Men G Chu

Author:

Men G. Chu

ISBN #:

0873395697

Author:

Men Glenn Chu

ISBN #:

0873393961

US Patent:

6386266, May 14, 2002

Filed:

Jul 7, 2000

Appl. No.:

09/611638

Inventors:

Men G. Chu - Export PA
William P. Chernicoff - Harrisburg PA

Assignee:

Alcoa Inc. - Pittsburgh PA

International Classification:

B22D 2300

US Classification:

164429, 164443, 164 46, 164479

Abstract:

A substrate system for receiving a deposit of sprayed metal droplets including a movable outer substrate on which the sprayed metal droplets are deposited. The substrate system also includes an inner substrate disposed adjacent the outer substrate where the sprayed metal droplets are deposited on the outer substrate. The inner substrate includes zones of differing thermal conductivity to resist substrate layer porosity and to resist formation of large grains and coarse constituent particles in a bulk layer of the metal droplets which have accumulated on the outer substrate. A spray forming apparatus and associated method of spray forming a molten metal to form a metal product using the substrate system of the invention is also provided.

US Patent:

6398882, Jun 4, 2002

Filed:

Mar 13, 2000

Appl. No.:

09/523883

Inventors:

Men Glenn Chu - Export PA
Siba P. Ray - Murrysville PA

Assignee:

Alcoa, Inc. - Pittsburgh PA

International Classification:

C22C 2100

US Classification:

148437, 148538, 148549

Abstract:

A novel product composed of a ceramic phase particle dispersoid in metal, including uniformly distributed, finely sized carbide phase particles formed in situ in a molten metal and a novel method for producing such a ceramic phase particle dispersoid in metal are disclosed. A salt-based liquid state reaction involving a liquid metal/alloy containing a liquid Ti, B, Si, Sc, Hf, Nb, Ta, Zr, Mo, Al (when the molten metal matrix is not aluminum), or V and a halide salt containing carbon particles forms a uniform distribution of finely sized ceramic phase particles formed and dispersed in-situ in the metal matrix. The ceramic dispersoid in metal product of the present invention includes at least about 50 volume percent of a matrix metal of aluminum; and up to about 50 volume percent of a uniform distribution of finely sized ceramic phase particles formed and dispersed in-situ in the aluminum metal matrix, wherein the finely sized ceramic phase particles have an average particle diameter of less than about 2. 5 microns, and wherein the uniform distribution consists of a substantially cluster-free distribution of no more than two particles attached to one another at a magnification of 500Ã.

US Patent:

6723282, Apr 20, 2004

Filed:

Jul 9, 1999

Appl. No.:

09/350858

Inventors:

Men Glenn Chu - Export PA
Siba P. Ray - Murrysville PA

Assignee:

Alcoa Inc. - Pittsburgh PA

International Classification:

C22C 2100

US Classification:

420552, 420590

Abstract:

A novel method for producing a ceramic phase particle dispersoid in metal and a novel product composed thereof. The method includes (a) providing a molten composition consisting essentially of molten aluminum alloy containing molten metal selected form the group consisting of Zr, V and combinations thereof; (b) providing a chloride salt containing fine carbon particles; and (c) reacting the chloride salt containing fine carbon particles in the molten aluminum metal liquid with the molten metal liquid to form a uniform distribution of finely sized carbide particles formed and dispersed in-situ in an aluminum alloy matrix.

US Patent:

6843865, Jan 18, 2005

Filed:

Feb 7, 2002

Appl. No.:

10/072161

Inventors:

Men Glenn Chu - Export PA, US
Siba P. Ray - Murrysville PA, US

Assignee:

Alcoa Inc. - Pittsburgh PA

International Classification:

C22C 2100

US Classification:

148437, 148538, 148549

Abstract:

A novel product composed of a ceramic phase particle dispersoid in metal, including uniformly distributed, finely sized carbide phase particles formed in situ in a molten metal and a novel method for producing such a ceramic phase particle dispersoid in metal are disclosed. A salt-based liquid state reaction involving a liquid metal/alloy containing a liquid Ti, B, Si, Sc, Hf, Nb, Ta, Zr, Mo, Al (when the molten metal matrix is not aluminum), or V and a halide salt containing carbon particles forms a uniform distribution of finely sized ceramic phase particles formed and dispersed in-situ in the metal matrix. The ceramic dispersoid in metal product of the present invention includes at least about 50 volume percent of a matrix metal of aluminum; and up to about 50 volume percent of a uniform distribution of finely sized ceramic phase particles formed and dispersed in-situ in the aluminum metal matrix, wherein the finely sized ceramic phase particles have an average particle diameter of less than about 2. 5 microns, and wherein the uniform distribution consists of a substantially cluster-free distribution of no more than two particles attached to one another at a magnification of 500×.

US Patent:

7000676, Feb 21, 2006

Filed:

Jun 29, 2004

Appl. No.:

10/880200

Inventors:

Men G. Chu - Export PA, US
Alvaro Giron - Murrysville PA, US
William A. Casada - Cheswick PA, US
Ho Yu - Murrysville PA, US

Assignee:

Alcoa Inc. - Pittsburgh PA

International Classification:

B22D 11/049

US Classification:

164487, 164444

Abstract:

A DC casting mold for casting molten metal alloy comprising a cooled tubular body that has a thermally insulated insert attached to its top surface. The thermally insulated insert has a bottom portion with a beveled sidewall, which forms an angle with the horizontal melt surface layer of the molten metal and creates an eddy. The eddy causes a substantial number of oxides that are formed during the casting process to remain in the bottom sidewall portion of the thermally insulated insert of the mold, thereby substantially reducing the number of ingot surface imperfections that promote ingot cracking. In addition, the eddy promotes break-up of the oxides into smaller pieces as the oxides flow toward the cooled inner walls of the cooled tubular body, thereby having limited surface area for growth of oxide folds. A method of casting molten metal alloys with improved surface quality is also disclosed.

US Patent:

7264038, Sep 4, 2007

Filed:

Jul 12, 2005

Appl. No.:

11/179835

Inventors:

Men G Chu - Export PA, US
Ho Yu - Murrysville PA, US
Alvaro Giron - Murrysville PA, US
Ken Kallaher - Trafford PA, US

Assignee:

ALCOA Inc. - Pittsburgh PA

International Classification:

B22D 27/04
B22D 35/00
B22D 35/04
B22D 37/00

US Classification:

1641221, 164133, 164337

Abstract:

Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting.

US Patent:

7377304, May 27, 2008

Filed:

Jul 11, 2006

Appl. No.:

11/484276

Inventors:

Men G. Chu - Export PA, US
Ho Yu - Murrysville PA, US
Alvaro Giron - Murrysville PA, US
Ken Kallaher - Trafford PA, US
Jeffrey J. Shaw - New Kensington PA, US

Assignee:

Alcoa Inc. - Pittsburgh PA

International Classification:

B22D 27/04
B22D 35/04
B22D 37/00

US Classification:

1641221, 164126, 164348

Abstract:

Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal or vertical direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting. A multiple layer ingot product is also provided comprising a base alloy layer and at least a first additional alloy layer, the two layers having different alloy compositions, where the first additional alloy layer is bonded directly to the base alloy layer by applying the first additional alloy in the molten state to the surface of the base alloy while the surface temperature of the base alloy is lower than the liquidus temperature and greater than eutectic temperature of the base alloy −50 degrees Celsuis.

US Patent:

7951468, May 31, 2011

Filed:

Mar 31, 2008

Appl. No.:

12/059620

Inventors:

Men G. Chu - Export PA, US
Ho Yu - Murrysville PA, US
Alvaro Giron - Murrysville PA, US
Kenneth Joseph Kallaher - Trafford PA, US
Jeffrey J. Shaw - New Kensington PA, US

Assignee:

Alcoa Inc. - Pittsburgh PA

International Classification:

B32B 15/20

US Classification:

428654, 428615, 428939

Abstract:

Molten metal is injected uniformly into a horizontal mold from a feed chamber in a horizontal or vertical direction at a controlled rate, directly on top of the metal already within the mold. A cooling medium is applied to the bottom surface of the mold, with the type and flow rate of the cooling medium being varied to produce a controlled cooling rate throughout the casting process. The rate of introduction of molten metal and the flow rate of the cooling medium are both controlled to produce a relatively uniform solidification rate within the mold, thereby producing a uniform microstructure throughout the casting, and low stresses throughout the casting. A multiple layer ingot product is also provided comprising a base alloy layer and at least a first additional alloy layer, the two layers having different alloy compositions, where the first additional alloy layer is bonded directly to the base alloy layer by applying the first additional alloy in the molten state to the surface of the base alloy while the surface temperature of the base alloy is lower than the liquidus temperature and greater than eutectic temperature of the base alloy −50 degrees Celsuis.