High pressure heat treatment system

Abstract

A furnace for heat treating a metal workpiece is provided. A method and system for processing a workpiece also are provided.

1 . A furnace for heat treating a workpiece, comprising;
 at least one high pressure heating zone including at least one fluid impingement device capable of directing a heated fluid medium at a workpiece within the furnace, wherein the fluid impingement device is less than about 6 inches from the workpiece.   
     
     
         2 . The furnace of  claim 1 , wherein the fluid impingement device is less than about 4 inches from the workpiece. 
     
     
         3 . The furnace of  claim 1 , wherein the fluid impingement device is about 2 inches from the workpiece. 
     
     
         4 . The furnace of  claim 1 , wherein at least one of the fluid impingement device and the workpiece is capable of oscillating at a predetermined interval. 
     
     
         5 . The furnace of  claim 1 , wherein the fluid impingement device is capable of directing the heated fluid medium at the workpiece at about 4,000 feet per minute. 
     
     
         6 . The furnace of  claim 1 , further comprising at least one of a rotating mechanism for rotating the workpiece and a gripping mechanism for inverting the workpiece. 
     
     
         7 . The furnace of  claim 1 , further comprising at least one soak zone including an air recirculation system downstream from the high pressure heating zone. 
     
     
         8 . A furnace for heat treating a workpiece, comprising:
 at least one high pressure heating zone including at least one fluid impingement device capable of delivering a heated fluid medium at from about 4,000 to about 40,000 feet per minute; and   at least one soak zone including an air recirculation system.   
     
     
         9 . The furnace of  claim 8 , wherein the fluid impingement device is capable of delivering a heated fluid medium at from about 8,000 to about 12,000 feet per minute. 
     
     
         10 . The furnace of  claim 8 , wherein at least one of the fluid impingement device and the workpiece is capable of oscillating at a predetermined interval. 
     
     
         11 . The furnace of  claim 8 , wherein the impingement device is a nozzle supplied by a channeling duct system. 
     
     
         12 . The furnace of  claim 8 , further comprising at least one of a rotating mechanism for rotating the workpiece and a gripping mechanism for inverting the workpiece. 
     
     
         13 . A system for processing a metal workpiece, comprising:
 a heat treatment station including a furnace, the furnace comprising at least one high pressure heating zone including at least one fluid impingement device capable of directing a heated fluid medium at a workpiece within the furnace; and   a quench station downstream from the heat treatment station.   
     
     
         14 . The system of  claim 13 , further comprising a process control temperature station positioned upstream from the heat treatment station, the process temperature control station including a temperature sensing device in communication with a heat source, wherein the temperature sensing device and the heat source communicate to maintain the temperature of the workpiece at or above a process control temperature for the metal of the workpiece. 
     
     
         15 . The system of  claim 14 , wherein the process control temperature is the temperature below which for every one minute of time the temperature of the workpiece decreases, more than one minute of additional heat treatment is required to attain the desired properties of the workpiece. 
     
     
         16 . The system of  claim 13 , the furnace including an entry zone for the workpiece;
 a temperature measuring device within the entry zone; and   a transfer mechanism in communication with the temperature measuring device,   wherein upon detection of a rejection temperature by the temperature measuring device, the transfer mechanism removes the workpiece prior to entry into the furnace.   
     
     
         17 . The system of  claim 13 , further comprising a sand reclamation system including:
 a chamber including an inlet, an outlet, and a plurality of baffles defining a circuitous path for the sand therebetween;   a heating element for providing heat to the chamber; and   a fluidizing air distributor for urging the sand through the chamber.   
     
     
         18 . A method of processing a workpiece, comprising:
 forming a workpiece from at least one of a metal and a metal alloy; and   impinging the workpiece with a heated fluid medium at a velocity of at least about 4,000 feet per minute from a distance of less than about 6 inches.   
     
     
         19 . The method of  claim 18 , further comprising continuously maintaining the formed workpiece at or above a process control temperature prior to impinging the workpiece with the heated fluid medium, where the process control temperature is defined as the temperature below which, for every one minute of time the temperature of the workpiece decreases, more than one minute of additional heat treatment is required to attain the desired properties of the workpiece. 
     
     
         20 . The method of  claim 18 , further comprising at least one of rotating and inverting the workpiece while impinging the workpiece with the heated fluid medium.