# Patent

## Title
Molten metal rotor with hardened top

## Abstract

Embodiments of the invention are directed to a rotor for a molten metal pump and a molten metal pump including the rotor. The rotor has a main body and a top comprised of a material that is at least twice as hard as the main body. The top, among other things, may form a first portion of each rotor blade wherein the first portion directs molten metal into a pump chamber or other structure in which the rotor is mounted.

## Background
FIELD OF THE INVENTION
The present invention relates to a rotor for pumping molten metal, the rotor having a hardened top wherein at least some of the ceramic top preferably forms part of one or more rotor blades. The purpose of the hardened top is to decrease wear on the portions of the rotor that are struck by dross or other hard objects found in molten metal.
BACKGROUND OF THE INVENTION
As used herein, the term “molten metal” means any metal or combination of metals in liquid form, such as aluminum, copper, iron, zinc and alloys thereof. The term “gas” means any gas or combination of gases, including argon, nitrogen, chlorine, fluorine, freon, and helium, that are released into molten metal.
Known molten-metal pumps include a pump base (also called a housing or casing), one or more inlets (an inlet being an opening in the housing to allow molten metal to enter a pump chamber), a pump chamber, which is an open area formed within the housing, and a discharge, which is a channel or conduit of any structure or type communicating with the pump chamber (in an axial pump the chamber and discharge may be the same structure or different areas of the same structure) leading from the pump chamber to an outlet, which is an opening formed in the exterior of the housing through which molten metal exits the casing. An impeller, also called a rotor, is mounted in the pump chamber and is connected to a drive system. The drive system is typically an impeller shaft connected to one end of a drive shaft, the other end of the drive shaft being connected to a motor. Often, the impeller shaft is comprised of graphite, the motor shaft is comprised of steel, and the two are connected by a coupling. As the motor turns the drive shaft, the drive shaft turns the impeller and the impeller pushes molten metal out of the pump chamber, through the discharge, out of the outlet and into the molten metal bath. Most molten metal pumps are gravity fed, wherein gravity forces molten metal through the inlet and into the pump chamber as the impeller pushes molten metal out of the pump chamber.
A number of submersible pumps used to pump molten metal (referred to herein as molten metal pumps) are known in the art. For example, U.S. Pat. No. 2,948,524 to Sweeney et al., U.S. Pat. No. 4,169,584 to Mangalick, U.S. Pat. No. 5,203,681 to Cooper, U.S. Pat. No. 6,093,000 to Cooper and U.S. Pat. No. 6,123,523 to Cooper, and U.S. Pat. No. 6,303,074 to Cooper, all disclose molten metal pumps. The disclosures of the patents to Cooper noted above are incorporated herein by reference, as are U.S. Pat. Nos. 7,402,276 and 7,507,367. The term submersible means that when the pump is in use, its base is at least partially submerged in a bath of molten metal.
Three basic types of pumps for pumping molten metal, such as molten aluminum, are utilized: circulation pumps, transfer pumps and gas-release pumps. Circulation pumps are used to circulate the molten metal within a bath, thereby generally equalizing the temperature of the molten metal. Most often, circulation pumps are used in a reverbatory furnace having an external well. The well is usually an extension of the charging well where scrap metal is charged (i.e., added).
Transfer pumps are generally used to transfer molten metal from the external well of a reverbatory furnace to a different location such as a ladle or another furnace.
Gas-release pumps, such as gas-injection pumps, circulate molten metal while releasing a gas into the molten metal. In the purification of molten metals, particularly aluminum, it is frequently desired to remove dissolved gases such as hydrogen, or dissolved metals, such as magnesium, from the molten metal. As is known by those skilled in the art, the removing of dissolved gas is known as “degassing” while the removal of magnesium is known as “demagging.” Gas-release pumps may be used for either of these purposes or for any other application for which it is desirable to introduce gas into molten metal. Gas-release pumps generally include a gas-transfer conduit having a first end that is connected to a gas source and a second submerged in the molten metal bath. Gas is introduced into the first end and is released from the second end into the molten metal. The gas may be released downstream of the pump chamber into either the pump discharge or a metal-transfer conduit extending from the discharge, or into a stream of molten metal exiting either the discharge or the metal-transfer conduit. Alternatively, gas may be released into the pump chamber or upstream of the pump chamber at a position where it enters the pump chamber. A system for releasing gas into a pump chamber is disclosed in U.S. Pat. No. 6,123,523 to Cooper. Furthermore, gas may be released into a stream of molten metal passing through a discharge or metal-transfer conduit wherein the position of a gas-release opening in the metal-transfer conduit enables pressure from the molten metal stream to assist in drawing gas into the molten metal stream. Such a structure and method is disclosed in a copending application entitled “System for Releasing Gas Into Molten Metal,” invented by Paul V. Cooper, and filed on Feb. 4, 2004, the disclosure of which is incorporated herein by reference.
When a conventional molten metal pump is operated, the rotor rotates within the pump housing and the pump housing, inlet and pump chamber remain stationary relative to the rotor, i.e., they do not rotate. A problem with such molten metal pumps is that the molten metal in which it operates includes solid particles, such as dross and brick. As the rotor rotates molten metal including the solid particles enters the pump chamber through the inlet. A solid particle may lodge between the moving rotor and the stationary inlet, potentially jamming the rotor and potentially damaging one or more of the pump components, such as the rotor or rotor shaft of the pump.
Many attempts have been made to solve this problem, including the use of filters or disks to prevent solid particles from entering the inlet and the use of a non-volute pump chamber to increase the space between the inlet and rotor to allow solid pieces to pass into the pump chamber without jamming, where they can be pushed through the discharge by the action of the rotor.
Gas-release pumps generally include a gas-transfer conduit having a first end that is connected to a gas source and a second end submerged in the molten metal bath. Gas is introduced into the first end and is released from the second end into the molten metal. The gas may be released downstream of the pump chamber into either the pump discharge or a metal-transfer conduit extending from the discharge, or into a stream of molten metal exiting either the discharge or the metal-transfer conduit. Alternatively, gas may be released into the pump chamber or upstream of the pump chamber at a position where molten metal enters the pump chamber.
The materials forming the components that contact the molten metal bath should remain relatively stable in the bath. Structural refractory materials, such as graphite or ceramics, that are resistant to disintegration by corrosive attack from the molten metal may be used. As used herein “ceramics” or “ceramic” refers to any oxidized metal (including silicon) or carbon-based material, excluding graphite, capable of being used in the environment of a molten metal bath. “Graphite” means any type of graphite, whether or not chemically treated. Graphite is particularly suitable for being formed into pump components because it is (a) soft and relatively easy to machine, (b) not as brittle as ceramics and less prone to breakage, and (c) less expensive than ceramics.
SUMMARY OF THE INVENTION
The present invention relates to rotors used for pumping molten metal wherein the rotor has a hardened top to alleviate damage to the rotor caused by dross or other hard particles striking the rotor as molten metal enters the chamber of a molten metal pump in which the rotor is retained. The top is at least twice as hard as the body portion of the rotor, and the top preferably covers the entire top surface of the rotor including the tops of the rotor blades.
In one embodiment, the hardened top extends to include all or part of the surface of the rotor blades that move molten metal into the pump chamber or that push molten metal outward towards the wall of the pump chamber. Aspects of the invention can be utilized on any molten metal rotor design.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a front, perspective view of a rotor according to the invention.
FIG. 2 shows a top view of the rotor of FIG. 1.
FIG. 3 shows a perspective, side view of the rotor of FIG. 1 with the top not assembled to the body.
FIG. 4 shows a perspective, side view of the rotor of FIG. 1 with the top assembled to the body.



DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
As used herein the relative hardness of materials is determined by the MOHS hardness scale. On the MOHS hardness scale, treated graphite may have a hardness between 1.5 and 2.5, whereas silicon carbide generally has a hardness of 9-10.
Turning now to the drawings, where the purpose is to describe a preferred embodiment of the invention and not to limit same, systems and devices according to the invention will be described.
FIGS. 1-4 show one preferred rotor according to aspects of the invention. Rotor 100 as shown preferably has three identical rotor blades (also called “vanes” herein) 102. As used herein, a rotor blade (or “vane”) is a structure separate from and spaced from other rotor blades. In rotor 100 each blade is dual flow, meaning that it has a first portion 102A that directs molten metal either downward or upward (if the rotor is used on a bottom feed pump) towards a second portion 102B that directs molten metal outward.
A rotor according to aspects of the invention has a body (or body portion) 101 with a hardened top surface 106. Rotor 100 may have a flow blocking and bearing plate 110. As shown, flow blocking and bearing plate 110 is cemented to the bottom 120 of rotor 100. If rotor 100 is used on a bottom feed pump, the flow blocking and bearing plate 110 may be at the top of the rotor (in essence, the rotor would be turned upside down, with the blades at the bottom, but the rotor shaft attachment mechanism would still be at the top). The flow blocking and bearing plate 110 is preferably comprised of a hard, wear-resistant material, such as silicon carbide. Alternatively, a rotor according to the invention may not have a flow blocking and bearing plate.
Rotor 100 further includes a connective portion 112, which is preferably a threaded bore, but can be any structure capable of drivingly engaging a rotor shaft (not shown). It is most preferred that the outer surface of the end of the rotor shaft that is received in portion 112 has tapered threads and connective portion 112 be threaded to receive the tapered threads.
The preferred dimensions of rotor 100 will depend upon the size of the pump chamber or other structure in which it is received.
Preferably each vane 102 has the same configuration so only one vane 102 shall be described. Each vane 102 preferably includes a horizontally-oriented first portion 102A and a vertically-oriented second portion 102B. The respective vertical and horizontal orientation of the portions described herein is in reference to a rotor positioned in a standard pump having an input port in its top surface. The invention, however, covers any rotor for use in a molten-metal pumping application, whether the flow of molten metal is first contacting the rotor at the top or bottom or both. It will be therefore understood that the terms “horizontal” and “vertical” refer to the rotor as shown in the orientation in FIGS. 1-4.
Top surface 106 is preferably flush with a pump chamber inlet, if used with a pump chamber.
Section 102A preferably has a leading edge 116 and an angled surface (or first surface) 118. Surface 118 is angled (as used herein the term angled refers to both a substantially planar surface, or a curved surface, or a multifaceted surface) such that, as rotor 100 turns (as shown it turns in a clockwise direction) surface 118 directs molten metal towards second portion 102B. Any surface that functions to direct molten metal towards second portion 102B can be used, but it is preferred that surface 118 is substantially planar and formed at a 30°-60°, and most preferably, a 45° angle.
Portion 102B, which is preferably vertical (but can be angled or curved), extends from the bottom of section 102A to the top of base (or bottom) 120. Portion 102B has a leading face (or second surface) 122. Leading face 122 is preferably planar and vertical, although it can be of any configuration that directs molten metal outward, such as towards the wall of a pump chamber or other structure in which the rotor 100 is housed.
A recess 130 is formed in top portion 104 and preferably extends from top surface 106 to at least as far as the trailing face 132 of second portion 102B. As shown, recess 130 begins at a position on surface 106 slightly forward of face 132 and terminates at a position even with trailing face 132. The purpose of recess 130 is to reduce the area of top surface 106, thereby creating a larger opening for more molten metal to enter into the rotor 100 thus enabling rotor 100 to move more molten metal per rotor revolution.
The hardened top 104 is shown in FIGS. 1-4. The hardened top (or entrance to the rotor, because what is shown as the top in the Figures may be at the bottom on a bottom-feed pump or on both the top and bottom if no flow blocking and bearing plate is used) preferably is at least twice as hard as the body portion 101, or 2-3 times harder than the body portion 101, or 2-4 times harder than the body portion 101, or 2-5 times harder than the body portion 101. In one preferred embodiment, the body portion 101 is graphite and the top 104 is silicon carbide. At least top surface 106 includes the harder material of the hardened top 104, and as shown the hardened top includes the first portion 102A of each rotor blade 102, which includes surface 118. Additionally, it is preferred that the hardened top 104 include a part of second portion 102B (and surface 122) immediately beneath surface 118, and recess 130, and a part of trailing face 132 immediately beneath trailing face 132.
FIG. 3 shows hardened top 104 prior to being assembled to the body portion. In order to secure the top 104 and body portion, it is preferred that portions of the corners of each blade section on body 101 be cut out to create recesses or gaps 150 and that the top portion 106 has sections 152 designed to fill gaps 150 when cemented in place. The mating of sections 152 and gaps 150 helps secure the top 104 and body portion to alleviate the possibility that they will come apart during use.
Additionally, gaps 150 may have openings 151 that mate with pins (not shown) in sections 152, or gaps 150 and sections 152 may have openings that receive dowel pins (not shown) to help secure top 104 to the body portion. The center opening 112 in the body portion may also include a locating ring 112A formed therein, which mates with an extending portion (not shown) in the top 104 to properly center the two.
A similar hardened top may be utilized in a rotor device such as the one described in U.S. Pat. No. 7,402,276.
The flow blocking and bearing plate 110 has a circumference and the first portion 102A of each blade 102 preferably extends beyond the circumference, as best seen in FIG. 2. The first portion 102A of each blade 102 has a leading edge 116, a recess 130 and a connecting portion that connects the leading edge 116 and the recess 130. As shown in the exemplary embodiment: (a) the entire leading edge 116 of each blade 102 is part of the hardened top 104; (b) the entire recess 130 of each blade 102 is part of the hardened top 104, and (c) the entire first surface 118 is part of the hardened top 104. The exemplary embodiment also shows: (d) part of the leading face 122 is part of the hardened top 104, and (e) part of the trailing surface 132 is part of the hardened top 104.
Having thus described some embodiments of the invention, other variations and embodiments that do not depart from the spirit of the invention will become apparent to those skilled in the art. The scope of the present invention is thus not limited to any particular embodiment, but is instead set forth in the appended 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 result.

## Claims

1. A rotor for use in a molten metal pump, the rotor comprising
(a) a graphite body;
(b) a plurality of blades, wherein each blade has a first portion and a second portion, wherein the first portion is above the second portion and is configured to push molten metal downwards towards the second portion, and the second portion is configured to push the molten metal outward;
(c) a hardened top portion comprising material at least twice as hard as the graphite body;
(d) wherein the hardened top portion forms at least part of the first portion and at least part of the second portion.

2. The rotor of claim 1 wherein the hardened top portion is comprised of material between 2-3 times as hard as the graphite body.

3. The rotor of claim 1 wherein the hardened top portion is comprised of material between 2-4 times as hard as the graphite body.

4. The rotor of claim 1 wherein the hardened top portion is comprised of material between 2-5 times as hard as the graphite body.

5. The rotor of claim 1 wherein the hardened top portion is cemented to the graphite body.

6. The rotor of claim 1 wherein the hardened top portion comprises silicon carbide.

7. The rotor of claim 1 wherein the at least part of the second portion formed by the hardened top portion is immediately beneath the first portion.

8. The rotor of claim 1 that includes a flow blocking and bearing plate having a circumference and each blade extends no more than 1 1⁄2′′ beyond the circumference.

9. The rotor of claim 1 that has a top surface having an area, and each rotor blade includes a recess on the side opposite the first portion, each recess for decreasing the area of the top surface so as to create a larger opening through which more molten metal can pass.

10. The rotor of claim 9 wherein the hardened top portion forms at least part of the recess.

11. The rotor of claim 10 wherein the recess extends from the top surface at a position forward of the trailing surface and terminates at the trailing surface.

12. The rotor of claim 1 that includes a body portion having gaps at the corner of each blade and the hardened top portion has sections that are received by and mate with the gaps.

13. The rotor of claim 12 wherein the gaps include openings that each receive a pin positioned in each respective section of the hardened top portion.

14. The rotor of claim 12 wherein the gap and the hardened top portion include mating openings wherein each two mating openings receive a dowel pin.

15. The rotor of claim 1 wherein the first portion has an angled bottom with an angle of between 30° and 60°.

16. A molten metal pump including the rotor of claim 1.

17. The molten metal pump of claim 16 that includes a superstructure on which a motor is supported, a pump base including a pump chamber in which the rotor is received, and a plurality of support posts connecting the superstructure to the pump base.

18. The rotor of claim 1 that further includes a flow blocking and bearing plate having a circumference and the first portion of each blade extends past the circumference.

19. The rotor of claim 18, wherein the first portion of each blade has a leading edge, and each blade includes a recess and a connecting portion that connects the leading edge and the recess.

20. The rotor of claim 1, wherein the first portion includes a leading edge and the entire leading edge is part of the hardened top portion.

21. The rotor of claim 1, wherein each blade includes a recess and the entire recess is part of the hardened top portion.

22. The rotor of claim 1, wherein the entire first portion is part of the hardened top portion.

23. The rotor of claim 1, wherein part of the leading surface is part of the hardened top portion.

24. The rotor of claim 1, wherein part of the trailing surface is part of the hardened top portion.

25. A rotor that includes a top surface and a bottom; a plurality of imperforate rotor blades for displacing molten metal, wherein each of the plurality of rotor blades includes a horizontally-oriented first portion with a surface angled at 30 degrees to 60 degrees that is configured to push molten metal downward, and a second portion beneath the first portion that is configured to push molten metal outward, a trailing face, and a recess that reduces the area of the top surface to help permit molten metal to pass therethrough and into pump chamber;
wherein the plurality of imperforate rotor blades are comprised of graphite; and
the top surface is comprised of ceramic.

26. The rotor of claim 25 that further includes a flow blocking and bearing plate.

27. The rotor of claim 26 wherein the flow blocking and bearing plate is comprised of ceramic.

28. The rotor of claim 25 wherein there are three imperforate rotor blades.

29. The rotor of claim 25 that includes a body portion and the top surface is cemented to the body portion.

30. The rotor of claim 25 that further includes a threaded connective portion at the top for connecting to a rotor shaft.

31. The rotor of claim 25 wherein the first portion of each rotor blade has a horizontally-extending projection with a top surface and a bottom surface, wherein the bottom surface is angled to move molten metal downward.

32. The rotor of claim 31 wherein the second portion of each rotor blade is vertical.

33. The rotor of claim 31 wherein the bottom surface of each horizontally-extending projection is formed at a 10°-60° downward angle relative a horizontal axis.

34. The rotor of claim 31 wherein the top surface of the first portion of each rotor blade is horizontal.

35. The rotor of claim 31 wherein the horizontally-extending projection has a leading edge that is at least 1⁄8′′ thick.

36. The rotor of claim 25 wherein each recess extends at an angle from the top surface downward to the trailing surface.

37. A molten metal pump including the rotor of claim 25.

38. The pump of claim 37 that includes a superstructure on which a motor is supported, a pump base including a pump chamber in which the rotor is received, and a plurality of support posts connecting the superstructure to the pump base.