Cooling systems for heat-treated parts and methods of use

Abstract

Systems and methods 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. Methods are also disclosed. In one embodiment, the method includes moving a plurality of outlets in a horizontal direction while the heat-treated part is stationary while directing an air and water mixture from the plurality of outlets onto the heat-treated metallic part

1 . A system for cooling a heat-treated metallic part, comprising:
 a housing configured to hold the heat-treated metallic part;   at least one shroud assembly comprising an array of atomization nozzles configured to be concentrically disposed about the part during operation of the system, each atomization nozzle comprising an outlet; and   a fluid source in fluid communication with the plurality of atomization nozzles, wherein the outlet is oriented to discharge atomized fluid at the heat-treated part.   
     
     
         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 heat-treated metallic part is axisymmetric. 
     
     
         4 . The system of  claim 1 , wherein the fluid source comprises a gas and a liquid. 
     
     
         5 . The system of  claim 4 , wherein the fluid is configured to provide atomization external to the nozzle 
     
     
         6 . The system of  claim 4 , wherein the atomization nozzles are configured to provide atomization within the nozzle. 
     
     
         7 . The system of  claim 4 , wherein the atomization nozzles are configured to provide atomization upstream of the atomization nozzle. 
     
     
         8 . The system of  claim 4 , wherein the gas is air and the liquid is water. 
     
     
         9 . The system of  claim 8 , 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. 
     
     
         10 . The system of  claim 8 , wherein the water is pressurized in a vessel by a gas and is in fluid communication with the atomization nozzles. 
     
     
         11 . The system of  claim 1 , wherein the at least one shroud assembly consists of an upper shroud assembly and a lower shroud assembly. 
     
     
         12 . The system of  claim 1 , wherein the at least one shroud assembly is configured to be rotatable in a horizontal direction relative to ground during operation, wherein the heat-treated part is stationary. 
     
     
         13 . The system of  claim 1 , wherein the atomization nozzles are configured to vertically oscillate relative to ground during operation. 
     
     
         14 . The system of  claim 12 , wherein the atomization nozzles are further configured to vertically oscillate in the vertical direction relative to ground. 
     
     
         15 . The system of  claim 1 , wherein the at least one shroud assembly is configured to be vertically adjustable relative to ground. 
     
     
         16 . The system of  claim 1 , wherein the atomization nozzles are radially disposed about the heat treated part at equal distances. 
     
     
         17 . The system of  claim 1 , wherein the atomization nozzles are at a distance of about 1 to about 24 inches from the heated-treated part during operation. 
     
     
         18 . The system of  claim 1 , wherein the arrays of atomization nozzles are configured to rapidly cool a thicker section of the heat-treated part relative to a thinner section. 
     
     
         19 . A method of cooling a heat-treated metallic part, comprising:
 inserting the heat-treated metallic part into a cooling system, the cooling system comprising a housing configured to maintain the heat-treated metallic part in a stationary position; at least one shroud assembly comprising an array of atomization nozzles configured to be concentrically disposed about the heat-treated metallic part during operation of the system;   forming an atomized fluid from the atomization nozzle, the atomized fluid consisting essentially of gas and water mixture, wherein the air is at a pressure greater than 0 to 300 psi and the water is at a pressure greater than 0 to 300 psi; and   spraying the heat-treated metallic part with the atomized fluid, wherein the atomized fluid consists of atomized droplets.   
     
     
         20 . The method of  claim 19 , wherein the gas is air. 
     
     
         21 . The method of  claim 19 , further comprising oscillating the at least one shroud assembly in a horizontal direction about the stationary heat treated metallic part during operation. 
     
     
         22 . The method of  claim 19 , wherein the at least one shroud assembly consists of an upper shroud assembly and a lower shroud assembly. 
     
     
         23 . The method of  claim 19 , wherein spraying the heat-treated metallic part with the atomized fluid is a substantially constant cooling rate. 
     
     
         24 . The method of  claim 19 , wherein spraying the heat-treated metallic part with the atomized fluid is at a ramped cooling rate. 
     
     
         25 . A method of cooling a heat-treated metallic part, comprising:
 positioning a plurality of outlets relative to the heat-treated metallic part; and   moving a plurality of outlets in a horizontal direction while the heat-treated metallic part is stationary while directing an air and water mixture from the plurality of outlets onto the heat-treated metallic part.   
     
     
         26 . The method of  claim 25 , wherein positioning the plurality of outlets relative to the heat-treated metallic part comprises concentrically positioning the plurality of outlets about the heat-treated part at regularly spaced intervals. 
     
     
         27 . The method of  claim 25 , wherein the air is at a pressure greater than 0 to 300 psi and the water is at a pressure greater than 0 to 300 psi. 
     
     
         28 . The method of  claim 25 , wherein the plurality of outlets comprise atomization nozzles. 
     
     
         29 . A system for cooling a heat-treated metallic part, comprising:
 a housing configured to hold the heat-treated metallic part in a stationary position;   at least one shroud assembly comprising an array of atomization nozzles configured to be concentrically disposed about the part during operation of the system and configured to discharge a fluid at the heat-treated part, wherein the at least one shroud assembly is configured to oscillate in a horizontal direction about the stationary heat treated metallic part; and   a fluid source in fluid communication with the array of atomization nozzles.   
     
     
         30 . The system of  claim 29 , wherein the fluid source comprises air and water. 
     
     
         31 . (canceled) 
     
     
         31 . (canceled) 
     
     
         32 . The system of  claim 29 , wherein the atomization nozzles are configured to articulate in a vertical direction during operation. 
     
     
         33 . The system of  claim 29 , wherein the at least one shroud assembly is configured to move in a vertical direction. 
     
     
         34 . The system of  claim 30 , 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. 
     
     
         35 . The system of  claim 30 , wherein the water is pressurized in a vessel by a gas.