US 6,306,214 B1Granted

Molten metal immersion bath for wire fabrication

AssigneeThe I.C.E. Group

InventorsGordon Bernard Cowie, Andrew James Rawlings

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Abstract

An apparatus and related process for immersing a moving wire within a both of molten metal is applicable to wire forming processes. A flat-bottomed tray has at one end a nozzle for dispersing molten metal across the floor of the tray, from a first end to a second end, in a sheetlike flow. The nozzle preferably includes a slot-like opening, and is associated with a chamber for receiving a supply of pressurized molten metal for discharge through the slot. The metal is discharged with sufficient velocity to create a hydraulic jump or standing wave, whereby the crest of the wave is elevated above the tray end walls. Within the wave, molten metal experiences a turbulent flow in a direction against the travel of the wire array. The wire array passes through the wave, thereby experiencing immersion while being drawn through the apparatus in a straight path without substantial declination. An arrangement of pumps, heaters and a reservoir for the metal permit the metal to be re-circulated through the device and maintained in a molten state.

Claims14

Dependent claims

An apparatus for immersing within a liquid molten metal bath a wire moving in a generally straight horizontal path, comprising:

an elongate tray having opposed ends and elongate sides, a generally flat floor, a dam at a first end of said tray and sidewalls along said sides for maintaining a volume of said liquid metal within said tray with the liquid surface being at a first height;
support means for supporting said wire at a second height above said first height along a substantially horizontal plane;
a source of pressurized liquid metal;
a nozzle at a first end of said tray communicating with said source, said nozzle having a slot for directing;
said liquid from said source in a sheet flow along said floor towards said second end of said tray and over said dam, with sufficient velocity to generate by means of a hydraulic jump a standing wave of said liquid within said tray wherein the crest of said wave is at a level above said second height thereby immersing a portion of said wire within said liquid at said standing wave;
recirculating means for receiving said liquid flowing over said dam and recirculating said liquid to said source;
and
the dimensions of said slot and said source for controlling the flow rate of said liquid conforming to the following formula:
D = d 2 ⁡ [ 1 + 8 g × Q 2 L 2 ⁢ d 3 - 1 ]
Where
D=wave height
d=slot height (distance “x”)
g=gravitational constant
Q=flow rate
L=slot width (distance “z”).

12 more elements

A apparatus for immersing within a molten liquid metal bath a wire moving in a generally straight horizontal path axial with said wire, comprising:

a pressurized source of liquid metal;
a tray having a substantially flat floor, first and second opposed ends, elongate opposed sides and sidewalls along said sides;
a nozzle at a first end of said tray communicating with said source, said nozzle having a slot for directing a stream of said liquid onto the floor of said tray, in a sheet flow parallel to the floor of said tray, towards an opposed second end of said tray, said liquid having a surface at a first height;
wire entry and exit means within said tray supporting said wire as said wire is drawn in a straight, linear path from said second end of said tray to said first end thereof, substantially parallel to said floor and at a second height above said first height;
liquid recirculating means for removing said liquid from said second end of said tray and recirculating said liquid to said source;
whereby said source is adapted to pump said liquid through said nozzle with sufficient velocity to create a hydraulic jump whereby a standing wave is created of said liquid elevating said liquid above said second height and directing a relatively turbulent flow of said liquid in a direction against the direction of said wire through said tray;
and
the dimensions of said slot and said source for controlling the flow rate of said source conforms to the following formula:
D = d 2 ⁡ [ 1 + 8 g × Q 2 L 2 ⁢ d 3 - 1 ]
Where
D=wave height
d=slot height (distance “x”)
g=gravitational constant
Q=flow rate
L=slot width (distance “z”).

12 more elements

Dependencies are inferred from the claim text.