CN1047233A - Shaping and casting method in plastic medium - Google Patents

Shaping and casting method in plastic medium Download PDF

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Publication number
CN1047233A
CN1047233A CN90104120A CN90104120A CN1047233A CN 1047233 A CN1047233 A CN 1047233A CN 90104120 A CN90104120 A CN 90104120A CN 90104120 A CN90104120 A CN 90104120A CN 1047233 A CN1047233 A CN 1047233A
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air
helium
casting
gas
cast
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唐·阿伦·道特
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Rio Tinto Alcan International Ltd
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Alcan International Ltd Canada
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/02Sand moulds or like moulds for shaped castings
    • B22C9/04Use of lost patterns
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/02Sand moulds or like moulds for shaped castings
    • B22C9/04Use of lost patterns
    • B22C9/046Use of patterns which are eliminated by the liquid metal in the mould
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/04Influencing the temperature of the metal, e.g. by heating or cooling the mould

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Mold Materials And Core Materials (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

A kind of method of utilizing non-bonding (loose) moulding medium to be carried out to mold casting, i.e. gasified pattern casting method.According to these new characteristics, if use the gas that has a high thermal conductivity coefficient more than air to replace the air that generally is present in the non-molding bonded medium void space, the cooling of foundry goods and solidification rate can obtain to significantly improve.Have been found that helium helps to realize this purpose especially.

Description

Shaping and casting method in plastic medium
The present invention relates to the shaping and casting method in plastic medium, particularly a kind of like this casting method, non-bonding moulding medium wherein contains the high-termal conductivity void gas.
Silica sand is used as the moulding medium of various metals of shape casting and alloy thereof traditionally.In the casting method of knowing, that can mention has: the sand casting method wherein is that metal is poured in the gula of being made by molding sand and binding agent; The carbon dioxide casting method, wherein binding agent (waterglass) and carbon dioxide are had an effect so that its activation; Investment casting method, wherein mold is to be made on a fusible model by coated around the refractory material slurry; Shell moulded casting method, mold are to form a shell mould and constitute by the molding sand particle is bonded to one another, and it has the profile of metal pattern.Another casting method with special interest is a gasification foamed material casting method, and the foamed material model that wherein will cast object generally contains foamed polystyrene.This foamed material model is placed in casting case or the molding box with a kind of suitable fireproof coating coated, and is used as the non-bonding silica sand encirclement of moulding medium.Foamed material cast gate extends to the upper surface of moulding medium from model, and a poured with molten metal passage is provided.Vibration casting case is to obtain the maximum consolidation density of sand.Through cast gate motlten metal is poured into the casting case then, motlten metal makes cast gate and model gasification, thus the consequently foundry goods of a fine reproduction mould shapes of replacement.The gas permeation coating and the molding sand that gasify polystyrene and generate are discharged through the steam vent in the casting case.
For improving thermal conductivity, various metal materials are tested as shaping medium.For example,, or make mold or be broken, use in relevant gasification foamed material method as ferromagnetism moulding medium at the Soviet Union the research and utilization pig iron or steel grit.These achievements in research are reported in the paper of 1979 disclosed " Lit ' e po Gazifitsiruemym.Modelyan " (English is cavityless casting) by casting research institute of Soviet Union Kiev Ukraine academy of sciences.Though above-mentioned material can provide required thermal conductivity, they are very heavy materials, make to be used for gasifying the polystyrene model deformation of foamed material method, cause casting inaccuracy.Moreover Chong shaping medium also is awkward the general device that is applicable to silica sand like this.
Disclosed 2,183, No. 517 UK Patent Application were put down in writing in gasification foamed material method and were used zircon sand as the moulding medium on June 10th, 1987.Because zircon sand has the volume density higher than silica sand, approximate the volume density of the motlten metal that will cast greatly, can be sure of that the static pressure that acts on the moulding part has reduced, thereby thereby the stability that has greatly improved mold greatly improved the last accuracy of foundry goods.On the other hand, under 600 ℃, the thermal conductivity factor of zirconium is 0.83W/m ° of K, only is quartzy (silica), the twice of thermal conductivity factor 0.54W/m ° K.Because rate of heat release approximately is directly proportional with the square root of the thermal conductivity factor of shaping medium, zirconium makes cooldown rate improve about 24%.
June in 1985, No. 4520858 United States Patent (USP)s of disclosed Ryntz on the 4th etc. were put down in writing the method for another kind of raising solidification rate.In this patent, one as the chilling metal element of potential radiator attached on the gasification foamed material model.When metal poured into mold, the Quench element quickened cooling and solidifies.But attached on each model being a kind of method of taking a lot of work, it is limited to increase solidification rate the Quench element.
Also having such suggestion, is exactly on the moulding media particle, and the coated flame retardant coating is to improve the moulding medium.March in 1987,4,651, No. 798 United States Patent (USP)s of disclosed Rikker on the 24th were put down in writing a kind of like this methods, a kind of like this flame retardant coating of coated on silica sand, aloxite, zircon sand or glass particle.This one deck has also changed coating of particles, makes its more subglobular, and is more even so that these particles flow around model, thereby improves casting accuracy.But, but these materials do not possess for improving the required high-termal conductivity of solidification rate.
The another kind of moulding medium that improves the gasified pattern casting method is an alumina particles.Have been found that this medium has efficiently at raising rate of heat dissipation aspect of performance, also can avoid the problem of using heavy metal to bring as the moulding medium simultaneously.Yet above-mentioned all researchs all only focus on the solid phase character of moulding medium, do not consider the effect of gas phase aspect the heat conductivility of control moulding medium that exists in the gap between particles.
Also has suggestion more early: utilize helium to improve thermal conduction rate.For example, 369, No. 972 Russian Patents announcing on November 15th, 1973 disclose the method for a condensation sand mold, put it briefly is before casting, the cementing medium particle wherein in order to improve condensing rate, uses the gas that has a higher thermal conductivity factor than air to be full of in the mold.The situation that does not relate to casting molten metal but this patent only relates to the mold cooling below 0 ℃.
On June 15th, 1985, disclosed No. 1161224 Russian Patents related to a kind of mold that has the porous core body, the coarse cavity of running through from lip-deep pore to the centre, and its voidage changes.These coarse cavities can be full of by enough different cooling mediums of helium that comprise on the core body, in order to the thermmal storage capacity of change core body and the cooldown rate of the foundry goods that change contacts with core body.
Disclosed 4,749, No. 027 United States Patent (USP) in 1987 has been described in producing the conticaster of sheet metal strip, uses helium film between the end face of deposite metal and mobile cast strip.Yet the purpose of using helium only is to produce an air film between metal and band.
SEngler and REllerbrok are at Giesserie 64(9) article of " all gases ambiance and the gas pressure to such as alusil alloy in the influence aspect some casting characteristics " by name delivered on the 227-230 described in smelting furnace, in the transportation casting ladle and at motlten metal when casting ladle pours into mold, the argon around motlten metal or the action effect of other gas.The purpose of using this gas is to reduce the cooldown rate of metal in fusing and transportation.Article is pointed out to reduce gas pressure and is replaced air with argon and can reach the purpose that reduces cooldown rate, promptly increases hardening time.
The object of the present invention is to provide a kind of improved casting method, make by the heat of moulding medium and conduct more piece.
Disclosed by the invention be with the gas with high coefficient of thermal conductivity for example helium replace air in the space that generally is present in non-bonding (loose) moulding medium, thereby can obtain bigger cooling and solidification rate.
Therefore, a primary aspect of the invention relates to a kind of method of making foundry goods, the step that comprises has: in the casting case, by utilizing non-bonding moulding medium, for example NAG heat proof material particle is made the model of the product of will casting; Pour into a mould a certain amount of motlten metal in the casting case with make with the moulding medium in the foundry goods of the same shape of model.According to this novel characteristics, the air that generally is present in the space of non-bonding (loose) moulding medium is replaced by the gas with coefficient of heat conduction higher than air.
Advantageous feature of the present invention is a kind of method of making foundry goods, and the step that comprises has: make the model of the cast article of wanting, its material therefor is gasifiable, because the motlten metal effect of being cast does not have residue basically; This model have with the corresponding to shape of the cast article of wanting; Fill out around the model of casting in the case with the moulding medium that comprises non-bonding particulate material; A certain amount of motlten metal of cast is with the foundry goods of a gasified pattern and a mould shapes of making in the casting case.Its novel feature comprises that such step promptly uses the gas that has a higher coefficient of heat conduction than air to substitute and generally be present in the interstitial air of particle moulding medium.
Helium is optimum gas, and is nontoxic, non-corrosive because it is an inertia, and relatively more cheap.Also there is other high-termal conductivity gas, it should be noted that hydrogen and neon.But, obviously because the security of hydrogen and the price of neon, physical constraints their application.Helium and other mixture with non-active gas of low heat conductivity carefully select the specific occasion of cooldown rate to have some advantage at needs, than wanting piece with air gained cooldown rate, use the low of helium gained but compare.To these application scenarios, the acquisition of needed cooldown rate is owing to utilize helium and air, or helium and nitrogen, or helium and argon, or helium and any neither with metal fusing or that solidify also not with the admixture of gas of moulding medium reaction.Make this cooling and the solidification rate that can obtain " specific " through the mixture of selecting.
In one embodiment of the invention, before beginning casting, just high-termal conductivity gas is single to be full of the void area of graininess moulding medium with having.Also can change a method, before input high-termal conductivity gas, motlten metal be filled with mold, so that under low radiating condition, be full of mold fully, then feed gas, for example helium or as above-mentioned helium and the AIR MIXTURES utilized, with the increase cooldown rate, thus the rate of heat dispation in the middle of obtaining.
Various granular materials can be used as the moulding medium, comprise silica sand, zircon sand, chrome-magnesite, steel grit, carborundum, alum clay, alumina particles or the like.Utilize method of the present invention, also can cast various metals, comprising such as aluminium, magnesium, zinc and their alloy.
By following non-limiting example most preferred embodiment of the present invention is described.
Example 1
Gasification foamed material casting method
Go up with comprising Styro-Kote 250.1(Thiem house mark at the model of making by expanded polystyrene (38.1 millimeters * 50.8 millimeters * 152.4 millimeters) for preparing) the adhering mo(u)lding material coated.These models are placed on various moulding media (20/+80 purpose alumina particles, 24 #Carborundum fine sand and casting sand) in, under 750 ℃, make foundry goods by cast a kind of aluminium-4.5% copper alloy on model.Put a thermocouple at the mid portion of foundry goods, be recorded in the cool time under the condition shown in the table 1.
Table 1: a kind of aluminium-4.5% bronze medal is 750 ℃ of cool times of casting down.Time representation in the table be the liquidus curve transformation temperature and shown in the second number that continues between the temperature.
Table 1
Alumina particles molding sand carborundum (Sic)
Ambiance air helium air helium air
Liquidus curve-solidus transformation temperature 330 220 420 220 345
Liquidus curve → 400 ℃ 580 430 760 430 635
Liquidus curve → 300 ℃ 955 720 1,300 740 1105
Casting weight (gram) 703 800 659 810 659
As can be seen under these conditions, use cooldown rate that molding sand and helium obtained to equal the cooldown rate that under alumina particles and helium condition, obtains.And be higher than the cooldown rate that in air, obtains at alumina particles or carborundum.The part casting cooldown rate of using helium approximately is the twice of the cooldown rate when air ambient atmosphere is used molding sand.
Example 2
In order to estimate helium under more approaching conventional sand casting operating condition, a series of independently experiments have been carried out to the impact effect of rate of heat dispation.
In these experimentations, the moulding medium is filled in around the hollow tank body that did not make.Under 700 ℃, metal (aluminium-4.5% bronze medal) is directly poured in the jar, on mold, put an adiabatic topped thing.In order to compare the relative cooldown rate under various casting conditions, measure temperature-time interocclusal record.
The gained result is illustrated in table 2 and table 3.Check these tables and can find that the existence of helium all has bigger influence under all examination conditions, and input helium is to increase a kind of very effective method of foundry goods cooldown rate in silica sand.
Table 2
Cool time (second), aluminium-4.5% bronze medal pouring temperature was Tpour=700 ℃
No coating mold
Moulding medium aluminium molding sand carborundum (Sic)
Ambiance air helium air helium air helium
Time (branch)
Liquid phase → solid phase 2.9 2.2 8.25 3.6 6.25 3.05
Liquid phase → 500 ℃ 3.6 2.6 10.25 4.6 8.0 3.9
Liquid phase → 400 ℃ 6.0 4.5 17.75 8.0 13.5 7.0
Liquid phase → 350 ℃ 86 23.5 10.75 17.5 9.25
Liquid phase → 300 ℃ 10.8 8.25 30.5 15.0 23.25 12.7
Example weight (gram) 601 557 684 589 467 713
Table 3
Cool time (second), aluminium-4.5% bronze medal pouring temperature was Tpour=100 ℃
The coating mold is arranged
Moulding medium aluminium molding sand carborundum (Sic)
Ambiance air helium air helium air helium
Time (branch)
Liquid phase → solid phase 6.4 3.3 9.25 3.3 6.5 3.5
Liquid phase → 500 ℃------
Liquid phase → 400 ℃ 12.5 6.3 19 6.5 13 7.3
Liquid phase → 300 ℃ 22 12 33 12 22.5 13.8
Example weight (gram) 649 630 752 430 683 614
Example 3
A series of tests that various different shaping media carry out when utilizing gasification foamed material model casting technology.
Table 4
Test material title explanation type
Casting sand U.S. casting standard (AFS) 26 #NAG porous,
Nonmetallic
Sheet (Tabular) 14 * 28 orders (Mesh) are NAG, porous
Alundum (Al provides the address by Kaiser company: nonmetallic
(Al 2O 3) Pleasantown,CA.USA
(Tabular) is the same for sheet, but with 5%W/W silicic acid bonding, it is non-porous,
(Boned) sodium of bonding, bonding (the 40-42% beryllium of sodium; With two nonmetallic
Alundum (Al (Al 2O 3) carbonoxide cooperation (setwithCo)
Carborundum 4 is partly formed NAG, porous,
Partly 200 orders are nonmetallic for 80 * 200 orders (Mesh)
Provide by White Abrasive company
Address: Niagara Falls, ON, Canada
36 * 54RA is by Canadian Carborundum
The address is provided: Niagara Falls,
ON,Canada
Alumina particles AAlloo aluminium powder is NAG, porous,
NMI 25 * 40 orders, by the Nuclear metal
Metal company provides, the address:
Concord,MA.USA
AMPAL AMPAL 603
By Atomized Metal Pow-
Ders company provides, the address:
Flemington,NJ.USA
TOYAL grade (Grade) 5600 aluminium powders
By Alcan Toyo America
Company provides, the address: Joliette IL.
J(﹠amp; ) M 20 * 80 order aluminium powders
By Johnson(﹠amp; ) Mathey
Co., Ltd provides, the address:
110 Industry Street
Toronto,ON,M6M 4M1
Adopting the Wisconsin(Wisconsin) to obtain measuring diameter be 38.1 millimeters for mistake bubble (Lost Foam) precision casting technology of sheboygan Falls, length is that (density equals 22.5 kilograms/meter for 152 millimeters garden cylindricality expanded polystyrene model 3).The weight of the metal of required these models of filling is 0.5 kilogram.
For 0.2 millimeter coating layer thickness is provided, the proportion of Styro-Kote 250.1 pastings adjusts to 1.56, and model is immersed in the pasting, and the model of coating just is produced.After soaking, model or dried overnight or dry in micro-wave oven in air.
Before model is inserted the moulding medium, a thermocouple is inserted into Cylinder center line vertical-depth at the mid point of length direction.Then model is put in the molding box, molding box fills up with the moulding medium again, meanwhile vibrates whole assembly.In order to prevent from molding box bottom loses heat, an insulating blanket (or 2.7 millimeters fiberboards or two-layer Frax *Fiber sheet) is placed on the bottom of molding box.( *The Carborundum house mark) tests in order to change gas phase, put a porose stainless steel gas distributor in the bottom of molding box, and it is received on the source of the gas, before casting, purge stratum granulosum (bed).In order to purge helium 2-3 minute that to be blown into 2.7SLPM.In order in cooling procedure, to keep gaseous environment atmosphere, before casting, immediately air-flow is reduced to about 0.3SLPM.
Sample is casting binary aluminium-4.5% copper alloy under 700 ℃ pouring temperature, and with belt drawing recorder monitor temperature.Select this alloy to be because its eutectic point under 548 ℃, very definite, so just be easy to distinguish hardening time.When under 700 ℃, casting, the metal of patch thermocouple has been located liquidus temperature, and the calculating liquidus curve of cooldown rate is carved into to the temperature range (100 ℃) of eutectic phase height that institute's elapsed time obtains between the moment that the eutectic phase height finishes divided by from cast the time.
(a) result of record solidification rate is when the uncoated foamed material model of gasification, replaces with helium to obtain under the air situation.Its result is illustrated in table 5, and solidification rate is higher when helium exists.
(b) an other test of carrying out is when the cated foamed material model of gasification, replaces air with helium.Its result is illustrated in table 6, shows that once more solidification rate is just higher when helium exists.
(c) an other test card understand to use still air and stops speed admittedly during the argon that flows.The two thermal conductivity factor is low than helium all.Result of the test is illustrated in table 7, can see that therefrom the solidification rate that observes when using air and argon all significantly is lower than the solidification rate when using helium.
(d) test of carrying out in addition is with 8 kilograms of metals; Use a big gasification foamed material model to cast, its result is illustrated in table 8, when replacing air with helium, to solidification rate and drop to subsequently+coolings of 445 ℃ and+395 ℃ can obtain same improvement.
Table 5
There is not coating on the solidification rate model in air and in helium
Solidification rate ℃/second (standard error)
In air in helium helium/air
Casting sand 0.34(0.02) 0.74(0.06) 2.2
Alumina particles
NMT 0.80(0.06) 1.24(0.80) 1.6
J(&)M 0.71(0.03) 1.10(0.05) 1.5
AMPAL 0.83(0.04) 1.29(0.04) 1.6
TOYAL 0.58(0.07) 0.99(0.09) 1.7
TABULAR Al 2O 30.42(0.01) 0.98(0.03) 2.3
Silicon·Carbide
(carborundum)
80 * 200 order 0.56(0.01) 0.96(0.04) 1.7
36×54RA 0.43(0.03) 1.02(0.10) 2.4
Table 6
Solidification rate in air and in helium
Cated model
Curing rate ℃/second (standard error)
In air in helium helium/air
Casting sand 0.35(0.02) 0.59(0.02) 1.7
Alumina particles
NMT 0.49(0.02) 0.90(0.07) 1.8
J & M 0.51(0.03) 0.84(0.05) 1.6
TOYAL 0.45(0.04) 0.72(0.07) 1.6
Carborundum
36×54RA 0.36(0.01) 0.71(0.03) 2.0
80 * 200 order 0.41(0.01) 0.64(0.01) 1.6
TABULAR Al 2O 30.36(0.01) 0.75(0.04) 2.1
Table 7
Helium and argon are to the influence of solidification rate
Measurement is the curing rate ℃/second (S) that carries out in the TOYAL alumina particles as standard
Air 1*Helium 2*Argon 2*
0.58(0.07) 0.99(0.09) 0.50(0.06)
1, static state 2, mobile 0.35SLPM
Thermal conductivity factor is at 1000 ° of K of 300 ° of K
*Air 0.026W/m ° of K 0.067W/m ° K
*Helium 0.151W/m ° of K 0.354W/m ° K
*Argon 0.018W/m ° of K 0.044W/m ° K
Table 8
As cool time of moulding medium and ambiance function to large-scale (8 kilograms) foundry goods
Time, (branch) was from being poured into:
445 ℃ 396 ℃ of moulding dielectric gas eutectic phase heights
Casting sand air 16 38 60
Casting sand helium 7 15.5 22.5
Alumina particles air 9 20.5 32
TABULAR helium 7.25 13.25 18
Al 2O 3
(sheet alundum (Al)
From above example as can be seen: gasification foamed material process, when utilizing the moulding medium of high-termal conductivity/thermal capacity, solidify and cooldown rate can obviously increase.It is because the thermal resistance that exists on the grain contact point that the use of this dielectric material is restricted eventually.Utilize high-termal conductivity gas, for example helium has increased curing and cooldown rate significantly.For example, utilize helium and silica sand improving aspect the solidification rate even in air, testing more effective than best alumina particles.The mould coatings of the conventional refractory material that uses is that a barrier coagulates to hot-fluid in gasification foamed material method, so integrate the optimum that just can obtain solidification rate at the high-termal conductivity medium.
It is found that effective method is helium and the Integrated using of gasification foamed material method. In addition, say in theory and utilize other medium can further increase solidification rate, in order to surpass the result who utilizes helium and molding sand gained, clearly need the mould coatings of high heat conduction or do not have coating process.
The top detailed description of doing mainly is that the people who is skilled in technique at process aspect will estimate about gasification foamed material method, and the present invention also will have the wider application that reaches for other casting method field, for example damp sand (green sand) moulding, shell mouding, fusible pattern moulding, core etc.

Claims (9)

1, a kind of shaping and casting method, the step that comprises is to make the model of the product that will cast in molding box of non-bonding moulding medium, a certain amount of motlten metal of cast is to make a foundry goods with mould shapes in the moulding medium in molding box, improvement is to comprise such step, promptly uses the gas that has a high thermal conductivity coefficient more than air to replace the air that generally is present in the moulding medium void space.
2, method according to claim 1, wherein non-bonding moulding medium contains the particle of loose heat proof material.
3, method according to claim 2, wherein gas is helium.
4, method according to claim 2, wherein gas is that helium is and air, the mixture of nitrogen or a kind of non-active gas.
5, method according to claim 3, wherein the metal that will cast is aluminium or its alloy.
6, a kind of shaping and casting method, the step that comprises is, makes the model of the product that will cast, and its material therefor is gasifiable, the casting metals charging effect of being melted and do not have residue basically, this model has the shape consistent with the product that will cast; Fill out around the model of casting in the case with the moulding medium that comprises non-bonding particulate material; A certain amount of motlten metal of cast is with gasified pattern with make the foundry goods of a mould shapes in the casting case, improves to comprise such step, promptly uses to have more than air that the gas of high thermal conductivity coefficient replaces the air that generally is present in the particle moulding medium void space.
7, method according to claim 6, wherein gas is helium.
8, method according to claim 6, wherein gas is helium and air, the mixture of nitrogen or a kind of non-active gas.
9, method according to claim 7, wherein the metal that will cast is aluminium or its alloy.
CN90104120A 1989-05-01 1990-05-01 Shaping and casting method in plastic medium Pending CN1047233A (en)

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Publication number Priority date Publication date Assignee Title
CN1044097C (en) * 1993-09-30 1999-07-14 上海卡拿翰五金电器有限公司 Casting technology for polyphenylacetylene foaming-type vanishing die and sand box thereof
CN102554120A (en) * 2012-03-02 2012-07-11 丽水市实达机械制造有限公司 Process for preparing plastic foam pattern for lost foam casting
CN102554120B (en) * 2012-03-02 2013-12-11 丽水市实达机械制造有限公司 Process for preparing plastic foam pattern for lost foam casting
CN107891122A (en) * 2017-12-12 2018-04-10 中国兵器工业第五九研究所 A kind of precision aluminium-alloy casting solidification defect control method

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EP0470968B1 (en) 1993-06-02
JPH04507064A (en) 1992-12-10
ES2041531T3 (en) 1993-11-16
KR920700803A (en) 1992-08-10
AU633077B2 (en) 1993-01-21
WO1990013374A1 (en) 1990-11-15
DD293971A5 (en) 1991-09-19
CS215590A3 (en) 1992-03-18
BR9007342A (en) 1992-03-24
EP0470968A1 (en) 1992-02-19
CA1328554C (en) 1994-04-19
AU5421190A (en) 1990-11-29

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