EP0519054A1 - Method of obtaining cast composite cylinder heads - Google Patents

Method of obtaining cast composite cylinder heads

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Publication number
EP0519054A1
EP0519054A1 EP92903814A EP92903814A EP0519054A1 EP 0519054 A1 EP0519054 A1 EP 0519054A1 EP 92903814 A EP92903814 A EP 92903814A EP 92903814 A EP92903814 A EP 92903814A EP 0519054 A1 EP0519054 A1 EP 0519054A1
Authority
EP
European Patent Office
Prior art keywords
layer
alloys
alloy
casting
cylinder heads
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
EP92903814A
Other languages
German (de)
French (fr)
Other versions
EP0519054B1 (en
Inventor
Eric Darsy
Philippe Meyer
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.)
Montupet SA
Original Assignee
Montupet SA
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Montupet SA filed Critical Montupet SA
Publication of EP0519054A1 publication Critical patent/EP0519054A1/en
Application granted granted Critical
Publication of EP0519054B1 publication Critical patent/EP0519054B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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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
    • B22D19/0009—Cylinders, pistons
    • 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
    • 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
    • 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
    • B22D19/16—Casting in, on, or around objects which form part of the product for making compound objects cast of two or more different metals, e.g. for making rolls for rolling mills
    • 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 the production of cylinder heads molded from aluminum alloys comprising at least two different alloys.
  • the liquid alloys can comprise solid particles with the casting of various size and shape so as to produce composites with metallic matrix after solidification.
  • This technique optimizes the choice of materials according to the main functions required in the different parts of the cylinder heads.
  • search in the vicinity of the combustion chamber, for a tolerance to maximum hot damage, in particular in the inter-seat areas of the valves.
  • the critical property is the mechanical strength, in order to give the cylinder head maximum rigidity and the best tightening capacity, with a minimum weight of the finished part.
  • the Applicant has therefore researched and developed production techniques allowing different alloys to be cast in a cylinder head, and in particular alloys with high tolerance to damage on the combustion chamber side and alloys with low cost price and high mechanical resistance in the rest of the room.
  • the part according to the invention consists of successive, contiguous and substantially horizontal layers.
  • each layer i-1 (i l 2) must satisfy the following conditions at the time of the casting of the subsequent layer i.
  • this involves defining the waiting time, t, between the end of casting of each layer (i-1) and the start of layer i (il 2), depending on the cooling conditions of the molded part.
  • the cooling of the molded part is generally ensured by a metal soleplate traversed by a heat transfer fluid such as water.
  • the solid fractions are determined beforehand experimentally by thermal analysis, for example by placing at least two thermocouples in each layer (i-1), one in the area close to the interface with the next layer, and the other near the base of the layer.
  • the solid fractions are determined from these thermal analyzes by the use of balance diagrams of the cast metal assimilated in general to a binary alloy based on Al. The principle of the calculation is given in the Appendix.
  • the feeding systems will be adapted so that the pouring of each layer i (il 2) does not create unacceptable erosion of the layer i-1 and that the layers are as uniform as possible. This adjustment is within the reach of those skilled in the art, for example, by optimizing feed channels or by using metallic or ceramic filters placed in the feed system, to regulate the flow rate. It is indeed necessary to obtain an interface (s) substantially flat and regular between the layers, controllable for example by micrography, macrography or scanning microscopy on cross section (s) perpendicular to the interface.
  • the feeding systems can be asymmetrical, but they are preferably made symmetrical to facilitate obtaining layers of uniform thickness.
  • a layer of material intended for heat resistance is typically formed, having a thickness of 15 to 25 mm on the combustion chamber side, the remainder consisting of the second alloy.
  • the process for obtaining a bi (or multi) metallic cylinder head is therefore carried out by successively pouring into the cavity of a mold, either metallic, either sand, or mixed, two (or more) alloys of separate aluminum with an interface zone (s) the thinnest possible (s) made up of a mixture of cast alloys and without trace of skins oxides.
  • the alloys are introduced into the mold cavity by independent feed systems.
  • the level of each layer is obtained by measuring its quantity, for example by volume.
  • the production of a multi-alloy cylinder head can be done by gravity casting technique, under low pressure, by liquid forging (squeeze casting) or any other industrial foundry technique suitable for obtaining cylinder heads.
  • FIGS. 1 to 7. Fig. 1 schematically represents a view of the molded part obtained and the direction of the thermal gradient applied (arrow).
  • Fig. 2 shows in transverse layer a schematic view of a mold usable for the implementation of the invention. .
  • Fig. 3 shows another version of said mold, which makes it possible to obtain the molded part shown in perspective in FIG. 4.
  • fig. 5 represents a transverse macrographic section of the connection zone between the two alloys of the cylinder head obtained under the conditions reported in Example 1 at magnification x 25.
  • fig. 6 shows a cross-sectional macrographic section of the connection zone between the 2 alloys of the cylinder head obtained in accordance with the conditions of Example 2 at magnification x 50.
  • fig. 7 shows a thermal analysis curve of the solidification of an Al-Si eutectic alloy and FIG. 8 the equilibrium diagram of the corresponding binary alloy (Al-Si).
  • the mold is composed of a metallic sole (1) in cuprochrome (approximate composition Cu 60%, Cr 40%) of thickness 100 mm and clods in sand (2).
  • This sole has a cooling circuit (3) in which the water circulates so as to maintain its temperature between 80 and 100 ° C.
  • the mold is provided with two supply systems (4) and (5), vents, cores of the water and oil circulation circuits, intake and exhaust pipes, and usual weights (not shown).
  • the coring process is the PEPSET process for clods (2), the cores of the oil circulation circuits and the intake and exhaust pipes, and ASHLAND for the cores of the water circulation circuits.
  • the first metal is poured, from AS7G0.3 (according to French standard NF A 57702) at the temperature of 710 ° C (target temperature) over a height of 20 mm corresponding to the thickness of the cylinder head table (volumetric dosage).
  • the supply system (5) is calculated so that the supply of AS7G0.3 lasts for approximately 15 s with a speed or flow rate of approximately 6.5 l / min at attacks (6).
  • the second alloy an AS5U3G (standard 57702) at the temperature of 720 ° C. is introduced through the feed system (5) at the speed or flow rate of 30 1 / min at attacks so that the horizontal component of the speed of this alloy is approx. 0.5 m / s to fill the rest of the mold without eroding the first metal.
  • Duralcan F3A consisting of AS7G0.3 + 15% of SiC particles, is used as the first alloy and is poured under the same conditions as 1 ⁇ S7G of Example No. 1.
  • the SiC particles do not modify the thermal analysis of the alloy, the method of calculating the solidified fractions for normal aluminum alloys is applicable.
  • the solidified fraction, fs, between Tl and T2 can be calculated either by this same rule of levers at each temperature, or by the following formula, faster, if we assimilate the solidus and the liquidus of the alloy with two straight lines between T1 and T2 (hypothesis entirely acceptable in the context of the use of this patent application):
  • the solidified fraction during an isothermal, notably eutectic, transformation stage can be estimated from thermal analysis using a thermocouple placed in the layer considered, assuming that the solidified fraction varies linearly over time during isothermal transformation.

Abstract

A process is disclosed for the production of cast cylinder heads made of aluminium alloys from at least two different "liquid" alloys. The liquid alloys at the time of casting may contain solid particles of varied size and shape so as to produce composites with a metal matrix after solidifying. The process for moulding composite cylinder heads includes a number of successive layers consisting of at least two different alloys and consists in casting each alloy layer in the cavity of a mould via a feed system with a waiting time between the end of casting of one layer and the beginning of the second layer, so that the first layer contains between 50 and 100% of solid fraction in its lower part and 0 to 80% of solid fraction in the upper part, the interface region, when the second alloy is introduced.

Description

METHODE D'OBTENTION DE CULASSES MOULEES COMPOSITES METHOD FOR OBTAINING COMPOSITE MOLDED HEADS
L'invention concerne la réalisation de culasses moulées en alliages d'aluminium comportant au moins deux alliages différents. Les alliages liquides peuvent comporter des particules solides à la coulée de taille et de forme variées de façon à réaliser des composites à matrice métallique après solidification.The invention relates to the production of cylinder heads molded from aluminum alloys comprising at least two different alloys. The liquid alloys can comprise solid particles with the casting of various size and shape so as to produce composites with metallic matrix after solidification.
Cette technique permet d'optimiser le choix des matériaux selon les fonctions principales requises dans les différentes parties des culasses. A titre d'illustration, on peut citer la recherche, au voisinage de la chambre de combustion, d'une tolérance aux dommages à chaud maximale, notamment dans les zones intersièges des soupapes. Par contre, dans la partie froide de la culasse, notamment les piliers de fixation, la propriété critique est la résistance mécanique, afin de conférer à la culasse une rigidité maximale et la meilleure aptitude au serrage, avec un poids minimal de la pièce finie.This technique optimizes the choice of materials according to the main functions required in the different parts of the cylinder heads. By way of illustration, mention may be made of the search, in the vicinity of the combustion chamber, for a tolerance to maximum hot damage, in particular in the inter-seat areas of the valves. On the other hand, in the cold part of the cylinder head, in particular the fixing pillars, the critical property is the mechanical strength, in order to give the cylinder head maximum rigidity and the best tightening capacity, with a minimum weight of the finished part.
Or actuellement, il n'existe pas de technique de fabrication permettant de résoudre de façon satisfaisante et économiquement viable le problème énoncé ci-dessus.However, at present, there is no manufacturing technique which makes it possible to solve the above-mentioned problem in a satisfactory and economically viable manner.
En effet, il est certes possible de rechercher des matériaux présentant à la fois une forte résistance mécanique et une bonne tenue à chaud. Cependant, l'expérience montre que ce type de matériaux est coûteux. Par exemple, des composites à matrice métallique renforcés de particules de carbure de silicium de type DURALCAN coûtent, d'après les estimations des producteurs, de 2 à 3 fois plus cher que les alliages conventionnels de moulage, ce qui exclut leur utilisation pour la totalité de la culasse.Indeed, it is certainly possible to search for materials having both a high mechanical strength and good heat resistance. However, experience shows that this type of material is expensive. For example, metal matrix composites reinforced with DURALCAN silicon carbide particles cost, according to producers' estimates, 2 to 3 times more expensive than conventional casting alloys, which excludes their use for all of the breech.
De façon générale, il est nécessaire de limiter l'emploi de matériaux à hautes caractéristiques à une application locale, dans les zones où ils sont indispensables, ceci en raison de leur coût.In general, it is necessary to limit the use of materials with high characteristics to a local application, in the areas where they are essential, this because of their cost.
Par ailleurs, il n'existe pas, à notre connaissance, de technique permettant d'insérer de tels matériaux dans une culasse. L'insertion d'alliages d'aluminium ou de composites à matrices métalliques (par exemple les alliages AlFe AlFeCe obtenus par métallurgie des poudres, puis corroyage, les alliages à hautes caractéristiques à chaud obtenus par procédé de type OSPREY, les composites à matrice métallique résultant d'imprégnation de préformes, par exemple par forgeage liquide - Squeeze Casting -...) placés à l'état solide dans la culasse au moment de la coulée se heurte à la difficulté de réussir à lier métallurgiquement le matériau de la culasse et celui du(ou des) insert(s).Furthermore, to our knowledge, there is no technique for inserting such materials in a cylinder head. The insertion of aluminum alloys or metal matrix composites (for example example AlFe AlFeCe alloys obtained by powder metallurgy, then wrought, alloys with high hot characteristics obtained by OSPREY type process, metal matrix composites resulting from impregnation of preforms, for example by liquid forging - Squeeze Casting -. ..) placed in the solid state in the cylinder head at the time of casting encounters the difficulty of succeeding in metallurgically bonding the material of the cylinder head and that of (or) insert (s).
Enfin, une autre voie actuellement développée pour renforcer localement le matériau d'une culasse consiste en l'imprégnation à la coulée de préformes (notamment d'alumine ou de carbure de silicium ou de renforts constitués de fibres longues). Mais ce type de technologie présente des surcoûts de fabrication élevés par rapport aux techniques usuelles de coulée par gravité et/ou sous basse pression, notamment en raison de la nécessité d'effectuer un vide partiel, puis d'imposer des surpressions de plusieurs Pa qui obligent à recouvrir les noyaux de sable d'une couche protectrice, afin de ne pas les imprégner eux-mêmes de métal liquide.Finally, another method currently being developed to locally reinforce the material of a cylinder head consists in impregnating with casting preforms (in particular alumina or silicon carbide or reinforcements made of long fibers). However, this type of technology has high manufacturing costs compared to the usual gravity and / or low pressure casting techniques, in particular because of the need to perform a partial vacuum, then to impose overpressures of several Pa which make it necessary to cover the sand cores with a protective layer, so as not to impregnate them themselves with liquid metal.
La demanderesse a donc recherché et mis au point des techniques d'élaboration permettant de couler différents alliages dans une culasse, et notamment des alliages à haute tolérance aux dommages côté chambre de combustion et des alliages à bas prix de revient et forte résistance mécanique dans le reste de la pièce.The Applicant has therefore researched and developed production techniques allowing different alloys to be cast in a cylinder head, and in particular alloys with high tolerance to damage on the combustion chamber side and alloys with low cost price and high mechanical resistance in the rest of the room.
La pièce selon l'invention est constituée de couches successives, jointives et sensiblement horizontales.The part according to the invention consists of successive, contiguous and substantially horizontal layers.
Plus précisément, il est apparu qu'il faut que chaque couche i-1 (i l 2) vérifie les conditions suivantes au moment de la coulée de la couche ultérieure i.More precisely, it appeared that each layer i-1 (i l 2) must satisfy the following conditions at the time of the casting of the subsequent layer i.
* Face inférieure de la couche i—1 : 50 à 100% de fraction solide* Bottom of layer i — 1: 50 to 100% solid fraction
* Face supérieure de la couche i-1 : 0 à 80% de fraction solide et de préférence : Face inférieure de la couche i-1 : 70 à 100% de fraction solide* Upper face of the i-1 layer: 0 to 80% solid fraction and preferably: Lower face of the i-1 layer: 70 to 100% solid fraction
Face supérieure de la couche i-1 : 10 à 40% de fraction solide Ces conditions peuvent s'obtenir par ajustement du mode de refroidissement du métal coulé, visant une extraction calorifique maximale par la base de chaque couche et en attendant le temps nécessaire à l'établissement des conditions ci-dessus.Upper face of the i-1 layer: 10 to 40% solid fraction These conditions can be obtained by adjusting the cooling mode of the cast metal, aiming for maximum heat extraction from the base of each layer and while waiting for the time necessary to establish the above conditions.
Dans la pratique, il s'agit de définir le temps d'attente, t , entre la fin de coulée de chaque couche (i-1) et le début de la couche i (i l 2), en fonction des conditions de refroidissement de la pièce moulée.In practice, this involves defining the waiting time, t, between the end of casting of each layer (i-1) and the start of layer i (il 2), depending on the cooling conditions of the molded part.
Pour des raisons évidentes de productivité, on cherche à ce que t soit aussi faible que possible dimensionnant en conséquence le système de refroidissement de la couche i-1. Le refroidissement de la pièce moulée est généralement assuré par une semelle métallique parcourue par un fluide caloporteur tel que l'eau.For obvious productivity reasons, it is sought that t be as small as possible correspondingly dimensioning the cooling system of the layer i-1. The cooling of the molded part is generally ensured by a metal soleplate traversed by a heat transfer fluid such as water.
Les fractions solides sont déterminées préalablement de façon expérimentale par analyse thermique, par exemple en plaçant au moins deux thermocouples dans chaque couche (i-1), l'un dans la zone proche de l'interface avec la couche suivante, et l'autre au voisinage de la base de la couche.The solid fractions are determined beforehand experimentally by thermal analysis, for example by placing at least two thermocouples in each layer (i-1), one in the area close to the interface with the next layer, and the other near the base of the layer.
Les fractions solides sont déterminées à partir de ces analyses thermiques par l'utilisation de diagrammes d'équilibre du métal coulé assimilé en général à un alliage binaire à base d'Al. Le principe du calcul est donné en Annexe.The solid fractions are determined from these thermal analyzes by the use of balance diagrams of the cast metal assimilated in general to a binary alloy based on Al. The principle of the calculation is given in the Appendix.
Les systèmes d'alimentation seront adaptés de sorte que la coulée de chaque couche i ( i l 2) ne crée pas d'érosion inacceptable de la couche i-1 et que les couches soient aussi uniformes que possible. Cet ajustement est à la portée de l'homme du métier par exemple, grâce à l'optimisation de chenaux d'alimentation ou par l'utilisation de filtres métalliques ou céramiques placés dans le système d'alimentation, pour en réguler le débit. Il faut en effet obtenir une (des) interface(s) sensiblement plane(s) et régulière(s) entre les couches, contrôlable(s) par exemple par micrographie, macrographie ou microscopie à balayage sur coupe(s) transversale(s) perpendiculaire(s) à l'interface. Les systèmes d'alimentation peuvent être dissymétriques, mais on les réalisera de préférence symétriques pour faciliter l'obtention de couches d'épaisseurs uniformes.The feeding systems will be adapted so that the pouring of each layer i (il 2) does not create unacceptable erosion of the layer i-1 and that the layers are as uniform as possible. This adjustment is within the reach of those skilled in the art, for example, by optimizing feed channels or by using metallic or ceramic filters placed in the feed system, to regulate the flow rate. It is indeed necessary to obtain an interface (s) substantially flat and regular between the layers, controllable for example by micrography, macrography or scanning microscopy on cross section (s) perpendicular to the interface. The feeding systems can be asymmetrical, but they are preferably made symmetrical to facilitate obtaining layers of uniform thickness.
Enfin, il est possible d'inerter la cavité du moule par un gaz inerte (CO , Argon, Azote, etc) afin de minimiser la couche d'oxyde naturellement formée à la surface du métal liquide en cours de coulée, et donc de favoriser la liaison métallurgique entre les couches.Finally, it is possible to inert the mold cavity with an inert gas (CO, Argon, Nitrogen, etc.) in order to minimize the oxide layer naturally formed on the surface of the liquid metal during casting, and therefore to favor the metallurgical bond between the layers.
En remplissant le moule dans ces conditions, on obtient des culasses présentant des couches successives d'alliages différents avec une liaison métallurgique de bonne qualité sans défauts d'oxydes (voir fig. 5 et 6), conformément au cahier des charges des constructeurs automobiles.By filling the mold under these conditions, cylinder heads are obtained having successive layers of different alloys with a good quality metallurgical bond without oxide defects (see FIGS. 5 and 6), in accordance with the specifications of the automobile manufacturers.
Dans le cas de culasses bi-alliages, on forme une couche de matériau destiné à la tenue à chaud ayant typiquement une épaisseur de 15 à 25 mm côté chambre de combustion, le reste étant constitué du second alliage.In the case of bi-alloy cylinder heads, a layer of material intended for heat resistance is typically formed, having a thickness of 15 to 25 mm on the combustion chamber side, the remainder consisting of the second alloy.
Selon l'invention, le procédé d'obtention d'une culasse bi (ou multi) métallique s'effectue donc en coulant successivement dans la cavité d'un moule soit métallique, soit en sable, soit mixte, deux (ou plusieurs) alliages d'aluminium distincts avec une (des) zone(s) d'interface(s) la(les) moins épaisse(s) possible(s) constituée(s) d'un mélange des alliages coulés et sans trace de peaux d'oxydes.According to the invention, the process for obtaining a bi (or multi) metallic cylinder head is therefore carried out by successively pouring into the cavity of a mold, either metallic, either sand, or mixed, two (or more) alloys of separate aluminum with an interface zone (s) the thinnest possible (s) made up of a mixture of cast alloys and without trace of skins oxides.
Pour ce faire, les alliages sont introduits dans la cavité du moule par des systèmes d'alimentation indépendants. Le niveau de chaque couche est obtenu en dosant sa quantité, par exemple en volume.To do this, the alloys are introduced into the mold cavity by independent feed systems. The level of each layer is obtained by measuring its quantity, for example by volume.
Afin d'éviter une zone de mélange trop importante en deux couches d'alliages différents et successifs, il convient de laisser refroidir l'alliage de la couche i-1 (i l 2) afin qu'il soit pâteux au moment de l'arrivée du métal liquide destiné à former la couche i.In order to avoid an excessively large mixing zone in two layers of different and successive alloys, it is advisable to allow the alloy of the layer i-1 (il 2) to cool so that it is pasty upon arrival. liquid metal intended to form layer i.
La réalisation de culasse multi-alliages peut se faire par technique de coulée par gravité, sous basse pression, par forgeage liquide (squeeze casting) ou tout autre technique industrielle de fonderie adaptée à l'obtention de culasses.The production of a multi-alloy cylinder head can be done by gravity casting technique, under low pressure, by liquid forging (squeeze casting) or any other industrial foundry technique suitable for obtaining cylinder heads.
L'invention sera mieux comprise à l'aide des exemples suivants illustrés par les fig. 1 à 7. . La fig. 1 représente schématiquement une vue de la pièce moulée obtenue et le sens du gradient thermique appliqué (flèche) . La fig. 2 représente en couche transversale une vue schématique d'un moule utilisable pour la mise en oeuvre de l'invention. . La fig. 3 représente une autre version dudit moule, qui permet d'obtenir la pièce moulée représentée en perspective à la fig. 4.The invention will be better understood with the aid of the following examples illustrated by FIGS. 1 to 7.. Fig. 1 schematically represents a view of the molded part obtained and the direction of the thermal gradient applied (arrow). Fig. 2 shows in transverse layer a schematic view of a mold usable for the implementation of the invention. . Fig. 3 shows another version of said mold, which makes it possible to obtain the molded part shown in perspective in FIG. 4.
. la fig. 5 représente une coupe macrographique transversale de la zone de liaison entre les deux alliages de la culasse obtenue dans les conditions rapportées à l'exemple 1 au grandissement x 25. . la fig. 6 représente une coupe macrographique transversale de la zone de liaison entre les 2 alliages de la culasse obtenue conformément aux conditions de l'exemple 2 au grandissement x 50. . la fig. 7 représente une courbe d'analyse thermique de la solidification d'un alliage eutectique Al-Si et la fig. 8 le diagramme d'équilibre de l'alliage binaire correspondant (Al-Si) .. fig. 5 represents a transverse macrographic section of the connection zone between the two alloys of the cylinder head obtained under the conditions reported in Example 1 at magnification x 25. fig. 6 shows a cross-sectional macrographic section of the connection zone between the 2 alloys of the cylinder head obtained in accordance with the conditions of Example 2 at magnification x 50.. fig. 7 shows a thermal analysis curve of the solidification of an Al-Si eutectic alloy and FIG. 8 the equilibrium diagram of the corresponding binary alloy (Al-Si).
EXEMPLE 1 - Culasse bi-alliage : AS7G - AS5U3G (fig. 2)EXAMPLE 1 - Bi-alloy cylinder head: AS7G - AS5U3G (fig. 2)
Le moule est composé d'une semelle métallique (1) en cuprochrome (composition approximative Cu 60%, Cr 40%) d'épaisseur 100 mm et de mottes en sable (2) . Cette semelle comporte un circuit de refroidissement (3) dans lequel circule l'eau de manière à maintenir sa température entre 80 et 100°C.The mold is composed of a metallic sole (1) in cuprochrome (approximate composition Cu 60%, Cr 40%) of thickness 100 mm and clods in sand (2). This sole has a cooling circuit (3) in which the water circulates so as to maintain its temperature between 80 and 100 ° C.
Le moule est muni de deux systèmes d'alimentation (4) et (5), d'évents, de noyaux des circuits de circulation d'eau et d'huile, de pipes d'admission et d'échappement, et de masselottes habituelles (non représentés) .The mold is provided with two supply systems (4) and (5), vents, cores of the water and oil circulation circuits, intake and exhaust pipes, and usual weights (not shown).
Le procédé de noyautage est le procédé PEPSET pour les mottes (2) , les noyaux des circuits de circulation d'huile et les pipes d'admission et d'échappement, et ASHLAND pour les noyaux des circuits de circulation d'eau. Par l'alimentation (4), on coule le premier métal, de l'AS7G0,3 (selon la norme française NF A 57702) à la température de 710°C (température visée) sur une hauteur de 20 mm correspondant à l'épaisseur de la table de la culasse (dosage volumétrique) . Le système d'alimentation (5) est calculé de façon à ce que l'amenée d'AS7G0,3 dure environ 15 s avec une vitesse ou débit d'environ 6,5 1/mn aux attaques (6). Dès la fin de la coulée du premier alliage, on introduit par le système d'alimentation (5) le deuxième alliage, un AS5U3G (norme 57702) à la température de 720°C à la vitesse ou débit de 30 1/mn aux attaques de manière à ce que la composante horizontale de la vitesse de cet alliage soit env. 0,5 m/s afin de remplir le reste du moule sans éroder le premier métal.The coring process is the PEPSET process for clods (2), the cores of the oil circulation circuits and the intake and exhaust pipes, and ASHLAND for the cores of the water circulation circuits. Through the supply (4), the first metal is poured, from AS7G0.3 (according to French standard NF A 57702) at the temperature of 710 ° C (target temperature) over a height of 20 mm corresponding to the thickness of the cylinder head table (volumetric dosage). The supply system (5) is calculated so that the supply of AS7G0.3 lasts for approximately 15 s with a speed or flow rate of approximately 6.5 l / min at attacks (6). At the end of the casting of the first alloy, the second alloy, an AS5U3G (standard 57702) at the temperature of 720 ° C. is introduced through the feed system (5) at the speed or flow rate of 30 1 / min at attacks so that the horizontal component of the speed of this alloy is approx. 0.5 m / s to fill the rest of the mold without eroding the first metal.
Le calcul des fractions solides dans le premier alliage (AS7G03) au moment de l'arrivée du deuxième métal à l'aide de l'enregistrement de la température du premier alliage, du diagramme Al-Si et de l'application de la règle des leviers en appliquant la méthode donnée en Annexe conduit aux résultats suivants :The calculation of solid fractions in the first alloy (AS7G03) at the time of the arrival of the second metal using the recording of the temperature of the first alloy, the Al-Si diagram and the application of the rule of applying the method given in the Appendix leads to the following results:
- partie inférieure 10 (au contact de la semelle) : 82 %. - partie supérieure 11 (dans la zone de l'interface) : 18%.- lower part 10 (in contact with the sole): 82%. - upper part 11 (in the interface area): 18%.
EXEMPLE 2 - Culasse bi-alliage - duralcan F3A - AS5U3GEXAMPLE 2 - Bi-alloy cylinder head - duralcan F3A - AS5U3G
Le Duralcan F3A, constitué de AS7G0,3 + 15% de particules de SiC, est utilisé comme premier alliage et est coulé dans les mêmes conditions que 1ΑS7G de l'exemple n° 1. Les particules de SiC ne modifiant pas l'analyse thermique de l'alliage, la méthode de calcul des fractions solidifiées pour les alliages d'aluminium normaux est applicable.Duralcan F3A, consisting of AS7G0.3 + 15% of SiC particles, is used as the first alloy and is poured under the same conditions as 1ΑS7G of Example No. 1. The SiC particles do not modify the thermal analysis of the alloy, the method of calculating the solidified fractions for normal aluminum alloys is applicable.
Néanmoins, la température de coulée du Duralcan est augmentée de 20°C de manière à obtenir la même fluidité que celle de l'alliage de base non chargé, et donc les mêmes vitesses de remplissage. ANNEXEHowever, the pouring temperature of Duralcan is increased by 20 ° C so as to obtain the same fluidity as that of the base alloy not loaded, and therefore the same filling speeds. ANNEX
Mode de calcul des fractions solidifiées dans le cas d'alliages de type Al-Si hypoeutectiques (cas général des alliages de fonderie pour culasses) .Method for calculating solidified fractions in the case of hypoeutectic Al-Si type alloys (general case of foundry alloys for cylinder heads).
A partir du diagramme d'équilibre de la figure 7, pour un alliage type AISi, de composition globale Co, on définit :From the equilibrium diagram in FIG. 7, for an AISi type alloy, of overall composition Co, we define:
T la température de l'alliage Tl température de début de solidification T2 température de fin de solidification (ici en coïncidence avec la température de palier eutectique) Cl concentration en élément d'addition du métal solidifié en premier C2 concentration en élément d'addition du métal solidifié en dernier, avant transformation du liquide eutectique.T the temperature of the alloy T1 temperature at the start of solidification T2 temperature at the end of solidification (here in coincidence with the eutectic plateau temperature) C1 concentration in addition element of the metal solidified first C2 concentration in addition element of the metal solidified last, before transformation of the eutectic liquid.
On assimile CM, composition moyenne, solidifiée avant la transformation eutectique à : CM = Cl + C2We assimilate CM, average composition, solidified before the eutectic transformation to: CM = Cl + C2
C3 concentration eutectiqueC3 eutectic concentration
On applique alors la règle habituelle des leviers pour déterminer la fraction solidifiée à chaque stade de la solidification précédant la transformation isotherme (ou eutectique).We then apply the usual rule of levers to determine the solidified fraction at each stage of solidification preceding the isothermal (or eutectic) transformation.
Soit fso la fraction solidifiée obtenue juste avant la solidification de 1'eutectique (T=T2) :Let fso be the solidified fraction obtained just before the solidification of the eutectic (T = T2):
fso = C3 - Co C3 - CMf so = C3 - Co C3 - CM
La fraction solidifiée, fs, entre Tl et T2 peut être calculée soit par cette même règle des leviers à chaque température, soit par la formule suivante, plus rapide, si on assimile le soliduε et le liquidus de l'alliage à deux droites entre Tl et T2 (hypothèse tout à fait acceptable dans le cadre de l'utilisation de cette demande de brevet) :The solidified fraction, fs, between Tl and T2 can be calculated either by this same rule of levers at each temperature, or by the following formula, faster, if we assimilate the solidus and the liquidus of the alloy with two straight lines between T1 and T2 (hypothesis entirely acceptable in the context of the use of this patent application):
fs = (C3-Co)(Tl-T) (T2 S T i Tl) (C3-CM)(Tl-T)+(Co-Cl)(T-T2)fs = (C3-Co) (Tl-T) (T2 S T i Tl) (C3-CM) (Tl-T) + (Co-Cl) (T-T2)
La fraction solidifiée au cours d'un palier de transformation isotherme, notamment eutectique, peut être estimée à partir de l'analyse thermique grâce à un thermocouple placé dans la couche considérée, en supposant que la fraction solidifiée varie linéairement dans le temps au cours de la transformation isotherme.The solidified fraction during an isothermal, notably eutectic, transformation stage can be estimated from thermal analysis using a thermocouple placed in the layer considered, assuming that the solidified fraction varies linearly over time during isothermal transformation.
Dans le cas d'une transformation de type binaire (figure n° 6), on peut donc écrire avec une très bonne approximation, que la fraction totale solidifiée Fs est égale à :In the case of a binary type transformation (figure n ° 6), we can therefore write with a very good approximation, that the total solidified fraction Fs is equal to:
Fs = fso + (1 - fso) (t - to) (to S t S tl)Fs = fso + (1 - fso) (t - to) (to S t S tl)
(tl - to)(tl - to)
puisque l'alliage est totalement solide au temps tl. since the alloy is completely solid at time tl.

Claims

REVENDICATIONS
1. Procédé de moulage de culasses composites comportant plusieurs couches successives (i) constituées d'au moins 2 alliages différents caractérisé en ce qu'il consiste à couler dans la cavité d'un moule (1,2) par un système d'alimentation (4,5) chaque couche d'alliage (i-1) (i l 2) avec temps d'attente (tA) entre fin de coulée de la couche (i-1) et début de la couche i, de manière à ce que la couche (i-1) contienne entre 50 et 100% de fraction solide dans sa partie inférieure et 0 à 80% de fraction solide dans la partie supérieure (zone d'interface) lors de l'introduction de l'alliage i.1. A method of molding composite cylinder heads comprising several successive layers (i) made up of at least 2 different alloys, characterized in that it consists in pouring into the cavity of a mold (1,2) by a supply system (4,5) each layer of alloy (i-1) (il 2) with waiting time (tA) between the end of casting of the layer (i-1) and the start of layer i, so that that the layer (i-1) contains between 50 and 100% of solid fraction in its lower part and 0 to 80% of solid fraction in the upper part (interface zone) during the introduction of alloy i.
2. Procédé selon revendication 1 caractérisé en ce que la (les) fraction(s) solidifiée(s) dans la(les) partie(s) supérieure(s) de la (les) couche(s) (i-1) (i l 2) soit (soient) de préférence comprise(s) entre 10 et 40%.2. Method according to claim 1 characterized in that the (the) fraction (s) solidified (s) in the (the) upper part (s) of the (the) layer (s) (i-1) ( it 2) is (are) preferably between 10 and 40%.
3. Procédé selon l'une des revendications 1 ou 2 caractérisé en ce que la (les) fraction(s) solidifiée(s) dans la(les) partie(s) inférieure(s) de la (les) couche(s) (i-1) (i i. 2) soit (soient) de préférence comprise entre 70 et 100%.3. Method according to one of claims 1 or 2 characterized in that the (the) fraction (s) solidified (s) in the (the) lower part (s) (s) of the (the) layer (s) (i-1) (i i. 2) either (preferably) between 70 and 100%.
4. Procédé selon l'une des revendications 1 à 3 caractérisé en ce que le moule comporte une semelle métallique (1) refroidie à l'aide d'un fluide caloporteur.4. Method according to one of claims 1 to 3 characterized in that the mold comprises a metal sole (1) cooled using a heat transfer fluid.
5. Procédé selon l'une des revendications 1 à 4 caractérisé en ce que le moule est protégé par une atmosphère inerte (C0 , Ar, N , etc), pendant la coulée.5. Method according to one of claims 1 to 4 characterized in that the mold is protected by an inert atmosphere (C0, Ar, N, etc.), during casting.
6. Procédé selon l'une des revendications 1 à 4 caractérisé en ce que les alliages utilisés sont des alliages à base d'Al.6. Method according to one of claims 1 to 4 characterized in that the alloys used are alloys based on Al.
7. Procédé selon les revendications 1 à 6 caractérisé en ce que les alliages coulés peuvent être chargés de fibres ou de particules céramiques (SiC, A1203, etc). 7. Method according to claims 1 to 6 characterized in that the cast alloys can be loaded with fibers or ceramic particles (SiC, A1203, etc.).
8. Procédé selon les revendication 1 à 7 caractérisé en ce que le moule en dehors de la semelle (1) est soit en sable, soit métallique ou mixte.8. Method according to claims 1 to 7 characterized in that the mold outside the sole (1) is either sand, or metallic or mixed.
9. Application du procédé selon l'une des revendications 1 à 8 à 1'obtention de culasses en Al ou un de ses alliages, coulés par les procédés:9. Application of the method according to one of claims 1 to 8 for obtaining Al cylinder heads or one of its alloys, cast by the methods:
— basse pression- low pressure
— gravité + basse pression- gravity + low pressure
— gravité. - gravity.
EP92903814A 1991-01-03 1992-01-02 Method of obtaining cast composite cylinder heads Expired - Lifetime EP0519054B1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
FR9100377 1991-01-03
FR9100377A FR2671310B1 (en) 1991-01-03 1991-01-03 METHOD FOR OBTAINING COMPOSITE MOLDED HEADS.
PCT/FR1992/000003 WO1992011962A1 (en) 1991-01-03 1992-01-02 Method of obtaining cast composite cylinder heads

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EP0519054A1 true EP0519054A1 (en) 1992-12-23
EP0519054B1 EP0519054B1 (en) 1997-11-19

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US6450237B1 (en) * 2001-04-02 2002-09-17 Alcoa Inc Compound cast product and method for producing a compound cast product
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JP5367341B2 (en) * 2008-11-05 2013-12-11 地方独立行政法人東京都立産業技術研究センター Aluminum alloy casting and method for producing aluminum alloy casting
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CN102089101B (en) * 2008-07-04 2014-07-09 阿勒里斯铝业科布伦茨有限公司 Method for casting a composite ingot

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EP0519054B1 (en) 1997-11-19
ATE160304T1 (en) 1997-12-15
FR2671310A1 (en) 1992-07-10
WO1992011962A1 (en) 1992-07-23
US5579822A (en) 1996-12-03
IE80792B1 (en) 1999-02-24
KR100227544B1 (en) 1999-11-01
CA2071222C (en) 2002-03-26
MX9200010A (en) 1992-07-01
PT99967B (en) 1999-02-26
KR920703248A (en) 1992-12-17
IE920017A1 (en) 1992-07-15
GR3026079T3 (en) 1998-05-29
DK0519054T3 (en) 1998-07-27
ES2111062T3 (en) 1998-03-01
PT99967A (en) 1994-03-31
BR9204096A (en) 1993-06-08
DE69223178T2 (en) 1998-05-20
CA2071222A1 (en) 1992-07-04
FR2671310B1 (en) 1995-06-23
DE69223178D1 (en) 1998-01-02
JPH05505147A (en) 1993-08-05

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