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    • 专利摘要:
    METHOD FOR MANUFACTURING A HIGH CURRENT ELECTRODE FOR AN ARC PLASMA TORCH. It is a method for manufacturing an electrode for use in an arc plasma torch that includes the formation of a conductive body to define a proximal end portion, a distal end portion, a distal end face arranged on the distal end portion, a central cavity and a central protuberance disposed within the central cavity close to the distal end portion. A plurality of emissive inserts are inserted through the distal end face and into the central protuberance. The plurality of emissive inserts are compressed in the central protuberance, and both a proximal end portion of the central protuberance and the plurality of emissive inserts are deformed so that the plurality of emissive inserts extend radially and outwardly from the distal end portion to a angle to the distal end portion
    公开号:BR112013020053B1
    申请号:R112013020053-7
    申请日:2012-02-28
    公开日:2020-10-27
    发明作者:Nakhleh Hussary；Christopher J. Conway
    申请人:Thermal Dynamics Corporation；
    IPC主号:
    专利说明:

    CROSS REFERENCE TO RELATED ORDERS
    The present application claims priority for 5 Provisional Application No. Serial No. 61 / 447,560, filed February 28, 2011, entitled "PLASMA ARC TORCH HAVING IMPROVED CONSUMABLES LIFE". The description of the application above is incorporated in this document as a reference in its entirety. FIELD
    The present description relates to arc plasma torches and, more specifically, methods of fabricating electrodes for use in arc plasma torches. BACKGROUND
    The claims in this section provide merely background information related to this description and may not constitute the prior art.
    Arc plasma torches, also known as electric arc torches, are commonly used to cut, mark, gouge and weld metal workpieces by directing a high-energy plasma stream consisting of particles of ionized gas in the direction of the workpiece. In a typical arc plasma torch, the gas to be ionized is supplied to a distal end of the torch and flows past an electrode before exiting through a hole in the tip, or nozzle, of the arc plasma torch. The electrode has a negative negative potential and operates as a cathode. Conversely, the tip of the torch constitutes a negative positive potential and operates as an anode 30 during piloting. Additionally, the electrode is in a spaced relationship with the tip, thus creating a gap at the distal end of the torch. During operation, a pilot arc is created in the gap between the electrode and the tip, often referred to as the plasma arc chamber, in which the pilot arc heats and ionizes the gas. The ionized gas is expelled from the torch and appears as a stream of plasma extending distally out of the tip. While the distal end of the torch is moved to a position close to the workpiece, the arc jumps or is transferred from the torch tip to the workpiece with the aid of a switching circuit activated by the power supply.
    Consequently, the workpiece serves as the anode, and the arc plasma torch is operated in a "transferred arc" mode.
    Consumables for the arc plasma torch, such as the electrode and tip, are susceptible to wear due to high current / power and high operating temperatures. After the pilot arc is initiated and the plasma current is generated, the electrode and tip are subjected to high heat and wear from the plasma current throughout the entire arc plasma torch operation. Enhanced consumables and operating methods for an arc plasma torch to extend consumable life, thereby increasing operating times and reducing costs, are continually desired in the plasma cutting technique. SUMMARY
    A method is provided for manufacturing an electrode for use in an arc plasma torch which comprises forming a conductive body to define a proximal end portion, a distal end portion, a distal end face disposed on the end portion distal, a central cavity, and a central protuberance disposed within the central cavity 5 close to the distal end portion. A plurality of emissive inserts are inserted through the distal end face and into the central protuberance. The plurality of emissive inserts are compressed in the central protuberance and a proximal end portion 10 of the central protuberance and the plurality of emissive inserts is deformed so that the plurality of emissive inserts extend radially and outwardly from the distal end portion at an angle in relation to the distal end portion.
    Otherwise, a method for manufacturing an electrode for use in a plasma arc torch is provided which comprises forming a conductive body to define a proximal end portion, a distal end portion, and a distal end face disposed on the distal end portion. A plurality of emissive inserts are inserted through the distal end face and into the distal end portion. The plurality of inserts are compressed at the distal end portion and the plurality of emissive inserts are deformed so that the plurality of emissive inserts extend at an angle to the distal end portion.
    In yet another way, a method for manufacturing an electrode for use in a plasma arc torch 30 is provided which comprises forming a conductive body to define a proximal end portion, a distal end portion, and a distal end face. arranged at the distal end portion. At least one emissive insert is inserted through the distal end face 5 and into the distal end portion. The at least one emissive insert is compressed at the distal end portion and deformed so that the emissive insert extends at an angle to the distal end portion.
    Additional areas of applicability will become evident from the description provided here. It should be understood that the description and specific examples are intended for purposes of illustration only and not to limit the scope of this description. DRAWINGS
    The drawings described in this document are for illustrative purposes only and are not intended to limit the scope of this description in any way.
    Figure 1 is a perspective view of an arc plasma torch built in accordance with the principles of the present description;
    Figure 2 is an exploded perspective view of an arc plasma torch constructed in accordance with the 25 principles of the present description;
    Figure 3 is an exploded cross-sectional view of an arc plasma torch, taken along line A-A of Figure 1 and constructed in accordance with the principles of the present description;
    Figure 4 is a cross-sectional view of a torch head of the arc plasma torch of Figure 3;
    Figure 5 is a perspective view of a consumable cartridge for an arc plasma torch built in accordance with the principles of the present description;
    Figure 6 is a cross-sectional view, taken along the line B-B of Figure 6, of the consumable cartridge according to the principles of the present description;
    Figure 7 is a perspective view of an electrode constructed in accordance with the principles of the present description;
    Figure 8 is a cross-sectional perspective view of an electrode constructed in accordance with the principles of the present description;
    Figure 9 is an end view of an electrode which includes overlapping emissive inserts and which is constructed in accordance with the principles of the present description;
    Figure 10 is a perspective view of an alternative form of an electrode constructed in accordance with the principles of the present description;
    Figures 11A to 11D are views of various forms of electrodes constructed in accordance with the principles of the present description;
    Figure 12 is a schematic cross-sectional view of a tip showing diameters of a central tip hole and a tip ream;
    Figure 13 is a schematic view showing steps for manufacturing an electrode constructed in accordance with the principles of the present description;
    Figure 14 is a cross-sectional view of an electrode, showing a compression device for a compression step according to a method of the present description;
    Figure 15 is an enlarged cross-sectional view of the central protrusion of the electrode of Figure 14 after the compression step;
    Figure 16 is an enlarged schematic view of a central protrusion of an electrode showing blind holes angled according to another method of the present description;
    Figure 17a is a cross-sectional view of an electrode showing a compression device for a compression step in accordance with yet another method of the present description;
    Figure 17b is another form of the compression device constructed in accordance with the teachings of the present description;
    Figure 18 is an enlarged cross-sectional view of the consumable cartridge showing the direction of the coolant flow.
    Figure 19 is a graph showing the life of electrodes in the prior art with a single hafnium insert, in which life is measured by the number of cuts made;
    Figure 20 is a graph showing the life of electrodes that have three hafnium inserts and constructed according to the principles of this description, in which life is measured by the number of cuts made;
    Figure 21 is a graph showing the life of electrodes that have four hafnium inserts with 5 deformed central protuberances and deformed emissive inserts constructed according to the principles of this description, in which life is measured by the number of cuts made;
    Figure 22 shows 10 wear depth plots versus the number of starts for electrodes that have a single emissive insert and multiple emissive inserts, respectively, in different operating cycles;
    Figure 23 shows graphs of wear rate versus operating cycles of electrodes that have a single emissive insert and multiple emissive inserts, respectively;
    Figure 24 shows graphs of electrode life measured by the number of starts as a function of the number of emissive inserts of hafnium in the electrodes; and
    Figure 25 shows graphs of the ratio property between single element versus number of emissive elements in the electrodes. DETAILED DESCRIPTION
    The following description is merely exemplary in nature 25 and is not intended to limit the present description, applications or uses. It should be understood that throughout the drawings, the corresponding numerical references indicate similar or corresponding parts or resources. It should also be understood that several hatch patterns used in the drawings are not intended to limit the specific materials that can be employed with the present description. Hatch patterns are merely examples of preferred materials or are used to distinguish between adjacent components or corresponding components illustrated in the drawings for clarity.
    Referring to the drawings, an arc plasma torch in accordance with the present description is illustrated and indicated by the numerical reference 10 in Figures 1 to 3. The arc plasma torch 10 generally comprises a torch head 12 arranged at a proximal end 14 of the arc plasma torch 10 and a consumable cartridge 16 attached to the torch head 12 and disposed at a distal end 18 of the arc plasma torch 10 as shown.
    As used herein, an arc plasma torch should be interpreted by the person skilled in the art as a device that generates or uses plasma for cutting, welding, spraying, gouging or marking operations, among others, manual or automated. Consequently, the reference specifies plasma arc cutting torches or plasma arc torches should not be construed as limiting the scope of the present invention. Furthermore, the specific reference to the supply of gas for an arc plasma torch should not be interpreted as a limitation on the scope of the present invention, so that other fluids, for example, liquids, can also be supplied for the plasma torch of arc in accordance with the teachings of the present invention. Additionally, proximal or proximal direction is the direction of the torch head 12 of the consumable cartridge 16 as described by arrow A ', and distal or distally direction is the direction of consumable components 16 of the torch head 12 as described by arrow B'.
    More specifically, referring to Figure 4, the torch head 12 includes an anode body 20, a cathode 22, a central insulator 24 that isolates cathode 22 from anode body 20, an external insulator 26 and a housing 28. The external insulator 26 surrounds the anode body 20 and isolates the anode body 20 from the housing 28. The housing 28 encapsulates and protects the torch head 12 and its components from the surrounding environment during operation. The torch head 12 is additionally adjacent to a coolant supply tube 30, a plasma gas tube 32, a coolant return tube 34 (shown in Figures 1 and 2) and a secondary gas tube 35, in which the plasma gas and the secondary gas and the cooling fluid are supplied and returned from the arc plasma torch 10 during operation as described in greater detail below.
    The central insulator 24 defines a cylindrical tube that houses the cathode 22 as shown. The central insulator 24 is additionally disposed within the anode body 20 and also engages in a torch compartment 70 that accommodates the coolant fluid supply tube 30, the plasma gas tube 32 and the coolant return tube 34. Anode body 20 is in electrical communication with the positive side of a power supply (not shown) and cathode 22 is in electrical communication with the negative side of the power supply. Cathode 22 defines a cylindrical tube that has a proximal end 38, a distal end 39 and a central hole 36 extending between the proximal end 38 and the distal end 39. Hole 36 is in fluid communication with the supply tube. coolant fluid 30 at the proximal end 5 38 and a coolant tube assembly 41 at the distal end 39. The coolant fluid flows from the coolant supply tube 30 to the central hole 36 of cathode 22 and is then distributed through of a central hole 46 of the fluid tube assembly 10 cooler 41 for the consumable components of the consumable cartridge 16. A cathode plug 40 is attached to the distal end 39 of the cathode 22 to protect the cathode 22 from damage during component replacement consumables or other repairs. The torch head 12 of the 15 arc plasma torch has been described in U.S. Patent No. 6,989,505, the contents of which are hereby incorporated by reference in their entirety.
    Referring to Figures 5 and 6, consumable cartridge 16 includes a plurality of consumables 20 including an electrode 100, a tip 102, a spacer 104 disposed between electrode 100 and tip 102, a cartridge body 106, a member anode 108, a baffle 110, a secondary plug 112 and a protective plug 114. The cartridge body 106 houses and positions, in general, the other 25 consumable components 16 and also distributes plasma gas, secondary gas and refrigerant during the operation of the arc plasma torch 10. The cartridge body 106 is manufactured from an insulating material and separates the anode member (for example, anode member 30 108) from cathode members (for example, electrode 100) . The baffle 110 is disposed between the cartridge body 106 and the protective cap 114 to direct the coolant.
    Anode member 108 connects anode body 20 (shown in Figure 4) on torch head 20 to tip 102 to provide electrical continuity from the power supply (not shown) to tip 102. Anode member 108 is attached to the cartridge body 106. Spacer 104 provides electrical separation between cathode electrode 100 and anode tip 102, and also provides certain gas distribution functions. The protective cap 114 surrounds the deflector 110 as shown, in which a secondary gas passage 150 is formed between it. Secondary plug 112 and tip 102 define a secondary gas chamber 167 in between. The secondary gas chamber 167 allows a secondary gas to flow through in order to cool the tip 102 during operation.
    As additionally shown, consumable cartridge 16 additionally includes a locking ring 117 for securing consumable cartridge 16 to torch head 12 (shown in Figure 4) when the arc plasma torch 10 is fully assembled. The consumable cartridge 16 additionally includes a secondary spacer 116 that separates the secondary plug 112 from the tip 102 and a retaining plug 149 that surrounds the anode member 108. The secondary plug 112 and the secondary spacer 116 are attached to a distal end 151 of the retention buffer 149.
    Tip 102 is electrically separated from electrode 100 by spacer 104, which results in a plasma chamber 172 being formed between electrode 100 and tip 102. Tip 102 additionally comprises a central orifice (or an exit orifice) 174, through from which a plasma current flows during the operation of the arc plasma torch 10 while the plasma gas is ionized into the plasma chamber 172. The plasma gas enters the tip 102 through the gas corridor 173 of the spacer 104.
    Referring to Figures 7 to 10, electrode 100 includes a conductive body 220 and a plurality of emissive inserts 222. Conductive body 200 includes a proximal end portion 224 and a distal end portion 226 and defines a central cavity 228 extending through the proximal end portion 224 and in fluid communication with the coolant tube assembly 41 (shown in Figures 4 and 18). The central cavity 228 includes a distal cavity 120 and a proximal cavity 118.
    The proximal end portion 224 includes an outer shoulder 230 which adjoins spacer 104 for proper positioning along the central longitudinal axis X of the arc plasma torch 10. The spacer 104 includes an inner annular ring 124 (shown in Figure 6 ) which adjoins the outer shoulder 230 of electrode 100 for proper positioning of electrode 100 along the central longitudinal axis X of the arc plasma torch 10.
    The electrode 100 additionally includes a central protrusion 232 at the distal end portion 226 and a recessed portion 235 surrounding the central protrusion 232 to define a cup-shaped configuration. The central protrusion 232 extends from a distal end face 234 forming the central cavity 228.
    When the consumable cartridge 16 is mounted for the torch head 12, the central protrusion 232 is received inside the central hole 46 of the coolant tube assembly 41 (shown in Figures 4 and 18) so that the cooling fluid 5 cooling of the central hole 36 of cathode 32 is directed to the assembly of coolant tube 41 and enters the central cavity 228 of the electrode 100. The central cavity 228 of the electrode 100 is thus exposed to a refrigerant during operation 10 of the arc plasma torch 10. The central protrusion 232 can be effectively cooled due to the fact that it is surrounded by the cooling fluid in the central cavity 228 of the electrode 100.
    The distal end portion 226 further includes the distal end face 234 and an angled side wall 236 extending from the distal end face 234 to a cylindrical side wall 238 of the conductive body 220. The plurality of emissive inserts 222 are arranged in the distal end portion 20 226 and extends across the distal end face 234 forming the central protrusion 232 and not forming the central cavity 228. Parts of the emissive inserts 22 are surrounded by the cooling fluid in the central cavity 228 of the electrode 100, resulting in more effective cooling 25 of the emissive inserts 222. The plurality of emissive inserts 222 are nested concentrically on the center line of the conductive body 220. The emissive inserts 222 each define a cylindrical configuration that has a diameter of approximately 0.11 cm ( 0.045 inch) and 30 include hafnium. Emissive inserts 222 can have the same or different diameters. The conductive body 238 comprises a copper alloy. Emissive inserts 222 can be arranged to overlap or be separated. When the emissive inserts 222 are separated, the emissive inserts 222 are spaced as close together as the manufacturing limitation allows. The space between the emissive inserts 222 can be less than about 0.03 cm (0.010 inch), in a form of the present description. When the emissive inserts 222 are arranged to overlap, the emissive inserts 222 can together form numerous configurations, including, for example, a clover leaf shape as shown in Figure 9.
    In one form, the electrode 100 additionally includes a dimple 246 (shown in Figure 10) 15 extending on the distal end face 234 and at least partially on the emissive inserts 222, and positioned concentrically around a center line of the conductive body 238 as shown. The dimple 246 extends, for example, approximately 50% of an exposed area 20 of the emissive inserts 222. Although not shown in the drawings, it should be understood that more than one dimple can be provided while remaining within the scope of the present description.
    As shown further, a plurality 25 of notches 240 is provided in a form of the present description, which extends on the angled side wall 236 and the distal end face 234 as shown. In one form, the notches 240 are evenly spaced around an interface 242 between the distal end face 234 30 and the angled side wall 236. The notches 240 are provided to enhance pilot arc initiation when starting the arc plasma torch 10.
    Referring to Figure 10, electrode 100 'is different from electrode 100 of Figures 7 and 9 since the 5 electrode 100' 'includes three emissive inserts 222 instead of four. The electrode 100 'also includes the dimple 246 which is lowered from the distal end face 234, although it should be understood that the dimple 246 may or may not be provided in any of the electrode forms 10 illustrated, described and contemplated.
    Referring to Figures 11A to 11D, the electrode can have any number of emissive inserts 222 without departing from the scope of the present description. For example, electrodes 100A, HOB, 100C, 100D can have any 15 out of three (3), four (4), six (6) and seven (7) emissive inserts 222. Emissive inserts 222 are arranged to define a wraparound ring C surrounding the emissive inserts 222 in this. The wraparound ring C can be smaller than, equal to or greater than the diameter D1 of the central hole 174 of the tip 102 or the diameter D2 of the tip countersink (pre-hole / hole inlet) in relation to the tip hole as shown in Figure 12. For example, wraparound ring C may be 50%, 100% or 150% of the diameter of the central hole 174 of the tip 102 or the diameter of the tip counter with respect to the tip hole. The diameter of the 222 hafnium inserts can be approximately 0.08 cm (0.030 inch) to approximately 0.15 cm (0.060 inch). Preferably, the diameter of the 222 hafnium inserts is 0.08, 0.11 or 0.15 cm (0, 030, 30 0.045 or 0.060 inches), which are a function of the tip dimensions such as D1 and / or diameters D2 as shown above. The dimple depth can be approximately 0.02 cm (0.007 inch) to approximately 0.08 cm (0.030 inch). Preferably, the dimple depth is approximately 0.02, 0.04. 0.06 or 0.08 cm (0.007, 0.015, 0.025 or 0.030 inch), which are also a function of tip dimensions such as Dl diameters and / or D2 as shown above. The hafnium billets, before being compressed to form the conductive body 238, in one form, are a combination of 0.11 cm and / or 0.15 cm (0.045 inch and / or 0.060 inch) inserts, or, in other words, different sized inserts can be used on the same electrode.
    Additionally, in a form of the present description, the emissive inserts are spaced relatively close together so that a space between their respective edges, (tangent lines parallel to each outer circumference of the emissive inserts 222), or a "network" of the material of electrode between the emissive inserts is at a specific distance. In one form, as shown in Figure 13 (c), this spacing S is between about 0.04 cm (0.015 ") and about 0.01 mm (0.0005") and, in another form, it is more specifically about 0.01 cm (0.003 "). These S spacings are particularly advantageous when the number of emissive inserts 222 is four (4), although these spacings can also be used with a different number of emissive inserts. It should be understood that others S spacing can be used while remaining within the scope of this description and these values are merely exemplary.
    By way of example, and in certain forms of the present description, the emissive inserts 222 of Figures 5 11A to 11D each have a diameter of 0.11 cm (0.045
    inch). In Figure 11A, the diameter of the surrounding ring C is approximately 0.25 or 0.28 cm (0.100 or 0.111 inch). In Figure 11B, the diameter of the surrounding ring C is approximately 0.28 or approximately 0.31 cm (0.11 or 10 approximately 0.121 inch). In Figures 11C and 11D, the diameter of the surrounding ring C is approximately 0.36 cm (0.141 inch).
    Referring to Figure 13, a method for manufacturing an electrode constructed according to the 15 principles of the present description is shown. First, a conductive body 238 of a cylindrical shape is prepared and machined to form a plurality of blind holes 221 and notches 240 in step (a). The electrode additionally includes a central protrusion 232 extending from the distal end face 234 in the central cavity 228.
    Subsequently, the emissive inserts 222 are inserted into the blind holes 221 in the conductive body 238 in step (b).
    Subsequently, the emissive inserts 222 are compressed forming the conductive body 238 until the distal faces 223 25 of the emissive inserts 222 are substantially flush with the distal end face 234 of the conductive body 238 in step (c). Finally, the distal end face 234 of the conductive body 238 and the distal end faces 223 of the emissive inserts 222 are machined to form a dimple 246 in step (d), thus ending the electrode 100 or 100 'of the present description. Although the drawings illustrate holes for the emissive inserts, it should be understood that any opening shape, such as tapered / tapered, rectangular or polygonal, among others, can also be used without departing from the scope of this description.
    Referring to Figures 14 and 15, the compression step (c) in Figure 13 can also include a step for deformation of the central protrusion 232 and the emissive inserts 222. A compression device 250 can be placed in the central cavity 228 of the electrode 100 and on top of a top surface 252 of the central protrusion 232. After the emissive inserts 222 are compressed in the blind holes 221, the central protrusion 232 is compressed between the compression device 250 and a support device (not shown) on the side of the distal end face 234. The compression step causes the central protrusion 232 to deform and expand radially and outwardly. The central protrusion 232 has an original height XI measured from the distal end face 234 to the top surface 252 before compression. The height of the central protrusion 232 after compression becomes X2. Deformation of the central protrusion 232 causes the emissive inserts 222 in the central protrusion 232 to deform. Due to the fact that the central protrusion 232 is deformed to expand radially and outwardly, the proximal end portions 272 of the emissive inserts 222 adjacent to the compression device 250 are compressed to expand radially and outwardly, while the distal end portions 270 of the emissive inserts 222 near the distal end face 234 may remain parallel to the longitudinal geometric axis of the electrode 100 or may also expand radially and outwardly by a small amount compared to the proximal end portions 272. The 5 distal end portions 270 and the proximal end portions 272 define an angle 0, which can be obtuse. The proximal end portions 272 can be slightly curved in relation to the distal end portions 270. The changed shape of the emissive inserts 222 10 results in increased contact pressure between the emissive inserts 222 and the central protrusion 232, resulting in thermal contact conductance enhanced between hafnium (which forms the emissive inserts 222 in a form of the present description) and copper (which forms the central protuberance 232 15 in a form of the present description). As a result, deformed emissive inserts 222 increase the life of electrode 100. It should also be understood that the teachings of the present invention about deformed emissive inserts can also be applied to a single emissive insert rather than a plurality of emissive inserts while remain within the scope of this description.
    The ratio (X2 / X1) between the height of the central protrusion 232 after compression and the original height of the central protrusion 232 before compression (hereinafter "ratio between height") can be in the range of approximately 0.75 to approximately 1, otherwise, in the range of approximately 0.9 to approximately 0.95.
    Similarly, a dimple 246 can be formed in the center of the distal end face 234 to improve the consumable life of electrode 100.
    Referring to Figure 16, a method for manufacturing the electrode according to another modality of the present description is similar to that described in connection with Figure 13 except for the step of forming the blind holes. In the present embodiment, the central protrusion 232 is drilled to form blind angled holes (or openings) 254 that can have a desired final shape of the emissive inserts 222. The emissive inserts 222 are compressed into the blind angled holes 254. The emissive inserts 222 are firmly attached to the central protrusion 232 due to the deformation of the emissive inserts 222 in the angled blind holes 254. As a result, the emissive inserts 222 can be deformed during compression to form the desired final shape with the desired shape and angle 0. The emissive inserts 222 tablets on the central protrusion 232 each include a distal end portion 270 near the distal end face 234 and a proximal end portion 272 near the top surface 252 of the central protrusion 232. The distal end portion 270 can be parallel to the longitudinal axis of the electrode 100 or slightly angled with respect to the lon axis length of the electrode 100, while the proximal end portion 272 extends radially and out of the distal end portion 272 to define an angle 0 with respect to the distal end portion 270. (i.e., the emissive inserts 222 are deformed during compression ). The 0 angle can be an obtuse angle. The central protrusion 232 may or may not be deformed in this mode. In addition, it should be understood that the blind openings / holes 254 may alternatively be parallel to a longitudinal geometric axis 5 of the electrode, or the angle may be outward as shown, or, alternatively, angled inward. In addition, it should be understood that the "angle" is a relative angle and that the emissive inserts 222 may not necessarily assume a linear deformation 10 to form a precise angle, or, in other words, the emissive inserts 222 may be curved or arched as required. shown in the picture in Figure 15 towards a central electrode line. In other ways, the inserts can be formed at different angles to each other, that is, an angled inward, an angled outward, a parallel, etc. Consequently, the shape illustrated and described in this document from angled outward to the obtuse angle of all inserts (or a single insert) should not be construed as limiting the scope of the present description.
    Referring to Figure 17a, a method for manufacturing the electrode according to yet another embodiment of the present description is similar to that described in connection with Figure 14 except for the configuration of the compression device. In the present embodiment, the compression device 256 defines an open chamber 258 to receive the central protrusion 232 therein. Open chamber 258 can be slightly larger than central protrusion 232 and has a desired final shape of central protrusion 232. 30 Therefore, central protrusion 232 is deformed to form a shape that is equal to the shape of open chamber 258, while also deforming the emissive inserts 222. The open chamber 258 can define a hemispherical shape or a rectangular shape, or any other suitable shape.
    Referring to Figure 17b, another form of a compression device is illustrated as the numerical reference 256 '. This compression device 256 'includes a protrusion 257, which, in this form, has a triangular geometry as shown, in order to control the deformation of the emissive inserts 222 during the compression operation. It should be understood that other geometries can also be employed to control deformation, such as a dimple (rounded) or a square or other polygonal shape while remaining within the scope of the present description. In addition, the compression device 256 'may have the chamber 258 open, or it may be flat along the compression area (as shown in Figure 14).
    Similar to the modality in Figure 14, the ratio 20 (X2 / X1) between the deformed height (X2) and the original height (XI) can be in the range of approximately 0.75 to approximately 1, and, preferably, in the range from approximately 0.9 to approximately 0.95.
    Referring to Figure 18, the life of electrode 100 25 is significantly enhanced not only through the unique structure of electrode 100, but also through the arrangement of electrode 100 in the arc plasma torch 10. As shown, when assembled, the protrusion center 232 of electrode 100 is disposed within central hole 30 46 of the coolant tube assembly 41 with a cooling channel 258 defined between the recessed portion 253 of the electrode 100 and the distal end 43 of the coolant tube assembly 41 During operation, the cooling fluid flows distally through the central hole 36 of the cathode 22, through the cooling fluid tube assembly 41, through the cooling channel 258 and in the distal cavity 120 of the electrode 100 and between the tube assembly of coolant fluid 41 and the cylindrical body 238 of electrode 100. The coolant fluid then flows proximally through proximal cavity 118 of electrode 100 to supply provide cooling for electrode 100 and cathode 22 which are operated at relatively high temperatures and currents.
    Advantageously, the cooling fluid tube assembly 41 (which is spring loaded) is forced upward by the electrode 100 near its proximal end portion 224, and, more specifically, by the inner face 231 of the electrode 100 adjacent to the tubular member 43 on its proximal flange 49. With this configuration, the distal end 43 of the coolant tube assembly 41 is not in contact with the electrode 100 and thus a more uniform cooling flow is provided around the emissive inserts 222 and the central protrusion 232, thereby further increasing the life of electrode 100. Referring to Figure 9, the external shoulder 230 in an alternative shape is rectangular in relation to the cylindrical side wall 238, instead of being tapered as shown in this figure.
    Referring to Figures 19 and 20, the graphs show the electrode life of the prior art and the electrode life according to the principles of the present description in relation to the number of cuts made, respectively. As shown in Figure 19, a prior art electrode that has a single hafnium insert wears out significantly after the electrode has made approximately 250 to 350 cuts. In contrast, an electrode 100 or 100 'of the present description wears out significantly after electrode 100 or 100' has made approximately 500 to 650 cuts as shown in Figure 20. Therefore, the life of electrode 100 can be increased by at least 70% compared to conventional models. Hafnium emissive inserts 222 are inserted, for example, through compression, forming the oxygen-free distal end portion 226 of the conductive body 220. This allows the inserted heat of the arc to be distributed in the plurality of emissive inserts 222. Each individual insert 222 is in contact with the conductive body 220 resulting in a significant increase in the heat dissipation of the emissive inserts of hafnium 20 222. Additional cooling of the emissive inserts 222 decreases the wear of hafnium. As an example, when three emissive inserts 222 are used, the emissive inserts 222 may have a diameter of 0.11 cm (0.045 inch) as opposed to a traditional electrode which in a single emissive insert 25 of 0.23 cm ( 0.092 inch) in diameter.
    Referring to Figure 21, the life of an electrode according to the present description is further increased when four emissive inserts are used. The electrode with four emissive inserts wears out significantly after the electrode has made approximately 950 to 1,000 cuts.
    Referring to Figure 22, the wear of electrodes that have a single emissive insert and multiple emissive inserts is compared under different operating cycles. Under the same 11-second operating cycle, an electrode that has a single emissive insert wears out significantly in approximately 300 starts, while an electrode that has multiple emissive inserts has the same wear depth in approximately more than 1,100 starts. When electrodes with multiple emissive inserts are operated under an operating cycle of less than 11 seconds, for example, 4 seconds, the wear depth is reduced for the same number of starts.
    Referring to Figure 23, the electrode wear rate versus operating cycle time for electrodes that have a single emissive insert and multiple emissive inserts, at 200A and 400A, is shown. Additionally, the R2 value is a correlation coefficient that represents the quality of the fit between the insert and the electrode (the closer to 1 the better).
    Referring to Figure 24, the electrode life measured by the number of starts for electrodes that have different numbers of emissive inserts is shown. The X coordinate indicates the number of emissive inserts in an electrode, while the Y coordinate indicates the life of the electrodes as measured by the number of starts. As shown, an electrode that has four emissive inserts has the longest life of approximately 1000 matches under 400A operating condition, as opposed to an electrode that has only one emissive insert and that has a life of approximately 300 matches. An electrode that has three emissive inserts has the second longest life of approximately 600 matches. The life of electrodes that have 5, 6 and 7 emissive inserts is not significantly different.
    Referring to Figure 25, the ratio properties of multiple inserts versus a single insert are shown. Two reasons are illustrated, volume and external surface area. "Ref-Vol" is the ratio between the total volume of multiple inserts and the total volume of a single insert. "Ref-Area" is the ratio between the total area of multiple inserts and the total surface area of a single insert. The use of more inserts will provide more surface area, and thus more total surface area for cooling.
    The description of the disclosure is merely exemplary in nature and, therefore, variations that are not far from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations should not be considered a departure from the spirit and scope of the description.
    权利要求:
    Claims (16)
    [0001]
    1. Method for manufacturing an electrode (100) for use in an arc plasma torch FEATURED for understanding: forming a conductive body (220) to define a proximal end portion (224), a distal end portion (226) and a distal end face (234) arranged on the distal end portion (226); and inserting at least one emissive insert (222) through the distal end face (234) and into the distal end portion (226), at least one emissive insert (222) comprising a distal end portion (270) and a proximal end portion (272 ), each portion (270, 272) defining a longitudinal axis; characterized by: pressing at least one emissive insert (222) into the distal end portion (226) and deforming at least one emissive insert (222) so that the longitudinal axis of the proximal end portion (272) of the at least one emissive insert (222) extends at an angle to the longitudinal axis of the distal end portion (270) of at least one emissive insert (222).
    [0002]
    Method according to claim 1, characterized in that the formation defines a central cavity (228) in the conductive body (220) and a central protuberance (232) that extends from the distal end face (234) to the central cavity ( 228), and the method further comprises: deforming a proximal end portion of the central protuberance (232) and the proximal end portion (272) of at least one insert (222) so that the longitudinal axis of the proximal end portion ( 272) of at least one emissive insert (222) extends at an angle to the longitudinal axis of the distal end portion (270).
    [0003]
    Method according to claim 2, characterized in that the central protuberance (232) defines a height ratio, between heights measured from the distal end face (234) after and before deformation, from approximately 0.75 to approximately 1.
    [0004]
    Method according to claim 1, CHARACTERIZED that at least one emissive insert (222) is deformed so that the longitudinal axis of the distal end portion (270) and the longitudinal axis of the proximal end portion (272) define an angle obtuse.
    [0005]
    Method according to claim 3, characterized in that the height ratio is approximately 0.9 to approximately 0.95.
    [0006]
    6. Method according to claim 2, CHARACTERIZED in that the central protrusion (232) is deformed using a compression device (256, 256 ') with an open chamber (258) slightly larger than the central protrusion (232) and which has a desired final shape of the central protrusion (232).
    [0007]
    Method according to claim 6, characterized in that the open chamber (258) defines a hemispherical shape.
    [0008]
    Method according to claim 6, characterized in that the open chamber (258) defines a rectangular shape.
    [0009]
    Method according to claim 6, characterized in that the open chamber (258) defines a protrusion (257) to control the deformation.
    [0010]
    10. Method according to claim 1, characterized by further comprising the formation of a dimple (246) in the center of the distal end face (234).
    [0011]
    11. Method according to claim 1, further characterized by: forming a blind opening in the distal end face anterior (234) to pressing at least one emitting insert (222).
    [0012]
    12. Method according to claim 1, CHARACTERIZED that at least one emissive insert (222) is compressed using a compression device (256 ') that has a protrusion (257) to control the deformation of at least one emissive insert ( 222).
    [0013]
    13. The method of claim 1, further comprising compressing a plurality of emissive inserts (222) on the distal end face (234).
    [0014]
    Method according to claim 13, characterized in that: the longitudinal axis of the proximal end portion (272) of each of the various emissive inserts (222) extends radially and externally from a longitudinal axis of the electrode (100 ).
    [0015]
    Method according to claim 2, characterized in that it further comprises: before insertion, perforate the central protuberance (232) to form an angular orifice or opening (254) through the distal end face (234) and the distal end portion (226), and during insertion and compression, at least one emitter insert (222) is inserted and compressed into the blind angled hole or opening (254) to cause deformation of at least one emitter insert (222).
    [0016]
    16. Method according to claim 2, characterized in that the deformation comprises: deforming the central protuberance (232) to cause deformation of at least one emissive insert (222).
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    法律状态:
    2018-12-18| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2020-01-28| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-06-02| B09A| Decision: intention to grant|
    2020-10-27| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 28/02/2012, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US201161447560P| true| 2011-02-28|2011-02-28|
    US61/447,560|2011-02-28|
    PCT/US2012/026975|WO2012118832A1|2011-02-28|2012-02-28|Method of manufacturing a high current electrode for a plasma arc torch|
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