EP2136943B1 - Matériau support pour la fabrication de pièces à usiner - Google Patents

Matériau support pour la fabrication de pièces à usiner Download PDF

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Publication number
EP2136943B1
EP2136943B1 EP08748941A EP08748941A EP2136943B1 EP 2136943 B1 EP2136943 B1 EP 2136943B1 EP 08748941 A EP08748941 A EP 08748941A EP 08748941 A EP08748941 A EP 08748941A EP 2136943 B1 EP2136943 B1 EP 2136943B1
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EP
European Patent Office
Prior art keywords
carrier material
meii
metal
mei
workpiece
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Application number
EP08748941A
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German (de)
English (en)
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EP2136943A1 (fr
Inventor
Markus Dirscherl
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HERMLE MASCHINENBAU GmbH
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HERMLE MASCHINENBAU GmbH
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Publication of EP2136943A1 publication Critical patent/EP2136943A1/fr
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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/10Cores; Manufacture or installation of cores
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D29/00Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
    • B22D29/001Removing cores
    • B22D29/002Removing cores by leaching, washing or dissolving
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12479Porous [e.g., foamed, spongy, cracked, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12708Sn-base component
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12729Group IIA metal-base component
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12736Al-base component
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12771Transition metal-base component
    • Y10T428/12785Group IIB metal-base component
    • Y10T428/12792Zn-base component
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12771Transition metal-base component
    • Y10T428/12861Group VIII or IB metal-base component
    • Y10T428/12903Cu-base component
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12771Transition metal-base component
    • Y10T428/12861Group VIII or IB metal-base component
    • Y10T428/12944Ni-base component
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12771Transition metal-base component
    • Y10T428/12861Group VIII or IB metal-base component
    • Y10T428/12951Fe-base component

Definitions

  • the invention relates to a method for producing a workpiece with at least one free space or other unfilled portion, and a suitable carrier material.
  • free space for the sake of simplicity, this term also including spaces that are not surrounded on all sides by a wall, such as undercuts.
  • the erasable material used as a "placeholder” is also referred to as a "lost core” or “lost shape”.
  • a material that can be used for lost cores has to meet a variety of requirements, including mechanical and thermal stresses. These requirements are not met by the desirable for lost cores water-soluble salts.
  • salts are an interesting material in terms of their solubility and availability, their use is not possible because of their brittleness in processes that require mechanical stress, such as thermal spraying, cold gas spraying, or compacting. The salts, because of their brittleness, can not withstand the mechanical stress associated with such processes.
  • this alloy should then be dissolved out with water or an acidic or basic solution. It has been found that this known material is not suitable for all molding processes.
  • US 3 722 574 A as a water soluble core for producing hollow superalloy parts by investment casting techniques.
  • the core can be formed by mixing slurries of magnesium oxide and magnesium oxiychloride, allowing the mixture to harden and then the body to form the certain oxide.
  • US Pat. No. 3,701,379 A Having a metal casting with internal passages and apertures. It can be formed by pouring molten metal into a mold having a magnesium. oxide core
  • the core can be made by forming a mixture of magnesium oxide and an evanescent resin and shaping this mixture by suitable molding techniques.
  • the evanescent resin is then substantially volatilized to leave a pure MgO which can be sintered to form a carbonaceous material-free, self-supporting body.
  • the material should also be removable when dealing with very complex or very delicate shapes, e.g. narrow channels.
  • a carrier material which can be used as a placeholder in the construction of workpieces with at least one free space, which consists of a compacted corrodible material, wherein the corrodible material is a mixture or alloy of at least two metals, MeI and MeII, the Normal potential of MeII under reaction conditions is less than that of MeI.
  • the compacted carrier material according to the invention preferably contains at least one metal MeII which on contact with a corrosive medium under defined conditions in a period of 30 minutes to 10 hours to at least 35, preferably at least 55 and more preferably at least 70% is corrodible.
  • the removal of the less noble metal MeII depends on the geometry of the workpiece and the free space. If the clearance is, for example, a channel or an elongate bore, it is preferred to use as metal a metal component which, on contact with a corrosive medium, leads to a removal of at least 1 mm per 24 hours, preferably at least 1 mm per 10 hours, in particular at least 1 mm per 5 Hours or even 1mm per hour or even faster.
  • a metal component which dissolves longitudinally by 1 mm per 24 hours, preferably 10 hours, more preferably 5 hours, and especially 1 hour in an elongated bore, so that the clearance eats in the specified time by 1 mm ".
  • the carrier material of the invention has a compacted structure which can be suitably obtained by a mechanically compacting method. This structure gives rise to a combination of interesting properties that accomplishes the above tasks.
  • corrosion any electrochemical reaction of a metal MeII with a liquid corrosive medium in the presence of a metal MeI or a MeI-containing metal component, which has a higher normal potential than MeII under reaction conditions, which leads to a substantial or complete dissolution of MeII with formation of gas.
  • a corrosive medium is an ion-containing liquid which dissolves MeII due to an electrochemical reaction in the presence of MeI.
  • normal potential always refers to the normal potential of a metal or a metal component under the reaction conditions (with respect to temperature, pressure, type and amount of ions in the solution, etc.) and not to the position in the electrochemical series.
  • metal component refers in particular to metals or metal alloys which promote the corrosion reaction.
  • a combination of a corrodible metal and at least one other metal component, which may or may not be corrodible, is used, which upon contact with a corrosive medium, such as water or an aqueous medium, rapidly loses its structure At least the corrodible metal dissolves and further existing metals possibly remain at least partially in particle form.
  • the material according to the invention has a structure which combines a combination of interesting properties. On the one hand, the material provides sufficient strength to serve as a placeholder in a variety of methods, which can withstand mechanical stress, for example, in the context of shaping and / or processing. On the other hand, the material decomposes very rapidly on contact with a corrosive medium.
  • the corrodible metal otherwise protective oxide or - hydroxide layer is disturbed so that then upon contact with a corrosive liquid, the metal particles or the structure are very easily attacked, resulting in rapid corrosion.
  • the compacting process brings the more noble metal into such close contact with the corrodible metal that the corrosive reaction can be very rapid.
  • the removal of the less noble metal MeII is dependent on the geometry of the workpiece and the free space.
  • a metal component which dissolves in an elongated bore per 24 hours, preferably 10 hours, more preferably 5 hours and especially 1 hour by at least 1mm in the longitudinal direction, so that the Free space accordingly in the specified time or even faster by 1mm or more "eats".
  • an electrochemical reaction is used to dissolve a compacted mixture of a less noble corrodible metal and at least one more noble metal by contact with a corrosive medium, typically water or an aqueous medium, at the desired rate.
  • a corrosive medium typically water or an aqueous medium
  • This reaction is particularly pronounced when a strongly ion-containing solution is used as the corrosive medium.
  • This corrodibility known per se is utilized according to the invention to remove a carrier material after completion of a workpiece in a simple manner and relatively environmentally friendly.
  • the support material is brought into contact after completion of the workpiece with a corrosive medium, wherein at least the corrodible metal dissolves and undissolved carrier material is then rinsed out of the formed form together with the medium containing the corroded metal.
  • the compaction of the metal components creates a material whose particles have sufficient contact to favor an electrochemical reaction.
  • the layer covering the particles may possibly be broken up to such an extent by stress or deformation that the reaction can take place and is not inhibited.
  • a corrosive medium usually water or an aqueous medium
  • corrosion is achieved at the desired rate.
  • the speed of the corrosion reaction can be adjusted in a targeted manner with the carrier material according to the invention. If in contrast High-porosity powder mixtures, which become saturated with the addition of water, can result in an uncontrollable reaction.
  • a material is used whose porosity is not higher than 20% by volume, more preferably not higher than 5% by volume. In a particularly suitable embodiment, the porosity is less than 1% by volume.
  • a material according to the invention i. a corrodible metal and a comparatively nobler metal component containing mixture or alloy which has been previously compacted, contacted with a corrosive medium, preferably a conductive (ion-containing) aqueous medium under defined conditions
  • a corrosive medium preferably a conductive (ion-containing) aqueous medium under defined conditions
  • the corrodible metal dissolves at least largely on. According to the invention, this effect is exploited to remove a carrier material after completion of a workpiece by the mixture is brought into contact with a corrosive medium and then carrier material and medium are rinsed out of the mold formed.
  • the difference in normal potentials may occur in basic and / or neutral and / or acidic solution, depending on the conditions to which the support material is exposed upon contact with the corrosive medium.
  • the invention makes it possible that in this way mechanically highly resilient material can be used as a carrier material and is easily removable after completion.
  • This material can be used in a variety of ways, in particular as a lost core for a wide variety of processes.
  • Particularly suitable is the carrier material according to the invention for the production of workpieces with recesses, recesses, undercuts and Cavities, in particular for the production of hollow bodies or workpieces with undercuts using thermal spraying.
  • the speed of corrosion is dependent on various factors or the setting of defined conditions, so that it is possible with routine measures to find out the optimal material or the optimal conditions and use.
  • Factors influencing the resolution include the temperature, the combination of metals, the type and amount of ions contained in the medium used for dissolution, surface area and mechanical stress of the surfaces, and hydrogen overvoltage.
  • Temperature is an important parameter as the higher the temperature, the faster the reaction.
  • the electrochemical reaction of the metals with water is exothermic.
  • the rate of dissolution can therefore be adjusted, if necessary or desired, by controlling the temperature of the reaction.
  • the reaction can be adjusted by or through the dissipation of heat, i. the conditions are adjusted. Supply and removal of heat in the simplest case by using appropriately tempered medium as a solvent.
  • Another important factor is the combination of the metal components used in the carrier material. It is essential to the invention that at least one metal MeII corrodible under defined conditions and a correspondingly nobler metal component MeI promoting the corrosion is contained. According to the invention, therefore, an alloy or mixture of at least two metal components whose normal potentials differ is used. Depending on the metals selected, the mechanism is corrosive stronger or less strong. By selecting one or more metal components, therefore, the speed of resolution can be influenced.
  • the corrosivity can be increased if at least one other metal component that is more noble with respect to MeII, i. in the reaction conditions has a higher normal potential than MeII, alloyed or mixed. Any metal or metal component which has a higher standard potential than MeII and which promotes the electrochemical reaction is therefore suitable for the carrier material according to the invention. It has been found that, especially in combination with magnesium, the metals iron, nickel and copper have a particularly high influence on the corrosivity, which are therefore preferably used individually or in combination as MeI, preferably with magnesium as MeII in the support material according to the invention. Most preferably, a combination of magnesium and iron is used.
  • the carrier material according to the invention is produced from at least two metal components by compaction. It has been found that when the material and thus the individual particles are heavily stressed before or during the formation, the corrosion proceeds very quickly. This may, without being bound by theory, be due to the fact that may be disturbed or destroyed by the stress existing, the corrosive metal MeII protecting, hydroxide or oxide layers, so that the corrosive attack can then be faster and more violent.
  • ions contained in the corrosive, preferably aqueous medium used for dissolution are ions contained in the corrosive, preferably aqueous medium used for dissolution. It has been found that the more ions are available, the faster the corrosion and hence the dissolution of the metal MeII. Particularly reactive in this context are chloride, nitrate and sulfate ions. These ions lead to the formation of easily soluble salts with many metals, which accelerate the dissolution.
  • aqueous solution Another influence on the corrosion reaction has the conductivity of the corroding, preferably aqueous solution, which in turn can be influenced by the proportion of ions.
  • a saline-containing solution is used.
  • seawater is a very suitable medium.
  • ion-containing wastewater from other processes is very advantageous, which can be utilized very well in this way.
  • Another factor which has an influence on the corrosion reaction is the area ratio of anodic particles to cathodic particles and the distance between anodic and cathodic particles.
  • the small distance between anode and cathode can be made by the compacting processing that the Structure of the carrier material according to the invention generated, and by adjusting the ratio of MeII to MeI.
  • the hydrogen overvoltage also has an influence on the corrosion, in particular for the corrosion of magnesium. It has been found that some low hydrogen overvoltage metals are effective cathodes. They are therefore preferably used as MeI to promote the reaction. Low hydrogen overvoltage metals include nickel, copper and iron, which are therefore particularly preferred in combination with magnesium.
  • the speed can be adapted to the method, wherein one of the above factors or more can be set.
  • the carrier material according to the invention is applicable to shaping methods of any kind.
  • the material according to the invention is characterized in particular by its formability, machinability, conformal layer formation, imaging properties and compatibility with other materials. It can be advantageously used especially when forms are formed by layer structure, which are then mechanically reworked to form simple and complex, even filigree body, which serve as a placeholder for any type of cavities incl. Undercuts in materials of any kind. Complex or filigree shapes can be formed by machining, usually machining, from the material.
  • the layers formed from the support material according to the invention follow the substrate to which they are applied, contour true and remain there adhere. The material according to the invention can therefore be used in many ways.
  • the body is built up in layers and applied in the areas which are to form the recess later, the material of the invention, which can be flushed out after completion of the workpiece.
  • Alloys are materials which are composed of at least two components and contain at least one metal, wherein the second alloy constituent in the metal is either dissolved and homogeneously distributed therein, or is only partially dissolved, so that a second alloy-rich phase is formed.
  • the second or further alloying ingredient is also metallic, it is intermetallic compounds, ie atoms of one metal are incorporated into the matrix of the other metal.
  • the macroscopic properties of the alloy differ from those of the individual metal powders. According to the invention, it is essential that a compacted material is used, as this provides the reactivity and close contact necessary for the corrosion reaction.
  • the carrier material according to the invention contains at least two metal powders MeI and MeII, whose essential property is that their normal potential differs.
  • the potential difference is at least 0.4 and is preferably greater than 1. Due to the potential difference, the addition of water or an aqueous medium leads to a redox reaction, which causes the less noble metal to dissolve. Since the reaction tends to make the solution more basic, the two metal powders MeI and MeII should have a different normal potential in basic and neutral solution than MeII.
  • An acidic aqueous medium can also be used for the dissolution so that, if appropriate, the reaction takes place in the acidic pH range and the normal potential at acidic pH is to be determined.
  • this difference in the normal potential is utilized according to the invention, i. in other words, the redox reaction underlying the corrosion or dissolution of a less noble metal.
  • two metal components one of which is noble and the other base is combined, so that a metal mixture is formed, which is then compacted, so that it is mechanically strong.
  • this component may contain a third component which contributes further desired properties.
  • This component can be selected from a wide variety of materials, with the proviso that it does not disturb the structure of the structure or the electrochemical decomposition of the same.
  • another material inert with respect to the electrochemical reaction may be added, which has an influence on the mechanical properties, eg, a harder material may be added as a third component in order to improve the adhesion during kinetic compaction.
  • a further component to add a material catalyzing the electrochemical reaction in order to influence the start and / or course of the reaction.
  • a third component is used for the support material according to the invention, its proportion should not exceed 25% by volume. The most appropriate amount can be determined by the expert by routine experimentation. The proportion should not be so high that it interferes with the formation of the structure and the course of the reaction. On the other hand, the amount must be sufficient to achieve the desired effect.
  • the metal powders which make up the material according to the invention are variable in terms of grain size and grain shape.
  • the shape of the particles is not critical, both spherical and flake-like or other forms come into consideration.
  • the particle size is not critical, with the proviso that the particles may not be larger than the space to be filled.
  • the particle size is less than 0.5 mm, more preferably the particle size is less than 0.25 mm.
  • the particle size of the two components can also be used to influence the dissolution behavior, so that the optimal material can be selected for each application with routine tests. Furthermore, compaction behavior and structure can be influenced by selecting the particle sizes of the two powders and their ratio. The particle size can therefore be selected specifically for a powder or both so that the desired properties arise in terms of structure and resolution.
  • the pH may shift to the acidic or basic range, depending on the material and medium used. Therefore, if a corrosion-prone material is used to make the workpiece, it can be protected by selecting material and / or media accordingly. For example, e.g. the emergence of a basic solution advantageous if the forming the body shape material is steel, since the basic solution acts here as it were as rust protection. For other materials, a slightly acidic pH, which can be achieved by the medium used, may be more advantageous.
  • a carrier material which does not dissolve completely, but whose structure is destroyed upon contact with water, since only a part is dissolved, which is sufficient, however, to flush out the entire material.
  • at least two metal components are necessary, which are preferably used in the purest possible form. Both components are preferably metals and are in pure form.
  • pure is understood to mean that the powders mainly consist of a metal and contain at most small amounts of impurities or alloy components or production-related or processing-related small amounts of oxides or other compounds. It was found that the best results can be achieved if the two metals in the after Apply present form as particles in a compacted structure.
  • Such a structure arises, for example, by thermal spraying, kinetic compaction or cold gas spraying.
  • a structure is achieved in which the particles are not melted, but form a compacted matrix.
  • the material applied by kinetic spraying preferably has a porosity of less than 20% by volume, more preferably less than 5% by volume, particularly preferably less than 1% by volume. If the porosity of the material and thereby the proportion of open pores becomes too high, the support material could become soaked with the aqueous medium and, depending on reaction conditions and reactants, dissolve so rapidly that an uncontrollable reaction with high gas pressure would result, which is undesirable. In addition, due to the volume increase of the hydroxide, the removal of the undissolved particles may be disturbed.
  • the matrix formed from the two metals is so dense that the surfaces of the particles have sufficient contact to promote the electrochemical reaction upon addition of a corrosive liquid.
  • the two metal components used for the support material must have a difference in normal potential to allow for the dissolution of the one component causing electrochemical reaction.
  • the normal potential under the conditions prevailing at the reaction site, e.g. in neutral, acidic or basic aqueous solution. It may be advantageous if the two metal components used under reaction conditions have a difference of the normal potentials of at least 0.4, preferably of more than 1.
  • the choice of the two metal components depends on the difference of their normal potentials and on the above and their reactivity, which is influenced, inter alia, by oxide formation, but also by availability. Furthermore, consideration can be given to the selection in addition to the economy and environmental considerations. Preferably, those metals are used which are readily available and whose disposal causes no problems.
  • the metal MeI metal powder may be used, which consist of particles which are coated with a noble metal, while the core may consist of any material.
  • the core material can then also contribute mechanical properties that does not have the precious metal. Suitable for the coating of such particles are, for example, gold, platinum, silver, copper, iron or nickel, etc.
  • the less noble metal MeII can be any metal with a lower or lower normal potential compared to MeI under reaction conditions.
  • Preferred are magnesium, aluminum, zinc, tin and iron. Particularly suitable is a combination of magnesium and iron has been found.
  • a combination of iron and / or copper and / or nickel as MeI and magnesium as MeII is therefore used as carrier material.
  • the two metal powders are used in proportions such that the electrochemical reaction proceeds to the desired extent.
  • a corrosive medium eg, an aqueous medium
  • the less noble metal dissolves at least partially, while the nobler metal remains as a powder. Therefore, the less noble metal in such a Be present proportion that its previously dissolved by dissolution structure is dissolved or destroyed by its dissolution so that the resulting material can be flushed out.
  • the metal powders are preferably combined in a volume ratio of MeI to MeII of 1: 250 to 10: 1, preferably 1: 5 to 10: 1 and particularly preferably 3: 1 to 1: 3. Most preferably, the metal powders are combined from MeI to MeII in approximately equal proportions by volume.
  • a corrosive liquid for example any corrosive medium can be used.
  • the corrosive, preferably aqueous medium is not critical and any medium that consists predominantly of water is suitable here. It is important to ensure that no negative influence on the electrochemical reaction ingredients in the water are included.
  • the corrosive medium used is preferably an aqueous medium which promotes the electrochemical reaction, in particular an ion-containing solution. Acid, neutral and basic ion-containing solutions, eg salt solutions, are suitable. It is also possible to use dilute acids or bases.
  • the invention relates to a method for producing a workpiece having at least one recess in which the space forming the free space is filled with a carrier material which is rinsed out after completion, wherein the carrier material is a material as defined in claim 1.
  • the carrier material according to the invention is very well suited to form a lost core for a molding process, in which workpieces are formed with at least one free space.
  • the carrier material according to the invention is characterized by its mechanical strength, so that it can be used wherever a mechanically strong material is necessary.
  • it can be processed by molding processes, in particular it can be formed by machining processes into complex shapes.
  • the carrier material according to the invention for processing with kinetic compaction or cold gas spraying is particularly suitable.
  • the material according to the invention is particularly preferably used for a process for the production of moldings, in which a layered structure is achieved by thermal spraying, wherein the layers are then optionally post-processed by machining.
  • a method for producing a workpiece in which a structure is built up by thermal spraying, wherein the regions which are to form a recess in the finished body are formed with the carrier material according to the invention, wherein the Carrier material is removed after completion of the workpiece by contact with an aqueous medium.
  • the carrier material according to the invention can also be used for other processes, but is particularly advantageous for processes in which thermal spraying is used.
  • the thermal spraying is carried out by kinetic spraying, wherein the particles are substantially not melted.
  • the carrier material according to the invention is very well suited for forming lost cores. It can be processed into a variety of forms. Upon completion of the workpiece, contact with an aqueous medium destroys the matrix formed upon application of the material by an electrochemical reaction, and the movement due to gas formation during the electrochemical reaction produces enough water exchange to appropriately promote the electrochemical reaction. The remaining of destruction of the matrix powder of nobler metal can then be easily rinsed out together with the resulting solution and possibly reused.
  • the electrochemical reaction and thus the dissolution of the less noble metal and the destruction of the structure can be promoted in a preferred embodiment by providing for movement of the medium during and after addition of the corrosive medium. This can e.g. by rinsing, by moving the workpiece or by ultrasonic treatment.
  • a support material which, due to its mechanical strength and ductility and its electrochemical reactivity provides an ideal combination of properties. Furthermore, a method is provided, with which also very complicated shapes can be produced, since it is possible to build the workpieces in layers by spraying and then even complicated recesses cavities, recesses, cavities, undercuts or other unfilled portions by purging the substrate to build.
  • the material according to the invention described above is very well suited for any form of placeholder. Due to the advantageous mechanical and electrochemical properties, the support material according to the invention can always be used when it is necessary to keep a place for a certain period of time and then to remove the placeholder material.
  • the carrier material according to the invention is suitable when the placeholder is mechanically stressed in its function, e.g. Is exposed to stress. Therefore, except for the above-mentioned use for the production of workpieces with cavities and cavities, the support material according to the invention can also be used as a spacer, spacer, spacer and lost core in any form.
  • a combination of magnesium and at least one of the metals iron, nickel or copper is used. Especially these combinations have an optimal combination of mechanical load capacity and corrosivity.
  • the combination of magnesium and iron is particularly preferred because upon dissolution of the support material, an aqueous suspension is formed which contains only magnesium or its decomposition products formed by corrosion, and iron as metals. This combination is environmentally friendly and can be easily disposed of either as wastewater without polluting or recycling the environment become. If other metals are used in addition to iron or instead of iron, it may be necessary to treat the resulting suspension before disposal.
  • the mechanical properties and the environmental friendliness of the product formed after dissolution contribute to the carrier material according to the invention being particularly advantageous.
  • the support material according to the invention which consists of magnesium and at least one other metal component which is selected from iron, nickel and copper, is compacted by a mechanically stressing process.
  • the same procedures as outlined above and the same ratios of the components as set out above are also generally suitable for use of the support material as placeholders.
  • the dissolution of the placeholder is carried out in the same manner as stated above, namely with an aqueous solution containing ions, in particular an aqueous medium containing active anions.
  • aqueous media with chloride, nitrate and / or sulfate ions can be mentioned.
  • seawater is a very suitable medium due to its good availability.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Powder Metallurgy (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Coating By Spraying Or Casting (AREA)
  • ing And Chemical Polishing (AREA)

Claims (15)

  1. Matériau support qui peut être utilisé comme substitut lors de la constitution de pièces à usiner avec au moins un espace libre, le terme de substitut comportant aussi un noyau perdu ou un moule perdu qui n'est pas entouré de tous les côtés par une paroi et les termes d'espace libre comportant aussi des espaces qui ne sont pas entourés de tous les côtés par une paroi tels que des cavités, des évidements, des contre-dépouilles, des espaces creux, lequel se compose d'un matériau sujet à la corrosion compacté, le matériau sujet à la corrosion étant un mélange ou alliage d'au moins deux composants métalliques «Mel» et «Mell», le potentiel normal de «Mell» dans des conditions de réaction étant inférieur à celui de «MeI».
  2. Matériau support selon la revendication 1, caractérisé en ce que «Mell» et «Mel» présentent un rapport de volume compris entre 250:1 et 1:10.
  3. Matériau support selon la revendication 1, caractérisé en ce que «MeII» et «Mel» présentent un rapport de volume compris entre 5:1 et 1:10.
  4. Matériau support selon la revendication 1, caractérisé en ce que le matériau peut être fabriqué par injection thermique.
  5. Matériau support selon la revendication 3, caractérisé en ce que le procédé de compactage est une injection cinétique ou injection de gaz froid ou en ce que le procédé de compactage est un pressage ou frittage.
  6. Matériau support selon l'une quelconque des revendications précédentes, caractérisé en ce qu'il est usinable et/ou déformable.
  7. Matériau support selon l'une quelconque des revendications précédentes, caractérisé en ce qu'il présente une porosité inférieure à 20% en volume, en particulier inférieure à 5% en volume ou inférieure à 1% en volume.
  8. Matériau support selon l'une quelconque des revendications précédentes, caractérisé en ce que «Mel» est du cuivre, du fer, du nickel ou de l'étain.
  9. Matériau support selon l'une quelconque des revendications précédentes, caractérisé en ce que «Mell» est du magnésium, de l'aluminium, du zinc, de l'étain ou du fer.
  10. Matériau support selon l'une quelconque des revendications précédentes, caractérisé en ce que la poudre métallique avec un potentiel normal supérieur est une poudre qui se compose de particules, dont l'enveloppe est en un métal plus noble que «Mell», le noyau étant constitué d'un matériau quelconque.
  11. Procédé de fabrication d'une pièce à usiner avec un procédé d'injection thermique ou procédé de compactage, sachant que pour la fabrication de la pièce à usiner, au moins un espace libre ou une part non remplie autrement est constituée d'un matériau support, les termes d'espace libre comportant aussi des espaces qui ne sont pas entourés de tous les côtés par une paroi tels que des cavités, des évidements, des contre-dépouilles, des espaces creux, le matériau support pouvant être retiré après l'achèvement du corps sans l'endommager par mise en contact avec un produit aqueux et rinçage de la suspension aqueuse du matériau support et du produit aqueux, sachant que le matériau support est constitué d'au moins deux métaux différents, dont les potentiels normaux se distinguent, et sachant que le matériau support peut être obtenu en compactant les poudres métalliques.
  12. Matériau support selon la revendication 11, caractérisé en ce que la fabrication de la pièce à usiner est effectuée par injection cinétique ou injection de gaz froid ou en ce que la fabrication de la pièce à usiner est effectuée par frittage ou pressage.
  13. Matériau support selon la revendication 11, caractérisé en ce que la vitesse de dissolution est réglée par l'équilibrage de la température du produit corrosif.
  14. Utilisation d'un mélange de deux composants métalliques «MeI» et «Mell» qui peuvent être des métaux ou des composants métalliques, le potentiel normal de «Mell» dans des conditions de réaction étant inférieur à celui de «Mel» pour la fabrication d'un moule perdu par application à l'aide d'un procédé de compactage.
  15. Utilisation d'un matériau support selon l'une quelconque des revendications 1 à 10 comme noyau perdu pour des procédés de laminage ou de revêtement.
EP08748941A 2007-04-16 2008-04-16 Matériau support pour la fabrication de pièces à usiner Active EP2136943B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102007017754.4A DE102007017754B4 (de) 2007-04-16 2007-04-16 Verfahren zur Herstellung eines Werkstücks mit mindestens einem Freiraum
PCT/EP2008/003050 WO2008125352A1 (fr) 2007-04-16 2008-04-16 Matériau support pour la fabrication de pièces à usiner

Publications (2)

Publication Number Publication Date
EP2136943A1 EP2136943A1 (fr) 2009-12-30
EP2136943B1 true EP2136943B1 (fr) 2012-11-21

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EP08748941A Active EP2136943B1 (fr) 2007-04-16 2008-04-16 Matériau support pour la fabrication de pièces à usiner

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US (1) US20100304178A1 (fr)
EP (1) EP2136943B1 (fr)
JP (1) JP5055426B2 (fr)
DE (1) DE102007017754B4 (fr)
ES (1) ES2396168T3 (fr)
WO (1) WO2008125352A1 (fr)

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Also Published As

Publication number Publication date
WO2008125352A1 (fr) 2008-10-23
US20100304178A1 (en) 2010-12-02
JP2010526665A (ja) 2010-08-05
EP2136943A1 (fr) 2009-12-30
DE102007017754B4 (de) 2016-12-29
DE102007017754A1 (de) 2008-10-23
ES2396168T3 (es) 2013-02-19
JP5055426B2 (ja) 2012-10-24

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