A method of forming a ceramic-metal composite part is described herein. The method includes maintaining molten metal in an interior of a housing in a liquefied state, the interior including a first chamber, a second chamber, and a port defined therebetween. The method further includes sealing the port such that the molten metal in the first chamber is maintained at a first liquid level, suspending a part at a height within the first chamber above the first liquid level, forming a pressure differential between the first chamber and the second chamber, unsealing the port such that molten metal from the second chamber flows into the first chamber, and resealing the port when the molten metal in the first chamber reaches a second liquid level such that the ceramic part is submerged in the molten metal.

The invention is a continuation of U.S. Pat. No. 9,617,610 issued on Apr. 11, 2017. It consists of a process to treat comingled and co-mixed ferrous and non-ferrous scrap by heat from flue gases generated in the hearth of the furnace, charging and melting the treated ferrous scrap after removing contaminants and non-ferrous elements of the scrap through a three step process in a triple chamber furnace (FIGS. 1 and 4). The furnace consists of a first chamber (4) where the scrap is loaded, and treated in an oxygen deficient flue gas atmosphere downstream of a heat recuperator (3), at high temperature to cause the peeling and melting of zinc from galvanized scrap, the melting of non-ferrous components of the scrap and their collection at the bottom of the chamber at a dedicated spout (23) to a crucible (24), the pyrolysis of paints, plastic and used tire contaminants of the scrap. Upstream of the recuperator flue gas from the second stage, or charging and melting chamber (2) rise to exchange heat in the recuperator (3) and pre-heat combustion air on its way to the primary burner of the furnace (11). Ferrous scrap after being separated from non ferrous elements is charged into the second stage or charging and melting chamber (2); the chamber having a floor sloped at an angle less than the angle of repose of steel in a solid form, so that the molten iron and steel can flow to the third stage or hearth (1) where carbon is added at the carburizer (5), alloying elements at the charging spout (6) and oxygen carrying gases, gaseous, liquid and pulverized solid fuel are applied at the burner (11) to complete the refining of the scrap and their discharge for castings. To achieve the pyrolysis needed to eliminate coating, paint, rubber tires, plastic scrap, the combustion in the hearth is completed at stoichometric ratio to deplete the flue gases from oxygen. Flue gases on the discharge of the triple chamber Cokeless furnace are treated by conventional methods to extract dust, condense and separate hydrocarbons that resulted from the pyrolysis in the scrap in the treatment chamber prior to discharge to the environment (27). Condensed hydrocarbons are burned in the hearth (1) for additional heat. Non-ferrous molten metals collected in a crucible or channel furnace (24) are further processed outside the triple chamber furnace. In a different embodiment of the invention, containers full of scrap tires, scrap plastics and non-ferrous scrap (34) are charged closed in the scrap processing chamber, heated externally by flue gases and the containers ven

A multi-chamber melting furnace for melting scrap of non-ferrous metals, in particular aluminum scrap, including a first shaft furnace with a shaft for charge material, in which impurities of the charge material can be removed, and at least one furnace chamber which is connected to the shaft of the first shaft furnace and has a first heat supply device, wherein at least one second shaft furnace with a shaft for charge material, in which shaft impurities of the charge material can be removed, the furnace chamber being connected to the shaft of the second shaft furnace and being arranged between the shafts in such a manner that the furnace chamber forms a main melting chamber in which the molten bath is located during operation.

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 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.

The disclosure relates to a melting furnace, for example a two-chamber furnace, for the recovery of aluminum from aluminum scrap. This has a scrap chamber (2), with a dry hearth (6), the surface of which provided for receiving aluminum scrap is arranged above the surface of an aluminum melt (7) located in the scrap chamber (2) during operation of the melting furnace (1), and a heating chamber (3), which has at least one burner (9) for fuel firing, the heating chamber (3) and the scrap chamber (2) being separated from one another by a partition wall (11), the partition wall (11) having at least one opening (12) for recirculation of the aluminum melt (7) between the heating chamber (3) and the scrap chamber (2). Further, a refractory lining of the surface of the dry hearth (6) and/or a refractory lining of the inner wall of the scrap chamber (2) in the region of the dry hearth (6) have channels (18) which can be acted upon by hot gas and are designed to absorb heat from the hot gas and to release it to the aluminum scrap located on the surface of the dry hearth (6) for its thermal pretreatment.

A metal melting and retention furnace is provided, wherein a tubular member in a furnace chamber, a table-like melting part is formed directly below the tubular member and a melting burner is arranged in the furnace chamber, a molten metal retention part in which the melting material which has been melted is introduced and which is provided with a retention burner for heating the introduced molten metal is formed around the outer circumference of the table-like melting part, and the molten metal in the molten metal retention part flows to a molten metal ladle part adjacent to the furnace chamber.

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.