CA1123196A - Exothermic bimetallic composition with small size refractory materials to fill holes in ferrous body - Google Patents
Exothermic bimetallic composition with small size refractory materials to fill holes in ferrous bodyInfo
- Publication number
- CA1123196A CA1123196A CA328,436A CA328436A CA1123196A CA 1123196 A CA1123196 A CA 1123196A CA 328436 A CA328436 A CA 328436A CA 1123196 A CA1123196 A CA 1123196A
- Authority
- CA
- Canada
- Prior art keywords
- metal
- particles
- slag
- metallic
- size less
- 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.)
- Expired
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/34—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material comprising compounds which yield metals when heated
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K23/00—Alumino-thermic welding
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Furnace Housings, Linings, Walls, And Ceilings (AREA)
- Ceramic Products (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
The invention provides a composition for use in the filling of a hole in an ingot mould base or other ferrous metal body which comprises (1) a mixture reactable on ignition to yield a molten slag containing a first metal in an oxidised state and a second metal in the fused metallic state by reaction of the first metal provided in particulate metallic form with the second metal provided in the form of a compound reactable exothermically with the first metal and (2) a refractory material, conveniently crushed firebrick present in an amount such as to be bound together by the slag when the slag has solidified by cooling, said refractory material being in particulate form. By having the refractory material present, at least in part, in the form of particles of size less than one-eighth inch whilst being substantially free from particles of size less than 400 microns (and preferably less than 600 microns) an improved working surface is obtained and the ignition properties of the composition are improved.
The invention provides a composition for use in the filling of a hole in an ingot mould base or other ferrous metal body which comprises (1) a mixture reactable on ignition to yield a molten slag containing a first metal in an oxidised state and a second metal in the fused metallic state by reaction of the first metal provided in particulate metallic form with the second metal provided in the form of a compound reactable exothermically with the first metal and (2) a refractory material, conveniently crushed firebrick present in an amount such as to be bound together by the slag when the slag has solidified by cooling, said refractory material being in particulate form. By having the refractory material present, at least in part, in the form of particles of size less than one-eighth inch whilst being substantially free from particles of size less than 400 microns (and preferably less than 600 microns) an improved working surface is obtained and the ignition properties of the composition are improved.
Description
All percentages referred to herein are percentages by weight and are based on the total weight of the composition.
The present invention relates to the repairing of ferrous metal bodies.
In U. K. Patent No. 1,479,146 of Goricon Metallur~ical Services Ltd., published ~uly 6, 1977, inventor Glanville John Richards, there are described a composition for, and method of, filling a hole in a ferrous metal body by reacting exothermic-ally therein a composition which produces a molten metal and a molten slag in the presence of a particulate refractory mat-erial. When the reaction products have cooled the hole is filled at least partially by solidified material having an upper non-metallic zone of solid slag and bound refractory material and a lower zone of solidified metal. The slag-bound refractory material provides a surface having erosion-resistant properties which are attractive in the principal application of the composition and method, i.e., in the repair of the cast iron bases of ingot moulds used in the steel in-dustry.
According to the said Specification, the particle size of the refractory material is not critical and it is indicated that good results have been obtained using, as the refractory material, firebrick sieved to less than one-eighth inch and improved results using firebrick granules which pass a half-inch sieve but are retained on an eighth-inch sieve.
In accordance with the present invention there is provided a composition for use in the filling of a hole in a ferrous metal body which comprises (1) a mixture reactable on ignition to yield a molten slag containing a first metal in an oxidi~ed state and a second metal in the fused metallic a~ -~23196 state by reaction of the first metal provided in particulate metallic form with the second metal provided in the form of a compound reactable exothermically with the first metal and
The present invention relates to the repairing of ferrous metal bodies.
In U. K. Patent No. 1,479,146 of Goricon Metallur~ical Services Ltd., published ~uly 6, 1977, inventor Glanville John Richards, there are described a composition for, and method of, filling a hole in a ferrous metal body by reacting exothermic-ally therein a composition which produces a molten metal and a molten slag in the presence of a particulate refractory mat-erial. When the reaction products have cooled the hole is filled at least partially by solidified material having an upper non-metallic zone of solid slag and bound refractory material and a lower zone of solidified metal. The slag-bound refractory material provides a surface having erosion-resistant properties which are attractive in the principal application of the composition and method, i.e., in the repair of the cast iron bases of ingot moulds used in the steel in-dustry.
According to the said Specification, the particle size of the refractory material is not critical and it is indicated that good results have been obtained using, as the refractory material, firebrick sieved to less than one-eighth inch and improved results using firebrick granules which pass a half-inch sieve but are retained on an eighth-inch sieve.
In accordance with the present invention there is provided a composition for use in the filling of a hole in a ferrous metal body which comprises (1) a mixture reactable on ignition to yield a molten slag containing a first metal in an oxidi~ed state and a second metal in the fused metallic a~ -~23196 state by reaction of the first metal provided in particulate metallic form with the second metal provided in the form of a compound reactable exothermically with the first metal and
(2) a modifier for modifying the slag when the slag has solidi-fied by cooling, said modifier being a non-metallic refractory material in particulate form which is present at least in part in the form of particles of size less than one-eighth inch whilst being substantially free from particles of size less then 400 microns.
There is further provided a method of filling a hole in a body of ferrous metal which comprises introduc,ing into the hole a composition as provided by the present invention, exo,hermically reacting the said compound with the first metal - to form molten slag and the second metal in the fused metallic state and allowing the second metal and the slag to set to the solid state with the slag binding the particles of refrac-tory material together, so that the hole is filled at least partially by solidified material having an upper zone of solid slag and bound refractory material and a lower zone of solidi-fied second metal.
Having at least a significant proportion of a re-fractory material present in the form of particles of smaller size than in previous practice gives the slag-bound refractory a desirably improved finish. Its appearance is more acceptable to those concerned. Additionally, by having the refractory, or a major part (e.g. more than 30%, desirably more than 80%
or even more than 95-98%) thereof, present in the form of much finer particles than ha~e been employed heretofore, the' inclusion of refractory in the adjacently formed part of the ingot is minimized so reducing wear of the repair as well as reducing difficulties in the use of the ingot,
There is further provided a method of filling a hole in a body of ferrous metal which comprises introduc,ing into the hole a composition as provided by the present invention, exo,hermically reacting the said compound with the first metal - to form molten slag and the second metal in the fused metallic state and allowing the second metal and the slag to set to the solid state with the slag binding the particles of refrac-tory material together, so that the hole is filled at least partially by solidified material having an upper zone of solid slag and bound refractory material and a lower zone of solidi-fied second metal.
Having at least a significant proportion of a re-fractory material present in the form of particles of smaller size than in previous practice gives the slag-bound refractory a desirably improved finish. Its appearance is more acceptable to those concerned. Additionally, by having the refractory, or a major part (e.g. more than 30%, desirably more than 80%
or even more than 95-98%) thereof, present in the form of much finer particles than ha~e been employed heretofore, the' inclusion of refractory in the adjacently formed part of the ingot is minimized so reducing wear of the repair as well as reducing difficulties in the use of the ingot,
- 3 -~æ~ 6 ~urther the ignition of the composition is facilitated and its rate of burning is increased. ~he proportion of aluminium powder (aluminuum is the preferred first metal) may be reduced correspondingly with consequent economy.
Previous attempts to include finely powdered refractory material have produced difficulties with the progress of the combustion. With the present composition the foll~wing further advantages may be obtained in the combustion.
(a) When the composltion is ignited at the top, the rate at which the combustion spreads downwards to the bottom is improved. (Previously the presence of refractory fines has inhibited the flow of liquid products to tne lower parts of the fill and there !' has been a marked tendency to burn from the top downwards). ~he early combustion of lower materials allows the filtering of fume by the unburnt materials above. ~here is, therefore, a significant reduction in fume level, ~b) Sometimes, in the method as previously practised, 3`:
-20 some unbound refractory particles are lef~ forming a -part periphery around the completed repairO
~c) Problems caused by the segregation of fine refractory `
particles (poor ignition, incomplete burn, too slow burning ~nd thus a poor repair) are significantl~ ;
reduced~
Increasing the lower limit of the size of the refractory particles above the 400 micron level gives further enhanced performance. A useful improvement is obtai~ed by increasing r the limit to 600 microns which is our preferred level. ~urther improvement is obtainable by increasing the limit beyond 600 microns but increasing beyond 1000 microns (eg to 1500 microns) has little further effect and may be avoided.
Previous attempts to include finely powdered refractory material have produced difficulties with the progress of the combustion. With the present composition the foll~wing further advantages may be obtained in the combustion.
(a) When the composltion is ignited at the top, the rate at which the combustion spreads downwards to the bottom is improved. (Previously the presence of refractory fines has inhibited the flow of liquid products to tne lower parts of the fill and there !' has been a marked tendency to burn from the top downwards). ~he early combustion of lower materials allows the filtering of fume by the unburnt materials above. ~here is, therefore, a significant reduction in fume level, ~b) Sometimes, in the method as previously practised, 3`:
-20 some unbound refractory particles are lef~ forming a -part periphery around the completed repairO
~c) Problems caused by the segregation of fine refractory `
particles (poor ignition, incomplete burn, too slow burning ~nd thus a poor repair) are significantl~ ;
reduced~
Increasing the lower limit of the size of the refractory particles above the 400 micron level gives further enhanced performance. A useful improvement is obtai~ed by increasing r the limit to 600 microns which is our preferred level. ~urther improvement is obtainable by increasing the limit beyond 600 microns but increasing beyond 1000 microns (eg to 1500 microns) has little further effect and may be avoided.
- 4 -. . . ~ .
~23~
Increasing the lower limit can cause segregation problems in manufacture~ transport and useO
- The same proportion of refractory matérial may be employed as previously ie. 15 to 30~ by weight based on the total waight of the composition.
To illustrate the efficacy of the present invention, the ?:
following details, are given of a~ comparative test in which a ~;, Mix A in accord~nce with the invention is compared with a ~, Mix B. Mix B. contained particles of crushed firebrick or other refractory having a range of particle sises extending downwardly from 600 microns and containing a substantial proportion of particles of sizes below 400 microns. 1!;
Mix ~ Mix B ~, - 18~0 Al ~ 18~0 ~r 62.0 MilI Scale % 62.0 ~, 20.0 Refractory Particles ~ 20.0 ~;
Refractory ~izeRefractory Size 15O7 ~ ~-2?360 microns14.8 40.8 ~ 1180 to 2360 "28.6 39.3 % 710 to 1180 "37.2 4.2 % 600 to 710 " 4.0 Nil %' ~ess than 600 microns 5.4 Two bottom plates of the same type with erosion cavities of similar area and depth were used for the test. The ~l aluminium powder, mill scale and refractory particles of ', A and B were the same in all respects excep,t that all refractory fines of less than 600 microns were removed from the refraotory used for mix A. 40Q Kg. of A wa~s ,' , ignitéd in the erosion hold of one plate and 40 kg. of B
was ignited in the other plate. ~he same starting device was used for A and B. ~he following was noted:-.
. .
~9L2~
Mix A Mix B
~ime taken before ignition 3 secs. 5 secs.
Time for complete combustion 55 secs. 75 secs~
Unreacted material None ~mall amount Amount of fums Slight Heavy ~ife of repair 7 heats 5 heats General observations were that Mix A ignited at the top ', but the ignited material and liquid products of thè reaction flowed to the bottom. ~here was very little fume. Mix B 5/
ignited at the ~op and the liquid products of reaction flowed over the top of the mix thus igniting the top layer of the powder. ~hus there was considerable fume. Mix A.
gave an important improvement in repair life compared to B.
In another test, results comparable with those given by Mix A were ootained using crushed firebrick of the following screen analysis: ~-0.6 to 0.7 mm 5%
? to 1~2 mm 37 1,2 to 2~36 mm 39 72.36 mm to 3~1Z inch 20 ~ he particle sizes referred to herein are sieve sizesO
~or irregular particles they are concerned with the maximum linear dimension taXen across the minimum projected cross section.
- 6 _
~23~
Increasing the lower limit can cause segregation problems in manufacture~ transport and useO
- The same proportion of refractory matérial may be employed as previously ie. 15 to 30~ by weight based on the total waight of the composition.
To illustrate the efficacy of the present invention, the ?:
following details, are given of a~ comparative test in which a ~;, Mix A in accord~nce with the invention is compared with a ~, Mix B. Mix B. contained particles of crushed firebrick or other refractory having a range of particle sises extending downwardly from 600 microns and containing a substantial proportion of particles of sizes below 400 microns. 1!;
Mix ~ Mix B ~, - 18~0 Al ~ 18~0 ~r 62.0 MilI Scale % 62.0 ~, 20.0 Refractory Particles ~ 20.0 ~;
Refractory ~izeRefractory Size 15O7 ~ ~-2?360 microns14.8 40.8 ~ 1180 to 2360 "28.6 39.3 % 710 to 1180 "37.2 4.2 % 600 to 710 " 4.0 Nil %' ~ess than 600 microns 5.4 Two bottom plates of the same type with erosion cavities of similar area and depth were used for the test. The ~l aluminium powder, mill scale and refractory particles of ', A and B were the same in all respects excep,t that all refractory fines of less than 600 microns were removed from the refraotory used for mix A. 40Q Kg. of A wa~s ,' , ignitéd in the erosion hold of one plate and 40 kg. of B
was ignited in the other plate. ~he same starting device was used for A and B. ~he following was noted:-.
. .
~9L2~
Mix A Mix B
~ime taken before ignition 3 secs. 5 secs.
Time for complete combustion 55 secs. 75 secs~
Unreacted material None ~mall amount Amount of fums Slight Heavy ~ife of repair 7 heats 5 heats General observations were that Mix A ignited at the top ', but the ignited material and liquid products of thè reaction flowed to the bottom. ~here was very little fume. Mix B 5/
ignited at the ~op and the liquid products of reaction flowed over the top of the mix thus igniting the top layer of the powder. ~hus there was considerable fume. Mix A.
gave an important improvement in repair life compared to B.
In another test, results comparable with those given by Mix A were ootained using crushed firebrick of the following screen analysis: ~-0.6 to 0.7 mm 5%
? to 1~2 mm 37 1,2 to 2~36 mm 39 72.36 mm to 3~1Z inch 20 ~ he particle sizes referred to herein are sieve sizesO
~or irregular particles they are concerned with the maximum linear dimension taXen across the minimum projected cross section.
- 6 _
Claims (14)
1. A composition for use in the filling of a hole in a ferrous metal body which comprises (1) a mixture reactable on ignition to yield a molten slag containing a first metal in an oxidized state and a second metal in the fused metallic state by reaction of the first metal provided in particulate metallic form with the second metal provided in the form of a compound reactable exothermically with the first metal and (2) a modifier for modifying the slag when the slag has solid-ified by cooling, said modifier being a non-metallic refractory material in particulate form which is present at least in part in the form of particles of size less than one-eighth inch whilst being substantially free from particles of size less than 400 microns.
2. A composition according to Claim 1 and substantially free from particles of size less than 600 microns.
3. A composition according to Claim 1 and substantially free from particles of size less than 1000 microns.
4. A mixture according to any one of Claims 1 to 3 in which the refractory material is firebrick or other material of the fired-clay type which has been reduced to the particu-late form.
5. A mixture according to any one of Claims 1 to 3 in which the first metal is aluminium and the second metal is iron in the form of ferric or other iron oxide.
6. A mixture according to any one of Claims 1 to 3 in which the refractory material is present in an amount of from 15 to 30% by weight based on the total weight of the composi-tion.
7. A composition for use in the filling of a hole in a ferrous metal body which comprises (1) a mixture of an iron oxide and particulate metallic aluminium reactable on ignition to yield metallic iron and a molten slag containing the alumin-ium and(2) a non-metallic refractory modifier present in an amount of from 15 to 30% by weight of the composition, said modifier being in particulate form and being present at least in part in the form of particles of size less than one-eighth inch whilst being substantially free from particles of size less than 400 microns.
8. A composition according to Claim 7 and substantially free from particles of size less than 1000 microns.
9. A method of filling a hole in a body of ferrous metal which comprises introducing into the hole a composition which comprises (1) a mixture reactable on ignition to yield a molten slag containing a first metal in an oxidized state and a second metal in the fused metallic state by reaction of the first metal provided in particulate metallic form with the second metal provided in the form of a compound reactable exothermic-ally with the first metal and (2) a modifier for modifying the slag when the slag has solidified by cooling, said modifier being a non-metallic refractory material in particulate form which is present at least in part in the form of particles of size less than one-eighth inch whilst being substantially free from particles of size less than 400 microns, exothermically reacting the composition and allowing the second metal and the slag thereby produced to set to the solid state with the slag binding the particles of refractory material together, so that the hole is filled at least partially by solidified material having an upper zone of solid slag and bound refractory material and a lower zone of solidified second metal.
10. A method according to Claim 9 in which the particulate refractory material is introduced into the hole in admixture with the heat generating composition.
11. A method according to Claim 9 in which the particu-late refractory material is added to the slag whilst the slag is in the molten state in the hole.
12. A method according to any one of Claims 9 to 11 in which the body of ferrous metal is formed of cast iron.
13. A method according to any one of Claims 9 to 11 in which the body of ferrous metal is an ingot mould base.
14. A body of ferrous metal having a hole which is filled through at least a part of its depth by solidified material having an upper zone of slag containing a first metal in an oxidized state and a lower zone of a second metal in the metallic state, said zones being produced by the exo-thermic reaction of a reaction mixture of the first metal in particulate metallic form with a compound of the second metal to yield the second metal in a fused metallic state and a slag containing the first metal in an oxidized state, said slag containing a non-metallic refractory modifier provided at least in part in the form of particles of size less than one-eighth inch whilst being substantially free from particles of size less than 400 microns.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB2449678A GB1602946A (en) | 1978-05-30 | 1978-05-30 | Exothermic compositions |
| GB24496/78 | 1978-05-30 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1123196A true CA1123196A (en) | 1982-05-11 |
Family
ID=10212581
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA328,436A Expired CA1123196A (en) | 1978-05-30 | 1979-05-24 | Exothermic bimetallic composition with small size refractory materials to fill holes in ferrous body |
Country Status (2)
| Country | Link |
|---|---|
| CA (1) | CA1123196A (en) |
| GB (1) | GB1602946A (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0367434A3 (en) * | 1988-11-01 | 1991-04-10 | Fosbel International Limited | Cermet welding |
-
1978
- 1978-05-30 GB GB2449678A patent/GB1602946A/en not_active Expired
-
1979
- 1979-05-24 CA CA328,436A patent/CA1123196A/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| GB1602946A (en) | 1981-11-18 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |