Diamond-Metal Composite X-Ray Anode for Heat Removal
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Solution Overview
Problem
Rotating X-ray anodes face high thermal stresses and reduced heat removal efficiency due to high energy input from electron bombardment, leading to thermomechanical fatigue and decreased dose performance, which existing technologies have not adequately addressed.
Innovation Solution
The X-ray anode incorporates a diamond-metal composite support body with a gradated structure, where diamond grains are surrounded by a binder phase comprising copper, silver, or aluminum, optimized for thermal conductivity and expansion matching, to minimize stresses and enhance heat removal efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional rotating anodes with molybdenum-based support bodies are used, then the anode structure is simple and manufacturable, but heat removal efficiency is insufficient leading to high focal spot temperatures and thermomechanical fatigue
Solution Approach 1:
The patent applies composite materials by combining diamond particles (for high thermal conductivity) with a metal matrix (such as copper, aluminum, or titanium) to create a diamond-metal composite support body. This composite structure achieves superior heat removal efficiency while maintaining mechanical strength, directly resolving the contradiction between temperature control and anode durability.
Solution Approach 2:
The patent implements local quality by concentrating diamond particles specifically in the focal track region where heat generation is most intense. This localized enhancement of thermal conductivity where needed most allows for effective heat removal from the focal spot while optimizing the overall anode structure for both thermal management and mechanical performance.
2Temperature
If diamond layers are introduced to improve thermal conductivity, then heat removal efficiency increases, but manufacturing complexity increases due to inability to use conventional powder-metallurgical joining
Solution Approach 1:
The patent merges the diamond particle reinforcement function with the metal matrix structure in a single integrated manufacturing process. By incorporating diamond particles directly into the metal matrix during casting or infiltration processes, the patent eliminates the need for separate diamond layer deposition and joining steps, thereby maintaining ease of manufacture while achieving superior heat removal.
Solution Approach 2:
The patent applies parameter changes by controlling the size distribution, concentration, and spatial distribution of diamond particles within the metal matrix. By optimizing these parameters, the patent achieves high thermal conductivity without requiring complex manufacturing processes, as the diamond-metal composite can be produced using modified conventional metallurgical techniques.
3Temperature
If diamond is used in the support body, then thermal conductivity increases, but thermal expansion mismatch induces stresses in the composite structure
Solution Approach 1:
The patent applies parameter changes by carefully selecting and controlling the metal matrix material composition and the diamond particle characteristics. By adjusting parameters such as matrix alloy composition, diamond particle size distribution, and volume fraction, the patent optimizes the thermal expansion characteristics of the composite to better match the coating layer, thereby reducing thermal stress while maintaining high thermal conductivity.
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 configuration significantly reduces thermal stresses and improves heat removal, allowing for increased efficiency and prolonged anode performance under high-energy conditions without critical stress levels, even at elevated temperatures.
Implementation Method 1
The thermal conductivities of W-10% by weight of Re, TZM and graphite are about 85, 125 and 135 W/m·K, respectively, but decrease significantly with increasing anode temperature
Implementation Method 2
In the generation of X-rays by bombardment of an anode material with a focused electron beam
Implementation Method 3
a coating which generates X-rays on bombardment with focused electrons
Implementation Method 4
rotating X-ray anodes in which the energy of the electron beam brought into line focus is distributed around a ring, known as the focal track, by rotation of the anode at high speed
Implementation Method 5
given off to the surrounding cooling medium during the pause between recording of images by radiation
Data Source
AI summary
An X-ray anode includes a coating and a support body. In addition to a strength-imparting region, the support body has a region formed of a diamond-metal composite material. The diamond-metal composite material is formed of 40 to 90% by volume diamond particles, 10 to 60% by volume binding phase(s) formed of a metal or an alloy of the metals of the group consisting of Cu, Ag, Al and at least one carbide of the elements of the group consisting of Tr, Zr, Hf, V, Nb, Ta, Cr, Mo, W, B, and Si. The highly heat-conductive region can be form-lockingly connected at the back to a heat-dissipating region, for example formed of Cu or a Cu alloy. The X-ray anode has improved heat dissipation and lower composite stress.