US3753690A - Treatment of liquid metal - Google Patents

Treatment of liquid metal Download PDF

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US3753690A
US3753690A US00071112A US3753690DA US3753690A US 3753690 A US3753690 A US 3753690A US 00071112 A US00071112 A US 00071112A US 3753690D A US3753690D A US 3753690DA US 3753690 A US3753690 A US 3753690A
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metal
flux
molten
bed
molten metal
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E Emley
M Brant
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British Aluminum Co Ltd
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British Aluminum Co Ltd
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B21/00—Obtaining aluminium
    • C22B21/06—Obtaining aluminium refining
    • C22B21/066—Treatment of circulating aluminium, e.g. by filtration
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/02—Making non-ferrous alloys by melting

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  • This invention relates to improvements in the treatment of liquid metal, particularly but not exclusively molten aluminium and especially molten aluminium intended for the production of ingots for working.
  • liquid aluminium contains varying amounts of non-metallic constituents, i.e. gas and non-metallic inclusions, and that their presence may give rise to defects in finished products.
  • non-metallic constituents i.e. gas and non-metallic inclusions
  • Many procedures have been proposed for the removal of the gas and inclusions.
  • the gas content may be reduced to an acceptable level by bubbling chlorine, nitrogen or argon through the melt or by treatment of the metal with hexachlorethane.
  • the use of chlorine and hexachlorethane give rise to a fume disposal problem necessitating expensive equipment, whereas with the nitrogen treatment as heretofore proposed, the metal becomes contaminated through formation of nonmetallic inclusions.
  • the filtered impurities are loosely contained in the filter bed and are readily released if the filter is accidentally jolted or is prodded in order to promote a faster metal flow.
  • the action of the filter bed is not one of filtration but of settlement of impurities from the liquid during quiescent flow through the many channels between the flakes.
  • a process for removing non-metallic constituents in motlen metal especially aluminium which comprises flowing the metal through a multiplicity of flux-lined channels.
  • the channels are desirably provided by a bed or layer of coarse refractory granules coated with a flux.
  • the coarse refractory granules are preferably of alumina and may be in the form of alumina balls of approximately 54 in. diameter and preferably not less than in. diameter.
  • Suitable flux compositions are given in Table 1 below.
  • the treated metal can, if desired, be stripped of any entrained chloride by passing it through a bed of uncoated granules, for example, alumina balls, which are readily wetted by chloride-base fluxes.
  • the cleaning step of the present invention is very effective in removing non-metallic constitutents, it is less so in removing clusters of intermetallic particles, e.g. titanium-rich particles, which may be suspended in the liquid metal.
  • the metal may be flowed through a second bed composed of uncoated refractory granules, whereby the intermetallic particles settle out in the interstices of the second bed.
  • the metal is flowed upwardly through the second bed.
  • the zdirtyin'g effect produced by nitrogen treatment of-lthe molten metal can be materially reduced, if not entirely obviated, by introducing the nitrogen intov the molten metal whilst maintaining a continuous liquid flux cover over the molten metal.
  • This treatment is not limited to the use of nitro-. gen as other gases inert to the molten metal being treated, such as argon, carbon monoxide and carbon dioxide may be used at least with some alloys.
  • the invention provides a process for removing non-metallic constituents from molten metal, especially aluminium, by passing a substantially inert gas therethrough whilst maintaining a liquid flux cover over the molten metal and subsequently flowing the metal through a device comprising a plurality of flux-lined channels.
  • the gas e.g. nitrogen
  • the gas e.g. nitrogen
  • the worst conditions for dirtying the metal are provided by introducing the gas through porous graphite or carbon tubes in the absence of a flux cover.
  • carbonaceous tubes can be employed if the liquid flux cover is maintained over the molten metal and especially where the latter is subsequently flowed through a bed or layer of coarse refractory granules coated with flux.
  • Even a perforated iron tube can be used, but this is not preferred since, even though the metal does not become dirtied, any protective dressing applied to the tube is liable to become wetted by the flux cover with consequent attack of the tube by the motlen aluminium.
  • the iron tube may be coated with a vitreous enamel to reduce attack by molten aluminrum.
  • a porous non-carbonaceous refractory tube or brick is used for introducing the nitrogen and a liguid flux cover is applied to the metal surface, then dirtying of the metal does not occur.
  • metal which has been made dirty for experimental purposes e.g. by addition of a porportion of oily swarf and/or by nitrogen treatment through a graphite tube in the absence of a flux cover, can actually be cleaned by providing a liquid flux cover and gassing the metal with nitrogen.
  • Such a process of degassing under a liquid flux is not readily applicable to the treatment of metal in a holding furnace such as the large reverberatory furnaces used in conventional practice, because of the quantity of flux required to maintain aliquid flux film over such a large area; it may however be carried out in a forewell to, or alcove, or cubicle within, such a reverberatory furnace or in a vessel of small cross-sectional area placed between the holding furnace and the casting machine and through which the metal is caused to flow.
  • liquid aluminium is cleaned and degassed in continuous manner by causing a stream of liquid metal to flow through a containing vessel of such capacity in relation to the metal flow that the residence time of the .metal in the containing vessel is at least 1% min., passing a substantially inert gas into the metal in the containing vessel at a rate sufficient to provide at least 10 cu.ft. per ton of liquid metal, and maintaining a cover of liquid flux upon the surface of the metal in the containing vessel.
  • the residence time of the metal in the degassing chamber' is at least 3 min.
  • the inert gas is preferably nitrogen.
  • the nitrogen flow rate may conveniently be such as to provide 30 cu.ft. per ton liquid metal in order to give a wide margin of safety, but good results have been obtained with flow rates as low as 10 cu.ft. per ton.
  • the minimum quantity of flux required is 1 lb for each 100 sq.in. of surface area of liquid metal in the degassing chamber and 2-3 lb per 100 sq.in. is preferred.
  • the degree of turbulence required is vigorous but should not be so great as to give rise to splashing of metal from the containing vessel.
  • Introduction of the required flow rate of gas into a chamber of the required size will normally result in an adequate degree of turbulence when the gas is diffused in through porous refractory bricks, tubes or diffuser plates. If a greater degree of turbulence is needed it is possible to introduce a proportion of the nitrogen into the degassing chamber through one or more narrow tubes whereby the jets of gas so produced give rise to a tumbling action of the metal which enhances the cleaning and degassing effect. lt is possible in this way to reduce the total flow rate of gas required. Satisfactory results have also been obtained where the whole of the nitrogen is introduced via jets.
  • the temperature of the molten aluminium during treatment should normally be in the range of 675-800C. 700-750C being preferred.
  • the metal is passed through a layer or column of uncoated coarse refractory granules in the second chamber and is then ready to be cast.
  • FIG. I is a somewhat schematic sectional view of an apparatus for degassing and cleaning molten aluminium in accordance with the invention.
  • FIG. 2 is a view similar to FIG. 1 illustrating a modification
  • FIGS. 3, 4 and 5 illustrate modifications of a part of the apparatus shown in FIG. 1;
  • FIG. 6 is a view similar to FIG. 1 but illustrating a further modification
  • FIGS. 7 and 8 illustrate still further modifications
  • FIG. 9 is a sectional view of an apparatus suitable for cleaning and degassing molten metal
  • FIG. 10 is a fragmentary view illustrating a modification of the apparatus of FIG. 9;
  • FIG. 11 is a sectional view of another cleaning and degassing apparatus
  • FIG. 12 is a sectional view of a further cleaning and degassing apparatus
  • FIG. I3 is a sectional view of another cleaning and degassing apparatus
  • FIGS. 14A and 14B are plan and sectional views respectively, of part of a reverberatory furnace modified for use in the method according to the invention.
  • FIGS. 15A and 15B are plan and sectional views respectively, of part of a reverberatory furnace modified in an alternative manner for use in the method according to the invention.
  • a crucible l having a long pouring lip la is fitted with a baffle 2 which extends into the crucible and effectively divides it into two chambers A and B which are in communication by way of a space left below the baffle 2.
  • a tube 3 extends into the chamber A towards the floor thereof and terminates in a-porous plug 3a of non-carbonaceous refractory material.
  • a gas jet 4 is provided externally of the crucible 1 to heat the contents thereof.
  • a bed of flux-coated alumina balls 5 of about l4 in. diameter is provided in the chamber A and a bed of uncoated alumina balls of about 36 in. diameter is provided in the chamber B.
  • the bed of uncoated balls 6 can extend below the baffle 2 and below the bed 5.
  • a launder 7 is provided to flow molten aluminium from a holding'furnace (not shown) to the chamber A.
  • the pouring lip Ia extends from the chamber 8 to a casting launder 8.
  • a body of molten aluminium is maintained in the chamber A and a flux cover 9 is maintained thereover.
  • Molten aluminium enters the chamber A from the launder 7 by falling through the flux cover 9.
  • the metal is degassed by a gas such as nitrogen which is supplied through the tube 3 and escapes from the plug 3a to bubble up through the molten aluminium in chamber A.
  • a gas such as nitrogen which is supplied through the tube 3 and escapes from the plug 3a to bubble up through the molten aluminium in chamber A.
  • the molten aluminium therefore leaves the launder 7, falls through the flux cover 9 into chamber A where it is degassed by the nitrogen, flows downwards through the bed of flux-coated balls 5 in which non-metallic inclusions are removed, passes under the baffle 2 and upwards through the bed of uncoated balls 6 in which intermetallic particles and residual flux are removed and then flows out over the pouring lip Ia to the casing launder 8 in a condition ready for casting.
  • FIG. 2 The arrangement shown in FIG. 2 is similar in many respects to that described with reference to FIG. 1 and like references are used to denote like parts.
  • the crucible 1 of the previous example is replaced by a box lb lined with refractory brick and the plug 3a is replaced by a porous refractory tube 3b of noncarbonaceous material.
  • the launder 7 opens to the chamber A below the level of the flux cover 9 which is confined between the baffle 2 and a further baffle 2a and the walls of the box lb.
  • the baffle 2a also serves to skim the molten aluminium flowing to the chamber A from the furnace tap hole which is shown at 10.
  • the box lb would be pre-heated with a gas flame before being charged with molten aluminium and the balls 5 and 6.
  • immersion heaters may be placed in the chamber A to provide a greater control over the metal temperature.
  • FIGS. 3, 4 and 5 illustrate alternative ways in which the molten aluminium can be introduced into the chamber A from the launder 7.
  • the launder 7 terminates in a spout 7a which extends through the flux cover 9.
  • the launder 7 terminates in a ,slight bowl the floor of which is in the fonn of a perforated refractory screen 7b which breaks up the molten metal as it enters the chamber A.
  • the porous screen 7b is disposed within the flux cover 9 and in the embodiment shown in FIG. 5 it is disposed above the flux cover 9.
  • a splash plate immersed in the flux cover 9 may be used in order to break up the molten aluminium as it enters the chamber A' and so assist in the cleaning and degassing of the molten metal.
  • the chambers A and B of the previous examples are followed by further chambers C and D defined by additional baffles 2b and 2c, the baffle 2b extending upwardly from the floor of the crucible I or box la (as the case may be) to below the level of the molten aluminium and the baffle 2c extending downwardly into the molten aluminium and into a further bed of uncoated coarse refractory balls 6a, e.g. of alumina, of about )4 in. diameter.
  • uncoated coarse refractory balls 6a e.g. of alumina, of about )4 in. diameter.
  • the molten aluminium leaving the chamber B flows over the baffle 2b into the chamber C, downwardly through the bed of uncoated balls 6a, under the baffle 20, upwardly through the bed of uncoated balls 6a and out over the casting launder 8.
  • This passage of the metal through the bed of balls 6a renders the treatment more effective particularly in respect of stripping the metal of any residual flux entrained therein due to the downward flow of the metal through the uncoated balls 6a in the chamber C.
  • the flux being lighter than the molten aluminium tends to rise in the chamber.
  • the two stages of the process described above namely, the first stage of degassing the molten aluminium and flowing it through the bed of flux-coated balls 5 and the second stage of flowing it through a bed of uncoated balls 6, can be carried out in separate vessels.
  • the chamber B could be omitted and replaced by chambers C and D, also where space between the holding furnace is not sufficient to accommodate apparatus such as shown in FIG. 2, at least one of the beds of balls 5 and 6 could be disposed along the casting launder 8 and retained by suitable baffles.
  • the degassing step could be carried out under a flux cover in the holding furnace, for example, in an alcove or forewell thereof.
  • FIG. 7 Another way of separating the process into two convenient stages is shown in FIG. 7. This is very similar to that shown in FIG. 6 except in this case the chambers A and B are contained in one crucible l and the chambers C and D are contained in a separate crucible 11, the two crucibles communicating by way of a launder 12. Also, in this example, the molten metal is introduced into the chamber A below the flux layer 9 by way of baffle 2a as in the example illustrated in FIG. 2 and the nitrogen is introduced through a side wall to escape from the porous refractory tube 3b.
  • the degassing under the flux is carried out in a separate first vessel 13 which may be a brick-lined box, the metal being introduced below the flux-layer 9 by means of baffle 2a and flowing under baffle 2 upwards to spill over into the launder 12 from which it pours into the baffled crucible 14 containing a bed of alumina balls of which at least the upper layers are flux-coated balls 5 followed on the other side of the baffle 2 by a bed of uncoated balls 6.
  • the bed of balls 5 need not initially be coated with flux as it takes but a few minutes of operation of the process for at least enough of them to become sufficiently coated with flux for the process to operate efficiently.
  • the nitrogen is supplied to the molten metal under the flux cover 9 through two porous refractory tubes 3b.
  • the porous refractory non-carbonaceous material used to introduce the gas, e.g. nitrogen, into the molten aluminium may be of any suitable known type. Examples are refractories with a high alumina content, silicon carbide, silicon carbide bonded with silicon nitride and zircon. These are generally satisfactory if of sufficient porosity, but a high silica content should be avoided. Lumps of the refractory material may be shaped into plugs or bricks and drilled to receive a refractory tube through which the gas is fed to the plug, or the refractories may be in tube form. The porous plugs or tubes may be cemented into the walls of the vessel or may even form part of the floor.
  • the granules should be of such a size as to be retained by a a in. screen and in. diameter balls are preferred.
  • the temperature of the molten aluminium during treatment should be in the range of 675-800C, 700750C being preferred.
  • the flux should be substantially free from oxides, oxysalts and fluosilicates and from volatile halides. It should consist essentially of the chlorides and fluorides of the alkali and alkaline earth metals including magnesium and should be thinly fluid at the melting point of the metal; when melted it should have a lower density than liquid aluminium.
  • Flux A As a flux for coating the balls and for providing a liquid flux cover on the top of the metal in the degassing chamber, mixtures of KCl and NaCl with small additions of CaF, are normally preferred (Flux A). Additions of NaF or cryolite may be included to reduce the melting point (Flux B), but a small amount of sodium will then be introduced into the metal and this may be detrimental to aluminium-magnesium alloys, e.g. of the A A 5356 type. For such alloys it is preferable to use a flux which, far from introducing sodium into the al loy, will reduce the very small content initially present as an impurity in primary metal. Suitable fluxes contain MgCl (Fluxes C, F.G.H.).
  • the method of the present invention may be applied to the continuous removal of sodium from liquid metal without the generation of objectionable fumes such as occur when liquid aluminium is treated with chlorine or hexachorethane.
  • a heavy fluid flux may be used to coat the alumina balls and thereby obviate the risk of flux being washed off the balls by the flow of aluminium (Fluxes 9 a 10 D and E).
  • Such fluxes contain BaCl and are in consewhich result have been in the range 0.12-0.17 quence more expensive.
  • cm /lOg which, though very satisfactory for normal using a flux of type A in that as the cleaning process purposes, is not as low as the figures obtained with the proceeds any flux which becomes entrained in the process of the present invention (0.04-0.12 cm/i00g).
  • the metal charge used consisted entirely of scrap granules followed by the bed or column of uncoated metal and included approximately l ton ofscalpings. in granules will ensure a high degree of freedom from this particular experiment the porous refractory tube oxide inclusions etc., it is possible by controlling the shown in FIG. 2 was replaced by porous carbon, so that conditions, as already indicated, to remove nonthe experiment represented a severe test of the effimetallic inclusions so effectively at the prior stage of ciency of the equipment in removing inclusions as well nitrogen treatment under a liquid flux cover that subseas gas.
  • baffles By placing one or more baffles in the exit launder from the degassing chamber it is possible to prevent seepage of liquid flux into the casting, but this can be more effectively ensured by applying to the metal surface on the inflowing side of an exit launder baffle a thin layer of powdered CaF or MgF This layer may be confined by two baffles to a short length of the launder, e.g. 6-9 in.
  • the CaF may if desired, be applied also to the surface of the metal in the exit chamber.
  • CaF may be replaced by an inspissated flux of the kind well known in the magnesium industry so as to form a pasty viscous flux cover with a high absorptive power for fluid fluxes of the type shown in Table l.
  • a crucible 101 provided with a baffle wall 102 extending towards the floor of the crucible to form the chambers A and B.
  • a launder 103 supplies molten metal to the chamber A allowing it to pass through a flux cover 104 floating on the metal in the chamber A.
  • the launder 103 can be disposed to admit molten metal to the chamber A under the flux cover 104 or into the flux cover 104.
  • a porous plug 105 for admitting the inert gas, which is preferably nitrogen, into themolten metal. Molten metal flows through the chamber A under the baffle 102 to the chamber B and overflows along an exit or casting launder 106.
  • a shallow bed 7 of in. diameter alumina balls may be disposed in the chamber A to provide a layer a few balls thick over the porous plug 105 to reduce buoyancy effects and to assist in absorbing inclusions.
  • the bed 107 of balls may extend to a point above the level of the base of the baffle 102 to reduce possible channelling effects of the molten metal in its flow from chamber A to chamber B. Additionally, also as shown, the bed 107 of balls may extend into the chamber B.
  • the bed 107 of balls tend to remove any flux entrained in the metal passing therethrough.
  • a launder baffle 108 may be disposed in the exit or casting launder 106 to prevent seepage of liquid flux to the casting location. This can even more effectively be prevented by applying to the metal surface on the inflowing side of the exit launder baffle 108 a thin layer 109 of powdered CaF, or MgF,.This can extend over the surface of the metal in the chamber or can be confined between two baffles 108a and 108b in the exit or casting launder a shown in FIG. 10.
  • the apparatus of FIG. is generally similar to that of FIG.9 and comprises a crucible 101 divided by a batfle 102 into chambers A and B.
  • Chamber A is supplied with molten metal through a launder 103, the molten metal passing under a flux cover 104 being prevented from running back along the launder by a baffle 110.
  • An open ended graphite tube 111 extends into the chamber A for admitting nitrogen into the molten metal.
  • the molten metal flows through the chamber A under the baffle I02 to the chamber II and overflows into an exit launder H2.
  • the launder 2 may lead direct to a casting launder (not shown) or to an intermediate baffled crucible (not shown) filled with coarse alumina balls or other coarse refractory granules.
  • the apparatus of FIG. 12 comprises a box of refractory brick divided by a baffle 102 into two chambers A and B.
  • Immersion heaters each consisting of a refractory sheath 121 of silicon carbide or nitride containing a gas burner 122 extend into the chamber A.
  • Molten metal enters the chamber A from a launder 103 and falls in a short unsupported stream 123 through a flux cover 104.
  • Rows of porous brick 124 communicate with steel tube inserts 125 through which nitrogen is directed into the chamber A.
  • the molten metal flows through the chamber A, under the baffle 102 to the chamber B and overflows into an exit launder 126 where entrapped salts are removed by means of a baffle 127 and a layer 128 of fluospar.
  • a refractory brick box 120 is divided into three chambers A, B and C by baffles 102 and 132.
  • a low deflecting wall 133 extends upwardly from the base of the box 101 between the baffles 102 and 132.
  • Molten metal enters the chamber A from a launder 103 and falls in a stream 123 through a flux cover 104 as described with reference to FIG. 12.
  • Nitrogen is introduced into the chamber A through a graphite tube 111 as described with reference to FIG. 3.
  • the molten metal flows through the chamber A under the baffle 102 and is deflected upwardly into chamber C by the wall 133.
  • the metal flows from the chamber C under the baffle 132 into the chamber B and overflows into an exit launder 134.
  • Flux (c) was applied to the metal surface in the ingoing chamber in amount corresponding to 3 lb per I00 sq.in. of surface area.
  • Coarse alumina balls (V4 in. diameter) were used to cover the diffuser tubes to a depth of two balls in the degassing chamber and to a few inches above the base of the baffle in the exit chamber.
  • Frequent Straube-Pfeiffer test samples were taken from the exit launder during the progress of the cast and the metal (12 ton) found to be of excellent quality, all the test samples being bubble-free on solidi- 'fication at a pressure of approx. 2 Torr.
  • Straube- Pfeiffer test samples were taken from the exit launder at frequent intervals during the course of the cast (12 tons) and no bubble was developed in any of the tests during solidification at a pressure of 2 Torr.
  • the sodium content of the ingoing metal was 0.0020-0.0025 percent and all outgoing samples analysed less than 0.0005 percent.
  • Two refractory baffles were placed in the outgoing launder approximately 8 in. apart and between them a layer of CaF approximately one-eighth in. deep was sprinkled on the metal surface. Chloride tests carried out on skimmings taken from the metal surface in the launder at a position 6 inches beyond the surface baffle gave negative results.
  • EXAMPLE lll ln a test similar to that of Example ll, dirty undegassed alloy of the A A 6063 type flowing at a rate of 200 lb/min, was successfully cleaned and degassed to show nil bubbles in the Straube-Pfeiffer test using a nitrogen flow rate corresponding approximately to 30 cu.ft. per ton of metal introduced via porous graphite diffusers.
  • a nitrogen flow rate corresponding approximately to 30 cu.ft. per ton of metal introduced via porous graphite diffusers.
  • the nitrogen passing through the diffusers was then reduced to approximately 15 cu.ft/ton making a total consumption of cu.ft/ton of nitrogen.
  • Metal processed by the present invention has been shown to be suitable for production of high quality semi-fabricated products for critical applications. in particular the incidence of blister defects in soft annealed sheet for deep drawing purposes is extremely low and frequently nil.
  • the corrosion resistance of the metal is somewhat better than that of conventionally furnace degassed metal, as judged by the Cass test.
  • a containing vessel such as a brick box or crucible placed between holding furnace and casting point
  • a forewell to, or an alcove within, the holding furnace itself, particularly where this is of a reverberatory type. Best results will then be obtained if the metal in the forewell or alcove is protected from direct contact with the products of combustion of the furnace.
  • brick walls may be built inwards from the wall of the furnace which includes the tapping hole, or from this wall and an adjacent wall, so as to partition off a cubicle of suitable size from the main part of the furnace, metal entering the cubicle by a passage underneath the partitioning walls or through holes left therein for the purpose.
  • a drossing door is needed through which to apply flux to the metal within the cubical walls.
  • Nitrogen or other inert gas may be introduced via porous bricks built into the floor of the cubicle or more conveniently by porous or non-porous graphite tubes, or steel orgcast iron tubes protected by vitreaous enamelling. These tubes may be introduced through the furnace walls into the cubicle. Operation of the process in a forewell or a cubicle within a reverberatoryfurnace has advantages under some conditions and particularly where it is desired to make frequent alloy changes or to operate the process intermittently.
  • the molten metal in the forewell being in direct communication with that in the main body of the reverberatory furnace will be maintained hot thereby, but if desired additional heating may be provided.
  • lFlGS. 14a and 14b show a reverberatory furnace R with a cubicle C defined by walls of refractory brick extending inwardly from walls 141 of the furnace R.
  • the walls 140 may, if desired, extend up to the ceiling (not shown) of the furnace.
  • a tapping hole 142 and a door 143 for dross removal are provided in respective walls 141 of the furnace to communicate with the cubicle C.
  • a drain hole 144 may also be provided in one of the walls 141 at a location outside the cubicle C, the floor 145 of the cubicle preferably sloping downward towards the drain hole 144.
  • Apertures 146 are provided at or near the bases of the walls 140 so that the cubicle C is in communication with the furnace R.
  • a flux cover 147 extends over the surface of the molten metal in the cubicle C and a graphite tube 148 extends into the cubicle for admitting an inert gas into the molten metal.
  • FIGS. 15a and 15b show a reverberatory furnace R with a forewell F.
  • Walls 150 extend outwardly from a wall 151 of the reverberatory furnace R to define the forewell F which is divided by a baffle [52 into two chambers F, and F Openings 153 at or near the base of the wall 151 permit the flow of molten metal to the chamber F, into which nitrogen is introduced through graphite or enamelled steel tubes 154.
  • a flux cover 155 is maintained over the liquid metal in the chamber F,.
  • the molten metal flows under the baffle 152 into the chamber F from which it flows to a casting launder (not shown) through a tapping hole 156. Heat is conserved in the molten metal by use of refractory lined lids 157. Additional heating is provided, where required, by means of gas burners 158.
  • the present invention provides a process for cleaning and degassing molten aluminium in a continuous manner which comprises flowing molten aluminium through a chamber in which a substantially inert gas such as, for example, nitrogen is passed into the metal whilst a liquid flux layer is maintained on the aluminium in the chamber, followed, if desired, by flowing the molten aluminium through a bed or column of coarse refractory flux-coated granules and then flowing the molten aluminium through a bed or column of uncoated coarse refractory granules.
  • Metal treated by this process has given excellent results when used for the production of bright anodised and other critical products.
  • the invention has application to the treatment of molten metals other than aluminium.
  • a process for removing solid, non-metallic constituents from molten metal which comprises flowing the molten metal at a temperature up to 800C. through a bed of coarse refractory granules substantially of such a size as to be retained on a in. aperture screen, while maintaining in a molten state on at least some of said granules in said bed a molten salt flux coating, said bed being submerged beneath the surface of the molten metal,
  • salt flux on said granules is in molten condition
  • said salt flux being selected from the group consisting of mixtures, which are molten at said temperature, of salts selected from the group consisting of chlorides and fluorides of alkali metals, alkaline earth metals and magnesium.
  • a process for removing non-metallic constituents including hydrogen and solid particles from liquid aluminum and its alloys in a continuous manner which comprises flowing such liquid metal at a temperature up to 800C. through a containing vessel,
  • the inert gas being passed into the container and into the liquid metal in such a manner as to create vigorous turbulence whereby a coating of said molten salt flux is produced and maintained on at least some of said granules, said salt flux being selected from mixtures of salts which are molten at said temperature and which salts are selected from the group consisting of chlorides and fluorides of alkali and alkaline earth metals and magnesium.
  • a process for removing solid non-metallic constituents from molten aluminum and its alloys in a continuous manner which comprises continuously flowing the molten metal at a temperature up to 800C. through a containing vessel, maintaining a molten salt flux layer on the surface of molten metal in the containing vessel, continuously creating vigorous turbulence in the molten metal in contact with the molten flux within the containing vessel; and
  • a flux trap comprising a bed of coarse refractory granules substantially of a size to be retained on a in. aperture screen, said bed being submerged beneath the surface of the molten metal, whereby at least some of said granules become coated with said molten salt flux,
  • said salt flux being selected from mixtures of salts which are molten at said temperature and which salts are selected from the group consisting of chlorides and fluorides of alkali and alkaline earth metals and magnesium.
  • a process in accordance with claim 10 for removing hydrogen and solid particles wherein the residence time of said molten metal in said containing vessel is at least 1% min., said vigorous turbulence is created by passing a substantially inert gas into said molten metal at a rate sufficient to provide at least 10 cu. ft. of inert gas per ton of molten metal.
  • said molten flux layer is provided in an amount of at least 1 lb. of flux for each sq. in. of surface area of said molten metal and wherein said flux is substantially free of oxides, oxysalts, fluorosilicates and volatile halides.
  • said flux trap further comprises a layer of fluoride.

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US00071112A 1969-09-12 1970-09-10 Treatment of liquid metal Expired - Lifetime US3753690A (en)

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US4032124A (en) * 1975-03-28 1977-06-28 Swiss Aluminium Ltd. Apparatus and method for in-line degassing and filtration of molten metal
US4087080A (en) * 1975-04-29 1978-05-02 Swiss Aluminium Ltd. Apparatus for filtering metal melts
US4093194A (en) * 1976-01-13 1978-06-06 E. I. Du Pont De Nemours And Company Process and reactor for making magnesium metal
US4138245A (en) * 1976-12-21 1979-02-06 Swiss Aluminium Ltd. Process for the removal of impurities from aluminum melts
US4138246A (en) * 1976-03-26 1979-02-06 Swiss Aluminium Ltd. Process for lowering the concentration of sodium in aluminum melts
US4144054A (en) * 1976-12-21 1979-03-13 Swiss Aluminium Ltd. Process for the removal of impurities from aluminum melts
US4169584A (en) * 1977-07-18 1979-10-02 The Carborundum Company Gas injection apparatus
US4394271A (en) * 1981-04-23 1983-07-19 Groteke Daniel E Apparatus and method for filtration of molten metal
WO1985004675A1 (fr) * 1984-04-13 1985-10-24 Aluminium Pechiney Perfectionnement au dispositif de traitement, au passage, d'un courant de metal ou alliage liquide a base d'aluminium ou de magnesium
EP0281508A1 (de) * 1987-02-03 1988-09-07 Alusuisse-Lonza Services Ag Vorrichtung für die Entgasung von geschmolzenem Metall
WO1992010595A1 (en) * 1990-12-11 1992-06-25 Christopher John English Apparatus and method for treating molten metal
US5171359A (en) * 1991-09-19 1992-12-15 Megy Joseph A Refractory metal SWARF composition
EP0490371A3 (en) * 1990-12-13 1993-10-06 Aluminum Company Of America Multistage rigid media filter for molten metal
WO1994008059A1 (en) * 1991-09-19 1994-04-14 Megy Joseph A Refractory metal sway composition and method of making same
US5405427A (en) * 1994-05-18 1995-04-11 Eckert; C. Edward Salt flux for addition to molten metal adapted for removing constituents therefrom and methods of using
US5435982A (en) * 1993-03-31 1995-07-25 Molten Metal Technology, Inc. Method for dissociating waste in a packed bed reactor
US5597401A (en) * 1992-10-05 1997-01-28 Megy; Joseph A. Refractory metal SWARF composition and method of making same
US5662725A (en) * 1995-05-12 1997-09-02 Cooper; Paul V. System and device for removing impurities from molten metal
US5673902A (en) * 1996-02-01 1997-10-07 Selee Corporation Dual stage ceramic foam filtration system and method
US5814126A (en) * 1994-01-12 1998-09-29 Cook; Thomas H. Method and apparatus for producing bright and smooth galvanized coatings
US5913353A (en) * 1994-09-26 1999-06-22 Ford Global Technologies, Inc. Process for casting light metals
US5944496A (en) * 1996-12-03 1999-08-31 Cooper; Paul V. Molten metal pump with a flexible coupling and cement-free metal-transfer conduit connection
US5951243A (en) * 1997-07-03 1999-09-14 Cooper; Paul V. Rotor bearing system for molten metal pumps
US6027685A (en) * 1997-10-15 2000-02-22 Cooper; Paul V. Flow-directing device for molten metal pump
US6303074B1 (en) 1999-05-14 2001-10-16 Paul V. Cooper Mixed flow rotor for molten metal pumping device
US6398525B1 (en) 1998-08-11 2002-06-04 Paul V. Cooper Monolithic rotor and rigid coupling
US6689310B1 (en) 2000-05-12 2004-02-10 Paul V. Cooper Molten metal degassing device and impellers therefor
US6723276B1 (en) 2000-08-28 2004-04-20 Paul V. Cooper Scrap melter and impeller
US20050026318A1 (en) * 2000-10-19 2005-02-03 Seiji Sarayama Crystal growth method, crystal growth apparatus, group-III nitride crystal and group-III nitride semiconductor device
US20060180962A1 (en) * 2004-12-02 2006-08-17 Thut Bruno H Gas mixing and dispersement in pumps for pumping molten metal
US7100669B1 (en) * 2003-04-09 2006-09-05 Brunswick Corporation Aluminum-silicon casting alloy having refined primary silicon due to pressure
US20080116148A1 (en) * 2004-02-17 2008-05-22 John Henry Courtenay Treatment of Metal Melts
US7402276B2 (en) 2003-07-14 2008-07-22 Cooper Paul V Pump with rotating inlet
US20080236336A1 (en) * 2007-03-27 2008-10-02 Thut Bruno H Flux injection with pump for pumping molten metal
US7470392B2 (en) 2003-07-14 2008-12-30 Cooper Paul V Molten metal pump components
US7507367B2 (en) 2002-07-12 2009-03-24 Cooper Paul V Protective coatings for molten metal devices
US7731891B2 (en) 2002-07-12 2010-06-08 Cooper Paul V Couplings for molten metal devices
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US8366993B2 (en) 2007-06-21 2013-02-05 Cooper Paul V System and method for degassing molten metal
US8444911B2 (en) 2009-08-07 2013-05-21 Paul V. Cooper Shaft and post tensioning device
US8449814B2 (en) 2009-08-07 2013-05-28 Paul V. Cooper Systems and methods for melting scrap metal
US8524146B2 (en) 2009-08-07 2013-09-03 Paul V. Cooper Rotary degassers and components therefor
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US8613884B2 (en) 2007-06-21 2013-12-24 Paul V. Cooper Launder transfer insert and system
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US3917242A (en) * 1973-05-18 1975-11-04 Southwire Co Apparatus for fluxing and filtering of molten metal
US4032124A (en) * 1975-03-28 1977-06-28 Swiss Aluminium Ltd. Apparatus and method for in-line degassing and filtration of molten metal
US4087080A (en) * 1975-04-29 1978-05-02 Swiss Aluminium Ltd. Apparatus for filtering metal melts
US4093194A (en) * 1976-01-13 1978-06-06 E. I. Du Pont De Nemours And Company Process and reactor for making magnesium metal
US4138246A (en) * 1976-03-26 1979-02-06 Swiss Aluminium Ltd. Process for lowering the concentration of sodium in aluminum melts
US4138245A (en) * 1976-12-21 1979-02-06 Swiss Aluminium Ltd. Process for the removal of impurities from aluminum melts
US4144054A (en) * 1976-12-21 1979-03-13 Swiss Aluminium Ltd. Process for the removal of impurities from aluminum melts
US4169584A (en) * 1977-07-18 1979-10-02 The Carborundum Company Gas injection apparatus
US4394271A (en) * 1981-04-23 1983-07-19 Groteke Daniel E Apparatus and method for filtration of molten metal
WO1985004675A1 (fr) * 1984-04-13 1985-10-24 Aluminium Pechiney Perfectionnement au dispositif de traitement, au passage, d'un courant de metal ou alliage liquide a base d'aluminium ou de magnesium
EP0281508A1 (de) * 1987-02-03 1988-09-07 Alusuisse-Lonza Services Ag Vorrichtung für die Entgasung von geschmolzenem Metall
WO1992010595A1 (en) * 1990-12-11 1992-06-25 Christopher John English Apparatus and method for treating molten metal
EP0490371A3 (en) * 1990-12-13 1993-10-06 Aluminum Company Of America Multistage rigid media filter for molten metal
WO1994008059A1 (en) * 1991-09-19 1994-04-14 Megy Joseph A Refractory metal sway composition and method of making same
US5171359A (en) * 1991-09-19 1992-12-15 Megy Joseph A Refractory metal SWARF composition
US5597401A (en) * 1992-10-05 1997-01-28 Megy; Joseph A. Refractory metal SWARF composition and method of making same
US5435982A (en) * 1993-03-31 1995-07-25 Molten Metal Technology, Inc. Method for dissociating waste in a packed bed reactor
US5814126A (en) * 1994-01-12 1998-09-29 Cook; Thomas H. Method and apparatus for producing bright and smooth galvanized coatings
US5405427A (en) * 1994-05-18 1995-04-11 Eckert; C. Edward Salt flux for addition to molten metal adapted for removing constituents therefrom and methods of using
US5913353A (en) * 1994-09-26 1999-06-22 Ford Global Technologies, Inc. Process for casting light metals
US5662725A (en) * 1995-05-12 1997-09-02 Cooper; Paul V. System and device for removing impurities from molten metal
US5673902A (en) * 1996-02-01 1997-10-07 Selee Corporation Dual stage ceramic foam filtration system and method
US5944496A (en) * 1996-12-03 1999-08-31 Cooper; Paul V. Molten metal pump with a flexible coupling and cement-free metal-transfer conduit connection
US6345964B1 (en) 1996-12-03 2002-02-12 Paul V. Cooper Molten metal pump with metal-transfer conduit molten metal pump
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US6027685A (en) * 1997-10-15 2000-02-22 Cooper; Paul V. Flow-directing device for molten metal pump
US6398525B1 (en) 1998-08-11 2002-06-04 Paul V. Cooper Monolithic rotor and rigid coupling
US6303074B1 (en) 1999-05-14 2001-10-16 Paul V. Cooper Mixed flow rotor for molten metal pumping device
US6689310B1 (en) 2000-05-12 2004-02-10 Paul V. Cooper Molten metal degassing device and impellers therefor
US6723276B1 (en) 2000-08-28 2004-04-20 Paul V. Cooper Scrap melter and impeller
US8562737B2 (en) 2000-10-19 2013-10-22 Ricoh Company, Ltd. Crystal growth method, crystal growth apparatus, group-III nitride crystal and group III nitride semiconductor device
US20050026318A1 (en) * 2000-10-19 2005-02-03 Seiji Sarayama Crystal growth method, crystal growth apparatus, group-III nitride crystal and group-III nitride semiconductor device
US20080282969A1 (en) * 2000-10-19 2008-11-20 Ricoh Company, Ltd, Crystal growth method, crystal growth apparatus, group-iii nitride crystal and group-iii nitride semiconductor device
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Also Published As

Publication number Publication date
SE365250B (enrdf_load_stackoverflow) 1974-03-18
FR2061246A5 (enrdf_load_stackoverflow) 1971-06-18
NL170311B (nl) 1982-05-17
AT325865B (de) 1975-11-10
CA941618A (en) 1974-02-12
GB1316578A (en) 1973-05-09
NL170311C (nl) 1982-10-18
BE756091A (fr) 1971-02-15
CH513982A (fr) 1971-10-15
US3741751A (en) 1973-06-26
IS950B6 (is) 1976-10-08
NL7013489A (enrdf_load_stackoverflow) 1971-03-16
DE2045258A1 (de) 1971-03-25
JPS556088B1 (enrdf_load_stackoverflow) 1980-02-13
IS1945A7 (is) 1971-03-13

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