THOMAS RICHARD HORNACK
Engineers in New Kensington, PA

5370171, Dec 6, 1994

Sep 20, 1993

8/124387

James R. Fields - Export PA
Men G. Chu - Export PA
Lawrence W. Cisko - Irwin PA
C. Edward Eckert - Plum Borough PA
Thomas R. Hornack - Lower Burrell PA
Marshall A. Klingensmith - New Kensington PA
Richard A. Manzini - Greensburg PA
M. K. Premkumar - Monroeville PA
Gerald D. Scott - Messena NY
Mohammad A. Zaidi - Monroeville PA

Aluminum Company of America - Pittsburgh PA

B22D 1720, B22D 1730

164312

The die casting machine includes a trough containing a supply of molten metal and a feed tube extending into the supply of molten metal in the trough. A flow of molten metal is maintained in the trough past the feed tube independent of the transfer of molten metal through the feed tube. The die casting machine further includes a filtering system.

6723221, Apr 20, 2004

Jul 18, 2001

09/908253

Thomas R. Hornack - Lower Burrell PA
Raymond Miller - Lower Burrell PA
Robert L. Kozarek - Apollo PA

Alcoa Inc. - Pittsburgh PA

C25C 300

205367, 205372, 205396, 204225, 2042431, 204245, 204279

Insulation assemblies provide reduced heat loss from electrolytic metal production cells such as inert anode aluminum production cells. The insulation assemblies may be located at the end, side and/or center aisles of the cell, and may be supported by the anodes and deckplate of the cell. The assemblies reduce heat loss and bath vaporization losses, and permit stable operation of the inert anode cell.

4596637, Jun 24, 1986

Apr 26, 1983

6/488749

Robert L. Kozarek - Washington Township, Fayette County PA
Thomas R. Hornack - Lower Burrell PA
Noel Jarrett - Lower Burrell PA

Aluminum Company of America - Pittsburgh PA

C25B 100, C25C 102, C25C 300, C25C 702

204 67

An electrolytic cell is disclosed including means for holding a first electrode in position relative to a second electrode to form an inter-electrode zone of specified dimension for containing the electrolyte; the means for holding including float means adapted for supporting the first electrode essentially free from support by internal surfaces of the cell; and conductive means for electrically connecting one electrode to a separate liquid pad of higher conductivity than the electrolyte. An electrolytic method is disclosed including floating a first electrode essentially free from support by the internal surfaces of an electrolytic cell; arranging a second electrode spaced from the first electrode to form an inter-electrode zone for containing electrolyte; and connecting one electrode electrically with a separate liquid pad of higher conductivity than the electrolyte.

5057194, Oct 15, 1991

Oct 13, 1989

7/435502

Donald L. Stewart - Greensburg PA
Jan H. L. Van Linden - Allison Park PA
Alfred F. LaCamera - Trafford PA
Thomas V. Pierce - Delmont PA
James O. Parkhill - Tarentum PA
John M. Urbanic - Pittsburgh PA
Thomas R. Hornack - Lower Burrell PA

Aluminum Company of America - Pittsburgh PA

C25C 306

204 67

A continuous salt-based process is provided for melting and reclaiming aluminum from aluminum scrap containing impurities including heating a molten salt in a heat bay, mixing the heated salt with aluminum scrap or skim in a charge bay to form a molten charge mixture, separating aluminum from impurities in the charge bay by coalescing aluminum to form a molten aluminum metal pad, chlorinating a portion of the charge mixture from the charge bay to form a chlorinated salt mixture and metal chlorides, removing metal chlorides from the salt mixture, and feeding the salt mixture back to the heat bay. In one aspect, the chlorinating step of the present invention includes introducing carbon monoxide or, preferably, solid carbon to control oxide concentration. The process further comprises adding fluorides and removing metal chlorides from the salt to maintain a preferred salt composition. The metal chlorides can be removed by withdrawing volatile metal chloride gases and electrolytically reducing metal chlorides in the molten salt.

4769830, Sep 6, 1988

Mar 27, 1986

6/844569

Richard W. Peterson - Lower Burrell PA
Thomas R. Hornack - Lower Burrell PA
Donald C. Morian - Murrysville PA

Aluminum Company of America - Pittsburgh PA

G01N 2310

328 54

An apparatus and method for measuring bulk density of solid particles. The apparatus is capable of simultaneously rotating and axially advancing a container containing a sample of solid particles past a source emitting a beam of gamma rays. The gamma rays are absorbed by a detector in proportion to the material density of the solid particles. The absorbed radiation is then compared to a preselected reference value to yield a bulk density for the material. This bulk density can then be used to ascertain the quantity of a binder which needs to be added to a homogeneous mass of coke to form a carbon anode useful in an electrolysis of alumina. The method includes the steps of placing a sample quantity of the solid particles in a container, optionally vibrating the container to settle the particles if desired, and then placing the container on the apparatus so as to be measured. The bulk density measurement is compared to a preselected reference value and this value is then visually displayed.

5114472, May 19, 1992

Dec 13, 1990

7/627000

C. Edward Eckert - New Kensington PA
Thomas R. Hornack - Lower Burrell PA
George E. Lyness - Pittsburgh PA
John A. Kaems - Maryville TN
Clarence J. Cox - Maryville TN
Ronald E. Miller - Murrysville PA
Diran Apelian - Worcester MA
Rajakkannu Mutharasan - Broomall PA

Aluminum Company of America - Pittsburgh PA

C22B 902

75412

A filter system for removing solid impurities from molten metal is described comprising a housing containing vertically disposed rigid coarse filter facing the incoming flow of molten metal and capable of removing solids having a particle size of at least 10 microns and a rigid fine filter mounted vertically behind the coarse filter and capable of removing solids having a particle size as small as 1 micron. The apparatus further includes a heater for maintaining the temperature of the molten metal and a sparger mounted adjacent the front face of one filter to provide an intermittent gas flow over the face of the filter to dislodge solids on the filter as filter cake. In a preferred embodiment, the rigid filters are nested cylinders, and the molten metal is directed to the center of the smaller coarse filter cylinder from which it then flows through the coarse filter outward to and through the fine filter cylinder and then from the fine filter out of the filter housing.

4504366, Mar 12, 1985

Apr 26, 1983

6/488756

Noel Jarrett - Lower Burrell PA
Thomas R. Hornack - Lower Burrell PA

Aluminum Company of America - Pittsburgh PA

C25B 140, C25C 300, C25C 306, C25C 702

204 1R

Disclosed is an electrolytic cell including means for holding a first electrode in position relative to a second electrode to form an inter-electrode zone of specified dimension for containing electrolyte, wherein the first electrode is held essentially free from support by the internal surfaces of the cell, said means for holding including means for supporting the first electrode from the second electrode; and conductive means for electrically connecting one electrode to a separate liquid pad of higher conductivity than the electrolyte. Also disclosed is a method of electrolysis including establishing a first electrode in relative position to a second electrode in an electrolytic cell to form an inter-electrode zone of specified dimension for containing an electrolyte; supporting the first electrode from the second electrode, wherein the first electrode is supported essentially free from support by internal cell surfaces; and connecting one electrode electrically with a separate liquid pad of higher conductivity than the electrolyte.

2003014, Jul 31, 2003

Jan 25, 2002

10/056915

Leroy D'Astolfo - Lower Burrell PA, US
Larry Wieserman - Apollo PA, US
Thomas Hornack - Lower Burrell PA, US
Calvin Bates - Monroeville PA, US

C25C003/00

205/367000, 204/286100, 204/297010

An anode system () in contact with a molten salt bath () in an electrolysis apparatus, contains a 50% to 95% dense refractory support () which comprises refractory material and from 2 wt %. to 20 wt. % of metal fibers (), where the metal fibers are from 1 cm to 4 cm long.

4705106, Nov 10, 1987

Jun 27, 1986

6/879619

Thomas R. Hornack - Lower Burrell PA
Melvin H. Brown - Allegheny Township, Armstrong County PA

Aluminum Company of America - Pittsburgh PA

F28F 140

165179

The present invention provides heat exchanger apparatus and method including a tubular heat transfer surface, a heat transfer fluid which is made to pass along the surface, and a wire brush heat exchanger insert positioned to impinge the fluid flowing within the heat transfer surface. The brush heat exchange insert is composed of a ceramic material having a high absorptance and emittance.