Submerged Combustion Burner Tip Joining
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Solution Overview
Problem
Current submerged combustion burners face challenges in joining noble metal alloy burner tips with common structural materials like stainless steels and Nickel-based steel alloys without compromising mechanical strength, coolant leak proofing, and noble metal recovery.
Innovation Solution
The development of fluid-cooled combustion burners with a burner tip made from corrosion-resistant and fatigue-resistant materials, such as platinum-rhodium alloys, and a burner body made from nickel-based alloys, using interference fits and heat-formed seams, particularly with titanium alloy rings for enhanced durability and compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If noble metal alloys are used for burner tips to improve corrosion and fatigue resistance, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies local quality by using noble metal alloys (such as platinum-rhodium) specifically for the burner tip where corrosion and fatigue resistance are most critical, while the burner body uses less expensive materials like stainless steel or nickel-based alloys. This localized application of high-performance material optimizes reliability where needed without unnecessarily increasing overall manufacturing cost.
Solution Approach 2:
The patent employs composite material construction by combining noble metal alloy burner tips with common structural materials for the burner body. This composite approach allows the system to achieve the corrosion and fatigue resistance of noble metals at the critical interface while maintaining cost-effectiveness through the use of more economical materials for the structural components.
2Ease of manufacture
If noble metal alloy burner tips are joined to common structural materials, then manufacturing cost is reduced, but joining difficulty increases
Solution Approach 1:
The patent uses an intermediary approach by employing compatible joining materials and methods (such as specialized alloys for interference fits and heat-formed seams) that facilitate the connection between dissimilar materials. The use of titanium alloy rings and carefully controlled heat formation processes acts as a mediator to enable joining of noble metal tips to steel burner bodies without compromising the integrity of either material.
Solution Approach 2:
The patent applies parameter changes by utilizing interference fits that rely on precise dimensional control and thermal expansion differences. The joining process involves heating the assembly to allow expansion, inserting the components, and then allowing cooling to create a tight interference fit. This parameter-based approach enables joining of dissimilar materials without complex welding procedures.
3Strength
If interference fits and heat-formed seams are used for joining, then mechanical strength is maintained, but manufacturing precision requirements increase
Solution Approach 1:
The patent utilizes parameter changes through thermal expansion and contraction to achieve proper fit and strength in the interference joints. By heating the assembly during assembly and allowing controlled cooling, the design compensates for dimensional variations and achieves the necessary mechanical strength while accommodating reasonable manufacturing tolerances.
Solution Approach 2:
The patent explicitly employs thermal expansion principles in the joining process. The interference fit components are heated to expand them for easier assembly, then allowed to cool and contract, creating a tight, strong joint. This thermal expansion approach enables achieving high mechanical strength without requiring extremely tight manufacturing tolerances.
4Ease of repair
If removable connections are used for burner tips, then ease of repair is improved, but connection reliability may decrease
Solution Approach 1:
The patent applies preliminary action by designing the removable connection system with pre-engineered interference fits and heat-formed seams that create extremely secure joints during assembly. The connection is established with such precision and strength during the initial assembly that it reliably maintains integrity during operation, while still allowing for controlled removal when needed for repair or replacement.
Solution Approach 2:
The patent uses parameter changes through thermal cycles to control the connection state. During normal operation, the thermal conditions maintain the interference fit and seam integrity, ensuring reliable connection. When repair is needed, the process can be reversed by heating to expand components and break the interference fit, allowing removal. This parameter-based control enables both reliability during operation and ease of repair when needed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution significantly increases the operating life of submerged combustion burners by providing improved thermal fatigue resistance and corrosion resistance, while allowing for the use of less expensive materials, maintaining mechanical strength and preventing coolant leaks.
Implementation Method 1
an external conduit (10) and a first internal conduit (12) substantially concentric therewith... forming a first annulus (11) for passing a cooling fluid there between
Implementation Method 2
The outer connection comprises first and second members (50, 52) interference fit to complementary portions of the burner tip (4) and burner body (6), respectively
Implementation Method 3
the first and second members (50, 52) joined to each other via a heat-formed seam (66)
Data Source
AI summary
Submerged combustion burners having a burner body and a burner tip connected thereto. The burner body has an external conduit and first and second internal conduits substantially concentric therewith, forming first and second annuli for passing a cooling fluid therethrough. The burner includes a generally central flow passage for a combustible mixture, the flow passage partially defined by an inner wall of the burner tip. The burner tip has an outer wall and crown connecting the inner and outer walls. The inner and outer walls and crown comprise materials having greater corrosion and/or fatigue resistance than the burner external conduit. The burner tip is connected to the burner body by inner and outer connections, at least one of which includes members interference fit to the burner tip and burner body, the members welded, soldered, or brazed together, in certain instances by fiber laser welding.