EP0968064A1 - Method and installation for low pressure die casting in a mould with ceramic casting die - Google Patents

Method and installation for low pressure die casting in a mould with ceramic casting die

Info

Publication number
EP0968064A1
EP0968064A1 EP98964545A EP98964545A EP0968064A1 EP 0968064 A1 EP0968064 A1 EP 0968064A1 EP 98964545 A EP98964545 A EP 98964545A EP 98964545 A EP98964545 A EP 98964545A EP 0968064 A1 EP0968064 A1 EP 0968064A1
Authority
EP
European Patent Office
Prior art keywords
pressure
value
casting
liquid metal
space
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
EP98964545A
Other languages
German (de)
French (fr)
Other versions
EP0968064B1 (en
Inventor
Jean-Louis Comarteau
Christophe Liebaut
Alain Remy
Didier Thomas
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.)
Saint Gobain SEVA SA
Original Assignee
SEVA SA
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Filing date
Publication date
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Application filed by SEVA SA filed Critical SEVA SA
Publication of EP0968064A1 publication Critical patent/EP0968064A1/en
Application granted granted Critical
Publication of EP0968064B1 publication Critical patent/EP0968064B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D18/00Pressure casting; Vacuum casting
    • B22D18/04Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould

Definitions

  • the invention relates to a method and an installation for low pressure casting of a metallic composition in the liquid state, in a mold comprising a ceramic shell, one face of which defines a casting space and a mass of sand without binder in contact with the other face of the shell, the mold being placed in a box having at its base an access connected to the casting space and connected by a liquid metal supply pipe to a source of liquid metal below, for example a casting furnace.
  • Casting methods and installations of this type are already known, in which the source of liquid metal such as a casting furnace is placed in communication with a source of pressurized gas so that it is applied to the liquid metal contained in the source of liquid metal, a first pressure value by which the liquid metal is brought and maintained in the region of the access of the box for this liquid metal.
  • the level of the liquid metal is raised above the threshold of the mold where it was located, by increasing the pressure to a second value slightly higher than the value required to bring the liquid metal remp the ir the casting space, to have a safety margin and to be certain that all the crevices of the mold, even the highest, are filled with metal li q uid, and the pressure is maintained at this second temperature for a time sufficient to allow the establishment of a system of rest, and a low static metallo pressure on the walls of the shell Marti q level.
  • the pressure is further increased to a third value in order to fill any cavities or recesses, and the pressure is maintained at this third value for a period making it possible to obtain the desired solidification of the metal contained in the mold, after which the pressure is reduced so that the level of the unused liquid metal drops approximately to the initial level, and this pressure is maintained for the time necessary for example to remove the mold, unmold the part, and replace a mold allowing the manufacture of another part.
  • the ceramic shells of these molds generally have an extremely small thickness and thus a certain flexibility which gives them, when they are subjected to the pressure of the liquid metal, a tendency to undergo deformations which harm their dimensional stability.
  • the box is provided with a second access connected to the space where the mass of sand is located, connected by a suction pipe to a device for putting under vacuum.
  • this depression of the mass of sand has the disadvantage of disturbing the rise and good distribution of the liquid metal in the casting space, by means of the porosity of the ceramic (filling "by vacuum”), which leads to too rapid filling generating defects in the castings.
  • the invention aims to remedy these drawbacks and for this purpose relates to a low-pressure casting process in a mold comprising a ceramic shell, one face of which delimits a space for casting and. a space containing a mass of sand without binder in contact with the other face of the shell, the mold being placed in a box having at its base an access connected to the casting space and connected to a source of liquid metal below , process in which a first pressure value adapted to bring liquid metal into the region of said access is applied to the liquid metal of the source, the pressure is increased to a second value slightly greater than a value necessary to fill the space and this second value is maintained for a first predetermined duration, then the pressure is increased to a third value and this third value is maintained for a second predetermined duration, then the pressure is reduced so that the level of the liquid metal drops approximately in the region of said access or below, characterized in that, approximately when the casting space becomes completely filled with liquid metal, the pressure in the space of the mass of sand is reduced below atmospheric pressure to a
  • the method according to the invention can also have one or more of the following characteristics: - the duration of the phase during which the pressure is reduced in the space where the mass of sand is located, below atmospheric pressure , up to a predetermined depression value, is shorter than the first predetermined duration; -. the phase during which the pressure in the space where the mass of sand is increased, approximately up to atmospheric pressure, is completed before the end of the phase during which the pressure is reduced to which is subjected to the liquid metal contained in the source of liquid metal so that the level of the liquid metal drops approximately in the region of said access or below; - the predetermined vacuum value corresponds to an absolute pressure in the range approximately from 0.5 to 0.9 bar;
  • the first pressure value is approximately 1.15 bars absolute; - the second pressure value is approximately
  • the third pressure value is approximately 1.7 bars absolute.
  • the invention also relates to an installation for implementing the above method, comprising a mold comprising a ceramic shell, one face of which defines a pouring space, and a space containing a mass of sand without binder in contact with the other. face of the shell, the mold being placed in a box having at its base an access connected to the casting space and connected to a source of liquid metal below, installation characterized in that the box has an internal vacuum chamber provided at least one wall region permeable to air and having an access opening provided with a vacuum connection to be connected to a suction device via a solenoid valve controlled by a programmable automaton also controlling a device for regulating the pressure of the liquid metal source.
  • the installation according to the invention can also have the characteristic that the vacuum chamber extends annularly in the box against a base wall and side walls of the latter.
  • the molding process can be implemented very quickly and be precisely controlled with an investment in material remaining moderate despite everything.
  • FIG. 1 is a general diagram of an installation for setting work of the process according to the invention
  • FIG. 2 is a diagram illustrating the succession of the phases of the process according to the invention.
  • the installation according to the invention comprises a box 1 in which a mold 2 is made up comprising a ceramic shell 21 which may be of the “consumable” type, one face of which defines a pouring space 22 whose shape corresponds to the external shape of the part to be cast, and a mass 23 of sand without binder in the space of the box delimited between the walls of the latter and the other face of the shell and thus in contact with this other face. Thanks to .'invention, the thickness of the shell
  • 21 can be weak, and for example a thickness of 2 mm can be reached.
  • the box 1 has a base wall 11 and side walls 12 having an edge common with the base wall and an upper edge bent outwards so as to constitute a flange 13 extending parallel to the base wall.
  • the base wall has an access opening 14 connected to the pouring space 22 by a tubular joint 15 having a part fitted into the opening of the base wall and a part serving as a bearing for the inner face, of form conjugate, from the mouth (lower) of the shell 21.
  • the box 1 comprises an annular vacuum chamber 3 extending against the peripheral region of its base wall 11 and the regions of the side walls 12 which terminate at this base wall.
  • This vacuum chamber has at least one wall 31 in contact with the mass of sand 23; this wall 31 comprises at least one region permeable to air but impermeable to sand.
  • One of the side walls of the box 1 and of the vacuum chamber 3 has a second access opening 16 opening into the vacuum chamber, provided with a vacuum outlet 17.
  • the mass of sand 23 fills the space of the box 1 between the walls of the latter and the shell 21, with the exception of the vacuum chamber 3.
  • the box is placed on a support plate
  • the support plate With a view to filling the caisson with sand, for example by means of a hopper, the base opening of which opens into the caisson, the support plate is first of all placed on a vibration device (also not shown) comprising, for example, eccentric rollers.
  • the box 1 can be filled with soft sand, that is to say without binder, while being vibrated to obtain maximum densification.
  • the level of sand is then equalized with the rule to obtain a regular level at the upper surface of the box.
  • the box 1 filled with sand is then ready to be transported near a casting furnace 4, arranged below the box.
  • the box is positioned so that the access opening 14 of its base wall provided with the seal 15 is opposite an outlet neck 41 of a pipe 42 for supplying liquid metal from the oven, so that the neck can be secured to the box and the supply line thus connects the casting space of the mold to the interior space of the oven.
  • a movable plate 5 under which is fixed a seal 51 is attached to the box for example by clamping to form the cover thereof, the seal 51 then being interposed between the plate and the flange 13 formed on the side walls of the box.
  • the seal crushed between the plate and the flange, matching the shape of the latter, therefore makes it possible to create a vacuum inside the box.
  • the vacuum socket 17 is tightly connected to a suction pipe 61 connecting this socket to a suction device 6 comprising a vacuum manifold 62 placed under vacuum by a pump 63 such as a vane pump.
  • a solenoid valve 64 controlled by a programmable automaton 7 is inserted between the vacuum feeder 62 and the vacuum outlet 17 of the box; a pressure gauge 65 measures the pressure at the inlet of the box.
  • the casting furnace 4 comprises, above the mass 43 of liquid metal, a vault 44 connected by a pipe 45 for pressurizing a device for pressure regulation 8 also controlled by the programmable controller 7.
  • a pressure of value PI for example of the order of 1.15 bar absolute, which brings the liquid metal by an upward movement in the region of the access opening 14 of the base of the box 1, at the threshold of the mouth of the mold 2.
  • phase AB the pressure is increased (phase AB), up to a value P2 for example of approximately 1.4 bar absolute, and more generally a value slightly greater than that necessary to fill the ascending space fully upward with a safety margin
  • phase BC ⁇ h sufficient, and this value is maintained to allow a rest regime to be established (phase BC).
  • point B the pressure in the mass of sand; the reduction is continued until a vacuum value is reached with respect to atmospheric pressure, corresponding to a predetermined absolute pressure preferably in the range approximately from 0.5 to 0.9 bar, and this is maintained depression value for a certain period of time as will be seen below.
  • the reduction in the pressure in the space of the mass of sand is carried out quickly, because the duration of this phase of reduction below atmospheric pressure to the selected vacuum value must be shorter than that of phase BC where the mass of liquid metal is subjected to the pressure of value P2.
  • the pressure of the liquid metal is therefore maintained at the value P2 here 1.4 bars, not only as long as the cavity 22 is not filled, but also as long as the depression in the mass of sand does not has not reached the chosen level.
  • the pressure applied to the liquid metal is further increased to a value P3 for example of the order of 1.7 bars in order to fill in any cavities or shrinkage, and this P3 value of overpressure is maintained for a period making it possible first to obtain a solidified crust against the shell, then the solidification of the metal contained in the mold (DE phase).
  • the depression in the mass of sand is maintained at a value corresponding to the absolute pressure of 0.5 to 0.9 bar here approximately up to point E, and in any case the "vacuum” must not be “broken” before the formation of the crust of metal against the shell 21.
  • the pressure on the liquid metal is reduced (phase EF) so that the level thereof descends approximately to the initial level (PI pressure value here equal to approximately 1.15 bars), and this pressure is maintained for the time necessary for example to remove the mold and put back another for the production of another part .
  • PI pressure value here equal to approximately 1.15 bars
  • the vacuum being applied to the mass of sand at the end of the filling of the shell it does not affect the flow of the metal in the latter, and this flow remains controlled by the pressure , while the depression in the mass of sand stiffens the shell in the overpressure phase at pressure P3, which is the most critical, at least as long as the shell is not stiffened by a metal crust.

Abstract

In a case (1) is arranged a ceramic casting die (21) defining a casting zone (22), surrounded by a sand mass (23) without binder. The casting zone is connected to a metal liquid source (4) below wherein are successively applied a pressure (P1) bringing the metal to the threshold of the casting zone (22), a pressure (P2) slightly higher than what is required to fill said zone, then an outright excess pressure (P3); finally the pressure is brought back to the first value (P1). When the casting zone is filled, the space containing the sand mass (23) is depressurized to prevent deformation of the casting die (21) caused by the excess pressure (P3), at least until a metal crust is formed on the casting die, and at most until the excess pressure start to decrease in the liquid metal source (4).

Description

" Procédé et installation de coulée sous basse pression dans un moule à coquille céramique". "Low pressure casting process and installation in a ceramic shell mold".
L'-invention concerne un procédé et une installation de coulée sous basse pression d'une composition métallique à l'état liquide, dans un moule comprenant une coquille en céramique dont une face délimite un espace de coulée et une masse de sable sans liant en contact avec l'autre face de la coquille, le moule étant placé dans un caisson présentant à sa base un accès raccordé à l'espace de coulée et relié par une conduite d'amenée de métal liquide à une source de métal liquide en contrebas, par exemple un four de coulée.The invention relates to a method and an installation for low pressure casting of a metallic composition in the liquid state, in a mold comprising a ceramic shell, one face of which defines a casting space and a mass of sand without binder in contact with the other face of the shell, the mold being placed in a box having at its base an access connected to the casting space and connected by a liquid metal supply pipe to a source of liquid metal below, for example a casting furnace.
On connaît déjà des procédés et des installations de coulée de ce type, dans lesquels la source de métal liquide telle qu'un four de coulée est mise en communication avec une source de gaz sous pression de telle manière que soit appliquée au métal liquide contenu dans la source de métal liquide, une première valeur de pression grâce à laquelle le métal liquide est amené et maintenu dans la région de l'accès du caisson pour ce métal liquide . Lorsque l'on désire couler une pièce en introduisant du métal liquide dans le moule, le niveau du métal liquide est élevé au-dessus du seuil du moule où il se trouvait, en augmentant la pression jusqu'à une deuxième valeur légèrement supérieure à la valeur nécessaire pour amener le métal liquide à remplir l'espace de coulée, afin de posséder une marge de sécurité et d'être certain que toutes les anfractuosités du moule, même les plus hautes, sont remplies de métal liquide, et on maintient la pression à cette deuxième valeur pendant une durée suffisante pour laisser s'établir un régime de repos, et une pression métallo- statique faible sur les parois de la coquille en céramique. Puis on augmente encore la pression jusqu'à une troisième valeur afin de combler les cavités ou retassures éventuelles, et on maintient la pression à cette troisième valeur pendant une durée permettant d'obtenir la solidification désirée du métal contenu dans le moule, après quoi on diminue la pression de telle sorte que le niveau du métal liquide inutilisé descende approximativement au niveau initial, et on maintient cette pression pendant le temps nécessaire par exemple pour retirer le moule, démouler la pièce, et remettre un moule permettant la fabrication d'une autre pièce.Casting methods and installations of this type are already known, in which the source of liquid metal such as a casting furnace is placed in communication with a source of pressurized gas so that it is applied to the liquid metal contained in the source of liquid metal, a first pressure value by which the liquid metal is brought and maintained in the region of the access of the box for this liquid metal. When it is desired to cast a part by introducing liquid metal into the mold, the level of the liquid metal is raised above the threshold of the mold where it was located, by increasing the pressure to a second value slightly higher than the value required to bring the liquid metal remp the ir the casting space, to have a safety margin and to be certain that all the crevices of the mold, even the highest, are filled with metal li q uid, and the pressure is maintained at this second temperature for a time sufficient to allow the establishment of a system of rest, and a low static metallo pressure on the walls of the shell Marti q level. Then the pressure is further increased to a third value in order to fill any cavities or recesses, and the pressure is maintained at this third value for a period making it possible to obtain the desired solidification of the metal contained in the mold, after which the pressure is reduced so that the level of the unused liquid metal drops approximately to the initial level, and this pressure is maintained for the time necessary for example to remove the mold, unmold the part, and replace a mold allowing the manufacture of another part.
Cependant, les coquilles en céramique de ces moules présentent en général une épaisseur extrêmement faible et ainsi une certaine flexibilité qui leur confère, lorsqu'elles sont soumises à la pression du métal liquide, une tendance à subir des déformations qui nuisent à leur stabilité dimensionnelle. Afin de remédier aux instabilités dimensionnelles qui surviennent dans le cas du procédé de coulée décrit ci-dessus, il a été proposé de maintenir en dépression la masse de sable en contact avec la coquille, afin d'assurer une stabilité dynamique aux grains de sable et ainsi la stabilité dimensionnelle de la coquille. A cette fin, le caisson est doté d'un deuxième accès raccordé à l'espace où se trouve la masse de sable, relié par une conduite d'aspiration à un dispositif de mise en dépression. Mais cette mise en dépression de la masse de sable a pour inconvénient de perturber la montée et la bonne répartition du métal liquide dans l'espace de coulée, par l'intermédiaire de la porosité de la céramique (remplissage « par le vide ») , ce qui conduit à un remplissage trop rapide générant des défauts dans les pièces coulées.However, the ceramic shells of these molds generally have an extremely small thickness and thus a certain flexibility which gives them, when they are subjected to the pressure of the liquid metal, a tendency to undergo deformations which harm their dimensional stability. In order to remedy the dimensional instabilities which arise in the case of the casting process described above, it has been proposed to keep the mass of sand in depression in contact with the shell, in order to ensure dynamic stability to the grains of sand and thus the dimensional stability of the shell. To this end, the box is provided with a second access connected to the space where the mass of sand is located, connected by a suction pipe to a device for putting under vacuum. However, this depression of the mass of sand has the disadvantage of disturbing the rise and good distribution of the liquid metal in the casting space, by means of the porosity of the ceramic (filling "by vacuum"), which leads to too rapid filling generating defects in the castings.
L'invention a pour but de remédier à ces inconvénients et concerne à cet effet un procédé de coulée sous basse pression dans un moule comprenant une coquille céramique dont une face délimite un espace de coulée et. un espace contenant une masse de sable sans liant en contact avec l'autre face de la coquille, le moule étant placé dans un caisson présentant à sa base un accès raccordé à l'espace de coulée et relié à une source de métal liquide en contrebas, procédé dans lequel on applique au métal liquide de la source une première valeur de pression adaptée pour amener du métal liquide dans la région dudit accès, on augmente la pression jusqu'à une deuxième valeur légèrement supérieure à une valeur nécessaire pour remplir l'espace de coulée et on maintient cette deuxième valeur pendant une première durée prédéterminée, puis on augmente la pression jusqu'à une troisième valeur et on maintient cette troisième valeur pendant une deuxième durée prédéterminée, puis on diminue la pression pour que le niveau du métal liquide descende approximativement dans la région dudit accès ou au-dessous, caractérisé en ce que, approximativement lorsque l'espace de coulée devient entièrement rempli de métal liquide, on diminue la pression dans l'espace de la masse de sable au-dessous de la pression atmosphérique jusqu'à une valeur de dépression prédéterminée, on maintient cette valeur de dépression au moins jusqu'à ce que soit obtenue contre la coquille une croûte solidifiée, et on remonte approximativement à la pression atmosphérique la pression dans l'espace de la masse de sable.The invention aims to remedy these drawbacks and for this purpose relates to a low-pressure casting process in a mold comprising a ceramic shell, one face of which delimits a space for casting and. a space containing a mass of sand without binder in contact with the other face of the shell, the mold being placed in a box having at its base an access connected to the casting space and connected to a source of liquid metal below , process in which a first pressure value adapted to bring liquid metal into the region of said access is applied to the liquid metal of the source, the pressure is increased to a second value slightly greater than a value necessary to fill the space and this second value is maintained for a first predetermined duration, then the pressure is increased to a third value and this third value is maintained for a second predetermined duration, then the pressure is reduced so that the level of the liquid metal drops approximately in the region of said access or below, characterized in that, approximately when the casting space becomes completely filled with liquid metal, the pressure in the space of the mass of sand is reduced below atmospheric pressure to a predetermined depression value, this depression value is maintained at least until either obtained against the shell a solidified crust, and the pressure in space of the mass of sand is raised to approximately atmospheric pressure.
Le procédé selon 1 ' invention peut de plus présenter une ou plusieurs des caractéristiques suivantes : - la durée de la phase au cours de laquelle on diminue la pression dans l'espace où se trouve la masse de sable, au-dessous de la pression atmosphérique, jusqu'à une valeur de dépression prédéterminée, est plus courte que la première durée prédéterminée ; - . la phase au cours de laquelle on augmente la pression dans l'espace où se trouve la masse de sable, approximativement jusqu'à la pression atmosphérique, est menée à son terme avant le terme de la phase au cours de laquelle on diminue la pression à laquelle est soumis le métal liquide contenu dans la source de métal liquide de telle sorte que le niveau du métal liquide descende approximativement dans la région dudit accès ou au- dessous ; - la valeur de dépression prédéterminée correspond à une pression absolue dans la gamme approximativement de 0,5 à 0,9 bar ;The method according to the invention can also have one or more of the following characteristics: - the duration of the phase during which the pressure is reduced in the space where the mass of sand is located, below atmospheric pressure , up to a predetermined depression value, is shorter than the first predetermined duration; -. the phase during which the pressure in the space where the mass of sand is increased, approximately up to atmospheric pressure, is completed before the end of the phase during which the pressure is reduced to which is subjected to the liquid metal contained in the source of liquid metal so that the level of the liquid metal drops approximately in the region of said access or below; - the predetermined vacuum value corresponds to an absolute pressure in the range approximately from 0.5 to 0.9 bar;
- la première valeur de pression est d'environ 1,15 bars absolus ; - la deuxième valeur de pression est d'environ- the first pressure value is approximately 1.15 bars absolute; - the second pressure value is approximately
1,4 bars absolus ;1.4 bar absolute;
- la troisième valeur de pression est d'environ 1,7 bars absolus.- the third pressure value is approximately 1.7 bars absolute.
Grâce au fait que c'est seulement lorsque l'espace de coulée est rempli de métal liquide que l'on diminue la pression dans l'espace de la masse de sable, le remplissage n'est pas perturbé par la dépression.Thanks to the fact that it is only when the pouring space is filled with liquid metal that the pressure in the space of the mass of sand is reduced, the filling is not disturbed by the depression.
L'invention concerne également une installation pour la mise en oeuvre du procédé ci-dessus, comportant un moule comprenant une coquille céramique dont une face délimite un espace de coulée, et un espace contenant une masse de sable sans liant en contact avec l'autre face de la coquille, le moule étant placé dans un caisson présentant à sa base un accès raccordé à l'espace de coulée et relié à une source de métal liquide en contrebas, installation caractérisée en ce que le caisson comporte intérieurement une chambre à vide munie d'au moins une région de paroi perméable à l'air et présentant une ouverture d'accès munie d'une prise de vide pour être reliée à un dispositif d'aspiration par l'intermédiaire d'une électrovanne commandée par un automate programmable commandant également un dispositif de régulation de pression de la source de métal liquide.The invention also relates to an installation for implementing the above method, comprising a mold comprising a ceramic shell, one face of which defines a pouring space, and a space containing a mass of sand without binder in contact with the other. face of the shell, the mold being placed in a box having at its base an access connected to the casting space and connected to a source of liquid metal below, installation characterized in that the box has an internal vacuum chamber provided at least one wall region permeable to air and having an access opening provided with a vacuum connection to be connected to a suction device via a solenoid valve controlled by a programmable automaton also controlling a device for regulating the pressure of the liquid metal source.
L'installation selon l'invention peut de plus présenter pour caractéristique le fait que la chambre à vide s'étend annulairement dans le caisson contre une paroi de base et des parois latérales de celui-ci.The installation according to the invention can also have the characteristic that the vacuum chamber extends annularly in the box against a base wall and side walls of the latter.
Grâce à cette installation, le procédé de moulage peut être mis en oeuvre très rapidement et être contrôlé avec précision avec un investissement en matériel restant malgré tout modéré .Thanks to this installation, the molding process can be implemented very quickly and be precisely controlled with an investment in material remaining moderate despite everything.
D'autres caractéristiques et avantages de l'invention ressortiront de la description qui va suivre d'un exemple de réalisation de l'invention illustré par les dessins joints dans lesquels : la figure 1 est un schéma général d'une installation pour la mise en oeuvre du procédé selon l'invention, et la figure 2 est un diagramme illustrant la succession des phases du procédé selon l'invention.Other characteristics and advantages of the invention will emerge from the description which follows of an embodiment of the invention illustrated by the accompanying drawings in which: FIG. 1 is a general diagram of an installation for setting work of the process according to the invention, and FIG. 2 is a diagram illustrating the succession of the phases of the process according to the invention.
L'installation selon l'invention comporte un caisson 1 dans lequel est constitué un moule 2 comprenant une coquille 21 en céramique pouvant être du type « consommable » dont une face délimite un espace de coulée 22 dont la forme correspond à la forme extérieure de la pièce à couler, et une masse 23 de sable sans liant dans l'espace du caisson délimité entre les parois de celui-ci et l'autre face de la coquille et ainsi en contact avec cette autre face. Grâce à .'invention, l'épaisseur de la coquilleThe installation according to the invention comprises a box 1 in which a mold 2 is made up comprising a ceramic shell 21 which may be of the “consumable” type, one face of which defines a pouring space 22 whose shape corresponds to the external shape of the part to be cast, and a mass 23 of sand without binder in the space of the box delimited between the walls of the latter and the other face of the shell and thus in contact with this other face. Thanks to .'invention, the thickness of the shell
21 peut être faiole, et par exemple une épaisseur de 2 mm peut être atteinte.21 can be weak, and for example a thickness of 2 mm can be reached.
En général, l'épaisseur est dans la gamme de 2 à 4 mm, mais le procédé convient également pour des épaisseurs plus importantes. Le caisson 1 comporte une paroi de base 11 et des parois latérales 12 présentant un bord commun avec la paroi de base et un bord supérieur coudé vers l'extérieur de manière à constituer une bride 13 s 'étendant parallèlement à la paroi de base.In general, the thickness is in the range of 2 to 4 mm, but the process is also suitable for larger thicknesses. The box 1 has a base wall 11 and side walls 12 having an edge common with the base wall and an upper edge bent outwards so as to constitute a flange 13 extending parallel to the base wall.
La paroi de base présente une ouverture d'accès 14 raccordée à l'espace de coulée 22 par un joint 15 tubulaire présentant une partie emmanchée dans l'ouverture de la paroi de base et une partie servant de portée à la face intérieure, de forme conjuguée, de l'embouchure (inférieure) de la coquille 21.The base wall has an access opening 14 connected to the pouring space 22 by a tubular joint 15 having a part fitted into the opening of the base wall and a part serving as a bearing for the inner face, of form conjugate, from the mouth (lower) of the shell 21.
Le caisson 1 comporte une chambre à vide 3 annulaire s' étendant contre la région périphérique de sa paroi de base 11 et les régions des parois latérales 12 qui aboutissent à cette paroi de base. Cette chambre à vide a au moins une paroi 31 en contact avec la masse de sable 23 ; cette paroi 31 comporte au moins une région perméable à l'air mais étanche au sable. L'une des parois latérales du caisson 1 et de la chambre à vide 3 comporte une deuxième ouverture d'accès 16 débouchant dans la chambre à vide, munie d'une prise de vide 17.The box 1 comprises an annular vacuum chamber 3 extending against the peripheral region of its base wall 11 and the regions of the side walls 12 which terminate at this base wall. This vacuum chamber has at least one wall 31 in contact with the mass of sand 23; this wall 31 comprises at least one region permeable to air but impermeable to sand. One of the side walls of the box 1 and of the vacuum chamber 3 has a second access opening 16 opening into the vacuum chamber, provided with a vacuum outlet 17.
La masse de sable 23 emplit l'espace du caisson 1 entre les parois de celui-ci et la coquille 21, à 1 ' exception de la chambre à vide 3. Le caisson est disposé sur un plateau supportThe mass of sand 23 fills the space of the box 1 between the walls of the latter and the shell 21, with the exception of the vacuum chamber 3. The box is placed on a support plate
(non représenté) présentant une ouverture en face de l'ouverture d'accès de sa paroi de base.(not shown) having an opening opposite the access opening of its base wall.
En vue du remplissage en sable du caisson au moyen par exemple d'une trémie dont l'orifice de base débouche dans le caisson, le plateau support est tout d'abord disposé sur un dispositif de vibration (également non représenté) comportant par exemple des rouleaux excentriques .With a view to filling the caisson with sand, for example by means of a hopper, the base opening of which opens into the caisson, the support plate is first of all placed on a vibration device (also not shown) comprising, for example, eccentric rollers.
Ainsi, lorsque la coquille 21 est positionnée sur le joint 15, le caisson 1 peut être rempli de sable flou, c'est-à-dire sans liant, tout en étant vibré pour obtenir une densification maximale. Le niveau de sable est ensuite égalisé à la règle pour obtenir un niveau régulier à la surfa.ce supérieure du caisson. Le caisson 1 rempli de sable est alors prêt à être transporté à proximité d'un four de coulée 4, disposé en contrebas du caisson. Le caisson est positionné de telle sorte que l'ouverture d'accès 14 de sa paroi de base garnie du joint 15 soit en vis-à-vis d'un col de sortie 41 d'une conduite 42 d'amenée de métal liquide du four, afin que le col puisse être solidarisé au caisson et que la conduite d'amenée relie ainsi l'espace de coulée du moule à l'espace intérieur du four.Thus, when the shell 21 is positioned on the joint 15, the box 1 can be filled with soft sand, that is to say without binder, while being vibrated to obtain maximum densification. The level of sand is then equalized with the rule to obtain a regular level at the upper surface of the box. The box 1 filled with sand is then ready to be transported near a casting furnace 4, arranged below the box. The box is positioned so that the access opening 14 of its base wall provided with the seal 15 is opposite an outlet neck 41 of a pipe 42 for supplying liquid metal from the oven, so that the neck can be secured to the box and the supply line thus connects the casting space of the mold to the interior space of the oven.
Egalement, un plateau mobile 5 sous lequel est fixé un joint d'étanchéité 51 est attaché sur le caisson par exemple par bridage pour constituer le couvercle de celui-ci, le joint 51 étant alors interposé entre le plateau et la bride 13 formée sur les parois latérales du caisson. Le joint, écrasé entre le plateau et la bride, épousant la forme de ceux-ci, permet donc de faire le vide à l'intérieur du caisson.Also, a movable plate 5 under which is fixed a seal 51 is attached to the box for example by clamping to form the cover thereof, the seal 51 then being interposed between the plate and the flange 13 formed on the side walls of the box. The seal, crushed between the plate and the flange, matching the shape of the latter, therefore makes it possible to create a vacuum inside the box.
Approximativement simultanément à l'application du plateau mobile 5 sur le caisson, la prise de vide 17 est raccordée de manière étanche à une conduite d'aspiration 61 reliant cette prise à un dispositif d'aspiration 6 comprenant une nourrice de vide 62 mise en dépression par une pompe 63 telle qu'une pompe à palettes.Approximately simultaneously with the application of the movable plate 5 on the box, the vacuum socket 17 is tightly connected to a suction pipe 61 connecting this socket to a suction device 6 comprising a vacuum manifold 62 placed under vacuum by a pump 63 such as a vane pump.
Une électrovanne 64 commandée par un automate programmable 7 est insérée entre la nourrice de vide 62 et la prise de vide 17 du caisson ; un manomètre 65 mesure la pression à l'entrée du caisson.A solenoid valve 64 controlled by a programmable automaton 7 is inserted between the vacuum feeder 62 and the vacuum outlet 17 of the box; a pressure gauge 65 measures the pressure at the inlet of the box.
Le four de coulée 4 comporte, au-dessus de la masse 43 de métal liquide, une voûte 44 reliée par une conduite 45 de mise en pression à un dispositif de régulation de pression 8 également commandé par 1 ' automate programmable 7.The casting furnace 4 comprises, above the mass 43 of liquid metal, a vault 44 connected by a pipe 45 for pressurizing a device for pressure regulation 8 also controlled by the programmable controller 7.
Grâce à cette installation, et sous la commande de 1 ' automate programmable 7 , on peut mettre en oeuvre le procédé selon l'invention qui va être décrit ci-après et qui est illustré par la figure 2.Thanks to this installation, and under the control of the programmable controller 7, it is possible to implement the method according to the invention which will be described below and which is illustrated in FIG. 2.
On applique au métal liquide du four de coulée 4 , au moyen de la conduite de mise en pression 45, une pression de valeur PI par exemple de l'ordre de 1,15 bars absolus, qui amène le métal liquide par un mouvement ascendant dans la région de l'ouverture d'accès 14 de la base du caisson 1, au seuil de l'embouchure du moule 2.Is applied to the liquid metal of the casting furnace 4, by means of the pressurizing pipe 45, a pressure of value PI for example of the order of 1.15 bar absolute, which brings the liquid metal by an upward movement in the region of the access opening 14 of the base of the box 1, at the threshold of the mouth of the mold 2.
Puis, on augmente la pression (phase AB) , jusqu'à une valeur P2 par exemple d'environ 1,4 bars absolus, et plus généralement une valeur légèrement supérieure à celle nécessaire pour emplir entièrement de manière ascendante 1 ' espace de coulée avec une marge de sécuritéThen, the pressure is increased (phase AB), up to a value P2 for example of approximately 1.4 bar absolute, and more generally a value slightly greater than that necessary to fill the ascending space fully upward with a safety margin
Δh suffisante, et on maintient cette valeur pour laisser s'établir un régime de repos (phase BC) . De plus, lorsque la pression a atteint approximativement sa valeur permettant le remplissage du moule, et de préférence sa valeur P2 avec la marge de sécurité, (point B) , on diminue rapidement, par l'intermédiaire de la conduite d'aspiration, et par suite de l'ouverture de l' électrovanne 64 commandée par l'automate programmable 7, la pression dans la masse de sable ; la diminution est poursuivie jusqu'à ce que l'on atteigne une valeur de dépression par rapport à la pression atmosphérique, correspondant à une pression absolue prédéterminée de préférence dans la gamme approximativement de 0,5 à 0,9 bar, et on maintient cette valeur de dépression pendant une certaine durée comme on le verra dans la suite.Δh sufficient, and this value is maintained to allow a rest regime to be established (phase BC). In addition, when the pressure has reached approximately its value allowing the filling of the mold, and preferably its value P2 with the safety margin, (point B), it decreases rapidly, via the suction line, and following the opening of the solenoid valve 64 controlled by the programmable controller 7, the pressure in the mass of sand; the reduction is continued until a vacuum value is reached with respect to atmospheric pressure, corresponding to a predetermined absolute pressure preferably in the range approximately from 0.5 to 0.9 bar, and this is maintained depression value for a certain period of time as will be seen below.
De préférence, on effectue la diminution de la pression dans l'espace de la masse de sable rapidement, car la durée de cette phase de diminution au-dessous de la pression atmosphérique jusqu'à la valeur de dépression choisie doit être plus courte que celle de la phase BC où la masse de métal liquide est soumise à la pression de valeur P2. Selon l'invention, on maintient donc la pression du métal liquide à la valeur P2 ici de 1,4 bars, non seulement tant que la cavité 22 n'est pas emplie, mais également tant que la dépression dans la masse de sable n'a pas atteint le niveau choisi. Après quoi, la coquille 21 étant rigidifiée par le compactage de la masse de sable dû à la dépression, on augmente encore la pression appliquée au métal liquide (phase CD) jusqu'à une valeur P3 par exemple de l'ordre de 1,7 bars afin de combler les cavités ou retassures éventuelles, et on maintient cette valeur P3 de surpression pendant une durée permettant d'obtenir tout d'abord une croûte solidifiée contre la coquille, puis la solidification du métal contenu dans le moule (phase DE) .Preferably, the reduction in the pressure in the space of the mass of sand is carried out quickly, because the duration of this phase of reduction below atmospheric pressure to the selected vacuum value must be shorter than that of phase BC where the mass of liquid metal is subjected to the pressure of value P2. According to the invention, the pressure of the liquid metal is therefore maintained at the value P2 here 1.4 bars, not only as long as the cavity 22 is not filled, but also as long as the depression in the mass of sand does not has not reached the chosen level. After which, the shell 21 being stiffened by the compaction of the mass of sand due to the vacuum, the pressure applied to the liquid metal (CD phase) is further increased to a value P3 for example of the order of 1.7 bars in order to fill in any cavities or shrinkage, and this P3 value of overpressure is maintained for a period making it possible first to obtain a solidified crust against the shell, then the solidification of the metal contained in the mold (DE phase).
La dépression dans la masse de sable est maintenue à une valeur correspondant à la pression absolue de 0,5 à 0,9 bar ici approximativement jusqu'au point E, et en tout cas le « vide » ne doit pas être « cassé » avant la formation de la croûte de métal contre la coquille 21. Lorsque la solidification désirée du métal de l'espace de coulée 22 est obtenue, on diminue la pression sur le métal liquide (phase EF) de telle sorte que le niveau de celui-ci descende approximativement au niveau initial (valeur de pression PI égale ici à 1,15 bars environ) , et on maintient cette pression pendant le temps nécessaire par exemple pour retirer le moule et en remettre un autre en vue de la fabrication d'une autre pièce. Comme on l'a vu, on peut casser le « vide »The depression in the mass of sand is maintained at a value corresponding to the absolute pressure of 0.5 to 0.9 bar here approximately up to point E, and in any case the "vacuum" must not be "broken" before the formation of the crust of metal against the shell 21. When the desired solidification of the metal of the casting space 22 is obtained, the pressure on the liquid metal is reduced (phase EF) so that the level thereof descends approximately to the initial level (PI pressure value here equal to approximately 1.15 bars), and this pressure is maintained for the time necessary for example to remove the mold and put back another for the production of another part . As we have seen, we can break the "vacuum"
(augmenter la pression) dans la masse de sable à partir du moment où la croûte solide est formée, mais généralement on n'effectue cette opération qu'immédiatement avant le relâchement de la pression appliquée au métal liquide ou au moment de ce relâchement ; cependant, cette phase d'augmentation de la pression dans l'espace où se trouve la masse de sable approximativement jusqu'à la pression atmosphérique est effectuée suffisamment tôt et/ou rapidement pour qu'elle soit menée à son terme avant le terme F de la phase EF au cours de laquelle on diminue la pression sur le métal liquide pour assurer son retour à la pression PI ou même au-dessous. La masse de sable n'étant plus en dépression, le métal liquide peut redescendre librement dans la conduite d'amenée 42, son niveau revenant alors approximativement dans la région de l'accès 14 ou au- dessous, et on peut retirer aisément le caisson sans craindre des retours de métal liquide.(increase pressure) in the mass of sand from the moment the solid crust is formed, but generally this operation is carried out only immediately before the release of the pressure applied to the liquid metal or at the time of this release; however, this phase of increasing the pressure in the space where the mass of sand is located approximately up to atmospheric pressure is carried out sufficiently early and / or quickly so that it is completed before the term F of the EF phase during which the pressure on the liquid metal is reduced to ensure its return to the pressure PI or even below. As the mass of sand is no longer under vacuum, the liquid metal can descend freely in the supply line 42, its level then returning approximately in the region of the access 14 or below, and the box can be easily removed without fear of liquid metal returns.
Ainsi, grâce à l'invention, la dépression étant appliquée à la masse de sable à l'issue du remplissage de la coquille, elle n'intervient pas sur l'écoulement du métal dans cette dernière, et cet écoulement reste piloté par la pression, tandis que la dépression dans la masse de sable assure la rigidification de la coquille dans la phase de surpression à la pression P3, qui est la plus critique, au moins tant que la coquille n'est pas rigidifiée par une croûte de métal. Thus, thanks to the invention, the vacuum being applied to the mass of sand at the end of the filling of the shell, it does not affect the flow of the metal in the latter, and this flow remains controlled by the pressure , while the depression in the mass of sand stiffens the shell in the overpressure phase at pressure P3, which is the most critical, at least as long as the shell is not stiffened by a metal crust.

Claims

REVENDICATIONS
1. Procédé de coulée sous basse pression dans un moule (2) comprenant une coquille céramique (21) dont une face délimite un espace de coulée (22) , et un espace contenant une masse de sable (23) sans liant en contact avec l'autre face de la coquille, le moule étant placé dans un caisson (1) présentant à sa base un accès (14) raccordé à l'espace de coulée et relié à une source (4) de métal liquide en contrebas, procédé dans lequel on applique au métal liquide de la source une première valeur de pression (PI) adaptée pour amener du métal liquide dans la région dudit accès, on augmente la pression jusqu'à une deuxième valeur (P2) légèrement supérieure à une valeur nécessaire pour remplir l'espace de coulée et on maintient cette deuxième valeur pendant une première durée (BC) prédéterminée, puis on augmente la pression jusqu'à une troisième valeur (P3) et on maintient cette troisième valeur pendant une deuxième durée (DE) prédéterminée, puis on diminue la pression pour que le niveau du métal liquide descende approximativement dans la région dudit accès (14) ou au- dessous, caractérisé en ce que, approximativement lorsque l'espace de coulée devient entièrement rempli de métal liquide, on diminue la pression dans l'espace de la masse de sable (23) au-dessous de la pression atmosphérique jusqu'à une valeur de dépression prédéterminée, on maintient cette valeur de dépression au moins jusqu'à ce que soit obtenue contre la coquille (21) une croûte solidifiée, et on remonte approximativement à la pression atmosphérique la pression dans l'espace de la masse de sable.1. A method of casting under low pressure in a mold (2) comprising a ceramic shell (21) one face of which defines a casting space (22), and a space containing a mass of sand (23) without binder in contact with the other side of the shell, the mold being placed in a box (1) having at its base an access (14) connected to the casting space and connected to a source (4) of liquid metal below, process in which a first pressure value (PI) adapted to bring liquid metal into the region of said access is applied to the liquid metal of the source, the pressure is increased to a second value (P2) slightly greater than a value necessary to fill the casting space and this second value is maintained for a first predetermined duration (BC), then the pressure is increased to a third value (P3) and this third value is maintained for a second predetermined duration (DE), then o n decreases the pressure so that the level of the liquid metal drops approximately in the region of said access (14) or below, characterized in that, approximately when the casting space becomes completely filled with liquid metal, the pressure is reduced in the space of the mass of sand (23) below atmospheric pressure up to a predetermined depression value, this depression value is maintained at least until a crust is obtained against the shell (21) solidified, and the pressure in space of the mass of sand is raised approximately to atmospheric pressure.
2. Procédé de coulée selon la revendication 1, caractérisé en ce que la durée de la phase au cours de laquelle on diminue la pression dans l'espace où se trouve la. masse de sable (23), au-dessous de la pression atmosphérique, jusqu'à une valeur de dépression prédéterminée, est plus courte que la première durée (BC) prédéterminée. 2. A casting method according to claim 1, characterized in that the duration of the phase during which the pressure is reduced in the space where find her. mass of sand (23), below atmospheric pressure, up to a predetermined vacuum value, is shorter than the first predetermined duration (BC).
3. Procédé de coulée selon la revendication 1, caractérisé en ce que la phase au cours de laquelle on augmente la pression dans l'espace où se trouve la masse de sable (23), approximativement jusqu'à la pression atmosphérique, est menée à son terme avant le terme (F) de la phase (EF) au cours de laquelle on diminue la pression à laquelle est soumis le métal liquide contenu dans la source (4) de métal liquide de telle sorte que le niveau du métal liquide descende approximativement dans la région dudit accès (14) ou au-dessous. 3. A casting method according to claim 1, characterized in that the phase during which the pressure in the space where the mass of sand (23) is increased, approximately up to atmospheric pressure, is carried out at its end before the end (F) of the phase (EF) during which the pressure to which the liquid metal contained in the liquid metal source (4) is subjected is reduced so that the level of the liquid metal drops approximately in the region of said access (14) or below.
4. Procédé de coulée selon l'une quelconque des revendications 1 à 3, caractérisé en ce que la valeur de dépression prédéterminée correspond à une pression absolue dans la gamme approximativement de 0,5 à 0,9 bar.4. Casting method according to any one of claims 1 to 3, characterized in that the predetermined vacuum value corresponds to an absolute pressure in the range approximately from 0.5 to 0.9 bar.
5. Procédé de coulée selon l'une quelconque des revendications 1 à 4, caractérisé en ce que la première valeur (PI) de pression est d'environ 1,15 bars absolus.5. A casting method according to any one of claims 1 to 4, characterized in that the first pressure value (PI) is approximately 1.15 bars absolute.
6. Procédé de coulée selon l'une quelconque des revendications 1 à 5, caractérisé en ce que la deuxième valeur (P2) de pression est d'environ 1,4 bars absolus. 7. Procédé de coulée selon l'une quelconque des revendications 1 à 6, caractérisé en ce que la troisième valeur (P3) de pression est d'environ 1,6. casting method according to any one of claims 1 to 5, characterized in that the second pressure value (P2) is about 1.4 bar absolute. 7. casting method according to any one of claims 1 to 6, characterized in that the third pressure value (P3) is approximately 1,
7 bars absolus.7 absolute bars.
8. Installation pour la mise en oeuvre du procédé selon l'une quelconque des revendications 1 à 7, comportant un moule (2) comprenant une coquille céramique (21) dont une face délimite un espace de coulée (22) , et un espace contenant une masse (23) de sable sans liant en contact avec l'autre face de la coquille, le moule étant placé dans un caisson (1) présentant à sa base un accès (14) raccordé à l'espace de coulée et relié à une source (4) de -métal liquide en contrebas, installation caractérisée en ce que le caisson comporte intérieurement une chambre à vide (3) munie d'au moins une région de paroi (31) perméable à l'air et présentant une ouverture d'accès (16) munie d'une prise de vide (17) pour être reliée à un dispositif d'aspiration (6) par l'intermédiaire d'une électrovanne (64) commandée par un automate programmable (7) commandant également un dispositif de régulation de pression (8) de la source (4) de métal liquide.8. Installation for implementing the method according to any one of claims 1 to 7, comprising a mold (2) comprising a ceramic shell (21) one face of which defines a casting space (22), and a space containing a mass (23) of sand without binder in contact with the other face of the shell, the mold being placed in a box (1) having at its base an access (14) connected to the casting space and connected to a source (4) of liquid metal below, installation characterized in that the box internally comprises a vacuum chamber (3) provided with at least one wall region (31) permeable to air and having an access opening (16) provided with a vacuum outlet (17) to be connected to a suction device (6) by means of a solenoid valve (64) controlled by a programmable automaton (7) also controlling a regulation device pressure (8) of the source (4) of liquid metal.
9. Installation selon la revendication 8, caractérisée en ce que la chambre à vide (3) s'étend annulairement dans le caisson contre une paroi de base (11) et des parois latérales (12) de celui-ci. 9. Installation according to claim 8, characterized in that the vacuum chamber (3) extends annularly in the box against a base wall (11) and side walls (12) thereof.
EP98964545A 1998-01-07 1998-12-29 Method and installation for low pressure die casting in a mould with ceramic casting die Expired - Lifetime EP0968064B1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
FR9800091 1998-01-07
FR9800091A FR2773337B1 (en) 1998-01-07 1998-01-07 LOW PRESSURE CASTING PROCESS AND INSTALLATION IN A CERAMIC SHELL MOLD
PCT/FR1998/002908 WO1999034945A1 (en) 1998-01-07 1998-12-29 Method and installation for low pressure die casting in a mould with ceramic casting die

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EP0968064B1 EP0968064B1 (en) 2002-10-23

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CA (1) CA2282673A1 (en)
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US6766850B2 (en) * 2001-12-27 2004-07-27 Caterpillar Inc Pressure casting using a supported shell mold
DE10352179B4 (en) * 2003-11-05 2007-09-06 Dihag Deutsche Giesserei- Und Industrie-Holding Ag Low pressure casting process for the production of a casting
DE102006045267A1 (en) * 2006-09-22 2008-03-27 Kurtz Gmbh Casting device for producing open-pored foam structures made of metal, metal alloys, plastic or ceramic with or without closed outer shell
CN102962433A (en) * 2012-12-06 2013-03-13 淄博宏泰防腐有限公司 Magnesium alloy low-pressure casting equipment
JP6406510B2 (en) * 2014-12-26 2018-10-17 日産自動車株式会社 Casting method and casting apparatus
JP6406509B2 (en) * 2014-12-26 2018-10-17 日産自動車株式会社 Casting apparatus and casting method
WO2016113879A1 (en) 2015-01-15 2016-07-21 日産自動車株式会社 Low-pressure casting method and low-pressure casting apparatus

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FR2534167B1 (en) * 1982-10-11 1985-06-07 Pont A Mousson METHOD FOR THE FOUNDRY MANUFACTURE OF MOLDED PARTS IN OXIDIZABLE METAL ALLOYS
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FR2773337A1 (en) 1999-07-09
ES2186248T3 (en) 2003-05-01
US6422293B1 (en) 2002-07-23
DE69808892D1 (en) 2002-11-28
WO1999034945A1 (en) 1999-07-15
CA2282673A1 (en) 1999-07-15
DE69808892T2 (en) 2003-02-20
EP0968064B1 (en) 2002-10-23

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