US4459154A — Alloy and process for producing and casting ducti…

Claim 1

Independent Claim 114 words

In the method of producing ductile or compacted graphite cast irons, the improvement which comprises the steps of holding molten iron that contains carbon in a vessel, adding to the molten iron bath an alloy predominately of iron which contains from about 3.0 to about 6.0% silicon by weight, from about 0.9 to about 2.0% magnesium by weight, and up to about 0.6% nickel by weight as the essential elements, continuing to hold said molten iron containing said alloy in said vessel until reaction between the magnesium and iron has taken place and thereafter in a second step adding more of said alloy to said molten iron to establish the desired chemical composition thereof.

Claim 2

Dependent Claim 114 words

In the method of producing ductile or compacted graphite cast irons, the improvement which comprises the steps of holding molten iron that contains carbon in a vessel, adding to the molten iron bath an alloy predominately of iron which contains from about 3.0 to about 6.0% silicon by weight, from about 0.9 to about 2.0% magnesium by weight, and up to about 0.6% nickel by weight as the essential elements, continuing to hold said molten iron containing said alloy in said vessel until reaction between the magnesium and iron has taken place and thereafter in a second step adding more of said alloy to said molten iron to establish the desired chemical composition thereof.

Claim 3

Dependent Claim 18 words

The method of claim 1 wherein the alloy has a density greater than that of the molten iron.

Claim 4

Dependent Claim 20 words

The method of claim 1 wherein the alloy has a density between about 6.5 to about 7.5 gms/cm 3 .

Claim 5

Dependent Claim 23 words

The method of claim 1 wherein the alloy predominately of iron also contains cerium in an amount not over about 2.0% by weight.

Claim 6

Dependent Claim 28 words

The method of claim 1 wherein the alloy predominately of iron also contains one or more rare earth elements in an amount not over about 2.0% by weight.

Claim 7

Dependent Claim 49 words

The method of claim 1 wherein the alloy predominately of iron contains by weight from about 0.1% to about 10.0% silicon, about 0.1 to about 2.0% rare earth elements, about 0.5 to about 4.0% magnesium, from about 0.1 to about 10.0% nickel and about 0.5 to about 6.5% carbon.

Claim 8

Dependent Claim 40 words

The method of claim 1 wherein the alloy comprises by weight from about 3.0 to about 6.0% silicon, up to about 2.0% cerium, about 0.9 to about 2.0% magnesium and up to about 0.6% nickel with the balance being iron.

Claim 9

Dependent Claim 15 words

The method of claim 1 wherein the holding vessel is the vessel of a furnace.

Claim 10

Dependent Claim 129 words

In the method of producing ductile or compacted graphite cast irons, the improvement which comprises the steps of holding molten iron that contains carbon in a vessel, treating said molten iron by adding to the molten iron bath a predominately iron alloy which as essential elements contains from about 0.1 to about 10.0% silicon by weight, from about 0.5 to about 4.0% magnesium by weight, and from about 0.1 to about 10.0% nickel by weight continuing to hold said molten iron in said vessel until the magnesium from said alloy has increased the magnesium content of said treated molten iron and thereafter adding more untreated molten iron that contains carbon to said vessel along with more of said alloy to increase the magnesium content of said untreated added iron.

Claim 11

Dependent Claim 129 words

In the method of producing ductile or compacted graphite cast irons, the improvement which comprises the steps of holding molten iron that contains carbon in a vessel, treating said molten iron by adding to the molten iron bath a predominately iron alloy which as essential elements contains from about 0.1 to about 10.0% silicon by weight, from about 0.5 to about 4.0% magnesium by weight, and from about 0.1 to about 10.0% nickel by weight continuing to hold said molten iron in said vessel until the magnesium from said alloy has increased the magnesium content of said treated molten iron and thereafter adding more untreated molten iron that contains carbon to said vessel along with more of said alloy to increase the magnesium content of said untreated added iron.

Claim 12

Dependent Claim 144 words

In the method of producing ductile or compacted graphite cast irons, the improvement which comprises the steps of holding molten iron that contains carbon in a vessel, adding to the molten iron bath an alloy predominately of iron which contains as essential elements thereof from about 0.1 to about 10.0% silicon by weight, from about 0.5 to about 4.0% magnesium by weight, and from about 0.1 to about 10.0% nickel by weight reacting the magnesium and nickel of said alloy with said molten iron to increase the magnesium content of the molten iron to a selected level, continuing to hold said treated molten iron in said vessel until the magnesium content in said treated molten iron falls below the selected level and then adding more of said alloy to said molten iron to increase the magnesium content thereof at least to a selected level.

Claim 13

Dependent Claim 144 words

In the method of producing ductile or compacted graphite cast irons, the improvement which comprises the steps of holding molten iron that contains carbon in a vessel, adding to the molten iron bath an alloy predominately of iron which contains as essential elements thereof from about 0.1 to about 10.0% silicon by weight, from about 0.5 to about 4.0% magnesium by weight, and from about 0.1 to about 10.0% nickel by weight reacting the magnesium and nickel of said alloy with said molten iron to increase the magnesium content of the molten iron to a selected level, continuing to hold said treated molten iron in said vessel until the magnesium content in said treated molten iron falls below the selected level and then adding more of said alloy to said molten iron to increase the magnesium content thereof at least to a selected level.

Claim 14

Dependent Claim 113 words

In the method of producing ductile or compacted graphite irons, the improvement which comprises the steps of holding molten iron that contains carbon and sulfur in a vessel, treating the molten iron by adding to the molten iron bath an alloy predominately of iron which contains as essential elements thereof from about 0.1 to about 10.0% silicon by weight, from about 0.9 to about 2.0% magnesium by weight and up to about 0.6% nickel by weight, continuing to hold said treated molten iron in said vessel until the sulfur content in the treated iron is reduced and thereafter adding more of said alloy to the molten iron to increase the magnesium content thereof.

Claim 15

Dependent Claim 113 words

In the method of producing ductile or compacted graphite irons, the improvement which comprises the steps of holding molten iron that contains carbon and sulfur in a vessel, treating the molten iron by adding to the molten iron bath an alloy predominately of iron which contains as essential elements thereof from about 0.1 to about 10.0% silicon by weight, from about 0.9 to about 2.0% magnesium by weight and up to about 0.6% nickel by weight, continuing to hold said treated molten iron in said vessel until the sulfur content in the treated iron is reduced and thereafter adding more of said alloy to the molten iron to increase the magnesium content thereof.

Claim 16

Dependent Claim 108 words

In the method of producing ductile or compacted graphite cast irons, the improvement which comprises the steps of holding molten iron that contains carbon in a vessel, agitating the molten iron to establish circulation in a downward flow in the middle of the bath, adding to the surface of the middle of the bath a predominately iron alloy which contains as essential ingredients thereof from about 0.1 to 10.0% silicon by weight, from about 0.5 to 4.0% magnesium by weight and from about 0.1 to about 10.0% nickel by weight whereby the alloy is carried below the surface of the bath by the downward flow of molten iron.

Claim 17

Dependent Claim 108 words

In the method of producing ductile or compacted graphite cast irons, the improvement which comprises the steps of holding molten iron that contains carbon in a vessel, agitating the molten iron to establish circulation in a downward flow in the middle of the bath, adding to the surface of the middle of the bath a predominately iron alloy which contains as essential ingredients thereof from about 0.1 to 10.0% silicon by weight, from about 0.5 to 4.0% magnesium by weight and from about 0.1 to about 10.0% nickel by weight whereby the alloy is carried below the surface of the bath by the downward flow of molten iron.

Claim 18

Dependent Claim 18 words

The method of claim 12 wherein an electric induction stirring coil provides said agitation of the molten iron.

Claim 19

Dependent Claim 51 words

The method of claim 12 wherein the molten iron is agitated to flow upwardly in the middle of the bath and downwardly on opposite sides of the bath and wherein said alloy is added to the molten iron in the downward flow to be carried under the surface of the bath.

Claim 20

Dependent Claim 22 words

The method of claim 12 wherein the alloy also contains up to about 2.0% cerium and/or other rare earth elements by weight.

Claim 21

Dependent Claim 92 words

In the method of producing castings of ductile or compacted graphite cast irons, the improvement which comprises flowing a stream of molten iron containing carbon into a mold and adding to the stream of molten iron as it enters the mold a predominately iron alloy which contains as essential elements thereof from about 0.1 to about 10.0% silicon by weight, from about 0.9 to about 2.0% magnesium by weight and up to about 0.6% nickel by weight whereby the alloy is carried into the mold by the flowing stream of molten iron.

Claim 22

Dependent Claim 92 words

In the method of producing castings of ductile or compacted graphite cast irons, the improvement which comprises flowing a stream of molten iron containing carbon into a mold and adding to the stream of molten iron as it enters the mold a predominately iron alloy which contains as essential elements thereof from about 0.1 to about 10.0% silicon by weight, from about 0.9 to about 2.0% magnesium by weight and up to about 0.6% nickel by weight whereby the alloy is carried into the mold by the flowing stream of molten iron.

Claim 23

Dependent Claim 91 words

In the method of producing ductile or compacted graphite cast irons, the improvement comprising the steps of flowing a stream of molten iron containing carbon into a holding vessel, adding to said stream of molten iron a predominately iron alloy which contains from about 0.1 to about 10.0% silicon by weight, from about 0.9 to about 2.0% magnesium by weight and up to 0.6% nickel by weight whereby said alloy is carried by the stream of molten iron into the holding vessel and below the surface of the bath established therein.

Claim 24

Dependent Claim 91 words

In the method of producing ductile or compacted graphite cast irons, the improvement comprising the steps of flowing a stream of molten iron containing carbon into a holding vessel, adding to said stream of molten iron a predominately iron alloy which contains from about 0.1 to about 10.0% silicon by weight, from about 0.9 to about 2.0% magnesium by weight and up to 0.6% nickel by weight whereby said alloy is carried by the stream of molten iron into the holding vessel and below the surface of the bath established therein.

Claim 25

Dependent Claim 129 words

In the method of producing castings of ductile and compacted graphite cast irons, the improvement which comprises supplying molten iron which contains carbon to at least one holding vessel, treating said molten iron by adding to the molten iron bath in the vessel a predominately iron alloy which contains as essential elements thereof from about 0.1 to about 10.0% silicon by weight, from about 0.5 to about 2.0% magnesium by weight and up to about 0.6% nickel by weight, moving a plurality of casting molds in sequence to bring one at a time into position below said vessel to receive treated molten iron from said vessel and adding more untreated molten iron containing carbon into said holding vessel along with more of said alloy in an iron casting operation.

Claim 26

Dependent Claim 129 words

In the method of producing castings of ductile and compacted graphite cast irons, the improvement which comprises supplying molten iron which contains carbon to at least one holding vessel, treating said molten iron by adding to the molten iron bath in the vessel a predominately iron alloy which contains as essential elements thereof from about 0.1 to about 10.0% silicon by weight, from about 0.5 to about 2.0% magnesium by weight and up to about 0.6% nickel by weight, moving a plurality of casting molds in sequence to bring one at a time into position below said vessel to receive treated molten iron from said vessel and adding more untreated molten iron containing carbon into said holding vessel along with more of said alloy in an iron casting operation.

Claim 27

Dependent Claim 29 words

The method of claim 18 wherein the plurality of molds are held stationary and the holding vessel is moved into position to supply treated molten iron to the molds.

Claim 28

Dependent Claim 30 words

The method of claim 18 wherein the holding vessel is held stationary and the plurality of molds are moved into position to receive treated molten iron from the holding vessel.

Claim 29

Dependent Claim 53 words

The method of claim 18 wherein the molten iron bath is agitated to circulate the molten iron downwardly in the middle of the bath and the alloy is added at the surface in the middle of the bath where it can be carried below the surface thereof by the downward flow of metal.

Claim 30

Dependent Claim 58 words

The method of claim 18 in which the alloy contains by weight from about 0.1 to about 10.0% silicon, about 0.5 to about 4.0% magnesium, and from about 0.1 to about 10.0% nickel as the essential ingredients in said predominately iron alloy and wherein the alloy has a density from about 6.5 to about 7.5 gms/cm 3 .

Claim 31

Dependent Claim 21 words

The method of claim 22 wherein the alloy includes up to about 2.0% cerium and/or other rare earth elements by weight.

Claim 32

Dependent Claim 29 words

The method of claim 18 wherein there are a plurality of holding vessels for treating the molten iron with alloy and for supplying treated molten iron to the molds.

Claim 33

Dependent Claim 164 words

In the method of producing castings of ductile or compacted graphite cast irons, the improvement which comprises moving a plurality of holding vessels in a first circular path, moving a plurality of casting molds in a second circular path to bring the plurality of molds into position below said plurality of holding vessels to receive treated molten iron therefrom, establishing in said plurality of holding vessels a supply of molten iron containing carbon which has been treated with a predominately iron alloy containing as essential elements thereof by weight from about 3.0 to about 6.0% silicon, from about 0.9 to about 2.0% magnesium, and up to about 0.6% nickel by weight, interrupting the movement of said holding vessels and molds to hold them in stationary position while at least one mold receives treated molten iron from at least one holding vessel, and re-establishing the supply of treated molten iron in said holding vessels when held in stationary position as required for a casting operation.

Claim 34

Dependent Claim 164 words

In the method of producing castings of ductile or compacted graphite cast irons, the improvement which comprises moving a plurality of holding vessels in a first circular path, moving a plurality of casting molds in a second circular path to bring the plurality of molds into position below said plurality of holding vessels to receive treated molten iron therefrom, establishing in said plurality of holding vessels a supply of molten iron containing carbon which has been treated with a predominately iron alloy containing as essential elements thereof by weight from about 3.0 to about 6.0% silicon, from about 0.9 to about 2.0% magnesium, and up to about 0.6% nickel by weight, interrupting the movement of said holding vessels and molds to hold them in stationary position while at least one mold receives treated molten iron from at least one holding vessel, and re-establishing the supply of treated molten iron in said holding vessels when held in stationary position as required for a casting operation.

Claim 35

Dependent Claim 37 words

The method of claim 25 wherein the iron alloy contains as essential elements by weight from about 0.1 to about 10.0% silicon, from about 0.5 to about 4.0% magnesium and from about 0.1 to about 10.0% nickel.

Claim 36

Dependent Claim 21 words

The method of claim 26 wherein said alloy includes up to about 2.0% cerium and/or other rare earth elements by weight.

Claim 37

Dependent Claim 48 words

The method of claim 25 wherein the untreated molten iron is supplied to said plurality of holding vessels and said alloy is added to the untreated molten iron to establish and re-establish said supply of treated molten iron in said plurality of vessels for transfer to said molds.

Claim 38

Dependent Claim 48 words

The method of claim 25 wherein the molten iron is treated with said alloy in one or more separate supply vessels which supply the treated molten iron to said plurality of holding vessels to establish and re-establish the supply of treated molten iron for transfer to said molds.

Claim 39

Dependent Claim 34 words

The method of claim 25 wherein additional alloy is added to the treated molten iron in said holding vessels to obtain a selected chemical composition of treated molten iron for transfer to the molds.

Claim 40

Dependent Claim 73 words

The method of claim 25 wherein untreated molten iron is partially treated with said alloy in one or more separate supply vessels which supply the partially treated molten iron to said plurality of holding vessels and additional alloy is added to said partially treated molten iron in said holding vessels to complete the treatment of the molten iron therein and establish and re-establish the supply of molten iron for transfer to said molds.

Claim 41

Dependent Claim 50 words

The method of claim 25 wherein the predominately iron alloy contains as essential elements by weight from about 3.0 to about 6% silicon, from about 0.9 to about 2.0% magnesium, up to about 0.6% nickel, up to about 2.0% cerium and/or other rare earth elements and 3.0 to 6.5% carbon.

Claim 42

Dependent Claim 21 words

The method of claim 25 wherein the density of said alloy is from about 6.5 to about 7.5 gms/cm 3 .

Claim 43

Dependent Claim 43 words

The method of claim 25 wherein the plurality of holding vessels and plurality of casting molds are moved in selected intersecting paths that are not circular and treated molten iron is transferred from the vessels to the molds where the selected paths intersect.

Claim 44

Dependent Claim 89 words

The method of claim 34 wherein the selected paths are oblong and the treated molten iron is transferred to the molds while the holding vessels and molds are moving along a first straight portion of the oblong path where the paths of the holding vessels and molds intersect and wherein a separate supply container moving along a path that intersects a second straight portion of the oblong path of said holding vessels is employed for establishing and re-establishing the supply of treated molten iron for transfer to said molds.

Claim 45

Independent Claim 82 words

The method of producing ductile or compacted graphite cast irons which comprises the step of introducing into molten iron that contains carbon an iron alloy comprising by weight from about 0.1 to about 10.0% silicon, from about 0.5 to about 4.0% magnesium, from about 0.1 to about 10.0% nickel and optionally from about 0.1 to about 2.0% of one or more rare earth elements with the balance of the alloy being iron to increase the magnesium content of said treated molten iron.

Claim 46

Independent Claim 82 words

The method of producing ductile or compacted graphite cast irons which comprises the step of introducing into molten iron that contains carbon an iron alloy comprising by weight from about 0.1 to about 10.0% silicon, from about 0.5 to about 4.0% magnesium, from about 0.1 to about 10.0% nickel and optionally from about 0.1 to about 2.0% of one or more rare earth elements with the balance of the alloy being iron to increase the magnesium content of said treated molten iron.

Claim 47

Dependent Claim 17 words

The method of claim 36 in which the one or more rare earth elements is predominately cerium.

Claim 48

Dependent Claim 41 words

The method of claim 36 in which the alloy is predominately iron having as essential elements from about 3.0 to about 6.0% silicon, up to about 0.6% nickel and about 0.9 to about 2.0% magnesium by weight of said iron alloy.

Claim 49

Dependent Claim 23 words

The method of claim 38 in which the density of the iron alloy is from about 6.5 to about 7.5 gms/cm 3 .

Claim 50

Dependent Claim 42 words

The method of claim 36 in which the iron alloy is added to the molten iron in an amount sufficient to provide in the molten iron from about 0.015% to about 0.08% magnesium based on the weight of the treated molten iron.

Claim 51

Dependent Claim 67 words

An iron alloy for treating molten iron containing carbon to produce ductile cast iron containing nodular carbon, or compacted graphite cast iron, said iron alloy comprising by weight from about 0.1 to about 10.0% silicon, about 0.1 to about 10.0% nickel, about 0.5 to about 4.0% magnesium, and optionally up to about 2.0% of one or more rare earth elements, the balance of the alloy being iron.

Claim 52

Dependent Claim 67 words

An iron alloy for treating molten iron containing carbon to produce ductile cast iron containing nodular carbon, or compacted graphite cast iron, said iron alloy comprising by weight from about 0.1 to about 10.0% silicon, about 0.1 to about 10.0% nickel, about 0.5 to about 4.0% magnesium, and optionally up to about 2.0% of one or more rare earth elements, the balance of the alloy being iron.

Claim 53

Dependent Claim 51 words

An alloy for treating molten iron containing carbon to produce ductile cast iron containing nodular carbon or compacted graphite cast iron, said alloy being predominately iron having as essential elements by weight from about 3.0 to about 6.0% silicon, up to about 0.6% nickel, and about 0.9% to about 2.0% magnesium.

Claim 54

Dependent Claim 51 words

An alloy for treating molten iron containing carbon to produce ductile cast iron containing nodular carbon or compacted graphite cast iron, said alloy being predominately iron having as essential elements by weight from about 3.0 to about 6.0% silicon, up to about 0.6% nickel, and about 0.9% to about 2.0% magnesium.

Claim 55

Dependent Claim 16 words

The alloy of claim 42 having density from about 6.5 to about 7.5 gms/cm 3 .

Claim 56

Independent Claim 97 words

The method of making an alloy for treating molten iron containing carbon to produce ductile or compacted graphite cast irons which comprises the steps of forming a molten iron bath comprising by weight from about 0.1 to about 10.0% silicon, about 0.1 to about 10.0% nickel, about 0.5 to about 4.0% magnesium, and optionally from about 0.1 to about 2.0% one or more rare earth elements, the balance being iron and maintaining said molten bath under superatmospheric pressure of an inert gas while reaction takes place and then rapidly solidifying the melt to form the iron alloy.

Claim 57

Independent Claim 97 words

The method of making an alloy for treating molten iron containing carbon to produce ductile or compacted graphite cast irons which comprises the steps of forming a molten iron bath comprising by weight from about 0.1 to about 10.0% silicon, about 0.1 to about 10.0% nickel, about 0.5 to about 4.0% magnesium, and optionally from about 0.1 to about 2.0% one or more rare earth elements, the balance being iron and maintaining said molten bath under superatmospheric pressure of an inert gas while reaction takes place and then rapidly solidifying the melt to form the iron alloy.

Claim 58

Independent Claim 111 words

The method of making an alloy for treating molten iron containing carbon to produce ductile or compacted graphite cast irons which comprises the steps of forming a molten iron bath comprising by weight from about 3.0 to about 6.0% silicon, up to about 0.6% nickel, about 0.9 to about 2.0% magnesium, and optionally up to about 2.0% one or more rare earth elements, the balance being iron, maintaining said molten bath under from about 50 to about 75 p.s.i.g. pressure of an inert gas while reaction takes place and adjusting the proportions of said metals to produce the iron alloy with density from about 6.5 to about 7.5 gms/cm 3 .

Claim 59

Independent Claim 111 words

The method of making an alloy for treating molten iron containing carbon to produce ductile or compacted graphite cast irons which comprises the steps of forming a molten iron bath comprising by weight from about 3.0 to about 6.0% silicon, up to about 0.6% nickel, about 0.9 to about 2.0% magnesium, and optionally up to about 2.0% one or more rare earth elements, the balance being iron, maintaining said molten bath under from about 50 to about 75 p.s.i.g. pressure of an inert gas while reaction takes place and adjusting the proportions of said metals to produce the iron alloy with density from about 6.5 to about 7.5 gms/cm 3 .

Claim 60

Dependent Claim 69 words

An iron alloy for treating molten iron containing carbon to produce ductile cast iron containing nodular carbon or compacted graphite cast iron, said alloy comprising by weight from about 0.1 to about 10.0% silicon, from 0.5 to about 4.0% magnesium, from about 0.1 to about 10.0% nickel, from about 0.1 to about 2.0% cerium and from about 0.5 to about 6.5% carbon, the balance of the alloy being iron.

Claim 61

Dependent Claim 69 words

An iron alloy for treating molten iron containing carbon to produce ductile cast iron containing nodular carbon or compacted graphite cast iron, said alloy comprising by weight from about 0.1 to about 10.0% silicon, from 0.5 to about 4.0% magnesium, from about 0.1 to about 10.0% nickel, from about 0.1 to about 2.0% cerium and from about 0.5 to about 6.5% carbon, the balance of the alloy being iron.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1987-07-10	1988-01-09	1988-07-10	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1991-07-10	1992-01-09	1992-07-10	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1995-07-10	1996-01-09	1996-07-10	$7700.00	Window Closed / Lapsed

Alloy and process for producing and casting ductile and compacted graphite cast irons

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