Ladle Bottom Diffusor Box Design for Metal Melt Flow Control

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Solution Overview

Problem

Metallurgical ladle bottoms experience significant wear and filler sand flushing issues during metal casting, leading to irregularities and defects, while gas treatment causes turbulences that displace filler sand, and a substantial amount of metal remains in the ladle after tapping.

Innovation Solution

A refractory ceramic ladle bottom with a diffusor box and stepped pouring channel design, featuring a deepened section at a distance from the impact area and gas purging elements, slows down the metal melt flow and reduces kinetic energy, thereby minimizing wear and filler sand displacement, and optimizing metal outflow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If filler sand is used to close the pouring channel, then uncontrolled outflow of metal melt is avoided, but the filler sand is flushed away by the metal stream and gas turbulences, causing irregularities and defects

Engineering Contradiction:

Improvecontrol of metal outflowVSAvoidintegrity of filler sand position

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The ladle bottom is divided into functionally distinct zones: an impact area for metal stream reception, a diffusor box for flow modulation, and a pouring channel for controlled outflow. This segmentation allows each zone to perform its specific function while protecting filler sand in the pouring channel from premature displacement.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The diffusor box acts as an intermediary structure between the impact area and the pouring channel. It modifies the metal stream characteristics, reducing velocity and kinetic energy before the melt reaches the pouring channel, thereby preventing filler sand flushing while maintaining controlled outflow capability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the metal stream hits the ladle bottom directly, then casting process is simple, but considerable wear of refractory material occurs at the impact area

Engineering Contradiction:

Improvecasting process efficiencyVSAvoidservice life of refractory material

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The diffusor box is positioned to intercept and modulate the metal stream before it reaches the pouring channel and impact area. By reducing the velocity and kinetic energy of the melt in advance, the system prevents severe wear of the refractory material while maintaining efficient casting operation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If gas treatment is applied to the metal melt, then metallurgical processing is improved, but turbulences are generated that flush away filler sand

Engineering Contradiction:

Improvemetallurgical treatment qualityVSAvoidposition stability of filler sand

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The diffusor box serves as a protective intermediary that shields the filler sand in the pouring channel from the turbulent flows generated during gas treatment. It allows gas bubbles to pass through while maintaining a protected zone that prevents filler sand displacement, thus preserving both metallurgical treatment effectiveness and filler sand position integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

The design significantly reduces metal remaining in the ladle after emptying and minimizes filler sand flushing, ensuring more controlled casting and reduced wear, while maintaining the integrity of the filler sand during gas treatment.

Implementation Method 1

a diffusor box, being defined by a deepened section of said upper surface... wherein the said diffusor box is characterized by the following features: it is arranged at a distance to a surface area of the ladle bottom used as an impact area

Methodology Applied

Scientific EffectDiffusion: Diffusion