EP0305653A1 - Foundry model and process for manufacturing a hollow cast piece - Google Patents

Foundry model and process for manufacturing a hollow cast piece Download PDF

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Publication number
EP0305653A1
EP0305653A1 EP88108579A EP88108579A EP0305653A1 EP 0305653 A1 EP0305653 A1 EP 0305653A1 EP 88108579 A EP88108579 A EP 88108579A EP 88108579 A EP88108579 A EP 88108579A EP 0305653 A1 EP0305653 A1 EP 0305653A1
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EP
European Patent Office
Prior art keywords
foam body
cast
molded part
foam
refractory
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
Application number
EP88108579A
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German (de)
French (fr)
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EP0305653B1 (en
Inventor
Wilhelm Kallen
Ulrich Quack
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Eisengiesserei Monforts GmbH and Co
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Eisengiesserei Monforts GmbH and Co
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Priority to AT88108579T priority Critical patent/ATE70749T1/en
Publication of EP0305653A1 publication Critical patent/EP0305653A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02—Lost patterns
    • B22C7/023—Patterns made from expanded plastic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/03—Sand moulds or like moulds for shaped castings formed by vacuum-sealed moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • B22C9/046—Use of patterns which are eliminated by the liquid metal in the mould
    • 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
    • B22D19/0081—Casting in, on, or around objects which form part of the product pretreatment of the insert, e.g. for enhancing the bonding between insert and surrounding cast metal
    • 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
    • B22D19/08—Casting in, on, or around objects which form part of the product for building-up linings or coverings, e.g. of anti-frictional metal

Definitions

  • the invention relates to a cast body model with a foam body for producing a hollow casting in the metal foundry, the foam body consisting of a material which decomposes in a gaseous manner in the heat of liquid metal, such as iron or aluminum, such as polystyrene particle foam or the like. It also relates to a method for producing the cast body model and a method for producing a hollow cast part.
  • models of the casting to be produced made of polystyrene particle foam or a similar plastic that decomposes gaseously by contact with liquid metal are used and are either embedded in binder-free molding material and, if appropriate, placed under reduced pressure together with this before and during casting or molded in bonded molding material.
  • the foam body consisting of polystyrene particle foam or the like is coated with a size customary in the foundry, e.g. B. treated by immersion, which can consist of a finely ground refractory containing slurry.
  • the surface facing the foam body forms the actual casting mold from its shell consisting of size, while the adjacent molding material, in particular sand, only serves to mechanically support the size shell, which is fragile like an egg shell.
  • a problem with this casting process arises from the manufacture of the cast body model itself. If it is a hollow model, four molds are used to manufacture it shells, namely two upper and two lower molds.
  • the finished, hardened foam body therefore consists of at least two shells, the boundary of which is inevitably apparent in the finished casting both on its outer and on its inner surface.
  • sizing penetrates between the abutting surfaces of adjacent parts of the foam body during the finishing of the foam body. Problems in this regard are particularly difficult to access parts, especially on the inside, of a hollow mold. Since the surface of the foam body facing the foam body forms the actual shape of the cast part to be produced, penetration projections that have penetrated into the foam body or in seams between foam body parts result in corresponding incisions in the resulting casting. If such cuts occur, scrap is created during casting.
  • Another problem with the casting process described arises from the fact that the foam used has a surface which is very sensitive to pressure or impact. Since, as said, the abutting edges of parts of the foam body to be assembled must remain as intact as possible, not only handling, but also storage and transportation are difficult. If a joint is worked inaccurately or is damaged during transport or handling, it can always be repaired by inserting a like the foam can be repaired in the heat of the liquid metal gaseous decomposing adhesive, such reworking is complex and in many cases, especially in inaccessible places on the inside of a hollow model, it is hardly feasible and verifiable with the required accuracy.
  • the invention has for its object to provide an undercut foam hollow model in principle, which has no seams or at least only seams where reworking possible damage or inaccuracies at the joints with tolerable effort, i.e. especially only on the outside .
  • the solution according to the invention for the above-mentioned cast body model with a foam body for producing the hollow cast part is that the contour of the foam body is covered on one side with a cast part to be produced in the cast part to be formed to form a corresponding part of the contour of the refractory mold.
  • the surface of the foam body which should not be reworked if possible, is to be covered with a refractory molded part which directly defines a contour of the cast part to be produced.
  • the term “refractory molded body” encompasses molded parts made of metallic or non-metallic material which can be molded directly into a cast metal part during casting and can form at least part of its outer surface. This includes metal parts made of sheet metal, cast iron or forged material, but also sintered materials, Ceramics, glass or the like.
  • the molded part can be provided as an insert part on the inner surface of a hollow cast part, but also as an envelope part on the outer surface of a cast part.
  • the invention also creates the possibility of producing a composite body consisting of different or differently alloyed metals or of metal and non-metal.
  • a hollow cast iron body can be cast, the inner contour of which is formed by a prefabricated insert made of sheet metal.
  • a composite body consisting of two metals can also be cast, which has, for example, an outer shell made of iron and a hollow inner part made of aluminum.
  • the many cast body variants to be produced according to the invention also include a cast iron part coated with ceramic or glass, internally or externally.
  • the foam body is seamlessly molded onto the refractory molded part.
  • the foam body can be molded onto the inner or outer surface of a hollow refractory molded part.
  • the molded part thus forms part of the shell of the hollow mold when the foam body is produced. It is essential that this procedure creates a one-piece foam body that does not have any seams that lead to errors or that need to be reworked.
  • the refractory molded part is to form an insert of the foam body into the cast body to be produced, it is sufficient to produce the complete one Foam model, a single shape corresponding to the intended outer contour of the foam body with a lower and upper shell, because an insert part determining the inner surface of the cast body to be produced is used as the core of this shape.
  • the outer shell of the foam body is to be covered with the refractory molded part.
  • the hollow foam body according to the invention is to be produced in one piece, unwanted incisions cannot occur - because of a missing seam - because the size to be applied to the foam body cannot penetrate into the body.
  • the upper and lower shell of an outer shape used to produce the foam body only burrs projecting outward can arise on the foam, which, however, can be reworked without problems.
  • the fireproof molded part covering at least part of the contour of the foam body can be covered with an insulating material jacket, in particular made of mineral fiber wool, on its surface facing the cast body to be produced.
  • an insulating material jacket in particular made of mineral fiber wool, on its surface facing the cast body to be produced.
  • the insulating liner is also favorable for components, e.g. B. in exhaust manifolds, which should have the lowest possible heat absorption. So that (in the exhaust gas flow) subsequent components, for. B. catalysts, get hot as quickly as possible.
  • the material jacket also offers the possibility of reducing the weight of the cast body without reducing its volume.
  • the jacket consisting of insulating material or the like can be provided not only on the inner or outer surface but also on the boundary of the different layers of a composite body according to the invention.
  • the use of the refractory molded part according to the invention is therefore also advantageous if, as in the chemical industry, a surface of a cast part has to be alloyed in a certain way in order to ensure the necessary chemical resistance.
  • a method for producing a hollow casting in the metal foundry using a foam body which decomposes in a gaseous manner in the heat of liquid metal, such as iron or aluminum, and in particular consists of polystyrene particle foam or the like, as a model that the foam body is one-sided during casting is covered with a refractory, as such to be included in the contour of the casting.
  • a foam body which decomposes in a gaseous manner in the heat of liquid metal, such as iron or aluminum, and in particular consists of polystyrene particle foam or the like, as a model that the foam body is one-sided during casting is covered with a refractory, as such to be included in the contour of the casting.
  • Fig. 1 shows a prepared mold for producing a cast body model according to the invention, generally designated 1.
  • 1 consists of a refractory molded part 2 and a one-piece foam body 3 to be molded thereon.
  • a mold consisting of an upper mold 4 and a lower mold 5, with a total of 6, is used as the mold for producing the foam body 3 designated outer shell used.
  • the drawing shows in FIG. 2 a section through a mold prepared for the iron foundry with a cast body model 1 according to FIG. 1.
  • the cast body model 1 consists, apart from the molded part 2 and the foam body 3, of an insulating material layer 8.
  • the entire cast body model 1 is embedded in a box 9 in binder-free molding material 10, in particular in sand, inside and outside, in particular vibrated, so that no cavity remains in box 9.
  • a pouring funnel 11 is attached to one end of the foam body 3.
  • the entire surface of the molding material 6 in the box 9 is surrounded with an airtight film 12 so that a vacuum pump acting into the molding material with an intake pipe 13 via a vacuum line 14 vent the interior of the film 12 or the box 9 so far can that the molding material 10, which preferably consists of free-flowing sand, becomes stiff overall.
  • the material of the foam body 3 is decomposed and drawn off in gaseous form via the vacuum line 14 to the extent that it is replaced by the liquid and solidifying iron.
  • the refractory molded part 2 (possibly also the insulating material layer 8) becomes part of the cast part produced.
  • the casting finally occupies the space that was originally displaced by the foam body 3 was.
  • the contour of the foam body 3, in the present case its outer contour 15, is or at the same time becomes the outer contour of the cast body.
  • FIG. 3 shows the case of a composite casting with an iron layer 17 on the outside and with a hollow aluminum body 19 with a passage 18 on the inside.
  • a foam body is provided on the inner surface of the iron body 18, for. B. directly foamed, which has a passage 18.
  • the passage 18 is filled with, for example, poured molding material.
  • the aluminum body 19 takes the place of the foam body.

Abstract

A foundry pattern (1) with a foam body (3) for the production of a hollow casting, can be produced and seams at points to which access is difficult, in particular on the inside, avoided if the contour of the foam body is covered on one side with a refractory moulding (2) which is to be moulded into the casting to be produced in order to form a corresponding part of the latter's contour. <IMAGE>

Description

Die Erfindung betrifft ein Gußkörpermodell mit einem Schaumstoffkörper zum Herstellen eines hohlen Gußteils in der Metallgießerei, wobei der Schaumstoffkörper aus einem in der Hitze von flüssigem Metall, wie Eisen oder Aluminium, gasförmig zerfallenden Material, wie Poly­styrolpartikelschaum oder dergleichen, besteht. Sie be­trifft ferner ein Verfahren zum Herstellen des Gußkör­permodells und ein Verfahren zum Herstellen eines hohlen Gußteils.The invention relates to a cast body model with a foam body for producing a hollow casting in the metal foundry, the foam body consisting of a material which decomposes in a gaseous manner in the heat of liquid metal, such as iron or aluminum, such as polystyrene particle foam or the like. It also relates to a method for producing the cast body model and a method for producing a hollow cast part.

In der Gießerei werden aus Polystyrolpartikelschaum oder einem ähnlichen sich durch Berührung mit flüssigem Me­tall gasförmig zersetzenden Kunststoff bestehende Model­le des herzustellenden Gußstücks eingesetzt und entweder in binderfreiem Formstoff eingebettet und gegebenenfalls zusammen mit diesem vor und während des Gießens unter Unterdruck gesetzt oder in gebundenem Formstoff einge­formt. Vor dem Einsetzen in die Gießform wird der aus Polystyrolpartikelschaum oder dergleichen bestehende Schaumstoffkörper mit einer in der Gießerei üblichen Schlichte, z. B. durch Eintauchen, behandelt, die aus einer feingemahlenes feuerfestes Material enthaltenden Aufschlämmung bestehen kann. In diesen Bereichen bildet die den Schaumstoffkörper zugewendete Fläche von dessen aus Schlichte bestehender Schale die eigentliche Gieß­form, während der angrenzende Formstoff, insbesondere Sand, lediglich zum mechanischen Stützen der wie eine Eierschale zerbrechlichen Schlichteschale dient.In the foundry, models of the casting to be produced made of polystyrene particle foam or a similar plastic that decomposes gaseously by contact with liquid metal are used and are either embedded in binder-free molding material and, if appropriate, placed under reduced pressure together with this before and during casting or molded in bonded molding material. Before being inserted into the casting mold, the foam body consisting of polystyrene particle foam or the like is coated with a size customary in the foundry, e.g. B. treated by immersion, which can consist of a finely ground refractory containing slurry. In these areas, the surface facing the foam body forms the actual casting mold from its shell consisting of size, while the adjacent molding material, in particular sand, only serves to mechanically support the size shell, which is fragile like an egg shell.

Ein Problem dieses Gießverfahrens ergibt sich aus der Herstellung des Gußkörpermodells selbst. Wenn es sich um ein Hohlmodell handelt, werden zum Herstellen vier Form­ schalen, nämlich zwei Ober- und zwei Unterformen, benö­tigt. Der fertige, erhärtete Schaumstoffkörper besteht daher aus mindestens zwei Schalen, deren Grenze sich im fertigen Gußteil unvermeidbar sowohl auf dessen Außen­als auch auf dessen Innenfläche abzeichnet.A problem with this casting process arises from the manufacture of the cast body model itself. If it is a hollow model, four molds are used to manufacture it shells, namely two upper and two lower molds. The finished, hardened foam body therefore consists of at least two shells, the boundary of which is inevitably apparent in the finished casting both on its outer and on its inner surface.

Wenn die Stoßflächen der Teilschalen des Schaumstoffkör­pers nicht exakt aufeinander passen oder nicht exakt aufeinander geklebt werden, dringt bei dem Schlichten des Schaumstoffkörpers Schlichte zwischen die Stoß­flächen aneinander grenzender Teile des Schaumstoffkör­pers. Probleme bereiten in dieser Hinsicht besonders schwierig zugängliche Teile, insbesondere auf der Innen­seite, einer Hohlform. Da die dem Schaumstoffkörper zu­gewendete Fläche von dessen aus Schlichte bestehender Schale die eigentliche Form des herzustellenden Gußteils bildet, haben in den Schaumkörper bzw. in Nähte zwischen Schaumstoffkörperteilen eingedrungene Schlichtevor­sprünge entsprechende Einschnitte im entstehenden Guß­teil zur Folge. Wenn solche Einschnitte vorkommen, wird beim Gießen Ausschuß erzeugt.If the abutting surfaces of the partial shells of the foam body do not fit exactly onto one another or are not glued exactly onto one another, sizing penetrates between the abutting surfaces of adjacent parts of the foam body during the finishing of the foam body. Problems in this regard are particularly difficult to access parts, especially on the inside, of a hollow mold. Since the surface of the foam body facing the foam body forms the actual shape of the cast part to be produced, penetration projections that have penetrated into the foam body or in seams between foam body parts result in corresponding incisions in the resulting casting. If such cuts occur, scrap is created during casting.

Ein weiteres Problem des beschriebenen Gießverfahrens ergibt sich daraus, daß der verwendete Schaumstoff eine gegen Druck- oder Stoßausübung sehr empfindliche Ober­fläche besitzt. Da wie gesagt die Stoßkanten zusammenzu­setzender Teile des Schaumstoffkörpers möglichst unver­sehrt bleiben müssen, sind nicht nur die Handhabung son­dern auch die Lagerung und der Transport schwierig. Wenn eine Stoßstelle ungenau gearbeitet oder beim Transport bzw. bei der Handhabung beschädigt wird, kann zwar grundsätzlich eine Ausbesserung durch Einfügen eines sich ebenso wie der Schaumstoff in der Hitze des flüssi­gen Metalls gasförmig zersetzenden Klebers ausgebessert werden, eine solche Nacharbeit ist aber aufwendig und in vielen Fällen, insbesondere an unzugänglichen Stellen auf der Innenseite eines Hohlmodells mit der erforder­lichen Genauigkeit kaum ausführbar und nachprüfbar.Another problem with the casting process described arises from the fact that the foam used has a surface which is very sensitive to pressure or impact. Since, as said, the abutting edges of parts of the foam body to be assembled must remain as intact as possible, not only handling, but also storage and transportation are difficult. If a joint is worked inaccurately or is damaged during transport or handling, it can always be repaired by inserting a like the foam can be repaired in the heat of the liquid metal gaseous decomposing adhesive, such reworking is complex and in many cases, especially in inaccessible places on the inside of a hollow model, it is hardly feasible and verifiable with the required accuracy.

Der Erfindung liegt die Aufgabe zugrunde, ein im Prinzip beliebig hinterschnittenes Schaumstoff-Hohlmodell zu schaffen, das keine Nähte oder zumindest nur dort Nähte besitzt, wo eine Nacharbeit eventueller Beschädigungen oder Ungenauigkeiten an den Stoßstellen mit erträglichem Aufwand, also insbesondere nur an der Außenseite, be­sitzt. Die erfindungsgemäße Lösung besteht für das ein­gangs genannte Gußkörpermodell mit einem Schaumstoffkör­per zum Herstellen des hohlen Gußteils darin, daß die Kontur des Schaumstoffkörpers einseitig mit einem in das herzustellende Gußteil zum Bilden eines entsprechenden Teils von dessen Kontur einzuformenden feuerfesten Form teil abgedeckt ist.The invention has for its object to provide an undercut foam hollow model in principle, which has no seams or at least only seams where reworking possible damage or inaccuracies at the joints with tolerable effort, i.e. especially only on the outside . The solution according to the invention for the above-mentioned cast body model with a foam body for producing the hollow cast part is that the contour of the foam body is covered on one side with a cast part to be produced in the cast part to be formed to form a corresponding part of the contour of the refractory mold.

Durch die Erfindung wird erreicht, daß die Fläche des Schaumstoffkörpers, die nach Möglichkeit nicht nachge­arbeitet werden soll, mit einem unmittelbar eine Kontur des herzustellenden Gußteils vorgebenden feuerfesten Formteil zu bedecken ist. Von dem Begriff "feuerfester Formkörper" werden erfindungsgemäß Formteile aus metal­lischem oder nichtmetallischem Material umfaßt, die un­mittelbar beim Gießen in ein Metallgußteil eingeformt und zumindest einen Teil von dessen Außenfläche bilden können. Hierzu gehören Metallformteile aus Blech, Guß oder geschmiedetem Material aber auch Sinterwerkstoffe, Keramik, Glas oder dergleichen. Das Formteil kann als Einlageteil auf der Innenfläche eines hohlen Gußteils aber auch als Hüllteil auf der Außenfläche eines Guß­teils vorgesehen werden. Unerwartet wird also durch die Erfindung auch die Möglichkeit geschaffen, einen aus verschiedenen oder verschieden legierten Metallen oder aus Metall und Nichtmetall bestehenden Verbundkörper herzustellen. Beispielsweise läßt sich erfindungsgemäß ein hohler Gußeisenkörper gießen, dessen Innenkontur durch ein vorgefertigtes Einlageteil aus Blech gebildet wird. Erfindungsgemäß kann aber auch ein aus zwei Metal­len bestehender Verbundkörper gegossen werden, der bei­spielsweise eine Außenschale aus Eisen und ein hohles Innenteil aus Aluminium besitzt. Zu den vielen erfin­dungsgemäß herzustellenden Varianten von Gußkörpern ge­hört schließlich auch ein mit Keramik oder Glas, innen oder außen beschichtetes Gußeisenteil.It is achieved by the invention that the surface of the foam body, which should not be reworked if possible, is to be covered with a refractory molded part which directly defines a contour of the cast part to be produced. According to the invention, the term “refractory molded body” encompasses molded parts made of metallic or non-metallic material which can be molded directly into a cast metal part during casting and can form at least part of its outer surface. This includes metal parts made of sheet metal, cast iron or forged material, but also sintered materials, Ceramics, glass or the like. The molded part can be provided as an insert part on the inner surface of a hollow cast part, but also as an envelope part on the outer surface of a cast part. Unexpectedly, the invention also creates the possibility of producing a composite body consisting of different or differently alloyed metals or of metal and non-metal. For example, according to the invention, a hollow cast iron body can be cast, the inner contour of which is formed by a prefabricated insert made of sheet metal. According to the invention, however, a composite body consisting of two metals can also be cast, which has, for example, an outer shell made of iron and a hollow inner part made of aluminum. Finally, the many cast body variants to be produced according to the invention also include a cast iron part coated with ceramic or glass, internally or externally.

Gemäß weiterer Erfindung wird der Schaumstoffkörper nahtlos auf das feuerfeste Formteil aufgeformt. Grund­sätzlich kann der Schaumstoffkörper auf die Innen- oder Außenfläche eines hohlen feuerfesten Formteils aufge­formt werden. Das Formteil bildet also beim Herstellen des Schaumstoffkörpers einen Teil der Schale der Hohl­form. Wesentlich ist, daß bei dieser Verfahrensweise ein einteiliger Schaumstoffkörper entsteht, der keine even­tuelle zu Fehlern führende bzw. nachzuarbeitende Nähte besitzt.According to a further invention, the foam body is seamlessly molded onto the refractory molded part. In principle, the foam body can be molded onto the inner or outer surface of a hollow refractory molded part. The molded part thus forms part of the shell of the hollow mold when the foam body is produced. It is essential that this procedure creates a one-piece foam body that does not have any seams that lead to errors or that need to be reworked.

Wenn das feuerfeste Formteil eine in den herzustellenden Gußkörper eingehende Einlage des Schaumstoffkörpers bil­den soll, genügt zum Herstellen des vollständigen Schaummodells, eine einzige, der vorgesehenen Außenkon­tur des Schaumstoffkörpers entsprechende Form mit Unter- und Oberschale, weil als Kern dieser Form ein die Innen­fläche des herzustellenden Gußkörpers bestimmendes Ein­lageteil verwendet wird. Entsprechendes gilt, wenn die Außenschale des Schaumstoffkörpers mit dem feuerfesten Formteil abzudecken ist.If the refractory molded part is to form an insert of the foam body into the cast body to be produced, it is sufficient to produce the complete one Foam model, a single shape corresponding to the intended outer contour of the foam body with a lower and upper shell, because an insert part determining the inner surface of the cast body to be produced is used as the core of this shape. The same applies if the outer shell of the foam body is to be covered with the refractory molded part.

Wenn der erfindungsgemäße hohle Schaumstoffkörper ein­teilig herzustellen ist, können sich ungewollte Ein­schnitte - wegen einer fehlenden Naht - nicht ergeben, weil die auf den Schaumstoffkörper aufzubringende Schlichte nicht in den Körper eindringen kann. An der Grenze zwischen Ober- und Unterschale einer zum Her­stellen des Schaumstoffkörpers verwendeten Außenform können lediglich nach außen vorspringende Grate am Schaumstoff entstehen, die jedoch problemlos nachzu­arbeiten sind.If the hollow foam body according to the invention is to be produced in one piece, unwanted incisions cannot occur - because of a missing seam - because the size to be applied to the foam body cannot penetrate into the body. At the boundary between the upper and lower shell of an outer shape used to produce the foam body, only burrs projecting outward can arise on the foam, which, however, can be reworked without problems.

Überraschend läßt die Erfindung noch eine weitere Ausge­staltung zu. Gemäß weiterer Erfindung kann nämlich das wenigstens einen Teil der Kontur des Schaumstoffkörpers abdeckende feuerfeste Formteil auf seiner den herzustel­lenden Gußkörper zugewandten Fläche mit einem Isolier­stoffmantel, insbesondere aus Mineralfaserwolle, belegt werden. Eine solche Anordnung wird besonders bei ther­misch belasteten Gußteilen bevorzugt. Günstig ist die isolierende Zwischenlage auch bei Bauteilen, z. B. bei Auspuffkrümmern, die eine möglichst geringe Wärmeauf­nahme besitzen sollen. Damit (im Abgasstrom) nachfolgen­de Bauteile, z. B. Katalysatoren, möglichst schnell heiß werden. Die Einfügung bzw. das Eingießen eines Isolier­ stoffmantels bietet aber auch die Möglichkeit, das Ge­wicht des Gußkörpers zu vermindern, ohne dessen Volumen zu verkleinern. In jedem Fall kann der aus Isolierstoff oder dergleichen bestehende Mantel nicht nur auf der Innen- oder Außenfläche sondern auch an der Grenze der verschiedenen Schichten eines erfindungsgemäßen Verbund­körpers vorgesehen werden. Die Verwendung des erfin­dungsgemäßen feuerfesten Formteils ist also auch dann von Vorteil, wenn, wie in der chemischen Industrie, eine Fläche eines Gußteils in bestimmter Weise zu legieren ist, um die nötige chemische Resistenz sicherzustellen.Surprisingly, the invention permits a further embodiment. According to a further invention, the fireproof molded part covering at least part of the contour of the foam body can be covered with an insulating material jacket, in particular made of mineral fiber wool, on its surface facing the cast body to be produced. Such an arrangement is particularly preferred for thermally stressed castings. The insulating liner is also favorable for components, e.g. B. in exhaust manifolds, which should have the lowest possible heat absorption. So that (in the exhaust gas flow) subsequent components, for. B. catalysts, get hot as quickly as possible. The insertion or pouring of an insulation But the material jacket also offers the possibility of reducing the weight of the cast body without reducing its volume. In any case, the jacket consisting of insulating material or the like can be provided not only on the inner or outer surface but also on the boundary of the different layers of a composite body according to the invention. The use of the refractory molded part according to the invention is therefore also advantageous if, as in the chemical industry, a surface of a cast part has to be alloyed in a certain way in order to ensure the necessary chemical resistance.

Gemäß weiterer Erfindung besteht ein Verfahren zum Her­stellen eines hohlen Gußteils in der Metallgießerei un­ter Verwendung eines in der Hitze von flüssigem Metall, wie Eisen oder Aluminium, gasförmig zerfallenden, ins­besondere aus Polystyrolpartikelschaum oder dergleichen bestehenden, Schaumstoffkörpers als Modell darin, daß der Schaumstoffkörper beim Gießen einseitig mit einem feuerfesten, als solches in die Kontur des Gußteils auf­zunehmenden Formteil bedeckt wird. Grundsätzlich be­deutet das, daß ein wesentlicher Teil der Innen- oder Außenkontur des herzustellenden Gußteils vorgefertigt und als solches in das fertige Gußteil eingeformt wird.According to a further invention, a method for producing a hollow casting in the metal foundry using a foam body which decomposes in a gaseous manner in the heat of liquid metal, such as iron or aluminum, and in particular consists of polystyrene particle foam or the like, as a model that the foam body is one-sided during casting is covered with a refractory, as such to be included in the contour of the casting. Basically, this means that a substantial part of the inner or outer contour of the cast part to be produced is prefabricated and as such is molded into the finished cast part.

Anhand der schematischen Zeichnung von Ausführungsbei­spielen werden Einzelheiten der Erfindung erläutert. Es zeigen:

  • Fig. 1 einen Schnitt durch eine Form zum Herstellen eines hohlen Schaumstoffkörpers;
  • Fig. 2 einen Schnitt durch eine Gießform unter Verwendung eines hohlen Schaumstoffkörpers nach Fig. 1; und
  • Fig. 3 einen Schnitt durch eine weitere Gießform.
Details of the invention are explained on the basis of the schematic drawing of exemplary embodiments. Show it:
  • 1 shows a section through a mold for producing a hollow foam body.
  • FIG. 2 shows a section through a casting mold using a hollow foam body according to FIG. 1; and
  • Fig. 3 shows a section through a further mold.

Fig. 1 zeigt eine vorbereitete Form zum Herstellen eines erfindungsgemäßen, insgesamt mit 1 bezeichneten Gußkör­permodells. Das Modell nach Fig. 1 besteht aus einem feuerfesten Formteil 2 und einem daran anzuformenden, einteiligen Schaumstoffkörper 3. Als Form zum Herstellen des Schaumstoffkörpers 3 werden außer dem als Innen­schale dienenden Formteil 2 eine aus einer Oberform 4 und einer Unterform 5 bestehende, insgesamt mit 6 be­zeichnete Außenschale verwendet.Fig. 1 shows a prepared mold for producing a cast body model according to the invention, generally designated 1. 1 consists of a refractory molded part 2 and a one-piece foam body 3 to be molded thereon. In addition to the molded part 2 serving as the inner shell, a mold consisting of an upper mold 4 and a lower mold 5, with a total of 6, is used as the mold for producing the foam body 3 designated outer shell used.

Bei dem Herstellen des Gußkörpermodells 1 bzw. des Schaumstoffkörpers 3 kann auf der Innenfläche keine un­kontrollierbare Naht entstehen, da die Innenkontur be­reits durch die Innenfläche des Formteils 2 vorgegeben wird. Auf der Außenfläche des Schaumstoffkörpers 3 kann an der Stoßfläche 7 zwischen Ober- und Unterform 4, 5 lediglich ein nach außen vorspringender Grat auftreten, wenn die beiden an der Stoßfläche 7 sich berührenden Flächen von Ober- und Unterform 4, 5 nicht ganz exakt sind. Ein solcher Grat läßt sich aber am fertigen Guß­körpermodell 1 problemlos nacharbeiten. Auf keinen Fall kommt ein ungewollter Einsprung oder Einschnitt in der Kontur des Gußkörpermodells 1 vor, der bei der Weiter­verarbeitung mit Schlichte gefüllt werden könnte.When manufacturing the cast body model 1 or the foam body 3, no uncontrollable seam can arise on the inner surface, since the inner contour is already predetermined by the inner surface of the molded part 2. On the outer surface of the foam body 3, only an outwardly projecting ridge can occur on the abutting surface 7 between the upper and lower molds 4, 5 if the two surfaces of the upper and lower molds 4, 5 touching on the abutting surface 7 are not quite exact. Such a burr can be reworked on the finished cast body model 1 without any problems. Under no circumstance there is an unwanted step or incision in the contour of the cast body model 1, which could be filled with size during further processing.

Die Zeichnung zeigt in Fig. 2 einen Schnitt durch eine für die Eisengießerei vorbereitete Form mit einem Guß­körpermodell 1 nach Fig. 1. Im Ausführungsbeispiel be­steht das Gußkörpermodell 1 außer aus dem Formteil 2 und dem Schaumstoffkörper 3 aus einer Isolierstoffschicht 8. Das ganze Gußkörpermodell 1 wird in einem Kasten 9 in binderfreiem Formstoff 10, insbesondere in Sand, innen und außen eingebettet, insbesondere eingerüttelt, so daß im Kasten 9 kein Hohlraum mehr verbleibt. An ein Ende des Schaumstoffkörpers 3 wird ein Eingießtrichter 11 an­gesetzt. Im übrigen wird die gesamte Oberfläche des im Kasten 9 befindlichen Formstoffs 6 mit einer luftdichten Folie 12 so umgeben, daß ein mit einem Ansaugstutzen 13 über eine Unterdruckleitung 14 in den Formstoff hinein­wirkende Unterdruckpumpe den Innenraum der Folie 12 bzw. des Kastens 9, so weit entlüften kann, daß der vorzugs­weise aus rieselförmigem Sand bestehende Formstoff 10 insgesamt steif wird.The drawing shows in FIG. 2 a section through a mold prepared for the iron foundry with a cast body model 1 according to FIG. 1. In the exemplary embodiment, the cast body model 1 consists, apart from the molded part 2 and the foam body 3, of an insulating material layer 8. The entire cast body model 1 is embedded in a box 9 in binder-free molding material 10, in particular in sand, inside and outside, in particular vibrated, so that no cavity remains in box 9. A pouring funnel 11 is attached to one end of the foam body 3. Otherwise, the entire surface of the molding material 6 in the box 9 is surrounded with an airtight film 12 so that a vacuum pump acting into the molding material with an intake pipe 13 via a vacuum line 14 vent the interior of the film 12 or the box 9 so far can that the molding material 10, which preferably consists of free-flowing sand, becomes stiff overall.

Beim Eingießen des flüssigen Eisens in den Eingießtrich­ter 11 wird das Material des Schaumstoffkörpers 3 zer­setzt und gasförmig über die Unterdruckleitung 14 in dem Maße abgezogen, wie es durch das flüssige und erstarren­de Eisen ersetzt wird. Bei diesem Gießvorgang wird das feuerfeste Formteil 2 (gegebenenfalls auch die Isolier­stoffschicht 8) Bestandteil des hergestellten Gußstücks. Das Gußstück nimmt also schließlich den Raum ein, der ursprünglich durch den Schaumstoffkörper 3 verdrängt war. Die Kontur des Schaumstoffkörpers 3, im vorliegen­den Fall dessen Außenkontur 15 ist oder wird also zu­gleich die Außenkontur des Gußkörpers. Die Innenkontur 16 des Gußkörpermodells 1, also im Ausführungsbeispiel die Innenfläche des Formteils 2, bildet zugleich die Innenkontur 16 des herzustellenden Gußteils.When pouring the liquid iron into the pouring funnel 11, the material of the foam body 3 is decomposed and drawn off in gaseous form via the vacuum line 14 to the extent that it is replaced by the liquid and solidifying iron. In this casting process, the refractory molded part 2 (possibly also the insulating material layer 8) becomes part of the cast part produced. The casting finally occupies the space that was originally displaced by the foam body 3 was. The contour of the foam body 3, in the present case its outer contour 15, is or at the same time becomes the outer contour of the cast body. The inner contour 16 of the cast body model 1, that is to say the inner surface of the molded part 2 in the exemplary embodiment, simultaneously forms the inner contour 16 of the cast part to be produced.

In Fig. 3 wird der Fall eines Verbund-Gußkörpers mit ei­ner Eisenschicht 17 auf der Außenseite und mit einem ei­nen Durchgang 18 aufweisenden hohlen Aluminiumkörper 19 auf der Innenseite. Beim Gießen eines Gußteils nach Fig. 3 wird ein Schaumstoffkörper auf der Innenfläche des Ei­senkörpers 18 vorgesehen, z. B. unmittelbar geschäumt, der einen Durchgang 18 besitzt. Während des Gießvorgangs wird der Durchgang 18 mit beispielsweise rieselförmigen Formstoff ausgefüllt. Der Aluminiumkörper 19 nimmt den Platz des Schaumstoffkörpers ein.3 shows the case of a composite casting with an iron layer 17 on the outside and with a hollow aluminum body 19 with a passage 18 on the inside. 3, a foam body is provided on the inner surface of the iron body 18, for. B. directly foamed, which has a passage 18. During the casting process, the passage 18 is filled with, for example, poured molding material. The aluminum body 19 takes the place of the foam body.

BezugszeichenlisteReference symbol list

  • 1 = Gußkörpermodell1 = cast body model
  • 2 = feuerfestes Formteil2 = fireproof molded part
  • 3 = Schaumstoffkörper3 = foam body
  • 4 = Oberform4 = upper form
  • 5 = Unterform5 = lower mold
  • 6 = Außenschale6 = outer shell
  • 7 = Stoßfläche (4, 5)7 = joint surface (4, 5)
  • 8 = Isolierstoffschicht8 = layer of insulating material
  • 9 = Kasten9 = box
  • 10 = Formstoff10 = molding material
  • 11 = Eingießtrichter11 = pouring funnel
  • 12 = Folie12 = foil
  • 13 = Ansaugstutzen13 = intake manifold
  • 14 = Unterdruckleitung14 = vacuum line
  • 15 = Außenkontur15 = outer contour
  • 16 = Innenkontur16 = inner contour
  • 17 = Eisenkörper17 = iron body
  • 18 = Durchgang18 = passage
  • 19 = Aluminiumkörper19 = aluminum body

Claims (9)

1. Gußkörpermodell (1) mit einem Schaumstoffkörper (3) zum Herstellen eines hohlen Gußteils in der Metallgieße­rei, wobei der Schaumstoffkörper (3) aus einem in der Hitze von flüssigem Metall, wie Eisen oder Aluminium, gasförmig zerfallenden Material, wie Polystyrolpartikel­schaum oder dergleichen, besteht,
dadurch gekennzeichnet,
daß die Kontur des Schaumstoffkörpers (3) einseitig mit einem in das herzustellende Gußteil zum Bilden eines entsprechenden Teils von dessen Kontur (16) einzuformen­den, feuerfesten Formteil (2) abgedeckt ist.1. cast body model (1) with a foam body (3) for producing a hollow casting in the metal foundry, the foam body (3) made of a material that decomposes in the heat of liquid metal, such as iron or aluminum, such as polystyrene particle foam or the like, consists,
characterized,
that the contour of the foam body (3) is covered on one side with a fire-resistant molded part (2) to be molded into the cast part to be formed to form a corresponding part of its contour (16). 2. Modell nach Anspruch 1,
dadurch gekennzeichnet,
daß die die Innenkontur (16) des herzustellenden Guß­teils bestimmende Seite des Schaumstoffkörpers (3) mit dem feuerfesten Formteil (2) abgedeckt ist.2. Model according to claim 1,
characterized,
that the inner contour (16) of the cast part to be produced determines the side of the foam body (3) covered with the refractory molded part (2). 3. Modell nach Anspruch 1 oder 2,
dadurch gekennzeichnet,
daß der Schaumstoffkörper (3) nahtlos auf das feuerfeste Formteil (2) aufgeformt ist.3. Model according to claim 1 or 2,
characterized,
that the foam body (3) is seamlessly molded onto the refractory molded part (2). 4. Modell nach einem der Ansprüche 1 bis 3,
dadurch gekennzeichnet,
daß das feuerfeste Formteil (2) auf einer dem Schaum­stoffkörper (3) zugewandten Fläche mit einer feuerfesten Isolierstoffschicht (8), wie Mineralfaserwolle, belegt ist.4. Model according to one of claims 1 to 3,
characterized,
that the refractory molded part (2) on a surface facing the foam body (3) is covered with a refractory insulating material layer (8), such as mineral fiber wool. 5. Modell nach einem der Ansprüche 1 bis 4,
dadurch gekennzeichnet,
daß das feuerfeste Formteil (2) aus Metall, insbesondere aus gewalztem Blech, besteht.5. Model according to one of claims 1 to 4,
characterized,
that the refractory molded part (2) consists of metal, in particular of rolled sheet metal. 6. Modell nach einem der Ansprüche 1 bis 4,
dadurch gekennzeichnet,
daß das feuerfeste Formteil (2) aus einem Sinterwerk­stoff, Keramik oder Glas, besteht.6. Model according to one of claims 1 to 4,
characterized,
that the refractory molded part (2) consists of a sintered material, ceramic or glass. 7. Verfahren zum Herstellen eines hohlen Gußteils in der Metallgießerei unter Verwendung eines in der Hitze von flüssigem Metall, wie Eisen oder Aluminium, gasförmig zerfallenden, insbesondere aus Polystyrolpartikelschaum oder dergleichen bestehenden, Schaumstoffkörpers (3) als Modell,
dadurch gekennzeichnet,
daß der Schaumstoffkörper (3) beim Gießen einseitig mit einem feuerfesten und als solches in die Kontur (16) des hohlen Gußteils aufzunehmenden Formteil (2) bedeckt wird.7. A method for producing a hollow casting in the metal foundry using a foam body (3), which decomposes in gaseous form in the heat of liquid metal, such as iron or aluminum, in particular consisting of polystyrene particle foam or the like, as a model,
characterized,
that the foam body (3) is covered on one side with a refractory and as such in the contour (16) of the hollow casting molded part (2) during casting becomes. 8. Verfahren zum Herstellen eines Gußkörpermodells nach einem oder mehreren der Ansprüche 1 bis 6,
dadurch gekennzeichnet,
daß das feuerfeste Formteil (2) unmittelbar als Teil ei­ner Hohlform zum Herstellen des Schaumstoffkörpers (3) verwendet wird.8. A method for producing a cast body model according to one or more of claims 1 to 6,
characterized,
that the refractory molded part (2) is used directly as part of a hollow mold for producing the foam body (3). 9. Verfahren nach Anspruch 8,
dadurch gekennzeichnet,
daß das feuerfeste Formteil (2) unmittelbar als Innen­schale einer eine aus Ober- und Unterform (4, 5) beste­hende Außenschale (6) besitzenden Hohlform zum Herstel­len des Schaumstoffkörpers (3) verwendet wird.9. The method according to claim 8,
characterized,
that the fireproof molded part (2) is used directly as the inner shell of an outer shell (6) consisting of upper and lower molds (4, 5) and having a hollow mold for producing the foam body (3).
EP88108579A 1987-08-29 1988-05-28 Foundry model and process for manufacturing a hollow cast piece Expired - Lifetime EP0305653B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AT88108579T ATE70749T1 (en) 1987-08-29 1988-05-28 CASTING MODEL AND METHOD OF MAKING A HOLLOW CASTING.

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE19873728918 DE3728918A1 (en) 1987-08-29 1987-08-29 MOLDED BODY MODEL AND METHOD FOR PRODUCING A HOLLOW MOLDED BODY
DE3728918 1987-08-29

Publications (2)

Publication Number Publication Date
EP0305653A1 true EP0305653A1 (en) 1989-03-08
EP0305653B1 EP0305653B1 (en) 1991-12-27

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US (1) US4942915A (en)
EP (1) EP0305653B1 (en)
JP (1) JP2721191B2 (en)
AT (1) ATE70749T1 (en)
DE (3) DE8717657U1 (en)
ES (1) ES2029299T3 (en)

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EP0506123A1 (en) * 1991-03-29 1992-09-30 Asahi Tec Corporation Method of preparing disappearing model
FR2676015A1 (en) * 1991-05-01 1992-11-06 Outboard Marine Corp Method and apparatus for the manufacture of a casing including an insert cast in situ by means of lost-foam casting
FR2698296A1 (en) * 1992-11-23 1994-05-27 Peugeot Process for manufacturing metal parts by molding in a lost model, model with incorporated hollow insert obtained by this method and metal part obtained using this model.
EP3763503A1 (en) * 2019-07-08 2021-01-13 PSA Automobiles SA Mould for injection of expanded polystyrene for forming a hollow element

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DE19612781C1 (en) * 1996-03-29 1997-08-21 Karmann Gmbh W Component made of metallic foam material, process for final shaping of this component and device for carrying out the process
KR100814794B1 (en) * 2006-10-09 2008-03-19 (주)동양특수주강 Method for mounting hi-cr casting on the elbow of dustcollecting duct and the elbow manufactured thereof
CN112846150B (en) * 2020-12-30 2023-02-28 中钢集团邢台机械轧辊有限公司 Multi-element composite manufacturing method for hot-rolled section steel hole type roller

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WO1990004472A1 (en) * 1988-10-24 1990-05-03 Hüttenes-Albertus Chemische Werke GmbH Process for manufacturing castings with remelted, at least approximately gastight high-temperature insulation
EP0506123A1 (en) * 1991-03-29 1992-09-30 Asahi Tec Corporation Method of preparing disappearing model
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EP1029615A1 (en) * 1991-03-29 2000-08-23 Asahi Tec Corporation Method of preparing disappearing model
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FR2698296A1 (en) * 1992-11-23 1994-05-27 Peugeot Process for manufacturing metal parts by molding in a lost model, model with incorporated hollow insert obtained by this method and metal part obtained using this model.
EP0599680A1 (en) * 1992-11-23 1994-06-01 Automobiles Peugeot Process for producing metal parts by lost pattern moulding, pattern with incorporated hollow insert obtained by said process and metal part obtained using said pattern
EP3763503A1 (en) * 2019-07-08 2021-01-13 PSA Automobiles SA Mould for injection of expanded polystyrene for forming a hollow element
FR3098436A1 (en) * 2019-07-08 2021-01-15 Psa Automobiles Sa EXPANDED POLYSTYRENE INJECTION MOLD FOR THE REALIZATION OF A HOLLOW ELEMENT

Also Published As

Publication number Publication date
JP2721191B2 (en) 1998-03-04
ATE70749T1 (en) 1992-01-15
DE3728918A1 (en) 1989-03-09
DE8717657U1 (en) 1989-09-21
JPS6471548A (en) 1989-03-16
DE3867178D1 (en) 1992-02-06
ES2029299T3 (en) 1992-08-01
EP0305653B1 (en) 1991-12-27
US4942915A (en) 1990-07-24

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