EP2082819A1 - Pressure-resistant core with improved adhesive - Google Patents

Pressure-resistant core with improved adhesive Download PDF

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Publication number
EP2082819A1
EP2082819A1 EP08018459A EP08018459A EP2082819A1 EP 2082819 A1 EP2082819 A1 EP 2082819A1 EP 08018459 A EP08018459 A EP 08018459A EP 08018459 A EP08018459 A EP 08018459A EP 2082819 A1 EP2082819 A1 EP 2082819A1
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Prior art keywords
mixture
water
salt core
binder
inorganic
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EP08018459A
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German (de)
French (fr)
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EP2082819B1 (en
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Manfred Laudenklos
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KS Huayu Alutech GmbH
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KS Aluminium Technologie GmbH
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Application filed by KS Aluminium Technologie GmbH filed Critical KS Aluminium Technologie GmbH
Priority to PL08018459T priority Critical patent/PL2082819T3/en
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    • 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

Abstract

The pressure-resistant core for casting consists of a mixture of mainly water-soluble salts and a binder. It also has a protein combination with inorganic components added to the mixture. The mixture may contain 0.5-5 wt.% of this protein combination, preferably 2% of it. The protein combination with the inorganic components may be in the form of a gelatine.

Description

Die vorliegende Erfindung betrifft wasserlösliche Salzkerne für Gießereizwecke, welche aus einem Gemisch aus im Wesentlichen wasserlöslichen Salzen und einem Bindemittel bestehen.The present invention relates to water-soluble salt cores for foundry purposes, which consist of a mixture of substantially water-soluble salts and a binder.

Bei verschiedenen Gütern, die mittels eines Gießverfahrens hergestellt werden, ist es erforderlich, Formhohlräume im Inneren dieser Güter zu erzeugen. Insbesondere beim Metallgießen, wobei hier insbesondere die Leichtmetalle und deren Legierungen angesprochen sind, gibt es verschiedene Möglichkeiten, die Güter zu gießen. Eine Möglichkeit, die Gießverfahren zu unterscheiden ist die Einteilung in drucklose und druckbeaufschlagte Gießverfahren. Bei den drucklosen Verfahren, wie beispielsweise das Schwerkraftgießen, wird ein Formkern aus verfestigtem Sand oder Salz innerhalb der Gießform angeordnet und mit Metallschmelze umgossen, wobei die Gießform gefüllt und der Formkern umschlossen wird. Bei den druckbeaufschlagten Gießverfahren besteht ein Hauptproblem darin, einen druckfesten Formkern zu erzeugen. Der Formkern muß einerseits druckfest, er muß andererseits aber nach dem Erkalten des Gußteils auch leicht zu entfernen sein. Darüber hinaus muß der Formkern eine Penetration des ihn umgebenden flüssigen Gießmetalls verhindern. Das flüssige Metall wird zumeist unter hohem Druck in die Gießform eingefüllt, so dass der Formkern neben der hohen Druckfestigkeit auch eine hohe Resistenz gegen das flüssige Metall besitzen sollte.In various goods made by a casting process, it is necessary to produce mold cavities inside these goods. In particular, in metal casting, which in particular the light metals and their alloys are addressed, there are various ways to pour the goods. One way of distinguishing the casting processes is the classification into pressureless and pressurized casting processes. In non-pressurized processes, such as gravity casting, a mold core of solidified sand or salt is placed within the mold and molten with molten metal, filling the mold and enclosing the mold core. In the pressurized casting process, a major problem is to produce a pressure-resistant mandrel. The mandrel must on the one hand pressure-resistant, but on the other hand, it must also be easy to remove after cooling of the casting. In addition, the mandrel must prevent penetration of the surrounding liquid casting metal. The liquid metal is usually filled under high pressure in the mold, so that the mold core in addition to the high pressure resistance should also have a high resistance to the liquid metal.

Ein Einsatzgebiet bei dem Formkörper zum Gießen verwendet werden sind Kolben von Verbrennungsmotoren. Besonders bei aufgeladenen Motoren und bei hochbelasteten Diesel- und auch Ottomotoren ist die im Kolben entstehende Wärme beim Brennvorgang so hoch, dass eine intensive Kolbenkühlung notwendig wird. In diesem Fall kann der Kolben durch einen im Kolbenboden angeordneten Kühlkanal besonders ausgerüstet werden, damit die notwendige Wärmeabfuhr gesichert ist.One application in which moldings are used for casting are pistons of internal combustion engines. Especially in turbocharged engines and heavily loaded diesel and gasoline engines, the heat generated in the piston during the firing process is so high that an intensive piston cooling is necessary. In this case, the piston can be specially equipped by a cooling channel arranged in the piston bottom, so that the necessary heat dissipation is ensured.

Dazu werden beim Gießen die vorgefertigten Salzkerne in die Gießform eingelegt, die die Geometrie des späteren Kühlkanals besitzen und die nach dem Erstarren des Metalls mit Wasser und Druckluft wieder ausgespült werden. Salzkerne zum Gießen sind aber nur zum Schwerkraftgießen geeignet, da sie wenig druckbeständig und gleichzeitig zur Penetration neigen, so dass im fertigen Kühlkanal Unebenheiten oder sogar kleine Trennwände entstehen, die den Kühlöldurchfluß behindern. Um das Eindringen von Metallschmelze in den Salzkern zu verhindern und den Salzkern gleichzeitig druckfest zu gestalten, sind verschiedene Verfahren bekannt geworden.For this purpose, the prefabricated salt cores are inserted into the casting mold during casting, which have the geometry of the later cooling channel and which are rinsed out after the solidification of the metal with water and compressed air. However, salt cores for casting are only suitable for gravity casting, as they are less resistant to pressure and at the same time tend to penetrate, so that in the finished cooling channel bumps or even small partitions arise that hinder the Kühlöldurchfluß. In order to prevent the penetration of molten metal into the salt core and to make the salt core pressure resistant at the same time, various methods have become known.

Aus der DE 10 2004 006 600 B4 ist ein Verfahren zur Herstellung eines gattungsgemäßen Salzkerns bekannt, bei welchem dem Salzkern 0,5% bis 5% eines phosphathaltigen Binders zugemischt wird. Hierdurch wird erreicht, dass der Binder unter einem hohen Druck von etwa 800bar und einer erhöhten Temperatur von ca. 350°C polymarisiert, wobei es auch zu einem Anschmelzen des Binders kommen kann, so dass ein druckbeständiger, gegen das flüssige Metall widerstandsfähiger Salzkern gebildet wird.From the DE 10 2004 006 600 B4 a method for producing a generic salt core is known in which the salt core 0.5% to 5% of a phosphate-containing binder is added. This ensures that the binder polymarized under a high pressure of about 800bar and an elevated temperature of about 350 ° C, which can also lead to a melting of the binder, so that a pressure-resistant, against the liquid metal resistant salt core is formed ,

Aufgabe der Erfindung ist es, einen verbesserten Salzkern sowie ein Verfahren zur Herstellung eines wasserlöslichen Salzkerns zu entwickeln, mit dem ein Salzkern hergestellt werden kann, der sich leicht entfernen läßt, eine gute Beständigkeit gegen das umgießende Metall aufweist und der gleichzeitig eine geringe Penetration des flüssigen Metalls zuläßt. Darüber hinaus soll das Verfahren kostengünstig und in den vorhanden Verfahrensablauf integrierbar sein.The object of the invention is to develop an improved salt core and a method for producing a water-soluble salt core, with which a salt core can be prepared, which can be easily removed, has a good resistance to the infiltrating metal and at the same time a low penetration of the liquid Metal permits. In addition, the process should be inexpensive and integrated into the existing process flow.

Diese Aufgabe ist erfindungsgemäß dadurch gelöst, dass das Gemisch aus wasserlöslichen Salzen und einem Bindemittel zusätzlich eine Protein-Kombination mit anorganischen Bestandteilen enthält. Versuche haben gezeigt, dass durch die Zugabe einer solchen Protein-Kombination mit anorganischen Bestandteilen, die beispielsweise in der Form einer Gelatine vorliegen kann, die Belastbarkeit, insbesondere Bruchsicherheit, der erfindungsgemäßen Salzkerne erhöht werden kann.This object is inventively achieved in that the mixture of water-soluble salts and a binder additionally contains a protein combination with inorganic constituents. Experiments have shown that by adding such a protein combination with inorganic constituents, which may be present for example in the form of a gelatin, the loading capacity, in particular resistance to breakage, of the salt cores according to the invention can be increased.

Es hat sich herausgestellt, dass gute Ergebnisse erzielt werden, wenn das Gemisch 0,5 bis 5 Gew.% und insbesondere etwa 2% der Protein-Kombination mit anorganischen Bestandteilen enthält.It has been found that good results are obtained when the mixture contains from 0.5 to 5% by weight and in particular about 2% of the protein combination with inorganic constituents.

Als Bindemittel wird vorzugsweise ein anorganisches Phosphat oder einer Mischung anorganischer Phosphate gewählt. Durch Einsatz solcher phosphathaltiger Bindemittel wird erreicht, dass der Salzkern dem flüssigen Metall einen erhöhten Widerstand gegenüberstellt und sich darüber hinaus durch eine ausgezeichnete Oberflächenglätte auszeichnet, so dass eine Penetration des flüssigen Metalls verhindert wird. Durch die Zumischung eines handelsüblichen Binders auf Phosphatbasis ist der Salzkern äußerst günstig herzustellen und kann ebenfalls ohne zusätzliche Verfahrensschritte in den Fertigungsablauf des Gießverfahrens integriert werden.The binder used is preferably an inorganic phosphate or a mixture of inorganic phosphates. The use of such phosphate-containing binders ensures that the salt core faces the liquid metal increased resistance and also characterized by an excellent surface smoothness, so that a penetration of the liquid metal is prevented. By adding a commercial binder based on phosphate, the salt core is extremely inexpensive to produce and can also be integrated without additional process steps in the production process of the casting process.

Der Anteil des Bindemittels beträgt vorzugsweise 0,5 bis 10 Gew.% des Gemischs. Als phosphathaltige Binder können dabei zum Beispiel Phosphate in der Form von Natriumhexametaphosphat, das auch unter dem Handelsnamen Budit 6 vertrieben wird, Borphosphatmonohydrat, das unter dem handelsüblichen Namen FFB 761 vertrieben wird, Monoaluminiumhydrogenorthophosphat, das unter dem Handelsnamen FFB 716 vertrieben wird oder eine Kombination aus anorganischen Boraten und Phosphaten, die unter dem Handelsnamen FFB 102 vertrieben werden und zu denen z.B. die Monozink-Phosphate gehören, eingesetzt werden.The proportion of the binder is preferably 0.5 to 10 wt.% Of the mixture. Phosphate-containing binders which can be used here are, for example, phosphates in the form of sodium hexametaphosphate, which is also sold under the trade name Budit 6, boron phosphate monohydrate, which is sold under the commercial name FFB 761, monoaluminum hydrogen orthophosphate sold under the trade name FFB 716 or a combination of inorganic borates and phosphates sold under the trade name FFB 102, and to which, for example the monozinc phosphates are used.

Zur Herstellung des Salzkerns wird zunächst die Protein-Kombination mit anorganischen Bestandteilen beispielsweise in der Form einer Gelatine mit dem Bindemittel auf Phosphatbasis vermischt. Die Mischung erfolgt so lange, bis ein homogenes Gemisch vorliegt. Anschließend wird das Gemisch aus Proteinkombination und Bindemittel homogen mit zum Beispiel Speisesalz vermischt, um das fertige Salzkerngemisch herzustellen. Die Bestandteile sind dabei so abgewogen, dass der Anteil der Protein-Kombination 0,5 bis 5% und insbesondere 2% des Salzkerngemischs und der Anteil des Bindesmittels 0,5 bis 10% und insbesondere etwa 0,5 bis 5 Gew.% beträgt.To prepare the salt core, first the protein combination with inorganic components, for example in the form of a gelatin, is mixed with the phosphate-based binder. The mixture is carried out until a homogeneous mixture is present. Subsequently, the mixture of protein combination and binder is homogeneously mixed with, for example, table salt to prepare the finished salt core mixture. The constituents are weighed in such a way that the proportion of the protein combination is 0.5 to 5% and in particular 2% of the salt core mixture and the proportion of the binding agent is 0.5 to 10% and in particular about 0.5 to 5% by weight.

Das so hergestellte Salzgemisch wird in ein Formwerkzeug zur Bildung des Salzkerns gefüllt. Das Formwerkzeug ist eine Dauerform, die zum Beispiel einen Kühlkanal für einen Kolben oder ein Zylinderkurbelgehäuse darstellen kann. Im Formwerkzeug wird das Salzgemisch bis zu eine Minute lang unter einem Druck von ca. 800bar verdichtet und bei einer erhöhten Temperatur von ca. 200°C zur Bindung des Salzkernes verpresst. Unter dem hohen Druck und dem Einfluss der erhöhten Temperatur polymerisiert der Binder, so dass ein druckbeständiger, gegen das flüssige Metall widerstandsfähiger Salzkern gebildet wird. Durch die Polymerisation oder das Anschmelzen des Binders wird eine sehr glatte Oberfläche am Salzkern erzeugt, die ein Penetrieren des flüssigen Metalls in den Salzkern verhindert. Bei Salzkernen mit geringen Massen, wie beispielsweise Salzkerne für Kühlkanäle in Kolben, ergeben sich Herstellungs- oder Formzeiten für die Salzkerne von kleiner oder gleich einer Minute. Bei größeren Massen wie beispielsweise Salzkernen zum Gießen für Zylinderkurbelgehäuse erhöhen sich die Formzeiten bis zu etwa 5 Minuten.The salt mixture thus prepared is filled in a mold to form the salt core. The mold is a permanent mold, which may, for example, constitute a cooling channel for a piston or a cylinder crankcase. In the mold, the salt mixture is compressed for up to one minute under a pressure of about 800 bar and pressed at an elevated temperature of about 200 ° C to bond the salt core. Under the high pressure and the influence of the elevated temperature, the binder polymerizes to form a pressure resistant, liquid metal resistant salt core. By the polymerization or the melting of the binder produces a very smooth surface on the salt core which prevents penetration of the liquid metal into the salt core. In salt cores with low masses, such as salt cores for cooling channels in pistons, resulting in manufacturing or molding times for the salt cores of less than or equal to one minute. For larger masses such as salt cores for casting for cylinder blocks, the molding times increase up to about 5 minutes.

Durch den Einsatz des phosphathaltigen Binders ist der Salzkern leicht aufzulösen und kann mittels Wasser aus dem gegossenen Bauteil sehr leicht herausgespült werden. Der Phosphatbinder und das Salz sind in der vorliegenden Form wasserlöslich, bieten aber gleichzeitig den Vorteil eines druckbeständigen Salzkerns und einer resistenten Oberfläche. Es können somit Gussteile hergestellt werden, die Hinterschnittkonturen aufweisen und die frei von der Oberfläche des fertigen Gussteils aufrauhenden Penetrationen oder sogar Trennwänden durch Brüche in den Salzkernen sind.By using the phosphate-containing binder, the salt core is easy to dissolve and can easily be rinsed out of the cast component by means of water. The phosphate binder and salt are water-soluble in the present form, but at the same time offer the advantage of a pressure-resistant salt core and a resistant surface. It can thus be produced castings that have undercut contours and are free from the surface of the finished casting roughening penetrations or even partitions by breaks in the salt cores.

Ein weiterer Vorteil ergibt sich dadurch, dass während des Umgießens der erfindungsgemäß hergestellten Salzkerne mit zum Beispiel flüssigem Aluminium Temperaturbereiche von etwa 700°C einstellen, die wieder zu einer Oberflächenpolymerisation führen und somit einer Penetration des flüssigen Aluminiums in dem Salzkern entgegenwirken.A further advantage results from the fact that during the transfusion of the salt cores produced according to the invention with, for example, liquid aluminum temperature ranges of about 700 ° C, which again lead to a surface polymerization and thus counteract penetration of the liquid aluminum in the salt core.

Claims (15)

Wasserlöslicher Salzkern für Gießereizwecke, welcher aus einem Gemisch aus im Wesentlichen wasserlöslichen Salzen und einem Bindemittel besteht, dadurch gekennzeichnet, dass das Gemisch zusätzlich eine Protein-Kombination mit anorganischen Bestandteilen enthält.Water-soluble salt core for foundry purposes, which consists of a mixture of substantially water-soluble salts and a binder, characterized in that the mixture additionally contains a protein combination with inorganic constituents. Wasserlöslicher Salzkern nach Anspruch 1, dadurch gekennzeichnet, dass das Gemisch 0,5 bis 5 Gew.% der Protein-Kombination mit anorganischen Bestandteilen enthält.Water-soluble salt core according to claim 1, characterized in that the mixture contains 0.5 to 5 wt.% Of the protein combination with inorganic constituents. Wasserlöslicher Salzkern nach Anspruch 2, dadurch gekennzeichnet, dass das Gemisch etwa 2% der Protein-Kombination mit anorganischen Bestandteilen enthält.A water-soluble salt core according to claim 2, characterized in that the mixture contains about 2% of the protein combination with inorganic constituents. Wasserlöslicher Salzkern nach einem der vorherigen Ansprüche, dadurch gekennzeichnet, dass die Protein-Kombination mit anorganischen Bestandteilen eine Gelatine ist.Water-soluble salt core according to one of the preceding claims, characterized in that the protein combination with inorganic constituents is a gelatin. Wasserlöslicher Salzkern nach einem der vorherigen Ansprüche, dadurch gekennzeichnet, dass das Bindemittel ein anorganisches Phosphat oder eine Mischung anorganischer Phosphate enthält.Water-soluble salt core according to one of the preceding claims, characterized in that the binder contains an inorganic phosphate or a mixture of inorganic phosphates. Wasserlöslicher Salzkern nach Anspruch 5, dadurch gekennzeichnet, dass der Anteil des Bindemittels 0,5 bis 10 Gew.% und insbesondere 0,5 bis 5 Gew.% des Gemischs ist.Water-soluble salt core according to claim 5, characterized in that the proportion of the binder is 0.5 to 10 wt.% And in particular 0.5 to 5 wt.% Of the mixture. Wasserlöslicher Salzkern nach Anspruch 5 oder 6, dadurch gekennzeichnet, dass das anorganische Phosphat ein Monoaluminiumhydrogenorthophosphat enthält.Water-soluble salt core according to claim 5 or 6, characterized in that the inorganic phosphate contains a monoaluminum hydrogen orthophosphate. Wasserlöslicher Salzkern nach einem der Ansprüche 5 bis 7, dadurch gekennzeichnet, dass das anorganische Phosphat ein Borphosphat-Monohydrat umfasst.Water-soluble salt core according to one of claims 5 to 7, characterized in that the inorganic phosphate comprises a boron phosphate monohydrate. Wasserlöslicher Salzkern nach einem der Ansprüche 5 bis 8, dadurch gekennzeichnet, dass das anorganische Phosphat ein Natriumpolyphosphat und insbesondere Natriumhexametaphosphat enthält.Water-soluble salt core according to one of claims 5 to 8, characterized in that the inorganic phosphate contains a sodium polyphosphate and in particular sodium hexametaphosphate. Verfahren zur Herstellung eines wasserlöslichen Salzkerns, bei welchem wasserlösliche Salze mit einem Bindemittel vermischt werden, das Gemisch in ein Formwerkzeug zur Bildung eines Salzkerns eingefüllt wird und der Formkern unter Druck und/oder erhöhter Temperatur verdichtet wird, dadurch gekennzeichnet, dass dem Gemisch 0,5 bis 5% einer Protein-Kombination mit anorganischen Bestandteilen zugesetzt wird.A process for producing a water-soluble salt core in which water-soluble salts are mixed with a binder, the mixture is introduced into a mold for forming a salt core and the mandrel is compressed under pressure and / or elevated temperature, characterized in that the mixture is 0.5 to 5% of a protein combination with inorganic ingredients is added. Verfahren nach Anspruch 10, dadurch gekennzeichnet, dass die Protein-Kombination mit den anorganischen Bestandteilen mit dem Bindemittel homogen vermischt und anschließend das Gemisch mit den Salzen vermischt wird.A method according to claim 10, characterized in that the protein combination is homogeneously mixed with the inorganic constituents with the binder and then the mixture is mixed with the salts. Verfahren nach Anspruch 10 oder 11, dadurch gekennzeichnet, dass die Mischung aus Protein-Kombination mit anorganischen Bestandteilen und Bindemittel homogen mit Speisesalz vermischt wird.A method according to claim 10 or 11, characterized in that the mixture of protein combination with inorganic constituents and binder is homogeneously mixed with table salt. Verfahren nach einem der Ansprüche 10 bis 12, dadurch gekennzeichnet, dass als Bindemittel ein Monoaluminiumphosphat verwendet wird.Method according to one of claims 10 to 12, characterized in that a monoaluminum phosphate is used as the binder. Verfahren nach einem der Ansprüche 10 bis 13, dadurch gekennzeichnet, dass das Gemisch in dem Formwerkzeug verdichtet und auf bis zu 200°C erwärmt wird.Method according to one of claims 10 to 13, characterized in that the mixture is compacted in the mold and heated to up to 200 ° C. Verfahren nach einem der Ansprüche 10 bis 14, dadurch gekennzeichnet, dass das Gemisch als Salze insbesondere Chloride, Sulfate und Borate von Alkali- oder Erdalkalimetallen verwendet.Method according to one of claims 10 to 14, characterized in that the mixture used as salts in particular chlorides, sulfates and borates of alkali or alkaline earth metals.
EP08018459A 2008-01-18 2008-10-22 Pressure-resistant core with improved adhesive Revoked EP2082819B1 (en)

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PL08018459T PL2082819T3 (en) 2008-01-18 2008-10-22 Pressure-resistant core with improved adhesive

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DE102008004929A DE102008004929A1 (en) 2008-01-18 2008-01-18 Pressure-resistant core with improved binder

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EP2082819A1 true EP2082819A1 (en) 2009-07-29
EP2082819B1 EP2082819B1 (en) 2011-12-14

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DE (1) DE102008004929A1 (en)
ES (1) ES2380071T3 (en)
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DE102012217939A1 (en) 2012-10-01 2014-04-03 Mahle International Gmbh Process for the production of cores for the casting production of workpieces

Citations (1)

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Publication number Priority date Publication date Assignee Title
DE102004006600B4 (en) 2004-02-11 2006-03-23 Ks Aluminium-Technologie Ag Removable metal casting core and method of making a core

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US5320157A (en) * 1993-01-28 1994-06-14 General Motors Corporation Expendable core for casting processes
US6467525B2 (en) * 2000-07-24 2002-10-22 Hormel Foods, Llc Gelatin coated sand core and method of making same
DE102006031531A1 (en) * 2006-07-07 2008-01-10 Emil Müller GmbH Salt cores for plastic (injection) casting
DE102006031532B3 (en) * 2006-07-07 2008-04-17 Emil Müller GmbH Water-soluble salt core with functional component

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Publication number Priority date Publication date Assignee Title
DE102004006600B4 (en) 2004-02-11 2006-03-23 Ks Aluminium-Technologie Ag Removable metal casting core and method of making a core

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EP2082819B1 (en) 2011-12-14
ATE536950T1 (en) 2011-12-15
PL2082819T3 (en) 2012-07-31
DE102008004929A1 (en) 2009-07-23
ES2380071T3 (en) 2012-05-08

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