EP1356131A2 - Method for the production of metallic foam and metal bodies produced according to said method - Google Patents

Method for the production of metallic foam and metal bodies produced according to said method

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Publication number
EP1356131A2
EP1356131A2 EP02708278A EP02708278A EP1356131A2 EP 1356131 A2 EP1356131 A2 EP 1356131A2 EP 02708278 A EP02708278 A EP 02708278A EP 02708278 A EP02708278 A EP 02708278A EP 1356131 A2 EP1356131 A2 EP 1356131A2
Authority
EP
European Patent Office
Prior art keywords
metal
foam
blowing agent
mold cavity
mold
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
EP02708278A
Other languages
German (de)
French (fr)
Other versions
EP1356131B1 (en
Inventor
Benno Niedermann
Wilfried Knott
Manfred Recksik
Andreas Weier
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.)
Buehler Druckguss AG
Evonik Operations GmbH
Original Assignee
Buehler Druckguss AG
TH Goldschmidt AG
Goldschmidt GmbH
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 Buehler Druckguss AG, TH Goldschmidt AG, Goldschmidt GmbH filed Critical Buehler Druckguss AG
Publication of EP1356131A2 publication Critical patent/EP1356131A2/en
Application granted granted Critical
Publication of EP1356131B1 publication Critical patent/EP1356131B1/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
    • B22D25/00—Special casting characterised by the nature of the product
    • B22D25/005—Casting metal foams
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/08—Alloys with open or closed pores
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/08—Alloys with open or closed pores
    • C22C1/083—Foaming process in molten metal other than by powder metallurgy
    • C22C1/087—Foaming process in molten metal other than by powder metallurgy after casting in solidified or solidifying metal to make porous metals

Definitions

  • the invention relates to a method for producing metal foam in a metal die casting machine, in particular metal foam made from aluminum materials, and to a metal body produced by this method, for example a component made from such an aluminum material.
  • foamable semi-finished aluminum products is atomized aluminum powder, to which a blowing agent is added.
  • a blowing agent is added.
  • a body pressed from a powder mixture is heated in a heatable, closed vessel to temperatures above the decomposition temperature of the blowing agent and / or the melting temperature of the metal.
  • the powder is compacted and the molded part thus created is placed in the area of a component to be foamed and foamed by heating up to 650 ° C. It can the "envelope" is subject to unacceptable deformations or the foaming process is uneven.
  • metallic articles with cavities are produced in that gases are dissolved in a metal melt and the foaming process is initiated by a sudden reduction in pressure.
  • the foam is stabilized by cooling the melt.
  • metallic foam is obtained with the controlled release of propellant gases by first melting a metal at temperatures below the decomposition temperature of the propellant used. A metal foam is established by subsequently dispersing the blowing agent in the molten metal and heating the matrix above the temperature then required to release blowing gases.
  • W.Thiele Filler-containing aluminum sponge - a compressible cast material for the absorption of impact energy, in: Metall 28, 1974, Issue 1, pp. 39 to 42 describes the production of foam aluminum.
  • the desired cavities are specified in size, shape and position in the form of a loose bed of easily compressible inorganic light materials, such as expanded clay minerals, expanded clay, glass foam balls or hollow-cored spheres etc.
  • the light material fill is placed in a casting mold. The remaining spaces in the fill are filled with metal.
  • the aluminum sponge obtained in this way is relatively poorly mechanically loadable and contains the material of the bed.
  • DE-B-11 64 103 relates to a process for the production of metal foam bodies.
  • a solid that decomposes when heated to form gas is mixed with a molten metal so that the solid is wetted by the metal.
  • a molten metal for example, powdered titanium hydride is added to a molten alloy of aluminum and magnesium at a temperature of 600 ° C.
  • the closed foam thus formed is then poured into a mold in order to cool and solidify there.
  • the work is obviously not in a closed system, but in an open system.
  • GB-A-892934 relates to the production of complex structures with a foamed metal core and a closed, non-porous surface, the implementation of the described method depending on the filling of the metal blowing agent mixture into the mold before the start of the foaming process.
  • DE-C-198 32 794 describes a process for producing a hollow profile which is filled with metal foam.
  • This method comprises the steps of pressing the hollow profile made of a shell material with an extrusion press, which has an extrusion tool with a die and a mandrel, feeding the metal foam made of a foam material through a feed channel to the hollow profile which is formed in the mandrel.
  • WO 92/21457 describes the production of aluminum foam in such a way that gas is blown in under the surface of a molten metal, whereby
  • Abrasives serve as stabilizers.
  • EP-B-0 666 784 describes a method for molding a metal foam stabilized by means of particles, in particular an aluminum alloy by heating a composite of a metal matrix and finely divided solid stabilizing particles above the solidus temperature of the metal matrix, and gas bubbles are released into the molten metal composite below its surface, thereby forming a stabilized liquid foam on the surface of the molten metal composite. It is characterized by a molding of the metal foam by pressing the stabilized liquid foam into a mold and with a pressure which is only sufficient for the liquid foam to take the shape of the mold without the cells of the foam being substantially compressed and subsequent cooling and solidification of the foam to obtain a shaped object. The foam is pressed into the mold using a movable plate.
  • a first movable plate presses the liquid foam into the mold and a smooth surface is formed on the molded foam article.
  • a second movable plate is pressed into the foam within the mold to form smooth inner surfaces on the foam article.
  • the shaping can also be done by means of rollers.
  • EP-A-0 804 982 teaches a further process for producing molded parts from metal foam. Foaming takes place in a heatable chamber outside a casting mold, the volume of the powder metallurgical starting material for the metal foam introduced into the chamber being equal to the total foaming capacity foamed phase essentially corresponds to the volume of a filling of the mold. All metal foam in the chamber is pressed into the mold, in which foaming is continued with the remaining foaming capacity until the mold is completely filled.
  • the mold is a sand or ceramic mold, the metal foam is introduced into the chamber as a semi-finished product and only pressed into the mold after foaming, for example using a piston. At the Pressing the foam into the mold shears it. The mold is not filled with a foam of an inherently inhomogeneous structure.
  • DE-A-19 501 508 discloses a method for producing a cavity profile with reduced weight and increased rigidity, for example a component for the chassis of a motor vehicle.
  • This consists of die-cast aluminum and in the cavities there is a core made of aluminum foam.
  • the integrated foam core is manufactured using powder metallurgy and then fixed to the inner wall of a casting tool and cast with metal using a die-casting process.
  • the dissolving or blowing in of propellant gases in molten metal is not suitable for the production of near-net-shape components, since a system consisting of melt with occluded gas bubbles is not sufficiently stable in time to be processed in shaping tools.
  • the solution to the aforementioned problem consists in a first embodiment in a process for producing metal foam by adding a blowing agent to a molten metal, which is characterized in that the molten metal is introduced into the mold cavity of a metal die-casting machine and fixed with a gas-releasing, solid at room temperature Foaming agent foams.
  • light metal foams for example made of aluminum or aluminum alloys
  • a closed outer skin specifically as a gradient material and close to the final contour in one step by a casting process in a commercially available die-casting machine, based on the use of solid, gas-releasing propellants
  • a metal hydride especially a light metal hydride.
  • liquid or pasty metal is pressed under high pressure into a mold which represents the mold cavity.
  • the metal is injected directly from the melting chamber into the mold at up to approx. 10 7 Pa; in the cold chamber process preferred according to the invention, for example for materials made of Al and Mg alloys, the melt is first poured into a cold intermediate chamber and thence pressed into the mold with more than 10 8 Pa.
  • the casting performance of the hot chamber process is higher, but so is the wear on the system.
  • the advantages of die casting are the good material strength, the clean one
  • the process sequence preferred according to the invention comprises filling the required volume of molten metal into the filling or casting chamber and introducing it into a mold cavity while adding the blowing agent to the molten metal.
  • molten metal and blowing agent are brought together in the mold cavity, the Volume is defined or filled with the melt-blowing agent mixture or underfilled.
  • the blowing agent is not brought into contact with the molten metal directly in the mold cavity, but in a filling or casting chamber, and the mixture is then introduced into the mold cavity.
  • the blowing agent can be introduced into the filling or casting chamber on the one hand and / or the mold cavity on the other hand before, during and / or after the metal melt has been introduced into the respective chamber.
  • a special mixing process is not necessary when bringing the molten metal and blowing agent together. Rather, the mixing in the process according to the invention takes place by introducing the molten metal into the molding chamber at high speed in the die casting machine, regardless of the time at which the blowing agent is added to the molten metal.
  • the foaming itself takes place in the mold cavity, which is a closed mold. However, as is usual in die casting or the like, this can have riser channels for ventilation.
  • the essentially foamed metal body is then ejected.
  • the blowing agent is added directly to the molten metal in the filling or casting chamber or in the mold cavity, integrally foamed metal bodies being produced in one operation.
  • These have a smooth surface, the formation of which is easily reproducible is. Due to the possible spray filling, different wall thicknesses can be easily adjusted. The walls are closed on all sides, clean, tight and homogeneous. Post-treatment is usually not necessary.
  • the metal bodies produced are increasingly porous on the inside and have a density gradient.
  • the decomposition temperature of the blowing agent should be matched to the melting temperature of the casting material (metal melt).
  • the decomposition may only start above 100 ° C and should not be higher than approx. 150 ° C above the melting temperature.
  • the proportion of metal in the metal body produced can be in the range from 5 to 95% by volume or% by weight, depending on the volume or thickness of the metal body, a lower volume to surface ratio indicating higher filling levels.
  • a vehicle part should be made from an aluminum material as an integrally foamed metal body.
  • a casting chamber of the die casting machine was filled with a corresponding amount of molten metal.
  • the "shot” took place before the foam was formed; the foaming process took place in situ in the mold cavity. It was quickly foamed into the cold mold.
  • the component had a mass of only about 40% compared to conventional die-cast parts.
  • the metal body made of an aluminum material according to the example had a lower density than magnesium, but its torsional rigidity, for example.

Abstract

The invention relates to a method for producing metallic foam and metal body produced according to said method. The aim of the invention is to produce a method which produces a metallic foam by adding a foaming agent to the metal melt, characterised in that the metal melt is introduced into the mould cavity in a metallic die casting machine and foamed by means of a gas-releasing foam-foaming agent which is solid at room temperature.

Description

Verfahren zur Herstellung von Metallschaum und danach hergestellter MetallkörperProcess for the production of metal foam and metal body produced thereafter
Die Erfindung betrifft ein Verfahren zur Herstellung von Metallschaum in einer Metall-Druckgießmaschine, insbesondere von Metallschaum aus Aluminiumwerkstoffen sowie einen nach diesem Verfahren hergestellten Metallkörper, zum Beispiel ein Bauteil aus einem solchen Aluminiumwerkstoff.The invention relates to a method for producing metal foam in a metal die casting machine, in particular metal foam made from aluminum materials, and to a metal body produced by this method, for example a component made from such an aluminum material.
Es ist bekannt, Bauteile aus geschäumten metallischen Werkstoffen herzustellen. Diese zeichnen sich durch leichte Bauweise, Steifigkeit, Druckfestigkeit, verbesserte mechanische und akus- tische Dämpfung u. a. aus. So werden zum Beispiel Gießkerne aus Aluminiumschaum mit einem Aluminiumwerkstoff umgössen oder solche als Formteile in ein Bauteil eingelegt. Hülle und Kern bzw. Formteil werden getrennt hergestellt und anschließend miteinander verbunden. Dies hat neben dem hohen Fertigungsaufwand auch eine geringe Fertigungsqualität zur Folge.It is known to produce components from foamed metallic materials. These are characterized by light construction, rigidity, pressure resistance, improved mechanical and acoustic damping and. a. out. For example, casting cores made of aluminum foam are cast around with an aluminum material or inserted as molded parts in a component. Shell and core or molded part are manufactured separately and then connected to each other. In addition to the high manufacturing effort, this also results in low manufacturing quality.
Die Basis von schaumfähigen Aluminiumhalbzeugen ist verdüstes Aluminiumpulver, welchem ein Treibmittel zugemischt wird. So wird zum Beispiel nach der DE-A-197 44 300 ein aus einer Pul- Vermischung gepresster Körper in einem beheizbaren, geschlossenen Gefäß auf Temperaturen oberhalb der Zersetzungstemperatur des Treibmittels und/oder der Schmelztemperatur des Metalls erwärmt .The basis of foamable semi-finished aluminum products is atomized aluminum powder, to which a blowing agent is added. For example, according to DE-A-197 44 300, a body pressed from a powder mixture is heated in a heatable, closed vessel to temperatures above the decomposition temperature of the blowing agent and / or the melting temperature of the metal.
Das Pulver wird verdichtet und das so entstandene Formteil wird in den auszuschäumenden Bereich eines Bauteils eingelegt und durch eine Erwärmung auf bis zu 650 °C geschäumt. Dabei kann die „Hülle" unzulässigen Verformungen unterliegen oder der Schäumvorgang erfolgt ungleichmäßig.The powder is compacted and the molded part thus created is placed in the area of a component to be foamed and foamed by heating up to 650 ° C. It can the "envelope" is subject to unacceptable deformations or the foaming process is uneven.
Möglich ist ebenso ein Sintern metallischer Hohlkugeln oder eine Infiltration von Metallschmelzen in Kerne bzw. Füllkδrper, die nach Erstarrung der Schmelze entfernt werden.It is also possible to sinter hollow metal spheres or infiltrate metal melts into cores or fillers, which are removed after the melt has solidified.
Nach einem Verfahren gemäss der JP-A-03017236 werden metallische Artikel mit Hohlräumen dadurch erzeugt, dass Gase in einer Metallschmelze gelöst werden und der Aufschäumvorgang durch plötzliche Druckverringerung eingeleitet wird. Durch Abkühlen der Schmelze wird der Schaum stabilisiert.According to a method according to JP-A-03017236, metallic articles with cavities are produced in that gases are dissolved in a metal melt and the foaming process is initiated by a sudden reduction in pressure. The foam is stabilized by cooling the melt.
Der Lehre der JP-A-09241780 folgend, wird metallischer Schaum unter kontrollierter Freisetzung von Treibgasen gewonnen, indem ein Metall zunächst bei Temperaturen unterhalb der Zersetzungstemperatur des verwendeten Treibmittels geschmolzen wird. Durch anschließendes Dispergieren des Treibmittels im geschmolzenen Metall und Erhitzen der Matrix über die dann zur Freisetzung von Treibgasen benötigte Temperatur etabliert sich ein Metallschaum.According to the teaching of JP-A-09241780, metallic foam is obtained with the controlled release of propellant gases by first melting a metal at temperatures below the decomposition temperature of the propellant used. A metal foam is established by subsequently dispersing the blowing agent in the molten metal and heating the matrix above the temperature then required to release blowing gases.
W.Thiele: Füllstoffhaitiger Aluminiumschwamm - ein kompres- sibler Gußwerkstoff zur Absorption von Stoßenergie, in: Metall 28, 1974, Heft 1, S. 39 bis 42 beschreibt die Herstellung von Schaumaluminium. Die angestrebten Hohlräume werden in Größe, Gestalt und Lage in Form einer losen Schüttung aus leicht komprimierbaren anorganischen Leichtstoffen, wie zum Beispiel geblähte Tonmineralien, Blähton, Glasschaumkugeln oder Hohlko- rundkugeln usw. vorgegeben. Die Leichtstoffschüttung wird in eine Gießform gebracht . Die verbleibenden Zwischenräume der Schüttung werden mit Metall aufgefüllt. Der so erhaltene Aluminiumschwamm ist relativ schlecht mechanisch belastbar und enthält das Material der Schüttung. DE-B-11 64 103 betrifft ein Verfahren zur Herstellung von Metallschaumkörpern. Bei diesem Verfahren wird ein fester Stoff, der sich bei Erhitzung unter Gasbildung zersetzt, mit einem geschmolzenen Metall in der Weise gemischt, dass der feste Stoff durch das Metall benetzt wird. So wird beispielsweise pulver- fδrmiges Titanhydrid einer geschmolzenen Legierung aus Aluminium und Magnesium bei einer Temperatur von 600 °C zugesetzt. Der so gebildete geschlossene Schaum wird anschließend in eine Form gegossen um dort abzukühlen und zu erstarren. Auch hier wird offensichtlich nicht in einem geschlossenen System, sondern in einem offenen System gearbeitet .W.Thiele: Filler-containing aluminum sponge - a compressible cast material for the absorption of impact energy, in: Metall 28, 1974, Issue 1, pp. 39 to 42 describes the production of foam aluminum. The desired cavities are specified in size, shape and position in the form of a loose bed of easily compressible inorganic light materials, such as expanded clay minerals, expanded clay, glass foam balls or hollow-cored spheres etc. The light material fill is placed in a casting mold. The remaining spaces in the fill are filled with metal. The aluminum sponge obtained in this way is relatively poorly mechanically loadable and contains the material of the bed. DE-B-11 64 103 relates to a process for the production of metal foam bodies. In this method, a solid that decomposes when heated to form gas is mixed with a molten metal so that the solid is wetted by the metal. For example, powdered titanium hydride is added to a molten alloy of aluminum and magnesium at a temperature of 600 ° C. The closed foam thus formed is then poured into a mold in order to cool and solidify there. Here too the work is obviously not in a closed system, but in an open system.
GB-A-892934 betrifft die Herstellung von komplexen Strukturen mit geschäumtem Metallkern und geschlossener nicht poröser Oberfläche, wobei die Ausführung des beschriebenen Verfahrens von dem Einfüllen der Metall-Treibmittelmischung in die Form vor dem Start des Aufschäumprozesses abhängt.GB-A-892934 relates to the production of complex structures with a foamed metal core and a closed, non-porous surface, the implementation of the described method depending on the filling of the metal blowing agent mixture into the mold before the start of the foaming process.
DE-C-198 32 794 beschreibt ein Verfahren zur Herstellung eines Hohlprofils, das mit Metallschaum gefüllt ist. Dieses Verfahren umfasst die Schritte des Pressens des Hohlprofils aus einem Hüllwerkstoff mit einer Strangpresse, die ein Strangpresswerkzeug mit einer Matrize und einem Dorn aufweist, des Zuführens des Metallschaums aus einem Schaumwerkstoff durch einen Zufuhr- kanal zu dem Hohlprofil, der in dem Dorn ausgebildet ist.DE-C-198 32 794 describes a process for producing a hollow profile which is filled with metal foam. This method comprises the steps of pressing the hollow profile made of a shell material with an extrusion press, which has an extrusion tool with a die and a mandrel, feeding the metal foam made of a foam material through a feed channel to the hollow profile which is formed in the mandrel.
Vorbekannt ist das Gießen von Metallteilen mit verlorenem Schaum ge äss EP-B-0 461 052. Die WO 92/21457 beschreibt die Herstellung von Aluminiumschaum dergestalt, dass Gas unter die Oberfläche eines geschmolzenen Metalls eingeblasen wird, wobeiIt is previously known to cast metal parts with lost foam according to EP-B-0 461 052. WO 92/21457 describes the production of aluminum foam in such a way that gas is blown in under the surface of a molten metal, whereby
Abrasivstoffe als Stabilisatoren dienen.Abrasives serve as stabilizers.
Die EP-B-0 666 784 beschreibt ein Verfahren zum Formgießen eines mittels Teilchen stabilisierten Metallschaums, insbesondere eine Aluminiumlegierung, indem ein Verbund aus einer Metall- matrix und fein verteilten festen Stabilisierungsteilchen über die Solidustemperatur der Metallmatrix erwärmt wird, und Gasblasen in den geschmolzenen Metallverbund unterhalb dessen Oberfläche abgelassen werden, um dadurch einen stabilisierten flüssigen Schaum an der Oberfläche des geschmolzenen Metallverbundes auszubilden. Kennzeichnend ist ein Formgießen des Metallschaumes durch Pressen des stabilisierten flüssigen Schaumes in eine Form und mit einem Druck, der nur ausreicht, dass der flüssige Schaum die Gestalt der Form annimmt, ohne dass die Zellen des Schaums wesentlich komprimiert werden und nachfolgendes Kühlen und Verfestigen des Schaums, um einen geformten Gegenstand zu erhalten. Der Schaum wird hierbei mittels einer beweglichen Platte in die Form gedrückt. Eine erste bewegliche Platte drückt den flüssigen Schaum in die Form und am geformten Schaumgegenstand wird eine glatte Oberfläche ausgebildet. Eine zweite bewegliche Platte wird in den Schaum innerhalb der Form gedrückt, um am Schaumgegenstand glatte Innenflächen auszubilden. Die Formgebung kann aber auch mittels Rollen erfolgen.EP-B-0 666 784 describes a method for molding a metal foam stabilized by means of particles, in particular an aluminum alloy by heating a composite of a metal matrix and finely divided solid stabilizing particles above the solidus temperature of the metal matrix, and gas bubbles are released into the molten metal composite below its surface, thereby forming a stabilized liquid foam on the surface of the molten metal composite. It is characterized by a molding of the metal foam by pressing the stabilized liquid foam into a mold and with a pressure which is only sufficient for the liquid foam to take the shape of the mold without the cells of the foam being substantially compressed and subsequent cooling and solidification of the foam to obtain a shaped object. The foam is pressed into the mold using a movable plate. A first movable plate presses the liquid foam into the mold and a smooth surface is formed on the molded foam article. A second movable plate is pressed into the foam within the mold to form smooth inner surfaces on the foam article. The shaping can also be done by means of rollers.
Ein weiteres Verfahren zur Herstellung von Formteilen aus Metallschaum lehrt die EP-A-0 804 982. Hierbei erfolgt das Aufschäumen in einer beheizbaren Kammer außerhalb einer Gussform, wobei das Volumen des in die Kammer eingebrachten pulvermetallurgischen Ausgangsmaterials für den Metallschaum in seiner mit der gesamten Schäumkapazität aufgeschäumten Phase dem Volumen einer Füllung der Gussform im Wesentlichen entspricht. Aller in der Kammer befindliche Metallschaum wird in die Gussform gedrückt, in der ein Aufschäumen mit der restlichen Schäumkapazität fortgesetzt wird, bis zum vollständigen Ausfüllen der Gussform. Die Gussform ist eine Sand- oder Keramikform, der Metallschaum wird als Halbzeug in die Kammer eingebracht und erst nach dem Aufschäumen zum Beispiel mittels eines Kolbens in die Gussform gedrückt . Beim Drücken des Schaumes in die Form wird dieser geschert . Die Form wird nicht mit einem Schaum von an sich gewollt inhomogener Struktur gefüllt.EP-A-0 804 982 teaches a further process for producing molded parts from metal foam. Foaming takes place in a heatable chamber outside a casting mold, the volume of the powder metallurgical starting material for the metal foam introduced into the chamber being equal to the total foaming capacity foamed phase essentially corresponds to the volume of a filling of the mold. All metal foam in the chamber is pressed into the mold, in which foaming is continued with the remaining foaming capacity until the mold is completely filled. The mold is a sand or ceramic mold, the metal foam is introduced into the chamber as a semi-finished product and only pressed into the mold after foaming, for example using a piston. At the Pressing the foam into the mold shears it. The mold is not filled with a foam of an inherently inhomogeneous structure.
Die DE-A-19 501 508 offenbart ein Verfahren zur Herstellung eines Hohlraumprofils mit reduziertem Gewicht und erhöhter Steifigkeit, zum Beispiel ein Bauteil für das Fahrwerk eines Kraftfahrzeuges. Dieses besteht aus Aluminiumdruckguss und in dessen Hohlräumen befindet sich ein Kern aus Aluminiumschaum. Der integrierte Schaumkern wird auf pulvermetallurgischem Weg hergestellt und anschließend an der Innenwand eines Gießwerkzeuges fixiert und mittels Druckgießverfahren mit Metall umgössen.DE-A-19 501 508 discloses a method for producing a cavity profile with reduced weight and increased rigidity, for example a component for the chassis of a motor vehicle. This consists of die-cast aluminum and in the cavities there is a core made of aluminum foam. The integrated foam core is manufactured using powder metallurgy and then fixed to the inner wall of a casting tool and cast with metal using a die-casting process.
Das Lösen bzw. Einblasen von Treibgasen in Metallschmelzen ist nicht zur Herstellung endkonturnaher Bauteile geeignet, da ein System, bestehend aus Schmelze mit okkludierten Gasblasen nicht ausreichend zeitstabil ist, um in formgebenden Werkzeugen verarbeitet zu werden.The dissolving or blowing in of propellant gases in molten metal is not suitable for the production of near-net-shape components, since a system consisting of melt with occluded gas bubbles is not sufficiently stable in time to be processed in shaping tools.
Es ist daher Aufgabe der Erfindung, ein einfaches und für die Massenfertigung taugliches Verfahren zur Herstellung von Metallschaum bereit zu stellen, welches mit geringem Aufwand die Herstellung von endkonturnahen Metallkörpern gestattet .It is therefore an object of the invention to provide a simple and suitable for mass production process for the production of metal foam, which allows the production of near-net-shape metal bodies with little effort.
Die Lösung der vorgenannten Aufgabe besteht in einer ersten Ausführungsform in einem Verfahren zur Herstellung von Metallschaum durch Zugabe eines Treibmittels zu einer Metallschmelze, das dadurch gekennzeichnet ist, dass man die Metallschmelze in den Formhohlraum einer Metall-Druckgießmaschine einbringt und mit einem gasabspaltenden, bei Raumtemperatur festen Treibmittel ausschäumt . Überraschend wurde gefunden, dass sich insbesondere Leichtmetallschäume zum Beispiel aus Aluminium oder Aluminiumlegierungen als Integralschäume, d. h. mit geschlossener Außenhaut, gezielt als Gradientenwerkstoff und endkonturnah in einem Schritt durch einen Gießvorgang in einer handelsüblichen Druckgießmaschine herstellen lassen, beruhend auf der Verwendung fester, gasabspaltender Treibmittel, zum Beispiel eines Metallhydrids, insbesondere eines Leichtmetallhydrids .The solution to the aforementioned problem consists in a first embodiment in a process for producing metal foam by adding a blowing agent to a molten metal, which is characterized in that the molten metal is introduced into the mold cavity of a metal die-casting machine and fixed with a gas-releasing, solid at room temperature Foaming agent foams. Surprisingly, it was found that, in particular, light metal foams, for example made of aluminum or aluminum alloys, can be produced as integral foams, that is to say with a closed outer skin, specifically as a gradient material and close to the final contour in one step by a casting process in a commercially available die-casting machine, based on the use of solid, gas-releasing propellants Example of a metal hydride, especially a light metal hydride.
Beim Druckgießen im Sinne der vorliegenden Erfindung wird flüssiges oder breiiges Metall mit hohem Druck in eine Form gedrückt, die den Formhohlraum darstellt. Beim Warmkammer-Verfahren wird das Metall direkt aus dem Schmelzraum mit bis ca. 107 Pa in die Form gespritzt, beim erfindungsgemäß bevorzugten Kaltkammer-Verfahren, zum Beispiel für Werkstoffe aus AI- und Mg-Legierungen wird die Schmelze erst in eine kalte Zwischenkammer und von dort mit mehr als 108 Pa in die Form gepresst . Die Gießleistung des Warmkammer-Verfahrens ist höher, allerdings auch die Abnutzung der Anlage. Die Vorzüge des Druckgus- ses liegen in der guten Werkstoff-Festigkeit, der sauberenIn die casting in the sense of the present invention, liquid or pasty metal is pressed under high pressure into a mold which represents the mold cavity. In the hot chamber process, the metal is injected directly from the melting chamber into the mold at up to approx. 10 7 Pa; in the cold chamber process preferred according to the invention, for example for materials made of Al and Mg alloys, the melt is first poured into a cold intermediate chamber and thence pressed into the mold with more than 10 8 Pa. The casting performance of the hot chamber process is higher, but so is the wear on the system. The advantages of die casting are the good material strength, the clean one
Oberfläche, der hohen Maßgenauigkeit, den geringen erforderlichen Wanddicken, der Möglichkeit komplexer Gussstückgestaltung und der hohen Arbeitsgeschwindigkeit . Diese Vorteile können durch Unterdruck (Vakuum) in der Kokille weiter verbessert wer- den. Vorteilhaft einsetzbar sind hierbei am Markt erhältliche, echtzeitgeregelte Druckgießmaschinen.Surface, the high dimensional accuracy, the small wall thickness required, the possibility of complex casting design and the high working speed. These advantages can be further improved by vacuum (vacuum) in the mold. Real-time controlled die casting machines available on the market can be used advantageously.
Der erfindungsgemäß bevorzugte Verfahrensablauf umfasst das Einfüllen des erforderlichen Volumens an Metallschmelze in die Füll- bzw. Gießkammer und deren Einbringen in einen Formhohlraum unter Zugabe des Treibmittels zu der Metallschmelze. Metallschmelze und Treibmittel werden in einer bevorzugten Aus- führungsform in dem Formhohlraum zusammengebracht, wobei die Form volumendefiniert mit dem Schmelze-Treibmittelgemisch gefüllt respektive unterfüllt wird.The process sequence preferred according to the invention comprises filling the required volume of molten metal into the filling or casting chamber and introducing it into a mold cavity while adding the blowing agent to the molten metal. In a preferred embodiment, molten metal and blowing agent are brought together in the mold cavity, the Volume is defined or filled with the melt-blowing agent mixture or underfilled.
In einer weiteren bevorzugten Ausführungsform wird das Treib- mittel nicht direkt in den Formhohlraum, sondern in einer Füll- oder Gießkammer mit der Metallschmelze in Kontakt gebracht und das Gemisch anschließend in den Formhohlraum eingebracht.In a further preferred embodiment, the blowing agent is not brought into contact with the molten metal directly in the mold cavity, but in a filling or casting chamber, and the mixture is then introduced into the mold cavity.
Das Einbringen des Treibmittels in die Füll- oder Gießkammer einerseits und/oder den Formhohlraum andererseits kann vor, während und/oder nach dem Einbringen der Metallschmelze in die jeweilige Kammer erfolgen. Beim Zusammenbringen von Metallschmelze und Treibmittel ist ein spezieller Mischvorgang nicht erforderlich. Vielmehr erfolgt die Durchmischung beim erfin- dungsgemäßen Verfahren durch das in der Druckgießmaschine mit hoher Geschwindigkeit erfolgende Einbringen der Metallschmelze in die Formkammer, und zwar unabhängig vom Zeitpunkt der Zugabe des Treibmittels zur Metallschmelze.The blowing agent can be introduced into the filling or casting chamber on the one hand and / or the mold cavity on the other hand before, during and / or after the metal melt has been introduced into the respective chamber. A special mixing process is not necessary when bringing the molten metal and blowing agent together. Rather, the mixing in the process according to the invention takes place by introducing the molten metal into the molding chamber at high speed in the die casting machine, regardless of the time at which the blowing agent is added to the molten metal.
Von Bedeutung für die vorliegende Erfindung ist jedoch, dass die Ausschäumung bedingt durch die Gasabspaltung des Treibmittels im Wesentlichen erst im Formhohlraum erfolgt .It is important for the present invention, however, that the foaming essentially only occurs in the mold cavity due to the fact that the blowing agent is split off from the gas.
Das Ausschäumen selbst erfolgt in dem Formhohlraum, der eine geschlossene Form darstellt. Diese kann jedoch, wie beim Druckgießen oder dergleichen üblich über Steigkanäle zur Entlüftung verfügen. Danach erfolgt das Ausstoßen des im Wesentlichen geschäumten Metallkörpers .The foaming itself takes place in the mold cavity, which is a closed mold. However, as is usual in die casting or the like, this can have riser channels for ventilation. The essentially foamed metal body is then ejected.
In einer weiteren Ausgestaltung wird das Treibmittel direkt in der Füll- oder Gießkammer oder in der Formkavität zur Metallschmelze hinzugegeben, wobei jeweils in einem Arbeitsgang integral geschäumte Metallkδrper hergestellt werden. Diese weisen eine glatte Oberfläche auf, deren Bildung gut reproduzierbar ist. Infolge der möglichen Sprühfüllung sind unterschiedliche Wandstärken gut einstellbar. Die Wandungen sind allseitig geschlossen, sauber, dicht und homogen. Eine Nachbehandlung ist in der Regel nicht erforderlich. Nach innen sind die herge- stellten Metallkörper zunehmend porös und weisen einen Dichtegradienten auf.In a further embodiment, the blowing agent is added directly to the molten metal in the filling or casting chamber or in the mold cavity, integrally foamed metal bodies being produced in one operation. These have a smooth surface, the formation of which is easily reproducible is. Due to the possible spray filling, different wall thicknesses can be easily adjusted. The walls are closed on all sides, clean, tight and homogeneous. Post-treatment is usually not necessary. The metal bodies produced are increasingly porous on the inside and have a density gradient.
Das Treibmittel sollte hinsichtlich seiner Zersetzungstemperatur auf die Schmelztemperatur des Gießwerkstoffes (Metall- schmelze) abgestimmt sein. Die Zersetzung darf erst oberhalb von 100 °C beginnen und sollte nicht höher als ca. 150 °C oberhalb der Schmelztemperatur sein.The decomposition temperature of the blowing agent should be matched to the melting temperature of the casting material (metal melt). The decomposition may only start above 100 ° C and should not be higher than approx. 150 ° C above the melting temperature.
Bezogen auf Vollmaterial kann der Metallanteil im hergestellten Metallkörper im Bereich von 5 bis 95 Vol.- oder Gew.-% liegen, in Abhängigkeit vom Volumen oder der Dicke des Metallkörpers, wobei ein niedrigeres Verhältnis Volumen zu Oberfläche für höhere Füllgrade spricht.Based on solid material, the proportion of metal in the metal body produced can be in the range from 5 to 95% by volume or% by weight, depending on the volume or thickness of the metal body, a lower volume to surface ratio indicating higher filling levels.
Die Erfindung wird nachfolgend in einem Ausführungsbeispiel näher beschrieben.The invention is described in more detail below in an exemplary embodiment.
Ausführungsbeispiel :Design example:
In einer handelsüblichen Druckgießmaschine, z. B. einer Druck- giessmaschine der Baureihe Evolution der Bühler Druckguss AG, sollte ein Fahrzeugteil aus einem Aluminiumwerkstoff als integral geschäumter Metallkörper hergestellt werden. Hierzu wurde eine Gießkammer der Druckgießmaschine mit einer entspre- chenden Menge an Metallschmelze gefüllt. In die geschlosseneIn a commercially available die casting machine, e.g. For example, a die casting machine from the Evolution series from Bühler Druckguss AG, a vehicle part should be made from an aluminum material as an integrally foamed metal body. For this purpose, a casting chamber of the die casting machine was filled with a corresponding amount of molten metal. In the closed
Gießkammer wurde als Treibmittel Magnesiumhydrid in Pulverform dem flüssigen Metall zugegeben. Nahezu gleichzeitig begann ein schnelles Einschieben des Gemisches aus Treibmittel und Metallschmelze in dem Formhohlraum. Der Formhohlraum wurde volumen- definiert unterfüllt. Durch die entstehenden Turbulenzen erfolgte eine gute Durchmischung in dem Formhohlraum und das Ausschäumen. Das Metall erstarrte an den Formwänden und bildete eine dichte und homogene Wandung des Metallkörpers aus, wobei sowohl die Wandstärken als auch die Porosität und deren Gradient durch Variation von Verfahrensparametern einstellbar waren.Pouring chamber magnesium powder as a blowing agent was added to the liquid metal in powder form. At almost the same time, the mixture of blowing agent and molten metal began to be quickly inserted into the mold cavity. The mold cavity was volume defined underfilled. Due to the resulting turbulence, the mold cavity was thoroughly mixed and foamed. The metal solidified on the mold walls and formed a dense and homogeneous wall of the metal body, both the wall thicknesses and the porosity and their gradient being adjustable by varying process parameters.
Der „Schuss" erfolgte vor der Schaumbildung; der Schäumungspro- zess lief in situ in dem Formhohlraum ab. Es wurde schnell in die kalte Form geschäumt. Das Bauteil wies eine Masse von nur ca. 40% gegenüber konventionellen Druckgießteilen auf.The "shot" took place before the foam was formed; the foaming process took place in situ in the mold cavity. It was quickly foamed into the cold mold. The component had a mass of only about 40% compared to conventional die-cast parts.
Der gemäss dem Beispiel hergestellte Metallkörper aus einem Aluminiumwerkstoff wies zwar eine geringere Dichte als Magnesium auf, aber etwa dessen Verwindungssteifigkeit . The metal body made of an aluminum material according to the example had a lower density than magnesium, but its torsional rigidity, for example.

Claims

Patentansprüche : Claims:
1. Verfahren zur Herstellung von Metallschaum durch Zugabe eines Treibmittels zu einer Metallschmelze, dadurch gekennzeichnet, dass man die Metallschmelze in den Formhohlraum einer Metall-Druckgießmaschine einbringt und mit einem gasabspaltenden, bei Raumtemperatur festen Treibmittel ausschäumt .1. A process for the production of metal foam by adding a blowing agent to a molten metal, characterized in that the molten metal is introduced into the mold cavity of a metal die casting machine and is foamed with a gas-releasing blowing agent which is solid at room temperature.
2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass man den Fo-rmhohlraum volumendefiniert füllt oder unterfüllt und das Schäumen in einem nicht beheizten Formhohlraum erfolgt.2. The method according to claim 1, characterized in that the foam cavity is filled or underfilled in a volume-defined manner and the foaming takes place in a non-heated mold cavity.
3. Verfahren nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass man das Treibmittel in einer Füll- oder Gießkammer mit der Metallschmelze in Kontakt bringt und anschließend das Gemisch in den Formhohlraum einbringt .3. The method according to claim 1 or 2, characterized in that the blowing agent is brought into contact with the molten metal in a filling or casting chamber and then the mixture is introduced into the mold cavity.
4. Verfahren nach Anspruch 1 oder 2 , dadurch gekennzeichnet, dass man das Treibmittel in den Formhohlraum einbringt.4. The method according to claim 1 or 2, characterized in that the blowing agent is introduced into the mold cavity.
5. Verfahren nach Anspruch 4, dadurch gekennzeichnet, dass man das Treibmittel vor, nach und/oder während des Einbringens der Metallschmelze in den Formhohlraum in diesen einbringt.5. The method according to claim 4, characterized in that the blowing agent is introduced into the mold cavity in the mold cavity before, after and / or during the introduction of the metal melt.
6. Verfahren nach einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, dass man eine Metallschmelze aus Leichtmetall, insbesondere aus Aluminium- oder einer Aluminiumlegierung einsetzt .6. The method according to any one of claims 1 to 5, characterized in that one uses a molten metal made of light metal, in particular made of aluminum or an aluminum alloy.
7 . Metallkörper, hergestellt nach einem Verfahren gemäß einem der /Ansprüche 1 bis 6 . Metallkörper nach Anspruch 7 mit einer allseitig geschlossenen Oberfläche und einer Hohlstruktur im Innern. 7. Metal body produced by a method according to one of claims 1 to 6. Metal body according to claim 7 with an all-round closed surface and a hollow structure inside.
EP02708278A 2001-02-01 2002-01-12 Method for the production of metallic foam and metal bodies produced according to said method Expired - Lifetime EP1356131B1 (en)

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DE10104339A DE10104339A1 (en) 2001-02-01 2001-02-01 Process for the production of metal foam and metal body produced thereafter
PCT/EP2002/000245 WO2002060621A2 (en) 2001-02-01 2002-01-12 Method for the production of metallic foam and metal bodies produced according to said method

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