SE2150464A1 - Fused overlay plate and method - Google Patents

Abstract

An electronically controlled apparatus for the manufacture of fused overlay plate including a conveyor assembly, two hopper assemblies, a number of wire feeder assemblies, and a perforated cooling drum to produce a metal plate with a fused weld overlay that is harder, more impact resistant, and demonstrates a longer lifespan with respect to abrasion than known in the prior art. A spring-loaded ground (earth) assembly with tensioned feet is configured to contact the metal plate to provide direct grounding. The apparatus includes two hoppers or boxes: a first hopper connected with a raking apparatus, whereby the assembly is vertically adjustable to accommodate the thickness of the plate to be clad as desirable, and whereby the apparatus maintains a uniform thickness of a first media such as a metal powder in preparation for fusion with the base metal plate; and a second hopper connected with a raking apparatus, whereby the assembly is vertically adjustable to accommodate the thickness of the plate to be clad as desirable, and whereby the apparatus maintains a uniform thickness of a second media such as an insulating powder in preparation for fusion with the base metal plate. Each head in each of the wire feeder assemblies further includes a gear-driven, individual filler-metal feed unit that is liquid- or gas-cooled and that supplies electrical current to a power head which supplies voltage and current through insulating element(s), continuing through the metal powder to contact the metal base plate, and in so doing creates a metallurgical fusion bonding. Each power head is individually controlled and every other power head is configured to permit a transverse "scissor" horizontal motion with an oscillating backward/forward of the forward indexing motion of the base metal plate in a multi-axis movement pattern designed to form a variety of weld patterns as may be desirable. The metal plate is passed along the conveyor over, between, and/or among a battery of sensors that feedback data instantaneously to the electronic control logic, which in turn can make instantaneous changes to the manufacturing process to reduce variability between plates.

Description

WO 2020/060969 PCT/US2019/051400 FUSED OVERLAY PLATE AND METHOD Your petitioner, ANDREW KOSTECKI, a citizen of Australia and a resident of 114TRADITION LANE, MOORESVILLE, NORTH CAROLINA 28115, prays that LettersPatent may be granted to him for improvements in a FUSED OVERLAY PLATE ANDMETHOD as set forth in the following specification.

WO 2020/060969 PCT/US2019/051400 This non-provisional patent application claims all benefits under 35 U.S.C. §l l9(e) of pendingU.S. provisional patent application Serial No. 62/732,04l filed l7 September 2018, entitled"METAL-FUSION-OVERLAY PROCESSÉ in the United States Patent and Trademark Office, Which is incorporated by reference in its entirety herein.F IELD OF THE NVENTION The invention herein pertains to a system and method of overlaying Weld metal of metalplates and particularly pertains to an improved apparatus and method of overlaying metal platesWith a thermally fused flux media and a variety of adjustable components controlled by acomputer control system to achieve enhanced plate performance metrics such as hardness and impact resistance.

DESCRIPTION OF THE PRIOR ARTAND OBJECTIVES OF THE TNVENTION Overlaying of Weld metal on metal plates and other implements is Well known in the art,particularly in industries such as agriculture, mining, and commercial vehicles. ln short, theprocess involves covering, enveloping, or otherwise coating a metal base With another Substanceand then adhering the Substance to the face of the plateto imbue said face With certain desirablecharacteristics. See for example the World"s only smooth metal plate overlay system and methoddescribed in U.S. Patent No. 5,362,937 granted 08 November 1994 entitled OVERLAYING OFPLATES, assigned to Gene Kostecki, the father of the applicant of the subject application, theentire disclosure of Which is hereby incorporated by reference. One method of overlaying platesis to form a plate into a cylinder and then to fit this cylinder into a machine so as to rotate thecylinder beneath an array of Weldingi heads positioned to deposit a layer of Welding material ontothe plates progressively as it is rotated until the entire surface of the plates in its cylindrical formis covered, after Which the plate is cut and straightened to produce the hard faced sheet of material. A problem in such an arrangement is first that considerable Work is entailed in forming WO 2020/060969 PCT/US2019/051400 the plates into a cylíndrical form and then to straighten the plates into the form in Which they Willbe used during the manufacture of products. Certain difficulties also exist in control of the Welding because of the cylindrical form of the plate at the time the Welding material Was applied i by the heads. lt is also a practical restriction on the size of a plate Which can be Welded by such a method. Another problem that exists With Weld overlaying is that in the sheet material someportions of the sheet are heated more than others because tWo Welding heads pass over the samearea and this gives an uneven thickness of Weld metal overlay and perhaps some change to themetallurgical structure of the underlying metal. Fortunately, development in computercontrollers, programmable logic, and computer numerical control (CNC) has vastly improved themanufacture of hardened metal members, decreasing variation between product batches andincreasing quality outputs. HoWever, there still exists a need for a system and method ofapplying Weld metal to form an overlay on the plate While the plate is in planar form, Withparticular emphasis on maintaining the planar nature of the plate When it is cooled after fusing the flux media to the plate.

Thus, in view of the problems and disadvantages associated With prior art plates andmethods of production, the present invention Was conceived and one of its objectives is toprovide a metal fusion plate and method of manufacture that maintains the cladded plate in a substantially planar configuration, even during cooling. lt is another objective of the present invention to provide a metal fusion plate and methodof manufacture that includes a drive carnber roller to interface With apertures formed at the sidesof the base metal plate to drive the plate through the cladding process and maintain it in a planar configuration. lt is still another objective of the present invention to provide a metal fusion plate andmethod of manufacture With an adjustable conveyor sliding apparatus configured to accommodate convex cambered feeder rolls and a variety of plate thicknesses as desirable.

WO 2020/060969 PCT/US2019/051400 It is yet another objective of the present invention to provide a metal fusion plate andmethod of manufacture comprising a Variable, spring-loaded ground (earth) apparatus withtensioned feet configured to contact the metal plate to provide direct grounding during the cladding process.

It is a further objective of the present invention to provide a metal fusion plate andmethod of manufacture configured to accommodate up to an eight (8) foot by twenty (20) foot metal plate during the cladding process.

It is still a further objective of the present invention to provide a metal fusion plate andmethod of manufacture including a first screening box or hopper connected with a rakingapparatus, whereby the assembly is vertically adjustable to accommodate the thickness of theplate to be clad as desirable, and Whereby the apparatus maintains a uniform thickness of a first media such-as a metal powder in preparation for fusion with the base metal plate.

It is yet a further objective of the present invention to provide a metal fusion plate andmethod of manufacture comprising a second screening box or hopper connected with a rakingapparatus (either the one described above or an independent device), the assembly verticallyadjustable to accommodate the thickness of the plate to be clad as desirable, and Whereby theapparatus maintains a uniform thickness of a second media such as an insulating powder in preparation for fusion with the base metal plate. lt is another objective of the present invention to provide a metal fusion plate and methodof manufacture including a plurality of metal thermal fusion power heads, spaced approximatelyfour inches apart, each head further comprising a gear-driven, individual filler-metal feed unitthat is liquid- or gas-cooled and that supplies electrical current to a power head which suppliesvoltage and current through insulating element(s), continuíng through the metal powder tocontact the metal base plate, and in so doing creates a metallurgical fusion bonding. Each power head is individually controlled in a transverse "scissor" horizontal motion with an oscillating WO 2020/060969 PCT/US2019/051400 backward/forward of the forward índexing motion of the base metal plate in a multi-axis movement pattern designed to form a variety of fusion weld patterns as may be desirable. lt is still another objective of the present invention to provide a metal fusion plate andmethod of manufacture having one or more internally plumbed, perforated spray bars following the thermal bonding process to cool the cladded plate underside.

It is a further objective of the present invention to provide a metal fusion plate andmethod of manufacture configured with liquid- or gas-cooled thermal support and Cleaningrollers to break the therrnal insulation element(s) for discharge cleaning and orienting thecladded plate into the cooling and biased straightening rollers to ensure the finished plate remains planar.

It is still a further objective of the present invention to provide a metal fusion plate and method of manufacture produced by a submerged arch Welding technique.

It is yet a fiirther objective of the present invention to provide a metal fusion plate andmethod of manufacture with a reduced coefficient of friction, an increased hardness score, andextended durability, particularly in view of impact rating, while being produced in consistent batches plate-to-plate.

Various other objectives and advantages of the present invention will become apparent to those skilled in the art as a more detailed description is set forth below.SUMMARY OF THE INVENTION The aforesaid and other objectives are realized by providing an apparatus configured toproduce fused overlay plates and a method of their manufacture. The apparatus includeselectronic control logic and sensors in communication with a vertically adjustable conveyor member configured to accommodate convex cambered feeder rolls and a variety of plate WO 2020/060969 PCT/US2019/051400 thicknesses asdesirable, the conveyor responsiblefor maintaining the metal plate in a planarorientation by virtue of a cambered drive roller to interface with apertures formed at the sides ofthe base metal plate to drive the plate through the cladding process. A variable spring-loadedground (earth) assembly With tensioned feet is configured to contact the metal plate to providedirect grounding. The apparatus includes two hoppers or boxes: a first hopper connected with araking apparatus, whereby the assembly is vertically adjustable to accommodate the thickness ofthe plate to be clad as desirable, and whereby the apparatus maintains a uniform thickness of afirst media such as a metal powder in preparation for fusion with the base metal plate; and asecond hopper connected with the raking apparatus, whereby the assembly is verticallyadjustable to accommodate the thickness of the plate to be clad as desirable, and whereby theapparatus maintains a uniform thickness of a second media such as an insulating powder inpreparation for fusion with the base metal plate. The apparatus further includes twenty-four (24)metal therrnal fusion wire feeder assemblies with power heads spaced approximately four inchesapart, each power head further comprising a gear-driven, individual filler-metal feed unit that isliquid- or gas-cooled and that supplies electrical current to the power head which suppliesvoltage and current through insulating element(s), continuing through the metal powder tocontact the metal base plate, and in so doing creates a metallurgical fusion bonding. Each powerhead is individually controlled and every other power head is configured to permit a transverse"scissor" horizontal motion With an oscillating backward/forward of the forward indexingmotion of the base metal plate in a multi-axis movement pattern designed to form a variety ofweld patterns as may be desirable. The metal plate is passed along the conveyor over, between,and/or among a battery of sensors that feedback data instantaneously to the electronic controllogic, which in turn can make instantaneous changes to the manufacturing process to reducevariability between plates. During or after bonding, one or more intemally plumbed, perforatedspray bars are used in maintain the fused plate at the optimal temperature, increasing thelikelihood of a resulting fused plate that is flat and planar in nature, unbeaded from the hardeningprocess, defming a reduced coefficient of friction relatíve to the original base metal plate,defining increased hardness and durability ratings, »and capable of being reproduced plate byplate by plate.

WO 2020/060969 PCT/US2019/051400BRIEP DESCRIPTION OP THE DRAWINGS Pig. 1 shows an elevated side view of an improved apparatus for manufacturing fused overlay plate;Pig. 2 pictures a top plan view of the apparatus of Pig. 1; Pig. 3 depicts an elevated side View of an adjustable conveyor component of the apparatus of Pig. 1; A Pig. 4 demonstrates an elevated perspective view of a ground component of the apparatus of Pig. 1; Pig. 5A illustrates an elevated perspective view of a drive component of the apparatus of Pig. 1;Pig. SB pictures an enlargement of a portion of the drive component of Pig. 5A; Pig. 6 features an elevated side view of the first and second hopper components of the apparatus of Pig. 1; Pig. 7 shows an enlarged side view of a cooling drum component of the apparatus of Pig.

Pig. 8 illustrates an elevated side view of a thermal power head component of the apparatus of Pig. 1; Pig. 9 depicts an elevated side view of support and cleaning roller component(s) of the apparatus of Pig. 1; WO 2020/060969 PCT/US2019/051400 Fig. 10 demonstrates an elevated side view of the straightening roller cornponent(s) of the apparatus of Fig. 1 ; and Fig. 11 displays a schematic overview of the welding pattems capable of being produced a by the apparatus of F ig. 1.

DETAILED DESCRIPTION OF THE PREFERREDEMBODIMENT AND OPERATION OF THE INVENTION For a better understanding of the invention and its operation, turning now to thedrawings, Figs. 1-10 illustrate the preferred plate apparatus 10 including conveyor assembly 11supporting ground members 12, hopper assemblies 13 and 14, wire feeder assembly 15, andstraightener assembly 16 that combine in whole or in part to overlay metal plate 101 with weld metal in a variety of pattems as illustrated in Fig. 11.

As shown in Figs. l-3, conveyor assembly 11 preferably defines a plurality of legs 17each that may vertically displace upwardly or downwardly as may be desirable for a specificoperation. One embodiment of conveyor 11 is further divided into a first orfront portion 18 anda second or rear conveyor portion 19, with a third or central frame portion 20 positioned in-between the first and second conveyor portions, respectively. One or more cylindrical rollers 21are preferably rotatably affixed between opposingly oriented frame members 22, 22" andconfigured so as to support embodiments of base metal plate 101 entering or exiting preferredapparatus 10 as seen by dírectional arrowsin Fig. 2. In one embodiment, frame members 22, 22"are spaced so as to accommodate up to an eight (8) foot by twenty (20) foot plate of A-36 steelthereon. As previously stated, legs 17 are verticallyidisplaceable, so as to accommodate thepreferred feed speed, angle, and thickness of base metal plate 101 into the central portion 20 ofconveyor assembly ll. Although not intended as a limitation of the instant invention, oneembodiment of leg 17 includes mounting bracket 23 attached to powered ram 24 that is sized, shaped, and otherwise configured to vertically adjust the height of the conveyor assembly with which it is associated, such as by pneumatics, hydraulics or otherwise as is known in the art, to WO 2020/060969 PCT/US2019/051400 properly orient camber of plate during cladding. Although not illustrated, one or more sensors incommunication with control logic 25 can determine the desired oríentation and configuration of one or more parts of conveyor 11 and make electronic adjustments accordingly.

As pictured in Figs. 1-2 and 4, ground assembly 12 in the preferred embodiment islocated proximate first conveyor assembly portion 18 at what may be considered the front ofplate apparatus 10. In an embodiment, ground assembly 12 is defined by a plurality of biasedarms 26 in the nature of a leaf spring with ground shoes 27, 27" attached at opposing longitudinalends of respective arms 26. ln the preferred embodiment, ground assembly 12 is verticallyadjustable by virtue of one or more rams 28 mounted within ground frame 29 to accommodate avariety of plate thicknesses. The material of the plate and the thickness thereof are twoimportant variables in the cladding process as described in further detail below. As the thicknessof base plate 101 is determined, rams 28 compress or release arms 26 with the goal of ensuringthat ground shoes 27, 27°, preferably formed from an electrical "eart " ground material such as copper, remain in frictíonal contact with the surface of base plate 101 during its progression through central frame portion 20 of apparatus 10.

Figs. 1-2, 5A and SB illustrate a portion of central conveyorframe portion 20 betweenground assembly 12 and first hopper assembly 13. In addition to conveyor rollers 21, one ormore drive rollers 30 are disposed herein. Preferably larger in diameter than conveyor rollers 21(twelve (12) inches compared to three (3) inches), drive rollers 30 are vertically adjustable toaccommodate and bias a range of thicknesses as defined by base plate 101. ln the preferredembodiment, drive rollers 30 define a camber such that the middle portion of the roller is greaterin terms of diameter than either roller end, resulting in a plate that maintains a consistent,desirable camber angle throughout the cladding process. In the enlarged illustration Fig. SB, atleast one drive roller 30 includes a plurality of annularly disposed cogs 31, either attached to aseparate gear or integrally forrned proximate the terminal ends of one (or more) drive rollers 30.Cogs 31 are ideally sized and shaped to engage within apertures 102 defined at the lateralmargins of base plate 101, in one ernbodirnent defining a two inch diameter. ln one embodiment, one or more sensors (not shown) monitor the advancement of base plate 101, WO 2020/060969 PCT/US2019/051400 communicating with drive rollers 30 to advance base plate 101 at a predetermined rate, forexample one inch or less per second, and more preferably 0.2 inches per indexing event, ameasurement that is determined inpart by the thickness of the plate being clad. As would beunderstood, the indexing event is measured as the time it takes for the wire feeder assemblies 15to make one pass (as described in further detail below), for example a horizontal pass, a verticalpass, a circular pass, or even an interlocking pass. By electronically controlling the rate ofadvancement, and securely engaging base plate 101 via cogs 31 and apertures 102, base plate101 can be maintained in a more planar configuration than known in the prior art, resulting in asuperior cladded plate 101 as described in further detail below. This described mechanism ofadvancement is preferable to anything known in the prior art because it reduces compressionotherwise needed to drive the cladded plate through the rollers and reduces or eliminates slippage in part resulting from the thermal expansion and/or contraction of the plate during the cladding process.

Figs. 1-2 and 6 demonstrate first and second hoppers 13 and 14 in further detail. As baseplate 101 is advanced as described above, the upper surface passes beneath first hopper assembly13, preferably in the nature of an open-ended box 32 disposed between one or more rakes 33. Inan embodiment, rakes 33 are defined as screen members that are vertically adjustable toaccommodate a wide range of thicknesses defined by base plate 101. Rakes 33 horizontallyscreen the top surface of base plate 101 as it receives the first layer of media (not shown) storedwithin first hopper 13, in the preferred embodiment a powderized metal composition such aschromium, iron, niobium, titanium, nickel, manganese, tungsten, boron, sulfur, carbon,phosphorus, copper, and combinations thereof. By horizontally raking the media surface as plate101 moves in the horizontal direction, a consistent media thickness and planar shape to achievethe nominal manufactured total thickness of the finalized cladded plate. iSimilarly, secondhopper assembly 14 is preferably defined as an open-topped box 34 disposed between rakes 35.Like rakes 33, rakes 35 are defined as screen members that are vertically adjustable toaccommodate a wide range of thicknesses defined by base plate 101 and horizontally screen thetop surface of base plate 101 as it receives the second layer of media (not shown), stored within second hopper 14, in the preferred embodiment a powderized insulation composition such as WO 2020/060969 PCT/US2019/051400 silica (i.e. sand)g(but may also contain other materials such as lime, calcium fluoride, manganeseoxide and other compounds) to reduce or eliminate the amount of oxygen present during thesubmerged arch welding process to follow. In an embodiment, first and second hopperassemblies 13 and 14 are movably mounted to an outer wall of plate apparatus 10, facilitatinglongitudinal and/or lateral displacement relative to base plate 101 as it moves horiztontallythrough apparatus 10. In the preferred embodiment, this displacement takes the form of slidingbackwards and forwards as well as moving up or down to account for plate and media thickness,rnaintaining the consistency of the media as described above. Preferably, _a rotational valveextends across the vertical length of one or both hopper assemblies 13, 14 which may control thedischarge rate of the affiliated media. Supporting base plate 101 as it travels beneath hopperassemblies 13 and 14 is preferably a cambered drive support roller that is vertically adjustable,either mechanically or via control logic 25. This support roller defines a camber to aid in themaintenance of the uniformity of the media thickness, specifically the first media thickness. Inthe preferred embodiment, this support roller evens the cambered load before the metal thermal fusion process and any contemporaneous and/or subsequent cooling as described in further detail below.

Figs. 1-2 and 7-8 illustrate various aspects of wire feeder assembly 15 and cooling drum36, preferably disposed in line vertically with one another within plate apparatus 10. In oneembodiment, a plurality of wire feeders are disposed above cooling drum 36, and in the preferredembodiment the number of wire feeder assemblies 15 is nurnbered at twenty-four (24). Unlikethe prior art that relies on a single control shaft to govern all wire feeders, preferred wire feederassemblies 15 have individual motor clearances and are oriented vertically with a lateral distancebetween respective wire feeder assemblies 15 of four inches or less. In one embodiment, eachwire feeder assembly 15 defines a power head 37 configured to receive and utilize direct current(DC) flow sufficient to render molten the metallized media carried by base plate 101, and in thepreferred embodiment each power head 37 is configured to handle at least 1000 amps (lk amps)per power head 37. Embodiments of plate apparatus 10, and specifically control logic 25, mayoperate all wire feeder assemblies 15 simultaneously, or predetermined groupings may be operated in sequence, for example a group of four (4) wire feeder assemblies 15 start before a 11 WO 2020/060969 PCT/US2019/051400 second, third, fourth, fifth, and sixth grouping of four (4) Wire feeder assemblies 15. Eachassembly 15 is ipreferably independently driven by a dedicated motor With a Wire speed encoderto maintain speed for the amps utilized and signal the Wire spool drive motors as the Wire is continuously consumed. ln the preferred embodiment, each of the Wire feeder assemblies 15 ' further comprises a gear-driven, individual filler, metal feed unit that is liquid- or gas-cooled that is configured to supply voltage and current through the insulating media and through the metallic powder to create a metallurgical fusion bond With the base metal plate 101, resulting in oneembodiment forming chromium carbide that eventually groWs out of the fused and cooled poWder mixture. In one preferred embodiment, each Wire feeder assembly 15 is individually controlled by control logic 25, and every other Wire feeder assembly 15 in the group of tWenty- four (24) is configured (i.e. sized, shaped, and oriented) for a transverse "scissor" type motion as i base plate 101 is advanced therebeneath. Coupled With the horizontal motion of base plate 101,this oscillating backWards, forwards, and lateral movement(s) in a multi-axis rotation createsdesirous Welding patterns in the surface of base plate 101 that have, heretofore, beenunachievable in the prior art (see Fig. 11 for some non-limiting examples of the patternsachieved by the instant apparatus). As previously noted, an indexing measurement is responsiblefor the longitudinal advancement of plate 101, deterrnined in large part on the lateral, transverse,or other motion of the Wire feeder assemblies as described above. In one embodiment, it takesapproximately ten seconds for each Wire feeder assembly 15 to lay doWn its predeterminedpattern of Weld, based on varíables including (but not limited to) plate thickness, Wire type,and/or matric media depth. Embodiments of apparatus 10 may even produce overlapping orinterlocking Weld patterns, fused into base plate 101 and cooled to produce a planar, unbeaded, hardened metal plate 1 10. « In order to produce the desirable hardened plates described above, the reaction mustinclude Welding at extremely high temperatures, but the temperatures must be checked or thematerial is rendered too molten and fails to bond to the base plate 101 or may become too brittleand crack. Therefore, sophisticated temperature control and measurement, for example includingthe use of one or more carbon sensors (not shoWn), is preferred to ensure that a substantial fusion bonding event takes place. In one embodiment, the temperature of base plate 101 during the 12 WO 2020/060969 PCT/US2019/051400 fusion process is controlled from beneath base plate by virtue of cooling drum 36. In thepreferred embodiment, cooling drum 36 is a 36-inch diameter, perforated cylindrical memberwith one or more spray bar(s) 38 plumbed therein. One embodiment includes a plurality ofdiamond shaped apertures formed in the surface of cooling drum 36 to perrnit Water to exitsubstantially the entire length of the drum, and the one or more spray bar(s) 38 may be angled orbiased to distribute water in View of the same. One or more embodiments may hold coolingdrum 36 in a water bath when not in use, facilitating a water-cooled surface when the claddingprocess is taking place. As the fusion process takes places, one or more temperature sensors (notshown) monitor Variables including, but not limited to, the temperature of the base plate and thetemperature of the fusion material. ln the event the temperature grows too hot, control logic 25engages the one or more spray bars 38, to spray air or Water into the perforated cylinder fortransference to the bottom surface of base plate l0l, cooling it throughout and facilitating arobust metallurgícal fusion bonding, instead of attempting to direct the water to the bottom platesurface through ribs, discs, or the like as taught in the prior art (see for example, the Kosteckipatent cited above). This prevents a creasing or buckling of the plate at high temperatures that issolVed With plate apparatus 10. In certain embodiments, the one or more spray bars 38 are in afixed position relative to cooling drum 36; in other embodiments, the one or more spray bars 38rotate or oscillate with rotating drum 36. Also within the purview of control logic 25 ís therotational speed of drum 36 and the pressure of the expelled fluid, and in one embodiment theone or more spray bars 38 are configured With Variable pressure outlets. A plurality of sensorsand infrared beam(s) (not shown) monitor the rate of plate 101 as well as the depth andsmoothness of media applied to the surface of plate 101, reporting this data back to control logic25.

Embodiments of cleaner roller(s) 39, therrnal roller(s) 40, straightener roller(s) 41, andexit roller(s) 42 that make up third conveyor portion 20 are demonstrated in Figs. 8, 9, 10. Inone embodiment, some or all off rollers 40, 41, and 42 are twelye inches in diameter. As plate101, newly minted with a hardened treatment such as chromium carbide, moves beyond power heads 37, an excess of material may build up on the plate that is undesirable or otherwise detrimental either to the plate or plate apparatus 10. ln one embodiment, one or more cleaner 13 WO 2020/060969 PCT/US2019/051400 rollers 39 are defined as a slag cracking Wheel Which comprises a plurality of annular discs fitted ~ _ onto a central boss and Which are run onto the Weld surface of the metal arc of welding Whichcauses any slag on the surface to crack. The cracked slag is drawn by means of a vacuumsuction arrangement before the slag cracking Wheel, after the slag cracking Wheel, or both.Embodiments of thermal roller(s) 40 may be interspersed With cleaner roller(s) 39 or may bepositíoned thereafter. Thermal rollers 40 preferably include temperature modifying componentstherein, for example to temper the temperature differential between the Welding heads 37 and theambient air to prevent cracking, or to slowly cool the newly Welded plates. In one iteration,thermal rollers 40 are comprised of liquid or gas-cooled rollers sized, Shaped, and otherwiseconfigured to pass the hardened plate therebetWeen. Straightener roller(s) 41 may take a varietyof forms, but one preferred embodiment includes a plurality of roller cylinders positioned aboveand below conveyor 11, With at least the upper roller embodirnents biased in the downwarddirection (for example by tensioner members, hydraulic pressure, or the like), applying pressureto the plate to confirm that it is maintained in the straightest possible configuration. One or moresensors (not shown), for example infrared beam detection, may be used to confirm the planarnature of the plate, and if minute, undesirable curvature is detected, these sensors may reportback to control logic 25 and Variations in the pressure exerted by rollers 41 may be effectuated.For example, the plus/minus calibration of the pressure or pressures exerted by Straightenerrollers 41 may be modified by control logic 25, resulting in a hardened finished plate 110 that ismaintained in the preferred orientation during cooling, further resulting in a more consistent plateproduction than known in the prior art. As finished plate 110 moves out of cleaner roller(s) 39,thermal roller(s) 40, and straightener roller(s) 41, it may be desirable to separate, divide, orotherwise cut the hardened plates into smaller sizes. Therefore, embodiments of plate apparatus10 may including a cutting member, in the preferred embodiment of plasma cutting torch (notshown) capable of cutting the hardened plate into any size, shape, or repeated width and/orlength as deterrnined by control logic 25. Additional features may include etching the plate Withidentifying information such as time, date, location, manufacturer, lot/batch numbers or the like,allowing for unparalleled consistency in the production of highly capable hardened metal members. 14 WO 2020/060969 PCT/US2019/051400 A method of manufacturing a hardened metal plate is also disclosed, including the step ofproviding preferred plate apparatus 10 as described above. One or more cylindrical rollers 21 arepreferably rotatably affixed between opposingly oriented frame members 22, 22" and configuredso as to support embodiments of base metal plate 101 entering or exiting preferred apparatus 10,in the preferred embodiment an 8 x 20 ft. plate of A36 steel. One embodiment of legs 17includes mounting bracket 23 attached to powered ram 24 that is sized, shaped, and otherwiseconfigured to vertically adjust the height of the conveyor assembly 11 with which it is associatedvia control logic 25. A ground assembly 12 is defined by a plurality of biased arms 26 in thenature of a leaf spring with a ground shoe 27, 27" attached at opposing longítudinal ends ofrespective arms 26 to contact base plate 101 to prevent electrical shock risk. One or moreapeitures 102 are formed within plate 101 to accommodate a plurality of annularly disposed cogs31, either attached to a separate gear or integrallyfforrned proximate the terminal ends of one (ormore) drive rollers 30 in order to advance plate 101 without slippage, preferably advancing plate101 at a rate of 0.2 inches per second through central frame portion 20. Plate 101 advancesunderneath the first of two hoppers, with a horizontally screen across the top surface of baseplate 101 as it receives the first layer of media stored within first hopper 13, in the preferredPlate 101 then advances under the second of two hoppers, with rakes 35 defined as screen members that are embodiment a powderized metal composition such as chromium or iron. vertically adjustable to accommodate a wide range of thicknesses defined by base plate 101 andhorizontally screen the top surface of base plate 101 as it receives the second layer of media,stored within second hopper 14, in the preferred embodiment a powderized insulationcomposition such as silica. Base plate 101 moves along to a plurality of preferred wire feederassemblies 15 which are oriented vertically with a lateral distance between respective wire feederassemblies 15 of four inches or less. ln one embodiment, each wire feeder assembly 15 defines apower head 37 configured to receive and utilíze direct current (DC) flow sufficient to rendermolten the metallized media carried by base plate 101, and in the preferred embodiment eachpower head 37 is configured to handle at least 1000 amps (lk amps) per power head 37. Heads37 weld a predeterrnined pattern into the surface of plate 101, including but not limitedto thepatterns displayed in Fig. 11. The temperature of base plate 101 during the fusion process is controlled from beneath base plate 101 by virtue of cooling drum 36. In the preferred WO 2020/060969 PCT/US2019/051400 embodiment, cooling drum 36 is a perforated cylindrical member with oneor more spray bar(s) f 1 a 38 plumbed therein. As the fusion process takes places, one or more temperature sensors (notshown) monitor variables including, but not limited to, the temperature of the base plate and thetemperature of the fusion material. In the event the temperature grows too hot, control logic 25,engages the one or more spray bars 38, to spray air or water into cooling drum 36 fortransference to the bottom surface of base plate lOl, cooling it throughout and facilitating arobust metallurgical fusion bonding. As plate lOl moves beyond power heads 37, an excess ofmaterial may build up on the plate that is undesirable or otherwise detrimental either to the plateor plate apparatus 10 and can be removed by a slag cracking Wheel which comprises a pluralityof annular discs fitted onto a central boss and which are run onto the weld surface of the metalarc of welding Which causes any slag on the surface to crack. Thermal rollers 40 receive thehardened plate and include temperature modifying components therein, for example to temperthe temperature differential between the welding heads 37 and the ambient air to preventcracking, or to slowly cool the newly welded plates, all while being monitored by additionalsensors in communication with control logic 25. Straightener roller(s) 4l may take a variety offorms, but one preferred embodiment includes a plurality of plates positioned above and belowconveyor ll, with at least the upper roller embodiments biased in the downward direction (forexample by tensioner members, hydraulic pressure, or the like), applying pressure to the plate toconfirm that it is maintained in the straightest possible configuration, again monitored by one ormore sensors communicating with control logic 25. As desired, a, cutting member, in thepreferred embodiment of plasma cutting torch (not shown) may cut the hardened plate into anysize, shape, or repeated width and/or length as detennined by control logic 25. Additional stepsmay include etching the plate with identifying information such as time, date, location,manufacturer, lot/batch numbers or the like, allowing for unparalleled consistency in the production of highly capable hardened metal members.

The illustrations and examples provided herein are for explanatory purposes and are not intended to limit the scope of the appended claims. 16

Claims (20)

1. WO 2020/060969 PCT/US2019/051400 I claim: a a An apparatus configured to produce fused overlay plates comprising a eonveyor assembly configured to receive and transport a metal plate through theapparatus, at least one hopper assembly configured to distribute a first layer of a mediastored within the at least one hopper assembly onto a surface of the metal plate, a plurality of wire feeder assemblies, each Wire feeder assembly including apower head configured to handle at least 1000 amps, and control logic in communication with the conveyor assembly, the at least onehopper assembly, and the plurality of wire feeder assemblies, whereby the plurality of wire feeder assemblies render molten the media carried by the metal plate, producing a hardened treatment thereon. The apparatus of claim 1 wherein the eonveyor assembly further comprises one or morecylindrical rollers rotatably affixed between opposingly oriented frame members and configured so as to accommodate an eight foot by twenty foot metal plate thereon. The apparatus of claim 1 Wherein the eonveyor assembly further comprises a plurality oflegs, each leg including a mounting bracket attached to a powered ram, each leg configured to vertieally adjust a height of the eonveyor assembly. The apparatus of claim l further comprising a ground assembly in communication with the metal plate. The apparatus of claim 4 Wherein the ground assembly is defined by a plurality of biasedarms, each biased arm in the nature of a leaf spring with a ground shoe attached atopposing longitudinal ends of each biased arm, the ground shoes in contact with the metal plate. 17 10» 10. 11. 1

2. 1

3. WO 2020/060969 PCT/US2019/051400 The apparatus of clairn l Wherein the conveyorfassembly comprises at least one driveroller including a plurality of annularly disposed cogs, either attached to a separate gearor integrally formed “proximate the terminal ends of the at least one drive roller, andWhereby the metal plate defines a plurality of apertures sized and shaped to receive theplurality of annularly disposed cogs therein to advance the metal plate along the conveyor assembly. The apparatus of claim l, Wherein the at least one hopper assembly is defined as first andsecond hopper assemblíes, each assembly including an open-ended box disposed between one or more rakes. The apparatus of claim 7, Wherein the first hopper assembly distributes a powderized metal and the second hopper assembly distributes silica. The apparatus of claim l Wherein the plurality of Wire feeder assemblíes are orientedvertically With a lateral distance between respective Wire feeder assemblíes of four inches or less. The apparatus of claim 9 Wherein the plurality of Wire feeder assemblíes define a total number of Wire feeder assemblíes as tWenty-four.The apparatus of claim 10, Wherein each Wire feeder assembly is individually controlledby the control logic, and every other Wire feeder assembly is configured for a transverse “scissor” type motion as the metal plate is advanced therebeneath. The apparatus of claim 10, Wherein the control logic predeterrnines Wire feeder assembly groups and operates said predeterrníned assembly groups in sequence. The apparatus of claim 1 further comprising a cooling drum positioned beneath the plurality of Wire feeder assemblíes. 18 1

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9. 20. WO 2020/060969 PCT/US2019/051400 The apparatus of claim 13, Wherein the cooling drum is defined as a perforated cylindrical member With one or more spray bar(s) plumbed therein. The apparatus of claim 14, Wherein the one or more spray bar(s) are in a fixed position relative to the Cooling drum. The apparatus of claim 14, Wherein the one or more spray bar(s) rotate With the cooling drum. The apparatus of claim l further comprising a cleaner roller configured to crack and remove excess slag from the metal plate and apparatus. The apparatus of claim l further comprising a therrnal roller to temper a temperature differential between the plurality of Wire feeder assemblies and ambient air. The apparatus of claim l further comprising a pluralíty of straightener rollers configured to maintain the metal plate in the straightest possible configuration. The apparatus of claim 19, Wherein the plurality of straightener rollers include at least an upper roller biased in a doWnWard position. 19