Scrap submergence device

Abstract

A scrap submergence device comprises a body of heat resistant and / or a refractory material that includes a side wall and a base that define a submergence chamber. The refractory body includes a frame embedded therein.

Description

SCRAP SUBMERGENCE DEVICEBACKGROUND

[0001] The present application claims the benefit of US 63 / 541 ,952, filed October 2, 2023, the disclosure of which is herein incorporated by reference.

[0002] Vehicle wheels have a circular wheel disc attached to an annular wheel rim. The wheel disc includes a central wheel hub having a pilot hole and plurality of wheel mounting holes formed therethrough. A plurality of equally spaced circumferential spokes typically support the wheel hub within the wheel rim. The wheel rim is adapted to support a pneumatic tire.

[0003] In the past vehicle wheels have been formed from steel. Wheels formed from light weight metals, however, such as aluminum, magnesium and titanium or alloys thereof, are increasingly popular. In addition to weighing less than conventional all-steel wheels, such light weight wheels can be manufactured having a pleasing aesthetic shape.

[0004] Light weight wheels are often formed by casting. A wheel casting furnace is typically smaller (e.g. <12,000 tons per year) in size than a recycling furnace. During a casting operation, molten metal is poured into a cavity formed in a multi-piece wheel mold. After the metal cools sufficiently to solidify, the mold is opened and a rough wheel casting is removed. The wheel casting is then machined to a final shape. Machining can include the outside and inside surfaces of the wheel rim facing the inboard and outboard wheel disc surfaces and drilling the center pilot hole and the mounting holes through the wheel hub. Machining of wheels produces valuable scrap pieces that are desirable to recycle. Recycling of machined wheel scrap however is challenging because the pieces are typically small and / or thin walled and tend to float on the surface of a molten metal bath. In addition, the wheel casting furnace provides a challenge in that operators prefer to avoid halting processing for the type of maintenance often conducted in a recycling furnace.

[0005] An exemplary chip recycling system for wheel production may have a capacity of 2,500lb / hour, chip recycling is challenging, since the extremely unfavorable ratio of surface area and volume causes a significant material loss through burn-off. The traditional method of recycling chips is to compact the chips before melting, which reduces the metal loss, however, it requires an additional workstep with considerable consumption of energy. In addition, the chips are frequently contaminated with adhering cooling lubricant.

[0006] Accordingly, in an alternative process, the chips are fed into the melting furnace. In a first step the chips can be heated in a dryer to approximately 400 degrees Celsius. Thereby moisture and organic contaminants are removed. The energy required can be provided by hot gas from the melting furnace and the flue gases from the burner supporting the heating of the furnace.

[0007] The preheated and cleaned chips are then fed into a downward directed melt flow and drawn under the bath surface towards the furnace bottom. This type of fast melting almost completely avoids metal loss due to oxidation - as a result, dross formation is low.

[0008] In known systems that rely on the shape of the chamber to create a metal vortex flow, the chargewell is typically made of a refractory material. Significant stress is imparted on the chargewell because the temperature of the molten metal inside of the chargewell is very high and the lower portion of the chargewell is typically submerged in the melt while the upper portion is not. This can create a large temperature gradient between the refractory material in the lower portion of the chargewell and the refractory material in the upper portion of the chargewell. In addition, the forces created by the high speed metal circulation impart stresses on the chamber walls. Since the chamber is often an integral component of the furnace, repair of the walls or can be a difficult and expensive undertaking, particularly in the form of furnace downtime.

[0009] Wheel casting facilities are particularly problematic in that operations typically do not shut-down for cleaning / maintenance. Accordingly, a permanent scrap submergence device can be problematic. The present disclosure solves this problem by providing a scrap submergence device having a mechanism for keeping the unit submerged and providing a mechanism for removal and replacement with a fresh device. The present disclosure solves various problems associated with molten metal processing in wheel manufacturing systems that recycle large volumes of chips and require cleaning.SUMMARY OF THE INVENTION

[0010] Various details of the present disclosure are hereinafter summarized to provide a basic understanding. This summary is not an extensive overview of thedisclosure and is neither intended to identify certain elements of the disclosure, nor to delineate scope thereof. Rather, the primary purpose of this summary is to present some concepts of the disclosure in a simplified form prior to the more detailed description that is presented hereinafter.

[0011] According to a first embodiment, a furnace associated with at least one aluminum wheel casting device is provided. The furnace includes a submergence scrap well; a pump well in communication with the submergence device well; a dross well in communication with the submergence device well; and a removable scrap submergence device disposed in the submergence well. The removable scrap submergence device includes a body comprised of a refractory material that defines a submergence chamber. A frame is embedded in the body. The frame includes at least three legs and at least three posts horizontal to the legs. The posts include a portion extending from the refractory body.

[0012] According to a second embodiment, a metal scrap submergence device is provided. The device includes a body of heat resistant and / or a refractory material. The body includes a side wall and a base that define a submergence chamber. In one embodiment, the body includes a frame embedded therein, wherein a gap is provided between the frame and the refractory material.

[0013] According to a further embodiment, a method of forming a scrap submergence device is provided. The method includes the step of providing a frame having a base portion with posts extending at least substantially perpendicular therefrom. The frame is wrapped in a material removable through exposure to heat and placed in a mold. A refractory material is cast around said frame in the mold and heated to at least 600°C.BRIEF DESCRIPTION OF THE FIGURES

[0014] The following is a brief description of the drawings, which are presented for the purposes of illustrating the exemplary embodiments disclosed herein and not for the purposes of limiting the same.

[0015] FIG. 1 is perspective view of the removable scrap submergence device of the present disclosure.

[0016] FIG. 2 is atop plan view of the metal scrap submergence device of FIG. 1 .

[0017] FIG. 3 is a front plan view of the scrap submergence device in FIG. 1 .

[0018] FIG. 4 includes a variety of cross-sectional views of the scrap submergence device of FIG. 1 , wherein Fig. 4A is a side view partially in phantom, Fig. 4B is a alternative side view not in phantom, Fig. 40 is a cross-sectional view taken through the outlet, Fig. 4D is a cross-sectional view taken through the inlet, Fig. 4E is a top view partially in phantom, and Fig. 4F is a cross-sectional view taken through the legs.

[0019] FIG. 5 is a perspective view of the scrap submergence device of FIG. 1 illustrating the relationship of the internal components.

[0020] FIG. 6 is a bottom view of the frame.

[0021] FIG. 7 is a perspective view of the frame prior to being cast in a mold into the scrap submergence device body.DETAILED DESCRIPTION OF THE INVENTION

[0022] A more complete understanding of the components, processes and apparatuses disclosed herein can be obtained by reference to the accompanying drawings. These figures are merely schematic representations based on convenience and the ease of demonstrating the present disclosure, and are, therefore, not intended to indicate relative size and dimensions of the devices or components thereof and / or to define or limit the scope of the exemplary embodiments.

[0023] Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the embodiments selected for illustration in the drawings and are not intended to define or limit the scope of the disclosure. In the drawings and the following description below, it is to be understood that like numeric designations refer to components of like function.

[0024] The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

[0025] As used herein, the terms about, generally and substantially are intended to encompass structural or numerical modifications which do not significantly affect purpose of the element or number modified by such term.

[0026] As used herein, the recitation of numerical ranges by endpoints includes all numbers subsumed within that range (e.g. 1 to 5 includes 1 ,1.5, 2, 2.75, 3, 3.6, 4 and 5 and the like). Similarly, where multiple ranges are set forth with respect ot an item, it is intended that the ranges reflect the various combinations thereof (e.g. 1 to 5 or 2 to 3 also includes the ranges 1 to 3 and 2 to 5, and the like).

[0027] As used in the specification and in the claims, the term “comprising” may include the embodiments “consisting of” and “consisting essentially of.” The terms “comprise(s),” “include(s),” “having,” “has,” “can,” “contain(s),” and variants thereof, as used herein, are intended to be open-ended transitional phrases, terms, or words that require the presence of the named ingredients / steps and permit the presence of other ingredients / steps. However, such description should be construed as also describing compositions or processes as “consisting of” and “consisting essentially of” the enumerated or process as “consisting of” and “consisting essentially of” the enumerated ingredients / steps, which allows the presence of only the named ingredients / steps, along with any impurities that might result therefrom, and excludes other ingredients / steps.

[0028] With reference to FIGS. 1 -5, a metal scrap submergence device 100 including side walls 102 and a base 104 is displayed. The side walls 102 and the base wall 104 are made from a refractory material, a non-limiting example being ceramic. The submergence device can be received inside of a well that would typically be referred to as a chargewell such as that disclosed in FIG. 1 of U.S. Pat. No. 6,217,823, herein incorporated by reference. A chargewell 106 of the submergence device 100 can be of a shape configured to perform in the manner disclosed in U.S. Patent 7,662,335, herein incorporated by reference.

[0029] More particularly, the submergence device 100 can include a sidewall inlet 107 that receives molten metal flow from an associated pump such as described in U.S. Pat. No. 6,217,823 and or 7,662,335. The base wall 104 can define a ramp 108 leading to an outlet 110. The ramp can create a vortex of molten metal that can submerge metal chips deposited therein.

[0030] In the embodiment depicted in FIGS. 1-5 a frame112 is provided. The scrap submergence device body is comprised of a refractory material that defines the submergence chamber. The frame 112 is embedded in the body and includes at least three legs 114 (four illustrated) and at least three posts 116 (four illustrated) at least substantially horizontal to the legs 114. The posts include a portion 116Aextending from the refractory body. The extending portion 116A can attach to a further frame to facilitate submergence of the device and / or to lifting elements. The extending portion 116 may also or alternatively be threaded.

[0031] The device can include four legs and four posts. The posts can engage the legs at an intersection of adjacent legs. The intersections can include strengthening and surface area enhancing projections 1 18.

[0032] Typically, the refractory body has a perimeter shape and the legs can form a substantially complimentary shape.

[0033] The legs can be rectangular in cross section and the posts can be an ellipse in cross-section. A typical leg can have a cross-sectional thickness of 0.2 in2to 1.0 in2. A typical post can have a diameter of 0.2 in2to 1.75 in2. In certain embodiments the legs can be formed of steel tube and the posts of steel rod that can be welded together.

[0034] A gap of at least 4mm, preferably at least 5mm is provided between the frame and the surrounding refractory material. A larger gap can be provided in at least some of a bottom area. Without being bound by theory, it is contemplated that a larger gap will be provided adjacent the legs than the posts (particularly an upper region of the posts). Moreover, since the posts include an extending portion 1 16A thermal expansion in length is more feasible without damaging (cracking the ceramic body).

[0035] The apparatus can be removed from a scrap submergence system and cleaned or repaired.

[0036] An additional external frame can attach to the upper portion of the side wall in a conventional manner to facilitate such removal.

[0037] With reference to FIG. 7 a method of constructing the scrap submergence device is illustrated. More particularly, the device is cast by packing ceramic 120, such as a refractory mix of silicon carbide or fused silica or a combination thereof, around the frame 112 within a mold 124.

[0038] A preform 122 can be used to form the chamber-inlet-outlet within the mold 124. The preform can be formed of a material that melts, burns or sublimes during curing of the device or a metal that is dissolved / melted into the molten aluminum when the device is put into use.

[0039] Prior to packing the ceramic, the frame can be covered and / or wrapped with a layer of ceramic paper 126, such as Superwool paper, to provide the above-described gap. An exemplary thickness of ceramic paper is 4-8mm but in some areas an additional 4-8mm may be provided such that there is 8-16mm of ceramic paper.

[0040] The device can be fired at 650°C so that the ceramic paper is compressed in service by thermal expansion, providing an expansion gap that accommodates expansion of the frame at the scrap submergence device normal operation temperature of 500°C.

[0041] The above-described scrap submergence device increases plant operation flexibility. One advantage of a removable submergence device is scrap feed flexibility. For example, fine or low-density particles may be suitable for a material submergence device that creates a vortex metal flow, but denser articles typically do not need the metal vortex flow to submerge into the molten metal bath. In a situation where denser articles are being submerged, the scrap submergence device can be removed from the furnace. Removal of the scrap submergence device can also increase the recirculation pump efficiency, since the pump no longer needs to generate the vortex flow in the material submergence device. Also, since the scrap submergence device is removable it can be easily cleaned. Accordingly, any solid that may accumulate on the sides of the device can be removed while another device is placed in the furnace, thus limiting the downtime of the furnace.

[0042] The apparatus has been described with reference to preferred embodiments. Modifications will occur to those who read the preceding description, along with the references incorporated by reference. It is intended that this disclosure covers all modifications disclosed by the preceding description, the incorporated references and the equivalents thereof.

Claims

What is claimed is:

1. A furnace associated with at least one aluminum wheel casting device, said furnace comprising: a scrap submergence well; a pump well in communication with the scrap submergence well; a dross well in communication with the scrap submergence well; a removable scrap submergence device disposed in the scrap submergence well with said removable scrap submergence device comprising: a body comprised of a refractory material or ceramic fiber composite that defines a submergence chamber; and a frame embedded in said body, the frame including at least three legs and at least three posts horizontal to said legs, a gap provides tension between the frame and the refractory material, and said posts including a portion extending from said refractory body.

2. A scrap submergence device comprising: a body comprised of a refractory material or graphite or ceramic fiber composite that defines a submergence chamber; and a frame including at least three legs and at least three posts horizontal to said legs, said frame embedded in the body with said posts including a portion extending from said body.

3. The device of claim 2, comprising four legs and four posts.

4. The device of claim 3, wherein said body has a perimeter shape and said legs form a substantially complimentary shape.

5. The device of claim 2, wherein the posts engage the legs at an intersection of adjacent legs.

6. The device of claim 5, wherein the intersections include strengthening and surface area enhancing projections.

7. The device of claim 2, wherein the legs are rectangular in cross section and the posts are an ellipse in cross-section.

8. The device of claim 2, wherein at least some of the portion is threaded.

9. The device of claim 2, wherein said frame includes a covering of superwool paper.

10. The device of claim 2, including a gap of at least 4mm, preferably at least 5mm, between the frame and the refractory material.11 . The device of claim 10, wherein a larger gap is provided in at least some of a bottom or side area.

12. The device of claim 2, further including a metal screen embedded in said body.

13. The device of claim 2, wherein said body is formed of at least two joined sections.

14. The device of claim 13, wherein a joining is configured to occur near an anticipated metal line in a scrap submergence well of an associated furnace.

15. The device of claim 2, wherein said body includes at least three feet extending from a bottom surface.

16. The device of claim 15, wherein said feet are friable and designed to break when the body is removed from the submergence chamber.

17. A method for improving the efficiency of a furnace associated with at least one aluminum wheel casting device said furnace comprising: a submergence scrap well; a pump well in communication with the submergence device well; a dross well in communication with the submergence device well;a removable scrap submergence device disposed in the submergence well, said removable scrap submergence device comprising: a body comprised of a refractory material that defines a submergence chamber; and a frame embedded in said body the frame including at least three legs and at least three posts horizontal to said legs, said posts including a portion extending from said refractory body.

18. A method of forming a scrap submergence device comprising: providing a frame having a base portion including legs extending at least substantially perpendicular therefrom; wrapping said frame in a material removeable through exposure to heat; placing said frame in a mold; casting a refractory material about said frame in said mold; and heating said cast refectory to at least 600°C.

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