Metal bellows

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Metal bellows are elastic vessels that can be compressed when pressure is applied to the outside of the vessel, or extended under vacuum. When the pressure or vacuum is released, the bellows will return to its original shape, provided the material has not been stressed past its yield strength. They are used both for their ability to deform under pressure and to provide a hermetic seal that allows movement.

Contents

Precision bellows technology of the 20th and 21st century is centered on metal bellows with less demanding applications using ones made of rubber and plastic. These products bear little resemblance to the original leather bellows used traditionally in fireplaces and forges.

Types

deep drawn tubes for bellows Parts made by deep drawing - 20100630.jpg
deep drawn tubes for bellows
Metal bellows Metal bellows.jpg
Metal bellows

There are three main types of metal bellows: formed, welded and electroformed.

Formed bellows are produced by reworking tubes, normally produced by deep drawing, with a variety of processes, including cold forming (rolling), and hydroforming. They are also called convoluted bellows or sylphons.

Welded bellows (also called edge-welded, or diaphragm bellows) are manufactured by welding a number of individually formed diaphragms to each other. The comparison between the two bellows types generally centers on cost and performance. Hydroformed bellows generally have a high tooling cost, but, when mass-produced, may have a lower piece price. However, hydroformed bellows have lower performance characteristics due to relatively thick walls and high stiffness. Welded metal bellows are produced with a lower initial tooling cost and maintain higher performance characteristics. The drawback of welded bellows is the reduced metal strength at weld joints, caused by the high temperature of welding. [1]

Electroformed bellows are produced by plating (electroforming) a metal layer onto a model (mandrel), and subsequently removing the mandrel. They can be produced with modest tooling costs and with thin walls (25 micrometres or less), providing such bellows with high sensitivity and precision in many exacting applications, and may also be produced in shapes that would be exceptionally difficult to produce by other means with little additional difficulty. [2] [3]

Another area of comparison is in metals of construction. Hydroformed and rolled bellows are limited to metals with high plastic elongation characteristics, whereas welded bellows may be fabricated from a wider variety of standard and exotic alloys, such as stainless steel and titanium, as well as other high-strength, corrosion-resistant materials. Electroformed bellows can be produced of nickel, its high-strength alloys, and copper.

Applications

Metal bellows are used in a large number of industrial applications. Below you will find a few;

Manufacture

Welded bellows can be fabricated from a variety of exotic metals and alloys, whereas formed bellows are limited to alloys with good elongation – brass being a prime example. Welded bellows are not fabricated from brass because of its fundamentally poor weldability. Other advantages to welded bellows include compactness (higher performance in a smaller package), ability to be compressed to solid height with no damage, resistance to nicks and dents, and dramatically greater flexibility.

The welding of metal bellows is a microscopic welding process, typically performed under laboratory conditions at high magnification.

Hydroformed bellows are produced by forcing a metal tube to expand under hydraulic pressure inside a bellows-shaped mold, and assume the convoluted shape of the mold.

Electroformed bellows are produced by plating metal onto a bellows-shaped model (mandrel), and the subsequent mandrel removal by chemical or physical means. Due to the low tooling cost and short manufacturing cycle, electroforming of bellows is not only an inexpensive manufacturing method, but also a perfect prototyping tool.

Deflections

There are a variety of expansion joints and not each one can accept the same types of deflection. The various types of deflections are axial, lateral, angular, torsional, cyclic, or any combination that can occur at the same time. [4]

Related Research Articles

Pressure measurement Analysis of force applied by a fluid on a surface

Pressure measurement is the analysis of an applied force by a fluid on a surface. Pressure is typically measured in units of force per unit of surface area. Many techniques have been developed for the measurement of pressure and vacuum. Instruments used to measure and display pressure in an integral unit are called pressure meters or pressure gauges or vacuum gauges. A manometer is a good example, as it uses the surface area and weight of a column of liquid to both measure and indicate pressure. Likewise, the widely used Bourdon gauge is a mechanical device, which both measures and indicates and is probably the best known type of gauge.

Vacuum pump Equipment producing low air pressure

A vacuum pump is a device that draws gas molecules from a sealed volume in order to leave behind a partial vacuum. The job of a vacuum pump is to generate a relative vacuum within a capacity. The first vacuum pump was invented in 1650 by Otto von Guericke, and was preceded by the suction pump, which dates to antiquity.

Vacuum Space that is empty of matter

A vacuum is a space devoid of matter. The word is derived from the Latin adjective vacuus for "vacant" or "void". An approximation to such vacuum is a region with a gaseous pressure much less than atmospheric pressure. Physicists often discuss ideal test results that would occur in a perfect vacuum, which they sometimes simply call "vacuum" or free space, and use the term partial vacuum to refer to an actual imperfect vacuum as one might have in a laboratory or in space. In engineering and applied physics on the other hand, vacuum refers to any space in which the pressure is considerably lower than atmospheric pressure. The Latin term in vacuo is used to describe an object that is surrounded by a vacuum.

End-face mechanical seal

An end-face mechanical seal, or a mechanical end-face seal, also referred to as a mechanical face seal but usually simply as a mechanical seal, is a type of seal used in rotating equipment, such as pumps, mixers, blowers, and compressors. When a pump operates, the liquid could leak out of the pump between the rotating shaft and the stationary pump casing. Since the shaft rotates, preventing this leakage can be difficult. Earlier pump models used mechanical packing to seal the shaft. Since World War II, mechanical seals have replaced packing in many applications.

Neon sign Electrified, luminous tube lights

In the signage industry, neon signs are electric signs lighted by long luminous gas-discharge tubes that contain rarefied neon or other gases. They are the most common use for neon lighting, which was first demonstrated in a modern form in December 1910 by Georges Claude at the Paris Motor Show. While they are used worldwide, neon signs were popular in the United States from about the 1920s to 1950s. The installations in Times Square, many originally designed by Douglas Leigh, were famed, and there were nearly 2,000 small shops producing neon signs by 1940. In addition to signage, neon lighting is used frequently by artists and architects, and in plasma display panels and televisions. The signage industry has declined in the past several decades, and cities are now concerned with preserving and restoring their antique neon signs.

Brazing High-temperature soldering; metal-joining technique by high-temperature molten metal filling

Brazing is a metal-joining process in which two or more metal items are joined together by melting and flowing a filler metal into the joint, with the filler metal having a lower melting point than the adjoining metal.

Gasket Type of mechanical seal

A gasket is a mechanical seal which fills the space between two or more mating surfaces, generally to prevent leakage from or into the joined objects while under compression. It is a deformable material that is used to create a static seal and maintain that seal under various operating conditions in a mechanical assembly.

A hydraulic accumulator is a pressure storage reservoir in which an incompressible hydraulic fluid is held under pressure that is applied by an external source of mechanical energy. The external source can be an engine, a spring, a raised weight, or a compressed gas. An accumulator enables a hydraulic system to cope with extremes of demand using a less powerful pump, to respond more quickly to a temporary demand, and to smooth out pulsations. It is a type of energy storage device.

Seal (mechanical) Device to prevent fluid leaks in mechanisms

A mechanical seal is a device that helps join systems or mechanisms together by preventing leakage, containing pressure, or excluding contamination. The effectiveness of a seal is dependent on adhesion in the case of sealants and compression in the case of gaskets. The seals are installed in pumps in a wide range of industries including chemicals, water supply, paper production, food processing and many other applications.

Ultra-high vacuum (UHV) is the vacuum regime characterised by pressures lower than about 100 nanopascals. UHV conditions are created by pumping the gas out of a UHV chamber. At these low pressures the mean free path of a gas molecule is greater than approximately 40 km, so the gas is in free molecular flow, and gas molecules will collide with the chamber walls many times before colliding with each other. Almost all molecular interactions therefore take place on various surfaces in the chamber.

Pressure sensor Pressure measurement device

A pressure sensor is a device for pressure measurement of gases or liquids. Pressure is an expression of the force required to stop a fluid from expanding, and is usually stated in terms of force per unit area. A pressure sensor usually acts as a transducer; it generates a signal as a function of the pressure imposed. For the purposes of this article, such a signal is electrical.

A hermetic seal is any type of sealing that makes a given object airtight. The term originally applied to airtight glass containers, but as technology advanced it applied to a larger category of materials, including rubber and plastics. Hermetic seals are essential to the correct and safe functionality of many electronic and healthcare products. Used technically, it is stated in conjunction with a specific test method and conditions of use.

Hydroforming Method of shaping metal through pressurized water

Hydroforming is a cost-effective way of shaping ductile metals such as aluminium, brass, low alloy steel, and stainless steel into lightweight, structurally stiff and strong pieces. One of the largest applications of hydroforming is the automotive industry, which makes use of the complex shapes made possible by hydroforming to produce stronger, lighter, and more rigid unibody structures for vehicles. This technique is particularly popular with the high-end sports car industry and is also frequently employed in the shaping of aluminium tubes for bicycle frames.

Diaphragm seal

A diaphragm seal is a flexible membrane that seals and isolates an enclosure. The flexible nature of this seal allows pressure effects to cross the barrier but not the material being contained.

Electroforming

Electroforming is a metal forming process in which parts are fabricated through electrodeposition on a model, known in the industry as a mandrel. Conductive (metallic) mandrels are treated to create a mechanical parting layer, or are chemically passivated to limit electroform adhesion to the mandrel and thereby allow its subsequent separation. Non-conductive mandrels require the deposition of a conductive layer prior to electrodeposition. Such layers can be deposited chemically, or using vacuum deposition techniques. The outer surface of the mandrel forms the inner surface of the form.

A leak is a way for fluid to escape a container or fluid-containing system, such as a tank or a ship's hull, through which the contents of the container can escape or outside matter can enter the container. Leaks are usually unintended and therefore undesired. The word leak usually refers to a gradual loss; a sudden loss is usually called a spill.

Compact Disc manufacturing Mass replication process for CDs

Compact disc manufacturing is the process by which commercial compact discs (CDs) are replicated in mass quantities using a master version created from a source recording. This may be either in audio form (CD-DA) or data form (CD-ROM). This process is used in the mastering of read-only compact discs. DVDs and Blu-rays use similar methods.

Glass-to-metal seal

Glass-to-metal seals are a very important element of the construction of vacuum tubes, electric discharge tubes, incandescent light bulbs, glass encapsulated semiconductor diodes, reed switches, pressure tight glass windows in metal cases, and metal or ceramic packages of electronic components.

Metal hose

A metal hose is a flexible metal line element. There are two basic types of metal hose that differ in their design and application: stripwound hoses and corrugated hoses.

Vacuum interrupter

In electrical engineering, a vacuum interrupter is a switch which uses electrical contacts in a vacuum. It is the core component of medium-voltage circuit-breakers, generator circuit-breakers, and high-voltage circuit-breakers. Separation of the electrical contacts results in a metal vapour arc, which is quickly extinguished. Vacuum interrupters are widely used in utility power transmission systems, power generation unit, and power-distribution systems for railways, arc furnace applications, and industrial plants.

References

  1. Edge Welded Metal Bellows, Bellowstech
  2. Precision Metal Bellows, NiCoForm
  3. "Electroformed Metal Bellows - Servometer". Servometer. Retrieved 2016-11-22.
  4. Types of metallic Bellows Deflections U.S. Bellows, (retrieved March 2012)