EP1645350A1 - Casting with integrated functional elements and manufacturing process - Google Patents

Casting with integrated functional elements and manufacturing process Download PDF

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Publication number
EP1645350A1
EP1645350A1 EP05022013A EP05022013A EP1645350A1 EP 1645350 A1 EP1645350 A1 EP 1645350A1 EP 05022013 A EP05022013 A EP 05022013A EP 05022013 A EP05022013 A EP 05022013A EP 1645350 A1 EP1645350 A1 EP 1645350A1
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EP
European Patent Office
Prior art keywords
component
functional element
casting
functional elements
functional
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EP05022013A
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German (de)
French (fr)
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EP1645350B1 (en
Inventor
Thorsten MÜLLER
Franz-Josef Wostmann
Matthias Busse
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Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
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Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
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Priority to EP08019322A priority Critical patent/EP2025433B1/en
Priority to PL05022013T priority patent/PL1645350T3/en
Priority to PL08019322T priority patent/PL2025433T3/en
Priority to SI200530744T priority patent/SI1645350T1/en
Publication of EP1645350A1 publication Critical patent/EP1645350A1/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
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/0081—Casting in, on, or around objects which form part of the product pretreatment of the insert, e.g. for enhancing the bonding between insert and surrounding cast metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/04—Casting in, on, or around objects which form part of the product for joining parts

Definitions

  • the present invention relates to the manufacture of a cast component with integrated functional elements, and to a method for its production.
  • sensors, actuators and temperature-sensitive functional elements i. Functional elements that are not or not temperature resistant for the duration of the casting process, poured.
  • the invention enables the integration of functional elements in metallic castings (during the casting process) as a permanent core.
  • the method according to the invention thus opens up the possibility of expanding the function of castings from the individual marking to the integrated load monitoring.
  • the present invention is therefore based on the object to overcome this disadvantage and to provide a component and a method for its production in which functional elements are poured, which are still functional even after the casting of the molten metal.
  • the components according to the invention are characterized in that they contain one or more molded-in functional elements.
  • Suitable functional elements are, in particular, adaptronic sensors and / or adaptronic actuators (eg piezoceramics) as well as temperature-sensitive functional elements.
  • These functional elements can also be, for example, electronic assemblies which are actively or passively supplied with energy, for example via cables discharged to the outside from the component, via induction, an integrated battery, a capacitor or via a mechanical, autonomous movement unit.
  • the connection to the receiver / transmitter or an external energy source outside of the casting can be done in particular via lines executed from the casting or without direct cable connection (telemetric / wireless). In a transmission via cable, the casting itself can serve as a connection or line and replace a phase.
  • electronic components by means of which a transmission by infrared or radio (eg Bluetooth) is possible, or even transponder or RFID can be used.
  • the functional elements can be integrated individually or in combination;
  • intelligent components with integrated data acquisition, processing and control can also be produced.
  • Areas of application for the components according to the invention are, for example, highly stressed safety components whose load status and load history can be permanently detected and influenced by the functional elements contained.
  • an increased security against component failure in operation can be achieved and made a lightweight construction by adapting safety factors to the real circumstances.
  • Examples include applications in motor vehicles and aviation, such as engine blocks or chassis parts of motor vehicles or aircraft.
  • the loads occurring during operation can be detected and stored with sensors, for example, a message at the onset of component damage, or be reported in case of overload of the component via cable, radio or induction to the vehicle electronics.
  • actuators targeted vibrations can be introduced into the component.
  • Combination with sensors and electronic controllers can suppress component vibrations.
  • By combining with one Memory module makes it possible to record the life history of the component.
  • Another area of application is the testing technology of components and component development, as forces occurring through the integration of the functional elements can be recorded and recorded directly in the component.
  • the functional elements to be integrated are positioned in a mold prior to casting and encased by the molten metal during the casting process.
  • the molded in the components functional elements are then preferably completely surrounded by potted metal.
  • components are also included in which the potted metal does not completely surround the functional element - for example, because an outlet for any outward-leading cable connections, dielectric gaps for RFIDs or the like. is provided or necessary.
  • the outlets can also be used for data transmission by optical or inductive signals.
  • outlets on the component but limited to the maximum required connection area or functional area.
  • the cast metal preferably has a uniform microstructure in the area of the functional elements, so that there are no undesired "predetermined breaking points".
  • Functional elements which inherently tolerate a high short-term temperature load in particular electronic or piezoelectric elements, can usually be cast directly without further measures by the method according to the invention. If the peak temperatures, as occur, for example, in aluminum and magnesium casting, too high or the temperature sensitivity of the einzug manenden functional element is too large, the heat input can be reduced in the components to be integrated by - especially in the areas in which functional elements are - About the mold, the heat is dissipated by suitable Temper mecanicshunt, such as cooling elements or heating-cooling units.
  • an envelope made of a thermally insulating material can be made to protect the functional elements, or a functional element enveloped in this manner can be used for the method according to the invention.
  • the protective layer used is preferably a compound with low thermal conductivity.
  • Suitable protective layer materials are, in particular, plastic, ceramic or low-melting metal alloys (ie alloys whose melting point or their solidus temperature and preferably also their liquidus temperature is below the temperature above which the function elements are permanently impaired in their function by the introduced energy).
  • low-melting metal alloys for example, alloys containing bismuth (preferably more than 50 wt .-%) are suitable.
  • the protective layer may dissolve in the cast molten metal (in particular a protective layer of a low-melting metal alloy) or disperse during the casting process and optionally also the solidification process (in particular if particles of the protective layer are entrained at faster flow velocities of the cast molten metal), but it can also - at least in part - remain on the surface of the functional element or decompose.
  • the layer thickness of the protective layer can be calculated, for example, by means of simulation programs on the basis of the material thickness of the metal surrounding the functional element, the temperature of the melt, the heat content and the heat dissipation via the casting mold.
  • the layer thickness is chosen so that it is as thin as possible, since the remaining in the finished component protective layer or remnants thereof may represent undesirable "break points" in the component in unfavorable cases.
  • the protective layer can also only partially envelop the functional element-for example, only in areas which are particularly sensitive to temperature or in which, owing to the geometry of the component to be produced, greater heat input from the molten metal to be cast can be expected.
  • the sensory or actuatoric functional elements are preferably encapsulated without protective layer, since error sources can be reduced by a direct material connection between component material and sensor / actuator. Nevertheless, if a protective layer is required, it is preferably made of materials with known mechanical properties Performed properties that allow a computational correction. In particular, ceramic layers come into question here.
  • the method for producing the components according to the invention is carried out such that a functional element, which may be coated at least partially with a protective layer, is positioned in the cavity of a casting mold and then cast around with a metal by means of a casting process, wherein the positioning in the casting mold is selected such that the flow rate of the molten metal to be cast in the region of the functional element is low.
  • low is meant in particular that the flow velocity in the region of the functional element is at most 100 m / s, preferably less than 80 m / s, and particularly preferably less than 50 m / s.
  • the flow velocities can be determined in advance, for example, by means of mold filling simulations (eg using the software Magamasoft or Procast).
  • the functional elements are positioned and potted in component regions with a low flow velocity, then so much heat can be withdrawn from the melt that during the casting process no heating of the functional elements via temperatures can take place, beyond which the functionality of the functional element is impaired or completely lost.
  • An additional heat extraction can be done very effectively by cooling elements.
  • the functional element is positioned so that only a small amount of metal has to flow around the functional element in order to fill regions of the component that lie behind the functional element.
  • the functional element can also be positioned so that the region of the component which lies behind the functional element is filled with molten metal by means of a suitable design of the sprue system via another flow path.
  • molten metal is understood to mean any material which contains or consists of one or more metals or alloys and which can be cast with the casting method applicable according to the invention (ie, for example, also tixotropic materials). If melts are used which do not consist of pure metal or alloy or mixtures thereof, the proportion of the remaining aggregates (eg ceramic constituents) is preferably not more than 40%.
  • the functional elements according to the invention are positioned like conventional permanent cores in the mold cavity and then cast.
  • casting process all methods are possible, which allow a sufficiently rapid removal of temperature.
  • hot chamber and cold chamber die casting including squeeze casting and thixocasting, should be mentioned here.
  • the gravity, low pressure and tilt or pan Kokilleng fond compiler come into consideration, since the metallic mold ensures good temperature control.
  • the Vollformg tellvon and the lost foam process thermal encapsulation must be increased according to the lower heat dissipation through the molding material or ensures sufficient heat dissipation by cooling elements be.
  • the method according to the invention is carried out such that the positioning of the functional element in the casting mold is selected so that the functional element is not located in the main flow of the molten metal during the casting of the molten metal.
  • the functional element is then positioned in the component region in which the lowest flow velocity prevails or is to be expected. If positioning in this area is not meaningful due to negative effects on the mechanical properties of the component, then the component area is selected in which the lowest flow velocity prevails or is to be expected given the same mechanical properties of the component.
  • the gate cross-section is advantageously increased compared to conventional die-casting methods; As a result, the flow velocity can be reduced.
  • the solidification process of the melt is carried out-preferably under pressure-in such a short time that the function elements are not impaired in their function by the introduced energy.
  • the surface of the functional element or the surface of the functional element adjoining the protective layer therefore exhibits during of the casting process and the solidification process preferably maximally at a temperature which is lower than the temperature from which the functionality of the temperature-sensitive element is impaired.
  • the surface temperature should generally not exceed 250-300 ° C.
  • Functional elements with piezoelectric components can be exposed for a short time to higher temperatures which are above the Curie temperature of the corresponding piezoelectric material.
  • the piezoelectric properties of the material are initially lost, but can be restored by applying a high voltage.
  • the casting process is therefore performed so that the piezoelectric properties are not lost.
  • Particular preference is given to using piezoelectric elements based on terfenol.
  • the process according to the invention is particularly preferably carried out in such a way that very rapid solidification of the melt is achieved, depending on the geometry of the component and the volume of the component, during very short mold filling times.
  • the casting process i.e., mold filling time and setting time
  • the casting process preferably lasts less than 10 seconds.
  • the inventive method is particularly suitable to produce components made of cast aluminum, magnesium casting, zinc casting and with suitable temperature control and resistance also from iron and steel casting. If a protective layer is provided for the functional elements to be infiltrated, then the method according to the invention is preferably carried out in such a way that the functional element is partially or completely homogeneously enveloped. Positioning in the mold determines the position of the elements and thus the position of the sensor data and the position of the component in space.
  • the casting process according to the invention for producing a component according to FIGS. 1 to 5 was carried out on a cold chamber die casting machine of the Buhler SC / N 66 type.
  • the casting material used was AlSi9Cu3.
  • RFIDs and piezoceramics have been positioned in the cavity of the die using a mold adapted holder.
  • the insert was chosen so that it is not crazy or destroyed by the fast flowing metal.
  • the areas in the component, which are suitable for receiving an insert, are to be selected individually depending on the component geometry and the gates. If a specific position is specified, design changes to the gate or component geometry may be necessary. In the present case, the RFIDs and piezoceramics were cast at the positions that can be seen in FIGS. 2 to 4.
  • the mold was closed and the shot fired. The mold filling took place within 25 ms.
  • the casting was cooled immediately after removal from the mold with air or water; the functional elements were fully functional and could be used as intended.

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  • Mechanical Engineering (AREA)
  • Engineering & Computer Science (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Encapsulation Of And Coatings For Semiconductor Or Solid State Devices (AREA)
  • Soft Magnetic Materials (AREA)
  • Braking Arrangements (AREA)
  • Pistons, Piston Rings, And Cylinders (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Glass Compositions (AREA)
  • Compositions Of Oxide Ceramics (AREA)
  • Shielding Devices Or Components To Electric Or Magnetic Fields (AREA)
  • Investigating Or Analyzing Materials Using Thermal Means (AREA)
  • Semiconductor Integrated Circuits (AREA)
  • Fixed Capacitors And Capacitor Manufacturing Machines (AREA)

Abstract

In a process to fabricate a cast metal component with integral functional elements e.g. sensors or temperature-sensitive functional elements, the heat-screened element is pre-positioned within a casting form cavity. The metal is then cast in the conventional way. The position of the form is so chosen that the flow speed of liquid metal is low in the vicinity of the functional element. Also claimed is a suitable cast assembly.

Description

Die vorliegende Erfindung betrifft die Herstellung eines Gussbauteils mit integrierten Funktionselementen, und ein Verfahren zu seiner Herstellung. Nach diesem Verfahren können insbesondere Sensoren, Aktoren und temperaturempfindliche Funktionselemente, d.h. Funktionselemente die nicht oder nicht für die Dauer des Gussverfahrens temperaturbeständig sind, eingegossen werden. Die Erfindung ermöglicht die Integration von Funktionselementen in metallische Gussteile (während des Gießprozesses) als Permanentkern. Mit dem erfindungsgemäßen Verfahren wird also die Möglichkeit eröffnet, die Funktion von Gussstücken von der individuellen Kennzeichnung bis hin zur integrierten Belastungsüberwachung zu erweitern.The present invention relates to the manufacture of a cast component with integrated functional elements, and to a method for its production. In particular, sensors, actuators and temperature-sensitive functional elements, i. Functional elements that are not or not temperature resistant for the duration of the casting process, poured. The invention enables the integration of functional elements in metallic castings (during the casting process) as a permanent core. The method according to the invention thus opens up the possibility of expanding the function of castings from the individual marking to the integrated load monitoring.

Nach dem Stand der Technik ist kein Verfahren bekannt, mit dem derartige Sensoren, Aktoren und temperaturempfindlichen Funktionselemente in einem Gussbauteil angeordnet werden können, ohne dass während des Gussverfahrens die Funktionsfähigkeit dieser Funktionselemente verloren geht.According to the prior art, no method is known with which such sensors, actuators and temperature-sensitive functional elements can be arranged in a cast component, without losing the functionality of these functional elements during the casting process.

Der vorliegenden Erfindung liegt daher die Aufgabe zugrunde, diesen Nachteil zu überwinden und ein Bauteil und ein Verfahren zu dessen Herstellung anzugeben, in dem Funktionselemente eingegossen sind, die auch nach dem Vergießen der Metallschmelze noch funktionstüchtig sind.The present invention is therefore based on the object to overcome this disadvantage and to provide a component and a method for its production in which functional elements are poured, which are still functional even after the casting of the molten metal.

Diese Aufgabe wird durch das Bauteil nach Anspruch 1 und das Verfahren zu dessen Herstellung nach Anspruch 7 gelöst. Unteransprüche geben vorteilhafte Weiterbildungen an. Anspruch 10 lehrt eine vorteilhafte Verwendung der erfindungsgemäßen Bauteile.This object is achieved by the component according to claim 1 and the method for its production according to claim 7. Subclaims indicate advantageous developments. Claim 10 teaches an advantageous use of the components according to the invention.

Die erfindungsgemäßen Bauteile zeichnen sich dadurch aus, dass sie ein oder mehrere eingegossene Funktionselemente enthalten.
Als Funktionselemente kommen insbesondere adaptronische Sensoren und/oder adaptronische Aktoren (z. B. Piezokeramiken) sowie temperaturempfindliche Funktionselemente in Betracht. Diese Funktionselemente können beispielsweise auch elektronische Baugruppen sein, die aktiv oder passiv mit Energie versorgt werden, z.B. über nach außen aus dem Bauteil abgeführte Kabel, über Induktion, eine integrierte Batterie, einen Kondensator oder über eine mechanische, autarke Bewegungseinheit. Die Verbindung zum Empfänger/Sender oder einer externen Energiequelle außerhalb des Gussstückes kann dabei insbesondere über aus dem Gussstück ausgeführte Leitungen oder ohne direkte Kabelverbindung (telemetrisch/wireless) erfolgen.
Bei einer Übertragung über Kabel kann das Gussstück selber als Anschluss bzw. Leitung dienen und eine Phase ersetzen. Für die drahtlose Übertragung können elektronische Komponenten, mittels derer eine Übertragung durch Infrarot oder Funk (z.B. Bluetooth) möglich ist, oder auch Transponder bzw. RFID eingesetzt werden.
Die Funktionselemente können einzeln oder in Kombination integriert werden; neben Bauteilen mit integrierten Funktionselementen für eine Bauteilidentifizierung, sensorischen Bauteilen und aktorischen Bauteilen sind auch intelligente Bauteile mit integrierter Datenerfassung, Verarbeitung und Regelung herstellbar.The components according to the invention are characterized in that they contain one or more molded-in functional elements.
Suitable functional elements are, in particular, adaptronic sensors and / or adaptronic actuators (eg piezoceramics) as well as temperature-sensitive functional elements. These functional elements can also be, for example, electronic assemblies which are actively or passively supplied with energy, for example via cables discharged to the outside from the component, via induction, an integrated battery, a capacitor or via a mechanical, autonomous movement unit. The connection to the receiver / transmitter or an external energy source outside of the casting can be done in particular via lines executed from the casting or without direct cable connection (telemetric / wireless).
In a transmission via cable, the casting itself can serve as a connection or line and replace a phase. For wireless transmission, electronic components, by means of which a transmission by infrared or radio (eg Bluetooth) is possible, or even transponder or RFID can be used.
The functional elements can be integrated individually or in combination; In addition to components with integrated functional elements for component identification, sensory components and actuator components, intelligent components with integrated data acquisition, processing and control can also be produced.

Einsatzgebiete für die erfindungsgemäßen Bauteile sind zum Beispiel hochbelastete Sicherheitsbauteile, deren Belastungszustand und Belastungsgeschichte mit den enthaltenen Funktionselementen permanent erfasst und beeinflusst werden kann. Damit kann eine erhöhte Sicherheit gegen Bauteilversagen im Betrieb erzielt werden und ein Leichtbau durch Anpassung von Sicherheitsfaktoren an die realen Umstände erfolgen. Als Beispiele sind Anwendungen in Kraftfahrzeugen und der Luftfahrt zu nennen, etwa Motorblöcke oder Fahrwerksteile von Kraftfahrzeugen oder Flugzeugen. Hier können mit Sensoren die im Betrieb aufkommenden Belastungen erfasst und gespeichert werden, um z.B. eine Meldung bei einsetzender Bauteilschädigung, oder bei Überlastung des Bauteils über Kabel, Funk oder Induktion an die Fahrzeugelektronik gemeldet werden. Bei Einsatz von Aktoren können gezielt Schwingungen in das Bauteil eingebracht werden. Durch Kombination mit Sensoren und elektronischen Reglern lassen sich dadurch Bauteilschwingungen unterdrücken. Durch die Kombination mit einem Speichermodul wird es möglich die Lebensgeschichte des Bauteils zu erfassen.
Ein weiteres Anwendungsgebiet ist die Prüftechnik von Bauteilen und die Bauteilentwicklung, da durch die Integration der Funktionselemente auftretende Kräfte direkt im Bauteil erfasst und aufgezeichnet werden können.Areas of application for the components according to the invention are, for example, highly stressed safety components whose load status and load history can be permanently detected and influenced by the functional elements contained. Thus, an increased security against component failure in operation can be achieved and made a lightweight construction by adapting safety factors to the real circumstances. Examples include applications in motor vehicles and aviation, such as engine blocks or chassis parts of motor vehicles or aircraft. Here, the loads occurring during operation can be detected and stored with sensors, for example, a message at the onset of component damage, or be reported in case of overload of the component via cable, radio or induction to the vehicle electronics. When using actuators targeted vibrations can be introduced into the component. Combination with sensors and electronic controllers can suppress component vibrations. By combining with one Memory module makes it possible to record the life history of the component.
Another area of application is the testing technology of components and component development, as forces occurring through the integration of the functional elements can be recorded and recorded directly in the component.

Die zu integrierenden Funktionselemente werden vor dem Abguss in einer Gussform positioniert und während des Gießvorgangs durch die Metallschmelze umhüllt. Die in den Bauteilen eingegossenen Funktionselemente sind dann bevorzugt vollständig von vergossenem Metall umgeben. Erfindungsgemäß sind allerdings auch Bauteile umfasst, bei denen das vergossene Metall das Funktionselement nicht vollständig umgibt - etwa weil ein Auslass für etwaige nach außen zu führende Kabelverbindungen, dielektrische Spalte für RFIDs o.ä. vorgesehen bzw. nötig ist. Bei einer teilweisen Umhüllung der Elemente und einer direkten Verbindung zur Bauteiloberfläche über die eingegossenen Elemente oder die Umhüllung können die Auslässe auch für die Datenübertragung durch optische oder induktive Signale genutzt werden.
Vorteilhafterweise sind derartige Auslässe am Bauteil aber auf den maximal nötigen Anschlussbereich bzw. Funktionsbereich beschränkt. Bevorzugt weist das vergossene Metall im Bereich der Funktionselemente eine einheitliche Gefügestruktur auf, so dass dort keine unerwünschten "Sollbruchstellen" auftreten.The functional elements to be integrated are positioned in a mold prior to casting and encased by the molten metal during the casting process. The molded in the components functional elements are then preferably completely surrounded by potted metal. According to the invention, however, components are also included in which the potted metal does not completely surround the functional element - for example, because an outlet for any outward-leading cable connections, dielectric gaps for RFIDs or the like. is provided or necessary. With a partial enclosure of the elements and a direct connection to the component surface via the cast-in elements or the enclosure, the outlets can also be used for data transmission by optical or inductive signals.
Advantageously, such outlets on the component but limited to the maximum required connection area or functional area. The cast metal preferably has a uniform microstructure in the area of the functional elements, so that there are no undesired "predetermined breaking points".

Zur Vermeidung einer Beschädigung der zu integrierenden Elemente durch einen zu hohen Wärmeeintrag stehen - falls erforderlich - verschiedene Möglichkeiten entsprechend der eingesetzten Elemente zur Auswahl.To avoid damage to the elements to be integrated by an excessive heat input are - if necessary - different options according to the elements used for selection.

Funktionselemente, die von Haus aus eine hohe kurzzeitige Temperaturbelastung tolerieren, insbesondere elektronische oder Piezoelektrische Elemente, können mit dem erfindungsgemäßen Verfahren üblicherweise direkt ohne weitere Maßnahmen eingegossen werden.
Sind die Spitzentemperaturen, wie sie z.B. beim Aluminium- und Magnesiumguss auftreten, zu hoch oder ist die Temperaturempfindlichkeit des einzugießenden Funktionselements zu groß, so kann der Wärmeeintrag in die zu integrierenden Komponenten reduziert werden, indem - insbesondere in den Bereichen, in denen sich Funktionselemente befinden - über die Gießform die Wärme durch geeignete Temperierungsmaßnahmen, wie Kühlelemente oder Heiz-Kühlgeräte abgeführt wird.Functional elements which inherently tolerate a high short-term temperature load, in particular electronic or piezoelectric elements, can usually be cast directly without further measures by the method according to the invention.
If the peak temperatures, as occur, for example, in aluminum and magnesium casting, too high or the temperature sensitivity of the einzugießenden functional element is too large, the heat input can be reduced in the components to be integrated by - especially in the areas in which functional elements are - About the mold, the heat is dissipated by suitable Temperierungsmaßnahmen, such as cooling elements or heating-cooling units.

Alternativ oder zusätzlich kann zum Schutz der Funktionselemente eine Umhüllung aus einem thermisch isolierenden Material (thermische Kapselung) vorgenommen werden bzw. ein derartig umhülltes Funktionselement für das erfindungsgemäße Verfahren verwendet werden. Hierdurch wird der Wärmeeintrag in die zu integrierenden Elemente unter die max. zulässige Wärmemenge reduziert. Als Schutzschicht wird bevorzugt eine Masse mit geringer Wärmeleitfähigkeit eingesetzt. Geeignete Schutzschichtmaterialien sind insbesondere Kunststoff, Keramik oder niedrigschmelzende Metalllegierungen (d.h. Legierungen deren Schmelzpunkt bzw. deren Solidustemperatur und bevorzugt auch deren Liquidustemperatur unterhalb der Temperatur liegt, ab der die Funktionselemente in ihrer Funktion durch die eingebrachte Energie dauerhaft beeinträchtigt werden). Als niedrigschmelzende Metalllegierungen sind z.B. Legierungen, die Bismut (bevorzugt mehr als 50 Gew.-%) enthalten geeignet. Die Schutzschicht kann sich während des Gussvorgangs und gegebenenfalls auch des Erstarrungsvorgangs in der vergossenen Metallschmelze auflösen (insbesondere eine Schutzschicht aus einer niedrigschmelzenden Metalllegierung) oder dispergieren (insbesondere wenn bei schnelleren Strömungsgeschwindigkeiten der vergossenen Metallschmelze Partikel der Schutzschicht mitgerissen werden), sie kann aber auch - zumindest zum Teil - auf der Oberfläche des Funktionselements verbleiben oder sich zersetzen.
Die Schichtdicke der Schutzschicht kann z.B. mittels Simulationsprogrammen anhand der Materialdicke des Metalls, das das Funktionselement umgibt, der Temperatur der Schmelze, dem Wärmeinhalt und der Wärmeabfuhr über die Gussform berechnet werden. Bevorzugt wird die Schichtdicke dabei so gewählt, dass sie möglichst dünn ist, da die im fertigen Bauteil verbleibende Schutzschicht bzw. Reste hiervon in ungünstigen Fällen unerwünschte "Sollbruchstellen" im Bauteil darstellen können. Die Schutzschicht kann das Funktionselement auch nur teilweise umhüllen - etwa nur in Bereichen, die besonders temperaturempfindlich sind oder in denen aufgrund der Geometrie des herzustellenden Bauteils ein größerer Wärmeeintrag aus der zu vergießenden Metallschmelze zu erwarten ist.
Die sensorischen oder aktorischen Funktionselemente werden aber bevorzugt ohne Schutzschicht vergossen, da durch einen direkten Stoffschluss zwischen Bauteilmaterial und Sensor/Aktor Fehlerquellen reduziert werden können. Wird dennoch eine Schutzschicht benötigt, so wird diese bevorzugt aus Materialien mit bekannten mechanischen Eigenschaften ausgeführt, die eine rechnerische Korrektur ermöglichen. Hier kommen insbesondere keramische Schichten in Frage.Alternatively or additionally, an envelope made of a thermally insulating material (thermal encapsulation) can be made to protect the functional elements, or a functional element enveloped in this manner can be used for the method according to the invention. As a result, the heat input into the elements to be integrated below the max. permitted amount of heat reduced. The protective layer used is preferably a compound with low thermal conductivity. Suitable protective layer materials are, in particular, plastic, ceramic or low-melting metal alloys (ie alloys whose melting point or their solidus temperature and preferably also their liquidus temperature is below the temperature above which the function elements are permanently impaired in their function by the introduced energy). As low-melting metal alloys, for example, alloys containing bismuth (preferably more than 50 wt .-%) are suitable. The protective layer may dissolve in the cast molten metal (in particular a protective layer of a low-melting metal alloy) or disperse during the casting process and optionally also the solidification process (in particular if particles of the protective layer are entrained at faster flow velocities of the cast molten metal), but it can also - at least in part - remain on the surface of the functional element or decompose.
The layer thickness of the protective layer can be calculated, for example, by means of simulation programs on the basis of the material thickness of the metal surrounding the functional element, the temperature of the melt, the heat content and the heat dissipation via the casting mold. Preferably, the layer thickness is chosen so that it is as thin as possible, since the remaining in the finished component protective layer or remnants thereof may represent undesirable "break points" in the component in unfavorable cases. The protective layer can also only partially envelop the functional element-for example, only in areas which are particularly sensitive to temperature or in which, owing to the geometry of the component to be produced, greater heat input from the molten metal to be cast can be expected.
However, the sensory or actuatoric functional elements are preferably encapsulated without protective layer, since error sources can be reduced by a direct material connection between component material and sensor / actuator. Nevertheless, if a protective layer is required, it is preferably made of materials with known mechanical properties Performed properties that allow a computational correction. In particular, ceramic layers come into question here.

Das Verfahren zur Herstellung der erfindungsgemäßen Bauteile wird so durchgeführt, dass ein gegebenenfalls mit einer Schutzschicht zumindest teilweise umhülltes Funktionselement in der Kavität einer Gussform positioniert wird und anschließend mittels eines Gussverfahrens mit einem Metall umgossen wird, wobei die Positionierung in der Gussform so gewählt wird, dass die Strömungsgeschwindigkeit der zu vergießenden Metallschmelze im Bereich des Funktionselements niedrig ist.
Unter niedrig ist hierbei insbesondere zu verstehen, dass die Strömungsgeschwindigkeit im Bereich des Funktionselements maximal 100 m/s beträgt, bevorzugt kleiner als 80 m/s beträgt und besonders bevorzugt kleiner als 50 m/s. Die Strömungsgeschwindigkeiten können vorab beispielsweise mittels Formfüllsimulationen (z.B. mittels der Software Magamasoft oder Procast) bestimmt werden.
Werden die Funktionselemente in Bauteilbereichen mit niedriger Strömungsgeschwindigkeit positioniert und vergossen, so kann hierbei der Schmelze so viel Wärme entzogen werden, dass während des Gussprozesses keine Erwärmung der Funktionselemente über Temperaturen erfolgen kann, ab denen die Funktionsfähigkeit des Funktionselements beeinträchtigt wird oder vollständig verloren geht. Ein zusätzlicher Wärmeentzug kann dabei besonders effektiv durch Kühlelemente erfolgen.
Besonders bevorzugt wird das Funktionselement so positioniert, dass nur wenig Metall das Funktionselement umfließen muss, um Bereiche des Bauteils, die hinter dem Funktionselement liegen, zu füllen. Das Funktionselement kann auch so positioniert werden, dass der Bereich des Bauteils, der hinter dem Funktionselement liegt, durch geeignete Auslegung des Angusssystems über einen anderen Strömungsweg mit Metallschmelze gefüllt wird.
Unter Metallschmelze wird erfindunggemäß jedes Material verstanden, das ein oder mehrere Metalle bzw. Legierungen enthält oder aus diesen besteht und das mit den erfindungsgemäß anwendbaren Gießverfahren vergießbar ist (also z.B. auch tixotrope Materialien). Werden Schmelzen eingesetzt, die nicht aus reinem Metall bzw. Legierung oder Gemischen hieraus besteht, so beträgt der Anteil der restlichen Zuschlagstoffe (z.B. keramische Bestandteile) bevorzugt nicht mehr als 40%.The method for producing the components according to the invention is carried out such that a functional element, which may be coated at least partially with a protective layer, is positioned in the cavity of a casting mold and then cast around with a metal by means of a casting process, wherein the positioning in the casting mold is selected such that the flow rate of the molten metal to be cast in the region of the functional element is low.
By "low" is meant in particular that the flow velocity in the region of the functional element is at most 100 m / s, preferably less than 80 m / s, and particularly preferably less than 50 m / s. The flow velocities can be determined in advance, for example, by means of mold filling simulations (eg using the software Magamasoft or Procast).
If the functional elements are positioned and potted in component regions with a low flow velocity, then so much heat can be withdrawn from the melt that during the casting process no heating of the functional elements via temperatures can take place, beyond which the functionality of the functional element is impaired or completely lost. An additional heat extraction can be done very effectively by cooling elements.
Particularly preferably, the functional element is positioned so that only a small amount of metal has to flow around the functional element in order to fill regions of the component that lie behind the functional element. The functional element can also be positioned so that the region of the component which lies behind the functional element is filled with molten metal by means of a suitable design of the sprue system via another flow path.
According to the invention, molten metal is understood to mean any material which contains or consists of one or more metals or alloys and which can be cast with the casting method applicable according to the invention (ie, for example, also tixotropic materials). If melts are used which do not consist of pure metal or alloy or mixtures thereof, the proportion of the remaining aggregates (eg ceramic constituents) is preferably not more than 40%.

Die erfindungsgemäßen Funktionselemente werden wie herkömmliche Permanentkerne in der Formkavität positioniert und anschließend vergossen. Als Gießverfahren kommen alle Verfahren in Betracht, die eine hinreichend schnelle Temperaturabfuhr ermöglichen. Hier ist insbesondere der Warmkammer- und Kaltkammerdruckguss, einschließlich des Squeeze Casting und Thixocasting zu nennen. Ebenso kommen die Schwerkraft-, Niederdruck- und Kipp- oder Schwenk-Kokillengießverfahren für den Einsatz in Betracht, da durch die metallische Form eine gute Temperierung gewährleistet ist. Für den Einsatz in konventionellen Sandgussverfahren, wie dem Hand-oder Maschinengeformten Schwerkraft- und Niederdrucksandgussverfahren, wie dem Kernpaketverfahren, dem Vollformgießverfahren und dem Lost Foam-Verfahren muss die thermische Kapselung entsprechend der geringeren Wärmeabfuhr über den Formstoff erhöht werden oder eine ausreichende Wärmeabfuhr durch Kühlelemente gewährleistet sein.The functional elements according to the invention are positioned like conventional permanent cores in the mold cavity and then cast. As casting process, all methods are possible, which allow a sufficiently rapid removal of temperature. In particular, hot chamber and cold chamber die casting, including squeeze casting and thixocasting, should be mentioned here. Likewise, the gravity, low pressure and tilt or pan Kokillengießverfahren come into consideration, since the metallic mold ensures good temperature control. For use in conventional sand casting processes, such as hand or machine-formed gravity and low-pressure sand casting process, such as the core package process, the Vollformgießverfahren and the lost foam process thermal encapsulation must be increased according to the lower heat dissipation through the molding material or ensures sufficient heat dissipation by cooling elements be.

In einer vorteilhaften Ausgestaltung wird das erfindungsgemäße Verfahren so durchgeführt, dass die Positionierung des Funktionselements in der Gussform so gewählt wird, dass dass sich während des Vergießens der Metallschmelze das Funktionselement nicht in der Hauptströmung der Metallschmelze befindet. Dies ist insbesondere dann sinnvoll, wenn das Bauteil eine komplizierte Geometrie aufweist und/oder neben einem Hauptströmungsbereich weitere Strömungsbereiche mit niedrigerer Strömungsgeschwindigkeit der Metallschmelze vorliegen. Besonders bevorzugt wird das Funktionselement dann in dem Bauteilbereich positioniert, in dem die niedrigste Strömungsgeschwindigkeit voliegt bzw. zu erwarten ist. Ist eine Positionierung in diesem Bereich aufgrund negativer Auswirkungen auf die mechanischen Eigenschaften des Bauteils nicht sinnvoll, so wird der Bauteilbereich gewählt in dem bei gleichbleibenden mechanischen Eigenschaften des Bauteils die niedrigste Strömungsgeschwindigkeit voliegt bzw. zu erwarten ist.In an advantageous embodiment, the method according to the invention is carried out such that the positioning of the functional element in the casting mold is selected so that the functional element is not located in the main flow of the molten metal during the casting of the molten metal. This is particularly useful if the component has a complicated geometry and / or other flow regions with a lower flow velocity of the molten metal are present in addition to a main flow region. Particularly preferably, the functional element is then positioned in the component region in which the lowest flow velocity prevails or is to be expected. If positioning in this area is not meaningful due to negative effects on the mechanical properties of the component, then the component area is selected in which the lowest flow velocity prevails or is to be expected given the same mechanical properties of the component.

Um eine einfache Positionierung zu ermöglichen, wird vorteilhafterweise der Anschnittsquerschnitt gegenüber herkömmlichen Druckgussverfahren vergrößert; hierdurch kann die Strömungsgeschwindigkeit reduziert werden.In order to allow easy positioning, the gate cross-section is advantageously increased compared to conventional die-casting methods; As a result, the flow velocity can be reduced.

Der Erstarrungsprozess der Schmelze, wird - bevorzugt unter Druck - in so kurzer Zeit durchgeführt, dass die Funktionselemente in ihrer Funktion durch die eingebrachte Energie nicht beeinträchtigt werden .Die Oberfläche des Funktionselements bzw. die an die Schutzschicht anschließende Oberfläche des Funktionselements weist daher während des Gussverfahrens und des Erstarrungsprozesses bevorzugt maximal eine Temperatur auf, die unter der Temperatur liegt, ab der die Funktionsfähigkeit des temperaturempfindlichen Elements beeinträchtigt wird. Insbesondere sollte die Oberflächentemperatur im Allgemeinen 250-300°C nicht überschreiten. Funktionselemente mit piezoelektrischen Komponenten können kurzzeitig auch höhere Temperaturen, die oberhalb der Curie-Temperatur des entsprechenden piezoelektrischen Materials liegen, ausgesetzt werden. Dabei gehen die piezoelektrischen Eigenschaften des Materials zunächst verloren, können jedoch über das Anlegen einer Hochspannung wieder hergestellt werden. Bevorzugt wird das Gussverfahren daher so durchgeführt dass die piezoelektrischen Eigenschaften nicht verloren gehen. Besonders bevorzugt werden piezoelektrische Elemente auf Basis von Terfenol verwendet.The solidification process of the melt is carried out-preferably under pressure-in such a short time that the function elements are not impaired in their function by the introduced energy. The surface of the functional element or the surface of the functional element adjoining the protective layer therefore exhibits during of the casting process and the solidification process preferably maximally at a temperature which is lower than the temperature from which the functionality of the temperature-sensitive element is impaired. In particular, the surface temperature should generally not exceed 250-300 ° C. Functional elements with piezoelectric components can be exposed for a short time to higher temperatures which are above the Curie temperature of the corresponding piezoelectric material. The piezoelectric properties of the material are initially lost, but can be restored by applying a high voltage. Preferably, the casting process is therefore performed so that the piezoelectric properties are not lost. Particular preference is given to using piezoelectric elements based on terfenol.

Besonders bevorzugt wird das erfindungsgemäße Verfahren so durchgeführt, dass - abhängig von der Bauteilgeometrie und dem Bauteilvolumen - sehr kurzen Formfüllzeiten eine sehr schnelle Erstarrung der Schmelze erreicht wird. Im Bereich der Funktionselemente dauert das Gussverfahren (d.h. die Formfüllzeit und Erstarrungszeit) bevorzugt weniger als 10s.The process according to the invention is particularly preferably carried out in such a way that very rapid solidification of the melt is achieved, depending on the geometry of the component and the volume of the component, during very short mold filling times. In the field of functional elements, the casting process (i.e., mold filling time and setting time) preferably lasts less than 10 seconds.

Das erfindungsgemäße Verfahren ist besonders geeignet, Bauteile aus Aluminiumguss, Magnesiumguss, Zinkguss und bei geeigneter Temperaturführung und -beständigkeit auch aus Eisen- sowie Stahlguss herzustellen. Ist eine Schutzschicht für die einzugießenden Funktionselemente vorgesehen, so wir das erfindungsgemäße Verfahren bevorzugt so durchgeführt, dass das Funktionselement teilweise oder vollständig homogen umhüllt wird. Durch die Positionierung in der Gussform wird die Lage der Elemente vorgegeben und somit die Position der Sensordaten und die spätere Lage des Bauteils im Raum.The inventive method is particularly suitable to produce components made of cast aluminum, magnesium casting, zinc casting and with suitable temperature control and resistance also from iron and steel casting. If a protective layer is provided for the functional elements to be infiltrated, then the method according to the invention is preferably carried out in such a way that the functional element is partially or completely homogeneously enveloped. Positioning in the mold determines the position of the elements and thus the position of the sensor data and the position of the component in space.

Im Folgenden wird - ohne Einschränkung der Allgemeinheit - das erfindungsgemäße Verfahren zu Herstellung von Gussbauteilen und die dabei erhaltenen Bauteile noch näher anhand von Abbildungen und einem Beispiel erläutert:In the following, the process according to the invention for the production of cast components and the components thereby obtained will be explained in more detail with reference to figures and an example without restricting generality.

Es zeigen:

  • Figur 1: Musterbauteil (1) ohne eingegossene Funktionselemente
  • Figur 2: Musterbauteil (1) mit RFID (2) und dielektrischem Spalt (3)
    Figur 2a: Detailansicht von Figur 2
  • Figur 3: Musterbauteil mit Piezokeramik (4) und Leitung nach Außen (5)
    Figur 3a: Detailansicht von Figur 3
  • Figur 4:Musterbauteil mit Piezokeramik(4), Elektronik (6) und RFID (2)
  • Figur 5: Bauteil mit eingegossenem Piezoelement
  • Figur 5a: Detailansicht von Figur 5
Show it:
  • Figure 1: pattern component (1) without molded functional elements
  • FIG. 2: Sample component (1) with RFID (2) and dielectric gap (3)
    FIG. 2a: detailed view of FIG. 2
  • FIG. 3: Sample component with piezoceramic (4) and line to the outside (5)
    FIG. 3a: detailed view of FIG. 3
  • FIG. 4: Sample component with piezoceramic (4), electronics (6) and RFID (2)
  • Figure 5: Component with cast piezoelectric element
  • FIG. 5a: detailed view of FIG. 5

Beispiel:Example:

Durchgeführt wurde das erfindungsgemäße Gussverfahren zur Herstellung eines Bauteils gemäß Figur 1 bis 5 auf einer Kaltkammer-Druckgießmaschine vom Typ Bühler SC/N 66. Als Gießwerkstoff kam AlSi9Cu3 zum Einsatz.The casting process according to the invention for producing a component according to FIGS. 1 to 5 was carried out on a cold chamber die casting machine of the Buhler SC / N 66 type. The casting material used was AlSi9Cu3.

Es wurden RFIDs und Piezokeramiken mit einem der Form angepassten Halter in der Kavität der Druckgussform positioniert. Der Einsatz wurde so gewählt, dass er nicht durch das schnell anströmende Metall verrückt oder zerstört wird.RFIDs and piezoceramics have been positioned in the cavity of the die using a mold adapted holder. The insert was chosen so that it is not crazy or destroyed by the fast flowing metal.

Die Bereiche im Bauteil, die für die Aufnahme eines Einlegeteils geeignet sind, sind individuell in Abhängigkeit der Bauteilgeometrie sowie der Anschnitte zu wählen. Ist eine bestimmte Position vorgegeben, müssen ggf. konstruktive Änderungen an Anschnitt bzw Bauteilgeometrie vorgenommen werden. Im vorliegenden Fall wurden die RFIDs und Piezokeramiken an den Positionen, die den Figuren 2 bis 4 zu entnehmen sind, vergossen.The areas in the component, which are suitable for receiving an insert, are to be selected individually depending on the component geometry and the gates. If a specific position is specified, design changes to the gate or component geometry may be necessary. In the present case, the RFIDs and piezoceramics were cast at the positions that can be seen in FIGS. 2 to 4.

Nach der Positionierung der Funktionselemente wurde die Form geschlossen und der Schuss ausgelöst. Die Formfüllung erfolgte innerhalb von 25 ms. Das Gusstück wurde sofort nach der Entnahme aus der Form mit Luft oder Wasser abgekühlt; die Funktionselemente waren voll funktionstüchtig und konnten bestimmungsgemäß verwendet werden.After positioning the functional elements, the mold was closed and the shot fired. The mold filling took place within 25 ms. The casting was cooled immediately after removal from the mold with air or water; the functional elements were fully functional and could be used as intended.

Claims (10)

Mittels eines Gussverfahrens herstellbares Bauteil aus Metall, das ein oder mehrere eingegossene Funktionselemente enthält,
wobei die Funktionselemente temperaturempfindlich sind und/oder adaptronische Sensoren und/oder adaptronische Aktoren sind.By means of a casting process manufacturable metal component containing one or more molded functional elements,
wherein the functional elements are temperature-sensitive and / or are adaptronic sensors and / or adaptronic actuators. Bauteil nach Anspruch 1, dadurch gekennzeichnet, dass zwischen dem Funktionselement und dem vergossenen Metall zumindest teilweise eine Schutzschicht oder die Reste einer Schutzschicht vorhanden sind.Component according to claim 1, characterized in that between the functional element and the cast metal at least partially a protective layer or the remains of a protective layer are present. Bauteil nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass das Bauteil mittels eines Druckgussverfahrens erhältlich ist.Component according to one of the preceding claims, characterized in that the component is obtainable by means of a die-casting process. Bauteil nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass das Funktionselement ein Sensor und/oder ein Aktor und/oder ein RFID ist.Component according to one of the preceding claims, characterized in that the functional element is a sensor and / or an actuator and / or an RFID. Bauteil nach Anspruch 4 dadurch gekennzeichnet, dass
das Funktionselement Materialermüdung und/oder Missbrauch detektiert und/oder eine Identifizierungsfunktion erfüllt.Component according to claim 4, characterized in that
the functional element detects material fatigue and / or abuse and / or fulfills an identification function. Bauteil nach einem der vorhergehenden Anprüche, dadurch gekennzeichnet, dass sich das Funktionselement nicht an einer Position innerhalb des Bauteils befindet, die während des Gussverfahrens zur Herstellung des Bauteils von der Hauptströmung der zu vergießenden Metallschmelze umströmt wird.Component according to one of the preceding Anprüche, characterized in that the functional element is not located at a position within the component, which is flowed around during the casting process for the preparation of the component of the main flow of the molten metal to be cast. Verfahren zur Herstellung eines Bauteils nach einem der vorhergehenden Ansprüche,
dadurch gekennzeichnet, dass
ein gegebenenfalls mit einer Schutzschicht zumindest teilweise umhülltes Funktionselement in der Kavität einer Gussform positioniert wird
und anschließend mittels eines Gussverfahrens mit einem Metall umgossen wird, wobei die Positionierung in der Gussform so gewählt wird, dass die Strömungsgeschwindigkeit im Bereich des Funktionselements niedrig ist.Method for producing a component according to one of the preceding claims,
characterized in that
an optionally with a protective layer at least partially enveloped functional element is positioned in the cavity of a mold
and is then encapsulated with a metal by means of a casting process, the positioning in the casting mold being selected such that the flow velocity in the area of the functional element is low. Verfahren nach Anspruch 7, dadurch gekennzeichnet, dass
das Funktionselement nicht so innerhalb des Bauteils positioniert wird, dass sich während des Vergießens der Metallschmelze das Funktionselement in der Hauptströmung der Metallschmelze befindet.A method according to claim 7, characterized in that
the functional element is not positioned within the component such that during the potting of the molten metal, the functional element is located in the main flow of the molten metal. Verfahren nach Anspruch 7 oder 8, dadurch gekennzeichnet, dass
der Erstarrungsprozess der Schmelze in so kurzer Zeit erfolgt, dass die Funktionselemente in ihrer Funktion durch die während des Gussverfahrens eingebrachte thermische Energie nicht beeinträchtigt werden.A method according to claim 7 or 8, characterized in that
the solidification process of the melt takes place in such a short time that the function elements are not impaired in their function by the thermal energy introduced during the casting process. Verwendung eines Bauteils nach den Ansprüchen 1 bis 6, insbesondere nach Anspruch 5, in Kraftfahrzeugen oder in der Luftfahrt, insbesondere in Motorblöcken oder Fahrwerken.Use of a component according to claims 1 to 6, in particular according to claim 5, in motor vehicles or in aviation, in particular in engine blocks or chassis.
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DE102015106002A1 (en) 2015-04-20 2016-10-20 Gottfried Wilhelm Leibniz Universität Hannover Electrical component, construction component of a technical object and method for its production
DE102018210138A1 (en) 2018-06-21 2019-12-24 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Labeling element for a metal casting and process for its manufacture
DE102018218773A1 (en) 2018-11-02 2020-05-07 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Cast component with sensor for detecting mechanical loads and / or deformations and device for detecting mechanical loads and / or deformations in a cast component

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CN112829178A (en) * 2019-11-22 2021-05-25 菲尼克斯电气公司 Apparatus and method for die casting metal

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EP2025433A3 (en) 2009-08-05
EP1645350B1 (en) 2009-06-17
SI1645350T1 (en) 2009-10-31
EP2025433B1 (en) 2012-08-22
DE502005007494D1 (en) 2009-07-30
DE202005021246U1 (en) 2007-08-23
ATE433811T1 (en) 2009-07-15
PL2025433T3 (en) 2012-12-31
PL1645350T3 (en) 2009-11-30
DE102005018936A1 (en) 2006-04-20
DK1645350T3 (en) 2009-10-12
EP2025433A2 (en) 2009-02-18

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