EP1631403B1 - Verfahren zur hestellung eines kern- und/oder formsandes für giessereizwecke - Google Patents

Verfahren zur hestellung eines kern- und/oder formsandes für giessereizwecke Download PDF

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Publication number
EP1631403B1
EP1631403B1 EP04739801A EP04739801A EP1631403B1 EP 1631403 B1 EP1631403 B1 EP 1631403B1 EP 04739801 A EP04739801 A EP 04739801A EP 04739801 A EP04739801 A EP 04739801A EP 1631403 B1 EP1631403 B1 EP 1631403B1
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EP
European Patent Office
Prior art keywords
additive
weight
grains
sand
less
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.)
Revoked
Application number
EP04739801A
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German (de)
English (en)
French (fr)
Other versions
EP1631403A2 (de
Inventor
Karl Koch
Cornelis Grefhorst
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.)
S & B Industrial Minerals GmbH
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S & B Industrial Minerals GmbH
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Application filed by S & B Industrial Minerals GmbH filed Critical S & B Industrial Minerals GmbH
Priority to PL04739801T priority Critical patent/PL1631403T3/pl
Publication of EP1631403A2 publication Critical patent/EP1631403A2/de
Application granted granted Critical
Publication of EP1631403B1 publication Critical patent/EP1631403B1/de
Anticipated expiration legal-status Critical
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
    • B22C1/167—Mixtures of inorganic and organic binding agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds

Definitions

  • the present invention relates to a method for producing a core and / or foundry sand for foundry purposes, after which a granular mineral molding base material, such as quartz sand, is mixed with an additive based on an organic and inorganic component, optionally with the addition of a binder, and wherein the mixture comprises substantially additive granules and molding matrix grains and / or aggregate granules of the additive and molding material.
  • a granular mineral molding base material such as quartz sand
  • the core sand for foundry purposes is used as usual to define cores in castings.
  • the foundry sand is generally understood to mean a sand, which dictates the outer shape of the casting concerned.
  • Core sand and foundry sand generally fall under the generic term foundry sand.
  • the granular mineral mold base material is meant a mineral base in granular form to represent the desired foundry mold.
  • This molding material is usually present at 80 to 90 wt .-%, preferably more than 90 wt .-%, most preferably more than 95 wt .-% in the mixture with the additive and optionally the binder before.
  • the weights are in each case based on the finished mixture.
  • the associated molding base grains have an average grain size of up to 0.5 mm, mainly in the range between 0.10 mm and 0.30 mm.
  • a method of the type described above is disclosed in DE 196 09 539 A1.
  • This is a composition containing foundry sand and an additive, the additive comprising cryolite.
  • Cryolite is known to be the mineral class of halides that characterize the compounds of metals with fluorine, chlorine, bromine and iodine. Cryolite is widely used in aluminum metallurgy.
  • a mixture of zeolite ie an inorganic component
  • at least a component of minerals, wood flours, organic fiber material, carbohydrates, carbon, etc. use ie an organic component
  • the metallic material flowing into the foundry mold produced from the foundry sand or core sand and / or foundry sand causes a thermally induced expansion of the respective molding material (the molded foundry sand) as a result of its heat radiation and thermal conduction.
  • temperature differences occur in individual molding zones, resulting in considerable stress differences. If the mechanical-thermal stresses associated with the stress differences exceed the deformability and the tensile strength of the molded part in the load cross-section and if the casting material is sufficiently flowable, then flaws appear due to liquid metal penetrating into cracks.
  • the actual casting process optionally leads to fine cracks in the molding material or foundry sand or foundry molding sand, in which the liquid metal can penetrate.
  • the metal thus leaves its predetermined shape, these flaws are referred to as expansion defects, furrows, leaf ribs, etc.
  • Leaf veins are formed preferentially when using chemically bonded molding materials on the inner contours (cores of the castings). Such leaf ribs are therefore difficult to access and require a time and cost consuming Post-processing by brushing the produced casting. Sometimes the leaf ribs can not be removed.
  • the cores concerned have been provided with a refractory coating by spraying, dipping, etc. by the process of so-called core finishing. This is intended to prevent or at least reduce the penetration of the liquid metal into the described fine cracks.
  • the core finishing is associated with considerable effort.
  • the additive comprises the mineral cryolite and additionally, for example, wood flour, organic fiber material, etc.
  • GB 1 444 280 A has disclosed a process for the production of a foundry molding material in which sand, an organic binder and bitumen are used.
  • the invention is based on the technical problem of further developing a method of the procedure described above so that not only are faulty effects on castings reduced or completely prevented, but also the cast piece produced has a flawless surface.
  • the additive (the additive granules) based on the organic and inorganic components added to the granular mineral molding base material is coarse-grained or pelletized with the mineral molding base material before mixing, more than 50% by weight of the respective grains having a particle size of at least approx. 05 mm.
  • the aggregate grains can also be ground or pelletized accordingly. It is therefore important that the additive grains and / or the aggregate grains are present as ground grains or corresponding pellets with the specified particle size.
  • the pellets can be produced by pelletizing powders. This then applies to both the additive grains and the aggregate grains.
  • the finished mixture is consequently composed of the molding material at the values already stated in the introduction (80-90% by weight, preferably more than 90% by weight and more preferably more than 95% by weight) and the remainder additive plus optionally binder together.
  • the molding material grains have the specified average particle size of less than 0.50 mm, generally in the range from 0.10 mm to 0.30 mm.
  • the additive grains ie the grains of the additive, of which more than 50% by weight (based on the additive) have a particle size of at least approximately 0.05 mm, are then added to this molding base material.
  • aggregate grains or an aggregate are used alternatively or additionally, ie mold base grains having an envelope of the additive, these are likewise present with the specified particle size spectrum of more than 50% by weight with a particle size of at least about 0.05 mm ago. Also in this case, the proportion by weight of the molding base material (based on the finished mixture) is measured at the indicated values (more than 80% by weight). The same applies to the additive (less than 20% by weight).
  • the additive grains and / or aggregate grains Preferably even more than 80 wt .-%, in particular more than 90 wt .-% of the additive grains and / or aggregate grains have a particle size of at least about 0.05 mm.
  • the previously mentioned particle size distributions are usually determined by known sieving processes in that the starting material to be screened is usually treated with the aid of one or more mechanical screening operations with regard to the required particle size. If the specified grain size has not yet been reached in the course of the described preceding grinding process, appropriately discharged fractions of the grains are circulated until the specified particle size distribution is present. It can be used for the grinding process on conventional mills such as roller mills, ball mills, or optionally muller gear. An ultra-rotor mill is also conceivable.
  • the additive grains and / or aggregate grains are always separated by screening (with the aid of mechanical sieves or by air classification) into or directly after the relevant mill into the fraction with the desired particle size and the material which is still too coarse to be recycled. The latter is thus in an indeterminate long cycle.
  • my approach will be when the additive granules and / or aggregate grains have attained their coarseness by pelletizing powders.
  • the desired grain fineness is provided by the described screening - optionally in conjunction with a grinding process - provided. That is, the processes of milling and pelletizing the additive grains and / or aggregate grains can be used both as an alternative and as a combination according to the invention.
  • the organic component takes into account the expansion of the molded part.
  • the inorganic component increasingly softens on a regular mineral basis or may also react with the molding material. All this means that possible compressive stresses are reduced by an expansion of the molding material or mold base material, in particular in the region of the core.
  • the additive or aggregate must be present overall coarse-grained in the described particle size distribution, so that the specific surface is reduced in size compared to a fine grain distribution (with grains smaller than 0.05 mm).
  • This reduction of the specific surface area of the additive or aggegate has the consequence that the binder consumption or consumption of binder in the production of the foundry cores or molds is lower than when a fine-grained additive is used, namely at comparable strengths of the molded part.
  • the binder addition is reduced with the same strength, of course, problems are reduced, which can result in the subsequent casting process by the volatilization of the binder and its partial burning.
  • the formation of a reducing gas atmosphere in the organic component of the additive ensures that binder decomposition is delayed in this process (the burning of the binder) and that expansion of the molding assumes increased values only at relatively high temperatures.
  • the released carbon of the organic component provides for the described reducing gas atmosphere which delays binder decomposition by its oxygen consumption. Consequently, the binder ensures that the molded part retains its shape over a wide temperature range and that the expansion of the molded part assumes increased values only at the higher temperatures mentioned.
  • the organic component of the additive at most about 60 wt .-%, preferably at most 50 wt .-% of up to temperatures of about 250 ° C to 500 ° C, in particular about 400 ° C has up to 500 ° C, preferably up to about 500 ° C, volatile ingredients. Because of this design rule ensures that the organic component during heating of the respective molded part, ie during the casting process, develops relatively little gas. The probability of the occurrence of flaws thereby decreases significantly. That is, as soon as the foundry mold or the core and / or foundry sand according to the invention has reached the indicated temperature (about 250 ° C. to 800 ° C., in particular about 400 ° C.
  • the solubility and volatility of generally organic compounds, hence the organic component of the additive are determined by the particular molecular size and intermolecular interactions. Small molecules tend to volatilize rather than large, and so do molecules that have lower binding energy than others. Accordingly, the preceding weight fraction of volatile ingredients of at most about 60 wt .-% and preferably at most about 50 wt .-% of the organic component of the additive, taking into account a heating in the range of about 250 ° C to 800 ° C, especially in the range of about 400 ° C to 500 ° C, preferably up to about 500 ° C easily adjust.
  • the oxygen content of the (organic) component is less than 30 wt .-%, in particular less than 20 wt .-% (based on the (organic) component).
  • This aspect also contributes to the fact that the binder decay is delayed. Because during the casting process, the volatilization and partial shrinkage of the binder causes the core in particular to shrink and then expand. This shrinkage process and concomitant binder decay is delayed when little oxygen escapes from the (organic) component, which favors the combustion process.
  • the limitation of the oxygen content of the preferably organic component of the additive ensures that in the casting process, the forming reducing gas atmosphere of the organic component of the additive is even able to slow down the binder decomposition and is not bound only by the liberated oxygen.
  • the organic component accounts for up to 90% by weight and the inorganic component for up to 80% by weight of the additive, the sum of organic and inorganic components being of course 100% by weight. Because, in conjunction with the fact that the organic component contains 50 to 98 wt .-% carbon or coal or hydrocarbons, a further advantage arises. This is because in the casting process and the associated Verflhouungsrea the organic component due to the high carbon content of the carbon is present in the gas phase or is introduced into the gas phase formed from the volatilizing organic component. Because the organic component partially inflates, becomes plastic and releases its volatile components to the outside, so that this carbon particles are free and can form bright coal from the gas phase. In this case, the lustrous carbon is able to ensure between molding and metal casting that the separating layer is maintained properly. As a result, the casting surface can be improved, so that it is generally possible to dispense with the core finishing described above.
  • coal Usually come as organic substances coal, hydrocarbon resins, bitumen, organic fiber materials, possibly oils, natural resins, etc. are used.
  • the invention recommends the use of perlites, spodumene, chromite, glass, foam glass, colemanite, mica, iron oxide or light ceramic materials, which optionally have a surface impregnation.
  • the water content of the additive is regularly less than 10 wt .-%.
  • the mixture of the granular mineral molding material and the additive can be dry. But it is also conceivable that the grains of the molding base material are coated with or from the additive.
  • the additive can be glued together with a binder coat or a corresponding binder on the mold base grains or can be the mold base grains with the additive optionally impregnated with the aid of the mentioned binder.
  • the mixture means that the respective grain of the molding material is disposed inside an additive shell, wherein the aggregate grain thus formed unchanged, the required particle size distribution of more than 50 wt .-% of the grains having a grain size of at least about 0.05 mm has. That is, the described blend includes aggregate granules of the additive and the masterbatch as described. Such aggregate grains are usually distinguished by the fact that the respective molding material grain is equipped with the coating of the additive.
  • the organic component in the additive favors the nuclear decay, whereby the core sand with additive residues is added to the remaining molding sand for the external form.
  • This molding sand usually has bentonite.
  • the additive acts like a lustrous carbon former in this case. So he has a dual function.
  • the additive according to the invention ensures that defects in the core of a casting are reduced or completely suppressed, and this applies in particular to leaf ribs. In addition, a very smooth surface compared to earlier achieved. In addition, the not inconsiderable and already described above carbon content in the additive in question to the effect that when mixing the core sand with the rest of the molding sand, the carbon as a gloss carbon (substance) channer for the entire casting, core and form effect.
  • Fig. 1 illustrates the individual process steps in the production of the foundry molding sand according to the invention.
  • core sand for the core of the casting to be produced
  • core sand for the external shape
  • Both different sands can also be produced according to the same procedure.
  • the binder already described for example, phenolic resin, in particular PUR or polyurethane resin
  • the coarse-grained additive of the organic and inorganic component for example, phenolic resin, in particular PUR or polyurethane resin
  • molding sand so-called loop sand, as well as new sand in conjunction with bentonite and a lustrous carbon, is used.
  • the additive according to the invention assumes all or part of the function of the lustrous carbon former for the foundry sand for the production of the outer mold. Due to the coarse structure of the additive according to the invention, the binding capacity of the binder in the production of the core sand is only minimally affected, taking into account a reduced binder consumption. At the same time, the described additive provides for an improved casting surface, so that the described finishing or core finishing is not necessary. Finally, the additive has a positive effect when mixed with the molding sand on the rest of the molding sand, because it can wholly or partly take over the function of the lustrous carbon-forming agent.
  • the core sand is mixed with the molding sand, so that thereby the existing in the core sand additive also enters the molding sand.
  • This can reduce the addition of lustrous carbon formers to the foundry sand.
  • the binder also passes over the core sand into the foundry sand. After sand preparation, the cycle sand thus obtained serves as a molding base for the molding sand.
  • the grain size of the additive according to the invention has an effect on the achieved strengths of the core sand.
  • quartz sand in a mean particle size of 0.19 mm to 0.30 mm has been used as a granular mineral molding material. It turns out that the strength is greatest when more than 90% by weight of the grains of the additive have a size of 0.09 mm or more. This applies over the entire hardening times shown up to 24 hours.
  • the curing times refer to the casting produced in the foundry mold.
  • the relative bond strength of the molding and / or core sand according to the invention has been determined on the basis of the expansion behavior. In this connection, the expansion / shrinkage behavior was determined and evaluated with the aid of a molding material dilatometer.
  • a grain size at which only 5% by weight of the ground grains of the additive are formed to be larger than 0.09 mm causes the relative bending strength to be significantly reduced.
  • the additive according to the invention was added to 3% by weight of the quartz sand.
  • the binder has a proportion of about 0.8 wt .-%, in each case based on the core sand mixture or foundry sand as a whole, taken.
  • the volatile constituents of the organic component of the additive Due to the inventive limitation of the volatile constituents of the organic component of the additive to a maximum of 60 wt .-%, preferably at most 50 wt .-%, based on the weight of the organic component as a whole, the gas evolution in comparison to previously used additives such Reduce wood flour and starch by 60 to 80%. It is very particularly preferred for the organic component of the additive to have a maximum of about 35% by weight of volatile constituents (in each case in the temperature range up to about 800 ° C.).
  • the time is extended to the maximum gas evolution due to the heating of the molding material over the prior art.
  • the maximum gas evolution in the additive according to the invention occurs only after more than 100 sec., Preferably even after a time of more than 2 minutes.
  • the maximum gas evolution in the prior art in wood flour or starch already after about 1 minute or 60 to 70 sec. Instead.
  • the decomposition of the binder or binder during casting is delayed overall because the organic component has little oxygen contains and incidentally, the gas evolution starts only after a longer time and therefore higher temperature of the core sand compared to the prior art.
  • the entire expansion of the core sand and the associated compressive stress is delayed, so that as a result, the formation of flaws in the casting is reduced.
  • This quartz sand of specification H 33 that is mixed with an average particle size of about 0.19 to 0.30 mm with the following components in a wing mixer.
  • About 0.6 wt .-% of a phenolic resin and 0.6 wt .-% isocyanate is used as a binder or binder.
  • 3% by weight is added to the mixture.
  • the rest (95.8% by weight) makes up the quartz sand.
  • the additive described is composed of 45% by weight of carbon or carbon with an average particle size of 0.2 mm and (up to about 500 ° C.) volatile constituents of 30% by weight and less.
  • At least 85% by weight (45% by weight + 10% by weight + 30% by weight) have a particle size of 0.2 mm or 0.3 mm, ie above 0.05 mm.
  • the binder content in the additive is about 8 wt .-% (5 wt .-% modified bituminous resin plus 3 wt .-% hydrocarbon resin).
  • the organic component (45% by weight + 10% by weight of carbon or carbon and 3% by weight of hydrocarbon resin, 5% by weight of bitumen resin is 63% by weight.)
  • the remaining 37% by weight form the inorganic portion of the additive (30% by weight of lithium mineral + 5% by weight of perlite and 2% by weight of iron oxide)
  • the organic component has volatile constituents of about 45% by weight (30% by weight +
  • the surface of the additive grains and / or the aggregate grains can be closed by a coating or by impregnation (with a binder).

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Mold Materials And Core Materials (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Casting Devices For Molds (AREA)
  • Epoxy Resins (AREA)
EP04739801A 2003-06-12 2004-06-11 Verfahren zur hestellung eines kern- und/oder formsandes für giessereizwecke Revoked EP1631403B1 (de)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL04739801T PL1631403T3 (pl) 2003-06-12 2004-06-11 Sposób wytwarzania masy rdzeniowej i/lub formierskiej do celów odlewniczych

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10326967A DE10326967A1 (de) 2003-06-12 2003-06-12 Verfahren zur Herstellung eines Kern- und Formsandes für Gießereizwecke
PCT/EP2004/006306 WO2004110670A2 (de) 2003-06-12 2004-06-11 Verfahren zur hestellung eines kern- und/oder formsandes für giessereizwecke

Publications (2)

Publication Number Publication Date
EP1631403A2 EP1631403A2 (de) 2006-03-08
EP1631403B1 true EP1631403B1 (de) 2007-05-30

Family

ID=33482915

Family Applications (1)

Application Number Title Priority Date Filing Date
EP04739801A Revoked EP1631403B1 (de) 2003-06-12 2004-06-11 Verfahren zur hestellung eines kern- und/oder formsandes für giessereizwecke

Country Status (7)

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US (1) US7281570B2 (pt)
EP (1) EP1631403B1 (pt)
AT (1) ATE363351T1 (pt)
BR (1) BRPI0411325B1 (pt)
DE (2) DE10326967A1 (pt)
PL (1) PL1631403T3 (pt)
WO (1) WO2004110670A2 (pt)

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8974587B2 (en) 2010-11-15 2015-03-10 Honda Motor Co., Ltd. Casting sand core composition
CN104174810A (zh) * 2014-08-29 2014-12-03 无锡柯马机械有限公司 一种铸造工艺
CN104384437A (zh) * 2014-11-17 2015-03-04 无锡市百顺机械厂 一种铸造工艺
CN104646598A (zh) * 2015-01-22 2015-05-27 安徽省繁昌县皖南阀门铸造有限公司 一种易回收利用型砂及其制备方法
US9868551B2 (en) 2015-03-30 2018-01-16 Worldvu Satellites Limited Passive thermal system comprising combined heat pipe and phase change material and satellites incorporating same
CN105798223A (zh) * 2016-03-23 2016-07-27 刘建荣 一种使用煤矸石铸造型砂的工艺
DE102022105961A1 (de) 2022-03-15 2023-09-21 Ks Huayu Alutech Gmbh Verfahren zur Herstellung eines Formkerns oder Speisers zur Erzeugung von Hohlräumen in Gussstücken

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2828214A (en) * 1953-06-15 1958-03-25 Archer Daniels Midland Co Foundry sand additive
NL7211534A (pt) 1972-08-24 1974-02-26
IT1209745B (it) 1980-01-21 1989-08-30 Ind Chimica Carlo Laviosa Spa Materiale granulare per la preparazione di terre di formatura di fonderia e suo procedimento di produzione
DE3017119A1 (de) 1980-05-03 1981-11-05 Dr. Heinze GmbH, 4554 Kettenkamp Verfahren zur herstellung eines aus quarzsand, bentonit und wasser bestehenden formsandes fuer eisengiessereizwecke
DE19609539A1 (de) 1996-03-11 1997-09-18 Ashland Suedchemie Kernfest Additive für Gießereisande
BR9710401A (pt) 1996-12-27 2000-01-11 Iberia Ashland Chem Sa Aeia de moldagem adequada para fabricar machos e moldes de fundição.

Also Published As

Publication number Publication date
BRPI0411325A (pt) 2006-07-25
DE10326967A1 (de) 2004-12-30
BRPI0411325B1 (pt) 2013-12-24
ATE363351T1 (de) 2007-06-15
US20060151145A1 (en) 2006-07-13
WO2004110670A2 (de) 2004-12-23
PL1631403T3 (pl) 2007-10-31
EP1631403A2 (de) 2006-03-08
US7281570B2 (en) 2007-10-16
WO2004110670A3 (de) 2005-02-24
DE502004003975D1 (de) 2007-07-12

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