A method for adding alloying material to a molten metal media, such as molten aluminum, is disclosed. The method includes converting the alloying material into a spray of superheated alloy material and directing the spray into the molten metal media at a depth below the media's surface to enhance dissolution and dispersion of the alloying material in the molten media.
A known "spark cup process" may be operated without the spark cup if the violent fluctuations in the melt surface with which the electric arc is struck are accommodated so as to allow the electric arc to be maintained substantially continuously. Controlling the dynamic profile of the melt surface without a spark cup allows continuous operation of the electric arc which generates enough plasma to permit addition of as much as 1000 lb/hr of a spray of superheated feed material to a flowing stream of melt which assimilates the feed material.
