Method of manufacturing a sacrificial anode rod assembly

Claim 1

The method of making a sacrificial anode assembly for the cathodic protection of the internal surfaces of ferrous metal water-containing vessels comprising: A. providing an anode rod member of a galvanically active metal and of a selected length and a selected substantially uniform diameter throughout its length and wherein the galvanically active metal surrounds a centrally disposed core wire; B. providing an externally threaded elongated hollow metal cap member of a dissimilar metal from the galvanically active metal anode member and of a selected wall thickness, said cap member being provided with an internal recess which extends axially inwardly from an opening at one end of the cap member for a selected distance therein, said recess having a diameter slightly greater than the diameter of the anode rod member and at least one portion of said recess remote from said end of said cap member having a relatively greater diameter with respect to the remainder of said recess, said recess having at its base a centrally located cavity; C. clamping and tightly holding the major portion of said anode rod member between a plurality of force-applying surfaces substantially conforming in shape to the external configuration of the anode rod member while allowing a minor portion of one extremity of the anode rod member to protrude a selected small amount from said force-applying surfaces; D. applying a selected amount of an electrical contact lubricant containing metal particles to at least one of said members in the area where the members are to be joined; E. positioning and aligning said cap member onto the anode rod member extremity which protrudes from said force-applying surfaces such that the anode rod member extremity fits snugly into said recess of said cap member and the cap member is axially aligned with the anode rod member extremity while ensuring that the engaging surfaces of said cap member and said anode rod member extremity have positioned therebetween a substantially uniform distribution of the electrical contact lubricant; and F. applying to the cap member a sufficient force in the longitudinal direction of the anode rod member and the elongated cap member positioned thereon to metallurgically upset the galvanically active metal of the said extremity of the anode rod member to cause the galvanically active metal to flow and substantially uniformly fill the recess of the cap member, including the portion of the recess having a relatively greater diameter and effect contact between the core wire and the walls of the centrally located cavity of the recess, thereby producing a sacrificial anode assembly while establishing a tight, leakproof joint with a multiple of current-carrying bridges of metal particles between the engaging wall surfaces of said anode rod member extremity and the walls of said recess and without materially disturbing the initial wall thickness and basic configuration including the external threads of the elongated cap member.

Claim 2

The method of making a sacrificial anode assembly for the cathodic protection of the internal surfaces of ferrous metal water-containing vessels comprising: A. providing an anode rod member of a galvanically active metal and of a selected length and a selected substantially uniform diameter throughout its length and wherein the galvanically active metal surrounds a centrally disposed core wire; B. providing an externally threaded elongated hollow metal cap member of a dissimilar metal from the galvanically active metal anode member and of a selected wall thickness, said cap member being provided with an internal recess which extends axially inwardly from an opening at one end of the cap member for a selected distance therein, said recess having a diameter slightly greater than the diameter of the anode rod member and at least one portion of said recess remote from said end of said cap member having a relatively greater diameter with respect to the remainder of said recess, said recess having at its base a centrally located cavity; C. clamping and tightly holding the major portion of said anode rod member between a plurality of force-applying surfaces substantially conforming in shape to the external configuration of the anode rod member while allowing a minor portion of one extremity of the anode rod member to protrude a selected small amount from said force-applying surfaces; D. applying a selected amount of an electrical contact lubricant containing metal particles to at least one of said members in the area where the members are to be joined; E. positioning and aligning said cap member onto the anode rod member extremity which protrudes from said force-applying surfaces such that the anode rod member extremity fits snugly into said recess of said cap member and the cap member is axially aligned with the anode rod member extremity while ensuring that the engaging surfaces of said cap member and said anode rod member extremity have positioned therebetween a substantially uniform distribution of the electrical contact lubricant; and F. applying to the cap member a sufficient force in the longitudinal direction of the anode rod member and the elongated cap member positioned thereon to metallurgically upset the galvanically active metal of the said extremity of the anode rod member to cause the galvanically active metal to flow and substantially uniformly fill the recess of the cap member, including the portion of the recess having a relatively greater diameter and effect contact between the core wire and the walls of the centrally located cavity of the recess, thereby producing a sacrificial anode assembly while establishing a tight, leakproof joint with a multiple of current-carrying bridges of metal particles between the engaging wall surfaces of said anode rod member extremity and the walls of said recess and without materially disturbing the initial wall thickness and basic configuration including the external threads of the elongated cap member.

Claim 4

The method of making a sacrificial anode assembly for the cathodic protection of the internal surfaces of ferrous metal water-containing vessels comprising: A. providing an anode rod member of an aluminum alloy and of a selected length and a selected substantially uniform diameter throughout its length and wherein the aluminum alloy metal surrounds a centrally disposed steel core wire; B. providing an externally threaded elongated hollow steel cap member of a selected wall thickness, said cap member being provided with an internal recess which extends axially inwardly from an opening at one end of the cap member for a selected distance therein, said recess having a diameter slightly greater than the diameter of the anode rod member and at least one portion of said recess remote from said end of said cap member having a relatively greater diameter with respect to the remainder of said recess, said recess having at its base a centrally located cavity; C. clamping and tightly holding the major portion of said anode rod member between a plurality of force-applying surfaces substantially conforming in shape to the external configuration of the anode rod member while allowing a minor portion of one extremity of the anode rod member to protrude a selected small amount from said force-applying surfaces; D. applying a selected amount of an electrical contact lubricant containing metal particles to at least one of said members in the area where the members are to be joined; E. positioning and aligning said cap member onto the anode rod member extremity which protrudes from said force-applying surfaces such that the anode rod member extremity fits snugly into said recess of said cap member and the cap member is axially aligned with the anode rod member extremity while ensuring that the engaging surfaces of said cap member and said anode rod member extremity have positioned therebetween a substantially uniform distribution of the electrical contact lubricant; and F. applying to the cap member a sufficient force in the longitudinal direction of the anode rod member and the elongated cap member positioned thereon to metallurgically upset the aluminum alloy anode metal of the said extremity of the anode rod member to cause the anode metal to flow and substantially uniformly fill the recess of the cap member, including the portion of the recess having a relatively greater diameter and effect contact between the core wire and the walls of the centrally located cavity of the recess, thereby producing a sacrificial anode assembly while establishing a tight, leakproof joint with a multiple of current-carrying bridges of metal particles between the engaging wall surfaces of said anode rod member extremity and the walls of said recess and without materially disturbing the initial wall thickness and basic configuration including the external threads of the elongated cap member.

Claim 5

The method of making a sacrificial anode assembly for the cathodic protection of the internal surfaces of ferrous metal water-containing vessels comprising: A. providing an anode rod member of an aluminum alloy and of a selected length and a selected substantially uniform diameter throughout its length and wherein the aluminum alloy metal surrounds a centrally disposed steel core wire; B. providing an externally threaded elongated hollow steel cap member of a selected wall thickness, said cap member being provided with an internal recess which extends axially inwardly from an opening at one end of the cap member for a selected distance therein, said recess having a diameter slightly greater than the diameter of the anode rod member and at least one portion of said recess remote from said end of said cap member having a relatively greater diameter with respect to the remainder of said recess, said recess having at its base a centrally located cavity; C. clamping and tightly holding the major portion of said anode rod member between a plurality of force-applying surfaces substantially conforming in shape to the external configuration of the anode rod member while allowing a minor portion of one extremity of the anode rod member to protrude a selected small amount from said force-applying surfaces; D. applying a selected amount of an electrical contact lubricant containing metal particles to at least one of said members in the area where the members are to be joined; E. positioning and aligning said cap member onto the anode rod member extremity which protrudes from said force-applying surfaces such that the anode rod member extremity fits snugly into said recess of said cap member and the cap member is axially aligned with the anode rod member extremity while ensuring that the engaging surfaces of said cap member and said anode rod member extremity have positioned therebetween a substantially uniform distribution of the electrical contact lubricant; and F. applying to the cap member a sufficient force in the longitudinal direction of the anode rod member and the elongated cap member positioned thereon to metallurgically upset the aluminum alloy anode metal of the said extremity of the anode rod member to cause the anode metal to flow and substantially uniformly fill the recess of the cap member, including the portion of the recess having a relatively greater diameter and effect contact between the core wire and the walls of the centrally located cavity of the recess, thereby producing a sacrificial anode assembly while establishing a tight, leakproof joint with a multiple of current-carrying bridges of metal particles between the engaging wall surfaces of said anode rod member extremity and the walls of said recess and without materially disturbing the initial wall thickness and basic configuration including the external threads of the elongated cap member.

Claim 7

The method of making a sacrificial anode assembly for the cathodic protection of the internal surfaces of ferrous metal water heater tanks comprising: A. providing an anode rod member of an aluminum alloy and of a selected length and a selected substantially uniform diameter throughout its length and wherein the aluminum alloy metal surrounds a centrally disposed steel core wire; B. providing an externally threaded elongated hollow steel cap member of selected wall thickness, said cap member being provided with an internal recess which extends axially inwardly from an opening at one end of the cap member for a selected distance therein, said recess having a diameter slightly greater than the diameter of the anode rod member and at least one portion of said recess remote from said end of said cap member having a relatively greater diameter with respect to the remainder of said recess, said recess having at its base a centrally located cavity; C. clamping and tightly holding the major portion of said anode rod member between a plurality of force-applying surfaces substantially conforming in shape to the external configuration of the anode rod member while allowing a minor portion of one extremity of the anode rod member to protrude a selected small amount from said force-applying surfaces; D. applying a selected amount of an electrical contact lubricant containing metal particles to at least one of said members in the area where the members are to be joined; E. positioning and aligning said cap member onto the anode rod member extremity which protrudes from said force-applying surfaces such that the anode rod member extremity fits snugly into said recess of said cap member and the cap member is axially aligned with the anode rod member extremity while ensuring that the engaging surfaces of said cap member and said anode rod member extremity have positioned therebetween a substantially uniform distribution of the electrical contact lubricant; and F. applying to the cap member a sufficient force in the longitudinal direction of the anode rod and the elongated cap member positioned thereon to metallurgically upset the aluminum alloy anode metal of the said extremity of the anode rod member to cause the anode metal to flow and substantially fill the recess of the cap member including the portion of the recess having a relatively greater diameter and effect contact between the core wire and the walls of the centrally located cavity of the recess thereby producing a sacrificial anode assembly wherein the anode rod member and the elongated cap member are in a tightly locked, leakproof joint and with a multitude of current-carrying bridges of metal particles between the engaging surfaces of said extremity of said anode rod member and said recess, said force being continued beyond that necessary to cause the anode metal to flow and substantially fill the recess in order to form an enlarged portion of anode metal extending peripherally around said anode rod to ensure sealing of the juncture between the anode rod member and the end of the cap member and to add additional anode metal thereto, the selected minimum wall thickness of the elongated cap member as measured between the surface of the internal recess and the base of the threads, being sufficient to withstand the force of joining the said cap member to the said anode rod member in order to maintain the integrity of its external configuration and its external threads.

Claim 8

The method of making a sacrificial anode assembly for the cathodic protection of the internal surfaces of ferrous metal water heater tanks comprising: A. providing an anode rod member of an aluminum alloy and of a selected length and a selected substantially uniform diameter throughout its length and wherein the aluminum alloy metal surrounds a centrally disposed steel core wire; B. providing an externally threaded elongated hollow steel cap member of selected wall thickness, said cap member being provided with an internal recess which extends axially inwardly from an opening at one end of the cap member for a selected distance therein, said recess having a diameter slightly greater than the diameter of the anode rod member and at least one portion of said recess remote from said end of said cap member having a relatively greater diameter with respect to the remainder of said recess, said recess having at its base a centrally located cavity; C. clamping and tightly holding the major portion of said anode rod member between a plurality of force-applying surfaces substantially conforming in shape to the external configuration of the anode rod member while allowing a minor portion of one extremity of the anode rod member to protrude a selected small amount from said force-applying surfaces; D. applying a selected amount of an electrical contact lubricant containing metal particles to at least one of said members in the area where the members are to be joined; E. positioning and aligning said cap member onto the anode rod member extremity which protrudes from said force-applying surfaces such that the anode rod member extremity fits snugly into said recess of said cap member and the cap member is axially aligned with the anode rod member extremity while ensuring that the engaging surfaces of said cap member and said anode rod member extremity have positioned therebetween a substantially uniform distribution of the electrical contact lubricant; and F. applying to the cap member a sufficient force in the longitudinal direction of the anode rod and the elongated cap member positioned thereon to metallurgically upset the aluminum alloy anode metal of the said extremity of the anode rod member to cause the anode metal to flow and substantially fill the recess of the cap member including the portion of the recess having a relatively greater diameter and effect contact between the core wire and the walls of the centrally located cavity of the recess thereby producing a sacrificial anode assembly wherein the anode rod member and the elongated cap member are in a tightly locked, leakproof joint and with a multitude of current-carrying bridges of metal particles between the engaging surfaces of said extremity of said anode rod member and said recess, said force being continued beyond that necessary to cause the anode metal to flow and substantially fill the recess in order to form an enlarged portion of anode metal extending peripherally around said anode rod to ensure sealing of the juncture between the anode rod member and the end of the cap member and to add additional anode metal thereto, the selected minimum wall thickness of the elongated cap member as measured between the surface of the internal recess and the base of the threads, being sufficient to withstand the force of joining the said cap member to the said anode rod member in order to maintain the integrity of its external configuration and its external threads.

Claim 9

The method of making a sacrificial anode assembly for the cathodic protection of the internal surfaces of ferrous metal water heater tanks comprising: A. providing an anode rod member of an aluminum alloy and of a selected length and a selected substantially uniform diameter throughout its length and wherein the aluminum alloy metal surrounds a centrally disposed steel core wire; B. providing an externally threaded and tapered elongated steel cap member of a selected wall thickness, said cap member being provided with an internal recess which extends axially inwardly from an opening at one end of the cap member for a selected distance, therein, said recess having a diameter slightly greater than the diameter of the anode rod member and at least one portion of said recess remote from said end of said cap member having a relatively greater diameter with respect to the reminder of said recess, said recess having at its base a centrally located cavity; C. clamping and tightly holding the major portion of said anode rod member between a plurality of force-applying surfaces substantially conforming in shape to the external configuration of the anode rod member while allowing a minor portion of one extremity of the anode rod member to protrude a selected small amount from said force-applying surfaces; D. applying a selected amount of an electrical contact lubricant containing metal particles to at least one of said members in the area where the members are to be joined; E. positioning and aligning said cap member onto the anode rod member extremity which protrudes from said force-applying surfaces such that the anode rod member extremity fits snugly into said recess of said cap member and the cap member is axially aligned with the anode rod member extremity while ensuring that the engaging surfaces of said cap member and said anode rod member extremity have positioned therebetween a substantially uniform distribution of the electrical contact lubricant; F. clamping and tightly holding said elongated cap member in a quick-operating die member having force-applying surfaces which are tapered and threaded to mate with the external longitudinal surfaces and threads of the cap member in order that the integrity of the external configuration and the external threads of the cap member are maintained during the application of force in a forming operation; and G. applying to the cap member a sufficient force in the longitudinal direction of the anode rod and the elongated cap member positioned thereon to metallurgically upset the aluminum alloy anode metal of the said extremity of the anode rod member to cause the anode metal to flow and substantially fill the recess of the cap member including the portion of the recess having a relatively greater diameter and effect contact between the core wire and the walls of the centrally located cavity of the recess, thereby producing a sacrificial anode assembly wherein the anode rod and the elongated cap member are in a tightly locked, leakproof joint and with a multitude of current-carrying bridges of metal particles between the engaging surfaces of said extremity of said anode rod and said recess and without materially disturbing the initial wall thickness and basic configuration including the external threads of the elongated cap member, said force being continued beyond that necessary to cause the anode metal to flow and substantially fill the recess in order to form an enlarged portion of anode metal extending peripherally around said anode rod, thereby sealing the juncture between the anode rod member and the end of the cap member and adding additional anode metal thereto.

Claim 10

The method of making a sacrificial anode assembly for the cathodic protection of the internal surfaces of ferrous metal water heater tanks comprising: A. providing an anode rod member of an aluminum alloy and of a selected length and a selected substantially uniform diameter throughout its length and wherein the aluminum alloy metal surrounds a centrally disposed steel core wire; B. providing an externally threaded and tapered elongated steel cap member of a selected wall thickness, said cap member being provided with an internal recess which extends axially inwardly from an opening at one end of the cap member for a selected distance, therein, said recess having a diameter slightly greater than the diameter of the anode rod member and at least one portion of said recess remote from said end of said cap member having a relatively greater diameter with respect to the reminder of said recess, said recess having at its base a centrally located cavity; C. clamping and tightly holding the major portion of said anode rod member between a plurality of force-applying surfaces substantially conforming in shape to the external configuration of the anode rod member while allowing a minor portion of one extremity of the anode rod member to protrude a selected small amount from said force-applying surfaces; D. applying a selected amount of an electrical contact lubricant containing metal particles to at least one of said members in the area where the members are to be joined; E. positioning and aligning said cap member onto the anode rod member extremity which protrudes from said force-applying surfaces such that the anode rod member extremity fits snugly into said recess of said cap member and the cap member is axially aligned with the anode rod member extremity while ensuring that the engaging surfaces of said cap member and said anode rod member extremity have positioned therebetween a substantially uniform distribution of the electrical contact lubricant; F. clamping and tightly holding said elongated cap member in a quick-operating die member having force-applying surfaces which are tapered and threaded to mate with the external longitudinal surfaces and threads of the cap member in order that the integrity of the external configuration and the external threads of the cap member are maintained during the application of force in a forming operation; and G. applying to the cap member a sufficient force in the longitudinal direction of the anode rod and the elongated cap member positioned thereon to metallurgically upset the aluminum alloy anode metal of the said extremity of the anode rod member to cause the anode metal to flow and substantially fill the recess of the cap member including the portion of the recess having a relatively greater diameter and effect contact between the core wire and the walls of the centrally located cavity of the recess, thereby producing a sacrificial anode assembly wherein the anode rod and the elongated cap member are in a tightly locked, leakproof joint and with a multitude of current-carrying bridges of metal particles between the engaging surfaces of said extremity of said anode rod and said recess and without materially disturbing the initial wall thickness and basic configuration including the external threads of the elongated cap member, said force being continued beyond that necessary to cause the anode metal to flow and substantially fill the recess in order to form an enlarged portion of anode metal extending peripherally around said anode rod, thereby sealing the juncture between the anode rod member and the end of the cap member and adding additional anode metal thereto.