CA2556247A1 - Gravity die casting plant for metal-foam mouldings - Google Patents
Gravity die casting plant for metal-foam mouldings Download PDFInfo
- Publication number
- CA2556247A1 CA2556247A1 CA002556247A CA2556247A CA2556247A1 CA 2556247 A1 CA2556247 A1 CA 2556247A1 CA 002556247 A CA002556247 A CA 002556247A CA 2556247 A CA2556247 A CA 2556247A CA 2556247 A1 CA2556247 A1 CA 2556247A1
- Authority
- CA
- Canada
- Prior art keywords
- metal
- foam
- casting plant
- melt
- die casting
- 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
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D25/00—Special casting characterised by the nature of the product
- B22D25/005—Casting metal foams
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Molding Of Porous Articles (AREA)
Abstract
A gravity die casting plant (1) for metal-foam mouldings is proposed, comprising at least one die (2, 3, 4), one reservoir (16) for the metal melt and at least one metering and mixing device (11, 12, 13) for metering and mixing the foam-generating medium with the melt, at least one gate box (7) being arranged between the die (2, 3, 4) and the reservoir (16), and the metering and mixing device (11, 12, 13) being arranged in the gate box (7).
Description
Gravity die casting plant for metal-foam mouldings The invention relates to a gravity die casting plant for metal-foam mouldings, comprising at least one die, one reservoir for the metal melt and at least one metering and mixing device for metering and mixing the foam-generating medium with the melt.
In motor vehicle construction, in order to save weight, increasing use is made of castings and mouldings which are produced in part from metal foam. The foam-generating medium used is a gas, for example air or inert gas, or a medium generating gas at the casting temperature. By means of an impeller, as it is known, the gas or the gas-generating medium is supplied to the melt in a gate box and is distributed uniformly into the melt.
EP 1259344 B1 discloses a generic device for the production of metal-foam mouldings. A mould for the metal-foam mouldings has a widening inlet port which remains submerged in the melt during filling with the metal foam. An impeller agitator is arranged below the inlet port in the melt. A gas supply is provided in the axis of rotation of the impeller agitator or directly adjacently to the agitator. The intensity of intermixing and the foam content of the metal melt can be set.
Proceeding from this prior art, the object of the invention is to specify a gravity die casting plant for metal-foam mouldings, in which the method parameters can be set as flexibly as possible.
This object is achieved by means of a gravity die casting plant for metal-foam mouldings, comprising at least one die, one reservoir for the metal melt and at least one metering and mixing device for metering and 3109fem mixing the foam-generating medium with the melt, at least one gate box being arranged between the die and the reservoir, and the metering and mixing device being arranged in the gate box.
Preferred developments of the invention may be gathered from the dependent claims.
It is advantageous that a plurality of metal-foam mouldings having different properties can be produced simultaneously in each casting cycle. This is achieved in that the gate box has a plurality of gate regions.
This is also achieved in that a metering and mixing device for metering and mixing the foam-generating medium with the melt is arranged in each gate region.
An exemplary embodiment of the invention is described with reference to the figures in which:
Figure 1 shows a perspective view of a gravity die casting plant according to the invention, and Figure 2 shows a section through the gravity die casting plant of Figure 1.
Figures 1 and 2 illustrate diagrammatically a gravity die casting plant 1 for the production of metal-foam mouldings, with three dies 2, 3, 4 next to one another.
Figure 1 shows a perspective illustration and Figure 2 a longitudinal section through the casting plant of Figure 1. The dies 2, 3, 4 are constructed in each case from two die halves 2a, 2b, 3a, 3b, 4a, 4b. The dies 2, 3, 4 are installed between two insulating walls 5, 6.
Heating or coolant lines may be installed in the insulating walls 5, 6. What is achieved thereby is that the dies 2, 3, 4 can be cooled or heated in a controlled way before and/or after the casting 3109fem operation. What is achieved thereby is that the structure of the metal-foam moulding can be influenced by adherence to a temperature/time program. If the lines to each die 2, 3, 4 are activated separately, three mouldings with different structures and/or qualities can be produced in one casting operation. One moulding with three or more different regions may also be produced, however, if one large die is installed between the insulating walls 5, 6, instead of three smaller dies.
A gate box 7 can be seen below the dies 2, 3, 4. The gate box 7 has three gate regions 8, 9, 10 arranged next to one another. Each die 2, 3, 4 is thus assigned a gate region 8, 9, 10. If a large die is used, a larger metal-foam body with three differently formed regions can be produced in one casting operation.
Three impeller agitators 11, 12, 13 are illustrated in Figure 1 perpendicularly to the plane of Figure 2 and more clearly. The impeller agitators 11, 12, 13 are in each case assigned to a gate region 8, 9, 10. The metal melt is agitated and gassed by means of the impeller agitator 11, 12, 13. For the formation of foam, a gaseous or foam-forming medium, for example air or inert gas, is supplied to the melt in the die through ports in the impeller agitator 11, 12, 13. The impeller agitator 11, 12, 13 consists of a hollow rotatable shaft which projects into the respective gate region 8, 9, 10 from the side into the metal melt and which drives at the shaft end a vane wheel or an impeller having gas outlet ports. By means of the impeller agitator 11, 12, 13, in each gate region 8, 9, 10, air or inert gas or another foam-generating medium is supplied or metered in a defined quantity ratio to the melt and mixed with the metal melt. By the impeller agitator 11, 12, 13 being arranged directly below the 3109fem die 2, 3, 4, the formation of foam takes place in the die 2, 3, 4 already filled with melt. As a result of the excess pressure which is generated by the impeller by means of the gas supply, part of the melt is driven out of the die 2, 3, 4 back into the gate box 7.
Foam formation and the stabilization of the foam can be improved if the melt has added to it solid particles which have a beneficial influence on the surface tension at the interface between the gas and the metal melt. Instead of the impeller agitator 11, 12, 13, another suitable metering and mixing device may also be installed. It is also conceivable that a plurality of gate regions 8, 9, 10 are operated by means of one impeller agitator 11, 12, 13, so that two cast mouldings having the same properties can be produced simultaneously.
The gate box 7 has on the underside a connection 14 for a riser pipe 15 or another line for connecting the metal melt to a reservoir 16. In the already kn own rising low-pressure casting method, as it is refer red to, the riser pipe 15 is immersed in the reservoir 16, and the reservoir 16 is closed off and acted upon by pressure, for example by inert gas. Owing to the pressure on the melt surface in the reservoir 16, the metal melt rises into the riser pipe 15 and into the gate box 7. It is also conceivable to fill via a plurality of riser pipes 15 a plurality of gate boxe s which could then, in turn, fill one or more dies 2, 3, 4. The metal melt may be a light-metal melt, for example an aluminium or magnesium melt. The gravity die casting plant 1 may, however, also be designed for other metals. The solid particles which may be ad ded for foam formation are administered in the reservoir 16 or in the melting furnace for the melt.
3109fem By means of the gravity die casting plant 1 described here, the method parameters for each gate region 8, 9, and for each die 2, 3, 4 can be set separately. The chemical parameters of the melt can be varied by 5 additions in the gate box 7. The temperature of the melt or of the metal foam can be varied by the preheating or precooling of the die 2, 3, 4 or by additional heating which may be installed in each gate region 8, 9, 10 of the gate box 7. By the action of 10 pressure upon the reservoir 16, the casting speed can be set. Foam formation and foam consistency can be set by means of the gas quantity and the impeller speed. A
separate temperature/time curve can be achieved for each die 2, 3, 4 by means of a control of the holding times.
Metal-foam bodies with different geometries can be produced simultaneously or, if one large die is connected to a plurality of gate regions 8, 9, 10, a larger metal-foam body with differently foamed regions can be produced. Larger castings may also be produced, which are foamed in some regions, but in other regions are not foamed, that is to say are filled completely.
3109fem
In motor vehicle construction, in order to save weight, increasing use is made of castings and mouldings which are produced in part from metal foam. The foam-generating medium used is a gas, for example air or inert gas, or a medium generating gas at the casting temperature. By means of an impeller, as it is known, the gas or the gas-generating medium is supplied to the melt in a gate box and is distributed uniformly into the melt.
EP 1259344 B1 discloses a generic device for the production of metal-foam mouldings. A mould for the metal-foam mouldings has a widening inlet port which remains submerged in the melt during filling with the metal foam. An impeller agitator is arranged below the inlet port in the melt. A gas supply is provided in the axis of rotation of the impeller agitator or directly adjacently to the agitator. The intensity of intermixing and the foam content of the metal melt can be set.
Proceeding from this prior art, the object of the invention is to specify a gravity die casting plant for metal-foam mouldings, in which the method parameters can be set as flexibly as possible.
This object is achieved by means of a gravity die casting plant for metal-foam mouldings, comprising at least one die, one reservoir for the metal melt and at least one metering and mixing device for metering and 3109fem mixing the foam-generating medium with the melt, at least one gate box being arranged between the die and the reservoir, and the metering and mixing device being arranged in the gate box.
Preferred developments of the invention may be gathered from the dependent claims.
It is advantageous that a plurality of metal-foam mouldings having different properties can be produced simultaneously in each casting cycle. This is achieved in that the gate box has a plurality of gate regions.
This is also achieved in that a metering and mixing device for metering and mixing the foam-generating medium with the melt is arranged in each gate region.
An exemplary embodiment of the invention is described with reference to the figures in which:
Figure 1 shows a perspective view of a gravity die casting plant according to the invention, and Figure 2 shows a section through the gravity die casting plant of Figure 1.
Figures 1 and 2 illustrate diagrammatically a gravity die casting plant 1 for the production of metal-foam mouldings, with three dies 2, 3, 4 next to one another.
Figure 1 shows a perspective illustration and Figure 2 a longitudinal section through the casting plant of Figure 1. The dies 2, 3, 4 are constructed in each case from two die halves 2a, 2b, 3a, 3b, 4a, 4b. The dies 2, 3, 4 are installed between two insulating walls 5, 6.
Heating or coolant lines may be installed in the insulating walls 5, 6. What is achieved thereby is that the dies 2, 3, 4 can be cooled or heated in a controlled way before and/or after the casting 3109fem operation. What is achieved thereby is that the structure of the metal-foam moulding can be influenced by adherence to a temperature/time program. If the lines to each die 2, 3, 4 are activated separately, three mouldings with different structures and/or qualities can be produced in one casting operation. One moulding with three or more different regions may also be produced, however, if one large die is installed between the insulating walls 5, 6, instead of three smaller dies.
A gate box 7 can be seen below the dies 2, 3, 4. The gate box 7 has three gate regions 8, 9, 10 arranged next to one another. Each die 2, 3, 4 is thus assigned a gate region 8, 9, 10. If a large die is used, a larger metal-foam body with three differently formed regions can be produced in one casting operation.
Three impeller agitators 11, 12, 13 are illustrated in Figure 1 perpendicularly to the plane of Figure 2 and more clearly. The impeller agitators 11, 12, 13 are in each case assigned to a gate region 8, 9, 10. The metal melt is agitated and gassed by means of the impeller agitator 11, 12, 13. For the formation of foam, a gaseous or foam-forming medium, for example air or inert gas, is supplied to the melt in the die through ports in the impeller agitator 11, 12, 13. The impeller agitator 11, 12, 13 consists of a hollow rotatable shaft which projects into the respective gate region 8, 9, 10 from the side into the metal melt and which drives at the shaft end a vane wheel or an impeller having gas outlet ports. By means of the impeller agitator 11, 12, 13, in each gate region 8, 9, 10, air or inert gas or another foam-generating medium is supplied or metered in a defined quantity ratio to the melt and mixed with the metal melt. By the impeller agitator 11, 12, 13 being arranged directly below the 3109fem die 2, 3, 4, the formation of foam takes place in the die 2, 3, 4 already filled with melt. As a result of the excess pressure which is generated by the impeller by means of the gas supply, part of the melt is driven out of the die 2, 3, 4 back into the gate box 7.
Foam formation and the stabilization of the foam can be improved if the melt has added to it solid particles which have a beneficial influence on the surface tension at the interface between the gas and the metal melt. Instead of the impeller agitator 11, 12, 13, another suitable metering and mixing device may also be installed. It is also conceivable that a plurality of gate regions 8, 9, 10 are operated by means of one impeller agitator 11, 12, 13, so that two cast mouldings having the same properties can be produced simultaneously.
The gate box 7 has on the underside a connection 14 for a riser pipe 15 or another line for connecting the metal melt to a reservoir 16. In the already kn own rising low-pressure casting method, as it is refer red to, the riser pipe 15 is immersed in the reservoir 16, and the reservoir 16 is closed off and acted upon by pressure, for example by inert gas. Owing to the pressure on the melt surface in the reservoir 16, the metal melt rises into the riser pipe 15 and into the gate box 7. It is also conceivable to fill via a plurality of riser pipes 15 a plurality of gate boxe s which could then, in turn, fill one or more dies 2, 3, 4. The metal melt may be a light-metal melt, for example an aluminium or magnesium melt. The gravity die casting plant 1 may, however, also be designed for other metals. The solid particles which may be ad ded for foam formation are administered in the reservoir 16 or in the melting furnace for the melt.
3109fem By means of the gravity die casting plant 1 described here, the method parameters for each gate region 8, 9, and for each die 2, 3, 4 can be set separately. The chemical parameters of the melt can be varied by 5 additions in the gate box 7. The temperature of the melt or of the metal foam can be varied by the preheating or precooling of the die 2, 3, 4 or by additional heating which may be installed in each gate region 8, 9, 10 of the gate box 7. By the action of 10 pressure upon the reservoir 16, the casting speed can be set. Foam formation and foam consistency can be set by means of the gas quantity and the impeller speed. A
separate temperature/time curve can be achieved for each die 2, 3, 4 by means of a control of the holding times.
Metal-foam bodies with different geometries can be produced simultaneously or, if one large die is connected to a plurality of gate regions 8, 9, 10, a larger metal-foam body with differently foamed regions can be produced. Larger castings may also be produced, which are foamed in some regions, but in other regions are not foamed, that is to say are filled completely.
3109fem
Claims (11)
1. Gravity die casting plant (1) for metal-foam mouldings, comprising at least one die (2, 3, 4), one reservoir (16) for the metal melt and at least one metering and mixing device (11, 12, 13) for metering and mixing the foam-generating medium with the melt, characterized in that at least one gate box (7) is arranged between the die (2, 3, 4) and the reservoir (16), and in that the metering and mixing device (11, 12, 13) is arranged in the gate box (7).
2. Gravity die casting plant (1) for metal-foam mouldings according to Claim 1, characterized in that the gate box (7) has a plurality of gate regions (8, 9, 10).
3. Gravity die casting plant (1) for metal-foam mouldings according to at least one of Claims 1 or 2, characterized in that a metering and mixing device (11, 12, 13) for metering and mixing the foam-generating medium with the melt is arranged in each gate region (8, 9, 10).
4. Gravity die casting plant (1) for metal-foam mouldings according to at least one of Claims 1 to 3, characterized in that at least one die (2, 3, 4) is arranged so as to be connectable to each gate region (8, 9, 10).
5. Gravity die casting plant (1) for metal-foam mouldings according to at least one of Claims 1 to 4, characterized in that at least one gate region (8, 9, 10) is arranged so as to be connectable to each die (2, 3, 4).
6. Gravity die casting plant (1) for metal-foam mouldings according to at least one of Claims 1 to 5, characterized in that the dies (2, 3, 4) have different geometries.
7. Gravity die casting plant (1) for metal-foam mouldings according to at least one of Claims 1 to 6, characterized in that the gate regions (8, 9, 10) in the gate box (7) are arranged so as to be spatially separated from one another.
8. Gravity die casting plant (1) for metal-foam mouldings according to at least one of Claims 1 to 7, characterized in that the dies (2, 3, 4) and/or the gate box (7) are/is designed with a heating and/or cooling system.
9. Use of the gravity die casting plant (1) for metal-foam mouldings according to at least one of Claims 1 to 8, characterized in that the gravity die casting plant (1) is designed for the rising low-pressure casting of metal melts.
10. Use of the gravity die casting plant (1) for metal-foam mouldings according to at least one of Claims 1 to 9, characterized in that the metal melt is a light-metal melt.
11. Method for the production of metal-foam mouldings in a gravity die casting plant according to at least one of Claims 1 to 8, having the method steps:
- feed of the melt in the reservoir (16), - build-up of pressure in the gravity die casting plant (1), the melt being pressed from the reservoir into the gate box (7) and into the die (2, 3, 4), - introduction of gas into the melt, - discharge of pressure from the gravity die casting plant (1), and - adherence to a holding time for cooling the die (2, 3, 4 ), characterized in that the gas is introduced by means of an impeller agitator (11, 12, 13) in the die (2, 3, 4) filled with melt, and in that, during the casting operation, at least the method parameters comprising the density of the metal foam and the temperature in the gate box (7), in the gate region (8, 9, 10) and in the die (2, 3, 4) can be set and controlled independently of one another in each gate box (7), in each die (2, 3, 4) and in each gate region (8, 9, 10).
- feed of the melt in the reservoir (16), - build-up of pressure in the gravity die casting plant (1), the melt being pressed from the reservoir into the gate box (7) and into the die (2, 3, 4), - introduction of gas into the melt, - discharge of pressure from the gravity die casting plant (1), and - adherence to a holding time for cooling the die (2, 3, 4 ), characterized in that the gas is introduced by means of an impeller agitator (11, 12, 13) in the die (2, 3, 4) filled with melt, and in that, during the casting operation, at least the method parameters comprising the density of the metal foam and the temperature in the gate box (7), in the gate region (8, 9, 10) and in the die (2, 3, 4) can be set and controlled independently of one another in each gate box (7), in each die (2, 3, 4) and in each gate region (8, 9, 10).
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP05022025A EP1772211A1 (en) | 2005-10-10 | 2005-10-10 | Low pressure die-casting machine for metal foam articles |
| EP05022025.0 | 2005-10-10 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2556247A1 true CA2556247A1 (en) | 2007-04-10 |
Family
ID=36061331
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002556247A Abandoned CA2556247A1 (en) | 2005-10-10 | 2006-08-16 | Gravity die casting plant for metal-foam mouldings |
Country Status (3)
| Country | Link |
|---|---|
| US (1) | US20070079947A1 (en) |
| EP (2) | EP1772211A1 (en) |
| CA (1) | CA2556247A1 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP6229087B1 (en) * | 2017-04-04 | 2017-11-08 | 太平洋工業株式会社 | Die-casting die, die-casting machine and die-cast product manufacturing method |
Family Cites Families (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB892934A (en) * | 1959-01-05 | 1962-04-04 | Lor Corp | Casting complex structures with foamed metal core and solid skin |
| DE1408468B2 (en) * | 1959-01-05 | 1972-10-19 | Lor Corp., Enid, OkIa. (V.St.A.) | PROCESS FOR THE PRODUCTION OF FOAM METAL IN ONE CONTINUOUS WORK |
| FR2287294A1 (en) * | 1974-10-09 | 1976-05-07 | Peugeot & Renault | LOW PRESSURE FOUNDRY PARTS PERFECTIONING |
| DE69212157T2 (en) * | 1991-05-31 | 1996-11-21 | Alcan Int Ltd | METHOD AND DEVICE FOR PRODUCING PROFILED PANELS FROM PARTICLE-STABILIZED METAL FOAM |
| DE4326982C1 (en) * | 1993-08-11 | 1995-02-09 | Alcan Gmbh | Process and apparatus for manufacturing formed (shaped, moulded) parts from metal foam |
| NO311708B1 (en) | 2000-02-25 | 2002-01-14 | Cymat Corp | Process and equipment for forming molded products |
| DE10127716A1 (en) * | 2001-06-07 | 2002-12-12 | Goldschmidt Ag Th | Production of metal/metal foam composite components comprises inserting a flat or molded metal part into the hollow chamber of a casting mold, inserting a mixture of molten metal |
| KR100592533B1 (en) * | 2002-01-07 | 2006-06-23 | 조순형 | Method and apparatus for the continuous production of foamed metals |
-
2005
- 2005-10-10 EP EP05022025A patent/EP1772211A1/en not_active Withdrawn
-
2006
- 2006-08-16 CA CA002556247A patent/CA2556247A1/en not_active Abandoned
- 2006-08-25 US US11/509,910 patent/US20070079947A1/en not_active Abandoned
- 2006-10-09 EP EP06121950A patent/EP1779945A3/en not_active Withdrawn
Also Published As
| Publication number | Publication date |
|---|---|
| EP1779945A2 (en) | 2007-05-02 |
| EP1779945A3 (en) | 2007-07-18 |
| EP1772211A1 (en) | 2007-04-11 |
| US20070079947A1 (en) | 2007-04-12 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Discontinued |