical area, and a height. In various embodiments, the furnace may have a cylindrical volume defined by an inner diameter D greater than 50 cm, 100 cm, 150 cm, 200 cm, 250 cm, 300 cm, 350 cm, 400 cm, 450 cm, 500 cm, or greater than a value within a range defined by any of these values. The melting furnace 108A, 108B may also have a height H such that when the melting furnace 108A, 108B is fully loaded with the molten alloy 110, the molten metal may have a fill line F at a height measured from the bottom surface of the furnace greater than 50 cm, 100 cm, 150 cm, 200 cm, 250 cm, 300 cm, 350 cm, 400 cm, 450 cm, 500 cm, or greater than a value within a range defined by any of these values.

[0077] The inventors have found that the disclosed inert gas flow rates, in combination with various other configurations of the melting furnace 108, produce a combination of bubble size, density per unit volume, and velocity distribution suitable for producing the various advantageous effects described herein. The density of the bubbles is such that excessive agglomeration of the bubbles within the molten metal is largely avoided, and the velocity and size are such that excessive turbulence is avoided. In some embodiments, the diffuser 106 can have an average pore distribution related to the bubble size and density per unit volume, so that the inert bubbles generally do not agglomerate or have excessive velocities.

[0078] When the melting furnace 108 is closed, the environment in contact with the molten alloy 110 in the melting furnace 108 can be determined by the inert gas introduced by the gas supply system. In some embodiments, the environment in the melting furnace is argon. In some embodiments, the environment in the melting furnace is nitrogen. In some embodiments, the environment in the melting furnace is any suitable inert gas.

[0079] Reference Figure 1A and Figure 1B The melting furnace 108 (108A, 108B) is configured to melt the feed material. Figure 1A , Figure 1B As shown in , the melting furnace 108 can be, but is not limited to, an induction type furnace. The melting furnace 108 can be configured to have a variable internal temperature to accommodate various copper-based alloy systems. In some embodiments, the temperature of the melting furnace 108 is between 700°F and 3000°F. In some embodiments, the temperature of the melting furnace 108 is 900°F, 1000°F, 1200°F, 1400°F, 1600°F, 1800°F, 2000°F, 2200°F, 2400°F, 2500°F, or 3000°F, or a value within a range defined by any of these values.

[0080] Still refer to Figure 1A and Figure 1BThe melting furnace 108 (108A, 108B) configured as an induction type includes an induction coil 138 that surrounds at least a portion of the melting furnace 108A, 108B. The induction heating system includes an induction power supply that converts line power into alternating current and delivers the alternating current to the coil 138 to form an electromagnetic field within the coil. The feedstock is arranged within the coil, wherein the field induces a current in the feedstock, which in turn generates heat sufficient to melt the feedstock. Advantageously, the inventors have realized that in some cases, for optimal results, the uppermost winding of the coil 138 should be kept below the fill line (F). This configuration allows the lower region of the molten alloy 110 to be at a higher temperature relative to the upper region of the molten alloy 110. The inventors have found that this configuration produces higher efficiency in removing impurities. Without being bound by any theory, the improved efficiency may be due in part to the fact that impurity removal can be performed at a higher efficiency at a hotter lower region due to increased local solubility of the impurities. Subsequently, in the upper region, the impurities become incorporated into the slag at the topmost surface of the molten alloy 110, thereby being removed from the molten copper-based alloy 110. According to an embodiment, the uppermost winding of the induction coil 138 is arranged at a vertical level or fill line F corresponding to the top surface of the molten copper-based alloy 110 or arranged below the vertical level or fill line F corresponding to the top surface of the molten copper-based alloy 110. Relative to the height of the molten copper-based alloy 110, the induction coil 138 may have a height corresponding to 90%, 80%, 60%, 50%, 40%, 30%, or a percentage within a range defined by any of these values ​​measured from the bottom inner surface of the melting furnace 108.

[0081] The operating frequency of the induction heating system can be affected by the range of feedstock sizes applied. Without being bound by any theory, this may be due to the "skin effect", which is related to the depth below the surface in the metal feedstock where the electromagnetic field induces an electric current. Generally, a higher operating frequency corresponds to a shallower skin depth, while a lower operating frequency corresponds to a deeper skin depth. The skin depth is in turn related to the penetration of the heating effect. The skin depth or penetration depth depends on the operating frequency, the material properties of the feedstock, and the temperature. In general, for a given material, heating of smaller feedstock pieces by induction can be performed at a higher operating frequency, while heating of larger feedstock pieces can be performed at a lower operating frequency. According to various embodiments, the feedstock can have a minimum major dimension, such as a width: the minimum major dimension is greater than 2 cm, 5 cm, 10 cm, 20 cm, 30 cm, 40 cm, 50 cm, or a value within a range defined by any of these values. The inventors have found that for melting a copper-based alloy feed block according to an embodiment, the optimal frequency of the melting furnace 108 is set to less than 10 kHz, 5 kHz, 2 kHz, 1 kHz, 500 kHz, or a frequency within a range defined by any of these values, such as 600 kHz.

[0082] As described above, the inventors have discovered that in order to enhance the removal of impurities including oxygen and oxygen-related impurities from the molten alloy 110, the molten alloy 110 is heated to a temperature 100°C to 400°C higher than the melting temperature of the alloy, such as the liquidus temperature. In another aspect, it is advantageous to reduce the temperature of the molten metal in the furnace to near the liquidus before transferring the molten alloy 110 to the mold. Therefore, according to various embodiments, the molten alloy 110 is cooled to a temperature greater than 50°C, 100°C, 150°C, 200°C, 250°C, 300°C, 350°C, 400°C, 450°C, or greater than any temperature within a range defined by any of these values, relative to the temperature at which the inert gas is bubbled through the molten alloy 110. However, the temperature inside the melting furnace 108 remains above the melting temperature of the alloy.

[0083] After forming the molten alloy 110 having a low content of impurities including oxygen or oxygen-related impurities, the molten alloy is transferred to a transfer ladle 116. The inventors have found that the content of oxygen or oxygen-related impurities may be inconsistent depending on the depth of the molten alloy 110. The inventors have found that, in general, the content of oxygen or oxygen-related impurities tends to be higher toward the surface of the molten alloy 110. Therefore, advantageously, when a portion of the molten alloy 110 containing a lower than average oxygen content is required, the molten alloy 110 located in the lower portion of the melting furnace is preferably transferred to the transfer ladle 116. This can be achieved, for example, by connecting the first speed control element 114 at the lower portion, such as within 10%, 20%, 30%, 40%, 50%, or 60% of the bottom of the melting furnace 108. Alternatively, a mechanical pump can be used to preferably pump the molten alloy 110 from the bottom portion of the molten alloy 110, and then transfer the pumped molten alloy 110 to the transfer ladle 116.

[0084] Still refer to Figure 1 As described above, after forming the molten alloy 110 having a low content of impurities including oxygen or oxygen-related impurities in the melting furnace 108, the molten alloy 110 can be transferred to the transfer ladle 116 via the first velocity control element 114, such as a launder or ramp, which can be in a closed and / or inert environment to reduce the reintroduction of oxygen or oxygen-related impurities into the molten alloy 110. In some embodiments, bubbling an inert gas through the molten alloy 110 can continue throughout the process of transferring the molten copper-based alloy to the transfer ladle 116. When the first velocity control element 114 is closed or isolated from the external environment, as shown, the environment within the first velocity control element can be the same as the environment of the melting furnace. Therefore, the environment within the first velocity control element is argon, nitrogen, and / or any suitable inert gas.

[0085] The first velocity control element 114 is configured to introduce the molten alloy 110 into the transfer ladle 116 at a controlled velocity to inhibit turbulence, which may introduce or reintroduce impurities, including oxygen or oxygen-related impurities. The inventors have discovered that controlling the velocity at this stage may also be critical to preventing or inhibiting the introduction or reintroduction of oxygen and oxygen-related impurities into the molten alloy 110 as it cools, and inhibiting the formation of voids in the molten alloy 110 as it cools. The first velocity control element 114 may be, for example, a flow channel or an inclined channel, which may be closed and isolated from the external environment, as shown. In some embodiments, the first velocity control element 114 is configured to transfer the molten alloy 110 from the melting furnace 108 to the transfer ladle 116 at the following velocities: 1 inch / second, 2 inches / second, 5 inches / second, 10 inches / second, 15 inches / second, 16 inches / second, 17 inches / second, 18 inches / second, 19 inches / second, 20 inches / second, 21 inches / second, 22 inches / second, 23 inches / second, 24 inches / second, 25 inches / second, 26 inches / second, 27 inches / second, 28 inches / second, 29 inches / second, 30 inches / second, 31 inches / second, 32 inches / second, 33 inches / second, 34 inches / second, 35 inches / second, 36 inches / second, 37 inches / second, 38 inches / second, 39 inches / second, 40 inches / second, 41 inches / second, 42 inches / second, 43 inches / second, 44 inches / second, 45 inches / second, 46 inches / second, 47 inches / second, 48 inches / second, 49 inches / second, 50 inches / second, 51 inches / second, 52 inches / second, 53 inches / second, 54 inches / second, 55 inches / second, 56 inches / second, 57 inches / second, 58 inches / second, 59 inches / second, 60 inches / second, 61 inches / second, 62 inches / second, 63 inches / second, 64 inches / second, 65 inches / second, 66 inches / second, 67 inches / second, 68 inches / second, 69 inches / second, 70 inches / second, 71 inches / second, 72 inches / second, 73 inches / second, 74 inches / second, 75 inches / second, 76 inches / second, In some embodiments, the first velocity control element 114 is configured to transfer the molten alloy 110 from the melting furnace 108 to the transfer ladle 116 at a velocity between 5 inches / second and 30 inches / second. In some embodiments, the first velocity control element 114 controls the velocity of the molten copper-based alloy as it is transferred from the melting furnace 108 to the transfer ladle 116.

[0086] Still refer to Figure 1In some embodiments, in order to control the velocity of the molten alloy 110 within the velocity range disclosed above, the closed injection furnace system 100 is configured to transfer the molten alloy 110 from the melting furnace 108 to the transfer ladle 116 using a first velocity control element 114 configured to use gravity to control the velocity of the flowing molten alloy 110 by being arranged to have, for example, a 0.5-inch to 5-inch vertical drop over a horizontal length of about 3 feet to 5 feet. In some embodiments, the first velocity control element 114 is configured to have a drop of 0.5-inch to 2-inch or 1-inch to 2-inch over a length of 3 feet, 4 feet, 5 feet, or over a length of 3 feet to 5 feet. Relative to a horizontal plane parallel to the ground, the first speed control element can have an angle of 5 to 10 degrees, 10 to 20 degrees, 20 to 30 degrees, 30 to 40 degrees, 40 to 50 degrees, 50 to 60 degrees, or a value within a range defined by any of these values.

[0087] As described above, after forming the molten alloy 110 having a low content of impurities including oxygen or oxygen-related impurities in the melting furnace 108, the molten alloy 110 can be transferred to the transfer ladle 116 in a closed and / or inert environment to further inhibit the reintroduction of impurities into the molten alloy 110. Therefore, as shown, according to various embodiments, the transfer ladle 116 and the first velocity control element 114 connecting the melting furnace 108 to the transfer ladle 116 can be closed. When the transfer ladle 116 is closed relative to the surrounding environment, the environment within the transfer ladle 116 can be common or shared with the environment of the melting furnace 108 and / or the first velocity control element 114. Therefore, the environment within the transfer ladle is argon, nitrogen, and / or any suitable inert gas.

[0088] Still refer to Figure 1, after the molten alloy 110 is transferred to the transfer ladle 116 at a controlled speed using the first speed control element 114, the molten alloy 110 is injected into the mold 118 using the injector 124. The injector 124 can be, for example, a gravity-driven injector, in which the molten alloy 110 is injected through the gravity-driven injector only by gravity. For example, the injector 124 can include a piston, which is usually resting on a valve seat, and the valve seat has an opening smaller than the diameter of the piston. In this configuration, the injector 124 is closed, and the system 100 including one or more of the transfer ladle 116, the first speed control element 114 and the melting furnace 108 can be enclosed in a common inert environment and connected by a common inert environment. When the piston is lifted upward from the valve seat, the molten alloy 110 is allowed to flow through the valve seat opening, thereby injecting the molten alloy 110 into the mold 118 by gravity. The inventors have discovered that the distance between the injection tip of the injector 124 and the mold 118 should not exceed 0.5", 1.0", 1.5", 2.0", 2.5", 3.0", 3.5", or a value within a range defined by any of these values ​​to prevent excessive turbulence, which could again result in the introduction or reintroduction of oxygen or oxygen-related impurities as the molten alloy 110 solidifies.

[0089] Figure 2 is a schematic diagram of a closed injection furnace system 200 for manufacturing a copper-based alloy, such as an ingot, a copper-based shot, or a copper-based component, having a low content of oxygen or oxygen-related impurities, according to one embodiment. The closed injection furnace system 200 shares various components that are configured to be substantially similar to corresponding components of the closed injection furnace system 100 described above, and detailed descriptions of some of these components may be omitted herein for the sake of brevity. The closed injection furnace system 200 includes a gas supply 102, which is connected to a diffuser 106 via a gas pipeline 104, and the diffuser 106 is configured to cause gas to bubble through a molten copper-based alloy 110 in a melting furnace 108. By the same method as described above Figure 1 In a manner similar to that described, when the inert gas flows through the diffuser 106, the system 200 is configured to form inert bubbles 112 that pass through the molten copper-based alloy 110. The bubbles 112 pass through the molten copper-based alloy 110 and entrain impurities including oxygen or oxygen-related impurities from the molten copper-based alloy 110, as described above. After the impurities are removed from the melting furnace 108, the molten copper-based alloy 110 is transferred from the melting furnace 108 to the transfer ladle 116 at a first controlled speed via the first speed control element 114. In some embodiments, the transfer ladle 116 includes one or more ejectors 124.

[0090] The inventors have discovered that in some cases, in addition to advantageously controlling the speed of the molten alloy 110 being transferred from the melting furnace 108 to the transfer ladle 116 using the first speed control element 114, it may also be advantageous to additionally control the speed of the molten alloy 110 being transferred from the transfer ladle 116 to the mold 118. To address these needs and other needs, a method for controlling the speed of the molten alloy 110 being transferred from the transfer ladle 116 to the mold 118 is provided. Figure 1 Unlike the system 100 that directly transfers the molten alloy 110 from the transfer ladle 116 to the mold 118, in Figure 2 In the system 200 shown in , after the molten copper-based alloy 110 is transferred to the transfer ladle 116, the molten copper-based alloy 110 is transferred to the mold 118 via the second speed control element 218. The second speed control element 218 can be, for example, a flow trough or an inclined channel, and can be closed and isolated relative to the external environment. The molten alloy 110 solidifies in the mold 118 to form a solidified copper-based alloy. The mold 118 can be moved via a conveyor belt 120, wherein the mold 118 can be further processed.

[0091] In addition to following the above Figure 1 The contents described are constructed except for the first speed control element 114, Figure 1 The system 200 shown in FIG. 1 includes a second speed control element 218. The added speed control element provides added speed control to further reduce oxygen or oxygen-related impurities that are reintroduced into the molten alloy 210 as the molten alloy 210 is introduced into the ingot mold 118. The second speed control element 218 can be constructed according to the various configuration parameters, including size and slope, described above with respect to the first speed control element 114, and a detailed description of the second speed control element 218 is omitted herein for the sake of brevity.

[0092] By constructing in this way, Figure 1 In the system 200 shown in , after the molten alloy 110 with a reduced content of oxygen or oxygen-related impurities is formed in the melting furnace 108 and transferred to the transfer ladle 116 at a first speed using the first speed control element 114, the molten alloy 110 can be transferred to the ingot mold 118 at a second speed using the second speed control element 218, which is further reduced relative to the first speed. In some embodiments, the speed control element 218 is closed relative to the surrounding environment. However, the embodiments are not limited to this, and in some other embodiments, the second speed control element 218 can be open relative to the surrounding environment. In some embodiments, the environment within the second speed control element 218 can be the same as the environment of the melting furnace 108 and / or the first speed control element 114 and / or the transfer ladle 116. Therefore, the environment within the second speed control element 218 can be argon, nitrogen, and / or any suitable inert gas.

[0093] The second speed control element 218 is configured to transfer the molten alloy 110 from the transfer ladle at a speed having any of the values ​​described above with respect to the speed of the molten copper-based alloy 110 controlled by the first speed control element 114. However, it will be appreciated that because the speed of the molten alloy reaching the second speed control element 218 has been reduced by the first speed control element 114, the speed of the molten alloy 110 reaching the mold 118 will be substantially lower than in the absence of the second speed control element 218, e.g., Figure 1 . According to various embodiments, the second velocity of the molten alloy 110 at the terminal end of the second velocity control element 218 is 20%, 30%, 40%, 50%, 60%, 70% of the first velocity of the molten alloy at the terminal end of the first velocity control element 112, or a value within a range defined by any of these values.

[0094] As mentioned above Figure 1 As discussed, the inventors have discovered that turbulence caused by the vertically falling molten alloy 110 may introduce or reintroduce oxygen or oxygen-related impurities into the molten alloy 110. Therefore, the vertical drop between the injection tip of the injector 124 and the second velocity control element 218 and the vertical drop between the second velocity control element 218 and the die 118 should not exceed 0.5", 1.0", 1.5", 2.0" or may have a value within a range defined by any of these values ​​to prevent excessive turbulence.

[0095] So configured, the second speed control element 218 is configured to transfer the molten copper-based alloy 110 from the transfer ladle 216 to the ingot mold 118 at a significantly reduced speed and without a vertical drop.

[0096] FIG3 is a schematic diagram of a closed injection furnace system 300 for manufacturing a copper-based alloy, such as an ingot, a copper-based shot, or a copper-based component, according to another embodiment. The copper-based alloy has a low content of oxygen or oxygen-related impurities. In particular, the system 300 shows an exemplary implementation of a conveying system 304. The upper illustration shows a top view of the system 300 including the conveying system 304, while the lower illustration shows a side view of the conveying system 304. The closed injection furnace system 300 is configured to be similar to the above-mentioned embodiments. Figure 1 and Figure 2 Various components of the closed jet furnace systems 100 and 200 described above are substantially similar to corresponding components, and detailed descriptions of these components may be omitted herein for the sake of brevity. Figure 1 and Figure 2Unlike the described systems 100 and 200, the system 300 includes two melting furnaces 108 for higher productivity. However, the embodiments are not limited thereto, and it is understood that any of the systems 100, 200, and 300 may have a suitable number of melting furnaces 108, such as one or more melting furnaces 108. After oxygen-related impurities are removed from the melting furnace 108 in a manner similar to that described above, the molten copper-based alloy 110 is transferred from the melting furnace 108 to the transfer wheel 316 via the first speed control element 114 at a first controlled speed and optionally also via the second speed control element at a second controlled speed, which second controlled speed may be the same as or lower than the first speed. As described above, Figure 1 and Figure 2 Unlike the described systems 100 and 200, the second velocity control element 218 (when present) is directly connected to the first velocity control element 114 without being separated by a transfer ladle. Thereafter, the molten alloy 110 is ejected into one or more molds 118. Further unlike the systems 100 and 200 ( Figure 1 and Figure 2 ) is different from the system 300 shown, the molten alloy 110 is ejected into the mold 118 using a transfer wheel 316, which is also referred to as a casting wheel, with reference to Figure 3B and Figure 3C The transport wheel 316 is described in further detail. Thus, the ejected molten alloy 110 falls into one or more molds 118 and is transported by a conveyor belt 120 of the transport system 304. The conveyor belt 120 may be driven by a suitable drive assembly, which may include, for example, a motor drive 324. The transport system 304 may optionally include, for example, a cooling fan 308 and a knocker 312 to loosen the ingot from the mold so that the ingot is collected in a collection box 320.

[0097] Figure 3B and Figure 3C The following are respectively shown for manufacturing a copper-based alloy according to some other embodiments. Figure 3A Detailed perspective and side views of a portion of system 300 are shown in FIG. 1 , the copper-based alloy having a low content of oxygen or oxygen-related impurities. Figure 3B and Figure 3C The various portions of the system 300 shown in FIG. 3 show additional details of the system 300 including the arrangement of the transfer wheel 316 and the conveyor belt 120. The side view of FIG. 3 is a side view along the direction of motion of the conveyor belt 120. In particular, as described above with respect to FIG. Figure 3A As described, in system 300, molten alloy 110 is transferred via transfer wheel 316 rather than Figure 1 and Figure 2The transfer ladle described is ejected into the mold 118. Figure 1 and Figure 2 Unlike the transport ladle 116 in which the ejectors 124 are separated by a linear distance, for example, along the bottom surface of the transport ladle 116, in the transport wheel 316, the ejectors 328 are separated by arcs defined by the separation angles between the ejectors 328 and extend in different directions. Figure 3B and Figure 3C As shown in FIG, the transfer wheel 316 is configured to rotate about a radial center axis (z). Without limitation, in the illustrated transfer wheel 316, the z-axis generally extends along the flow direction of the molten alloy 110 in the second velocity control element 218.

[0098] The plurality of ejectors 328 of the transport wheel 316 are tilted to extend in the radial direction at an angle of inclination relative to the z-axis. The extended inclination angle of the ejectors 328 is such that: the inclination of the ejectors 328 allows the velocity of the molten metal 110 to be further reduced when the molten metal 110 is delivered to the mold 118, rather than the above systems 100 and 200 ( Figure 1 and Figure 2 ) as described in the arrangement structure shown in FIG. 1 , the molten alloy 110 is ejected vertically into the mold 118.

[0099] The motor drive 324 is configured to synchronize the motion of the transfer wheel 316 and the conveyor belt 120. The motor drive 324 is configured to rotate the transfer wheel 316 at a predetermined angular velocity about the z-axis and to linearly translate the molds 118 arranged at regular intervals so that adjacent ones of the inclined ejectors 328 of the transfer wheel 316 are separated by an arc corresponding to the linear distance between adjacent ones of the molds 118. Thus, as the transfer wheel 316 rotates, adjacent ones of the molds 118 are filled with molten metal 110 by corresponding ones of the ejectors 328.

[0100] Reference Figure 3B , a gate valve 332 is arranged at the end of each arm of the first speed control element 114. The gate valve 332 is configured to keep the molten metal 110 closed and in an inert environment until the molten metal 110 is ready to be transferred to the transfer wheel 316. For illustrative purposes, the second speed control element 218 is shown as being open at the top portion of the second speed control element 218. However, in operation, the second speed control element 218 can also be closed in an inert environment to benefit from it as described above.

[0101] According to various embodiments, the apparatus is configured such that: relative to copper-based alloys produced using conventional copper furnaces, the molten copper-based alloy formed in the mold 118 according to embodiments and ultimately solidified has a significantly lower oxide content. In some embodiments, the solidified copper-based alloy has an oxide content that is 5%, 10%, 15%, 20%, 25%, 30%, 50%, 75%, or up to 99% lower, or any value therebetween, than the solidified copper-based alloy produced using the same feed material in a conventional reference furnace.

[0102] According to various embodiments, the apparatus according to the embodiments is configured such that one or more test results obtained from the solidified copper-based alloy using the ASTM E8 / E8M-21 method have one or more of the following, relative to a reference solidified copper-based alloy formed by a reference apparatus that is configured identically to the apparatus according to the embodiments except that the melting furnace and the transfer ladle are in the same closed inert environment: an increase in ultimate tensile strength of at least 10 psi, 20 psi, 40 psi, 50 psi, or a value within a range defined by any of these values; an increase in 0.5% yield strength of at least 1 psi, 2 psi, 3 psi, 6 psi, 8 psi, 10 psi, or a value within a range defined by any of these values; an increase in elongation of at least 3%, 5%, 10%, 20%, 30%, 40%, 50%, or a value within a range defined by any of these values; and an increase in reduction in cross-sectional area of ​​at least 3%, 5%, 10%, or a value within a range defined by any of these values.

[0103] System for manufacturing high purity copper-based alloys including an enhanced diffuser assembly

[0104] In the above, various aspects of a furnace system configured to manufacture a copper-based alloy with reduced impurity content and a method of manufacturing a copper-based alloy using such a system have been described. As described above, among other things, controlling the inert bubble characteristics may be critical to producing optimized conditions for reducing the impurity content of the molten copper-based alloy 110. The bubble characteristics include bubble size, density per unit volume, and velocity distribution. These bubble characteristics are in turn determined by various flow characteristics, including flow velocity, flow rate, and pore size distribution through the diffuser 106.

[0105] In the melting furnaces 108A, 108B ( Figure 1A and Figure 1B ), the diffuser has a diameter d( Figure 1A ), the diameter d is smaller than the diameter D of the melting furnace 108. FIG. 4A to FIG. 4C The diffuser 106 is further described. Figure 4AAs shown in , the diffuser material or medium 412 is connected to the inlet 404, which is used to flow the inert gas through the inlet 404. The diameter d of the diffuser 106 in contact with the molten copper-based alloy 110 can be optimized to make the inert gas flow out of the outer surface of the diffuser 106 uniformly. The porosity can be optimized to control the size of the inert bubbles. The inventors have found that because the diameter d or area of ​​the diffuser 106 is smaller than the diameter D or area of ​​the melting furnace 108A, 108B, the inert bubbles 112 may not flow through the entire cross-section of the molten copper-based alloy 110. Therefore, depending on the diffusion rate of impurities, the molten copper-based alloy 110 outside the path of the inert bubbles 112 may not be effectively purified. Therefore, the inventors have recognized the need to increase the following cross-sectional area of ​​the molten copper-based alloy 110: the inert bubbles pass through the cross-sectional area toward the surface of the molten copper-based alloy 110.

[0106] To address these needs and other needs, and to further improve the various embodiments disclosed herein, additional embodiments of an apparatus for manufacturing a copper-based alloy include a melting furnace configured to form a molten copper-based alloy comprising at least 50% copper by weight. According to an embodiment, the melting furnace 108 includes a diffuser assembly including one or more diffuser liners. The diffuser assembly includes a diffusion liner formed on a surface of a melting chamber wall. The diffusion liner may be employed in addition to or in place of the diffuser 106 described above.

[0107] Fig. 6A and Figure 6B FIG. 4 is a schematic side view of a melting furnace for producing a high-purity copper-based alloy according to some embodiments, the melting furnace including a diffuser assembly. The diffuser assembly includes a diffuser 400 and one or both of a diffusion liner 400A, 400B. Figure 1A and Figure 1B Unlike the melting furnaces 108A, 108B described above, in which the diffuser 400 is configured to contact the molten copper-based alloy 110, in Fig. 6A and Figure 6B In the embodiment shown in , the diffuser 400 is arranged at a depth inside the diffusion liner 400A, 400B. As configured, the inert gas diffused out of the diffuser 400 passes through the diffusion liner 400A arranged on the diffuser 400, so that the inert gas is further diffused by the diffusion liner before being introduced into the molten copper-based alloy 110. According to various embodiments, the diffusion liner 400A, 400B includes a porous high-temperature refractory ceramic material. The ceramic material includes aluminum silicate, which has a porous structure suitable for bubbling the inert gas through the molten copper-based alloy. It can be understood that although the above is Figure 1A , Figure 1BThe depicted refractory linings 130A, 130B may have similar structures and / or may be formed using similar methods as the diffusion liners 400A, 400B, as described herein, but the diffusion liners 400A, 400B provide the important function of further diffusing the inert gas prior to being introduced into the molten metal 110 to form inert bubbles in the molten metal.

[0108] Fig. 6A A melting furnace 600A is shown including a diffusion liner 400A that substantially covers the bottom interior surface of the melting furnace 600A and has a porous structure suitable for bubbling an inert gas into the molten copper-based alloy 110 . Figure 6B A melting furnace 600B is shown including diffusion liners 400A, 400B formed on at least two different inner surfaces of the melting furnace 600B, for example, on a bottom wall surface and a side wall surface of the melting furnace 608B.

[0109] The melting furnace 608A includes the Figure 1 , Figure 1A , Figure 1B and Figure 2 The melting furnace 108 (FIG. 108A, FIG. 108B) described above has various features. The melting furnace 608A can be configured to be similar to the melting furnace 108A ( Figure 1A ) or a similar closed melting furnace or an open melting furnace 108B ( Figure 1B ). As disclosed herein, references to the melting furnace 108 will be understood to apply to either or both of the melting furnaces 108A, 108B unless otherwise indicated. Figure 1A and Figure 1B As depicted, the melting furnaces 608A, 608B receive the inert gas supply 102 via the diffuser 400. The melting furnaces 608A, 608B are enclosed by a chamber wall 134 comprising a suitable refractory material. The chamber wall 134 may be formed of a relatively airtight refractory material so that ambient air does not contaminate the molten copper-based alloy 110. The melting furnaces 608A, 608B are surrounded by a coil 138 to inductively heat the feed material, as described above.

[0110] exist Fig. 6AIn the melting chamber 608A shown in FIG. 1 , the diffuser assembly according to the embodiment includes a diffuser 400 and a diffusion liner 400A. Advantageously, the diffusion liner 400A encapsulates the diffuser 400, thereby covering a larger area relative to the diffuser 400. As configured, the upper surface of the diffuser 400 is arranged below the upper surface of the diffusion liner 400A. The inert gas diffused from the diffuser 400 passes through and further diffuses on the thickness portion of the diffusion liner 400A formed on the diffuser 400. Therefore, compared with a diffuser having only the diffuser 400, such as described above, Figure 1A and Figure 1B As described, the diffusion liner 400A significantly increases the cross-sectional area of ​​the molten copper-based alloy 110 through which the inert gas bubbles 612 pass in the vertical direction. The inventors have discovered that when the inert gas enters the molten copper-based alloy 110 directly from the diffuser 400, due to the limited thickness and surface area of ​​the diffuser 400, the inert gas bubbles may not enter the molten copper-based alloy 110 uniformly across the cross-section of the molten copper-based alloy 110, but rather pass through an effective area that is much smaller than the effective area of ​​the cross-sectional area of ​​the molten copper-based alloy 110. In another aspect, through the two-stage diffuser assembly shown, the inert gas is first diffused through the diffuser 400, and further diffused through the diffusion liner 400A. Since the inert gas leaving the diffuser 400 has already flowed out through the increased cross-sectional area relative to the cross-sectional area of ​​the gas line, it is facilitated to further diffuse the inert gas through the diffusion liner 400A, and the inert gas leaving the diffusion liner 400A can flow approximately uniformly through approximately the entire cross-sectional area of ​​the molten copper-based alloy 110. Therefore, as Fig. 6A As shown in , the inert bubbles 612 cover a significantly larger cross-sectional area relative to the cross-sectional area covered by the diffuser alone. The inventors have discovered that for a given inert gas flow rate, the impurity removal efficiency can be significantly improved by using a two-stage diffuser assembly.

[0111] exist Figure 6B In the melting chamber 608B shown in FIG. , the melting chamber 608A ( Fig. 6A), the diffuser assembly according to the embodiment includes a diffuser 400 and a diffusion liner 400A. Advantageously, in addition to the diffusion liner 400A covering the bottom surface of the melting chamber 608B, the melting chamber 608 also includes a diffusion liner 400B covering the side wall of the melting chamber 608B. The diffusion liners 400A and 400B covering the bottom inner surface and the side wall inner surface are suitable for further increasing the cross-sectional area of ​​the molten copper-based alloy 110 for the inert bubbles 612 to pass through. In addition to the diffusion liner 400A, which covers a larger area of ​​the molten copper-based alloy 110 for the inert bubbles to pass through in the vertical direction relative to having only the diffuser 400, the diffusion liner 400B also allows the inert bubbles 612 to enter the molten copper-based alloy 110 in the lateral direction or horizontal direction at the surface of the molten copper-based alloy 110. With the three-stage diffuser assembly shown, the inert gas is first diffused through diffuser 400 and further diffused through diffuser liner 400A, as described above. Fig. 6A In addition, the portion of the inert gas that leaves the diffusion liner 400A that does not form bubbles through the molten copper-based alloy 110 enters the diffusion liner 400B. The inert gas that enters the diffusion liner 400B further diffuses in the diffusion liner 400B before entering the molten copper-based alloy 110 in the lateral direction at the side. Figure 6B As shown in , the inert bubbles 612 cover a significantly larger cross-sectional area relative to diffuser 400 alone, diffuser liner 400A alone, or a combination of diffuser 400 and diffuser liner 400. The inventors have discovered that for a given inert gas flow rate, the impurity removal efficiency can be significantly improved by using a three-stage diffuser assembly.

[0112] It can be appreciated that, in addition to increasing the surface area of ​​the molten copper-based alloy 110 for the introduction of inert gas to improve the removal of impurities already present in the feed material, the diffusion liners 400A, 400B allow for the removal of excess moisture or oxygen that may be absorbed on the chamber walls of the melting furnace 608A, 608B prior to melting the feed material. Since a large amount of the surface area of ​​the melting furnace 608A, 608B is covered with the diffusion liners 400A, 400B, flowing the inert gas through the diffuser 400, diffusion liners 400A, 400B prior to melting the feed material can substantially prevent oxygen and / or moisture from the chamber walls from entering the molten copper-based alloy 110. In the absence of the diffusion liners 400A, 400B, oxygen and / or moisture absorbed on the interior surfaces of the melting furnace 608A, 608B can be released and introduced into the molten copper-based alloy 110, which can have a detrimental effect on the resulting copper-based alloy, including ingots and pellets, as described above.

[0113] The various parameters related to the operation of the melting furnaces 608A, 608B are generally similar to those described above. Figure 1 , Figure 1A , Figure 1B and Figure 2 Parameters described, and details of the same features are not repeated herein for the sake of brevity.

[0114] Figure 6C 4 is a cross-sectional view of a diffusion liner 400A, 400B according to various embodiments. The diffusion liner 400A, 400B according to various embodiments includes a refractory material including alumina, silicon dioxide, and aluminum silicate. The composition prevents the molten copper-based alloy 110 from being contaminated at high temperatures. In addition to a chemical composition suitable for high temperature melting of the copper-based alloy, the diffusion liner 400A, 400B also has a physical structure suitable for mechanical strength and has an optimized porosity for controlling the inert bubble characteristics in a manner similar to that described above for the diffuser 400.

[0115] The inventors have found that diffusion liners 400A, 400B having at least two different layers or regions can be used to meet various chemical and physical characteristics suitable for effective spraying as described herein. The diffusion liner 400A includes an upper layer or region 400A-2 and a lower layer or region 400A-1, while the diffusion liner 400B includes an upper layer or region 400B-2 and a lower layer or region 400B-1. The upper layers 400A-2, 400B2 are configured to be closer to the molten copper-based alloy 110, for example, in contact with the molten copper-based alloy 110, and the upper layers 400A-2, 400B2 are configured to be placed between the lower layers 400A-1, 400B-1 and the molten copper-based alloy 110.

[0116] According to an embodiment, the upper layer 400A-2, 400B-2 is formed of a sintered ceramic layer, while the lower layer 400A-1, 400B-1 is formed of an unsintered ceramic layer. In particular, the upper layer 400A-2, 400B-2 can be a partially or partially sintered layer, wherein adjacent ceramic particles are partially melted while leaving gaps between adjacent ceramic particles, thereby maintaining a porous surface for allowing the inert gas to diffuse through the porous surface. In contrast, the lower layer 400A-1, 400B-1 can be an unsintered ceramic layer, such as a compacted ceramic powder layer, wherein adjacent ceramic particles are in contact with each other but are not melted by sintering, thereby also having gaps between adjacent ceramic particles for allowing the inert gas to diffuse through the gaps. This double-layer structure provides mechanical stability for the diffusion liner 400A, 400B, while providing a high porosity that facilitates the diffusion of the inert gas into the molten copper-based alloy 110.

[0117] However, the embodiments are not limited thereto, and in some embodiments, the upper layers 400A-2, 400B-2 and the lower layers 400A-1, 400B-1 are formed from the same initial compacted ceramic powder layer. As further described below, the surface portion of the compacted ceramic powder layer may be partially sintered to form a double-layer structure. In these embodiments, the sintered upper layers 400A-2, 400B-2 and the unsintered lower layers 400A-1, 400B-1 have substantially the same chemical composition, but have different phases. That is, the initial compacted ceramic powder layer may include a ceramic composition component that forms a new phase of the upper layers 400A-1, 400B-2 upon sintering. The inventors have discovered that a particularly suitable ceramic powder composition is a mixture of alumina and silica that is configured to form mullite upon sintering.

[0118] Mullite (3A12O3·2SiO2) is particularly suitable as the upper layer 400A-1, 400B-1 due to its low density, high thermal stability, high chemical stability in harsh environments, low thermal conductivity, and good strength and creep behavior. Mullite is the only thermodynamically stable crystalline compound in the phase diagram of the alumina-silicon dioxide (Al2O3-SiO2) system. The compound melts inconsistently at a temperature of 1828±10°C. Therefore, according to an embodiment, the initial compacted powder layer includes a mixture of ingredients that can form a large mullite volume fraction.

[0119] As further described below, the double-layer structure is formed by subjecting the surface of the compacted ceramic powder layer to a sintering temperature sufficient to form mullite from the powder composition locally. The resulting double-layer structure includes an upper sintered layer 400A-2, 400B-2 containing mullite and a lower unsintered layer 400A-1, 400B-1 mainly formed of aluminum oxide and silicon dioxide. According to some embodiments, a powder composition is used to form a double-layer structure, the powder composition comprising the following amount of aluminum oxide: 50mol% to 80mol%, 55mol% to 75mol%, 60mol% to 70mol%, or a molar percentage within a range defined by any of these values, such as about 65mol%. The powder composition also contains the following amount of silicon dioxide: 10mol% to 35mol%, 15mol% to 30mol%, 20mol% to 25mol%, or a molar percentage within a range defined by any of these values, such as about 24mol%. The powder composition may also include: SiC, the amount of SiC is 2 mol% to 8 mol%, 4 mol% to 6 mol% or about 5 mol%; TiO2, the amount of TiO2 is 1 mol% to 3 mol%, 1.5 mol% to 2.5 mol% or about 2.2 mol%; and Fe2O3, the amount of Fe2O3 is 0.5 mol% to 2 mol%, 1 mol% to 1.5 mol% or about 1.2 mol%. It is understood that substantial deviations from the mullite-forming composition may result in insufficient mechanical, thermal or chemical stability. For example, the Al2O3-SiO2 system has a eutectic composition with a melting point of 1587±10°C, corresponding to an Al2O3 composition of about 6 mol%, which may result in reduced performance with respect to the various properties mentioned above.

[0120] The inventors have discovered that a suitable average particle size of the starting powders used to form the diffusion liners 400A, 400B can be defined using a scale known in the industry as phi (φ), which is based on the relationship D = D0 (2 -φ ), where D0 is a reference diameter of 1 mm. For example, φ scales of 2 to 1, 3 to 2, 4 to 3, and 8 to 4 correspond to 0.25 mm to 0.5 mm, 125 μm to 250 μm, 62.5 μm to 125 μm, and 3.9 μm to 62.5 μm, respectively. The inventors have determined that suitable average particle sizes for mullite-forming powders are less than 125 μm, 100 μm, 75 μm, 50 μm, for example, less than 63 μm corresponding to a φ number of 4.

[0121] According to various embodiments, the diffusion liner 400A, 400B has a suitable thickness so that the inert gas diffuses out of the diffusion liner 400A, 400B through a large area portion of the diffusion liner 400A, 400B. The diffusion liner 400A, 400B according to various embodiments has a thickness greater than 2 inches, 3 inches, 4 inches, 5 inches, 6 inches, 7 inches, or a thickness within a range defined by any of these values. Fig. 6A and Figure 6B In , this thickness corresponds to the thickness of the diffusion liner 400A above the surface of the diffuser 400, while in Figure 6B , the thickness corresponds to the thickness of the diffusion liner 600B. For example, the diffusion material or medium of the diffuser 400 may be about 2 inches, while the thickness of the diffusion liner 400A above the diffuser 400 may be about 3 inches to 4 inches, for a combined thickness of 5 inches to 6 inches. Similarly, the thickness of the diffusion liner 400B may be about 3 inches to 4 inches. It will be appreciated that if the thickness of the diffusion liners 400A, 400B is too thin, insufficient diffusion of the inert gas may occur, resulting in the formation of localized bubbles rather than bubbles forming over a majority of the cross-sectional area of ​​the molten copper-based metal 110.

[0122] Still refer to Figure 6C According to various embodiments, the thickness of the sintered top layer 400A-2, 400B-2 is less than 1 inch, 0.8 inch, 0.6 inch, 0.4 inch, 0.2 inch, 0.1 inch, or a value within a range bounded by any of these values. The remainder of the diffusion liner 400A, 400B may be the unsintered bottom layer 400A-1, 400B-1.

[0123] Furthermore, the diffusion liners 400A, 400B have a porosity, defined as the ratio of void space to total macroscopic volume, that is greater than 10%, 15%, 20%, 25%, 30%, 35%, or a value within a range bounded by any of these values.

[0124] According to some embodiments, the diffusion liners 400A, 400B have the same structure and / or composition as the diffuser 400. That is, the diffuser 400 may have the same mullite forming composition, and the diffuser 400 may have a double-layer structure including a sintered ceramic layer and an unsintered ceramic layer. Advantageously, matching the composition and / or structure of the refractory material between the diffuser 400 and the diffusion liners 400A, 400B may allow for an optimized flow of the inert gas through the diffuser 400, further through the refractory liners 400A and 400B, and into the molten copper-based metal 110. However, embodiments are not limited thereto, and in other embodiments, the diffusion liners 400A, 400B may have a composition and structure different from that of the diffuser 400.

[0125] Return to reference Fig. 6A and Figure 6B Although in the illustrated embodiment, the diffusion liners 400A and 400B substantially cover the entire bottom surface and sidewall surface of the melting furnaces 6008A and 608B, respectively, the embodiment is not limited thereto. For example, the diffusion liner 400A may have a diameter that is larger than the diameter of the diffuser 400 but smaller than the inner diameter D ( Figure 1A ). For example, the diameter of the diffusion liner 400A can be less than 0.8D, 0.6D, 0.4D, or a value within a range defined by any of these values. Similarly, the diffusion liner 400B can have a fill line height F ( Figure 1A ) is smaller than the height of the diffusion liner 400B. For example, the height of the diffusion liner 400B may be less than 0.8F, 0.6F, 0.4F, or a value within a range defined by any of these values.

[0126] In the following, a method for manufacturing a melting furnace comprising a diffusion lining is described. Fig. 7A A method of forming a diffusion liner in a melting furnace for producing a high purity copper-based alloy according to various embodiments is shown. The method 700 includes providing 704 a melting furnace chamber configured for forming a molten alloy. The method also includes forming 708 a diffusion liner on an inner surface of the melting furnace chamber, wherein the diffusion liner includes a ceramic material having a porous structure suitable for bubbling an inert gas through the molten copper-based alloy.

[0127] According to various embodiments, providing 704 the molten alloy includes providing a copper-based alloy comprising at least 50% copper by weight. According to various embodiments, forming 708 a diffusion liner includes providing a diffusion liner comprising a ceramic material, such as an aluminum silicate ceramic material, having a porous structure suitable for bubbling inert gases through the molten copper-based alloy. According to various embodiments, forming 708 the diffusion liner includes: substantially covering the bottom inner surface of the melting furnace and having a porous structure suitable for bubbling inert gases into the molten copper-based alloy. According to various embodiments, providing 708 the diffusion liner includes: forming a diffusion liner having a porous structure on at least two different inner surfaces of the melting furnace, such that the diffusion liner is suitable for bubbling inert gases into the molten copper-based alloy from at least two different inner surfaces.

[0128] According to various embodiments, forming 708 a diffusion liner includes arranging a compacted powder layer on an inner surface of a melting furnace chamber. The compacted ceramic powder layer includes a mixture of silicon dioxide and aluminum oxide. Forming 708 a diffusion liner also includes sintering the compacted ceramic powder layer in the melting furnace to form a diffusion liner on the inner surface. According to an embodiment, sintering includes selectively sintering a surface portion of the compacted ceramic powder layer, thereby forming a diffusion liner on the inner surface comprising a double-layer structure, the double-layer structure comprising a sintered ceramic layer located on an unsintered ceramic layer. According to an embodiment, sintering the compacted ceramic powder layer includes sintering on-site using electricity from the melting furnace itself. In particular, sintering the compacted ceramic powder layer includes forming a diffusion liner on the inner surface using heat from a heated material arranged in the melting furnace chamber. The diffusion liner so formed includes an aluminum silicate ceramic material having a porous structure suitable for allowing an inert gas to diffuse through the aluminum silicate ceramic material. In this article FIG. 7B to FIG. 7F The method 700 is further described.

[0129] FIG. 7B to FIG. 7F is based on Fig. 7A 7 is a schematic side view of a melting furnace at various stages of forming a diffusion liner in a melting furnace for producing a high purity copper-based alloy.

[0130] Reference Figure 7B , providing 704 melting chamber including providing the above Figure 1A and Figure 1B The melting furnace 700B is similar to the melting chambers 108A, 108B described above. The melting furnace 700B includes a frame including a chamber wall 134 formed of a relatively gas-tight suitable refractory material. The diffuser 400 is mounted on a central area of ​​the bottom inner surface of the melting furnace 700B. The inert gas is introduced into the molten copper-based alloy 110 via a gas inlet 404 formed through the bottom plate of the melting furnace 700B, as described above. Figure 4C shown.

[0131] After the diffuser 400 is installed, a diffusion lining 400A ( FIG. 6A to FIG. 6C ) of the compacted ceramic powder layer 704. To form the compacted ceramic powder layer 704A, the FIG. 6A to FIG. 6C Ceramic powder of the composition and particle size described above is poured onto the bottom surface of the melting furnace 700B and onto the diffuser 400. The ceramic powder is tapped to remove air cavities and densify the ceramic powder into a compacted ceramic powder layer 704A having the above-described FIG. 6A to FIG. 6C Describes the thickness.

[0132] Reference Figure 7C and Fig.7D , in the melting furnace 700B( Figure 7B ) is formed at the base or bottom surface of the melting furnace 700C, and then a diffusion liner 400B ( FIG. 6B to FIG. 6C ) of another compacted ceramic powder layer 704B. Figure 7C , the heating tank 708 is arranged on the compacted ceramic powder layer 704A. The heating tank 708 is formed of a metal, which can be formed into a molten metal liquid by induction heating the metal using an induction coil 138 on site. The heating tank 708 is configured to be heated to a temperature sufficient to melt the heating tank 708 together with the feed material arranged in the heating tank 708, so as to provide heat for partially or locally sintering the compacted ceramic powder layers 704A, 704B in contact with the heating tank 708. According to an embodiment, without limitation, the heating tank 708 can be formed of an iron-based alloy, such as low carbon steel. The heating tank 708 has a size such that the width of the gap 712 formed between the outer surface of the heating tank 708 and the inner side wall of the melting furnace 700C corresponds to the final thickness of the diffusion liner 400B.

[0133] Reference Fig.7D To form a compacted ceramic powder layer 704B, the Figures 6A to 6C Ceramic powders of the described composition and particle size were poured into a melting furnace at 700°C ( Figure 7C ) and the outer surface of the heating tank 708. The ceramic powder is struck to remove the air cavities and densify the ceramic powder into a compacted ceramic powder layer 704B having a thickness defined by the width of the gap 712 and a height corresponding to the fill line (F) or a portion of the fill line (F), as described above. FIG. 6A to FIG. 6C It is understood that if only the diffusion liner 403A is formed, for example Figure 6BAs shown in , the formation of the ceramic powder layer 704B can be omitted.

[0134] Reference Fig. 7E and Figure 7F The compacted ceramic powder layers 704A and 704B formed on the bottom surface and the side wall surface of the melting furnace 700E are ready to be partially or partially sintered to form the above-mentioned Figure 6C The double-layer structure described. The ceramic powder layers 704A, 704B are partially or locally sintered at the surface areas using the induction coil 138 in situ. In particular, the local sintering is performed indirectly using the induction coil 138, and the local sintering is performed using heat from the molten liquid formed by melting the tank 708 and the heated feed disposed in the tank 708, as described herein. Fig. 7E , the tank 708 is filled with a heating feedstock 712. Similar to the heating tank 708, the heating feedstock 712 is formed of a metal, such as an iron-based feedstock, which can form a heated molten metal mixture and can be heated in the melting furnace 700E using the induction coil 138 on site to a temperature sufficient to partially or locally sinter the compacted ceramic powder layers 704A, 704B in contact with the metal. According to an embodiment, without limitation, the heating feedstock 712 can be formed of an iron-based material, such as low carbon steel or cast iron. The heating feedstock 712 and the heating tank 708 can be formed of the same material or different materials. In any case, both the heating feedstock 712 and the heating tank 708 are suitable for melting and forming a heated molten metal mixture, which can be heated to a temperature sufficient to sinter at least the surface area of ​​the compacted ceramic powder layers 704A, 704B.

[0135] Reference Figure 7F After the heating tank 708 is filled with the heating feed material 712, the heating tank 708 and the heating feed material 712 are both inductively heated using the induction coil 138 to a temperature sufficient to form a heated molten metal mixture 716 including molten mild steel and / or cast iron. The heated molten metal mixture 716 is further heated to a temperature sufficient to provide the following heat: the heat is sufficient to partially or locally melt the compacted ceramic powder layers 704A, 704B located on the bottom surface and the side wall surface of the melting furnace 700F, for example, at the surface area of ​​the compacted ceramic powder layers 704A, 704B.

[0136] It is understood that the heating conditions for forming the heated molten metal mixture 716 depend on the sintering temperature of the compacted ceramic powder layers 704A, 704B, so as to sinter at least the surface area of ​​the compacted ceramic powder layers 704A, 704B to form, for example, Figure 6C According to the embodiment, the sintering temperature used may be greater than 0.7T.m , 0.75T m , 0.8T m and 0.85T m And less than 0.9T m , or may be a value within a range defined by any of these values, where T m is the melting temperature of the compacted ceramic powder layers 704A, 704B. For example, for a ceramic powder having a mullite-forming component with a melting temperature of 1828°C, the heated molten metal mixture 716 can be heated to between about 1280°C and 1650°C, for example, to about 1430°C (about 2600°F). After sintering, the final diffusion liner 403A, 403B is formed, which has, for example, the Figure 6C Then, the heated molten metal mixture 712 is poured out, and the melting furnace 608A ( Fig. 6A ) or 608B( Figure 6B ).

[0137] Figure 8 A method for producing a copper-based alloy with a low impurity content using a melting furnace with a diffusion lining according to an embodiment is shown. The method shown may include the above Figure 5 Various features of the method 500 for making a copper-based alloy having a low impurity content are described. For the sake of brevity, the following descriptions of the various features of the method 500 that may be used in the method 500 ( Figure 5 ) and method 800( Figure 8 ) are common characteristics. Figure 5 Similar to method 500, method 800 includes providing 804 a feedstock in a melting furnace. Without limitation, the feedstock may have a composition configured to form a molten copper-based alloy including at least 50% copper by weight. Method 800 also includes heating 808 the feedstock, thereby melting the feedstock to form a molten alloy, such as a copper-based alloy. The method also includes bubbling 818 an inert gas into the molten alloy, such as a copper-based alloy. However, similar to method 500 ( Figure 5 ), method 800 includes using a diffusion liner formed on the inner surface of the melting furnace chamber to bubble the inert gas through the alloy 812. The diffusion liner may have the FIG. 6A to FIG. 6CAny configuration of the described diffusion liners 400A, 400B. For example. The diffusion liners 400A, 400B include an aluminum silicate ceramic material having a porous structure suitable for bubbling an inert gas through a molten copper-based alloy. According to an embodiment, bubbling an inert gas 812 through the molten copper-based alloy may include using a diffusion liner that substantially covers a bottom inner surface of the melting furnace and has a porous structure suitable for bubbling an inert gas into the molten copper-based metal. According to an embodiment, bubbling an inert gas 812 through the molten copper-based alloy may include using a diffusion liner formed on at least two different inner surfaces of the melting furnace, such that the diffusion liner is suitable for bubbling an inert gas into the molten copper-based alloy from at least two different inner surfaces.

[0138] Experimental Example

[0139] To prepare the specimens for obtaining mechanical test results, a copper feedstock, such as that of alloy C87850, was melted in a 4000 lb furnace at 1950°F, and argon was bubbled through the copper-based alloy into the melting furnace at a rate of 4 liters / minute for a period of 90 minutes. A reference ingot was also produced using the same system, but without argon gas being sprayed, such as bubbled, through the molten copper-based alloy in the melting furnace. Both the reference copper ingot and the copper ingot produced using argon were tested using ASTM E8 / E8M-21 (the American Society for Testing Materials Standard Test Methods for Tension Testing of Metallic Materials E8 / E8M-21). The results of these tests can be seen in Table 1.

[0140] Table 1

[0141]

[0142]

[0143] As shown, for the specific C87850 alloy, the measured mechanical properties are significantly superior. For example, the ultimate tensile strength is improved by 47%. Similar results were repeatedly obtained for various copper-based alloys. Similar comparisons were made for four representative copper-based alloys including C87850, C89833, C99500 and C96400. The nominal compositions of the four alloys are shown in Table 2.

[0144] Table 2

[0145]

[0146] For each alloy system shown in Table 2, copper ingots were produced by spraying with argon and without argon, and the copper ingots were tested using ASTM E8 / E8M-21 (the American Society for Testing Materials Standard Test Methods for Tension Testing of Metallic Materials E8 / E8M-21, the American Society for Testing Materials Standard Test Methods for Tension Testing of Metallic Materials E8 / E8M-21). The results of these tests can be found in Table 3.

[0147] Table 3

[0148]

[0149]

[0150] The measured mechanical properties of the sprayed ingots are significantly superior. For example, the ultimate tensile strength is improved by 46%, 189%, 6% and 82% for alloys with alloy compositions of C87850, C89833, C99500 and C96400.

[0151] As disclosed herein, copper-based alloy compositions including feedstock compositions according to various embodiments may include, by weight percentage: copper in an amount greater than 50%, 60%, 70%, 80%, 90%, 95%, or a value within a range defined by any of these values; tin in an amount greater than 0.1%, 0.2%, 0.5%, 1%, 2%, 5%, 10%, or a value within a range defined by any of these values; lead in an amount greater than 0.01%, 0.02%, 0.05%, 0.1%, 0.2%, 0.5%, or a value within a range defined by any of these values; zinc in an amount greater than 0.1%, 0.2%, 0.5%, 1%, 2%, 5%, 10%, or a value within a range defined by any of these values; .2%, 0.5%, 1%, 2%, 5%, 10%, 20%, 30%, or a value within a range defined by any of these values; iron, the amount of iron is greater than 0.1%, 0.2%, 0.5%, 1%, 2%, 5%, 10%, or a value within a range defined by any of these values; antimony, the amount of antimony is greater than 0.01%, 0.02%, 0.05%, 0.1%, 0.2%, 0.5%, or a value within a range defined by any of these values; nickel, the amount of nickel is greater than 0.1%, 0.2%, 0.5%, 1%, 2%, 5%, 10%, 20%, 30%, 40%, or a value within a range defined by any of these values %, 0.1%, 0.2%, 0.5%, or a value within a range defined by any of these values; sulfur, the amount of sulfur is greater than 0.01%, 0.02%, 0.05%, 0.1%, 0.2%, 0.5%, or a value within a range defined by any of these values; phosphorus, the amount of phosphorus is greater than 0.01%, 0.02%, 0.05%, 0.1%, or a value within a range defined by any of these values; aluminum, the amount of aluminum is greater than 0.01%, 0.02%, 0.05%, 0.1%, 0.2%, 0.5%, 1%, 2%, 5%, or a value within a range defined by any of these values; silicon, the amount of silicon is greater than 0.01%, 0.02%, 0.05%, 0.1%, 0.2%, 0.5%, 1% , 2%, 5%, or a value within a range defined by any of these values; manganese, manganese in an amount greater than 0.01%, 0.02%, 0.05%, 0.1%, 0.2%, 0.5%, 1%, 2%, or a value within a range defined by any of these values; bismuth, bismuth in an amount greater than 0.01%, 0.02%, 0.05%, 0.1%, 0.2%, 0.5%, 1%, 2%, 5%, or a value within a range defined by any of these values; niobium, niobium in an amount greater than 0.01%, 0.02%, 0.05%, 0.1%, 0.2%, 0.5%, 1%, 2%, or a value within a range defined by any of these values. Additionally, the copper-based alloy composition may include any one or more of the elements disclosed in Table 2 within a range defined by any of the corresponding amounts, including elements corresponding to the C87850, C89833, C99500, and C96400 alloy compositions.

[0152] In the following, various additional examples are disclosed. It is understood that any one of the additional examples may be combined with any other one or more of the additional examples, unless doing so is contrary to the present disclosure.

[0153] Additional Example I:

[0154] 1. A device for manufacturing a copper-based alloy, the device comprising:

[0155] A closed melting furnace configured to: form a molten copper-based alloy comprising at least 50% by weight copper in a closed inert environment; and bubble an inert gas through the molten copper-based alloy; and

[0156] A transfer ladle is configured to: receive molten copper-based alloy from a melting furnace in a closed inert environment; and transfer the molten copper-based alloy to a shot-shaped depression or one or more molds configured to solidify the molten copper-based alloy.

[0157] 2. A device for manufacturing a copper-based alloy, the device comprising:

[0158] A closed melting furnace configured to: form a molten copper-based alloy comprising at least 50% by weight copper in a closed inert environment; and bubble an inert gas through the molten copper-based alloy; and

[0159] A transfer ladle is configured to: receive molten copper-based alloy from a melting furnace through a speed control element; and transfer the molten copper-based alloy to a shot-shaped depression or one or more molds configured to solidify the molten copper-based alloy.

[0160] 3. The apparatus of embodiment 1, wherein the transfer ladle is configured to receive the molten copper-based alloy from the melting furnace via a speed control element.

[0161] 4. The apparatus of embodiment 2, wherein the transfer ladle is configured to receive the molten copper-based alloy from the melting furnace in a closed inert environment.

[0162] 5. The apparatus of any of the above embodiments, wherein the transfer ladle is configured to transfer the molten copper-based alloy into the shot-shaped recess, the shot-shaped recess being configured to solidify the molten copper-based alloy into copper-based shots.

[0163] 6. The apparatus of any of the preceding embodiments, wherein the one or more molds are ingot molds configured to solidify a molten copper-based alloy into a copper-based ingot.

[0164] 7. The apparatus of any of the preceding embodiments, wherein the closed melting furnace and transfer ladle are configured to substantially exclude outside air from mixing with the closed inert environment.

[0165] 8. The apparatus according to any of the preceding embodiments, wherein the melting furnace and the transfer ladle are integrally connected to be sealed from the external environment while being in a common closed inert environment.

[0166] 9. The apparatus according to any of the preceding embodiments, wherein the inert gas and the closed inert environment comprise argon.

[0167] 10. The apparatus according to any of the preceding embodiments, wherein the inert gas is hydrogen-free.

[0168] 11. The apparatus of any one of embodiments 1, 3, and 5 to 10 above, further comprising a speed control element configured to transfer the molten copper-based alloy from the closed melting furnace to the enclosed transfer ladle at a controlled speed, the transfer speed being suitable for reducing speed-induced entrainment in the copper-based alloy relative to a reference copper-based alloy formed by a reference apparatus, the reference apparatus being configured identically to the apparatus but without the speed control element.

[0169] 12. The apparatus of embodiment 11, wherein the speed control element comprises a ramp.

[0170] 13. The apparatus of embodiments 11 or 12, wherein the controlled velocity is less than 100 inches per second.

[0171] 14. The apparatus of any of the above embodiments, further comprising a second speed control element configured to transfer the molten copper-based alloy from the enclosed transfer ladle to the shot depression or one or more molds at a second controlled speed suitable for reducing speed-induced entrainment in the molten copper-based alloy relative to a reference molten copper-based alloy formed by a reference apparatus configured identically to the apparatus but without the speed control element.

[0172] 15. The apparatus of embodiment 14, wherein the second speed control element comprises a ramp.

[0173] 16. The apparatus of embodiment 14 or 15, wherein the second controlled speed is less than 30 inches per second.

[0174] 17. Apparatus according to any of the preceding embodiments, wherein the enclosed transfer ladle is thermally insulated.

[0175] 18. The apparatus according to any one of the above embodiments, further comprising a diffuser, which is arranged at the bottom of the melting furnace and has a plurality of through holes, wherein the plurality of through holes are suitable for bubbling an inert gas into the molten copper-based alloy in the form of inert bubbles having a size distribution suitable for reducing the oxygen content of the molten copper-based alloy.

[0176] 19. The apparatus of embodiment 18, wherein the diffuser is configured to allow the inert gas to flow through the diffuser at a flow rate of 2 to 6 liters per minute.

[0177] 20. The apparatus of embodiments 18 to 19, wherein the diffuser has a porosity greater than 20%.

[0178] 21. The apparatus according to embodiments 18 to 19, wherein the diameter of the diffuser is greater than 5 cm and smaller than the inner diameter of the melting furnace.

[0179] 22. The apparatus according to embodiments 18 to 19, wherein the melting furnace has an inner diameter exceeding 50 cm.

[0180] 23. An apparatus according to any of the above embodiments, wherein the apparatus is configured so that: the molten copper-based alloy has an oxygen content that is reduced by at least 10% relative to a reference molten copper-based alloy formed by a reference apparatus, and the reference apparatus is configured identically to the apparatus except that the melting furnace and the transfer ladle are in the same closed inert environment.

[0181] 24. An apparatus according to any of the above embodiments, wherein the apparatus is configured so that: the molten copper-based alloy has an oxygen content that is reduced by at least 10% relative to a reference molten copper-based alloy formed by a reference apparatus, and the reference apparatus is configured identically to the apparatus except that the melting furnace is configured to bubble an inert gas through the molten copper-based alloy.

[0182] 25. The apparatus of any of the preceding embodiments, wherein the apparatus is configured such that: relative to a reference copper-based alloy formed by a reference apparatus configured identically to the apparatus except that the melting furnace and the transfer ladle are in the same closed inert environment, one or more test results obtained from the copper-based alloy using the ASTM E8 / E8M-21 method have:

[0183] Increase the ultimate tensile strength by at least 5 ksi;

[0184] Increase the 0.5% yield strength by at least 3 ksi;

[0185] Increase elongation by at least 5%; and

[0186] Increase cross-sectional area reduction by at least 5%.

[0187] 26. An apparatus according to any of the above embodiments, wherein the apparatus is configured so that: the copper-based alloy has an ultimate tensile strength increased by at least 20 ksi relative to a reference copper-based alloy formed by a reference apparatus, and the reference apparatus is configured identically to the apparatus except that the melting furnace is configured to bubble an inert gas through the molten copper-based alloy.

[0188] 27. The apparatus of embodiment 1, wherein the transfer ladle is configured to transfer the molten copper-based alloy into the shot-shaped recess, the shot-shaped recess being configured to solidify the molten copper-based alloy into copper-based shots.

[0189] 28. The apparatus of embodiment 1, wherein the transfer ladle is configured to transfer the molten copper-based alloy into one or more ingot molds configured to solidify the molten copper-based alloy into a copper-based ingot.

[0190] 29. The apparatus of embodiment 1, wherein the melting furnace is configured to transfer the molten copper-based alloy from a lower half of the volume of the molten copper-based alloy to the transfer ladle before transferring the remainder of the molten copper-based alloy.

[0191] 30. The apparatus according to embodiment 1, wherein the first speed element is connected to a lower half of the melting furnace.

[0192] 31. The apparatus of any of the preceding embodiments, wherein the melting furnace further comprises a diffusion lining comprising an aluminum silicate ceramic having a porous structure suitable for bubbling an inert gas through the molten copper-based alloy.

[0193] 32. The apparatus of any one of embodiments 1 to 30, wherein the melting furnace further comprises a diffusion liner substantially covering a bottom inner surface of the melting furnace and having a porous structure suitable for bubbling an inert gas into the molten copper-based alloy.

[0194] 33. An apparatus according to any one of embodiments 1 to 30, wherein the melting furnace further comprises a diffusion lining comprising a porous structure, wherein the diffusion lining is formed on at least two different inner surfaces of the melting furnace, so that the diffusion lining is suitable for bubbling the inert gas into the molten copper-based alloy from the at least two different inner surfaces.

[0195] 34. The apparatus of embodiment 32 or 33, wherein the diffusion liner comprises an aluminum silicate ceramic.

[0196] 35. The apparatus of embodiment 31 or 33, wherein the diffusion lining substantially covers the bottom inner surface of the melting furnace.

[0197] 36. The apparatus of embodiment 31 or 32, wherein the diffusion lining is formed on at least two different inner surfaces of the melting furnace, such that the diffusion lining is adapted to bubble the inert gas from the at least two different inner surfaces into the molten copper-based alloy.

[0198] 37. An apparatus according to any of the preceding embodiments, further comprising an apparatus according to any of the embodiments in Additional Example III.

[0199] Additional Examples II

[0200] 1. A method for manufacturing a copper-based alloy, the method comprising:

[0201] providing a plurality of feed blocks in a melting furnace, the feed blocks having a combined composition configured to form a molten copper-based alloy comprising at least 50% by weight copper;

[0202] Prior to heating, an inert gas is flowed through the gaps between the feed blocks.

[0203] heating the feedblock while flowing an inert gas through the feedblock to melt the feedblock to form a molten copper-based alloy;

[0204] bubbling an inert gas through a molten copper-based alloy;

[0205] The molten copper-based alloy is transferred to a transfer ladle.

[0206] 2. A method for manufacturing a copper-based alloy, the method comprising:

[0207] providing a plurality of feed blocks in a melting furnace, the feed blocks having a combined composition configured to form a molten copper-based alloy comprising at least 50% by weight copper;

[0208] heating the feed block to form a molten copper-based alloy;

[0209] bubbling an inert gas through the molten copper-based alloy; and

[0210] Transfer the molten copper-based alloy to a transfer ladle,

[0211] Wherein one or more of heating the feedblock, bubbling the inert gas, and transferring the molten copper-based alloy is performed at least in part in a closed inert environment configured to substantially exclude external air from mixing with the closed inert environment.

[0212] 3. A method for manufacturing a copper-based alloy, the method comprising:

[0213] providing a plurality of feed blocks in a melting furnace, the feed blocks having a combined composition configured to form a molten copper-based alloy comprising at least 50% by weight copper;

[0214] heating the feed block to form a molten copper-based alloy;

[0215] bubbling an inert gas through the molten copper-based alloy; and

[0216] Transfer the molten copper-based alloy to a transfer ladle,

[0217] Wherein the transporting includes limiting the velocity of the molten copper-based alloy being transported from the melting furnace to the transport ladle to less than 100 inches per second.

[0218] 4. The method of embodiment 2 or 3, further comprising flowing an inert gas through gaps between feedblocks prior to heating, and wherein heating comprises heating the feedblocks while flowing the inert gas through the feedblocks.

[0219] 5. A method according to embodiment 1 or 3, wherein one or more of heating the feed block, bubbling the inert gas, and conveying the molten copper-based alloy is at least partially performed in a closed inert environment, which is configured to substantially exclude external air from mixing with the closed inert environment.

[0220] 6. The method of embodiment 1 or 2, wherein transporting includes limiting the velocity of the molten copper-based alloy being transported from the melting furnace to the transport ladle to less than 100 inches / second.

[0221] 7. The method according to any of the preceding embodiments, wherein the feedstock block comprises one or both of an alloy block and an elemental metal block.

[0222] 8. The method of any of the preceding embodiments, wherein bubbling the inert gas comprises flowing prior to initiating heating of the feedblock.

[0223] 9. The method of any of the preceding embodiments, wherein flowing the inert gas comprises flowing at a sufficient flow rate such that the feedblock is substantially in a flowing inert gas environment prior to and during heating.

[0224] 10. The method of any of the preceding embodiments, further comprising, prior to delivering, adding additional feed blocks while bubbling an inert gas through the molten copper-based alloy.

[0225] 11. The method according to any of the preceding embodiments, wherein bubbling of the inert gas continues during the transport of the molten copper-based alloy.

[0226] 12. The method of any of the preceding embodiments, wherein bubbling the inert gas comprises bubbling the inert gas at a sufficient rate such that the molten copper-based alloy is substantially in a flowing inert gas environment during bubbling the inert gas.

[0227] 13. The method of any of the preceding embodiments, wherein one or more of heating the feedblock, bubbling the inert gas, and conveying the molten copper-based alloy are performed under a common inert environment.

[0228] 14. The method of embodiment 13, wherein the common inert environment comprises a common closed inert environment shared by the melting furnace and the transfer ladle.

[0229] 15. The method of embodiment 14, wherein the common closed inert environment is closed by keeping the ejector of the transfer ladle closed until just before ejecting the molten copper-based alloy from the transfer ladle into the mold.

[0230] 16. The method of any of the preceding embodiments, wherein flowing and bubbling an inert gas comprises flowing and bubbling an inert gas consisting essentially of argon.

[0231] 17. The method of any of the preceding embodiments, wherein flowing and bubbling the inert gas comprises flowing and bubbling an inert gas that is substantially free of hydrogen.

[0232] 18. A method according to any of the above embodiments, wherein flowing and bubbling the inert gas includes diffusing through a diffuser, which is arranged at the bottom of the melting furnace and has a plurality of holes, wherein the plurality of holes are suitable for bubbling the inert gas into the molten copper-based alloy in the form of inert bubbles.

[0233] 19. The method of any of the preceding embodiments, wherein flowing and bubbling the inert gas comprises flowing through a diffuser having a porosity greater than 20% at a flow rate of 2 to 6 liters per minute.

[0234] 20. The method of any of the preceding embodiments, wherein flowing and bubbling the inert gas comprises flowing at a flow rate of 2 to 6 liters per minute through a diffuser having a diameter greater than 5 cm and less than an inner diameter of the melting furnace.

[0235] 21. The method of embodiment 17, wherein flowing and bubbling the inert gas comprises flowing through a melting furnace having an inner diameter greater than 50 cm.

[0236] 22. The method according to any of the preceding embodiments, wherein heating comprises heating to a temperature that is 100° C. to 400° C. higher than the temperature of the molten copper-based alloy.

[0237] 23. The method of embodiment 22, further comprising cooling the molten copper-based alloy by 100° C. to 400° C. prior to transferring.

[0238] 24. The method according to any of the preceding embodiments, wherein the transferring comprises pouring the molten copper-based alloy in the lower part of the melting furnace.

[0239] 25. The method of any of the preceding embodiments, wherein transferring includes limiting the velocity of the molten copper-based alloy transferred from the melting furnace to the transfer ladle using an inclined ramp.

[0240] 26. The method according to any of the preceding embodiments, wherein after the molten copper-based alloy is transferred to the transfer ladle by limiting its velocity by means of an inclined ramp, the molten copper-based alloy is ejected from the transfer ladle by opening one or more ejection valves.

[0241] 27. The method of embodiment 26, wherein the inclined ramp is in an inert environment.

[0242] 28. The method of embodiment 24, wherein the transporting of the molten copper-based alloy is performed in a common closed inert environment shared by the melting furnace, the transport ladle, and the inclined ramp.

[0243] 29. A method according to any one of the above embodiments, wherein, after the molten copper-based alloy is transferred to a transfer ladle by limiting the velocity of the molten copper-based alloy by means of an inclined ramp, the molten copper-based alloy is injected into a shot-shaped depression or one or more molds by opening one or more injection valves to solidify the molten copper-based alloy.

[0244] 30. A method according to any of the above embodiments, wherein after the molten copper-based alloy is transferred to a transfer ladle by limiting the velocity of the molten copper-based alloy by means of an inclined ramp, the molten copper-based alloy is ejected from the transfer ladle to a second inclined ramp to further limit the velocity of the molten copper-based alloy before the molten copper-based alloy is placed in a shot-shaped depression or one or more molds to solidify the molten copper-based alloy.

[0245] 31. A method according to any of the above embodiments, wherein bubbling the inert gas includes bubbling using a diffusion liner, which is formed on the inner surface of the melting furnace, and the diffusion liner includes an aluminum silicate ceramic material, which includes a porous structure suitable for bubbling the inert gas through the molten copper-based alloy.

[0246] 32. A method according to any one of embodiments 1 to 30, wherein bubbling the inert gas includes bubbling using a diffusion liner, which is formed in the melting furnace chamber, the diffusion liner roughly covering the bottom inner surface of the melting furnace and having a porous structure suitable for bubbling the inert gas through the molten copper-based alloy.

[0247] 33. A method according to any one of embodiments 1 to 30, wherein bubbling the inert gas includes bubbling using a diffusion liner, the diffusion liner having a porous structure, the diffusion liner being formed on at least two different inner surfaces of the melting furnace, so that the diffusion liner is suitable for bubbling the inert gas into the molten copper-based alloy from the at least two different inner surfaces.

[0248] 34. The method of embodiment 32 or 33, wherein the diffusion liner comprises an aluminum silicate ceramic.

[0249] 35. The method of embodiment 31 or 33, wherein the diffusion lining substantially covers the bottom inner surface of the melting furnace.

[0250] 36. The method of embodiment 31 or 32, wherein the diffusion lining is formed on at least two different inner surfaces of the melting furnace, such that the diffusion lining is adapted to bubble the inert gas into the molten copper-based alloy from the at least two different inner surfaces.

[0251] 37. A method according to any of the above embodiments, wherein the method is also according to any of the embodiments in Additional Example VI.

[0252] Additional Example III:

[0253] 1. A device for manufacturing a copper-based alloy, the device comprising:

[0254] a melting furnace configured to form a molten copper-based alloy comprising at least 50% by weight copper; and

[0255] A diffusion liner is formed on an inner surface of a melting furnace and includes an aluminum silicate ceramic having a porous structure suitable for bubbling an inert gas through a molten copper-based alloy.

[0256] 2. A device for manufacturing a copper-based alloy, the device comprising:

[0257] a melting furnace configured to form a molten copper-based alloy comprising at least 50% by weight copper; and

[0258] A diffusion liner substantially covers the bottom inner surface of the melting furnace and has a porous structure suitable for bubbling an inert gas into the molten copper-based alloy.

[0259] 3. A device for manufacturing a copper-based alloy, the device comprising:

[0260] a melting furnace configured to form a molten copper-based alloy comprising at least 50% by weight copper; and

[0261] A diffusion lining in a melting furnace, the diffusion lining having a porous structure,

[0262] Wherein, the diffusion lining is formed on at least two different inner surfaces of the melting furnace, so that the diffusion lining is suitable for bubbling the inert gas into the molten copper-based alloy from the at least two different inner surfaces.

[0263] 4. The apparatus of embodiment 2 or 3, wherein the diffusion liner comprises an aluminum silicate ceramic.

[0264] 5. The apparatus of embodiment 1 or 3, wherein the diffusion lining substantially covers the bottom inner surface of the melting furnace.

[0265] 6. The apparatus according to embodiment 1 or 2, wherein the diffusion lining is formed on at least two different inner surfaces of the melting furnace, such that the diffusion lining is suitable for bubbling the inert gas into the molten copper-based alloy from the at least two different inner surfaces.

[0266] 7. The apparatus according to any of the preceding embodiments, wherein the diffusion liner comprises alumina and silicon dioxide.

[0267] 8. The apparatus of any of the preceding embodiments, wherein the diffusion liner comprises mullite.

[0268] 9. The device according to any of the preceding embodiments, wherein the diffusion liner comprises at least two layers, at least two of the layers comprising a sintered ceramic layer and an unsintered ceramic layer.

[0269] 10. The apparatus of embodiment 9, wherein the sintered ceramic layer comprises mullite.

[0270] 11. The apparatus of embodiment 9, wherein the unsintered ceramic layer comprises alumina and silica.

[0271] 12. The apparatus of embodiment 10, wherein the sintered ceramic layer is configured to be in contact with a molten copper-based alloy.

[0272] 13. The apparatus of embodiment 9, wherein the unsintered ceramic layer comprises a compacted ceramic powder layer comprising alumina and silica.

[0273] 14. The apparatus of embodiment 9, wherein the sintered ceramic layer is formed by partially sintering a compacted ceramic powder layer such that the sintered ceramic layer and the unsintered ceramic layer have substantially the same composition but different phases.

[0274] 15. The apparatus of embodiment 9, wherein the unsintered ceramic layer comprises 60% to 70% alumina and 20% to 25% silica.

[0275] 16. The apparatus of embodiment 9, wherein the unsintered ceramic layer comprises a layer of compacted ceramic powder having an average particle size of less than 63 μm or corresponding to a number 4 on the φ scale.

[0276] 17. The apparatus of any of the preceding embodiments, wherein the diffusion liner has a thickness of 3 inches to 6 inches.

[0277] 18. Apparatus according to any of the preceding embodiments, wherein the diffusion lining covers the entire bottom inner surface of the melting furnace.

[0278] 19. The apparatus of any of the preceding embodiments, wherein the diffusion lining on the bottom inner surface of the melting furnace has a thickness of 4 inches to 6 inches.

[0279] 20. The apparatus according to any of the preceding embodiments, wherein the diffusion lining covers at least the inner sidewall surface of the molten green.

[0280] 21. The apparatus of any of the preceding embodiments, wherein the diffusion lining on the inner side wall of the melting furnace has a thickness of 3 inches to 4 inches.

[0281] 22. The apparatus of any of the preceding embodiments, wherein the diffusion liner is configured to be in contact with a molten copper-based alloy.

[0282] 23. Apparatus according to any of the preceding embodiments, wherein the inert gas consists essentially of argon.

[0283] 24. Apparatus according to any of the preceding embodiments, wherein the inert gas is hydrogen-free.

[0284] 25. According to the device described in any of the embodiments above, the device also includes a diffuser, which is centrally arranged in the diffusion lining at the bottom inner surface of the melting furnace, the diffuser includes diffuser material, which is arranged in a container connected to an inert gas source, and the diffuser has an upper surface arranged below the upper surface of the diffusion lining covering the bottom inner surface.

[0285] 26. The apparatus of embodiment 25, wherein the diffuser overlaps a portion of a diffusion lining on a bottom inner surface of the melting furnace.

[0286] 27. An apparatus according to embodiment 26, wherein the diffuser is in contact with the diffusion liner and comprises the same material as the diffusion liner.

[0287] 28. The apparatus of any one of embodiments 25 to 27, wherein one or both of the diffuser and the diffuser liner have a porosity greater than 20%.

[0288] 29. The apparatus according to any one of embodiments 25 to 28, wherein the diffuser has a lateral dimension that is less than 50% of a lateral dimension of a diffusion lining covering the bottom inner surface of the melting furnace.

[0289] 30. The apparatus according to any one of embodiments 25 to 29, wherein the diffuser has a diameter greater than 5 cm and smaller than the diameter of a diffusion lining covering the bottom inner surface of the melting furnace.

[0290] 31. The apparatus according to any one of embodiments 25 to 30, wherein the diffusion lining covering the bottom inner surface of the melting furnace has a diameter exceeding 50 cm.

[0291] 32. The apparatus of any one of embodiments 25 to 31, wherein the melting furnace is configured to melt the copper-based alloy in a closed chamber configuration in which the environment above the molten copper-based alloy is isolated from the external environment.

[0292] 33. The apparatus of any one of embodiments 25 to 31, wherein the melting furnace is configured to melt the copper-based alloy in an open chamber configuration in which the environment above the molten copper-based alloy is exposed to the external environment.

[0293] 34. The apparatus of embodiment 32, wherein, in the closed chamber configuration, the apparatus is configured to diffusely flow the inert gas at a flow rate of 2 to 6 L / min.

[0294] 35. The apparatus of embodiment 33, wherein in the open chamber configuration, the apparatus is configured to flow the inert gas in a diffuse manner at a flow rate of 4 to 13 L / min.

[0295] 36. The apparatus according to any of the preceding embodiments, wherein the melting furnace is an induction furnace comprising an induction coil surrounding the induction furnace and configured to melt the copper-based alloy.

[0296] 37. The apparatus of embodiment 36, wherein the induction furnace is configured to operate at a frequency of less than 1000 Hz.

[0297] 38. The apparatus of embodiments 36 and 37, wherein the uppermost winding of the induction coil is arranged at a vertical position below the fill line of the molten copper-based alloy.

[0298] 39. The apparatus according to any of the preceding embodiments, further comprising an inert gas source connected to the diffusion liner to supply the inert gas to the melting furnace.

[0299] 40. The apparatus according to any one of the preceding embodiments, further comprising a diffuser which is smaller than and embedded in the diffusion lining covering the bottom inner surface of the melting furnace.

[0300] 41. An apparatus according to embodiment 40, wherein the diffuser and the diffuser liner comprise the same diffuser material.

[0301] 42. An apparatus according to embodiment 40, wherein the diffuser includes a diffuser material arranged in a container connected to an inert gas source and including an upper surface arranged below an upper surface of a diffusion lining covering the bottom inner surface of the melting furnace.

[0302] 43. An apparatus according to any of the above embodiments, wherein the apparatus is also according to any of the embodiments in Additional Example I.

[0303] Additional Example IV:

[0304] 1. A method for manufacturing a device for manufacturing a copper-based alloy, the method comprising:

[0305] providing a melting furnace chamber configured to form a molten copper-based alloy comprising at least 50% by weight copper; and

[0306] A diffusion liner is formed on an inner surface of a melting furnace chamber, the diffusion liner comprising an aluminum silicate ceramic material having a porous structure suitable for bubbling an inert gas through a molten copper-based alloy.

[0307] 2. A method for manufacturing a device for manufacturing a copper-based alloy, the method comprising:

[0308] providing a melting furnace chamber configured to form a molten copper-based alloy comprising at least 50% by weight copper; and

[0309] A diffusion liner is formed that substantially covers the bottom inner surface of the melting furnace and has a porous structure suitable for bubbling an inert gas into a molten copper-based alloy.

[0310] 3. A method for manufacturing a device for manufacturing a copper-based alloy, the method comprising:

[0311] providing a melting furnace chamber configured to form a molten copper-based alloy comprising at least 50% by weight copper; and

[0312] A diffusion liner having a porous structure is formed on at least two different inner surfaces of the melting furnace, such that the diffusion liner is suitable for bubbling an inert gas into the molten copper-based alloy from the at least two different inner surfaces.

[0313] 4. The method of embodiment 2 or 3, wherein the diffusion liner comprises an aluminum silicate ceramic.

[0314] 5. The method of embodiment 1 or 3, wherein forming the diffusion lining includes substantially covering a bottom inner surface of the melting furnace.

[0315] 6. The method according to embodiment 1 or 2, wherein forming the diffusion lining includes forming it on at least two different inner surfaces of the melting furnace, so that the diffusion lining is suitable for bubbling the inert gas into the molten copper-based alloy from the at least two different inner surfaces.

[0316] 7. The method according to any of the preceding embodiments, wherein the diffusion liner comprises aluminum oxide and silicon dioxide.

[0317] 8. The method of any of the preceding embodiments, wherein the diffusion liner comprises mullite.

[0318] 9. The method according to any of the preceding embodiments, wherein forming the diffusion liner comprises forming at least a sintered ceramic layer and an unsintered ceramic layer.

[0319] 10. The method of embodiment 9, wherein forming the sintered ceramic layer comprises sintering a portion of the compacted ceramic powder layer to form mullite.

[0320] 11. The method of embodiment 9, wherein forming the unsintered ceramic layer comprises forming a compacted ceramic powder layer comprising alumina and silica.

[0321] 12. The method of embodiment 10, wherein forming the sintered ceramic layer comprises being configured to contact a molten copper-based alloy.

[0322] 13. The method of embodiment 9, wherein forming the sintered layer and the unsintered layer comprises forming from the same layer of compacted ceramic powder comprising alumina and silica.

[0323] 14. The method of embodiment 9, wherein forming the sintered ceramic layer comprises sintering the compacted ceramic powder layer such that the sintered layer and the unsintered layer have substantially the same chemical composition but different phases.

[0324] 15. The method of embodiment 9, wherein the unsintered ceramic layer comprises 60% to 70% alumina and 20% to 25% silica.

[0325] 16. The method of embodiment 9, wherein the unsintered ceramic layer comprises a compacted ceramic powder layer having an average particle size of less than 63 μm or corresponding to a number 4 on the φ scale.

[0326] 17. The method of any of the preceding embodiments, wherein the diffusion liner has a thickness of 3 inches to 6 inches.

[0327] 18. The method according to any of the preceding embodiments, wherein forming the diffusion lining comprises covering the entire bottom inner surface of the melting furnace.

[0328] 19. The method of any of the preceding embodiments, wherein the diffusion lining on the bottom inner surface of the melting furnace has a thickness of 4 inches to 6 inches.

[0329] 20. The method according to any of the preceding embodiments, wherein forming the diffusion lining comprises covering at least a side wall of the melting furnace.

[0330] 21. The method of any of the preceding embodiments, wherein the diffusion lining on the sidewalls of the melting furnace has a thickness of 3 inches to 4 inches.

[0331] 22. The method of any of the preceding embodiments, wherein forming the diffusion liner comprises configuring for contact with a molten copper-based alloy.

[0332] 23. The method according to any of the preceding embodiments, wherein the inert gas consists essentially of argon.

[0333] 24. The method according to any of the preceding embodiments, wherein the amorous gas is hydrogen-free.

[0334] 25. The method according to any of the preceding embodiments, further comprising arranging a diffuser centrally below a diffusion lining at a bottom of the melting furnace.

[0335] 26. The method of embodiment 25, wherein arranging the diffuser includes positioning to overlap a portion of a diffuser lining located at a bottom of the melting furnace.

[0336] 27. The method of embodiment 26, wherein arranging the diffuser comprises contacting a diffuser liner with the diffuser, the diffuser comprising the same material as the diffuser liner.

[0337] 28. The method of any one of embodiments 25 to 27, wherein one or both of the diffuser and the diffuser liner has a porosity greater than 20%.

[0338] 29. The method according to any one of embodiments 25 to 28, wherein the diffuser has a lateral dimension that is less than 50% of a lateral dimension of a diffusion lining covering the bottom inner surface of the melting furnace.

[0339] 30. The method according to any one of embodiments 25 to 29, wherein the diffuser has a diameter greater than 5 cm and smaller than a diffusion lining covering the bottom inner surface of the melting furnace.

[0340] 31. The method according to any one of embodiments 25 to 30, wherein the diffusion lining covering the bottom inner surface of the melting furnace has a diameter of more than 50 cm.

[0341] 32. The method according to any one of embodiments 25 to 31, further comprising configuring the melting furnace to melt the copper-based alloy in a closed chamber configuration, in which the environment above the molten copper-based alloy is isolated from the external environment.

[0342] 33. The method according to any one of embodiments 25 to 31, further comprising configuring the melting furnace to melt the copper-based alloy in an open chamber configuration, wherein the environment above the molten copper-based alloy is exposed to an external environment.

[0343] 34. The method of embodiment 32, further comprising configuring the apparatus to flow the inert gas in a diffuse manner in a closed chamber configuration at a flow rate of 2 L / min to 6 L / min.

[0344] 35. The method of embodiment 33, further comprising configuring the apparatus to flow the inert gas in a diffuse manner in an open chamber configuration at a flow rate of 4 to 13 L / min.

[0345] 36. The method according to any of the preceding embodiments, wherein the melting furnace is an induction furnace comprising a surrounding induction coil configured to melt the copper-based alloy.

[0346] 37. The method of embodiment 36, wherein the induction furnace is configured to operate at a frequency of less than 1000 Hz.

[0347] 38. The method according to embodiments 36 and 37, wherein the uppermost winding of the induction coil is arranged at half the height of the molten copper-based alloy.

[0348] 39. A method according to any of the above embodiments, wherein the method is also according to any of the embodiments in additional example V.

[0349] Additional Example V:

[0350] 1. A method for manufacturing an alloy manufacturing device, the method comprising:

[0351] providing a melting furnace chamber;

[0352] disposing a compacted ceramic powder layer on an inner surface of a melting furnace chamber, the compacted ceramic powder layer comprising a mixture of silicon dioxide and aluminum oxide; and

[0353] The compacted ceramic powder layer in the melting furnace is sintered to form a diffusion lining on the inner surface, the diffusion lining comprising an aluminum silicate ceramic material having a porous structure suitable for gas diffusion therethrough.

[0354] 2. A method for manufacturing an apparatus for manufacturing an alloy, the method comprising:

[0355] providing a melting furnace chamber;

[0356] disposing a layer of compacted ceramic powder on an inner surface of a melting furnace chamber; and

[0357] The compacted ceramic powder layer is selectively sintered to form a diffusion liner on the inner surface including a sintered ceramic layer and an unsintered ceramic layer.

[0358] 3. A method for manufacturing an apparatus for manufacturing an alloy, the method comprising:

[0359] providing a melting furnace chamber;

[0360] disposing a layer of compacted ceramic powder on an inner surface of a melting furnace chamber; and

[0361] The compacted ceramic powder layer is sintered using heat from the heated material disposed in the melting furnace chamber to form a diffusion lining on the inner surface.

[0362] 4. A method according to embodiment 2 or 3, wherein sintering the compacted ceramic powder layer includes sintering in a melting furnace to form a diffusion liner, which diffusion liner includes an aluminum silicate ceramic material having a porous structure suitable for gas diffusion therethrough.

[0363] 5. The method according to embodiment 2 or 3, wherein the sintering includes selectively sintering a surface portion of the compacted ceramic powder layer to form a diffusion liner including a sintered ceramic layer and an unsintered ceramic layer on the inner surface.

[0364] 6. The method of embodiment 1 or 2, wherein sintering includes using heat from heated material disposed in a melting furnace chamber to form a diffusion lining on the inner surface.

[0365] 7. The method according to any of the above embodiments, wherein arranging the compacted ceramic powder layer comprises covering a bottom surface of the melting furnace chamber with the compacted ceramic powder layer.

[0366] 8. The method according to any of the above embodiments, wherein arranging the compacted ceramic powder layer comprises covering the sides of the melting furnace chamber with the compacted ceramic powder layer with side walls.

[0367] 9. The method of any of the preceding embodiments, wherein sintering comprises using heat from a material that is arranged in a melting furnace chamber and heated using electricity applied to the melting furnace chamber.

[0368] 10. The method of embodiment 9, wherein the power applied to the melting furnace chamber comprises inductive power delivered via a coil surrounding the melting furnace chamber.

[0369] 11. The method of embodiment 9, wherein sintering comprises heating the iron-containing material inductively using heat from the iron-containing material by applying electricity to the melting furnace chamber.

[0370] 12. The method of embodiment 9, wherein sintering comprises using heat from the iron-containing material to melt the iron-containing material using electricity applied to a melting furnace chamber.

[0371] 13. The method of embodiment 9, wherein the material is heated to a temperature sufficient to form mullite from silica and alumina.

[0372] 14. The method according to any of the preceding embodiments, wherein the diffusion liner comprises aluminum oxide and silicon dioxide.

[0373] 15. The method of any of the preceding embodiments, wherein the diffusion liner comprises mullite.

[0374] 16. The method of any of the preceding embodiments, wherein forming the diffusion liner comprises forming at least a sintered ceramic layer and an unsintered ceramic layer.

[0375] 17. The method of embodiment 16, wherein forming the sintered ceramic layer comprises sintering a portion of the compacted ceramic powder layer to form mullite.

[0376] 18. The method of embodiment 17, wherein the unsintered ceramic layer comprises a remaining portion of the compacted ceramic powder layer that has not formed mullite.

[0377] 19. The method of embodiment 16, wherein forming the sintered ceramic layer comprises configuring in contact with a molten copper-based alloy.

[0378] 20. The method of embodiment 17, wherein forming the sintered layer and the unsintered layer comprises forming from the same compacted ceramic powder layer comprising alumina and silica.

[0379] 21. The method of embodiment 16, wherein forming the sintered ceramic layer comprises partially sintering the compacted ceramic powder layer such that the sintered layer and the unsintered ceramic layer have substantially the same chemical composition but different phases.

[0380] 22. The method according to any of the preceding embodiments, wherein the compacted ceramic powder layer comprises 60% to 70% alumina and 20% to 25% silica.

[0381] 23. The method according to any of the preceding embodiments, wherein the compacted ceramic powder layer comprises particles having an average particle size of less than 63 μm or corresponding to a number 4 on the φ scale.

[0382] 24. The method of any of the preceding embodiments, wherein the compacted ceramic powder layer has a thickness of 3 inches to 6 inches.

[0383] 25. The method according to any of the preceding embodiments, wherein arranging the compacted ceramic powder layer comprises covering the entire bottom inner surface of the melting furnace.

[0384] 26. The method of any of the preceding embodiments, wherein the layer of compacted ceramic powder on the bottom inner surface of the melting furnace has a thickness of 4 inches to 6 inches.

[0385] 27. The method according to any of the preceding embodiments, wherein arranging the compacted ceramic powder layer comprises covering at least an inner surface of a side wall of the melting furnace.

[0386] 28. The method of any of the preceding embodiments, wherein the layer of compacted ceramic powder on the inner surface of the side wall of the melting furnace has a thickness of 3 inches to 4 inches.

[0387] 29. The method of any of the preceding embodiments, wherein forming the diffusion liner comprises configuring for contact with a molten copper-based alloy.

[0388] 30. The method according to any of the preceding embodiments, further comprising arranging a diffuser centrally below a diffusion lining at a bottom of the melting furnace.

[0389] 31. The method of embodiment 30, wherein arranging the diffuser includes positioning to overlap a portion of a diffuser lining located at a bottom of the melting furnace.

[0390] 32. The method of embodiment 31, wherein arranging the diffuser comprises contacting a diffuser liner with the diffuser, the diffuser comprising the same material as the diffuser liner.

[0391] 33. The method of any one of embodiments 30 to 32, wherein one or both of the diffuser and the diffuser liner has a porosity greater than 20%.

[0392] 34. The method according to any one of embodiments 30 to 33, wherein the diffuser has a lateral dimension that is less than 50% of a lateral dimension of a diffusion lining covering the bottom inner surface of the melting furnace.

[0393] 35. The method according to any one of embodiments 30 to 34, wherein the diffuser has a diameter greater than 5 cm and smaller than a diffusion lining covering the bottom inner surface of the melting furnace.

[0394] 36. The method according to any one of embodiments 30 to 35, wherein the diffusion lining covering the bottom inner surface of the melting furnace has a diameter of more than 50 cm.

[0395] 37. The method according to any one of embodiments 30 to 36, further comprising configuring the melting furnace to melt the copper-based alloy in a closed chamber configuration, in which the environment above the molten copper-based alloy is isolated from the external environment.

[0396] 38. The method according to any one of embodiments 30 to 37, further comprising configuring the melting furnace to melt the copper-based alloy in an open chamber configuration, in which the environment above the molten copper-based alloy is exposed to the external environment.

[0397] 39. The method of embodiment 38, further comprising configuring the apparatus to flow the inert gas in a diffuse manner in a closed chamber configuration at a flow rate of 2 L / min to 6 L / min.

[0398] 40. The method of embodiment 38, further comprising configuring the apparatus to flow the inert gas in a diffuse manner in an open chamber configuration at a flow rate of 4 L / min to 13 L / min.

[0399] 41. The method according to any one of the preceding embodiments, wherein the melting furnace is an induction furnace comprising a surrounding induction coil configured to melt the copper-based alloy.

[0400] 42. The method of embodiment 41, wherein the induction furnace is configured to operate at a frequency of less than 1000 Hz.

[0401] 43. The method according to embodiments 41 and 42, wherein the uppermost winding of the induction coil is arranged at half the height of the molten copper-based alloy.

[0402] 44. The method according to any of the preceding embodiments, further comprising connecting an inert gas supply to the diffusion liner.

[0403] 45. A method according to any of the above embodiments, wherein the method is also according to any of the embodiments in Additional Example IV.

[0404] Additional Example VIs

[0405] 1. A method for manufacturing a copper-based alloy, the method comprising:

[0406] providing a feedstock in a melting furnace, the feedstock having a composition configured to form a molten copper-based alloy, the molten copper-based alloy comprising at least 50% by weight copper;

[0407] heating the feed material to melt the feed material to form a molten copper-based alloy; and

[0408] An inert gas is bubbled into a molten copper-based alloy using a diffusion liner formed on an inner surface of a melting furnace chamber, the diffusion liner comprising an aluminum silicate ceramic material having a porous structure suitable for bubbling an inert gas through the molten copper-based alloy.

[0409] 2. A method for manufacturing a copper-based alloy, the method comprising:

[0410] providing a feedstock in a melting furnace, the feedstock having a composition configured to form a molten copper-based alloy, the molten copper-based alloy comprising at least 50% by weight copper;

[0411] heating the feed material to melt the feed material to form a molten copper-based alloy; and

[0412] An inert gas is bubbled through the molten copper-based alloy using a diffusion liner formed in the melting furnace chamber, the diffusion liner substantially covering the bottom inner surface of the melting furnace and having a porous structure suitable for bubbling the inert gas into the molten copper-based alloy.

[0413] 3. A method for manufacturing a copper-based alloy, the method comprising:

[0414] providing a feedstock in a melting furnace, the feedstock having a composition configured to form a molten copper-based alloy, the molten copper-based alloy comprising at least 50% by weight copper;

[0415] heating the feed material to melt the feed material to form a molten copper-based alloy; and

[0416] A diffusion liner having a porous structure is used to bubble an inert gas through a molten copper-based alloy, the diffusion liner being formed on at least two different inner surfaces of a melting furnace such that the diffusion liner is suitable for bubbling an inert gas into the molten copper-based alloy from the at least two different inner surfaces.

[0417] 4. The method of embodiment 2 or 3, wherein the diffusion liner comprises an aluminum silicate ceramic.

[0418] 5. The method of embodiment 1 or 3, wherein the diffusion lining substantially covers the bottom inner surface of the melting furnace.

[0419] 6. The method according to embodiment 1 or 2, wherein the diffusion lining is formed on at least two different inner surfaces of the melting furnace, so that the diffusion lining is suitable for bubbling the inert gas into the molten copper-based alloy from the at least two different inner surfaces.

[0420] 7. The method according to any of the preceding embodiments, wherein the diffusion liner comprises aluminum oxide and silicon dioxide.

[0421] 8. The method of any of the preceding embodiments, wherein the diffusion liner comprises mullite.

[0422] 9. The method according to any of the preceding embodiments, wherein the diffusion liner comprises at least two layers, at least two of the layers comprising a sintered ceramic layer and a green ceramic layer.

[0423] 10. The method of embodiment 9, wherein the sintered ceramic layer comprises mullite.

[0424] 11. The method of embodiment 9, wherein the unsintered ceramic layer comprises aluminum oxide and silicon dioxide.

[0425] 12. The method of embodiment 10, wherein the sintered ceramic layer is in contact with a molten copper-based alloy.

[0426] 13. The method of embodiment 9, wherein the unsintered layer comprises a compacted ceramic powder layer comprising alumina and silica.

[0427] 14. The method of embodiment 9, wherein the sintered ceramic layer is formed by partially sintering a compacted ceramic powder layer such that the sintered layer and the unsintered ceramic layer have substantially the same chemical composition but different phases.

[0428] 15. The method of embodiment 9, wherein the unsintered ceramic layer comprises 60% to 70% alumina and 20% to 25% silica.

[0429] 16. The method of embodiment 9, wherein the unsintered ceramic layer comprises a compacted ceramic powder layer having an average particle size of less than 63 μm or corresponding to a number 4 on the φ scale.

[0430] 17. The method of any of the preceding embodiments, wherein the diffusion liner has a thickness of 3 inches to 6 inches.

[0431] 18. The method according to any of the preceding embodiments, wherein the diffusion lining covers the entire bottom inner surface of the melting furnace.

[0432] 19. The method of any of the preceding embodiments, wherein the diffusion lining on the bottom inner surface of the melting furnace has a thickness of 4 inches to 6 inches.

[0433] 20. The method according to any of the preceding embodiments, wherein the diffusion liner covers at least the molten sidewalls.

[0434] 21. The method of any of the preceding embodiments, wherein the diffusion lining on the sidewalls of the melting furnace has a thickness of 3 inches to 4 inches.

[0435] 22. The method according to any of the preceding embodiments, wherein the diffusion liner is configured to be in contact with a molten copper-based alloy.

[0436] 23. The method according to any of the preceding embodiments, wherein the inert gas consists essentially of argon.

[0437] 24. The method according to any of the preceding embodiments, wherein the inert gas is hydrogen-free.

[0438] 25. The method according to any of the preceding embodiments, further comprising a diffuser arranged centrally below a diffusion lining at the bottom of the melting furnace.

[0439] 26. The method of embodiment 25, wherein the diffuser overlaps a portion of a diffusion lining at the bottom of the melting furnace.

[0440] 27. The method of embodiment 26, wherein the diffuser is in contact with the diffuser liner and comprises the same material as the diffuser liner.

[0441] 28. The method of any one of embodiments 25 to 27, wherein one or both of the diffuser and the diffuser liner has a porosity greater than 20%.

[0442] 29. The method according to any one of embodiments 25 to 28, wherein the diffuser has a lateral dimension that is less than 50% of a lateral dimension of a diffusion lining covering the bottom inner surface of the melting furnace.

[0443] 30. The method according to any one of embodiments 25 to 29, wherein the diffuser has a diameter greater than 5 cm and smaller than a diffusion lining covering the bottom inner surface of the melting furnace.

[0444] 31. The method according to any one of embodiments 25 to 30, wherein the diffusion lining covering the bottom inner surface of the melting furnace has a diameter exceeding 50 cm.

[0445] 32. The method of any one of embodiments 25 to 31, wherein melting the feedstock comprises melting in a closed chamber configuration in which an environment above the molten copper-based alloy is isolated from an external environment.

[0446] 33. The method of any one of embodiments 25 to 31, wherein melting the feedstock comprises melting in an open chamber configuration wherein the environment above the molten copper-based alloy is exposed to an external environment.

[0447] 34. The method of embodiment 32, wherein bubbling the inert gas comprises flowing the inert gas in a diffuse manner through a diffusion liner at a flow rate of 2 liters / minute to 6 liters / minute in a closed chamber configuration.

[0448] 35. The method of embodiment 33, wherein bubbling the inert gas comprises flowing the inert gas in a diffuse manner in an open chamber configuration at a flow rate of 4 liters / minute to 13 liters / minute through the diffusion liner.

[0449] 36. The method of any of the preceding embodiments, wherein melting comprises heating the feed material inductively by supplying power to an induction coil surrounding a melting furnace.

[0450] 37. The method according to any one of the above embodiments,

[0451] wherein providing feedstock comprises: providing a plurality of feedstock blocks having a composition configured to form a molten copper-based alloy; and flowing an inert gas through gaps between the feedstock blocks prior to heating,

[0452] wherein heating comprises: heating the feed block while flowing an inert gas through the feed block, thereby melting the feed block to form a molten copper-based alloy, and

[0453] The method further includes: after bubbling the inert gas through the molten copper-based alloy, transferring the molten copper-based alloy to a transfer ladle.

[0454] 38. The method according to any one of embodiments 1 to 36,

[0455] wherein providing feedstock comprises: providing a plurality of feedstock blocks having a composition configured to form a molten copper-based alloy; and flowing an inert gas through gaps between the feedstock blocks prior to heating,

[0456] The method further comprises: after bubbling the inert gas through the molten copper-based alloy, transferring the molten copper-based alloy to a transfer ladle, and

[0457] Wherein one or more of heating the feedblock, bubbling the inert gas, and conveying the molten copper-based alloy is at least partially performed in a closed inert environment that is configured to substantially exclude external air from mixing with the closed inert environment.

[0458] 39. The method according to any one of embodiments 1 to 36,

[0459] Wherein, providing feedstock comprises: providing a plurality of feedstock blocks having a combination composition, wherein the combination composition is configured to form a molten copper-based alloy,

[0460] The method further comprises: after bubbling the inert gas through the molten copper-based alloy, transferring the molten copper-based alloy to a transfer ladle, and

[0461] Wherein the transporting includes limiting the velocity of the molten copper-based alloy being transported from the melting furnace to the transport ladle to less than 100 inches per second.

[0462] 40. The method of embodiment 38 or 39, further comprising flowing an inert gas through gaps between feedblocks prior to heating, and wherein heating comprises heating the feedblock while flowing the inert gas through the feedblock.

[0463] 41. In the method of embodiment 37 or 39, one or more of heating the feed block, bubbling the inert gas, and conveying the molten copper-based alloy is at least partially performed in a closed inert environment, which is configured to substantially exclude external air from mixing with the closed inert environment.

[0464] 42. The method of embodiment 37 or 38, wherein transporting includes limiting the velocity of the molten copper-based alloy being transported from the melting furnace to the transport ladle to less than 100 inches per second.

[0465] 43. The method of any one of embodiments 37 to 42, wherein the method is further described according to any one of the methods of any one of embodiments 7 to 30 in Additional Examples - Part II.

[0466] 44. The method according to any of the preceding embodiments, wherein the melting furnace is an induction furnace comprising a surrounding induction coil configured to melt the copper-based alloy.

[0467] 45. The method of embodiment 44, wherein the induction furnace is configured to operate at a frequency of less than 1000 Hz.

[0468] 46. ​​The method according to embodiment 44 or 45, wherein the uppermost winding of the induction coil is arranged at half the height of the molten copper-based alloy.

[0469] 47. A method according to any of the above embodiments, wherein the method is also according to any of the embodiments in Additional Example II.

[0470] Unless the context requires otherwise, throughout the specification and claims, the words "comprise", "comprises", "includes", etc. should be interpreted in an inclusive sense, rather than in an exclusive or exhaustive sense; that is, in the sense of "including but not limited to". The word "connection" as commonly used herein refers to two or more elements that can be directly connected or connected by means of one or more intermediate elements. Similarly, the word "connection" as commonly used herein refers to two or more elements that can be directly connected or connected by means of one or more intermediate elements. In addition, the words "herein", "above", "below" and words of similar meanings, when used in this application, should refer to the entire application, rather than to any particular part of the application. Where the context permits, the words used in the above specific embodiments in the singular or plural may also include the plural or singular, respectively. When the word "or" refers to a list of two or more items, the word "or" covers all the following interpretations of the word: any item in the items in the list, all items in the items in the list, and any combination of items in the list.

[0471] Furthermore, unless expressly stated otherwise or understood otherwise in the context of use, conditional language such as "can," "can," "might," "may," "could," "for example," "such as," and the like as used herein is generally intended to convey that certain embodiments include certain features, elements, and / or states, while other embodiments do not. Thus, such conditional language is generally not intended to indicate that features, elements, and / or states are in any way required for one or more embodiments or whether such features, elements, and / or states are included in any particular embodiment or will be performed in any embodiment.

[0472] Although certain embodiments have been described, these embodiments are presented only by way of example and are not intended to limit the scope of the present disclosure. In fact, the novel devices, methods, and systems described herein can be implemented in various other forms; in addition, without departing from the spirit of the present disclosure, various omissions, replacements, and changes can be made to the forms of the methods and systems described herein. For example, although a block diagram is presented with a given arrangement structure, alternative embodiments can perform similar functions through different components and / or circuit topologies, and some boxes can be deleted, moved, added, subdivided, combined, and / or modified. Each box in these boxes can be implemented in various different ways. Any suitable combination of the elements and actions of the various embodiments described above can be combined to provide additional embodiments. The various features and processes described above can be implemented independently of each other, or can be combined in various ways. All possible combinations and subcombinations of the features of the present disclosure are intended to fall within the scope of the present disclosure.

[0473] In addition, unless otherwise specified, any of the steps in the method of the present disclosure is not limited to any specific execution order. Those skilled in the art may modify the disclosed examples in combination with the spirit and substance of the present disclosure, and these modifications are within the scope of the present disclosure. In addition, all references cited herein are fully incorporated by reference.

[0474] Although the methods and devices described herein may be susceptible to various modifications and alternative forms, the specific examples of these methods and devices have been shown in the accompanying drawings and are described in detail herein. However, it is understood that the present invention is not limited to the specific form or method disclosed, on the contrary, the present invention will cover all modifications, equivalents and alternatives falling within the spirit and scope of the various examples described and the appended claims. In addition, the disclosure of any specific features, aspects, methods, properties, characteristics, qualities, attributes, elements, etc. related to the examples herein can be used for all other examples set forth herein. Any method disclosed herein does not need to be performed in the order listed. According to the example, one or more actions, events or functions of any one of the algorithms, methods or processes described herein can be performed in different orders, can be added, merged or completely omitted (for example, not all the actions or events described are necessary for practicing the method). In some examples, actions or events can be performed simultaneously. In addition, for each example, no element, feature, block or step, or group of elements, features or steps is necessary or indispensable. Furthermore, all possible combinations, subcombinations, and rearrangements of systems, methods, features, elements, modules, blocks, etc. are within the scope of the present disclosure. Unless otherwise expressly stated or understood otherwise in the context of use, language using sequential or chronological order such as "then," "next," "after," "subsequently," etc. is generally intended for ease of presentation and is not intended to limit the order of operations performed. Thus, some examples may be performed using the order of operations described herein, while other examples may be performed following a different order of operations.

[0475] The ranges disclosed herein also include any and all overlaps, sub-ranges, and combinations thereof. Languages ​​such as "up to", "at least", "greater than", "less than", "between" include the listed numbers. Numbers preceded by terms such as "about" or "approximately" include the listed numbers and should be interpreted based on the specific circumstances (e.g., as accurately as reasonably possible in this case, such as ±5%, ±10%, ±15%, etc.). For example, "about 1V" includes "1V". Numbers preceded by no terms such as "about" or "approximately" can be understood as being as accurately as reasonably possible in this case, such as ±5%, ±10%, ±15%, etc., based on the specific circumstances. For example, "1V" includes "0.9V to 1.1V". Terms preceded by terms such as "approximately" include the listed terms and should be interpreted based on the specific circumstances (e.g., as reasonably as possible in the specific circumstances). For example, "approximately vertical" includes "vertical". Unless otherwise stated, all measurements are under standard conditions, including temperature and pressure. The phrase "at least one of..." is intended to require at least one item from the subsequent list, rather than to require a type of every item from every item in the subsequent list. For example, "at least one of A, B, and C" may include A, include B, include C, include A and B, include A and C, include B and C, or include A, B, and C.

Claims

1. A method for manufacturing a copper-based alloy, the method comprising: providing a feedstock in a melting furnace, the feedstock having a composition configured to form a molten copper-based alloy, the molten copper-based alloy comprising at least 50% by weight copper; heating the feed material to melt the feed material to form the molten copper-based alloy; as well as An inert gas is bubbled into the molten copper-based alloy using a diffusion liner formed on an inner surface of the melting furnace, the diffusion liner comprising an aluminum silicate ceramic material having a porous structure suitable for bubbling the inert gas through the molten copper-based alloy.

2. The method according to claim 1, wherein: The inert gas mainly includes argon.

3. The method according to claim 2, wherein: The inert gas is hydrogen-free.

4. The method according to claim 1, wherein: The diffusion lining substantially covers at least a bottom inner surface of the melting furnace.

5. The method according to claim 1, wherein: The diffusion liner comprises at least two layers, at least two of the layers comprising a sintered ceramic layer and an unsintered ceramic layer.

6. The method according to claim 5, wherein: The sintered ceramic layer includes mullite.

7. The method according to claim 5, wherein: The unsintered ceramic layer includes aluminum oxide and silicon dioxide.

8. The method according to claim 5, wherein: The sintered layer and the unsintered ceramic layer have substantially the same chemical composition but have different phases.

9. The method according to claim 1, wherein: Providing the feedstock includes providing a plurality of feedblocks having a combined composition configured to form the molten copper-based alloy, the method further comprising flowing the inert gas through gaps between the feedblocks prior to heating.

10. The method according to claim 9, wherein: Heating includes: The feedblock is heated while flowing the inert gas through the feedblock, thereby melting the feedblock to form the molten copper-based alloy.

11. A method for manufacturing a copper-based alloy, the method comprising: providing a feedstock in a melting furnace, the feedstock having a composition configured to form a molten copper-based alloy, the molten copper-based alloy comprising at least 50% by weight copper; heating the feed material to melt the feed material to form the molten copper-based alloy; as well as An inert gas is bubbled through the molten copper-based alloy using a diffusion liner formed in the melting furnace, the diffusion liner substantially covering the bottom inner surface of the melting furnace and having a porous structure suitable for bubbling the inert gas into the molten copper-based alloy.

12. The method according to claim 11, wherein: The inert gas mainly includes argon.

13. The method according to claim 11, wherein: Providing the feedstock includes providing a plurality of feedblocks having a combined composition configured to form the molten copper-based alloy, the method further comprising flowing the inert gas through gaps between the feedblocks prior to heating.

14. The method according to claim 13, wherein: Heating includes: The feedblock is heated while flowing the inert gas through the feedblock, thereby melting the feedblock to form the molten copper-based alloy.

15. The method according to claim 13, wherein: Bubbling the inert gas through the molten copper-based alloy includes flowing the inert gas through a diffuser embedded in the diffusion liner covering the bottom inner surface of the melting furnace before flowing the inert gas through the diffusion liner.

16. The method according to claim 15, wherein: The diffuser and the diffuser liner include the same diffuser material, and wherein the diffuser includes the diffuser material disposed within a container connected to a source of inert gas.

17. The method according to claim 15, wherein: The diffusion lining also covers the inner surface of the side wall of the melting furnace.

18. The method according to claim 11, wherein: The diffusion liner comprises at least two layers, at least two of the layers comprising a sintered ceramic layer and an unsintered ceramic layer.

19. The method according to claim 18, wherein: The unsintered ceramic layer includes aluminum oxide and silicon dioxide.

20. The method according to claim 18, wherein: The sintered ceramic layer includes mullite.

21. A method for manufacturing a copper-based alloy, the method comprising: providing a feedstock in a melting furnace, the feedstock having a composition configured to form a molten copper-based alloy, the molten copper-based alloy comprising at least 50% by weight copper; heating the feed material to melt the feed material to form the molten copper-based alloy; as well as A diffusion liner having a porous structure is used to bubble an inert gas through the molten copper-based alloy, the diffusion liner being formed on at least two different inner surfaces of the melting furnace such that the diffusion liner is suitable for bubbling the inert gas through at least two different inner surfaces into the molten copper-based alloy.

22. The method according to claim 21, wherein: Providing the feedstock includes providing a plurality of feedblocks having a combined composition configured to form the molten copper-based alloy, the method further comprising flowing the inert gas through gaps between the feedblocks prior to heating.

23. The method according to claim 22, wherein: Heating includes: The feedblock is heated while flowing the inert gas through the feedblock, thereby melting the feedblock to form the molten copper-based alloy.

24. The method according to claim 21, wherein: The at least two different inner surfaces include a bottom inner surface and a side wall inner surface.

25. The method according to claim 24, wherein: Bubbling the inert gas also includes diffusing the inert gas through a diffuser, wherein the diffuser is centrally arranged within the diffusion liner located at the bottom inner surface, the diffuser includes a diffuser material disposed within a container connected to an inert gas source, and the diffuser has an upper surface arranged below an upper surface of the diffusion liner covering the bottom inner surface.

26. The method according to claim 25, wherein: Bubbling the inert gas includes diffusing the inert gas through the diffuser, then diffusing the inert gas through the diffusion liner disposed on the inner surface of the bottom, and then diffusing the inert gas through the diffusion liner located on the inner surface of the side wall.

27. The method according to claim 26, wherein: One or both of the diffuser and the diffusion liner have a porosity greater than 20%.

28. The method of claim 21, wherein: The melting furnace is configured to melt the copper-based alloy in an open chamber configuration in which an environment above the molten copper-based alloy is exposed to an external environment.

29. The method according to claim 21, wherein: The melting furnace is an induction furnace including an induction coil surrounding the melting furnace and configured to melt the feed material.

30. The method of claim 29, wherein: The induction furnace is configured to operate at a frequency of less than 1000 Hz.

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