JP2009543948A - Rod or wire manufacturing system, associated method, and associated product - Google Patents

Abstract

  Cooling unit, heating-cooling operation including cooling unit, rod or wire manufacturing system, method of manufacturing rod or wire, method of heat treatment of rod or wire, method of processing metal, steel rod or steel wire and improved tensile strength A treated metal having is disclosed. The cooling unit includes at least one adaptable quenching area and at least one adaptable immersion area. At least one adaptable quenching zone is quenchable to the immersion temperature. At least one adaptable soaking zone is capable of substantially maintaining the soaking temperature.

Description

This application is a US application Ser. No. 11 / 487,004, filed Jul. 14, 2006, entitled “THERMDYNAMIC METAL TREATING APPARATUS AND METHOD”, which is incorporated herein by reference in its entirety. Is a part of the continuation application.

The present invention relates to a rod or wire manufacturing system that includes at least one heating-cooling unit. The present invention also relates to a method for manufacturing a rod or wire, comprising heating the rod or wire and then cooling it. The present invention further relates to a method of manufacturing a rod or wire comprising the step of heating the rod or wire and then cooling the product resulting from the use of the rod or wire manufacturing system and / or.

BACKGROUND Industrial drawn rods or wires may be composed of various metals or alloys including, but not limited to, aluminum, copper, alloy steel and carbon steel. When constructed using carbon steel, the carbon content can range from about 0.35% to 1.1% by weight. Carbon steel may also include alloying elements such as chromium (Cr), boron (B), silicon (Si) or combinations of these elements.

  Prior to drawing, the material is usually subjected to a heat treatment known as annealing. For carbon steel, heat treatment consists of passing the rod or wire through a heat source such as a furnace and heating the rod or wire from about 930 ° C to 1020 ° C. This high temperature treatment helps to produce a uniform face centered cubic austenite phase with regulated grain size and to determine the ductility of subsequent products. Body cores placed in alternating plates, called perlite, from face-centered cubic austenite, by subsequent cooling in air or more generally in molten lead or fluidized sand Phase transformation to cubic ferrite and orthorhombic cementite occurs. This transformation is abrupt because the section being processed is relatively small (generally less than 3.5 mm). The resulting structure is preferably composed of very fine pearlite without intergranular ferrite or cementite. The fineness of pearlite depends on the chemical nature of the product and the temperature at which the product is reduced after austenitization. When annealed, fine pearlite rods or wires can be drawn to reduce the area by up to 97% and sometimes beyond, resulting in very high drawn filament strength. The final drawn filament strength provides exceptional fatigue resistance, excellent surface quality and an array of cementite plates in the drawing direction due to the very fine pearlite size.

  Heat treated metal bodies with a fluidized bed are known and regulate the thermal conductivity using the temperature of a solid medium such as sand suspended in a gas. The thermal conductivity to the surrounding medium per unit surface area of the rod or wire is determined by the temperature of the medium since the convective heat transfer coefficient is constant for the selected medium.

Heat-treated metal bodies with a liquid lead bath or medium are also known, and the temperature of the liquid lead bath is used to regulate the thermal conductivity. The thermal conductivity to the surrounding medium per unit surface area of the wire is determined by the temperature of the medium.

  Heat treated metal bodies with air are also known and regulate the thermal conductivity using the temperature and velocity of the air.

  However, once the physical properties of the fluid sand or molten lead bath are set, the flexibility of the heat treatment process is limited. When processing helical structure products of different chemical properties, such as SAE 1070 steel and SAE 1090 steel, which require different quenching temperatures, only one temperature can be maintained in either one of the quenching zone or the bath, both It is impossible to accommodate.

  Metal alloys such as alloy steels are produced with many different properties to be used in different industries for different purposes. Durable against steel helix structures and wires, bridge helix structures, prestressed helix structures, galvanized wire drawing, music wires, saw wires and other products used in industrial applications such as vehicle tires in recent years There is an increasing demand for improved performance and strength. With regard to vehicle use, such tires are generally referred to as steel belt radials, which are stronger and ultimately realized as much longer tires than conventional non-belt tires.

  Various companies manufacture tire wire cords used by tire manufacturers, but they are usually supplied on spools and are equivalent to SAE 1070, 1080, 1090 designated standard alloys and the type of steel used Designated non-standard alloys 1090Cr, 1090B, 1090CrB, 1080SiCr with total area reduction in breaking load and final wire drawing.

  It is not uncommon for some of the wires in a steel belt tire to wear, fatigue and break after prolonged use. Tire manufacturers and suppliers strive to improve the quality of steel belt tires by changing manufacturing techniques and testing other less expensive steel compounds, wire diameters, etc. and changing the results.

  In view of the above, new and improved rod or wire manufacturing systems, new and improved heating-cooling operations, new and improved cooling units, new and improved methods of manufacturing rods or wires, while addressing the shortage of the above technical systems, And / or providing new and improved rods or wires would be highly desirable.

SUMMARY OF THE INVENTION The present invention provides a cooling unit, a heating-cooling operation including a cooling unit, a rod or wire manufacturing system, a method of manufacturing a rod or wire, a method of heat treatment of a rod or wire, a method of processing a metal, a steel rod or These and other needs are met by providing any one of steel wires and / or treated metals with improved tensile strength. Such a cooling unit includes at least one heat transfer coefficient adaptable quenching zone and at least one heat transfer coefficient adaptable immersion zone. The at least one heat transfer coefficient adaptable quenching zone is capable of quenching at least one continuous feed rod or at least one continuous feed wire to an immersion temperature. The at least one heat transfer coefficient adaptable dipping zone is capable of maintaining at least one continuous feed rod or at least one continuous feed wire at a substantially dipping temperature so that the heat treatment can be substantially completed. In addition to the cooling unit component, the heating-cooling operation includes at least one heating unit. Such a heating unit is capable of heating at least one continuous supply rod or at least one continuous supply wire to a preselected temperature. When performed as a single operation, the heating-cooling operation also includes at least one supply unit and at least one winding unit. The at least one supply unit is capable of continuously supplying at least one rod or at least one wire. The at least one winding unit is capable of continuously collecting at least one heat treated rod or at least one heat treated wire.

  One aspect of the present invention is to provide a heating-cooling operation that includes a cooling unit or cooling unit that can be used together in a rod or wire manufacturing system. Such a cooling unit includes at least one heat transfer coefficient applicable quenching area and at least one heat transfer coefficient applicable immersion area. The at least one heat transfer coefficient applicable quenching zone is capable of quenching at least one continuously fed rod or at least one continuously fed wire to a soaking temperature. The at least one heat transfer coefficient adaptable dipping area substantially includes at least one continuously fed rod or at least one continuously fed wire at a dipping temperature so that the heat treatment can be substantially completed. It is possible to maintain. In addition to the cooling unit component, the heating-cooling operation includes at least one heating unit. Such a heating unit is capable of heating at least one continuously fed rod or at least one continuously fed wire to a preselected temperature. In the case of an independent operation, the heating-cooling operation further includes at least one supply unit and at least one winding unit. The at least one supply unit is capable of continuously supplying at least one rod or at least one wire. The at least one winding unit is capable of continuously collecting at least one heat treated rod or at least one heat treated wire.

  Another aspect of the present invention is to provide a rod or wire manufacturing system that includes at least one supply unit, at least one heating unit, at least one cooling unit, and at least one winding unit. . At least one supply unit is capable of continuously supplying at least one rod or at least one wire. The at least one heating unit is capable of heating at least one continuously fed rod or at least one continuously fed wire to a preselected temperature. At least one cooling unit downstream of the at least one heating unit includes at least one adaptable quenching zone and at least one adaptable soaking zone. Similarly, the at least one adaptable quenching zone is capable of quenching at least one continuously fed rod or at least one continuously fed wire to a preselected soaking temperature. Similarly, the at least one adaptable dipping area can substantially maintain at least one continuously fed rod or at least one continuously fed wire at a preselected dipping temperature. Thus, the at least one adaptable dipping zone facilitates a substantially complete heat treatment of at least one continuously fed rod or at least one continuously fed wire. The at least one winding unit is capable of continuously collecting at least one heat treated rod or at least one heat treated wire.

Yet another aspect of the present invention is to provide a method of manufacturing a rod or wire. Such methods include supplying, heating, quenching, maintaining at a substantially preselected temperature, and collecting at least one rod or wire. The feeding step can be a continuous feed of at least one rod or at least one wire. The step of heating includes heating at least one continuously fed rod or at least one continuously fed wire to a preselected temperature. The step of quenching includes cooling at least one continuously fed rod or at least one continuously fed wire to a preselected soaking temperature. The step of substantially maintaining the preselected soaking temperature provides at least a foamed liquid quenching agent to substantially complete the heat treatment of at least one continuously fed rod or at least one continuously fed wire. Can be achieved. The collecting step can be a continuous collection of at least one heat treated rod or at least one heat treated wire.

  A further aspect of the present invention is to provide a method for heat treatment of a rod or wire. Such heat treatment includes a heating step, a quenching step, and a dipping step. The step of heating includes heating at least one continuously fed rod or at least one continuously fed wire to a preselected temperature. The step of quenching includes quenching at least one continuously fed rod or at least one continuously fed wire to an immersion temperature. The dipping step provides at least one continuously fed rod or at least one continuously fed wire to a dipping temperature so as to provide at least a foamed liquid quenchant to substantially complete the heat treatment. Substantially maintaining the process.

  Another further aspect of the present invention is to provide a method of treating a metal. The method includes heating, exposing to at least one quenchant, controlling, and removing. The step of heating includes a step of heating the metal. The exposing step includes exposing the heated metal to at least one quenching agent comprising a liquid and a gas or gaseous medium mixture. Controlling includes controlling at least one liquid / gas or gaseous medium mixture. The removing step includes removing the treated metal from the quenching agent.

  Yet another further aspect of the present invention is to provide a steel rod or steel wire comprising at least about 39 area percent fine pearlite. In another aspect, such steel rods or wires comprise up to about 45 area percent fine pearlite.

  An alternative aspect of the present invention is to provide a treated metal having improved tensile strength. Such metals can be formed by heating, leading to at least one liquid and gas or gaseous medium mixture, and removing. The step of heating includes the step of heating the metal to a selected temperature. The step of directing includes directing the heated metal into at least one liquid and a gas or gaseous medium mixture to treat the metal. The removing step includes removing the treated metal from the at least one liquid and / or gaseous medium mixture.

  These and other aspects, advantages, and salient features of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

Figure 3 shows a side view schematic of a cooling unit including a heating unit according to an aspect of an embodiment of the present invention that can be used with the rod or wire manufacturing system of Figure 2; 1B shows a schematic plan view of the cooling unit of FIG. 1A. FIG. 3 shows a cross-sectional schematic detail of a cooling unit according to an aspect of an embodiment of the present invention that can be used with the rod or wire manufacturing system of FIG. 1 shows a schematic side view of a rod or wire manufacturing system according to an aspect of an embodiment of the present invention. FIG. Figure 3 shows a graph of air / water volume percent convection coefficient for a quenchant mixture. Figure 2 shows a typical time-temperature transformation (TTT) curve for SAE 1080 steel. Figure 2 shows a typical time-temperature transformation (TTT) curve for co-folded steel. 1 shows a first time-temperature transformation (TTT) curve for SAE 1070 steel. Figure 2 shows a second time-temperature transformation (TTT) curve for SAE 1070 steel. Figure 3 shows a third time-temperature transformation (TTT) curve for SAE 1070 steel. Figure 3 shows true stress strain curves for FBP products, PBP products, LQF products (products according to aspects of embodiments of the invention). The microstructure analysis results for PBP products and LQF products are shown.

Detailed Description of the Invention In the following description, identical reference characters designate identical or corresponding parts throughout the several views shown in the figures. It is also understood that terms such as “top”, “bottom”, “outside” and “inside” are terms used for convenience and should not be interpreted as limiting terms.

  Referring to the entire drawing and in particular to FIGS. 1A, 1B, 1C and 2, the illustration is intended to illustrate one or more aspects and / or embodiments of the invention and is intended to limit the invention. It will be understood that not. As best seen in FIG. 2, a rod or wire manufacturing system, indicated generally at 10, is shown configured according to the present invention. The rod or wire manufacturing system 10 includes at least one supply unit 14, at least one heating-cooling operation 12, and at least one winding unit 16. The rod or wire manufacturing system 10 includes one or more wire drawing units 20, 20 'and 20 ", one or more cleaning units 24 and 24", one or more coating units 26, and one or more strand units. It will be understood that other components such as one or more finishing or coupling units, such as 30, may be included. Further, the rod or wire manufacturing system 10 includes some of the components depicted in FIG. 2, all of the components depicted in FIG. 2, components added to those depicted in FIG. 2, or any combination thereof. It will be appreciated that you get. As will be appreciated, FIG. 1A, FIG. 1B, FIG. 1C and FIG. 2 do not fully illustrate all mechanical, electrical and / or other components as used herein. Absent. For example, one such as one or more drawing units 20, 20 ′ and 20 ″, one or more cleaning units 24 and 24 ″, one or more coating units 26, and one or more stranded units 30. These finishing or coupling units can be standard to those skilled in the art and can vary in size, shape and efficiency depending on the specific requirements.

The rod or wire manufacturing system 10 shown in FIG. 2, operating with the supply unit 14, is provided with one or more rods or wires 11, while the winding unit 16 is an aspect of an embodiment of the present invention. Now collect one or more intermediate or finished product 18, which may be one or more heat treated rods or wires 11. Between the units 14 and 16, one or more rods or wires 11 are carried, for example, through a first wire drawing unit 20 to supply an intermediate product 17. Such an intermediate product 17 is subjected to a first heating-cooling operation 12 to anneal and quench the intermediate product 17 and in turn produce another intermediate product 17 '. This other intermediate product 17 'can then be transported to a second wire drawing operation 20' to supply the intermediate product 17 ". One or more intermediate products 17, 17 by each unit performing one or more operations. It will be appreciated that ′, 17 ″,... 17 ⁽ⁿ⁾ , 17 ⁽ⁿ⁻¹⁾ can be produced.

As mentioned above, at the end of the rod or wire manufacturing system 10, the winding unit 16 collects one or more intermediate or finished products 18 that can be used individually as feedstock in further manufacturing steps. Or alternatively, such as by using the strand unit 30 shown in FIG. 2 to produce an intermediate product or finished product 18 that is used in a joined or bonded form as a feedstock in a further manufacturing process, etc. It can be joined or combined in one or more operations. To that end, the intermediate product or finished product 18 includes wires (eg, but not limited to animal wires, trellises, including but not limited to fence wires: cattle enclosures, sheep enclosures, horse enclosures, rabbit enclosures, etc.). , Horticultural wires, including but not limited to marine wire cages, aquaculture wires, bright wires, galvanized wires, chain mesh wires, mechanical spring wires, nail wires, concrete reinforced wires ...), rods and And / or bars (eg, coiled rods, straight rods, circular shapes, square shapes, hexagonal shapes, deformed bars, flattened, lightweight structures, etc.), reinforcements (eg mesh bars, reinforced bars, mining meshes, industrial meshes, Agricultural mesh, etc.), steel in concrete (roads, bridges, tunnels, residences, residential buildings, Warehouses, shopping centers, factories, accessories, complete pipes, railway sleepers, etc.), mining (eg, tow rope, shovel rope, formation control belt, formation control mesh, cable belt, etc.), manufacturing (eg, rail clips, Including but not limited to general springs, mattress coils and / or springs ... etc., including but not limited to welding, screens, grids and sheds, including but not limited to welding electrodes and / or welding wires. Automobiles including, but not limited to, but not limited to fasteners, including but not limited to nail and other fasteners, springs, tire cords, tire bead wires, other steel tire reinforcements, bright bars, etc. ) Such that it may contain any one of It may be used, or may be included therein, but is not limited thereto.

1A and 1B illustrate a heating-cooling operation 12 as a top view and a top view, respectively, according to aspects of the present invention. Similar to FIG. 2, FIGS. 1A and 1B provide one or more rods or wires 11 to one or more heating units 32, 32 ', bringing one or more rods or wires 11 to a preselected temperature. A supply unit 14 for heating is shown. After the one or more rods or wires 11 are heated to a preselected temperature, one or more adaptable quenching zones 36, ..., 36 ^(n-1) and one or more adaptable immersion zones 37, ... , 37 ⁽ⁿ⁻¹⁾ , 37 ⁽ⁿ⁾ are supplied to the cooling unit 8.

One or more heated rods or wires 11 may enter one or more adaptable quenching zones 36, 36 ^(n-1) upon exiting the heating unit 32 ', as shown in FIGS. 1A and 1B. 1A, 1B and 1C show a second cell type 90 in a quenchant tank 40 according to an aspect of an embodiment of the present invention used as one or more adaptable quenching zones 36, 36 ^(n-1). . FIG. 1C shows further details for the second cell type 90. For example, the second cell type 90 may be capable of supplying the quenching agent as a liquid that overflows above the upper level of the second cell type 90, for example. The flow of the liquid quenchant 38 is controlled by a second heat transfer regulator 50 that includes a liquid quencher supplier 52 such as a pump and a regulating mechanism 54 such as a valve, a flow meter or a valve combined with a flow meter. Can be done.

Applicant adjusts the flow rate of the liquid quenchant 38 to the second cell type 90 in the adaptive quench zone 36, 36 ⁽ⁿ⁻¹⁾ to pass through the liquid quenchant 38 and the overflowing liquid quencher 38. It has been found that the thermal conductivity coefficient between one or more traveling rods or wires 11 can be adjusted. In particular, Applicants have found that the flow rate of the liquid quenchant 38 interacting with the rod or wire 11 can affect the coefficient of thermal conductivity at the wire quenchant interface. Applicants have shown that as the quenching agent flow rate increases, the tendency to form a boiling film (also referred to as film boiling or film water cooling) at the rod or wire 11 / liquid quenching 38 interface decreases and the rod or wire progressing. Since the wire 11 and the liquid quenchant 38 are in closer contact, it is believed that the thermal conductivity coefficient at such an interface can be increased.

  In addition to adjusting the heat transfer coefficient to adjust the rate of heat removal from the proceeding rod or wire 11, the composition of the hot liquid quenchant 38 is changed to produce a smaller or larger heat transfer coefficient, and thus It will be appreciated that the heat removal rate may be adjusted by producing a smaller or greater heat removal rate.

In addition to adjusting the heat transfer coefficient to adjust the rate of heat removal from the traveling rod or wire 11, the temperature of the liquid quenchant 38 is preselected to produce a smaller or larger temperature difference, and thus It will be appreciated that the heat removal rate can be adjusted by producing smaller or larger temperature gradients. Thus, the adaptive quench zone 36, 36 ^(n-1) according to aspects of an embodiment of the present invention can be achieved through independent operation of the thermal conductivity coefficient or liquid quenchant 38 temperature, or through the thermal conductivity coefficient and liquid quenching. One or more adjustable quenching zones 36, 36 ^(n-1) having the function of adjustable heat removal rate which can be adjusted substantially continuously through the combined operation of the agent 38 temperature. obtain.

Alternatively, the one or more adaptable quenching areas 36, 36 ^(n-1) may contain a quenching agent, such as a foam (eg, formed by trapping many bubbles in the liquid quenching agent 38), A second cell type 90 that can be fed above the upper level of the second cell type 90 may be used. The amount of gas trapped in the liquid quenchant 38 as bubbles is a valve, flow rate in communication with a gas medium supply 44, such as a blower or a compressed gas source, and a diffuser 82 including a porous medium 84 submerged in the quenchant 38. It can be controlled by a first heat transfer regulator 42 which includes a regulating mechanism 46 such as a valve combined with a meter or flow meter. Further details of the heat transfer regulator 42 in communication with the second cell type 90 are shown in FIG. 1C, and a gas medium washer that cleans the gas supplied by the gas medium supply 44, pressure equalizer 47, and pressure regulator 48. 45 may be included. Note that the gas medium supply 44, the pressure equalizer 47, and the pressure regulator 48 are all supplied with a preselected gas volume to the diffuser 82 at a preselected pressure to produce a foam composition (eg, liquid quenching agent 38). The amount of gas trapped as bubbles to produce a foam) and / or volume can be adjusted to obtain a preselected thermal conductivity.

  A further feature of the second cell type 90 is shown in FIG. 1C, in which a liquid quenchant 38 is fed through the quenchant feeder 52 at an appropriate volume and pressure to allow the upper level of the second cell type 90 to rise. The ability to overflow the liquid quenching agent 38 and the liquid quenching agent supply unit 52 from the quenching agent tank 40 when the liquid quenching agent 38 is supplied as foaming above the upper level of the second cell type 90. And the ability to supply quenching agent 38 by passing through. In aspects of embodiments of the present invention, such flexibility is a mechanism that allows the volume fraction of the second cell type 90 to be separated from the quenchant tank 40 while receiving the liquid quenchant 38 from the quencher supply 52. Alternatively, it can be achieved by using a selector 94 (such as a three-way valve as shown in FIG. 1C). Alternatively, such a mechanism or selector 94 (such as a three-way valve as shown in FIG. 1C) allows the volume fraction of the second cell type 90 to be quenched when the liquid quenchant 38 is supplied as a foam. In communication with the agent tank 40, the liquid agent 38 can be received from the agent tank 40. Applicants have also noted that region 96 (eg, defined by the space between the wall of the second cell type 90 and the wall of the diffuser 82) in order to be able to achieve a suitable liquid quenchant 38 flow rate. Has been found to be at least twice the cross-sectional area of the supply line 92.

After one or more rods or wires 11 have traveled through one or more adaptable quenching zones 36, 36 ^(n-1) , one or more rods or wires 11 have one or more adaptable immersion zones 37. ,... Travels through 37 ^(n-1) , 37 ⁽ⁿ⁾ . 1A, 1B and 1C show a quenchant tank according to another aspect of an embodiment of the present invention for use as one or more adaptable immersion zones 37, ... 37 ^(n-1) , 37 ^(n). A first cell type 80 within 40 is shown. FIG. 1C shows further details regarding the first cell type 80. For example, the first cell type 80 supplies the quenching agent, for example, as a foam (eg, formed by trapping many bubbles in the liquid quenching agent 38) above the upper level of the first cell type 80. It may be possible to do. The amount of gas trapped in the liquid quenchant 38 as bubbles is a valve, flow rate in communication with a gas medium supply 44, such as a blower or a compressed gas source, and a diffuser 82 including a porous medium 84 submerged in the quenchant 38. It may be controlled by a first heat transfer regulator 42 that includes a meter, or a regulating mechanism 46 such as a valve combined with a flow meter. Further details of the heat transfer regulator 42 in communication with the first cell type 80 are shown in FIG. 1C, and a gas medium washer that cleans the gas supplied by the gas medium supply 44, the pressure equalizer 47, and the pressure regulator 48. 45 may be included. Note that the gas medium supply 44, the pressure equalizer 47, and the pressure regulator 48 are all supplied with a preselected gas volume to the diffuser 82 at a preselected pressure to produce a foam composition (eg, liquid quenching agent 38). The amount of gas trapped as bubbles to produce a foam) and / or volume can be adjusted to obtain a preselected thermal conductivity.

Applicant adjusts the flow rate of gas to the first cell type 80 in the adaptable immersion zone 37, ... 37 ^(n-1) , 37 ⁽ⁿ⁾ , through the foam quench and the foam quench. It has been found that the thermal conductivity coefficient between one or more traveling rods or wires 11 can be adjusted. In particular, Applicants have found that the flow rate of the gas used to produce a foam quench that interacts with the rod or wire 11 can affect the thermal conductivity coefficient. Applicants tend to reduce the amount of intimate contact between the proceeding rod or wire 11 and the foam liquid quenching agent 38 as the flow rate of the gas used to produce the foam quenching agent increases. Found that there is. Therefore, the thermal conductivity coefficient is reduced.

  In addition to adjusting the heat transfer coefficient to adjust the heat removal rate from the advancing rod or wire 11, the heat removal rate can be changed by changing the composition of the liquid quenchant 38 to produce a smaller or larger heat transfer coefficient. It will be appreciated that the heat removal rate can be adjusted by producing and thus producing a smaller or greater heat removal rate.

In addition to adjusting the heat transfer coefficient to adjust the rate of heat removal from the advancing rod or wire 11, by pre-selecting the temperature of the liquid quenching agent 38 used to produce the foam quenching agent, It will be appreciated that the heat removal rate can be adjusted. Thus, according to aspects of embodiments of the present invention, the adaptable immersion zones 37, ... 37 ^(n-1) , 37 ⁽ⁿ⁾ are independent of each other and / or the adaptive quench zones 36, 36 ^{(n-1 If)} independently from containing quenchant tank 40, through the independent operation of the composition of the heat transfer coefficient or liquid quenchant 38 temperature or liquid quenchant 38, or above or any combination of the combination operation ( For example, manipulation of thermal conductivity coefficient and liquid quenching agent 38 temperature, manipulation of liquid quenching agent 38 composition and liquid quenching agent 38 temperature, manipulation of thermal conductivity coefficient and liquid quenching agent 38, thermal conduction coefficient and liquid quenching agent 38 One or more adaptable immersion zones 37, ... 37 having the function of an adjustable heat removal rate which can be adjusted substantially continuously via the manipulation of the temperature and the composition of the liquid quenchant 38) ^(N-1) , 37 ⁽ⁿ⁾ may be provided.

  Additional features of the second cell type 90 and the first cell type 80 are shown in FIG. 1C, where the diffuser 82 is removably attached using the socket 86 to attach the diffuser 82 to either cell type 80,90. Including the ability to provide ease of installation and / or replacement. Although not shown, the socket 86 may be created by providing one or more detents to accommodate one or more seals (eg, O-rings) on either the inner periphery or the outer periphery. Will be understood. For one or more perimeter detents, after installation of one or more seals (eg, O-rings), a conduit having an inner circumference substantially coincident with the outer circumference may be engaged with the socket 86. In the case of one or more inner detents, a conduit having an outer periphery substantially coincident with the inner periphery may be engaged with the socket 86 after the installation of one or more seals (eg, O-rings). It will be appreciated that the one or more detents may be formed on the circumference rather than the socket 86.

The diffuser 82 of the second cell type 90 and the first cell type 80 is capable of supplying a large amount of gas to cause bubble trapping in the liquid quenchant 38 to produce a foamed quenchant. Any design is acceptable. To that end, the Applicant must
Commercially available from EEP (based in Tulsa, OK, Houston, TX, Shelby, NC, St. Catharines, Ontario, Canada, and Dalton, GA), and as POROPLATE (R) sintered laminated screen packs We have found that porous media 84, such as those sold, will function. Applicants may also allow the outer surface of the porous medium 84 of the diffuser 82 to be submerged in the quenching agent tank 40 by an amount that is substantially slightly below the surface of the liquid quenching agent 38 of the quenching agent tank 40. I found. Similarly, applicants may suffice if, for example, the pressure in pressure equalizer 47 and / or pressure regulator 48 is only slightly higher than the height of liquid quenchant 38 above the outer surface of porous medium 84 of diffuser 82. I found out. Further, Applicants have noted that the trapping of the liquid quenchant 38 gas in producing the foam quenchant results in such recirculation of the liquid quenchant 38 in the quenchant tank 40, and the temperature of the liquid quenchant 38 is maintained throughout. It has been found that it can be substantially uniform.

With respect to the liquid quenchant 38 in the quenchant tank 40, one or more adaptable quenching zones 36, 36 ^(n-1) and / or one or more adaptable soaking zones 37, ... 37 ^(n-1) , 37 Each ⁽ⁿ⁾ can be any liquid or liquid mixture capable of functioning for its intended purpose. Referring also to FIGS. 1A, 1B, and 1C, the liquid quenching agent 38 may include one or more second cell types 90 and / or one or more adaptive quenching zones 36, 36 ^(n-1). Or one or more first cell types 80 of one or more adaptable immersion zones 37, ... 37 ^(n-1) , 37 ⁽ⁿ⁾ can each function for its intended purpose. It can be any liquid or liquid mixture. To that end, Applicants must be able to work with water or water mixed with either a RAQ-TWT quenching solution or a RAQ-TWT-2 quenching solution sold by Richard Apex, Inc. of Philadelphia, Pennsylvania. I found. The RAQ-TWT quenching solution has a polyalkylene glycol—about 45.5%, a polyethylene glycol ester—about 12%, a dedicated metalworking fluid additive—about 12%, an antifoaming agent—about 0.5% and water—about 30. Is a proprietary formulation with a typical pH of about 3-9%. The RAQ-TWT-2 quenching solution is substantially the same as the RAQ-TWT-2 quenching solution, but does not contain an antifoaming agent. These quenching solutions can be diluted up to about 90% by volume or more with water prior to use. The measured properties of each quenching solution when added to water at a concentration of about 1% are summarized in Tables 1 and 2 below. It will be appreciated that other commercial quenching liquids or water may be used as well or instead.

Another aspect of the quenching agent tank 40 of the cooling system 8 is a quenching agent level control 60 that may include a quenching agent level setter 62, a quenching agent supply 64, and a quenching agent resupply 66. The quenching agent level control 60 includes one or more adaptable quenching zones 36, 36 ^(n-1) and one or more adaptable soaking zones 37 ... 37 ^(n-1) , 37 ⁽ⁿ⁾ of the cooling system 8. Any structure or any that allows maintaining a predetermined level of liquid quenchant 38 in quenchant tank 40 so as to be able to operate in the various modes or methods described herein. It will be understood that it can be a combination of structures. To that end, FIGS. 1A and 1B show the quencher level setter 62 as a conduit toward the top of the quenchant tank 40 to allow excess liquid quenchant 38 to flow toward the quenchant supply 64. Show. Similarly, quenchant supply 64 is shown as a tank, while quenching resupply 66 is shown as a pump. In this way, the quencher level setter 62 may include one or more second cell types 90 and one of one or more adaptable quenching areas 36, 36 ^(n-1) , each functioning for that purpose. The level of the liquid quenchant 38 on top of one or more first cell types 80 of the above-described adaptable immersion areas 37, ... 37 ^(n-1) , 37 ⁽ⁿ⁾ may be maintained.

  According to aspects of an embodiment of the present invention, it may be desirable to adjust the temperature of the liquid quenchant 38 so that the thermal conductivity from one or more rods or wires 11 can be adjusted. . To that end, one or more temperature regulators (not shown in FIGS. 1A, 1B and 1C) are added to the quenchant tank 40, the quenchant supply 64, or any one of the quenchant tank 40 and the quenchant supply 64. It may be desirable to provide it. According to various aspects of this embodiment, such one or more temperature regulators could include a heater, a cooler, or a heater and a cooler. Further, it will be understood that one or more such temperature regulators are commercially available.

According to another aspect of an embodiment of the present invention, the plurality of rods or wires 11 includes one or more heating-cooling operations 12, 12 ', or the rod or wire manufacturing system 10 shown in FIG. It can be processed using any of the heating-cooling operations 12 shown in 1A and FIG. 1B. For example, a bundle of wires having about 5 to 90 or more wires per bundle could be processed simultaneously during normal production. Other metal helical structural materials could be treated as well. Such a plurality of rods or wires 11 may advantageously include a plurality of rods or wires 11 chemistry, a plurality of rods or wires 11 chemistry, or a plurality of rods or wires 11 chemistry and diameter. In operation, Applicant believes that rods or wires 11 having substantially the same chemistry and / or substantially the same diameter could be carried as a bank. For example, FIG. 1A shows one or more rods or wires 11 with one or more heating units 32, 32 ', one or more adaptable quenching areas 36, 36 ^(n-1) , one or more adaptable immersions. A bank is shown as the area 37,... 37 ⁽ⁿ⁻¹⁾ , 37 ⁽ⁿ⁾ , and at least one supply unit 14 supplying the corresponding at least one winding unit 16. As a further example, FIG. 1A shows that one or more rods or wires 11 are connected to one or more heating units 32 _(k) , 32 ' _(k) , one or more adaptable quenching zones 36 _(k) , 36 ^{(n -1)} _(k) , supplied to one or more adaptable immersion zones 37 _(k) , ... 37 ^(n-1) _(k) , 37 ⁽ⁿ⁾ _(k) and corresponding at least one winding unit 16 A second bank is shown as at least one supply unit 14. One or more heating-cooling operations 12, 12 ′ of the rod or wire manufacturing system 10 shown in FIG. 2 or the heating-cooling operation 12 shown in FIGS. 1A and 1B may include one or more heating-cooling operations 12, It will be understood that such a function may be provided as a result of the 12 'independent adjustment function. In particular, the independent adjustment function described above can result from an independent adjustment function within one or more heating-cooling operations 12, 12 '. As mentioned above, the heat removal rate is determined for one or more of the adaptive quenching zones 36, 36 ^(n-1) and one or more of the adaptive soaking zones 37, ... 37 ^(n-1) , 37 ⁽ⁿ⁾ . It can be adjusted independently for each. In addition, the first number of adaptive quenching zones 36, 36 ^{(n-1) and} the second number of adaptive immersion zones 37, ... 37 ^(n-1) , 37 ⁽ⁿ⁾ in one bank are: A third number of adaptable quenching areas 36, 36 ^(n-1) and adaptable immersion areas 37 of another bank, which may be defined to suit the characteristics of the first rod or wire diameter and composition, ... a fourth number of 37 ^(n-1) , 37 ⁽ⁿ⁾ may be defined to suit the characteristics of the second rod or wire diameter and composition. To that end, the cooling unit 8 changes the length of the adaptive quenching zone 36, 36 ^(n-1) and / or the length of the adaptive immersion zone 37, ... 37 ^(n-1) , 37 ^(n). It will be appreciated that it has additional adjustment capabilities through capabilities.

In one aspect of an embodiment of the present invention, one or more adaptable quenching zones 36, 36 ^(n-1) supply either overflow liquid quenching agent or foaming liquid quenching agent, while one or more. 37 ^(n-1) , 37 ⁽ⁿ⁾ supply the foamed liquid quenching agent. In another aspect of embodiments of the present invention, one or more adaptable quenching zones 36, 36 ^(n-1) supply a foamed liquid quenching agent, while one or more adaptable soaking zones 37 ... 37 ^{(n -1)} and 37 ⁽ⁿ⁾ supply foamed liquid quenching agent. In yet another aspect of an embodiment of the present invention, one or more adaptable quenching zones 36, 36 ^(n-1) supply a foamed liquid quenching agent, while one or more adaptable soaking zones 37, ... 37 ^(n-1) and 37 ⁽ⁿ⁾ supply either a foamed liquid quenching agent or a gas quenching agent such as air or an inert gas. In yet another aspect of an embodiment of the present invention, one or more adaptable quenching zones 36, 36 ^(n-1) supply an overflowing liquid quenching agent, while one or more adaptable soaking zones 37, ... a part of 37 ^(n-1) , 37 ⁽ⁿ⁾ is supplied with a foamed liquid quenching agent, and one or more other applicable immersion zones 37, ... 37 ^(n-1) , 37 ⁽ⁿ⁾ other The part supplies a gas quenching agent such as air or an inert gas.

Another aspect of embodiments of the present invention is the rod or wire manufacturing system 10 shown in FIG. 2, including one or more heating-cooling operations 12, 12 ', or the heating-shown in FIGS. 1A and 1B. A controller 70 is included that can communicate with one or more of any unit or component of the cooling operation 12. Such a controller 70 regulates, for example, the speed of the rod or wire payout from the supply unit 14 and the winding speed of the intermediate or finished product 18 by the winding unit 16, thereby providing one or more rods or wires. As 11 travels through heating units 32, 32 ′ and cooling unit 8, it may have the function of exerting a predetermined tension on one or more rods or wires 11. The controller 70 is also in communication with any of the various heat transfer regulators 42, 50, for example, the heat transfer coefficient, the liquid quenchant 38 temperature, the number of adaptable quench zones 36, 36 ^(n-1) , adaptable. It may be configured to allow adjustment of the thermal conductivity by changing the number of immersion zones 37, ... 37 ^(n-1) , 37 ⁽ⁿ⁾ or any combination of any of the foregoing as appropriate.

  The controller 70 may be a commercially available controller with multiple inputs and outputs that meet the requirements of any peripheral device. The controller 70 can be any one of a microcontroller, a PC with appropriate hardware and software, and a combination of one or more thereof. Details regarding the controller that may be used in the rod or wire manufacturing system 10 or in one or more heating-cooling operations 12, 12'a are disclosed in US Pat. No. 5, for example, the entire disclosure of each of which is incorporated herein by reference. 980,078, 5,726,912, 5,689,415, 5,579,218, 5,351,200, 4,916,600 4,646,223, 4,344,127 and 4,396,976.

Although not shown in FIGS. 1A and 1B, the temperature of the one or more rods or wires 11 is such that one or more of the one or more heating units 32, 32 ′, respectively, one or more adaptable quenching zones 36, 36 ⁽ each of ^n-1) , via one or more of one or more adaptable immersion areas 37 ... 37 ^(n-1) , 37 ⁽ⁿ⁾ , or any one of any combination described above, May be measured using, for example, an optical type pyrometer or any other suitable alternative type, such as a thermometer such as Raytex Equipment Company Raytex 500-1100 ° C. proximity focus fiber optic type from Houston Texas . Thus, the aspect of the heating-cooling operation 12 could be adjusted to correspond to a level appropriate to obtain a predetermined or desired intermediate or finished product 18. Alternatively, the rod or wire 11 temperature can be measured while installing the system, operation, unit and / or area when the rod or wire 11 is initially fed to the system. In this case, temperature measurements of the rod or wire 11 may be made as it progresses through the operations, units and / or areas, or thereafter, so as to set the appropriate level for each operation.

  For an understanding of aspects and embodiments of the present invention, Applicants provide the following non-limiting examples. A heating-cooling operation 12 including the supply operation 14, the heating unit 32, the cooling unit 8, and the winding unit 16 was configured. The heating unit 32 (eg, Thermcraft, length 6 ′, 1600 ° C. tube furnace manufactured by Thermcraft, Inc. of Winston Salem, North Carolina 27177-2037) is a temperature measuring device (Windsor, New Jersey, 08561-0479). Equipped with a Pyrometer Instrument Company (pyrometer (700-1400 ° C.)), the temperature of the wire 11 was measured when it was discharged, as an adaptive quenching zone 36 and an adaptive dipping zone 37, the cooling unit 8 is Contains 5 consecutive cells.

  The first cell (20) is substantially the type of the second cell type 90 shown in FIG. 1C, and is further pre-selected as a heat source (eg, rated at 240V, 4.5Kw, about 100 ° C., etc. A three-phase conventional electric immersion heater sized to maintain a liquid quenchant at temperature. As the adjustment mechanism 46 of the heat conduction regulator 42, the cooling unit 8 includes a gas medium supply 44 (for example, a rated XPXPSI ACSI digital pressure gauge (part number 1200-0030, 602056), Ashcroft.com (Ashcroft, Inc) 0 Air regulator (Michigan City, Indiana Dwyer Instruments, Inc. rated 0-50 L / min) in communication with a ~ 200 PSF barometer and a Speedair 2Z767D, 200 PSI 125 ° F air regulator (sold at Grainger.com) Dwyer Air Flow meter). The cooling unit 8 includes a quenching agent supply 52 (Bell & Gossett NBF-220 110 ° C., 15 PASI, 115 V, 2 Watt (P83033 model) recirculation pump, etc.) as the adjustment mechanism 54 of the heat conduction controller 50. The four subsequent cells (21, 22, 23, and 24) are substantially the same type as the first cell type 80 shown in FIG. 1C, and also have a heat source (eg, rated 240V, 4.5Kw, three-phase Conventional electric immersion heater).

  A coil of wire 11, a conventional steel wire designated 1090 with a nominal diameter of 2.0 mm (eg AISI-SAE alloy steel designation) or alternatively 1070 with a nominal diameter 1.2 mm (eg AISI- SAE alloy steel designation) is mounted in the supply operation 14 as well as typical waterfall industrial processing operations. The wire 11 is supplied through a heating unit 32 for heating the wire 11 made of, for example, steel to about 930 to 1020 ° C. The heated wire 11 is then slightly above the first cell (20) configured to operate as an adaptive quenching area 36, for example, by a roller guide (not shown in FIGS. 1A and 1b). Where the liquid quenchant 38 covers the top surface of the first cell by introducing a gaseous medium into the liquid quenchant 38 resulting in a foamed liquid quenchant that substantially completely covers the wire 11. To be moved. The wire 11 proceeds continuously through the foamed liquid quenchant over the upper surface of the subsequent four cells (21, 22, 23 and 24). The first of the subsequent four cells can be configured as either an adaptive quenching zone 36 or an adaptive soaking zone 37, while the second through fourth of the following four cells are typically adaptable soaking zones. 37. After passing through the fourth (24) foamed liquid quenchant of the subsequent four cells, the wire 11 is dried by evaporation through air to form an intermediate or finished product 18 (eg, a processing wire). It passes through the roll guide and is wound on a reel take-up unit 16 at the end of the heating-cooling operation 12.

  As described above, a gaseous medium (eg, one or more substantially inert gases, one or more reactive gases, or one or more inert gases and one or more reactions) supplied by the gaseous medium supply 44. Any one of the sex gases may be suitable) to form a foamed liquid quenchant. The amount of gaseous medium trapped in the liquid quenchant 38 can be varied, for example, by adjusting the forced convective heat transfer coefficient by changing the gas medium flow rate and / or the volume fraction of the trapped gaseous medium. For example, FIG. 3 represents the change in the convective heat transfer coefficient for air trapped in the liquid quenchant 80, where the air is estimated to be about 0.5 W / (sq.m * K) Agent 80 (eg, substantially air-free water) is about 10,000 W / sq. m * K). Such a forced convection heat transfer coefficient can change linearly as the amount of air trapped in the liquid quenchant 80 (eg, water) changes as shown in FIG.

  FIG. 4 represents a typical time, temperature, transformation (TTT) curve for 1080 steel (eg, AISI-SAE alloy steel designation). The desired structure for industrial drawing of 1080 steel is to heat 1080 steel to a certain temperature (about 930-1020 ° C.) for a sufficient time to obtain a sufficiently uniform structure in a stable austenite field, after which an unstable austenite Theoretically developed by heat treatment, including rapidly cooling austenitized 1080 steel wire to about 540 ° C. (eg, about 1 second) while still in the field and staying on the left hand side of all curves shown in FIG. The Once at about 540 ° C., the 1080 steel wire is maintained at about 540 ° C. for a suitable time (eg, about 6 seconds), and unstable austenite to a pearlite structure (eg, ferrite and cementite phases) having a predetermined morphology It would be desirable to control structural transformations. Once a predetermined form is obtained, it may be desirable to preserve it, for example, by further cooling the advancing rod or wire. In a manufacturing environment, this can be very difficult. This is because it is difficult to rapidly heat and cool the rod or wire that proceeds in the first moment, and it is currently difficult to keep the traveling rod or wire substantially isothermal. In particular, even though the heating unit and / or cooling unit may be maintained substantially isothermal, heating the rod or wire that progresses to raise its temperature in a manner that is currently virtually unaccountable. Possible transformational heat is accompanied by a phase transformation of the rod or wire (eg, unstable austenite to pearlite).

FIG. 5 shows a TTT curve for co-folded steel (iron / carbon steel with about 0.8 to 0.83 carbon) and treatment of rods or wires with such composition to obtain the desired structure. It shows that there can be at least three different rates of heat removal zone at times. According to aspects of an embodiment of the present invention, such different rates of the heat removal region may include one or more adaptable quenching zones 36, ..., 36 ^(n-1) and one or more adaptable soaking zones 37, ..., 37 ^(n-1) , 37 ⁽ⁿ⁾ may be provided using a heating-cooling operation 12 having. To that end, FIG. 5 shows such one or more adaptable quenching zones 36, ... 36 ^(n-1) and one or more adaptable soaking zones 37, ..., 37 ^(n-1) , 37 ⁽ⁿ⁾ . A guide can be provided on how to identify and obtain the desired structure.

  If the thermal conductivity is mainly due to convection, this is typically abundant in industrial work, but theoretically the thermal conductivity (Q) per unit surface area (A) for the surrounding medium is Can be expressed as:

1. Where (1) Q / A is the ratio (Q) of heat conducted to the surrounding medium per unit surface area (A) of the rod or wire (Q / A is sometimes also called the heat flow rate)
2. Tw is the temperature of the traveling rod or wire,
3. Tm is the temperature of the medium that absorbs or receives heat (eg, liquid quenching agent, foam quenching agent, gas quenching agent, etc.),
4). h is the convective heat conduction coefficient.

This simplification of the complex situation may involve one or more adaptable quenching zones 36, ..., 36 ^(n-1) and one or more adaptable immersion zones 37, ..., 37 ^(n-1) , 37 ⁽ⁿ It will be understood that it can be used as a guide to identify the type and number of ⁾ . Once the type and number are identified, this simplification can be used as a guide to identify how such varying thermal conductivity can be achieved. For example, as discussed herein, the heat flow rate can be changed by changing either one of the thermal conductivity coefficient (h), the temperature difference (Tw−Tm), or both. Similarly, as discussed herein, the coefficient of thermal conductivity (h) is most ascribed to one or more quenchant compositions, quenchant forms, quenchant compositions and quencher forms, quenchant heat capacities, advancing rods or wires. It can be varied by changing the rate at which the near quenching agent is fed or refreshed.

  For example, high thermal conductivity may be desired to reduce the advancing rod or wire temperature from about 930-1020 ° C. to 540 ° C. in a short time (eg, less than about 1 second). To do so, some of the above options are useful for increasing the heat flux in region (60) of FIG. It appears that there may be gain in heat flux by manipulating the temperature of the liquid quenchant 38 to achieve a larger temperature difference (Tw-Tm). It also appears that there may be a greater gain in heat flux by manipulating the convective heat transfer coefficient in region (60) of FIG. Accordingly, at least one adaptable quench zone 36 can be identified.

In region (61) of FIG. 5, the advance rod or wire 11 should be kept substantially isothermal. However, to do so, it would be desirable to account for heat dissipation from the austenite to the rod or wire 11 by the pearlite transformation (eg, exothermic transformation). There appears to be a challenge with heat flux control by manipulating the temperature of the liquid quenchant 38 to achieve a greater temperature difference (Tw-Tm). Alternatively, there seems to be a better gain in heat flux by manipulating the convective heat transfer coefficient in region (60) of FIG. Accordingly, at least one adaptable quenching zone 36 or at least one adaptable soaking zone 37 or at least one so as to be suitable to keep the rod or wire 11 proceeding to the temperature during the exothermic reaction from austenite to pearlite. An adaptive quench zone 36 and at least one adaptable immersion zone 37 could be identified.

  In the region (62) of FIG. 5, the advancing rod or wire 11 should be kept substantially isothermal, for example to substantially complete the transformation of austenite to pearlite and then cooled at a safe working temperature. It is. Here, the heat flux is either by manipulating the temperature of the liquid quenchant 38 to achieve a larger temperature difference (Tw-Tm) or by manipulating the convective heat transfer coefficient in region (62) of FIG. It seems desirable to have an option to control Thus, at least one adaptable immersion area 37 could be identified to be suitable for controlling the temperature of the traveling rod or wire 11.

  Some examples of cooling units 8, methods and / or heating-cooling operations 12 according to aspects of embodiments of the present invention, including AISI-SAE 1090 steel, are provided in Table 3 below.

As can be seen from the data in Table 3, a nominal 2 mm diameter AISI-SAE 1090 steel wire comprises a plurality of cells (20-24) configured as at least one adaptable quench zone 36 and at least one adaptable soak zone 37. When processed using the included heating-cooling operation 12, the breaking load and tensile strength of such wire 11 can be adjusted. In particular, a heated nominal 2 mm diameter AISI-SAE 1090 steel wire can be used with a liquid quenchant 38 (eg, consisting of water mixed with a RAQ-TWT quenching solution as described above) and a gaseous medium (eg, Air supply) to a plurality of cells (20-24) and thereby to a cooling unit 8 including a regulating mechanism 46 of a gaseous medium supply 44 for forming various foamed liquid quenchant configurations. It was.

  In Example 1 summarized in Table 3, when a nominal 2 mm diameter wire (1090 steel) is processed using a cooling unit 8 comprised of four of a plurality of cells (20-24), 3600 Newton ( A treated wire having a breaking load of N) and a tensile strength of 1192 megapascals (MPa) was produced. In Example 6 summarized in Table 3, when the same nominal 2 mm diameter wire (1090 steel) is processed using a cooling unit 8 comprised of only two of the plurality of cells (20-24), A treated wire with an increased breaking load of 3947 N and a tensile strength of 1305 MPa was produced. In Example 20, summarized in Table 3, when a nominal 2 mm diameter wire (1090 steel) is processed using a cooling unit 8 comprised of all cells of the plurality of cells (20-24), 4171N Produced a treated wire with an increased breaking load and an increased tensile strength of 1381 MPa. In all of the examples summarized in Table 3, a rod or wire 11 consisting of a nominal 2 mm diameter wire (1090 steel) was carried at a constant wire speed of about 7 meters per minute.

  These examples have shown that by providing a cooling unit 8 constructed in accordance with various aspects of various embodiments of the present invention, an increased breaking load and tensile strength of 1090 wire can be realized. These examples also showed that an improved breaking load and tensile strength of the 1090 wire can be achieved by using methods according to various aspects of various embodiments of the present invention. In addition, these examples have shown that by providing a heating-cooling operation 12 according to various aspects of various embodiments of the present invention, an increased breaking load and tensile strength of the 1090 wire can be realized. A cooling unit 8 configured according to various aspects of various embodiments of the present invention is provided, using methods according to various aspects of various embodiments of the present invention, and / or various embodiments of the present invention. It will be apparent that similar or identical advantages may be achieved when processing rods or wires 11 having any of a variety of different compositions, provided with a heating-cooling operation 12 according to the various aspects of FIG.

  Some examples of the cooling unit 8, method and / or heating-cooling operation 12 according to aspects of embodiments of the invention relating to AISI-SAE 1070 steel are provided in Table 4 below, and FIGS. The corresponding TTT curve is shown.

As can be seen from the data in Table 4, a nominal 1.2 mm diameter AISI-SAE 1070 steel wire comprises a plurality of cells (20-24) configured as at least one adaptable quench zone 36 and at least one adaptable soak zone 37. This was processed using a heating-cooling operation 12 including: Specifically, the heated nominal 1.2 mm diameter AISI-SAE 1090 steel wire is liquid quenching at different rates with liquid quenching agent 38 (eg, consisting of water mixed with a RAQ-TWT quenching solution as described above). An adjustment mechanism 54 of the quenchant supply 52 for supplying the agent 38 to the first cell (20) of the plurality of cells (20-24), and a plurality of gaseous media (eg, composed of air) at different speeds. To the cell (20-24) and thereby to the cooling unit 8 including the adjustment mechanism 46 of the gaseous medium supply 44 for forming various foamed liquid quenchant configurations.

  In Example A, the first cell (20) of the plurality of cells (20-24) was modified to apply about 3/8 inch round spray orthogonal to the traveling rod or wire 11.

  In Examples B-E, the first cell (20) of the plurality of cells (20-24) is about 6 inches flat spray (about 1/8 inch thick) parallel to the traveling rod or wire 11. A) to be applied.

  In Examples F to K, the first cell (20) of the plurality of cells (20 to 24) supplies the liquid quenchant 38 at various flow rates ranging from 1.5 to 3 g / m. Modified, while the advancing rod or wire 11 was wrapped in a nominal 3/8 inch diameter, 4 inch long pipe.

  In Example A summarized in Table 4, processing a nominal 1.2 mm diameter wire (1070 steel) using the configured cooling unit 8 resulted in an increased failure load of 1289 Newtons (N), and 1148 Mega A treated wire having a tensile strength of Pascal (MPa) was produced. In Example D, summarized in Table 4, processing a nominal 1.2 mm diameter wire (1070 steel) using the configured cooling unit 8 has an increased failure load of 1276 N and a tensile strength of 1168 MPa. A processing wire was generated. In Example H summarized in Table 4, a complete liquid quenching agent of the constructed cooling unit 8 and the advancing rod or wire 11 that is heated when guided through a pipe filled with flowing liquid quenching agent 38. Processing a nominal 1.2 mm diameter wire (1070 steel) using a first cell (20) configured to provide 38 immersions resulted in an increased failure load of 1267 N and a tensile strength of 1153 MPa. A processing wire having was produced. In Example I summarized in Table 4, the complete liquid quenching agent of the constructed cooling unit 8 and the advancing rod or wire 11 that is heated when guided through a pipe filled with flowing liquid quenching agent 38. Processing a nominal 1.2 mm diameter wire (1070 steel) using a first cell (20) configured to provide 38 immersions resulted in an increased failure load of 1407 N and a tensile strength of 1234 MPa. A processing wire having was produced. In all of the examples summarized in Table 3, a rod or wire 11 consisting of a nominal 2 mm diameter wire (1090 steel) was carried at a constant wire speed of about 12.5 meters per minute.

These examples show that by providing a cooling unit 8 constructed according to various aspects of various embodiments of the present invention, an increase in the breaking load and tensile strength of the 1070 wire can be realized. These examples also show that an improved breaking load and tensile strength of 1090 wire can be realized by using methods according to various aspects of various embodiments of the present invention. Furthermore, these examples show that by providing a heating-cooling operation 12 according to various aspects of various embodiments of the present invention, an increased breaking load and tensile strength of the 1070 wire can be realized. A cooling unit 8 configured according to various aspects of various embodiments of the present invention is provided, using methods according to various aspects of various embodiments of the present invention, and / or various embodiments of the present invention. It will be apparent that similar or identical advantages may be achieved when processing rods or wires 11 having any of a variety of different compositions, provided with a heating-cooling operation 12 according to the various aspects of FIG.

  In a further embodiment, AISI-SAE 1090 wire drawing wire from one heat of steel obtained from a single manufacturing process was purchased and divided into lots, and liquid quenching fluid bed technology (also of the present invention). A cooling unit 8 and / or heating-cooling operation 12 according to an aspect of an embodiment, referred to herein as LQF, lead-based operation (referred to herein as lead patenting and STD), and air Provided to tire cord manufacture participants for comparison of air fluidized sand bed based operation (also referred to herein as fluid bed patenting and FBP). A nominal 1.95 mm wire was patented and plated using various techniques (eg, as described with reference to FIG. 2) and then drawn to a nominal 0.35 mm. A true stress strain curve was generated by determining the tensile strength and true stress at each position during the mold run. Each curve was similar and in each case the LQF product produced a higher final strength. The torsional characteristics of the product subjected to LQF and lead patenting (STD) were stable. The air fluidized sand (FBP) product was not stable in torsion. The results of the tensile strength and true stress investigation are summarized in Table 3 below, and FIG. 9 shows the true stress strain curve of the investigation.

  Microstructural analysis was completed for the product with lead (STD) patenting and the product with LQF patenting. The nominal diameter was about 2.0 mm and various chemistries were examined. To complete the study, the percentages of fine pearlite, modified pearlite and baylite (degenerative perlite & bainite) and fragment pearlite were evaluated. In either case, no pro-eutectoid microscopic component was observed. As a result, the LQF product was found to have a generally high proportion of fine pearlite, similar amounts of modified pearlite and baylite, and slightly less fragmented pearlite. Applicants predict that through further improvements, LQF patenting will be able to increase the amount of fine pearlite at the expense of modified pearlite and baylite. The results of the survey are summarized in Table 4 below and are shown graphically in FIG.

  The illustrations and examples provided herein are for illustrative purposes and are not intended to limit the scope of the claims.

  Those skilled in the art will recognize certain modifications and improvements upon reading the foregoing description. For example, other helical structural materials as well as metal shapes and sizes may also depend on system, operation, unit, area, product and / or processing requirements, system, one or more operations, one or more units, It could be provided by changes to any one or more of the areas and / or one or more processing steps. All such variations and modifications have been omitted for the sake of brevity and readability, but it should be understood that they are strictly within the scope of the claims.

Cooling unit 8
Rod or wire manufacturing system 10
Rod or wire 11
Heating-cooling operation 12
Supply unit 14
Winding unit 16
Intermediate product 17
Intermediate product 17 '
Intermediate 17 ″
Intermediate product 17 ^(n-1)
Intermediate product 17 ⁽ⁿ⁾
Intermediate product or finished product 18
First wire drawing unit 20
Second wire drawing unit 20 '
Third wire drawing unit 20 ″
First cleaning unit 24
Second washing unit 24 '
Coating unit 26
Stranded wire unit 30
First heating (annealing) unit 32
Second heating (annealing) unit 32 '
Cooling (quenching) unit 34
Adaptable quenching area 36
Adaptable quenching zone 36 '
Adaptable quenching zone 36 ^(n-1)
Adaptable quenching area 36 ⁽ⁿ⁾
Adaptable immersion area 37
Adaptable immersion area 37 '
Applicable immersion area 37 ^(n-1)
Applicable immersion area 37 ⁽ⁿ⁾
Liquid quenching agent 38
Hardener tank 40
First heat conduction regulator 42
Gas medium supply 44
Gas medium washer 45
Adjustment mechanism 46
Pressure equalizer 47
Pressure regulator 48
Second heat conduction regulator 50
Quenching feeder 52
Adjustment mechanism 54
Flow control 56
Hardener level control 60
Hardener level setter 62
Hardener supply 64
Hardener re-feeder 66
Controller 70
First cell type 80
Diffuser 82
Porous medium 84
Socket 86
Second cell type 90
Line 92
Selector 94
Bypass 96
Residue remover 98

Claims (47)

A rod or wire manufacturing system,
a. At least one supply unit capable of continuously supplying at least one rod or at least one wire;
b. At least one heating unit capable of heating the at least one continuously fed rod or the at least one continuously fed wire to a preselected temperature;
c. At least one cooling unit downstream of the at least one heating unit, the cooling unit comprising:
i. At least one adaptable quenching zone, wherein the at least one continuously fed rod or the at least one continuously fed wire can be quenched to a preselected immersion temperature Quenching area,
ii. At least one applicable dipping area, wherein the at least one continuously fed rod or the at least one continuously fed wire is substantially maintained at a preselected dipping temperature, the at least one continuous At least one adaptable dipping area capable of substantially completing a heat treatment of the fed rod or the at least one continuously fed wire;
Including a cooling unit;
d. At least one winding unit capable of continuously collecting the at least one heat treated rod or the at least one heat treated wire;
Including a rod or wire manufacturing system.   The at least one heating unit includes at least one annealing unit capable of heating the at least one continuously fed rod or the at least one continuously fed wire to a preselected annealing temperature. Item 2. The rod or wire manufacturing system according to Item 1.   The rod or wire manufacturing system according to claim 2, wherein the at least one cooling unit includes at least one phase transformation unit.   The at least one adaptable immersion zone substantially removes transformation heat from the at least one continuously fed rod or the at least one continuously fed wire, and the at least one continuously fed rod. 4. A rod or wire manufacturing system according to claim 3, comprising at least one adaptable phase transformation zone capable of substantially maintaining said at least one continuously fed wire substantially isothermal.   The rod or wire manufacturing system of claim 1, further comprising at least one wire drawing unit downstream of the at least one cooling unit.   The rod or wire manufacturing system of claim 5, further comprising at least one wire drawing unit upstream of the at least one heating unit. At least one cleaning unit upstream of the heating unit, at least one cleaning unit downstream of the cooling unit, at least one coating unit downstream of the cooling unit, a second heating unit and the at least one cooling A second cooling unit downstream of the second heating unit downstream of the unit, at least one wire drawing unit upstream of the heating unit, at least one wire drawing unit downstream of the cooling unit, or the cooling 6. The rod or wire manufacturing system of claim 5, further comprising one or more of at least one strand unit downstream of the unit, or any combination of any of the foregoing.   The said at least one supply unit includes a supply unit capable of continuously providing any one of a plurality of rods or a plurality of wires or a plurality of rods and a plurality of wires. Rod or wire manufacturing system.   The at least one adaptable quenching zone of the at least one cooling unit includes the plurality of continuously fed rods or the plurality of continuously fed wires, or the plurality of continuously fed rods and the plurality of continuously fed. 9. A rod or wire manufacturing system according to claim 8, comprising a plurality of adaptable quenching zones capable of quenching any one of the wires to be subjected to a plurality of preselected temperatures.   The at least one adaptable immersion area of the at least one cooling unit includes the plurality of continuously fed rods or the plurality of continuously fed wires, or the plurality of continuously fed rods and the plurality of continuously fed. 9. The rod or wire manufacturing system of claim 8, comprising a plurality of adaptable dipping areas capable of dipping said any one of the wires to be dipped into a plurality of preselected dipping temperatures.   The plurality of continuously fed rods or the plurality of continuously fed wires, or any one of the plurality of continuously fed rods and the plurality of continuously fed wires are variously different. The rod or wire manufacturing system of claim 9, comprising a material comprising a composition.   The plurality of continuously fed rods or the plurality of continuously fed wires, or any one of the plurality of continuously fed rods and the plurality of continuously fed wires are variously different. The rod or wire manufacturing system according to claim 9, comprising a cross-sectional shape.   The rod or wire manufacturing system of claim 12, wherein the substantially different cross-sectional shapes include substantially different diameters.     The plurality of continuously fed rods or the plurality of continuously fed wires, or any one of the plurality of continuously fed rods and the plurality of continuously fed wires are variously different. The rod or wire manufacturing system of claim 9, comprising a material comprising a composition and a variety of substantially different cross-sectional shapes. A cooling unit usable with a rod or wire manufacturing system, the rod or wire manufacturing system comprising: (a) at least one supply unit capable of continuously supplying at least one rod or at least one wire; (B) at least one heating unit capable of heating the at least one continuously fed rod or the at least one continuously fed wire to a preselected temperature; and (c) the at least one heat treatment. And at least one winding unit capable of continuously collecting the at least one heat treated wire, the cooling unit comprising:
a. At least one heat transfer coefficient adaptable quenching zone, wherein the at least one continuously fed rod or the at least one continuously fed wire can be quenched to an immersion temperature An adaptive quenching area;
b. At least one heat transfer coefficient applicable dipping area, wherein the at least one continuously fed rod or the at least one continuously fed wire is maintained at a substantially dipping temperature to substantially complete the heat treatment. At least one heat transfer coefficient adaptable immersion area that can be
Including a cooling unit.   The at least one heat transfer coefficient adaptable quenching zone supplies either one of a liquid quenching agent or a foam quenching agent to the at least one continuously fed rod or the at least one continuously fed wire. 16. A cooling unit according to claim 15, comprising at least one first cell type capable of.   The cooling unit according to claim 16, wherein the at least one first cell type includes at least one diffuser capable of producing the foam quench.   The cooling unit of claim 17, further comprising at least one first heat transfer regulator in communication with the at least one diffuser.   The cooling unit of claim 16, further comprising at least one second heat transfer regulator in communication with the at least one first cell type.   The at least one heat transfer coefficient adaptable quenching zone supplies either one of a liquid quenching agent or a foam quenching agent to the at least one continuously fed rod or the at least one continuously fed wire. 16. A cooling unit according to claim 15, comprising a plurality of first cell types capable of.     The at least one heat transfer coefficient adaptable dipping area is capable of supplying a foam quench to the at least one continuously fed rod or the at least one continuously fed wire. The cooling unit according to claim 15, comprising a cell type.   The cooling unit of claim 21, wherein the at least one second cell type includes at least one diffuser capable of producing the foam quench.   23. The cooling unit of claim 22, further comprising at least one first heat transfer regulator in communication with the at least one diffuser.   The at least one heat transfer coefficient adaptable dipping section can provide a plurality of second cells capable of supplying a foam quench to the at least one continuously fed rod or the at least one continuously fed wire. 16. A cooling unit according to claim 15, comprising a type.   The cooling unit of claim 15 further comprising at least one quenchant level control.   At least one in communication with any one of the first heat transfer controller, the second heat transfer controller, the quenching agent level control, the supply unit, the heating unit, the winding unit or any combination of any of the foregoing. The cooling unit of claim 15, further comprising one controller. A method of manufacturing a rod or wire, the method comprising:
a. Continuously supplying at least one rod or at least one wire;
b. Heating the at least one continuously fed rod or the at least one continuously fed wire to a preselected temperature;
c. Quenching the at least one continuously fed rod or the at least one continuously fed wire to a preselected soaking temperature;
d. Providing at least one continuous feed by substantially maintaining the at least one continuously fed rod or the at least one continuously fed wire at a preselected soaking temperature by feeding at least a foamed liquid quenching agent; Substantially completing the heat treatment of the rod or the at least one continuously fed wire,
e. Continuously collecting the at least one heat treated rod or the at least heat treated wire;
Including a method. A method of heat treating a rod or wire, the method comprising:
a. Heating the at least one continuously fed rod or the at least one continuously fed wire to a preselected temperature;
b. Quenching the at least one continuously fed rod or the at least one continuously fed wire to an immersion temperature;
c. Providing at least a foaming liquid quenchant to substantially maintain the at least one continuously fed rod or the at least one continuously fed wire at the soaking temperature to substantially complete the heat treatment;
Including a method. A method of treating a metal, the treatment comprising:
a. Heating the metal;
b. Exposing the heated metal to at least one quenching agent comprising a liquid and gas mixture;
c. Controlling the at least one liquid / gas mixture;
d. Removing the treated metal from the quenching agent;
Including a method.   28. The method of claim 27, wherein heating the metal comprises heating the metal to at least about 930 ° C.   30. The method of claim 28, wherein the metal comprises a rod or wire having a diameter between about 0.7 mm and about 3.5 mm.   30. The method of claim 29, wherein the metal comprises a steel rod or steel wire having a diameter between about 0.8 mm and about 2.8 mm.   30. The method of claim 29, wherein the metal comprises a steel rod or steel wire having a diameter between about 0.9 mm and about 2.2 mm.   28. The method of claim 27, wherein the metal comprises a steel product having a carbon content of at least about 0.35 weight percent.   28. The method of claim 27, wherein the metal further comprises any one of chromium, boron, silicon, or any combination of any of the foregoing.   28. The method of claim 27, wherein exposing the heated metal to at least one quenching agent comprises exposing the heated metal to a plurality of cells containing a liquid and gas mixture. 28. The method of claim 27, wherein exposing the heated metal to at least one quenching agent comprises exposing the heated metal to an aqueous solution at a temperature of about 100 <0> C.   28. The method of claim 27, wherein exposing the heated metal to at least one quenching agent comprises exposing the metal to a mixture having at least 4% by volume gas.   28. The method of claim 27, wherein exposing the heated metal to at least one quenching agent comprises exposing the metal to a mixture having a gas in the range of about 4-25% by volume.   28. The method of claim 27, wherein controlling the liquid / gas mixture comprises controlling a flow rate of gas through the liquid.   28. The method of claim 27, further comprising exposing the heated metal to at least one additional quenching agent comprising a liquid and gas mixture and controlling the liquid / gas mixture of the at least one further quenching agent. .   40. The method of claim 39, wherein exposing the heated metal to at least one quenching agent comprises exposing the metal to a mixture having at least 0-25% by volume air.   41. The method of claim 40, wherein exposing the heated metal to at least one additional quenching agent comprises exposing the metal to a mixture having a gas in the range of about 4-25% by volume.   A steel rod or steel wire comprising at least about 39 area percent fine pearlite.   43. The steel rod or steel wire of claim 42, comprising up to about 45 area percent fine pearlite. A treated metal having improved tensile strength, the treated metal comprising:
a. Heating the metal to a selected temperature;
b. Directing heated metal into at least one liquid and gas mixture and treating the metal;
c. Removing the treated metal from the at least one liquid and gas mixture;
And processed metal.   45. The metal formed according to claim 44, wherein heating the metal comprises heating the metal between about 930 ° C and about 1050 ° C.

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