Explosion Welded Copper Cooling Element Thermal Contact
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Solution Overview
Problem
Existing cooling elements used in metallurgical furnaces face challenges in achieving effective thermal contact between the copper base element and metal coatings, leading to inefficient heat transfer.
Innovation Solution
The method involves drilling holes in the copper base element, plugging them, and applying a metal coating via explosion welding, which creates a strong thermal energy transfer joint and optionally includes a ceramic lining or specific metal alloys like stainless steel with high chromium content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a metal coating is applied to the copper base element using conventional methods, then the cooling element gains protective coating, but the thermal contact between base element and coating is insufficient
Solution Approach 1:
Holes are drilled into the copper base element before coating application, and these holes are subsequently plugged during the explosion welding process. This preliminary structural modification enables the coating to be mechanically anchored to the base element, ensuring intimate thermal contact from the outset rather than relying on post-application adjustments.
Solution Approach 2:
The invention changes the physical state and bonding mechanism by using explosion welding instead of conventional coating methods. The explosive force creates a metallurgical bond between the coating and base element, fundamentally altering the interface properties to achieve superior thermal contact and heat transfer efficiency.
2Temperature
If the base element is drilled with holes and plugged, then thermal contact between base element and coating is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The invention merges multiple operations into a single integrated process: holes are drilled in the base element, and the same holes serve as receptacles for plugs that are installed during the explosion welding process itself. This consolidation eliminates separate plugging operations and reduces overall manufacturing complexity despite the added drilling step.
Solution Approach 2:
The drilled holes serve multiple functions: they provide mechanical anchoring for the plugs, facilitate intimate contact between coating and base element, and enable the explosion welding process to create strong thermal bonds. This multi-functionality reduces the need for additional specialized features or processes.
3Reliability
If explosion welding is used to apply metal coating, then thermal energy transfer between base element and coating is significantly improved, but the process requires specialized equipment and higher energy input
Solution Approach 1:
The invention changes the energy delivery mechanism from gradual, low-intensity conventional coating methods to a high-intensity, instantaneous explosive energy input. This parameter change in energy delivery creates a metallurgical bond with superior thermal contact, overcoming the limitation of insufficient heat transfer that plagues conventional coating methods.
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 approach enhances thermal contact and energy transfer between the copper base element and the metal coating, improving the cooling element's performance in metallurgical furnace applications.
Implementation Method 1
the base element is coated with a metal coating at the plugs by explosion welding, so that the metal coating at least partly covers the plugs fitted in the holes
Data Source
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AI summary
The invention relates to a method for coating the frame element of a cooling element (1) used in connection with a metallurgical furnace or the like, said frame element being mainly made of copper, at least partly with a metal coating (3). In the method, the metal coating (3) is explosion welded to the frame element of a cooling element (1) mainly made of copper. The invention also relates to a cooling element, particularly to be used in connection with metallurgical furnaces or the like, said cooling element comprising a frame element (1) mainly made of copper, in which frame element there is arranged a cooling water channel system (2), said frame element of the cooling element (1) being at least partly coated with a metal coating (3). The metal coating (3) is explosion welded to the frame element (1) that is mainly made of copper.