Gusseted rotary spinners for producing fiber from molten material

Abstract

Rotary spinner apparatuses, systems and methods for producing fibers from molten materials are disclosed. Certain exemplary embodiments include substantially net shape single pattern rotary spinner castings that include gussets extending radially inward from a side wall and axially upward form a lower wall to an upper wall. A dispenser may be structured to supply molten material in a downward direction through a hollow interior of the casting to the lower wall. A plenum may be structured to direct elevated temperature gas toward an exterior surface of the casting.

What is claimed is: 
     
         1 . A centrifugal spinner apparatus for producing fibers from molten material comprising:
 a substantially net-shaped single-pattern casting including a base extending radially outward to a substantially circular periphery extending about a central axis line, a sidewall extending about the circular periphery in an axially upward direction from the base, an upper flange extending radially inward from the sidewall, and a plurality of gussets extending radially inward from the sidewall and extending axially from the base to the upper flange;   wherein the casting defines a plurality of pockets bounded by surfaces of the base, the sidewall, the flange, and respective pairs of the plurality of gussets and opening inwardly to a central structural void, and a plurality of holes are formed through portions of the sidewall bounding the plurality of pockets.   
     
     
         2 . The centrifugal spinner apparatus of  claim 1  further comprising a shaft extending along and rotatable about the central axis line, the shaft being coupled with the base and extending from a side of the base opposite the central structural void. 
     
     
         3 . The centrifugal spinner apparatus of  claim 2  wherein the shaft is coupled with the base by first and second clamping members and wherein the first clamping member contacts the upper surface of the base. 
     
     
         4 . The centrifugal spinner apparatus of  claim 2  further comprising a dispenser structured to direct a stream of molten material in a downward direction through the central structural void to the base. 
     
     
         5 . The centrifugal spinner apparatus of  claim 4  further comprising a plenum structured to direct a stream of elevated temperature gas toward an exterior surface of the side wall in a direction generally parallel to the side wall. 
     
     
         6 . The centrifugal spinner apparatus of  claim 1  wherein the plurality of gussets comprise an odd number of gussets. 
     
     
         7 . The centrifugal spinner apparatus of  claim 1  wherein the radially inward edges of the gussets are substantially perpendicular to the base. 
     
     
         8 . The centrifugal spinner apparatus of  claim 1  wherein the casting is formed of an alloy selected from the group consisting of FSX-414, HS-21, X-45, F-75, and IN-625. 
     
     
         9 . A method comprising:
 producing a net-shaped casting from a single wax pattern, the casting including a lower wall extending in a radial direction to a substantially circular circumference, a sidewall extending in an axial direction from the lower wall, an upper flange extending in a radially inward direction from the sidewall, and a plurality of gussets extending in a radially inward direction from the sidewall and in an axially upward direction from the lower wall to the upper flange;   forming a plurality of holes through the sidewall of the casting;   attaching the casting to a rotatable member; and   introducing molten material into the central void of the casting while rotating the casting with the rotating member effective to cause the molten material to flow through the plurality of holes to produce a plurality of fibers.   
     
     
         10 . The method of  claim 9  wherein the lower wall of the casting contacts a portion of the rotatable member. 
     
     
         11 . The method of  claim 10  wherein the molten material is introduced to a central structural void of the casting by a dispenser positioned on a side of the casting opposite the lower wall. 
     
     
         12 . The method of  claim 9  further comprising attaching the casting to the rotatable member with fastening members that contact the upper surface of the lower wall of the casting. 
     
     
         13 . The method of  claim 9  further comprising directing a stream of elevated temperature gas at the exterior surface of the sidewall of the casting. 
     
     
         14 . The method of  claim 13  wherein the stream of elevated temperature gas flows in a direction generally parallel to the sidewall of the casting. 
     
     
         15 . The method of  claim 13  wherein a first portion of the casting is heated to a temperature of at least 2000 degrees F. by at least one of the stream of elevated temperature gas and the molten material. 
     
     
         16 . The method of  claim 15  wherein the first portion of the casting is located in the side wall. 
     
     
         17 . The method of  claim 15  wherein the first portion of the casting is located at the intersection of the side wall and the upper flange. 
     
     
         18 . The method of  claim 15  wherein a second portion of the casting is heated to a temperature of at most 900 degrees F. by at least one of the stream of elevated temperature gas and the molten material. 
     
     
         19 . The method of  claim 18  wherein the second portion of the casting is located in the lower wall. 
     
     
         20 . A system comprising:
 a shaft extending along and being rotatable about an axis;   a spinner having a lower wall extending outwardly relative to the axis, a side wall extending upwardly from the lower wall, an upper wall extending inwardly from the side wall, and a plurality of gussets extending inwardly from the side wall and extending upwardly from the lower wall to the upper wall, a plurality of extrusion holes being defined in the side wall, the lower wall being coupled with the shaft, the spinner defining a plurality of pockets bounded by surfaces of the lower wall, the side wall, the upper wall, and respective pairs of the plurality of gussets and opening inwardly to a hollow interior;   a dispenser structured to supply molten material in a downward direction through the hollow interior to the lower wall; and   a plenum structured to direct elevated temperature gas toward an exterior surface of the spinner.   
     
     
         21 . The system of  claim 20  wherein the plurality of gussets comprise at least six gussets. 
     
     
         22 . The system of  claim 20  wherein the gussets are substantially perpendicular to the lower wall. 
     
     
         23 . The system of  claim 20  wherein the spinner comprises a substantially net-shaped casting. 
     
     
         24 . The system of  claim 23  wherein the casting is a single pattern casting. 
     
     
         25 . The system of  claim 23  wherein the casting consists essentially of one of a Co-based alloy and a Ni-based alloy. 
     
     
         26 . The system of  claim 23  wherein the casting is formed of an alloy selected from the group consisting of FSX-414, HS-21, X-45, F-75, and IN-625. 
     
     
         27 . The system of  claim 23  wherein the a plurality of extrusion holes are formed by drilling into the casting.