Cryogenic Chill Block Cooling for Hard Metal Welding
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Solution Overview
Problem
The application of hard metal to an alloy steel substrate using existing methods often results in temperature fluctuations during the welding process, leading to an oversized weld puddle and heat-affected zone, as the substrate's temperature can rapidly exceed the maximum allowable limit when using arc welding.
Innovation Solution
An apparatus featuring a chill block made of a heat-conducting material, such as copper, with a coolant passage and ejector ports for cryogenic coolant, is used to rapidly cool the hard metal applied to the substrate, ensuring the temperature remains within the optimal range by conducting cryogenic coolant through the block and ejecting it onto the metal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If arc welding process is used to apply hard metal to the substrate, then the hard metal is successfully applied to the surface, but the substrate temperature rises rapidly and may exceed the maximum allowable temperature
Solution Approach 1:
The substrate is preheated to a controlled temperature (300-600°F) before welding to establish a safe thermal baseline, preventing excessive temperature rise during the welding process
Solution Approach 2:
A chill block made of heat-conducting material is introduced as an intermediary between the welding zone and the substrate to absorb and conduct away excess heat, acting as a thermal buffer that prevents substrate temperature from exceeding maximum allowable limits
2Manufacturing precision
If the substrate temperature is kept near the prescribed preheat temperature, then the weld puddle size and heat-affected zone depth are controlled, but the welding process becomes difficult to maintain without interruption
Solution Approach 1:
The chill block serves as a thermal intermediary that actively manages heat flow during continuous welding, enabling uninterrupted welding while maintaining precise control over weld puddle size and heat-affected zone depth
Solution Approach 2:
The chill block dynamically adjusts thermal parameters by conducting heat away from the weld zone, allowing the welding process to proceed continuously while maintaining optimal temperature parameters for controlled weld characteristics
3Temperature
If the welding process is interrupted to control temperature, then the substrate temperature remains within limits, but the welding time increases and productivity decreases
Solution Approach 1:
The chill block enables continuous welding by acting as an intermediary heat sink, eliminating the need to interrupt the welding process while maintaining substrate temperature within acceptable limits
Solution Approach 2:
The chill block allows the welding process to continue without interruption by continuously conducting heat away from the weld zone, maintaining both temperature control and productivity
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 controls the temperature, reducing the size of the weld puddle and heat-affected zone, enhancing the hardness and consistency of the applied hard metal, while increasing welding speed and reducing residual stress, thus improving the wear resistance and appearance of the surface.
Implementation Method 1
A coolant passage in the chill block conducts a cryogenic coolant through the chill block to cool the chill block
Implementation Method 2
At least one ejector port in the chill block in communication with the coolant passage ejects cryogenic coolant from the chill block onto the hard metal for further cooling the hard metal
Implementation Method 3
cryogenic coolant being ejected from the at least ejector port in the chill block onto the hard metal for further cooling the hard metal
Data Source
AI summary
An apparatus and related method for cooling a hard metal applied in a molten or semi-molten state to the surface of a metal substrate employ a chill block chilled by a cryogenic coolant conducted through a coolant passage in the chill block with at least one ejector port in communication with the coolant passage arranged to eject cryogenic coolant from the chill block onto the hand metal for further cooling the hard metal. An alloy steel substrate preheated to 300 to 600 degrees Fahrenheit has a hard metal applied thereto by an arc welding process.