DE102020131832A1 - Process for the manufacture of casting molds or casting cores - Google Patents
Process for the manufacture of casting molds or casting cores Download PDFInfo
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- DE102020131832A1 DE102020131832A1 DE102020131832.4A DE102020131832A DE102020131832A1 DE 102020131832 A1 DE102020131832 A1 DE 102020131832A1 DE 102020131832 A DE102020131832 A DE 102020131832A DE 102020131832 A1 DE102020131832 A1 DE 102020131832A1
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- 238000005266 casting Methods 0.000 title claims abstract description 26
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 7
- 238000000034 method Methods 0.000 title claims description 22
- 230000008569 process Effects 0.000 title description 10
- 239000012778 molding material Substances 0.000 claims abstract description 58
- 239000011230 binding agent Substances 0.000 claims abstract description 42
- 238000010146 3D printing Methods 0.000 claims abstract description 28
- 238000009832 plasma treatment Methods 0.000 claims abstract description 26
- 230000004913 activation Effects 0.000 claims abstract description 5
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 10
- 239000000203 mixture Substances 0.000 claims description 7
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 claims description 6
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 6
- 239000006004 Quartz sand Substances 0.000 claims description 4
- 229910010293 ceramic material Inorganic materials 0.000 claims description 4
- 239000007849 furan resin Substances 0.000 claims description 4
- 229910052910 alkali metal silicate Inorganic materials 0.000 claims description 3
- 229910021529 ammonia Inorganic materials 0.000 claims description 3
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 3
- 229910052757 nitrogen Inorganic materials 0.000 claims description 3
- 239000001301 oxygen Substances 0.000 claims description 3
- 229910052760 oxygen Inorganic materials 0.000 claims description 3
- 239000005011 phenolic resin Substances 0.000 claims description 3
- 229920001568 phenolic resin Polymers 0.000 claims description 3
- 230000002123 temporal effect Effects 0.000 claims description 3
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims description 2
- 230000002596 correlated effect Effects 0.000 claims description 2
- 229910052609 olivine Inorganic materials 0.000 claims description 2
- 239000010450 olivine Substances 0.000 claims description 2
- 239000000654 additive Substances 0.000 description 6
- 239000004576 sand Substances 0.000 description 5
- 239000000463 material Substances 0.000 description 4
- 239000012190 activator Substances 0.000 description 2
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- 230000015572 biosynthetic process Effects 0.000 description 2
- 125000002915 carbonyl group Chemical group [*:2]C([*:1])=O 0.000 description 2
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 2
- 230000003993 interaction Effects 0.000 description 2
- 238000007528 sand casting Methods 0.000 description 2
- 239000007858 starting material Substances 0.000 description 2
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 1
- MYMOFIZGZYHOMD-UHFFFAOYSA-N Dioxygen Chemical compound O=O MYMOFIZGZYHOMD-UHFFFAOYSA-N 0.000 description 1
- 229910004298 SiO 2 Inorganic materials 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 239000012080 ambient air Substances 0.000 description 1
- 150000001412 amines Chemical class 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
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- 239000002131 composite material Substances 0.000 description 1
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- 125000000879 imine group Chemical group 0.000 description 1
- 238000005058 metal casting Methods 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 125000002081 peroxide group Chemical group 0.000 description 1
- 235000019353 potassium silicate Nutrition 0.000 description 1
- 238000007639 printing Methods 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
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- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
- B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
- B22C1/18—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents
- B22C1/186—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents contaming ammonium or metal silicates, silica sols
- B22C1/188—Alkali metal silicates
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
- B22C1/20—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents
- B22C1/22—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents of resins or rosins
- B22C1/2233—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents of resins or rosins obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
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- B22C1/20—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents
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- B22C1/2233—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents of resins or rosins obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- B22C1/2246—Condensation polymers of aldehydes and ketones
- B22C1/2253—Condensation polymers of aldehydes and ketones with phenols
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/10—Cores; Manufacture or installation of cores
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
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- B29C64/188—Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
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- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
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Abstract
Gegenstand der Erfindung ist ein Verfahren zur Herstellung von Gussformen oder Gusskernen aus einem granularen Formstoff (1) mittels 3D-Druck, wobei dem Formstoff (1) schichtweise und selektiv ein Binder (2) zugeführt wird. Erfindungsgemäß wird vor dem Zuführen des Binders (2) eine Plasmabehandlung des Formstoffes (1) zur Oberflächenaktivierung durchgeführt.The subject matter of the invention is a method for producing casting molds or casting cores from a granular molding material (1) by means of 3D printing, a binder (2) being selectively added to the molding material (1) in layers. According to the invention, a plasma treatment of the molding material (1) for surface activation is carried out before the binder (2) is supplied.
Description
Die vorliegende Erfindung betrifft ein Verfahren zur Herstellung von Gussformen oder Gusskernen aus einem granularen Formstoff mittels 3D-Druck, wobei dem Formstoff schichtweise und selektiv ein Binder zugeführt wird. Weiterhin betrifft die Erfindung eine entsprechende 3D-Druckvorrichtung.The present invention relates to a method for producing casting molds or casting cores from a granular molding material by means of 3D printing, with a binder being added to the molding material in layers and selectively. Furthermore, the invention relates to a corresponding 3D printing device.
STAND DER TECHNIKSTATE OF THE ART
Beim Sandform- oder Sandgussverfahren zur Herstellung von metallischen Gussteilen werden Gussformen und/oder Gusskerne aus einem granularen Formstoff („Sand“) verwendet, welche nach dem Prinzip der verlorenen Form für typischerweise nur einen einzigen Gießvorgang oder eine kleine Anzahl an Gießvorgängen eingesetzt werden. Zur Herstellung der Sandform wird traditionell ein Gießereimodell in dem Formstoff abgeformt, wobei die rheologischen Eigenschaften des Formstoffes durch Zugabe eines Binders zweckmäßig ausgebildet werden.In the sand molding or sand casting process for the production of metal castings, casting molds and/or casting cores made of a granular molding material ("sand") are used, which are used according to the lost mold principle for typically only a single casting process or a small number of casting processes. To produce the sand mold, a foundry model is traditionally molded in the mold material, with the rheological properties of the mold material being appropriately developed by adding a binder.
Als Formstoff dient häufig natürlicher Quarzsand, welcher aufgrund seiner reichlichen Verfügbarkeit besonders kostengünstig ist. Die Eignung von natürlichem Quarzsand für Gussformen ist beispielsweise begrenzt durch sein unstetiges thermisches Ausdehnungsverhalten (Volumensprung beim Phasenübergang zwischen Tief- und Hochquarz) oder seine durch die Gestalt der Sandkörner und die Sieblinie bestimmten rheologischen Eigenschaften. Daher werden je nach konkretem Anwendungsfall alternative Formstoffe mit optimierten Eigenschaften eingesetzt, insbesondere synthetische Sande aus granularen Keramikwerkstoffen.Natural quartz sand is often used as the molding material, which is particularly inexpensive due to its plentiful availability. The suitability of natural quartz sand for casting molds is limited, for example, by its discontinuous thermal expansion behavior (volume jump during the phase transition between low and high quartz) or its rheological properties determined by the shape of the sand grains and the grading curve. Therefore, depending on the specific application, alternative molding materials with optimized properties are used, in particular synthetic sands made from granular ceramic materials.
Als Binder werden vorwiegend Furanharze eingesetzt, des Weiteren Phenolharze oder anorganische Alkalisilikate (Wasserglas). Letztere zeichnen sich durch eine besondere Umweltverträglichkeit aus, da sie im Gegensatz zu den organischen Bindern keine COx-Emissionen beim Gießvorgang freisetzen.Furan resins are primarily used as binders, as well as phenolic resins or inorganic alkali silicates (water glass). The latter are characterized by their particular environmental compatibility, since, unlike organic binders, they do not release any CO x emissions during the casting process.
Zur Verbesserung der Benetzbarkeit der Körner des Formstoffes und zur Verbesserung der Haftung des Binders werden dem Formstoff zudem oftmals noch Zusatzstoffe in Form von chemischen Haftvermittlern und Aktivatoren zugesetzt. Beispielsweise ist die Kompatibilität zahlreicher synthetischer Sande mit Furanharzen sehr gering, so dass die Zugabe von Zusatzstoffen notwendig ist, um einen ausreichend festen Verbund aus dem Formstoff-Binder-Gemisch zu erhalten.In order to improve the wettability of the grains of the molding material and to improve the adhesion of the binder, additives in the form of chemical adhesion promoters and activators are often added to the molding material. For example, the compatibility of numerous synthetic sands with furan resins is very low, so that the addition of additives is necessary in order to obtain a sufficiently strong bond from the mold material-binder mixture.
Im Stand der Technik werden Formen und Kerne für das Sandgussverfahren aus den vorgenannten Bestandteilen auch mittels des additiven Fertigungsverfahrens des 3D-Druckes (vgl. VDI-Richtlinie 3405) hergestellt, dem sogenannten Binder Jetting, bei dem der pulverförmige Formstoff als Ausgangsmaterial mithilfe des zugeführten Binders schichtweise und selektiv verklebt wird. Dabei wird der Binder mittels eines verfahrbaren Druckkopfes lokal auf die Oberfläche des Formstoffes bzw. des Formstoff-Zusatzstoff-Gemisches appliziert. Um die Förderbarkeit des Binders in diesem Prozess zu gewährleisten, muss die Viskosität des Binders typischerweise herabgesetzt werden. Dies hat den Nachteil, dass der niedrig-viskose Binder auf der Formstoffoberfläche verläuft und somit Bereiche außerhalb des von dem Druckkopf adressierten „Pixels“ verklebt, wodurch die Konturenschärfe und die Maßhaltigkeit der gefertigten Formen und Kerne verringert wird. Des Weiteren wird dabei auch die erzielbare Festigkeit des Verbundes herabgesetzt.In the prior art, molds and cores for the sand casting process are also produced from the aforementioned components using the additive manufacturing process of 3D printing (cf. VDI guideline 3405), so-called binder jetting, in which the powdered molding material is used as the starting material with the aid of the binder supplied is bonded in layers and selectively. The binder is applied locally to the surface of the molding material or the mixture of molding material and additives using a movable print head. In order to ensure the conveyability of the binder in this process, the viscosity of the binder typically has to be reduced. The disadvantage of this is that the low-viscosity binder runs on the surface of the molding material and thus sticks to areas outside of the "pixel" addressed by the print head, which reduces the sharpness of contours and the dimensional accuracy of the molds and cores produced. Furthermore, the achievable strength of the composite is also reduced.
Zur Minderung dieser Effekte werden vor dem 3D-Druck entsprechende Mengen an Zusatzstoffen zur Aktivierung der Oberflächen der Formstoffkörner und zur beschleunigten Aushärtereaktion mit dem Binder in den Formstoff eingebracht. Der derart „aktivierte“ Formstoff ist nur teilweise wiederverwendbar und kann einen Anteil von maximal 30-50% des Formstoffes einer nachfolgenden Füllung der 3D-Druckvorrichtung bilden, so dass ein nachteilig hoher Ressourcenverbrauch vorliegt.To reduce these effects, appropriate amounts of additives are introduced into the molding material before 3D printing to activate the surfaces of the molding material grains and to accelerate the curing reaction with the binder. The molding material “activated” in this way can only be partially reused and can form a maximum proportion of 30-50% of the molding material of a subsequent filling of the 3D printing device, so that there is a disadvantageously high consumption of resources.
OFFENBARUNG DER ERFINDUNGDISCLOSURE OF THE INVENTION
Es ist daher die Aufgabe der vorliegenden Erfindung, ein Verfahren und eine Vorrichtung zur Herstellung von Gussformen oder Gusskernen aus einem granularen Formstoff mittels 3D-Druck vorzuschlagen, welche die vorgenannten Nachteile des Standes der Technik überwindet.It is therefore the object of the present invention to propose a method and a device for producing casting molds or casting cores from a granular molding material using 3D printing, which overcomes the aforementioned disadvantages of the prior art.
Diese Aufgabe wird ausgehend von einem Verfahren und einer 3D-Druckvorrichtung gemäß der Oberbegriffe der Ansprüche 1 und 8 gelöst. Vorteilhafte Weiterbildungen der Erfindung sind in den abhängigen Ansprüchen angegeben.This object is achieved based on a method and a 3D printing device according to the preambles of
Die technische Lehre der Erfindung offenbart, dass vor dem Zuführen des Binders eine Plasmabehandlung des Formstoffes zur Oberflächenaktivierung durchgeführt wird.The technical teaching of the invention reveals that before the binder is supplied, a plasma treatment of the molding material is carried out for surface activation.
Die Erfindung geht dabei von dem Gedanken aus, die Benetzbarkeit der Oberflächen der Formstoffkörner sowie deren Bindungsaffinität mit dem Binder mittels der Plasmabehandlung zu erhöhen, so dass Maßhaltigkeit und Festigkeit der gefertigten Gussformen und Gusskerne signifikant verbessert werden und insbesondere auf den Einsatz von Zusatzstoffen in Form von Haftvermittlern und Aktivatoren verzichtet werden kann.The invention is based on the idea of increasing the wettability of the surfaces of the molding material grains and their binding affinity with the binder by means of plasma treatment, so that the dimensional accuracy and strength of the manufactured casting molds and casting cores are significantly improved and, in particular, the use of additives in the form of Adhesion promoters and activators can be dispensed with.
Die Plasmabehandlung erzeugt durch Wechselwirkung der Plasmaspezies, insbesondere ionisierter Moleküle und Radikale, mit dem Formstoff eine temporär chemisch reaktive Oberfläche. Wird der Formstoff beispielsweise mit einem Luftplasma behandelt, so werden in erster Linie sauerstoffhaltige Gruppen, wie Hydroxyl-, Carbonyl- oder Carboxylgruppen, an die Oberflächen der Formstoffkörner angebunden, welche dadurch einen polaren und reaktionsfreudigen Charakter gewinnen. Durch die Einwirkung des Plasmas werden somit die Oberflächenenergie und die Benetzbarkeit erhöht, und die Haftungseigenschaften für den Binder werden verbessert.The plasma treatment creates a temporarily chemically reactive surface through the interaction of the plasma species, in particular ionized molecules and radicals, with the mold material. If the molding material is treated with an air plasma, for example, groups containing oxygen, such as hydroxyl, carbonyl or carboxyl groups, are primarily bound to the surfaces of the molding material grains, which thereby gain a polar and reactive character. Thus, exposure to the plasma increases surface energy and wettability, and improves adhesion properties for the binder.
In vorteilhafter Ausführungsform des erfindungsgemäßen Verfahrens wird die Plasmabehandlung des Formstoffes schichtweise und selektiv durchgeführt und kann insbesondere zeitlich und örtlich korreliert mit dem Zuführen des Binders erfolgen. Die Plasmabehandlung erfolgt vorzugsweise also als ein mit dem 3D-Druck synchronisierter und diesem unmittelbar vorangehender Prozess, wobei sukzessive kleinteilige Formstoffvolumina plasmabehandelt werden, welche zur nachfolgenden Zufuhr von Binder vorgesehen sind. Dadurch wird gewährleistet, dass der Binder stets auf eine frisch aktivierte Formstoffoberfläche appliziert wird. Alternativ wäre erfindungsgemäß auch eine Plasmabehandlung des gesamten als Ausgangsmaterial verwendeten Formstoffes oder zumindest eine schichtweise vollflächige Plasmabehandlung durchführbar, was nachteiligerweise jedoch mit einer potentiellen Degradation des Oberflächenaktivierungsgrades vor dem Applizieren des Binders einhergehen könnte, sowie mit einem unverhältnismäßig hohen Energiebedarf der Plasmabehandlung.In an advantageous embodiment of the method according to the invention, the plasma treatment of the molding material is carried out in layers and selectively and can, in particular, be correlated in terms of time and location with the supply of the binder. The plasma treatment is preferably carried out as a process that is synchronized with the 3D printing and immediately preceding it, with successive small-scale molding material volumes being plasma-treated, which are provided for the subsequent supply of binder. This ensures that the binder is always applied to a freshly activated mold surface. Alternatively, according to the invention, a plasma treatment of the entire molding material used as the starting material or at least a layered, full-surface plasma treatment could be carried out, which, however, could disadvantageously be associated with a potential degradation of the degree of surface activation before the application of the binder, as well as with a disproportionately high energy requirement for the plasma treatment.
Beispielsweise wird die Plasmabehandlung des Formstoffes mit einem LuftPlasma, einem Sauerstoff-Plasma, einem Stickstoff-Plasma oder einem Ammoniak-Plasma durchgeführt. Beim Einsatz von (gereinigter und getrockneter) Umgebungsluft oder reinem Sauerstoff als Plasmagase werden vorwiegend Hydroxyl-, Carboxyl-, Carbonyl- oder Peroxid-Gruppen auf den Oberflächen der behandelten Formstoffkörner gebildet. Wird hingegen Stickstoff oder Ammoniak verwendet, so führt das zur Bildung von Amin- oder Imin-Gruppen, welche für bestimmte Binder ebenfalls interessant sein können.For example, the plasma treatment of the molding material is carried out with an air plasma, an oxygen plasma, a nitrogen plasma or an ammonia plasma. When using (purified and dried) ambient air or pure oxygen as plasma gases, predominantly hydroxyl, carboxyl, carbonyl or peroxide groups are formed on the surfaces of the treated molding material grains. If, on the other hand, nitrogen or ammonia is used, this leads to the formation of amine or imine groups, which can also be of interest for certain binders.
Vorzugsweise wird die Plasmabehandlung des Formstoffes mit einem Atmosphärendruck-Plasma durchgeführt. Im Vergleich zu einer Behandlung mit einem Niederdruck-Plasma ist der dazu notwendige apparative Aufwand gering, da keine evakuierbare Reaktionskammer um die verwendete 3D-Druckvorrichtung herum aufgebaut werden muss.The plasma treatment of the molding material is preferably carried out with an atmospheric pressure plasma. Compared to a treatment with a low-pressure plasma, the equipment required for this is low, since no evacuatable reaction chamber has to be set up around the 3D printing device used.
Sämtliche aus Verfahren nach dem Stand der Technik verwendeten Formstoffe und Binder können auch zur Herstellung von Gussformen oder Gusskernen mittels des erfindungsgemäßen Verfahrens verwendet werden. Beispielsweise wird der Formstoff als ein natürlicher Quarzsand, ein Schamott, ein Chromit, ein Olivin, ein synthetischer Keramikwerkstoff oder als ein Gemisch daraus ausgewählt. Ein Beispiel eines gebräuchlichen Formstoffes aus synthetischem Keramikwerkstoff stellt der unter dem Markennamen CERABEADS vertriebene künstliche Sand aus einem Al2O3 / SiO2 Gemisch dar. Der Binder wird etwa als ein Furanharz, ein Phenolharz oder ein Alkalisilikat ausgewählt.All molding materials and binders used in processes according to the prior art can also be used to produce casting molds or casting cores using the process according to the invention. For example, the molding material is selected from a natural quartz sand, a fireclay, a chromite, an olivine, a synthetic ceramic material, or a mixture thereof. An example of a common molding material made of synthetic ceramic material is the artificial sand made from an Al 2 O 3 /SiO 2 mixture sold under the brand name CERABEADS. The binder is selected as a furan resin, a phenolic resin or an alkali silicate.
Des Weiteren betrifft die Erfindung eine 3D-Druckvorrichtung zur Herstellung von Gussformen oder Gusskernen aus einem granularen Formstoff, wobei die 3D-Druckvorrichtung wenigstens umfasst:
- - eine Arbeitsplattform,
- - eine Dosiereinheit zum schichtweisen Auftragen des Formstoffes auf die Arbeitsplattform, und
- - einen verfahrbaren Druckkopf zum selektiven Zuführen eines Binders zu dem Formstoff auf der Arbeitsplattform,
- - a working platform,
- - a dosing unit for applying the molding material in layers to the working platform, and
- - a movable print head for selectively feeding a binder to the molding material on the work platform,
Der grundsätzliche Aufbau der erfindungsgemäßen Vorrichtung entspricht also einer 3D-Druckvorrichtung aus dem Stand der Technik, worin typischerweise die Arbeitsplattform höhenverstellbar ist und beim Druckprozess sukzessive schichtweise abgesenkt wird, und wobei die Dosiereinheit beispielsweise nach dem Prinzip einer Rakel arbeitet. Erfindungsgemäß wir eine solche 3D-Druckvorrichtung um eine Plasmadüse zur Plasmabehandlung des Formstoffes erweitert. Die Plasmadüse umfasst dabei sämtliche Komponenten zur Erzeugung und zielgerichteten Ausbringung eines Plasmas, d.h. insbesondere eine geeignete Elektrodenanordnung mit Hochspannungsversorgung, eine Prozessgasversorgung und eine Austrittsdüse zum Ausblasen des Plasmas.The basic structure of the device according to the invention thus corresponds to a 3D printing device from the prior art, in which the working platform is typically height-adjustable and is successively lowered in layers during the printing process, and the dosing unit works, for example, according to the principle of a squeegee. According to the invention, such a 3D printing device is expanded by a plasma nozzle for plasma treatment of the molding material. The plasma nozzle includes all components for the generation and targeted application of a plasma, i.e. in particular a suitable electrode arrangement with a high-voltage supply, a process gas supply and an outlet nozzle for blowing out the plasma.
In vorteilhafter Ausführungsform der 3D-Druckvorrichtung ist die Plasmadüse an dem Druckkopf angeordnet und gemeinsam mit diesem verfahrbar. Beim Herstellungsprozess fährt die Plasmadüse dem Druckkopf voraus und führt die erfindungsgemäße Oberflächenaktivierung mittels Plasmabehandlung an den nachfolgend mit dem Druckkopf „bedruckten“, d.h. mit Binder beaufschlagten, Bereichen des Formstoffes durch. Vorzugsweise umfasst die 3D-Druckvorrichtung dazu eine Steuereinheit, welche zur Steuerung der Plasmabehandlung des Formstoffes in zeitlicher und örtlicher Korrelation mit dem Zuführen des Binders ausgebildet ist. Die Steuerung der Plasmabehandlung sowie des Druckkopfes basiert auf dem in der Steuereinheit hinterlegten digitalen Modell der herzustellenden Gussform bzw. des Gusskerns.In an advantageous embodiment of the 3D printing device, the plasma nozzle is arranged on the print head and can be moved together with it. During the manufacturing process, the plasma nozzle moves ahead of the print head and carries out the surface activation according to the invention by means of plasma treatment on the areas of the molding material that are subsequently “printed” with the print head, ie that have been subjected to binder. For this purpose, the 3D printing device preferably comprises a control unit, which is designed to control the plasma treatment of the molding material in temporal and spatial correlation with the supply of the binder. The control of the plasma treatment and the print head is based on the digital model of the cast mold or the cast core stored in the control unit.
Figurenlistecharacter list
Weitere, die Erfindung verbessernde Maßnahmen werden nachstehend gemeinsam mit der Beschreibung eines bevorzugten Ausführungsbeispiels der Erfindung anhand der Figuren näher dargestellt. Es zeigt:
-
1 eine schematische Ansicht der erfindungsgemäßen 3D-Druckvorrichtung bei der Durchführung des erfindungsgemäßen Verfahrens, und -
2 eine quergeschnittene Teilansicht zur1 .
-
1 a schematic view of the 3D printing device according to the invention when carrying out the method according to the invention, and -
2 a cross-sectional view of the1 .
Die 3D-Druckvorrichtung 100 umfasst den Druckkopf 20 und die daran angeordnete Plasmadüse 30, welche gemeinsam entlang der horizontalen y-Richtung verfahrbar an der Traverse 60 aufgenommen sind, wobei die Traverse 60 in der horizontalen x-Richtung verfahrbar ausgebildet ist. Der Druckkopf 20 und die Plasmadüse 30 sind in einem vertikalen Abstand oberhalb der Arbeitsplattform 10 gehalten, welcher einem geeigneten Arbeitsabstand zur Zufuhr des Binders 2 bzw. zur Behandlung mit dem Plasma 3 des auf der Arbeitsplattform 10 aufliegenden granulären Formstoffes 1 entspricht. Durch horizontales Verfahren des Druckkopfes 20 samt Plasmadüse 30 und der Traverse 60 kann rasterweise und selektiv jeder Bereich der Oberfläche des Formstoffes 1 adressiert und behandelt werden. Durch sukzessives Absenken der Arbeitsplattform 10 um je die Dicke der aktiven Schicht I entsteht aus der Gesamtheit der bedruckten Schichten II schichtweise die gewünschte Gussform. Dabei muss die Verfahrrichtung entlang der y-Richtung so gewählt sein, dass die Plasmadüse 30 während der Plasmabehandlung dem Druckkopf 20 voranfährt, so dass der Binder 2 stets frisch aktiviertem Formstoff 1 zugeführt wird. Das dabei gebildete Formstoff-Binder-Gemisch 12 zeichnet sich dank der erfindungsgemäßen Plasmabehandlung durch eine starke Wechselwirkung der aktivierten Oberflächen des Formstoffes 1 mit dem Binder 2 aus, was letztlich zur Bildung von scharf konturierten und festen Gussformen bzw. Gusskernen führt.The
Die Steuerung der Plasmabehandlung des Formstoffes 1 in zeitlicher und räumlicher Korrelation mit dem Zuführen des Binders 2 wird durch die Steuereinheit 40 ausgeführt, welche auf hier nicht gezeigte Weise mit der Plasmadüse 30 und/oder dem Druckkopf 20 verbunden ist, beispielsweise über die Zuleitungen 50, welche weiterhin der Spannungsversorgung sowie der Zufuhr der diversen Prozessmedien dienen.The control of the plasma treatment of the
Die Erfindung beschränkt sich in ihrer Ausführung nicht auf die vorstehend angegebenen bevorzugten Ausführungsbeispiele. Vielmehr ist eine Anzahl von Varianten denkbar, welche von der dargestellten Lösung auch bei grundsätzlich anders gearteten Ausführungen Gebrauch macht. Sämtliche aus den Ansprüchen, der Beschreibung oder den Zeichnungen hervorgehenden Merkmale und/oder Vorteile, einschließlich konstruktiver Einzelheiten oder räumlicher Anordnungen oder Verfahrensschritte, können sowohl für sich als auch in den verschiedensten Kombinationen erfindungswesentlich sein.The implementation of the invention is not limited to the preferred exemplary embodiments given above. Rather, a number of variants are conceivable which make use of the solution shown even in the case of fundamentally different designs. All of the features and/or advantages resulting from the claims, the description or the drawings, including structural details or spatial arrangements or process steps, can be essential to the invention both on their own and in a wide variety of combinations.
BezugszeichenlisteReference List
- 11
- Formstoffmolding material
- 22
- Binderbinder
- 1212
- Formstoff-Binder-GemischMixture of molding material and binder
- 33
- Plasmaplasma
- 100100
- 3D-Druckvorrichtung3D printing device
- 1010
- Arbeitsplattformworking platform
- 2020
- Druckkopfprinthead
- 3030
- Plasmadüseplasma jet
- 4040
- Steuereinheitcontrol unit
- 5050
- Zuleitungsupply line
- 6060
- Traversetraverse
- II
- aktive Schichtactive layer
- 1111
- bedruckte Schichtenprinted layers
- x, yx, y
- horizontale Richtunghorizontal direction
- ze.g
- vertikale Richtungvertical direction
Claims (10)
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| DE102020131832.4A DE102020131832A1 (en) | 2020-12-01 | 2020-12-01 | Process for the manufacture of casting molds or casting cores |
| PCT/EP2021/082810 WO2022117410A1 (en) | 2020-12-01 | 2021-11-24 | Method for producing casting molds or casting cores |
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Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0343038A1 (en) | 1988-05-10 | 1989-11-23 | Societe De Prestations De Services, S.P.S. | Surface cleaning method with a transported plasma |
| WO2001061743A1 (en) | 2000-02-16 | 2001-08-23 | Ziptronix, Inc. | Method for low temperature bonding and bonded structure |
| US8632651B1 (en) | 2006-06-28 | 2014-01-21 | Surfx Technologies Llc | Plasma surface treatment of composites for bonding |
| US20170259501A1 (en) | 2016-03-09 | 2017-09-14 | Universities Space Research Association | 3D Printed Electronics Using Directional Plasma Jet |
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| JP2015189007A (en) * | 2014-03-27 | 2015-11-02 | セイコーエプソン株式会社 | Production method of shaped article |
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2020
- 2020-12-01 DE DE102020131832.4A patent/DE102020131832A1/en active Pending
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Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0343038A1 (en) | 1988-05-10 | 1989-11-23 | Societe De Prestations De Services, S.P.S. | Surface cleaning method with a transported plasma |
| WO2001061743A1 (en) | 2000-02-16 | 2001-08-23 | Ziptronix, Inc. | Method for low temperature bonding and bonded structure |
| US8632651B1 (en) | 2006-06-28 | 2014-01-21 | Surfx Technologies Llc | Plasma surface treatment of composites for bonding |
| US20170259501A1 (en) | 2016-03-09 | 2017-09-14 | Universities Space Research Association | 3D Printed Electronics Using Directional Plasma Jet |
Non-Patent Citations (1)
| Title |
|---|
| Ramakrishnan, Robert: 3-D-Drucken mit einem anorganischen Formstoffsystem, Diss. TU München, 2016 |
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