US3838185A - Formation of filaments directly from molten material - Google Patents

Formation of filaments directly from molten material Download PDF

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Publication number
US3838185A
US3838185A US00251985A US25198572A US3838185A US 3838185 A US3838185 A US 3838185A US 00251985 A US00251985 A US 00251985A US 25198572 A US25198572 A US 25198572A US 3838185 A US3838185 A US 3838185A
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United States
Prior art keywords
disk
melt
molten
filament
edge
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US00251985A
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English (en)
Inventor
R Maringer
A Rudnick
C Mobley
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Battelle Development Corp
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Battelle Development Corp
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Publication date
Application filed by Battelle Development Corp filed Critical Battelle Development Corp
Priority to US00251985A priority Critical patent/US3838185A/en
Priority to IT24401/72A priority patent/IT960671B/it
Priority to GB2321772A priority patent/GB1396788A/en
Priority to CA142,464A priority patent/CA970511A/en
Priority to NLAANVRAGE7207018,A priority patent/NL171132B/xx
Priority to FR7218644A priority patent/FR2139020B1/fr
Priority to ES403231A priority patent/ES403231A1/es
Priority to BE784051A priority patent/BE784051A/xx
Priority to ES403232A priority patent/ES403232A1/es
Priority to NO1859/72A priority patent/NO139111C/no
Priority to DE19722225684 priority patent/DE2225684C3/de
Priority to CH787472A priority patent/CH555199A/fr
Priority to SE7206893A priority patent/SE378534B/xx
Priority to JP47052880A priority patent/JPS518821B1/ja
Priority to US443349A priority patent/US3904344A/en
Application granted granted Critical
Publication of US3838185A publication Critical patent/US3838185A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/005—Continuous casting of metals, i.e. casting in indefinite lengths of wire
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/10—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying using centrifugal force
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B37/00—Manufacture or treatment of flakes, fibres, or filaments from softened glass, minerals, or slags

Definitions

  • This invention relates to a method capable of the continuous production of a filament or wire, directly from a pool-like supply of molten material by the use of a rotating disk in contact with that molten material and without the use of a forming orifice.
  • the conventional method of producing metal products of small cross section such as wire involves the casting of billets and their subsequent formation into the final product by mechanical Working that may include extrusion, drawing, rolling, and other normal mechanicalforming techniques.
  • mechanical Working may include extrusion, drawing, rolling, and other normal mechanicalforming techniques.
  • mechanical Operations there may be the necessity of intermittent heat treatment beforethe intermediate product can be further mechanically worked.
  • the cost of these subsequent operations has created a long standing search for a means to form small cross-section continuous products directly from the molten metal.
  • inorganic compounds do not have the mechanical properties to withstand forming processes as used on metallic materials.
  • the formation of compounds into final shapes is usually carried out while the material is molten such as casting directly into a forming mold.
  • the subject invention forms the desired product directly from the molten state, and therefore, inorganic compounds having properties in the molten state similar to that of molten metals and metal alloys may be formed in substantially the same manner.
  • the properties that must be similar to that of molten metal are the viscosity and surface tension in the molten state as well as the compound having a substantially discrete melting point rather than a broad continuous range of viscosities characteristic of molten glasses.
  • Prior art patents and publications show many methods for producing metallic wire using a rotating disk-like surface.
  • the processes typically have molten metal flowing out an orifice determining the size of the final product.
  • U.S. Pat. 745,786, Cole is typical of the prior art devices where the disk-like surface is a rotating metallic wheel upon which molten metal is impinged by way of an orifice.
  • the prior art methods of producing wire products use flow conditions varying from the removal of the metal from a stable meniscus disclosed in U.S. Pat. 3,522,- 836, King, to the forcing of molten metal in a free-standing stream through the orifice directly on a rotating heatextracting surface as disclosed by U.S. Pat 2,825,108, Pond.
  • the prior art means of direct formation of a filament or wire-like product all have one feature in common-the use of an orifice to control the size and flow of the molten metal.
  • an orifice has several attendant difiiculties in that it must function in the severe environment of flowing molten metal.
  • the metal product desired is composed of low melting point alloys such as lead, tin, zinc, etc.
  • the problems with the orifice are not severe.
  • processes using orifices are plagued with several difficult problems.
  • orifice materials begin to react with the molten metal or the surrounding atmosphere degrading the properties of the orifice material as well as its physical dimensions. Consequently, the orifice tends to erode and wash, becoming larger, and providing out of gage products. Further, insoluble materials such as silicates or refractory particles from the refractory container tend to clog orifices particularly where fine gage products are involved. As a consequence, the usual materials for orifices which resist erosion are expensive and difiicult to form into the shape needed for the application; and, once formed, the erosion due to the flowing metal makes the size of the final product difiicult to control.
  • an orifice usually requires additional heating to insure that metal does not solidify in the orifice and thereby change the shape of the product formed.
  • the use of small orifices requires extremely clean melts to prevent intermittent plugging or restriction of the orifices.
  • the present method invention forms a filamentary product without the use of any type of orifice and, therefore, is free of all problems attendant the flow of molten metal through an orifice.
  • the size of the final product is controllable and is primarily affected by the shape and properties of the rotating disk applied to the surface of a molten pool, its heat-extracting properties, its depth of entry into the melt, its velocity in contact with the melt, the melt superheat, and the melt material.
  • the invention as herein disclosed is a method for producing continuous or controlled length discontinuous filaments directly from a pool-like supply of molten material.
  • the method invention uses a rotating disk-shaped memher having an axis of rotation substantially parallel to the surface of a molten pool of the material.
  • the invention provides a method for producing a solid filament from molten material normally solid at ambient temperature having properties in the molten state at their conventional casting temperatures substantially similar to molten metals by the steps of introducing the outer edge of a rotating disk-shaped member to the surface of a pool of molten material, controlling the contact area and time of contact of said edge in said pool so that the maximum cross sectional dimension of said filament is greater than the cross section of said edge parallel to the axis of rotation at the average depth of immersion of the edge, removing heat at the circumferential extremity of said member to cause solidification of said material in filament form on said member and allowing said final filamentary product to spontaneously release from said member.
  • a pool or pool-like source of molten material is one that is not confined by a limiting orifice and has a free surface relatively free of turbulence. Turbulence does not prevent operation of the process, but makes the quality of the product somewhat irregular.
  • flow induced by induction heating of the melt does not detrimentally affect the process.
  • productivity of the process may be enhanced by flowing molten material parallel to the direction of rotation of the rotating member and increasing the speed of rotation of the member. Generally flow directed across the member will disturb the filament formation if the magnitude of the flow is sutficiently large.
  • a continuous product can be produced by passing the disk through this buildup of molten material without having an initially solidified product on the surface of the disk before entering the buildup.
  • the periphery of the disk may be above the equilibrium level of molten material and pass only through the aforementioned buildup of molten material.
  • the essence of the present invention resides in a method of extracting molten material from the surface of a molten pool by contacting such surface with the edge of a rotating disk.
  • the disk may act at least in part as a heatextracting member or chill block, its essential function is extracting the molten material from the molten pool in continuous or semicontinuous fashion into the surrounding atmosphere or controlled gaseous environment where quenching occurs. It is our belief that a film of molten material initially wets the surface of the rotating disk and thus clings to such surface as it passes from contact with the molten material.
  • the thin filament contracts, separates from the disk surface, and is ejected into the surrounding gaseous environment by the uninhibited centrifugal force of the rotating disk where solidification of any liquid portion with the film is completed. Since the disk presents a limited contact area and rotates at relatively high speed the product is thin gage wire or filament rather than heavy gage material attained in prior art processes.
  • the shape of the final product is dependent in part on the shape of the rotating disk introduced to the melt surface.
  • the periphery of the shell is V-shaped or radiused with only the tip of the member being introduced to the surface of the molten material.
  • a wire or filament shall be defined as an elongated member having a crosssectional area less than .020 in. and a width measurement less than 0.20 in.
  • FIG. 1 is an isometric view of the apparatus producing a filamentary product in accordance with one method of the present invention.
  • FIG. 2 is a vertical section of the melt container of FIG. 1 showing the spinning disk producing a fiber or filament from a buildup of molten material above the equilibrium surface level of the melt.
  • FIG. 3 is a vertical cross section of the apparatus of FIGS. 1 and 2 showing the shape of the disk-like member used to produce fiber or filament with that member introduced to the melt below its equilibrium surface level.
  • FIG. 4 shows an enlarged cross section of the tip of a disk-like member in a melt illustrating the physical dimensions that effect the properties of filamentary products.
  • FIG. 5 is a cross-sectional view of a disk-like member that is kept at substantially constant temperature by the internal circulation of a liquid coolant.
  • FIG. 6 shows two views of a disk-like member that produces filaments having a controlled length.
  • FIG. 7 shows a cross section of a radiused disk-like member in a melt showing such a member as used for the production of filament.
  • FIG. 8 shows a partial cross section of a multiple edge disk-shaped heat-extracting member.
  • FIG. 1 The means by which the process of making a filamentary product is illustrated in one configuration in FIG. 1.
  • a disk 3th is rotated by its attachment through some type of power transmission device such as the shaft 35 to a rotating motor herein disclosed as an electric motor 40.
  • the motor 40 is mounted on a platform 41 that is capable of being adjusted vertically through the use of a jack 45. This vertical adjustment should not be accomplished by any substantial rotation around the axis of the jack 45 since this would affect the direction of the emission of the filament 20.
  • the placement of the jack base 4-7 is not critical and the process is not adversely affected by minor misalignments or deviations from the true vertical.
  • the electric motor 40 should have some method of controlling its rotational speed and, as illustrated, the apparatus is equipped with a rheostat-type control 42.
  • the motor support plate 41 may be extended toward the disk 30 to provide a support for a shaft bearing (not shown) if the length of the shaft 35 and the size of the disk 30 pose alignment or vibrational problems. It would also be possible to extend the shaft 35 through the disk 30 to the other side to another support bearing (not shown).
  • the shaft 35 is substantially parallel to the surface 15 of the melt 10; however, this angle may be acute with no substantial detriment to the process.
  • centrifugal force would then eject the fibers away from the melt rather than straight up above the melt only, to fall back in and possibly disturb the process.
  • the disk 30 must introduce a relatively narrow surface to the melt 10 to form a filamentary product 20, but the exact shape of the surface will be discussed with other process parameters; however, in general a nonreplicating filament 20 will emanate from a disk 30 that rotationally introduces a small area 32 of its circumference having substantially line contact with the surface of the melt 10 or to a buildup of molten material above the surface.
  • Normally filament is formed in the melt by controlling the area of contact of the rotating member as well as its contact time with the molten material so that the typical cross sectional dimension of the filamentary product is less than .060 inches but greater than the width of the cross section of the edge introduced to the molten material as measured parallel to the axis of rotation of the member at the average depth of immersion of the edge of the rotating member. Referring to FIG. 4, the width of 20, and subsequently 20, will be greater than the width of the radiused portion of the member 30 at r.
  • the supply of molten material referred to as the melt 10 may be composed of an elemental metal, metal alloy, or an inorganic compound heated and contained by a vessel 11 having elements 12 to heat the material contained to a temperature above its melting point. While the amount of superheat (number of degrees in excess of the materials equilibrium melting point) will affect the size or gage of the filament 20, we have found that substantially constant diameter filaments 20 can be produced with a melt at a temperature less than 125 percent of the equilibrium melting point (in K.) of the material used with no need for the precise control of the melt temperature during operations. While this quantitative definition of the preferred temperature will normally encompass the desired melt temperature, it should be understood that the process does not require unusual melt temperatures.
  • the process is known to be operable with metals and metal alloys at conventional casting temperatures that represent a compromise between the cost of heating versus fluidity of the molten material.
  • the melt 10 may have a thin protective flux coating to prevent excessive reaction with the surrounding atmosphere without substantially disturbing the formation of the filament 20.
  • the filament is initially formed, as illustrated in FIGS. 2 and 3, below a surface of the melt 10 and will pass through most surface fluxes without any adverse etfects. Where it is desired or necessary, the simplicity of the apparatus lends itself to the use of a simple container (not shown) for the process where the atmosphere surrounding the melt 10 and the filament 20 while it is still at high temperatures can be kept inert.
  • Filamentary material has been successfully produced from several metals and metal alloys including tin, zinc, copper, nickel, aluminum, aluminum alloys, aluminum bronze, cast iron, ductile iron, high and low carbon steel, 18-8 stainless steel, and Hadfield steel. While these materials are known to be readily formed into filaments by the subject invention, the present invention is obviously applicable to a wider range of molten materials.
  • the present process may be used with any material having several specific properties similar to those of a molten metal, i.e., having a low viscosity in the range of from 1O to 1 poise, a high surface tension in the range of from 10 to 2500 dynes/cm., a reasonably discrete melting point, and being at least momentarily compatible with a solid material having sufficient heat capacity or thermal conductivity to initiate solidification on the outer edge 32 of the disk 30 made of that solid material.
  • a reasonably discrete melting point shall be defined as one exhibited by materials changing state from liquid to solid, changing state of one alloy component passing through a liquidus line on a temperaturecomposition phase diagram, or any change in state exhibiting a discontinuous viscosity increase upon reduction of melt temperature.
  • Filamentary products have been produced from a molten alkali nitrate heat-treating salt known commercially as Houghtons Draw Temp 430 available from E. F. Houghton & Company, Philadelphia, Pa., which is typical of inorganic compounds having the aforementioned properties in the molten state.
  • the disk 30 as shown in FIGS. 1 through 4 has a configuration that produces continuous metallic filaments 20 from the melt 10.
  • FIGS. 2 and 3 show two different orientations of the disk 30 with relation to the melt 10 while FIG. 4 illustrates the dimensions of the outer portions 31 of the disk 30.
  • the disk 30 is rotated within the melt 10 just below its surface 15, and subsequent to its entry into the melt 10 at 13 the disk 30 nucleates solid metal on the edge 32 of the disk 30 not necessarily at point 13 by removing the superheat and the heat of fusion of the melt 10. During the rotation of the disk 30 the melt 10 continues to solidify on the disk edge 32 forming the filament 20'.
  • the size of the final filament 20 is determined by the size and shape of the imposed disk surface 32 and the amount of heat removed by the disk 30.
  • the amount of heat removed therefore, depends on several controlled vari ables, one of which is the residence time of a point on the disk edge 32 within the melt 10 which is a function of the distance along the disk edge 32 from point 13 to 14 and the speed of rotation of the disk 30.
  • the size of the final filament 20 is determined by the amount of molten material 1t) that is deposited on 20' when it passes through the buildup of molten material 16.
  • the shape of the disk edge 32 Another variable affecting heat removal is the shape of the disk edge 32. It must nucleate and grow a filamentary product yet dissipate enough heat to maintain it at a temperature below that of the melt 10. The amount of this temperature differential will be discussed in a subsequent portion of the disclosure.
  • the shape of the disk 30 as illustrated in FIG. 4 shows the physical dimensions that affect the rate of heat removal. The disk 30 is inserted into the melt 10 at a depth shown in the figure as d. While the process is operable to form replicating strip-like products at large values of d, filamentary products are most efliciently produced when the value of d is less than .060 inches and yields a filamentary product less than .010 in. in cross sectional area.
  • this value of d remains substantially constant through the entire process; however, the process is operable for some materials with the edge of disk 30 at or above the equilibrium surface level 15 passing through a buildup of molten material 61 generated by rotation of the member 30.
  • the buildup 16 is generated by initially rotating the member 30 below the surface 15 of the melt as shown in FIG. 3. The member 30 is then slowly raised until it contacts the melt only at that buildup of molten material 16 at the exit side of the rotating member.
  • the radius of curvature r at this disk edge 32 will affect the final form of the filament 20 since it is essentially a mold for one side of the filament 20' as well as providing the site for initial nucleation of 20'.
  • Filaments have successfully been produced with r ranging from .015 inch to co (i.e., a narrow, fiat projection into the melt 10).
  • a preferred embodiment would have r within the range of from .001 to 0.10 inches.
  • a member 30 having a radiused peripheral edge may also be used. A filamentary product is formed with such a member if the depth of insertion is less than 0.020 and the radius of curvature is less than .50 inches.
  • All of edges 32 of the member 30 have a common characteristic in that they are all rounded or in some way relieved and a change in cross sectional direction so as to freely release any product solidified thereon.
  • the variables 0, T, and D as shown in FIG. 4 affect the conductivity of the heat emanating from 32 to the cooler portions of the disk 30. These variables are controlled by the chill material and any form of external cooling of the disk 30. The manipulation of these variables is not critical and one skilled in the art can successfully arrive at a workable configuration without excessive trial and error.
  • the value of R affects the process in two ways, one of which is affecting the mass of the member 30 and hence its thermal capacity.
  • the thermal capacity of the disk 30 can be controlled by material selection, external cooling, and the manipulation of the variables 0, T, and D; therefore, variation of R is not primarily used to control the total thermal capacity of the disk 30.
  • R does, however, directly affect several important process variables; namely, the aforementioned residence time of a point on the disk edge 32 within the melt 10 and the generation of centrifugal forces that affect the spontaneous removal of the filament 20 from the disk 30 at point 25.
  • Various disks 30 having a radius as small as fit-inch (the end of a rotating rod introduced at an angle to the melt) and as large as inches have successfully been used to produce a filament without any indication of their being the minimum or maximum feasible radii defining a critical range of disk sizes.
  • FIG. 5 shows a disk 30 having the means to circulate a coolant within the disk 30 thereby keeping the disk 30 and the disk edge 32 at a constant temperature once thermal equilibrium is established.
  • the means by which the coolant flow rate is determined is readily discernible to one skilled in the art since the process is operable within a broad range of disk temperatures.
  • the product as it leaves the disk 30 in some cases will not be completely solid and will consist of a solid film that was formerly adjacent to the disk 30 and a liquid portion that is carried out of the source of molten material by this solid portion.
  • the product may continue to solidify or if its liquid portion possesses enough mass and superheat, it may remelt the entire filament after it leaves the thermal influence of the disk 30. Proper adjustment of parameters may result in this fully molten condition long enough to reform the filament into a circular cross section by the effect of the materials high surface tension.
  • gaseous environment of the filament 20 is important to this type of process since the filament cannot be completely molten for a significant period of time without breaking down into globules.
  • Gaseous coolants such as air or nonoxidizing gases such as nitrogen or argon may be used either solely or in conjunction with a fog or mist of liquid coolant.
  • FIG. 6 illustrates a disk 30 having a plurality of indentations 34 along the disk edge 32.
  • the function of these indentations is to disturb the formation of the filament 20' on the disk edge 32 sufliciently to produce a discontinuous product of a length equal to the distance along the disk edge 32 between successive indentations 34.
  • the shape of the indentations 34 that has successfully produced a discontinuous filament is essentially in the form of a slanted V as shown in FIG. 6. Undoubtedly other indentation shapes would also work.
  • the slanted V-shape has proved to limit effectively the length of the filament while not accumulating solidified metal in the indentation 34 that would eventually affect the intended function of the indentations 34. Since the distance along the disk edge 32 between successive indentations 34 controls the length of the filaments produced, the spacing of these indentations can be controlled to produce short filaments of equal length, a controlled distribution of filament lengths, or a series of longer filaments with a length limited to the circumference of the disk 30 by the use of a single indentation 34. The presence of the indentations 34 enables the disk to be rotated at higher speeds and at a smaller insertion into the melt, with the only other difference being the discontinuous final product 20 and the indentations 34 on the disk edge 32.
  • the parameters that are herein disclosed to affect the process need not be controlled precisely and the production of a filamentary metal product 20 will result from the introduction of a relatively small area 32 on the periphery of a rotating disk 30 to a pool of molten metal 10 when the disk 30 has a peripheral speed in the range of 3 ft./ sec. to 200 ft./sec. and has sufficient temperature difference to solidify at least a rudimentary filament 20 on the disk edge 32.
  • the disk 30 is rotated above the melt 10 at the desired speed to give a peripheral speed within the desired range.
  • the jack 45 is adjusted to lower the disk 30 into the melt 10 where initially a fragmented filament is formed upon contact with the surface 15.
  • the disk 30 is lowered into the melt 10 and upon the disk 30 reaching sufficient depth within the melt 10 a continuous product 20 will emanate from the melt 10 in substantially the manner illustrated in FIGS. 1 and 3. As previously described, it is also possible to raise the disk 30 to or above the equilibrium surface 15 after a filament 20 is bein produced and thereafter pass the periphery of the disk 30 through a buildup of molten material 16 to form a filament 20.
  • FIG. 7 illustrates another embodiment of the present invention where the disk edge 32 is radiused and inserted into the molten material at a depth less than .020 inch so as to form a filamentary product. If the product to be formed by this embodiment is to be filamentary, then the radius of curvature at the edge 32 should be less than 0.50 inch.
  • FIG. 8 illustrates an embodiment of the invention where the disk-shaped rotating heat-extracting member has multiple edges in contact with the molten material thereby producing multiple filaments.
  • the present invention was used in several configurations to form filamentary products from various materials.
  • the surface of the disk that contacts the melt consistently has a 16 to 20 micro-inch CLA (center line average) surface finish produced by 600 grit paper, and, except where noted, the depth of insertion of the disk within the melt was approximately 10 mils.
  • Example 1 A continuous filamentary product was produced using a. copper disk having a V-shaped peripheral edge and having the following physical dimensions:
  • the same disk was used to produce a nickel-base alloy filament by rotating the disk at 400 r.p.m. giving the disk a peripheral speed of 14 ft./sec.
  • the nickel alloy (3 Al, balance Ni) was at a temperature of 2700 F. during the process and continuous filament 6 mils by 35 mils was productd.
  • Example 4 A continuous filamentary product of zinc was produced by using an aluminum disk having substantially the same V-shaped periphery as the copper disk but having the following dimensions:
  • the disk was rotated at 290 r.p.m. giving a peripheral speed of 7.4 ft./sec.
  • the melt was commercially pure zinc at a temperature of approximately 850 F.
  • the disk operated at a temperature ranging from 140 F. to 300 F. and its rotation produced a continuous filament 7 x 17 mils in cross section.
  • Example 1 The same disk and melt material were used to produce a continuous filament with a speed of disk rotation of 700 r.p.m. At the peripheral speed of 17.9 ft./sec. the disk was introduced to the surface of the melt at approximately 850 F. The disk operated at a temperature ranging from 200 F. to 410 F. and produced a filament with a cross section of 10 mils x 30 mils.
  • Example 6 The same disk was used to produce filaments from a molten inorganic compound.
  • the compound was an alkali metal nitrate salt used commercially in the molten condition as a heat-treating bath. Its commercial name is Houghtons Draw Temp 430 made by E. F. Houghton & Company in Philadelphia, Pa. This compound was heated to approximately 450 F. and the disk was introduced to its surface at 240 r.p.m. (6.1 ft./sec.). The disk operated in the range of 80 F. to 200 F. during the process and filaments of 12 mils by 30 mils in cross section were produced.
  • Both products were made at a disk speed of 1000 r.p.m. and 20.7 ft./ sec. with the aluminum 1100 molten at 1250 F. and the 2024 at 1400 F. In both cases the disk operated at approximately 200 F. and produced filament of a cross section 6 mils by 15 mils.
  • Example 9 The present invention was used to produce a discontinuous filament of controlled length by using a copper disk having indentations on its V-shaped peripheral edge.
  • the disk had the following physical dimensions.
  • the disk also had indentations on its peripheral edge substantially the same as those shown in FIG. 6 with the depth of the indentation being approximately 0.03 inches and having a length along the circumference of the disk of 0.15 inches.
  • the disk was rotated at 700 r.p.m. yielding a peripheral speed of 12.1 ft./sec. It was introduced to the surface of a pool of molten zinc at 890 F. and the disk operated within a temperature range of F. to 200 F.
  • a filamentary product having a cross section 8 mils by 16 mils and consistent lengths of approximately 1 inch was formed.
  • Example 10 The same disk and melt material were used with the melt temperature and disk temperature substantially the same as Example 9.
  • the rotational speed of the disk was increased to 1190 r.p.m. giving a peripheral velocity of 20.6 ft./ sec. and the depth of insertion into the melt was reduced to 2 mils.
  • the filament produced had a cross section of approximately 2 mils x 12 mils and a length of .9 inches.
  • Example 11 The same disk was used as in Examples 9 and 10 to produce filament of nodular cast iron.
  • the disk was rotated at 3200 r.p.m. yielding a peripheral surface velocity of 55.5 ft./sec. 2 mils below the surface of a molten pool of nodular cast iron at 2700 F.
  • the disk operated at a temperature initially of 75 F. and still produced filament at a temperature of 600 F.
  • the filament had the dimensions of 10 mils by 35 mils and was approximately 1 inch in length.
  • Example 12 Discontinuous fibers have also been produced using a disk of different dimensions.
  • a copper disk having the following dimensions was used to produce discontinuous fiber of Manganese Steel (12.4 Mn, 1.3 C, balance Fe):
  • the disks V-shaped peripheral edge had the same type of indentations as Examples 9, 10, and 11 placed every inch along the circumference of the disk. It was rotated 1 l at 550 rpm. yielding a peripheral velocity of 19.2 ft./ sec. and operated in the temperature range from 150 F. to 440 F.
  • the manganese steel melt was at approximately 2900 F. and the filaments produced had a V-shaped cross section with a 10 mil height and a 40 mil width with a length of 1 inch.
  • Step (b) there is deposition of an additional liquid portion of said molten material on the solid portion adherent to said disk as said disk and said partially solidified filament exit the surface of said pool.
  • edge of said rotating disk rotates less than 0.060 inch below the surface of said molten material and has a tapered edge producing a filament of cross-sectional area less than 0.01 square inch.
  • a method for producing a solid filament from molten ferrous metal comprising:
  • said molten material is a metal alloy having a base metal selected from the group consisting of iron, nickel, aluminum, copper, and zinc.
  • said molten material consists of a material selected from the group of a metal, a metal alloy, and an inorganic compound.

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  • Geochemistry & Mineralogy (AREA)
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  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Continuous Casting (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
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  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
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US00251985A 1971-05-27 1972-05-10 Formation of filaments directly from molten material Expired - Lifetime US3838185A (en)

Priority Applications (15)

Application Number Priority Date Filing Date Title
US00251985A US3838185A (en) 1971-05-27 1972-05-10 Formation of filaments directly from molten material
IT24401/72A IT960671B (it) 1971-05-27 1972-05-16 Formazione di filamenti diretta mente da materiale fuso
GB2321772A GB1396788A (en) 1971-05-27 1972-05-17 Formation of filaments directly from molten material
CA142,464A CA970511A (en) 1971-05-27 1972-05-18 Formation of filaments directly from molten material
FR7218644A FR2139020B1 (no) 1971-05-27 1972-05-25
NLAANVRAGE7207018,A NL171132B (nl) 1971-05-27 1972-05-25 Werkwijze voor het vervaardigen van een langgestrekte materiaalstrook uit een gesmolten metaal of metaallegering.
BE784051A BE784051A (fr) 1971-05-27 1972-05-26 Procede et appareil de formation de filaments directement a partir de matieres en fusion
ES403232A ES403232A1 (es) 1971-05-27 1972-05-26 Aparato para producir un filamento solido de material fun- dido.
ES403231A ES403231A1 (es) 1971-05-27 1972-05-26 Procedimiento para producir un filamento solido de materialfundido.
NO1859/72A NO139111C (no) 1971-05-27 1972-05-26 Fremgangsmaate for fremstilling av faste filamenter fra smeltet material
DE19722225684 DE2225684C3 (de) 1971-05-27 1972-05-26 Verfahren und Vorrichtung zum kontinuierlichen Gießen von Fäden
CH787472A CH555199A (fr) 1971-05-27 1972-05-26 Procede et appareil de production d'un filament solide a partir d'une matiere en fusion.
SE7206893A SE378534B (no) 1971-05-27 1972-05-26
JP47052880A JPS518821B1 (no) 1971-05-27 1972-05-27
US443349A US3904344A (en) 1972-05-10 1974-02-19 Apparatus for the formation of discontinuous filaments directly from molten material

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US14739071A 1971-05-27 1971-05-27
US00251985A US3838185A (en) 1971-05-27 1972-05-10 Formation of filaments directly from molten material

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BE (1) BE784051A (no)
CA (1) CA970511A (no)
CH (1) CH555199A (no)
ES (2) ES403231A1 (no)
FR (1) FR2139020B1 (no)
GB (1) GB1396788A (no)
IT (1) IT960671B (no)
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US3908745A (en) * 1974-06-21 1975-09-30 Nl Industries Inc Method and means for producing filaments of uniform configuration
US4124664A (en) * 1976-11-30 1978-11-07 Battelle Development Corporation Formation of filaments directly from an unconfined source of molten material
EP0000926A1 (en) * 1977-08-22 1979-03-07 Battelle Development Corporation Method and apparatus for producing flakes from molten material
US4215084A (en) * 1978-05-03 1980-07-29 The Battelle Development Corporation Method and apparatus for producing flake particles
US4217089A (en) * 1975-02-03 1980-08-12 Gte Products Corporation Photoflash lamp
US4290993A (en) * 1980-01-10 1981-09-22 Battelle Development Corp. Method and apparatus for making nodule filament fibers
US4326579A (en) * 1980-01-23 1982-04-27 National-Standard Company Method of forming a filament through melt extraction
US4337886A (en) * 1979-04-09 1982-07-06 United Technologies Corporation Welding with a wire having rapidly quenched structure
US4339508A (en) * 1977-11-28 1982-07-13 Shiro Maeda Method for manufacturing a thin and flexible ribbon of superconductor material
WO1982004200A1 (en) * 1981-06-08 1982-12-09 Development Corp Battelle Method and apparatus for producing particulate
US4375426A (en) * 1979-10-18 1983-03-01 Johnson, Matthey & Co., Limited Catalytic fibre packs for ammonia oxidation
US4475583A (en) * 1980-05-09 1984-10-09 Allegheny Ludlum Steel Corporation Strip casting nozzle
US4479528A (en) * 1980-05-09 1984-10-30 Allegheny Ludlum Steel Corporation Strip casting apparatus
US4484614A (en) * 1980-05-09 1984-11-27 Allegheny Ludlum Steel Corporation Method of and apparatus for strip casting
US4523621A (en) * 1982-02-18 1985-06-18 Allied Corporation Method for making metallic glass powder
US4552199A (en) * 1982-04-08 1985-11-12 Nippon Yakin Kogyo Co., Ltd. Apparatus for producing flake particles
US4617981A (en) * 1980-05-09 1986-10-21 Battelle Development Corporation Method and apparatus for strip casting
US4647511A (en) * 1984-03-28 1987-03-03 Nippon Yakin Kogyo Co., Ltd. Flake like metal chips, a method of and an apparatus for making the same
WO1988007979A1 (en) * 1987-04-10 1988-10-20 Battelle Development Corporation Melt extraction of ceramics
US4936371A (en) * 1988-12-23 1990-06-26 Aluminum Company Of America Molten metal sampling, wave damping, flake removal and means for collecting and forwarding flakes for composition analysis
US4970194A (en) * 1989-07-21 1990-11-13 Iowa State University Research Foundation Method of producing superconducting fibers of YBA2CU30X
WO1991014270A1 (en) * 1990-03-12 1991-09-19 Iowa State University Research Foundation, Inc. METHOD OF PRODUCING SUPERCONDUCTING FIBERS OF BISMUTH STRONTIUM CALCIUM OXIDE (Bi(2212) AND Bi(2223))
US5213151A (en) * 1992-08-20 1993-05-25 Ribbon Technology Corporation Melt overflow control for constant linear density fiber mat and strip
US5238048A (en) * 1992-01-02 1993-08-24 Ribbon Technology Corporation Round wire from strip
US5550102A (en) * 1987-04-02 1996-08-27 Sumitomo Electric Industries, Ltd. Superconductor and method of manufacturing the same
CN108754637A (zh) * 2018-08-15 2018-11-06 北京化工大学 一种薄膜连续直接塑化供料的熔体微分电纺装置及方法
CN112872303A (zh) * 2021-04-09 2021-06-01 于立豪 一种合金制造装置和方法
WO2022003376A1 (en) 2020-07-03 2022-01-06 Fibre technology ltd Improved melt overflow casting device and method

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GB8524081D0 (en) * 1985-09-30 1985-11-06 Babcock Wire Equipment Transfer means
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CN110961641A (zh) * 2019-12-27 2020-04-07 深圳微纳增材技术有限公司 一种3d打印用金属粉末的制备装置及制备方法
CN113351883B (zh) * 2021-08-11 2021-11-02 天津大学 基于激光增材制造技术制备CuCrZr/316L连接件的方法

Cited By (33)

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Publication number Priority date Publication date Assignee Title
US3908745A (en) * 1974-06-21 1975-09-30 Nl Industries Inc Method and means for producing filaments of uniform configuration
US4217089A (en) * 1975-02-03 1980-08-12 Gte Products Corporation Photoflash lamp
US4124664A (en) * 1976-11-30 1978-11-07 Battelle Development Corporation Formation of filaments directly from an unconfined source of molten material
EP0000926A1 (en) * 1977-08-22 1979-03-07 Battelle Development Corporation Method and apparatus for producing flakes from molten material
US4154284A (en) * 1977-08-22 1979-05-15 Battelle Development Corporation Method for producing flake
US4339508A (en) * 1977-11-28 1982-07-13 Shiro Maeda Method for manufacturing a thin and flexible ribbon of superconductor material
US4215084A (en) * 1978-05-03 1980-07-29 The Battelle Development Corporation Method and apparatus for producing flake particles
US4337886A (en) * 1979-04-09 1982-07-06 United Technologies Corporation Welding with a wire having rapidly quenched structure
US4375426A (en) * 1979-10-18 1983-03-01 Johnson, Matthey & Co., Limited Catalytic fibre packs for ammonia oxidation
US4290993A (en) * 1980-01-10 1981-09-22 Battelle Development Corp. Method and apparatus for making nodule filament fibers
US4326579A (en) * 1980-01-23 1982-04-27 National-Standard Company Method of forming a filament through melt extraction
US4617981A (en) * 1980-05-09 1986-10-21 Battelle Development Corporation Method and apparatus for strip casting
US4475583A (en) * 1980-05-09 1984-10-09 Allegheny Ludlum Steel Corporation Strip casting nozzle
US4479528A (en) * 1980-05-09 1984-10-30 Allegheny Ludlum Steel Corporation Strip casting apparatus
US4484614A (en) * 1980-05-09 1984-11-27 Allegheny Ludlum Steel Corporation Method of and apparatus for strip casting
WO1982004200A1 (en) * 1981-06-08 1982-12-09 Development Corp Battelle Method and apparatus for producing particulate
US4385013A (en) * 1981-06-08 1983-05-24 Battelle Development Corporation Method and apparatus for producing particles from a molten material using a rotating disk having a serrated periphery and dam means
US4523621A (en) * 1982-02-18 1985-06-18 Allied Corporation Method for making metallic glass powder
US4552199A (en) * 1982-04-08 1985-11-12 Nippon Yakin Kogyo Co., Ltd. Apparatus for producing flake particles
US4647511A (en) * 1984-03-28 1987-03-03 Nippon Yakin Kogyo Co., Ltd. Flake like metal chips, a method of and an apparatus for making the same
US5550102A (en) * 1987-04-02 1996-08-27 Sumitomo Electric Industries, Ltd. Superconductor and method of manufacturing the same
WO1988007979A1 (en) * 1987-04-10 1988-10-20 Battelle Development Corporation Melt extraction of ceramics
CH671351A5 (no) * 1987-04-10 1989-08-31 Battelle Memorial Institute
US5067554A (en) * 1987-04-10 1991-11-26 Battelle Development Corporation Melt extraction of ceramics
US4936371A (en) * 1988-12-23 1990-06-26 Aluminum Company Of America Molten metal sampling, wave damping, flake removal and means for collecting and forwarding flakes for composition analysis
US4970194A (en) * 1989-07-21 1990-11-13 Iowa State University Research Foundation Method of producing superconducting fibers of YBA2CU30X
WO1991014270A1 (en) * 1990-03-12 1991-09-19 Iowa State University Research Foundation, Inc. METHOD OF PRODUCING SUPERCONDUCTING FIBERS OF BISMUTH STRONTIUM CALCIUM OXIDE (Bi(2212) AND Bi(2223))
US5238048A (en) * 1992-01-02 1993-08-24 Ribbon Technology Corporation Round wire from strip
US5213151A (en) * 1992-08-20 1993-05-25 Ribbon Technology Corporation Melt overflow control for constant linear density fiber mat and strip
CN108754637A (zh) * 2018-08-15 2018-11-06 北京化工大学 一种薄膜连续直接塑化供料的熔体微分电纺装置及方法
CN108754637B (zh) * 2018-08-15 2023-07-25 北京化工大学 一种薄膜连续直接塑化供料的熔体微分电纺装置及方法
WO2022003376A1 (en) 2020-07-03 2022-01-06 Fibre technology ltd Improved melt overflow casting device and method
CN112872303A (zh) * 2021-04-09 2021-06-01 于立豪 一种合金制造装置和方法

Also Published As

Publication number Publication date
NO139111B (no) 1978-10-02
IT960671B (it) 1973-11-30
ES403231A1 (es) 1976-01-01
SE378534B (no) 1975-09-08
DE2225684B2 (de) 1977-02-24
CH555199A (fr) 1974-10-31
ES403232A1 (es) 1975-12-01
BE784051A (fr) 1972-09-18
NL7207018A (no) 1972-11-29
DE2225684A1 (de) 1972-11-30
CA970511A (en) 1975-07-08
FR2139020A1 (no) 1973-01-05
JPS518821B1 (no) 1976-03-22
GB1396788A (en) 1975-06-04
FR2139020B1 (no) 1974-10-25
NL171132B (nl) 1982-09-16
NO139111C (no) 1979-01-10

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