EP1691944B1 - Method for the production of a cast part from a molten metal - Google Patents

Method for the production of a cast part from a molten metal Download PDF

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Publication number
EP1691944B1
EP1691944B1 EP04802904A EP04802904A EP1691944B1 EP 1691944 B1 EP1691944 B1 EP 1691944B1 EP 04802904 A EP04802904 A EP 04802904A EP 04802904 A EP04802904 A EP 04802904A EP 1691944 B1 EP1691944 B1 EP 1691944B1
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EP
European Patent Office
Prior art keywords
cooling liquid
casting
mold
cooling
molten metal
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EP04802904A
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German (de)
French (fr)
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EP1691944A2 (en
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Wilfried Bender
Wolfgang Müller
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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
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
    • B22D27/045—Directionally solidified castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/06—Permanent moulds for shaped castings
    • B22C9/068—Semi-permanent moulds

Definitions

  • the present invention relates to a method for producing a casting from a molten metal, in which the molten metal is poured into a porous casting mold and the molten metal-filled porous casting mold is cooled by means of a cooling liquid.
  • the area which is wetted by the cooling liquid, the actual immersion depth due to a suitable selection of the dipping speed of the casting mold into the cooling liquid, the thickness and porosity of the casting mold wall and the density and viscosity of the cooling liquid the penetration range of the cooling liquid, seen in the direction of movement of the solidification front, the solidification front after.
  • the prerequisite for the penetration of cooling liquid into the pores of the known ceramic casting mold is that the cooling liquid acts with a certain pressure on the casting mold.
  • a method and a device for controlled casting cooling in particular vacuum-compacted sand molds is known.
  • a cooling medium is passed under pressure through the casting mold containing the casting.
  • the cooling medium is either through a cooling pipe system through the mold or directly into the Sand mold ushered in.
  • the second known method explained above has the disadvantage that the cooling liquid has to be passed under pressure via a complex cooling pipe system into the casting mold.
  • the known solutions have little flexibility.
  • An adaptation of the molds to changing casting geometries and correspondingly changing requirements for the cooling can be accomplished with the known from the prior art solutions only with great time and material costs.
  • the object of the invention was, in a method for producing a casting from a molten metal, a fast and targeted controllable Cooling of a casting located in a mold in a simple manner to allow at the same time high flexibility to form a certain microstructure during the solidification of the casting, which determines the mechanical properties of the resulting casting.
  • the porous casting mold is wetted after casting the molten metal in the region of at least a portion of its outer surfaces with a cooling liquid by spraying or application by means of a sponge (or a comparatively absorbent element) and the porous casting mold is produced, at least in the region wetted with the cooling liquid, from a material whose capillarity is matched to the cooling liquid such that the casting mold automatically absorbs at least a partial volume of the cooling liquid wetting it in its region produced from this material, by the material the mold absorbs the wetting cooling liquid.
  • the invention provides for applying the cooling liquid by spraying or application with a sponge, and for designing the porous casting mold used in accordance with the invention so that it actively sucks the cooling liquid.
  • the casting mold used according to the invention is designed such that it has a capillarity in the region of its portions which come into contact with the cooling liquid, by means of which a surface activity sufficient for the suction of the cooling liquid is ensured. Accordingly, the contact angle between the respective wetted surface portion and the liquid surface is less than 90 in casting molds used according to the invention at least in the region of their surface in contact with the cooling liquid (see Section 11.1.3 in H. Kuchling "Taschenbuch der Physik", 5th edition) , Published by Harri Deutsch, Thun and Frankfurt / Main, 1984).
  • the process according to the invention can be used particularly economically in that the absorbent material from which the casting mold is at least partially made is a molding material for the production of lost casting molds mixed from a molding base material and a binder, and the molding base material and the molding material Binder of the molding material are coordinated such that the mold part when wetted with the cooling liquid maintains its shape over at least the time required for the formation of a dimensionally stable outer shell of the casting by solidification of the cast into the mold molten metal.
  • a mold is assembled from at least one mold part.
  • the mold part is made of a mixed from a molding sand and a binder molding material which is brought by a suitable treatment in an at least temporarily solid form.
  • the molding material can be brought, for example in a conventional manner in a core molding machine in the form of the respective mold part and then cured by supplying heat, gassing or other measures.
  • the molten metal is then poured into the "lost" casting mold formed from such molded parts. Subsequently, the wetting of the mold according to the invention is carried out with the cooling liquid.
  • the surface activity of the finished molded part is adjusted so that the liquid coming into contact with the molded part is absorbed due to the capillary effect and that at the same time the binder and the molding base material are used in the molding material used to produce the molded article are coordinated so that the molding remains dimensionally stable even with at least partially complete saturation with the cooling liquid its shape over a sufficient time for the formation of a solid outer shell of the casting time.
  • cooling of the molten metal during the solidification phase can be carried out in a targeted and precisely controlled manner without the need for expensive device or process engineering measures.
  • Secured over a sufficient treatment time dimensional stability and the capillarity of the mold used in the invention make it possible in a simple way to make the cooling of the casting so that a certain, optimal for the desired properties of the component solidification profile is achieved.
  • the thermal conductivity of the casting mold and thus the cooling of the melt is increased by the coolant absorbed by the casting mold.
  • the cooling liquid is actively absorbed by the casting mold and permeates the casting mold completely or only in sections, depending on the respective surface activity of the casting material, the duration of action, the location of the wetting and the quantity of coolant supplied. In this way, the desired rapid and specifically controlled via the supply of cooling liquid cooling of the sections of the hitherto not completely solidified molten metal is ensured, which come into contact with the areas covered by the cooling liquid of the mold.
  • a cooling made according to the invention can be carried out without difficulty in a wide variety of casting geometries.
  • only the parts of the casting mold can be brought into contact with cooling liquid, which adjoin regions of large thickness of the casting to be produced.
  • the contour of the casting mold itself can be adapted to the cooling requirements.
  • the casting mold for example, in the areas in which the cooling of the invention is to be particularly effective, has thin wall thicknesses, the wetting the liquid form very quickly in these areas, so that in the areas concerned a particularly intensive cooling is achieved.
  • other areas of the mold can be made thicker, so that the cooling will start there later.
  • the cooling liquid When the cooling liquid reaches the peripheral layer of the inner surface of the casting mold adjacent to the melt, the cooling liquid begins to evaporate.
  • the associated with this evaporation energy removal causes a significant reduction in the temperature in the edge zone, with the result that the adjacent melt solidifies faster.
  • the liquid vapor thus formed escapes at least partially from the casting mold or condenses with the result that sets a directed from the wetted outer surface to the inner surface of the mold concentration gradient. This promotes the suction of coolant in addition, so that in a continuous and automatically running process continuously fresh coolant enters the heated from the heat of the casting area of the mold.
  • the fact that the evaporation of the cooling liquid, especially in the initial phase of cooling due to the then still very high casting temperature already starts before the cooling liquid reaches the casting itself, thereby ensuring that the surface quality of the casting is not affected by vapor bubble formation.
  • the amount of cooling liquid taken up by the casting mold can be controlled over the duration of the contact between the casting mold and the cooling liquid and the amount of cooling liquid brought into contact. Since the mold automatically aspirates the cooling liquid, complete cooling of the casting mold into cooling liquid is not required to achieve cooling of the entire molten metal, as is introduction of cooling liquid into the casting mold under pressure. With regard to the introduction of cooling liquid, the casting mold according to the invention thus constitutes the active part, while the cooling liquid is merely offered, that is to say is not actively driven into the casting mold.
  • the suction effect is largely determined by the type and shape of the pores present in the mold. Also, by setting a certain surface activity of the mold parts can thus be targeted to the cooling effect influence. Smaller pores lead due to the increased total surface area to a greater capillary action and thus a stronger suction of water.
  • the mold wetted with cooling liquid also remains dimensionally stable at least until solidification of the molten metal. This is achieved on the one hand by a suitable combination of binder and molding material of the molding material.
  • the vaporisation of the cooling liquid which already starts in the casting mold as a result of the heat of the casting metal, promotes drying of the casting mold. In this way, a premature disintegration of the mold before solidification of the casting is additionally counteracted.
  • the wetting of the casting mold with cooling liquid according to the invention can be carried out at any time during the solidification phase, ie from the start of the casting of the melt until complete solidification and cooling of the casting. Depending on the desired cooling process, the wetting can be maintained continuously or can only be carried out over certain periods of time.
  • the capillary effect can be used in accordance with the invention to specifically impart a certain direction to the cooling liquid as it enters the casting mold.
  • the mold wets depending on the surface activity of the components used against gravity, when the mold is brought into contact only with its lower, near-ground area with the cooling liquid.
  • the amount of cooling fluid absorbed by the casting mold can thus be controlled both via the surface activity of the respectively processed casting mold material and the size of the surface wetted with cooling liquid.
  • the accuracy with which the cooling liquid is introduced into the mold can be increased by the fact that the mold is brought into contact with a moisture carrier. In this way, targeted and flexible cooling liquid can be brought into areas of the casting mold adjacent to casting areas, which, for example, have a special cooling requirement due to their thickness.
  • One way of applying the cooling liquid to be absorbed by the casting mold is to spray the casting mold at least in sections with cooling liquid.
  • the spray pressure and the sprayed-on amount of liquid are to be coordinated so that the cooling liquid is not driven into the mold, but that the respective sprayed surface portions of the mold are particularly uniformly charged with a precisely metered amount of liquid. It is particularly advantageous to use the spraying of the casting mold in an automated processing process.
  • a further embodiment of the invention which is particularly easy to implement and which provides targeted wetting of the casting mold with cooling liquid, which is restricted to certain regions of the casting mold, provides for the formation of pockets on the casting mold.
  • the amount of liquid filled in these pockets constitutes a supply that is absorbed by the mold over a certain time interval.
  • the depth and shape of the pockets can be designed so that internal areas of the mold are reached particularly quickly by the cooling liquid.
  • Additives may be added to the water to affect its wettability.
  • emulsions can also be used as cooling liquids whose properties are thus matched are that the desired cooling effect occurs safely.
  • the casting mold part is a casting core.
  • cooling can be achieved in a simple manner, especially in the case of casting cores which are difficult to access.
  • the casting mold can be formed from a core package, that is to say composed of a plurality of casting cores and casting moldings. In such a mold, the advantages of the method according to the invention in terms of accessibility and flexibility for cooling are particularly relevant.
  • molding materials which are mixed with an inorganic binder are particularly suitable for the production of casting moldings used according to the invention.
  • moldings cured using a suitable inorganic binder have a particularly high dimensional stability over a long treatment time upon penetration with cooling fluid. At the same time they are particularly uncritical with regard to the burden on the environment.
  • the use of water glass-based binder systems has proven particularly suitable.
  • the molding sand may contain cost-effectively available quartz sand.
  • the molding material then, if the molding sand contains alumina sand.
  • a mullite-containing molding sand can be used.
  • the inventive method is particularly suitable for the production of Gussatücken from achtomatallschmelze, in particular from an aluminum or a magnesium alloy.
  • Fig. 1 illustrated device A is used for cooling of molds 1, after they have been filled in a conventional manner with an aluminum melt by the molds 1 in the cooling liquid, as in the EP 571 703 B1 described, be immersed.
  • the device A comprises a lifting device 4 and a basin 2, which is filled with a cooling liquid K.
  • the cooling liquid K is water which is mixed with an additive to improve its wettability.
  • the molded parts of the casting molds 1, not shown in detail, have been produced from a molding material which has been mixed, for example, from an inorganic, water glass-based binder system and a mullite-containing molding base material.
  • the moldings have been produced in a machine, also not shown, in which the molding material has been cured after being injected into a shaping space of the machine by supplying heat.
  • the structure of the mold and its individual parts corresponds to the conventional, often described in the prior art construction of such forms, so that is omitted at this point to a more detailed explanation.
  • the casting mold is transported to the device A and taken over by the lifting device 4.
  • the lifting device 4 then lowers the casting mold 1 into the basin 2.
  • the sinking depth is controlled so that the casting mold 1, starting from its bottom 1a, is permanently in contact with the cooling liquid K.
  • the mold is lowered, for example about about one-eighth of its height H in the cooling liquid K.
  • the casting mold 1 As soon as the casting mold 1 dips into the cooling liquid K, the casting mold 1 actively absorbs cooling liquid K against the direction of gravity owing to its own surface activity.
  • Fig. 1 the direction of the cooling liquid intake of the mold 1 is indicated by arrows P.
  • a volume region 3 wetted by the cooling liquid K forms in the casting mold 1 and extends from the bottom 1a over the optimum height H of the casting mold 1 for the respective cooling result.
  • the capillary action and the associated active suction of cooling liquid K through the casting mold 1 thereby cause the volume 3 of the casting mold 1 moistened by the cooling liquid K to significantly exceed the casting mold portion immersed in the cooling liquid K.
  • the cooling liquid K which has penetrated into the casting mold 1 begins to evaporate. It leads in this way to a strong cooling, with the result that the directly adjacent to the inner walls of the mold 1 molten aluminum melt solidifies quickly and evenly to a solid shell.
  • the vaporizing liquid exits the casting mold 1 and is replaced by cooling liquid K which, starting from the section immersed in the cooling liquid K, pushes into the casting mold 1.
  • Fig. 2 is the mold 1, after the previously explained cooling is completed in the formed by the cooling liquid Kdestattkeitsbad, lifted from the cooling liquid. The remaining in the mold 1 cooling liquid K ensures that a residual cooling of the lower portion 3 of the mold is maintained.
  • the lateral areas 1b, 1c of the mold 1 are assigned, is now on the first lateral region 1b by means of nozzles 4, a cooling liquid mist Kn abandoned.
  • the cooling liquid quantities K applied in this way to the respective regions 1 b, 1 c of the casting mold 1 are also actively absorbed by the molding material of the casting mold due to the capillary action, so that areas 7, 8 soaked in cooling liquid K are set in the casting mold 1. Also in these areas there is a targeted intensive cooling of the melt contained in the mold 1.
  • a mold 100 varied from the mold 1 only in terms of shape has an outer pocket 9 formed on an outer surface of the mold 100 and two inner pockets 10, 11 formed in the mold 100.
  • the pockets 9,10,11 are each filled with coolant K.
  • the mold 1 can be removed from the casting.
  • the amount, location and, due to the active suction of cooling liquid, the direction of penetration of the casting molds 1,100 with cooling liquid K can be predefined precisely and flexibly in a simple manner.
  • a rapid and directional solidification of the melt is achieved, which leads to particularly good product properties of the cast obtained.

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  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Description

Die vorliegende Erfindung betrifft ein Verfahren zum Herstellen eines Gussteils aus einer Metallschmelze, bei dem die Metallschmelze in eine poröse Gießform vergossen und die mit Metallschmelze gefüllte poröse Gießform mit Hilfe einer Kühlflüssigkeit gekühlt wird.The present invention relates to a method for producing a casting from a molten metal, in which the molten metal is poured into a porous casting mold and the molten metal-filled porous casting mold is cooled by means of a cooling liquid.

Eine beim Gießen von Teilen für Verbrennungsmotore und anderen im praktischen Einsatz hoch belasteten Bauelementen stets zu beachtende Anforderung besteht darin, dass sich im Zuge der Erstarrung des Gussstücks eine bestimmte Gefügestruktur ausbilden soll, die die mechanischen Eigenschaften des erhaltenen Gussstücks entscheidend bestimmt.A requirement which must always be taken into consideration when casting components for internal combustion engines and other components that are highly stressed in practical use is that during the solidification of the casting a specific microstructure should be formed which decisively determines the mechanical properties of the resulting casting.

Es ist bekannt, dass eine schnelle Erstarrung der Metallschmelze zu einem feinen Gefüge des Gussteils führt und daher wünschenswert ist. Außerdem ist für ein dichtes Gefüge ein gelenkter Erstarrungsverlauf erstrebenswert.It is known that a rapid solidification of the molten metal leads to a fine structure of the casting and is therefore desirable. In addition, a controlled solidification process is desirable for a dense structure.

In der Praxis lassen sich beide Anforderungen insbesondere dann nur mit großem Aufwand erfüllen, wenn Gussstücke mit stark schwankenden Dicken hergestellt werden sollen. Ein typisches Beispiel für derartige Gussstücke sind aus Leichtmetallschmelzen gegossene Zylinderköpfe oder Motorblöcke, in die neben den jeweils erforderlichen Verbrennungsräumen, Ventilsitzen etc. komplex geformte Kühl- und Ölversorgungskanäle sowie Lagerelemente eingeformt werden sollen.In practice, both requirements can be met only with great effort, in particular, if castings are to be produced with widely varying thicknesses. A typical example of such castings are cast from light metal melts Cylinder heads or engine blocks, in addition to the respectively required combustion chambers, valve seats, etc. complex shaped cooling and oil supply channels and bearing elements are to be formed.

Es ist versucht worden, den angestrebten Erstarrungsverlauf durch eine Flüssigkeitskühlung der in der Gießform befindlichen Metallschmelze zu verwirklichen. So ist aus der EP 0 571 703 B1 ein Feingussverfahren zum Herstellen von metallischen Gusskörpern bekannt, bei dem eine die Metallschmelze enthaltende poröse Keramikgießform nach dem Abgießen in einer stetigen Bewegung in eine Kühlflüssigkeit eingetaucht wird. Die Kühlflüssigkeit durchtritt dann die poröse Keramikform und penetriert die Gießformwand. Dabei eilt der Bereich, der von Kühlflüssigkeit benetzt wird, der tatsächlichen Eintauchtiefe aufgrund einer geeigneten Auswahl der Eintauchgeschwindigkeit der Gießform in die Kühlflüssigkeit, der Dicke und Porosität der Gießformwand sowie der Dichte und Viskosität der Kühlflüssigkeit der Penetrationsbereich der Kühlflüssigkeit, in Bewegungsrichtung der Erstarrungsfront gesehen, der Erstarrungsfront nach. Voraussetzung für das Eindringen von Kühlflüssigkeit in die Poren der bekannten keramischen Gießform ist dabei, dass die Kühlflüssigkeit mit einem gewissen Druck auf die Gießform wirkt.Attempts have been made to realize the desired course of solidification by means of liquid cooling of the molten metal present in the casting mold. So is out of the EP 0 571 703 B1 a precision casting method for producing metal castings is known, in which a porous ceramic mold containing the molten metal is immersed after casting in a steady motion in a cooling liquid. The coolant then passes through the porous ceramic mold and penetrates the mold wall. In this case, the area which is wetted by the cooling liquid, the actual immersion depth due to a suitable selection of the dipping speed of the casting mold into the cooling liquid, the thickness and porosity of the casting mold wall and the density and viscosity of the cooling liquid the penetration range of the cooling liquid, seen in the direction of movement of the solidification front, the solidification front after. The prerequisite for the penetration of cooling liquid into the pores of the known ceramic casting mold is that the cooling liquid acts with a certain pressure on the casting mold.

Aus der DE 32 40 808 A1 ist zudem ein Verfahren und eine Vorrichtung zur gesteuerten Gussstückabkühlung in insbesondere vakuumverdichteten Sandformen bekannt. Bei diesem bekannten Verfahren wird ein Kühlmedium unter Druck durch die das Gussstück enthaltende Gießform geleitet. Das Kühlmedium wird dabei entweder durch ein Kühlrohrsystem durch die Form hindurch oder direkt in die Sandform hineingeleitet. Durch die infolge der Hitze der Metallschmelze eintretende Verdampfung des Wassers sollen die noch heiße Form und damit einhergehend das Gussstück gekühlt werden.From the DE 32 40 808 A1 In addition, a method and a device for controlled casting cooling in particular vacuum-compacted sand molds is known. In this known method, a cooling medium is passed under pressure through the casting mold containing the casting. The cooling medium is either through a cooling pipe system through the mold or directly into the Sand mold ushered in. By entering due to the heat of the molten metal evaporation of the water, the still hot mold and concomitantly the casting to be cooled.

Ein wesentlicher Nachteil des voranstehend erläuterten, aus dem Stand der Technik bekannten ersten Kühlverfahrens ist, dass dazu aufwändig herzustellende, teure Keramikformen erforderlich sind und die Genauigkeit, mit der die der Benetzung nacheilende Abkühlung der in der Gießform enthaltenen Schmelze fortschreitet, nur ungenau eingestellt werden kann.A major disadvantage of the above-explained, known from the prior art first cooling method is that consuming elaborate, expensive ceramic molds are required and the accuracy with which the wetting lagging after cooling of the melt contained in the mold, can be adjusted only inaccurate ,

Das zweite voranstehend erläuterte bekannte Verfahren hat den Nachteil, dass die Kühlflüssigkeit unter Druck über ein aufwändiges Kühlrohrsystem in die Gießform geleitet werden muss. Sowohl die Verwendung von keramischen Gießformen nach dem Feingussverfahren ( EP 0 571 703 B1 ) als auch die Notwendigkeit, eine Verrohrung in die Gießform einzubringen ( DE 32 40 808 A1 ), führen dazu, dass sich mit diesen bekannten Verfahren komplex geformte Gusssteile mit gesteuertem Erstarrungsverlauf nur unter erhöhtem Kosten- und Herstellaufwand erzeugen lassen. Darüber hinaus besitzen die bekannten Lösungen nur eine geringe Flexibilität. Eine Anpassung der Gießformen an wechselnde Gussteilgeometrien und sich dementsprechend ändernde Anforderungen an die Kühlung kann mit den aus dem Stand der Technik bekannten Lösungen nur mit großem Zeit- und Materialaufwand bewerkstelligt werden.The second known method explained above has the disadvantage that the cooling liquid has to be passed under pressure via a complex cooling pipe system into the casting mold. Both the use of ceramic casting molds by precision casting ( EP 0 571 703 B1 ) as well as the need to introduce a casing into the casting mold ( DE 32 40 808 A1 ), cause with these known methods complex shaped castings with controlled solidification process can be generated only with increased cost and Herstellaufwand. In addition, the known solutions have little flexibility. An adaptation of the molds to changing casting geometries and correspondingly changing requirements for the cooling can be accomplished with the known from the prior art solutions only with great time and material costs.

Die Aufgabe der Erfindung bestand darin, bei einem Verfahren zum Herstellen eines Gussteils aus einer Metallschmelze eine schnelle und gezielt steuerbare Abkühlung eines in einer Giessform befindlichen Gussteils in einfacher Weise bei gleichzeitig hoher Flexibilität zu ermöglichen, um im Zuge der Erstarrung des Gussstücks eine bestimmte Gefügestruktur auszubilden, die die mechanischen Eigenschaften des erhaltenen Gussstücks bestimmt. The object of the invention was, in a method for producing a casting from a molten metal, a fast and targeted controllable Cooling of a casting located in a mold in a simple manner to allow at the same time high flexibility to form a certain microstructure during the solidification of the casting, which determines the mechanical properties of the resulting casting.

Diese Aufgabe ist erfindungsgemäss dadurch gelöst worden, dass bei einem Verfahren der eingangs angegebenen Art die poröse Giessform nach dem Vergiessen der Metallschmelze im Bereich mindestens eines Abschnitts ihrer Aussenflächen mit einer Kühlflüssigkeit durch Ansprühen oder Auftragen mittels eines Schwamms (oder ein vergleichbar saugfähiges Element) benetzt wird und die poröse Giessform mindestens in dem mit der Kühlflüssigkeit benetzten Bereich aus einem Material erzeugt ist, dessen Kapillarität so auf die Kühlflüssigkeit abgestimmt ist, dass die Giessform in ihrem aus diesem Material erzeugten Bereich mindestens ein Teilvolumen der sie benetzenden Kühlflüssigkeit selbsttätig aufnimmt, indem das Material der Giessform die sie benetzende Kühlflüssigkeit aufsaugt.This object has been achieved according to the invention in that in a method of the type specified above, the porous casting mold is wetted after casting the molten metal in the region of at least a portion of its outer surfaces with a cooling liquid by spraying or application by means of a sponge (or a comparatively absorbent element) and the porous casting mold is produced, at least in the region wetted with the cooling liquid, from a material whose capillarity is matched to the cooling liquid such that the casting mold automatically absorbs at least a partial volume of the cooling liquid wetting it in its region produced from this material, by the material the mold absorbs the wetting cooling liquid.

Anders als beim eingangs erläuterten Stand der Technik sieht die Erfindung vor, die Kühlflüssigkeit durch Ansprühen oder Auftragen mit einem Schwamm zu applizieren, und die erfindungsgemäss verwendete poröse Giessform so auszubilden, dass sie die Kühlflüssigkeit aktiv ansaugt. Zu diesem Zweck ist die erfindungsgemäss verwendete Giessform so ausgebildet, dass sie im Bereich ihrer mit der Kühlflüssigkeit in Berührung kommenden Abschnitte eine Kapillarität aufweist, durch die eine für das Ansaugen der Kühlflüssigkeit ausreichende Oberflächenaktivität gewährleistet ist. Der Randwinkel zwischen dem jeweils benetzten Oberflächenabschnitt und der Flüssigkeitsoberfläche ist demzufolge bei erfindungsgemäss eingesetzten Giessformen mindestens im Bereich ihrer mit der Kühlflüssigkeit in Kontakt kommenden Oberfläche kleiner als 90 (s. Abschnitt 11.1.3 in H. Kuchling "Taschenbuch der Physik", 5. Auflage, Verlag Harri Deutsch, Thun und Frankfurt/Main, 1984).Unlike the prior art described at the outset, the invention provides for applying the cooling liquid by spraying or application with a sponge, and for designing the porous casting mold used in accordance with the invention so that it actively sucks the cooling liquid. For this purpose, the casting mold used according to the invention is designed such that it has a capillarity in the region of its portions which come into contact with the cooling liquid, by means of which a surface activity sufficient for the suction of the cooling liquid is ensured. Accordingly, the contact angle between the respective wetted surface portion and the liquid surface is less than 90 in casting molds used according to the invention at least in the region of their surface in contact with the cooling liquid (see Section 11.1.3 in H. Kuchling "Taschenbuch der Physik", 5th edition) , Published by Harri Deutsch, Thun and Frankfurt / Main, 1984).

Besonders wirtschaftlich lässt sich das erfindungsgemäße Verfahren dabei dadurch einsetzen, dass das saugfähige Material, aus dem die Gießform mindestens teilweise hergestellt ist, ein Formstoff für die Herstellung von verlorenen Gießformen ist, der aus einem Formgrundstoff und einem Binder gemischt ist, und der Formgrundstoff und der Binder des Formstoffes derart aufeinander abgestimmt sind, dass das Gießformteil bei Benetzung mit der Kühlflüssigkeit seine Gestalt über mindestens die Zeit beibehält, die für die Ausbildung einer formstabilen Außenschale des Gussstücks durch Erstarrung der in die Gießform eingegossenen Metallschmelze benötigt wird.The process according to the invention can be used particularly economically in that the absorbent material from which the casting mold is at least partially made is a molding material for the production of lost casting molds mixed from a molding base material and a binder, and the molding base material and the molding material Binder of the molding material are coordinated such that the mold part when wetted with the cooling liquid maintains its shape over at least the time required for the formation of a dimensionally stable outer shell of the casting by solidification of the cast into the mold molten metal.

Gemäß dieser Ausgestaltung der Erfindung wird aus mindestens einem Gießformteil eine Gießform zusammengestellt. Das Gießformteil ist dabei aus einem aus einem Formsand und einem Binder gemischten Formstoff hergestellt, der durch eine geeignete Behandlung in eine mindestens zeitweise feste Form gebracht wird. Zu diesem Zweck kann der Formstoff beispielsweise in an sich bekannter Weise in einer Kernformmaschine in die Form des jeweiligen Gießformteils gebracht und anschließend durch Wärmezufuhr, Begasung oder sonstige Maßnahmen ausgehärtet werden. In die aus derart erzeugten Formteilen gebildete "verlorene" Gießform wird dann die Metallschmelze gegossen. Anschließend erfolgt die erfindungsgemäße Benetzung der Gießform mit der Kühlflüssigkeit.According to this embodiment of the invention, a mold is assembled from at least one mold part. The mold part is made of a mixed from a molding sand and a binder molding material which is brought by a suitable treatment in an at least temporarily solid form. For this purpose, the molding material can be brought, for example in a conventional manner in a core molding machine in the form of the respective mold part and then cured by supplying heat, gassing or other measures. The molten metal is then poured into the "lost" casting mold formed from such molded parts. Subsequently, the wetting of the mold according to the invention is carried out with the cooling liquid.

Wesentlich ist, dass die Oberflächenaktivität des fertigen Formteils so eingestellt ist, dass von dem Formteil mit ihm in Kontakt kommende Flüssigkeit aufgrund des Kapillareffektes aufgesogen wird und dass gleichzeitig im zur Herstellung des Formteils eingesetzten Formstoff der Binder und der Formgrundstoff so aufeinander abgestimmt sind, dass das Formteil auch bei mindestens abschnittsweise vollständiger Sättigung mit der Kühlflüssigkeit seine Form über einen für die Entstehung einer festen Außenschale des Gussteils ausreichende Zeitdauer formstabil bleibt.It is essential that the surface activity of the finished molded part is adjusted so that the liquid coming into contact with the molded part is absorbed due to the capillary effect and that at the same time the binder and the molding base material are used in the molding material used to produce the molded article are coordinated so that the molding remains dimensionally stable even with at least partially complete saturation with the cooling liquid its shape over a sufficient time for the formation of a solid outer shell of the casting time.

Indem diese Anforderungen eingehalten werden und die Benetzung in geeigneter Weise durchgeführt wird, lässt sich ein Kühlen der Metallschmelze während der Erstarrungsphase gezielt und exakt gesteuert durchführen, ohne dass es dazu aufwändiger vorrichtungs- oder verfahrenstechnischer Maßnahmen bedarf. Die über eine ausreichende Behandlungszeit gesicherte Formstabilität und die Kapillarität der erfindungsgemäß verwendeten Gießform ermöglichen es dabei auf einfache Weise, die Kühlung des Gussstücks so vorzunehmen, dass ein bestimmter, für die angestrebten Eigenschaften des Bauteils optimaler Erstarrungsverlauf erreicht wird.By adhering to these requirements and carrying out the wetting in a suitable manner, cooling of the molten metal during the solidification phase can be carried out in a targeted and precisely controlled manner without the need for expensive device or process engineering measures. Secured over a sufficient treatment time dimensional stability and the capillarity of the mold used in the invention make it possible in a simple way to make the cooling of the casting so that a certain, optimal for the desired properties of the component solidification profile is achieved.

Dies wird unter anderem dadurch erreicht, dass durch die von der Gießform aufgenommene Kühlflüssigkeit die Wärmeleitfähigkeit der Gießform und damit die Kühlung der Schmelze erhöht wird. Die Kühlflüssigkeit wird von der Gießform aktiv aufgesogen und durchdringt die Gießform abhängig von der jeweiligen Oberflächenaktivität des Gießformmaterials, der Einwirkungsdauer, dem Ort der Benetzung und der zugeführten Kühlflüssigkeitsmenge ganz oder lediglich abschnittsweise. Auf diese Weise wird die angestrebte schnelle und über die Zuführung von Kühlflüssigkeit gezielt gesteuerte Abkühlung der Abschnitte der bis dahin noch nicht vollständig erstarrten Metallschmelze sichergestellt, die mit den von Kühlflüssigkeit erfassten Gebiete der Gießform in Kontakt kommen.This is achieved, inter alia, that the thermal conductivity of the casting mold and thus the cooling of the melt is increased by the coolant absorbed by the casting mold. The cooling liquid is actively absorbed by the casting mold and permeates the casting mold completely or only in sections, depending on the respective surface activity of the casting material, the duration of action, the location of the wetting and the quantity of coolant supplied. In this way, the desired rapid and specifically controlled via the supply of cooling liquid cooling of the sections of the hitherto not completely solidified molten metal is ensured, which come into contact with the areas covered by the cooling liquid of the mold.

Eine erfindungsgemäß vorgenommene Kühlung lässt sich problemlos bei unterschiedlichsten Gussteilgeometrien durchführen. Dazu können beispielsweise nur die Teile der Gießform mit Kühlflüssigkeit in Kontakt gebracht werden, die an Bereiche großer Dicke des zu erzeugenden Gussteils angrenzen.A cooling made according to the invention can be carried out without difficulty in a wide variety of casting geometries. For this purpose, for example, only the parts of the casting mold can be brought into contact with cooling liquid, which adjoin regions of large thickness of the casting to be produced.

Alternativ oder ergänzend kann die Kontur der Gießform selbst an die Kühlungsanforderungen angepasst werden. Indem die Gießform beispielsweise in den Bereichen, in denen die erfindungsgemäße Kühlung besonders schnell wirksam werden soll, dünne Wandstärken aufweist, gelangt die die Form benetzende Flüssigkeit besonders schnell in diese Bereiche, so dass in den betreffenden Bereichen eine besonders intensive Kühlung erreicht wird. Gleichzeitig können andere Bereiche der Gießform dicker ausgebildet werden, damit dort die Kühlung später einsetzt.Alternatively or additionally, the contour of the casting mold itself can be adapted to the cooling requirements. By the casting mold, for example, in the areas in which the cooling of the invention is to be particularly effective, has thin wall thicknesses, the wetting the liquid form very quickly in these areas, so that in the areas concerned a particularly intensive cooling is achieved. At the same time, other areas of the mold can be made thicker, so that the cooling will start there later.

Zum selben Zweck ist es möglich, einen Abschnitt der Gießform, der einem besonders intensiv zu kühlenden Abschnitt des Gussstücks zugeordnet ist, zuerst mit Kühlflüssigkeit zu benetzen, während andere Abschnitte der Gießform erst später oder gar nicht der Kühlflüssigkeit ausgesetzt werden.For the same purpose, it is possible to first moisten a portion of the mold, which is associated with a particularly intensive to be cooled portion of the casting with coolant, while other portions of the mold are exposed later or not at all of the cooling liquid.

Wenn die Kühlflüssigkeit in die Randschicht der an die Schmelze angrenzenden Innenfläche der Gießform gelangt, beginnt die Kühlflüssigkeit zu verdampfen. Der mit dieser Verdampfung einhergehende Energieentzug bewirkt eine deutliche Minderung der Temperatur in der Randzone mit der Folge, dass die angrenzende Schmelze schneller erstarrt. Der so gebildete Flüssigkeitsdampf entweicht mindestens teilweise aus der Gießform oder kondensiert mit der Folge, dass sich ein von der benetzten Außenfläche zur Innenfläche der Gießform gerichtetes Konzentrationsgefälle einstellt. Dieses fördert das Ansaugen von Kühlflüssigkeit zusätzlich, so dass in einem kontinuierlich und selbsttätig ablaufenden Vorgang laufend frische Kühlflüssigkeit in den von der Hitze des Gussstücks erwärmten Bereich der Gießform gelangt. Der Umstand, dass die Verdampfung der Kühlflüssigkeit insbesondere in der Anfangsphase der Kühlung infolge der dann noch besonders hohen Gussstücktemperatur bereits einsetzt, bevor die Kühlflüssigkeit das Gussstück selbst erreicht, stellt dabei sicher, dass die Oberflächenqualität des Gussstücks nicht durch Dampfblasenbildung beeinträchtigt wird.When the cooling liquid reaches the peripheral layer of the inner surface of the casting mold adjacent to the melt, the cooling liquid begins to evaporate. The associated with this evaporation energy removal causes a significant reduction in the temperature in the edge zone, with the result that the adjacent melt solidifies faster. The liquid vapor thus formed escapes at least partially from the casting mold or condenses with the result that sets a directed from the wetted outer surface to the inner surface of the mold concentration gradient. This promotes the suction of coolant in addition, so that in a continuous and automatically running process continuously fresh coolant enters the heated from the heat of the casting area of the mold. The fact that the evaporation of the cooling liquid, especially in the initial phase of cooling due to the then still very high casting temperature already starts before the cooling liquid reaches the casting itself, thereby ensuring that the surface quality of the casting is not affected by vapor bubble formation.

Die Menge an durch die Gießform aufgenommener Kühlflüssigkeit kann dabei über die Dauer des Kontakts zwischen Gießform und Kühlflüssigkeit sowie über die Menge an in Kontakt gebrachter Kühlflüssigkeit gesteuert werden. Da die Gießform die Kühlflüssigkeit selbsttätig ansaugt, ist zum Erreichen einer Kühlung der gesamten Metallschmelze ein vollständiges Eintauchen der Gießform in Kühlflüssigkeit ebenso wenig erforderlich, wie ein Einleiten von Kühlflüssigkeit in die Gießform unter Druck. In Bezug auf das Einbringen von Kühlflüssigkeit stellt die Gießform bei erfindungsgemäßer Vorgehensweise somit das aktive Teil dar, während die Kühlflüssigkeit lediglich angeboten wird, also nicht aktiv in die Gießform eingetrieben wird.The amount of cooling liquid taken up by the casting mold can be controlled over the duration of the contact between the casting mold and the cooling liquid and the amount of cooling liquid brought into contact. Since the mold automatically aspirates the cooling liquid, complete cooling of the casting mold into cooling liquid is not required to achieve cooling of the entire molten metal, as is introduction of cooling liquid into the casting mold under pressure. With regard to the introduction of cooling liquid, the casting mold according to the invention thus constitutes the active part, while the cooling liquid is merely offered, that is to say is not actively driven into the casting mold.

Die Ansaugwirkung wird maßgeblich durch Art und Form der in der Gießform vorhandenen Poren bestimmt. Auch durch die Einstellung einer bestimmten Oberflächenaktivität der Gießformteile lässt sich somit die Abkühlwirkung gezielt beeinflussen. Kleinere Poren führen aufgrund der vergrösserten Gesamtoberfläche zu einer grösseren Kapillarwirkung und damit einem stärkeren Ansaugen von Wasser.The suction effect is largely determined by the type and shape of the pores present in the mold. Also, by setting a certain surface activity of the mold parts can thus be targeted to the cooling effect influence. Smaller pores lead due to the increased total surface area to a greater capillary action and thus a stronger suction of water.

Erfindungsgemäss bleibt auch die mit Kühlflussigkeit benetzte Gießform mindestens bis zur Erstarrung der Metallschmelze formstabil. Dies wird einerseits durch eine geeignete Kombination von Binder und Formgrundstoff des Formstoffs erreicht. Zum anderen unterstützt die infolge der Hitze des Gussmetalls schon in der Giessform einsetzende Verdampfung der Kühlflüssigkeit ein Trocknen der Giessform. Auf diese Weise wird einem vorzeitigen Zerfall der Giessform vor Erstarrung des Gussteils zusätzlich entgegengewirkt.According to the invention, the mold wetted with cooling liquid also remains dimensionally stable at least until solidification of the molten metal. This is achieved on the one hand by a suitable combination of binder and molding material of the molding material. On the other hand, the vaporisation of the cooling liquid, which already starts in the casting mold as a result of the heat of the casting metal, promotes drying of the casting mold. In this way, a premature disintegration of the mold before solidification of the casting is additionally counteracted.

Die erfindungsgemässe Benetzung der Giessform mit Kühlflüssigkeit kann zu jedem Zeitpunkt der Erstarrungsphase, also vom Beginn des Abgiessens der Schmelze bis zur vollständigen Erstarrung und Abkühlung des Gussteils, durchgeführt werden. Je nach gewünschtem Kühlverlauf kann die Benetzung dabei kontinuierlich aufrechterhalten oder nur über bestimmte Zeitabschnitte durchgeführt werden.The wetting of the casting mold with cooling liquid according to the invention can be carried out at any time during the solidification phase, ie from the start of the casting of the melt until complete solidification and cooling of the casting. Depending on the desired cooling process, the wetting can be maintained continuously or can only be carried out over certain periods of time.

Die Kapillarwirkung lässt sich in erfindungsgemässer Weise dazu nutzen, der Kühlflüssigkeit bei ihrem Eindringen in die Giessform gezielt eine bestimmte Richtung zu geben. So benetzt sich die Giessform abhängig von der Oberflächenaktivität der eingesetzten Komponenten entgegen der Schwerkraft, wenn die Giessform nur mit ihrem unteren, bodennahen Bereich mit der Kühlflüssigkeit in Kontakt gebracht wird.The capillary effect can be used in accordance with the invention to specifically impart a certain direction to the cooling liquid as it enters the casting mold. Thus, the mold wets depending on the surface activity of the components used against gravity, when the mold is brought into contact only with its lower, near-ground area with the cooling liquid.

Die Menge der durch die Giessform aufgenommenen Kühlflüssigkeit kann somit sowohl über die Oberflächenaktivität des jeweils verarbeiteten Giessformmaterials und die Grösse der mit Kühlflüssigkeit benetzten Fläche gesteuert werden.The amount of cooling fluid absorbed by the casting mold can thus be controlled both via the surface activity of the respectively processed casting mold material and the size of the surface wetted with cooling liquid.

Die Genauigkeit, mit der die Kühlflüssigkeit in die Giessform eingebracht wird, lässt sich dadurch noch erhöhen, dass die Giessform mit einem Feuchtigkeitsträger in Kontakt gebracht wird. Auf diese Weise kann gezielt und flexibel Kühlflüssigkeit in Bereiche der Giessform gebracht werden, die an Gussteilbereiche, angrenzen, die beispielsweise aufgrund ihrer Dicke einen besonderen Bedarf an Kühlung aufweisen.The accuracy with which the cooling liquid is introduced into the mold, can be increased by the fact that the mold is brought into contact with a moisture carrier. In this way, targeted and flexible cooling liquid can be brought into areas of the casting mold adjacent to casting areas, which, for example, have a special cooling requirement due to their thickness.

Eine Möglichkeit, die von der Giessform aufzunehmende Kühlflüssigkeit zu applizieren, besteht darin, dass die Giessform mindestens abschnittsweise mit Kühlflüssigkeit besprüht wird. Der Sprühdruck und die aufgesprühte Flüssigkeitsmenge sind dabei so aufeinander abzustimmen, dass die Kühlflüssigkeit nicht in die Form eingetrieben wird, sondern dass die jeweils besprühten Flächenabschnitte der Giessform besonders gleichmässig mit einer genau dosierten Flüssigkeitsmenge beaufschlagt werden. Besonders vorteilhaft lässt sich das Besprühen der Giessform in einem automatisierten Verarbeitungsprozess einsetzen.One way of applying the cooling liquid to be absorbed by the casting mold is to spray the casting mold at least in sections with cooling liquid. The spray pressure and the sprayed-on amount of liquid are to be coordinated so that the cooling liquid is not driven into the mold, but that the respective sprayed surface portions of the mold are particularly uniformly charged with a precisely metered amount of liquid. It is particularly advantageous to use the spraying of the casting mold in an automated processing process.

Eine weitere, besonders einfach zu realisierende Möglichkeit einer gezielten, auf bestimmte Bereiche der Giessform beschränkte Benetzung der Giessform mit Kühlflüssigkeit gewährleistende Ausgestaltung der Erfindung sieht vor, dass an der Giessform Taschen ausgebildet werden. Die in diese Taschen gefüllte Flüssigkeitsmenge bildet einen Vorrat, der über ein bestimmtes Zeitintervall verteilt von der Giessform aufgesaugt wird. Auch kann die Tiefe und Form der Taschen so ausgelegt werden, dass innenliegende Bereiche der Giessform besonders schnell von der Kühlflüssigkeit erreicht werden.A further embodiment of the invention, which is particularly easy to implement and which provides targeted wetting of the casting mold with cooling liquid, which is restricted to certain regions of the casting mold, provides for the formation of pockets on the casting mold. The amount of liquid filled in these pockets constitutes a supply that is absorbed by the mold over a certain time interval. Also, the depth and shape of the pockets can be designed so that internal areas of the mold are reached particularly quickly by the cooling liquid.

In praktischen Versuchen hat sich Wasser als kostengünstig in grossen Mengen zur Verfügung stehende Kühlflüssigkeit bewährt, die zudem leicht aufbereitet werden kann. Dem Wasser können Additive zugegeben werden, um seine Benetzungsfähigkeit zu beeinflussen.In practical experiments, water has proved to be cost-effective in large quantities available cooling liquid, which can also be easily processed. Additives may be added to the water to affect its wettability.

Dementsprechend lassen sich als Kühlflüssigkeiten auch Emulsionen einsetzen, deren Eigenschaften so abgestimmt sind, dass die jeweils erwünschte Kühlwirkung sicher eintritt.Accordingly, emulsions can also be used as cooling liquids whose properties are thus matched are that the desired cooling effect occurs safely.

Gemäß einer bevorzugten Ausgestaltung der Erfindung handelt es sich bei dem Gießformteil um einen Gießkern. Durch das erfindungsgemäße Verfahren lässt sich gerade bei schlecht zugänglichen Gießkernen eine Kühlung in einfacher Weise realisieren. Insbesondere kann die Gießform aus einem Kernpaket gebildet werden, also aus mehreren Gießkernen und Gießformteilen zusammengesetzt sein. Bei einer solchen Gießform sind die Vorteile des erfindungsgemäßen Verfahrens hinsichtlich der Zugänglichkeit und Flexibilität für die Kühlung besonders relevant.According to a preferred embodiment of the invention, the casting mold part is a casting core. By means of the method according to the invention, cooling can be achieved in a simple manner, especially in the case of casting cores which are difficult to access. In particular, the casting mold can be formed from a core package, that is to say composed of a plurality of casting cores and casting moldings. In such a mold, the advantages of the method according to the invention in terms of accessibility and flexibility for cooling are particularly relevant.

Praktische Versuche haben belegt, dass sich Formstoffe, die mit einem anorganischer Binder versetzt sind, zur Herstellung erfindungsgemäß eingesetzter Gießformteile besonders eignen. So weisen unter Verwendung von einem geeigneten anorganischen Bindern ausgehärtete Formteile eine besonders hohe, über eine lange Behandlungszeit bestehende Formstabilität bei Durchdringung mit Kühlflüssigkeit auf. Gleichzeitig sind sie besonders unkritisch im Hinblick auf die Belastung der Umwelt. Als besonders geeignet hat sich in diesem Zusammenhang die Verwendung von auf Wasserglas basierenden Bindersystemen herausgestellt.Practical experiments have shown that molding materials which are mixed with an inorganic binder are particularly suitable for the production of casting moldings used according to the invention. For example, moldings cured using a suitable inorganic binder have a particularly high dimensional stability over a long treatment time upon penetration with cooling fluid. At the same time they are particularly uncritical with regard to the burden on the environment. In this context, the use of water glass-based binder systems has proven particularly suitable.

Um eine hohe Formstabilität der aus Formsand und Binder hergestellten Gießform während der Erstarrungsphase bei Durchdringung mit Kühlflüssigkeit zu gewährleisten, hat es sich als günstig erwiesen, den Binder durch Wärmezufuhr, beispielsweise durch Bestrahlung mit Mikrowellen, auszuhärten.In order to ensure a high dimensional stability of the mold made of molding sand and binder during the solidification phase when penetrating with cooling liquid, it has proven to be favorable to cure the binder by heat, for example by irradiation with microwaves.

Alternativ führte auch eine Begasung mit CO2-Gas zu einer zufriedenstellenden Formstabilität und Porosität der Giessform.Alternatively, a fumigation with CO2 gas to a satisfactory dimensional stability and porosity of the mold.

Gemäss einer weiteren Ausgestaltung der Erfindung kann der Formsand kostengünstig erhältlichen Quarzsand enthalten.According to a further embodiment of the invention, the molding sand may contain cost-effectively available quartz sand.

Besonders leicht entfernen und aufbereiten lässt. sich der Formstoff dann, wenn der Formsand Aluminiumoxid-Sand enthält. Insbesondere kann erfindungsgemäss ein Mullit enthaltender Formsand zum Einsatz kommen.Especially easy to remove and process. the molding material then, if the molding sand contains alumina sand. In particular, according to the invention a mullite-containing molding sand can be used.

Das erfindungsgemässe Verfahren eignet sich insbesondere zur Herstellung von Gussatücken aus einer Leichtmatallschmelze, insbesondere aus einer Aluminum- oder einer Magnesiumlegierung.The inventive method is particularly suitable for the production of Gussatücken from a Leichtomatallschmelze, in particular from an aluminum or a magnesium alloy.

Nachfolgend wird ein Ausführungsbeispiel der Erfindung anhand einer Zeichnung näher erläutert. Es zeigen jeweils in einer schematischen, seitlichen Ansicht :

  • Fig. 1 eine Vorrichtung zum Kühlen von mit einer Aluminiumschmelze gefüllten Giessformen in einem ersten Betriebszustand, bei der die Form nach einem Verfahren aus dem Stand der Technik in die Kühlflüssigkeit eingetaucht wird,
  • Fig. 2 die Vorrichtung zum Kühlen von mit einer Aluminiumschmelze gefüllten Giessformen in einem zweiten Betriebszustand,
  • Fig. 3 die Vorrichtung zum Kühlen von mit einer Aluminiumschmelze gefüllten, alternativ gestalteten Giessformen.
An embodiment of the invention will be explained in more detail with reference to a drawing. Each shows in a schematic, lateral view:
  • Fig. 1 a device for cooling molds filled with an aluminum melt in a first operating state, in which the mold is immersed in the cooling liquid according to a method of the prior art,
  • Fig. 2 the device for cooling molds filled with an aluminum melt in a second operating state,
  • Fig. 3 the device for cooling, filled with an aluminum melt, alternatively shaped molds.

Die in Fig. 1 dargestellte Vorrichtung A dient zum Kühlen von Giessformen 1, nachdem diese in an sich bekannter Weise mit einer Aluminiumschmelze gefüllt worden sind, indem die Gießformen 1 in die Kühlflüssigkeit, wie in der EP 571 703 B1 beschrieben, eingetaucht werden.In the Fig. 1 illustrated device A is used for cooling of molds 1, after they have been filled in a conventional manner with an aluminum melt by the molds 1 in the cooling liquid, as in the EP 571 703 B1 described, be immersed.

Die Vorrichtung A umfasst eine Hebevorrichtung 4 sowie ein Becken 2, dass mit einer Kühlflüssigkeit K gefüllt ist. Bei der Kühlflüssigkeit K handelt es sich um Wasser, das zur Verbesserung seiner Benetzungsfähigkeit mit einem Additiv versetzt ist.The device A comprises a lifting device 4 and a basin 2, which is filled with a cooling liquid K. The cooling liquid K is water which is mixed with an additive to improve its wettability.

Die im Einzelnen nicht dargestellten Formteile der Giessformen 1 sind aus einem Formstoff hergestellt worden, der beispielsweise aus einem anorganischen, wasserglasbasierten Bindersystem und einem mullithaltigen Formgrundstoff gemischt worden ist. Die Formteile sind in einer ebenfalls nicht dargestellten Maschine erzeugt worden, in der der Formstoff nach dem Einschiessen in einen formgebenden Raum der Maschine durch Wärmezufuhr ausgehärtet worden ist. Der Aufbau der Giessform und ihrer Einzelteile entspricht dem konventionellen, im Stand der Technik vielfach beschriebenen Aufbau derartiger Formen, so dass an dieser Stelle auf eine ins Einzelne gehende Erläuterung verzichtet wird.The molded parts of the casting molds 1, not shown in detail, have been produced from a molding material which has been mixed, for example, from an inorganic, water glass-based binder system and a mullite-containing molding base material. The moldings have been produced in a machine, also not shown, in which the molding material has been cured after being injected into a shaping space of the machine by supplying heat. The structure of the mold and its individual parts corresponds to the conventional, often described in the prior art construction of such forms, so that is omitted at this point to a more detailed explanation.

Nachdem die Aluminiumschmelze in an sich ebenfalls bekannter Weise in die Giessform 1 abgegossen worden ist, wird die Giessform zur Vorrichtung A transportiert und von der Hebevorrichtung 4 übernommen. Die Hebevorrichtung 4 senkt die Giessform 1 dann in das Becken 2. Die Absenktiefe wird dabei so gesteuert, dass die Giessform 1 ausgehend von ihrem Boden la permanent mit der Kühlflüssigkeit K in Kontakt steht. Dazu wird die Giessform beispielsweise über etwa ein Achtel ihrer Höhe H in die Kühlflüssigkeit K gesenkt.After the aluminum melt has been poured into the casting mold 1 in a manner also known per se, the casting mold is transported to the device A and taken over by the lifting device 4. The lifting device 4 then lowers the casting mold 1 into the basin 2. The sinking depth is controlled so that the casting mold 1, starting from its bottom 1a, is permanently in contact with the cooling liquid K. For this purpose, the mold is lowered, for example about about one-eighth of its height H in the cooling liquid K.

Sobald die Gießform 1 in die Kühlflüssigkeit K eintaucht, saugt die Gießform 1 aufgrund der ihr eigenen Oberflächenaktivität Kühlflüssigkeit K aktiv entgegen der Schwerkraftrichtung an. In Fig. 1 ist die Richtung der Kühlflüssigkeitsaufnahme der Gießform 1 durch Pfeile P angedeutet.As soon as the casting mold 1 dips into the cooling liquid K, the casting mold 1 actively absorbs cooling liquid K against the direction of gravity owing to its own surface activity. In Fig. 1 the direction of the cooling liquid intake of the mold 1 is indicated by arrows P.

In Folge des Ansaugens bildet sich in der Gießform 1 ein von Kühlflüssigkeit K benetzter Volumenbereich 3, der sich ausgehend vom Boden 1a über die für das jeweilige Abkühlergebnis optimale Höhe H der Gießform 1 erstreckt. Die Kapillarwirkung und das damit einhergehende aktive Ansaugen von Kühlflüssigkeit K durch die Gießform 1 bewirken dabei, dass das von Kühlflüssigkeit K benetzte Volumen 3 der Gießform 1 deutlich über den in Kühlflüssigkeit K eingetauchten Gießformabschnitt hinausgeht.As a result of the suction, a volume region 3 wetted by the cooling liquid K forms in the casting mold 1 and extends from the bottom 1a over the optimum height H of the casting mold 1 for the respective cooling result. The capillary action and the associated active suction of cooling liquid K through the casting mold 1 thereby cause the volume 3 of the casting mold 1 moistened by the cooling liquid K to significantly exceed the casting mold portion immersed in the cooling liquid K.

Bei Annäherung an die in der Gießform 1 enthaltene, nicht gezeigte heiße Aluminiumschmelze beginnt die in die Gießform 1 eingedrungene Kühlflüssigkeit K zu verdampfen. Sie führt auf diese Weise zu einer starken Abkühlung mit der Folge, dass die an die Innenwände der Gießform 1 direkt angrenzende Aluminiumschmelze schnell und gleichmäßig zu einer festen Schale erstarrt. Die verdampfende Flüssigkeit tritt aus der Gießform 1 aus und wird durch Kühlflüssigkeit K ersetzt, die ausgehend vom in die Kühlflüssigkeit K eingetauchten Abschnitt in die Gießform 1 nachdrängt.When approaching the hot aluminum melt, which is contained in the casting mold 1 and not shown, the cooling liquid K which has penetrated into the casting mold 1 begins to evaporate. It leads in this way to a strong cooling, with the result that the directly adjacent to the inner walls of the mold 1 molten aluminum melt solidifies quickly and evenly to a solid shell. The vaporizing liquid exits the casting mold 1 and is replaced by cooling liquid K which, starting from the section immersed in the cooling liquid K, pushes into the casting mold 1.

Ergänzend oder alternativ durchführbare Maßnahmen zur Kühlung der Gießform 1 und der in ihr enthaltenen Schmelze sind in den Figuren 2 und 3 dargestellt.Additional or alternatively feasible measures for cooling the mold 1 and the melt contained in it are in the Figures 2 and 3 shown.

Gemäß Fig. 2 wird die Gießform 1, nachdem die zuvor erläuterte Kühlung im durch die Kühlflüssigkeit K gebildeten Kühlflüssigkeitsbad abgeschlossen ist, aus der Kühlflüssigkeit gehoben. Die dabei in der Gießform 1 verbleibende Kühlflüssigkeit K stellt sicher, dass eine Restkühlung des unteren Bereichs 3 der Gießform aufrechterhalten wird.According to Fig. 2 is the mold 1, after the previously explained cooling is completed in the formed by the cooling liquid K Kühlflüssigkeitsbad, lifted from the cooling liquid. The remaining in the mold 1 cooling liquid K ensures that a residual cooling of the lower portion 3 of the mold is maintained.

Um zusätzlich eine gezielte Kühlung von Abschnitten der Metallschmelze durchzuführen, die seitlichen Bereichen 1b,1c der Gießform 1 zugeordnet sind, wird nun auf den ersten seitlichen Bereich 1b mittels Düsen 4 ein Kühlflüssigkeitsnebel Kn aufgegeben.In order to additionally perform a targeted cooling of portions of the molten metal, the lateral areas 1b, 1c of the mold 1 are assigned, is now on the first lateral region 1b by means of nozzles 4, a cooling liquid mist Kn abandoned.

An den anderen zu kühlenden seitlichen Bereich 1c wird dagegen ein mit Kühlflüssigkeit getränkter Schwamm 6 angelegt.On the other side area 1c to be cooled, on the other hand, a sponge 6 soaked with cooling liquid is applied.

Die auf diese Weise auf die betreffenden Bereiche 1b, 1c der Gießform 1 aufgebrachten Kühlflüssigkeitsmengen K werden aufgrund der Kapillarwirkung ebenfalls aktiv vom Formstoff der Gießform aufgesogen, so dass sich von Kühlflüssigkeit K getränkte Bereiche 7,8 in der Gießform 1 einstellen. Auch in diesen Bereichen findet eine gezielte intensive Kühlung der in der Gießform 1 enthaltenen Schmelze statt.The cooling liquid quantities K applied in this way to the respective regions 1 b, 1 c of the casting mold 1 are also actively absorbed by the molding material of the casting mold due to the capillary action, so that areas 7, 8 soaked in cooling liquid K are set in the casting mold 1. Also in these areas there is a targeted intensive cooling of the melt contained in the mold 1.

Gemäß Fig. 3 weist eine gegenüber der Gießform 1 lediglich hinsichtlich ihrer Formgebung variierte Gießform 100 eine an eine Außenfläche der Grießform 100 angeformte äußere Tasche 9 sowie zwei in die Gießform 100 eingeformte innere Taschen 10,11 auf. Die Taschen 9,10,11 sind jeweils mit Kühlflüssigkeit K gefüllt.According to Fig. 3 For example, a mold 100 varied from the mold 1 only in terms of shape has an outer pocket 9 formed on an outer surface of the mold 100 and two inner pockets 10, 11 formed in the mold 100. The pockets 9,10,11 are each filled with coolant K.

Ausgehend von den Taschen 9,10,11 bilden sich von Kühlflüssigkeit K durchdrungene Bereiche 12,13,14, deren Ausdehnung davon vom Füllstand der Taschen 9,10,11 abhängig ist.Starting from the pockets 9, 10, 11, areas 12, 13, 14 penetrated by the cooling liquid K form, the extent of which depends on the level of the pockets 9, 10, 11.

Nachdem eine ausreichende Erstarrung der Metallschmelze erfolgt ist, kann die Gießform 1 von dem Gussteil entfernt werden.After a sufficient solidification of the molten metal has taken place, the mold 1 can be removed from the casting.

Mit den bei dem erfindungsgemäßen Verfahren zur Verfügung stehenden Methoden zur Kühlung der Metallschmelze in der Gießform 1 lassen sich also Menge, Ort und aufgrund der aktiven Ansaugung von Kühlflüssigkeit auch die Richtung der Durchdringung der Gießformen 1,100 mit Kühlflüssigkeit K in einfacher Weise präzise und flexibel vorgeben. Somit wird eine schnelle und gerichtete Erstarrung der Schmelze erreicht, die zu besonders guten Produkteigenschaften des erhaltenen Gussstücks führt.With the methods available for the method according to the invention for cooling the molten metal in the casting mold 1, therefore, the amount, location and, due to the active suction of cooling liquid, the direction of penetration of the casting molds 1,100 with cooling liquid K can be predefined precisely and flexibly in a simple manner. Thus, a rapid and directional solidification of the melt is achieved, which leads to particularly good product properties of the cast obtained.

BezugszeichenlisteLIST OF REFERENCE NUMBERS

1,1001,100
Gießformmold
1 a1 a
Boden (der Gießform)Bottom (the mold)
1 b,c1 b, c
seitliche Bereiche (der Gießform)lateral areas (the mold)
22
Beckenpool
33
benetzter Volumenbereichwetted volume range
44
Hebevorrichtunghoist
55
Düsenjet
66
Schwammsponge
7,87.8
getränkte Bereichesoaked areas
99
angeformte äußere Taschemolded outer pocket
10,1110.11
eingeformte innere Taschemolded inner pocket
12,13,1412,13,14
von Kühlflüssigkeit durchdrungene Bereicheareas penetrated by coolant
AA
Vorrichtungcontraption
KK
Kühlflüssigkeitcoolant
Knkn
KühlflüssigkeitsnebelCoolant mist
PP
Pfeilearrows

Claims (9)

  1. Method for the production of a cast part from a molten metal, wherein the molten metal is cast into a porous casting mould (1, 100), and said porous casting mould (1, 100), which is filled with the molten metal, is cooled with the aid of a cooling liquid (K),
    with said casting mould (1, 100) being wetted in the area of at least one section of the exterior surface thereof following casting of the molten metal,
    characterised in that
    wetting is performed by spraying or by application by means of a sponge (6), the sections of the exterior surface of the casting mould (1, 100) being wetted, one section after another, with the cooling liquid (K),
    the porous casting mould (1, 100) is mixed from a mould base material and a binder, and is hardened by application of heat or by gassing with a reaction gas,
    whereby, at least in the area (3) of the porous mould (1, 100) that is wetted with the cooling liquid, a capillarity is produced through which the casting mould (1, 100) automatically, by active suction, picks up at least a partial volume of the cooling liquid that is wetting the mould,
    and that the cooling liquid (K) evaporates in a surface layer of the interior surface of the casting mould (1, 100), which surface layer adjoins the molten metal.
  2. Method according to claim 1, characterised in that the capillarity has a surface activity that is sufficient for suction of the cooling liquid, with the surface activity of at least one casting mould section which comes into contact with the cooling liquid (K) being adjusted to a contact angle between the respective wetted surface section and the surface of the liquid of less than 90°.
  3. Method according to any one of the preceding claims, characterised in that, for wetting, pockets (9, 10, 11) are formed in or on the casting mould (1, 100) into which cooling liquid (K) is conveyed.
  4. Method according to any one of the preceding claims, characterised in that, for wetting, the casting mould (1, 100) is wetted, simultaneously, in sections of the exterior surface thereof which are separate from one another.
  5. Method according to any one of the preceding claims, characterised in that the cooling liquid (K) is an emulsion.
  6. Method according to any one of the preceding claims, characterised in that the cooling liquid (K) is an oil.
  7. Method according to any one of the preceding claims, characterised in that the casting mould (1, 100) is formed from a core package.
  8. Method according to any one of the preceding claims, characterised in that the molten metal is a light metal melt.
  9. Method according to claim 8, characterised in that the light metal melt is made from an aluminium alloy and a magnesium alloy.
EP04802904A 2003-12-10 2004-12-09 Method for the production of a cast part from a molten metal Not-in-force EP1691944B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE2003157618 DE10357618B4 (en) 2003-12-10 2003-12-10 Method for producing a casting from a molten metal
PCT/DE2004/002698 WO2005056218A2 (en) 2003-12-10 2004-12-09 Method for the production of a cast part from a molten metal

Publications (2)

Publication Number Publication Date
EP1691944A2 EP1691944A2 (en) 2006-08-23
EP1691944B1 true EP1691944B1 (en) 2013-01-23

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Family Applications (1)

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Country Status (3)

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EP (1) EP1691944B1 (en)
DE (1) DE10357618B4 (en)
WO (1) WO2005056218A2 (en)

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JP4748426B2 (en) * 2008-03-26 2011-08-17 独立行政法人科学技術振興機構 Magnesium alloy mold and magnesium alloy casting method
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US11001917B2 (en) 2016-04-28 2021-05-11 Alotech Limited, Llc Ablation casting process

Also Published As

Publication number Publication date
WO2005056218A3 (en) 2006-02-02
EP1691944A2 (en) 2006-08-23
WO2005056218A2 (en) 2005-06-23
DE10357618A1 (en) 2005-07-14
DE10357618B4 (en) 2008-01-24

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