Alvaro J Giron

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.

US Patent:

20050043189, Feb 24, 2005

Filed:

Aug 18, 2003

Appl. No.:

10/642709

Inventors:

Patricia Stewart - Pittsburgh PA, US
Ray Richter - Murrysville PA, US
Thomas Kasun - Export PA, US
Joseph Laemmle - Delmont PA, US
Nickolas Kotow - Bethel Park PA, US
David DeYoung - Export PA, US
J. Kirby - Delmont PA, US
Alvaro Giron - Murrysville PA, US
Raymond Colbert - Pittsburgh PA, US
Larry Wieserman - Apollo PA, US

International Classification:

C10M125/18
C10M015/38
C10M147/00
B22D011/07

US Classification:

508112000, 508154000, 508155000, 508161000, 508162000, 508165000, 508181000, 508582000, 508590000, 164459000

Abstract:

In an oxidation inhibiting lubricant composition suitable for use in the manufacture of aluminum alloys comprising lubricant base selected from the group consisting of solid lubricants, liquid lubricants, grease lubricants, emulsion lubricants, and dispersion lubricants, the improvement wherein the lubricant composition further comprises: an effective amount of a fluorine-containing passivating compound.

US Patent:

20080000608, Jan 3, 2008

Filed:

Jun 20, 2007

Appl. No.:

11/765753

Inventors:

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

International Classification:

B22D 30/00
B22C 9/08
B22D 45/00

US Classification:

164122100, 249105000

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 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 casing, and low stresses throughout the casting.

US Patent:

20110100579, May 5, 2011

Filed:

Dec 31, 2010

Appl. No.:

12/982980

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

International Classification:

B22D 19/16
B22D 23/00

US Classification:

164 94

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:

52320421, Aug 3, 1993

Filed:

Feb 18, 1992

Appl. No.:

7/836661

Inventors:

Alvaro Giron - Pittsburgh PA
John E. Jacoby - Murrysville PA
Ho Yu - Murrysville PA

Assignee:

Aluminum Company of America - Pittsburgh PA

International Classification:

B22D 300
B22D 706
B22D 2704

US Classification:

164128

Abstract:

A mold for casting metal ingot sows having an aspect ratio of at least 4:1. The mold comprises a bottom wall from which a side wall extends upwardly and outwardly and from which heat transfer structure extends downwardly for transferring heat away from the bottom wall.