Molten Metal Refining Wire Sheath Rigidity and Sealing
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Solution Overview
Problem
Existing refining wires for molten metal have thin sheaths that are easily deformed, allow air and oxygen ingress, and are not rigid enough to penetrate solidified slag, leading to reduced recovery and quality of refining materials.
Innovation Solution
A refining wire with a thicker, low carbon-low silicon steel sheath encapsulating a core of refining material, sealed by welding to prevent gas ingress and made more rigid through deep rolling or drawing, allowing for higher sheath thicknesses and improved penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the sheath thickness is increased to improve rigidity and prevent deformation, then the wire can better penetrate slag and resist deformation, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent applies parameter changes by modifying the sheath thickness from the conventional 0.2-0.6mm range to a thicker range of 0.8-2.0mm. This parameter change directly addresses the rigidity issue, enabling the wire to resist deformation from pinch rolls and penetrate solidified slag surfaces effectively, while the welding closure method enables this thickness increase without proportionally increasing manufacturing complexity
2Reliability
If the sheath is sealed by welding to prevent air and oxygen ingress, then core material recovery improves and quality increases, but manufacturing complexity increases
Solution Approach 1:
The welding closure method creates a sealed environment that prevents air and oxygen from entering the core, effectively creating an inert atmosphere protection. This ensures high core material recovery and maintains material quality by preventing oxidation, while the welding process itself is a standard manufacturing technique that doesn't excessively increase complexity
Solution Approach 2:
The invention extracts the harmful elements (air and oxygen) from the wire structure by implementing a sealed welding closure. This eliminates the source of oxidation and contamination, ensuring that the core material remains pure and recoverable throughout the refining process
3Reliability
If deep rolling or drawing is applied to reduce wire diameter and expel air, then wire integrity improves and air is removed, but the sheath may deform or break
Solution Approach 1:
The patent applies preliminary action by implementing the welding closure method before deep rolling or drawing operations. This pre-sealing ensures that the sheath is structurally sound and air-tight before subjected to the deformative forces of deep rolling, preventing deformation or breakage while still allowing air expulsion and integrity improvement
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 solution achieves higher core material recovery and improved refining wire integrity by reducing air and oxygen presence, enhancing the wire's ability to penetrate slag and maintain refining material quality.
Implementation Method 1
the longitudinal edges of the metal strip are sealed together by welding to encapsulate the refining material core within the metal sheath in a fluid-tight manner
Implementation Method 2
the wire has been deep rolled or drawn to a smaller diameter
Implementation Method 3
deep rolling or drawing
Data Source
AI summary
A molten metal refining wire (11) comprises a metal sheath (12) encapsulating a core (14) of refining material, such as pure calcium powder, wherein the core (14) is sealed within the sheath (12) in a fluid-tight manner. A corresponding method of manufacturing the molten metal refining wire (11) is disclosed, as well as a method of refining molten metal by injecting the refining wire (11) into the molten metal.