Field of Invention
The present invention relates to the development of an Annealing
Simulator.
Background of Invention
Annealing simulators have been used for quite a long time. The annealing
simulators should be capable of providing varied conditions to the sample
so that the sample can be tested in various conditions.
The annealing simulators comprise mainly a hot chamber for heating
sample upto the required temperature. The annealing simulators having
the hot chamber can be well utilized for the batch type annealing.
But for continuous type annealing, simulators are not effective. This is
because for cooling, one has to rely on the hot chamber only and
somehow it has to be cooled. As the temperature of the hot chamber can
be raised as high as 1000°C, effective rapid cooling is not possible.
Moreover the amount of cooling gases used is too high. Further, the rapid
cooling also affects the life of the hot chamber.
Some of the prior arts, for instances KR100727736 are only useful with
batch type annealing and can be used with a limited operating parameter
of continuous annealing process.
In the prior-Art sample is loaded in the hot chamber and the hot chamber
with sample is subjected to annealing simulation process by engaging with
furnace. For continuous annealing where the heating rates to reach
annealing temperature are very high, the achievable heating rates of hot
chamber and sample are limited because of large mass have to be heated
to attain high heating rates.

Second most important factor is high cooling rates at which specimens are
required to be cooled. In the prior-art cooling is done by cooling the hot
chamber along with samples. This involves large mass to be cooled at
specific high cooling rates. Heating and cooling of large mass at any
specific rate is a major restriction for simulation of continuous annealing,
hence provide limited simulation parameters.
Objects of the Invention
In view of the foregoing limitations inherent in the prior-art, it is an object
of the invention to develop a detachable cold chamber that can be
coupled to an annealing simulator to rapidly cool sample once heat treated
in a hot chamber.
Another object of the invention is to measure the real time temperature
experienced by the sample during entire annealing process.
Still another object of the invention is to facilitate simulation of both batch
and continuous annealing process at a single platform.
Still another object of the invention is to provide a high pressure mixed
gases jet spray directly onto the sample to achieve rapid to ultrafast
cooling (>200°C/s) of the sample.
SUMMARY OF THE INVENTION
In one aspect, the invention provides an annealing simulator comprising a
hot chamber, a detachable cold chamber and a sample mounting
arrangement. The cold chamber is coupled to the hot chamber and the
detachable cold chamber comprises a sample mounting arrangement, the
sample mounting arrangement is configured to move to and fro between
the detachable cold chamber and the hot chamber along with sample.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
FIG. 1 shows side view cut section of an annealing simulator.
FIG. 1(a) shows an isometric view cut section of a hot chamber coupled
to a detachable cold chamber of the annealing simulator.
FIG. 1(b) shows cut section view of detached detachable cold chamber
of the annealing simulator with a sample mounting arrangement.
FIG. 1(c) shows cut section view of the detachable cold chamber of the
annealing simulator with cover kept open and plurality of openings in a 1st
guide rail in the detachable cold chamber.
FIG. 1(d) shows an isometric cut section view of the sample mounting
arrangement located at the cold chamber without being enclosed by the
hot chamber.
FIG. 2(a) - 2(d) shows various annealing profiles of different samples
obtained from the annealing simulator.
Detailed Description of Invention
Various embodiments of the invention provide an annealing simulator, the
annealing simulator comprising a hot chamber, a detachable cold chamber
coupled to the hot chamber, the detachable cold chamber comprising a
sample mounting arrangement, the sample mounting arrangement being
configured to move along with sample between the detachable cold
chamber and the hot chamber, the hot chamber being configured to heat
the sample and the detachable cold chamber being configured to cool the
sample.

FIG. 1 shows various parts of an annealing simulator (100) in accordance
with an embodiment of the invention. The two important elements of the
annealing simulator (100) are a hot chamber (104) and a detachable cold
chamber (108). The hot chamber (104) is supported on a platform (112)
by means of a coupling plate (116). An electric furnace (120) is placed
and is moveable on the platform (112). The hot chamber (104) while in
operation (i.e. for heating sample) is positioned inside the electric furnace
(120) by moving it towards the hot chamber.
The annealing simulator (100) further comprises a gas mixing cylinder
(124). The gas mixing cylinder (124) is configured to supply cooling gas to
the hot chamber (104) and the detachable cold chamber (108) for cooling.
The cooling gas is mixture of H2-N2. The proportion of H2 and N2 gas in H2-
N2 mixed gas lies in 5-25% and 75-95% (by volume) respectively. The gas
mixing cylinder (124) has H2 gas intake from H2 cylinder (128) and N2 gas
intake from N2 cylinder (132). The mixed gas in the mixing (124) is
analyzed by an analyzer (136) and regulates set mixture composition.
It should be appreciated that though the cooling of the sample is done
only in the cold chamber. The supply of the H2-N2 mixed gases in the
hot chamber is carried out only to maintain environment inside it.
In some embodiment, cooling may be possible only with H2 gas without a
requirement of N2 gas, therefore in such cases the supply line of the N2
gas to gas mixing cylinder (124) can be disconnected. In some other
embodiment may be also be used, in combination with H2-
N2 or H2 gas as per the cooling requirement.
The detachable cold chamber (108) comprises a flange (140) for coupling
with the hot chamber (104) also shown in FIG. l(a)-l(d).

The detachable cold chamber (108) comprises a gas spraying channel
(144) The gas spraying channel (144) comprise plurality of openings (152)
(shown in FIG. 1(d)). The 2nd guide rail (188) comprises gas spraying
channel having plurality of openings (156) (shown in FIG. 1(a)). These
openings (152) and (156) are configured to spray H2-N2 mixture to cool
down the sample in the cold chamber.
In an embodiment separate gas spraying channels having plurality of
openings may also be used in the hot chamber for gas spraying.
The electric furnace (120) also comprises thermocouple (122) to measure
its temperature.
Shown in FIGS. 1(a)-1(d) the detachable cold chamber (108) comprises
a sample mounting arrangement (160) at various positions. Shown in
FIG. 1(a) the sample mounting arrangement (160) is at hot chamber, in
FIG. 1(b) it is in between the hot chamber and the cold chamber, in FIG.
1(c) and 1(d) it is at the cold chamber.
The detachable cold chamber (108) comprises an opening (164) covered
by a cover (168). The opening (164) is configured to route samples (172)
over the sample mounting arrangement (160). The sample can be a
tensile real sized steel specimens or of any other form of the material.
It is to be noted that on the sample mounting arrangement (160) one or
more than one sample can be mounted as shown in FIG. 1(c).
Each end of the sample mounting arrangement (160) comprises a 1st end
cover (176) (shown in FIG. 1(a)) and a 2nd end cover (180) (shown in
FIG. 1(b). The detachable cold chamber (108) comprises a 1st guide rail
(184). The 1st end cover (176) is configured to travel over the 1st guide

rail (184). The shape of the 1st end cover (176) and the 2nd end cover
(180) is in V-shape with rounded edge. Similarly the hot chamber (104)
comprises a 2nd guide rail (188). The 1st end cover (176) and the 2nd end
cover (180) gets engaged over and moves over the 1st guide rail (184)
and the 2nd guide rail (188) respectively.
The sample mounting arrangement (160) is configured to move along with
samples between cold chamber and the hot chamber and is guided by a
push rod (192). The samples (172) are loaded in the sample mounting
arrangement (160) from the cold chamber side. To push the samples in
the hot chamber, the sample mounting arrangement (160) is pushed via
the push rod (192). While pushing, the 1st end cover (176) and the 2nd
end cover (180) travels over the 1st guide rail (184) and the 2nd guide rail
(188) respectively. In this manner junction between the hot chamber
(104) and the detachable chamber (108) is completely blocked by the 1st
end cover (176). This blocking prevents the flow of heat from the hot
chamber (104) to the detachable cold chamber (108).
The 1st guide rail (184) and the 2nd guide rail (188) can also comprise a
gas spraying channel. Both the guide rails comprise plurality of openings
(152) (shown in FIG. 1(d)) and (156) (shown in FIG. 1(a)). These
openings are configured to spray H2-N2 mixture to cool down the sample
in the cold chamber.
In an embodiment separate gas spraying channels having plurality of
openings may also be used for gas spraying.
After the samples are annealed for the set time duration, the push rod
(192) is pulled. While pulling, the pull causes the 2nd end cover (180) to

completely block the junction between the hot chamber (104) and the
detachable cold chamber (108).
It should be noted that the push rod is manually operated. In another
embodiment the movement of the sample mounting arrangement can be
automatically controlled between the cold chamber and the hot chamber.
Shown in FIG. 1(a) is a 1st thermocouple (196) is spot welded to the
samples (172) to measure the temperature of the samples (172) moving
between the hot chamber (104) and the detachable cold chamber (108). A
2nd thermocouple (200) is coupled to the sample mounting arrangement
(160) to measure the temperature of the surrounding of the samples
(inside the hot chamber and the cold chamber) for computing the
temperature profile. A 3rd thermocouple (204) is also positioned in the hot
chamber (104) to note the temperature of the hot chamber, and thereby
change of temperature of the hot chamber.
Both the 1st and 2nd thermocouples help in capturing the true temperature
experienced by the samples in hot chamber (104) and the detachable cold
chamber (108) while annealing treatment. Thereby, a true temperature
profile of heating cycle can be recorded.
The annealing simulator (100) is controlled by a main control panel, MCP
(208) shown in FIG. 1(a). For this reason, the entire readings of the 1st,
2nd and 3rd thermocouples are directly fed into MCP on real time basis.
These data are analyzed by MCP (208) and accordingly steps are taken for
control.

In some other embodiment, movement of the sample mounting
arrangement can be automatically controlled by the MCP, replacing the
manual pull push by the push rod.
During operation, sample is first loaded over the sample mounting
arrangement (160) in the detachable cold chamber (108) by removing the
cover (168). The detachable cold chamber (108) is an air tight
compartment where the sample can be loaded at a room temperature.
Environment of the cold chamber is maintained at conditions similar to hot
chamber so that no oxidation takes place when the sample enters from
the hot chamber to the cold chamber.
After placing the sample, the cover (168) is placed. The sample mounting
arrangement (160) is pushed to the hot chamber (104) by pushing the
push rod (192).
Now, the electric furnace (120) is brought towards the hot chamber (104)
enclosing it entirely and heated. The sample is heated upto the required
temperature by radiation.
The hot chamber (104) provides controlled environment similar to the one
that the steel experiences in plant during various operations.
After the sample is annealed, the sample is guided back to the detachable
cold chamber where it is rapidly cooled. MCP can generate a template of
annealing simulation scheme i.e. heating rate, isothermal annealing time,
and cooling rate. Accordingly, the MCP gives the signal when the sample
has to be moved in the hot chamber and when the sample has to be
guided back in the cold chamber. On receiving the signal, the push rod is
either pushed or pulled manually to insert or retract the sample
respectively.

Now, to cool the sample (172) in the detachable cold chamber (108), the
plurality of holes (156) of the 1st guide rail (184) is provided with as
shown in FIGS. 1(c) and 1(d). Via plurality of holes (156), gas is sprayed
over the sample at an appropriate pressure so as to cool the sample
(172). It should be appreciated that it is important to maintain inlet
pressure at which the gas is sprayed over the sample and the gas flow
rate inside the cold chamber. For rapidly cooling the sample, the gas is
sprayed at a certain high pressure over the sample.
All the real time temperature and the various heat treatments done on the
annealing simulator on other different samples are recorded can be
graphically shown in FIGS. 3(a), 3(b), 3(c) and 3(d).
FIG. 3(a) shows the sample being continuously heated to 680°C in 75
seconds. After that the sample is isothermally annealed for 237.5 seconds.
After that the sample is rapidly cooled where the temperature is dropped
down from 775°C to 100 °C in few seconds. Similar type of heat
treatment is shown in FIGS. 3(b), 3(c) and 3(d) that can be achieved
using the annealing simulator.
In some embodiments when the cold chamber is not required, it can be
separated from the annealing simulator, and a separate cover can be
installed over the hot chamber to close it.
Again in some embodiments, if required the 1st end cover can be engaged
over the 1st channel, hence not requiring the 1st guide rail. Similarly, 2nd
end cover can be engaged over the second channel, hence not requiring
the 2nd guide rail.

Following are the advantages of the annealing simulator:
i. The cold chamber is detachable and can be used as an attachment
to the annealing simulator.
ii. Varieties of unique annealing simulations can be made easier using
the annealing simulator i.e. it is versatile for several applications.
iii. The annealing simulator can be applied for batch as well as
continuous annealing of steel samples.
iv. Flexibility of heat treatment is provided under controlled
atmosphere as and when required.
v. Smooth temperature control on the annealing process.
vi. Close control on the heating rate in annealing simulation.
vii. Precise control on the cooling rate of annealing simulation.
Moreover ultrafast cooling (>200°C/s) can also be done.
viii.Life of the hot chamber increases as it is not required to be cooled
ultrafast.
ix. Reduced amount of cooling gas is required.
x. Flexible control on the soaking time during annealing simulation.
xi. Several steel specimens can undergo annealing simulation in one
go.
xii. Faster and real time data acquisition (such as thermocouples
temperature) for temperature recording for entire cycle of
annealing simulation.
xiii.Precision environmental control on annealing simulation.
xiv. The annealing simulator is compact and cost effective.

We claim:
1. An annealing simulator (100), the annealing simulator (100)
comprising:
a hot chamber (104);
a detachable cold chamber (108) coupled to the hot chamber (104);
the detachable cold chamber (108) comprising a sample mounting
arrangement (160), the sample mounting arrangement (160) being
configured to move along with sample between the detachable cold
chamber (108) and the hot chamber (104); and
the hot chamber (104) being configured to heat the sample and the
detachable cold chamber (108) being configured to cool the sample.
2. The annealing simulator (100) as claimed in claim 1, wherein the
hot chamber (104) is placed in an electric furnace (120) for heating
the sample.
3. The annealing simulator (100) as claimed in claim 2, wherein the
electric furnace (120) is positioned and movable on a platform
(112).
4. The annealing simulator (100) as claimed in claims 1 and 3,
wherein the hot chamber (108) is attached to the platform (112) by
a coupling plate (116).
5. The annealing simulator (100) as claimed in claim 1, wherein the
detachable cold chamber (108) and the hot chamber (104)
comprises a 1st guide rail (184) and a 2nd guide rail (188)
respectively.

6. The annealing simulator (100) as claimed in claims 1 and 5,
wherein each ends of the sample mounting arrangement (160)
comprises a 1st end cover (176) and a 2nd end cover (180), the 1st
end cover (176) and the 2nd end cover (180) are configured to
travel on the 1st guide rail (184) and the 2nd guide rail (188)
respectively, the 1st end cover (176) and the 2nd end cover (180)
are configured to restrict flow of heat between the hot chamber
(104) and the detachable cold chamber (108).
7. The annealing simulator (100) as claimed in claim 1, wherein the
detachable cold chamber (108) comprises a flange (140), the
flange (140) being configured to couple the detachable cold
chamber (108) with the hot chamber (104).
8. The annealing simulator (100) as claimed in claim 1, wherein the
sample mounting arrangement (160) is being configured to mount
atleast one sample.
9. The annealing simulator (100) as claimed in claim 1, wherein the
detachable cold chamber (108) comprises an opening (164), the
opening (164) being configured to route the sample in the sample
mounting arrangement (160), the opening (164) can be closed by a
cover (168).
10.The annealing simulator (100) as claimed in claim 1, wherein the
detachable cold chamber (108) comprises a 1st gas spraying
channel (144), the 1st gas spraying channel (144) comprises
plurality of openings (152), the plurality of openings being
configured to spray cooling gas to cool the sample.
11.The annealing simulator (100) as claimed in claim 10, wherein the
cooling gas is Hydrogen gas.

12.The annealing simulator (100) as claimed in claim 10, wherein the
cooling gas is mixture of Hydrogen gas and Nitrogen gas in
proportion of H2 gas 5-25% and N2 gas 75-95% (by vol.).
13.The annealing simulator (100) as claimed in claim 1, wherein the
sample is connected to a 1st thermocouple to measure the
temperature of the sample.
14. The annealing simulator (100) as claimed in claim 1, wherein the
sample mounting arrangement (160) comprises a 2nd thermocouple
to measure the temperature of surrounding of the sample
15.The annealing simulator (100) as claimed in claim 1, wherein the
hot chamber comprises a 3rd thermocouple to measure the
temperature inside the hot chamber.
16. The annealing simulator (100) as claimed in claim 1, wherein the
sample mounting arrangement along with the sample is guided
between the hot chamber and the cold chamber by means of a
push rod (192).