EP1449601A1 - Moule de coulée dissoluble dans l'eau et méthode de fabrication dudit moule - Google Patents

Moule de coulée dissoluble dans l'eau et méthode de fabrication dudit moule Download PDF

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Publication number
EP1449601A1
EP1449601A1 EP04003620A EP04003620A EP1449601A1 EP 1449601 A1 EP1449601 A1 EP 1449601A1 EP 04003620 A EP04003620 A EP 04003620A EP 04003620 A EP04003620 A EP 04003620A EP 1449601 A1 EP1449601 A1 EP 1449601A1
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Prior art keywords
water
sulfate
binder
magnesium sulfate
casting sand
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EP04003620A
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German (de)
English (en)
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EP1449601B1 (fr
Inventor
Yuji Hori
Naohiro Miura
Yutaka Tsuchiyoshi Industry Co. Ltd. Kurokawa
Hitoshi Kambayashi
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Mazda Motor Corp
Tsuchiyoshi Industry Co Ltd
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Mazda Motor Corp
Tsuchiyoshi Industry Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/12—Treating moulds or cores, e.g. drying, hardening
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C15/00—Moulding machines characterised by the compacting mechanism; Accessories therefor
    • B22C15/23—Compacting by gas pressure or vacuum
    • B22C15/24—Compacting by gas pressure or vacuum involving blowing devices in which the mould material is supplied in the form of loose particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores

Definitions

  • the invention relates to a water-soluble casting mold and a method for manufacturing the mold, more particularly to a technique wherein a binder is water-soluble and repeatedly usable but the strength of a mold can be sufficiently maintained.
  • binders to be used in such cases can broadly be divided into organic binders and inorganic binders.
  • Organic binders in general, start decomposing at about 400°C, so that it is impossible to repeatedly recover the binders and use them. Therefore, in the case that it is required to recover binders and use them repeatedly, inorganic binders have often been used in many cases.
  • the inorganic binders specifically, if sulfate compounds such as magnesium sulfate that are easy to be dissolved in water are used, a mold can easily be collapsed only by immersing the mold in water after pouring a molten metal into the mold, and the binders can be easily recovered.
  • the molten metal pouring temperature reaches about 770°C. Accordingly, when the melting point of an inorganic sulfate compound in a binder to be used for a mold for an aluminum alloy cast is lower than 770°C, the inorganic sulfate compound is melted and vitrified and it becomes impossible to recover the binder after pouring the molten metal. Accordingly, an inorganic sulfate compound having a melting point of 770°C or higher should be used.
  • magnesium sulfate or the like can be exemplified and conventionally, a variety of techniques for using the magnesium sulfate for casting molds has already been proposed.
  • Japanese Patent Publication No. 46-4818 discloses, in pages 1 and 2 thereof, for example, a technique of forming magnesium sulfate itself as aggregate and using it as a water-soluble core for a high pressure die- casting.
  • Japanese Patent Laid-Open Publication No. 53-119724 discloses, in pages 1 and 2 thereof, for example, a technique of using magnesium sulfate as a binder for a refractory granular material for casting sand and mixing the refractory granular material with magnesium sulfate and water, thereafter forcibly drying the obtained mixture at a temperature of 200 to 300°C, thereby obtaining a mold.
  • Japanese Patent Laid-Open Publication No. 11-285777 discloses, in pages 3, 4 and Fig. 3 thereof, for example, a technique of obtaining a mold by using calcium sulfate and magnesium sulfate as binders and mixing a refractory granular material such as siliceous sand with the binders and drying the mixture at 350°C for 4 hours.
  • magnesium sulfate in the anhydride state has a rather decreased strength as compared with that in hydrate state containing crystal water. Therefore, in order to retain a sufficient strength of the mold, the addition amount of magnesium sulfate has to be increased and that is significantly disadvantageous in terms of moldability of the mold, easiness of drying, or recovery of the binder and results in decrease of working efficiency.
  • the basic objects of the present invention are to make recovery of a binder easy and allow repeat use of the binder efficiently by using a binder containing water-soluble sulfate compounds as a main ingredient, and to assure sufficient strength of a mold by using an appropriate amount of the binder.
  • a water-soluble casting mold comprising a refractory granular material for casting sand and a water-soluble binder containing at least one inorganic sulfate compound selected from magnesium sulfate, aluminum sulfate, sodium sulfate, nickel sulfate, manganese sulfate and wherein the inorganic sulfate compound contains crystal water in dry state.
  • the magnesium sulfate, aluminum sulfate, sodium sulfate, nickel sulfate, and manganese sulfate to be used as the inorganic sulfate compound contained in the binder for the mold respectively have good solubility in water. Accordingly, a mold obtained using the binder can easily be collapsed only by being submerged and it is possible to recover the binder, thereby it is possible to use the binder repeatedly, even if the mold is used as a core for a casting with a complicated shape. Further, these inorganic sulfate compounds respectively have a melting point of 770°C or higher.
  • the mold is used to cast an aluminum alloy casting product such as an automotive part, since the pouring temperature of the molten metal for the aluminum alloy casting is generally at about 770°C, the sulfate compounds are prevented from melting and their vitrification can be avoided, and thus the binder can easily be recovered.
  • an inorganic sulfate compound has a high strength in the hydrated state having crystal water as compared with that in the anhydride state having no crystal water.
  • the inorganic sulfate compound of the binder contains crystal water in dry state, the strength of the mold is extremely high.
  • the binder is not limited to those containing only one inorganic sulfate compounds among a plurality of kinds of such sulfate compounds.
  • the respective inorganic sulfate compounds show the maximum strength in prescribed hydrated states, and when the quantity of the contained crystal water is fluctuated owing to humidification deterioration or the like, the strength of the respective inorganic sulfate compounds is decreased. Also, at the time of drying the casting sand, it may be possible that the crystal water of the inorganic sulfate compounds is not evenly evaporated in the casting sand.
  • a plurality of the inorganic sulfate compounds are mixed at prescribed ratios and at the time of drying the casting sand, they are made to be a mixed crystal to make the peak of the strength moderate in relation to the quantity of the crystal water contained in the binder and consequently, the strength of the entire body of the mold can sufficiently be assured even if the quantity of the crystal water is fluctuated or the content of the crystal water in the mold is uneven.
  • a water-soluble casting mold comprising 100 parts by weight of a refractory granular material for casting sand and a binder containing 0.5 to 10.0 parts by weight on the basis of magnesium sulfate equivalent to hepta-hydrate and wherein the magnesium sulfate contains crystal water in dry state. Since magnesium sulfate has good solubility in water, it is easy to recover a binder by collapsing the mold only by adding water after pouring molten metal.
  • the melting point of magnesium sulfate is 1,185°C and even if the mold is used to cast an aluminum alloy casting product such as an automotive part, since the pouring temperature of the molten metal of the aluminum alloy casting is generally about 770°C, magnesium sulfate is prevented from melting and its vitrification can be avoided, and thus the binder can easily be recovered.
  • the binder contains 0.5 to 10.0 parts by weight of magnesium sulfate, a sufficient strength of the mold can be assured with an appropriate amount of magnesium sulfate. That is, if the amount of magnesium sulfate is less than 0.5 parts by weight, the mold cannot be provided with a sufficient strength. On the other hand, if the amount of magnesium sulfate is more than 10.0 parts by weight, in the case of mixing the binder with the refractory granular material for casting sand, a large quantity of water for dissolving magnesium sulfate has to be added.
  • the magnesium sulfate contains crystal water equivalent to mono- to penta-hydrate in dry state. Since magnesium sulfate shows higher strength in the hydrate state than that in anhydride state, a sufficient strength of the mold can be assured by making magnesium sulfate have crystal water equivalent to mono- to penta-hydrate in dry state. Further, since magnesium sulfate exhibits the maximum strength in a form of tri- to tetra-hydrate, it is further preferable that magnesium sulfate in the mold has crystal water equivalent to tri to tetra-hydrate in dry state.
  • the binder contains the inorganic sulfate compounds and not more than 75% by weight of at least one of sodium dihydrogen phosphate and potassium dihydrogen phosphate.
  • the inorganic sulfate compounds become anhydrides to result in decrease of the strength. Consequently, at least one of sodium dihydrogen phosphate and potassium dihydrogen phosphate in an amount of 75% or less by weight is added to the inorganic sulfate compounds so as to retain the water-solubility of the mold and improve the heat resistance property
  • the binder contains the inorganic sulfate compounds and not more than 50% by weight of at least one of tricalcium phosphate, aluminum phosphate, trisodium phosphate, sodium diphosphate, and disodium hydrogen phosphate dodecahydrate.
  • the binder contains the inorganic sulfate compounds and not more than 50% by weight of at least one of tricalcium phosphate, aluminum phosphate, trisodium phosphate, sodium diphosphate, and disodium hydrogen phosphate dodecahydrate.
  • the inorganic sulfate compounds become anhydrides to result in decrease of the strength.
  • At least one of tricalcium phosphate, aluminum phosphate, trisodium phosphate, sodium diphosphate, and disodium hydrogen phosphate dodecahydrate in an amount of 50% or less by weight is added to the inorganic sulfate compounds so as to retain the water-solubility of the mold and improve the heat resistance.
  • the binder contains the inorganic sulfate compounds and not more than 75% by weight of magnesium chloride.
  • the inorganic sulfate compounds become anhydrides to result in decrease of the strength. Consequently, magnesium chloride in an amount of 75% or less by weight is added to the inorganic sulfate compounds so as to retain the water-solubility of the mold and improve the heat resistance.
  • a method for manufacturing a water-soluble casting mold including a first step of obtaining casting sand by mixing a refractory granular material for casting sand with a water-soluble binder containing at least one inorganic sulfate compound selected from magnesium sulfate, aluminum sulfate, sodium sulfate, nickel sulfate, and manganese sulfate and water; a second step of forming a mold with the resulting casting sand; and a third step of obtaining a casting mold by drying the casting sand in such a manner that the inorganic sulfate compound in the casting sand is kept retaining at least a portion of the crystal water.
  • a water-soluble binder containing at least one inorganic sulfate compound selected from magnesium sulfate, aluminum sulfate, sodium sulfate, nickel sulfate, and manganese sulfate and water by which the binder is dissolved are added to and mixed with a refractory granular material such as siliceous sand or the like to obtain casting sand.
  • a refractory granular material such as siliceous sand or the like
  • the molded casting sand is dried by heating or the like to remove water from the casting sand, and at that time, since the casting sand is dried in the state that the inorganic sulfate compound therein is kept retaining at least a portion of crystal water, the inorganic sulfate compound exists in hydrate state in the mold after the drying and consequently, the strength of the mold can be obtained.
  • a method for drying the casting sand is preferably a method of evaporating water in the casting sand with a higher dielectric constant than that of the crystal water by irradiating microwave to the casting sand since water has to be removed while at least a portion of the crystal water being kept in the inorganic sulfate compound.
  • the inorganic sulfate compound becomes an anhydride, any method other than such a method using microwave can be employed.
  • a method for manufacturing a water-soluble casting mold including a first step of obtaining casting sand by mixing 100 parts by weight of a refractory granular material for casting sand with a binder containing 0.5 to 10.0 parts by weight of magnesium sulfate equivalent to hepta-hydrate and water in an amount sufficient to completely dissolve the magnesium sulfate in the binder; a second step of forming the resulting casting sand; and a third step of obtaining a mold by drying the casting sand in such a manner that the magnesium sulfate in the casting sand is kept retaining at least a portion of the crystal water.
  • a water-soluble binder containing magnesium sulfate heptahydrate in an amount of 0.5 to 10.0 parts by weight and water in an amount sufficient to completely dissolve the magnesium sulfate in the binder are added to and mixed with 100 parts by weight of a refractory granular material for casting sand such as siliceous sand or the like to obtain casting sand.
  • a refractory granular material for casting sand such as siliceous sand or the like
  • the molded casting sand is dried by heating or the like to remove water from the casting sand and at that time, since the casting sand is dried in the state that the magnesium sulfate therein is kept retaining at least a portion of crystal water, the magnesium sulfate exists in hydrate state in the mold after the drying and consequently, the strength of the mold can be obtained.
  • the binder since a proper quantity of water is added to completely dissolve magnesium sulfate, the binder is sufficiently mixed with the refractory granular material for casting sand and the refractory granular material for casting sand is reliably coated with the binder.
  • the binder contains the inorganic sulfate compound and not more than 75% by weight of at least one of sodium dihydrogen phosphate and potassium dihydrogen phosphate.
  • the water-solubility of the mold can be retained and the heat resistance is improved, by adding at least one of sodium dihydrogen phosphate and potassium dihydrogen phosphate in an amount of 75% or less by weight to the inorganic sulfate compound.
  • the binder contains the inorganic sulfate compound and not more than 50% by weight of at least one of tricalcium phosphate, aluminum phosphate, trisodium phosphate, sodium diphosphate, and disodium hydrogen phosphate dodecahydrate.
  • the water-solubility of the mold can be retained and the heat resistance is improved, by adding at least one of tricalcium phosphate, aluminum phosphate, trisodium phosphate, sodium diphosphate, and disodium hydrogen phosphate dodecahydrate in an amount of 50% or less by weight to the inorganic sulfate compound.
  • the binder contains the inorganic sulfate compound and not more than 75% by weight of magnesium chloride.
  • the water-solubility of the mold can be retained and the heat resistance is improved by adding magnesium chloride in an amount of 75% or less by weight to the inorganic sulfate compound.
  • the casting sand is dried by microwave or heating with hot air in the third step.
  • microwave is radiated to the casting sand, since water in the casting sand has a higher dielectric constant than that of the crystal water of the inorganic sulfate compound, the water in the casting sand is easily evaporated than that of the crystal water. Accordingly, the water can be removed while the inorganic sulfate compound is kept retaining at least a portion of the crystal water.
  • the temperature of the hot air is set to be a prescribed temperature (e.g. 200°C) or lower at which the crystal water contained in the inorganic sulfate compound is not completely dehydrated, the water in the casting sand is evaporated prior at 100°C under a normal pressure condition and therefore, similarly to the above-mentioned drying by using microwave, the water can be removed while the inorganic sulfate compound is kept retaining at least a portion of the crystal water.
  • the second step of forming the casting sand is carried out by filling a cavity of a ventilative ceramic mold with the casting sand. Accordingly, at the time of drying the casting sand in the third step, the evaporated water can be released evenly to the outside from the ceramic mold, so that the strength of the manufactured mold can be made uniform.
  • a water-soluble casting mold containing a binder that contains magnesium sulfate hydrate which is to be mixed with a refractory granular material for casting sand such as flatterry siliceous sand or the like (hereinafter, referred to as a refractory granular material) will be described.
  • a refractory granular material such as flatterry siliceous sand or the like
  • magnesium sulfate heptahydrate and water sufficient to completely dissolve the magnesium sulfate heptahydrate are added to and mixed with the refractory granular material to coat the refractory granular material with the binder and obtain the casting sand.
  • water in the casting sand is evaporated to obtain a mold.
  • Fig. 1 shows the correlation between the hydration quantity of magnesium sulfate and the strength of the casting mold. It was obtained by the following experiments. That is, 100 parts by weight of flatterry siliceous sand is used as the refractory granular material and 3 parts by weight of magnesium sulfate heptahydrate and water are added thereto to obtain casting sand. Each specimen of the casting sand with a diameter of 30 mm and a height of 50 mm is formed by using a specimen beating and hardening apparatus standardized according to JIS Z 2601. Each specimen is formed by beating and hardening three times using the apparatus.
  • the specimen is then dried by irradiating microwave of 700 W output.
  • the drying duration microwave radiation duration
  • the quantity of the crystal water contained in magnesium sulfate of each specimen is determined by drying further magnesium sulfate at 300°C after drying with microwave until it becomes completely anhydride, assuming decrease of the weight of the specimen before and after the drying to be the crystal water contained in magnesium sulfate in the specimen, and carrying out calculation by mole ratio from the amount of magnesium sulfate added.
  • Hydrates of magnesium sulfates include mono, tetra, hepta, and dodeca hydrates and as shown in Fig. 1, about mono- to hexa-hydrates are applicable for a casting mold. Further, mono to penta-hydrates are preferable to provide strength. Accordingly, it is desirable for magnesium sulfate in the mold in dry state to have crystal water equivalent to mono to penta hydrates. Further, it is more desirable for magnesium sulfate to have crystal water equivalent to tri to tetra hydrates.
  • magnesium sulfate heptahydrate is 12.5 parts by weight or more, voids are formed in the inside of the specimens owing to evaporation of a large quantity of free water existing in the specimens at the time of drying of the specimens and consequently the strength is decreased.
  • the addition amount of magnesium sulfate heptahydrate is increased, the amount of water to be added so as to dissolve the magnesium sulfate heptahydrate is inevitably increased. Consequently, in the case of forming the casting sand, the filling property of the casting sand into a mold is significantly deteriorated. Especially, when a core with a complicated shape just like a core for a water jacket in an automotive engine is manufactured, the filling property is a particularly important matter. The strength needed for a casting mold and excellent filling property into a mold can be obtained in the case where the addition amount of the magnesium sulfate heptahydrate is in a range of 0.5 parts by weight to 10 parts by weight.
  • magnesium sulfate heptahydrate is added alone, as shown in Fig. 1, the compressive strength becomes the maximum when the content of crystal water is a prescribed amount (crystal water equivalent to tri to tetrahydrate) and the crystal water in the casting mold is not necessarily evaporated uniformly at the time of drying. Further, magnesium sulfate has a problem that the amount of crystal water is fluctuated owing to moisture absorption to result in decrease of the strength.
  • inorganic sulfate compound aluminum sulfate dodecahydrate, aluminum sulfate, sodium sulfate decahydrate, nickel sulfate hexahydrate, and manganese sulfate pentahydrate are used.
  • refractory granular material flatterry siliceous sand is used.
  • magnesium sulfate heptahydrate 2.7 parts by weight and another inorganic sulfate compound 0.3 parts by weight are added to the refractory granular material and further water 2.4 parts by weight is added to obtain casting sand.
  • the forming is carried out in the same manner as described above to obtain each specimen with a diameter of 30 mm and a height of 50 mm.
  • Microwave radiation duration is set to be 1 minute and 3 minutes and the compressive strength is measured immediately after drying. Further, in order to absorb moisture in each specimen, the specimen after microwave drying is left for 24 hours in a desiccator containing water and after moisture absorption of the specimen in such a manner, the compressive strength is again measured.
  • the compressive strength is deteriorated after 3-minute microwave radiation in the case of using magnesium sulfate heptahydrate alone, meanwhile the strength decrease is prevented by using another inorganic sulfate compound in combination. Further, the strength after moisture absorption is more increased by adding aluminum sulfate dodecahydrate, aluminum sulfate, nickel sulfate hexahydrate, or manganese sulfate pentahydrate than adding solely magnesium sulfate heptahydrate and thus it is confirmed that the strength is improved after moisture absorption.
  • the following inorganic sulfates shown in Table 3 are preferable. They have a melting point of 770°C or higher, an average molten metal pouring temperature of an aluminum alloy casting product, and are thus not melted at the time of the pouring molten metal and are easy to be dissolved in water and to form a mixed crystal with magnesium sulfate.
  • Specimens of casting molds containing binders containing these inorganic sulfate compounds are easily collapsed in water in a 600°C water-solubility test.
  • the 600°C water-solubility test is carried out by firing each specimen subjected to 1-minute microwave radiation at 600°C for 15 minutes and immersing the specimen in water after cooling to find whether the specimen is collapsed or not.
  • any inorganic compound may be used if it has a melting point of 770°C or higher and, similarly to the inorganic sulfate compounds shown in Table 3, has a high water-solubility at lowest 19.4 g (at 20°C), the minimum value of the solubility in 100 g water.
  • Table4 to Table 7 show the compressive strength and the result of the 600°C water-solubility test of each specimen in the case where other inorganic sulfate compounds are added at different mixing ratios to magnesium sulfate heptahydrate.
  • refractory granular material flatterry siliceous sand is used and a binder 3 parts by weight in total and water 2.4 parts by weight are added to produce specimens. And a compressive test is carried out after the specimens are dried by microwave radiation and 1-hour drying at 200°C for reference data to find compressive strength. Even in the case where aluminum sulfate dodecahydrate, sodium sulfate decahydrate, nickel sulfate hexahydrate, and manganese sulfate pentahydrate are used alone as a binder, the strength is provided by drying with microwave radiation and also in the case where they are added to magnesium sulfate heptahydrate, the strength can be obtained.
  • the results of the 600°C water-solubility test are excellent and molds containing binders using those inorganic compounds in combination can easily be collapsed while being submerged.
  • Table 4 to Table 7 especially in the case of mixing magnesium sulfate and aluminum sulfate, a high compressive strength can be obtained.
  • the average molten metal pouring temperature of an aluminum alloy cast is about 770°C and a portion of a mold locally becomes high temperature at the time of pouring molten metal, however crystal water of magnesium sulfate is isolated, evaporated, and dehydrated at 200°C or higher, and magnesium sulfate becomes an anhydride, so that the strength is decreased locally.
  • another inorganic compound as described below is added to the refractory granular material so as to improve the heat resistance.
  • Table 8 and Table 9 show the compressive strength and the results of the 600°C water-solubility test given in the case of casting molds using sodium dihydrogen phosphate or potassium dihydrogen phosphate in combination with magnesium sulfate heptahydrate.
  • refractory granular material flatterry siliceous sand is used and a binder 3 parts by weight in total and water 2.4 parts by weight are added to produce specimens and a compressive test is carried out after the specimens are dried by microwave radiation and 1-hour drying at 200°C for reference data to find compressive strength.
  • Both of sodium dihydrogen phosphate and potassium dihydrogen phosphate are effective to give the strength even in the case of using them alone and therefore they are usable as a binder, however specimens become water-insoluble in the 600°C water-solubility test.
  • the specimens are collapsed into sand particles by stirring the specimens in water under pressurizing condition (described as collapsed by pressurizing for 60 seconds or longer) and show water-solubility. Further, since strength is exhibited even after 1-hour drying at 200°C, the heat resistance is excellent and various problems such as washing, deformation, cracking and the like of molds at the time of pouring molten metal can be solved.
  • both of sodium dihydrogen phosphate and potassium dihydrogen phosphate contribute to heat resistance improvement as described above, they can be mixed and in such a case, both are preferable to be added in an amount of 75% or less by weight to magnesium sulfate heptahydrate.
  • Table 10 to Table 14 show the compressive strength and the results of the 600°C water-solubility test given in the case where molds are produced by using other inorganic phosphate compounds in combination with magnesium sulfate heptahydrate.
  • inorganic phosphate compounds tricalcium phosphate, aluminum phosphate, trisodium phosphate dodecahydrate, sodium diphosphate, and disodium hydrogen phosphate dodecahydrate are used. These phosphate compounds cannot give the strength if they are used alone and therefore, they cannot solely be used as a binder. However, in the case of mixing them in an amount of 50% or less by weight to magnesium sulfate, they give the compressive strength and assure the water-solubility in both cases; microwave drying and 1-hour drying at 200°C and therefore, they can be used as a binder.
  • Table 15 shows the compressive strength test and the results of the 600°C water-solubility test given in the case where molds are produced by using magnesium chloride in combination with magnesium sulfate heptahydrate.
  • the strength can be given and therefore magnesium chloride can be used alone as a binder, however the specimen becomes water-insoluble in the 600°C water-solubility test.
  • magnesium chloride in an amount of 75% or less by weight in combination with magnesium sulfate heptahydrate, water solubility is assured.
  • the strength is given even after 1-hour drying at 200°C and the heat resistance is thus improved and various problems such as washing, deformation, cracking and the like of casting molds at the time of pouring molten metal can be solved.
  • high strength can be given by radiation for a duration as short as 30 seconds, the productivity of forming the molds can be improved.
  • Table 16 shows the compressive strength in the case of producing molds by using magnesium sulfate heptahydrate alone for a variety of refractory granular materials, which are used commonly, or adding other inorganic sulfate compounds having a melting point of 770°C or higher and showing water-solubility at various mixing ratios to magnesium sulfate heptahydrate and drying in various drying manners.
  • Table 17 shows the results of a confirmation test for the molds described in the foregoing Prior art 2.
  • Example-1 melted ceramic sand 100 parts by weight magnesium sulfate heptahydrate 100% 1.5 1.2 1-minute microwave drying 17.6
  • Example-2 flatterry siliceous sand 100 parts by weight magnesium sulfate heptahydrate 100% 5.0 --- after vapor ventilation, 1-minute microwave drying 44.4
  • Example-3 flatterry siliceous sand 100 parts by weight magnesium sulfate heptahydrate 100% 3.0 1.0 1-minute microwave drying after addition of a solution containing a binder and water after heating to 100°C.
  • Example-9 melted ceramic sand 100 parts by weight magnesium sulfate heptahydrate 75% aluminum sulfate dodecahydrate 25% 1.5 1.2 1-minute microwave drying 20.9
  • Example-10 melted ceramic sand 100 parts by weight magnesium sulfate heptahydrate aluminum sulfate dodecahydrate 50% 25% sodium sulfate decahydrate 25% 1.5 1.2 1-minute microwave drying 24.7
  • Example-11 melted ceramic sand 100 parts by weight magnesium sulfate heptahydrate sodium dihydrogen phosphate 75% 25% 1.5 1.2 1-minute microwave drying 28.9
  • Example-12 melted ceramic sand 100 parts by weight magnesium sulfate heptahydrate 50% aluminum sulfate dodecahydrate 25% sodium dihydrogen phosphate 25% 1.5 1.2 1-minute microwave drying 27.3 refractory granular material for casting sand binder water parts by weight drying method compressive strength kg/cm 2 type of binder parts by weight Comparative Example-1 Albany siliceous sand 100 parts by weight magnesium
  • molds in the scope of the invention are produced with a small amount of a binder and are provided with sufficiently high compressive strength as compared with molds described in Prior art 2.
  • the binder in the invention based on the data of the compressive strength and the collapsing property of molds of the respective tables, the mixture of magnesium sulfate and aluminum sulfate, the mixtures of magnesium sulfate with sodium dihydrogen phosphate and potassium dihydrogen phosphate, the mixtures of magnesium sulfate with aluminum sulfate, sodium dihydrogen phosphate and potassium dihydrogen phosphate are preferable examples.
  • any type can be used if it can be used as casting sand and has a particle size satisfying an average particle diameter in a range from about 0.05 mm (280 mesh) to 1 mm (16 mesh).
  • the following are examples of a variety of refractory granular materials for casting sand such as domestically produced siliceous sand, imported siliceous sand, zircon sand, chromite sand, olivine sand, slag sand, carbon sand, mullite sand, alumina sand, chamotte sand, ceramic sand, porous ceramic sand, melted ceramic sand, various glass sand, hollow glass spherical sand, crushed materials of various refractory materials, metal granular materials such as shot beads, and their reproduced sand.
  • the casting sand or the binder may also contain a prescribed amount of a rouge, an iron powder, a coal powder, a graphite powder, a wood powder, a talc, a starch powder, a grain powder, a silica flour, a zircon flour, an olivine flour and the like, which are commonly added to casting sand for preventing casting defects.
  • a rouge an iron powder, a coal powder, a graphite powder, a wood powder, a talc, a starch powder, a grain powder, a silica flour, a zircon flour, an olivine flour and the like, which are commonly added to casting sand for preventing casting defects.
  • the casting sand or the binder may contain a prescribed amount of tungsten disulfide and molybdenum disulfide as an inorganic lubricant and a hydrocarbon-based lubricant, polyalkylene glycol, a silicone-based lubricant, a fluoro type lubricant, phenyl ether, and a phosphoric acid ester type lubricant as an organic lubricant for improving the filling property into a mold.
  • materials generally applied to the surface of a casting mold such as an alcohol-based mold wash, a water-based mold wash, a powder-based mold wash, a surface stabilizer, a tellurium powder for preventing shrinkage can be used.
  • the mold manufacturing method is an example in which the invention is applied as a core for aluminum alloy casting.
  • the mold manufacturing method include a first step of obtaining casting sand by mixing a refractory casting sand with the above-mentioned water-soluble binder containing inorganic sulfate compounds and water; a second step of forming the resulting casting sand; and a third step of obtaining a mold by drying the casting sand in such a manner that the inorganic sulfate compounds in the casting sand are kept retaining at least a portion of the crystal water.
  • the binder to be added to the refractory casting sand includes inorganic sulfate compounds having a melting point equal to or higher than the average molten metal pouring temperature (770°C) of aluminum alloy casting.
  • the binder includes magnesium sulfate heptahydrate alone; mixtures of magnesium sulfate heptahydrate with other inorganic sulfate compounds such as aluminum sulfate or the like; or solely another inorganic sulfate compound.
  • mixtures containing a variety of the foregoing phosphate compounds such as sodium dihydrogen phosphate or the like and magnesium chloride in a prescribed amount with which the water-solubility can be assured may be used in order to improve the heat resistance of the binder.
  • the addition amount of water is desirable to be satisfactory to dissolve the binder. That is because the binder can be applied evenly to the refractory granular material and gives high strength only in the case where the binder is dissolved.
  • the solubility differs depending on the temperature. For example, in the case where the refractory granular material is previously heated at 200°C (the temperature at which crystal water in the inorganic sulfate compounds is dehydrated) or lower or in the case where the mold is dried by heating at 200°C or lower, the solubility of the binder is increased because water is heated. Accordingly, the minimum amount of water to be added in the first step is an amount sufficient to completely dissolve the binder at 200°C and the maximum amount is the amount sufficient to completely dissolve the binder at around a normal temperature.
  • Fig. 2 shows the solubility of magnesium sulfate heptahydrate in water at different water temperatures.
  • the solubility of magnesium sulfate is also increased as the temperature of water is increased.
  • the solubility at 0°C is 53.9% and in such a case, the ratio of water to be added is 46.1 to a binder 53.9.
  • the solubility at 200°C is 95.5% and the ratio of water is 4.5 to a binder 95.5 to make it possible to considerably decrease the water addition amount.
  • the casting sand S obtained in the first step is blown to a cavity 2 of a ventilative ceramic die 1 for forming a core.
  • the ceramic die 1 is composed of an upper and a lower separate die parts 1a and 1b.
  • the ceramic die is covered with a case member 3 made of an aluminum.
  • pressurized air is supplied to a blow head 4 installed on the top part of the ceramic die 1 and the casting sand S is blown into the cavity 2 of the ceramic die 1 for forming a core through the blow nozzle 5 and thus the casting sand S is compressed and filled into the cavity 2 to form the casting sand S in a prescribed shape.
  • the moisture generated by evaporation is discharged to the outside of the ceramic die by a suction pump 8 through a suction hood 9 and a suction hose 10. Since the inorganic sulfate compounds in the binder contain crystal water even in dry state by drying the casting sand in such a manner to result in exhibition of strength, the resulting mold obtained by such drying can surely be provided with a sufficient strength.
  • the ceramic die 1 Since the ceramic die 1 has the ventilation property, the evaporated moisture can be released uniformly to the outside from the ventilative ceramic die 1. Therefore, unevenness in the quantity of crystal water contained in the inorganic sulfate compounds can be restrained as small as possible and the strength of the obtained mold can be made uniform.
  • a die forming the cavity 2 is not necessarily limited to the ceramic die 1 and may be any die made of another material such as a die made of a synthetic resin if it can transmit microwave.
  • the casting sand S may be dried by supplying hot air to the die filled with the casting sand S and heating the casting sand S by the hot air. That is, as shown in Fig. 5, hot air is supplied through an air hose 12 to an air hood 11 formed in the upper part of the die 1 and hot air is supplied to the die 1 from the air hood 11 to heat the casting sand S packed in the cavity 2 of the die 1. In that case, it is required to supply the hot air at a proper temperature (for example, 200°C or lower) for a sufficient supply time to avoid dehydration of the inorganic sulfate compounds in the casting sand S.
  • a proper temperature for example, 200°C or lower
  • the following methods are also applicable: a method for filling the casting sand into a die heated to 200 °C or lower, thereby hardening the casting sand; a method for packing the casting sand heated at 200°C or lower in a die so as to evaporate water and thereby hardening the casting sand; a method for packing the casting sand in a die and then evaporating water by decreasing the pressure; and the like. Any method can be employed if the method is capable of drying the casting sand in such a manner that the inorganic sulfate compounds contained in the binder are kept retaining crystal water.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Mold Materials And Core Materials (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
EP04003620A 2003-02-21 2004-02-18 Moule de coulée dissoluble dans l'eau et méthode de fabrication dudit moule Expired - Lifetime EP1449601B1 (fr)

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DE102006031191A1 (de) * 2006-07-04 2008-01-10 Dracowo Forschungs- Und Entwicklungs Gmbh Anorganische Kernsandbinder und Schlichten für den Aluminiumguss und ihre weitere Verwendung als Düngemittel
EP2022580A1 (fr) * 2006-05-16 2009-02-11 Lignyte. Co., Ltd. Appareil et procédé de fabrication d'un moule
WO2019085124A1 (fr) * 2017-11-02 2019-05-09 深圳市爱能森科技有限公司 Noyau soluble à base de système de sel fondu ternaire, procédé de préparation s'y rapportant et application
CN114873601A (zh) * 2022-07-12 2022-08-09 天津包钢稀土研究院有限责任公司 利用微波加热低温合成纳米稀土硼化物材料的制备方法

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JP6143347B2 (ja) * 2013-07-26 2017-06-07 リグナイト株式会社 鋳型の製造装置
JP6096378B1 (ja) * 2016-02-15 2017-03-15 技術研究組合次世代３Ｄ積層造形技術総合開発機構 ３次元積層造形鋳型製造用粒状材料の製造方法および３次元積層造形鋳型の製造方法
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CN107511450B (zh) * 2017-09-18 2019-07-05 桂林中铸机械科技有限公司 消失模铸件铸造时表层渗铸耐磨颗粒层用的涂敷剂
JP7311965B2 (ja) * 2018-12-07 2023-07-20 群栄化学工業株式会社 鋳型の製造方法および鋳型造型用型
JP7269727B2 (ja) * 2018-12-07 2023-05-09 群栄化学工業株式会社 鋳型およびその製造方法
US11724306B1 (en) 2020-06-26 2023-08-15 Triad National Security, Llc Coating composition embodiments for use in investment casting methods
CN116372071B (zh) * 2023-06-06 2023-08-08 江苏金源高端装备股份有限公司 一种轨道交通变速箱行星齿轮箱支撑组件的铸造设备

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Publication number Priority date Publication date Assignee Title
WO2004080145A2 (fr) * 2003-03-14 2004-09-23 Laempe + Gies Gmbh Formes et noyaux contenant du magnesium et/ou de l'aluminium, avec un supplement de phosphate/borate, leur preparation et leur utilisation
WO2004080145A3 (fr) * 2003-03-14 2005-11-17 Laempe & Gies Gmbh Formes et noyaux contenant du magnesium et/ou de l'aluminium, avec un supplement de phosphate/borate, leur preparation et leur utilisation
EP2022580A1 (fr) * 2006-05-16 2009-02-11 Lignyte. Co., Ltd. Appareil et procédé de fabrication d'un moule
EP2022580A4 (fr) * 2006-05-16 2012-01-25 Lignyte Co Ltd Appareil et procédé de fabrication d'un moule
DE102006031191A1 (de) * 2006-07-04 2008-01-10 Dracowo Forschungs- Und Entwicklungs Gmbh Anorganische Kernsandbinder und Schlichten für den Aluminiumguss und ihre weitere Verwendung als Düngemittel
WO2019085124A1 (fr) * 2017-11-02 2019-05-09 深圳市爱能森科技有限公司 Noyau soluble à base de système de sel fondu ternaire, procédé de préparation s'y rapportant et application
CN114873601A (zh) * 2022-07-12 2022-08-09 天津包钢稀土研究院有限责任公司 利用微波加热低温合成纳米稀土硼化物材料的制备方法

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US20040238157A1 (en) 2004-12-02
JP4223830B2 (ja) 2009-02-12
JP2004249340A (ja) 2004-09-09
CN1524644B (zh) 2010-09-15
CN1524644A (zh) 2004-09-01

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