U.S. patent application number 11/606761 was filed with the patent office on 2007-06-07 for fluidized bed cryogenic apparatus and continuous cooling method for quenching of steel parts.
This patent application is currently assigned to IO Technologies, Inc.. Invention is credited to Michael A. Aronoy, Mykola I. Kohasko, Joseph A. Powell.
Application Number | 20070125463 11/606761 |
Document ID | / |
Family ID | 38117546 |
Filed Date | 2007-06-07 |
United States Patent
Application |
20070125463 |
Kind Code |
A1 |
Kohasko; Mykola I. ; et
al. |
June 7, 2007 |
Fluidized bed cryogenic apparatus and continuous cooling method for
quenching of steel parts
Abstract
Apparatus and method for cryogenically heat treating steel
work-pieces to cause the super-strengthening (higher strength,
ductility, better fatigue properties, etc.) of same is disclosed.
The apparatus includes a retort having a cavity containing a
fluidized bed of particles. A cryogenic liquid cools the fluidized
bed of particles and a fluidizing gas activates the fluidized bed.
Steel work-pieces placed within the fluidized bed are rapidly and
continuously cooled from their austenite phase through their
martensitic phase transformation causing the work-pieces to have a
finer martensitic structure, with higher dislocation density, than
that which occurs in work-pieces that are hardened by other heat
treating apparatus and/or methods, and which exhbit better physical
properties (e.g., higher strength, ductility, better fatigue
properties, etc.).
Inventors: |
Kohasko; Mykola I.;
(Richmond Heights, OH) ; Aronoy; Michael A.;
(Beachwood, OH) ; Powell; Joseph A.; (Uniontown,
OH) |
Correspondence
Address: |
James A. Hudak, Esq.
Suite #304
29425 Chagrin Blvd.
Cleveland
OH
44122
US
|
Assignee: |
IO Technologies, Inc.
|
Family ID: |
38117546 |
Appl. No.: |
11/606761 |
Filed: |
November 30, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60740777 |
Dec 1, 2005 |
|
|
|
Current U.S.
Class: |
148/630 ;
148/660; 266/259 |
Current CPC
Class: |
C21D 1/62 20130101 |
Class at
Publication: |
148/630 ;
148/660; 266/259 |
International
Class: |
C21D 1/62 20060101
C21D001/62 |
Claims
1. Apparatus for quenching a steel work-piece comprising a retort
having a cavity therein, a fluidized bed of particles within said
cavity, means for maintaining said fluidized bed of particles in a
substantially fluidic state, a cooling medium, and means for
directing said cooling medium toward said cavity within said retort
to cool same so as to provide a pre-determined quench cooling rate
resulting in the substantially continuous cooling of the work-piece
from its austenite phase through its martinsitic phase
transformation.
2. The apparatus as defined in claim 1 wherein said cooling medium
is cryogenic in nature.
3. The apparatus as defined in claim 1 wherein said fluidized bed
of particles cools the work-piece placed within said fluidized bed
from its austenite phase through its martensitic phase
transformation.
4. The apparatus as defined in claim 3 wherein the resulting
structure of the work-piece after being cooled by said fluidized
bed of particles from its austenite phase through its martensitic
phase transformation has a finer martensitic structure than that
produced by other heat treating apparatus causing the
super-strengthening of the work-piece.
5. The apparatus as defined in claim 3 wherein the resulting
structure of the work-piece after being cooled by said fluidized
bed of particles from its austenite phase through its martensitic
phase transformation has a martensitic structure with higher
dislocation density than that produced by other heat treating
apparatus causing the super-strengthening of the work-piece.
6. The apparatus as defined in claim 3 wherein said cooling of the
work-piece from its austenite phase through its martensitic phase
transformation is at a rate sufficient to cause the
super-strengthening of the work-piece.
7. The apparatus as defined in claim 1 wherein said fluidized bed
maintaining means comprises a fluidizing gas.
8. The apparatus as defined in claim 7 wherein said fluidizing gas
includes gas that has been evaporated from said cooling medium.
9. The apparatus as defined in claim 7 wherein said fluidizing gas
includes gas with a high thermal conductivity to improve the heat
transfer rate in the work-piece.
10. The apparatus as defined in claim 1 further including means for
agitating said fluidized particles to improve the heat transfer
rate in the work-piece.
11. The apparatus as defined in claim 1 further including means to
permit the release of said fluidizing gas from said retort.
12. The apparatus as defined in claim 1 further including means to
permit the release of vapors that have been evaporated from said
cooling medium from said retort.
13. A method for heat treating a steel work-piece comprising the
steps of: a) applying a cooling medium to a fluidized bed of
particles to cool said fluidized bed; b) applying a fluidizing gas
to said fluidized bed to activate same; c) placing the work-piece
into said fluidized bed; d) cooling the work-piece so as to
transform the work-piece from its austensite phase to its
martensite phase at a sufficiently high rate to cause the
super-strengthening of the work-piece; and e) removing the
work-piece from the fluidized bed.
14. The method as defined in claim 13 further including in step b,
combining at least a portion of the vapors from said cooling medium
with said fluidizing gas to activate said fluidized bed.
15. The method as defined in claim 13 further including, before
step c, the step of heat treating the work-piece utilizing the
intensive quenching process.
Description
TECHNICAL FIELD
[0001] The present invention relates, in general, to cryogenic heat
treating apparatus, a heat treating method utilizing the apparatus,
and the microstructure that results from the application of same to
steel parts and, more particularly, to cryogenic heat treating
apparatus that utilizes a fluidized bed, a method for the
continuous cooling of steel parts in the fluidized bed from the
austenite phase through the martensitic phase transformation of the
parts, and the resulting microstructure of the steel parts that
evidences the super-strengthening of same.
BACKGROUND ART
[0002] When a fully martensitic structure is required in a steel
part after quenching, it is necessary to cool the part below its
martensite finish temperature. It is known that the martensite
finish temperatures for high carbon, high alloy steel, and
carburized case hardened steels are relatively low, sometimes below
zero degrees centigrade. In fact, the martensite finish temperature
is lower than the bath temperature of a typical quenchant media
(mineral oil, water, brine, gas, etc.) used for hardening the steel
parts. To complete the martensitic transformation in steel parts
made of high alloy steels or carburized case hardened steels, a
cryogenic treatment may be applied to enhance the mechanical
properties and stabilize the part. Such cryogenic treatments take
place in a chamber (a freezer) where a low temperature in the range
of -120.degree. F. to -300.degree. F. is provided. Freezers
typically utilize a cooling media that is either chilled air or a
mixture of nitrogen gas vapors with liquid nitrogen depending on
process requirements. A liquid nitrogen bath, with its slow,
vapor-blanket cooling phase, can be used to cool the parts to
subzero temperatures if the rate of cooling is not deemed to be
critical. The rate of cooling of a steel part in the freezer is
typically not of concern since the primary objective of the
traditional freezing or cryogenic treatment of the part is to cool
the part below its martensite finish (M.sub.f) temperature so as to
reduce the (unstable) retained austenite and to ensure that the
martensitic transformations have occurred within the part.
[0003] When hardening steel parts, very rapid and continuous quench
cooling of the steel parts from the austenite phase through the
martensitic phase transformation provides the steel parts with
superior mechanical properties and performance characteristics. The
hardening process begins with heating the steel part to its
austenizing temperature, then cooling the part very rapidly
(quenching) from the austenite phase through the entire martensitic
phase transformation range. For parts made of medium alloy and
medium carbon steels, the martensitic phase transformation is
performed in conventional quenching equipment using a quenchant
media, such as water, oil, polymer/water, high-pressure gas, etc.
However, parts made of high carbon or high alloy steel and
carburized case hardened parts with a surface layer having high
carbon content are characterized by a low martensite finish
temperature. To eliminate retained austenite and further refine the
martensite, these parts should be further cooled in a freezer
immediately after the first phase of quenching has been completed
in conventional equipment. It should be noted that the heat
extraction rate from the part in a typical freezer provided by a
slow moving gas media is much less than that which occurs in
quenching processes utilizing water, oil, polymer/water, or
high-pressure gas.
[0004] In view of the foregoing, it has become desirable to develop
cryogenic heat treating apparatus that, when combined with
traditional or intensive quenching methods, provides greater
cooling rates continuously from the austenite phase through the
entire martensitic phase transformation range of the steel part
being hardened. When compared to existing freezing apparatus and
quenching methods, the continuous quench cooling of the steel part
from its austenite phase through its martensitic phase
transformation provides improved steel part performance because of
its resulting super-strengthened martensitic structure. The higher
heat extraction rates in the cryogenic heat treating apparatus can
be achieved by implementing a cryogenically cooled, gas-solid
fluidized bed with (or without) physical agitation and the use of
helium gas for fluidization.
SUMMARY OF THE INVENTION
[0005] The present invention solves the problems associated with
the prior art freezing apparatus, and other problems, by utilizing
a retort containing a gas-solid fluidized bed. In a typical heat
exchanger using a fluidized bed, the small solid particles
fluidized by a gas significantly enhance the heat transfer rate
compared to the heat transfer rate provided by gas convection (with
no solid particles). In a freezing apparatus equipped with a retort
containing a gas-solid fluidized bed, the small solid particles
fluidized by a gas significantly enhances the heat transfer rate
from the part to be cooled compared to the heat transfer rate which
occurs when only gas convection is utilized.
[0006] The heat transfer mechanism in the fluidized bed involves
transferring heat to a particle during its contact with the surface
of the steel part mainly by conduction and through the gaseous gap
in the vicinity of the contact point, thereby increasing the
internal energy of the particles. Through the motion of the
fluidized particles, gas flow and by physical agitation, the
surplus internal energy is carried into the bulk of the bed where
it is transferred almost instantaneously to the gas and to the
other fluidized bed particles. The particles and the gas then
transfer this surplus energy to the retort walls that are cooled
from their opposite sides by a cryogenic liquid (for example, by a
jet impingement of liquid nitrogen).
[0007] The sequence of operations in the apparatus of the present
invention is as follows. A bed of particles in a retort is
fluidized by a suitable "dry" gas. The annulus between the walls of
the particle bed and the outer walls is chilled with liquid
nitrogen. The fluidized bed cools the freezer to the set point
temperature. The steel part, heated to its austenitic state, is
then either: (1) placed into the fluidized bed in the retort for a
"direct" cryogenic quench, or (2) "pre-quenched" with a first stage
of traditional quenching (in water, oil, martemper salt, gas,
etc.), or after an "intensive quench" process done in intensively
agitated water until the shell properties are optimized. (The
IntesiQuenche.RTM. process utilizes no oil, salt or other quench
media that will contaminate the cryogenic quench bed). The steel
part is then removed from the freezer after the martensitic phase
transformation within same has been completed (in some cases the
part is cooled down to the set freezer temperature). The
un-tempered part is then tempered to the final desired hardness in
a conventional manner.
[0008] The rapid, uniform lowering of the temperature of the steel
part from the austenite phase continuously through the martensitic
phase transformation (to, or below, the martensite finish
temperature) finalizes the martensitic transformations within the
part and provides the part with a finer martensitic structure
having a very high dislocation density which results in "better"
physical properties than can be provided by discrete conventional
quenching, followed (at an indeterminate time) by conventional deep
freezing, and then tempering. It should be noted that the cooling
rate of the part during the aforementioned process can be adjusted
to compensate for the steel alloy involved. Benefits of the
preferred embodiment of the present invention and the new quenching
method are higher as-quenched hardness, finer martensitic
structure, less or no retained austenite (for better part size
stability), better fatigue resistance and better ductility after
tempering in most alloys of steel. All of these benefits result in
the super-strengthening of the steel part as evidenced by its finer
microstructure with higher dislocation density.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The single figure of the drawings is a cross-sectional view
of the freezer of the present invention having a fluidized bed and
an internal wall cooled by a cryogenic liquid and a physical
agitator positioned adjacent the bottom thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0010] Referring now to the drawings where the illustration is for
the purpose of describing the preferred embodiment of the invention
and is not intended to limit the invention described herein, the
single Figure of the drawing is a cross-sectional view of the
freezer 1 of the present invention. The freezer 1 of the present
invention includes a retort 2 which contains a fluidized bed 3 of
particles (such as, aluminum oxide, sand, copper powder, etc.) and
an internal wall 4 which is cooled by a cryogenic liquid contained
within an annulus and which passes therethrough forming a plurality
of jets 5 which impinge on the internal wall 4 of the freezer 1.
The freezer 1 of the present invention also includes an outer
housing 6 and a cover 7 which sealing engages the outer housing 6.
The outer housing 6 and the cover 7 are both thermally insulated. A
piping system 8 is provided in the freezer 1 to provide the
cryogenic fluid (such as liquid nitrogen) to a plurality of nozzles
9 which create the impingement jets 5. A diffusion plate 10 having
a plurality of apertures therein is provided to retain the
fluidized bed 3 of particles when the bed 3 is not activated. When
the fluidized bed 3 of particles is to be activated, a fluidizing
gas 11, provided by a blower, pressurized tank (both not shown),
and/or gas that has been evaporated from the cryogenic liquid in
the annulus flows through the apertures provided in the diffusion
plate 10 and activates the fluidized bed 3 of particles i.e., a
mixture of a fluidizing gas and randomly moving solid particles.
The fluidizing gas 11 is exhausted from the retort 2 in the freezer
1 through an outlet 12. The cryogenic liquid vapors 13 are
exhausted from the freezer 1 through an outlet 14.
[0011] Operationally, before loading a steel work-piece 15 into the
freezer 1, the freezer 1 is chilled to the required temperature. To
improve the heat transfer within the bed during quenching the
work-piece 15, a gas having a higher thermal conductivity than
nitrogen, (for example, helium) can be substituted for the nitrogen
gas used for fluidizing the bed during cooling the freezer 1. In
addition, paddles or agitators 16 can be placed within the bed
adjacent the bottom thereof to enhance the heat transfer from the
work-piece 15 to the bed particles. The work-piece 15, which has
been heated to its austenitic state, is then either: (1) placed
into the fluidized bed 3 in the retort 2 for a "direct" cryogenic
quench, or (2) pre-quenched using a traditional quenching process
or an "intensive quench" process such as that disclosed in pending
U.S. patent application Ser. No. 10/983,879, filed Nov. 8, 2004,
which is incorporated herein by reference, prior to placing the
work-piece 15 into the fluidized bed 3. In order to load a
work-piece 15 into the freezer 1, the cover 7 is opened permitting
the work-piece 15 to be loaded into the retort 2 and the cover 7 is
closed. It should be noted that the work-piece 15 is in the hot
condition, i.e., it has been heated to its austenitic temperature
or is partially quenched before being loaded into the retort 2.
After loading into the retort 2, the work-piece 15 is kept in the
freezer 1 until the martensitic phase transformation has been
completed within same or until the work-piece temperature reaches
the freezer temperature. When the martensitic phase transformation
in the work-piece 15 has been completed or until the work-piece
temperature reaches the freezer temperature, the work-piece 15 is
removed from the freezer 1 and then tempered to its final desired
hardness. It should be noted that in the foregoing cooling process,
the cooling rate can be adjusted and/or varied depending on the
type of steel processed and apparatus can be utilized to monitor
the cooling rate, both of which are referred to in U.S. Pat. No.
6,099,666, issued Aug. 8, 2000, which is also incorporated herein
by reference. It should also be noted that the ability to adjust
the cooling rate in the apparatus will result in an overall
reduction in the consumption of the cooling media used for cooling
the fluidized bed.
[0012] Certain modifications and improvements will occur to those
skilled in the art upon reading the foregoing. It is understood
that all such modifications and improvements have been deleted here
from for the sake of conciseness and readability, but are properly
within the scope of the following claims.
* * * * *