EP0190114A1 - Molded metal object and method to manufacture the same - Google Patents
Molded metal object and method to manufacture the same Download PDFInfo
- Publication number
- EP0190114A1 EP0190114A1 EP86850031A EP86850031A EP0190114A1 EP 0190114 A1 EP0190114 A1 EP 0190114A1 EP 86850031 A EP86850031 A EP 86850031A EP 86850031 A EP86850031 A EP 86850031A EP 0190114 A1 EP0190114 A1 EP 0190114A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- shell
- layer
- tube
- sand
- metal object
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/0072—Casting in, on, or around objects which form part of the product for making objects with integrated channels
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
- F02F1/00—Cylinders; Cylinder heads
- F02F1/24—Cylinder heads
Definitions
- the invention relates to a molded metal object and a method to manufacture the same.
- the background of the invention is a desire to achieve a molded metal object comprising one or more channels or cavities, the internal surfaces of which are formed by surface layers of a high temperature and corrosion resistant metal alloy.
- prefabricated, thermally sprayed tubes can be molded into an object with a remaining mandrel or core . Then it has only been possible to use tubes with a simple, especially cylindrical shape, since the mandrel or core must be removed after molding.
- the object of the invention is therefore to accomplish a molded metal object having at least one internal channel or cavity of a complicated configuration, and this object is achieved in that the wall surface of each channel or cavity consists of a prefabricated tube or shell, and in that the remaining portions of the metal object is made by molding in a sand mould with said shell or tube included in the mould and filled with sand.
- the prefabricated tubes or shells may be made in accordance with the patent application relating to a "Shell and tubular object and method to manufacture the same" filed simultaneously herewith.
- a core body 1 is made of molding sand containing phenol resin as a binding agent. As shown in Fig. 1, this core body 1 has an external configuration corresponding to the desired, internal configuration of the tubular object, and additionally holding portions Ia, lb at each end for holding the core body.
- the desired object consists of an exhaust channel in a cylinder head in a combustion engine.
- a relatively thin and essentially pore-free layer 2 of a metal alloy containing abuut 5X A1, 22% Cr and the rest mainly Fe (the contents are by weight) is sprayed onto the core body.
- the layer thickness amounts to at least 0.5 mm, preferably about 1 mm
- the spraying operation is interrupted, whereupon the sand core 1 is removed by heating the sprayed sand core in a furnace at about 600 'C during 2-3 hours, and thereafter discharging the sand from the thin, tubular metal alloy layer 2.
- a second layer 3 is sprayed externally onto the first, self-supporting thin layer 2.
- the first layer 2 is permitted to expand and shrink freely due to variations of temperature, without any risk of tensions and accompanying cracking.
- the thickness of the second layer may be at least 1.5 mm. The spraying process can be performed without interruption for cooling.
- the first, relatively thin layer 2 is sprayed by means of a wire-fed flame sprayer so as to form a dense layer.
- the layer may be applied by plasma spraying.
- the second layer 3 may preferably be applied by means of a powder-fed flame sprayer in order to obtain a suitable quantity of pores and oxides. In this case a total quantity of 5 - 25X, preferably about 15X, pores and oxides is desired.
- the second layer 3 does not have to be of the same material composition as the first layer 2, but may consist of another metal alloy with high heat resistance or of a ceramic material. However, there are no requirements of corrosion resistance.
- the prefabricated tube 2,3 is mounted into a tool for the manufacture of a sand mould for the desired metal object.
- the tube 2,3 is again filled with sand, in order to enclose the corresponding part of the sand mould.
- the metal object is molded in a conventional way, wherein the tube 2,3 forms a channel, as schematically shown in Fig. 4. (In practice, the external outline of the metal object has a complicated geometry but is shown, for the sake of simplicity, as a box-like object).
- the channel formed by the tube 2,3 molded therein has an internal surface consisting of the first sprayed layer 2, which is substantially pore-free and resistant against high temperatures and corrosive gases. Therefore, this layer may serve as an exhaust channel in a combustion engine.
- the second layer 3 being located inside the surface layer 2 has more pores and oxides and is also thicker, and it will therefore serve as an effective heat barrier against the other material in the metal object.
- cavities may also form a part of the outside of the metal object, i.e. in order to form, together with another object, a space exposed to intense heat and corrosive gases, e.g. a combustion chamber, a valve chamber, an exhaust channel or the like.
- the tube or shell to be molded into the metal object can be produced by methods other than thermal spraying, such as e.g. a powder metallurgical process or plate pressing. It is also possible to press a thin plate into a tube or shell and therafter apply at least one layer of a heat and corrosion resistant metal alloy by thermal spraying.
Abstract
Description
- The invention relates to a molded metal object and a method to manufacture the same.
- The background of the invention is a desire to achieve a molded metal object comprising one or more channels or cavities, the internal surfaces of which are formed by surface layers of a high temperature and corrosion resistant metal alloy.
- According to methods previously known, prefabricated, thermally sprayed tubes can be molded into an object with a remaining mandrel or core . Then it has only been possible to use tubes with a simple, especially cylindrical shape, since the mandrel or core must be removed after molding.
- The object of the invention is therefore to accomplish a molded metal object having at least one internal channel or cavity of a complicated configuration, and this object is achieved in that the wall surface of each channel or cavity consists of a prefabricated tube or shell, and in that the remaining portions of the metal object is made by molding in a sand mould with said shell or tube included in the mould and filled with sand.
- Hereby, it is possible, practically without any restrictions, to provide any desired configuration of the cavities or channels of the metal object. This is accomplished by removing the core body during or after the prefabrication of the tube or shell, and thereafter filling the tube or shell again with sand when making the sand mould.
- As appears from the sub-claims, the prefabricated tubes or shells may be made in accordance with the patent application relating to a "Shell and tubular object and method to manufacture the same" filed simultaneously herewith.
- The invention will be explained further below with reference to the appended drawings schematically illustrating an embodiment in which the tube is made by thermal spraying onto a sand core.
-
- Fig. 1 shows a sand core onto which a metal alloy is to be thermally sprayed;
- Fig. 2 shows the sand core having a sprayed, thin first layer;
- Fig. 3 shows the tube, to be molded into an object, after removal of the sand core and spraying a relatively thick second layer onto the first layer;
- Fig. 4 shows schematically a molded metal object with a tube molded therein so as to form a channel in the metal object.
- In a way known per se, a core body 1 is made of molding sand containing phenol resin as a binding agent. As shown in Fig. 1, this core body 1 has an external configuration corresponding to the desired, internal configuration of the tubular object, and additionally holding portions Ia, lb at each end for holding the core body. In the embodiment, the desired object consists of an exhaust channel in a cylinder head in a combustion engine.
- In accordance with Fig. 2, a relatively thin and essentially pore-
free layer 2 of a metal alloy containing abuut 5X A1, 22% Cr and the rest mainly Fe (the contents are by weight) is sprayed onto the core body. When the layer thickness amounts to at least 0.5 mm, preferably about 1 mm, the spraying operation is interrupted, whereupon the sand core 1 is removed by heating the sprayed sand core in a furnace at about 600 'C during 2-3 hours, and thereafter discharging the sand from the thin, tubularmetal alloy layer 2. - Thereafter, a second layer 3 is sprayed externally onto the first, self-supporting
thin layer 2. In absence of a core body, thefirst layer 2 is permitted to expand and shrink freely due to variations of temperature, without any risk of tensions and accompanying cracking. The thickness of the second layer may be at least 1.5 mm. The spraying process can be performed without interruption for cooling. - Different methods of spraying are possible. Preferably, the first, relatively
thin layer 2 is sprayed by means of a wire-fed flame sprayer so as to form a dense layer. In case a surface layer with great purity is desired (small quantities of oxides and pores), the layer may be applied by plasma spraying. The second layer 3 may preferably be applied by means of a powder-fed flame sprayer in order to obtain a suitable quantity of pores and oxides. In this case a total quantity of 5 - 25X, preferably about 15X, pores and oxides is desired. - However, the second layer 3 does not have to be of the same material composition as the
first layer 2, but may consist of another metal alloy with high heat resistance or of a ceramic material. However, there are no requirements of corrosion resistance. - Thereupon, the
prefabricated tube 2,3 is mounted into a tool for the manufacture of a sand mould for the desired metal object. Thetube 2,3 is again filled with sand, in order to enclose the corresponding part of the sand mould. Thereafter, the metal object is molded in a conventional way, wherein thetube 2,3 forms a channel, as schematically shown in Fig. 4. (In practice, the external outline of the metal object has a complicated geometry but is shown, for the sake of simplicity, as a box-like object). - Thus, the channel formed by the
tube 2,3 molded therein has an internal surface consisting of the first sprayedlayer 2, which is esentially pore-free and resistant against high temperatures and corrosive gases. Therefore, this layer may serve as an exhaust channel in a combustion engine. On the other hand, the second layer 3 being located inside thesurface layer 2 has more pores and oxides and is also thicker, and it will therefore serve as an effective heat barrier against the other material in the metal object. - Naturally, by the method according to the invention, one may make metal objects of practically any configuration of internal cavities and channels by prefabricating shell or tube bodies of a corresponding geometry. Cavities may also form a part of the outside of the metal object, i.e. in order to form, together with another object, a space exposed to intense heat and corrosive gases, e.g. a combustion chamber, a valve chamber, an exhaust channel or the like.
- The tube or shell to be molded into the metal object can be produced by methods other than thermal spraying, such as e.g. a powder metallurgical process or plate pressing. It is also possible to press a thin plate into a tube or shell and therafter apply at least one layer of a heat and corrosion resistant metal alloy by thermal spraying.
- Compared with prior art technology, the following advantages are obtained:
- - complicated cavities or channels may be prefabricated quickly and simply and thereafter molded into a metal object;
- - the handling becomes easier and the waste will be less;
- - the molding precision is increased;
- - compared with applying ceramic material as a surface layer, the inventive method is cheaper and better due to good metal-to-metal adherence, and there are no problems with expansion due to varying temperatures.
Claims (8)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
SE8500474 | 1985-02-01 | ||
SE8500474A SE453968B (en) | 1985-02-01 | 1985-02-01 | CASTED METAL BODY AND SET TO MAKE IT SAME |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0190114A1 true EP0190114A1 (en) | 1986-08-06 |
EP0190114B1 EP0190114B1 (en) | 1989-04-05 |
Family
ID=20358979
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP19860850031 Expired EP0190114B1 (en) | 1985-02-01 | 1986-01-31 | Molded metal object and method to manufacture the same |
Country Status (3)
Country | Link |
---|---|
EP (1) | EP0190114B1 (en) |
DE (1) | DE3662654D1 (en) |
SE (1) | SE453968B (en) |
Cited By (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO1998050687A1 (en) * | 1997-05-03 | 1998-11-12 | Regler Industrievertretungen Gmbh | Exhaust collector for combustion engines and method for the production thereof |
JP2017109242A (en) * | 2015-12-17 | 2017-06-22 | ゼネラル・エレクトリック・カンパニイ | Method and assembly for forming components having internal passage defined therein |
JP2017109246A (en) * | 2015-12-17 | 2017-06-22 | ゼネラル・エレクトリック・カンパニイ | Method and assembly for forming components having internal passages using jacketed core |
JP2017110662A (en) * | 2015-12-17 | 2017-06-22 | ゼネラル・エレクトリック・カンパニイ | Method and assembly for forming components having internal passage defined therein |
EP3184199A1 (en) * | 2015-12-17 | 2017-06-28 | General Electric Company | Method and assembly for forming components having internal passages using a jacketed core |
EP3238859A1 (en) * | 2016-04-27 | 2017-11-01 | General Electric Company | Method and assembly for forming components using a jacketed core |
EP3238860A1 (en) * | 2016-04-27 | 2017-11-01 | General Electric Company | Method and assembly for forming components using a jacketed core |
US9975176B2 (en) | 2015-12-17 | 2018-05-22 | General Electric Company | Method and assembly for forming components having internal passages using a lattice structure |
US9987677B2 (en) | 2015-12-17 | 2018-06-05 | General Electric Company | Method and assembly for forming components having internal passages using a jacketed core |
US10099284B2 (en) | 2015-12-17 | 2018-10-16 | General Electric Company | Method and assembly for forming components having a catalyzed internal passage defined therein |
US10099276B2 (en) | 2015-12-17 | 2018-10-16 | General Electric Company | Method and assembly for forming components having an internal passage defined therein |
US10150158B2 (en) | 2015-12-17 | 2018-12-11 | General Electric Company | Method and assembly for forming components having internal passages using a jacketed core |
WO2018228726A1 (en) * | 2017-06-14 | 2018-12-20 | Siemens Aktiengesellschaft | Casting core for a cast housing of a fluid machine, housing for a fluid machine, and fluid machine |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH01302617A (en) * | 1988-02-09 | 1989-12-06 | Ngk Insulators Ltd | Formation of zinc sleeve for insulator pin |
US5012853A (en) * | 1988-09-20 | 1991-05-07 | Sundstrand Corporation | Process for making articles with smooth complex internal geometries |
DE4134066A1 (en) * | 1991-10-15 | 1993-04-22 | Thyssen Guss Ag | METHOD FOR PRODUCING SMALL AND SMALLEST CHANNELS IN MOLDED PARTS |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE1285680B (en) * | 1963-08-27 | 1968-12-19 | Bridgestone Cycle Ind Co | Process for the production of cast metal bodies with high thermal conductivity and wear and heat-resistant inner surfaces |
FR2431335A1 (en) * | 1978-07-21 | 1980-02-15 | Peugeot | Coating of internal cavities in castings - esp. to provide thermal insulation preventing the cooling of exhaust gas in cylinder heads on IC engines |
EP0071047A2 (en) * | 1981-07-25 | 1983-02-09 | Hoesch Aktiengesellschaft | Process for making cast pieces with inserted steel tubes |
-
1985
- 1985-02-01 SE SE8500474A patent/SE453968B/en not_active IP Right Cessation
-
1986
- 1986-01-31 EP EP19860850031 patent/EP0190114B1/en not_active Expired
- 1986-01-31 DE DE8686850031T patent/DE3662654D1/en not_active Expired
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE1285680B (en) * | 1963-08-27 | 1968-12-19 | Bridgestone Cycle Ind Co | Process for the production of cast metal bodies with high thermal conductivity and wear and heat-resistant inner surfaces |
FR2431335A1 (en) * | 1978-07-21 | 1980-02-15 | Peugeot | Coating of internal cavities in castings - esp. to provide thermal insulation preventing the cooling of exhaust gas in cylinder heads on IC engines |
EP0071047A2 (en) * | 1981-07-25 | 1983-02-09 | Hoesch Aktiengesellschaft | Process for making cast pieces with inserted steel tubes |
Non-Patent Citations (1)
Title |
---|
PATENTS ABSTRACTS OF JAPAN, vol. 8, no. 67 (C-216) [1504], 29th March 1984; & JP - A - 58 217 671 (MITSUBISHI JUKOGYO K.K.) 17-12-1983 * |
Cited By (29)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO1998050687A1 (en) * | 1997-05-03 | 1998-11-12 | Regler Industrievertretungen Gmbh | Exhaust collector for combustion engines and method for the production thereof |
US9975176B2 (en) | 2015-12-17 | 2018-05-22 | General Electric Company | Method and assembly for forming components having internal passages using a lattice structure |
CN106925721B (en) * | 2015-12-17 | 2020-10-09 | 通用电气公司 | Method and assembly for forming a component having an internal passage defined therein |
JP2017110662A (en) * | 2015-12-17 | 2017-06-22 | ゼネラル・エレクトリック・カンパニイ | Method and assembly for forming components having internal passage defined therein |
EP3184199A1 (en) * | 2015-12-17 | 2017-06-28 | General Electric Company | Method and assembly for forming components having internal passages using a jacketed core |
EP3184197A1 (en) * | 2015-12-17 | 2017-06-28 | General Electric Company | Method and assembly for forming components having an internal passage defined therein |
EP3184198A1 (en) * | 2015-12-17 | 2017-06-28 | General Electric Company | Method and assembly for forming components having internal passages using a jacketed core |
CN106925721A (en) * | 2015-12-17 | 2017-07-07 | 通用电气公司 | There is the method and component of the component for being limited to internal path therein for being formed |
JP2017121663A (en) * | 2015-12-17 | 2017-07-13 | ゼネラル・エレクトリック・カンパニイ | Method and assembly for forming components having internal passages using jacketed core |
CN107042289A (en) * | 2015-12-17 | 2017-08-15 | 通用电气公司 | For the method and component using component of the set core formation with internal path |
JP2017109242A (en) * | 2015-12-17 | 2017-06-22 | ゼネラル・エレクトリック・カンパニイ | Method and assembly for forming components having internal passage defined therein |
US10150158B2 (en) | 2015-12-17 | 2018-12-11 | General Electric Company | Method and assembly for forming components having internal passages using a jacketed core |
US10137499B2 (en) | 2015-12-17 | 2018-11-27 | General Electric Company | Method and assembly for forming components having an internal passage defined therein |
US10118217B2 (en) | 2015-12-17 | 2018-11-06 | General Electric Company | Method and assembly for forming components having internal passages using a jacketed core |
JP2017109246A (en) * | 2015-12-17 | 2017-06-22 | ゼネラル・エレクトリック・カンパニイ | Method and assembly for forming components having internal passages using jacketed core |
US10099276B2 (en) | 2015-12-17 | 2018-10-16 | General Electric Company | Method and assembly for forming components having an internal passage defined therein |
US10046389B2 (en) | 2015-12-17 | 2018-08-14 | General Electric Company | Method and assembly for forming components having internal passages using a jacketed core |
US10099284B2 (en) | 2015-12-17 | 2018-10-16 | General Electric Company | Method and assembly for forming components having a catalyzed internal passage defined therein |
US10099283B2 (en) | 2015-12-17 | 2018-10-16 | General Electric Company | Method and assembly for forming components having an internal passage defined therein |
US9987677B2 (en) | 2015-12-17 | 2018-06-05 | General Electric Company | Method and assembly for forming components having internal passages using a jacketed core |
KR102261351B1 (en) | 2016-04-27 | 2021-06-09 | 제네럴 일렉트릭 컴퍼니 | Method and assembly for forming components using a jacketed core |
CN107309403A (en) * | 2016-04-27 | 2017-11-03 | 通用电气公司 | For the method and component using chuck core formation part |
EP3238860A1 (en) * | 2016-04-27 | 2017-11-01 | General Electric Company | Method and assembly for forming components using a jacketed core |
US10286450B2 (en) | 2016-04-27 | 2019-05-14 | General Electric Company | Method and assembly for forming components using a jacketed core |
US10335853B2 (en) | 2016-04-27 | 2019-07-02 | General Electric Company | Method and assembly for forming components using a jacketed core |
EP3238859A1 (en) * | 2016-04-27 | 2017-11-01 | General Electric Company | Method and assembly for forming components using a jacketed core |
US10981221B2 (en) | 2016-04-27 | 2021-04-20 | General Electric Company | Method and assembly for forming components using a jacketed core |
KR20170122676A (en) * | 2016-04-27 | 2017-11-06 | 제네럴 일렉트릭 컴퍼니 | Method and assembly for forming components using a jacketed core |
WO2018228726A1 (en) * | 2017-06-14 | 2018-12-20 | Siemens Aktiengesellschaft | Casting core for a cast housing of a fluid machine, housing for a fluid machine, and fluid machine |
Also Published As
Publication number | Publication date |
---|---|
SE453968B (en) | 1988-03-21 |
DE3662654D1 (en) | 1989-05-11 |
SE8500474D0 (en) | 1985-02-01 |
SE8500474L (en) | 1986-08-02 |
EP0190114B1 (en) | 1989-04-05 |
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