EP1604756A2 - method for producing metallic reticular structures - Google Patents

method for producing metallic reticular structures Download PDF

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Publication number
EP1604756A2
EP1604756A2 EP05011668A EP05011668A EP1604756A2 EP 1604756 A2 EP1604756 A2 EP 1604756A2 EP 05011668 A EP05011668 A EP 05011668A EP 05011668 A EP05011668 A EP 05011668A EP 1604756 A2 EP1604756 A2 EP 1604756A2
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EP
European Patent Office
Prior art keywords
webs
cuvette
metal
container
reticulated
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EP05011668A
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German (de)
French (fr)
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EP1604756A3 (en
EP1604756B1 (en
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Dieter Dr. Girlich
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mpore GmbH
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Girlich Dieter Dr
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Priority to PL05011668T priority Critical patent/PL1604756T3/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • B22D25/005—Casting metal foams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02—Lost patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02—Lost patterns
    • B22C7/023—Patterns made from expanded plastic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • B22C9/043—Removing the consumable pattern

Definitions

  • the invention relates to a method for producing metallic lattice structures in the form of open-pored foam.
  • Reticular structures of metal and other materials are due their properties a wide range of applications. For example, you can these structures as low weight components, accumulator plates, electrochemical anodes and cathodes, filters and mixers for fluids, catalyst, Gas absorbers, heat exchangers and many other applications be used.
  • U.S. Patent 3,616,841 discloses a method of manufacture a foam material having a predetermined reticulated structure. This method involves the preparation of a self-supporting reticulated Polyurethane foam; the production of a refractory mass by the cavities of the polyurethane foam with an aqueous molding material suspension are filled and this suspension sets; heating the refractory Mass at a temperature of about 120 ° C (250 ° F) over a period of two hours to dry; the creation of cavities in the refractory Molding composition by raising the temperature of the refractory molding composition to 650 to 850 ° C is increased to volatilize the entire foam; the introduction a molten substance consisting of metals or metal alloys, into the refractory molding compound, the amount of substance being sufficient to fill the cavities previously occupied by the reticulated structure were; and solidifying the molten substance in which the Temperature is reduced so that it is below the melting point of the substance lies; and washing out the material forming
  • DE 199 39 155 discloses a method for producing metallic lattice structures, in which a reticulated foam pre-structure in a hinged container is used, the foam preform with a refractory Material infiltrated and the refractory material is then solidified. Subsequently the solidified refractory material is removed from the hinged container, the foam pre-structure removed from the refractory material and the resulting, preheated body is inserted into a heat-resistant container. This body is infiltrated with a molten metal and after the Solidification of the molten metal removed from the heat-resistant container. Subsequently, the refractory material is removed from the body, thereby As a result, a reticular metal structure is obtained.
  • the object of the invention is therefore to overcome the disadvantages of the prior art remove. It is intended in particular a method for producing metallic Grid structures are given, which require less material and a faster production of such structures and consequent mass production allows.
  • the pre-structure by flat or separately thermally compressing the pre-structure so as to be external inward growing pores and thus a graded structure in the Having area of compression, and for the production of metallic lattice structures
  • a reticulated Prestructure preferably a PU foam structure to use, but whose Previously by single or multiple coating, by means of one or more various organic materials, to thicken.
  • Procedural steps the inflow of the metal is facilitated.
  • the mechanical properties of the structure can be targeted be influenced, wherein it is essential that the reproducibility of the characteristics is sustainably improved over the prior art.
  • the thickness of the Webs of PU foam structure the respective, from the purpose of the Metal grid structure determine requirements adapted.
  • the coating of the webs of the pre-structure by means of liquid and / or solid Materials provided, for. B. by dipping the Vor Quilt in liquid Wax and then coating with wax powder (this is another Melting temperature) or a polymer powder, such as polystyrene or polyamide powder, which also imply a small amount of adhesive, preferably 5% by volume can.
  • the use of powder prevents sticking of the Structure and ensures a uniformly thick layer, especially since there are no membranes Form (cell skins) between the webs.
  • VorDeutsch After such a Vortechnik has been generated, it is for the casting in fixed to a molding material.
  • the Vor Carl is inserted in register in a frame and with Molded material poured so that it is not completely covered, but rather a boundary of 2 to 5 mm remains free.
  • the remaining cavities are filled with sand and pressed.
  • the sheathing of the pre-structure is done with a ceramic slurry, the coating being optionally repeated, to create a stable layer.
  • the embedded molding can be used previously Need be reworked, such. B. by milling and drilling to nubs or to create other geometric shapes of solid material in the structure, or through holes to pipes by means of core pins in the structure pour.
  • the incorporation of consistent, but also non-consistent Holes, grooves or the like in the cast Vortechnik takes place according to the invention at a distance of at least two pores from each other. This process step has the consequence that the density of the material and consequently its stability can be increased application specific; At the same time there is a sustained improvement in thermal conductivity.
  • the Diameter of the recesses will be according to the strength requirements optimized
  • Vor Vor Modell by melting and / or burnout
  • this is the solidified Structure-ceramic composite removed from the frame and in a cuvette whose bottom is made of loose refractory material, preferably Foundry sand, filled, introduced.
  • the cuvette comprises a molding sand / ceramic stencil for the runners; In addition, it has insulation to prevent premature cooling of the molded part to prevent.
  • the cuvette consists of a pressed molding sand / ceramic composite, where the molding sand is recyclable and also the use of molding material is reduced to the necessary volume.
  • the cuvette with the molded part is placed in a pressure-resistant container, filled with liquid metal, the container closed and evacuated to the Molding and the melt to degas.
  • the melt By aerating the container is the Melt pressed into the molding.
  • the crucible is in the container, the cuvette is connected to the melt through a tube.
  • the Molded part removed from the cuvette.
  • the solidification can be directed over the cast metal parts done.
  • the preliminary structure can also by pouring granular mineral Substances or granular organic substances with a mineral coating be generated.
  • granular structures preferably in spherical Pellets
  • the pore sizes of the lattice structure substantially to expand.
  • PU foam structures usually pore sizes by Max. 5 ppi, which corresponds to an average pore diameter of 8 to 10 mm, can be hereby pore sizes in the range from 1 to 3 cm.
  • the pellets are large to each other glue, so that is sure that only the voids between the Pellets are used.
  • a coating of the preliminary structure thus created is not intended and not necessary because the desired ceramic Coating already exists. The other method steps according to the invention are retained.
  • the structure thus created presents itself as more diverse Lightweight material.

Abstract

The method for producing reticulated metal structures involves thickening of elements of reticulated foam structures by organic coatings, filling of the resultant structure with a fire-resistant compound, and removal of the foam structure by application of heat before casting operations.

Description

Die Erfindung betrifft ein Verfahren zur Herstellung metallischer Gitterstrukturen in Form offenporigen Schaums.The invention relates to a method for producing metallic lattice structures in the form of open-pored foam.

Retikuläre Strukturen aus Metall und anderen Materialien besitzen aufgrund ihrer Eigenschaften ein breites Anwendungsgebiet. Beispielsweise können diese Strukturen als Bauteile mit niedrigem Gewicht, Akkumulatorenplatten, elektrochemische Anoden und Kathoden, Filter und Mischer für Fluide, Katalysator, Gasabsorber, Wärmeüberträger und für zahlreiche weitere Anwendungen verwendet werden.Reticular structures of metal and other materials are due their properties a wide range of applications. For example, you can these structures as low weight components, accumulator plates, electrochemical anodes and cathodes, filters and mixers for fluids, catalyst, Gas absorbers, heat exchangers and many other applications be used.

Verfahren zur Herstellung retikulärer metallischer Strukturen sind seit längerem bekannt, wobei diese Verfahren in der Regel einer industriellen Anwendung aufgrund schwieriger Handhabbarkeit der eingesetzten Materialien, komplizierter Verfahrensschritte und hohem Zeitaufwand nicht genügen.Methods for producing reticular metallic structures have been for some time known, these methods usually an industrial application due to difficult handling of the materials used, more complicated Procedural steps and a high amount of time are not enough.

Beispielsweise offenbart das US-Patent 3.616.841 ein Verfahren zur Herstellung eines Schaummaterials mit einer vorbestimmten retikulierten Struktur. Dieses Verfahren umfaßt die Herstellung eines selbsttragenden retikulierten Polyurethanschaums; die Herstellung einer feuerfesten Masse, indem die Hohlräume des Polyurethanschaums mit einer wässerigen Formstoffsuspension gefüllt werden und diese Suspension abbindet; das Erhitzen der feuerfesten Masse auf eine Temperatur von etwa 120 °C (250 °F) über einen Zeitraum von zwei Stunden zum Trocknen; das Erzeugen von Hohlräumen in der feuerfesten Formmasse, indem die Temperatur der feuerfesten Formmasse auf 650 bis 850°C erhöht wird, um den gesamten Schaum zu verflüchtigen; das Einbringen einer geschmolzenen Substanz, die aus Metallen oder Metallegierungen besteht, in die feuerfeste Formmasse, wobei die Menge der Substanz ausreicht, um die Hohlräume zu füllen, die zuvor von der retikulierten Struktur eingenommen wurden; und das Verfestigen der geschmolzenen Substanz, in dem die Temperatur so verringert wird, daß sie unter dem Schmelzpunkt der Substanz liegt; und das Auswaschen des Materials, das die feuerfeste Formmasse bildet.For example, U.S. Patent 3,616,841 discloses a method of manufacture a foam material having a predetermined reticulated structure. This method involves the preparation of a self-supporting reticulated Polyurethane foam; the production of a refractory mass by the cavities of the polyurethane foam with an aqueous molding material suspension are filled and this suspension sets; heating the refractory Mass at a temperature of about 120 ° C (250 ° F) over a period of two hours to dry; the creation of cavities in the refractory Molding composition by raising the temperature of the refractory molding composition to 650 to 850 ° C is increased to volatilize the entire foam; the introduction a molten substance consisting of metals or metal alloys, into the refractory molding compound, the amount of substance being sufficient to fill the cavities previously occupied by the reticulated structure were; and solidifying the molten substance in which the Temperature is reduced so that it is below the melting point of the substance lies; and washing out the material forming the refractory molding compound.

Dieses Verfahren erscheint jedoch für eine industrielle Anwendung, insbesondere für eine automatisierte Herstellung retikulärer metallischer Strukturen aus folgenden Gründen nicht sonderlich gut geeignet: Die Schaumstruktur bestimmt die technischen Parameter des Endproduktes, so daß die statistische Schwankungsbreite möglichst gering sein muß, um das Erreichen der technischen Parameter des Endproduktes zu gewährleisten. Überdies ist es notwendig, um die verzweigten Hohlräume der feuerfesten Formmasse mit einem geschmolzenen Metall zu füllen, die Formmasse auf Temperaturen zu erwärmen, die über der Schmelztemperatur der verwendeten Substanz liegen. Das führt dazu, daß das Metall nur sehr langsam erstarrt, wodurch das erstarrte Metall eine grobkörnige Gefügestruktur erhält, die eine geringere Festigkeit der Struktur zur Folge hat. Zur Lösung dieses Problems schlägt US 3.616.841 verschiedene Kühlmethoden wie beispielsweise Besprühen mit Wasser oder Luft vor. Der Kühleffekt wird jedoch erheblich abgeschwächt, da die Formmasse den Wärmefluß behindert. Auch die Herstellung massiver Metallbereiche gemeinsam mit der Gitterstruktur ist mit dem Problem der sehr langsam erfolgenden Abkühlung verbunden. Die angegebenen Verfahrensschritte lassen eine gelenkte Erstarrung des Metalls, um eine lunkerfreie und feinkörnige Gefügestruktur zu erhalten, kaum bzw. nicht zu. Überdies führt die langsam verlaufende Erstarrung des Metalls zu langen Prozeßzeiten, die einer automatisierten Fertigung ebenfalls entgegenstehen.However, this method appears for industrial application, in particular for automated production of reticular metallic structures The following reasons are not very well suited: The foam structure determined the technical parameters of the final product, so that the statistical fluctuation range must be as low as possible to achieve the technical To ensure parameters of the final product. Moreover, it is necessary to the branched cavities of the refractory molding compound with a molten To fill metal, to heat the molding compound to temperatures that above the melting temperature of the substance used. This leads to, that the metal solidifies only very slowly, whereby the solidified metal a receives coarse-grained microstructure, which reduces the strength of the structure Episode has. To solve this problem, US 3,616,841 suggests various Cooling methods such as spraying with water or air before. Of the Cooling effect is, however, significantly attenuated because the molding material heat flow with special needs. The production of solid metal areas in common with the lattice structure is with the problem of very slow cooling connected. The specified process steps leave a steered Solidification of the metal to a void-free and fine-grained microstructure too received, hardly or not too. Moreover, the slow solidification leads the metal to long process times, the automated production also oppose.

DE 199 39 155 offenbart ein Verfahren zur Herstellung metallischer Gitterstrukturen, bei dem eine retikulierte Schaum-Vorstruktur in einen aufklappbaren Behälter eingesetzt wird, die Schaum-Vorstruktur mit einem feuerfesten Material infiltriert und das feuerfeste Material dann verfestigt wird. Anschließend wird das verfestigte feuerfeste Material aus dem aufklappbaren Behälter entnommen, die Schaum-Vorstruktur aus dem feuerfesten Material entfernt und der resultierende, vorgewärmte Körper in einen hitzebeständigen Behälter eingesetzt. Dieser Körper wird mit einer Metallschmelze infiltriert und nach dem Erstarren der Metallschmelze aus dem hitzebeständigen Behälter entnommen. Im Anschluß daran wird das feuerfeste Material aus dem Körper entfernt, wodurch im Ergebnis eine retikuläre Metallstruktur erhalten wird.DE 199 39 155 discloses a method for producing metallic lattice structures, in which a reticulated foam pre-structure in a hinged container is used, the foam preform with a refractory Material infiltrated and the refractory material is then solidified. Subsequently the solidified refractory material is removed from the hinged container, the foam pre-structure removed from the refractory material and the resulting, preheated body is inserted into a heat-resistant container. This body is infiltrated with a molten metal and after the Solidification of the molten metal removed from the heat-resistant container. Subsequently, the refractory material is removed from the body, thereby As a result, a reticular metal structure is obtained.

Vorteil dieses Verfahrens ist unter anderem, daß im Vergleich zu dem genannten US-Patent Nr. 3.616.841 ein Verkleben der Schaum-Vorstruktur mit dem Eingußsystem und dem Eingußtrichter nicht mehr nötig ist. Dadurch wird nicht nur der Material- und Zeitverbrauch bei der Herstellung der Gußform deutlich gesenkt, sondern auch eine automatisierte Herstellung von retikulären metallischen Strukturen möglich.Advantage of this method is, inter alia, that in comparison to the mentioned US Pat. No. 3,616,841 discloses adhering the foam precursor to the Pouring system and the pouring funnel is no longer necessary. It will not only the material and time consumption in the production of the mold clearly lowered, but also an automated production of reticular metallic Structures possible.

Auch wenn das in DE 199 39 155 offenbarte Verfahren eine deutliche Vereinfachung der Herstellung von retikulären metallischen Strukturen bietet, ist nicht zu übersehen, daß der Material- und Zeitaufwand noch immer vergleichsweise hoch ist, so daß zwar eine automatisierte Fertigung möglich, eine Serienfertigung derartiger Strukturen aber noch immer einem - im Vergleich zur Serienfertigung vergleichbarer Erzeugnisse - hohen Aufwand verbunden ist. Insbesondere die große Menge an Formstoff, die getrocknet, gebrannt und nicht in den Prozeß zurückgeführt werden kann, stellt einen nicht zu kompensierenden Kostenfaktor dar. Die isolierende Wirkung des Formstoffes erfordert lange Prozeßzeiten. Eine Produktion unter Marktbedingungen ist so nicht möglich.Even if the method disclosed in DE 199 39 155 a significant simplification The production of reticular metallic structures is not to overlook that the material and time expenditure is still comparatively is high, so that although an automated production possible, a series production such structures but still one - in comparison to the series production comparable products - high expenditure is connected. Especially the large amount of molding material, which is dried, fired and not in can be traced back to the process, represents an uncompensated Cost factor. The insulating effect of the molding material requires a long time Process times. A production under market conditions is not possible.

Aufgabe der Erfindung ist es daher, die Nachteile des Standes der Technik zu beseitigen. Es soll insbesondere ein Verfahren zur Herstellung metallischer Gitterstrukturen angegeben werden, das einen geringeren Materialeinsatz und eine schnellere Fertigung derartiger Strukturen und daraus folgend eine Serienfertigung ermöglicht.The object of the invention is therefore to overcome the disadvantages of the prior art remove. It is intended in particular a method for producing metallic Grid structures are given, which require less material and a faster production of such structures and consequent mass production allows.

Diese Aufgabe wird durch die Merkmale des Anspruchs 1 gelöst. Zweckmäßige Ausgestaltungen ergeben sich aus den Merkmalen der Ansprüche 2 bis 11. This object is solved by the features of claim 1. expedient Embodiments emerge from the features of claims 2 to 11.

Nach Maßgabe der Erfindung ist zunächst vorgesehen, daß durch flächiges oder separates thermisches Verpressen der Vorstruktur derart, daß sie von au-βen nach innen größer werdende Poren und damit einen gradierten Aufbau im Bereich der Verpressung aufweist, und für die Herstellung metallischer Gitterstrukturen zwar gleichfalls in grundsätzlich bekannter Weise eine retikulierte Vorstruktur, bevorzugt eine PU-Schaumstruktur, zu verwenden, aber deren Stege zuvor durch ein- oder mehrmaliges Beschichten, mittels eines oder mehrerer verschiedener organischer Materialien, zu verdicken. Überraschenderweise wurde nämlich gefunden, daß somit, gepaart mit den sonstigen erfindungsgemäßen Verfahrensschritten, das Einfließen des Metalls erleichtert wird. Gleichzeitig können so die mechanischen Eigenschaften der Struktur gezielt beeinflußt werden, wobei wesentlich ist, daß die Reproduzierbarkeit der Kennwerte gegenüber dem Stand der Technik nachhaltig verbessert ist.According to the invention, it is initially provided that by flat or separately thermally compressing the pre-structure so as to be external inward growing pores and thus a graded structure in the Having area of compression, and for the production of metallic lattice structures Although also in principle known a reticulated Prestructure, preferably a PU foam structure to use, but whose Previously by single or multiple coating, by means of one or more various organic materials, to thicken. Surprisingly namely, it was found that thus, coupled with the other invention Procedural steps, the inflow of the metal is facilitated. At the same time, the mechanical properties of the structure can be targeted be influenced, wherein it is essential that the reproducibility of the characteristics is sustainably improved over the prior art.

Durch Änderung der Rezeptur und/oder der Prozeßführung wird die Dicke der Stege der PU-Schaumsstruktur den jeweiligen, vom Verwendungszweck der Metallgitterstruktur bestimmen Anforderungen angepaßt. Erfindungsgemäß ist das Beschichten der Stege der Vorstruktur mittels flüssigen und/oder festen Materialien vorgesehen, z. B. durch Eintauchen der Vorstruktur in flüssiges Wachs und anschließendem Beschichten mit Wachspulver (das eine andere Schmelztemperatur hat) oder einem Polymerpulver, etwa Polystyrol- oder Polyamidpulver, die auch einen geringen Anteil Kleber, bevorzugt 5 Vol.%, implizieren können. Namentlich der Einsatz von Pulver verhindert ein Verkleben der Struktur und sichert eine gleichmäßig dicke Schicht zumal sich keine Membranen (Zellhäute) zwischen den Stegen ausbilden.By changing the recipe and / or the process control, the thickness of the Webs of PU foam structure the respective, from the purpose of the Metal grid structure determine requirements adapted. According to the invention the coating of the webs of the pre-structure by means of liquid and / or solid Materials provided, for. B. by dipping the Vorstruktur in liquid Wax and then coating with wax powder (this is another Melting temperature) or a polymer powder, such as polystyrene or polyamide powder, which also imply a small amount of adhesive, preferably 5% by volume can. In particular, the use of powder prevents sticking of the Structure and ensures a uniformly thick layer, especially since there are no membranes Form (cell skins) between the webs.

Nachdem derart die Vorstruktur erzeugt wurde, wird sie für den Gießvorgang in einem Formstoff fixiert.After such a Vorstruktur has been generated, it is for the casting in fixed to a molding material.

Hierbei wird die Vorstruktur paßgenau in einen Rahmen eingelegt und mit Formstoff so ausgegossen, daß sie nicht vollständig umhüllt ist, sondern vielmehr eine Berandung von 2 bis 5 mm frei bleibt. Die verbleibenden Hohlräume werden mit Sand gefüllt und verpreßt. Die Umhüllung der Vorstruktur erfolgt mit einem Keramikschlicker, wobei die Umhüllung gegebenenfalls wiederholt wird, um eine stabile Schicht zu erzeugen. Das eingebettete Formteil kann zuvor bei Bedarf nachgearbeitet werden, so z. B. durch Fräsen und Bohren, um Noppen oder andere geometrische Gebilde aus festem Material in der Struktur zu erzeugen, oder durch Durchbohrungen, um mittels Kernstifte Rohre in die Struktur einzugießen. Die Einarbeitung von durchgängigen, aber auch nichtdurchgängigen Bohrungen, Rillen oder dergleichen in die eingegossene Vorstruktur erfolgt erfindungsgemäß in einem Abstand von wenigstens zwei Poren zueinander. Dieser Verfahrensschritt hat zur Folge, daß die Dichte des Werkstoffes und daraus folgend seine Stabilität anwendungsspezifisch erhöht werden kann; gleichzeitig ergibt sich eine nachhaltig verbesserte Wärmeleitfähigkeit. Die Durchmesser der Aussparungen werden entsprechend den Festigkeitsanforderungen an den Werksstoff optimiert.Here, the Vorstruktur is inserted in register in a frame and with Molded material poured so that it is not completely covered, but rather a boundary of 2 to 5 mm remains free. The remaining cavities are filled with sand and pressed. The sheathing of the pre-structure is done with a ceramic slurry, the coating being optionally repeated, to create a stable layer. The embedded molding can be used previously Need be reworked, such. B. by milling and drilling to nubs or to create other geometric shapes of solid material in the structure, or through holes to pipes by means of core pins in the structure pour. The incorporation of consistent, but also non-consistent Holes, grooves or the like in the cast Vorstruktur takes place according to the invention at a distance of at least two pores from each other. This process step has the consequence that the density of the material and consequently its stability can be increased application specific; At the same time there is a sustained improvement in thermal conductivity. The Diameter of the recesses will be according to the strength requirements optimized to the material.

Ein wesentlicher weiterer Verfahrensschritt ist die thermische Entfernung der Vorstruktur durch Ausschmelzen und/oder Ausbrennen, hierfür wird der verfestigte Struktur-Keramikverbund aus dem Rahmen herausgenommen und in eine Küvette, deren Boden mit losem feuerfesten Material, vorzugsweise Gießereisand, gefüllt ist, eingebracht. Alternativ ist es auch möglich das Formteil ohne Küvette mittels Infrarot oder Mikrowellen zu trocknen und auszubrennen.An essential further process step is the thermal removal of Vorstruktur by melting and / or burnout, this is the solidified Structure-ceramic composite removed from the frame and in a cuvette whose bottom is made of loose refractory material, preferably Foundry sand, filled, introduced. Alternatively, it is also possible the molding without cuvette by means of infrared or microwaves to dry and burn out.

Die Küvette umfaßt eine Schablone aus Formsand/Keramik für die Gießkanäle; zudem besitzt sie eine Isolierung, um ein vorzeitiges Auskühlen des Formteiles zu verhindern. Vorzugsweise besteht die Küvette aus einem gepreßten Formsand/Keramikverbund, wobei der Formsand recycelbar und zudem die Verwendung von Formstoff auf das notwendige Volumen reduziert ist.The cuvette comprises a molding sand / ceramic stencil for the runners; In addition, it has insulation to prevent premature cooling of the molded part to prevent. Preferably, the cuvette consists of a pressed molding sand / ceramic composite, where the molding sand is recyclable and also the use of molding material is reduced to the necessary volume.

Diesen Verfahrensschritten schließt sich das Gießen und Gutformen an. Die Küvette mit dem Formteil wird hierzu in einen druckfesten Behälter eingebracht, mit flüssigem Metall gefüllt, der Behälter geschlossen und evakuiert, um das Formteil und die Schmelze zu entgasen. Durch Belüften des Behälters wird die Schmelze in das Formteil gepreßt. Der Schmelztiegel befindet sich im Behälter, die Küvette ist durch ein Rohr mit der Schmelze verbunden.These process steps are followed by casting and molding. The For this purpose, the cuvette with the molded part is placed in a pressure-resistant container, filled with liquid metal, the container closed and evacuated to the Molding and the melt to degas. By aerating the container is the Melt pressed into the molding. The crucible is in the container, the cuvette is connected to the melt through a tube.

Nach dem Gießen und dem Erstarren der äußersten Metallschicht wird das Formteil aus der Küvette entnommen. Die Erstarrung kann gerichtet über die angegossenen Metallteile erfolgen.After casting and solidification of the outermost metal layer is the Molded part removed from the cuvette. The solidification can be directed over the cast metal parts done.

Grundsätzlich kann die Vorstruktur auch durch Schüttung granularer mineralischer Stoffe oder granularer organischer Stoffe mit einem mineralischen Überzug erzeugt werden. Durch solche granularen Strukturen, bevorzugt in kugelförmigen Pellets, ist es möglich, die Porengrößen der Gitterstruktur wesentlich zu erweitern. Während mit PU-Schaumstrukturen üblicherweise Porengrößen von max. 5 ppi, das entspricht einen mittleren Porendurchmesser von 8 bis 10 mm, erzeugt werden können, lassen sich hiermit Porengrößen im Bereich von 1 bis 3 cm realisieren. Hierzu sind die Pellets großflächig miteinander zu verkleben, damit sicher ist, daß als Gießkanal nur die Hohlräume zwischen den Pellets genutzt werden. Eine Beschichtung der damit geschaffenen Vorstruktur ist nicht vorgesehen und auch nicht notwendig, da der gewünschte keramische Überzug bereits vorhanden ist. Die sonstigen erfindungsgemäßen Verfahrensschritte werden beibehalten. Die so erzeugte Struktur bietet sich als vielfältiger Leichtbauwerkstoff an.Basically, the preliminary structure can also by pouring granular mineral Substances or granular organic substances with a mineral coating be generated. By such granular structures, preferably in spherical Pellets, it is possible, the pore sizes of the lattice structure substantially to expand. While with PU foam structures usually pore sizes by Max. 5 ppi, which corresponds to an average pore diameter of 8 to 10 mm, can be hereby pore sizes in the range from 1 to 3 cm. For this purpose, the pellets are large to each other glue, so that is sure that only the voids between the Pellets are used. A coating of the preliminary structure thus created is not intended and not necessary because the desired ceramic Coating already exists. The other method steps according to the invention are retained. The structure thus created presents itself as more diverse Lightweight material.

Nachfolgend wird die Erfindung anhand von Ausführungsbeispielen näher erläutert. Dabei zeigen

  • Fig. 1 in schematischer Darstellung einen Ausschnitt der beschriebenen retikulierten Vorstruktur, ausgeführt als PU-Schaumstruktur 1 (Vorstruktur) mit den Stegen 2;
  • Fig. 2 die PU-Schaumstruktur 1 mit der Beschichtung 3, die sich bevorzugt aus zwei Schichten, nämlich einer Schicht, die aus flüssigem Wachs erzeugt ist, und einer Polymerschicht, zusammensetzt;
  • Fig. 3 die mit dem Formstoff 4 (Keramikschlicker) umhüllte PU-Schaumstruktur 1, die so in beschriebener Weise bearbeitet werden kann;
  • Fig. 4 in Draufsicht die mögliche Form (kreisförmig, oval) von Pellets 7, die aus granularen mineralischen Stoffen oder granularen organischen Stoffen mit einem mineralischen Überzug bestehen, und durch Schüttung und Verklebung zusammengefügt sind, wobei sich die so erzeugte Vorstruktur gegenüber der PU-Schaumstruktur 1 durch wesentlich vergrößerte Poren auszeichnet;
  • Fig. 5 den gebrannten Formstoff/Formteil 5 und die Poren 6, die durch das thermische Entfernen der Stege entstanden sind;
  • Fig. 6 das Formteil 5, das in die Küvette 8 eingebracht ist;
  • Fig. 7 die Küvette 8, die ihrerseits in den druckfesten Behälter 9 eingebracht ist.
    • The invention will be explained in more detail by means of exemplary embodiments. Show
  • Figure 1 shows a schematic representation of a section of the described reticulated Vorstruktur, executed as PU foam structure 1 (Vorstruktur) with the webs 2.
  • 2 shows the PU foam structure 1 with the coating 3, which is preferably composed of two layers, namely a layer which is produced from liquid wax, and a polymer layer;
  • FIG. 3 shows the PU foam structure 1 encased in the molding material 4 (ceramic slip), which can be processed in the manner described; FIG.
  • 4 shows in plan view the possible shape (circular, oval) of pellets 7, which consist of granular mineral substances or granular organic substances with a mineral coating, and are joined together by pouring and bonding, wherein the preliminary structure thus produced is opposite to the PU Foam structure 1 characterized by significantly enlarged pores;
  • 5 shows the fired molding material / molded part 5 and the pores 6, which are formed by the thermal removal of the webs;
  • 6 shows the molded part 5, which is introduced into the cuvette 8;
  • Fig. 7, the cuvette 8, which in turn is introduced into the pressure-resistant container 9.

    • Liste der verwendeten BezugszeichenList of reference numbers used

    11
    PU-Schaumstruktur (Vorstruktur)PU foam structure (pre-structure)
    22
    Stegweb
    33
    Beschichtungcoating
    44
    Formstoffmolding
    55
    gebrannter Formstoff/Formteilburned molding material / molding
    66
    Porepore
    77
    Pelletpellet
    88th
    Küvettecuvette
    99
    Behältercontainer

    Claims (11)

    Verfahren zur Herstellung metallischer Gitterstrukturen unter Verwendung einer retikulierten Struktur, bevorzugt einer retikulierten Schaumstruktur, bei dem die durch solche Strukturen gebildeten Gießkanäle vor dem Einfüllen des Metalls mittels organischer Materialien stabilisiert werden, dadurch gekennzeichnet, daß es die Schritte (a) Flächiges oder separates thermisches Verpressen der Vorstruktur derart, daß sie von außen nach innen größer werdende Poren und damit einen gradierten Aufbau im Bereich der Verpressung aufweist; (b) Verdicken der Stege der retikulierten Struktur durch ein- oder mehrmaliges Beschichten mittels eines organischen Materials oder verschiedener, dann bevorzugt zweier organischer Materialien; (c) Einlegen der beschichteten Struktur in einen formschlüssigen, oben offenen Behälter und Ausgießen der Struktur mit einer feuerfesten Masse; (d) Einarbeiten von durchgängigen und/oder nicht durchgängigen Bohrungen, Rillen oder dergleichen in die eingegossene Vorstruktur mit einem Abstand von wenigstens zwei Poren zueinander; (e) Entnahme des verfestigten Struktur/Keramik-Verbundes aus den Behälter und Einbringen in eine Küvette, deren Boden mit losem feuerfesten Material gefüllt ist; (f) Entfernen der Vorstruktur durch thermische Umsetzung in einen Ofen; (g) Einbringen der Küvette in einen druckfesten Behälter; (h) Aufsetzen einer Gießereischablone aus Formsand oder Keramik so auf die Küvette und die obere Fläche des Keramikkörpers, daß die Ränder des Keramikkörpers als Gießkanal frei bleiben und die Gießschablone eine Isolierung zur Küvette bildet, um ein vorzeitiges Erstarren des einzugießenden Metalls zu vermeiden; (i) Einfüllen des Metalls/Schließen des druckfesten Behälters; (j) Evakuieren des druckfesten Behälters, um Metall und Platzhalter zu entgasen; und (k) Belüften des Behälters, Küvette entnehmen und abkühlen lassen; umfaßt.A method for producing metallic lattice structures using a reticulated structure, preferably a reticulated foam structure, in which the casting channels formed by such structures are stabilized prior to filling the metal by means of organic materials, characterized in that it comprises the steps (a) surface or separate thermal compression of the pre-structure in such a way that it has pores which increase from outside to inside and thus a graded structure in the region of the compression; (B) thickening of the webs of the reticulated structure by one or more times coating by means of an organic material or different, then preferably two organic materials; (c) placing the coated structure in a positive, open-topped container and pouring the structure with a refractory mass; (D) incorporation of continuous and / or non-continuous holes, grooves or the like in the cast-in pre-structure with a distance of at least two pores to each other; (e) removing the solidified structure / ceramic composite from the container and placing it in a cuvette the bottom of which is filled with loose refractory material; (f) removing the pre-structure by thermal conversion to an oven; (g) placing the cuvette in a pressure-resistant container; (H) placing a foundry stencil of molding sand or ceramic on the cuvette and the upper surface of the ceramic body, that the edges of the ceramic body remain free as a pouring channel and the Gießschablone an insulation to the cuvette to prevent premature solidification of the metal to be infused; (i) filling the metal / closing the pressure-resistant container; (j) evacuating the pressure-resistant container to degas metal and blank; and (k) vent the container, remove the cuvette and allow to cool; includes. Verfahren zur Herstellung metallischer Gitterstrukturen nach Anspruch 1, dadurch gekennzeichnet, daß das zur Beschichtung der Stege dienende organische Material flüssiges Wachs ist.Process for producing metallic lattice structures according to Claim 1, characterized in that the organic material used to coat the webs is liquid wax. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß das zur Beschichtung der Stege dienende organische Material ein Wachspulver ist.A method according to claim 1, characterized in that the organic material used to coat the webs is a wax powder. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß das zur Beschichtung der Stege dienende organische Material Polystyrol-Pulver ist.Process according to Claim 1, characterized in that the organic material used to coat the webs is polystyrene powder. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß das zur Beschichtung der Stege dienende organische Material Polyamid-Pulver ist.A method according to claim 1, characterized in that the organic material serving to coat the webs is polyamide powder. Verfahren nach Anspruch 1, 4 und 5, dadurch gekennzeichnet, daß das Polystyrol/Polyamid einen geringen, bevorzugt 5 %-igen, Anteil Kleber impliziert. A method according to claim 1, 4 and 5, characterized in that the polystyrene / polyamide implies a small, preferably 5%, proportion of adhesive. Verfahren nach Anspruch 1 bis 6, dadurch gekennzeichnet, daß bei mehrfacher Beschichtung der Stege der retikulierten Struktur die einzelnen Beschichtungen bei unterschiedlichen Temperaturen im Bereich von 40 bis 80 °C aufgebracht werden.Process according to Claims 1 to 6, characterized in that, when the webs of the reticulated structure are coated several times, the individual coatings are applied at different temperatures in the range from 40 to 80 ° C. Verfahren nach Anspruch 1 bis 7, dadurch gekennzeichnet, daß die Mehrfachbeschichtung der Stege mit zwei Wachsmodifikationen, die unterschiedliche Schmelztemperaturen aufweisen, durchgeführt wird.Process according to Claims 1 to 7, characterized in that the multiple coating of the webs is carried out with two wax modifications which have different melting temperatures. Verfahren nach Anspruch 1 bis 7, dadurch gekennzeichnet, daß die Mehrfachbeschichtung der Stege mit einer Wachs- und einer Pulverschicht erzeugt wird.A method according to claim 1 to 7, characterized in that the multiple coating of the webs with a wax and a powder layer is produced. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß das lose feuerfeste Material, gemäß Verfahrensschritt (c), Gießereisand ist.A method according to claim 1, characterized in that the loose refractory material, in accordance with process step (c) is foundry sand. Verfahren nach Anspruch 1, dadurch gekennzeichnet, daß als Vorstruktur aufgeschüttete granulare mineralische Stoffe oder granulare organische Stoffe mit mineralischem Überzug verwendet werden.Process according to Claim 1, characterized in that granular mineral substances or granular organic substances with a mineral coating which have been poured on as a preliminary structure are used.
    EP05011668A 2004-06-02 2005-05-31 method for producing metallic reticular structures Not-in-force EP1604756B1 (en)

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    EP3047923A1 (en) * 2015-01-20 2016-07-27 United Technologies Corporation Investment technique for solid mold casting of reticulated metal foams
    EP3047922A1 (en) * 2015-01-20 2016-07-27 United Technologies Corporation Dual investment technique for solid mold casting of reticulated metal foams
    US9737930B2 (en) 2015-01-20 2017-08-22 United Technologies Corporation Dual investment shelled solid mold casting of reticulated metal foams
    US9789536B2 (en) 2015-01-20 2017-10-17 United Technologies Corporation Dual investment technique for solid mold casting of reticulated metal foams
    US9789534B2 (en) 2015-01-20 2017-10-17 United Technologies Corporation Investment technique for solid mold casting of reticulated metal foams
    US10029302B2 (en) 2015-01-20 2018-07-24 United Technologies Corporation Dual investment shelled solid mold casting of reticulated metal foams
    US10252326B2 (en) 2015-01-20 2019-04-09 United Technologies Corporation Dual investment technique for solid mold casting of reticulated metal foams
    US10035174B2 (en) 2015-02-09 2018-07-31 United Technologies Corporation Open-cell reticulated foam

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    PL1604756T3 (en) 2007-08-31
    DE102004026959B3 (en) 2006-02-16
    EP1604756B1 (en) 2007-03-21

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