Patent Grant
7192624
The present invention relates to the surface treatment technology, wherein an external protective and/or decorative layer is created on the surface of metallic component. More particularly, the present invention refers to thermal diffusion coating technology, in which the external layer is created on the surface of the metallic component by diffusing thereinto suitable specie, which is metal or element. The diffusing specie in combination with the solvent metal or alloy from which the component is manufactured, provides a coating thereon, having the required resistance to the corrosive medium or imparting to the component the required external appearance. The other term used in connection with this technology is pack cementation.
Usually thermal diffusion coating process utilizes zinc diffusion to apply zinc coating on components made of ferrous materials like iron, low-carbon steels, medium carbon and alloy steels, high carbon steels and cast irons. This process is known also as sherardizing, named after its English inventor, Sherard O. Cowper-Coles. This term means formation of a uniform corrosion-resistant coating of zinc on the surface of iron or steel components by heating them in a sealed container. The components are embedded in finely divided zinc powder and heated to a temperature, corresponding to the point at which zinc melts, usually at 350–450° C. Since the component to be coated is covered by zinc powder to provide close intimate contact therewith, heating up to this temperature is accompanied by diffusion of zinc atoms into the bulk of the object and formation of external coating layer. This layer consists either of pure zinc or of its alloys with the atoms of the host component. The coating is corrosion-resistant; it has good appearance and makes a good paint base. Due to the small dimensional changes involved in this process it is of particular value for the treatment of small parts, e.g., bolts, nuts, bushings, and small hardware articles such as hose clamps and electrical components, etc.
The present invention refers mostly to the thermal diffusion process for manufacturing zinc coatings; however, it should not be considered as restricted exclusively to zinc coatings. The present invention applies also to thermal diffusion of aluminium, nickel, copper or other species, including metals or non metals so as to make coatings on components made of ferrous or non-ferrous metals and alloys.
The present invention relates in particular to a new method of thermal diffusion coating and a new apparatus for its implementation.
A general description of the sherardizing process can be found in numerous technical monographs or handbooks. See, for example, the monograph “Corrosion and protection of metals” by Bakhvalov and Turkovskaya, Pergamon Press, 1965.
The typical sherardizing process described in this monograph involves the following three main steps:
The last step consists of slow heating of closed receptacle to 440° C. and holding thereof at that temperature for several hours.
There are known in the art various furnaces, in which the above-mentioned thermal treatment step can be carried out. For example, in RU2031186 and RU2130508 are disclosed periodically operating furnaces, in which closed receptacle is placed and heated. The receptacle is formed as elongated tubular, preferably cylindrical container. The parts to be coated are loaded within the container together with the zinc containing powder. During the thermal treatment the receptacle is rotated about its longitudinal or transversal axis. The advantage of the above-mentioned devices is associated with rotational movement of the receptacle. By virtue of rotation the powder more efficiently mixes with the loaded articles and this improves the homogeneity of diffusion and so the quality of the obtained coating. The disadvantage of the above-mentioned furnaces is associated with the fact that they operate periodically and therefore changing the amount of supplied thermal energy creates temperature gradient within the heating zone. This fact is associated with the necessity to wait until the process is fully completed before the new container enters the furnace. It can be readily appreciated, that the disadvantage of periodically operating furnace is associated with insufficient efficiency and capacity. Furthermore the maintenance of periodically operating furnace is complicated due to the necessity to repeat the same operations during each run.
In JP7173605 is described a furnace for carrying out of pack cementation. This furnace comprises an inlet chamber for loading containers with articles packed in the cementation powder, a heating chamber and a cooling chamber. The containers are configured as rectangular boxes, which are not tightly closed. Plurality of containers is transferred in sequence from the inlet chamber to the heating chamber and then to the cooling chamber. This furnace operates continuously, however it is not suitable for carrying out the sherardizing process, since it is designed to heat opened container, which is advanced strictly along the furnace and without a possibility for any additional movement.
In GB2082299 is described continuously operating heat-treatment furnace for pipes. This furnace comprises a furnace chamber for heating a plurality of pipes, arranged in parallel and transportable by a chain conveyor along the furnace. The pipes are oriented within the chamber in such a manner, that their longitudinal axes are perpendicular to the transport direction. There are provided plurality of stopper means for stopping the pipes intermittently at spaced-apart positions in the path of transport. The stopping causes each of the pipes to rotate about its own axis in co-operation with the chain conveyor. Pipes can be heat-treated in succession with a high efficiency. The force of transport of the chain conveyor causes the pipe to rotate once it reaches the stopper means and there is no necessity in any additional device for the rotation. In the above furnace the thermally treated objects are pipes opened from both ends and their rotation is utilized for preventing thermal deformation to an elliptical shape. Unfortunately the furnace, disclosed in the above patent is not designed and is not suitable for thermal treatment of parts, placed in sealed tubular containers, as it is required for thermal diffusion coating.
It should be pointed out that despite the process of thermal diffusion coating as such is known for a long time and there are known various furnaces, devised for carrying out this process, nevertheless there is still felt a strong need in a new and improved furnace, which is dedicated to this process and is free of the above-mentioned disadvantages of the known in the art devices.
The main object of the present invention is to provide a new method for carrying out the thermal diffusion coating and a new furnace for its implementation in which the above-mentioned drawbacks are sufficiently reduced or overcome.
In particular, the main object of the present invention is to provide a new apparatus and method for thermal diffusion coating, which operates continuously and has improved capacity in comparison with periodically operating furnaces.
The further object of the present invention is to provide a new and improved apparatus and method for continuous thermal diffusion coating, in which closed tubular container could be advanced through the furnace and heated, while efficient intimate contact between the articles and powder mixture is maintained during the carrying out the process.
The third object of the invention is to provide a new and improved apparatus for continuous thermal diffusion coating, which is simple, reliable and inexpensive.
The above and other objects and advantages of the present invention can be achieved in accordance with the following combination of its essential features, referring to the different embodiments thereof.
According to the embodiment of the invention, referring to an apparatus for obtaining thermal diffusion coating on the outside surface of articles of manufacture, wherein the articles are heated within a closed tubular container, said articles are embedded in a powder mixture, containing a specie, capable upon heating to diffuse within the articles surface, said apparatus comprises:
According to the embodiment of the invention, referring to a method for obtaining thermal diffusion coating on the outside surface of articles of manufacture by heating thereof within a furnace, while said articles are placed within a closed tubular containers and embedded within a powder mixture, containing a specie, capable upon heating to diffuse within the articles surface, said method comprises:
The present invention has been only briefly summarized with reference to its two main embodiments as an apparatus and as a method.
For better understanding of the invention in connection with its further embodiments complementing the above, as well of the advantages of the invention, reference will now be made to the following description of the main and complementing embodiments with reference to the accompanying drawings.
a shows partially cross-sectioned side view of the apparatus of the invention.
b shows upper view of the apparatus of the invention.
a is cross-sectional view of the apparatus seen in
b is enlarged view of detail B, circled in
c is partial enlarged view of the chain conveyor.
a is partially cross-sectional view of the apparatus, shown in
b is partial cross-sectional view of the stopper means seen in
Referring to FIGS. 1,2 it is shown the apparatus 10 of the invention, configured as a furnace, comprising a heating chamber 12, which is defined by parallel lateral walls 14, 16, a bottom 18 and a ceiling 20. It is not shown specifically but should be understood, that the walls of the chamber are made of appropriate refractory material and are thermally insulated.
The chamber is provided with an inlet door 22 and an outlet door 24, which could be opened and closed by appropriate driving mechanism (not shown in details). In
On the ceiling of the heating chamber are mounted electrical heating elements 30, which are energized by appropriate power supply (not shown). The preferred type of heating energy is electrical, however other sources of energy and appropriate heating means could be used as well.
Before the input door a container 32 is seen, residing in initial position, ready for bringing thereof into the chamber. The container is filled with the articles to be coated and is tightly closed by a cover C.
It is not shown specifically but should be understood, that container is filled also with a powder mixture, containing specie, capable to diffuse within the article's outside surface upon heating up to the temperature required for initiation and maintaining the diffusion. The articles are embedded within the powder mixture to provide intimate contact with the particles of the powder mixture and thus to facilitate the diffusion. When the container is brought within the heating chamber the heating elements provide necessary heat for initiation the diffusion. Upon completing the diffusion the container is evacuated from the heating chamber, is cooled outside and ready coated articles are discharged therefrom.
In contrast to the known in the art heating chambers employed for carrying out the diffusion coating process, in which the container is stationary during the process the heating chamber of the present invention is configured as elongated tunnel, along which the container is advanced during the heating. The container is brought in the heating chamber through the inlet door and is evacuated from the chamber through the outlet door. It can be readily appreciated that in this embodiment the apparatus of the invention in fact constitutes a continuously operating furnace, which heating chamber is configured as a tunnel. For bringing the container within the chamber, advancing thereof along the chamber and evacuating thereof from the chamber there is employed a conveyor 34, extending along the longitudinal axis of the chamber. The conveyor starts before the inlet door at the outside loading position LP, passes along the tunnel's interior and terminates at the outside unloading position UP, situated beyond the outlet door. For advancing the conveyor a dedicated drive 36 is provided. In the further disclosure the route from the loading position and up to the unloading position will be referred to as the transportation path. At the beginning of the transportation path, i.e. in the loading position LP is arranged a platform 35 for receiving new container to be processed in the heating chamber. A cylinder 37 is provided, which can lift or lower the platform with respect to the conveyor. After the fresh container is put on the platform by appropriate loading device (not shown) it can be easily put on the conveyor by lowering the platform below the conveyor level. Similar platform 35′ is arranged at the end of the transportation path in the unloading position UP. Lifting this platform disengages the conveyor from the container and appropriate hoist or forklift can easily evacuate it.
The conveyor consists of at least two parallel chains 38, 40, advanced by the drive within the corresponding slots 42,44, made in the furnace bottom and situated close to the lateral walls of the heating chamber. The chains consist of plurality of links 45 connected by pins P.
As best seen in
Residing under the conveyor a plurality of stopper means SM1, SM2, SM3, SM4, SM5, SM6 is provided, which are disposed in discrete locations along the transportation path and divide it accordingly into plurality of discrete positions. The discrete positions are situated along the whole transportation path, including the heating chamber. Particular construction of the stopper means as well the significance of the discrete positions will be explained in details further. The purpose of the stopper means is to prevent intermittently the advancement of the container along the transportation path without however discontinuation the advancement movement of the conveyor. The stopper means are capable to rise above the conveyor or to go down beneath the conveyor. Rising of stopper means is associated with retaining the container in a discrete position, while lowering of stopper means is associated with restoration of the advancement of the container along the transportation path. Since container always is directed perpendicularly to the transportation path, it is forced to rotate along its longitudinal axis, when it reaches a discrete position, in which the stopper means prevent its advancement along the transportation path. By virtue of this provision the powder mixture and the articles within the container are intensively mixed and are brought in a very intimate contact. It can be easily appreciated that when the container means rotates within the heating chamber the mixing intensifies the diffusion and thus improves the quality and homogeneity of the diffusion coating. On the other hand since the conveyor continuously brings new containers in succession within the heating chamber the capacity of the furnace significantly increases without however to deteriorate the quality of the coating.
Having described in general the principle of operation of the furnace of the invention it will be disclosed now the construction of stopper means.
As explained above the stopper means are designed to discontinue intermittently the advancement movement of the container along the transportation path and to cause its rotation above the longitudinal axis. Referring to FIGS. 1,2,3 it is shown that each stopper means comprises two L-shaped levers 52,54, which are rigidly secured on an axle 56 in a spaced-apart fashion. Each lever consists of two branches, which are substantially perpendicular to each other. In
The axle is directed perpendicular to the transportation path and is mounted under the bottom of the furnace with possibility for rotation in bearings 58,60. The distance between the axle and the bottom as well the configuration of the levers are selected in such a manner, that one of their branches can either to protrude above the bottom of the furnace and thus to prevent the advancement of the container along the transportation path or to be lowered under the bottom and thus to allow further advancement of the container. Since the levers are spaced-apart along the axle their protruding branches touch the peripheral surface of the container in two spaced-apart locations and thus efficiently prevent advancement of the container. The protruding branches of the levers are provided with rollers 61,61′, sitting with possibility for rotation on a common axis 55. It can be appreciated that when the container reaches the rollers it is forced to rotate about its longitudinal axis, since the conveyor tries to advance the container further against the levers. The rollers contacting the container's periphery rotate together with the container. This situation is depicted in
Axle 56 is connected to a piston rod 64, driven by a cylinder 66. By virtue of this provision the axle can be rotated clockwise or anticlockwise, when the cylinder pushes or pulls the rod. It can be appreciated, that rotating of the axle is associated with pivoting of the levers sitting thereon and thus with bringing the levers either in the protruding position, shown in
As mentioned above the apparatus of the invention is provided with plurality of stopper means, dividing the transportation path into plurality of discrete positions. Some of the stopper means are disposed under the bottom of the furnace. These stopper means are seen in
Each discrete position, associated with its stopper means is provided with a dedicated sensor means 68, capable to detect the presence of a fresh container in this discrete position and to generate appropriate signal thereupon. The sensor means is electrically connected with automatic and control system (not shown), which upon receiving signal from the sensor means operates cylinder 66 and other components of the furnace. Once the cylinder is activated it rotates axle 56 and urges levers 52,54 to pivot. By virtue of this provision the container can be either intermittently stopped in the discrete position or released therefrom.
It is not disclosed specifically but should be understood that there is also provided appropriate control panel with necessary instrumentation, which is required both for running the furnace and for automatic control the processing cycle.
As best seen in
Now with reference to
In the beginning of the cycle the inlet door and the outlet door of the heating chamber are closed, the conveyor does not operate. In the initial stage all stopper means are in protruded position. As seen in
After completing the heating cycle, which is required for heating the third container, residing in heating position III, the outlet door is opened, stopper means SM4 is brought in lowered position and conveyor advances the first container until it reaches first cooling position, which is located outside the heating chamber. In this position, which is designated by numeral VI (see
After completing the heating cycle as required for heating the container, residing in position III, the outlet door is opened, stopper means SM4, SM5 are lowered and the first container proceeds to the second cooling position, which is designated in
The above-described sequence of steps allows continuous processing of all containers by advancing them from the loading position I up to unloading position VIII. The advancement of containers is intermittently stopped and containers are retained in their current positions by stopper means for heating up to required temperature or holding at required temperature during certain time.
It is not shown in the drawings, but should be understood, that the apparatus is provided with automatic control system, which is capable to perform the following:
The above description referred to manual mode of operation. In the automatic mode the apparatus functions as follows. Conveyor's drive is switched on; first fresh container is brought on the loading platform. Sensing means detects container on the platform and generates signal, which energizes the inlet door drive. The inlet door opens and platform puts first container on the conveyor. Container proceeds forward, enters heating chamber and reaches first heating position II. Sensing means, which is associated with position II detects container and generates a signal, which closes the inlet door. Simultaneously a signal for elevating the platform is generated and a signal for switching on the timer for heating position II. The time for heating in this position is programmed to be about a half of the whole heating cycle. In practice this heating time is 25–30 min.
Power supply for all or part of the heating elements is switched on manually before the conveyor is switched on. If, however this has not been done the sensing means of position II switches on the heating elements referring to this position and all or part of the heating elements referring to heating position III. The required amount of heating elements to be switched on after the first container reaches position II is established empirically when the furnace is tested.
When the first container is being heated in the first heating position a second fresh container is put on the loading platform. Once the heating time is over the timer switches on the cylinder of stopper means SM1 to bring it in lowered position. Container is free to advance further and it reaches second heating position III, in which it is retained by stopper means SM2. For controlling heating cycle in position III a controller e.g. Eurotherm is provided, and a timer. Sensing means, referring to position III switches on the controller, the timer and cylinder of stopper means SM1 to bring it in protruded position. A thermocouple is inserted within the bottom of the first container for measuring temperature if its interior. Sensing means referring to position II switches on pantograph mechanism of the inlet door and it opens. The loading platform is brought in lowered position and second fresh container is put on the conveyor. The conveyor advances the second container from the loading position I to the first heating position II. The inlet door closes and loading platform is elevated. Third fresh container is put on the loading platform and is ready for loading on the conveyor.
Upon reaching required temperature within the first container and after elapsing the required heating time the controller generates a signal, which brings stopper means SM2 in lowered position. The first container advances from heating position III to the next heating position IV, in which it is retained by stopper means SM3. Advancement of the first container in the next position is allowed only when two conditions are satisfied, i.e. the required temperature is reached and the required heating time is elapsed. If the temperature is reached before elapsing the heating time, the controller switches off at least part of the heating elements. In this situation the first container is allowed to advance only after the heating time is elapsed. When sensing means, referring to position IV detects presence of the first container it switches on cylinder of stopper means SM2 to bring it in protruded position. The second container advances from position II to position III and retains therein by virtue of stopper means SM2. The loading platform lowers, places on the conveyor the next fresh container and it proceeds from the loading position towards first heating position II. After the heating cycle, referring to position III is completed the controller generates a signal, which lowers stopper means SM3. Now the first container is free to advance from position IV to position V. The rest of containers displace one position forward in accordance with the above-described procedure.
Each time, when the heating cycle associated with position III is completed a signal is generated, which activates pantograph mechanism 28 and it opens the outlet door 24. It is not shown specifically, but should be understood that there is provided also a sensor, which detects upper position of the door and when the door is brought in this position a signal is generated, which causes lowering the stopper means SM4. By virtue of this provision the container, which is currently retained in position V is free to advance further and exit from the heating chamber. This container reaches first cooling position VI and is retained therein by stopper means SM5. Upon detecting by the sensing means of presence of the container in this position a signal is generated, which activates pantograph mechanism and it closes the outlet door. The further advancement of containers is carried out similarly to described-above procedure. The apparatus is provided with automatic control circuit, which is designed in such a manner that controller generates appropriate signal for lowering stopper means referring to the last occupied position and only after that the containers can be advanced by the conveyor to the next positions.
Once the processed container reaches position VIII and is retained therein by steady support 74 a signal is generated by the sensing means to activate the unloading platform, which elevates the processed container above the chains. Appropriate hoist unloads the processed container from the platform.
Now with reference to non-limiting example 1 it will be explained the advantages of the present invention in comparison with commercially available thermal diffusion coating furnaces, operating periodically.
Zinc thermal diffusion coating was applied on small articles, made of low carbon steel. The articles were loaded in containers together with powder mixture, containing Zinc powder as diffusion specie. The mass of articles in one container was 1000 kg. Closed containers with the articles were thermally treated in the apparatus of the invention, operating continuously and provided with discrete positions as described above. The containers were heated in heating position II during 0.5 hour until temperature T1 within the containers reaches 190–210 Degrees C. and then in heating position III until temperature T within the containers reaches 380–420 Degrees C. This temperature corresponds to steady-state diffusion. After that the containers were advanced to heating position III and IV and held in these positions for about 0.5 hour at temperature T to reach saturation of the surface layer by the diffusion specie. The whole process cycle took 2 hours. Capacity of the furnace with four discrete positions within the heating chamber was 2 containers per hour or 2000 articles per hour. For comparison capacity of a periodically operating furnace, suitable for processing containers of the same size is 500 articles per hour. In other words for processing of the same amount of articles it would be required four periodically operating furnaces.
It should be also mentioned, that maintenance of separate periodically operating furnaces requires much more time and labor, since periodically operating furnaces are less suitable for automation and mechanization. Furthermore, several periodically operating furnaces require 2.5–3 times more space, than one continuous furnace.
By virtue of the present invention it is possible to carry out the process efficiently and at the same time to ensure accurate control of the process parameters individually with respect to each position.
It should be understood that the present invention should not be limited to the above described example and embodiments. One ordinarily skilled in the art can make changes and modifications without deviation from the scope of the invention.
The scope of the present invention is defined in the appended claims.
However it should be understood that the features disclosed in the foregoing description, in the following claims and/or accompanying examples may separately and in any combination thereof, be material for realizing the present invention in diverse forms thereof.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/IL00/00841 | 12/26/2000 | WO | 00 | 10/24/2003 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO02/052057 | 7/4/2002 | WO | A |
| Number | Date | Country |
|---|---|---|
| 2082299 | Mar 1982 | GB |
| 07-173605 | Jul 1995 | JP |
| 2031186 | Mar 1995 | RU |
| 2130508 | May 1999 | RU |
| Number | Date | Country | |
|---|---|---|---|
| 20040062859 A1 | Apr 2004 | US |
