Patent ID: 6410878
Filing Date: 2002-06-25
Classification: B22F,F23D

Abstract:
A process for manufacturing a flame supporting element, for a burner fed with gas, the process comprising the following steps:a) making distinct metallic fibers from a metallic alloy heatproof up to at least substantially 750Â° C. and comprising iron, chromium and aluminum, b) joining the distinct metallic fibers under a determined pressure, creating a mat of agglomerated fibers, and c) heating the mat of agglomerated fibers to a temperature which is sufficient for intimely joining the agglomerated fibers which forms the mat, at zones where said fibers intersect, wherein during the step a): providing a tank containing a metallic alloy having an aluminum content higher than substantially 4%, heating the tank up to a temperature higher or equal to the temperature for fusing said metallic alloy, setting a contact between said fused metallic alloy and a surface of movable extracting means, so that the movement of the extracting means induces a determined quantity of said fused metallic alloy to adhere the surface thereof, to be extracted from the tank, then to be cooled and solidified at first on said surface of the extracting means, then in air, or in a neutral gas, when said quantity of extracted metallic alloy has left the surface of the extracting means under the effect of a separating force induced by the movement of the extracting means, wherein during step b): disposing the distinct metallic fibers obtained from the step a) in a mold where they are substantially uniformly compressed for forming said agglomerated mat, in such a way that the gas porosity in the mat is substantially uniform, and wherein, during step c): exerting a pressure not notably higher than the pressure exerted during step b) to the compressed fibers of said agglomerated mat, connecting the mat of the compressed fibers to electrodes and to a capacitor, and through said electrodes and by electrically discharging the capacitor, heating the compressed fibers at the points where they are in contact to each other, to a temperature higher or equal to their temperature of fusing, for inducing a welding of the fibers to each other, exclusively, under a high voltage, so that the porosity of the mat comprising said fibers welded to each other is substantially uniform and substantially equal to the porosity of the agglomerated mat obtained from step b).