Revert blend algorithm

Abstract

A revert alloy is used in the manufacture of a target alloy having a different composition. The weight percent of the elemental constituents of this first alloy and a second or target alloy are obtained, and the ratio of the percentage by weight of each elemental constituent in the first alloy to the second alloy is determined. The lowest ratio is used to determine the amount of the first alloy that is melted and the necessary elemental constituents that are added to the melt to produce the desired composition of the target alloy. The melt is solidified to produce the target alloy.

1 . A method of using a first alloy having a first composition in the manufacture of a second alloy of a second composition, the method comprising:
 identifying the first alloy;   identifying the second alloy;   obtaining a percentage by weight all the elemental constituent of the first alloy and of the second alloy from a data base;   calculating a ratio of a percentage by weight of each elemental constituent in the second alloy to a percentage by weight of a corresponding elemental constituent in the first alloy;   determining which elemental constituent ratio is lowest;   using the lowest constituent ratio to select an amount of the first alloy;   melting the selected amount of the first alloy to form a melt;   adding additional quantities of elemental constituents to the melt so that the melt has the second composition of the second alloy; and   solidifying the melt to form the second alloy.   
   
   
       2 . The method of  claim 1 , wherein the first alloy is a revert alloy and the second alloy is a target alloy. 
   
   
       3 . The method of  claim 1 , wherein the weight percent of each of the elemental constituents is obtained from a reference table. 
   
   
       5 . The method of  claim 1 , wherein the first and second alloys are super alloys having different elemental constituents. 
   
   
       6 . The method of  claim 1 , wherein the calculating the ratio comprises:
 (a) determining if an amount of each elemental constituent of the second alloy is present in the first alloy;   (b) assigning a ratio of 100% if the constituent is not present in the first alloy, or is present in a lower percentage by weight in the first alloy than in the second alloy;   (c) determining the element constituent ratio for each constituent that is present in a greater percentage in the first alloy than in the second alloy by dividing the percentage of the constituent in the first alloy by percentage of the constituent in the second alloy;   (d) continuing to calculate a ratio for each elemental constituent using steps (a) through (c) above.   
   
   
       7 . The method of  claim 6 , wherein the first alloy is a revert alloy, the second alloy is a target alloy, and the weight percent of each of the elemental constituents is obtained from a reference table. 
   
   
       8 . A system for using a first alloy having a first composition in the manufacture of a second alloy, the system comprising:
 the first alloy having been prepared for melting;   the second alloy having been selected a source of elemental constituents for obtaining the weight percent of each of the elemental constituents of the first alloy and of the second alloy;   a processor for calculating the ratio of the percentage by weight of each elemental constituent in the second alloy to the percentage by weight of the same elemental constituent in the first alloy;   the processor further being adapted to compare all the ratios to determine the one elemental constituent ratio that is lowest;   a furnace for melting an amount of the first alloy based upon the lowest constituent ratio as the amount of the first alloy to be used in the manufacture and then melting that amount of the first alloy;   a source for adding additional quantities of the remaining elemental constituents to the melted first alloy to convert the melt to the second alloy; and   a mold for receiving and solidifying the second alloy from the furnace.   
   
   
       9 . The system of  claim 8 , wherein the first alloy is a revert alloy and the second alloy is a target alloy. 
   
   
       10 . The system of  claim 8 , wherein the source of the weight percent of each of the elemental constituents is a reference table. 
   
   
       11 . The system of  claim 8 , wherein the processor calculates the ratios using a linear programming algorithm. 
   
   
       12 . The system of  claim 8 , wherein the first and second alloys are have different elemental constituents. 
   
   
       13 . The system of  claim 8 , wherein the processor calculates the ratios by:
 (a) determining if each elemental constituent in the first alloy is zero or greater than zero;   (b) assigning a ratio of 100% if zero;   (c) comparing the same elemental constituent in the second alloy to determine if the first alloy constituent is less than that in the second alloy and assigning a ratio of 100% if it is less and assigning an actual ratio if it is equal to or more than the second alloy;   (d) continuing to calculate a ratio for each elemental constituent using steps (a) through (c) above; and   (e) selecting the lowest ratio to determine the amount of first alloy used.   
   
   
       14 . The system of  claim 13 , wherein the first alloy is a revert alloy, the second alloy is a target alloy, and the weight percent of each of the elemental constituents is obtained from a reference table. 
   
   
       15 . An alloy prepared according to the method of  claim 1 .