Steel-shelled ceramic spacer block

Abstract

A spacer member for supporting a metallic alloy product during heat treatment comprising a ceramic core and a tubular housing is disclosed. The tubular housing, which encloses the ceramic core, comprises a bore, a wall portion, and two end portions. In order to resist deformation during usage, the tubular housing is made from high temperature steel, a high temperature steel alloy, or cold rolled steel. The wall portion has at least two substantially flat surfaces having corner edges that have a radius of at least ⅜ inch and ends that are tapered at least ¼ inch. In addition, the flat surfaces also have a coating that reduces the sticking of a metallic alloy product. The end portions each have at least one aperture to allow the inside to adjust itself to ambient atmospheric pressure. A method of making a spacer member is also disclosed.

1 . A spacer member for supporting a metallic alloy product during heat treatment, said spacer member comprising: 
 a ceramic core; and    a tubular housing comprising a wall portion, a bore defined by said wall portion that is structured to receive said ceramic core, and two end portions, said housing enclosing said ceramic core, said housing wall portion having at least two substantially flat surfaces in parallel with each other, said flat surfaces having corner edges having a radius of at least ⅜ inch and ends being tapered at least ¼ inch inward toward said bore of said tubular housing, said end portions each having at least one aperture.    
   
   
       2 . A spacer member of  claim 1  wherein said flat surfaces have a non-stick coating comprising a thermal oxide of nickel.  
   
   
       3 . A spacer member of  claim 2  wherein said non-stick coating consists of nickel aluminide.  
   
   
       4 . A spacer member of  claim 2  wherein said non-stick coating has a thickness of from about 5 nm to about 50 microns.  
   
   
       5 . A spacer member as in  claim 1  wherein said tubular housing comprises a metal selected from the group consisting of a high temperature steel, a high temperature steel alloy, or a cold rolled steel.  
   
   
       6 . A spacer member as in  claim 1  wherein said aperture of said end portion is from about 1/64 inch to about 1/16 inch in diameter.  
   
   
       7 . A spacer member for supporting a metallic alloy product during heat treatment, said spacer member comprising: 
 a ceramic core; and    a tubular housing comprising a wall portion, a bore defined by said wall portion that is structured to receive said ceramic core, and two end portions, said housing enclosing said ceramic core, said housing wall portion having at least two substantially flat surfaces in parallel with each other, said flat surfaces having corner edges having a radius of at least ⅜ inch and ends being tapered at least ¼ inch inward toward said bore of said tubular housing, said end portions each having at least one aperture, said flat surfaces having a non-stick coating comprising a thermal oxide of nickel.    
   
   
       8 . A spacer member of  claim 7  wherein said non-stick coating consists of nickel aluminide.  
   
   
       9 . A spacer member of  claim 7  wherein said non-stick coating has a thickness of from about 5 nm to about 50 microns.  
   
   
       10 . A spacer member as in  claim 7  wherein said tubular housing comprises a metal selected from the group consisting of a high temperature steel, a high temperature steel alloy, or a cold rolled steel.  
   
   
       11 . A spacer member as in  claim 7  wherein said aperture of said end portion is from about 1/64 inch to about 1/16 inch in diameter.  
   
   
       12 . A method of making a spacer member for supporting a metallic alloy product during heat treatment, said method comprising the steps of: 
 providing a tubular housing comprising a bore and a wall portion having at least two substantially flat surfaces in parallel with each other, said flat surfaces having corner edges and ends;    tapering said ends at least ¼ inch inward toward said bore of said tubular housing;    attaching an end portion comprising at least one aperture to one of said ends of said flat surfaces;    filling the tubular housing with a ceramic material;    attaching another of said end portions comprising at least one aperture to another of said ends of said flat surfaces; and    applying to said flat surfaces of said wall portion a non-stick coating for preventing sticking of a heat treated metallic alloy product to said spacer member.    
   
   
       13 . The method of  claim 12  further comprising subjecting said tubular housing to a high temperature heating step after applying said non-stick coating wherein said tubular housing is held at an elevated temperature of from about 800 degrees F. to about 1200 degrees F. (427°-649° C.).  
   
   
       14 . The method of  claim 12  wherein tapering said ends comprises cutting said ends along said corner edges and tapering said ends via the use of a tapering means.  
   
   
       15 . The method of  claim 14  wherein said tapering means comprises a break or radius forming jig.  
   
   
       16 . The method of  claim 12  wherein said tubular housing comprises a metal selected from the group consisting of a high temperature steel or steel alloy or cold rolled steel.  
   
   
       17 . The method of  claim 12  wherein said non-stick coating comprises a thermal oxide of nickel.  
   
   
       18 . The method of  claim 12  wherein said non-stick coating consists of nickel aluminide.  
   
   
       19 . The method of  claim 12  wherein said non-stick coating has a thickness of from about 5 nm to about 50 microns.  
   
   
       20 . The method of  claim 12  wherein said aperture of said end portion is from about 1/64 inch to about 1/16 inch in diameter.  
   
   
       21 . The method of  claim 12  wherein said flat surfaces have corner edges having a radius of at least ⅜ inch.  
   
   
       22 . A method of making a spacer member for supporting a metallic alloy product during heat treatment, said method comprising the steps of: 
 providing a tubular housing comprising a bore and a wall portion having at least two substantially flat surfaces in parallel with each other, said flat surfaces having corner edges and ends;    tapering said ends at least ¼ inch inward toward said bore of said tubular housing,    wherein said ends are cut along said corner edges and tapered via the use of a tapering means;    attaching an end portion having at least one aperture to one of said ends of said flat surfaces;    filling the tubular housing with a ceramic material;    attaching another of said end portions comprising at least one aperture to another of said ends of said flat surfaces; and    applying to said flat surfaces of said wall portion of said tubular housing a non-stick coating for preventing sticking of a heat treated metallic alloy product to said spacer member,    wherein said tubular housing is held at an elevated temperature of from about 800 degrees F. to about 1200 degrees F. (427° C.-649° C.) after applying said non-stick coating.    
   
   
       23 . The method of  claim 22  wherein said tapering means comprises a break or radius forming jig.  
   
   
       24 . The method of  claim 22  wherein said tubular housing comprises a metal selected from the group consisting of a high temperature steel or steel alloy or cold rolled steel.  
   
   
       25 . The method of  claim 22  wherein said non-stick coating comprises a thermal oxide of nickel.  
   
   
       26 . The method of  claim 22  wherein said non-stick coating consists of nickel aluminide.  
   
   
       27 . The method of  claim 22  wherein said non-stick coating has a thickness of from about 5 nm to about 50 microns.  
   
   
       28 . The method of  claim 22  wherein said aperture of said end portion is from about 1/64 inch to about 1/16 inch in diameter.  
   
   
       29 . The method of  claim 22  wherein said flat surfaces have corner edges having a radius of at least ⅜ inch.