A containerless processing method for materials under a state of compensated-gravitation and an apparatus therefor

Abstract: The present invention is to provide a processing method of a material under a state of compensated-gravitation, the method which is capable of forming an easy-handling weightless state for a long period time at low cost in a simple manner and which can contribute to developing useful materials and novel materials and supplying them in bulk; and the apparatus thereof. A pressure medium composed of plural kinds of fluids each of which has a different density is charged in a pressure chamber(1) forming, for example, fluid layers. A material(4, 5) is suspended by way of buoyancy brought by this pressure medium. By properly controlling the density of the pressure medium of plural kinds of fluids, a various kinds of materials having different densities can be supported in a suspending state at an almost constant pressure.

Description: The present invention relates to a containerless method of processing a material under a state of compensated-gravitation and a corresponding apparatus. Processing materials under a state of compensated-gravitation makes it possible to form true spheres, or to melt materials without using a crucible so that it is possible to avoid a contamination of impurities into the melt. For this reason, various experiments for preparing materials have been conducted under a state of compensated-gravitation. A processing method and apparatus as defined above is disclosed in EP-A-0 313 069. The known apparatus comprises a chamber containing the material, fluid in the chamber and treating means for treating the material in the chamber. The fluid comprises three layers of liquid each having a different density. The top layer has a lower density, the intermediate layer has a density corresponding to the material to be treated and a bottom layer has a higher density. The material is therefore suspended in the intermediate liquid layer under a state of non-gravitation. This known method and apparatus, however, has the draw back that the intermediate layer must be selected according to the properties of the material and the flexibility of the apparatus is therefore rather limited. US-A-4,344,787 discloses an apparatus comprising a volume of pressurized fluid for forming spheres of a material. The pressure is controlled to correspond to the gas pressure within the spheres rather than to the density of the material. Thus, the material is not suspended in the chamber but drops to the bottom. In document JP 61-168596 material is suspended in a gas stream, and in SU-A-444735 glass balls are processed when flowing upwards as a result of gravity difference within a surrounding liquid. It is the object of the invention to provide a method and apparatus for reducing the costs and enhancing the flexibility of processing a material under a state of compensated gravitation. This object is achieved by a method as defined in claims 1 and 2 and an apparatus as defined in claims 8 and 9. Hence, either a density variation in a vertical direction is generated according to claims 2 and 9, or no such density variation occurs according to claims 1 and 8, respectively. The pressure medium or fluid may consist of a highly pressurized single gas or fluid or of a highly pressurized mixture of plural gases or liquids. These gases and liquids may be either of static fluid or drifting fluid. In a case where the pressure medium consists of plural kinds of fluids each having a different density, these fluids can be arranged separately in layers, or mixed. Subjecting a material to a physical, chemical or metallurgical treatment means: producing another material from a material by providing a physical, chemical or metallurgical change to the material; and manufacturing or processing ways of material in various phases such as physical composition of a material, synthesis of a material by a chemical reaction, glass-formation from a melt by heating and solidifying, and controlling of a fine structure. A physical, chemical or metallurgical change of materials means softening of the material, shape-transformation of the material and transformation of composition or structure. In this invention, a state of compensated-gravitation is formed in a highly pressurized medium. When a medium of such as gas or liquid is pressurized to a high pressure, the specific gravity of this medium becomes very large. Accordingly, an extremely large buoyancy acts on materials in this medium having a large specific gravity, thus making it possible to form a state of compensated-gravitation. Generally, a gas is assumed to have a small specific gravity. However, when a gas is subjected under a high pressure, its specific gravity markedly is increased. For example, when Ar gas is pressurized to 1,000 atm. at room temperature, its specific gravity will be almost equal to that of water. Fig.1 shows a relation of pressure and density of Ar gas at various temperatures, taking pressure (MPa) as axis of abscissa, and density of Ar gas (kg/m 3 ) as axis of ordinate. This graph shows that a gas highly pressurized is capable of yielding an extremely large buoyancy. As stated above, according to the present invention, a large buoyancy is obtained by a medium being subjected under a high pressure and therefore being given a large specific gravity. Accordingly, if a substance with a large molecular weight or atomic weight is selected for use, a large enough specific gravity to form a state of compensated-gravitation can be easily obtained at a relatively low pressure. In other words, use of a gas having a large specific gravity at ordinary pressure, makes it possible to generate a further larger buoyancy. Meanwhile, using a mixture of plural kinds of fluids each having a different density as a pressure medium for providing buoyancy to a material, makes it possible to achieve containerless processing at the same pressure in a case where materials to be processed under a state of compensated-gravitation have various densities. In other words, by properly adjusting mixing ratio of plural kinds of fluids, the influence of pressure on materials can be made to be equivalent, regardless of kinds of materials to be processed. On the other hand, by providing variation for a single medium or a mixture medium of plural fluids in density along a vertical direction, does become unnecessary a fine control of the medium pressure, which is required for suspending a material when a medium has no variation in density. Further, when oxygen, nitrogen or other reactive gas is mixed into the medium, it is possible to oxidize, nitride or react with the material to be processed, whereas if the material to be processed is an oxide, a nitride or other compounds (chloride and the like), it is possible to prevent its decomposition. As discussed heretofore, according to the present invention, a material is suspended in a pressure medium consisting of single fluid or plural kinds of fluids each of which has a different density and subjected to a physical or chemical treatment. With this treatment, the material is provided with physical, chemical, metallurgical or other changes and processed into a production. As a result, it is possible to exert an extremely large buoyancy on the material, whereby the material can be processed or produced under a state of substantially compensated-gravitation. In this invention, since such a weightless state can be obtained by an easy-controllable means, that is, a control of pressurizing the medium, it is possible to carry out readily and industrially on the ground a processing of a material or manufacturing which requires a state of non-gravitation, and which, therefore, has been performed in outer space or by free-falling experiment. For this reason, the present invention can make a great contribution to developing and manufacturing useful or novel materials. Fig. 1 is a graph showing relations between pressure and density at temperatures of 300K, 600K, 1000K and 1500K of Ar gas; Fig.2 is a schematic view showing an embodiment of the present invention, in which a material is processed by an apparatus comprising pressure vessel 1, heater 2 and sample plate 3; Fig.3 is a schematic view showing an embodiment of the present invention, in which a mixture as a pressure medium is adapted to be circulated by convection heater 8; Fig.4 is a schematic view showing another embodiment of the present invention, in which convection fan 9 is installed in place of the convention heater illustrated in Fig.3; Fig.5 is a schematic view showing still another embodiment of the present invention, in which heater is installed at only upper part for forming a buoyancy distribution; Fig.6 is a schematic view showing still another embodiment of the present invention, in which a material can be continuously processed under a substantially weightless state; Fig.7 is a schematic view showing still another embodiment of the present invention, in which a plurality of materials can be processed simultaneously using a horizontally long pressure chamber; Fig.8 is a schematic view showing still another embodiment of the present invention, in which a material or a pressuring medium can be locally heated by using an optical means such as an infra-red beam or the like; Fig.9 is a schematic view showing still another embodiment of the present invention, in which a supersonic generator is disposed outside a pressure chamber; and Fig.10 is a schematic view showing still another embodiment of the present invention, in which a supersonic generator is installed inside a pressure chamber. Now referring to the accompanying drawings, the embodiment of the present invention will be described. Fig.2 is a schematic view showing a method according to a first embodiment of the present invention. Heater 2 is installed in pressure chamber 1 for processing a material. Material 4 to be processed is put on a sample plate 3 and inserted into pressure chamber 1. In Fig.2, unprocessed material 4 is shown with a one-dot chain line. A medium such as a highly pressurized gas or the like is introduced into pressure chamber 1. Then, with the influence of the high density of the pressure medium, material 4 is lifted by buoyancy of the medium from the position on sample plate 3 to the position aligned to heater 2 (as shown by material 5) and is kept floating at the position aligned to heater 2. Material 5 in this state is subjected to heat treatment by means of heater 2. In this process, when a mixture composed of plural kinds of fluids each of which has a different density is used as the pressure medium, it is possible to equal the influence of pressure on a material regardless of the kind of the material to be processed. In addition, by mixing oxygen, nitrogen, chlorine or other reactive gas into the medium used, it is possible to oxidize, nitride, chlorinate or react with the material to be processed, whereas it is also possible to prevent the material to be processed from dissolving when the material is compounds of oxygen, nitrogen, chlorine, or other. In this case, if the mixture tends to be separate, the separation can be prevented by generating convection using convection heater 8, as shown in Fig.3, which heats the medium inside pressure chamber 1, or installing convection fan 9 at the bottom of pressure chamber 1, as shown in Fig.4. Here, in a case where plural kinds of medium each of which has a different density is used as the pressure medium, these fluids are made to be separated from one another and the separated fluid occupying the lower part of the vessel is selected so as to have a higher density than that of a material to be processed meanwhile the medium occupying the upper part of the vessel is selected so as to have a lower density than that of the material. Consequently, the material is stabilized to be positioned at the interface between the fluid layers. With this method, a fine control of the pressure required when a single substance is used as the pressure medium becomes unnecessary. On the other hand, a pressure medium consisting of a single kind of gas can be adapted to vary in density along a vertical direction to change its buoyancy. By utilizing the variations of the buoyancy distribution, it is possible to automatically adjust the buoyancy in accordance with the weight of a material to be processed. Fig.5 shows an embodiment in which heater 2 for heating only the pressure medium occupying the upper part of the pressure chamber 1 so as to effectively generate an uneven buoyancy. With this, there occurs density variation along a vertical direction in pressure chamber 1, or a varying state of buoyancy occurs, and consequently it is possible to keep material 4 floating in a position in correspondence with its density. As in this case, the pressure medium consists of, as stated above, a single substance it is also needless to say that plural kinds of fluids each of which has a different density may be used as the pressure medium. Further, with application of this method, it is possible to process a material continuously. Fig.6 shows this embodiment of the present invention which enables continuous processing of a material. In this embodiment, heater 2 is provided for both heating a material positioned in the upper part of pressure chamber 1 and yielding a buoyancy distribution in the pressure medium. Above heater 2 is disposed sample plate 3 holding a material. With this arrangement, this heater 2 is adapted to heat the pressure medium at the upper part of pressure chamber 1 in order to make the density of the upper medium lower than that of the lower medium, thus forming a buoyancy distribution in which density becomes large from the top toward the bottom. In forming this distribution, the medium density at the upper part of the chamber is made to be lower than that of a material to be processed whereas the medium density at the lower part of the chamber is made to be higher than that of the material. In the apparatus thus constructed, material 4 (the unprocessed material) is supplied as droplets from the lower center portion of sample plate 3. The medium density is relatively low at the upper chamber, so that material 5 (the material in process) gradually moves downward, and is heated by heater 2 at the position in which heater 2 is disposed. Then, the material moves downward below heater 2, and thus falling material 6 (the processed material falling) is cooled down. With the material moving downward, the material is exerted by an increasing buoyancy, whereby material 7 (the processed material suspended) stops moving at the lower part of the chamber 1 and is suspended. As stated above, according to the present invention, the material is processed while falling in the medium having a buoyancy distribution, and thus processed material 7 can be cooled and collected with being floated and suspended. As a result, it is possible to process materials continuously without using a vessel therefor. Fig.7 is a schematic view showing still another embodiment of the present invention. In this embodiment, flat or laterally long pressure chamber 10 is used, and sample plate 3 is disposed on the bottom. Material 4 are fed in a large amount on this sample plate 3 and therefore can be subjected simultaneously to various treatments as stated above, such as physical, chemical and metallurgical treatment. Fig.8 is a schematic view showing still another embodiment of the present invention. In this embodiment, the material being suspended can he manipulated so as not to move freely and touch, for example, to the heater in vessel. In this embodiment, there are disposed optical heat source 11 such as emitting an infrared or the like, and concave mirrors 12 in the upper part of the vessel. With this configuration, it is possible to locally heat the place around the focal point of concave mirrors 12, thus making low the density of the pressure medium around the focal position. Consequently, when material 5 ascends and comes to around the low density portion, material 5 halts or rests at the interface between the low density portion and the high density portion with a part of the material being positioned in the low density portion and the rest part being positioned in the high density portion. In addition, since there is provided a density distribution in a horizontal direction, if material 5 is likely to move in a horizontal direction, the material 5 is inhibited from moving and rests at that position. Thus, according to this embodiment, it is possible to stabilize material 5 at a predetermined position. With regard to each of the processing, it is possible to halt the material in a lateral direction or provide an auxiliary support of the material in a vertical direction by utilizing supersonic and/or electro-magnetic induction. Fig.9 shows an embodiment in which supersonic generator 13 is disposed outside the chamber 1. With this supersonic generator 13, material 5 can be suspended not only by the buoyancy of the pressure medium but also the sound pressure of supersonic. Accordingly, the sound pressure generated by this supersonic generator 13 can be used as a lateral support as well as an auxiliary suspending means supplementing the pressure medium. Fig.10 shows an embodiment in which supersonic generator 14 is disposed inside the pressure chamber 1 for performing the same effect. In place of using the sound pressure of supersonic for secondarily supporting the material, it is also possible, if a material is electrically conductive, to make the material carry magnetic force by means of electro-magnetic induction coil, for utilizing it as an auxiliary suspending means. Further, in using any of the apparatuses described above, it is also possible to subject a material to heat treatment or other treatment by the procedure comprising the steps of: pressurizing a medium at room temperature, introducing the pressurized medium into the chamber to suspend a material, charging and enclosing this pressure medium into the chamber by closing a valve, and heating at constant volume the pressure medium enclosed in the chamber while keeping the buoyancy constant, that is, with keeping the material suspending at a constant position. With this method, it is possible to keep a material suspending as it does in ordinary temperature if the suspending state of the material is assured at ordinary temperature. To this method is applied the fact that specific gravity of gas medium does not vary in isometric change. In each of the embodiments stated above, as for the means for pressurizing a medium, an HIP (hot isostatic pressing) unit, for instance, can be used. The HIP unit has been widely used as a means for obtaining a highly pressurized environment in various fields of the material manufacture, and this makes this invention feasible on industrial level. In use of the HIP unit, a material is charged into a chamber of this HIP. When the inside of the chamber is highly pressurized after the chamber is filled with a predetermined medium, for example, argon gas, the material charged in the chamber is exerted by buoyancy, thus enabling the material to be suspend. In this state, the material is treated or formed into a desired material by providing physical, chemical, metallurgical or other changes. The variations of the features of treatments can be widened by preparing a specific HIP unit for the purpose of the present invention. As discussed above, according to the present invention, it becomes possible to conduct on the ground the material manufacturing processes, specifically, material synthesis by melting without using container, control of crystal growth, preparation of true sphere and the like, which has been conventionally carried out in outer space, or by free-falling experiment. Moreover, since the pressurizing means itself is an established technology, the present invention has a high generality and industrially feasibility. Note that the medium used in this invention is in the state of fluid, i.e., gas or liquid before pressurization. Even though a gas is used as a medium, some kinds of media may change from the gas state into the liquid state when the medium is pressurized. Anyway the fluid state includes liquid and gas state, which are not possible to differentiate above the critical point of the substance. Accordingly, even if, for example, a gas-state medium is charged into the chamber of the HIP unit, the medium may change into the liquid state when the medium is being pressurized to create a state of compensated-gravitation. A liquid medium can be also pressurized. When a liquid-state medium in which a material is charged is to be pressurized, however, the compression ratio of a liquid is smaller than that of a gas, so that the variation in specific gravity due to pressure is small. So only a solid which has a specific gravity close to that of the liquid medium can be suspended as in a state of compensated-gravitation, therefore a liquid exhibits ineffectiveness as a medium. In contrast with this, when a gas medium is pressurized, a large variation in specific gravity can be obtained with small change in pressure, so that various kinds of solids can be advantageously suspended as in a state of compensated-gravitation by controlling the pressure. The examples of the present invention in which a normal HIP unit is used will be described hereinafter with reference to the comparative examples. Example 1 In this example, a sphere of polyethylene was produced. A pressure medium of argon gas was used in HIP unit. The material was heated at temperature of 160 °C for one minute in the pressure medium of 130 MPa. The pressure of the pressure medium was controlled in a narrow range to suspend the material in the chamber. Example 2 In this example, B 2 O 3 glass sphere was produced in HIP unit by using a pressure medium of xenon gas. In this treatment, the glass material was heated to 600 °C for 30 minutes. In order to suspend the glass material, hydrostatic pressure of about 200 MPa was applied to the pressure medium. This treatment condition was for the glass sphere of about 10 mm diameter. The thus formed glass sphere was measured on its sphericity was 0.05 µm, which was as high as the highest precision of the steel balls used for the industrial bearings. Example 3 In this example, a sphere of Nylon-6 was produced. A pressure medium of argon gas was used in HIP unit. The material was heated at temperature of 250 °C for 30 minutes in the pressure medium of 350 MPa. The pressure of the pressure medium was controlled in a narrow range to suspend the material in the chamber. These conditions were for producing a sphere of about 10 mm diameter. A sphericity of the obtained Nylon-6 sphere was about 2 µm, which was as high as the balls of Nylon-6 which was produced in the industry. Example 4 In this example, a material was to be treated using a pressure medium of plural fluids being arranged in layers horizontally. B 2 O 3 glass was treated with a pressure medium consisting of xenon gas and argon gas. In filling the gases, at first argon gas, and then xenon gas was injected. In this treatment the glass material was heated to 600°C and at this temperature kept for 230 minutes. In order to float the glass material, a hydrostatic pressure of 200 MPa was applied to the above-mentioned gas mixture. In this case, no fine controlling of pressure was required unlike the case of using a single gas. The thus formed glass sphere was measured on its sphericity by a sphericity measuring device. The resultant sphericity was 0.05 µm, which is as high as the highest precision of the steel balls used for the industrial bearings. Example 5 In this example, mass-production was performed according to the present invention. At first, continuous processing was effected using a continuous processing apparatus as shown in Fig.6 with B 2 O 3 under xenon gas at 400 MPa, 600°C. As a result, an equivalent result with example 4 was obtained. Next to this, a large amount of material was processed at the same time using a flat cylindrical pressure vessel as shown in Fig.7. The use of a pressure vessel having such a shape allows a large area for setting material thus making it possible to treat large quantities at once.

Claims: A containerless method of processing a material under a state of compensated gravitation, said method comprising the steps of introducing said material into a chamber which is filled with a volume of a compressible fluid; pressurizing said fluid so as to raise its density, and controlling the pressure so that the density of the pressurized fluid is equal to that of said material whereby said material is suspended by buoyancy and freely floats within said volume under a state of substantially non-gravitation, and subjecting said material to a physical, chemical or metallurgical treatment in said state. A containerless method of processing a material under a state of compensated gravitation, said method comprising the steps of introducing said material into a chamber which is filled with a volume of a compressible fluid; pressurizing said fluid so as to raise its density; selectively heating said fluid to generate a density variation in said fluid, the density decreasing in a vertical direction from a value above that of said material at the bottom of said chamber to a value below that of said material at the top of said chamber, whereby said material is suspended by buoyancy and freely floats within said chamber under a state of substantially non-gravitation, and subjecting said material to a physical, chemical or metallurgical treatment under said state. A method according to claim 2, characterized in that said fluid is a single fluid. The method according to claim 2, characterized in that said fluid consists of a plurality of different fluids, said fluids being arranged within said chamber in horizontal layers with the less dense fluid floating on the denser fluid. A method according to any of the claims 1 to 4, characterized by heating the upper part of said chamber. A method according to any preceding claim, characterized in that, after suspending said material at ordinary temperature, said material is heated to a desired temperature by sealing said fluid in said chamber and heating said fluid isometrically at constant density. A method according to any preceding claim, characterized by applying an electro-magnetic induction and/or a supersonic induction to said material for providing auxiliary suspension. A containerless processing apparatus for a material under a state of compensated gravitation, said apparatus comprising a chamber (1, 10) containing said material (4, 5, 6); a pressure-medium filling means for filling said chamber (1, 10) with a fluid; and treating means for treating said material in said chamber (1, 10) physically, chemically or metallurgically, characterized in that said fluid is a compressible fluid; and said apparatus further comprises means for compressing said fluid and controlling the pressure of said fluid so as to obtain a density of said fluid which is equal to that of said material. A containerless processing apparatus for a material under a state of compensated gravitation, said apparatus comprising a chamber (1, 10) containing said material (4, 5, 6); a pressure-medium filling means for filling said chamber (1, 10) with a fluid; and treating means for treating said material in said chamber (1, 10) physically, chemically or metallurgically, characterized in that said apparatus comprises heating means for selectively heating portions of said fluid so as to generate a density variation in said fluid, said density decreasing in a vertical direction from a value above that of said material at the bottom of said chamber to a value below that of said material at the top of said chamber. The apparatus of claim 8 or 9, characterized in that said fluid is a single fluid or a plurality of different fluids having different densities.

Inventors: ISHIZAKI KOZO, NANKO MAKOTO, ISHIZAKI, KOZO, NANKO, MAKOTO
Applicants: PLATA LTD CO, PLATA LTD. CO.
Application year: 1992
Main classification: B01J19
IPC codes: B29C39, B29D22, B01J19, B22F9, B22F1, B22F3, B29C67, B29D99