US3811850A - High speed production of filaments from low viscosity melts - Google Patents

High speed production of filaments from low viscosity melts Download PDF

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Publication number
US3811850A
US3811850A US00319133A US31913372A US3811850A US 3811850 A US3811850 A US 3811850A US 00319133 A US00319133 A US 00319133A US 31913372 A US31913372 A US 31913372A US 3811850 A US3811850 A US 3811850A
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United States
Prior art keywords
orifice
jet
gas
plate
zone
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US00319133A
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English (en)
Inventor
E Dobo
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Monsanto Co
Original Assignee
Monsanto Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Monsanto Co filed Critical Monsanto Co
Priority to US00319133A priority Critical patent/US3811850A/en
Priority to US422933A priority patent/US3904381A/en
Priority to ZA739625A priority patent/ZA739625B/xx
Priority to NL7317585A priority patent/NL7317585A/xx
Priority to GB6008673A priority patent/GB1460750A/en
Priority to ES421852A priority patent/ES421852A1/es
Priority to LU69086A priority patent/LU69086A1/xx
Priority to SE7317522A priority patent/SE389979B/xx
Priority to AR251770A priority patent/AR199018A1/es
Priority to BE139388A priority patent/BE809247A/fr
Priority to SU731989758A priority patent/SU592339A3/ru
Priority to AU64045/73A priority patent/AU481595B2/en
Priority to AT1089273A priority patent/AT337232B/de
Priority to CA189,056A priority patent/CA995030A/en
Priority to BR10291/73A priority patent/BR7310291D0/pt
Priority to DE2364944A priority patent/DE2364944A1/de
Priority to DD175724A priority patent/DD108911A5/xx
Priority to RO7377175A priority patent/RO65573A/fr
Priority to CS739130A priority patent/CS207301B2/cs
Priority to IE2349/73A priority patent/IE38710B1/xx
Priority to FR7400076A priority patent/FR2212197B1/fr
Priority to JP49004572A priority patent/JPS49125226A/ja
Priority to IN198/CAL/74A priority patent/IN138625B/en
Application granted granted Critical
Publication of US3811850A publication Critical patent/US3811850A/en
Priority to CA237,597A priority patent/CA994982A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/005—Continuous casting of metals, i.e. casting in indefinite lengths of wire
    • 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
    • Y10S264/00—Plastic and nonmetallic article shaping or treating: processes
    • Y10S264/19—Inorganic fiber

Definitions

  • ABSTRACT Improvements in method and apparatus are provided for the fabrication of fibers and filaments from extremely low viscosity melts by continuous extrusion. Realizable production rates are increased up to threefold over existing capability. This is made possible by an improved orifice assembly which permits very high attenuation of the filamentary jet without an attending disturbance of the jet stream.
  • the filamentary jet is brought into a zone of pressurized inert gas upon emergence from the extrusion orifice.
  • the jet is then passed with the inert gas in concurrent flow through a supersonic nozzle and into a first zone occupied by a film-forming, gaseous atmosphere followed by passage through a converging orifice and into a second zone of film-forming gas.
  • This invention pertains to improvements in methods and apparatus for fabricating fibers and filaments by the continuous extrusion of very low viscosity melts. That is, the essentially inviscid melts of materials such as those of the various metals, metal alloys, metalloids and ceramics where poise measurements are less than and often less than 1.
  • process economy is greatlyimproved by a substantial increase in realizable production rates.
  • the resulting product exhibits superior structure characteristics in that porosity is greatly reduced.
  • the orifice of the second plate is larger in diameter than that of the first and has a straight or a tapered bore.
  • the second plate referred to as the gas plate" is provided with gas'inlet ports and gas distribution means in the formof a gap space, which defines an essentially enclosed chamber between the opposing faces of the two plates.
  • a quantity of inert gas is supplied under pressure through the inlet port of the gas plate and contacts the jet as it emerges from the extrusion orifice in a direction perpendicular to the jet path.
  • the inert gas is then caused to change direction and flow cocurrently with the jet through the gas plate exit orifice and thence, into a reactive atmosphere.
  • the resulting attenuation occurs in part as a result of the viscous drag interaction of the inert gas with the jet.
  • the principal object of this invention is to provide process and apparatus improvements which permit productivity rates of up to 4,200 feet per minute when fabricating fibers and filaments from essentially inviscid melts a three fold increase over that presently possible.
  • FIG. 1 is a schematic vertical cross-sectionof a typical filament extrusion apparatus employing an orifice assembly in accordance with the present invention.
  • FIG. 2 is an enlarged, partial view of the orifice assembly of FIG. 1.
  • FIG. 3 is an enlarged partial view of the gas plate orifice in the orifice assembly of FIG. 1.
  • FIG. 1 depicts a crucible l enclosing a quantity of molten essentially inviscid material 11.
  • an orifice plate 12 having an extrusion orifice l3.
  • a gas plate 14 having a convergent-divergent shaped orifice 15 which is aligned substantially coaxial with orifice l3.
  • Plates l2 and 14 define an essentially enclosed chamber 16, which can be referred to as inert gas zone.
  • Beneath gas plate 14 is a third plate 17 hereinafter called a stream control plate.
  • Stream control plate 17 has an orifice or throat 18 which is aligned substantially coaxial with throat 15 (and consequently with orifice 13).
  • the walls of orifice l8 converge in the direction of its exit with the included angle of convergence being between 7 and 20.
  • Stream control plate 17 and gas plate 14 define a second substantially enclosed chamber 19, which can be referred to as a first reactive gas zone.
  • Pedestal 20 supports the entire apparatus and also defines cavity 21, which can be referred to as the second reactive gas zone, since the molten jet further reacts therein with a film forming gas.
  • a positive pressure head is supplied to molten material 11, generally by means of an inert gas under pressure, such as for example, argon.
  • the jet 22 is thus caused to issue from the extrusion orifice 13 into chamber 16.
  • Chamber 16 is provided with a quantity of inert gas which is supplied under pressure through inert gas line 23.
  • the inert gas is constrained to move laterally between orifice plate 12 and gas plate 14 and thus contacts the emerging jet 22 in a direction initially normal to the path of jet 22. This flow is in a large measure self-distributing toward symmetrical flow.
  • the inert gas then flows co-currently with jet 22 through the gas plate throat 15 and into chamber 19.
  • the nature of the inert gas is not critical so long as the gas is inert to the extruded materials, the orifice plate and other parts of the extrusion apparatus. Helium and argon have been used successfully with helium being particularly suitable.
  • Chamber 19 is provided with a quantity of gas reactive with jet 22 via gas line 24.
  • the reactive filmstabilizing gas contacts jet 22 at the entrance of orifice l8 and is at a flow rate sufficient to penetrate the shroud of inert gas which has been caused to envelope the jet as it issues from gas plate'orifice 15.
  • a further quantity of reactive gas is supplied by gas line 25 into cavity 21 for contact with jet 22 proximate to the exit of orifice 18.
  • the nature of the reactive gas is not critical so long as it is capable of forming a film about the surface of molten jet 22. In many instances oxidizing gases such as carbon monoxide and air have been successfully employed. For other suitable film-forming gases that may be used see US. Pat. No. 3,658,979.
  • FIG. 2 illustrates the general geometrical relationship between plates 12, 14 and 17 together with their respective orifices.
  • the diameter of the throat section (most narrow section) of gas plate orifice 15 may be larger than the exit diameter of extrusion orifice 13, best results are obtained when it is of an equal or lesser diameter than that of the exit of orifice 13. Particularly good results may be obtained when the ratio of the exit diameter of orifice 13 to the throat diameter of orifice l5 lies in the range of from about l.l:l.O to 1.5210.
  • the length of orific'e 15 is generally maintained at from about 5 to times greater than the exit diameter of orifice 13.
  • orifice 18 converges in the direction of its exit at an included angle of from about 7 20. It is generally desirable although not critical that the entrance diameter of orifice 18 be from about 2 to 5 times larger than the throat diameter of gas plate orifice 15.
  • gap distance of gap 31 between orifice plate 12 and gas plate 14 should be substantially equal to the diameter of gas plate throat 15.
  • the dimensions of gap 32 between gas plate 14 and stream control plate 17 is not considered to be critical. However, enough space should be provided to accommodate a sufficient quantity of reactive gas to penetrate the inert gas which flows co-currently with jet stream 22. Generally, it has been found that a gap distance of from about 5 to 20 mils between gas plate 14 and stream control plate 17 in the vicinity of their respective orifices is satisfactory.
  • FIG. 3 illustrates gas plate 14 and its shaped orifice l5 schematically in an enlarged vertical section.
  • the entry area or convergent section 28 is rounded gently to reduce friction.
  • the extent of convergence is not critical, it being merely necessary that the orifice walls converge in some degree at the entry.
  • the convergence terminates at throat section 29 from where the walls diverge to form divergent exit section 30.
  • the included angle of divergence in this section should be between 4 and 12, with from 6 to 8 being of preference for attenuation at the higher speeds. Best results are achieved when divergent section 30 is of greater length than convergent section 28, and particularly when the length is from 10 to 20 times greater.
  • Arrows 26 and 27 illustrate the flow paths of the inert and reactive stabilization geses, respectively.
  • EXAMPLE An apparatus such as depicted in FIG. 1 was employed to form' filaments by extruding the melt of steel alloyed with 1.0 percent by weight of aluminum at a realized production rate of 3500 feet per minute.
  • the orifice assembly used was of a design as typified by FIG. 2 of the drawings.
  • the orifice plate 12 was 125 mils thick with the filament shaping orifice 13 in the plate measuring 8 mils in both length and diameter, i.e., having an aspect ratio L/D of 1.
  • Gas plate 14 was also 125 mils thick with the throat of the supersonic nozzle 15 therein being 8 mils in diameter or equivalent to the diameter of filament shaping orifice l3.
  • Stream control plate 17 was 62 mils thick and orifice 18 therein had an exit diameter approximately 4 times that of the throat diameter of convergent-divergent orifice 15. An included angle of 15 was formed by the converging walls of orifice 18.
  • an argon gas head pressure of 100 p.s.i.g. was used to force the melt through the orifice of extrusion plate 12 to form a filamentary jet emerging into gap space 16 between plates 12 and 14.
  • Gap 16 was supplied with helium at a pressure of 76.8 p.s.i.g. and at a flow rate of 301 em /min (STP).
  • STP flow rate of 301 em /min
  • the filamentary jet Upon exit from nozzle 15, the filamentary jet enteredv gap space 19, which was supplied with carbon monoxide as the film-forming gas.
  • the carbon monoxide flow rate into gap space 19 was 5080 em /min (STP).
  • the jet then passed through stream control orifice l8 and into cavity 21 where additional carbon monoxide was supplied at a rate of 1630 em /min. (STP).
  • the film sta bilized jet which solidified upon cooling was then taken up as a filamentary product. During the course of this high-speed extrusion, the molten jet remained continuous and did not deviate from a straight path.
  • the steel wire produced without further treatment had an average tensile strength of 248,000 p.s.i.
  • the porosity of the wire as measured by the Quantimet machine of Metals Research, Ltd. averaged 0.05 percent.
  • the materials which are utilized in fabricating the plates which comprise the orifice assembly of this invention should be essentially inert, each to the other, under the conditions employed during extrusion. Moreover, the materials must be resistant to thermal shock and have sufficient strength to withstand the substantial mechanical stresses imposed by the extrusion process.
  • ceramic materials such as high density alumina, beryllia, and zirconia.
  • materials such as molybdenum and graphite can be employed.
  • stainless steel assemblies have been found to perform well. I
  • filamentary products produced in accordance with this invention have a myriad of practical uses.
  • small diameter copper and aluminum wire find wide use in various electrical devices.
  • filamentary steel is becoming even more widely used as a reinforcement element in the manufacture of modern automobile tires as well as tires for other vehicles.
  • An orifice assembly for extrudingafilamentary jet of said second orifice is from about to 100 times from an essentially inviscid melt to form fibers and filagreater than the exit diameter of said first orifice.
  • ments which comprises in combination: 3.
  • a second orifice e. a second orifice, said second orifice being centrally disposed in said second plate in co-axial alignment with said first orifice, said second orifice having a nozzle configuration with a convergent entry section, an intermediate throat section and a divergent exit section, said exit section having an included angle of divergence of .between 4 to 12;
  • a third orifice said third orifice being centrally disposed in said third plate in co-axial alignment with said first and second orifices, said third orifice having walls which converge towards the exit thereof at an included angle of between about 7 to 20;
  • a first substantially enclosed chamber said chamber being defined by a gap space between the opposing faces of said first and second plates, said gap space having a vertical distance which is substantially equal to the diameter of the throat section of said second plate orifice;
  • cluded angle of divergence in the divergent exit section of said second orifice is in the range of from about 6 to 8.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Crystals, And After-Treatments Of Crystals (AREA)
  • Communication Cables (AREA)
  • Wire Bonding (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Continuous Casting (AREA)
US00319133A 1972-12-29 1972-12-29 High speed production of filaments from low viscosity melts Expired - Lifetime US3811850A (en)

Priority Applications (24)

Application Number Priority Date Filing Date Title
US00319133A US3811850A (en) 1972-12-29 1972-12-29 High speed production of filaments from low viscosity melts
US422933A US3904381A (en) 1972-12-29 1973-12-07 Cast metal wire of reduced porosity
ZA739625A ZA739625B (en) 1972-12-29 1973-12-20 Low porosity cast wire
NL7317585A NL7317585A (fr) 1972-12-29 1973-12-21
DE2364944A DE2364944A1 (de) 1972-12-29 1973-12-28 Kontinuierlich gegossener metallfaden sowie verfahren und vorrichtung zu seiner herstellung
LU69086A LU69086A1 (fr) 1972-12-29 1973-12-28
SE7317522A SE389979B (sv) 1972-12-29 1973-12-28 Forfarande och munstycksaggregat for tillverkning av med hog hastighet gjuten legerad staltrad
AR251770A AR199018A1 (es) 1972-12-29 1973-12-28 Resistencia a la traccion, procedimiento y dispositivo un procedimiento de alambre de acero aleado fundido a alta velocidad, de pequeno diametro, que tiene una gran para su produccion
BE139388A BE809247A (fr) 1972-12-29 1973-12-28 Fils metalliques coules de porosite reduite
SU731989758A SU592339A3 (ru) 1972-12-29 1973-12-28 Способ изготовлени тонкой проволоки
AU64045/73A AU481595B2 (en) 1973-12-28 Highspeed production of fibers and from low viscosity melts
AT1089273A AT337232B (de) 1972-12-29 1973-12-28 Verfahren zum herstellen eines legierten dunnen stahldrahtes und vorrichtung zur durchfuhrung des verfahrens
GB6008673A GB1460750A (en) 1972-12-29 1973-12-28 Process and apparatus for extruding molten steel to produce a cast steel wire and wire thereby produced
BR10291/73A BR7310291D0 (pt) 1972-12-29 1973-12-28 Fio de aco liga fundido em alta velocidade, de pequeno diametro, bem como processo aperfeicoado e conjunto de orificio para produzir o mesmo
ES421852A ES421852A1 (es) 1972-12-29 1973-12-28 Un procedimiento de tratamiento de un acero aleado de cola-da muy rapida.
CA189,056A CA995030A (en) 1972-12-29 1973-12-28 Low porosity cast wire
DD175724A DD108911A5 (fr) 1972-12-29 1973-12-29
RO7377175A RO65573A (fr) 1972-12-29 1973-12-29 Fil de metal coule procede et dispositif de realisation
CS739130A CS207301B2 (cs) 1972-12-29 1973-12-29 Drát z legované ocele, způsob jeho výroby a zařízení k provádění tohoto způsobu
IE2349/73A IE38710B1 (en) 1972-12-29 1973-12-31 Process and apparatus for extruding molten steel to produce a cast steel wire and wire thereby produced
FR7400076A FR2212197B1 (fr) 1972-12-29 1974-01-02
JP49004572A JPS49125226A (fr) 1972-12-29 1974-01-04
IN198/CAL/74A IN138625B (fr) 1972-12-29 1974-01-30
CA237,597A CA994982A (en) 1972-12-29 1975-10-10 Low porosity cast wire

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US00319133A US3811850A (en) 1972-12-29 1972-12-29 High speed production of filaments from low viscosity melts

Publications (1)

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US3811850A true US3811850A (en) 1974-05-21

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US00319133A Expired - Lifetime US3811850A (en) 1972-12-29 1972-12-29 High speed production of filaments from low viscosity melts

Country Status (12)

Country Link
US (1) US3811850A (fr)
AR (1) AR199018A1 (fr)
BE (1) BE809247A (fr)
BR (1) BR7310291D0 (fr)
CA (1) CA995030A (fr)
CS (1) CS207301B2 (fr)
IN (1) IN138625B (fr)
LU (1) LU69086A1 (fr)
RO (1) RO65573A (fr)
SE (1) SE389979B (fr)
SU (1) SU592339A3 (fr)
ZA (1) ZA739625B (fr)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3853171A (en) * 1973-12-28 1974-12-10 Monsanto Co Apparatus for producing wire from the melts of steel alloys
US3854518A (en) * 1973-12-28 1974-12-17 Monsanto Co Melt extrusion method for producing wire from steel alloys
US3957933A (en) * 1975-03-05 1976-05-18 General Atomic Company Apparatus for producing microspherical particles and method for operating such apparatus
US4001357A (en) * 1972-08-02 1977-01-04 Alfred Walz Process for the manufacture of fibers from fusible materials
US20060001952A1 (en) * 2004-07-02 2006-01-05 Liekki Oy Method and device for producing optical material, and an optical waveguide
US20080047736A1 (en) * 2006-08-25 2008-02-28 David Levine Lightweight composite electrical wire

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4001357A (en) * 1972-08-02 1977-01-04 Alfred Walz Process for the manufacture of fibers from fusible materials
US3853171A (en) * 1973-12-28 1974-12-10 Monsanto Co Apparatus for producing wire from the melts of steel alloys
US3854518A (en) * 1973-12-28 1974-12-17 Monsanto Co Melt extrusion method for producing wire from steel alloys
US3957933A (en) * 1975-03-05 1976-05-18 General Atomic Company Apparatus for producing microspherical particles and method for operating such apparatus
US20060001952A1 (en) * 2004-07-02 2006-01-05 Liekki Oy Method and device for producing optical material, and an optical waveguide
US20080047736A1 (en) * 2006-08-25 2008-02-28 David Levine Lightweight composite electrical wire
US7626122B2 (en) 2006-08-25 2009-12-01 David Levine Lightweight composite electrical wire
US20100071931A1 (en) * 2006-08-25 2010-03-25 David Levine Lightweight composite electrical wire with bulkheads
US8697998B2 (en) 2006-08-25 2014-04-15 David Levine Lightweight composite electrical wire with bulkheads

Also Published As

Publication number Publication date
CA995030A (en) 1976-08-17
IN138625B (fr) 1976-03-06
AR199018A1 (es) 1974-07-31
BR7310291D0 (pt) 1974-08-15
ZA739625B (en) 1974-11-27
SU592339A3 (ru) 1978-02-05
RO65573A (fr) 1979-07-15
AU6404573A (en) 1975-07-03
CS207301B2 (cs) 1981-07-31
SE389979B (sv) 1976-11-29
BE809247A (fr) 1974-06-28
LU69086A1 (fr) 1974-08-19

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