Apparatus and method for production of high purity copper-based alloys

Abstract

In an aspect, a method of manufacturing a high purity copper-based alloy comprises providing in a melting furnace a feedstock and melting the feedstock. The method additionally includes bubbling an inert gas into the molten copper-based alloy to form the high purity copper-based alloy. Aspects are also directed to an apparatus and a method of fabricating an apparatus for manufacturing the high purity copper-based alloy.

What is claimed is: 
     
         1 . A method of manufacturing a copper-based alloy, the method comprising:
 providing in a melting furnace a feedstock having a composition configured to form a molten copper-based alloy comprising at least 50 weight % copper, wherein the melting furnace is configured to rotate around a central axis;   heating the feedstock to melt the feedstock to form the molten copper-based alloy; and   bubbling an inert gas through the molten copper-based alloy.   
     
     
         2 . The method according to  claim 1 , further comprising bubbling an inert gas through the molten copper-based alloy using one or more diffuser blocks comprising a porous diffusing material. 
     
     
         3 . The method according to  claim 2 , wherein the porous diffusing material has a porosity greater than 20%. 
     
     
         4 . The method according to  claim 2 , wherein the porous diffusing material comprises one or more of alumina, silica, an aluminum-silicate ceramic and Cr 2 O 3 . 
     
     
         5 . The method according to  claim 1 , further comprising heating the feedstock or the molten copper-based alloy under a substantially inert atmosphere. 
     
     
         6 . The method according to  claim 1 , wherein providing the feedstock comprises providing a plurality of feedstock pieces having a combined composition configured to form the molten copper-based alloy. 
     
     
         7 . The method according to  claim 6 , further comprising, prior to and during heating the feedstock pieces, flowing the inert gas through gaps between the plurality of feedstock pieces. 
     
     
         8 . The method according to  claim 1 , further comprising, prior to heating, rotating the melting furnace such that one or more diffuser blocks adapted for diffusing the inert gas therethrough are positioned under the feedstock. 
     
     
         9 . The method according to  claim 1 , further comprising bubbling the inert gas from a bottom surface of the molten copper-based alloy. 
     
     
         10 . The method according to  claim 1 , further comprising, after bubbling the inert gas through the molten copper-based alloy, rotating the melting furnace such that one or more diffuser blocks adapted for diffusing the inert gas therethrough are positioned above the molten copper-based alloy for transferring the molten copper-based alloy out of the melting furnace. 
     
     
         11 . The method according to  claim 10 , further comprising cooling the molten copper-based alloy under a substantially inert atmosphere prior to transferring the molten copper-based alloy out of the melting furnace. 
     
     
         12 . The method according to  claim 1 , wherein the inert gas consists essentially of a noble gas. 
     
     
         13 . The method according to  claim 1 , wherein the inert gas is essentially hydrogen-free and moisture-free. 
     
     
         14 . The method according to  claim 1 , further comprising heating the molten copper-based alloy under an enclosed chamber configuration in which an atmosphere above the molten copper-based alloy is isolated from an outside atmosphere. 
     
     
         15 . The method according to  claim 1 , wherein heating the feedstock comprises injecting a stream of flame into the melting furnace. 
     
     
         16 . The method according to  claim 15 , wherein injecting the stream of flame comprises injecting into the melting furnace along a central axis of the melting furnace. 
     
     
         17 . The method according to  claim 16 , wherein injecting the stream of flame comprises injecting and igniting a stream of fuel. 
     
     
         18 . The method according to  claim 17 , wherein the stream of fuel comprises a natural gas. 
     
     
         19 . The method according to  claim 1 , further comprising rocking the melting furnace around the central axis while bubbling the inert gas into the molten copper-based alloy. 
     
     
         20 . The method according to  claim 1 , wherein the central axis is substantially parallel to a ground plane.