METHOD AND APPARATUS UTILIZING MULTIPLE FORCES TO CREATE INCREASED TENSILE STRENGTH, INCREASED STRUCTURAL COHERENCE, AND REDUCED CORROSION OF METALLICS

Abstract

A method for increasing tensile strength in a workpiece, the method including obtaining a workpiece to be treated, heating the workpiece to an elevated temperature, inducing a magnetic field onto the workpiece, detecting a natural oscillation frequency of the workpiece, generating a frequency onto the workpiece in response to the detected natural oscillation frequency of the workpiece, monitoring continuously a frequency of the workpiece, inducing multiple applied forces on the workpiece to maintain the frequency at which the workpiece is oscillated, and thermal quenching the workpiece to below ambient temperature.

Claims

1. An apparatus for increasing tensile strength in a workpiece comprising: a controller; a heating member configured generate a thermal force to heat a workpiece to a temperature above 0° C.; a vibration generator configured to generate vibration onto the workpiece; a magnetic field generating member configured to induce a magnetic field into the workpiece above 0.15 Tesla; and a vibration meter member configured to detect a natural oscillation frequency of the workpiece; a frequency generator coupled to the controller and the vibration meter, the frequency generator configured to output at least one frequency onto the workpiece based on the natural oscillation frequency of the workpiece detected by the vibration meter; wherein the controller maintains a frequency at which the workpiece is oscillated by controlling at least one of the heating member, the vibration generator, and the magnetic field generating member to apply a combined force onto the workpiece.

2. The apparatus of claim 1, wherein the vibration meter continuously detects the natural oscillation frequency of the workpiece.

3. The apparatus of claim 1, wherein the combined force includes at least one of a sonic vibration, a resonance frequency, a magnetic frequency, and a thermal force.

4. The apparatus of claim 3, wherein the sonic vibration, resonance frequency, magnetic frequency, and thermal force are variable.

5. The apparatus of claim 3, wherein when the combined force includes the resonance frequency and the sonic vibration, the sonic vibration is a swept wave of multiple frequencies.

6. The apparatus of claim 5, wherein the controller maintains the frequency at which the workpiece is oscillated by controlling the combined force applied to the workpiece.

7. The apparatus of claim 6, wherein the vibration generator is configured to simultaneously induce multiple different frequencies into the workpiece.

8. The apparatus of claim 7, wherein the vibration meter receives a sine wave from the workpiece, the controller multiplies the sine wave by a whole number or a half value multiple, the controller then transmits the sine wave to an amplifier to generate a new impulse and controls the vibration generator to generate the new impulse into the workpiece.

9. The apparatus of claim 8, wherein the vibration generator is operative to induce all frequencies at newly attenuated resonant frequencies of the workpiece, whereby the multiple resonant frequencies is due to workpiece resonance as well as individual element constituent resonance, and wherein the controller is dynamic and self-adjusting for pressure and temperature variance as well as dynamic modulation due to part coherence changes during the process.

10. The apparatus of claim 6, wherein the frequency at which the workpiece is oscillated by the combined force is determined by feedback signals received from a sensor detachably coupled to the workpiece.

11. A method for increasing tensile strength in a workpiece, the method comprising: obtaining a workpiece to be treated; heating the workpiece to an elevated temperature; inducing a magnetic field onto the workpiece; detecting a natural oscillation frequency of the workpiece; generating a frequency onto the workpiece in response to the detected natural oscillation frequency of the workpiece; monitoring continuously a frequency of the workpiece; inducing multiple applied forces on the workpiece to maintain the frequency at which the workpiece is oscillated; and thermal quenching the workpiece to below ambient temperature.

12. The method of claim 11, wherein the elevated temperature is about eutectoid temperature.

13. The method of claim 12, wherein the multiple applied forces include sonic and magnetic forces.

14. The method of claim 12, wherein the inducing the magnetic field is to above Tesla.

15. The method of claim 13, wherein the thermal quenching the workpiece is to between ambient temperature and −456° F.

Description

BRIEF DESCRIPTIONS OF THE DRAWINGS

[0031] These and/or other aspects of the present general inventive concept will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:

[0032] FIG. 1 is a schematic view of an apparatus for increasing tensile strength in a workpiece according to an embodiment of the present general inventive concept;

[0033] FIG. 1A is a schematic view of the apparatus illustrated in FIG. 1, wherein a vibration generator and a vibration meter member are detachably coupled to a workpiece;

[0034] FIG. 2 is a schematic view of an apparatus for increasing tensile strength in a workpiece according to another embodiment of the present general inventive concept; and

[0035] FIG. 3 is a flow chart illustrating steps in a method 300 for increasing tensile strength in a workpiece according to an embodiment of the present inventive concept.

DETAILED DESCRIPTION OF THE INVENTION

[0036] The present inventive concept will now be described more fully with reference to the accompanying drawings, in which exemplary embodiments of the present general inventive concept are illustrated. The inventive concept may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of the invention to those skilled in the art.

[0037] Eutectoid is a term that is generally used to describe a specific type of phase transformation that occurs in certain alloys when they are cooled from a high temperature. In this process, a single solid phase transforms into two different solid phases at a specific temperature, known as the eutectoid temperature. The eutectoid transformation occurs at a lower temperature than other types of phase transformations, making it relatively easy to achieve.

[0038] One example of a eutectoid transformation occurs in steel, which is an alloy of iron and carbon. When steel is heated to a high temperature and then cooled, it undergoes a series of phase transformations as the temperature decreases. At the eutectoid temperature of around 723° C., a single solid phase of iron and carbon, known as austenite, transforms into two different solid phases, ferrite and cementite. This process is known as the eutectoid transformation, and the resulting microstructure is called pearlite.

[0039] The eutectoid transformation can have a significant impact on the mechanical properties of the material. The microstructure (or crystalline structure) produced by the eutectoid transformation can affect the strength, toughness, and ductility of the material, making it an important consideration in the design and manufacturing of various components and structures.

[0040] Crystalline structure is a phrase that is generally used to refer to the arrangement of atoms, ions or molecules in a crystal, which gives the crystal its characteristic shape and properties. In a crystalline material, the atoms, ions, or molecules are arranged in a regular, repeating pattern that extends throughout the entire crystal.

[0041] The arrangement of atoms in a crystalline material is determined by the chemical bonds between the atoms and the surrounding environment, including temperature and pressure. These factors influence the way in which the atoms or molecules come together to form a crystal lattice, which is a three-dimensional network of repeating units called unit cells.

[0042] There are several different types of crystal structures, each characterized by a different arrangement of atoms in the lattice. Some common crystal structures include the face-centered cubic (FCC) structure, the body-centered cubic (BCC) structure, and the hexagonal close-packed (HCP) structure. These structures are important in the study of materials science and engineering, as they can influence the physical, mechanical, and electronic properties of materials.

[0043] Sonics is a term that is generally used to refer to the application of sound waves. Sound waves are a type of mechanical wave that travels through a medium and are characterized by their frequency (or pitch) and amplitude (or loudness).

[0044] Magnetic force is the force that is exerted by a magnetic field on a magnetic object or a moving charged particle. It is a manifestation of the electromagnetic force and is used in many applications such as electric motors and MRI machines.

[0045] The present general inventive concept also provides an apparatus that is operative to apply sonic and concurrent magnetic forces (i.e., sonic and magnetic force at the same time) at or near eutectoid, which is a significant breakthrough in the art of heat-treating metals. The subsequent quench to lower temperatures, room temperatures or cryogenic temperatures, results in a permanent “locked in” new and improved metallic structure.

[0046] The present general inventive concept also provides a method and apparatus for increasing tensile strength of a workpiece rapidly and at a very low cost through simple energy input to the workpiece.

[0047] The present general inventive concept also provides a method and apparatus for increasing tensile strength and modifying the workpiece to reduce the risk of failure, warping, heat-checking, and corrosion of the workpiece. Enhanced corrosion resistance is due to increased coherence of structure. Reducing surface area by grain refinement presents less oxidative availability (e.g., surface area peaks and valleys of sandpaper vs. glass).

[0048] FIG. 1 is a schematic view of an apparatus for increasing tensile strength in a workpiece 100 according to an embodiment of the present inventive concept. FIG. 1A is a schematic view of the apparatus illustrated in FIG. 1, wherein a vibration generator and a vibration meter member are coupled to a workpiece.

[0049] Referring to FIG. 1, the exemplary apparatus, designated generally as 100, is illustrated. In the present embodiment, the apparatus 100 is designed and configured to provide a method of modifying molecular structure in a workpiece 10 by manipulating the material of the workpiece 10, while the workpiece 10 is at or near eutectoid. The exemplary apparatus 100 is designed to significantly increase bending tensile strength and stabilization of the crystalline structure of a workpiece 10. The apparatus 100 according to the present invention is designed to apply numerous types of forces to the workpiece 10 including, but not limited to, sonic and concurrent magnetic forces (i.e., both sonic and magnetic force applied at the same time), while the workpiece 10 is at or near eutectoid. However, the present general inventive concept is not limited thereto. That is, in alternative embodiments, the exemplary apparatus 100 may be designed to apply a thermal force, a magnetic force, and/or an electromagnetic force.

[0050] In the present embodiment, the apparatus 100 for increasing tensile strength in a workpiece 10 includes a controller 110 in operative communication with a heating member 120, a vibration generator 130 (i.e., a first transducer), a magnetic field generating member 140, a vibration meter member 150 (i.e., a second transducer), and a quenching chamber 155.

[0051] The controller 110 is designed to send/receive signals from the heating member 120, the vibration generator 130 (i.e., frequency generator), the magnetic field generating member 140, the vibration meter member 150, and the quenching chamber 155 in order to concurrently apply at least two different forces (i.e., a combined force), such as sonic and magnetic forces onto a workpiece 10, when the workpiece 10 is at or near its eutectoid temperature.

[0052] The controller 110 maintains constant a frequency at which the workpiece 10 is oscillated by controlling the combined force that is applied to the workpiece 10 by dynamically controlling the heating member 120, the vibration generator 130, and the magnetic field generating member 140 according to the natural oscillation frequency of the workpiece 10 detected by the vibration meter member 150, in real-time.

[0053] In the present embodiment, the heating member 120 is configured generate a thermal force to heat a workpiece 10 to a temperature above 0° C. The heating member 120 may include various types of heating methods including induction or resistance. However, the present general inventive concept is not limited thereto.

[0054] In the present embodiment, the vibration generator 130 is configured to generate vibration onto the workpiece 10. The vibration generator 130 may be used to simultaneously apply multiple different frequencies into the workpiece 10.

[0055] In the present embodiment, the magnetic field generating member 140 is configured to induce a magnetic field into the workpiece 10 above 0.15 Tesla. This magnetic field may range from 0.15 Tesla to 10 Tesla. However, the present general inventive concept is not limited thereto.

[0056] Referring to FIG. 1A, the vibration meter member 150 is configured to continuously detect a natural oscillation frequency of the workpiece 10.

[0057] In the present embodiment, the vibration generator 130 is coupled to the controller 110 and the vibration meter 150. The vibration generator 130 is configured to output at least one frequency onto the workpiece 10 based on a natural oscillation frequency of the workpiece 10 detected by the vibration meter member 150.

[0058] In the present embodiment, the controller 110 maintains a frequency at which the workpiece 10 is oscillated by controlling at least one of the heating member 120, the vibration generator 130, and the magnetic field generating member 140 to apply a combined force onto the workpiece, while the workpiece is at or near its eutectoid temperature.

[0059] In the present embodiment, the controller 110 controls the quenching chamber 155 temperature, duration, and speed to thermal quench the workpiece 10 to below ambient temperature to about −456 degrees Fahrenheit ° F.

[0060] In alternative embodiments, the combined force includes at least one of a sonic vibration, a resonance frequency, a magnetic frequency, and a thermal force.

[0061] In alternative embodiments, the combined force may include a variable sonic vibration, a variable resonance frequency, a variable magnetic frequency, and a variable thermal force. The sonic vibration may be a swept wave of multiple frequencies.

[0062] In alternative embodiments, the vibration meter receives a sine wave from the workpiece 10, the controller 110 multiplies the sine wave by a whole number or a half value multiple and then controller 110 transmits the sine wave to an amplifier to generate a new impulse. The controller 110 then controls the vibration generator 130 to generate the new impulse frequency into the workpiece 10.

[0063] The vibration generator 130 is operative to induce all frequencies at newly attenuated resonant frequencies of the workpiece 10. As such, the multiple resonant frequencies is due to workpiece resonance as well as individual element constituent resonance. The controller 110 is dynamic and self-adjusting for pressure and temperature variance as well as dynamic modulation due to part coherence changes during the process.

[0064] In alternative embodiments, the frequency at which the workpiece 10 is oscillated by the combined force is determined by feedback signals received from a sensor 150 detachably coupled to the workpiece 10 and to the controller 110.

[0065] FIG. 2 is a schematic view of an apparatus 200 for increasing tensile strength in a workpiece according to another embodiment of the present inventive concept. The apparatus 200 is substantially similar to the previous embodiment 100, but further includes an impact tester 270 in operative communication with the controller 210.

[0066] In the present embodiment, the apparatus 200 for increasing tensile strength in a workpiece 10 includes a controller 210 in operative communication with a heating member 220, a vibration generator 230 (i.e., a first transducer), a magnetic field generating member 240, a vibration meter member 250 (i.e., a second transducer), and a quenching chamber 255. The apparatus 200 for increasing tensile strength in a workpiece 10 further includes an impact tester 270 in operative communication with the controller 210.

[0067] FIG. 3 is a flow chart illustrating steps in a method 300 for increasing tensile strength in a workpiece according to an embodiment of the present inventive concept.

[0068] In a first step 310, a workpiece for which treatment is to be performed is obtained.

[0069] In step 320, the workpiece is heated to an elevated temperature to approaching plastic or about eutectoid temperature of the workpiece.

[0070] In step 330, a magnetic field to above 0.15 Tesla is induced on the workpiece.

[0071] In step 340, a natural oscillation frequency of the workpiece is detected.

[0072] In step 350, in response to the detected natural oscillation frequency of the workpiece, a frequency is generated onto the workpiece.

[0073] In step 360, a frequency of the workpiece is monitored continuously.

[0074] In step 370, multiple applied forces are induced on the workpiece to maintain the frequency which the workpiece is oscillated. The multiple applied forces include sonic and magnetic forces. That is, a combination of sound waves and magnetic fields will be used to manipulate or process the workpiece. The multiple applied forces may act upon the workpiece at the same time which enhances their effect of the workpiece.

[0075] In step 380, the workpiece is thermal quenched to between ambient temperature to −456° F. That is, the workpiece may then undergo a sudden cooling process, either continuously or in intervals to alter the microstructure of the workpiece. The thermal quenching may occur as multiple cooling steps in a sequence.

[0076] Although a few exemplary embodiments of the present general inventive concept have been illustrated and described, it will be appreciated by those skilled in the art that changes may be made in these exemplary embodiments without departing from the principles and spirit of the general inventive concept, the scope of which is defined in the appended claims and their equivalents.