Mold Cavity with Chill Plate and Thermocouple Slot for Metal Analysis

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Solution Overview

Problem

Current metal analysis methods for cast iron, such as spectrometer, combustion, and thermal analysis, face challenges including inner defects, uneven microstructure, high hygiene demands, and environmental hazards due to the use of tellurium, which affects accuracy and recyclability.

Innovation Solution

An apparatus and method utilizing a mold cavity with a gating system, vent, chill plate, and longitudinal slot for faster cooling and solidification of molten metal, eliminating the need for tellurium by using a thermocouple wire to monitor the cooling curve, enabling efficient thermal and spectrometer analysis of cast and ductile iron.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a metal mold is used for casting specimens repeatedly during a shift, then productivity increases, but mold temperature increases which adversely affects cooling effect and leads to uneven microstructure

Engineering Contradiction:

Improvenumber of specimens cast per shiftVSAvoiduniformity of microstructure

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The mold is segmented into two separate halves (first mold half and second mold half) that can be independently temperature-controlled. This allows each half to be optimized for its specific function - one for casting and the other for cooling - resolving the contradiction between repeated use and temperature control.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the temperature parameter control by providing independent temperature control for each mold half. The first mold half can be maintained at a higher temperature for efficient casting, while the second mold half is maintained at a lower temperature for effective cooling, thus maintaining microstructure uniformity even during repeated use.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If tellurium is used to prevent graphite formation and achieve homogeneous microstructure, then manufacturing precision improves, but harmful factors increase due to environmental and health hazards

Engineering Contradiction:

Improvehomogeneity of microstructureVSAvoidenvironmental and health hazards

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The invention extracts and removes tellurium from the casting process entirely. By using independent temperature control of mold halves to achieve the desired microstructure uniformity, the harmful substance tellurium is completely eliminated from the process, resolving the contradiction between microstructure quality and environmental safety.

Inventive Principle:

Principle #2Taking out (Extraction)

3Measurement precision

If combustion analysis is used to achieve accurate chemical composition detection, then measurement precision improves, but device complexity and cost increase due to expensive equipment and strict hygiene requirements

Engineering Contradiction:

Improvedetection accuracy of chemical compositionVSAvoidequipment complexity and hygiene requirements

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The invention replaces the complex mechanical combustion analysis system with a simpler thermal analysis approach using thermocouples and temperature monitoring. This substitution maintains sufficient measurement precision for chemical composition determination while dramatically reducing equipment complexity, cost, and hygiene requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 allows for faster, accurate, and environmentally friendly analysis of cast and ductile iron without tellurium, reducing defects and enabling easy recycling of specimens, while maintaining high surface quality and precision in determining chemical composition.

Implementation Method 1

a sensor element, to be introduced into the sample of the molten metal through the longitudinal slot, is a thermocouple wire

Methodology Applied

Scientific EffectThermocouple effect: Thermocouple

Implementation Method 2

at least one chill plate adjacent to the mold cavity for enabling cooling and solidification of the sample of the molten metal

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

a gating system, extending from the mold cavity, for allowing the molten metal to be poured

Methodology Applied

Scientific EffectGravity flow: Gravitation

Implementation Method 4

a vent, extending from the mold cavity, for allowing gases to escape from the apparatus when the molten metal is poured

Methodology Applied

Scientific EffectGas escape:

Data Source

PatentUS11293887B2Apparatus for analysis of metals

Publication Date: 2022.04.05 NOVACAST

AI summary

An apparatus for analysis of metals is provided. The apparatus includes a molding cavity for receiving a sample of a molten metal, a gating system for allowing the molten metal to be poured, and a vent for allowing gases to escape from the apparatus when the molten metal is poured. The apparatus further includes at least one chill plate, adjacent to the molding cavity, for enabling faster cooling and solidification of the sample of the molten metal. The apparatus also includes a longitudinal slot, extending from the molding cavity, for allowing a sensor element to be introduced into the sample of the molten metal, the sensor element is a thermocouple wire that is used to monitor a cooling curve of the molten metal, while the molten metal solidifies.