Ultrasonic Device with Integrated Gas Delivery System

• US 20120042751A1
• Filed: 10/11/2011
• Published: 02/23/2012
• Est. Priority Date: 04/09/2010
• Status: Active Grant

• Current Assignee: Southwire Company
• Original Assignee: Southwire Company
• Inventors: Rundquist, Victor F., Gill, Kevin S.
• Granted Patent: US 8,652,397 B2
• Time in Patent Office: Days
• US Class Current: 75/646
• CPC Class Codes: B01D 19/0005 with one or more auxiliary substances
• CPC Class Codes: B01D 19/0078 by vibration
• CPC Class Codes: B22D 1/002 Treatment with gases C21C7/072, C22B9/05 take precedence
• CPC Class Codes: B22D 1/005 Injection assemblies therefor features relating to gas injection, provided on closures of the sliding gate type B22D41/42; provided on pouring nozzles B22D41/58; provided on closures of the stopper-rod type B22D41/186
• CPC Class Codes: C21C 7/072 Treatment with gases C21C7/06, C21C7/064, C21C7/068 take precedence
• CPC Class Codes: C22B 21/06 refining electrolytic refining C25C; C22B21/0046, C22B21/0061 take precedence
• CPC Class Codes: C22B 21/064 using inert or reactive gases C22B21/066 and C22B21/068 take precedence
• CPC Class Codes: C22B 9/02 Refining by liquating, filtering, centrifuging, distilling, or supersonic wave action including acoustic waves; C22B9/003, C22B9/006, C22B9/05, C22B9/22 take precedence
• CPC Class Codes: C22B 9/026 by acoustic waves, e.g. supersonic waves
• CPC Class Codes: C22B 9/05 Refining by treating with gases, e.g. gas flushing also refining by means of a material generating gas in situ
• CPC Class Codes: Y02P 10/20 Recycling

Abstract

Methods for degassing and for removing impurities from molten metals are disclosed. These methods can include operating an ultrasonic device in a molten metal bath, and adding a purging gas into the molten metal bath through the tip of the ultrasonic device.

Claims

1. An ultrasonic device comprising:

an ultrasonic transducer;

a probe attached to the ultrasonic transducer, the probe comprising a tip; and

a gas delivery system, the gas delivery system comprising;

a gas inlet,

a gas flow path through the probe, and

a gas outlet at the tip of the probe.

2. The ultrasonic device of claim 1, wherein the probe comprises stainless steel, titanium, niobium, a ceramic, or a combination thereof.

3. The ultrasonic device of claim 2, wherein the probe is a unitary part.

4. The ultrasonic device of claim 3, wherein the probe comprises a Sialon, a Silicon carbide, a Boron carbide, a Boron nitride, a Silicon nitride, an Aluminum nitride, an Aluminum oxide, a Zirconia, or a combination thereof.

5. The ultrasonic device of claim 4, wherein the probe comprises a Sialon.

6. The ultrasonic device of claim 1, wherein the probe is an elongated probe, and the elongated probe is secured to the ultrasonic transducer with an attachment nut.

7. The ultrasonic device of claim 1, wherein the probe is an elongated probe, and a length to diameter ratio of the elongated probe is in a range from about 5:

1 to about 25;

1.

8. The ultrasonic device of claim 1, wherein the probe is an elongated probe, and a ratio of the cross-sectional area of the tip of the elongated probe to the cross-sectional area of the gas outlet is in a range from about 30:

1 to about 1000;

1.

9. The ultrasonic device of claim 1, wherein the ultrasonic device further comprises a thermal protection system surrounding at least a portion of the probe.

10. The ultrasonic device of claim 9, wherein a fluid is circulated within the thermal protection system.

11. The ultrasonic device of claim 1, wherein the ultrasonic device further comprises a booster between the ultrasonic transducer and the probe.

12. The ultrasonic device of claim 11, wherein the gas inlet is in the booster.

13. A method for reducing an amount of a dissolved gas and/or an impurity in a molten metal bath, the method comprising:

(a) operating an ultrasonic device in the molten metal bath, the ultrasonic device comprising;

an ultrasonic transducer;

a probe attached to the ultrasonic transducer, the probe comprising a tip; and

a purging gas delivery system, the gas delivery system comprising;

a purging gas inlet,

a purging gas flow path through the probe, and

a purging gas outlet at the tip of the probe; and

(b) introducing a purging gas through the purging gas delivery system and into the molten metal bath at a rate in a range from about 0.1 to about 150 L/min.

14. The method of claim 13, wherein:

the dissolved gas comprises oxygen, hydrogen, sulfur dioxide, or a combination thereof;

the impurity comprises an alkali metal;

the molten metal bath comprises aluminum, copper, zinc, steel, magnesium, or a combination thereof;

the purging gas comprises nitrogen, helium, neon, argon, krypton, xenon, chlorine, or a combination thereof;

or

any combination thereof.

15. The method of claim 13, wherein the purging gas is introduced into the molten metal bath at a rate in a range from about 10 to about 500 mL/hr of purging gas per kg/hr of output from the molten metal bath.

16. The method of claim 13, wherein:

the purging gas is introduced into the molten metal bath at a rate in a range from about 1 to about 50 L/min;

the dissolved gas comprises hydrogen;

the molten metal bath comprises aluminum, copper, or a combination thereof;

the purging gas comprises argon, nitrogen, or a combination thereof;

or

any combination thereof.

17. The method of claim 16, wherein the purging gas is introduced into the molten metal bath at a rate in a range from about 1 to about 10 L/min.

18. The method of claim 16, wherein the purging gas is introduced into the molten metal bath at a rate in a range from about 30 to about 200 mL/hr of purging gas per kg/hr of output from the molten metal bath.