Method and apparatus for forming ferrous liquid-solid metal compositions

Claim 1

The method for forming a ferrous metal composition having solid discrete degenerate dendrites homogeneously dispersed within a liquid phase of said ferrous metal composition which comprises: a. heating a first ferrous metal composition to form a liquid-solid mixture of said first ferrous metal composition, b. vigorously agitating said liquid-solid mixture in an agitation zone to convert the solid therein to discrete degenerate dendrites derived from said first ferrous metal compositon, said degenerate dendrites comprising up to about 85 weight percent of the heated metal composition and wherein the remainder of the heated ferrous metal composition is liquid wherein the surface in said agitation zone contacting said liquid-solid mixture comprises high density recrystallized alumina, c. continuously monitoring the apparent viscosity or an analog of the apparent viscosity of the liquid-solid mixture thereby to control the heat extracted from said mixture when the descrete degenerate dendrites content of said mixture is above about 65 weight percent and d. removing said heated metal composition from said agitation zone through an outlet that is protected from contact with air by an inert to protective gas surrounding said outlet.

Claim 2

The method for forming a ferrous metal composition having solid discrete degenerate dendrites homogeneously dispersed within a liquid phase of said ferrous metal composition which comprises: a. heating a first ferrous metal composition to form a liquid-solid mixture of said first ferrous metal composition, b. vigorously agitating said liquid-solid mixture in an agitation zone to convert the solid therein to discrete degenerate dendrites derived from said first ferrous metal compositon, said degenerate dendrites comprising up to about 85 weight percent of the heated metal composition and wherein the remainder of the heated ferrous metal composition is liquid wherein the surface in said agitation zone contacting said liquid-solid mixture comprises high density recrystallized alumina, c. continuously monitoring the apparent viscosity or an analog of the apparent viscosity of the liquid-solid mixture thereby to control the heat extracted from said mixture when the descrete degenerate dendrites content of said mixture is above about 65 weight percent and d. removing said heated metal composition from said agitation zone through an outlet that is protected from contact with air by an inert to protective gas surrounding said outlet.

Claim 3

The method for forming a solid ferrous metal composition containing discrete degenerate dendrites homogeneously dispersed within a secondary phase of said solid ferrous metal composition which comprises; a. heating a first ferrous metal composition to form a liquid-solid mixture of said first ferrous metal composition, b. vigorously agitating said liquid-solid mixture in an agitation zone to convert the solid therein to discrete degenerate dendrites derived from said first metal composition, said degenerate dendrites comprising up to about 85 weight percent of the heated ferrous metal composition wherein the surface in said agitation zone contacting said liquid-solid mixture comprises high density recrystallized alumina, c. continuously monitoring the apparent viscosity or an analog of the apparent viscosity of the liquid-solid mixture thereby to control the heat extracted from said mixture when the discrete degenerate dendrites content of said mixture is above 65 weight percent, d. removing said heated ferrous metal composition from said agitation zone through an outlet that is protected from contact with air by an inert or protective gas surrounding said outlet and e. cooling said heated composition to solidify the liquid remaining after the degenerate dendrites are formed thereby forming a solid secondary phase of said metal composition.

Claim 4

The method for forming a solid ferrous metal composition containing discrete degenerate dendrites homogeneously dispersed within a secondary phase of said solid ferrous metal composition which comprises; a. heating a first ferrous metal composition to form a liquid-solid mixture of said first ferrous metal composition, b. vigorously agitating said liquid-solid mixture in an agitation zone to convert the solid therein to discrete degenerate dendrites derived from said first metal composition, said degenerate dendrites comprising up to about 85 weight percent of the heated ferrous metal composition wherein the surface in said agitation zone contacting said liquid-solid mixture comprises high density recrystallized alumina, c. continuously monitoring the apparent viscosity or an analog of the apparent viscosity of the liquid-solid mixture thereby to control the heat extracted from said mixture when the discrete degenerate dendrites content of said mixture is above 65 weight percent, d. removing said heated ferrous metal composition from said agitation zone through an outlet that is protected from contact with air by an inert or protective gas surrounding said outlet and e. cooling said heated composition to solidify the liquid remaining after the degenerate dendrites are formed thereby forming a solid secondary phase of said metal composition.

Claim 5

The method for shaping a ferrous metal composition which comprises: a. forming a ferrous metal composition having solid discrete degenerate dendrites homogeneously dispersed within a liquid phase of said metal composition by: i. heating a first ferrous metal composition to form a liquid-solid mixture of said first ferrous metal composition, ii. vigorously agitating said mixture in an agitation zone to convert the liquid-solid mixture therein to discrete degenerate dendrities derived from said ferrous metal composition, said degenerate dendrites comprising up to about 85 weight percent of the heated ferrous metal composition and wherein the remainder of the heated ferrous metal composition is liquid, wherein the surface in said agitation zone contacting said liquid-solid mixture is high density recrystallized alumina, b. continuously monitoring the apparent viscosity or an analog of the apparent viscosity of the liquid-solid mixture thereby to control the heat extracted from said mixture when the discrete degenerate dendrite content of said mixture is above about 65 weight percent, c. removing said heated ferrous metal composition from said agitation zone through an outlet that is protected from contact with air by an inert or protective gas surrounding said outlet and d. shaping the heated ferrous metal composition comprising degenerate dendrites and liquid metal.

Claim 6

The method for shaping a ferrous metal composition which comprises: a. forming a ferrous metal composition having solid discrete degenerate dendrites homogeneously dispersed within a liquid phase of said metal composition by: i. heating a first ferrous metal composition to form a liquid-solid mixture of said first ferrous metal composition, ii. vigorously agitating said mixture in an agitation zone to convert the liquid-solid mixture therein to discrete degenerate dendrities derived from said ferrous metal composition, said degenerate dendrites comprising up to about 85 weight percent of the heated ferrous metal composition and wherein the remainder of the heated ferrous metal composition is liquid, wherein the surface in said agitation zone contacting said liquid-solid mixture is high density recrystallized alumina, b. continuously monitoring the apparent viscosity or an analog of the apparent viscosity of the liquid-solid mixture thereby to control the heat extracted from said mixture when the discrete degenerate dendrite content of said mixture is above about 65 weight percent, c. removing said heated ferrous metal composition from said agitation zone through an outlet that is protected from contact with air by an inert or protective gas surrounding said outlet and d. shaping the heated ferrous metal composition comprising degenerate dendrites and liquid metal.

Claim 7

The method for forming a ferrous metal composition comprising a ferrous metal alloy matrix and third phase solid particles homogeneously suspended in said matrix, said ferrous metal alloy having solid discrete degenerate dendrites homogeneously dispersed within a secondary phase of said metal alloy which comprises: a. heating a first ferrous metal alloy to form an initial liquid-solid mixture of said first ferrous metal alloy, b. vigorously agitating said liquid-solid mixture in an agitation zone to convert the solid therein to discrete degenerate dendrites comprising up to about 85 weight percent of said heated ferrous alloy and wherein the remainder of said heated ferrous metal alloy is a liquid secondary phase wherein the surface in said agitation zone contacting said liquid-solid mixture is high density recrystallized alumina, c. continuously monitoring the apparent viscosity or an analog of the apparent viscosity of the liquid-solid mixture thereby to control the heat extracted from said mixture when the discrete degenerate dendrite content of said mixture is above about 65 weight percent, d. adding solid third phase particles to said alloy comprising degenerate dendrites and liquid secondary phase, e. dispersing said third phase particles and said degenerate dendrites homogeneously in said secondary phase, said third phase particles comprising up to about 30 weight percent of the weight of the metal alloy and third phase particles, and f. removing said heated ferrous alloy and third phase particles from said agitation zone through an outlet that is protected from contact with air by an inert gas surrounding said outlet.

Claim 8

The method for forming a ferrous metal composition comprising a ferrous metal alloy matrix and third phase solid particles homogeneously suspended in said matrix, said ferrous metal alloy having solid discrete degenerate dendrites homogeneously dispersed within a secondary phase of said metal alloy which comprises: a. heating a first ferrous metal alloy to form an initial liquid-solid mixture of said first ferrous metal alloy, b. vigorously agitating said liquid-solid mixture in an agitation zone to convert the solid therein to discrete degenerate dendrites comprising up to about 85 weight percent of said heated ferrous alloy and wherein the remainder of said heated ferrous metal alloy is a liquid secondary phase wherein the surface in said agitation zone contacting said liquid-solid mixture is high density recrystallized alumina, c. continuously monitoring the apparent viscosity or an analog of the apparent viscosity of the liquid-solid mixture thereby to control the heat extracted from said mixture when the discrete degenerate dendrite content of said mixture is above about 65 weight percent, d. adding solid third phase particles to said alloy comprising degenerate dendrites and liquid secondary phase, e. dispersing said third phase particles and said degenerate dendrites homogeneously in said secondary phase, said third phase particles comprising up to about 30 weight percent of the weight of the metal alloy and third phase particles, and f. removing said heated ferrous alloy and third phase particles from said agitation zone through an outlet that is protected from contact with air by an inert gas surrounding said outlet.