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Method of Making a Lead-Calcium-Aluminium Alloy

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Method of Making a Lead-Calcium-Aluminium Alloy Europaisches Patentamt à European Patent Office JO Publication number: 0 079 765 Office européen des brevets B1 ® EUROPEAN PATENT SPECIFICATION (§) Dateof publication of patent spécification: 12.03.86 ® Int. Cl.4: C 22 C 1/02, C 22 C 1 1/02 (21) Application number: 82306008.2 (22) Dateoffiling: 11.11.82 (§) Method of making a lead-calcium-aluminium alloy. (1) Priority: 13.11.81 US 321051 (73) Proprietor: RSR CORPORATION 1111 West Mockingbird Lane Dallas, Texas 75247 (US) (43) Date of publication of application: 25.05.83 Bulletin 83/21 (72) Inventor: Prengaman, Raymond David 2207 Ravinia Drive @ Publication of the grant of the patent: Arlington Texas 76012 (US) 12.03.86 Bulletin 86/11 (74) Representative: Myerscough, Philip Boyd et al (84) Designated Contracting States: J.A.Kemp & Co. 14, South Square Gray's Inn AT BE CH DE FR GB IT LI LU NL SE London, WC1 R 5EU (GB) (58) References cited: DE-C- 381 527 DE-C- 513 623 FR-A- 772 826 FR-A- 947 953 CÛ FR-A-2 232 606 FR-A-2 343 336 m <o M.HANSEN: "Constitution of binary alloys", 2nd h» Edition, 1958, McGraw Hill, New York (USA); G) N O Note: Within nine months from the publication of the mention of the grant of the European patent, any person may give notice to the European Patent Office of opposition to the European patent granted. Notice of opposition shall CL be filed in a written reasoned statement. It shall not be deemed to have beenfiled until the opposition fee has been LU paid. (Art. 99(1 ) European patent convention). Courier Press, Leamington Spa, England. This invention relates to a method of making a lead-calcium-aluminium alloy at relatively low temperatures and without resorting to use of inert gases or fluxes. Aluminium is often added to lead-calcium and lead-calcium-tin alloys to prevent oxidation of the calcium during remelting of the alloy and subsequent casting and handling of the molten alloy. Such use of aluminium in lead-calcium-tin alloys is described in U.S. Patent 4,125,690. A common method of alloying aluminium into lead entails melting and heating the lead to a temperature above the melting point of aluminium (660°C). At this temperature the aluminium melts and becomes alloyed with the lead readily with some loss due to oxidation. At temperatures below the melting point of aluminium an external adherent oxide skin prevents the aluminium from dissolving in the lead even though it is soluble in small amounts. Therefore aluminium and lead cannot be effectively alloyed at temperatures below 660°C. Calcium is generally alloyed into lead under an inert gas or molten salt cover to prevent oxidation. High temperatures are required to keep the salt cover molten or to effect complete dissolution of Pb3Ca compounds into the lead. By means of this procedure a master alloy of 1-2% calcium is normally produced. The master alloy is then added to lead or lead-aluminium alloy to produce the final alloyed product. DE-C-513623 describes lead alloys containing, as hardening additives, alkali and alkaline earth metals, aluminium and magnesium, wherein the amounts of the alloying ingredients are 0.6 to 0.65% sodium, 0.75 to 1% calcium, 0.2 to 0.25% magnesium and 0.1% aluminium, the ratio of Ca:Mg:AI being about 8:2:1. in orderto produce these alloys, in particular in order to achieve the desired aluminium content, it is said to be necessary to introduce metallic aluminium into molten lead simultaneously with metallic magnesium or metallic calcium rather than as a pre-alloy of AI-Mg or AI-Ca. Several problems are associated with the current approach to alloying calcium and aluminium into lead. First, the kettles used in alloying the lead must be heated to temperatures above 660°C to permit efficient addition of aluminium. This dramatically reduces the life of the alloying kettle. In addition recovery of calcium in making the 1-2% master alloy is generally less than 90% because of oxidation of the calcium during alloying and pouring despite the use of inert gas and salt covers. Finally, because of the limited solubility of aluminium in lead, it is not possible directly to alloy the aluminium into the calcium-lead master alloy. A direct method of calcium and aluminium with lead has been discovered. The . new alloying now method avoids the use of inert atmospheres or flux covers; gives nearly 100% recovery of calcium and aluminium and is operative' at low temperatures where damage to alloying kettles is negligible. Moreover, because of the lower temperature requirements, fuel requirements are reduced. This invention provides a method of making an alloy consisting of lead, calcium, aluminium and incidental impurities characterized by melting lead, heating the molten lead at a temperature from 549 to 660°C and stirring into the heated molten lead an eutectic calcium-aluminium alloy having an average content of 73% by weight calcium and 27% by weight aluminium. The method of this invention makes possible the production of a lead-calcium-aluminium alloy without use of a lead-calcium master alloy and at relatively low temperatures. By means of the method losses of alloying elements are minimized. Since the calcium-aluminium eutectic melts at 549°C (1020°F) it is unnecessary to resort to temperatures above the melting point of aluminium, i.e. above 660°C. The calcium-aluminium eutectic can be alloyed at temperatures as low as 549°C (1020°F). The aluminium in the eutectic alloy protects the calcium from oxidation during alloying. The process of the invention thus permits high levels of recovery of calcium and aluminium. The eutectic alloy employed in the present method is known in the art and its manufacture is not a part of the present invention. Typically the eutectic alloy may be formed by simply melting aluminium and thereupon adding the calcium. The eutectic alloy need not contain precisely 73% by weight calcium and 27% by weight aluminium. Use of alloys which deviate a few percentage points for either or both materials is within the scope of the present invention provided the deviations do not necessitate significantly elevating the temperature at which the present method is effective. Similarly other materials which do not require substantially elevating the temperature of operation may be present in the eutectic alloy. The following example illustrates the invention. Example 182 Kg (402 pounds) of pure lead was melted in a cast iron melt pot and heated to 590°C (1100°F). 463 grams of calcium-aluminium master alloy (manufactured by Pfizer, Inc., Materials, Pigments and Metals Division, Wallingford, Conn.) averaging 72.4% by weight calcium and 25.3% by weight aluminium was added with stirring to the heated lead. The resulting lead alloy was poured into ingots and sampled. The chemical analyses and losses of alloying elements were as follows: The aluminium in the Ca-Al master alloy protected the calcium and almost eliminated loss thereof. A method of making an alloy consisting of lead, calcium, aluminium and incidental impurities characterized by melting lead, heating the molten lead at a temperature from 549 to 660°C and stirring into the heated molten lead an eutectic calcium-aluminium alloy having an average content of 73% by weight calcium and 27% by weight aluminium. Ein Verfahren zur Herstellung einer Legierung, bestehend aus Blei, Calcium, Aluminium und gegebenenfalls vorhandenen Verunreinigungen, gekennzeichnet durch Schmelzen von Blei, Erhitzen des geschmolzenen Bleis auf eine Temperatur von 549 bis 660°C und Einrühren einer eutektischen Calcium- Aluminium-Legierung mit einem durchschnittlichen Gehalt von 73 Gew.-% Calcium und 27 Gew.-% Aluminium in das erhitzte geschmolzene Blei. Procédé de fabrication d'un alliage constitué de plomb, de calcium, d'aluminium et d'impuretés accidentelles, caractérisé en ce qu'on fond du plomb, on chauffe le plomb fondu à une température de 549 à 660°C et on agite dans le plomb fondu chauffé un alliage eutectique calcium-aluminium ayant une teneur moyenne de 73% en poids de calcium et de 27% en poids d'aluminium. .
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