TENSIONED SUPPORT POST AND OTHER MOLTEN METAL DEVICES

Abstract

A vertically-elongated member, which is preferably a support post used in a molten metal pump, includes a ceramic tube and tensioning structures to add a compressive load to the tube along its longitudinal axis. This makes the tube less prone to breakage. Another vertically-elongated member, such as a support post, includes one or more reinforcement members to help alleviate breakage. A device, such as a pump, used in a molten metal bath includes one or more of such vertical members.

Claims

1. A component for use in a molten metal pump, the component comprising: an outer core constructed of graphite or ceramic; a tension rod positioned partially inside the outer core, wherein the tension rod has a first end and a second end, and is configured to apply an axial compressive force to the outer core in order to make the outer core less susceptible to breakage; wherein the first end of the tension rod extends beyond the outer core and has an axially-compressive component positioned thereon, the axially-compressive component positioned against the outer core to place an axial-compressive force on the outer core.

2. The component of claim 1, wherein the tension rod has a first end and a second end, the outer core has a first end and a second end, and at least one of the first end or second end of the tension rod extends beyond either the first end or second end of the outer core.

3. The component of claim 2, wherein either the first end or the second end of the outer core has a cap, and the end of the tension rod that extends beyond the end of the outer core is tightened against the cap.

4. The component of claim 1, wherein the tension rod comprises at least one elongate, metal rod.

5. The component of claim 4, wherein the elongate, metal rod is comprised of steel.

6. The component of claim 1 that is a molten metal pump support post.

7. The component of claim 1, wherein the tension rod is secured in the outer core by cement.

8. The component of claim 7, wherein the tension rod is bonded to the outer core by the cement.

9. The component of claim 1, wherein the outer core comprises graphite.

10. The component of claim 1, wherein the outer core comprises silicon carbide.

11. The component of claim 1, wherein the second end of the tension rod is inside of the outer core.

12. The component of claim 1, wherein the first end of the tension rod is threaded and the first axially-compressive component is a nut threaded onto the tension rod and tightened against the outer core.

13. The component of claim 1 that further includes a second axially-compressive component on the second end of the tension rod.

14. The component of claim 1, wherein the second end of the tension rod is threaded and that further comprises a second axially-compressive component at the second end of the tension rod.

15. The component of claim 14, wherein the second axially-compressive component is a nut threaded onto the second end.

16. The component of claim 1 that further comprises a first support block at the first end of the outer core.

17. The component of claim 16, wherein the second axially-compressive component is positioned inside of a second support block.

18. The component of claim 16, wherein the first support block has a narrow portion positioned inside of the outer core and an enlarged portion that presses against at least part of the wall of the outer core to provide axially-compressive force to the outer core.

19. The component of claim 17, wherein the second support block has an extension positioned inside of the outer core and an enlarged portion that presses against at least part of the wall of the outer core to provide axially-compressive force to the outer core.

20. The component of claim 1, wherein the second end of the extension rod extends beyond a stationary plate and a third axially-compressive component is positioned on the second end of the extension rod on a side of the stationary plate opposite the outer core, and the third axially-compressive component is compressed against the stationary plate.

21. The component of claim 20, wherein the stationary plate is a molten metal pump superstructure.

22. The component of claim 20 that includes a compression device between the third axially-compressive component and the stationary plate.

23. The component of claim 22, wherein the compression device is a spring.

24. The component of claim 16, wherein the first support block is comprised of graphite.

25. The component of claim 17, wherein the second support block is comprised of graphite.

26. The component of claim 14 that further includes a cap at the second end distal to the second axially-compressive component.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] FIG. 1 is a side, partial cross-sectional view of a support post according to this disclosure.

[0024] FIG. 2 is a side, partial cross-sectional view of the support post of FIG. 1 being mounted to a pump superstructure.

[0025] FIG. 2B is an optional bottom portion of the support post of FIGS. 1 and 2.

[0026] FIG. 2C is a top view of the bottom portion of the support post of FIG. 2B.

[0027] FIG. 2D is a cross-sectional view taken along lines D-D of FIG. 2C.

[0028] FIG. 2E is a cross-sectional view taken along lines E-E of FIG. 2C.

[0029] FIG. 3 is a side view of an alternate support post according to this disclosure.

[0030] FIG. 4 is a side, cross-sectional view of the support post of FIG. 3.

[0031] FIG. 5 is a top view of the support post of FIG. 3.

[0032] FIG. 6 is a partial, side view of the support post of FIG. 3 without the outer casing.

[0033] FIG. 7 is a partial, side view of the support post of FIG. 3 without the outer casing.

[0034] FIG. 8 is a top view of the support post of FIG. 6.

[0035] FIG. 9 is a close up view of detail B of FIG. 7.

[0036] FIG. 10 is a side view taken along lines A-A of FIG. 7.

[0037] FIG. 11 is a bottom view of the support post of FIGS. 6 and 7.

[0038] FIG. 11A is an end view of the support post of FIG. 11.

[0039] FIG. 12 is a cross-sectional side view of the support post of FIG. 11 taken along lines E-E.

[0040] FIG. 13 is a side view of an alternate support post according to this disclosure.

[0041] FIG. 14 is an exploded view of the support post of FIG. 13.

[0042] FIG. 15 is a top view of the support post of FIG. 13.

[0043] FIG. 16 is a cross-sectional, partial side view of the support post of FIG. 15 taken along lines A-A.

[0044] FIG. 17 is a close-up view of detail B shown in FIG. 16.

[0045] FIG. 18 is a close-up view of detail C shown in FIG. 16.

[0046] FIG. 19 is a side view of the base of the support post of FIGS. 3 and 6.

[0047] FIG. 20 is a top view of the base of FIG. 19.

[0048] FIG. 21 is a cross-sectional side view taken along line D-D of FIG. 20.

[0049] FIG. 22 is a cross-sectional side view taken along line E-E of FIG. 20.

[0050] FIG. 23 is a perspective, side view of an outer core according to this disclosure.

[0051] FIG. 24 is a top view of the outer core of FIG. 23.

[0052] FIG. 25 is a side, cross-sectional view of the outer core taken along line F-F of FIG. 24.

[0053] FIG. 26 is a perspective side view of a tension rod according to this disclosure.

[0054] FIG. 27 is a partial, side view of the tension rod of FIG. 26.

[0055] FIG. 28 is a perspective, top view of a support post top according to this disclosure.

[0056] FIG. 29 is a top view of the support post top of FIG. 28.

[0057] FIG. 30 is a side, cross-sectional view taken along line G-G of FIG. 29.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0058] For any device described herein, any of the components that contact the molten metal are preferably formed by a material that can withstand the molten metal environment. Preferred materials are oxidation-resistant graphite and ceramic, such as silicon carbide.

[0059] FIG. 1 shows a support post 10 in accordance with aspects of the disclosure. Shaft has an outer core 50 that has axial tension applied to it to make outer core 50 more resistant to breakage. Similar techniques, however, may be used to tension rotor shafts or other elongate molten metal pump components. Shaft 10 has a tension rod 20, a top support block 30, a bottom support block 60, an outer core 50, and a bottom 70.

[0060] Tension rod 20 is preferably comprised of steel and has a body 24, a first end 24 and a second end 26. As shown, tension rod 20 is threaded along about 5% to 25% of its length starting at first end 24 and moving upward, and along about 10% to 25% of its length starting at second end 26 and moving downward. The threaded portion 24A juxtaposed end 24 is preferably configured to be threaded into a channel 64 in second end 60 and into channel 76A in section 76. Portion 24A need only have sufficient threads to anchor it in second end 60 and/or section 76. Alternatively, shaft 20 need not be threaded into second end 60 and/or section 76, but could instead pass through them and be retained by nut 85 (or other suitable fastener) in section 76 or section 74.

[0061] Threaded portion 26A can optionally be threaded partially into bore 39 of top block 30. Nut 40 and nut 120 are threaded onto portion 26A as further described.

[0062] Tension rod 20 includes a top, threaded portion 26A that (as shown) threaded partially into top block 30. Top block 30 has an upper portion 34, a top surface 35, an opening 32, a sleeve 38, an internal wall surface 36, and a passage 39. Upper portion 34 is on top of and outside of outer core 50, and surface 36 rests on the top 52 to apply axial tension to outer core 50. Passage 39 is configured so rod 20 can pass therethrough. Opening 32 is formed in top surface 35, is preferably about 1.5 to 2.5 times the diameter of rod 20, and extends into top block 30 from upper surface 35 by about 1″ to 3″, although opening 32 can be of any suitable dimension. Sleeve 38 fits inside of outer coating 50 and extends downward about 10-30% of the length (although any suitable distance would work, or top bock 30 could be stabilized in another manner) of outer coating 50 in order to stabilize top block 30 to outer coating 50.

[0063] Channels 80 and 82 are for injecting cement into the bottom of support post 20 to help connect it to a molten metal pump base in a manner known in the art. Any suitable molten metal pump base could be utilized.

[0064] FIG. 2 shows the support post 10 of FIG. 1 being connected to a superstructure 100 of a molten metal pump, wherein the superstructure 100 supports the pump motor. The superstructure 100 is preferably a steel plate or platform, and is known in the art. Here, it has an opening 102 formed therethrough, a bottom surface 104, and a top surface 106. To add additional tension to outer core 50, a compression spring 110 and nut 120 are positioned on tension rod 20 above surface 106. Nut 120 is then tightened, which ultimately tightens surface 35 of top block 30 against bottom surface 104. Spring 110 need not be used but it or a similar flexible structure is preferred.

[0065] Outer core 50 could instead be comprised of graphite and/or blocks 30 and 60 could be comprised of ceramic. Further, any of sections 72, 74, 76 could be comprised of graphite or ceramic.

[0066] FIGS. 3-5 show an alternate support post 200 with graphite core 210 and an outer ceramic (preferably silicon carbide) core 250. Alternatively, core 210 could be comprised of ceramic and/or outer core 250 could be comprised of graphite. A reinforcement member 300 is positioned in graphite core 210. In this embodiment outer core 250 is optional. Further, there may be more than one reinforcement member at either one end, or both ends of core 210. Or core 210 could have a single reinforcement member at each end or that extends therethrough or substantially therethrough.

[0067] As shown, the reinforcement member 300 is positioned in a manner, and is comprised of a material, such that it helps prevent the core 210 from breaking. Reinforcement member 300 is preferably comprised of steel, has a length of about 10% to 35%, or 15%-25% of the length of core 210, or a length of about 8″ to 12″, 10″ to 16″, or 12″ to 16″, and the cylindrical with a diameter about 1/10″, ⅛″, ⅙″, ¼″ or ½″, or about 10%-30% the diameter of portion 214 of core 210.

[0068] Core 210 has a top end 212, a bottom end 214, a top section 212A, a bottom section 214A, and a central portion 216. A bore 220 is formed in core 210 and extends from end 214, preferably through bottom section 214A and partially into section 216. As shown, bore 220 is formed in the center of core 210, although it could be off center.

[0069] Reinforcement member 300 is positioned in bore 220 and may be secured by cement. Member 300 has a first end 302 that is preferably tapered and a second end 304. As shown, second end 304 is wider than the body portion 306. A cap 230 is positioned over second end 304 and preferably cemented in place to prevent molten metal from contacting reinforcement member 300. All or part of body portion 306 may be threaded so that member 300 is threaded into bore 220. As shown in FIG. 12, reinforcement member has a smaller-diameter portion 306A that is threaded. Portion 306A is threaded into smaller diameter portion 220A of bore 220. Larger diameter bore portion 220B receives second end 204.

[0070] Bores 250 and 252 are for connecting first end 212 of support post 200 to a support post clamp preferably positioned above the superstructure of a molten metal pump.

[0071] Some non-limiting examples of the disclosure are as follows:

EXAMPLE 1

[0072] A component for use in a molten metal pump, the component comprising:

[0073] an outer core constructed of graphite or ceramic;

[0074] a tension rod positioned partially inside the outer core, wherein the tension rod has a first end and a second end, and is configured to apply an axial compressive force to the outer core in order to make the outer core less susceptible to breakage;

[0075] wherein the first end of the tension rod extends beyond the outer core and has an axially-compressive component positioned thereon, the axially-compressive component positioned against the outer core to place an axial-compressive force on the outer core.

EXAMPLE 2

[0076] The component of example 1, wherein the tension rod has a first end and a second end, the outer core has a first end and a second end, and at least one of the first end or second end of the tension rod extends beyond either the first end or second end of the outer core.

EXAMPLE 3

[0077] The component of example 2, wherein either the first end or the second end of the outer core has a cap, and the end of the tension rod that extends beyond the end of the outer core is tightened against the cap.

EXAMPLE 4

[0078] The component of example 1, wherein the tension rod comprises at least one elongate, metal rod.

EXAMPLE 5

[0079] The component of example 4, wherein the tension rod is comprised of steel.

EXAMPLE 6

[0080] The component of example 1 that is a molten metal pump support post.

EXAMPLE 7

[0081] The component of example 1, wherein the tension rod is secured in the outer core by cement.

EXAMPLE 8

[0082] The component of example 7, wherein the tension rod is bonded to the outer core by the cement.

EXAMPLE 9

[0083] The component of example 1, wherein the outer core comprises graphite.

EXAMPLE 10

[0084] The component of example 1, wherein the outer core comprises silicon carbide.

EXAMPLE 11

[0085] The component of example 1, wherein the outer core comprises material harder than graphite.

EXAMPLE 12

[0086] The component of example 1, wherein the second end of the tension rod is inside of the outer core.

EXAMPLE 13

[0087] The component of example 1, wherein the first end of the tension rod is threaded and the first axially-compressive component is a nut threaded onto the tension rod and tightened against the outer core.

EXAMPLE 14

[0088] The component of example 1 that further includes a second axially-compressive component on the second end of the tension rod.

EXAMPLE 15

[0089] The component of example 1, wherein the second end of the tension rod is threaded and that further comprises a second axially-compressive component at the second end of the tension rod.

EXAMPLE 16

[0090] The component of example 15, wherein the second end of the tension rod is threaded and the second axially-compressive component is a nut threaded into the second end.

EXAMPLE 17

[0091] The component of example 13, wherein the nut is hexagonal.

EXAMPLE 18

[0092] The component of example 16, wherein the nut is hexagonal.

EXAMPLE 19

[0093] The component of example 1 that further comprises a first support block at the first end of the outer core.

EXAMPLE 20

[0094] The component of example 19, wherein the second axially-compressive component is positioned inside of the second support block.

EXAMPLE 21

[0095] The component of example 19, wherein the first support block has a narrow portion positioned inside of the outer core and an enlarged portion that presses against at least part of the wall of the outer core.

EXAMPLE 22

[0096] The component of example 20, wherein the second support block has an extension positioned inside of the outer core and an enlarged portion that presses against at least part of the wall of the outer core to provide axially-compressive force to the outer core.

EXAMPLE 23

[0097] The component of example 1, wherein the second end of the extension rod extends beyond a stationary plate and a third axially-compressive component is positioned on the second end of the extension rod on a side of the stationary plate opposite the outer core, and the third axially-compressive component is compressed to the stationary plate.

EXAMPLE 24

[0098] The component of example 23, wherein the stationary plate is a molten metal pump superstructure.

EXAMPLE 25

[0099] The component of example 23 that includes a compression device between the third axially-compressive component and the stationary plate.

EXAMPLE 26

[0100] The component of example 25, wherein the compression device is a spring.

EXAMPLE 27

[0101] The component of example 19, wherein the first support block is comprised of graphite.

EXAMPLE 28

[0102] The component of example 22, wherein the second support block is comprised of graphite.

EXAMPLE 29

[0103] The component of example 20 that further includes a cap at the second end distal to the second axially-compressive component.

[0104] Some other non-limiting examples of the disclosure follow:

EXAMPLE 1

[0105] A support post comprising an elongated body having a longitudinal axis and a height, a first end configured to connect to a superstructure and a second end configured to connect to a pump base, wherein the second end comprises at least one reinforcement section configured to make the second end resistant to breakage.

EXAMPLE 2

[0106] The support post of example 1, wherein the at least one reinforcement section is elongated and has a longitudinal axis.

EXAMPLE 3

[0107] The support post of example 2, wherein the longitudinal axis of the at least one reinforcement section is aligned with the longitudinal axis of the support post.

EXAMPLE 4

[0108] The support post of example 1, wherein the support post is comprised of graphite and the at least one reinforcement section is comprised of one or more of the group consisting of: silicon carbide and steel.

EXAMPLE 5

[0109] The support post of example 1, wherein the at least one reinforcement section is completely surrounded by the material of the support post so the reinforcement section is configured not to contact molten metal.

EXAMPLE 6

[0110] The support post of example 1, wherein the at least one reinforcement section is less than 50% of the height of the support post.

EXAMPLE 7

[0111] The support post of example 1, wherein the at least one reinforcement section is between 15%-35% of the height of the support post.

EXAMPLE 8

[0112] The support post of example 1, wherein the at least one reinforcement section is between 15%-25% of the height of the support post.

EXAMPLE 9

[0113] The support post of example 1, wherein the at least one reinforcement section has a cross-sectional area that is between ¼ and 1/10 the cross-sectional area of the second end of the support post.

EXAMPLE 10

[0114] The support post of example 1, wherein the at least one reinforcement section has a cross-sectional area that is between ⅕ and ⅛ the cross-sectional area of the second end of the support post.

EXAMPLE 11

[0115] The support post of example 1, wherein the support post has a bore in its second end and the at least reinforcement section is positioned in the bore.

EXAMPLE 12

[0116] The support post of example 11 that further includes cement in the bore to anchor the at least one reinforcement section.

EXAMPLE 13

[0117] The support post of example 1 that further includes a ceramic outer cover.

EXAMPLE 14

[0118] The support post of example 1 that is cylindrical.

EXAMPLE 15

[0119] The support post of example 1, wherein the reinforcement section is cylindrical.

EXAMPLE 16

[0120] The support post of example 1, wherein the second end includes a first portion having a first diameter, and a second portion having a second diameter, wherein the second diameter is less than the first diameter.

EXAMPLE 17

[0121] The support post of example 1, wherein the second end includes a first portion having a first cross-sectional area, and a second portion having a second cross-sectional area is less than the first cross-sectional area.

EXAMPLE 18

[0122] The support post of example 16, wherein the at least one reinforcement section is positioned partially in the first portion and partially in the second portion.

EXAMPLE 19

[0123] The support post of example 17, wherein the reinforcement section is positioned partially in the first portion and partially in the second portion.

EXAMPLE 20

[0124] The support post of example 1 that is cylindrical with a center and the reinforcement section is positioned in the center.

EXAMPLE 21

[0125] The support post of example 1 that further includes one or more channels in the second end, wherein the channels are configured to receive cement.

EXAMPLE 22

[0126] The support post of example 1, wherein the first end is configured to fit into a coupling.

EXAMPLE 23

[0127] The support post of example 11 that further includes a plug at a second tip of the support post, wherein the plug is configured to cover the bore.

EXAMPLE 24

[0128] The support post of example 1 that includes a single reinforcement section.

EXAMPLE 25

[0129] The support post of example 1, wherein the at least one reinforcement section is concrete, positioned in a bore inside of the second end of the support post.

EXAMPLE 26

[0130] The support post of example 1, wherein the at least one reinforcement section extends the length of the support post.

EXAMPLE 27

[0131] The support post of example 1, wherein the at least one reinforcement section has an outer surface including threads, wherein the at least one reinforcement section is threadingly received in the support post.

EXAMPLE 28

[0132] The support post of example 27, wherein the threads are received in the support post at its first diameter and first cross-sectional area.

EXAMPLE 29

[0133] The support post of example 27, wherein the at least one reinforcement section has a length and the threads extend along the entire length.

EXAMPLE 30

[0134] The support post of example 27, wherein the at least one reinforcement section has a length and the threads extend at least 50% of the length.

EXAMPLE 31

[0135] The support post of example 27, wherein the at least one reinforcement section has a length and the threads extend at least 25% of the length.

EXAMPLE 32

[0136] The support post of example 1 that has one or more air-relief grooves.

EXAMPLE 33

[0137] The support post of example 32 that has two air-relief grooves.

EXAMPLE 34

[0138] The support post of example 16, wherein the second diameter is between 3.5″ and 4.5″.

EXAMPLE 35

[0139] The support post of example 16, wherein the second portion has a height of between 6.0″ and 7.0″.

EXAMPLE 36

[0140] The support post of example 1, wherein the reinforcement section has a diameter of between 0.75″ and 1.25″.

[0141] Having thus described different embodiments, other variations and embodiments that do not depart from the spirit of this disclosure will become apparent to those skilled in the art. The scope of the claims is thus not limited to any particular embodiment, but is instead set forth in the claims and the legal equivalents thereof. Unless expressly stated in the written description or claims, the steps of any method recited in the claims may be performed in any order capable of yielding the desired product. No language in the specification should be construed as indicating that any non-claimed limitation is included in a claim. The terms “a” and “an” in the context of the following claims are to be construed to cover both the singular and the plural, unless otherwise indicated herein.