CN1122587C - Apparatus for pressure casting materials with high melting point - Google Patents
Apparatus for pressure casting materials with high melting point Download PDFInfo
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- CN1122587C CN1122587C CN99127818.6A CN99127818A CN1122587C CN 1122587 C CN1122587 C CN 1122587C CN 99127818 A CN99127818 A CN 99127818A CN 1122587 C CN1122587 C CN 1122587C
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/2015—Means for forcing the molten metal into the die
- B22D17/2023—Nozzles or shot sleeves
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
A die casting apparatus for making articles composed of material having a melting temperature in excess of 2000 F, such as superalloys and titanium alloys includes a melting unit for melting at least a charge of the material, and a multi part, die-cavity-defining die. A generally cylindrical shot sleeve of the apparatus is in fluid communication with the die, and receives molten material from the melting unit. The sleeve has outer and inner radii Ro, Ri. The apparatus also includes a plunger unit in sealing and moveable engagement with the shot sleeve. The plunger moves along a plunger stroke, for forcing material from the shot sleeve into the die cavity. At least the radii and the ratio of the outer to inner radii are selected to minimize thermal distortion of the sleeve when molten material is poured into the sleeve.
Description
The present invention relates generally to die casting, more specifically to the device of a kind of die casting high-melting-point as the material that surpasses 2000 (1093 ℃).
Materials with high melting point is widely used in various industries as nickel-base heat resisting superalloy and titanium-base alloy.Usually, word " superalloy " is meant at high temperature and has high-intensity material as under 900 and the above temperature.Such typical material is nickel-base alloy, cobalt-base alloys and/or ferrous alloy.Titanium alloy adopts in requiring application in light weight and highly strong-weight ratio.These alloys have good anti-corrosion and keep good intensity under reaching as the moderate temperature of 1000 (538 ℃).
For example in gas turbine, generally partly adopt materials with high melting point such as the Ni-based and super heat proof material of cobalt-based at turbine, sometimes at the rear portion of the compressor section of engine, include but not limited to screw for example blade and blade, and static also adopt materials with high melting point with structure member such as plug ring, housing and sealing ring.The fusing point of these materials generally surpasses 2500 °F (1371 ℃).A kind of nickel-base heat resisting superalloy that is widely used in gas turbine is inconel 718 (IN718), and its main component percentage by weight is: carbon (C) 0.01-0.05, chromium (Cr) 13-25, molybdenum (Mo) 2.5-3.5, columbium (Cb) (refer to also that niobium (Nb)+tantalum (Ta) is about 21 for 5.0-5.75, titanium (Ti) 0.7-1.2, aluminium (Al) 0.3-0.9, iron (Fe), all the other are nickel (Ni) basically.The fusing point of IN718 is 2450 °F (1343 ℃).
General also adopt titanium alloy, include but not limited to screw such as blade and blade, and on static and structure member such as middle part, compressor housing and compressor disk, adopt titanium alloy in the quencher moiety such as the compressor section of engine.The fusing point of general titanium alloy surpasses 3000 °F (1649 ℃).A kind of titanium alloy that is widely used on the gas turbine is Ti6Al-4V (" Ti6-4 "), and its composition is: the aluminium of 4-8w/o (percentage by weight), the vanadium of 3-5w/o, all the other are titanium.Application for higher temperature, improve its high temperature creep property if desired, can use Ti6Al-2Sn-4Zr-2Mo (" Ti6-2-4-2 "), its composition is: the tin (tin) of the aluminium of 5-7w/o (percentage by weight), 1.5-2.5w/o, the zirconium of 3.0-5.0w/o, the molybdenum of 1.5-2.5w/o, all the other are generally titanium.Other titanium alloy comprises Ti8-1-1 and titanium aluminide.The composition of Ti8-1-1 is: the vanadium of the aluminium of 7-8.5w/o, the molybdenum of 0.5-1.5w/o and 0.5-1.5w/o, all the other are generally titanium.Usually, titanium aluminide mainly is to form by titanium and aluminium amount that chemical molecular formula calculates, as TiAl and TiAl3.Except above-mentioned performance, these materials should can form relative complex, 3D shape such as screw at least, and especially should be anti-oxidant under moderate temperature.
In the gas turbine industry, produce parts such as blade and blade with complex three-dimensional forms with forging.
Concise and to the point, in order to forge parts as the screw, blocks of material is become the billet shape, generally be cylindrical for blade and blade, in order to make the material plastic deformation become desired component shape, carry out hot-working then and handle, as heating and punching press between mould and/or forging hammer several times, form gradually and be similar to desired shape.General forge die can heat.Each parts is heat-treated usually to obtain desired performance, as hardness/intensity, eliminate stress, stop crackle to stretch and the HCF drag of specified level, the words of the parts of precise shape, physical dimension and/or surface property are provided as needs, also can carry out fine finishining, as machined, chemical grinding and/or medium polishing.
Producing parts by forging method is a kind of costliness, time-consuming technology, thereby its general parts that only guarantee to require to have special balance quality, as high strength, low weight and the durability under room temperature and two kinds of situations of middle temperature.As for obtaining forged material, the time of delivery that some material requirements is long.The general forging comprises that sequence of operations, each operation require independent mould and relevant equipment.Carry out the root of finishing operation as machined blade after the forging and carry out suitable surface treatment, constitute the pith of production forging totle drilling cost, comprise the pith that must abandon forging.
During forging, many raw materials (reach 85%, this depends on the forging size) are removed, and do not become the part of final forging, that is, and and processing loss.The complexity of the forging shape of producing has only increased the expense that workload and institute require the parts of manufacturing, and this needs the problem considered just for the gas turbine component with special complicated shape.Some alloys also have elasticity.Characteristic during the forging should count during forging, and that is to say, forging should carry out " excessively forging " (" overforged ").As mentioned above, final forging may still need a large amount of forging post processings.In addition,, produce and to have more the screw shape that air force is renderd a service, such screw and parts even have more complicated 3D shape if appliance computer software carries out the Fluid Computation kinematic analysis.The more complicated shape of titanium alloy fine thickly being forged into these advanced persons is very difficult or impossible, complicated shape also increases the cost of parts or makes the parts costliness, being uneconomic aspect some advanced technology of using engine, perhaps some component shape are adopted specific alloy.
Forging may contain the forging defect that is difficult to check.And, should consider that also accurate repeatability-forging can not make forging accurately identical with size between the forging.After inspection, many forging also must be processed again.Usually, forging must be scrapped or about 20% time processes again.In addition, newer, advanced or high alloy material will increase the difficulty (if not impossible words) of forging, and correspondingly increase the forging expense.These will only relate to the geometry that adopts complicated three-dimensional spiral oar.
Casting has been widely used in producing quite the foundry goods near Accurate Shaping (near-finished-shape).
Motlten metal is injected the precision-investment casting that has in the die cavity ceramic case of wanting the casting shape, can be used to produce such foundry goods.Yet hot investment casting produces huge crystal grain, and as ASTMO or bigger (forging can obtain relatively little average grain size), in some cases, whole foundry goods is a monocrystalline.In addition, because each foundry goods is with a mould production, this processing technology is very expensive.Between foundry goods and the foundry goods very the reproducibility of accurate dimension be difficult to reach.If material is melted, particularly for the material that contains reactive element such as titanium or aluminium, there is under the situation of gas casting and/or solidifying, foundry goods may have undesirable characteristic as being mingled with and pore.The division of ceramic case also will cause being mingled with the existence with impurity.
Motlten metal is injected manifold, a reusable casting mold, flow under the influence of gravity into the permanent mould casting of casting mold, generally also be used for cast component.See the U.S. Pat 5,505,246 that proposes by colvin.Yet the permanent mould casting has some shortcomings.For light casting such as screw, gravity may be not enough to force material to enter thin part, and is particularly all the more so under the situation of materials with high melting point and low overheat, thereby casting mold can not evenly be full of, and foundry goods is scrapped certainly.Dimensional tolerance is big relatively certainly, requires corresponding more casting follow-up work, and repeatability is difficult to reach.The permanent mould casting also causes poor surface accuracy, also needs to process after a large amount of castings.
With the compression casting that motlten metal injects a reusable casting mold under pressure, be successfully applied in the past casting than low melting point as being lower than the foundry goods of 2000 (1093 ℃) materials.As previously mentioned, for example in U.S. Pat 2,932,865, US3,106,002, US3,532, in 561 and US3,646,990, traditional die casting machine comprises that one installs (generally being fixing) shot sleeve on a multi-part clamping cap, for example, a mould, mold cavity of the common formation of these two pressing plates with two parts of fixing and displacable platen.Shot sleeve is level, vertically or in level with vertically tilts to place.Shot sleeve is generally only fixed with mould at the one end, as, shot sleeve not in the built in items.Shot sleeve is connected with the runner gate of mould, and comprises an opening that passes through at shot sleeve top casting motlten metal.Piston is placed in shot sleeve movably, and a driving mechanism mobile piston also makes motlten metal enter mould from shot sleeve.In " cold house " die casting machine, shot sleeve generally is positioned at horizontal level and does not heat.Usually cast under atmospheric condition, promptly equipment is not to be positioned in the non-reaction environment as in vacuum chamber or the inert atmosphere.
For example in U.S. Pat 3,646, discussed the shortcoming of these die casting machines in 990, particularly can not use these apparatus for casting high-melting-points as surpassing the problem of 2000 (1093 ℃) materials.The melted material that injects shot sleeve only occupy and promptly heat shot sleeve than lower part.Therefore only in the heating of the bottom of shot sleeve.Because shot sleeve one end stress deformation, so shot sleeve distortion or " archwise or banana-shaped ".If the linear deformation along the shot sleeve length direction is enough big, will stops piston moving in shot sleeve, thereby cause the damage of device.Suppose that tolerance between piston and the shot sleeve is necessary and closely, only little distortion just can cause bonding or the damage between piston and the shot sleeve.These distortion generally with the temperature difference between material, motlten metal and the shot sleeve of the external diameter of shot sleeve, internal diameter, length, formation shot sleeve, be melted shot sleeve part (causing the inhomogeneous heating of shot sleeve) and the process cycle that metal occupies (time that molten alloy is injected between the shot sleeve to be spent) and change.Have realized that these distortion are to cause cold-chamber die casting machine can not be used for the main cause of die casting fusing point at 2000 (1093 ℃) above materials referring to ' 440 and ' 990 patents.
Thermal deformation also influences the shape of cross section of shot sleeve.As mentioned above, shot sleeve generally is a cylindrical shape, thereby has circular cross section (vertical shot sleeve length direction is observed).When motlten metal injected shot sleeve, shot sleeve was the demi-inflation that shot sleeve seldom heats than lower part (with the contacted part of motlten metal) with respect to top.Shot sleeve is like this distortion, i.e. the shape of cross section of shot sleeve some ellipse (comprising that a part becomes littler than the shot sleeve of not heating) that becomes, and piston then keeps the shape of circle, has little thermal deformation.Therefore, shot sleeve shape and piston-shapedly just do not match does not differ greatly if match, and piston just sticks together with shot sleeve so, or allow molten alloy between piston and the shot sleeve by-promptly so-called " leakage ", thereby cause device not work or to damage.Cross-sectional deformation generally changes with the same factor of above-mentioned shot sleeve bananaization.
In addition,, shot sleeve maintains the temperature that is lower than the mould material fusing point if not heating or heated, motlten metal is set on the inwall of shot sleeve and skinning or " crust ", for mobile piston in shot sleeve injects mould with motlten metal, piston must make the skinning on the shot sleeve come off and " broken crust ".Yet if can form parts firm in structure, as with by the cylindrical form that shot sleeve was supported, piston and/or the associated components that is used for mobile piston can be damaged or destroy.
In a word, common " cold house " die casting equipment can not be successfully used to produce for example material of Tm more than 2000 (1093 ℃) of high-melting-point, as the foundry goods of superalloy and titanium alloy.Propose as patent ' 990, use common unit will cause die casting machine not work and/or damage, cause the with low quality of foundry goods simultaneously as (for example contain impurity, because the material that solidifies injects with melted material), unacceptable porosity, lower intensity and low fatigue period performance.
An object of the present invention is to provide a kind of device that is used for pressure casting materials with high melting point, materials with high melting point such as Ni-based, cobalt-based, iron-based superalloy and titanium-base alloy.
Another object of the present invention provides a kind of device that die casting has the complex three-dimensional forms foundry goods that is difficult to but not can not forges that is used for.
According to an aspect of the present invention, be used for die casting high-melting-point (Tm is more than 2000 (1093 ℃)) and/or contain the device of foundry goods of the material of the alloy that responds.This device utilizes one to limit mold cavity and contain two-part at least reusable mould.The fluxed parts of this device melts the metal of batch at least, for example is enough to be full of the charge of mold cavity and relevant runner gate and down gate.This device also comprises one section shot sleeve that is generally horizontal positioned, and this shot sleeve is connected with mould and has a cylindrical shape that has internal diameter and external diameter.Preferably select shot sleeve to make its volume, be preferably three times at least greater than the twice of mold cavity volume (volume that comprises relevant runner gate, ingate and clout), and general with H13 tool steel material manufacturing as sclerosis.In some instances, to be equal to or slightly greater than the volume of mold cavity also be acceptable to the volume of shot sleeve.
The ratio of shot sleeve outer radius and inside radius (Ro/Ri) preferably is at least 1.3, and more preferably 1.5.Such combination can provide enough motlten metal volumes, also fully reduced when motlten metal partly is full of shot sleeve, and the ovalization on the trend of shot sleeve thermal deformation-arcization along its length and the cross section, thus prevented the die casting machine fault.The piston element of this device is used for motlten metal is injected mould from shot sleeve, as transshipment acitivity motlten metal is transported to shot sleeve from fluxed parts equally.
Typical high-melting-point alloy comprises: titanium alloy (Tm is generally more than 3000 (1649 ℃)), cobalt-based and nickel-base heat resisting superalloy (Tm is generally more than 2400 (1315 ℃)).Typical reaction alloy comprises: titanium alloy and superalloy (Tm is generally more than 2400 (1315 ℃)).
Advantage of the present invention is to think that the common die casting machine that can not be used to cast materials with high melting point comes the pressure casting materials with high melting point foundry goods before can using.
Now with reference to accompanying drawing, the preferred embodiments of the present invention are described.
Fig. 1 represents to use the foundry goods of apparatus of the present invention die casting;
Fig. 2 and Fig. 3 represent the schematic diagram according to die casting machine of the present invention;
Fig. 4 is the profile of the shot sleeve of Fig. 2 device along the 5-5 line, the distortion of expression shot sleeve cross section;
Fig. 5 is a chart, and expression is when the part is full of motlten metal in the shot sleeve, and the distortion of shot sleeve changes with outer radius in the shot sleeve;
Chart and Fig. 5 of Fig. 6 are similar, and the trend of expression shot sleeve cross-sectional deformation changes with outer radius in the shot sleeve.
With reference now to Fig. 1,, superalloy foundry goods that be made of materials with high melting point and the die casting according to the present invention is represented with numeral 10.In an illustrated embodiment, this foundry goods is the turbo blade 10 on the gas turbine, and it comprises a screw 12, terrace part 14 and root 16.As used herein, materials with high melting point is meant those fusing points at least about 2000 °F (1093 ℃), up to 3000 °F (1649 ℃) even higher.The present invention can be widely used in having materials with high melting point such as Ni-based, cobalt-based and the iron-based superalloy and the titanium-base alloy of different purposes, is not limited to any concrete superalloy or gas turbine component.
As mentioned above, the typical nickel-base heat resisting superalloy that is used for gas turbine is Inconel alloy 718 (IN718), and its main component percentage by weight is: carbon (C) 0.01-0.05, manganese (Mn) are about 0.4, silicon (Si) is about 0.2, chromium (Cr) 13-25, cobalt (Co) are about 1.5, molybdenum (Mo) 2.5-3.5, columbium (Cb)+tantalum (Ta) are 5.0-5.75, titanium (Ti) 0.7-1.2, aluminium (Al) 0.3-0.9, iron (Fe) are about 21, all the other are nickel (Ni) basically.The fusing point of IN718 is 2450 °F (1343 ℃).Also can adopt other alloys, as IN713, its standard analysis percentage is: carbon (C) 0.025, manganese (Mn) are about 0.4, silicon (Si) is about 0.4, chromium (Cr) 12-16, molybdenum (Mo) 3-6, columbium (Cb)+tantalum (Ta) are 0.8-3.5, titanium (Ti) 0.7-1.3, aluminium (Al) 5.25-6.75, iron (Fe) are about 1, all the other are nickel (Ni) and cobalt (Co) basically.The fusing point of IN713 is 2300 °F (1260 ℃).Waspaloy (Waspaloy) is the material that another kind can be used for this application, and in U.S. Pat 4,574, the form with example in 015 and US5,120,373 discloses.Usually, the composition percentage by weight of waspaloy is: carbon (C) 0.02-0.15, chromium (Cr) 12-20, the about 10-20 of cobalt (Co), molybdenum (Mo) 2-5.5, titanium (Ti) 3-7, aluminium (Al) 1.2-3.5, zirconium (Zr) 0.01-0.15, boron (B) 0.002-0.05, all the other are nickel (Ni) basically.The fusing point of waspaloy is 2400 °F (1315 ℃).
Other alloys comprise B-1900, and its composition is: chromium (Cr) is about 8, cobalt (Co) 10, molybdenum (Mo) 6, tantalum (Ta) 4, aluminium (Al) 6, titanium (Ti) 1, carbon (C) 0.1, boron (B) 0.015 and zirconium (Zr) 0.1.Referring to " superalloy " (Wiley ﹠amp as Sims and Hagel showed; Sons 1972), the 596-7 page or leaf.Cobalt-base alloys also is used for the application of higher temperature as MAR-M-509.The composition percentage by weight of MAR-M-509 is about: chromium (Cr) 23.5, nickel (Ni) 10, tungsten (W) 7, tantalum (Ta) 3.5, titanium (Ti) 0.2, zirconium (Zr) 0.5, all the other are cobalt basically.Referring to U.S. Pat 3,647,517 and " superalloy " (Wiley ﹠amp that Sims and Hagel showed; Sons 1972), the 596-7 page or leaf.IN939 is another kind of nickel-base alloy, usable temp reaches 1500 °F approximately, its composition is about: chromium (Cr) 22.5, cobalt (Co) 19, molybdenum (Mo) 6, aluminium (Al) 2, titanium (Ti) 3.7, tungsten (W) 2, columbium (Cb)+tantalum (Ta) are 3.3, carbon (C) 0.15, boron (B) 0.005, and all the other are generally nickel (Ni).Gatorized Waspaloy is a kind of waspaloy (Waspaloy) that improves composition, surpasses common waspaloy aspect intensity and temperature performance.Referring to U.S. Pat 4,574,015 and US5,120,373, its composition percentage by weight is: chromium (Cr) 15.00-17.00, cobalt (Co) 12.00-15.00, molybdenum (Mo) 3.45-4.85, titanium (Ti) 4.45-4.75, aluminium (Al) 2.0-2.40.Gator Waspaloy alloy also has a spot of other elements, as zirconium (Zr) 0.02-0.12, boron (B) 0.003-0.010, magnesium (Mg) 0.0010-0.005.
As mentioned above, also can adopt titanium alloy, and its fusing point generally surpasses 3000 °F (1649 ℃).The exemplary alloy that is widely used on the gas turbine is Ti6Al-4V (" Ti6-4 "), and its composition is: the aluminium of 4-8w/o (percentage by weight), the vanadium of 3-5w/o, all the other are titanium.Application for higher temperature, need to improve its high-temperature behavior, can use Ti6Al-2Sn-4Zr-2Mo (" Ti6-2-4-2 "), its composition is: the tin (tin) of the aluminium of 5-7w/o (percentage by weight), 1.5-2.5w/o, the zirconium of 3.0-5.0w/o, the molybdenum of 1.5-2.5w/o, all the other are generally titanium.Other titanium alloy comprises Ti8-1-1 and titanium aluminide.The composition of Ti8-1-1 is: the vanadium of the aluminium of 7-8.5w/o, the molybdenum of 0.5-1.5w/o and 0.5-1.5w/o, all the other are generally nickel.Titanium aluminide is to form with titanium that calculates by chemical molecular formula and aluminium amount, and its typical compound is TiAl and TiAl3.
With reference now to Fig. 2 and Fig. 3,, device of the present invention is represented with reference number 18.It can prepare high-quality die casting, and molten material in non-reaction environment importantly is to prevent from the final casting quality is had the generation of dysgenic reaction, pollution or other situations.Because may be entrapped in the melted material at any gas of fusing in the environment, and cause pore too much in the die casting, we are preferably under the vacuum environment molten material rather than under inert environments, as molten material under the ar gas environment.Be preferably in molten material in the melting chamber 20 that links to each other with a vacuum source 22, keep low pressure in this melting chamber, as less than 100 μ mHg, preferably less than 50 μ m Hg.
We preferably melt charge once, because the material of fusing lesser amt is general faster than the material of fusing larger amt, and because easier being arranged in the vacuum chamber of melting unit of the less charge of fusing.Particularly contain under the situation of reacted constituent at material, our the most handy induction furnace remelting or melting unit (ISR) 24 (induction skull remelting or melting) fusing materials with high melting point, for example, the equipment of being produced by the Consarc company of New Jersey Rancocas melts, it has fast, cleans melts the ability that the list that is used to cast is criticized charge, and single batch of charge is as 50 pounds (22.7 kilograms).In ISR, material melts in a crucible, and this crucible is side by side arranged and formed by a plurality of metals (generally copper) bar.Crucible is centered on by the induction coil that is connected with power supply 26.Bonding jumper contains to be useful on to be made from the water source and arrives the passage of the cooling water (not shown) circulation at water source, to prevent the fusing of bonding jumper.The material that electric field heating that is produced by coil and fusing are positioned at crucible.This electric field also makes motlten metal stir or stirs.One thin-material layers is condensed on crucible wall and is formed crust.By suitable selection crucible and coil and be applied to power level and frequency on the coil, just might impel melted material to leave crucible, further reduce the impact of melted material to crucible wall.
Need the regular hour amount in the mould because be injected in material fusing with melted material, a conditional degree of superheat-enough height keeps molten condition at least basically with the assurance material before injection so the material fusing will have, but to enough hang down to guarantee rapid solidification after injection, can form little crystal grain, and also can make thermic load on the die casting equipment drop to minimum (particularly device is gone up those and the contacted part of motlten metal).Rule, we generally are limited to more than the fusing point its degree of superheat in about 200 °F (111 ℃) for materials with high melting point, and are preferably less than 100 °F (55 ℃), better less than 50 °F (28 ℃).We find, casting and inject the process of melted material in 1 or 2 second makes to have the die casting machine work of not heating shot sleeve and get well.
If we wish to adorn many batch of materials with an ISR equipment, this material can melt with other modes, as adopting vacuum induction melting (VIM) and electron-beam melting, as long as the material of fusing is not obviously contaminated.In addition, we are not precluded within the vacuum environment melts wide variety of materials, as once melting many batches of charges, then single melted material in batches is transported to the shot sleeve that is used for injecting the progressive die tool.Yet under the situation of vacuum fusion material, any equipment that is used to transport motlten metal generally all must have the ability of bearing high temperature and be positioned at vacuum chamber, so vacuum chamber should be big relatively.Auxiliary device increases expense, and corresponding big vacuum chamber will take a long time bleeds, thereby has influenced cycle period.
For melted material being transported to from crucible in the shot sleeve 30 of device, crucible is installed makes it can translation (arrow 32 among Fig. 3) and can rotate (arrow 33 among Fig. 2) with respect to the casting axis, this crucible is connected with a motor (not shown) again, and this motor is used for rotating crucible melted material is cast by the cast gate 35 of shot sleeve 30 from crucible.The transhipment of crucible occurs between the position of independent vacuum chamber 34 at the melting chamber 20 of molten material and shot sleeve place.Casting chamber 34 also remains non-reaction environment, and preferably air pressure is more preferably the vacuum environment of air pressure less than 50 μ m less than the vacuum environment of 100 μ m.Melting chamber 20 and casting chamber 34 may be separated by a valve or other parts (not shown) that is suitable for, the loss of vacuum when for example adding a component to reduce to be exposed to a chamber in certain chamber in the atmosphere.Though illustrated embodiment comprises melting chamber separately and casting chamber, it also is possible melting and cast in a chamber.In order to reduce that a certain specific features must be exposed in the atmosphere as maintenance fluxed parts shot sleeve or the loss of vacuum environment when removing foundry goods, we preferably adopt independent vacuum chamber.
Shot sleeve 30 generally is to make with the H13 tool steel of sclerosis.We can eliminate above-mentioned after measured shot sleeve thermal deformation problem, make such die casting machine can be used to cast the material that fusing point surpasses 2000 (1093 ℃) even 3000 (1649 ℃).Relation in this uses and depends on to a great extent between the outer radius.As shown in Figure 4, when shot sleeve when being cylindrical, when for example cooling off, shot sleeve has an inside radius Ri and an outer radius Ro.As shown in phantom in FIG., when melted material is poured into the lower part of shot sleeve, with respect to upper expansion and distortion, or make shot sleeve become " ellipse " basically than lower part.Ellipse (non-circular) shape that forms generally can be represented with major axis Ma and minor axis Mm respectively.The excessive ovalization and the shot sleeve of shot sleeve is out of shape (in Fig. 2 shown in the dotted line) longitudinally makes the main cause that can not be used for pressure casting materials with high melting point before such device.To discuss the parameter and the design of the shot sleeve that can carry out such die casting below.
Shot sleeve is preferably selected like this, makes its volume at least greater than the mold cavity volume twice of (comprising extra volume, for example running channel that links to each other with foundry goods and metal derby), preferably at least three times.For the given material volume that will inject, use has the shot sleeve of less interior (with outer) radius, needs to use the piston stroke (and therefore with the injection length than length) than length, because for cylinder, its volume is general relevant with piston stroke/length, and volume=π * R
i 2* stroke/length.Preferably the ratio (Ro/Ri) of shot sleeve internal diameter and external diameter is at least about 1.3, better is about 1.5.We after measured, such combination can provide enough melted material volumes, particularly when shot sleeve only partly is full of melted material, and can fully reduce the trend (among Fig. 2 shown in the dotted line) of shot sleeve thermal deformation-be arc along its length and on the cross section ovalize (Fig. 4), therefore can avoid the stifled base of die casting machine.Surprisingly, can make this die casting machine be used for the combinations thereof of pressure casting materials with high melting point such as superalloy and titanium alloy, very important on reducing cost.The research work that is approximately in the casting weight of using titanium on the prototype die casting machine of 7 pounds (3.2kg) shows that best inside radius is at least 1.5 inches (38mm), best outer radius is at least 2.25 inches (57mm).Though above-mentioned shot sleeve size is preferred to the melted material weight that can estimate,, may be summarized to be the shot sleeve geometry for the critical ratio of shot sleeve radius with for the fusing of a relative broad range and the weight of casting.Though can use less shot sleeve size, less than 1.5 inches (38mm),, be under the situation of titanium particularly as interior diameter at melted material for avoiding crust, the full level of shot sleeve must remain on about below 50%.If shown in shot sleeve 30 are non-heating, but, for keep shot sleeve at ask for something as reducing the purpose aspect the temperature, shot sleeve can be connected with the heater block (not shown) to reduce the thermal balance of when melted material injects shot sleeve caused thermal shock or shot sleeve.On the contrary, can cool off shot sleeve to remove heat and to keep lower temperature.In some example, can use dual material shot sleeve or compound shot sleeve to keep thermal balance.
As mentioned above, melted material is transported in the shot sleeve 30 by cast gate 35 from crucible 24.Shot sleeve 30 is connected with multi-part, reusable mould 36, and this mould defines a mold cavity 38.The melted material of q.s is cast in the shot sleeve being full of mold cavity, and mold cavity can comprise a part or more than a part.We have successfully cast nearly 12 parts in a die casting, as with a mould that 12 die cavities are arranged.
Mould can constitute with various materials, and it should have good pyroconductivity (can make the melted material rapid solidification and obtain thin crystal grain), can resist corrosion and chemical shock when injecting from melted material.Comprehensive inventory of a possible material will be very big, and the material that comprises has metal, pottery, graphite, ceramic matric composite and metal-base composites.For mold materials, we successfully adopt copper beryllium alloy " Moldmax ", cobalt-base alloys such as the F75 of tool steel such as H13 and V57, molybdenum and tungsten sill such as TZM and Anviloy, copper-based material such as high rigidity and L605, Ni-Fe base alloy such as IN100 and Rene95, iron-based superalloy such as IN718 and mild steel as 1018 and 1030.The selection of mold materials is very crucial for the economy of producing die casting, and depends on the complexity and the quantity of foundry goods, also depends on the current cost of assembly.
Every kind of mold materials has such characteristic,, makes it to be suitable for different application that is.For low-cost mold materials, owing to carry out machined and mfg. moulding die easily, our preferred mild steel and copper beryllium alloy.Use for higher cost and high volume, because it has good intensity, refractory metals such as tungsten and molybdenum base material under higher temperature.Cobalt-based and nickel-base alloy and high alloy tool steel provide a compromise proposal between these two groups of materials.Also can adopt and utilize coating and surface treatment to come the performance of intensifier and the quality of finished product.During operation, mould also can be connected to for example water of a liquid coolant sources, or on for example oily (not shown) of heating source, with the temperature of control mould.In addition, also die lubricant can be applied on the one or more selected parts of mould and on the die casting equipment.Any lubricant generally should be able to improve the quality of gained die casting finished product, more particularly should be able to resist cause thermal damage, makes it not pollute the material that will inject.
Motlten metal is transported to the shot sleeve 30 from crucible 24.The motlten metal of sufficient amount is injected shot sleeve so that only part is full of shot sleeve, but be full of mould subsequently.As previously mentioned and as shown in Figure 4, the loading of shot sleeve is preferably less than 40% (with dashed lines 52 expressions) preferably less than 50% (with dashed lines 50 expressions), is more preferably less than 30%-33% (representing with chain-dotted line 54).In some instances, when being IN718 as material, it also is acceptable being full of shot sleeve fully.
Injection part such as piston 40 and shot sleeve 30 cooperations, hydraulic pressure or other suitable components (not shown) driven plunger on the direction of arrow 42, make piston position 40 shown in position shown in the solid line and the dotted line ' between move, thereby melted material is injected die cavity 38 from shot sleeve 30.In position shown in the solid line, piston and shot sleeve define a volume jointly, and as mentioned above, this volume is basically greater than the volume of the melted material that will inject.Because shot sleeve only part is full of, so any material or the shell that are set on the shot sleeve only form a part cylinder, as an open arcuate surfaces, it was easy to peel off or broken in metal injection period, entered into melted material again.For some materials, its freezing range is enough big, so the formation of its shell reduces, and may more all be full of shot sleeve.
With reference now to Fig. 5 and Fig. 6,, we have measured the relation between outer radius and the inside radius, and radius itself is to make traditional cold-chamber die casting machine can be used to produce the key of materials with high melting point foundry goods.Fig. 5 and Fig. 6 are based on the melted material of 3100 (1704 ℃) and shot sleeve and are full of 25% situation and make.Fig. 5 represents outer radius and inside radius (Ro/Ri) and the shot sleeve relation between the deformation tendency along its length, is meant above-mentioned linear deformation or " banana-shapedization " (seeing part shown in the with dashed lines among Fig. 2).Usually, less linear deformation or banana-shapedization are corresponding to the obstruction possibility that reduces.When the ratio of outer radius and inside radius near 1.0 the time, as shot sleeve thin wall is arranged, the distortion of the shot sleeve that part is full of obviously increases.When ratio surpassed 2.0, distortion trended towards smaller relatively, and its order of magnitude is less than 0.005 inch (0.127mm).If this distortion is too big, we think that the distortion that is taken place greater than 0.005 inch (0.127mm) (for the shot sleeve of 12 inches (305mm)), will make piston be blocked in the shot sleeve so, thereby cause die casting machine not worked owing to the damage of piston.
As shown in Figure 5 and Figure 6, for the shot sleeve with about 1 inch (25mm) inside radius, we recommend the ratio of outer radius and inside radius to be at least 1.3, and outer radius is at least about 1.3 inches (33mm).For the shot sleeve with about 1.5 inches (38mm) inside radius, we recommend the ratio of outer radius and inside radius to be at least 1.3, are preferably 1.5, and outer radius is at least 2.25 inches (57mm).For the shot sleeve with about 2 inches (51mm) inside radius, we recommend the ratio of outer radius and inside radius to be at least 1.7, and outer radius is at least 3.4 inches (86mm).Though use the shot sleeve of little inside radius (less than 1 inch (25mm)) will cause shot sleeve more is out of shape impedance, but in order to reduce shot sleeve " crust " (canning), the less shot sleeve of these of use must adapt with the requirement of control shot sleeve full level.Thereby we recommend the ratio of outer radius and inside radius to be positioned at the right of each curve " flex point ".
Fig. 6 represents when shot sleeve partly is full of melted material, relation between outer radius and inside radius (Ro/Ri) and the shot sleeve ovalization trend, for example, when shot sleeve partly was full of with melted material along the stopping than lower part of shot sleeve, the shot sleeve cylindrical cross-section had and becomes non-circle or oval trend.When outer radius and inside radius ratio near 1.0 the time because part is full of melted material (less than 50%), the distortion or the ovalization of shot sleeve obviously increase.When ratio surpassed 2.0, distortion trended towards smaller relatively, and its order of magnitude is less than 1.5%, and this is greatly about every point of inflexion on a curve position.When melted material be full of shot sleeve than lower part, expansion than lower part surpasses top part, make the shot sleeve ovalization, this ellipse is general availablely to have a major axis and bigger slightly than original size (radius) and represents than the slightly little minor axis of original size (radius).If this ovalization is too big, just, minor axis becomes and is smaller than the radius of piston, and cylindrical piston will block in oval shot sleeve, or melted material between piston and the shot sleeve by (" leakage "), thereby cause die casting machine not work.Therefore, we recommend, and the ratio of outer radius and inside radius should be positioned at the right of every curve " flex point ".For the shot sleeve with about 1 inch (25mm) inside radius, we recommend the ratio of outer radius and inside radius to be at least 1.3, and outer radius is at least 1.3 inches (33mm).For the shot sleeve with about 1.5 inches (38mm) inside radius, we recommend the ratio of outer radius and inside radius to be at least 1.3, are preferably 1.5, and outer radius is at least 2.25 inches (57mm).For the injection with about 2 inches (51mm) inside radius, we recommend the ratio of outer radius and inside radius to be at least 1.5, and outer radius is at least 3 inches (76mm).
Shot sleeve should be able to bear linear deformation and horizontal ovalization.In addition, shot sleeve should have certain volume, and this volume is enough to receive melted material, and full level (best) is less than 33%, and the stroke of piston can not oversize (injection will spend the oversize time, and the melted material in the shot sleeve will solidify).Therefore, for as the die casting of blade and blade (as, the charge of Ti6-4 material about 7 pounds (3.2kg)), we take a kind of compromise proposal, and the shot sleeve inside radius of use is 1.5 inches (38mm), and the ratio of external diameter and internal diameter is about 1.5.
Die casting equipment according to the present invention has very big advantage.The present invention can use " cold house " die casting machine to produce the foundry goods of materials with high melting point, surpasses 2000 °F (1093 ℃) even surpasses 3000 °F (1649 ℃) as Tm.The present invention can the such material of die casting foundry goods.And can in one-step casting, produce a plurality of foundry goods, thereby reduce the production cost of each foundry goods.
Though described in detail the present invention above, do not break away from the present invention spirit or below under the scope of claim, can make multiple variation and replacement.Therefore, it should be understood that the above-mentioned description of this invention is to explanation of the present invention and non-limiting.
Claims (10)
1, a kind of die casting equipment that is used for the foundry goods of production material melting point above 3000, this device comprises:
One fluxed parts (24), the charge that is used to melt at least one batch;
The mould (36) of one multi-part, qualification mold cavity;
One is columniform shot sleeve (30), and this shot sleeve (30) is communicated with mould (36) fluid, and is used for the melted material of acceptance from fluxed parts (24), and shot sleeve has outer radius (Ro) and inside radius (Ri); And
One piston element (40), this piston element seal shot sleeve and along piston stroke and removable combination of shot sleeve (30), are used for the material of shot sleeve (30) is pressed into mold cavity (38); Wherein, select the ratio (Ro/Ri) of outer radius and inside radius, make the thermal deformation minimum of shot sleeve (30) when injecting shot sleeve with convenient melted material for given shot sleeve inside radius Ri; Wherein
Thermal deformation comprises the cylinder deflection along its length and the distortion of shot sleeve cylindrical cross-section, and described inside radius (Ri) is at least 1 inch (25mm), and described ratio (Ro/Ri) is at least 1.25; And
This device also comprises the parts (22) that are used for providing reduced pressure atmosphere to fluxed parts (24), mould (36) and shot sleeve (30).
2, device according to claim 1, wherein decompression member provides reduced pressure atmosphere to fluxed parts (24), mould (36) and shot sleeve (30) respectively.
3, device according to claim 1 and 2, wherein said ratio (Ro/Ri) is at least 1.5.
4, device according to claim 3, wherein inside radius (Ri) is at least about 1.5 inches (38mm).
5, device according to claim 1 and 2, wherein said mould (36) are to be made by the material of selecting from mild steel, copper beryllium alloy, tungsten-bast alloy, cobalt-base alloys and molybdenum-base alloy group.
6, device according to claim 1 and 2, wherein said shot sleeve (30) is made with H13 tool steel.
7, device according to claim 1 and 2, wherein said mould (30) define a mold cavity volume (38), and the volume that shot sleeve (30) limits is at least the twice of mold cavity (36) volume.
8, device according to claim 1 and 2 wherein also comprises: one is used to control the parts of shot sleeve temperature.
9, a kind of columniform shot sleeve (30) that is used for die casting equipment, shot sleeve (30) has the inside radius Ri of 25mm at least, and the ratio of outer radius Ro and inside radius Ri is at least 1.3.
10, a kind of usefulness has the method for the device for pressure casting materials with high melting point of a cylindrical shot sleeve (30), this shot sleeve has an inside radius (Ri) and an outer radius (Ro), wherein, select radius (Ro and Ri) and Ro/Ri ratio, the ovalization that makes the linear deformation of shot sleeve (30) keep below 0.005 inch (0.13mm) and/or shot sleeve (30) keeps below 1.5%.
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| US11356698P | 1998-12-23 | 1998-12-23 | |
| US06/113,566 | 1998-12-23 |
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| JP (1) | JP2000197957A (en) |
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| US3646990A (en) * | 1969-10-10 | 1972-03-07 | Raymond E Cross | Die casting machine |
| JPS5118220A (en) * | 1974-08-06 | 1976-02-13 | Toyota Motor Co Ltd | KOJUTENKINZOKUYODAIKASUTOSOCHI |
| US4086953A (en) * | 1975-02-24 | 1978-05-02 | Kraklau David M | Shot sleeve |
| JPS61103658A (en) * | 1984-10-29 | 1986-05-22 | Nichiei Kozai Kk | Injection cylinder for die casting machine |
-
1999
- 1999-12-20 EP EP99310240A patent/EP1013363B1/en not_active Expired - Lifetime
- 1999-12-20 DE DE69923930T patent/DE69923930T2/en not_active Expired - Lifetime
- 1999-12-20 JP JP11360518A patent/JP2000197957A/en active Pending
- 1999-12-20 ES ES99310240T patent/ES2235445T3/en not_active Expired - Lifetime
- 1999-12-20 IL IL13360799A patent/IL133607A/en not_active IP Right Cessation
- 1999-12-23 CN CN99127818.6A patent/CN1122587C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| IL133607A0 (en) | 2001-04-30 |
| DE69923930D1 (en) | 2005-04-07 |
| CN1260254A (en) | 2000-07-19 |
| ES2235445T3 (en) | 2005-07-01 |
| IL133607A (en) | 2004-03-28 |
| DE69923930T2 (en) | 2006-04-06 |
| EP1013363A1 (en) | 2000-06-28 |
| EP1013363B1 (en) | 2005-03-02 |
| JP2000197957A (en) | 2000-07-18 |
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