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EP2629906A1 - Injecteurs mouillables pour dégazage de métal fondu - Google Patents

Injecteurs mouillables pour dégazage de métal fondu

Info

Publication number
EP2629906A1
EP2629906A1 EP11776661.8A EP11776661A EP2629906A1 EP 2629906 A1 EP2629906 A1 EP 2629906A1 EP 11776661 A EP11776661 A EP 11776661A EP 2629906 A1 EP2629906 A1 EP 2629906A1
Authority
EP
European Patent Office
Prior art keywords
molten metal
diffuser
purge gas
dissolved hydrogen
gas bubbles
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP11776661.8A
Other languages
German (de)
English (en)
Inventor
J. Daniel Bryant
Norbert Babcsan
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Alcoa Corp
Original Assignee
Alcoa Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Alcoa Corp filed Critical Alcoa Corp
Publication of EP2629906A1 publication Critical patent/EP2629906A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D1/00—Treatment of fused masses in the ladle or the supply runners before casting
    • B22D1/002—Treatment with gases
    • B22D1/005—Injection assemblies therefor
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B21/00—Obtaining aluminium
    • C22B21/06—Obtaining aluminium refining
    • C22B21/064—Obtaining aluminium refining using inert or reactive gases
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B9/00—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals
    • C22B9/05—Refining by treating with gases, e.g. gas flushing also refining by means of a material generating gas in situ
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D3/00—Charging; Discharging; Manipulation of charge
    • F27D3/16—Introducing a fluid jet or current into the charge

Definitions

  • This invention relates generally to degassing of molten metal alloys, and more particularly, to an apparatus and method for reducing the dissolved hydrogen content of a molten metal alloy.
  • molten liquid metal alloys must often be degassed to remove dissolved hydrogen.
  • the monatomic hydrogen that has been absorbed by the molten alloy, from such sources as atmospheric moisture will precipitate upon solidification as pores of diatomic hydrogen gas within the cast metal product.
  • Such gas porosity represents a threat to the structural integrity of the product because gas porosity cannot be eliminated by secondary processing such as rolling, forging or extrusion.
  • the hydrogen content of molten metal alloys is closely monitored in commercial casting facilities, and means must be employed to reduce the level of dissolved hydrogen within the molten alloy prior to the casting operation.
  • FIG. 1 Various illustrative embodiments of an apparatus and method for reducing the dissolved hydrogen content of a molten metal alloy are provided herein.
  • the disclosed embodiments can be utilized for the processing of molten metal alloys such as aluminum, and more particularly, for the removal of dissolved hydrogen from molten metal alloys such as aluminum.
  • Gas permeable diffusers can be employed that are wettable by molten metal. When used as gas injectors, either in combination with ultrasonic oscillation or without, the gas permeable wettable diffusers can provide a high density of ultrafine inert gas bubbles that can be used to rapidly and efficiently reduce the level of dissolved hydrogen within the molten metal.
  • an apparatus for degassing a molten metal alloy can include a container for holding the molten metal and a dispenser capable of dispensing purge gas.
  • a diffuser can be provided that is in fluid communication with the molten metal.
  • the diffuser can be wettable with respect to the molten metal and capable of receiving purge gas from the dispenser.
  • the dispenser can also be capable of forming purge gas bubbles and emitting the purge gas bubbles into the molten metal.
  • the diffuser can have a face with a plurality of pores formed thereon. The pores can be in fluid communication with the molten metal and capable of emitting the purge gas bubbles into the molten metal.
  • the average diameter of the pores on the diffuser face is not greater than 200 microns.
  • the molten metal can be aluminum.
  • the molten metal can also comprise other metal alloys.
  • the molten metal can contain dissolved hydrogen gas, and the purge gas bubbles can remove the dissolved hydrogen gas from the molten metal.
  • the apparatus can also include an ultrasonic oscillator in direct mechanical communication with the diffuser.
  • the ultrasonic oscillator can be disposed adjacent to the diffuser such that the diffuser lies within a sonicated field of the oscillator.
  • the ultrasonic oscillator can also oscillate both below and above the cavitation power required for the molten metal.
  • a method for degassing a molten metal is provided.
  • a molten metal can be provided with hydrogen gas dissolved therein.
  • a purge gas can be introduced into a diffuser.
  • the diffuser can be wettable with respect to the molten metal.
  • Purge gas bubbles can be formed at the diffuser - molten metal interface.
  • the dissolved hydrogen gas can be transferred from within the molten metal to the purge gas bubbles, such that the concentration of dissolved hydrogen gas in the molten metal is reduced.
  • a method for degassing a molten metal containing dissolved hydrogen gas is provided.
  • a face of a diffuser can be wetted with the molten metal.
  • a purge gas can be flowed through a plurality of pores in the face.
  • the pores can have a pore size in the range from approximately 2 - 200 microns.
  • Purge gas bubbles can be produced at the pores in the diffuser.
  • the purge gas bubbles can be emitted from the pores and into the molten metal.
  • the dissolved hydrogen in the molten metal can be transferred to the purge gas bubbles, such that the concentration of the dissolved hydrogen gas in the molten metal is reduced.
  • an ultrasonic oscillator can be provided that is in direct mechanical communication with the diffuser. The ultrasonic oscillator can also oscillate both below and above the cavitation power required for the molten metal.
  • FIG. 1 is a front perspective view of an apparatus for reducing the dissolved hydrogen content of a molten metal alloy according to certain illustrative embodiments set forth herein.
  • FIG. 2 is a front view of a contact angle ( ⁇ ) at the liquid-vapor and solid-liquid interface for a liquid droplet according to certain illustrative embodiments set forth herein.
  • FIG. 3A is a front perspective view of a purge gas bubble formed from a wettable injector according to certain illustrative embodiments set forth herein.
  • FIG. 3B is a front perspective view of a purge gas bubble formed from a non- wettable injector according to certain illustrative embodiments set forth herein.
  • FIG. 4 is a top view of a diffuser according to certain illustrative embodiments set forth herein.
  • FIG. 5 is a front perspective view of an apparatus for reducing the dissolved hydrogen content of a molten metal alloy having a sonotrode disposed adjacent the diffuser according to certain illustrative embodiments set forth herein.
  • FIG. 6 is a front perspective view of an apparatus for reducing the dissolved hydrogen content of a molten metal alloy having a sonotrode disposed in direct mechanical communication with the diffuser according to certain illustrative embodiments set forth herein.
  • FIG. 7 is a front perspective view of an apparatus for reducing the dissolved hydrogen content of a molten metal alloy having a sonotrode with a retaining cap disposed thereon according to certain illustrative embodiments set forth herein.
  • the apparatus and method can employ gas permeable ceramic diffusers that are wettable by molten metal.
  • the gas permeable diffusers can function as wettable injectors to provide ultrafine inert gas bubbles to the molten metal to reduce the level of dissolved hydrogen within the metal.
  • the diffusers can be used in combination with ultrasonic oscillation to increase the dispersion of the gas bubbles in the metal.
  • the dissolved hydrogen concentration can preferably be reduced to less than about 0.4 ml/100 gm at standard temperature and pressure.
  • an apparatus 5 can include a container 10 for holding a molten metal alloy 20 and a dispenser 30 capable of dispensing purge gas into the molten metal alloy 20.
  • the molten metal alloy 20 can comprise, for example, an aluminum alloy or other similar metal alloy.
  • the purge gas can comprise argon gas or other similar inert gases. In certain embodiments, a small percentage of chlorine gas can also be included with the purge gas, as needed, to increase the effectiveness of the purge.
  • a diffuser 40 can be positioned adjacent to dispenser 30 and utilized to inject and disperse the purge gas into molten metal alloy 20.
  • diffuser 40 can receive the purge gas from dispenser 30, form a plurality of purge gas bubbles 50, and then emit purge gas bubbles 50 into molten metal alloy 20.
  • the dissolved hydrogen in molten metal alloy 20 will preferably diffuse through the interfaces of purge gas bubbles 50 as bubbles 50 pass through molten metal alloy 20.
  • diffuser 40 can have a face 60 with a plurality of pores 70 formed thereon, each pore having a lip 75 formed at its interface with face 60.
  • Diffuser 40 can be gas permeable, such that purge gas bubbles 50 can be emitted into molten metal alloy 20 through pores 70.
  • Diffuser 40 is preferably in at least partial fluid communication with molten metal alloy 20, which means that face 60 of diffuser 40 can directly contact the fluid of molten metal alloy 20.
  • Pores 70 are also preferably in fluid communication with molten metal alloy 20, which means that to some extent, the surface area near the lip 75 of any pore 70 also directly contacts molten metal alloy 20.
  • Various parts of apparatus 5, including but not limited to dispenser 30 and diffuser 40, can be constructed from a material that includes a wettable ceramic material such as titanium diboride (TiB 2 ) or silicon carbide (SiC) to produce and inject a fine dispersion of purge gas bubbles 50 in molten metal alloy 20.
  • a wettable ceramic material such as titanium diboride (TiB 2 ) or silicon carbide (SiC) to produce and inject a fine dispersion of purge gas bubbles 50 in molten metal alloy 20.
  • the material from which pores 70 are formed can also preferably be constructed from a wettable material.
  • Purge gas bubbles 50 can provide increased degassing efficacy and can degas molten metal alloy 20 in shorter times than can be accomplished using conventional rotary nozzle methods, and can also remove dissolved hydrogen from greater volumes of molten metal alloy 20 than can be treated using non-wettable gas injectors.
  • Wettable generally means that the material 41 from which the diffuser 40 is constructed is capable of a contact angle of less than 90 degrees to a drop of the molten metal alloy 20.
  • the contact angle ( ⁇ ) is the angle at which the liquid- vapor interface (between alloy 20 and purge gas 51) meets the solid- liquid interface (between diffuser material 41 and alloy 20).
  • the tendency of any drop of the molten metal 20 to spread out over a flat, solid surface increases as the contact angle decreases.
  • the contact angle provides an inverse measure of wettability.
  • a contact angle less than 90° (low contact angle) usually indicates that wetting of the surface is favorable, and the fluid drop will spread over a large area of the surface.
  • a contact angle greater than 90° (high contact angle) generally means that wetting of the surface is unfavorable so the fluid will minimize contact with the surface and form a compact liquid droplet.
  • the effectiveness of apparatus 5 can be increased if apparatus 5 is used in combination with ultrasonic vibration.
  • Diffuser 40 can be placed within the ultrasonic field of a sonotrode 90 (See FIG. 5), or alternatively, used as part of sonotrode 90 itself.
  • an ultrasonic oscillator 80 (operating either below or above the cavitation power for molten metal 20) can be fitted with diffuser 40 at the end of sonotrode 90 (See FIG. 6).
  • ultrasonic oscillator 80 can be used to provide ultrasonic energy to molten metal 20 in the vicinity of diffuser 40 and increase the dispersion of purge gas bubbles 50 in molten metal alloy 20.
  • oscillator 80 can operate above and/or below the cavitation power for molten metal alloy 20.
  • Cavitation power refers to the amount of power needed to create cavities with molten metal alloy 20.
  • Oscillator 80 can have sonotrode 90 connected thereto or disposed adjacent thereto.
  • oscillator 80 and sonotrode 90 can be disposed adjacent to the diffuser (FIG. 5), or alternatively, oscillator 80 and sonotrode 90 can be disposed to directly contact the diffuser (FIG. 6).
  • Oscillator 80 and sonotrode 90 can also surround all of, or part of, dispenser 30 to provide ultrasonic vibration to the diffuser 40 (FIG. 6).
  • Sonotrode 90 can be exposed to ultrasonic vibration from oscillator 80, and then assist in transferring this vibratory energy to molten metal 20.
  • Sonotrode 90 can be constructed from a wettable material such as TiB 2 or SiC or from a refractory metal.
  • a retaining cap 100 can be utilized to secure diffuser 40 in a position in direct mechanical communication with the sonotrode 90. (See FIG. 7).
  • Retaining cap 100 can have an orifice 110 formed therein that allows purge gas bubbles 50 to exit dispenser 30, pass through diffuser 40 and orifice 110, and enter molten metal alloy 20.
  • Retaining cap 100 can be securely affixed to sonotrode 90 such that diffuser 40 cannot be misaligned or substantially displaced due to ultrasonic vibration.
  • Retaining cap 100 can be removable from sonotrode 90 such that diffuser 40 can be replaced, if desired.
  • dispenser 30 can extend into the interior region of sonotrode 90 and deliver purge gas to the diffuser 40 (see FIG. 6).
  • diffuser 40 can be mechanically or chemically bonded to sonotrode 90, or alternatively, sonotrode 90 can be fabricated entirely from wettable ceramics such as TiB2 , such that diffuser 40, including face 60 and pores 70, can all be subject to ultrasonic vibration.
  • a purge gas can be introduced into diffuser 40.
  • Diffuser 40 can be wettable with respect to molten metal 20.
  • Purge gas bubbles 50 can be formed with diffuser 40. Purge gas bubbles 50 can be emitted from pores 70 of diffuser 40 and into molten metal 20 at a contact angle of less than 90° to molten metal 20.
  • the dissolved hydrogen gas in molten metal 20 can diffuse into purge gas bubbles 50 such that all or substantially all of the dissolved hydrogen gas is removed from molten metal 20.
  • face 60 of diffuser 40 can be wetted with molten metal 20.
  • Purge gas can be flowed through a plurality of pores 70 in face 60.
  • pores 70 can have a pore size in the range from about 2 - 200 microns.
  • Purge gas bubbles 50 can be produced at a number of pores 70, with each bubble 50 initiating as a hemi-spherical bubble with a diameter related to the diameter of the particular pore 70 from which it emerged.
  • Purge gas bubbles 50 can be emitted from diffuser 40 and injected or dispersed into molten metal 20.
  • the dissolved hydrogen gas can diffuse into purge gas bubbles 50 and can reduce the amount of dissolved hydrogen gas in molten metal 20.
  • diffuser 40 can be oscillated below and/or above the cavitation power of molten metal 20 to assist in dispersing purge gas bubbles 50.
  • the diameter of any particular pore 70 will affect the diameter of the purge gas bubble 50 emerging from that particular pore 70 (see FIGS. 3A and 3B). If diffuser 40 is wettable by molten metal 20 such as, for example, liquid aluminum, the initial diameter of the hemispherical bubble 50 emerging from pore 70 will be set by the pore diameter.
  • This pore diameter can therefore be selected by appropriate sizing of the particle size and volume fraction of the fugitive binders used in the fabrication of diffuser 40. For example, smaller pore diameters can result in an increased number of bubbles 50 each having a smaller size, but an overall increase in total surface area of bubbles 50 within molten metal alloy 20. Significantly, as the Stokes' velocity of bubbles 50 rising through a Newtonian fluid is reduced at smaller bubble diameters, the residence time of bubbles 50 within molten metal alloy 20 can likewise be increased.
  • FIG. 4 An illustrative example of a wettable diffuser 40 is shown in FIG. 4, wherein diffuser 40 has been fabricated from a titanium diboride (TiB 2 ) material so as to have pores 70 on its face 60 that are gas permeable. TiB 2 can be sintered with fugitive binders (such as graphite) to yield connected porosity and also provide sufficient resilience to withstand the rigors of ultrasonic vibration.
  • Other representative examples of wettable materials include SiC. Wettable diffuser 40 can provide a continuous stream of purge gas bubbles 50 into molten metal 20 when diffuser 40 is in fluid connection with a flow of inert purge gas.
  • the reduced diameter of bubbles 50 formed from diffuser 40 constructed of a wettable material according to the presently disclosed subject matter can preferably increase the surface to volume ratio of the purge gas and can promote longer residence times for bubbles 50 within molten metal alloy 20. These two effects can enhance the kinetics of dissolved hydrogen diffusion into the inert gas. If a purge gas injector was constructed of non-wettable materials (such as some ceramics and transition metals), the diameter of the hemispherical bubble cap that forms would be determined not by the inner diameter of pore 70 from which bubble 50 emerges, but rather by the outer diameter of the pipe encompassing pore 70 (see, e.g., FIG. 3B).
  • the embodiments of a degassing apparatus and method provided herein utilize minimal volumes of inert gas, thus reducing gas cost. Also, enrichment with chlorine gas can be decreased or avoided, which reduces environmental concerns and saves on maintenance in the exhaust systems. Also, removal of hydrogen using decreased flows of purge gas can reduce dross formation during processing, which directly reduces metal loss and indirectly reduces dross reclamation costs. Also, rapid degassing may allow for effective in-trough degassing, thus reducing the need for draining and/or flushing of large rotary head treatment boxes during alloy changes and the associated losses in productivity.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Manufacture And Refinement Of Metals (AREA)

Abstract

Différents modes de réalisation illustratifs de l'invention portent sur un appareil et sur un procédé pour réduire la teneur en hydrogène dissous d'un alliage de métal fondu. Les modes de réalisation décrits peuvent être utilisés pour le traitement d'alliages de métal fondu, tels que l'aluminium, et, plus particulièrement, pour le retrait d'hydrogène dissous à partir d'alliages de métal fondu, tels que l'aluminium. Des diffuseurs perméables aux gaz peuvent être employés, lesquels sont mouillables par un métal fondu. Lors de l'utilisation comme injecteurs de gaz, soit en combinaison avec une oscillation d'ultrasons, soit sans celle-ci, les diffuseurs mouillables perméables aux gaz peuvent produire une densité élevée de bulles de gaz inerte ultrafines qui peuvent être utilisées pour réduire rapidement et efficacement le niveau d'hydrogène dissous à l'intérieur du métal fondu.
EP11776661.8A 2010-10-18 2011-10-18 Injecteurs mouillables pour dégazage de métal fondu Withdrawn EP2629906A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US39411710P 2010-10-18 2010-10-18
PCT/US2011/056708 WO2012054478A1 (fr) 2010-10-18 2011-10-18 Injecteurs mouillables pour dégazage de métal fondu

Publications (1)

Publication Number Publication Date
EP2629906A1 true EP2629906A1 (fr) 2013-08-28

Family

ID=44898217

Family Applications (1)

Application Number Title Priority Date Filing Date
EP11776661.8A Withdrawn EP2629906A1 (fr) 2010-10-18 2011-10-18 Injecteurs mouillables pour dégazage de métal fondu

Country Status (4)

Country Link
US (1) US20120090432A1 (fr)
EP (1) EP2629906A1 (fr)
CA (1) CA2815185A1 (fr)
WO (1) WO2012054478A1 (fr)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ES2378367T3 (es) 2008-03-05 2012-04-11 Southwire Company Sonda de ultrasonidos con capa protectora de niobio
PT2556176T (pt) 2010-04-09 2020-05-12 Southwire Co Dispositivo ultrassónico com sistema integrado de entrega de gás
US8652397B2 (en) * 2010-04-09 2014-02-18 Southwire Company Ultrasonic device with integrated gas delivery system
HUE045644T2 (hu) 2013-11-18 2020-01-28 Southwire Co Llc Ultrahang szondák gázkimenetelekkel fémolvadék gáztalanítására
CN107073522B (zh) * 2014-11-05 2019-07-26 伊苏瓦尔肯联铝业 使用管状超声波发生器的方法
US10233515B1 (en) 2015-08-14 2019-03-19 Southwire Company, Llc Metal treatment station for use with ultrasonic degassing system
FR3096987B1 (fr) * 2019-06-07 2021-08-27 Constellium Issoire Dispositif pour piéger l’hydrogène

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Publication number Priority date Publication date Assignee Title
BE756091A (fr) * 1969-09-12 1971-02-15 Britsh Aluminium Cy Ltd Procede et dispositif pour le traitement de metal
JPS6274030A (ja) * 1985-09-27 1987-04-04 Showa Alum Corp アルミニウム溶湯の処理方法
US6199836B1 (en) * 1998-11-24 2001-03-13 Blasch Precision Ceramics, Inc. Monolithic ceramic gas diffuser for injecting gas into a molten metal bath
FR2792948B1 (fr) * 1999-04-27 2001-06-08 Pechiney Rhenalu Procede et dispositif ameliores de degazage et de separation des inclusions d'un bain de metal liquide par injection de bulles de gaz
US7682556B2 (en) * 2005-08-16 2010-03-23 Ut-Battelle Llc Degassing of molten alloys with the assistance of ultrasonic vibration
PT2556176T (pt) * 2010-04-09 2020-05-12 Southwire Co Dispositivo ultrassónico com sistema integrado de entrega de gás

Non-Patent Citations (1)

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Title
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Also Published As

Publication number Publication date
CA2815185A1 (fr) 2012-04-26
US20120090432A1 (en) 2012-04-19
WO2012054478A1 (fr) 2012-04-26

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