Patent ID: 6539620
Filing Date: 2003-04-01
Classification: B21C,B23K,C22F,Y10T

Abstract:
A method of producing weld wire having low inclusion content, comprising the steps of:casting a molten superalloy having a preselected composition into a mold having at least one ingot cavity in the shape of a rod having a diameter of less than about Â½ inch; directionally solidifying the rod-shaped ingot by feeding an advancing solidification interface with molten metal to eliminate creation of shrinkage cavities and simultaneously causing impurities and inclusions to segregate as slag to the top and sides of the ingot during solidification, while growing grains into the molten metal substantially parallel to the axial direction of the rod-shaped ingot; following completion of solidification, removing a portion of the rod-shaped ingot having inclusions and impurities; cutting the rod-shaped ingot into a plurality of preselected lengths; placing a plurality the preselected cut lengths of rod into a container; filling the remaining volume of the container with an inert oxide; capping the container; sealing the capped container; extruding the rod-filled container so as to form wire for welding having a preselected diameter; and removing the wire from the container.