Cooling systems for heat-treated parts and methods of use

Abstract

Systems for cooling a heat-treated metallic part include a plurality of atomization nozzles disposed on a stage and radially disposed about the part to be cooled; and a fluid in fluid communication with the atomization nozzles. The fluid may gas, liquid, or a combination thereof, e.g., water and gas. During use, the atomization nozzles are generally configured to rapidly cool the thicker sections of the part relative to the thinner section since the thicker sections are generally slower to cool. In some embodiments, the stage can be configured to rotate about the part during cooling.

what is claimed is: 
     
         1 . A system for cooling a heat-treated metallic part, comprising:
 a housing configured to hold the heat-treated metallic part;   an upper shroud assembly comprising at least one sub-assembly coupled to the housing comprising an annular-shaped body, at least two annular channels disposed within the annular shaped body, a cover attached to the annular shaped body including at least two fluid inlets for receiving a fluid source, and a plurality of atomization nozzles annularly arranged on an outer surface of the annular shaped body comprising outlets oriented to discharge atomized fluid at the metallic part, wherein the at least two fluid inlets are in fluid communication with the atomization nozzles via the at least two annular channel; and   a lower shroud assembly comprising at least one sub-assembly coupled to the housing comprising an annular-shaped body, at least two annular channels disposed within the annular shaped body, a cover attached to the annular shaped body including at least two fluid inlets, and a plurality of atomization nozzles annularly arranged on an outer surface of the annular shaped body comprising outlets oriented to cool the metallic part, wherein the at least two fluid inlets are in fluid communication with the atomization nozzles via the at least two annular channels;   wherein the at least two inlets in the upper and lower shroud assemblies are in fluid communication with at least one liquid source and at least one gas source such that each one of the plurality of atomization nozzles are in fluid communication with the at least one liquid source and the at least one gas source produce an atomized fluid discharge when in use.   
     
     
         2 . The system of  claim 1 , wherein the heat-treated metallic part is substantially circular in shape with radial cross-sections having complex geometries and varying thickness across a diameter of the part. 
     
     
         3 . The system of  claim 1 , wherein the at least one subassembly of the upper shroud comprises a first subassembly, wherein the outlets of the plurality of atomization nozzles are oriented to discharge the discharge atomized fluid along a y-axis; a second subassembly, wherein the outlets of the plurality of atomization nozzles are oriented to discharge the discharge atomized fluid along a z-axis; and a third subassembly, wherein the outlets of the plurality of atomization nozzles are oriented to discharge the atomized fluid along an x-axis, wherein the y-, z-, and x-axes are relative to ground, and wherein the annular shaped body of the first subassembly has a smaller diameter than a diameter of the annular shaped body of the second subassembly, and the second subassembly diameter is smaller than a diameter of the annular shaped body of the third subassembly; and
 wherein the at least one subassembly of the lower shroud comprises a first subassembly, wherein the outlets of the plurality of atomization nozzles are oriented to discharge the discharge atomized fluid along a y-axis; and at least one second subassembly, wherein the outlets of the plurality of atomization nozzles are oriented to discharge the discharge atomized fluid along a z-axis, wherein the y- and z-axes are relative to ground, and wherein the annular shaped body of the first subassembly has a smaller diameter than a diameter of the annular shaped body of the second subassembly.   
     
     
         4 . The system of  claim 1 , wherein the at least one subassembly of the upper shroud comprises a first subassembly, wherein the outlets of the plurality of atomization nozzles are oriented to discharge the discharge atomized fluid along a y-axis; a second subassembly, wherein the outlets of the plurality of atomization nozzles are oriented to discharge the discharge atomized fluid a z-axis; and a third subassembly, wherein the outlets of the plurality of atomization nozzles are oriented to discharge the discharge atomized fluid along an x-axis, wherein the y-, z-, and x-axes are relative to ground, and wherein the annular shaped body of the first subassembly has a smaller diameter than a diameter of the annular shaped body of the second subassembly, and the second subassembly diameter is smaller than a diameter of the annular shaped body of the third subassembly. 
     
     
         5 . The system of  claim 1 , wherein the at least one subassembly of the lower shroud comprises a first subassembly, wherein the outlets of the plurality of atomization nozzles are oriented to discharge the discharge atomized fluid along a y-axis; and at least one second subassembly, wherein the outlets of the plurality of atomization nozzles are oriented to discharge the discharge atomized fluid along a z-axis, wherein the y- and z-axes are relative to ground, and wherein the annular shaped body of the first subassembly has a smaller diameter than a diameter of the annular shaped body of the second subassembly. 
     
     
         6 . The system of  claim 1 , wherein the heat-treated metallic part is axisymmetric. 
     
     
         7 . The system of  claim 1 , wherein the at least one gas source is air and the at least one liquid source is water. 
     
     
         8 . The system of  claim 7 , wherein the plurality of atomization nozzles are configured to provide atomization external to the nozzle 
     
     
         9 . The system of  claim 7 , wherein the plurality of atomization nozzles are configured to provide atomization within the nozzle. 
     
     
         10 . The system of  claim 7 , wherein the plurality of atomization nozzles are configured to provide atomization upstream of the atomization nozzle. 
     
     
         11 . The system of  claim 7 , wherein the air is at a pressure of greater than 0 to 300 pounds per square inch (psi) and the water is at a pressure of greater than 0 to 300 psi. 
     
     
         12 . The system of  claim 7 , wherein the water is pressurized in a vessel by a gas and is in fluid communication with the atomization nozzles. 
     
     
         13 . The system of  claim 1 , wherein a selected one or both of the upper and lower shroud assemblies are independently coupled to a plate rotatable in a horizontal direction relative to ground during operation, wherein the heat-treated part is stationary. 
     
     
         14 . The system of  claim 1 , wherein the plurality of atomization nozzles are configured to vertically oscillate relative to ground during operation. 
     
     
         15 . The system of  claim 12 , wherein the plurality of atomization nozzles are further configured to vertically oscillate in the vertical direction relative to ground. 
     
     
         16 . The system of  claim 1 , wherein the at least one shroud assembly is configured to be vertically adjustable relative to ground. 
     
     
         17 . The system of  claim 1 , wherein the plurality of atomization nozzles are radially disposed about the heat treated part at equal distances. 
     
     
         18 . The system of  claim 1 , wherein the plurality of atomization nozzles are at a distance of about 1 to about 24 inches from the heated-treated part during operation. 
     
     
         19 . The system of  claim 1 , wherein the plurality of atomization nozzles are configured to rapidly cool a thicker section of the heat-treated part relative to a thinner section. 
     
     
         20 . The system of  claim 1 , wherein the upper shroud assembly and/or the lower shroud assembly are movably coupled to the housing.