Claims:We claim:
1. A sampler (100) for the collection of a molten metal sample by dipping in the molten metal, the sampler (100) comprising:
a tube (102);
a cup sampler (104) which at its outer surface is coupled to the tube (102); and
a lid (106) disposed at the top of the cup sampler (104), the lid (106) having melting point lower than that of the cup sampler (104) so that, once the cup sampler (104) is dipped in the molten metal, the lid (106) prevents the inflow slag, floating above the molten metal, in the cup sampler (104).
2. The sampler (100) as claimed in claim 1, wherein the tube (102) is hollow.
3. The sampler (100) as claimed in claim 1, wherein the tube (102) is solid.
4. The sampler (100) as claimed in claim 1, wherein molten metal is steel.
5. The sampler (100) as claimed in claim 1, wherein the tube (102) is press fitted with a cardboard tube (302) to increase the length.
6. The sampler (100) as claimed in claim 1, wherein the cup sampler (104) is tapered from inside for easy removal of the steel sample on solidifying.
7. The sampler (100) as claimed in claim 1, wherein the cup sampler (104) is carved out by removing material from a steel rod.
8. The sampler (100) as claimed in claim 1, wherein the lid (106) is press-fitted with the cup sampler (104).
9. The sampler (100) as claimed in claim 1, wherein the cup sampler (104) is welded with the tube (102).
10. The sampler (100) as claimed in claim 1, wherein the lid (106) is made up of copper.
, Description:[0001] The present disclosure, in general, relates to sampling devices for taking samples of high-temperature liquids such as molten metals and, more particularly, to a sampler for collection of a molten metal sample by dipping into the molten metal.
BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] With the advent of clean metal manufacturing for various end applications, it is often desired in the metal industry to obtain samples of steel at various manufacturing stages during its production in order to measure the cleanliness in motel metal present in the metal bath. The cleanliness in the metal is generally the measure of inclusion level in steel. Examples of inclusions can be magnesium oxide, aluminium oxide, spinel (magnesium aluminum oxide or MgAl2O4), silicon oxide, aluminum carbide, silicon carbide etc. These inclusions in metal generally affect the performance during the manufacturing stages and the in the end applications.
[0004] Currently, the inclusions in the molten metal are analyzed and classified by destructive testing by taking a sample of the molten metal from liquid metal bath using a probe type (lollypop) sampler and then metallographically analyzing the sample for the inclusions. However, the lollypop sampler is generally found not suitable for cleanliness assessment as it contains deoxidizing elements such as aluminum or zirconium which alter the amount/fraction of the inclusions and their characteristics from those originally present in molten metal. Additionally, the lollypop sampler takes a flat lollypop sample, quality of which is often not up to the mark and hence unsuitable for the evaluation of cleanliness level.
[0005] Despite the aforementioned issues, those skilled in the art can appreciate that collection of a molten metal sample from liquid metal bath using the lollypop sampler is a regular activity to get chemical analysis. The regular sampling is done conveniently and with a simple arrangement in the plant.
[0006] Therefore, there is a need of a sampler which is adaptable to existing arrangement used for lollypop sampler, as a new separate arrangement for the molten metal sampling towards the cleanliness measurement may add difficulty in routine manufacturing stages, requiring additional time, thus affecting the overall production.
OBJECTS OF THE DISCLOSURE
[0007] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed hereinbelow.
[0008] It is a general object of the present disclosure to provide a sampler to collect a sound and non-contaminated sample from the liquid metal bath for measurement of cleanliness level.
[0009] It is another object of the present disclosure to provide a sampler for which can be used in existing arrangement for regular sampling in the plant so that regular process monitoring can be performed conveniently without the need for an additional facility.
[0010] These and other objects and advantages will become more apparent when reference is made to the following description and accompanying drawings.

SUMMARY
[0011] This summary is provided to introduce concepts related to a sampler for collection of the molten metal sample by dipping in the molten metal. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
[0012] In an embodiment, the present disclosure relates to a sampler for collection of the molten metal sample by dipping in the molten metal. The sampler includes a tube, a cup sampler which at its outer surface is coupled to the tube, and a lid disposed at the top of the cup sampler. The lid is having melting point lower than that of the cup sampler so that, once the cup sampler is dipped in the molten metal, the lid prevents the inflow slag floating above the molten metal.
[0013] In an aspect, the tube is hollow.
[0014] In another aspect, the tube is solid.
[0015] In an aspect, the molten metal is steel.
[0016] In an aspect, the tube is press fitted with a cardboard tube to increase the length.
[0017] In an aspect, the cup sampler is tapered from inside for easy removal of the steel sample on solidifying.
[0018] In an aspect, the cup sampler is carved out by removing material from a steel rod.
[0019] In an aspect, the lid is press-fitted with the cup sampler.
[0020] In an aspect, the cup sampler is welded with the tube.
[0021] In an aspect, the lid is made up of copper.
[0022] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The illustrated embodiments of the subject matter will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:
[0024] FIG. 1 illustrates a perspective view of a sampler, in accordance with an embodiment of the present disclosure;
[0025] FIG. 2 illustrates a cup sampler of the sampler with an intake manifold in accordance with an embodiment of the present disclosure; and
[0026] FIG. 3 illustrates a complete assembly of sampler having its cup sampler welded with of a hollow steel tube fitted with a cardboard tube, in accordance with another embodiment of the present disclosure.
DETAILED DESCRIPTION
[0027] The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0028] It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
[0029] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a”, “an”, and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises”, “comprising”, “includes”, “consisting” and/or “including” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
[0030] It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
[0031] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0032] Embodiments explained herein pertain to a sampler for collection of the molten metal sample by dipping the sampler into a ladle or tundish of metal manufacturing plant. The sampler include a tube, a cup sampler which is coupled to the tube at its outer surface, and a lid at the top of the cup, wherein the lid is formed of a material having a melting point less than that of the cup sampler so that, once the cup sampler is dipped in the molten metal, the lid delays the inflow of the slag in the cup sampler. Such delay of the inflow of the slag in the cup sampler inhibits the entry of slag, which floats on top of molten metal in the molten metal bath, in the cup sampler while the cup sampler is dipped into the molten metal bath for sampling.
[0033] FIG. 1 shows a sampler 100 for the collection of molten metal, such as molten steel, in accordance with an embodiment of the present disclosure. The sampler 100 includes a tube 102. Using the tube 102, the entire sampler 100 can be dipped into and taken out from the molten metal bath in ladle or tundish of a metal manufacturing plant.
[0034] In an aspect, the tube 102 can be a hollow steel tube or a solid steel tube. In case of hollow steel tube, the tube 102 is closed at its bottom portion by welding a 2 mm thick circular disc 102-2. The circular disc 102-2 prevents entry of the molten metal within the tube 102 through the bottom portion during dipping of the sampler 100 into the molten metal bath.
[0035] In an aspect, the tube 102 is formed with a 215 mm length, 39 mm outer diameter, and 1 mm wall thickness. However, as can be appreciated by those skilled in the art, the dimensions of the tube 102 mentioned herein can be varied depending on the size of the sampler 100 and should not be construed as a limitation within the scope of the present disclosure.
[0036] The sampler 100 further includes a cup sampler 104 coupled at its outer surface with the tube 102. In an aspect, the cup sampler 104 is welded with the tube 102. Also, in order to strengthen the integrity of the cup sampler 104 and the tube 102, the length of a welded portion 102-4 of the tube 104 is kept 25 mm.
[0037] FIG. 2 shows the cup sampler 104 in detail in accordance with an embodiment of the present disclosure. The cup sampler 104 is designed as a tapered cylindrical hollow cup. For instance, the cup sampler 104 includes a circular base 104-2 and a cylindrical wall 104-4. In an aspect, a first end 104-6 of the cylindrical wall 104-4 is formed over the periphery of the circular base 104-2 and a second end 104-8 is open to receive the molten metal sample. Also, the cylindrical wall 104-4 is tapered from inside in such a way that the first end 104-6 has an inner diameter smaller than the inner diameter of the second end 104-8. Such tapered design of the cup sampler 104 is carved out by removing material in a lathe machine from, for example, 88 mm long and 50 mm diameter steel rod. The tapered design of the cup sampler 104 takes care of solidification shrinkage of molten metal which is sampled out from molten metal bath and ensures sound specimen/sample without any porosity and facilitates easy removal of specimen/sample from the cup sampler 104 after discarding 25 mm from top (104-8) and 10 mm from bottom portion (104-6). For such sampling out, after collection of the molten metal sample in the cup sampler 104, a cut across the transverse of the cup sampler is made at 104-10 and slightly below from its top. The solidifies sample can be further taken out by hammering.
[0038] Further, the sampler 100 includes a lid 106 press-fitted at the top (104-8) of the cup sampler 104. The lid 106 is formed from a copper sheet of, say, 0.5 mm thickness and is mechanically pressed on the top 104-8 of the cup sampler 104 to prevent entry of slag, which floats on top of molten metal in the molten metal bath, in the cup sampler 104 while the cup sampler 104 is dipped into the molten metal bath for sampling. Copper is having a melting point lower than the steel forming the cup sampler 104 and therefore will melt when it comes in contact with molten metal and thus allows molten steel to fill up the cup sampler 104 without altering the characteristics of inclusions present in molten metal.
[0039] The embodiment of the welded sampling assembly, shown in FIG. 1, of the cup sampler 104 and the tube 102 provides an integrated device but cannot be used for sampling purpose in the present form unless the welded sampling assembly is further modified.
[0040] For modification, a cardboard tube 302 is press-fitted with the tube 102 (shown with dash lines) in accordance with an embodiment shown in FIG. 3. The narrow margin between the outer diameter of the tube 102 and the inner diameter of the cardboard tube 302 helps to hold them together tightly. However, in order to strengthen the integrity of the press-fit connection of both the tubes 102 and 302, two rectilinear holes (not shown in figures) are made in the tube 102 and two rectilinear holes 304-1, 304-2 are made in the cardboard tube 302 so as to facilitate a nut and bolt connection through these rectilinear holes.
[0041] Further, in an aspect, the cardboard tube 302 has a length longer than the tube 102 so as to increase the height of the tube 102 for dipping and taking a molten metal sample from the molten metal bath as a part of cleanliness evaluation activity. The length of the cardboard tube 302 can vary depending on the molten metal bath height and the platform or location from which sample need to be collected.
[0042] Thus, with the embodiments of the present disclosure, a special tapered hollow cylindrical cup sampler is provided for the collection of the molten metal sample, such as liquid steel sample, from the ladle to obtain a shrinkage or porosity free sound metal sample. Such sample is amenable for checking inclusion population and their characteristics to get an idea on the cleanliness level of steel under given process conditions.
[0043] Further, in metal manufacturing plant, a cardboard tube of 40 mm inner diameter and 5 mm wall thickness is generally fixed with a conventional lollypop sampler so that the cardboard tube can be fitted with steel lance pipe available in a manufacturing plant for dipping and taking steel sample from liquid steel bath as a part of routine process monitoring activity. The thicker cardboard does not get burnt in the molten metal bath and thus the molten metal sample can be taken out very easily. In manufacturing plant, generally, the length of the cardboard tube with the conventional lollypop sampler is typically 1200 mm for ladle furnace and 650 mm for tundish. Accordingly, without deviating from the scope of the present disclosure, a cardboard of the required dimension can be chosen and used in the welded sampling assembly of cup sampler 104 and the tube 102, so that it’s open end fits properly with the steel lance pipe available in the manufacturing plant for easy dipping into the molten metal bath.
[0044] Thus, the present disclosure describes the development of an arrangement which is attached with the cylindrical cup sampler to fit with the existing steel lance pipe available in the plant for regular sample collection using lollypop sampler as a part of routine process monitoring activity.
[0045] The present disclosure further relates to an example method of fabricating the sampler 100 for the collection of a molten metal sample in accordance with an embodiment of the present disclosure. The order in which the method is described herein is not intended to be construed as a limitation, and any number of the described method steps may be combined in any order to implement the methods or an alternative method.
[0046] In the first step, the method includes preparing the tapered cylindrical cup sampler 104 from a steel rod using a lathe machine. In an example, the steel rod has 88 mm length and 50 mm diameter. Further, the cup sampler 104 includes the circular base 104-2 and the cylindrical wall 104-4, where the first end 104-6 of the cylindrical wall 104-2 is formed over the periphery of the circular base 104-2 and the second end 104-8 of the cylindrical wall 104-2 is open to receive the molten steel sample. Yet further, the cylindrical wall 104-4 is tapered from inside in such a way that the first end 104-6 has an inner diameter smaller than the inner diameter of the second end 104-8.
[0047] In the second step, the method includes mechanical press fitting of the lid 106 on top of the second end 104-8 of the cylindrical wall 104-4 of the tapered cylindrical cup sampler 104. In an aspect, wherein the lid 106 is formed from a copper sheet of 0.5 mm thickness.
[0048] In the third step, the method includes cutting the hollow steel tube 102 and closing the lower end of the hollow steel tube 102 with the circular steel sheet 102-2 by welding while leaving the upper end of the hollow steel tube 102 in open state. In an aspect the, the hollow steel tube 102 is having 215 mm length and 39 mm outer diameter.
[0049] In the fourth step, the method includes welding the hollow steel tube 102 from the closed lower end with the cup sampler 104.
[0050] In the fifth step, the method includes drilling two holes in the diametrically opposite direction in the hollow steel tube 102 near the open upper end.
[0051] In the sixth step, the method includes cutting a cardboard tube 302 and drilling two holes at a position matching with the holes made in the hollow steel tube 102.
[0052] In the seventh step, the method includes press-fitting the hollow steel 102 with the cardboard tube 302.
[0053] In the eighth step, the method includes tightening the hollow steel tube 102 with the cardboard tube 302 using nut and bolt fastening in the holes formed on the tubes 102 and 302.
[0054] The above description does not provide specific details of the manufacture or design of the various components. Those of skill in the art are familiar with such details, and unless departures from those techniques are set out, techniques, known, related art or later developed designs and materials should be employed. Those in the art are capable of choosing suitable manufacturing and design details.
[0055] Further, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims.
[0056] Although examples for the present disclosure have been described in language specific to structural features and/or methods, it should be understood that the appended claims are not necessarily limited to the specific features or methods described. Rather, the specific features and methods are disclosed and explained as examples of the present disclosure.
[0057] The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.