CN101823136A - Bi-crucible low pressure casting method for magnesium alloy hub and equipment thereof - Google Patents
Bi-crucible low pressure casting method for magnesium alloy hub and equipment thereof Download PDFInfo
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- CN101823136A CN101823136A CN200910180922A CN200910180922A CN101823136A CN 101823136 A CN101823136 A CN 101823136A CN 200910180922 A CN200910180922 A CN 200910180922A CN 200910180922 A CN200910180922 A CN 200910180922A CN 101823136 A CN101823136 A CN 101823136A
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Abstract
The invention aims to provide a method for producing a magnesium alloy hub based on bi-crucible low pressure casting equipment, thus improving production efficiency, enabling production process to be convenient and safe and enhancing quality of magnesium alloy automobile hub castings. The aim of the invention can be realized by adopting the bi-crucible low pressure casting equipment which mainly comprises a melting heat preservation furnace (1), a melting heat preservation crucible (2), a communicating tube (3), a casting crucible (4), an one-way valve (5), an intake tube (6), an air bleeder (7), a riser tube (8), a casting crucible (9), a casting mould (10) and a control system (11), wherein metal liquid in the melting heat preservation crucible (2) is controlled by the one-way valve (5), and liquid levels in the two crucibles are maintained to be same by communicating the communicating tube (3) and the casting crucible (4).
Description
Technical field
The present invention relates to a kind of low-pressure casting method and equipment thereof, relate in particular to a kind of bi-crucible low pressure casting machine, go for the low pressure casting of magnesium alloy hub.
Background technology
Along with countries in the world government is strict day by day to energy-conservation, safety, environmental protection requirement, automobile industry will run into more and more higher technical threshold.Wheel hub is as the high-speed moving part on the vehicle, and weight saving can effectively reduce energy consumption, improve acceleration and braking ability, raising ride comfort and the security of car load.Adopt the lightweight material to realize that the update of wheel hub is to realize this purpose effective way, the magnesium alloy parts that is used at present on the automobile has 60 kinds at least, mainly contains instrument board, chair framework, steering wheel, bonnet, gearbox, air inlet pipe, wheel hub etc.Wherein tool typical case of wheel hub and sign meaning.On vehicle, adopt magnesium alloy hub can reach light-weighted purpose, compare with aluminium alloy wheel hub, except that weight saving about 30%, also have other significant advantage: (1) high damping behavior: magnesium alloy materials has higher damped coefficient, be 15 times of aluminium alloy, 60 times of steel.(2) damped coefficient is big more, and amplitude fading is fast more, and damping property is good more.Use magnesium alloy hub can reduce the vibrations of car engine, suspention carriage and gearbox, improve its service life; The stationarity in the vehicle traveling process, security and comfortableness have also been improved simultaneously.A kind of magnesium alloy auto hub that it is reported U.S.'s development still can be travelled with the speed that is not higher than 48km/h after puncturing at tire, and automobile is without prejudice, and can prevent personal injury.The magnesium alloy hub of same specification alleviates about 30% than aluminium alloy.The magnesium alloy new material becomes the focus that people pay close attention to its excellent characteristic.In American-European countries, the automobile vendor of various countries just is being used as the sign of method for vehicles level with automobile magnesium alloy consumption.The numerous and confused investment in capital magnesium raw material of various countries' auto producer manufacturing enterprise, purpose is control steady price and quantity supply, this will further promote magnesium alloy and use in the expansion of car industry.
As far back as 1967, BMC ASTIN (Austin) automobile just began to adopt magnesium alloy hub on this car of Mini Cooper 1275S, and the 911T of German luxurious car Porsche (Porsche) is also in first Application magnesium alloy hub in 1973.Owing to cost an arm and a leg, the puzzlement of anticorrosion problem, magnesium alloy hub universal on car always with ing, just uses on racing car and a small amount of senior car.But along with the decline of former magnesium material price, the raising of magnesium alloy anticorrosion process and the improvement of Mg alloy formed technology, the use of magnesium alloy hub on automobile, motorcycle, bicycle will get more and more.At present in car industry, magnesium alloy hub is except application in racing car is more, on the concept car that each big automobile factory releases, also be equipped with magnesium alloy hub, at present, magnesium alloy die casting drops into practical application on the automobile that companies such as general, benz, Ford, masses, Chrysler, Fiat-Alpha produce.The magnesium alloy hub application is mainly high-grade motorcycle and sedan limousine, and along with the continuous research and development of magnesium alloy correlation technique, its cost will reduce, and following wheel will progressively be popularized magnesium alloy materials.At present domestic Wanfeng Magnesium Industry Sci. ﹠ Tech. Development Co., Ltd., Weihai adopts extrusion process to begin to produce in batches magnesium alloy hub, and Wenxi County, Shanxi silver light magnesium industry group company adopts Forging Technology also to begin to produce in batches high-grade magnesium alloy hub.The price of the automotive hub of magnesium alloy forging and pressing at present is higher about one times than aluminium alloy wheel hub, makes magnesium alloy auto hub replace aluminium alloy wheel hub and has a lot of difficulties.
Based on the liquid cast method and apparatus, improved magnesium alloy hub foundry work efficient and economical with materials, thereby obviously reduced production cost, but the cast magnesium alloy wheel hub also has problems at present.For example, former design (size, shape invariance) substitutes, and it is huge that the fatigue strength of magnesium alloy auto wheel and aluminium alloy wheel hub are compared gap.Therefore, high-quality, the exploitation of the casting method of magnesium alloy hub cheaply will be the keys that magnesium alloy hub is widely applied.There is the casting method of the production magnesium alloy hub of report that methods such as gravity casting, evacuated die-casting process, pore-free die casting, low pressure casting are arranged, but, requires still to have gap apart from method standard from disclosed data analysis.
Low pressure casting obtains immense success in the casting of aluminium alloy wheel hub, many problems occur but low pressure casting is used for the production of magnesium alloy hub.Be used for the easy oxidation of liquid magnesium alloy, burning and the blast of high temperature, so the production process that low pressure casting is used for magnesium alloy hub becomes complicated, comprise that the interpolation of metal, liquid magnesium purification are handled, the cleaning of oxidizing slag etc.For the carrying out that guarantees to produce, the crucible volume generally can not be too little, big volume crucible high temperature pressurising repeatedly, make the crucible bulge easily, even cracking, crucible cracking is followed the magnesium liquid burner hearth that bleeds, the major accident that must blast this moment, so poor stability is the bad dream of magnesium alloy low-pressure casting all the time.Carry out with production, liquid level constantly changes in the crucible, thereby causes the casting technological parameter instability, and magnesium alloy is very responsive to technological parameter, and therefore, low pressure casting magnesium-alloy material quality stability is bad.The crystallization temperature of cast magnesium alloy is generally all bigger at interval, and the eutectic scale of construction in its tissue is also less, and body contraction and linear shrinkage are all bigger; The density of magnesium is little, thermal capacity is low (volume specific heat and latent heat of solidification are respectively aluminium 75% and 36%), thereby pressure head is little, easily solidify to make and fill the type difficulty; Organize thick, loose, thin hole very responsive, make wall thickness effect problem ten outstanding casting thickness; The hot cracking tendency of foundry goods is also bigger, and it is poor that the casting character of magnesium alloy is compared with aluminium alloy.Therefore, to the explanation of magnesium alloy cast Study on Basic Theory, low pressure casting can not guarantee the good wheel hub product of obtained performance, and especially above-mentioned casting flaw is very unfavorable to the fatigue strength of wheel hub.Therefore, conventional low cast magnesium alloy wheel hub performance is lower, can not satisfy the requirement of method standard.
For market and the application that enlarges magnesium alloy hub, need energy production quality to meet the cast moulding method of car mass standard.
Summary of the invention
The objective of the invention is to be to provide a kind of production method, thereby make the productivity ratio height, production process is easy and safety, magnesium alloy auto hub casting quality height based on bi-crucible low pressure casting device fabrication magnesium alloy hub.
The object of the present invention is achieved like this, use bi-crucible low pressure casting equipment, this equipment is mainly by by melting and heat preservation stove (1), melting and heat preservation crucible (2), communicating pipe (3), casting crucible (4), check valve (5), air inlet pipe (6), vent valve (7), stalk (8), casting mould (9) and control system formations such as (10), molten metal in the melting and heat preservation crucible (2) is controlled by check valve (5), be communicated with by communicating pipe (3) and casting crucible (4), keep two crucible liquid levels identical.Utilize capacity only to supply the casting crucible of low capacity of the molten metal of one-step casting, fill the low-pressure casting process that type and pressurize are up to 1.5MPa, and constantly reinforced by the melting and heat preservation crucible, keep the low pressure casting process technological parameter of every wheel hub not change substantially with production process.What bear pressure is the littler casting crucible of relative conventional low casting, allow to use higher filling type and dwell pressure and have higher security, therefore will fill type and dwell pressure and bring up to 1.5MPa from 0.7Mpa from the maximum working pressure (MWP) of conventional low casting.Because the melting and heat preservation crucible can add furnace charge at any time, keep the level change scope very little simultaneously, the casting crucible of Lian Tonging is cast each wheel hub with narrower changes in process parameters range with it, and the repeatability of technological parameter is very high.
Study common air injection machine and produced the cavity filling process and the wheel hub quality problems of magnesium alloy hub.Roughly press the production technology of aluminium alloy wheel hub and produce magnesium alloy hub.The operating temperature of the metal die of 17 inch wheel hubs is controlled at 300～350 ℃, and the temperature of molten metal is 700 ℃ when pouring into a mould in the crucible.When filling type, alloy liquid has been filled the core wheel part at first very reposefully, gently enters into spoke then.The alloy liquid forward position arrives spoke and the junction of taking turns net in the time of about 1 second, and the alloy liquid in the time of about 2 seconds between each spoke top converges, and the temperature of this moment is about 630 ℃.Cast liquid forward position arrives wheel net middle part in the time of about 5 seconds, and this moment, the alloy liquid temperature was about 580 ℃.Alloy liquid arrives wheel net top in the time of 7 seconds, and whole wheel hub is all filled type.With narrower changes in process parameters scope, the repeatability of technological parameter also makes the consistent of wheel hub performance improve.In addition, because casting crucible is little and continuous, and preparation and the shortening of casting operation cycle, productivity ratio of the present invention obviously improves.
The inventor thinks that the crystallization temperature of cast magnesium alloy is generally all bigger at interval, and the eutectic scale of construction in its tissue is also less, and body contraction and linear shrinkage are all bigger; The density of magnesium is little, thermal capacity is low (volume specific heat and latent heat of solidification are respectively aluminium 75% and 36%), thereby pressure head is little, easily solidify to make and fill the type difficulty; Organize thick, loose, thin hole very responsive, make wall thickness effect problem ten outstanding casting thickness; The hot cracking tendency of foundry goods is also bigger, and it is poor that the casting character of magnesium alloy is compared with aluminium alloy.Therefore, the conventional low casting can not guarantee the good wheel hub product of obtained performance.Especially above-mentioned casting flaw is very unfavorable to the fatigue strength of wheel hub.After adopting high-pressure process of the present invention, the casting flaw of magnesium alloy generated basic restriction, makes such as filling the type difficulty, organizing the harmfulness of thick, loose, thin hole, crackle to alleviate.Accurately control of technological parameter control in addition, the product degree of stability also is improved.
Description of drawings
Fig. 1 bi-crucible low pressure casting machine schematic diagram
1-melting and heat preservation stove, 2-melting and heat preservation crucible, 3-communicating pipe, 4-casting crucible, 5-check valve, 6-air inlet pipe, 7-vent valve, 8-stalk, 9-casting crucible, 10-casting mould, 11-control system
The specific embodiment
Below with reference to accompanying drawings embodiments of the present invention are described.
Embodiment 1
Melting and heat preservation crucible (2) is communicated with by communicating pipe (3) and casting crucible (4), and the molten metal in the melting and heat preservation crucible (2) need be supplied to casting crucible (4) by producing by check valve (5).High chromium heat resisting steel ball valve of check valve (5), the ball handle is fixed into fork, often is parked in the mouth of pipe under gravity, and the liquid in the melting and heat preservation crucible (2) is under the promotion of gravity, can push steel ball open and in trend casting crucible (4), replenish molten metal, basic identical until two crucible liquid levels.Air inlet pipe (6) is when type is filled in air inlet, and ball valve blocks the mouth of pipe, makes the middle molten metal of casting crucible (4) fill type and process of setting pressurize along stalk (8) to casting mould (9).Release after casting solidification is finished, the not solidifying liq in the stalk falls, check valve (5) is opened, and the molten metal in the melting and heat preservation crucible (2) enters casting crucible (4), for next production cycle is prepared.Said process can make program in advance by control system (10) and finish automatically.
High chromium heat resisting steel ball valve of check valve (5), the ball handle is fixed into fork, often be parked in the mouth of pipe under gravity, but the liquid in the melting and heat preservation crucible (2) is under the promotion of gravity, can push steel ball open and in the trend casting crucible, replenish molten metal, basic identical until amount crucible liquid level, the temperature of the molten metal of melting and heat preservation crucible (2) is 700 ℃.Air inlet pipe (6) is when type is filled in air inlet, and steel ball valve blocks the mouth of pipe, makes the middle molten metal of casting crucible (2) fill type and process of setting pressurize along stalk (8) to casting mould (9).Casting crucible (4) is the bigger low capacity crucible of a kind of wall thickness, the liquid magnesium alloy that can hold the one-step casting action need, therefore allow to use higher filling type and dwell pressure and allow to set narrower changes in process parameters scope, about 7 seconds of filling process, about 3 minutes of pressure hold time.The maximum working pressure (MWP) of general casting crucible allows to reach 1.5MPa even higher.Because high pressure energy arrives the thermal resistance that reduces wheel interface, hub casts homotype chamber, improve setting rate, make the grain refinement of wheel hub, performance increases substantially.Fill type and dwell pressure increases substantially, can realize solidifying under the high pressure of magnesium alloy hub when permanent mold casting, also make the casting hot tearing be difficult to produce or healing again after generation, solved the thorny difficult problem of common low pressure casting wheel hub.Release after wheel hub solidifies and finishes, the not solidifying liq in the stalk (8) falls, check valve (5) is opened, and the molten metal in the melting and heat preservation crucible (2) enters casting crucible (4), prepares for next production cycle, and the operation cycle of producing a wheel hub is 5 minutes.Said process can make program in advance by control system (10) and finish automatically.In the production process, can add master alloy ingot at any time in melting and heat preservation crucible (2), thereby keep liquid level to be in the par scope, the liquid level of casting crucible (4) all is identical, guarantees to cause the stable of production process technology parameter.General low pressure casting, because liquid level constantly descends with production process in the crucible, foundry goods can not keep a fixing casting parameter, the also product of impossible quality of production unanimity.
Two crucibles install at two independently in the resistance furnace respectively.Middle employing interior diameter is that 40 millimeters heat resisting pipe is communicated with.The length of communicating pipe generally is controlled in 1 meter, substantially be equivalent to two heating furnaces near after, the distance of two crucibles, heat-insulation layer was arranged outside communicating pipe, it is that temperature reduces that the placement molten metal flows through, if in particular cases need longer communicating pipe, the outside needs to increase electrically heated attemperator, and is excessive to avoid the molten metal temperature to reduce.The method of casting crucible and communicating pipe employing welding is fixed.Being connected of melting and heat preservation crucible and communicating pipe, then adopt the connection that can tear open, tube connector is sleeved on inside the Pass the lining on the fusion crucible wall, and both gaps are 50% brown iron oxide, 45% alumina powder, 5% boric acid powder mixed powder filling obstruction with composition.Mixed-powder is shutoff magnesium liquid seepage effectively, when needs are taken apart, does not also have difficulties simultaneously.
Two crucible oral areas are in identical horizontal line substantially, and two interior molten metals of crucible also keep identical liquid level in the course of work.In casting process, pass through constantly to add furnace charge, liquid level is remained unchanged, thereby keep the static pressure of molten metal to remain unchanged, at this moment, as long as the gas boosting pressurize when fixing each the casting keeps stable (automation is controlled and is easy to realize), just can keep the repeatability of whole process of production guarantor production technology very accurately.
In addition, the present invention is not because the melting and heat preservation crucible is subjected to huge cycle bulge pressure, and the danger of leakage reduces greatly, and improve service life.Casting process fills the type power operation and is limited in the little casting crucible, and monkey is not easy leakage and causes big accident.On the other hand, shortened Compressed Gas and be full of the time of ullage space and save production cost, thereby improved material productivity ratio and reduce production costs; Little casting casting crucible shortens the casting cycle of each part, and productivity ratio obviously improves.
Embodiment 2
The bi-crucible low pressure casting technology of certain type 17 inch magnesium alloy hub
17 inch magnesium alloy hubs adopt the AM60 alloy, and wheel hub net weight 7.5Kg, cast blank heavily are 12.5Kg, and casting mould adopts combination forged steel mould.Low pressure casting die is for the combination metal pattern and unlatching and closed and locked device are arranged.Die casting fabrication technique process mainly comprise casting mold preheat temperature, casting mold coating, pouring temperature, fill type, supercharging, pressurize, cooling, die sinking and take out foundry goods etc.Compare with aluminium alloy, the magnesium alloy cast poor-performing, in order to guarantee the complete type that fills, the casting mold preheat temperature reaches 300 ℃, and the mold cavity surface coating of casting mold is the water slurry of zinc oxide boric acid.The pouring temperature of molten metal is 710 ℃, will be controlled to be by 0.2Mpa through the pressure of super-dry when filling type and begin, rise to the compressed nitrogen of the pressure of 1.5Mpa gradually by predetermined speed, feed the sealing casting crucible middle and upper part of 710 ℃ magnesium liquid, magnesium liquid is through stalk under air pressure, magnesium hydraulic pressure is gone in the mould, under the pressure of 1.5Mpa, kept 3 minutes then.This moment, magnesium liquid solidified, and opened vent valve, bled off the compressed air in the crucible, started mould, took out foundry goods.
When filling type, alloy liquid has been filled the core wheel part at first very reposefully, gently enters into spoke then.The alloy liquid forward position arrives spoke and the junction of taking turns net in the time of about 1 second, and the alloy liquid in the time of about 2 seconds between each spoke top converges, and the temperature of this moment is about 630 ℃.Cast liquid forward position arrives wheel net middle part in the time of about 5 seconds, and this moment, the alloy liquid temperature was about 580 ℃.Alloy liquid arrives wheel net top in the time of 7 seconds, and whole wheel hub is all filled type.About 7 seconds of whole filling process.At the wheel hub filling process, when the alloy liquid forward position arrives the spoke middle part,, in solidification stages, and produce thermal center, so have potential shrinkage cavity defect in these zones in the junction of spoke and wheel net because the existence of groove produces gas hole defect.If, can reduce the casting flaw of wheel hub quality and generation so whole process of setting can not be controlled solidifying herein, for example cooling is herein become forced heat radiation, then can reduce generation of defects.In addition, during magnesium alloy cast the anti-oxidation of special requirement and avoiding be involved in oxide skin prerequisite, boosting should be by accelerating slowly.Studied further that to fill type and dwell pressure very remarkable to pore and shrinkage cavity influence, improved and fill type and dwell pressure, pore and shrinkage cavity defect degree reduce, hot tearing alleviates.Reduce the thermal resistance of foundry goods with the die cavity interface because high pressure energy arrives, improve setting rate, make the grain refinement of foundry goods, cast properties increases substantially.Fill type and dwell pressure increases substantially, can realize solidifying under the high pressure of Mg alloy castings when permanent mold casting, thereby can obtain fine and close high-quality Mg alloy castings.With narrower changes in process parameters scope, the repeatability of technological parameter also makes the consistent of wheel hub performance improve.
The present invention carries out the production experiment of magnesium alloy hub, and operations is functional.Experimental result shows, the present invention have the design productivity ratio higher, security performance is good, the casting of automobile hub that can be used for the production higher quality, the mechanical performance of the magnesium alloy parts of being produced increases substantially, and the pore of foundry goods and ardent tendency reduce, tensile strength on average improves 20%, percentage elongation on average improves 1%.The quality of automotive hub can satisfy the method standard requirement of general type automobile.
Claims (3)
1. the bi-crucible low pressure casting machine of a magnesium alloy hub, it is characterized in that: it is by melting and heat preservation stove (1), melting and heat preservation crucible (2), communicating pipe (3), casting crucible (4), check valve (5), air inlet pipe (6), vent valve (7), stalk (8), casting mould (9) and control system formations such as (10), molten metal in the melting and heat preservation crucible (2) is controlled by check valve (5), be communicated with by communicating pipe (3) and casting crucible (4), keep two crucible liquid levels identical.
2. bi-crucible low pressure casting machine as claimed in claim 1 is characterized in that: casting crucible (4) is only to hold one-step casting with the low capacity crucible of amount of metal, allows to use to fill type and dwell pressure up to 1.5Mpa.
3. the bi-crucible low pressure casting method of 17 o'clock magnesium alloy hubs, it is characterized in that adopting the described bi-crucible low pressure casting machine of claim 1, its method is for adopting the AM60 alloy, wheel hub net weight 7.5Kg, cast blank heavily is 12.5Kg, casting mould adopts the combination forged steel mould with unlatching and closed and locked device, die casting fabrication technique process mainly comprises the casting mold preheat temperature, the coating of casting mold, cast, fill type, supercharging, pressurize, cooling, foundry goods is taken out in die sinking, the casting mold preheat temperature is 300 ℃, the mold cavity surface coating of casting mold is the water slurry of zinc oxide boric acid, the pouring temperature of molten metal is 710 ℃, to be controlled to be by 0.2Mpa through the pressure of super-dry when filling type and begin, rise to the compressed nitrogen of the pressure of 1.5Mpa gradually, feed the sealing casting crucible middle and upper part of 710 ℃ magnesium liquid, magnesium liquid is through stalk under air pressure, magnesium hydraulic pressure is gone in the mould, under the pressure of 1.5Mpa, kept 3 minutes then, open vent valve, bleed off the compressed air in the crucible, start mould, take out foundry goods.
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Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102039394A (en) * | 2010-11-25 | 2011-05-04 | 西北工业大学 | Low-pressure casting liquid level suspension control method and device |
| CN102527994A (en) * | 2012-03-07 | 2012-07-04 | 威海万丰镁业科技发展有限公司 | Low-pressure casting device |
| CN102728819A (en) * | 2012-07-05 | 2012-10-17 | 西北工业大学 | Device and method for integration vacuum melting precise quantitative pouring of aluminum alloy and magnesium alloy |
| CN102935500A (en) * | 2012-11-09 | 2013-02-20 | 南京云海轻金属精密制造有限公司 | Heat-preserving furnace for magnesium alloy die casting |
| CN103422096A (en) * | 2013-07-11 | 2013-12-04 | 山西东义煤电铝集团有限公司 | Manufacturing technology of cathode protection product |
| CN105268949A (en) * | 2014-06-05 | 2016-01-27 | 住友橡胶工业株式会社 | Fragment casting method and casting equipment |
| CN112045164A (en) * | 2020-08-14 | 2020-12-08 | 江苏大学 | Near-liquidus differential pressure casting method and device for large complex magnesium alloy component |
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2009
- 2009-10-22 CN CN200910180922A patent/CN101823136A/en active Pending
Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102039394A (en) * | 2010-11-25 | 2011-05-04 | 西北工业大学 | Low-pressure casting liquid level suspension control method and device |
| CN102039394B (en) * | 2010-11-25 | 2013-04-17 | 西北工业大学 | Low-pressure casting liquid level suspension control method and device |
| CN102527994A (en) * | 2012-03-07 | 2012-07-04 | 威海万丰镁业科技发展有限公司 | Low-pressure casting device |
| CN102728819A (en) * | 2012-07-05 | 2012-10-17 | 西北工业大学 | Device and method for integration vacuum melting precise quantitative pouring of aluminum alloy and magnesium alloy |
| CN102935500A (en) * | 2012-11-09 | 2013-02-20 | 南京云海轻金属精密制造有限公司 | Heat-preserving furnace for magnesium alloy die casting |
| CN103422096A (en) * | 2013-07-11 | 2013-12-04 | 山西东义煤电铝集团有限公司 | Manufacturing technology of cathode protection product |
| CN103422096B (en) * | 2013-07-11 | 2016-01-20 | 山西东义煤电铝集团有限公司 | A kind of production technology of cathodic protection product |
| CN105268949A (en) * | 2014-06-05 | 2016-01-27 | 住友橡胶工业株式会社 | Fragment casting method and casting equipment |
| CN112045164A (en) * | 2020-08-14 | 2020-12-08 | 江苏大学 | Near-liquidus differential pressure casting method and device for large complex magnesium alloy component |
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