U.S. patent number 3,917,242 [Application Number 05/470,028] was granted by the patent office on 1975-11-04 for apparatus for fluxing and filtering of molten metal.
This patent grant is currently assigned to Southwire Company. Invention is credited to Joseph A. Bass, Lewis A. McKenzie, Frank M. Powers.
United States Patent |
3,917,242 |
Bass , et al. |
November 4, 1975 |
Apparatus for fluxing and filtering of molten metal
Abstract
This disclosure relates to a method of and apparatus for
treating molten metal for substantially removing gas and
finely-divided solids therefrom. A two-stage tandem apparatus is
provided comprising a treating chamber divided into first and
second sections by a vertically extending weir which is spaced from
the floor of the chamber. Hydrogen gas is fluxed from the metal in
the first section by means of a chlorine-nitrogen fluxing gas which
is bubbled upwardly therethrough. After fluxing, the molten metal
is passed upwardly through a refractory filtering medium disposed
in the second section for filtering finely-divided solids
therefrom. The filter media is supported in the chamber on a
perforated filter media table which permits even flow of the metal
upwardly therethrough. The chamber includes a removable lid by
means of which a protective atmosphere is maintained within the
chamber. Burner block assemblies having damper controls are mounted
in the lid.
Inventors: |
Bass; Joseph A. (Bremen,
GA), McKenzie; Lewis A. (Carrollton, GA), Powers; Frank
M. (Carrollton, GA) |
Assignee: |
Southwire Company (Carrollton,
GA)
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Family
ID: |
27001346 |
Appl.
No.: |
05/470,028 |
Filed: |
May 15, 1974 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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361589 |
May 18, 1973 |
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Current U.S.
Class: |
266/207; 75/412;
266/220; 431/154; 75/681; 266/225; 266/227; 431/155 |
Current CPC
Class: |
C22B
9/055 (20130101); C22B 21/066 (20130101); C22B
9/05 (20130101) |
Current International
Class: |
C22B
21/06 (20060101); C22B 21/00 (20060101); C22B
9/00 (20060101); C22B 9/05 (20060101); C21C
007/04 () |
Field of
Search: |
;266/34R,34A,34PP,34T
;75/68R,46 ;431/154,155 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Custer, Jr.; Granville Y.
Assistant Examiner: Bell; Paul A.
Attorney, Agent or Firm: Wilks; Van C. Hanegan; Herbert M.
Tate; Stanley L.
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of co-pending
application Ser. No. 361,589, filed May 18, 1973.
Claims
We claim:
1. A two-stage tandem apparatus for continuously treating molten
metal to substantially remove gas and finely-divided solids
therefrom, comprising a treating chamber having side walls and a
floor, a refractory weir dividing said chamber into first and
second sections, said weir extending vertically and being spaced
from said floor for providing communication between said first and
second sections, means for introducing a fluxing gas into said
first section for fluxing gas from molten metal contained therein,
a filtering medium disposed in said second section for filtering
finely-divided solids from molten metal passed upwardly
therethrough, a removable lid having sealing means associated
therewith disposed over said chamber for preventing the infusion of
air and moisture from the surrounding atmosphere and for providing
a protective atmosphere over molten metal contained therein, burner
means mounted on said lid and communicating with the interior of
said chamber through at least one opening extending therethrough
for providing heat to the molten metal, means for closing said at
least one opening when said burner means are not in use whereby
said protective atmosphere may be maintained, said burner means
being mounted in at least one burnerblock assembly mounted in said
at least one opening, said at least one burnerblock assembly
including a refractory burner block extending into said chamber and
having an axial bore extending therethrough and communicating with
the atmosphere during operation to provide secondary air for
supporting combustion, and wherein said means for closing said at
least one opening includes damper means for closing said axial bore
thereby preventing said communication.
2. Apparatus as defined in claim 1, wherein said damper means is a
damper plate slidably mounted in a U-shaped plate carried by said
at least one burnerblock assembly and disposed between said burner
means and said burner block.
3. Apparatus as defined in claim 2, wherein a said burner-block
assembly is provided in said lid for each of said first and second
sections of said chamber.
4. Apparatus as defined in claim 1, further including a filter
media table disposed in said second section for supporting said
filter medium a predetermined distance above said floor, said table
including a plurality of perforations whereby molten metal may flow
evenly upwardly therethrough.
5. Apparatus as defined in claim 4, wherein said table is spaced
from said floor a distance corresponding to the spacing of said
weir therefrom.
6. Apparatus as defined in claim 1, wherein said lid is removable
from said chamber.
7. Apparatus as defined in claim 1, further including a clean-out
door disposed in one of said side walls of said chamber adjacent
said second section whereby said filter medium can be readily raked
out.
8. Apparatus as defined in claim 1, wherein said filtering medium
is adapted to assume a buoyant condition as molten metal is passed
upwardly therethrough, and including means disposed over said
filtering medium for preventing floatation thereof.
9. Apparatus as defined in claim 8, wherein said floatation
preventing means is a perforated screen.
10. Apparatus as defined in claim 1, wherein said filtering medium
includes alumina balls.
11. Apparatus as defined in claim 1, wherein said filtering medium
includes crushed alumina.
12. Apparatus as defined in claim 1, including means for by-passing
molten metal past said filtering medium in the event of clogging
thereof.
13. Apparatus as defined in claim 12, wherein said by-passing means
includes spacing said weir from said removable lid to permit the
flow of molten metal over said weir from said first section into
said second section on the downstream side of said filtering
medium.
14. Apparatus as defined in claim 1, wherein said means for
introducing a fluxing gas includes at least one tube extending
downwardly through said first section and having a porous carbon
head disposed at the lower end thereof for dispersing fluxing gas
bubbles into the molten metal adjacent the bottom of said
chamber.
15. Apparatus as defined in claim 1, wherein said means for
introducing a fluxing gas includes at least one porous carbon block
mounted in the bottom of said first section for dispersing fluxing
gas bubbles upwardly through the molten metal.
16. A two-stage tandem apparatus for continously treating molten
aluminum to remove hydrogen gas and finely-divided solids
therefrom, comprising a treating chamber having side walls, a floor
and a removable lid, a refractory weir dividing said chamber into
first and second sections, said weir extending vertically and being
spaced from said floor for providing communication thereunder
between said first and second sections, an inlet for admitting
molten aluminum into said first section and an outlet for
discharging molten aluminum from said second section, said inlet
and outlet, together with said weir, defining a flow path for
molten aluminum through said first section, under said weir and
upwardly through said second section, means for introducing a
chlorine-containing fluxing gas into said first section for fluxing
hydrogen gas from molten aluminum contained therein, and a
filtering medium disposed in said second section and supported on a
perforated filter media table for filtering finely-divided solids
from molten aluminum passed upwardly therethrough, said table being
spaced from said floor at least a distance corresponding to the
spacing of said weir therefrom thereby acting as a distributor
plate to assure an even flow of molten aluminum upwardly through
said filter medium and prevent molten aluminum by-passing said
table and channeling upwardly through said filtering medium along
the surface of said weir.
17. Apparatus as defined in claim 16, wherein said filtering medium
is adapted to assume a buoyant condition as molten aluminum is
flowed upwardly therethrough, and including means disposed over
said filtering medium for preventing flotation thereof.
18. Apparatus as defined in claim 17, wherein said floatation
preventing means is a perforated screen.
19. Apparatus as defined in claim 16, wherein said filter media
table is constructed from refractory material and has a surface
area substantially equivalent to the cross-sectional area of said
second section.
20. Apparatus as defined in claim 16, wherein said table is spaced
from said floor by means of a plurality of legs extending from the
underside of said table.
21. Apparatus as defined in claim 16, wherein said filtering medium
includes crushed alumina.
22. Apparatus as defined in claim 16, wherein said filtering medium
includes alumina balls.
23. Apparatus as defined in claim 22, wherein said filter media
table is perforated with a plurality of holes of a diameter less
than the diameter of said alumina balls.
Description
BACKGROUND OF THE INVENTION
This invention relates generally to the treatment of metals and
metal alloys. More particularly, this invention relates to a method
of and apparatus for the treatment of metals and metal alloys in
the molten state prior to the casting thereof to provide molten
metal substantially free of gas and finely-divided solid
particles.
In the casting of light metals, e.g., aluminum and aluminum alloys,
it has been a common practice to melt the metal in open hearth or
other type melting furnaces which are heated by the burning of
conventional fuels. In preparing the metal for casting, the charges
of metal and desired alloying constituents are generally added to
the melting furnace to be melted, and thereafter the molten metal
is transferred to a holding furnace where close control of both the
composition and the temperature of the molten metal may be
maintained. Thereafter, the molten metal may be transferred by
suitable means from the holding furnace to either a transfer
crucible or directly to the pouring tundish of a casting
machine.
In the melting of the metal and its transfer from receptacle to
receptacle and finally to the casting machine, hydrogen gas is
generated by the reaction of the metal with any moisture existing
throughout the system. Moreover, oxides of the metal and its
alloying constituents may be formed and dispersed throughout the
molten metal. Consequently, in the casting of metal, e.g., in a
continuous process, the cast product may contain a large proportion
of the hydrogen gas in solution in the solid metal, as well as
small occluded oxide particles which tend to nucleate about
hydrogen-filled voids within the solidified metal.
The presence of hydrogen gas and finely-divided particles within
the cast product is, of course, a serious problem inasmuch as the
final product worked from the cast bar, such as continuously-formed
rod and wire, will have poor grain structure and, consequently,
reduced mechanical properties. Moreover, when the product is used
as an electrical conductor, the existence of undesirable
constituents may seriously reduce the electrical conductivity of
the product. The prior art has, therfore, proposed several methods
for fluxing molten metals with inert gases to reduce the hydrogen
content thereof, as well as for filtering the molten metal through
refractory filter media to remove finely-divided solid particles
therefrom.
Conventionally, molten metals have been batch fluxed by treating
the entire body of the melt in the holding furnace or in an
intermediate receptacle, such as a ladle. However, this method has
not been totally satisfactory because it is time-comsuming and
requires large quantities of fluxing gas. Moreover, large
quantities of the hydrogen gas generally remain in the cast article
even after the batch fluxing due, primarily, to reabsorption of the
hydrogen gas and further generation thereof by reaction of the
metal with moisture that may be present throughout the system.
Moreover, while prior art methods of filtering molten metals
through refractory filter media to remove finely-divided solid
particles have been generally satisfactory in this respect, they
have not been beneficial in appreciably reducing the gas content of
a molten metal.
U.S. Pat. Nos. 3,039,864 and 3,172,757 granted, respectively, June
19, 1962 and Mar. 9, 1965 to P.D. Hess et al, disclose methods of
treating molten metals to both flux hydrogen gas therefrom as well
as to filter out finely-divided non-metallic solids. The method
according to each of these patents involves passing the molten
metal downwardly through a bed of refractory filter medium while,
at the same time, passing an inert gas therethrough.In U.S. Pat.
No. 3,039,864 the fluxing gas is disclosed as being passed in
counter-current flow relation to the flow of molten metal, while in
U.S. Pat. No. 3,172,757 the fluxing gas is disclosed as being
passed in co-current flow relation to the flow of molten metal.
While chlorine gas is generally recognized by the prior art as the
superior and desirable gas for use in fluxing hydrogen from molten
aluminum, each of the two above-noted prior art patents teaches
that chlorine gas is unsuitable for use in methods disclosed
therein because of its tendency to form chlorides as well as to
result in clogging of the filter medium after only short periods of
operation. Consequently, the Hess et al patents disclose the use of
inert fluxing gases for use in fluxing hydrogen from aluminum, as
well as the use of nitrogen gas where the problem of
nitride-formation is not of significance.
It has been suggested that the reason that chlorine gas is superior
for fluxing hydrogen gas from molten aluminum is that the chlorine
will break down or otherwise overcome some film or surface
phenomenom that exists about the hydrogen gas bubbles, thereby
facilitating diffusion of the hydrogen gas into the fluxing
chlorine gas. Apparently, this surface phenomenon or film is not
broken down as completely with other inert fluxing gases.
It should be apparent, therefore, that even though the methods
disclosed in the Hess et al patents recognize the superiority of
chlorine gas for fluxing molten aluminum, the fact that the Hess et
al methods involve passing the fluxing gas directly through the
filter medium prohibits the use of chlorine gas because the
formation of chlorides will tend to clog the filter medium.
SUMMARY OF THE INVENTION
It is, therefore, a primary object of this invention to provide an
improved system for fluxing and filtering of molten metal.
More particularly, it is an object of this invention to provide a
system for both fluxing and filtering of molten metals,
particularly aluminum and aluminum alloys, that permits the fluxing
gas to at least partially include chlorine gas.
Still more particularly, it is an object of this invention to
provide a two-stage tandem treating system for fluxing and
filtering molten metals wherein the molten metal is fluxed in the
first stage of the system to remove hydrogen gas therefrom, and
then filtered through a granular filtering medium contained in the
second stage to remove finely-divided solids therefrom.
Another object of this invention is to provide a method for
continuously fluxing and filtering molten aluminum by passing a
fluxing gas at least partially comprised of chlorine gas through
the molten aluminum to flux hydrogen gas therefrom and to form
chlorides and other reacted solid products therewith, and then
separating the fluxed hydrogen gas, chlorides and other reacted
solid products from the fluxed molten aluminum before passing the
fluxed molten aluminum through a filtering medium to remove
finely-divided solids therefrom.
Still another object of this invention is to provide a method as
above described wherein a buoyant condition is effected on the
filtering medium as the molten metal is passed upwardly
therethrough which tends to prohibit the quick clogging of the
filtering medium thus extending the operating time thereof.
Yet another object of this invention is to provide a two-stage
tandem apparatus for continuously treating molten metal to
substantially remove hydrogen gas and finely-divided solids
therefrom, comprising a treating chamber having a refractory weir
which divides the chamber into first and second sections, the
fluxing gas being admitted near the bottom of the first section and
permitted to sweep the hydrogen gas and any solid particles that
may be formed by reaction of the fluxing gas with the molten metal
upward unobstructedly to the surface of the molten metal in the
first section, and a filtering medium disposed in the second
section for filtering finely-divided solids from molten metal
passed upwardly therethrough.
A further object of this invention is to provide apparatus as
above-described wherein the treating chamber includes a removable
lid having suitable sealing means for providing a sealed protective
atmosphere within the interior of the chamber, and wherein burner
block means are mounted in the lid for mounting gas burners whereby
heat may be supplied to the metal in the chamber, and damper means
for closing the passage through the burner block assemblies when
the burners are turned off so as to maintain the protective
atmosphere within the chamber.
Still another object of this invention is to provide apparatus as
above-described wherein the filtering medium is supported in the
second section of the chamber on a perforated filter media table
which acts as a distributor plate to assume an even flow of the
molten metal upwardly therethrough.
Yet another object of this invention is to provide apparatus as
above-described which facilitates cleaning and replacement of the
filter media, in particular a clean-out door provided in the side
of the chamber adjacent the lower portion of the second section
thereof, the door adapted to be swung open thereby permitting
raking out of the filter media. Briefly, these and other objects
that may become hereinafter apparent are accomplished in accordance
with this invention by providing a two-stage or double-compartment
receptacle into which the molten metal to be treated is introduced.
A fluxing gas consisting preferably of approximately 15% chlorine
gas and 85% nitrogen gas is introduced into the receptable at or
near the bottom of the first compartment or section and passed
upwardly through the molten metal contained therein. Approximately
50 cubic feet per hour of this gas mixture is required for
completely removing hydrogen gas from an aluminum alloy such as No.
5005 when the metal flow rate is 8,000 pounds per hour. This is
approximately 5% of the chlorine gas normally used to batch flux a
holding furnace of molten aluminum. In one embodiment of the
invention, the gas is introduced through a suitable number of
carbon or metallic tubes and dispersed in small bubbles through
porous carbon heads, thereby furnishing a multitude of bubbles
which facilitates contact with a maximum amount of molten metal. In
another embodiment of the invention, the fluxing gas is introduced
into the receptable through porous carbon blocks located in the
bottom of the fluxing compartment. The chlorine and nitrogen gas is
metered through valves, regulators and flow meters in such a way as
to provide the melt with the proper amount of gas mixture. The top
of the receptacle may be sealed with a removable lid and suitable
gaskets thereby facilitating the creation of a positive pressure,
such as of aluminum chloride, inside the compartment which
prohibits the entrance of oxygen and hydrogen-bearing air from the
outside, and provides an atmosphere control over the top of the
surface of the metal inside the container thereby preventing the
molten metal from reabsorbing hydrogen gas fluxed therefrom.
After the molten metal has been fluxed in the first stage of the
receptacle, it is then admitted into the second stage and passed
upwardly through a granular filtering medium consisting preferably
of alumina in the form of balls, crushed alumina, crushed anode
butts, or other suitable inert filtering material. By passing the
molten metal upwardly through the filter medium, the medium is
caused to be buoyant which prohibits the quick clogging of the
filter material. Inasmuch as the material has a tendency to float,
a perforated screen of stainless steel, cast iron, carbon or other
suitable meterial is placed over the filter material to prohibit
the floatation of the filter material downstream into the casting
system.
The fluxed and filtered metal is then passed out of the double
compartment receptacle through a suitable launder, down spout and
float assembly. This structure prevents any turbulence in the
pouring tundish and provides gas-free clean metal at the pour
point.
With the above and other objects in view that may become
hereinafter apparent, the nature of the invention may be more
clearly understood by reference to the several views illustrated in
the attached drawings, the following detailed description thereof,
and the appended claimed subject matter.
IN THE DRAWINGS:
FIG. 1 is an exploded perspective view of a two-stage tandem system
according to this invention, and illustrates the removable lid
disposed above the two-compartment receptacle, the lid having two
gas inlet tubes extending downwardly therefrom for admitting
mixtures of fluxing gas into the interior of the receptacle, and
further including two burner block assemblies having gas burners
mounted thereon for admitting heat into the interior of the
receptacle;
FIG. 2 is a vertical sectional view taken through the treating
chamber or receptacle of this invention, and illustrates details of
the system including the refractory weir spaced from both the lid
and floor of the receptacle which divides the compartment into
first and second sections, alternate valve and meter lines for
controlling the mixture of fluxing gas, as well as two refractory
burner blocks extending into the interior of the compartment for
providing heat to the molten metal;
FIG. 3 is an exploded perspective view of the burner block assembly
of this invention, and illustrates the damper plate which is
adapted to close the passage through the assembly thereby closing
the interior of the compartment and providing a sealed protective
atmosphere therein; and
FIG. 4 is a perspective view of the filter media table which
supports the filter media in the second section of the
compartment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
Referring now to the drawings in detail, there is illustrated a
two-stage tandem treating system constructed in accordance with
this invention and designated generally by the numeral 10. The
system 10 includes a double compartment receptacle 12 having side
walls 14, 16, a floor 18, and a removable lid 20, all of which are
formed of suitable refractory material. An inlet launder 22 and an
outlet launder 24 extend from the side walls 14, 16,
respectively.
Molten metal M is introduced into the system from the melting or
holding furnace (not shown) through an intermediate launder 26
which communicates with the inlet launder 22 through a suitable
trough 28. Skimmer blocks 30, 32 seal off the interior of the
receptacle 12, while permitting molten metal M to flow thereunder.
The skimmer blocks 30, 32, in cooperation with the removable lid 20
and suitable gaskets 33, provide a sealed protective atmosphere
within the interior of the receptacle 12 above the surface of the
molten metal M for a purpose to be described in more detail
hereinafter.
As seen most clearly in FIG. 2, the receptacle 12 is divided into
first and second sections 34, 36, respectively, by means of a
refractory weir 38. The weir 38 is spaced from the floor 18 so as
to provide for communication between the sections 34 and 36.
Moreover, the weir 38 is also spaced downwardly from the lid 20 in
the fashion of a dam so as to permit overflow of the molten metal M
from section 34 to section 36 under certain conditions as will be
described hereinafter.
After the metal has been treated in the receptacle 12, it may be
conveyed from the outlet launder 24 into a pour pot or tundish 40
through a down spout 42 in the bottom of the outlet launder 24. A
float valve 44 may be provided in the tundish 40 for automatically
controlling the admission of molten metal M thereto. The float
valve 44 includes a conical plug portion 45 which is adapted to
controllably close the outlet of the down spout 42. Inasmuch as the
plug 45 is constructed preferably from cast iron or other heavy
material, it does not float sufficiently on the molten metal M to
regulate the flow of metal through the down spout 42. Consequently,
the float valve 44 is provided with an arm 46 pivotably mounted on
an edge of the tundish 40 and having a slidable weight 48 mounted
at the end thereof whereby the effective weight of the float valve
44 can be adjusted, allowing it to more precisely regulate the flow
of metal M from the launder 24 to the tundish 40.
In accordance with this invention, fluxing gas may be introduced
into the first section 34 of the receptacle 12 through tubes 50, 52
which extend downwardly therein through the lid 20. The tubes 50,
52 may be formed of carbon or suitable refractory metal and include
porous carbon heads 54, 56 through which the fluxing gas may be
dispersed in small bubbles. In the preferred embodiment of this
invention, chlorine and nitrogen gas from suitable sources (not
shown) may be supplied and proportioned through meters 58, 60 and
conducted through a line 62 to metered valves 64, 66 which admit
the suitably proportioned gas to the tubes 50, 52 for admission
into the first section 34 of the receptacle 12.
Alternatively, the chlorine and nitrogen gases may be proportioned
through meters 68, 70 and conducted through line 72 to metered
valves 74, 76 which admit the gas mixture through porous carbon
blocks 78, 80 located in the floor 18 of the receptacle 12.
The second section 36 is filled to a predetermined level with a
filtering medium 82 consisting of a granular refractory material of
suitable mesh size, preferably 3-14 mesh. The filter medium 82 may
be any suitable material that is inert with respect to the molten
metal which, in the case of aluminum, may be alumina in the form of
balls, crushed alumina, crushed carbon anode butts, or other
suitable material. The particles comprising the filter material 82
are so chosen and arranged such that they become buoyant upon the
occurrence of molten metal being passed upwardly therethrough. This
tendency on the part of the filter material 82 to float during
metal flow prohibits the quick clogging of the filter material 82
with small solid particles and thus facilitates longer operating
times. Because of the tendency of the filter material 82 to float
during metal flow, however, a perforated screen 84 is disposed over
the filter material 82 so as to retain the material 82 in the lower
portion of the second section 36. The screen 84 may be formed of
stainless steel, cast iron, carbon or other suitable material.
The filter medium 82 is supported on a filter media table 86, most
clearly illustrated in FIG. 4. The filter media table 86 is
constructed from refractory material approximately one-half inch in
thickness and generally about the same surface area as the
cross-sectional area of the second section 36. Ih a preferred
embodiment, the filter media table 86 is perforated with
approximately 200 holes of five-eighths inch diameter which are
somewhat smaller than the diameter of the aluminum balls, from
which the filter material 82 is preferably constructed, in order
that the balls may be supported while the molten metal M is flowing
upwardly therethrough without permitting the balls to fall through
the holes in the table 86.
The filter media table 86 includes legs 88 whereby the table 86 is
positioned a predetermined distance above the floor 18, preferably
at a distance corresponding to the distance at which the weir 38 is
spaced from the floor 18. This arrangement prevents the filter
medium 82 from clogging the entrance to the section 36 beneath the
weir 38, and assures an even flow of the molten metal M upwardly
through the medium 82 which accomplishes a more complete and
satisfactory filtering of finely-divided particles out of the
molten metal M than was accomplished in prior art construction.
Moreover, provision of the filter media table 86 prevents
channeling of the molten metal M upwardly along the inside edge of
the weir 38 which tendency has been found to prevail when the
filter medium 82 extends completely to the bottom of the second
section 36.
Furthermore, provision of the table 86 prevents the filter medium
82 from sliding back down under the weir 38 into the first section
34 of the receptacle 12. Consequently, the first section 34 is
always maintained free of the filter medium 82 and the fluxing gas
is thus permitted to bubble unobstructedly upward through the
molten metal M in the first section 34 without ever coming in
contact with the filter medium 82. Accordingly, the efficiency of
the system is maximized due to the fact that the fluxing gas does
not react with the filter medium 82 to form oxide particles which
would normally tend to clog the filter medium 82 and thus
necessitate more frequent cleaning thereof.
It should be further understood that even though the filter medium
82 is disclosed herein as preferably being buoyant when the molten
metal M is passed upwardly therethrough, this condition does not
negate the necessity for providing the filter media table 86.
Consequently, it should be apparent that in the absence of the
table 86 the portion of the filter medium 82 nearest the weir 38
will tend to be forced upwardly by the flowing metal while the
remainder thereof will tend to shift somewhat to the right and
downward as viewed in FIG. 2. This will, of course, result in
channeling the molten metal M upwardly along the edge of the weir
38.
During periods when the casting operation is stopped, heat must be
applied to the interior of the receptacle 12 so that the
temperature of the molten metal M does not drop to the point where
it begins to solidify or freeze-up. To this end, as seen in FIGS. 1
and 2, gas burners 90 are provided for providing heat to the
interior of the receptacle 12. These burners 90 are mounted in
burnerblock assemblies 91 situated in suitable openings 92 in the
lid 20.
As seen most clearly in FIG. 3, the burnerblock assemblies 91
include a refractory burner block 93 having an axial bore 94
extending therethrough whereby the heat from the burners 90 is
adapted to communicate with the interior of the receptacle 12.
Suitable mounting plates 95, 96, having circular openings 97, 98,
concentric with the bore 94, are adapted to be disposed on the
upper portion of the block 93. A U-shaped plate 99 having leg
portions 100 which define a rectangular opening 101, is adapted to
be disposed over the plate 96. The leg portions 100 include
suitable tracks 102 for slidably receiving a damper plate 103 which
is adapted to selectively open and close the opening 101.
A burner holder 104, having a mounting plate 105, is adapted to be
secured to the U-shaped plate 99. The burner holder 104 includes a
burner bracket 106 having circular ring portions 107, 108, in which
the burner 90 is adapted to be suitably retained.
When the burnerblock assembly 91 is in assembled condition by
securing the plates 95, 96, 99 and 105 by means of suitable bolts
109, an axial opening will extend through the burnerblock assembly
91 from the tips of the burners 90 to the interior of the
receptacle 12. During operation of the burners 90, the damper plate
103 is maintained in its outermost position on the tracks 102.
However, when the burners 90 are not being used, the damper plate
103 is simply slid inwardly so as to close the opening 101, thereby
closing the axial opening through the burnerblock assembly 91. This
will effectively seal the interior of the receptacle 12, thereby
maintaining a positive pressure within the receptacle 12 and
preventing the entrance of so-called tramp air and moisture to come
into communication with the molten metal M.
Another feature of this invention includes the provision of a
clean-out door 110 provided in a side of the receptacle 12 which
communicates with the interior of the second section 36. The
clean-out door 110 is suitably hinged at 111, 112 so as to be
readily swung open whereby the filter media 82 can be readily
cleaned or replaced. Additionally, a drain port 115 is provided in
a side of the receptacle 12 communicating with the interior of the
first section 34.
In prior art filters, when it was time to change the filter medium
and put in a newly reconditioned medium, the molten metal had to be
drained and the receptacle removed from the operating area
whereupon it was turned on its side and the filter medium raked
out. However, this lapse of time between the draining of the metal
and the raking out of the filter medium was often sufficient to
permit the molten metal adhering to the filter medium to freeze and
cause the medium to stick, making it impossible to remove it from
the receptacle except by reheating or breaking it out with a
jackhammer. On the other hand, with the construction according to
the instant invention, the molten metal can be drained through the
port 115 and the clean-out door 110 immediately opened whereupon
the filter medium 82 can be raked out and cleaned while the
temperature is still high enough for the adhering metal to be in
the molten condition, thereby saving considerable amount of time
and effort.
In operation of the system 10, molten metal is introduced into the
interior of the receptacle 12 through the inlet launder 22 and is
flowed through the first section 34, the second section 36, and out
through the outlet launder 24. While the molten metal M is in the
first section 34, a suitable proportion of chlorine and nitrogen
fluxing gases is introduced either through the tubes 50, 52 or the
carbon blocks 78, 80. The fluxing gas will bubble upwardly through
the molten metal M thereby diffusing hydrogen gas therefrom and
sweeping the hydrogen gas upwardly to the top of the receptacle 12
along with any chlorides, nitrides, and other solid oxide particles
that are either in the molten aluminum or that have been formed by
reaction with the fluxing gases. Thus, a positive pressure of
aluminum chloride is maintained inside the sealed receptacle 12
above the surface of the molten metal M which prohibits the
entrance of oxygen and hydrogen-bearing air from the outside, and
provides an atmosphere control over the top of the surface of the
metal M inside the sealed receptacle 12 thereby preventing the
molten metal M from reabsorbing the fluxed hydrogen gas. Moreover,
the reacted solid particles can be simply skimmed from the surface
of the molten metal M periodically or when the buildup so
dictates.
The molten metal M then flows under the weir 38, which is
preferably spaced approximately one-half inch from the floor 18,
and into the second section 36 where it flows upwardly through the
filter medium 82, which thus assumes a buoyant condition as above
described, thereby having finely-divided particles filtered
therefrom.
In the event that the filter medium 82 does in fact become clogged
with solid particles, the molten metal M in the first section 34
will simply overflow the top of the weir 38 into the second section
36, thus by-passing the filter medium 82 and thereby preventing an
overflow of molten metal M from the receptacle 12.
It should be apparent that providing the filtering medium 82 only
in the second section 36 of the receptacle 12 leaves the first
section 34 free for the fluxing treatment. Thus, the fluxing gas
may bubble unobstructedly upward through the molten metal M to the
top of the first section 34, thereby sweeping the hydrogen gas and
reacted solid particles to the surface of the molten metal M.
Inasmuch as the fluxing gas does not have to travel through the
filtering medium 82, it does not matter that chlorides or other
solid particles may be formed by reaction of the fluxing gas with
the molten metal M. Consequently, the fluxing gas may contain a
suitable percentage of the superior chlorine fluxing gas, and any
chlorides that are formed will be merely swept to the top of the
first section 34 and in no way be caused to clog the filtering
medium 82.
In view of the foregoing, it should be apparent that there is
provided in accordance with this invention a novel method of and
apparatus for degassing and filtering molten metals, particularly
molten aluminum and aluminum alloys, consisting of a two-stage
tandem system for fluxing hydrogen gas and filtering finely-divided
solids therefrom which permits both the use of chlorine in the
fluxing gas and facilitates long-period operation of the filter
section.
Although the invention has been specifically illustrated and
described herein with reference to specific embodiments thereof, it
is to be understood that further minor modifications could be made
therein without departing from the spirit of the invention.
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