EP0513523A1 - Druckgussverfahren zur Herstellung von Teilen mit hoher mechanischer Leistungsfähigkeit aus thixotropem Metall - Google Patents

Druckgussverfahren zur Herstellung von Teilen mit hoher mechanischer Leistungsfähigkeit aus thixotropem Metall Download PDF

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Publication number
EP0513523A1
EP0513523A1 EP92106005A EP92106005A EP0513523A1 EP 0513523 A1 EP0513523 A1 EP 0513523A1 EP 92106005 A EP92106005 A EP 92106005A EP 92106005 A EP92106005 A EP 92106005A EP 0513523 A1 EP0513523 A1 EP 0513523A1
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EP
European Patent Office
Prior art keywords
alloy
ingots
fact
metal alloy
semiliquid
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
EP92106005A
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English (en)
French (fr)
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EP0513523B1 (de
Inventor
Renzo Moschini
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Marelli Europe SpA
Original Assignee
Weber SRL
Magneti Marelli SpA
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Application filed by Weber SRL, Magneti Marelli SpA filed Critical Weber SRL
Publication of EP0513523A1 publication Critical patent/EP0513523A1/de
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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
    • B22D17/007—Semi-solid pressure die casting
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/12—Making non-ferrous alloys by processing in a semi-solid state, e.g. holding the alloy in the solid-liquid phase

Definitions

  • the present invention relates to a die casting process for producing internal combustion engine components from a light alloy, in particular, aluminium alloy to which ceramic particles are added.
  • the present Applicant has perfected a semiliquid casting process as described in Italian Patent Application n.67 627-A/89, filed on 25.07.1989, and entitled: "Continuous semiliquid casting process and furnace", the content of which is incorporated herein purely by way of reference as required.
  • the static mixer is connected to a pressurized tiltable reverberatory furnace, for casting under steady conditions, and is equipped with a barometric column enabling it to be refilled without interrupting or affecting steady flow of the casting.
  • Metal alloys produced using semiliquid casting processes as described above are said to be "rheocast", and present particularly good microstructural characteristics.
  • Rheocast light alloys in fact, have recently be found to present a globular as opposed to a traditional dendritic microstructure, thus resulting in improved fluid dynamic characteristics (temperatures within the solidification range).
  • known semiliquid casting processes have yet to be applied to the manufacture of internal combustion engine components, which, for cost reasons, are normally die cast.
  • a major drawback of die casting is the formation of blowholes in the casting, resulting from the turbulence produced by the high speed at which the liquid alloy is injected.
  • a process for producing die castings in particular, light alloy internal combustion engine components, characterized by the fact that it comprises stages consisting in:
  • a process for die casting aluminium alloy characterized by the fact that it consists in heating an ingot, produced by casting said alloy in semiliquid form to produce a globular micrographic structure of the alloy, to a temperature within the solidification range of the alloy and such as to reduce the alloy to a highly viscous, semiliquid form; and in subsequently exerting mechanical pressure on the ingot.
  • pigs 1 of a metal alloy in the example shown, light aluminium-based casting alloy UNI 3600 (UNI coding) are first melted normally in a known pot furnace 2.
  • the initial alloy is A356, a casting alloy produced and marketed by ALCAN of San Diego (CA) U.S.A., which presents a nominal matrix of 93% Al and 7% Si in which is dispersed uniformly a ceramic phase consisting, in this case, of SiC (silicon carbide) particles.
  • furnace 2 is equipped with a known mechanical mixer 3 (or other similar known means not shown for the sake of simplicity) for maintaining the SiC particles uniformly dispersed in the molten alloy.
  • the resulting liquid phase 4 (possibly also containing solid SiC particles) is fed into a pressurized rocking furnace 6 as described in Italian Patent Application n. 67627-A/89, filed by the present Applicant on 25.07.1989, and the content of which is incorporated herein purely by way of reference as required; which furnace 6 is connected to a known static mixer 7 as described in Italian Patent n. 1.119.287 filed on 20 June, 1979, and the content of which is also incorporated herein purely by way of reference as required.
  • Liquid phase 4 is then cast as described in the above patents, the mixer 7 being cooled so as to separate from liquid phase 4, as it is fed through mixer 7, a solid phase (not shown) which gradually increases as the alloy is cooled through mixer 7, and which is mixed uniformly with liquid phase 4 to produce a temporary stable solid-liquid suspension 8 at the output of mixer 7.
  • any solid SiC particles in the original alloy are also mixed continually with liquid phase 4 in mixer 7 to form an integral part of suspension 8 with no risk of the particles being segregated.
  • Suspension 8 is cast, for example, in an ingot mold 10 to produce an ingot 11 consisting of the original metal alloy, and possibly also containing dispersed SiC particles, but which, due to being cast in semiliquid form, presents an entirely different crystal structure.
  • pig 1 form for example, a UNI 3600 alloy presents a dendritic structure as shown in Fig.3, whereas, when rheocast (i.e. cast in semiliquid form through mixer 7) and solidified, the same alloy presents a globular structure as shown in Fig.4.
  • Ingot 11 is then divided, e.g. cut mechanically using known means, such as a circular saw, into a number of smaller ingots 12, each, including the feedhead and channels, roughly equal to the weight of the component for casting, and which are fed, in stainless steel containers 13 (Fig.2), into an electric resistance furnace 14, preferably specially designed and equipped with automatic robot handling devices 15, where they are heated (for 50-60 minutes) to a temperature within the solidification range of the initial metal alloy.
  • the rheocast globular-structure alloy of ingots 12 (with or without uniformly dispersed SiC particles) thus assumes a semiliquid state having, in the example shown, a liquid phase percentage of roughly 50% by volume, i.e. substantially the same as at the semiliquid casting stage through mixer 7.
  • the semiliquid alloy When cast through mixer 7, however, the semiliquid alloy, by virtue of mixer 7, presents at most a viscosity of a few P, whereas, in ingot 12 form, by appropriately selecting the chemical composition and the heating temperature within the solidification range of the initial alloy (roughly 580°C for aluminium alloys), the same semiliquid alloy, but with a globular structure and heated to said temperature within the solidification range of the initial alloy, has been found to present substantially pseudoplastic rheologic characteristics and a viscosity at rest of about 107 P.
  • the alloy of ingots 12 therefore presents a pasty, pudding-like consistency preventing the segregation of any solid ceramic particles, which thus remain uniformly dispersed in the alloy, and enabling ingots 12 to maintain their shape.
  • Ingots 12 processed as described above are then fed one at a time on to a known die casting machine 18 (not described in detail) fitted with the same molds normally used for liquid alloys, with the exception of the gates, the thickness of which is increased from 0.8:1 mm to 2:2.5 mm to assist throughput of the semiliquid alloy.
  • the semiliquid ingot 12 is fed into a known injection chamber 20 on machine 18, where it is subjected by a piston 21 to a predetermined mechanical pressure, equal to that usually employed for die casting liquid alloys, e.g. 650 Kg/cm2, and injected into a mold 22 where the alloy solidifies to produce a finished casting 25 consisting, for example, of an internal combustion engine component, such as an injection manifold.
  • the alloy as compared with a liquid alloy of the same composition, presents a much higher viscosity and, therefore, a very low Reynolds number, thus enabling injection under laminar flow conditions, as opposed to turbulent flow conditions typical of known liquid alloy die casting processes.
  • the high viscosity at rest combined with laminar-flow injection of the alloy provides, on the one hand, for preventing the inclusion of air bubbles and the formation of blowholes in the finished casting, and, on the other, for preventing the segregation of any solid ceramic particles contained in the semiliquid alloy fed on to machine 18, which particles therefore remain uniformly dispersed both in the semiliquid alloy injected into mold 22 and in the finished casting 25.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
EP92106005A 1991-04-19 1992-04-07 Druckgussverfahren zur Herstellung von Teilen mit hoher mechanischer Leistungsfähigkeit aus thixotropem Metall Expired - Lifetime EP0513523B1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITTO910299 1991-04-19
ITTO910299A IT1245080B (it) 1991-04-19 1991-04-19 Procedimento per l'ottenimento di pressocolati ad alte prestazioni meccaniche mediante iniezione di una lega metallica allo stato semiliquido.

Publications (2)

Publication Number Publication Date
EP0513523A1 true EP0513523A1 (de) 1992-11-19
EP0513523B1 EP0513523B1 (de) 1998-07-29

Family

ID=11409273

Family Applications (1)

Application Number Title Priority Date Filing Date
EP92106005A Expired - Lifetime EP0513523B1 (de) 1991-04-19 1992-04-07 Druckgussverfahren zur Herstellung von Teilen mit hoher mechanischer Leistungsfähigkeit aus thixotropem Metall

Country Status (7)

Country Link
EP (1) EP0513523B1 (de)
JP (1) JP2793430B2 (de)
BR (1) BR9201567A (de)
DE (1) DE69226397T2 (de)
ES (1) ES2119786T3 (de)
IT (1) IT1245080B (de)
RU (1) RU2081725C1 (de)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0590402A1 (de) * 1992-09-29 1994-04-06 MAGNETI MARELLI S.p.A. Verfahren zum Herstellen von Blöcken nach dem Rheocasting-Verfahren, insbesondere für hochfeste Werkstücke
EP0645206A1 (de) * 1993-09-29 1995-03-29 MAGNETI MARELLI S.p.A. Verfahren und Vorrichtung zum thixotropen Druckgiessen von hochfesten Werkstücken
EP0663251A1 (de) * 1994-01-13 1995-07-19 Rheo-Technology, Ltd Verfahren zum thixotropen Druckgiessen von Graphitgusseisen
EP0692328A1 (de) * 1994-06-14 1996-01-17 Salzburger Aluminium Aktiengesellschaft Verfahren zur Herstellung von Formgussteilen aus Aluminiumlegierungen
EP0703300A1 (de) * 1994-09-23 1996-03-27 Reynolds Wheels International Ltd. Verfahren und Vorrichtung zum Erwärmen von Werkstücken aus Metallegierungen bis zum halbfesten oder halbflüssigen Zustand zwecks Formgebung im thixotropen Bereich
EP0713736A2 (de) 1994-11-22 1996-05-29 Alusuisse-Lonza Services AG Haltevorrichtung für Bolzen
EP0733422A1 (de) * 1995-03-21 1996-09-25 Alusuisse-Lonza Services AG Verfahren und Vorrichtung zur Herstellung von Formteilen aus Metall
WO2007004241A1 (en) * 2005-07-05 2007-01-11 Aluminio Tecno Industriales Orinoco C.A. Process and plant for producing components made of thixotropic billets of an aluminium alloy for vehicules , and components obtained thereby

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19842333C2 (de) 1998-09-16 2000-10-19 Bosch Gmbh Robert Modul einer elektrohydraulischen Getriebesteuerung
JP4051350B2 (ja) * 2004-03-05 2008-02-20 日精樹脂工業株式会社 低融点金属合金の成形方法
JP4051393B2 (ja) * 2007-06-13 2008-02-20 日精樹脂工業株式会社 低融点金属合金の成形方法
EP2396436B1 (de) * 2010-04-07 2013-07-24 Rheinfelden Alloys GmbH & Co. KG Aluminiumdruckgusslegierung
DE102011011801A1 (de) * 2011-02-19 2012-08-23 Volkswagen Ag Verfahren und Anordnung zum Gießen eines Bauteilrohlings aus einer Leichtmetalllegierung
WO2014041569A1 (en) * 2012-09-12 2014-03-20 Aluminio Tecno Industriales Orinoco C.A. Process and plant for producing components made of an aluminium alloy for vehicles and white goods, and components obtained thereby

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2112676A (en) * 1982-01-06 1983-07-27 Olin Corp Method and apparatus for forming a thixoforged copper base alloy cartridge casing

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS63149343A (ja) * 1986-12-11 1988-06-22 Nippon Light Metal Co Ltd セラミツクス分散強化軽合金製シリンダ−およびその製造法
JP2639552B2 (ja) * 1988-04-01 1997-08-13 東芝機械株式会社 半溶融金属射出成形装置

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2112676A (en) * 1982-01-06 1983-07-27 Olin Corp Method and apparatus for forming a thixoforged copper base alloy cartridge casing

Non-Patent Citations (3)

* Cited by examiner, † Cited by third party
Title
MéMOIRES ET ETUDES SCIENTIFIQUES DE LA REVUE DE MéTALLURGIE vol. 80, no. 7/8, August 1983, PARIS pages 355 - 365; C. MILLIERE ET AL.: 'Structure, propriétés et mise en forme des alliages brassés à l'état semi-solide (suite)' *
METALLURGICAL TRANSACTIONS B vol. 22B, no. 3, June 1991, WARRENDALE, PA, US pages 269 - 293; MERTON C. FLEMINGS: 'Behavior of Metal Alloys in the Semisolid State' *
VDI ZEITSCHRIFT vol. 133, no. 3, March 1991, DUESSELDORF WOLFGANG SCHNEIDER: 'Formgiessverfahren für innovative Aluminiumgussteile' p. 127-128, 131-133 *

Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5464053A (en) * 1992-09-29 1995-11-07 Weber S.R.L. Process for producing rheocast ingots, particularly from which to produce high-mechanical-performance die castings
EP0590402A1 (de) * 1992-09-29 1994-04-06 MAGNETI MARELLI S.p.A. Verfahren zum Herstellen von Blöcken nach dem Rheocasting-Verfahren, insbesondere für hochfeste Werkstücke
EP0645206A1 (de) * 1993-09-29 1995-03-29 MAGNETI MARELLI S.p.A. Verfahren und Vorrichtung zum thixotropen Druckgiessen von hochfesten Werkstücken
US5533562A (en) * 1993-09-29 1996-07-09 Weber S.R.L. Method and system for semiliquid die casting high performance mechanical components from rheocast ingots
US5531261A (en) * 1994-01-13 1996-07-02 Rheo-Technology, Ltd. Process for diecasting graphite cast iron at solid-liquid coexisting state
EP0663251A1 (de) * 1994-01-13 1995-07-19 Rheo-Technology, Ltd Verfahren zum thixotropen Druckgiessen von Graphitgusseisen
EP0692328A1 (de) * 1994-06-14 1996-01-17 Salzburger Aluminium Aktiengesellschaft Verfahren zur Herstellung von Formgussteilen aus Aluminiumlegierungen
EP0703300A1 (de) * 1994-09-23 1996-03-27 Reynolds Wheels International Ltd. Verfahren und Vorrichtung zum Erwärmen von Werkstücken aus Metallegierungen bis zum halbfesten oder halbflüssigen Zustand zwecks Formgebung im thixotropen Bereich
US5665302A (en) * 1994-09-23 1997-09-09 Reynolds Wheels International Ltd. Method and equipment for bringing metal alloy ingots, billets and the like to the semisolid or semiliquid state in readiness for thixotropic forming
US5869811A (en) * 1994-09-23 1999-02-09 Reynolds Wheels International Ltd. Method and equipment for bringing metal alloy ingots, billets and the like to the semisolid or semiliquid state in readiness for thixotropic forming
EP0713736A3 (de) * 1994-11-22 1996-06-12 Alusuisse Lonza Services Ag
EP0713736A2 (de) 1994-11-22 1996-05-29 Alusuisse-Lonza Services AG Haltevorrichtung für Bolzen
CH691354A5 (de) * 1994-11-22 2001-07-13 Alusuisse Tech & Man Ag Aufnahmevorrichtung für Bolzen.
EP0733422A1 (de) * 1995-03-21 1996-09-25 Alusuisse-Lonza Services AG Verfahren und Vorrichtung zur Herstellung von Formteilen aus Metall
CH689448A5 (de) * 1995-03-21 1999-04-30 Alusuisse Lonza Services Ag Verfahren und Vorrichtung zur Herstellung von Formteilen aus Metall.
WO2007004241A1 (en) * 2005-07-05 2007-01-11 Aluminio Tecno Industriales Orinoco C.A. Process and plant for producing components made of thixotropic billets of an aluminium alloy for vehicules , and components obtained thereby

Also Published As

Publication number Publication date
EP0513523B1 (de) 1998-07-29
ES2119786T3 (es) 1998-10-16
BR9201567A (pt) 1992-12-01
DE69226397D1 (de) 1998-09-03
DE69226397T2 (de) 1998-12-03
JP2793430B2 (ja) 1998-09-03
ITTO910299A0 (it) 1991-04-19
JPH06142870A (ja) 1994-05-24
RU2081725C1 (ru) 1997-06-20
ITTO910299A1 (it) 1992-10-20
IT1245080B (it) 1994-09-13

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