WO2021243406A1 - Outil défibreur et procédé de fabrication d'un outillage similaire - Google Patents

Outil défibreur et procédé de fabrication d'un outillage similaire Download PDF

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Publication number
WO2021243406A1
WO2021243406A1 PCT/AU2021/050542 AU2021050542W WO2021243406A1 WO 2021243406 A1 WO2021243406 A1 WO 2021243406A1 AU 2021050542 W AU2021050542 W AU 2021050542W WO 2021243406 A1 WO2021243406 A1 WO 2021243406A1
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WO
WIPO (PCT)
Prior art keywords
tool
passages
fiberizer
flow
spinner
Prior art date
Application number
PCT/AU2021/050542
Other languages
English (en)
Inventor
Barrie Robert Finnin
Jason Anthony Miller
Salvatore TARTAGLIA
Dacian TOMUS
Original Assignee
Amaero Engineering Pty Ltd
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 claimed from AU2020901806A external-priority patent/AU2020901806A0/en
Application filed by Amaero Engineering Pty Ltd filed Critical Amaero Engineering Pty Ltd
Publication of WO2021243406A1 publication Critical patent/WO2021243406A1/fr

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Classifications

    • 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • 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
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/30—Process control
    • B22F10/38—Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
    • 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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
    • 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
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B37/00—Manufacture or treatment of flakes, fibres, or filaments from softened glass, minerals, or slags
    • C03B37/01—Manufacture of glass fibres or filaments
    • C03B37/04—Manufacture of glass fibres or filaments by using centrifugal force, e.g. spinning through radial orifices; Construction of the spinner cups therefor
    • C03B37/045—Construction of the spinner cups
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D4/00—Spinnerette packs; Cleaning thereof
    • D01D4/02—Spinnerettes
    • D01D4/022—Processes or materials for the preparation of spinnerettes
    • 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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F2005/002—Tools other than cutting tools
    • 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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F2005/005—Article surface comprising protrusions
    • 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • This invention relates to spinner tools for rotary fiberization processes, and methods for manufacturing and refurbishment of such tools.
  • Fibres of glass and other thermoplastic materials are useful in a variety of applications including acoustical and thermal insulation materials.
  • High temperature rotary fiberization processes form fibres from molten thermoplastic materials (e.g. a glass composition) by using centrifugal force to pass the molten thermoplastic material through patterns of holes in an annular peripheral sidewall of a spinner tool.
  • the spinner is subjected to high temperatures and high rotational speeds that exert substantial force on the spinner.
  • An example of such a process is a high temperature rotary glass fiberizing process wherein molten glass is typically fiberized at temperatures in excess of 1000° C. by passing the molten glass through rows of fiberizing holes in an annular peripheral sidewall of a spinner disc that is rotating at thousands of revolutions per minute.
  • the temperature of the spinner disc sidewall must be maintained high enough for proper glass flow through the fiberizing holes in the sidewall.
  • the peripheral sidewall includes a large number (typically 20,000 - 40,000) of holes distributed across the face of the sidewall.
  • Spinners are operated at elevated temperatures, under high mechanical stress due to high rotational speeds (for example in the range of approximately 2,000 rpm to 4,000 rpm), often in an extremely corrosive environment, particularly where the thermoplastic material is a molten glass.
  • Spinners are therefore typically formed from materials having high rupture strength and high oxidation resistance at elevated temperatures.
  • the holes through the sidewall of the spinner weaken the face and the punishing conditions encountered during use results in the eventual failure of even such highly robust materials.
  • the operating environment and the nature of the materials being processed causes the holes to wear and enlarge over time, and failure of the spinner may then be caused by cracks that grow from one hole to another along the sidewall.
  • the hole patterns of the prior art spinners are generally designed to spread the holes across the entire face of the sidewall to maximize the distance between adjacent holes.
  • a method for fabricating a fiberizer spinner tool comprising: forming a spinner base plate having a circular peripheral interface surface; and fabricating a circularly symmetric sidewall structure onto the base plate interface surface (the circular peripheral interface surface), the sidewall structure including an array of fiberization passages therethrough.
  • the operation of fabricating the sidewall structure comprises building the sidewall structure layer-by-layer onto the base plate by way of a selective laser melting process.
  • At least a subset of the array of fiberization passages includes non-linear geometry.
  • the spinner base plate may be formed from a portion of a previously used fiberizer spinner tool.
  • the spinner base plate may formed by way of a selective laser melting process.
  • the sidewall structure comprises a plurality of flow-paths configured to direct a material for fiberization to said array of fiberization passages.
  • the sidewall structure may be fabricated with an internal geometry including projections, protrusions, and/or recessed regions that define the flow-paths.
  • the sidewall structure comprises fluting that delimits at least some of said plurality of flow- paths.
  • the sidewall structure may comprises grooves or channels that delimit at least some of said plurality of flow-paths.
  • the sidewall structure may comprise fins and/or ribs that delimit at least some of said plurality of flow-paths.
  • the flow-paths may be configured to increase the pressure and/or flow of the material to the fiberizer holes.
  • the flow-paths may be configured to adjust the flow of the material up the sidewall to enhance the distribution of material to the fiberization passages.
  • the sidewall structure may comprises strengthening features.
  • the sidewall structure may be fabricated with an internal geometry including projections, protrusions, and/or recessed regions that define strengthening features.
  • the strengthening features comprise fins and/or ribs.
  • strengthening features e.g. fins or ribs
  • the sidewall structure comprises strengthening features, said strengthening features delimiting a plurality of flow-paths configured to direct a material for fiberization to said array of fiberization passages.
  • a method of fabricating componentry for channelling flowable material through passages down to sub-millimetre restriction comprising designing a component wall structure with an array of passages, and building the component with said wall structure including passages in an additive manufacturing process using selective laser melting.
  • the method further comprises designing the component wall structure such that it further comprises a plurality of flow-paths configured to direct the flowable material to said passages; wherein building the component further comprises building the component with said wall structure including the plurality of flow-paths in the additive manufacturing process using selective laser melting.
  • a method of fabricating a manufacturing tool having passages for channelling flowable material therethrough comprising building the tool structure including passages in an additive manufacturing process using selective laser melting, wherein said passages have non-linear geometry.
  • the tool further comprises a plurality of flow-paths configured to direct the flowable material to said passages; wherein building the tool structure further comprises building the tool structure having said flow-paths in the additive manufacturing process using selective laser melting.
  • the present invention also contemplates a method of fabricating a manufacturing tool having features for optimal load distribution under operating conditions with respect to minimised mass, and/or a method of fabricating a manufacturing tool having features for optimal fluid dynamics affecting desirable outcomes in mixing, heat distribution and viscoelastic behaviour of an input process material.
  • the present invention also provides a manufacturing tool fabricated according to a method as described above, or comprising componentry fabricated according to a method as described above.
  • a fiberizer tool having non-linear fiberization passages.
  • the non-linear fiberization passages each pass through a sidewall structure, and the sidewall structure comprises a plurality of flow- paths configured to direct a material for fiberization to said non-linear fiberization passages.
  • Said sidewall structure may have an internal geometry including projections, protrusions, and/or recessed regions that define the flow-paths as described above.
  • said sidewall structure may have an internal geometry including projections, protrusions, and/or recessed regions that define strengthening features as described above.
  • Linear fiberization passages are passages which are oriented radially and have a consistent diameter profile along the passage. Fiberization passages with a non-linear geometry depart from the linear configuration in relation to orientation and/or diameter profile. Thus, in some embodiments, the non-linear geometry provides a tortuous flow- path through the fiberization passage.
  • Non-linear fiberization passages may have a non-linear diameter profile.
  • the non-linear fiberization passages may have a non-linear diameter profile providing a constriction at: the portion of the passage near the internal face of the sidewall; the portion of the passage near the external face of the sidewall; both portions (i.e. a constriction at each end of the passage); and/or an intermediate portion of the passage.
  • a constriction in the passage may be concentric with the remainder of the passage.
  • the centre of the constriction may be aligned with the average centreline of the passage.
  • the constriction may be eccentric.
  • one or more of the constrictions may be offset from each other.
  • the non-linear fiberization passages may have a non-linear diameter profile providing an enlarged portion (e.g. ballooning or flaring) at: the portion of the passage near the internal face of the sidewall; the portion of the passage near the external face of the sidewall; both portions (i.e. a enlarged portion at each end of the passage); and/or an intermediate portion of the passage.
  • An enlarged portion in the passage may be concentric with the remainder of the passage.
  • the centre of the enlarged portion may be aligned with the average centreline of the passage.
  • the enlarged portion may be eccentric.
  • one or more of the enlarged portions may be offset from each other.
  • the non-linear fiberization passages may have an angular or curved path relative to the radial direction.
  • the radial direction is perpendicular to the rotational Z-axis of the tool.
  • angular non-linear fiberization passages may be oriented at an angle to the X-Y plane or a non-perpendicular angle relative to the rotational Z-axis.
  • the curved path of a curved non-linear fiberization passage may be a two-dimensional curve or a three-dimensional curve.
  • the non-linear fiberization passages may be oriented radially when having a non-linear diameter profile.
  • Altering the geometry of the passages may alter the flowrate and/or pressure gradient in the material flowing through the passages.
  • the flow passages may each be configured to provide a predetermined flowrate and/or pressure gradient in the material flowing through the passage during use of the fiberizer tool.
  • the fiberization passages of the fiberizer tool may each be the same. Alternatively, the tool may have more than one type of passage. There may be one or more subsets of different fiberization passages. In some embodiments, the fiberizer tool may have a combination of linear and non-linear fiberization passages. In some embodiments, the geometry of the passages may change up the height of the sidewall. For example, the fiberization passages may be adapted for the differing flow characteristics of the flowable material as it travels up the sidewall of the fiberizer tool. Changing the geometry of the passages, including adjusting the number and/or location of holes with a particular type of geometry, can change the proportion of fibres produced for a given size range.
  • the geometry of the passages may be configured to produce fibres with a desired proportion(s) in a given size range(s).
  • the present invention also relates to fabricating componentry for channelling flowable material through passages down to sub-millimetre restriction or to fabricating a manufacturing tool having passages for channelling flowable material therethrough.
  • non-linear fiberization passages refers to passages for a fiberizer tool, it will be appreciated that passages in the componentry and the passages in the manufacturing tool may have non-linear geometries as described above, including a combination of different geometries.
  • Figure 1 is a perspective view of a representative fiberizing spinner tool seen in central vertical cross-sectional;
  • Figure 2 is a diagrammatic side sectional view of a fiberizing spinner tool in operation
  • Figures 3 A and 3B are flow-chart diagrams of a tool fabrication process according to an embodiment of the invention.
  • Figures 4A-4D illustrate a fiberizing spinner tool in various stages during fabrication according to an embodiment of the invention, seen in upper perspective view;
  • Figures 5A-5D illustrate a fiberizing spinner tool in various stages during fabrication according to an embodiment of the invention, seen in front view;
  • Figure 6 is a sectional perspective view of a spinner tool during fabrication according to embodiments of the invention.
  • Figure 7 is a side view of the spinner tool corresponding to Figure 6;
  • Figure 8 is an enlarged perspective view of a sidewall structure of the spinner tool during fabrication
  • Figure 9 is a sectional perspective view of a spinner tool according to embodiments of the invention when fabrication is complete;
  • Figures 10A-10D are diagrammatic horizontal cross-sectional views of a spinner tool sidewall illustrating examples of fiberizer channel configurations according to embodiments of the invention.
  • FIGS. 11A and 11B are diagrammatic illustrations of a selective laser melting apparatus used in embodiments of the invention.
  • Figure 12 is a partial sectional view of a fiberizer spinner tool structure according to an embodiments of the invention.
  • Figure 13 is a horizontal cross-sectional view of the embodiment of a fiberizer spinner tool structures shown in Figure 12; and Figures 14 and 15 are quarter sectional views of examples of fiberizer spinner tool structures according to embodiments of the invention.
  • FIG. 1 An example of a fiberizing spinner tool 10 is shown in a central vertical cross-section in Figure 1.
  • Figure 2 diagrammatically illustrates the spinner tool 10 in use.
  • Spinner tools of this kind are especially suited for fiberizing molten thermoplastic fiberizable materials, such as but not limited to glass, into fibres in elevated temperature (e.g. operating temperatures of about 1000°C and greater) rotary fiberizing processes.
  • the spinner tool 10 for fiberizing molten thermoplastic fiberizable materials in a rotary fiberizing process typically has a base plate 20, an annular peripheral sidewall 30, and an annular reinforcing flange 25.
  • the annular peripheral sidewall 30 has a lower annular edge portion and an upper annular edge portion.
  • the lower annular edge portion of the annular peripheral sidewall 30 is integral with and extends upward from an outer peripheral edge portion of the base plate 20.
  • the annular reinforcing flange 25 is integral with and extends radially inward from the upper annular edge portion of the annular peripheral sidewall 30.
  • the annular peripheral sidewall 30 has a plurality of rows of fiberizing holes 40 therein through which the molten thermoplastic fiberizable material (e.g. glass 50 shown in Figure 2) is passed by centrifugal force to form glass fibres 55.
  • the fibres 50 produced by passing the molten glass through the rows of fiberizing holes 40 in the spinner tool 10 are further attenuated by an annular curtain of hot, high velocity products of combustion and/or a high velocity annular curtain of air, steam, etc., discharged from a burner, manifold assembly or the like (not shown).
  • the base plate 20 has a central bore 22 located on the rotational axis of the spinner tool 10.
  • the spinner tool 10 is mounted on a drive shaft 12 which passes through the central bore 22 of the base plate and is clamped or otherwise secured to the base plate 20.
  • the molten fiberizable material 50 is poured or otherwise introduced into the interior of the spinner tool from above and onto base plate 20.
  • the centrifugal force caused by the rapid rotation of the spinner tool causes the molten thermoplastic fiberizable material 50 to flow outward from its point of introduction onto the base plate 20 and up the inner surface of the sidewall 30.
  • the centrifugal force is sufficient to cause the molten thermoplastic fiberizable material 50 to flow out through the rows of fiberizing holes 40 whereupon it is formed into fibres 55.
  • the spinner tool 10 for a high temperature rotary fiberizing operation typically ranges from about 20 centimetres to over one metre in diameter; has a sidewall 30 that ranges from about 2 centimetres to about 10 centimetres in height; and contains thousands to tens of thousands of small diameter fiberizing holes 40.
  • the holes 40 may be in the order of 0.5 millimetres or less in diameter (the holes shown in Figures 1 and 2 are greatly exaggerated in diameter relative to the overall size of the tool for ease of illustration).
  • the fiberizing holes 40 While a spinner tool is in service, the fiberizing holes 40 become progressively larger in diameter due to the erosive action of the molten fiberizable material on the passages forming the fiberizing holes.
  • the fiberizing holes 40 can become so enlarged that the sidewall 30 of the spinner tool 10 can rupture or otherwise structurally fail, typically along one or more of the rows of fiberizing holes in the sidewall.
  • the spinner tool 10 can be made from various elevated temperature resistant alloys ('superalloys') such as but not limited to elevated temperature resistant stainless iron, nickel and cobalt alloys. Conventionally the spinner tool 10 is fabricated, typically by casting, although some machining may additionally be employed. After fabrication of the spinner tool body, the fiberizing holes 40, typically numbering in the thousands to tens of thousands and ranging in diameter from about 0.3 millimetres to about 1 millimetre, are formed in the annular peripheral sidewall 30 by commercially available drilling methods, such as by laser, electron beam, twist, EDM, etc. There are challenges and limitations to this manufacturing process, however.
  • Embodiments of the present invention allow for fabrication of a fiberizer spinner tool that is not subject to the limitations mentioned above.
  • a method according to embodiments of the invention can be used to refurbish and improve an existing spinner tool, or can be used to construct a new spinner from scratch.
  • FIGs 3A and 3B are flow-chart diagrams of a procedure 80 whereby an existing spinner tool, for example a spinner that has failed or otherwise reached the end of its operational life, is refurbished according to an embodiment of the invention.
  • the procedure is described below with reference also to Figures 4-13.
  • Step 102 of the spinner tool refurbishment procedure 80 represents fabrication of a spinner tool 10 according to conventional techniques as described above.
  • the spinner 10 is used (step 84) in suitable apparatus to create fibres and eventually, through corrosion or the like, reaches the end of its operational life (step 86). Ordinarily the expired spinner tool 10 would be discarded and replaced with a new one that has been fabricated in conventional manner.
  • embodiments of the present invention provide for the expired spinner tool to be refurbished to include potential improvements over the originally manufactured spinner.
  • step 88 of the procedure 80 involves machining the expired spinner tool to remove the original flange 25 and sidewall 30, leaving essentially the base plate portion 20.
  • the failed tool rim is machined to just below the array of holes, producing a flat and parallel surface relative to the hub section of the spinner tool.
  • FIG. 11 A is a diagrammatic illustration of selective laser melting in the form of a laser powder bed fusion (L-PBF) metal additive manufacturing apparatus 200.
  • L-PBF laser powder bed fusion
  • each 2D slice of the part geometry is fused by selectively melting the powder. This is accomplished with a beam from a high-power laser 208.
  • the laser beam is directed in the X and Y directions with two high frequency scanning mirrors (210).
  • the laser energy is intense enough to permit full melting (welding) of the particles to form solid metal.
  • the process is repeated layer after layer until the part is complete.
  • a purpose designed adapter build plate 212 is manufactured (step 90 of procedure 80) to accommodate the machined base plate 120.
  • the adapter build plate is provided with a recess 214 that matches the height of the machined surface 129 of the base plate to minimise the powder required to start printing.
  • the adapter build plate is diagrammatically illustrated in Figure 11B which shows the fabrication in process.
  • the additive manufacturing process utilised by embodiments of the invention allow for the resulting fabricated spinner tool to include specific geometry of the fiberizing holes that would not be possible in conventionally constructed spinner tools.
  • a non-linear hole trajectory through the spinner sidewall can provide a longer path that potentially disperses erosion resulting in longer tool life.
  • Other geometry advantages may be in the addition of strengthening features such as fins or ribs in the spinner tool structure.
  • the resulting fabricated spinner tool can include specific internal geometry configured to direct the flowable material to the fiberizing holes.
  • the internal geometry may include projections, protrusions, and/or recessed regions configured to define the bounds of flow-paths for the flowable material.
  • the strengthening features may be configured to delimit the flow-paths.
  • step 92 of procedure 80 can involve development of a selection of array hole geometries designed to control parameters such as glass flow rate, fibre diameter and length. These designs may be optimised and stored in a library for a range of product configurations/applications based on customer requirements.
  • step 92A of procedure 80 can involve (i) development of a selection of array hole geometries; and (ii) development of the internal geometry of the rim to provide strengthening features and/or flow-paths for the flowable material.
  • the spinner rim may be designed so as to have features for advantageous fluid dynamics affecting desirable outcomes in mixing, heat distribution and viscoelastic behaviour of the input process material.
  • FIGS 10A-10D diagrammatically illustrate several exemplary fiberizer hole passage geometries.
  • a portion of a spinner tool sidewall 130 is shown in horizontal section with the fiberizer hole passages 145A-145D extending therethrough from an interior surface 131 to an exterior surface 132 of the sidewall.
  • the passages 145A seen in Figure 10A have a conventional linear form with constant diameter, oriented radially with respect to the spinner axis (i.e. perpendicular to the sidewall at each of the interior and exterior surfaces).
  • the passages 145B and 145C seen in Figure 10B and IOC are also oriented radially, but have a non-linear diameter profile, notably near the interior and/or exterior surfaces.
  • the passages 145D seen in Figure 10D curve from their entrance (interior surface 131) to their exit (exterior surface 132).
  • Other non-linear passage profile geometries are also possible.
  • the non-linear passages may have an angular path relative to the radial direction.
  • the fiberizer passages are the same in each instance, it is also possible to design and construct a spinner tool which has more than one type of fiberizer hole.
  • the spinner sidewall is fabricated using the laser powder bed fusion (L-PBF) metal additive manufacturing technique, printing onto the base plate rim surface 129.
  • L-PBF laser powder bed fusion
  • the recrystallization conditions may create a variation in mechanical properties which can lead to a localized weak zone, cracking, corrosion susceptibility, and anisotropy.
  • SLM parts may have anisotropy between the X-Y plane and the Z build direction. This can be more pronounced with specific alloy types, especially where the alloy phases have different volumetric crystal structures, such as in titanium alloys.
  • a shielding gas such as argon or nitrogen where reactive metals are being applied.
  • an interfacing layer (step 94 of procedure 80) of compatible material onto the base plate to enable consistent/integral fusion between it and a specialized alloy (e.g. superalloy, refractory metal and or ceramic) developed for the selective laser melting process. If the sidewall alloy is able to interface directly with the base plate then a separate interfacing layer may be obsolete.
  • a metal superalloy such as the nickel cobalt variants or an alloy combination optimised for thermal fatigue durability and wear resistance.
  • Fabrication of the sidewall structure including the optimised design for an array of fiberizer holes is completed at step 96 of procedure 80.
  • This may also include fabrication of the top flange 25, which can be formed from the same material as the sidewall, or a different material.
  • a stress relieving heat treatment and, depending on the alloy selection, post heat treatment may be performed (step 98) although bearing in mind that the spinner in use operates at temperatures likely in excess of 1000°C the material structure will probably be fully normalized in the first use.
  • the spinner tool would then be inspected for defects (for example by use of x-rays) and balanced.
  • a final surface treatment may also be performed.
  • the spinner tool sidewall including fiberizer passages may be built up on a recycled base plate prepared from an expired spinner tool.
  • This may include utilizing materials for the printed section that are dissimilar from the base recovered material, or there may be numerous new materials printed in various discrete stages forming a composite (referred to as hybrid tooling solution).
  • hybrid tooling solution One of the advantages is that the 3D printing technology provides novel design freedom with materials and design features, and it is expected to be a cost effective solution compared to the conventional methods such as laser/electron beam drilling used to create the fine array of holes in the tool.
  • SLM tool refurbishment will be a reduction in lead time and/or material and labour cost. Improved tool durability and performance would also be an expected advantage.
  • This method of refurbishing tools may also be suitable for a range of other applications requiring intricate features that are costly to produce using conventional methods.
  • 3D printing onto a wrought machined base or a recycled substrate the printing time and cost would be reduced significantly as compared to printing a complete tool. Nevertheless, it is also possible to form the entire spinner tool, including the base plate, by way of metal additive manufacturing.
  • SLM selective laser melting
  • SLS selective laser sintering
  • DMLS direct metal laser sintering
  • Sintering processes produce porous parts that require a post processing step whereby the parts undergo hot isostatic pressing (HIP) to reduce the pores between partially melted metal particles.
  • HIP hot isostatic pressing
  • binder jet method that effectively glues the powder together, like sintering, until it is consolidated in a post heat treatment.
  • Embodiments of the present invention enable a non-linear fiberizer hole trajectory through the spinner tool sidewall which may result in a longer flow-path that potentially disperses erosion resulting in longer tool life.
  • These features may be only able to be fabricated using a metal 3D printing process that is highly precise, such as SLM or EBM.
  • Other direct energy deposition (DED) processes currently utilized for tool refurbishment do not have the accuracy for fine details such as the holes in the spinner tool rim.
  • DED direct energy deposition
  • other geometry advantages may be provided in the addition of strengthening features such as fins or ribs in the spinner tool structure.
  • the internal geometry of the sidewall structure may be configured to provide advantageous flow-paths for the flowable material.
  • FIG 12 shows a partial sectional view of a fiberizer spinner tool 100 including a plurality of curved fins 160 projecting from the sidewall 130 (the fiberizer holes are not shown in this drawing).
  • a horizontal cross-section view of this embodiment of the tool 100 is shown in Figure 13 (the fiberizer holes are not shown in this drawing).
  • a plurality of curved fins 160 are provided at equidistant intervals around the circumference of the internal surface of the sidewall 130.
  • the fins 160 provide an impeller-like structure that can provide an advantageous flow of the flowable material (e.g. glass) through the tool 100.
  • Adjacent fins 160 each define flow-paths 170 that direct the flowable material to fiberizer holes (not shown) around the sidewall 130.
  • the fins 160 also act as strengthening features that improve the rigidity of the sidewall 130, which can enhance tool-life.
  • the embodiment shown in Figures 12 and 13 is a refurbished fiberizer spinner tool 100.
  • the fins 160 are configured such that they are not connected to the base plate 120. Instead, the fins 160 are fabricated along with the rest of the sidewall 130.
  • the fins 160 are designed to project from the sidewall 130 starting from above the interfacing layer (printed in step 94 of procedure 80).
  • the interfacing layer may include a portion of the fin or similar projection from the sidewall.
  • the fins may be configured to extend along the sidewall, from the base plate to the flange.
  • a combination of projections, protrusions, and/or recessed regions may be provided so as to provide an internal geometry with the desired flow-paths for the flowable material and/or strengthening features.
  • the fins 160 can also act a frame to support the fabrication of the flange 125. It is known in additive manufacturing to provide sacrificial frames of material to support the fabrication of protruding features such as a flange. Such sacrificial frames can be used to manufacture embodiments of the invention, such as embodiments in accordance with Figures 4A to 4D. Typically, when a sacrificial frame is used to support the fabrication of the flange, the frame is removed as part of a finishing step. Thus, configuring fins 160 so as to act as a frame for the fabrication of the flange 125 may be advantageous, as it avoids the step of removing the frame after fabrication.
  • the general shape of the sidewall structure may typically, although not necessarily, follow that of the original tool.
  • the refurbished spinner tool 100 shown in Figures 4 and 5 has a sidewall structure 130 that projects vertically from the base plate 120 in an annular formation.
  • tool fabrication according to embodiments of the present invention enables other variations of sidewall structures, such as shown in Figures 14 and 15 (the fiberizer holes are not shown in these drawings).
  • Figure 14 shows a tool having a sidewall 230 that is frustoconical in form in its lower section, angled outwardly from the base plate 220.
  • the sidewall 330 shown in Figure 15 has a form with a continuous curvature.

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  • Manufacturing & Machinery (AREA)
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  • Mechanical Engineering (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Plasma & Fusion (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Physics & Mathematics (AREA)
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  • Organic Chemistry (AREA)
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  • Automation & Control Theory (AREA)
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Abstract

L'invention concerne des outils centrifugeurs entrant dans des processus de défibrage rotatifs, comprenant des outils ayant des passages de défibrage non linéaires, et des procédés de fabrication et de remise en état de tels outils. Selon un aspect, l'invention concerne un procédé de fabrication d'un outil défibreur centrifugeur comprenant : la formation d'une plaque de base de centrifugeuse, qui peut utiliser une partie d'un outil défibreur centrifugeur précédemment utilisé, ayant une surface d'interface périphérique circulaire ; la fabrication d'une structure de paroi latérale à symétrie circulaire sur la surface d'interface de plaque de base, la structure de paroi latérale comprenant un réseau de passages de défibrage la traversant.
PCT/AU2021/050542 2020-06-02 2021-06-02 Outil défibreur et procédé de fabrication d'un outillage similaire WO2021243406A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2020901806A AU2020901806A0 (en) 2020-06-02 A Fiberizer Tool and Method For Fabricating Like Tooling
AU2020901806 2020-06-02

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WO2021243406A1 true WO2021243406A1 (fr) 2021-12-09

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2023211817A1 (fr) * 2022-04-26 2023-11-02 Owens Corning Intellectual Capital, Llc Fileurs

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1995029882A1 (fr) * 1994-05-02 1995-11-09 Owens Corning Panier centrifugeur de production de fibres a deux composants
WO2017009247A1 (fr) * 2015-07-13 2017-01-19 Siemens Aktiengesellschaft Brûleur pour turbine à gaz
CN110228944A (zh) * 2019-06-26 2019-09-13 王辉 岩棉成纤高速离心机辊头
WO2020046894A1 (fr) * 2018-08-27 2020-03-05 Knauf Insulation, Inc. Appareils centrifugeurs rotatifs, procédés, et systèmes de production d'une fibre à partir d'une matière fondue

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1995029882A1 (fr) * 1994-05-02 1995-11-09 Owens Corning Panier centrifugeur de production de fibres a deux composants
WO2017009247A1 (fr) * 2015-07-13 2017-01-19 Siemens Aktiengesellschaft Brûleur pour turbine à gaz
WO2020046894A1 (fr) * 2018-08-27 2020-03-05 Knauf Insulation, Inc. Appareils centrifugeurs rotatifs, procédés, et systèmes de production d'une fibre à partir d'une matière fondue
CN110228944A (zh) * 2019-06-26 2019-09-13 王辉 岩棉成纤高速离心机辊头

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2023211817A1 (fr) * 2022-04-26 2023-11-02 Owens Corning Intellectual Capital, Llc Fileurs

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