Carbonated Water Flushing for Casting Internal Passageways
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Solution Overview
Problem
Complex metal castings with internal passageways pose difficulties in removing residual materials such as sand, clay, and release agents, as conventional cleaning methods are inefficient in accessing and flushing these internal areas.
Innovation Solution
The use of carbonated water is introduced into the internal passages of metal castings to flush out residual materials, followed by a cleanliness test using a particle detector to ensure thorough removal, with the system incorporating filters and a recirculation process for water reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cleaning methods (brushing, water washing, shot blasting) are used on complex metal castings with internal passageways, then exterior surfaces can be cleaned, but residual materials in internal passageways cannot be effectively removed
Solution Approach 1:
The patent uses pressurized fluid (water or air) to flush residual materials through internal passageways. The fluid is introduced at one end and exits at the other, carrying contaminants with it. This hydraulic/pneumatic approach enables effective cleaning of complex internal geometries that are inaccessible to mechanical methods like brushing or shot blasting.
Solution Approach 2:
The cleaning process is divided into separate stages: initial mechanical cleaning of exterior surfaces, followed by internal passageway flushing using pressurized fluid, and finally filtration of the exit stream to capture removed contaminants. This segmentation allows each cleaning method to address specific areas effectively.
2Manufacturing precision
If water is used to flush internal passageways, then residual materials can be removed, but water consumption increases and waste water must be disposed of
Solution Approach 1:
The patent implements a filtration system that captures residual materials from the exit water stream. The filtered water can then be reused for subsequent flushing operations, while only the concentrated contaminants are discarded. This recovery approach significantly reduces overall water consumption compared to a single-use flush system.
Solution Approach 2:
The system maintains continuous circulation of water through the passageways and filtration system. Rather than discrete flush operations followed by disposal, the water continuously circulates, picking up contaminants and being filtered for reuse, maximizing the utility of each unit of water consumed.
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 method effectively removes residual materials from complex internal passageways, ensuring a high level of cleanliness and allowing for the reuse of filtered water, thereby optimizing the cleaning process and reducing material waste.
Implementation Method 1
introduces carbon dioxide into a stream of water. This carbonated water is directed into a passage in a workpiece to flush residue from the passage
Implementation Method 2
passing carbonated water through the passage to flush residual material from the passage
Implementation Method 3
the step of passing the water through a first filter before passing the water through the passage in the workpiece
Implementation Method 4
passing the collected water through a particle detector which provides an indication of whether particles of a size greater than a predetermined size are present
Data Source
AI summary
A method for cleaning a component comprises a first stage including the steps of: (i) loading a component into the cleaning chamber of a flush station, (ii) directing a deionized water stream through first filter means, (iii) introducing carbon dioxide into the filtered water stream, (iv) directing the carbonated water stream into a fluid passage to be cleaned in the component, and (v) collecting the dirty water stream after it passes through the component and directing the collected dirty water stream through second filter means for reuse. The method can further include a second stage including the steps of: (vi) loading the component into a testing chamber of a testing station, (vii) directing a deionized water stream through third filter means, (viii) directing the filtered water stream into the fluid passage in the component, and (ix) collecting the water stream after it passes through the component and directing the collected water stream into a particle counter.