A device for preparing a test sample for on-site analysis of a metal material

Abstract

The utility model relates to a kind of metal material furnace front component detection sample preparation device.The utility model includes sprue cup, metal mould, mould bottom plate, support plate and cooling medium storage tank, through inner cavity is provided in the middle part of metal mould, top surface cavity is in upper part of inner cavity, lower part is sample handle cavity, sprue cup is set in top surface cavity, two oblique gas sample cavities are symmetrically distributed in the inner cavity of metal mould, mould bottom plate is set below the bottom of metal mould, sample cavity is set in the middle part of mould bottom plate, sample cavity is below sample handle cavity and gas sample cavity, cooling medium storage tank is set in the bottom of metal mould, mould bottom plate is set in cooling medium storage tank, and cooling medium is stored in cooling medium storage tank.The utility model can improve the efficiency and quality of sample preparation, ensure the accuracy of detection result, enhance the versatility of device, meet the accurate, fast demand of different metal material furnace front sample test result.

Description

TECHNICAL FIELD

[0001] The utility model belongs to the technical field of metal material sampling detection, specifically relates to a kind of furnace composition detection sample preparation device suitable for cast iron, alloy steel, copper alloy and other various metal materials, especially suitable for spark direct-reading spectrometer, X-ray fluorescence detector furnace detection sample preparation, also suitable for infrared carbon sulfur instrument, nitrogen hydrogen oxygen instrument detection sample preparation. BACKGROUND

[0002] In the production process of metal material, furnace composition detection is crucial to ensure product quality.Accurate composition detection can timely adjust production process to ensure that the performance of metal material meets the requirements.Sample preparation is a key early link of composition detection, and its quality directly affects the accuracy and reliability of detection results.

[0003] Spark source direct-reading spectrometer, high-frequency infrared carbon sulfur instrument, nitrogen hydrogen oxygen instrument and other detection equipment are commonly used furnace composition detection equipment.In order to ensure the accuracy and reliability of detection results and improve furnace detection efficiency, the prepared furnace composition test samples must meet certain requirements:1) alloy solidification structure does not interfere with detection, and the formed structure should avoid affecting the signal of detection equipment, for example, the graphite precipitated during slow solidification of cast iron can interfere with the excitation signal of spark direct-reading spectrometer, resulting in deviation of C and Si element detection values, and the coarse dendrites formed during solidification of aluminum alloy and copper alloy may cause uneven elements during X-ray fluorescence detection;2) solidification is not allowed to produce obvious segregation, and alloy elements should be avoided to be enriched and depleted due to difference in cooling speed, for example, manganese element is enriched at grain boundary during solidification of steel liquid, which can make local manganese content higher than actual composition in furnace, so that the real composition of metal liquid cannot be reflected;3) sample pretreatment is simple and has no detection interference, sample processing should not affect detection results, and steps should be less and time-consuming, for example, in the detection of carbon element in cast iron, drill chip method can affect the accurate test of C element, and the use of wire cutting method for sampling can increase sample processing procedures and prolong detection time;4) sample detection surface should be free of cracks, pores, slag inclusion, loose and other defects, and defects can cause signal interruption or introduce impurities, affecting the accuracy of detection results.

[0004] Traditional methods for preparing samples for pre-furnace composition analysis of metallic materials have several problems. For cast iron samples, to improve the degree of white cast iron formation, thin-walled sheet-like or stamp-shaped samples are often prepared using steel molds. Sheet-like samples require a dedicated magnetic grinding tool, which carries the risk of misoperation or sample ejection due to magnetic tape issues during grinding. Thin-walled stamp-shaped samples are prone to defects such as cracks and inclusions, reducing sample preparation efficiency and testing accuracy. For materials such as aluminum alloys and alloy steels, steel block samples are used, which are prone to significant compositional segregation due to differences in solidification time, and different test results vary depending on the depth of the layer. When performing gaseous element analysis on metallic materials, sampling is typically done using drilling machines or wire cutting, prolonging sample testing time. Furthermore, existing sample preparation methods generally employ mold-following cooling, resulting in low sample preparation efficiency and increased mold temperature, extending the time for secondary sampling. The utility model patent announcement number CN204988778U discloses a sampling mold for the spectral and carbon-sulfur detection of cast iron. The sample handheld end adopts an inverted cone structure, which is prone to fracture due to large stress at the root when the molten iron solidifies. The use of a flash structure is not convenient for sample pretreatment and poses a risk of deviation in the test results. Utility Model Content

[0005] To address the aforementioned technical problems in the background art, this utility model provides a sample preparation device for pre-furnace composition detection of metallic materials, which can improve the efficiency and quality of sample preparation, ensure the accuracy of detection results, and enhance the versatility of the device to meet the needs of accurate and rapid pre-furnace sample testing results for different metallic materials.

[0006] The technical solution of this utility model is as follows: This utility model is a sample preparation device for pre-furnace composition testing of metallic materials. Its special feature is that the sample preparation device includes a pouring cup, a metal mold, a mold base plate, a support plate, and a cooling medium storage box. The metal mold has a through-cavity in the middle, with a top cavity at the top and a sample handle cavity at the bottom. The top cavity is where the gating system is located. The sample handle cavity is used for forming the sample handle. The cylindrical handle can be used for handheld or mechanical clamping. The pouring cup is located within the top cavity. Two inclined gas sample cavities are symmetrically distributed on both sides of the inner cavity. They are used for venting during the filling process of the molten metal and for preparing carbon, sulfur, oxygen, nitrogen and hydrogen gas samples. The mold base plate is located below the bottom of the metal mold. The sample cavity is located in the middle of the mold base plate. The sample cavity is located below the sample handle cavity and the gas sample cavity. The mold base plate is used to support the metal mold and to detect the forming of the sample. The cooling medium storage box is located at the bottom of the metal mold. The mold base plate is located inside the cooling medium storage box. The cooling medium is used to absorb the heat added by the mold base plate.

[0007] Furthermore, the pouring cup contains a molten metal cavity and an ingate. The ingate is located below the bottom of the molten metal cavity, and the inner surface of the molten metal cavity is coated with a refractory coating. The pouring cup is used to buffer the molten alloy, and the filling rate is adjusted through the ingate to prevent the molten alloy from directly entering the mold cavity, which could lead to air entrapment and slag entrapment problems.

[0008] Furthermore, the inner cavity is a cylinder that is larger at the top and smaller at the bottom, the top cavity is a large cylinder, and the gas sample cavity is a small cylinder.

[0009] Furthermore, a boss is provided at the center of the bottom of the metal mold, and the boss is embedded in the sample cavity.

[0010] Furthermore, a hoop is provided around the outside of the metal mold to fix the metal mold.

[0011] Furthermore, the gas sample cavity is a cylindrical cavity.

[0012] Furthermore, the metal mold, hoop, and cooling medium storage tank are made of carbon steel, while the mold base plate is made of copper.

[0013] Furthermore, a support plate is provided on the cooling medium storage tank, and the mold base plate is set inside the cooling medium storage tank through the support plate.

[0014] Furthermore, cooling medium inlets and cooling medium outlets are respectively provided on both sides of the support plate.

[0015] Furthermore, the lower surface of the support plate and the inner surface of the cooling medium storage tank are coated with anti-rust paint.

[0016] This invention provides a sample preparation device for pre-furnace composition analysis of metallic materials, mainly composed of three parts: a casting system, a sample preparation system, and a cooling system. The casting system is a pouring cup used to supply molten metal at a constant temperature and flow rate to the sample cavity. The sample preparation system consists of a metal mold, a mold base plate, and a clamping ring, used for preparing samples for pre-furnace composition analysis, and also for preparing samples for gas analysis. The cooling system consists of a support plate and a cooling medium storage tank, used to float the sample preparation system on the cooling medium, accelerating the rapid solidification of the molten metal in the sample preparation system. Simultaneously, the cooling medium prevents the mold temperature in the sample preparation system from becoming too high, facilitating secondary sample preparation. This invention can be used for preparing samples for spark direct-reading spectrometers and X-ray fluorescence spectrometers for materials such as cast iron, alloy steel, aluminum alloys, and copper alloys, and also for preparing samples for high-frequency infrared carbon-sulfur analyzers and nitrogen-hydrogen-oxygen analyzers. Therefore, this invention has the following advantages:

[0017] 1) The gating system designed in this utility model is used to solve the problem that the molten metal directly impacts the metal wall of the mold in conventional methods, resulting in uneven temperature of the molten metal, unstable liquid flow, sample composition segregation and easy casting defects.

[0018] 2) The sample preparation system designed in this utility model decomposes sample preparation into two parts: the upper part is a metal mold used to prepare the sample handle. The cylindrical design solves the problem of increased solidification stress at the root of the handle that is easily caused by the inverted conical design, thus avoiding breakage during sample pretreatment. In addition, the cylindrical design facilitates clamping of non-ferrous metal samples during lathe machining. The lower part is the mold base plate, with the sample cavity set in the center. The mold base plate is made of a metal with a high thermal conductivity to improve the solidification rate of the molten metal in the cavity and solve the problems of graphite precipitation and segregation of other alloying elements in cast iron samples.

[0019] 3) The metal mold of the sample preparation system designed in this utility model is designed with a through cylindrical cavity. On the one hand, it is used for venting of the cavity during the casting process, which is conducive to filling the mold; on the other hand, it is used to prepare carbon, sulfur, oxygen, nitrogen and hydrogen gas samples. The samples are easy to pre-treat, which helps to improve the efficiency of furnace detection of the element and the accuracy of the detection results.

[0020] 4) This utility model is designed with a cooling system, which can increase the solidification rate of the sample by adding a cooling medium, prevent the mold from overheating, solve the problem of low efficiency in traditional sample preparation, and realize a fast and efficient sample preparation process to meet the timeliness requirements of pre-furnace component detection.

[0021] 5) This invention helps ensure the quality of metal material samples before furnace testing. The pouring cup smoothly injects uniformly heated molten metal into the sample cavity, completing the filling from bottom to top, avoiding defects such as porosity and inclusions that are prone to occur in samples without a pouring cup. Using a copper base plate with high thermal conductivity promotes rapid solidification of the molten metal in the sample cavity, while the cooling device absorbs the heat from the copper base plate, maintaining its high thermal conductivity. This prevents the precipitation of graphite in cast iron and the segregation of alloying elements in the molten metal, thus improving the accuracy of the test results.

[0022] 6) This invention helps improve the sample preparation efficiency for pre-furnace testing of metallic materials. The cylindrical handle of the sample avoids the stress concentration and breakage that can occur with inverted conical handles during solidification at the root, thus improving the success rate of sample preparation. The sample does not require manual grinding with the aid of a grinding machine, saving preparation time. Furthermore, the mechanically clamped handle facilitates lathe machining, improving sample pretreatment efficiency. This invention utilizes a cooling system, reducing the time required for a single sample preparation. Simultaneously, the mold base cools down rapidly, allowing for multiple sample preparations. This invention also considers the preparation of gaseous element detection samples, reducing pre-test processing and saving testing time.

[0023] 7) The device developed by this invention is more versatile. The sample handle designed in this invention eliminates the magnetic permeability requirement of the grinding mill, making it suitable for preparing samples for pre-furnace testing of various metallic materials. The increased sample cavity height, in addition to meeting the requirements for white cast iron samples for pre-furnace testing, also accommodates the sample preparation requirements of alloy steel, aluminum alloys, copper alloys, and other materials. This invention also considers the preparation of samples for gaseous element detection in alloys, meeting the needs of alloy gaseous element detection. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of this utility model;

[0025] Figure 2 This is a top view of the present invention;

[0026] Figure 3 This utility model relates to the microstructure (100×) of cast iron (carbon equivalent: 4.26%) samples analyzed before furnace preparation;

[0027] Figure 4 This utility model describes the microstructure (500×) of cast iron (carbon equivalent: 4.26%) samples analyzed before furnace preparation.

[0028] The annotations in the attached figures are explained as follows:

[0029] 1. Pour cup; 2. Molten metal cavity; 3. Ingate; 4. Hoop ring; 5. Metal mold; 6. Gas sample cavity; 7. Sample handle cavity; 8. Mold base plate; 9. Sample cavity; 10. Support plate; 11. Cooling medium inlet or outlet; 12. Cooling medium storage box; 13. Cooling medium. Detailed Implementation

[0030] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0031] See Figure 1 , 2 The structure of this utility model in a specific embodiment includes a pouring cup 1, a metal mold 5, a mold base plate 8, a hoop 4, a support plate 10, and a cooling medium storage box 12.

[0032] The pouring cup 1 is formed by 3D printing with resin sand or by molding with refractory ceramic. Its core cavity consists of a molten metal cavity 2 and an inner gate 3, with the inner gate 3 having a size of φ(4~8)mm. Before use, a refractory coating needs to be applied to the inside of the molten metal cavity 2, and it needs to be dried and preheated before use. The preheating temperature is 120℃.

[0033] The metal mold 5 is made of 45 steel and is shaped like a frustum, with its diameter gradually increasing from top to bottom (φ80mm→φ90mm). It is designed for a split-type fit. The inner cavity of the metal mold 5 is cylindrical, wider at the top and narrower at the bottom. The larger cylindrical cavity is the top cavity, in which the pouring cup 1 is embedded, forming the gating system. The smaller cylindrical cavity is the sample handle cavity 7, used for forming the sample handle. The cylindrical handle can be used for handheld use or mechanical clamping. A boss with a diameter of φ(40~45)mm is machined at the lower core of the metal mold 5. This boss serves two purposes: positioning the metal mold 5 when it is assembled onto the sample cavity 9 and forming the top surface of the sample cavity 9. The core of the boss is the sample handle cavity 7, with a diameter of φ(15~20)mm. The root of the sample handle cavity 7 needs to be machined into an arc with a radius of 4~8mm. Two inclined gas sample cavities 6, with a specification of φ(2~4)mm, are symmetrically distributed on both sides of the inner cavity of the metal mold 5. They are used for venting during the filling process of the molten metal and for preparing carbon, sulfur, oxygen, nitrogen and hydrogen gas samples. The gas sample cavities 6 are cylindrical cavities. The metal mold 5 needs to be preheated before use, with a preheating temperature of (120~200)℃.

[0034] The hoop 4 is arranged around the outside of the metal mold 5 to fix the metal mold 5. The hoop 4 is made of steel with a minimum inner diameter of 80mm. It is used in conjunction with the metal mold 5. When the mold is closed, it is placed on the top of the metal mold 5. As the height of the hoop 4 decreases, the metal mold 5 is tightly fitted.

[0035] The mold base plate 8 is used to support the metal mold 5 and also to test the forming of the sample. The mold base plate 8 is made of copper, and the core is machined with countersunk holes with a diameter of (40-45) mm and a depth of (10-15) mm to form the sample cavity 9. The entire mold base plate 8 is disc-shaped.

[0036] Support plate 10 is used to support mold base plate 8. Support plate 10 is made of stainless steel or an alloy with corrosion protection treatment, and is in the shape of a ring. The inner step of support plate 10 is used to support mold base plate 8, and the outer step is used to connect to the outer edge of cooling medium storage tank 12. A circular hole with a diameter of φ (10~20) mm is machined on the circumference of support plate 10. The circular hole forms a cooling medium inlet or outlet 11 for the injection or outflow of cooling medium 13.

[0037] The cooling medium storage tank 12 stores the cooling medium 13, which absorbs the increased heat from the mold base plate 8. The cooling medium storage tank 12 is made of stainless steel or a corrosion-resistant alloy. During use, it contains the cooling medium, ensuring it is in contact with the mold base plate 8. The cooling medium 13 can be water, brine, ice, liquid nitrogen, etc. The lower surface of the support plate 10 and the inner surface of the cooling medium storage tank 12 are coated with anti-rust paint.

[0038] Before using this invention, a metal mold release coating needs to be applied to the metal mold 5, mold base plate 8, and sample cavity 9. During use, the metal mold 5 and mold base plate 8 need to be preheated to 200℃. During assembly, first place the support plate 10 on the cooling medium storage tank 12, ensuring a tight fit, and then place it in an area in front of the melting furnace for easy pouring. Next, place the mold base plate 8 on the support plate 10, with the sample cavity 9 opening of the mold base plate 8 facing upwards, and its outer edge fitting with the inner edge of the support plate 10. After manually closing the metal mold 5, align its lower end face boss with the sample cavity 9 of the mold base plate 8, and use the clamping ring 4 to lock the metal mold 5. The pouring cup 1 is embedded in the top cavity of the metal mold 5. 1-2 minutes before pouring, inject water, brine, or liquid nitrogen through the round hole (cooling medium inlet or outlet 11) on the support plate 10. Ice needs to be placed in the cooling medium storage tank 12 during molding.

[0039] When preparing the cast iron pre-furnace composition test sample, a sufficient amount of molten iron is scooped from the sampling spoon and slowly poured into the molten metal cavity 2 of the pouring cup 1. The molten iron flows along the inner gate 3 of the pouring cup 1 and the sample handle cavity 7, then into the sample cavity 9 of the mold base plate 8, completing the filling of the sample cavity 9, sample handle cavity 7, and gas sample cavity 6. After the molten iron pouring is completed, water is injected into any round hole (cooling medium inlet or outlet 11) on the support plate 10. The molten iron is rapidly heat-conducted by the metal mold 5, and the cast iron solidifies from the bottom of the sample upwards and from the wall of each metal cavity inwards. The molten iron in the sample cavity 9 solidifies rapidly due to the rapid heat transfer from the mold base plate 8. See [link to relevant documentation]. Figure 3 , 4 Carbon elements do not have time to precipitate into graphite structure and transform into white iron structure, which is beneficial for the full element detection of spark source direct-reading spectrometer, a commonly used instrument for furnace front detection. In addition, the sample prepared in gas sample cavity 6, after surface polishing, can be cut to an appropriate length using sample clamps and used for high-frequency infrared carbon-sulfur analyzer to test the carbon and sulfur content in cast iron.

[0040] The content of this utility model and the technical content not specifically described in the above embodiments are the same as the prior art.

[0041] The above are merely specific embodiments disclosed in this utility model, but the scope of protection disclosed in this utility model is not limited thereto. The scope of protection disclosed in this utility model shall be determined by the scope of protection of the claims.

Claims

1. A sample preparation device for pre-furnace composition analysis of metallic materials, characterized in that: The metal material pre-furnace composition detection sample preparation device includes a pouring cup, a metal mold, a mold base plate, a support plate, and a cooling medium storage box. The metal mold has a through-cavity in the middle, with a top surface cavity at the top and a sample handle cavity at the bottom. The pouring cup is located in the top surface cavity. Two inclined gas sample cavities are symmetrically distributed on both sides of the inner cavity of the metal mold. The mold base plate is located below the bottom of the metal mold, and a sample cavity is located in the middle of the mold base plate. The sample cavity is located below the sample handle cavity and the gas sample cavity. The cooling medium storage box is located at the bottom of the metal mold, and the mold base plate is located inside the cooling medium storage box, which stores the cooling medium.

2. The metal material pre-furnace composition detection sample preparation device according to claim 1, characterized in that: The pouring cup is provided with a molten metal cavity and an ingate. The ingate is located below the bottom of the molten metal cavity, and the inner surface of the molten metal cavity is coated with a refractory coating.

3. The metal material pre-furnace composition detection sample preparation device according to claim 2, characterized in that: The inner cavity is a cylinder that is larger at the top and smaller at the bottom, the top surface cavity is a large cylinder, and the gas sample cavity is a small cylinder.

4. The metal material pre-furnace composition detection sample preparation device according to claim 3, characterized in that: The metal mold has a boss at the center of its bottom, which is embedded in the sample cavity.

5. The metal material pre-furnace composition detection sample preparation device according to claim 4, characterized in that: The metal mold is surrounded by a hoop.

6. The metal material pre-furnace composition detection sample preparation device according to claim 5, characterized in that: The gas sample cavity is a cylindrical cavity.

7. The metal material pre-furnace composition detection sample preparation device according to claim 6, characterized in that: The metal mold, hoop, and cooling medium storage tank are made of carbon steel, and the mold base plate is made of copper.

8. The metal material pre-furnace composition detection sample preparation device according to any one of claims 1 to 7, characterized in that: A support plate is provided on the cooling medium storage box, and the mold base plate is set inside the cooling medium storage box through the support plate.

9. The metal material pre-furnace composition detection sample preparation device according to claim 8, characterized in that: The support plate has a cooling medium inlet and a cooling medium outlet on each side.

10. The metal material pre-furnace composition detection sample preparation device according to claim 9, characterized in that: The lower surface of the support plate and the inner surface of the cooling medium storage tank are coated with anti-rust paint.

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