EP1832357B1 - Forme ou pièce brute, mélange de matériaux de formage de fonderie et son procédé de fabrication - Google Patents
Forme ou pièce brute, mélange de matériaux de formage de fonderie et son procédé de fabrication Download PDFInfo
- Publication number
- EP1832357B1 EP1832357B1 EP07004766A EP07004766A EP1832357B1 EP 1832357 B1 EP1832357 B1 EP 1832357B1 EP 07004766 A EP07004766 A EP 07004766A EP 07004766 A EP07004766 A EP 07004766A EP 1832357 B1 EP1832357 B1 EP 1832357B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- sand
- binder
- aluminium oxide
- moulding
- binding agent
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Not-in-force
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
- B22D29/001—Removing cores
- B22D29/002—Removing cores by leaching, washing or dissolving
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
- B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
- B22C1/18—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents
- B22C1/186—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents contaming ammonium or metal silicates, silica sols
- B22C1/188—Alkali metal silicates
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/12—Treating moulds or cores, e.g. drying, hardening
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
- B22D29/001—Removing cores
- B22D29/005—Removing cores by vibrating or hammering
Definitions
- the invention relates to molds or foundries for foundry purposes according to the preamble of patent claim 1, a foundry molding material mixture according to the preamble of claim 4 and a method for producing a mold or a molding according to the preamble of claim. 7
- Foundry-molding mixtures are known in many forms. Basically, a distinction must be made between clay-bound foundry sand, sand mixtures with inorganic or organic binders, and binderless molding sands with physical bonding.
- the requirements of the foundry-molding mixtures are very diverse and include properties such as flowability of the molding material mixture, solidification behavior, achievable ultimate strength, separability or mold release.
- WO 2006/024540 describes a molding material mixture for the production of casting molds for metal processing, in which a free-flowing, refractory molding base material and a water glass-based binder is used.
- a particulate metal oxide selected from a group consisting of silica, alumina, titania or zinc oxide, most preferably synthetic amorphous silica.
- Molded materials of spherical shape and / or organic additives are used to improve the surface quality of the casting.
- the strength of the molded article in a moist environment should be improved by intensively combining the surface of the particulate metal oxide with a strongly alkaline water glass phase in the binder. Since the binder has a deteriorated flowability, it should be achieved by addition of platelet-shaped lubricants that even complex shapes can be produced.
- the particle size of the metal oxide is less than 200 micrometers in the known molding material mixture, wherein the proportion of metal oxide, based on the amount of binder is preferably between 4 and 40%.
- quartz sand as a molding material is preferably less than 5% binder contained in the known molding material mixture.
- the invention has for its object to provide a molding material mixture having an improved flowability, wherein the solidification behavior and the mold release of the mold or molded article is improved.
- the castings produced with the molding or the molding material mixture according to the invention should allow an improved quality of the surface of the cast part.
- the molding material mixture should have good disintegration properties after the intended use and the spent molding sand can be easily processed with low emission.
- aluminum oxide is suitable as a supplement to a foundry-molding material mixture if, after mixing and drying, it covers the sand or quartz particles of the molding material as an opaque layer.
- the alumina in a certain amount based on the binder and in a certain particle size based on the average diameter of the sand or quartz grains to use.
- alumina significantly improves the flowability and the solidification behavior of the molding material mixture. This will be explained in more detail by means of subsequent comparative experiments. Furthermore, it was surprising that the molding / core or the mold had particularly good disintegration properties after their intended use. For example, it has been observed that the core contacted with water immediately disintegrates and can be fully processed as a homogeneous suspension.
- the inventors have then specifically investigated the conditions during casting in the contact area between molding sand and metal surface. It has been found that the wettability of the molding surface with the liquid metal plays a role on the one hand in the described processes, on the other hand, however opposite effect was observed during demolding or reprocessing of the molding sand. Thus, for a faithful reproduction, good wetting conditions are important; on the other hand, this sometimes leads to problems during demoulding, since with the removal of the casting, parts of the mold or of the molded article are also entrained in the form of fine sand particles. In particular, in a poor wetting behavior of the molding sand already in the state of mixing with the partially liquid binder adverse effects that led to poor reusability of the spent molding material mixture (segregation, inhomogeneities, etc.).
- an aluminum oxide with 99.9% purity was first added directly to a molding material mixture as an oxide and homogeneously distributed. It was found that homogenous distributions in common molding sands with mean particle sizes between 75 and 250 micrometers could only be obtained by repeated and lengthy mixing processes. In order to be able to effectively use above all established systems, which are designed for the use of liquid binders in the form of resins, alcohols, oils or inorganic suspensions, the oxide was first added to the binder, homogeneously dispersed and then added to the molding material via established methods.
- Flowability relates to the flow behavior of the molding material mixture while it is being filled into the mold. It is influenced by the cohesion of the molding material mixture components with each other and the adhesion of the molding material to the wall of the mold. Particularly in the field of dry molding mixtures, in which the ratio of foundry sand to binders and aggregates can be in the range of 3 to 1 - 2, the properties of the aggregates are clearly evident.
- Dry sand trials showed breakage of the mold during withdrawal of the cylinder.
- the cylinder then accelerated upward without resistance and triggered the timing t1.
- the alumina causes at a high content of the total mixture earlier breaking of the molding and a flatter angle of the cone flanks.
- the additionally added water glass binder enhances the cohesive forces between the particles of the molding material mixture.
- the breaking up of the molding occurred at comparable height of exposed form. This means that the significantly lower value for t1 and t2 can be explained by a higher take-off speed and a reduced adhesion to the mold wall with an aluminum oxide content of 40%.
- the solidification behavior describes the ability of a molding mixture to fill a mold while arranging its particles in the closest possible way. Separability or releasability relates to the interactions between the molding material mixture and the mold. If too strong adhesion forces occur, parts of the molding can adhere to the mold during demoulding and break out of the molding.
- a foundry sand binder mixture with a binder content of 2.5% and a varied alumina content of 10% and 40% and 80% in the binder (percent by weight based on the binder) was injected via a core shooter into a mold until sufficient green strength pre-dried and removed. After examination of the green compacts for defects, these microwaves were completely dried ready-to-use moldings and finally examined.
- the blend without additive shows the occurrence of defects in the fine profiling during drying, while this is not the case with the mixtures according to the invention.
- In the drying behavior of the mixture according to the invention shows a better resistance of the molding material mixture against thermal effects.
- molding mixtures according to the invention based on quartz sand were prepared according to Table 3 and dried under different conditions and tested for their profile fidelity.
- the improved resistance to thermal effects was confirmed.
- the inventors assume that the free spaces in the molding material mixture, due to the Al 2 O 3 particles which space the quartz sand grains apart, allow the unhindered transfer of the solvent into the gas phase during drying.
- a dried in a drying oven at 60 ° C within 48 hours molding had too high final weight and showed in the microscopic examination bulky, coated with a glassy layer throughout binder bridges and had clearly set during drying.
- a test series with varied oxide content in the binder showed that with oxide contents from 10%, oxide particle coverage could be observed, while at 80% to 90%, the increasing concentration in the total mixture resulted in more and more particle-coated sand grains. Preference was given to working with contents of 40% to 60%, particularly preferably 50% of oxide.
- the castings produced showed a significantly smoother surface compared to the standard castings after demoulding.
- the number of average adherent grains per square centimeter dropped from 47 to 49 to 0.4 to 0.5.
- the adhesion force of the individual grains to the metal surface was extremely low, so that cleaning could be carried out by means of compressed air or ultrasound instead of the usual sandblasting. This opens up the possibility of the final cleaning of the castings with methods such.
- the fine profiles were formed exactly in the manner specified in the molding.
- the barking out time for binders based on water glass was additionally lowered. This can be explained by an additional weakening of the adhesion-promoting phase of the binder bridges by dissolving with water.
- the coring time was found to be 20% lower compared to industrial products of the same particle size distribution.
- the improved barking out time for freshly ground Al 2 O 3 particles is attributed to a reduced adhesive force of the binder on the fresh fracture surfaces of the particles and a more easily detachable framework from the irregularly comminuted particles:
- milled oxides oxides which have been adjusted in their morphology by grinding, crushing, crushing, blasting, impact milling, vibratory milling, etc., during production are referred to as milled oxides. It was found that even with ground aluminum oxides with a purity of 90%, the advantages according to the invention could be achieved.
- the finely ground aluminum oxides especially in the limits of 100-200 microns, preferably immediately after the grinding must be added to the binder and used, otherwise there is a risk of dissolution or aluminate formation in the case of prolonged storage.
- the aluminate formation takes place by direct transition of the aluminum from the oxidic surface into the solution in the form of a negatively charged complex.
- the aluminum is kept in solution in the complex, spreads by diffusion, and tends to agglomerate and flocculate with longer residence time of the solution. This is especially at elevated temperatures as they can occur anywhere in foundry.
- the agglomeration and flocculation causes inhomogeneously altered Flow properties of the binder and makes use of the binder mixture impossible.
- the foundry molding material mixture according to the invention consists of molding sand, binder, aggregates and aluminum oxide as an emulsion-free and thus emission-free additive. It results in improved flowability and resistance to thermal effects of the molding material mixture, a significantly reduced number of adhering grains on the finished casting, a reduced adhesive force of the adhering grains on the casting and a significantly reduced coring time.
- the inventive method for producing a foundry molding mixture provides that the alumina with a purity of> 90% and a particle size of 1-200 microns is added directly to the binder and processed.
- the proportion may be between 10 and 85%, based on the amount of binder.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Mold Materials And Core Materials (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Claims (13)
- Forme ou pièce brute pour utilisation en fonderie, comprenant de la potée, de liants et d'agrégats, en utilisant de la silice comme potée et de l'oxyde d'aluminium dans le liant, caractérisée en ce que la silice est utilisée avec une taille du grain entre 0,05 et 5 mm et comme agrégat on utilise l'oxyde d'aluminium avec une taille du grain entre 1 et 200 micromètres, en ayant l'oxyde d'aluminium de surfaces de rupture ou de bordures de rupture et en étant le liant contenant l'oxyde d'aluminium aligné comme couche couvrant sur la surface de la silice, et caractérisée en ce que une verre soluble contenue dans le liant est contractée sur les surfaces de contact des graines de silice sous forme de gousset, et en ayant une structure microporeuse dans les phases de limitation sous forme de ponts poreux de liaison, en étant le liant et la silice connectés l'un avec l'autre par les surfaces de rupture et / ou par les bordures de rupture des particules en oxyde d'aluminium dans la structure de la pièce brute en formant de ponts de liaison microporeux.
- Forme ou pièce brute selon revendication 1, caractérisée en ce que on utilise un oxyde d'aluminium rompu et / ou pulvérisé dont la taille du grain est entre 1 et 100 im.
- Forme ou pièce brute selon une des revendications précédentes, caractérisée en ce que la taille de pores de la structure microporeuse est entre 0,1 et 2,5 im.
- Mixture de matière formant pour fonderie pour la production d'une forme ou d'une pièce brute selon une des revendications précédentes, étant constituée de silice, de liant et d'agrégats, caractérisée en ce que les agrégats sont constitués d'oxyde d'aluminium récemment rompu ou pulvérisé sans contenu d'émulsion dans une quantité > 10 % par rapport au contenu du liant, caractérisée en ce que l'oxyde d'aluminium avec une taille du grain entre 1 et 200 micromètres est contenu dans le liant avec une quantité entre les 10 et les 65 %, en étant contenu un liant sur la base de verre soluble avec un contenu de liant entre les 1 et les 10 % dans une mixture de matière formant et caractérisée en ce que comme sable formant on utilise la silice avec une taille du grain entre 0,05 et 5 mm.
- Mixture de matière formant pour fonderie pour la production d'une forme ou d'une pièce brute selon une des revendications précédentes, caractérisée en ce que l'agrégat d'oxyde d'aluminium est un oxyde d'aluminium du type alpha.
- Mixture de matière formant pour fonderie pour la production d'une forme ou d'une pièce brute selon une des revendications précédentes, caractérisée en ce que l'oxyde d'aluminium est un oxyde d'aluminium pur ayant un degré de pureté supérieur aux 90 %.
- Procédée pour la production d'une forme ou d'une pièce brute, en utilisant une mixture de matière formant pour fonderie, constituée de sable formant, de liants et d'agrégats, caractérisée en ce que comme sable formant on utilise de la silice avec une taille de grain entre 0,05 et 5 mm, caractérisée en ce que comme agrégat on ajoute de l'oxyde d'aluminium pulvérisé frais, ayant une taille du grain entre 1 et 200 micromètres, dans une quantité entre les 10 et les 85 % du poids du liant pour le mélanger de manière homogène avec le liant, caractérisée en ce que on mélange la mixture d'oxyde et le liant avec le sable formant, en fermant la mixture dans un armoire de forme pour la solidifier, en maintenant la relation de mixture du liant / oxyde et du sable formant dans un rapport de 1 - 10 jusqu'à 90 et en exécutant le séchage du liant liquide en telle façon que on produit de ponts de liaison poreux entre les graines du quartz.
- Procédée selon une de revendications précédentes, caractérisée en ce que l'oxyde d'aluminium est pulvérisé ou rompu avec une taille du grain de départ de > 200 im pour achever une taille du grain < 100 im et que le produit pulvérisé est mélangé au début avec le liant avec un PH > 10 en obtenant les surfaces de rupture et les bordures de rupture produites et puis avec le sable formant entre 1 et 10 seconds.
- Procédée selon une de revendications précédentes, caractérisée en ce que la mixture additionnelle de l'oxyde d'aluminium pulvérisé est exécutée avec un liant liquide, en achevant une partie de la mixture entre le liant et l'oxyde de 1,5-4 pourcent du poids de la mixture complète.
- Procédée pour la production d'un produit fondu en utilisant une forme ou une pièce brute selon une de revendications précédentes, caractérisée en ce que pour le dénoyautage du produit fondu on utilise une oscillation de fréquence basse pour une durée maximale de 10 seconds.
- Procédée selon une de revendications précédentes, caractérisée en ce que les produits fondus finis en fin sont libérés des grains du sable adhérents par un traitement ultrasonique.
- Procédée selon une de revendications 9 à 10, caractérisée en ce que la forme ou la pièce brute est décomposée en ajoutant de l'eau à ses composants.
- Procédée selon une de revendications 9 à 11, caractérisée en ce que la décomposition est exécutée dans un milieu humide jusqu'à qu'on achève la taille du graine primaire, en étant la durée de traitement depuis le début de l'ajoute de l'humidité jusqu'à la décomposition complète inférieure à 1 second.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PL07004766T PL1832357T3 (pl) | 2006-03-10 | 2007-03-08 | Forma lub półwyrób, odlewnicza mieszanina materiałów formierskich i sposób ich wytwarzania |
SI200730240T SI1832357T1 (sl) | 2006-03-10 | 2007-03-08 | Kalup ali surovec, zmes materiala za ulivanje v livarni in postopek za njegovo izdelavo |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102006011530A DE102006011530A1 (de) | 2006-03-10 | 2006-03-10 | Form oder Formling, Gießerei-Formstoffgemisch und Verfahren zu seiner Herstellung |
Publications (2)
Publication Number | Publication Date |
---|---|
EP1832357A1 EP1832357A1 (fr) | 2007-09-12 |
EP1832357B1 true EP1832357B1 (fr) | 2010-03-10 |
Family
ID=38198259
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP07004766A Not-in-force EP1832357B1 (fr) | 2006-03-10 | 2007-03-08 | Forme ou pièce brute, mélange de matériaux de formage de fonderie et son procédé de fabrication |
Country Status (7)
Country | Link |
---|---|
EP (1) | EP1832357B1 (fr) |
AT (1) | ATE460243T1 (fr) |
DE (2) | DE102006011530A1 (fr) |
ES (1) | ES2342733T3 (fr) |
PL (1) | PL1832357T3 (fr) |
SI (1) | SI1832357T1 (fr) |
WO (1) | WO2007104469A1 (fr) |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102007012660B4 (de) * | 2007-03-16 | 2009-09-24 | Chemex Gmbh | Kern-Hülle-Partikel zur Verwendung als Füllstoff für Speisermassen |
DE102014004914A1 (de) * | 2013-08-26 | 2015-02-26 | Gebrüder Dorfner GmbH & Co. Kaolin- und Kristallquarzsand-Werke KG | Gießform oder einen Gießformkern aus beschichtetem Formsand für Metallguss |
Family Cites Families (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
IT8024122A0 (it) * | 1979-08-20 | 1980-08-12 | Gen Electric | Forme di fonderia, composizioni di trattamento e relativi metodi di preparazione. |
SU1163958A1 (ru) * | 1982-10-22 | 1985-06-30 | Институт проблем литья АН УССР | Состав дл изготовлени литейный форм и стержней |
JPH0613137B2 (ja) * | 1989-06-30 | 1994-02-23 | 岡崎鑛産物株式会社 | 鋳型材 |
JPH0663683A (ja) * | 1992-08-18 | 1994-03-08 | Mitsubishi Heavy Ind Ltd | 鋳型の製造方法 |
US6371194B1 (en) * | 1996-08-09 | 2002-04-16 | Vaw Aluminium Ag | Method for producing core preforms and recycling core sand for a foundry |
DK172825B1 (da) * | 1996-12-18 | 1999-08-02 | Dti Ind | Fremgangsmåde til fremstilling af partikler belagt med et lag af vandglas og af emner omfattende sådanne belagte partikler. |
FR2791282B1 (fr) * | 1999-03-23 | 2001-05-11 | Forward Tech Industries Sa | Procede de nettoyage ou de debourrage d'une piece de fonderie |
DE19951622A1 (de) * | 1999-10-26 | 2001-05-23 | Vaw Ver Aluminium Werke Ag | Bindemittelsystem auf Wasserglasbasis |
DE10216464B4 (de) * | 2002-04-12 | 2004-04-15 | Deutsches Zentrum für Luft- und Raumfahrt e.V. | Silica gebundene Kernwerkstoffe, Verfahren zu deren Herstellung und deren Verwendung |
DE102004042535B4 (de) * | 2004-09-02 | 2019-05-29 | Ask Chemicals Gmbh | Formstoffmischung zur Herstellung von Gießformen für die Metallverarbeitung, Verfahren und Verwendung |
-
2006
- 2006-03-10 DE DE102006011530A patent/DE102006011530A1/de not_active Withdrawn
-
2007
- 2007-03-08 PL PL07004766T patent/PL1832357T3/pl unknown
- 2007-03-08 DE DE502007003051T patent/DE502007003051D1/de active Active
- 2007-03-08 EP EP07004766A patent/EP1832357B1/fr not_active Not-in-force
- 2007-03-08 SI SI200730240T patent/SI1832357T1/sl unknown
- 2007-03-08 ES ES07004766T patent/ES2342733T3/es active Active
- 2007-03-08 WO PCT/EP2007/002008 patent/WO2007104469A1/fr active Search and Examination
- 2007-03-08 AT AT07004766T patent/ATE460243T1/de active
Also Published As
Publication number | Publication date |
---|---|
SI1832357T1 (sl) | 2010-07-30 |
DE102006011530A1 (de) | 2007-09-13 |
DE502007003051D1 (de) | 2010-04-22 |
ES2342733T3 (es) | 2010-07-13 |
EP1832357A1 (fr) | 2007-09-12 |
PL1832357T3 (pl) | 2010-08-31 |
WO2007104469A1 (fr) | 2007-09-20 |
ATE460243T1 (de) | 2010-03-15 |
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