US3822820A - Sonic agitation of molten metal - Google Patents

Sonic agitation of molten metal Download PDF

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Publication number
US3822820A
US3822820A US00398946A US39894673A US3822820A US 3822820 A US3822820 A US 3822820A US 00398946 A US00398946 A US 00398946A US 39894673 A US39894673 A US 39894673A US 3822820 A US3822820 A US 3822820A
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US
United States
Prior art keywords
vessel
shell
sonic energy
transducers
sonic
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
US00398946A
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English (en)
Inventor
N Brouwer
D Smucker
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.)
Alcoa Corp
Original Assignee
Aluminum Company of America
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
Priority to US00398946A priority Critical patent/US3822820A/en
Application filed by Aluminum Company of America filed Critical Aluminum Company of America
Publication of US3822820A publication Critical patent/US3822820A/en
Application granted granted Critical
Priority to AU71203/74A priority patent/AU472477B2/en
Priority to GB3147874A priority patent/GB1465097A/en
Priority to IT52465/74A priority patent/IT1018853B/it
Priority to DE19742439380 priority patent/DE2439380B2/de
Priority to BR6824/74A priority patent/BR7406824D0/pt
Priority to AT679874A priority patent/AT335254B/de
Priority to NL7411123A priority patent/NL7411123A/xx
Priority to JP49095464A priority patent/JPS5057050A/ja
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
    • B23K3/06—Solder feeding devices; Solder melting pans
    • B23K3/0646—Solder baths
    • B23K3/0661—Oscillating baths
    • 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
    • C23C2/32—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor using vibratory energy applied to the bath or substrate

Definitions

  • ABSTRACT Simultaneous fluxless joining, tinning and/or coating of components or workpieces is effected by the use of a sonically agitated molten metal bath maintained at a uniform temperature and contained in a vessel comprised of a curved (in cross section), solid, unitary shell.
  • the sonic agitation is provided by multiple arrays of sonic energy transducers disposed about and along the shell, and in energy transfer relationship with the bath via the shell.
  • the arrays of transducers are grouped, and the groups individually energized by sonic power generators each having means for controlling the sonic power output thereof, as well as the sonic frequency, to provide individually controllable zones of sonic energy within the vessel and molten 1 metal bath.
  • the present invention relates generally to the sonic agitation and resulting cavitation in a molten metal bath, and particularly to an arrangement whereby, in a solder bath medium, maintained at a uniform temperature, cavitation is produced to provide reliable, consist ant joining, tinning and/or coating of components with out the need of flux, and of the type required for industrial, production purposes.
  • sonic energy refers to subsonic, sonic or ultrasonic frequency energies.
  • sonic energy sources to agitate molten metal baths
  • past and present apparatus employing such sources have certain disadvantages for ambient and elevated temperature applications in an industrial environment.
  • the majority of vessels employed in the industry for containing sonically agitated moltenmetal have a generally rectangular or square configuration in cross section, the vessel being either cast in such a configuration or fabricated from metal plates welded togetheralong abutting edges to form a square or rectangularly shaped vessel.
  • Such a vessel configuration provides a bottom shell surface of limited area for attaching sonic transducers, thereby limiting the number of transducers that can be used, and thus limiting the sonic power transmitted into the molten metal.
  • the side walls of a square or rectangular shaped vessel do not readily lend themselves for the attachment of a large number of sonic energy transducers because the sidewalls are usually employed to apply heat to the vessel and thus to the molten metal contained therein. 1
  • rectangularly shaped vessels tend to be highly rigid such that the mechanical forces produced in the shell of the vessel by the sonic agitation, and resulting cavitation of the molten metal, fatigue the shell, particularly along the right angle intersections of the side and base walls thereof, the intersections forming areas of stress concentration.
  • the welds are located along the intersections of the sides and base and thus at the areas of stress concentration such that welds are weakened by the sonic agitation and cavitation.
  • Those welds that extend lengthwise of the vessel are especially susceptible to the detrimental effects of the mechanical forces generated within the vessel shell since the magnitude of the'sonic energy is substantially greater in the more central areas of the base of the vessel.
  • welded areas of a vessel may be subject to corrosive attack by components of the molten medium, such as the zinc in a zinc solder bath.
  • the welds and vessel walls are weakened such that over a period of time the vessel must either be repaired or replaced.
  • a problem associated with past and present sonic energy soldering techniques employing a bath of molten metal solder is the unevenness or non-uniformity of the agitation and cavitation along the base of the vessel, where the transducers are attached, such that sonically quiescent or dead zones occur within the medium of the bath along with zones having a high concentration of sonic energy.
  • Such zones become particularly critical when a plurality of components having a multiplicity of joining surfaces, occupying a broad area within the vessel, are immersed in the bath to effect simultaneous soldering of the joining surfaces.
  • An example of a structure having such multiplicity of joining surfaces is a heat exchanger having a multiplicity of socket joints formed by U-shaped, return bend tubes disposed on the ends of elongated tubes of the heat exchanger to serially connect the tubes together.
  • a soldering arrangement is thus unsuitable for soldering heat exchangers since all joints in a heat exchanger must be equally and satisfactorily soldered or the heat exchanger is or soon becomes a defective unit with normal use thereof.
  • the present invention overcomes the problems and disadvantages of prior and present apparatus employed to sonically agitate molten metal baths by the use of a vessel comprised of a unitary, solid, curved shell in cross section, the unitary shell providing a vessel having no welds extending between the ends of the vessel, and no welds at all if the vessel is made as a one piece unit, such as would be provided by a castingor forging process, for example. In this manner, there are no welds to be severely attacked'by a component or components of the molten metal bath andby the cavitation produced in the bath medium.
  • the arrays of sonic energy transducers are attached respectively to corresponding arrays of sonic energy coupling devices projecting outwardly from the curved, outer surface of the vessel shell.
  • the arrays of sonic transducers and coupling devices are divided into groups and energized by a correspond-' ing plurality of generators to provide individual control and/or tuning of the groups of transducers and thus provide sonic power input control to the areas of said I vessel associated respectively with the corresponding transducer groups.
  • the transducers are preferably located away from the heaters by the extent of coupling devices.
  • FIG. 2 is a side elevation view of the structure of FIG. 1, with the vessel proper being shown in section.
  • FIG. 1 of the drawing a soldering vessel or tank is shown in cross section, the vessel being comprised of a unitary, solid and curved wall or shell 12, the curve of the shell preferably extending the full length thereof, as indicated in FIG. 2. As shown in the figures, the shell may have opposed, outwardly extending flange portions 13 that extend the length thereof.
  • the vessel 10 being primarily a single piece unit has no weld areas extending the length thereof for attack by components of the molten metal (not shown) contained therein or by the cavitation of the bath, as discussed earlier.
  • the vessel includes end wall portions 14 and 16, as shown in FIG. 2, which may be an integral, unwelded portion of the shell 12, or, the end walls 14 and 16 can be made separately from shell 12 and joined to the ends of the shell by weld seams (not shown) located at the intersections of the curved ends of the shell and the planar surfaces of the end walls.
  • weld seams are not subject to severe sonic agitation and resulting cavitation of the bath since the intensity of sonic energy adjacent the ends of the vessel is minimal in comparison to that existing along the more central areas of the vessel.
  • FIG. 1 On and around the outside surfaces of the curved shell 12 are mounted, as shown in FIG. 1, four, spaced apart elongated sound energy coupling bars 18, (only one such bar being visible in FIG. 2), the number (four) of coupling bars depicted in FIG. 1 being given only for purposes of illustration. As explained hereinafter, the number of coupling bars, coupling extensions and sonic energy transducers are chosen on the basis of such factors as the amount of sonic power desired or required for a particular vessel and operation.
  • the coupling bars 18 may be formed as an integral part of the shell 12, thereby providing a continuous path between the bars and shell for maximum transfer of sonic energy into the vessel from the bars.
  • the coupling bars have outwardly projecting sound energy coupling extensions, such as horns or studs 20 spaced along the length of the bars, that provide multiple arrays of the coupling devices extending lengthwise of the vessel. In FIG. 1, only one such array is visible.
  • the coupling bars 18 are not formed as an integral part of shell 12, the bars should be attached to the shell in a manner that presents a minimum acoustical impedance to the sonic energy to be directed into the vessel. This can be accomplished with means and materials that produce a good metallurgical and sonic bond between each bar and the shell, for example, as provided by the full penetration welds 22 shown in FIG. 1, which welds extend the length of the bars.
  • the bars serve further to strengthen the vessel, and to uniformly distribute sonic energy over the vessel area.
  • Sonic energy transducers 24 are shown attached to the ends of the coupling extensions 20 remote from the shell 12, the transducers being preferably magnetostrictive devices schematically represented in the figures by cores 26 and windings 28, the transducers, like the coupling extensions, being circumferentially spaced apart around the curve of the shell, and along the length thereof (FIG. 2) to provide multiple arrays of sonic sources.
  • the transducers 24 are preferably magnetostrictive because such transducers have metallic cores that can be brazed or welded to a metal surface in a manner that presents a minimum impedance to the sonic energy developed in the core by its winding while simultaneously providing a high strength joint particularly suitable for industrial purposes.
  • the coupling extensions are stainless steel and the cores of the transducers are comprised of nickel or nickel alloy laminations
  • the laminations can be joined to the ends of the coupling extensions by silver soldering or brazing the joining materials providing a high strength, good metallurgical bond between the laminations of the transducers and the stainless steel of the coupling extensions, and thus a minimum acoustical impedance at the interfaces between the transducer cores and the coupling extensions.
  • magnetostn'ctive transducers are reliable, rugged devices that can withstand the high temperatures associated with molten metal.
  • the thickness dimension of the shell 12 and the length of each coupling extension 20 (including the bar portion 18) together is preferably one half wave length long at the resonant frequency of transducers 24.
  • heating devices 29 for heating and maintaining the molten metal bath within the vessel 10 at an elevated, molten temperature.
  • Heating devices suitable for such a purpose are preferably elongated, electric resistance heating rods located in close proximity to the vessel shell 12 but with minimum physical contact therewith to minimize damage of the rod elements by the sonic vibration.
  • the reflectors located behind the rods and facing in the direction of the vessel shell, the reflectors with the rods, serving to direct radiant heat, i.e., the heat radiated by the rods, at the vessel shell, when the rod elements conduct appropriate amounts of electrical current.
  • Such heating devices are particularly advantageous in heating an industrial soldering vessel since they can be conveniently disposed to evenly heat the vessel and soldering bath, and can be precisely, automatically controlled by thermocouples, and associate electrical apparatus, operatively associated with the vessel or with the solder content within the vessel.
  • the desirability of such control is especially critical when cavitation of the soldering bath is employed in the soldering process.
  • the cavitation phenomenon can be aggressive to the point of attacking and destroying the metal of components immersed in the bath.
  • the velocity of sound energy in the bath, which energy produces the cavitation is itself a function of the temperature of the bath.
  • control of the velocity of the sound, and thus cavitation, in the bath can be effected throughout the bath medium. In this manner, only the oxides and other impurities on the components to be soldered are removed therefrom by the cavitation, and since the cavitation is relatively uniform throughout the bath, the soldering is even and effective regardless of the location of the components within the bath.
  • vessels having different sizes and shapes have difference sonic resonant frequency characteristics, and these characteristics change to an extent when a workpiece or pieces are disposed in the molten metal bath, the degree of change depending, in turn, upon the size and configuration of the workpiece.
  • the load on the transducer is changed somewhat when the workpiece or pieces are inserted in the vessel and molten metal thereby changing somewhat the resonant frequency of the transducer.
  • a sonic frequency that is the resonant frequency of the transducer as it is affected by the load, i.e., by the configuration of the workpiece and the alteration of the vessel configuration when the workpiece is disposed in the vessel.
  • the tuning accomplished here effects optimum conversion of the electrical energy, produced by generators presently to be described, to mechanical, sonic energy at the resonant frequency of the total vessel and molten metal structure.
  • the present invention includes grouping the transducers and coupling extensions to provide selective control of sonic power into the vessel, and selective tuning of the vessel, as shown and suggested schematically in FIG. 2. More particularly, the twelve transducers 24 associated with each coupling bar 18 are shown electrically divided into three groups of four transducers by being respectively electrically connected to three electrical power generators 32, 33 and 34 designed to energize the three groups at their resonant frequency. Thus, with the arrangement depicted in the drawing, in which four coupling bars 18 each having twelve coupling extensions 20 and transducers 24, twelve generators are required, though only three are shown in FIG. 2.
  • transducers and coupling devices are given by way of example only, the number of generators, transducers and groups of transducers being chosen on the basis of such factors as the size of the vessel tobe employed and the power requirements for a particular volume and type of molten metal to be agitated.
  • each of the generators has means to control the level of its power output to its particular group of four transducers, thereby providing means to control both the magnitude and the locations of sonic energy input to the molten metal within vessel 10.
  • All of the generators can be triggered synchronously by a single, common, variable oscillator 38 (FIG. 2), designed to oscillate approximately at some range around the resonant frequency of the transducers 24, or, each generator can be individually triggered and tuned by its own variable oscillator, such oscillators being shown in dash outline in FIG. 2, and indicated by numerals 42, 43 and 44.
  • a variable frequency oscillator associated with each generator the electrical output of each generator, and thus the sonic frequency produced by its associated array of transducers, can be tuned to the resonant frequency of the transducers as they are loaded and affected by the geometry of the vessel 10 with workpieces disposed therein. In this manner, maximum transfer of sonic power to the molten metal, and to the area thereof associated with the particular group of transducers being tuned, is obtained.
  • solid as used herein in reference to the vessel refers to a shell structure that has no or substan tially no perforations or openings.
  • a vessel for containing molten metal at elevated temperatures comprising a unitary, solid, curved shell in cross section, multiple arrays of sonic energy transducers spaced apart about and along the outside of said shell, and in sonic energy transfer relationship with the shell for directing sonic energy through the shell and into a work area of the vessel whenthe transducers are energized, a plurality of electrical power generators having means for individually controlling the power output thereof, and an oscillator for commonly, synchronously triggering said generators, groups of the arrays of transducers being respectively electrically connected to and energized by said generators for providing individually controllable zones of sonic energy within the vessel, and means for uniformly heating the vessel and molten metal.
  • the coupling devices include elongated, sound energy coupling bars extending lengthwise of the vessel, and the coupling extensions form an integral part of the elongated coupling bars.
  • the heating means comprise a plurality of heaters disposed around the outside surface of the vessel shell.
  • a vessel for containing molten metal at elevated temperatures comprising a unitary, solid, curved shell in cross section, multiple arrays of sonic energy coupling devices spaced apart about the outside of said shell, with one end of each device disposed in sonic energy transfer relationship with the shell for directing sonic energy through the shell, multiple arrays of sonic energy transducers respectively attached to the ends of said coupling devices remote from the shell, the arrays of devices and transducers being capable of directing the major portion of the sonic energy produced by the transducers, when the transducers are energized, into a work area of the vessel, a plurality of electrical power generators each having an oscillator that individually triggers and tunes the generator at the frequency of said oscillator, groups of the arrays of the transducers being respectively electrically connected to and energized by the generators to provide individual tuning of zones of sonic energy within the vessel for optimum transfer of sonic energy within said zones, and means for uniformly heating the vessel
  • a vessel for containing molten metal at elevated temperatures comprising a solid, curved shell in cross section and wall portions closing the respective ends of said shell, said wall portions being welded to the ends of said shell, multiple arrays of sonic energy coupling devices spaced about the outside of the shell, with one end of each device disposed in sonic energy transfer relationship with the shell, multiple arrays of sonic energy transducers respectively attached to the ends of the coupling devices remote from the shell, the arrays of devices and transducers being capable of directing the major portion of the sonic energy produced by the transducers, when the transducers are energized, into a work area of the vessel, a plurality of electrical power generators having means for individually controlling the power output thereof and an oscillator for commonly, synchronously triggering said generators, groups of said arrays of transducers being respectively electrically connected to and energized by said generators for providing individually controllable zones of sonic energy within the vessel, and means for uniformly heating the vessel and mol

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Coating With Molten Metal (AREA)
  • Waste-Gas Treatment And Other Accessory Devices For Furnaces (AREA)
  • Electric Connection Of Electric Components To Printed Circuits (AREA)
  • Molten Solder (AREA)
US00398946A 1973-09-20 1973-09-20 Sonic agitation of molten metal Expired - Lifetime US3822820A (en)

Priority Applications (9)

Application Number Priority Date Filing Date Title
US00398946A US3822820A (en) 1973-09-20 1973-09-20 Sonic agitation of molten metal
AU71203/74A AU472477B2 (en) 1973-09-20 1974-07-15 Sonic agitation of molten metal
GB3147874A GB1465097A (en) 1973-09-20 1974-07-16 Apparatus for vibrating molten metal
IT52465/74A IT1018853B (it) 1973-09-20 1974-08-06 Agitazione sonica di un bagno di metallo fuso
DE19742439380 DE2439380B2 (de) 1973-09-20 1974-08-14 Vorrichtung zur beschallung von metallschmelzen
BR6824/74A BR7406824D0 (pt) 1973-09-20 1974-08-19 Aperfeicoamentos em aparelho para agitacao sonica a temperaturas elevadas de metal fundido contido em um vaso
AT679874A AT335254B (de) 1973-09-20 1974-08-20 Vorrichtung zur beschallung von metallschmelzen, insbesondere von lotbadern
NL7411123A NL7411123A (nl) 1973-09-20 1974-08-20 Inrichting voor het sonisch agiteren bij hoge temperaturen van gesmolten metaal.
JP49095464A JPS5057050A (enrdf_load_html_response) 1973-09-20 1974-08-20

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US00398946A US3822820A (en) 1973-09-20 1973-09-20 Sonic agitation of molten metal

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US3822820A true US3822820A (en) 1974-07-09

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US00398946A Expired - Lifetime US3822820A (en) 1973-09-20 1973-09-20 Sonic agitation of molten metal

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US (1) US3822820A (enrdf_load_html_response)
JP (1) JPS5057050A (enrdf_load_html_response)
AT (1) AT335254B (enrdf_load_html_response)
AU (1) AU472477B2 (enrdf_load_html_response)
BR (1) BR7406824D0 (enrdf_load_html_response)
DE (1) DE2439380B2 (enrdf_load_html_response)
GB (1) GB1465097A (enrdf_load_html_response)
IT (1) IT1018853B (enrdf_load_html_response)
NL (1) NL7411123A (enrdf_load_html_response)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4071179A (en) * 1975-10-31 1978-01-31 Blackstone Corporation Apparatus and methods for fluxless soldering
US20150096942A1 (en) * 2013-10-04 2015-04-09 Baker Hughes Incorporated Distributive Temperature Monitoring Using Magnetostrictive Probe Technology
CN104551289A (zh) * 2015-01-20 2015-04-29 武汉理工大学 一种异频多触点超声波辅助钎焊方法

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS52124170A (en) * 1976-04-13 1977-10-18 Standard Kogyo Kk Method of soldering printed circuit board and soldering tank
JP4635825B2 (ja) * 2005-10-28 2011-02-23 トヨタ自動車株式会社 ハンダ塗布装置およびハンダ塗布方法

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3249281A (en) * 1964-01-13 1966-05-03 Sanders Associates Inc Multiple ultrasonic solder fountain machine
US3752381A (en) * 1972-03-17 1973-08-14 Branson Instr Ultrasonic soldering apparatus

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3249281A (en) * 1964-01-13 1966-05-03 Sanders Associates Inc Multiple ultrasonic solder fountain machine
US3752381A (en) * 1972-03-17 1973-08-14 Branson Instr Ultrasonic soldering apparatus

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4071179A (en) * 1975-10-31 1978-01-31 Blackstone Corporation Apparatus and methods for fluxless soldering
US20150096942A1 (en) * 2013-10-04 2015-04-09 Baker Hughes Incorporated Distributive Temperature Monitoring Using Magnetostrictive Probe Technology
US9598642B2 (en) * 2013-10-04 2017-03-21 Baker Hughes Incorporated Distributive temperature monitoring using magnetostrictive probe technology
CN104551289A (zh) * 2015-01-20 2015-04-29 武汉理工大学 一种异频多触点超声波辅助钎焊方法

Also Published As

Publication number Publication date
GB1465097A (en) 1977-02-23
AU7120374A (en) 1976-01-15
AT335254B (de) 1977-03-10
BR7406824D0 (pt) 1975-09-23
DE2439380B2 (de) 1976-04-29
ATA679874A (de) 1976-06-15
IT1018853B (it) 1977-10-20
JPS5057050A (enrdf_load_html_response) 1975-05-19
DE2439380A1 (de) 1975-04-03
NL7411123A (nl) 1975-03-24
AU472477B2 (en) 1976-05-27

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