EP1844881B1 - Procédé destiné à la fabrication de composants à pores ouverts en métal, plastique ou céramique dotés d'une structure de grille de mousse ordonnée - Google Patents

Procédé destiné à la fabrication de composants à pores ouverts en métal, plastique ou céramique dotés d'une structure de grille de mousse ordonnée Download PDF

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Publication number
EP1844881B1
EP1844881B1 EP07007332A EP07007332A EP1844881B1 EP 1844881 B1 EP1844881 B1 EP 1844881B1 EP 07007332 A EP07007332 A EP 07007332A EP 07007332 A EP07007332 A EP 07007332A EP 1844881 B1 EP1844881 B1 EP 1844881B1
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EP
European Patent Office
Prior art keywords
core
lattice
core lattice
planes
lattice planes
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
Application number
EP07007332A
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German (de)
English (en)
Other versions
EP1844881A2 (fr
EP1844881A3 (fr
Inventor
Ulrich Munz
Bernd Kuhs
Raimund Strub
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.)
Laempe & Mossner GmbH
Kurtz GmbH
Original Assignee
Laempe & Mossner GmbH
Kurtz GmbH
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Publication of EP1844881A3 publication Critical patent/EP1844881A3/fr
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Classifications

    • 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
    • B22D19/14—Casting in, on, or around objects which form part of the product the objects being filamentary or particulate in form
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B22C9/105—Salt cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • B22D25/005—Casting metal foams
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/08—Alloys with open or closed pores
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/08—Alloys with open or closed pores
    • C22C1/081—Casting porous metals into porous preform skeleton without foaming

Definitions

  • the invention relates to a method for the production of open-pored lightweight components made of metal, metal alloys, plastic or ceramic of any geometry according to the teaching of claim 1.
  • casting molds are produced from amorphous disordered lattice structures which are poured out in a casting apparatus.
  • Connected single spheres can be used to produce components with an open or closed outer wall, which have an amorphous undefined lattice structure in the interior, since the core stack used in the casting process is formed from an accumulation of disorderedly interconnected spheres.
  • a clear definition of the mechanical properties of the component is impossible due to the unpredictability of the disordered lattice structure inside the components.
  • the core is a lost core, that is, a core that no longer exists in the final part.
  • the core consists of a larger number of mineral foam balls with ball diameters between 1-8 mm, which are glued together at their points of contact.
  • the core represents a three-dimensional dense sphere packing used as a core stack.
  • the resulting from the casting process components can be open-pored, since it is possible to fill only edge regions of the core with melt. However, this results after elimination of the core at least one side of the casting, which has open pores.
  • the core stack thus consists of a ball packing, the individual balls touching each other, since they are glued together. An adjustment of the distances of the balls - and thus a variation of the pore distances - by using webs between the balls is not provided.
  • the casting cores are produced in each case by firstly combining sand particles corresponding to the contour of the part to be produced in a layer by means of a binder. After completion of this layer, a new layer is built up over it, in which again individual sand particles are connected to one another by means of a binder and furthermore a connection of this layer to the previously created layer takes place.
  • the casting core is thus constructed in layers.
  • none of the cited references discloses a connection of the individual particles / grains of sand of the respective layer by webs; furthermore, the cores disclosed therein are not suitable for producing open-pored castings.
  • the object of the invention is to propose a method which allows the production of lightweight components made of metal, metal alloys, plastic or ceramic arbitrary geometry, in which by a clearly defined inner lattice structure of the core stack mechanical requirements, such as density, rigidity or strength of the component predictable are, and if necessary, a defined outer skin desired thickness can be produced.
  • Such components can be used under the umbrella term “light and stiff” and / or “energy and sound absorbing” everywhere where, for example, moving masses must have corresponding properties, e.g. in vehicle construction for road or rail, in aircraft or mechanical engineering / kinematics. Furthermore, components produced in this way are particularly suitable for heat exchangers of any type because of the open-pored and ordered foam grid structure, since they separate two spheres which are simply connected.
  • the component is produced by pouring liquid material into a casting device when using the method for producing lightweight porous components made of metal, metal alloys, plastic or ceramic of any geometry.
  • a core stack in the casting mold of the casting apparatus stored, drained and gutted.
  • This core stack is designed as a regular multi-dimensional core lattice with defined core lattice planes, in which each lattice plane is composed of individual regular core bodies.
  • a casting device known from the prior art can be used, but in which the casting mold as a core stack differs in that it is constructed as a regular ordered core lattice.
  • the core lattice consists of at least one core lattice plane, which is composed of individual regular core bodies. Shape, size and number of core bodies and their spacing determine the porosity and the mechanical properties of the resulting from the process components.
  • a closed outer shell of the components can be produced in that the core stack has a certain distance from the outer wall of the mold, which is then filled with the liquid material and forms the closed outer wall. The distance between the core stack and the outer wall of the mold determines the thickness of the component outer wall.
  • a macroscopic regular lattice structure of the material can be produced, so that the component has a macroscopic structural structure and combines the structural advantages, namely low density, high rigidity and high strength, with the microscopic properties of the material.
  • the application of the method thus serves to produce components which have metamaterials properties, ie whose characteristic parameters not only determined by the parameters of the original material but also by the defined macroscopic structure of the component.
  • individual core lattice planes are connected to one another as web-connected, spherical, polygonal or other voluminous core bodies of freely determinable dimension in two or more layers in a lattice-offset manner, such that the previously lightened ones or contact with adhesive core body of the individual levels by means of binder or adhesive bridges.
  • a core lattice plane is characterized in that the spherical, polygonal or other voluminous individual bodies of freely determinable dimension are interconnected with webs.
  • the core body can thus have any shape and deviate from a classic spherical shape, in particular they can be flattened spherical, polygonal or otherwise arbitrarily designed.
  • a lattice plane may consist of two or more interconnected bodies and may be both plane and in the spherical plane or otherwise arbitrarily curved.
  • a core stack is built up of individual core lattice planes and can thus fill the component layer by layer.
  • the method for producing the individual core lattice planes can in principle be carried out arbitrarily. It has proved to be particularly advantageous to form the individual core lattice planes in a first operation by connecting the core body to solid planar, curved or arbitrarily curved plates. Only by stacking the individual core lattice planes, in particular the plates representing them, is a desired shape of the core lattice generated. By such a layered structure, it is advantageously possible to produce the core grid independently and after the production of the individual core lattice planes; in particular, it is conceivable to prefabricate core lattice planes, to cut them into a desired shape if necessary and to assemble them into a core lattice. This allows a cheap, efficient and fast production of the core lattice from prefabricated core lattice planes, in particular from prefabricated plates.
  • the individual core lattice planes can be produced as desired in the first work step.
  • bridge connections a reliable fixation of the core body is achieved in the core lattice plane, so that a planar or arbitrarily curved shape of the core lattice plane can be made stable.
  • individual core lattice planes After individual core lattice planes have been fabricated according to the embodiments presented above, they must be interconnected to form a core body. This can be done in any way, as this is particularly easy by connecting the individual core lattice planes by a suitable binder and hardening process, as they are already known in the creation of core bodies in the foundry technology. For example, a treatment with hot air, with carbon dioxide or with an amine, or else only a heat treatment by microwaves, may be suitable for connecting the core lattice planes to one another.
  • binders many different organic and inorganic foundry binders are available which decompose by the action of heat of the hot metal, plastic or other pourable material, or they must be water-soluble to be removed from the component after pouring the casting material ,
  • the process for producing the individual core lattice planes can be carried out arbitrarily.
  • the bodies within the core grid structure have a defined size, for example 10 mm, and can be produced in a grid.
  • a suitable foundry core sand can be mixed with a known core sand binder and this core lattice layer starting material can be shaped and cured by a suitable core production process.
  • known betaset, coldbox, hotbox or croning processes with organic binder fractions are used. With these known methods for producing casting molds can be produced inexpensively and easily the core lattice planes without special conversion of the foundry process.
  • water-soluble inorganic binder components based on magnesium sulfate, phosphate or silicate or a mixture of these are used in the production of the core lattice planes.
  • These inorganic binders are eminently suitable for inexpensively and easily producing robust core lattice planes which can be assembled into complex core stacks.
  • the material used to construct the individual core lattice planes can, in principle, be arbitrarily selected from the range of materials conventionally used for casting molds.
  • inorganic flours or sands which consist in particular of quartz, feldspar, aluminum oxide, chamotte, olivine, chrome ore, clay, kaolin, fluorspar, silicate or bentonite or a mixture of these, are suitable for the production of core lattice planes .
  • core bodies can be produced in a particularly simple manner, and connected to the above-mentioned core sand binders, so that it is possible to produce particularly durable and easily machinable core lattice planes.
  • salts to prepare the core lattice planes, especially sodium chloride (NaCl), potassium chloride (KCl), potassium sulfate (K 2 SO 4 ) or magnesium sulfate (Mg 2 SO 4 ).
  • NaCl sodium chloride
  • KCl potassium chloride
  • K 2 SO 4 potassium sulfate
  • Mg 2 SO 4 magnesium sulfate
  • the individual core lattice planes can be built up from these salts.
  • the shape and size of the core body within the core grid can in principle be chosen arbitrarily. However, it has turned out to be particularly advantageous if the core bodies have a size of 1 mm to 30 cm. In particular, it is particularly advantageous if the core body has a diameter of about 5 mm to 20 mm.
  • individual core lattice planes are cured, they are coated or sized with a binder or adhesive and stacked on top of each other in two or more planes so that the core bodies of the individual planes contact one another in a grid-offset manner.
  • the core bodies are connected to one another at the contact points / contact surfaces. This can in principle be carried out arbitrarily, but it has been shown to be particularly advantageous if the core lattice planes are produced in part or in sets in a multipart sandwich core bushing, wherein the core lattice planes are sized therein, assembled with one another and deposited in the core bushing.
  • the core lattice frames used are components of a tool, preferably a robot-controlled tool, which are arranged within a core production tool and the finishing, assembly and removal of the core lattice is performed outside the core production tool.
  • a tool preferably a robot-controlled tool
  • the individual core lattice planes are produced by means of a core lattice frame within a core making tool, preferably by a robot controlled tool comprising the core lattice frame.
  • the individual core lattice planes are removed from the core manufacturing tool, and the sizing, assembly and deposition of the core lattice is performed outside the core manufacturing tool.
  • the core lattice stack thus produced may in turn be transformed into a casting mold, e.g. a mold, to be stored.
  • a casting mold e.g. a mold
  • the later geometry and outer wall thickness of the casting can be determined.
  • a suitable casting process so these cavities are filled with metal, plastic, metal alloys or a ceramic mass.
  • the entire core is pre-formed, e.g. in an oven, heated to ensure the fluidity of the metal to all fine interstices.
  • the liquid material flows through the static pressure to the level of the material sump in the mold and then pulled by a vacuum generated by a vacuum station, so far into the mold until it is the mold fills.
  • the liquid material runs up to the level of the material sump in the mold, wherein the material sump is generated by flowing liquid material from a furnace.
  • a vacuum pump pulls the material higher into the mold by a vacuum, so that eventually the entire shape of liquid material is filled.
  • all the core material can then be removed from the component by vibration, blasting or by floating with water.
  • at least one side of the component is generated without outer skin, or it is subsequently the outer skin at a suitable location reopened, eg drilled out, so that all core material can be removed without leaving any residue, since all the core bodies contacted via the binder / intermediate bridges are in communication with each other.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Catalysts (AREA)
  • Porous Artificial Stone Or Porous Ceramic Products (AREA)

Claims (14)

  1. Procédé pour la fabrication d'éléments constructifs légers à pores ouverts en métal, en alliages métalliques, en matière plastique ou en céramique de géométries quelconques, dans lequel l'élément constructif est fabriqué par le coulage d'un matériau liquide dans un dispositif de coulée (01), une pile de noyaux (04) est placée dans un moule (3), est coulée et dénoyautée, la pile de noyaux (04) étant façonnée en forme d'une grille de noyaux (09) multidimensionnelle régulière présentant des plans de grilles de noyaux (12) définis, chaque plan de grilles de noyaux (12) étant constitué de corps de noyaux (10) individuels réguliers,
    caractérisé en ce que,
    pour la fabrication de ladite grille de noyaux (09), des plans de grilles de noyaux (12) individuels, en forme de corps de noyaux (10) sphériques, polygonales ou autrement volumineux de dimensions librement déterminables étant liés entre eux au moyen d' âmes, sont reliés entre eux en deux ou plusieurs couches au travers de grilles décalées de telle manière que les corps de noyaux (10) desdits plans individuels (12) étant préalablement lissés ou munis d'un adhésif entrent en contact les uns avec les autres au moyen de ponts de liaison ou de ponts adhésifs.
  2. Procédé selon la revendication 1,
    caractérisé en ce que,
    pour la fabrication de la grille de noyaux, dans une première phase de fabrication les corps de noyaux (10) sont reliés entre eux dans un plan de grilles de noyaux (12) afin de former de préférence de plaques solides planaires, courbées ou bien coudées d'une façon quelconque, la forme souhaitée de la grille de noyaux (09) étant créée seulement au moyen d'un empilement des plans de grilles de noyaux (10) individuels, en particulier des plaques.
  3. Procédé selon la revendication 2,
    caractérisé en ce que,
    dans la première phase de fabrication de la grille de noyaux, des corps de noyaux (10) voisins sont reliés entre eux au moyen d' âmes dans un seul processus de façonnement pour la fabrication des plans de grilles de noyaux (12).
  4. Procédé selon l'une quelconque des revendications précédentes,
    caractérisé en ce que
    le lien entre les plans de grilles de noyaux (12) individuels est réalisé par l'application d'un agent liant susceptible et d'une procédure de durcissement.
  5. Procédé selon l'une quelconque des revendications précédentes,
    caractérisé en ce que
    les plans de grilles de noyaux (12) sont fabriqués au moyen de procédures connues du Bétaset, du Coldbox, du Hotbox ou bien du Croning en utilisant des composants organiques de l'agent liant.
  6. Procédé selon l'une quelconque des revendications précédentes,
    caractérisé en ce que
    les plans de grilles de noyaux (12) sont fabriqués au moyen de procédures utilisant des composants anorganiques hydrosolubles de l'agent liant sur la base de sulfate de magnésium, de phosphate ou de silicate ou bien d'un mélange de ces derniers.
  7. Procédé selon l'une quelconque des revendications précédentes,
    caractérisé en ce que
    le matériau utilisé pour la fabrication des plans de grilles de noyaux (12) est une poudre ou un sable anorganique, en particulier du quartz, du feldspath, de l'oxyde d'aluminium, de la chamotte, de l'olivine, du minerai de chrome, de l'argile, du kaolin, de la fluorine, du silicate ou du bentonite ou bien un mélange de ces derniers.
  8. Procédé selon l'une quelconque des revendications 1 à 6,
    caractérisé en ce que
    le matériau utilisé pour la fabrication des plans de grilles de noyaux (12) est un sel, en particulier le NaCl, le KCl, le K2SO4 ou bien le Mg2SO4.
  9. Procédé selon l'une quelconque des revendications précédentes,
    caractérisé en ce que
    les corps de noyaux (10) dans la grille de noyaux (09) présentent un diamètre de 1 mm à 30 cm.
  10. Procédé selon la revendication 9,
    caractérisé en ce que
    les corps de noyaux (10) dans la grille de noyaux (09) présentent un diamètre de 5 mm à 20 mm.
  11. Procédé selon l'une quelconque des revendications précédentes,
    caractérisé en ce que
    les plans de grilles de noyaux (12) sont fabriqués à la pièce ou par lots dans une boîte à noyaux en plusieurs parties de structure sandwich, les plans de grilles de noyaux (12) étant lissés, assemblés entre eux et placés dans la boîte à noyaux.
  12. Procédé selon la revendication 11,
    caractérisé en ce que
    les cadres des grilles de noyaux utilisés pour la fabrication des plans de grilles de noyaux (12) constituent des composants d'un outil, de préférence d'un outil contrôlé au moyen de robots, en dedans d'un outil pour la fabrication des noyaux, sachant que le lissage, l'assemblage et le placement de la grille de noyaux sont exécutés en dehors de l'outil pour la fabrication des noyaux.
  13. Procédé selon la revendication 12,
    caractérisé en ce qu'
    au moins deux robots travaillent en cycle, un robot travaillant en dedans de l'outil pour la fabrication afin de fabriquer les noyaux, le deuxième robot exécutant parallèlement le lissage, l'assemblage et le placement de la grille de noyaux.
  14. Procédé selon l'une quelconque des revendications précédentes,
    caractérisé en ce que
    le matériau liquide coule dans le moule au cours du processus de coulée au moyen de la pression statique jusqu'au niveau du bassin de coulée et est ensuite tiré dans le moule au moyen d'un vacuum généré par une station de vacuum (2) jusqu'à ce que le moule soit rempli de celui-ci.
EP07007332A 2006-04-10 2007-04-10 Procédé destiné à la fabrication de composants à pores ouverts en métal, plastique ou céramique dotés d'une structure de grille de mousse ordonnée Not-in-force EP1844881B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE102006017104A DE102006017104A1 (de) 2006-04-10 2006-04-10 Verfahren zur Herstellung von offenporigen Bauteilen aus Metall, Kunststoff oder Keramik mit geordneter Schaumgitterstruktur

Publications (3)

Publication Number Publication Date
EP1844881A2 EP1844881A2 (fr) 2007-10-17
EP1844881A3 EP1844881A3 (fr) 2007-11-21
EP1844881B1 true EP1844881B1 (fr) 2010-01-27

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EP07007332A Not-in-force EP1844881B1 (fr) 2006-04-10 2007-04-10 Procédé destiné à la fabrication de composants à pores ouverts en métal, plastique ou céramique dotés d'une structure de grille de mousse ordonnée

Country Status (6)

Country Link
US (1) US7588069B2 (fr)
EP (1) EP1844881B1 (fr)
JP (1) JP2007275992A (fr)
AT (1) ATE456410T1 (fr)
DE (2) DE102006017104A1 (fr)
ES (1) ES2338468T3 (fr)

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CN111496194B (zh) * 2020-04-22 2023-07-11 陈万红 一种多孔浇筑构件及其生产工艺
CN116104893B (zh) * 2023-01-03 2023-07-28 中国机械总院集团沈阳铸造研究所有限公司 一种高阻尼变刚度点阵复合结构减振器及其制备方法

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US20070296106A1 (en) 2007-12-27
US7588069B2 (en) 2009-09-15
ATE456410T1 (de) 2010-02-15
EP1844881A2 (fr) 2007-10-17
DE502007002714D1 (de) 2010-03-18
DE102006017104A1 (de) 2007-10-11
EP1844881A3 (fr) 2007-11-21
JP2007275992A (ja) 2007-10-25
ES2338468T3 (es) 2010-05-07

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