8602 results about "Molten metal" patented technology

A simulator facilitating virtual welding activity. The simulator may include a logic processor based subsystem operable to generate an interactive welding environment in virtual reality space that emulates welding activity by simulating a virtual weld puddle having dynamic, real time molten metal fluidity and heat dissipation characteristics, responsive to performing a simulated welding activity in real time. The simulator may include a foot pedal device in operative communication with the logic processor based subsystem and configured to affect a characteristic of the virtual weld puddle in real time, responsive to user control of the foot pedal device. The simulator may be configured to track the movements of a mock welding tool and a mock filler wire and determine interaction between the virtual weld puddle, a corresponding virtual welding tool, and a corresponding filler wire in virtual reality space that would result in the welding tool becoming contaminated.

An electric arc welding apparatus for depositing molten metal from an advancing welding wire into a weld puddle in an open root between two juxtapositioned plates where the root extends in a welding path and is formed by converging walls terminating in generally parallel walls spaced to define a gap, which apparatus comprises a contact holder with a wire outlet, a switching power supply directing welding current to the wire as the wire passes from the outlet toward the open root, with the advancing wire defining an electrode stick out between the contact holder and the weld puddle, a circuit for sensing the length of the stick out, and control means for adjusting the welding current as a function of the sensed stick out length.

A metal distribution system for the simultaneous production of a plurality of logs or round billets from molten metal comprising: 1) a trough for the introduction of molten metal; 2) a plurality of side streams extending from the trough and each of the side streams including a plurality of opposing apertures each of the apertures including a thimble for the shaping of molten metal passing through the trough and the side streams and into the thimbles. A uniform flow of molten metal into the side streams and the individual apertures is provided by the controlled negative angular orientation of the most upstream opposing pair of apertures thereby providing relative uniformity of the temperature of molten metal reaching each of the plurality of apertures. A unique unitized thimble configuration and trough damming arrangement are also described.

The disclosed method relates to manufacture of a near net-shaped products such as ceramic containing products such as ceramic-metal composites. The method entails forming a mixture of a build material and a binder and depositing that mixture onto a surface to produce a layer of the mixture. An activator fluid then is applied to at least one selected region of the layer to bond the binder to the build material to yield a shaped pattern. These steps may be repeated to produce a porous whitebody that is heat treated to yield a porous greenbody preform having a porosity of about 30% to about 70%. The greenbody then is impregnated with a molten material such as molten metal. Where the build material is SiC, the molten metal employed is Si to generate a SiC—Si composite.

A device for use in a molten metal pump helps alleviate jams between a rotating rotor and stationary inlet. The device includes an inlet structure including one or more openings and a displacement structure that preferably includes one or more rotor blades. The inlet structure and displacement structure are connected to one another (preferably, but not necessarily, as a unitary piece), thus enabling them both to rotate. A pump including the device is also enclosed. The invention further includes a bearing surface for an impeller or for a device according to the invention, wherein the bearing surface includes grooves that help reduce molten metal build up between the bearing surface of the impeller or device and the bearing surface of a pump chamber.

Improved components for a molten metal pump include a coupling for connecting a rotor shaft to a motor shaft, a rotor shaft and a rotor. The rotor shaft has a first end and a second end wherein the first end optionally has a vertical keyway formed in the outer surface of the shaft. The second end optionally has flat, shallow threads. The coupling can be one-piece or multi-piece, includes a cavity for receiving the first end of the rotor shaft and, if the first end of the rotor shaft has a keyway, the coupling includes a projection in the cavity for being received at least partially in the keyway. The rotor includes a connective portion that connects to the second end of the rotor shaft. If the second end of the rotor shaft includes flat, shallow threads, the connective portion is essentially a bore having flat, shallow threads configured to receive the second end of the rotor shaft. Optionally, the first end of the rotor shaft may have flat, shallow threads in which case the coupling would have a cavity that receives the first end of the rotor shaft, wherein the cavity has flat, shallow threads.

Metal nanowires, such as silver nanowires coated on a substrate were fused together to form fused metal nanowire networks that have greatly improved conductivity while maintaining good transparency. Materials formed form the fused metal nanowire networks described herein can have a transparency to visible light of at least about 85% and a sheet resistance of no more than about 100 Ohms / square or a transparency to visible light of at least about 90% and a sheet resistance of no more than about 250 Ohms / square. The method of forming such a fused metal nanowire networks are disclosed that involves exposure of metal nanowires to various fusing agents on a short timescale. When formed into a film, materials comprising the metal nanowire network demonstrate low sheet resistance while maintaining desirably high levels of optical transparency, making them suitable for transparent electrode formation.

A centrifugal pump has a pump base with inlet inducer openings that receive molten metal into an impeller chamber. An impeller structure in the impeller chamber passes the metal in a radial direction through an outlet inducer opening into a volute passage for discharge into the pool of metal in which the pump is located.

A method of making a microelectronic assembly includes providing a microelectronic element having a front face and contact pads accessible at the front face, providing a dispensing tool containing a molten metal and having a discharge port for dispensing the molten metal, and aligning the discharge port of the dispensing tool with one of the contact pads of the microelectronic element. A mass of the molten metal is dispensed through the discharge port and onto the one of the contact pads of the microelectronic element; and ultrasonic waves are applied to the mass of molten metal during the dispensing step for facilitating wetting of the mass of molten metal with the one of the contact pads of the microelectronic element.

A shaft coupling apparatus used in a pump assembly for pumping molten metal. The apparatus includes an impeller shaft, a drive shaft, and first and second coupling members. The first member engages the impeller shaft and includes a tube and two diametrically opposed pins. The second member includes a sleeve having an inner diameter adequate to receive the tube, a plate fixed to the sleeve having a mating surface cooperatively aligned with a mating surface of the impeller shaft, structure defining pin receiving slots, each slot adapted for guiding a pin into a retained position extending through the slot, and structure defining a plurality of voids in a sleeve outer surface. The pins and voids are rotatably engagable by a tool set such that the impeller and motor shafts are connectable and disconnectable by manual operation of the tool set. The apparatus may form a quick disconnect / connect gas injection shaft.

A molten metal pump including a pump base with an inlet and outlet, a mixing impeller chamber for mixing gas and molten metal, a pumping impeller chamber for pumping molten metal. First and second impeller members supported by a shaft are adapted to rotate in mixing and pumping chambers respectively. The impeller members may be integrally formed of a single impeller or separate impellers on one or more shafts. A gas passageway extends from a gas source to the mixing chamber in the base. A gas dispersement pump includes a base with an impeller chamber and inlet and an outlet. An impeller is mounted to a shaft and adapted to be rotated in the impeller chamber. A gas passageway extends from a gas source to a gas outlet proximate to the impeller chamber. A gas dispersement member of porous refractory material is adapted to disperse gas from the gas passageway. In a gas dispersement and gas / molten metal mixing pump, the dispersement member disperses the gas stream entering the mixing chamber where the gas is mixed with molten metal. Molten metal is pumped in the pumping chamber. A gas / molten metal mixture is discharged from the mixing chamber and molten metal is discharged from the pumping chamber.

A method for repair welding a titanium compressor blisk using laser twist welding. A blisk assembly has damaged portions removed. The surface to be repaired is provided with a predetermined geometry. The portions to be repaired are surrounded by a fixture which contains a laser nozzle. The fixture can provide a protective atmosphere to the area under repair while also shielding adjacent areas from damage resulting form welding. The welding is accomplished using preprogrammed patterns. The welding within the fixture is monitored remotely and is adjusted when stand-off between the weld nozzle and the molten metal are not within a predetermined range.

One aspect of the invention is directed to an impeller made of a non-metallic, heat resistant material, comprising a generally cylindrical shaped body, first and second generally planar end faces and a side wall extending between the first and second faces. A plurality of passages have inlets circumferentially spaced apart from each other on the first face, outlets at the impeller sidewall, and connecting portions extending between the inlets and the outlets transverse to the central axis. Another aspect of the invention is directed to an impeller comprising a central hub portion and first and second impeller bases, including end faces, transverse to a central axis. Vanes extend from the central hub portion between the impeller bases. Cavities are formed between the impeller bases and between adjacent vanes. Molten metal inlets on the end faces for molten metal to reach the cavities. Pumps are also disclosed using the inventive impellers.

A molten metal pump system which generally provides a refractory connection joint for connecting a refractory pump post to a pump base, the pump post including a refractory post with a first end, the first end including an internal joint peg aperture; a refractory base with a post aperture configured to receive the first end of the refractory post, and with a peg aperture contiguous with the post aperture; and a joint peg with a first end and a second end, the joint peg including a retention shoulder, the joint peg configured to insert through the peg aperture in the refractory base with a retention bar or bolt inserted through an aperture in the joint peg of refractory post, and the retention shoulder engaging the refractory base.

The present invention features a vortexer apparatus including a vessel comprising an exterior surface, an interior surface containing fluid and a mouth for receiving material at an upper end portion of the interior surface. In one application the material is metal scrap that is melted in molten metal as the fluid. All components that contact the molten metal are formed of refractory material. An outlet passageway extends downwardly from the interior surface. A vessel inlet opening is located between the exterior and interior surfaces above the outlet passageway. A center line passes through a center of the interior surface and the vessel inlet opening is disposed at a location offset from the center line. A pump is adapted to pump fluid into the vessel effective to form a vortex of fluid in the vessel. The base and impeller are configured and arranged effective to provide molten metal leaving the base outlet with a positive pressure. An outlet conduit extends from the base outlet to near the vessel inlet opening and can be maintained at a temperature above which molten metal solidifies, along its entire length. Instead of the vortexer vessel, the inventive vortexer apparatus may integrate a chamber of a furnace (e.g., a charge well). The chamber may be rectangularor include arcuate portions. Corner inserts may be used to provide the chamber with an oval or generally circular shape that may facilitate the vortex. One feature of the invention is a vortex vessel that includes an offset inlet opening and lower circulation opening. Also featured is a baffle impeller that may be vaned or barrel type. In addition, the invention features a pump having upper and lower impeller chambers separated by a web in the base, and impeller outlets that are isolated from fluid communication with each other.

A system for transferring molten metal from a vessel and into one or more of a ladle, ingot mold, launder, feed die cast machine or other structure is disclosed. The system includes at least a vessel for containing molten metal, an overflow (or dividing) wall, and a device or structure, such as a molten metal pump, for generating a stream of molten metal. The dividing wall divides the vessel into a first chamber and a second chamber, wherein part of the second chamber has a height H2. The device for generating a stream of molten metal, which is preferably a molten metal pump, is preferably positioned in the first chamber. When the device operates, it generates a stream of molten metal from the first chamber and into the second chamber. When the level of molten metal in the second chamber exceeds H2, molten metal flows out of the vessel and into another structure, such as into one or more ladles and / or one or more launders.

A device for releasing gas into molten metal includes a base having a discharge. The discharge has a first section including a first cross-sectional area and a second section including a second cross-sectional area, wherein the first section is upstream of the second section and the first cross-sectional area is smaller than the second cross-sectional area. A gas-release opening is positioned so that it can release gas into one or more of the first section or the second section. As the molten metal moves from the first cross-sectional area to the second cross-sectional area gas is released into the molten metal and the molten metal flow helps to draw the gas into the flow, thereby lowering the pressure required to release gas into the molten metal. Metal-transfer conduits other than a discharge incorporated in a pump base are also disclosed, as are pumps including either a discharge or other metal-transfer conduit according to the invention.

An improved post clamp for a molten metal pump includes a support post clamp that supports the weight of a pump superstructure on the top of the support posts. The clamp preferably includes (a) a bottom flange for connecting to the pump superstructure, (b) a cavity for receiving an end of a support post, wherein the end has a top surface, and (c) a top flange for being positioned above the top surface. In operation the top flange rests on the top surface of the support post thereby supporting at least part of the weight of the superstructure. It is preferred that a plurality of support posts and post clamps according to the invention be used with a molten metal pump wherein the top surface of each support post supports some of the weight of the superstructure. Also disclosed are novel support posts that may be used with the post clamp, and a pump in which the post clamp and / or support posts may be used.

A device for use in a molten metal pump helps alleviate jams between a rotating rotor and stationary inlet. The device includes an inlet structure including one or more openings and a displacement structure that preferably includes one or more rotor blades. The inlet structure and displacement structure are connected to one another (preferably, but not necessarily, as a unitary piece), thus enabling them both to rotate. A pump including the device is also enclosed. The invention further includes a bearing surface for an impeller or for a device according to the invention, wherein the bearing surface includes grooves that help reduce molten metal build up between the bearing surface of the impeller or device and the bearing surface of a pump chamber.

An inline degassing apparatus for removing solid solution gases as well as nonmetallic inclusions from molten metal in a degassing container, to which the molten metal is continuously introduced for degassing operation and from which the degassed molten metal is continuously removed. A rotary diffusing device is arranged in the degassing container for generating bubbles of inert gas diffused into the molten metal, thereby entrapping solid solution gases as well as nonmetallic inclusions into the bubbles, which are then floated and separated. Heaters are provided, which extend, in a cantilever fashion, from a side wall of container at a position adjacent the bottom wall of the container substantially parallel to the bottom wall.

An apparatus for filtering molten metal held in a vessel before the metal enters the dosing tube. The filtering apparatus includes an attachment portion that mounts to the dosing tube, a filter body connected to the attachment portion and a planar surface attached to an end of the filter body opposite the attachment portion. The filter body can include a beveled end opposite the attachment portion where the planar surface is attached. The apparatus can be made from a bonded-particle material made from silicon carbide or aluminum oxide held together by an aluminum-resistant binder.

Disclosed are components covered with a protective coating for use in a molten metal bath (or comparable environment) and devices including such components. The protective coating is preferably a ceramic sleeve adhered to a non-coated component by cement. A component with the protective coating is more resistant to degradation in molten metal than is the component without the coating, and may be manufactured by the process of (a) placing the protective coating over the non-coated component, and (b) injecting cement into the space between the non-coated component and protective coating, wherein at least some of the cement is injected through a passage in either the non-coated component or the protective coating.

A method for making a turbine airfoil includes providing a mold core and an outer shell which cooperatively define a cavity in the shape of a hollow airfoil having an outer wall, a root, and a tip. A tip portion of the core extends completely through the portion of the cavity defining the tip of the airfoil. The core is restrained to prevent movement between the core and outer shell. Molten metal is introduced into the cavity and solidified to form an airfoil having at least one outer wall which defines an open tip and a hollow interior. A metallic tip cap is formed on the outer wall which substantially closes off the open tip. The tip cap may be formed by packing the airfoil with metallic powder; and laser sintering the exposed powder so as to form a tip cap which is metallurgically bonded to the outer wall.

The present invention includes a molten metal pump and associated components that enable gas to be released into a stream of molten metal. The gas may be released into the molten metal stream (preferably into the bottom of the stream) flowing through a passage. Such a stream may be within the pump discharge and / or within a metal-transfer conduit extending from the pump discharge. The gas is released by using a gas-transfer foot that is positioned next to and is preferably attachable to the pump base or to the metal-transfer conduit. Preferably, the conduit (and / or discharge) in which the gas is released comprises two sections: a first section having a first cross-sectional area and a second section downstream of the first section and having a second cross-sectional area, wherein the second cross sectional area is larger than the first cross-sectional area. Preferably, the gas is released into or near the second section so that the gas is released into an area of relatively lower pressure.

A molten metal pump system which generally provides a refractory connection joint for connecting a refractory pump post to a pump base, the pump post including a refractory post with a first end, the first end including an internally threaded joint screw aperture; a refractory base with a post aperture configured to receive the first end of the refractory post, and with a screw aperture contiguous with the post aperture; and a joint screw with a first end and a second end, the joint screw including a threaded external surface and a retention shoulder, the joint screw configured to insert through the screw aperture in the refractory base with the threaded external surface engaging the internally threaded joint screw aperture of the refractory post, and the retention shoulder engaging the refractory base.

Improved components for a molten metal pump include a coupling for connecting a rotor shaft to a motor shaft, a rotor shaft and a rotor. The rotor shaft has a first end and a second end wherein the first end optionally has a vertical keyway formed in the outer surface of the shaft. The second end optionally has flat, shallow threads. The coupling can be one-piece or multi-piece, includes a cavity for receiving the first end of the rotor shaft and, if the first end of the rotor shaft has a keyway, the coupling includes a projection in the cavity for being received at least partially in the keyway. The rotor includes a connective portion that connects to the second end of the rotor shaft. If the second end of the rotor shaft includes flat, shallow threads, the connective portion is essentially a bore having flat, shallow threads configured to receive the second end of the rotor shaft. Optionally, the first end of the rotor shaft may have flat, shallow threads in which case the coupling would have a cavity that receives the first end of the rotor shaft, wherein the cavity has flat, shallow threads.

A device for releasing gas into molten metal includes a base having a discharge. The discharge has a first section including a first cross-sectional area and a second section including a second cross-sectional area, wherein the first section is upstream of the second section and the first cross-sectional area is smaller than the second cross-sectional area. A gas-release opening is positioned so that it can release gas into one or more of the first section or the second section. As the molten metal moves from the first cross-sectional area to the second cross-sectional area gas is released into the molten metal and the molten metal flow helps to draw the gas into the flow, thereby lowering the pressure required to release gas into the molten metal. Metal-transfer conduits other than a discharge incorporated in a pump base are also disclosed, as are pumps including either a discharge or other metal-transfer conduit according to the invention.

A system for adding gas to and transferring molten metal from a vessel and into one or more of a ladle, ingot mold, launder, feed die cast machine or other structure is disclosed. The system includes at least a vessel for containing molten metal, an overflow (or dividing) wall, a device or structure, such as a molten metal pump, for generating a stream of molten metal, and one or more gas-release devices.