A furnace assembly for a metal-making process, including: an electric arc furnace configured for flat bath operation and having a bottom, and an electromagnetic stirrer configured to be arranged underneath the bottom of the electric arc furnace to enable stirring of molten metal in the electric arc furnace.

A molten metal rotor receives and retains an end of a molten metal rotor shaft. The rotor shaft has one or more projections at the end received in the rotor. The rotor has an inner cavity, a top surface with an opening leading to the inner cavity, and at least one abutment. The opening includes one or more portions for allowing each projection to pass through the opening and into the inner cavity. The rotor and/or shaft are then rotated so at least one of the outwardly-extending projections is under the top surface of the rotor and is against an abutment. A molten metal pump, rotary degasser scrap melter or other device used in molten metal may utilize a rotor/shaft combination as disclosed herein.

Disclosure provides a two-segment electromagnet stirring member, and a two-segment electromagnet semi-solid die-casting apparatus including the same, and a die-casting method using the same. The two-segment electromagnet stirring member includes a plurality of magnetic field generation parts therein, and includes a first electromagnetic stirring part and a second electromagnetic stirring part separated from each other. The first electromagnetic stirring part and the second electromagnetic stirring part are coupled to each other in a ring shape to surround an outer circumferential surface of a sleeve to perform electromagnetic stirring to molten metal in the sleeve, and are coupled to each other so as to position the plurality of magnetic field generation parts at radially equal gaps around the sleeve.

A launder for use in moving molten metal includes at least one relatively narrow channel through which molten metal flows. Using a narrow, rather than broad, channel permits better control of the flow and helps prevent overflowing the launder or a structure adjacent the launder. A molten metal pumping or transfer system may utilize a launder as disclosed herein.

A system according to aspects of the invention includes a pump and a refractory casing that houses the pump or is in fluid communication with the pump. As the pump operates it moves molten metal upward through an uptake section of the casing until it reaches a rectangular outlet wherein it exits the vessel. The rectangular outlet is configured to be connected to, or may be attached to, a launder. Another system uses a wall to divide a cavity of the chamber into two portions. The wall has an opening and a pump pumps molten metal from a first portion into a second portion until the level in the second portion reaches an outlet and exits the vessel.

A system and method for filling a mold with molten aluminum includes a molten metal pump, a vessel configured to contain molten metal, a mold for receiving molten metal, and a conduit between the vessel and the mold. Molten metal is pumped in the vessel until it reaches a level at which it flows through the conduit and into the mold. The flow of molten metal into the mold is stabilized to maintain a level of molten metal in the mold. A skin of solid metal forms between the mold and the conduit, at which time the pumping of molten metal can cease. The mold with solid metal in it can be moved.

A pump system for transferring molten metal includes a pump for pumping molten metal. The pump includes a motor. The pump also includes a base adapted to be submerged in molten metal contained in a vessel including at least one inlet opening, an outlet opening and an impeller chamber fluidly communicating with the at least one inlet opening and the outlet opening. A shaft sleeve is part of the pump and is adapted to fasten to the base and extends outside the molten metal. An impeller is part of the pump and is adapted for rotation inside the impeller chamber. The pump includes a shaft driven by the motor and extends in the shaft sleeve. The impeller is fastened to the shaft. The pump system also includes a transfer block that is adapted to be submerged in the molten metal and to extend outside the molten metal. The transfer block includes an interior wall extending along its height, an inlet opening that receives molten metal from the base, and an outlet. The transfer block includes an obstruction member disposed in an interior thereof that disrupts an initial flow path of molten metal inlet into the transfer block from the base. The transfer block includes a diffuser plate inside the interior thereof. The diffuser plate includes through holes formed therein. Another aspect is a refractory transfer block with an obstruction member and a diffuser plate, which, for example, can be used with a pump for pumping molten metal.

A metal melting furnace including a stirring device as includes: a furnace body defining a chamber for accommodating molten metal; the stirring device including a stirring disc and a drive device, the stirring disc including a disc body, a feedstock holding portion, and a feedstock inlet via which feedstock is replenished to the feedstock holding portion, a stirring rod being connected on the disc body, a plurality of vertically through openings being provided on the disc body and/or on the feedstock holding portion, the drive device being in drive connection to the stirring rod, the drive device being configured to drive the stirring rod to lift such that the stirring disc is immersed in or lifted out of the molten metal in the chamber, the feedstock holding portion being configured to hold the feedstock on the stirring disc such that the feedstock move together with the stirring disc.

A metal melting furnace including a stirring device as includes: a furnace body defining a chamber for accommodating molten metal; the stirring device including a stirring disc and a drive device, the stirring disc including a disc body, a feedstock holding portion, and a feedstock inlet via which feedstock is replenished to the feedstock holding portion, a stirring rod being connected on the disc body, a plurality of vertically through openings being provided on the disc body and/or on the feedstock holding portion, the drive device being in drive connection to the stirring rod, the drive device being configured to drive the stirring rod to lift such that the stirring disc is immersed in or lifted out of the molten metal in the chamber, the feedstock holding portion being configured to hold the feedstock on the stirring disc such that the feedstock move together with the stirring disc.

A smart molten metal pump system and method automatically controls the operating speed of the pump rather than requiring an operator to control the speed. The system includes a pump, a controller for controlling the speed of the pump and one or more vibration sensors (such as an accelerometer) to measure vibration. The controller receives input about the vibration of the pump or one or more pump components, and possibly other data, such as the temperature of the molten metal, and/or the depth of the molten metal, ad/or parameters related to the operation of the pump. The controller analyzes the one or more inputs to vary the speed of the pump, turn the pump off, and/or send a communication to an operator.