Ultrasonic device with integrated gas delivery system

• US 9,382,598 B2
• Filed: 01/16/2014
• Issued: 07/05/2016
• Est. Priority Date: 04/09/2010
• Status: Active Grant

• Current Assignee: Southwire Company
• Original Assignee: Southwire Company
• Inventors: Rundquist, Victor F., Gill, Kevin S.
• Primary Examiner(s): Wyszomierski, George
• Assistant Examiner(s): MCGUTHRY BANKS, TIMA MICHELE
• Application Number:
  US14/156,520
• Publication Number:
  US 20140123812A1
• Time in Patent Office: 901 Days
• US Class Current: 1/1
• 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;

an elongated 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;

wherein;

the probe comprises a ceramic; and

a length to diameter ratio of the probe is in a range from about 5;

1 to about 25;

1.

2. The ultrasonic device of claim 1, wherein the probe is a unitary part.

3. The ultrasonic device of claim 2, 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.

4. The ultrasonic device of claim 2, wherein the probe comprises a Sialon.

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

6. The ultrasonic device of claim 1, wherein the probe has a radius of curvature of at least about ½

-inch on an attachment side of the probe.

7. The ultrasonic device of claim 1, wherein:

the probe comprises a Sialon;

the probe is generally cylindrical; and

the ultrasonic device further comprises a booster between the ultrasonic transducer and the probe.

8. The ultrasonic device of claim 7, wherein the length to diameter ratio is in a range from about 7:

1 to about 22;

1.

9. The ultrasonic device of claim 7, wherein a ratio of the cross-sectional area of the tip of the probe to the cross-sectional area of the gas outlet is in a range from about 60:

1 to about 750;

1.

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

(a) operating the ultrasonic device of claim 1 in the molten metal bath; and

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

11. The method of claim 10, 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.

12. The method of claim 10, 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.

13. The method of claim 10, wherein:

the dissolved gas comprises hydrogen;

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

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

14. An ultrasonic device comprising:

an ultrasonic transducer;

an elongated probe comprising a tip;

a booster between the ultrasonic transducer and the elongated probe; and

a gas delivery system, the gas delivery system comprising;

a gas inlet in the booster,

a gas flow path through the probe, and

a gas outlet at the tip of the probe;

wherein;

the probe comprises a ceramic; and

a length to diameter ratio of the probe is in a range from about 5;

1 to about 25;

1.

15. The ultrasonic device of claim 14, 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.

16. The ultrasonic device of claim 14, wherein the probe is a unitary, generally cylindrical probe comprising a Sialon.

17. The ultrasonic device of claim 16, wherein the probe is secured to the ultrasonic transducer with an attachment nut.

18. The ultrasonic device of claim 16, wherein:

a ratio of the cross-sectional area of the tip of the probe to the cross-sectional area of the gas outlet is in a range from about 60;

1 to about 750;

1; and

the length to diameter ratio is in a range from about 7;

1 to about 22;

1.

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

(a) operating the ultrasonic device of claim 14 in the molten metal bath; and

(b) introducing a purging gas through the gas delivery system and into the molten metal bath.

20. The method of claim 19, wherein:

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

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

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

21. The method of claim 19, wherein:

the dissolved gas comprises hydrogen;

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

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

22. The method of claim 19, 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.

23. An ultrasonic device comprising:

an ultrasonic transducer;

an elongated probe comprising a tip;

a booster between the ultrasonic transducer and the elongated probe; and

a gas delivery system, the gas delivery system comprising;

a gas inlet in the booster,

a gas flow path through the probe, and

a gas outlet at the tip of the probe;

wherein a length to diameter ratio of the probe is in a range from about 5;

1 to about 25;

1.

24. The ultrasonic device of claim 23, wherein the probe comprises stainless steel, titanium, niobium, a ceramic, or a combination thereof.

25. The ultrasonic device of claim 23, wherein the probe comprises a Sialon.

26. The ultrasonic device of claim 23, wherein:

a ratio of the cross-sectional area of the tip of the probe to the cross-sectional area of the gas outlet is in a range from about 60;

1 to about 750;

1; and

the length to diameter ratio is in a range from about 7;

1 to about 22;

1.

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

(a) operating the ultrasonic device of claim 23 in the molten metal bath; and

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