Upper Nozzle Plate Welded Joint for Leakage Prevention
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Solution Overview
Problem
The existing sliding nozzle assemblies face challenges in accurately managing the thickness of the joint between the upper nozzle and the upper plate, leading to issues such as gaps or excessive wear, which can result in molten metal leakage or difficulty in detaching the assembly from the molten metal vessel.
Innovation Solution
An upper nozzle/plate integral unit is designed where the upper nozzle and upper plate are integrated with a weldingly joined metal member and metal sheet, allowing for easy separation after use, with a weld leg of 2 to 5 mm and a total weld length of 5 to 60 mm, enabling controlled detachment and replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the joint thickness between upper nozzle and upper plate is reduced to prevent gaps, then gap occurrence is reduced, but wear is accelerated and molten metal leakage risk increases
Solution Approach 1:
The upper nozzle and upper plate are merged into a single integral unit through welding, eliminating the joint between them. This combines two separate components into one unified structure, preventing both gap occurrence and wear-related leakage issues that affect separate jointed components
Solution Approach 2:
The integral unit combines refractory materials (upper nozzle and upper plate) with metal materials (welding joints) to create a composite structure. This composite construction provides both the refractory properties needed for molten metal contact and the structural integrity of metal welds, ensuring reliable sealing without wear
2Productivity
If the sliding nozzle assembly is designed as detachable for easy replacement, then replacement efficiency is improved, but joint thickness management becomes more difficult
Solution Approach 1:
The sliding nozzle assembly is segmented into multiple detachable components (upper nozzle/upper plate integral unit, intermediate plate, lower plate, lower nozzle) that can be replaced independently or in groups. This segmentation allows efficient replacement while each component's critical joints are manufactured with precise thickness control during production
Solution Approach 2:
The upper nozzle and upper plate are pre-integrated into an integral unit during manufacturing with precisely controlled dimensions. This preliminary integration ensures accurate joint thickness is built-in during production, and the complete integral unit is then installed as a single component, eliminating the need for on-site joint thickness management
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 solution ensures a stable joint thickness, preventing molten metal leakage and wear, while facilitating easy detachment and replacement, enhancing operational efficiency and reducing the risk of assembly conflicts.
Implementation Method 1
the metal member of the upper nozzle is weldingly joined to the metal sheet of the upper plate
Data Source
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AI summary
Disclosed is an upper nozzle/plate integral unit comprising an upper nozzle and an upper plate integrated together, which is capable of being easily split into the upper nozzle and the upper plate after use, while adequately maintaining a thickness of a joint between the upper nozzle and the upper plate during use. A metal casing 4 is bent inwardly along an outer peripheral surface of a lower end portion of an alumina carbon-based refractory body of the upper nozzle 1 to form a metal member. The metal member formed by bending the metal casing 4 inwardly has a length of 15 mm. A gap between the metal casing and the refractory body is filled with mortar having a thickness of about 0.5 mm. A recess 11 of the lower end portion of the upper nozzle 1 is fitted onto a raised portion 21 of the upper plate 2 through mortar, and the metal casing 4 of the upper nozzle 1 is in contact with a metal casing of the upper plate 2. A peripheral edge of the metal casing of the upper plate 2 is fixedly joined to the metal casing 4 of the upper nozzle 1 through a plurality of welded portions 6.