EP1841553A1 - Method of casting an article - Google Patents

Method of casting an article

Info

Publication number
EP1841553A1
EP1841553A1 EP05818016A EP05818016A EP1841553A1 EP 1841553 A1 EP1841553 A1 EP 1841553A1 EP 05818016 A EP05818016 A EP 05818016A EP 05818016 A EP05818016 A EP 05818016A EP 1841553 A1 EP1841553 A1 EP 1841553A1
Authority
EP
European Patent Office
Prior art keywords
mould
article
coating
metal
halogen
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.)
Withdrawn
Application number
EP05818016A
Other languages
German (de)
English (en)
French (fr)
Inventor
Jonathan Paul Evans
Andrew Mark Tomkinson
Nicholas Russell Green
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Mahle Powertrain Ltd
Original Assignee
Mahle Powertrain Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Mahle Powertrain Ltd filed Critical Mahle Powertrain Ltd
Publication of EP1841553A1 publication Critical patent/EP1841553A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • 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
    • B22C9/06—Permanent moulds for shaped castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/0009—Cylinders, pistons
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/02—Coating starting from inorganic powder by application of pressure only
    • C23C24/06—Compressing powdered coating material, e.g. by milling
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/01—Selective coating, e.g. pattern coating, without pre-treatment of the material to be coated
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
    • C23C4/11—Oxides

Definitions

  • the present invention relates to a method of casting an article, particularly, but not exclusively to a method of sand-casting an aluminium alloy engine block.
  • an engine block is made by sand casting an aluminium alloy.
  • a tubular cast iron liner In order to provide a suitable low friction, wear resistant, reciprocating surface, it is known to line the surface of each cylinder in the engine block in which a piston reciprocates, with a tubular cast iron liner.
  • Such liners increase the weight of the engine and, as cast iron has a lower thermal conductivity than aluminium based alloys, the use of such liners is detrimental to the removal of heat from the engine cylinders.
  • various processes of coating the inner surface of each cylinder with a metal that is harder than aluminium to provide a low friction, wear resistant reciprocating surface have been developed, and these include electro-coating, plasma transfer wire arc coating, and laser alloying.
  • the plasma-spraying of a ferrous coating is described in US6548195, and use of laser alloying is described in
  • the brass inserts can be difficult, particularly in a V-engine where the cylinders are inclined relative to the engine block, and adds an extra, relatively labour intensive step in the manufacturing process.
  • the brass inserts are susceptible to mechanical damage, particularly after repeated exposure to molten aluminium alloy has caused the brass to anneal and soften, and must be replaced at regular intervals, which further increases the cost of the casting process.
  • a method of casting an article using a mould including a mould cavity including the steps of providing a compound containing a halogen at at least a portion of a surface of the mould adjacent the mould cavity, pouring molten metal into the mould cavity, allowing the metal to cool and solidify, and removing the article from the mould.
  • the halogen is fluorine.
  • the coating may, for example, include dipotassium fluorotitanate.
  • the halogen may be chlorine, and may for example, be a potassium chloride-magnesium chloride eutectic.
  • the halogen containing compound is provided in a coating applied to at least a portion of the mould surface which forms at least part of the mould cavity.
  • the method further includes the step of subjecting the article to isostatic pressure.
  • the method further includes the step of heating the article to a temperature at which the entire article remains solid whilst applying the isostatic pressure. Subjecting the article to an isostatic pressure, particularly at high pressure, generally eliminates internal pores within the cast article, which improves the mechanical integrity of the article and reduces the risk of any such pores being exposed at the article surface during machining of the article.
  • the metal is preferably predominantly aluminium.
  • the metal may be an aluminium- silicon alloy, and is preferably a hypoeutectic aluminium-silicon alloy.
  • the coating is sprayed onto the mould surface.
  • the mould is made predominantly from sand.
  • the article may be an engine block. In this case, preferably the portions of the mould which are coated with the coating form cylinders in the engine block.
  • the method is applied to sand casting an engine block 10 from a conventional hypoeutectic aluminium-silicon alloy, such as the 356 or 354 alloys detailed below.
  • a conventional hypoeutectic aluminium-silicon alloy such as the 356 or 354 alloys detailed below.
  • a mould 12 is formed from first 12a and second 12b mould parts made from zircon or silicon sand using conventional sand-casting techniques.
  • the cylindrical portions of an upper mould part 12a which form cylindrical cavities, i.e. the cylinders in the engine block, are then coated with a coating 14 containing a halogen such as fluorine.
  • the halogen is fluorine
  • the coating material contains dipotassium fluorotitanate powder (K 2 TiF 6 ).
  • Other halogen containing compounds such as a mixed potassium chloride - magnesium chloride eutectic, potassium borofluoride, or aluminium chloride may alternatively be used.
  • the K 2 TiF 6 powder is mixed with a solvent, a filler material such as zircon powder and a gelling agent.
  • the coating material may, for example, comprise 60 wt% powder (the powder comprising 25 wt% zircon flour and 75 wt% K 2 TiF 6 dry milled powder) and 40% IPA solvent.
  • the coating is typically sprayed onto the mould surface, but may also be painted onto the mould.
  • dry K 2 TiF 6 powder may be rubbed onto the mould surface, or even added directly to the sand used to form the mould at levels of approximately 0.5 wt% K 2 TiF 6 .
  • the mould parts 12a, 12b are then clamped together to form a mould cavity, and molten aluminium-silicon alloy is pored into the mould cavity, and the mould allowed to cool until the alloy has solidified.
  • the as-cast engine block 10 is then removed from the mould 12.
  • the coating reduces transfer of hydrogen ions into the molten alloy, and hence significantly reduces the surface and sub-surface microporosity of the casting. It is believed that this occurs because fluorine in the coating reacts with the hydrogen ions before they can dissolve in the molten alloy.
  • the surface of the casting adjacent the coating in this example the interior surfaces of the cylinders in the engine block, may be machined and coated as described above without surface microporosity having a deleterious effect on the integrity of the coating.
  • Such a casting will, however, include internal pores, formed not as a result of reaction with the mould as described above, but as a result of the relatively low cooling rate associated with sand casting.
  • the internal pores may be exposed at the article surface during machining of the casting, and therefore it is desirable to eliminate these pores in addition to the surface microporosity.
  • the as-cast engine block is therefore subjected to hot isostatic pressing using a conventional, commercially available Al HIPPING process, the Bodycote Densal® II process, for example.
  • the engine block is placed in a container of fluid, heated to a temperature close to the melting temperature of the alloy but at which the alloy remains solid, for example 40 0 C below the solidus temperature of the alloy, and the fluid pressurised, for example to 1000 atmospheres of pressure.
  • the engine block is typically retained in the pressurised, heated fluid for forty five minutes to one hour.
  • the combination of fluid pressure and elevated temperature causes the internal pores to cave in and the material formerly surrounding each pore to diffusion bond.
  • the internal pores are substantially eliminated and the mechanical integrity of the casting improved.
  • the casting may thus be machined with substantially reduced risk of exposing internal pores at the casting surface. It should be appreciated that HIPPING cannot be used to remedy surface microporosity, since the pressurised fluid would fill the surface pores and provide internal support preventing the pore from caving in.
  • HIPPING is ineffective in eliminating sub-surface microporosity, since the layer of aluminium alloy separating each pore from the article surface is relatively thin, and is easily ruptured under the pressure of the pressurised fluid, thus exposing the pore interior to the pressurised fluid and preventing consolidation of the material around the pore.
  • the casting is then machined to the required dimensions and surface roughness.
  • the interior surfaces of the cylinders are machined in preparation for the application of a low friction, wear resistant coating using plasma transfer wire arc coating, electro-plating, or the like.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
  • Pistons, Piston Rings, And Cylinders (AREA)
  • Mold Materials And Core Materials (AREA)
EP05818016A 2004-12-16 2005-12-08 Method of casting an article Withdrawn EP1841553A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0427501A GB2421207A (en) 2004-12-16 2004-12-16 Casting with a halogen containing compound provided on the mould surface
PCT/GB2005/004712 WO2006064188A1 (en) 2004-12-16 2005-12-08 Method of casting an article

Publications (1)

Publication Number Publication Date
EP1841553A1 true EP1841553A1 (en) 2007-10-10

Family

ID=34090104

Family Applications (1)

Application Number Title Priority Date Filing Date
EP05818016A Withdrawn EP1841553A1 (en) 2004-12-16 2005-12-08 Method of casting an article

Country Status (7)

Country Link
US (1) US20070227689A1 (zh)
EP (1) EP1841553A1 (zh)
JP (1) JP2008523994A (zh)
KR (1) KR20070099603A (zh)
CN (1) CN101090784A (zh)
GB (1) GB2421207A (zh)
WO (1) WO2006064188A1 (zh)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102012210958A1 (de) 2012-06-27 2014-04-03 Bayerische Motoren Werke Aktiengesellschaft Gekühltes Werkzeug zum Warmumformen und/oder Presshärten eines Blechmaterials sowie Verfahren zur Herstellung einer Kühleinrichtung für dieses Werkzeug
DE202017107670U1 (de) * 2017-12-18 2019-03-20 Lothar Thoni Drehgestellrahmen für Schienenfahrzeuge aus einem Aluminiumgussteil
KR102444623B1 (ko) * 2018-01-29 2022-09-16 퍼듀 리서치 파운데이션 다이-캐스팅에서 윤활유로 사용하기 위한 조성물, 상기 조성물의 사용 방법, 및 이로써 제조된 제품
CN108607996B (zh) * 2018-07-27 2021-01-05 共享智能铸造产业创新中心有限公司 一种应用于3d打印技术的电弧喷涂设备
CN111534768B (zh) * 2020-06-15 2021-08-03 中北大学 一种含Cu铸造Al-Si-Mg铝合金铸件的分级热等静压方法

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SU498092A1 (ru) * 1974-01-10 1976-01-05 Научно-Исследовательский Институт Специальных Способов Литья Способ получени отливок
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DE19533529C2 (de) * 1995-09-11 2001-10-11 Vaw Alucast Gmbh Verfahren zum Gießen eines Motorblockes aus Aluminium
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JP4307614B2 (ja) * 1999-03-10 2009-08-05 三和油化工業株式会社 ダイカスト用水性離型剤及びそれを用いたダイカスト鋳造法
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Title
See references of WO2006064188A1 *

Also Published As

Publication number Publication date
GB2421207A (en) 2006-06-21
GB0427501D0 (en) 2005-01-19
US20070227689A1 (en) 2007-10-04
WO2006064188A1 (en) 2006-06-22
KR20070099603A (ko) 2007-10-09
CN101090784A (zh) 2007-12-19
JP2008523994A (ja) 2008-07-10

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