US2839292A - Refractory reservoir for aluminum - Google Patents
Refractory reservoir for aluminum Download PDFInfo
- Publication number
- US2839292A US2839292A US448609A US44860954A US2839292A US 2839292 A US2839292 A US 2839292A US 448609 A US448609 A US 448609A US 44860954 A US44860954 A US 44860954A US 2839292 A US2839292 A US 2839292A
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- United States
- Prior art keywords
- molybdenum
- molten aluminum
- aluminum
- tube
- coating
- Prior art date
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- Expired - Lifetime
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- 229910052782 aluminium Inorganic materials 0.000 title claims description 48
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims description 48
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 28
- 239000011733 molybdenum Substances 0.000 claims description 28
- 229910052750 molybdenum Inorganic materials 0.000 claims description 28
- 229910052751 metal Inorganic materials 0.000 claims description 17
- 239000002184 metal Substances 0.000 claims description 17
- 239000000919 ceramic Substances 0.000 claims description 14
- 239000000203 mixture Substances 0.000 claims description 12
- 230000003647 oxidation Effects 0.000 claims description 11
- 238000007254 oxidation reaction Methods 0.000 claims description 11
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 claims description 6
- 230000007797 corrosion Effects 0.000 claims description 6
- 238000005260 corrosion Methods 0.000 claims description 6
- 239000011248 coating agent Substances 0.000 description 14
- 238000000576 coating method Methods 0.000 description 14
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 10
- 238000002844 melting Methods 0.000 description 9
- 230000008018 melting Effects 0.000 description 9
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 8
- 150000002739 metals Chemical class 0.000 description 8
- 238000005507 spraying Methods 0.000 description 7
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 6
- 229910052721 tungsten Inorganic materials 0.000 description 6
- 239000010937 tungsten Substances 0.000 description 6
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 5
- 229910052804 chromium Inorganic materials 0.000 description 5
- 239000011651 chromium Substances 0.000 description 5
- 238000000034 method Methods 0.000 description 5
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 4
- 229910045601 alloy Inorganic materials 0.000 description 4
- 239000000956 alloy Substances 0.000 description 4
- 238000005524 ceramic coating Methods 0.000 description 4
- 239000007789 gas Substances 0.000 description 4
- 229910002804 graphite Inorganic materials 0.000 description 4
- 239000010439 graphite Substances 0.000 description 4
- 229910052742 iron Inorganic materials 0.000 description 4
- 229910052759 nickel Inorganic materials 0.000 description 4
- 238000007654 immersion Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 238000005266 casting Methods 0.000 description 2
- -1 chromium land nickel Chemical class 0.000 description 2
- 238000005253 cladding Methods 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 238000007747 plating Methods 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910000599 Cr alloy Inorganic materials 0.000 description 1
- 229910000881 Cu alloy Inorganic materials 0.000 description 1
- 229910000640 Fe alloy Inorganic materials 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229910001182 Mo alloy Inorganic materials 0.000 description 1
- 229910000990 Ni alloy Inorganic materials 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 239000010953 base metal Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical class [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 1
- 235000012255 calcium oxide Nutrition 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 239000000460 chlorine Substances 0.000 description 1
- 229910052801 chlorine Inorganic materials 0.000 description 1
- 239000008199 coating composition Substances 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000009713 electroplating Methods 0.000 description 1
- 238000010285 flame spraying Methods 0.000 description 1
- 239000004519 grease Substances 0.000 description 1
- 239000011396 hydraulic cement Substances 0.000 description 1
- 229910001026 inconel Inorganic materials 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 235000012245 magnesium oxide Nutrition 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 230000000737 periodic effect Effects 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000011253 protective coating Substances 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 239000011214 refractory ceramic Substances 0.000 description 1
- 239000011819 refractory material Substances 0.000 description 1
- 238000009877 rendering Methods 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000012808 vapor phase Substances 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B21/00—Obtaining aluminium
- C22B21/0084—Obtaining aluminium melting and handling molten aluminium
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/003—Apparatus
- C23C2/0034—Details related to elements immersed in bath
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
- C23C2/003—Apparatus
- C23C2/0036—Crucibles
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B14/00—Crucible or pot furnaces
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S428/00—Stock material or miscellaneous articles
- Y10S428/922—Static electricity metal bleed-off metallic stock
- Y10S428/9335—Product by special process
- Y10S428/934—Electrical process
- Y10S428/935—Electroplating
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S428/00—Stock material or miscellaneous articles
- Y10S428/922—Static electricity metal bleed-off metallic stock
- Y10S428/9335—Product by special process
- Y10S428/937—Sprayed metal
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
- Y10T428/12611—Oxide-containing component
- Y10T428/12618—Plural oxides
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12771—Transition metal-base component
- Y10T428/12806—Refractory [Group IVB, VB, or VIB] metal-base component
- Y10T428/12826—Group VIB metal-base component
Definitions
- This invention relates to refractory articles or parts that are' resistant to corrosion by molten aluminum and to a method for making such articles. l t
- molybdenum and tungsten olfer surprising resistance to corrosion by molten aluminum and that these metals serve admirably as a coating for materials that are normally subject to attack by molten aluminum.y These metals are highly refractory, molybdenum having a melting point of 4750 F., and tungsten having a melting point of 6l70 F. That molybdenum and tungsten should be capable of resisting attack by molten aluminum was especially surprising in view of the fact that chromium, which is also in group Vl of the periodic table, and would predictably react chemically in the same manner as molybdenum and tungsten, is vigorously disintegrated by molten aluminum.
- molybdenum is the most throttledily available and the easier to fabricate, and it is, therefore, preferred over tungsten. Molybdenum has been known and commercially available for many years,
- My invention consists in rendering parts or articles that are normally attacked by molten aluminum resistant to' such attack by coatingk tht.L surface thereof with molybdenum or tungsten.
- Molybdenum may be conveniently applied lby Well known processes including metallizing (spraying), plating or cladding. I have found that an especially convenient means of applying a uniform continuous molybdenum coating is by spraying.
- the part being sprayed is made from a ferrous metal or ferrous alloy, the molybdenum bonds tenaciously to a clean, Warm surface, Steel parts have been provided with a wear resistant coating Aof molybdenum by spraying for some time.
- Inconel an alloy comprising substantially 80% nickel, 12-l4% chromium and 6-8% iron, is preferred as the base metal due to its similar coefficient of expansion.
- refractory parts associated with an aluminum melting furnace or the like are completely submerged in molten aluminum. However, some parts may become exposed to air at temperatures ,approaching the temperature prevailing within the furnace as, for example, when the level of the molten aluminum falls below its maximum height. Under such conditions the molybdenum coating will oxidize and lose its refractoriness andcorrosion re; sistance. Therefore, parts lsubject to oxidation are rst coated with molybdenum and then given an external coating of a suitable refractory material that will protect the metallic coating from oxidation, such as a conventional ceramic coating composition, or a molybdenum alloy containing a minor proportion of chromium and/ or nickel.
- a suitable refractory material that will protect the metallic coating from oxidation
- Ceramic compositions can be applied by dip v Vcoating or spraying an aqueous solution or suspensionv Both graphite and they ceramic thereof, or they may be applied by what is known as llame spraying. This process involves the use of a gun equipped with a hot gas flame through which the powdered ceramic material is blown, thus converting the solid powder into fused flaming particles which deposit on the part and solidify as a firmly adhering coating.
- Figure 1 is a vertical section through an electric melting furnace having a connecting tube constructed inaccordance with the invention
- FigureY 2 is a sectional View taken alongv the line ⁇ 2 2 of Figure 1;
- a magnetic core 15. is arranged around the tubes and is energized by alternating current windings (not shown) to induce a melting-current in the aluminum metal within the tubes. .Since all of the melting occurs within the tubes, the prevailing current density is .very high and, consequently, this portionl of the furnace deteriorates much more rapidly than Vthe melting and holding chambers.
- the improvement in the construction illustrated lies in the tube 18, which is made from molybdenum metal.
- the supporting block 20 may be conveniently made from a mixture similar to the ceramic composition 156, which consists of Lumnite cement (commercial heat-,resistant hydraulic cement) and a suitable aggregate. If the enclosed tube is prepared separately in this'way, the bond to the ceramic mass may be more carefully controlled.
- Another method consists in casting the ceramic composition 16 around the tube 18 simultaneously with the formation of the melting and holding chambers.
- the molybdenum tube will outlast theconventional ceramic tube many times, and, of course, is not subject to breakage. denum tube, it is preferred that the molybdenum tube be coated inside and out prior to enclosure in cast composition 16, or in the block 20, with a suitable oxidation protective coating that will withstand temperatures in the vicinity of -1500 F., and which preferably will also resist molten aluminum.
- a vapor-phase deposited silicon coating or other ceramic coating, such as magnesium or calcium oxides, are suitable for this purpose.
- the primary source of oxygen is due to permeation of air through the ceramic composition 1,6. The oxidation that might occur would not be severe, but it is preferable to protect against it n the manner described.
- Figure 3 shows a bubble tube which is commonly used in aluminum foundries to introduce gases, such as nitrogen or chlorine, into molten aluminum.
- the conventional tube is made from graphite and deteriorates rather rapidly due to oxidation and, of course, such tubes are highly brittle and are frequently broken.
- the bubble tube of Figure 3 has been made in accordance with the invention and consists of a standard length of suitable diameter standard iron pipe 32 threaded at one end and closed at the other.
- the closed lower end contains a suitable number of holes 36 for permitting the escape of gas through the wall of the tube.
- the surface of the metal is cleaned thoroughly to remove any dirt or grease and a coating 33 of molybdenum, about .005 inch thick or more, is sprayed over the surface.
- a ceramic coating 34 is applied thereover by flame spraying or by applying a coating by other means.
- Thestandard ferrous metal base coated in this manner is practically unbreakable since the layers are securely bonded together. It will resist attack by molten aluminum almost indelinitely.
- the tube 35 is connected to the gas line 37 through an elbow 38, and dips into molten aluminum 31 in the refractory container 30.
- FIGS. 4 and 5 illustrate an electrical immersion heater 40 of conventional construction, which has been treated according to the invention.
- the heater contains the usual electrical resistor core 44 sheathed in an insulating material 45 and an external metal housing 46 which is normally subject to corrosion by molten aluminum.
- This immersion unit may be protected from the action of molten aluminum in accordance With this invention by rst spraying the surface with about )g6 to .O08 inch of molybdenum 47.
- the unit may be coated with molybdenum by cladding or electroplating instead of spraying.
- An oxidation protective eeramie coating then may be applied over the molybdenum ⁇ coating over any areas not to be covered by molten-aluminum.
- Such an immersion unit has been found to provide very satisfactory service in molten aluminum.
- An aluminum melting furnace having two ichainhers ⁇ adapted to hold molten aluminum, said chamhersibeing interconnected by a ferrous metal tube having its sui-face coated with an intermediate layer of molybdenum and an external layer of ceramic composition.
Description
June 17, 1958 H. T;`BE|.LAMY
RERRAcToRY RESERVOIR FoR ALUMINUM Filed Aug. 9, 1954 United States PatentO .l 2,839,292 "REFRACTORY RESERVOIR FOR ALUMINUM i Harry T. Bellamy, Evanston, Ill.
f Application August 9, 1954, serial No. 443,609rv a claims. (ci. zas-s4) This invention relates to refractory articles or parts that are' resistant to corrosion by molten aluminum and to a method for making such articles. l t
At its melting point of 12,16 F. orabove, aluminum is highly corrosive and rapidly attacks common structural metals. Tubing of iron, ferrous alloys, alloys of chromium, nickel and copper, for example, when dipped into molten aluminum will pit and develop holes completely through the wall thereof Within a relatively short time. Attempts to coat or plate these metals and alloys to protect them from this corrosivek action have been disappointing.` Common plating metals, such as chromium land nickel, are vigorously attacked by molten aluminum. Ceramic compositions, although resistant to molten aluminum, cannot successfully be applied in a continuous film, primarily due to difference in the coecient of thermal expansion between the ceramic and the metal base. Invariably some surface defect develops, such as pinholes or cracks in the coating, to blemish the continuity of the surface, and attack by the molten aluminum results at these points. jConsequently, parts which must be capable of resisting attack by molten aluminum are conventionally made from cast or otherwise shaped solid ceramic compositions. Pyrometer protecting tubes, for example, are formed by extruding a refractory ceramic which contains a high proportion of siliconcarbide with a suitable bonding material.
Other parts adapted to resist molten made from graphite. parts stand up fairly well under the corrosive action of aluminum, but are disadvantageous in that they are brittle and break very easily during installation or other handling. Graphite has the additional disadvantage of quickly oxidizing at elevated temperatures. These nonmetallic. parts are also rather difficult and expensive to fabricate as compared with ferrous metals, for'example. The aluminum casting industry has been in need of a suitable material that will withstand molten aluminum and which at the same time does not have the shortcomings of the brittle non-metallic parts now commonly used.
I Vhave discovered that molybdenum and tungsten olfer surprising resistance to corrosion by molten aluminum and that these metals serve admirably as a coating for materials that are normally subject to attack by molten aluminum.y These metals are highly refractory, molybdenum having a melting point of 4750 F., and tungsten having a melting point of 6l70 F. That molybdenum and tungsten should be capable of resisting attack by molten aluminum was especially surprising in view of the fact that chromium, which is also in group Vl of the periodic table, and would predictably react chemically in the same manner as molybdenum and tungsten, is vigorously disintegrated by molten aluminum.
Of the two operable metals, molybdenum is the most vreadily available and the easier to fabricate, and it is, therefore, preferred over tungsten. Molybdenum has been known and commercially available for many years,
aluminum are IKC@ 2 but so far asl am aware, no one previously appreciated its remarkable resistance to the corrosive action of molten aluminum.
My invention consists in rendering parts or articles that are normally attacked by molten aluminum resistant to' such attack by coatingk tht.L surface thereof with molybdenum or tungsten. Molybdenum may be conveniently applied lby Well known processes including metallizing (spraying), plating or cladding. I have found that an especially convenient means of applying a uniform continuous molybdenum coating is by spraying. When the part being sprayed is made from a ferrous metal or ferrous alloy, the molybdenum bonds tenaciously to a clean, Warm surface, Steel parts have been provided with a wear resistant coating Aof molybdenum by spraying for some time. When the molybdenum sprayed part is to be subjected to thermal shock, Inconel, an alloy comprising substantially 80% nickel, 12-l4% chromium and 6-8% iron, is preferred as the base metal due to its similar coefficient of expansion.
Most refractory parts associated with an aluminum melting furnace or the like are completely submerged in molten aluminum. However, some parts may become exposed to air at temperatures ,approaching the temperature prevailing within the furnace as, for example, when the level of the molten aluminum falls below its maximum height. Under such conditions the molybdenum coating will oxidize and lose its refractoriness andcorrosion re; sistance. Therefore, parts lsubject to oxidation are rst coated with molybdenum and then given an external coating of a suitable refractory material that will protect the metallic coating from oxidation, such as a conventional ceramic coating composition, or a molybdenum alloy containing a minor proportion of chromium and/ or nickel. Ceramic compositions can be applied by dip v Vcoating or spraying an aqueous solution or suspensionv Both graphite and they ceramic thereof, or they may be applied by what is known as llame spraying. This process involves the use of a gun equipped with a hot gas flame through which the powdered ceramic material is blown, thus converting the solid powder into fused flaming particles which deposit on the part and solidify as a firmly adhering coating.' A
coating will provide protection for molybdenum against' oxygen in areas which become exposed to air upon re-l moval from molten aluminum. In areas where the ceramic coating may fail, the extent of the oxidation is not suiicient to permit any substantial attack by the aluminum because the oxidized areas are small and the exposure to aluminum is not continuous.
Various examples of my invention are illustrated in the accompanying drawings, in which:
Figure 1 is a vertical section through an electric melting furnace having a connecting tube constructed inaccordance with the invention;
chamber 14 interconnected by means of horizontallyspaced channels or tubes 18. A magnetic core 15. is arranged around the tubes and is energized by alternating current windings (not shown) to induce a melting-current in the aluminum metal within the tubes. .Since all of the melting occurs within the tubes, the prevailing current density is .very high and, consequently, this portionl of the furnace deteriorates much more rapidly than Vthe melting and holding chambers. The improvement in the construction illustrated lies in the tube 18, which is made from molybdenum metal.
One method of incorporating the molybdenum tube 18 into the furnace is to support it by a refractory block 20, which is cast around the tube. The supporting block 20 may be conveniently made from a mixture similar to the ceramic composition 156, which consists of Lumnite cement (commercial heat-,resistant hydraulic cement) and a suitable aggregate. If the enclosed tube is prepared separately in this'way, the bond to the ceramic mass may be more carefully controlled.
Another method, however, consists in casting the ceramic composition 16 around the tube 18 simultaneously with the formation of the melting and holding chambers.
The molybdenum tube will outlast theconventional ceramic tube many times, and, of course, is not subject to breakage. denum tube, it is preferred that the molybdenum tube be coated inside and out prior to enclosure in cast composition 16, or in the block 20, with a suitable oxidation protective coating that will withstand temperatures in the vicinity of -1500 F., and which preferably will also resist molten aluminum. A vapor-phase deposited silicon coating or other ceramic coating, such as magnesium or calcium oxides, are suitable for this purpose. In an installation of this kind the primary source of oxygen is due to permeation of air through the ceramic composition 1,6. The oxidation that might occur would not be severe, but it is preferable to protect against it n the manner described.
Figure 3 shows a bubble tube which is commonly used in aluminum foundries to introduce gases, such as nitrogen or chlorine, into molten aluminum. The conventional tube is made from graphite and deteriorates rather rapidly due to oxidation and, of course, such tubes are highly brittle and are frequently broken.
The bubble tube of Figure 3 has been made in accordance with the invention and consists of a standard length of suitable diameter standard iron pipe 32 threaded at one end and closed at the other. The closed lower end contains a suitable number of holes 36 for permitting the escape of gas through the wall of the tube. The surface of the metal is cleaned thoroughly to remove any dirt or grease and a coating 33 of molybdenum, about .005 inch thick or more, is sprayed over the surface. To protect the molybdenum coating 33 from oxidation a ceramic coating 34 is applied thereover by flame spraying or by applying a coating by other means. Thestandard ferrous metal base coated in this manner is practically unbreakable since the layers are securely bonded together. It will resist attack by molten aluminum almost indelinitely. In use, the tube 35 is connected to the gas line 37 through an elbow 38, and dips into molten aluminum 31 in the refractory container 30.
To insure against oxidation of the molyb- Figures 4 and 5 illustrate an electrical immersion heater 40 of conventional construction, which has been treated according to the invention. The heater contains the usual electrical resistor core 44 sheathed in an insulating material 45 and an external metal housing 46 which is normally subject to corrosion by molten aluminum. This immersion unit may be protected from the action of molten aluminum in accordance With this invention by rst spraying the surface with about )g6 to .O08 inch of molybdenum 47. The unit may be coated with molybdenum by cladding or electroplating instead of spraying. An oxidation protective eeramie coating then may be applied over the molybdenum `coating over any areas not to be covered by molten-aluminum. Such an immersion unit has been found to provide very satisfactory service in molten aluminum.
It is also within the scope of the invention to provide parts for pumps and the like, used inccntastwitll, molten aluminum. made from molybdenum or tuestemmetal- The invention has been illustrated by way ainumber of articles or parts which commonly areused inrnolten aluminum, but it is not mylintention to limit theinvenf tion thereto otherwise than as necessitated `by the.ap.
pended claims. Furthermore, various modifications tof, the invention will become apparent to those skilled 4', th art without departing from the spirit of the invention,
l claim as my invention: y t
1- In combination, a refractory 4reservoir for molten aluminum and a tube disposed therein below the normal level of the molten aluminum, said tube being made from a ferrous -metal coated with'an intermediate layer Iof molybdenum and an external layer of ceramic composition whereby said tube is protected from corrosion `by molten aluminum and from oxidation.
2. In combination, a refractory reservoir `for moltenv aluminum and a tube disposed therein belowthe normal level of the molten aluminum, said tube being made from an alloy containing substantially nickel, 1,-2 to 1,4% chromium and 6 to 8% iron and coated with-,anlintermediate layer of molybdenum and an external `layenpf` ceramic composition whereby said tubeis protectedfram` corrosion by molten aluminum and fromoxidation.V ,t
3. An aluminum melting furnace having two ichainhers` adapted to hold molten aluminum, said chamhersibeing interconnected by a ferrous metal tube having its sui-face coated with an intermediate layer of molybdenum and an external layer of ceramic composition. f i
References Cited in the le of this patent UNITED STATES PATENTS Beidler et al Ian. 12,
OTHER REFERENCES Y Metals Handbook. 1948 edition, published by Thel American Society of Metals (pages 1057-1058 relied on).
Claims (1)
1. IN COMBINATION A REFRACTORY RESERVOIR FOR MOLTEN ALUMINUM AND A TUBE DISPOSED THEREIN BELOW THE NORMAL LEVEL OF THE MOLTEN ALUMINUM, SAID TUBE BEING MADE FROM A FERROUS METAL COATED WITH AN INTERMEDIATE LAYER OF MOLYBDENUM AND AN EXTERNAL LAYER OF CERAMIC COMPOSITION WHEREBY SAID TUBE IS PROTECTED FROM CORROSION BY MOLTEN ALUMINUM AND FROM OXIDATION.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US448609A US2839292A (en) | 1954-08-09 | 1954-08-09 | Refractory reservoir for aluminum |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US448609A US2839292A (en) | 1954-08-09 | 1954-08-09 | Refractory reservoir for aluminum |
Publications (1)
Publication Number | Publication Date |
---|---|
US2839292A true US2839292A (en) | 1958-06-17 |
Family
ID=23780968
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US448609A Expired - Lifetime US2839292A (en) | 1954-08-09 | 1954-08-09 | Refractory reservoir for aluminum |
Country Status (1)
Country | Link |
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US (1) | US2839292A (en) |
Cited By (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3006782A (en) * | 1956-03-09 | 1961-10-31 | Norton Co | Oxide coated articles with metal undercoating |
US3015579A (en) * | 1959-06-15 | 1962-01-02 | Chromizing Corp | Metal coating process |
US3031331A (en) * | 1959-10-23 | 1962-04-24 | Jr William L Aves | Metal-ceramic laminated skin surface |
US3054694A (en) * | 1959-10-23 | 1962-09-18 | Jr William L Aves | Metal-ceramic laminated coating and process for making the same |
US3083422A (en) * | 1959-04-13 | 1963-04-02 | Finkl & Sons Co | Porous stopper rod |
US3415631A (en) * | 1965-03-12 | 1968-12-10 | Norton Co | Protective coated article |
US4148468A (en) * | 1977-03-03 | 1979-04-10 | Messer Griesheim Gmbh | Lance for the flush gas treatment of non-ferrous molten metals |
US6534196B2 (en) * | 2001-02-26 | 2003-03-18 | Cincinnati Thermal Spray | Refractory metal coated articles for use in molten metal environments |
EP1785506A1 (en) | 2005-11-09 | 2007-05-16 | Centre de compétence de l'Ind. Techn. (CRIF) - Kenniscentrum van de Tech. Ind. (WICM) | Protective coating for casting moulds |
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US1582407A (en) * | 1925-05-06 | 1926-04-27 | Standard Oil Co | Apparatus for hydrocarbon-oil-cracking operations |
US2149657A (en) * | 1936-03-12 | 1939-03-07 | Tungsten Electrodeposit Corp | Thermionic tube |
US2447672A (en) * | 1944-11-20 | 1948-08-24 | American Smelting Refining | Apparatus for chloridizing aluminum-base alloys |
US2508466A (en) * | 1944-10-02 | 1950-05-23 | Westinghouse Electric Corp | Method of manufacturing lined metal tubes |
US2508465A (en) * | 1944-03-18 | 1950-05-23 | Westinghouse Electric Corp | Lined metal tube and method of manufacture |
US2588421A (en) * | 1947-12-19 | 1952-03-11 | Metallizing Engineering Co Inc | Application of sprayed metal coatings to solid objects |
US2648715A (en) * | 1950-06-06 | 1953-08-11 | Lindberg Eng Co | Furnace for molten metal |
US2650903A (en) * | 1947-07-05 | 1953-09-01 | Westinghouse Electric Corp | Protection of molybdenum against oxidation |
US2665474A (en) * | 1950-03-18 | 1954-01-12 | Fansteel Metallurgical Corp | Highly refractory molybdenum alloys |
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US1582407A (en) * | 1925-05-06 | 1926-04-27 | Standard Oil Co | Apparatus for hydrocarbon-oil-cracking operations |
US2149657A (en) * | 1936-03-12 | 1939-03-07 | Tungsten Electrodeposit Corp | Thermionic tube |
US2508465A (en) * | 1944-03-18 | 1950-05-23 | Westinghouse Electric Corp | Lined metal tube and method of manufacture |
US2508466A (en) * | 1944-10-02 | 1950-05-23 | Westinghouse Electric Corp | Method of manufacturing lined metal tubes |
US2447672A (en) * | 1944-11-20 | 1948-08-24 | American Smelting Refining | Apparatus for chloridizing aluminum-base alloys |
US2650903A (en) * | 1947-07-05 | 1953-09-01 | Westinghouse Electric Corp | Protection of molybdenum against oxidation |
US2588421A (en) * | 1947-12-19 | 1952-03-11 | Metallizing Engineering Co Inc | Application of sprayed metal coatings to solid objects |
US2665474A (en) * | 1950-03-18 | 1954-01-12 | Fansteel Metallurgical Corp | Highly refractory molybdenum alloys |
US2648715A (en) * | 1950-06-06 | 1953-08-11 | Lindberg Eng Co | Furnace for molten metal |
Cited By (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3006782A (en) * | 1956-03-09 | 1961-10-31 | Norton Co | Oxide coated articles with metal undercoating |
US3083422A (en) * | 1959-04-13 | 1963-04-02 | Finkl & Sons Co | Porous stopper rod |
US3015579A (en) * | 1959-06-15 | 1962-01-02 | Chromizing Corp | Metal coating process |
US3031331A (en) * | 1959-10-23 | 1962-04-24 | Jr William L Aves | Metal-ceramic laminated skin surface |
US3054694A (en) * | 1959-10-23 | 1962-09-18 | Jr William L Aves | Metal-ceramic laminated coating and process for making the same |
US3415631A (en) * | 1965-03-12 | 1968-12-10 | Norton Co | Protective coated article |
US4148468A (en) * | 1977-03-03 | 1979-04-10 | Messer Griesheim Gmbh | Lance for the flush gas treatment of non-ferrous molten metals |
US6534196B2 (en) * | 2001-02-26 | 2003-03-18 | Cincinnati Thermal Spray | Refractory metal coated articles for use in molten metal environments |
EP1785506A1 (en) | 2005-11-09 | 2007-05-16 | Centre de compétence de l'Ind. Techn. (CRIF) - Kenniscentrum van de Tech. Ind. (WICM) | Protective coating for casting moulds |
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