CA2170714A1 - Process and device for manufacturing shaped parts out of metal - Google Patents

Process and device for manufacturing shaped parts out of metal

Info

Publication number
CA2170714A1
CA2170714A1 CA002170714A CA2170714A CA2170714A1 CA 2170714 A1 CA2170714 A1 CA 2170714A1 CA 002170714 A CA002170714 A CA 002170714A CA 2170714 A CA2170714 A CA 2170714A CA 2170714 A1 CA2170714 A1 CA 2170714A1
Authority
CA
Canada
Prior art keywords
mould cavity
metal
mould
holding chamber
thixoforming
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
CA002170714A
Other languages
French (fr)
Inventor
Hans Thurner
Jean-Pierre Gabathuler
Erich Rollin
Hansjorg Huber
Helmut Schelling
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
3A Composites International AG
Original Assignee
Alusuisse Lonza Services Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Alusuisse Lonza Services Ltd filed Critical Alusuisse Lonza Services Ltd
Publication of CA2170714A1 publication Critical patent/CA2170714A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21JFORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/004Thixotropic process, i.e. forging at semi-solid state
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/007Semi-solid pressure die casting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/14Machines with evacuated die cavity

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Powder Metallurgy (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)
  • Chemically Coating (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)

Abstract

A process for manufacturing shaped parts out of metal by pressing a thixotropic metal billet (20) by means of a piston (16) out of a holding chamber (12) into a mould cavity (30) is such that, at least up to the point in time (tE) at which the metal enters the mould cavity (30), the said mould cavity (30) is forcibly evacuated. A corresponding thixoforming unit is such that the mould cavity (30) is connected to a vacuum chamber (48).

Shaped parts having reduced gas porosity can be manufactured using the process.

Description

2 1 70~1~
, Process and Device for Manufacturin~ Shaoed Parts out of Metal The invention relates to a process for m~nl~f~cturing shaped parts out of metal by pressing a thixotropic metal billet by means of a piston out of a holding chamber into a mould cavity.
5 Also within the scope of the invention is a thixoforming unit suitable for carrying out the process according to the invention.

The process for mAmlf~cturing shaped parts out of thixotropic i.e. partially solid/partially liquid metal billets is known as thixofo,mlng. Metal billets that come into consideration for 10 this purpose are all billets of metal that can be ~ nsru,lncd to the thixotropic state. In particular, the metal billets may be of ~ mini~lm m~gnecillm or zinc and their alloys.

Thixoforming of thoxotropic materials is generally known. In this process the thixotropic properties of partially solid and partially liquid metal alloys are exploited. By the tlfi~ollopic 15 behaviour of a metal alloy is to be understood that a suitably prepared metal behaves as a solid, if not subjected to force, if shear forces are applied to it, however, its viscosity is reduced to such a degree that it behaves in a manner similar to that of molten metal. For that purpose it is necessary for the alloy to be heated to the solidification interval between the solidus and the liquidus telllpelalllres. The temperature has to be adjusted such that e.g. 20 to 20 80% of the structure is molten while the rest is in the solid state. In thixofo",ling the partially solid/partially liquid metal is introduced in the form of a thixotropic metal billet into a -normally horizontal - holding chal"bel and, by means of a piston, introduced or injected into a mould cavity in which the thixotropic metal alloy solidifies.

25 In the ~ oro"""~g process the filling of the mould cavity with the partial solid/partially liquid metal takes place essentially under laminar flow conditions The metal forms a closed front which pushes the air ahead of it in the direction of the evacuation channels and the air can escape via these ch~nn~lc. Although the filling of the mould cavity takes place relatively slowly, air and/or other gaseous conctit~lents may become trapped in the shaped part - which 30 can lead to porosity and blisters, especially after heat lre~ Also, with the passage of time, the evacuation chA--n~lc may become at least partially blocked by deposits of mould sepalalillg material. This leads to increased gas pressure ahead of the metal front and ~helero,e to inc,eased levels of gas in the shaped part. Consequently the gas porosity in the shaped parts can vary, depending on the degree of co~ l ion When m~nllf~cturing shaped parts of special shape e.g. with lugs, it is inevitable that two or more metal fronts form, which on collision can lead to localised e"l,ap"~ent of gases between n~() 217~

the fronts. This occurs especially if no evacuation is provided or is impossible at the region where the two fronts meet; consequently this leads systematically to defects in the part.

In view of the above, the object of the present invention is to provide a process of the kind 5 mentioned at the start by means of which the gas porosity in the shaped parts may be reduced further. To this end a thixorolllling unit suitable for carrying out the process has to be provided.

The objective of the invention is achieved by way of the invention in that at least up to the 10 point in time at which the metal enters the mould cavity, the said mould cavity is forcibly evacuated. Special and further developed forms of the invention are presented in dependent patent claims.

Using the process according to the invention thixoformed parts can be m~nllf~ctured that 15 exhibit a reduced degree of porosity compaled with shaped parts that are m~n~lf~ctured by state of the art methods.

Investigations show that the gas content of thixorolllled parts is already at a very low level so that no problems regarding porosity should arise. In spite of this, in certain parts and when 20 the quality requil~lllenls are very high, the gas content may be too high in some regions of the part in question. One reason for locally elevated gas porosity can be e.g. that the filling speed for thin-walled parts has to be made so high that the metal front is no longer compact.
Also, in some specific shaped parts, it is practically impossible to remove the gases from certain regions that cannot be evacuated. Provided no full solution heat lre~l."e.~l is required, 25 the gases remain in solution or colllpressed under very high pressure - which presents no special problem. If, however, high lllech~Lcal propellies are required, and thererore heat lle~ .l is n ecessa,y, then even small amounts of gases that are concentrated at particular sites may cause problelns. Forcible evacuation of the mould cavity in accordance with the invention is of ~csi~t~nce here.
Particularly good results may be oblail1ed if forced evacuation is l"A;~IA;~-ed practically right up to the complete filling of the mould.

An advantageous further development of the process is such that the holding challlber is 35 thermally in~ ted and/or heated. This reduces the cooling of the metal billet, and so allows more time for evacuation.

case 2060 ~17071 4 _ - 3 -Forced evacuation of the mould cavity makes it possible to accelerate the speed of the piston after the point in time of metal entering the mould cavity; the filling of the mould can therefore also be accelerated, making it possible to produce thin-walled parts.
A thixoforming unit suitable for carrying out the process according to the invention exhibits a 5 holding chanlber to accommodate a thixotropic metal billet, a mould cavity following on from the holding ch~llber and a piston for pressing the metal billet out of the holding chamber into the mould cavity. In accoldance with the invention, the mould cavity is connected to a vacuum chamber.

10 Provided between the mould cavity and the vacuum is usefully a re~ ting facility for opening and closing the connection b~lween the mould cavity and the vacuum ch~lber.

In a p-ere led version of the thixofolllllllg unit the re~ ting facility features a control shaft with a closure head; the latter serves to open the and close an evacuation channel following 15 on immediately from the mould cavity.

In order to achieve good thermal insulation, the holding cl~,lber may be made of a ceramic material, especially Si3N4. It is also possible to provide the heating challlber with heating facilities. These heating facilities may e.g. be in the form of heating rods or challl-els in the 20 wall of the holding cha,lll~er through which a heated medium flows, for example oil.

Further advantages, features and details of the invention are revealed in the following description of a pr~rell~;d exemplified embodiment and with the aid of the drawing showing sçhem~tically in Fig. 1 a longitll-lin~l section through a thixoforming unit with forced evacuation;

Fig. 2 a typical sequence of events during the filling of the mould during thixoforming.

30 A thixoforming unit 10 shown in figure 1 exhibits a ho.i~ol-lal, cylindrical holding chamber 12 with interior 14. An openillg 18 in the holding chamber 12 enables a thixotropic metal billet 20 to be introduced into the interior 14. The displ~cement of the metal billet 20 in the interior 14 of the holding chamber 12 is effected by a piston 16 which can move along the axis x of the holding cha,llber 12.
The holding ch~llbel- 12 terminates at a stationary mould plate 22 which faces a moveable mould plate 24. Each of the mould plates 22, 24 forms a mould half 26, 28 which, when case 2060 ~170~1~

closed, together form a mould interior 30 in which the shaped part is created when the metal solidifies.

The mould interior 30 features one or more evacuating chatmels 34 which, if desired lead to a 5 main ch~nnel A reg~ ting unit 36 with re~ ting shaft 38 is provided in the moveable form plate 24. The reg~ ting shaft 38 features a closure head 40 for ope~ g and closing the ev~A.~u~ting channel 34. Displacement of the re~ ting shaft 38 takes place via an actuating cylinder 42 flanged onto the outside of the moveable mould plate 24. This arrangement allows forcible evacuation of the mould cavity 30 to be ,~ ed right up until the cavity 10 30 has been completely filled. Only when the filling has been completed is the eviqc~ tinE
channel 34 closed at the end of the mould cavity 30 by means of the closure head 40 on the re~ ting shaft 38.

Connected to the re~ ting facility 36 is a vacuum pipeline 44 which is in turn connected to 15 a vacuum cha-nber 48 via a valve 46. The vacuum chamber 48 is evacu~ted by means of a vacuum pump 50 and held at reduced pressure. Manometers 52 are provided for checking the pressure.

The closure head 40 on the re~ tin~ shaft 38 acts as a valve and serves a number of 20 purposes:

- Before filling the mould, the valve is closed and the vacuum creates a reduced pressure in the vacuum ch~llber 48.

25 - During the first filling phase the valve is opened in a controlled manner and effects the start of the forced evacuation.

- When the filling of the mould has been completed, the valve is closed in order that no metal may enter the unit. It is also neces~ry to close the valve in order that the mould halves 26, 30 28 may be separated and the mould opened, and to allow the reduced pressure to be formed again in the vacuum ch~l.ber 48.

Forced evacuation starts at the earliest when the piston 16 has closed opening 18 in the holding chamber 12 and at the latest when the tool is opened again by sep~ g the two 35 halves of the mould 26, 28. Usefully and advantageously, forced evacuation ends as soon as the filling ofthe mould has been completed i.e. the piston 16 is no longer moving. The forced evacuation may of course also be te".~ Ale~ earlier. The points at which forced evacuation case 2060 Z170~1~

starts and stops may be determined by displacement sensors on the piston rod. The starting and stopping points may, however, also be controlled as a function of time, speed or pressure. A further possibility is to employ sensors detecting the metal front i.e. sensors that release a switch when the metal front reaches a particular site.
s Shown in figure 2 is a typical sequence of events accompanying the filling of the mould in a ~hixofolllling unit with forced evacuation. During a first filling phase the piston delivers the metal up to the gate of the mould; in a second filling phase that begins at the point in time (t~) when the metal starts to enter the mould cavity, the mould is filled with metal. Both 10 filling phases in thixorolllling are typically of about the same duration e.g. 0.5 sec. The time of evacuation is thelefore less than 1 sec. The removal of the gases may begin only after the piston has closed off the entry port. On the other hand the speed of the piston can not be reduced at will, as this could cause too much metal to freeze in the holding chamber.

15 It is not necess~y to ~ a very high vacuum i.e. Iow pressure. It is sufflcient to suck off the gases present in the mould cavity before and during the filling of the mould so that no counter-pressure is created by these gases. By means of trials it was possible to confirm that it is not essential to provide a very high vacuum i. e. very low pressure, in order to achieve extremely good results with respect to porosity.

case 2060

Claims (9)

1. Process for manufacturing shaped parts out of metal by pressing a thixotropic metal billet (20) by means of a piston (16) out of a holding chamber (12) into a mouldcavity (30), characterised in that, at least up to the point in time (tE) at which the metal enters the mould cavity (30), the said mould cavity (30) is forcibly evacuated.
2. Process according to claim 1, characterised in that the forcible evacuation is main-tained until the mould has been completely filled.
3. Process according to claim 1 or 2, characterised in that the holding chamber (12) is thermally insulated and/or heated.
4. Process according to one of the claims 1 to 3, characterised in that the speed of the piston is increased after the point in time (tE) at which the metal enters the mould cavity (30).
5. Thixoforming unit for carrying out the process of the invention according to one of the claims 1 to 4 having a holding chamber (12) to accommodate a thixotropic metal billet (20), a mould cavity (30) following on from the holding chamber (12) and a piston (16) for pressing the metal billet (20) out of the holding chamber (12) and into the mould cavity (30), characterised in that the mould cavity (30) is connected to a vacuum chamber (48).
6. Thixoforming unit according to claim 5, characterised in that a regulating facility for opening and closing the connection between the mould cavity (30) and the vacuum chamber (48) is provided between the mould cavity (30) and the vacuum chamber (48).
7. Thixoforming unit according to claim 6, characterised in that the regulating facility features a regulating shaft (38) with a closure head (40), said closure head (40) serving the purpose of opening and closing an evacuating channel (34) immediately following the mould cavity (30).
8 Thixoforming unit according to one of the claims 5 to 7, characterised in that the holding chamber (30) is of a ceramic material, in particular Si3N4.
9. Thixoforming unit according to one of the claims 7 to 8, characterised in that the holding chamber (30) features heating facilities.
CA002170714A 1995-03-21 1996-02-29 Process and device for manufacturing shaped parts out of metal Abandoned CA2170714A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CH00797/95-1 1995-03-21
CH00797/95A CH689448A5 (en) 1995-03-21 1995-03-21 Producing shaped metal components

Publications (1)

Publication Number Publication Date
CA2170714A1 true CA2170714A1 (en) 1996-09-22

Family

ID=4195412

Family Applications (1)

Application Number Title Priority Date Filing Date
CA002170714A Abandoned CA2170714A1 (en) 1995-03-21 1996-02-29 Process and device for manufacturing shaped parts out of metal

Country Status (11)

Country Link
EP (1) EP0733422B1 (en)
JP (1) JPH08257729A (en)
AT (1) ATE189634T1 (en)
CA (1) CA2170714A1 (en)
CH (1) CH689448A5 (en)
DE (1) DE59604390D1 (en)
DK (1) DK0733422T3 (en)
ES (1) ES2143743T3 (en)
GR (1) GR3033176T3 (en)
NO (1) NO312182B1 (en)
PT (1) PT733422E (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104259430A (en) * 2014-10-21 2015-01-07 湖南航天诚远精密机械有限公司 Metal and alloy vacuum die casting forming device and method

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10022560A1 (en) * 2000-05-10 2001-11-15 Fuchs Lubritech Gmbh Pressure casting machine comprises a two-part casting mold forming a casting chamber via a ventilating channel, and a pressure monitoring device connected to the ventilating channel and arranged between a valve and a filter
DE10043717A1 (en) * 2000-09-04 2002-03-14 Buehler Druckguss Ag Uzwil Process for compressive reforming of aluminum or magnesium alloys comprises conveying the liquid or liquid material from a preparation chamber into a casting chamber of a die casting machine
DE10144945B4 (en) * 2001-09-12 2005-05-04 Alcan Bdw Gmbh & Co. Kg A method of controlling a vacuum valve of a vacuum die casting apparatus and vacuum die casting apparatus
DE102009033532B4 (en) * 2009-07-10 2020-11-19 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Extruder for manufacturing a component made of light metal
JP5556108B2 (en) * 2009-09-25 2014-07-23 トヨタ自動車株式会社 Semi-molten metal casting method and semi-molten metal casting apparatus

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS54151513A (en) * 1978-04-27 1979-11-28 Leibfried Dieter Low pressure dieecasting of metal* particularly of ne metal and apparatus therefor
CA2053990A1 (en) * 1990-11-30 1992-05-31 Gordon W. Breuker Apparatus and process for producing shaped articles from semisolid metal preforms
FR2671992B1 (en) * 1991-01-30 1997-08-01 Transvalor Sa COLD CHAMBER PRESSURE CASTING PROCESS.
IT1245080B (en) * 1991-04-19 1994-09-13 Weber Srl PROCEDURE FOR OBTAINING HIGH MECHANICAL PERFORMANCE DIE CASTINGS BY INJECTION OF A METALLIC ALLOY TO THE SEMI-LIQUID STATE.

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104259430A (en) * 2014-10-21 2015-01-07 湖南航天诚远精密机械有限公司 Metal and alloy vacuum die casting forming device and method
CN104259430B (en) * 2014-10-21 2016-03-30 湖南航天诚远精密机械有限公司 Metal and alloy evacuated die-casting process Forming Equipments thereof and method

Also Published As

Publication number Publication date
GR3033176T3 (en) 2000-08-31
CH689448A5 (en) 1999-04-30
PT733422E (en) 2000-06-30
NO961110L (en) 1996-09-23
ES2143743T3 (en) 2000-05-16
EP0733422A1 (en) 1996-09-25
DK0733422T3 (en) 2000-07-24
DE59604390D1 (en) 2000-03-16
ATE189634T1 (en) 2000-02-15
JPH08257729A (en) 1996-10-08
EP0733422B1 (en) 2000-02-09
NO312182B1 (en) 2002-04-08
NO961110D0 (en) 1996-03-19

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Legal Events

Date Code Title Description
EEER Examination request
FZDE Discontinued