Method and Apparatus for Manufacturing Titanium Alloys

Abstract

A system and method for producing a metallic ingot using, for example, a VAR furnace, includes a primary crucible receiving a melted metal from a source of metal and collecting the melted metal to for a pool of melted metal, the primary crucible including an overflow lip, a secondary crucible receiving the melted metal from the overflow lip of the primary crucible, the secondary crucible being smaller than and electrically isolated from the primary crucible, and a withdrawal device withdrawing the molten metal, solidified by cooling, from the secondary crucible in the form of solidified ingots, wherein the solidified ingots have a smaller diameter than a diameter of the source of metal. A cutting device periodically cuts the withdrawn solidified ingots as they are withdrawn from the secondary crucible.

1 . A system for producing a metallic ingot comprising:
 a primary crucible receiving a melted metal from a source of metal and collecting the melted metal to for a pool of melted metal, the primary crucible including an overflow lip;   a secondary crucible receiving the melted metal from the overflow lip of the primary crucible, the secondary crucible having heated side walls, being smaller than and electrically isolated from the primary crucible and having an opening through which the molten metal may pass as the metal solidifies into an ingot, the opening having a smaller diameter than a diameter of the source of metal; and   a withdrawal device withdrawing the melted metal, solidified by cooling, from the secondary crucible in the form of a solidified ingot   
     
     
         2 . The system of  claim 1 , further comprising a cutting device periodically cutting the withdrawn solidified ingot as the ingot is withdrawn from the secondary crucible. 
     
     
         3 . The system of  claim 1 , further comprising a heat source provided above the secondary crucible for keeping the melted metal at the top molten. 
     
     
         4 . The system of  claim 3 , wherein the heat source comprises a non-consumable electrode. 
     
     
         5 . The system of  claim 1 , wherein the source of metal comprises titanium or a titanium alloy. 
     
     
         6 . The system of  claim 1 , wherein the source of metal comprises a consumable electrode of the metal. 
     
     
         7 . The system of  claim 1 , wherein the source of metal is melted using a VAR furnace. 
     
     
         8 . A method of manufacturing a metal comprising:
 melting a source of metal to form a pool of melted metal in a primary crucible;   transferring the melted metal from the primary crucible to a secondary crucible, the secondary crucible having sidewalls and being smaller than and electrically isolated from the primary crucible;   heating the sidewalls of the secondary crucible;   allowing a portion of the melted metal to cool and solidify within the secondary crucible; and   continuously withdrawing the cooled and solidified metal from the secondary crucible.   
     
     
         9 . The method of  claim 8 , further comprising periodically cutting the withdrawn cooled and solidified metal as it is withdrawn from the secondary crucible to form solidified ingots. 
     
     
         10 . The method of  claim 8 , wherein the transferring step comprises directing the melted metal from the primary crucible via an overflow lip which allows the melted metal to flow from the primary crucible to the secondary crucible. 
     
     
         11 . The method of  claim 8 , further comprising heating the secondary crucible to keep the melted metal at the top molten. 
     
     
         12 . The method of  claim 8 , wherein the source of metal comprises titanium or a titanium alloy. 
     
     
         13 . The method of  claim 8 , wherein the source of metal comprises a consumable electrode of the metal. 
     
     
         14 . The method of  claim 8 , wherein the source of metal is melted using a VAR furnace. 
     
     
         15 .- 19 . (canceled) 
     
     
         20 . A method of manufacturing a metal comprising:
 melting a source of metal to form a pool of melted metal in a crucible, wherein the crucible includes a hole formed at a bottom thereof, the hole defined by sidewalls extended downward from the crucible bottom;   providing a starter piece of metal in the crucible hole, wherein the starter piece of metal is compositionally the same as the source of metal;   allowing the melted metal to pool in the crucible; and   upon the pooled melted metal reaching approximately 1-2″ in height in the crucible, withdrawing the starter piece of metal from the crucible hole, wherein the starter piece of metal has cooled and solidified metal attached to it.   
     
     
         21 . The method of  claim 20 , further comprising periodically cutting the withdrawn cooled and solidified metal as it is withdrawn from the crucible hole to form solidified ingots. 
     
     
         22 . The method of  claim 20 , wherein the source of metal comprises titanium or a titanium alloy. 
     
     
         23 . The method of  claim 20 , wherein the source of metal comprises a consumable electrode of the metal. 
     
     
         24 . The method of  claim 20 , wherein the source of metal is melted using a VAR furnace.