1006 results about "Molten alloy" patented technology

A method for forming an object, including providing at least a first material having a melting point at a first temperature and a second material having a melting point at a second temperature; heating at least a portion of the first and second materials above the first and second temperatures to form a substantially molten alloy, the molten alloy having a solidifying point at a third temperature, the third temperature being less than the first temperature and the second temperature; and providing substantially solid further material to at least a portion of the molten alloy, the further material having a melting point at a temperature greater than the third temperature.

A method for manufacturing a railcar coupler knuckle includes providing a cope mold portion and a drag mold portion. The cope and drag mold portions have internal walls defining at least in part perimeter boundaries of a coupler knuckle mold cavity. The method includes positioning one or two internal cores within either the cope mold portion or the drag mold portion. The one or two internal cores are configured to define a kidney cavity, a finger cavity and a pivot pin cavity of a coupler knuckle. The method includes closing the cope and drag mold portions with the one or two internal cores therebetween and at least partially filling the mold cavity with a molten alloy, the molten alloy solidifying after filling to form the coupler knuckle.

An apparatus and method are disclosed in which ultrasonic vibration is used to assist the degassing of molten metals or metal alloys thereby reducing gas content in the molten metals or alloys. High-intensity ultrasonic vibration is applied to a radiator that creates cavitation bubbles, induces acoustic streaming in the melt, and breaks up purge gas (e.g., argon or nitrogen) which is intentionally introduced in a small amount into the melt in order to collect the cavitation bubbles and to make the cavitation bubbles survive in the melt. The molten metal or alloy in one version of the invention is an aluminum alloy. The ultrasonic vibrations create cavitation bubbles and break up the large purge gas bubbles into small bubbles and disperse the bubbles in the molten metal or alloy more uniformly, resulting in a fast and clean degassing.

A method for manufacturing a railcar coupler knuckle includes providing a cope mold portion and a drag mold portion. The cope and drag mold portions have internal walls defining at least in part perimeter boundaries of a coupler knuckle mold cavity. The method includes positioning one or two internal cores within either the cope mold portion or the drag mold portion. The one or two internal cores are configured to define a kidney cavity, a finger cavity and a pivot pin cavity of a coupler knuckle. The method includes closing the cope and drag mold portions with the one or two internal cores therebetween and at least partially filling the mold cavity with a molten alloy, the molten alloy solidifying after filling to form the coupler knuckle.

The present invention provides a method for producing a half Heuslar alloy including quench-solidifying a molten alloy at a cooling rate of 1×102 to 1×103° C. / sec to produce a Heuslar alloy represented by the formula: ABC (wherein A and B each is at least one member selected from transition metals such as Fe, Co, Ni, Ti, V, Cr, Zr, Hf, Nb, Mo, Ta and W, and C is at least one member selected from Group 13 or 14 element such as Al, Ga, In, Si, Ge and Sn), and a high-performance thermoelectric power generating device using the thermoelectric semiconductor alloy.

This invention pertains to a product and a method for making the product. The product is a lightweight solid porous metallic product containing small solid spheres having a coating of a primary alpha phase thereon disposed in a solid metal alloy eutectic matrix. The method includes the steps of mixing the hollow rigid spheres and a metal alloy, which metal alloy can be preheated to render it molten, in order to form a dispersion of the spheres distributed in the molten alloy; initially cooling the dispersion to render it semi-solid whereby the spheres are coated by a solid and the coated spheres are disposed in the semi-solid mixture of the solid and liquid; and finally cooling the sphere-containing semi-solid mixture to a temperature at which the sphere-containing semi-solid mixture becomes solid and the product is formed.

A method for preparing a high entropy alloy thin film coating includes preparing a melt alloy by arc melting raw materials including five or more elements, casting the melt alloy into a mold to form a target, placing the target inside a vacuum chamber of a magnetron sputtering system, and rotatably fixing a substrate inside the vacuum chamber, spaced apart from the target. A high entropy alloy thin film is deposited on the substrate by high vacuum radio frequency sputtering inside the vacuum chamber.

Methods and apparatus for producing large diameter superalloy ingots are disclosed. A material comprising at least one of a metal and a metallic alloy is introduced into a pressure-regulated chamber in a melting assembly. The material is subjected to a wide-area electron field within the pressure-regulated chamber to heat the material to a temperature above the melting temperature of the material to form a molten alloy. At least one stream of molten alloy from the pressure-regulated chamber is provided from the melting assembly and is fed into an atomizing assembly, where particles of the molten alloy are generated by impinging electrons on the molten alloy to atomize the molten alloy. At least one of an electrostatic field and an electromagnetic field are produced to influence the particles of the molten alloy. The particles of the molten alloy are deposited onto a collector in a spray forming operation to form an alloy ingot.

One non-limiting embodiment of an apparatus for forming an alloy powder or preform includes a melting assembly, an atomizing assembly, and a collector. The melting assembly produces at least one of a stream of a molten alloy and a series of droplets of a molten alloy, and may be substantially free from ceramic in regions contacted by the molten alloy. The atomizing assembly generates electrons and impinges the electrons on molten alloy from the melting assembly, thereby producing molten alloy particles.

A molten alloy was pressure-solidified under a pressure exceeding one atmospheric pressure to eliminate casting defects. The molten alloy was solidified by applying a cooling rate difference to the surface and the interior of the molten alloy to allow a compressive stress layer to remain on the surface of the amorphous alloy ingot and a tensile stress layer in the interior portion. Thus, a amorphous alloy sheet having a thickness of 1 mm or more and excellent in bending strength and impact strength is obtained.

An antigravitational casting technology includes putting a lost mould in a bottom running type sand box, adding sand, vibration compacting, loading molten MgAl alloy in filler while introducing protecting gas, introducing the pressure controllable inertial gas to the filler, and pouring the molten alloy into said sand box to gasify said list mould. Its apparatus is composed of filler, sand box, pouring pipe, crucible in the filler, and heating coil surrounding said pouring pipe. It is suitable for precision casting.

A method and apparatus for the semisolid forming of alloys to enable shaped parts having a fine-grained, spherical thixotropic structure to be produced in a convenient, easy and inexpensive manner without relying upon the conventional mechanical or electromagnetic agitation. In the method, a molten alloy having crystal nuclei at a temperature not lower than the liquidus temperature or a partially solid, partially molten alloy having crystal nuclei at a temperature not lower than a molding temperature is fed into an insulated vessel and is maintained in the insulated vessel for 5 seconds to 60 minutes as it is cooled to the molding temperature where a specified liquid fraction is established, thereby crystallizing fine primary crystals in the alloy solution, and the alloy is fed into a forming mold, where it is shaped under pressure.

A core for investment casting processes includes a core having one or more ceramic materials; and an exterior layer of metal material not susceptible to oxidation under investment casting operating conditions. A method for casting a turbine engine component having an internal passageway includes the steps of forming one or more mold sections each having internal surfaces and at least one of the aforementioned cores for forming one or more turbine engine components having at least one internal passageway; assembling the one or more mold sections; introducing a molten alloy into the one or more assembled mold sections; and consuming the metal of the at least one core during the process.

A method for manufacturing a railcar coupler knuckle includes providing a cope mold portion and a drag mold portion. The cope and drag mold portions have internal walls defining at least in part perimeter boundaries of a coupler knuckle mold cavity. The method includes positioning one or two internal cores within either the cope mold portion or the drag mold portion. The one or two internal cores are configured to define a kidney cavity, a finger cavity and a pivot pin cavity of a coupler knuckle. The method includes closing the cope and drag mold portions with the one or two internal cores therebetween and at least partially filling the mold cavity with a molten alloy, the molten alloy solidifying after filling to form the coupler knuckle.

The present invention relates to a preparation processing method of amorphous alloy workpiece. Said method includes the following steps: heating and melting alloy mother material, then pouring the molten alloy mother material into a breakable mould, after the molten alloy is cooled, an amorphous alloy can be obtained, after the mould is broken, cleaning the test sample so as to obtain the invented required workpiece.

A method for forming an object, including providing at least a first material having a melting point at a first temperature and a second material having a melting point at a second temperature; heating at least a portion of the first and second materials above the first and second temperatures to form a substantially molten alloy, the molten alloy having a solidifying point at a third temperature, the third temperature being less than the first temperature and the second temperature; and providing substantially solid further material to at least a portion of the molten alloy, the further material having a melting point at a temperature greater than the third temperature.

One non-limiting embodiment of an apparatus for forming an alloy powder or preform includes a melting assembly, an atomizing assembly, and a field generating assembly, and a collector. The melting assembly produces at least one of a stream of a molten alloy and a series of droplets of a molten alloy, and may be substantially free from ceramic in regions contacted by the molten alloy. The atomizing assembly generates electrons and impinges the electrons on molten alloy from the melting assembly, thereby producing molten alloy particles. The field generating assembly produces at least one of an electrostatic field and an electromagnetic field between the atomizing assembly and the collector. The molten alloy particles interact with the at least one field, which influences at least one of the acceleration, speed, and direction of the molten alloy particles. Related methods also are disclosed.

A method for manufacturing a railcar coupler knuckle includes providing cope and drag mold portions having internal walls defining at least in part perimeter boundaries of a knuckle mold cavity; positioning a first internal core within either the cope mold or the drag mold portions, the first internal core configured to define a kidney cavity and a pivot pin hub as a single void within the knuckle; positioning a second internal core within either the cope mold portion and the drag mold portion, the second internal core configured to define a finger cavity; closing the cope and drag mold portions with the two internal cores therebetween; and at least partially filling the mold cavity with a molten alloy, the molten alloy solidifying after filling to form the knuckle, wherein the first internal core defines the kidney cavity and the pivot pin hub of the coupler knuckle, and wherein the second internal core defines the finger cavity of the knuckle.

A method for manufacturing a railcar coupler knuckle includes providing a cope mold portion and a drag mold portion, the cope and drag mold portions having internal walls defining at least in part perimeter boundaries of a coupler knuckle mold cavity, wherein the mold cavity includes a finger section; positioning at least one internal core within either the cope mold portion or the drag mold portion, the at least one internal core configured to define a kidney cavity and a pivot pin cavity within a coupler knuckle; closing the cope and drag mold portions with the single core therebetween; and at least partially filling the mold cavity with a molten alloy, the molten alloy solidifying after filling to form the coupler knuckle, wherein the at least one core defines the kidney and pivot pin cavities, and the finger section of the mold cavity defines at least one finger cavity of the coupler knuckle.

The present invention is a process for producing a rare earth alloy including heating a raw material alloy which is compounded so as to have a composition represented by the formula: A3−XBXC (wherein A and B each is at least one member selected from transition metals consisting of Fe, Co, Ni, Ti, V, Cr, Zr, Hf, Nb, Mo, Ta and W, and C is at least one member selected from Group 13 or 14 elements consisting of Al, Ga, In, Si, Ge and Sn) to be a molten ally, and quench-solidifying the molten alloy at a cooling rate of 1×102 to 1×103° C. / sec.

A liquid-loop compound recuperator is disclosed for high-ε heat exchange between a first shell-side fluid stream and a second shell-side fluid stream of similar thermal capacity rates (W / K). The compound recuperator is comprised of at least two fluid-to-liquid (FL) recuperator modules for transfer of heat from a shell-side fluid, usually a gas, to an intermediary tube-side heat transfer liquid (HTL). Each FL module includes a plurality of thermally isolated, serially connected, adjacent exchanger cores inside a pressure vessel. The cores are rows of finned tubes for cross-flow transfer of heat, and they are arranged in series to effectively achieve counterflow exchange between the HTL and the shell-side stream. The HTL may be water, an organic liquid, a molten alloy, or a molten salt.

The invention discloses a machining method of a porous thin-wall protective tube with a large length-to-diameter ratio. The method comprises the following steps of: firstly cutting a tube material at a desired length of the protective tube; heating to melt a low-temperature lead / tin alloy material into liquid and then pouring the molten alloy into the inner hole of the tube material; clamping a threaded plug at one end of the tube material by use of a dividing head chuck, compacting a threaded plug at the other end of the tube material by use of a miller center, and straightening and clampingthe two sides of the outer wall of the tube material by use of flat tongs; milling kidney-shaped holes which are uniformly distributed on the wall of the tube material by use of a milling cutter which is mounted on a numerically-controlled milling machine, and milling kidney-shaped holes which are arranged in rows in the axial direction of the tube material; and vertically hanging the tube material subjected to milling, and heating such that the low-temperature lead / tin alloy material is molten and breaks away from the inner hole of the tube material, thus obtaining the porous thin-wall protective tube with large length-to-diameter ratio. The process of machining the porous thin-wall protective tube with large length-to-diameter ratio by the method disclosed in the invention has the advantages that the rate of qualified products is high and is up to above 99%; the machining accuracy is increased and fully meets the design requirement on product accuracy; and the machining efficiency is increased by more than 50%.

The invention discloses high-chromium cast iron which comprises the following chemical components in percentage by weight: 2.3%-2.7% of C, 14%-16% of Cr, 0.4%-0.6% of Mo, 0.3%-0.5% of Ni, 0.3%-0.5% of Cu, 0.8%-1.3% of Si, 0.6%-1.0% of Mn, not more than 0.04% of S, not more than 0.04% of P and the balance of Fe. A preparation method of the high-chromium cast iron comprises the following steps: smelting in a smelting furnace to form molten alloy, deoxidizing, adding 0.3%-0.6% of a compound inoculant and 0.1%-0.2% of a compound modifier based on the total weight of the molten alloy for inoculating and modifying for the first time, and pouring the molten alloy into a casting ladle for inoculating and modifying for the second time, wherein 0.2%-0.4% of the compound inoculant and 0.3%-0.6% of the compound modifier based on the total weight of the molten alloy are prearranged in the casting ladle, the compound inoculant is a Ti-V-CaO-BaCO3-Zn compound inoculant, and the compound modifier is a rare earth ferrosilicon alloy modifier. According to the preparation method, the recession resistance of an inoculation and modification structure can be improved, so that the high-chromium cast iron is relatively good in bending strength and wear resistance.

The invention relates to a method for preparing selectively enhanced aluminum-based composite from ceramic particles and belongs to the field of metal matrix composites (MMCs). The preparation method comprises the following steps: firstly, preparing porous ceramic blanks; and secondly, putting the porous ceramic blanks at a part needing to be enhanced, injecting molten alloy into a mould at 750-1,100 DEG C, applying pressure of 20-50MPa to forcibly fill the molten alloy into the porous ceramic blanks and a mold cavity, and solidifying, thus obtaining the selectively enhanced aluminum-based composite. The method has the advantages that a foaming technology, an injection molding and a gel casting process are combined, thus leading the porous ceramic blank to have designability; the MMC reinforcement and an aluminum matrix are integrally formed by adopting extrusion casting process, thus fully playing the advantages of high strength and high toughness of the aluminum matrix and wear resistance of the MMC reinforcement. The composite has the advantages of high thermal conductivity, good radiation capability, excellent wear resistance and light weight.

In a rare earth magnet, an added heavy rare earth element RH such as Dy is effectively used without any waste, so as to effectively improve the coercive force. First, a molten alloy of a material alloy for an R-T-Q rare earth magnet (R is a rare earth element, T is a transition metal element, and Q is at least one element selected from the group consisting of B, C, N, Al, Si, and P), the rare earth element R containing at least one kind of element RL selected from the group consisting of Nd and Pr and at least one kind of element RH selected from the group consisting of Dy Tb, and Ho is prepared. The molten alloy is quenched, so as to produce a solidified alloy. Thereafter, a thermal treatment in which the rapidly solidified alloy is held in a temperature range of 400° C. or higher and lower than 800° C. for a period of not shorter than 5 minutes nor longer than 12 hours is performed. By the thermal treatment, the element RH can be moved from the grain boundary phase to the main phase, so that the coercive force is increased.

An electronic package having a solder interconnect liquidus temperature hierarchy to limit the extent of the melting of the C4 solder interconnect during subsequent second level join / assembly and rework operations. The solder hierarchy employs the use of off-eutectic solder alloys of Sn / Ag and Sn / Cu with a higher liquidus temperature for the C4 first level solder interconnections, and a lower liquidus temperature alloy for the second level interconnections. When the second level chip carrier to PCB join / assembly operations occur, the chip to chip carrier C4 interconnections do not melt completely. They continue to have a certain fraction of solids, and a lower fraction of liquids, than a fully molten alloy. This provides reduced expansion of the solder join and consequently lower stresses on the C4 interconnect.

Methods and apparatus for producing large diameter superalloy ingots are disclosed. A material comprising at least one of a metal and a metallic alloy is introduced into a pressure-regulated chamber in a melting assembly. The material is subjected to a wide-area electron field within the pressure-regulated chamber to heat the material to a temperature above the melting temperature of the material to form a molten alloy. At least one stream of molten alloy from the pressure-regulated chamber is provided from the melting assembly and is fed into an atomizing assembly, where particles of the molten alloy are generated by impinging electrons on the molten alloy to atomize the molten alloy. At least one of an electrostatic field and an electromagnetic field are produced to influence the particles of the molten alloy. The particles of the molten alloy are deposited onto a collector in a spray forming operation to form an alloy ingot.