EP2576100A1 - Noyaux de sel stabilisés par un infiltrat - Google Patents

Noyaux de sel stabilisés par un infiltrat

Info

Publication number
EP2576100A1
EP2576100A1 EP11726376.4A EP11726376A EP2576100A1 EP 2576100 A1 EP2576100 A1 EP 2576100A1 EP 11726376 A EP11726376 A EP 11726376A EP 2576100 A1 EP2576100 A1 EP 2576100A1
Authority
EP
European Patent Office
Prior art keywords
cores
salt
core
infiltrate
binder
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP11726376.4A
Other languages
German (de)
English (en)
Inventor
Harald Hudler
Dieter Käfer
Josef Baron
Peter Stingl
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.)
Emil Mueller GmbH
Original Assignee
Emil Mueller GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Emil Mueller GmbH filed Critical Emil Mueller GmbH
Publication of EP2576100A1 publication Critical patent/EP2576100A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/34—Silicon-containing compounds
    • 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
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
    • B29C33/52—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles soluble or fusible
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/40—Removing or ejecting moulded articles
    • B29C45/44—Removing or ejecting moulded articles for undercut articles
    • B29C45/4457—Removing or ejecting moulded articles for undercut articles using fusible, soluble or destructible cores

Definitions

  • the invention relates to salt-based cores, to processes for the preparation of salt-based cores, and to the use of such cores as cavity locators in the production of metallic castings, preferably in die casting technology, characterized by solvent, preferably water, complete and can be easily removed without leaving any residue from the workpieces.
  • the cores must be inexpensive to produce, dimensionally stable and accurate contour and the materials used for their preparation and the solvent dissolving them should not affect the casting quality, the environment or cause any health hazards. If special demands are placed on the surface and the contour accuracy of the cavities of the workpieces, the surface of the cores must be particularly smooth and contour-accurate and the cores must dissolve completely residue-free in a suitable solvent and easily without leaving solid residues from the cavities of the workpieces have it removed.
  • the object of the present invention is to provide cores based on salt with as low a porosity as possible, good surface quality and the highest possible To produce strength that can be easily and completely removed from the workpieces after the casting of the workpieces.
  • cores based on salt via the core shooting method, which withstand both the extreme mechanical stresses that occur during die casting, as the cores warp or break, or in their Change situation. That is, cores based on salt, which on the one hand must have a high mechanical strength and on the other hand can easily be dissolved out of the casting after casting, and leave as good as possible a smooth surface finish in the casting, are not in the prior art yet produced using the so-called core shooting method for die casting applications.
  • the cores according to the invention consist of salt and can be produced by molding and compacting a core material mixture, wherein the core material mixture contains at least one salt, at least one binder and optionally adjuvants such as additives, fillers, wetting agents and catalysts and stabilizes the cores by an infiltrate are.
  • These cores are preferably intended for workpieces, which are cast in the die-casting of non-ferrous metals, preferably aluminum.
  • the cores according to the invention are composed of substances which can be removed without residue and easily from the cavities of the workpieces with water, as a preferred solvent for reasons of environmental protection.
  • the cores are formed by the core shooting method or by press molding. With this method, geometrically very complicated shapes can be realized, which can not be realized by means of the conventional dry-press sintering route.
  • the binder system extreme demands are made in terms of the stability of the cores.
  • the mechanical and thermal loading of the cores during casting is extreme during die casting.
  • the inflow velocity of the melt can be up to 6 m / sec.
  • the hydrostatic pressure can rise up to 1200 bar.
  • the cores according to the invention can also be used in other casting methods such as, for example, low-pressure chill casting
  • Suitable materials for the cores according to the invention are the salts of alkali and alkaline earth elements such as in particular sodium chloride, potassium chloride and magnesium chloride, the sulfates and nitrates of alkali and alkaline earth elements such as in particular potassium sulfate, magnesium sulfate, and ammonium salts such as ammonium sulfate in particular.
  • the water-soluble representatives of these materials are preferred. These substances can be used individually or as a mixture, as far as they do not react with each other and thus negatively affect the desired properties, because the core material is to undergo no material conversion in the core production, which negatively affects its residue-free removal.
  • all easily soluble salts are suitable whose decomposition or melting point is above the temperature of the liquid molten metal.
  • the selected grain size distribution and the selected degree of compaction have a positive influence on the surface quality and the mechanical strength of the cores. The smaller the grain size, the smoother the surface.
  • the highest possible degree of compaction is sought, which can be achieved by mixing different salts and optionally by admixing additional substances with different distribution curves, for example by a bi- or trimodal grain distribution in the mixture, or by suitable fillers.
  • grain sizes in the range of 0.01 mm to 2 mm are preferred, depending on the material, the desired surface quality and contour accuracy of the workpiece to be cast. Depending on the desired degree of compaction different particle size fractions are mixed in different proportions.
  • Fillers which can also be removed completely by water as a solvent and residue-free, can optionally replace part of the salt as far as density and strength are not adversely affected. According to the invention, it has been found that up to 30% by weight of the salt can be replaced by corresponding fillers.
  • the grain size of the filler is suitably adjusted to the grain size or the particle size distribution of the salt.
  • At least one suitable salt is added to the salt prior to compaction Binder, preferably inorganic binder or a suitable binder system added. All binders are possible which can be removed without residue after the curing process with water as the solvent and which wet well the salt and optionally the additives, the mixture of these substances having to be flowable and formable by means of firing to lost cores. In general, silicate binders or mixtures of these binders are suitable if they can be removed without residue with water as solvent. Preference is given to using binders of soluble waterglass with a waterglass modulus of 1 to 5, waterglasses having different waterglass moduli also being able to be present as a mixture.
  • the amount added depends on the water glass module used and, depending on the wetting behavior, is between 0.5% by weight and 20% by weight, preferably between 5% by weight and 10% by weight. In order to achieve the properties necessary for the subsequent casting process, such as strength and dimensional stability, it is also possible to use special mixtures of binders.
  • the properties of the mixture of salt and binder or binder system according to the invention can be influenced by the targeted addition of additives. It is also a prerequisite here that these additives or the reaction products of these additives with water as the solvent are completely removable from the cavity of a workpiece completely and residue-free and no casting-negative gases are released during casting, which can lead to casting defects.
  • these additives may be selected from: wetting agents, for example surfactants, additives affecting the consistency of the mixture, lubricants, deagglomerating additives, gelling agents, additives which modify the thermophysical properties of the core, for example the thermal conductivity, additives which adhere the composition Metal at the cores prevent additives that become one improved homogeneity and miscibility, additions that increase shelf life, additives that prevent premature curing, and additives that accelerate curing.
  • wetting agents for example surfactants
  • additives affecting the consistency of the mixture lubricants
  • deagglomerating additives for example the thermal conductivity
  • additives which adhere the composition Metal at the cores prevent additives that become one improved homogeneity and miscibility, additions that increase shelf life, additives that prevent premature curing, and additives that accelerate curing.
  • additives are known to those skilled in the art of making conventional cores. Their added quantity depends on the type and composition of the core material.
  • the cores in order for the cores to have the required strength, it may be necessary to use tailored catalysts to initiate and accelerate the cure.
  • the gas influencing the core material preferably CO 2 or air, in particular for hardening and drying of the cores after casting, can be inserted into the still closed mold.
  • the pressure can be up to 5 bar.
  • the core material is composed of the salt, the binder and, if necessary, the additives such as fillers, additives and catalysts, wherein the fillers and the binder are inorganic. All substances can be homogeneously mixed with known mixing units.
  • the amount of binder and additives to be added depends on the purpose of the cores and determines the surface quality and the density and strength of the cores. For the further processing of the core material to the usable core, it is of fundamental importance in which form the core material is present. If, as in the present invention, solid core materials are preferred, then it depends crucially on whether the core materials are agglomerated or deagglomerated and whether they are in flowable form. This flowability of the mixture is useful to fill the mold evenly and with the best possible compression during firing. Particularly preferred as the core material according to the invention are therefore flowable mixtures of the salt, the water glass used as binder and the other admixtures.
  • the cores are exposed to extreme thermal and mechanical stresses, which in the case of conventional cores lead either to breakage or to a more or less pronounced offset of the cores in the casting.
  • an infiltration of the shot core with an infiltrate is therefore provided according to the invention. Only by the stiffening and solidification of the cores according to the invention by a suitable infiltration of the cores, it has surprisingly been possible to realize dimensionally accurate die-cast parts with salt cores. In addition, the surface quality of the cores can be significantly improved by infiltration.
  • An infiltrate suitable for the present invention contains at least one finely ground material selected from at least one of the following finely ground substances: diatomite, calcined kaolins, zirconium oxide, zirconium silicate (zircon, zircon, zircon, zircon, alumina, andalusite, chamotte, iron oxides, kyanite, bauxite, olivine, quartzes , Graphites and carbon blacks.
  • finely ground material which has no platelet structure is preferred, zirconium silicate (zirconium flour) is particularly preferred. or zirconium oxide, most preferably zirconium silicate (zirconium flour) or zirconium oxide with D 50 ⁇ 1 ⁇ .
  • the at least one selected finely ground material is dispersed in a suitable infiltrant medium (hereinafter also referred to as liquid component or solvent component).
  • the infiltrant medium of the infiltrate according to the invention is selected from water or at least one volatile, preferably aliphatic alcohol or from a mixture of alcohols with optionally further components, for example at least one organic solvent, which differs from or is different from the alcohols Mixtures of this solu tion solvent com ponent.
  • the preferred infiltrate medium is water.
  • a preferred embodiment of the invention comprises the water-based infiltrate suspension (also called infiltrate dispersion in the context of this invention), based on all constituents of the infiltrate suspension, 10-50% by weight of solvent, 90 wt .-% finely ground material, optionally dispersants, binders and other additives such as other particulate materials, wetting agents, defoamers, dyes and / or pigments and / or biocides.
  • infiltrate dispersion also called infiltrate dispersion in the context of this invention
  • the binder is water-soluble.
  • the binders are used in an amount of 0-20% by weight, preferably in an amount of 5-10% by weight, based on the entirety of the water-based infiltrant.
  • Suitable wetting agents are preferably anionic and non-anionic surfactants of medium and high polarity (HSB value of 7 and higher) known to the person skilled in the art.
  • the wetting agents are used in an amount of 0-5% by weight, preferably in an amount of 0.01-1% by weight, more preferably in an amount of 0.05-0.3% by weight, based on the entirety of the infiltrate components.
  • Defoamers are in the present invention in an amount of 0-1 wt .-%, preferably in an amount of 0.01-1 wt .-%, particularly preferably in an amount of 0.05-0.3 wt .-% , used.
  • any commonly used pigments and dyes may be used. These can be added to track the depth of penetration of the infiltrate into the nucleus or to visualize contrast, eg, between different layers.
  • the dyes and pigments are usually used in an amount of 0-10% by weight, preferably in an amount of 0.01-10% by weight, more preferably in an amount of 0.1-5% by weight .
  • Optionally commonly used dispersants may optionally be added to the infiltrate dispersion of the invention.
  • the dispersants are used in an amount of 0-3% by weight, preferably in an amount of 0.01-1.5% by weight, more preferably in an amount of 0.02-0.5% by weight ,
  • an infiltrate dispersion according to the invention contains, in addition to the finely ground material, the following further components:
  • binder 0.5-3.0% by weight of binder
  • the infiltrant medium preferably water is used.
  • the infiltrate dispersions according to the invention are prepared by customary processes, for example by initially introducing a large part of the total amount of the liquid component (solvent component), preferably the entire infiltrant medium, and breaking up the finely ground material by using a high shear stirrer (eg 400-2000 rpm). Subsequently, if appropriate, the other components are stirred in individually or as a mixture until a homogeneous mixture is formed. The order of addition plays no role or only a minor role.
  • the infiltrate dispersion of the invention is prepared at a temperature of preferably 5-50 ° C.
  • the infiltrate dispersions according to the invention can be used for stabilizing casting cores, preferably for stabilizing shot-up salt cores as described herein.
  • the infiltration method according to the invention can also be applied to sand cores.
  • salt core includes all types of bodies useful in making a casting, such as cores, molds, and molds.
  • salt cores may be only partially contacted
  • the infiltrate dispersions according to the invention are suitable for all conceivable applications in which stabilization of salt cores is desired.
  • the shot salt core is subjected to the infiltrate after shaping, for example by immersing the core in an infiltrate dispersion according to the invention.
  • the infiltration can also be done by means of a vacuum. If only parts of the core are to be stabilized by the infiltrate, only the parts of the core to be stabilized are brought into contact with the infiltrate dispersion.
  • the contact time of the core with the infiltrate dispersion depends on the desired penetration depth of the infiltrate into the core, wherein a penetration depth of 2 mm has been found to be particularly suitable for complete infiltration.
  • Salt cores preferably salt cores as described above, were infiltrated by dipping with the infiltrate dispersion according to the invention.
  • the salt core to be stabilized if appropriate only the region to be stabilized, is immersed in a container with a ready-to-use infiltrate dispersion according to the invention as long as it has been determined for the degree of stabilization to be achieved, which was determined in preliminary experiments. is required. It has been found that immersion times of 0.1 second to minutes, preferably 10 seconds to 20 seconds, usually give the desired degree of stabilization.
  • the infiltrated core is dried appropriately. In particular, when using the cores in the die casting process, it has been found that completely infiltrated cores achieve the best results with respect to the exact core layer in the casting.
  • the infiltrated cores can additionally be provided with a size (salt sizing, graphite size or other commercially available sizes).
  • composition and properties of a core have a significant impact on the quality of the casting.
  • the infiltrated salt cores based on sodium chloride prepared according to the invention usually have a density of 1.2 g / cm 3 to 2.5 g / cm 3 , preferably from 1.6 g / cm 3 to 2.0 g / cm 3 .
  • the flexural strength, measured according to VDG leaflet P73, is between 400 N / cm 2 and 2000 N / cm 2 . With reference to an embodiment, the most important properties are listed below. The properties given refer to cores that are not coated with a size.
  • the core according to the invention was formed at a pressure of up to 15 bar on a commercial core shooter.
  • This core according to the invention is particularly suitable for use in aluminum die-casting, but can also be used in other casting processes (eg low-pressure chill casting). In order to withstand the temperatures and forces that occur during casting, the core must be dimensionally stable.
  • the core according to the invention has a corresponding surface strength. After the casting is completely solidified, the core of the invention is removed. It is important that the core completely and easily dissolves immediately and without residues.
  • the present invention accordingly relates to cores based on salt which can be produced by molding and compacting a core material mixture, this core material mixture comprising at least one salt, at least one binder and optionally adjuvants such as additives, fillers, wetting agents and catalysts, and the cores are stabilized by an infiltrate.
  • the salt, the binder and any auxiliary agents used are inorganic, these core materials can be dissolved with water as solvent and the cores are shaped by means of core shooting; that the salt, the binder and any auxiliary agents used are inorganic, these core materials are soluble with water as a solvent and the cores are brought into shape by means of pressing; that the core material mixture is flowable; the core material mixture is free-flowing; salts are used whose decomposition or melting point is above the temperature of the liquid metal surrounding the cores; in that the salts used are chlorides of the alkali and alkaline earth elements, in particular sodium chloride, potassium chloride and / or magnesium chloride, sulfates and nitrates of the alkali and alkaline earth elements, in particular potassium sulfate and / or magnesium sulfate, ammonium salts, in particular ammonium sulfate or mixtures of these salts; that the salt is
  • the teaching of the invention further relates to a process for the preparation of cores based on salt, in which: - at least one salt, at least one binder and optionally additional auxiliaries such as additives, fillers, wetting agents and catalysts homogeneously mixed in non-liquid form and formed into a core and compressing and infiltrating the compressed core with an infiltrate suspended / dispersed in a suitable infiltrant medium, followed by drying.
  • auxiliaries such as additives, fillers, wetting agents and catalysts homogeneously mixed in non-liquid form and formed into a core and compressing and infiltrating the compressed core with an infiltrate suspended / dispersed in a suitable infiltrant medium, followed by drying.
  • the core is compacted in the core shooting method; the core is made by dry pressing; Salt is used and mixed with grain sizes of different distribution curves, preferably in a bi-, tri- or multimodal grain distribution; as S alze C chlorides of alkali and alkaline earth elements, in particular sodium chloride, potassium chloride and / or magnesium chloride, sulfates and nitrates d he Al ka l i- and alkaline earth elements, especially potassium sulfate and / or magnesium sulfate, and ammonium salts, in particular ammonium sulfate or mixtures of these salts which, optionally mixed with the additional excipients, are mixed homogeneously, shaped and compacted to the core by means of the core shooting or press molding; the core materials, depending on the material, desired surface quality and contour accuracy of the workpiece to be cast from metal, are used with grain sizes in the range of 0.01 mm to 2 mm, formed into a
  • the infiltration of the nuclei is effected by sucking in the filtrate suspension by means of a vacuum; the infiltration is carried out to a depth of 1 mm until preferably complete infiltration; the shot or pressed salt cores are additionally subjected to a sintering treatment before being infiltrated; the shot or pressed cores are infiltrated and then subjected to an additional sintering treatment; the cores are additionally provided with a sizing.
  • the teaching according to the invention furthermore relates to the use of the cores according to the invention as cavity placeholders in the production of metal castings by metal casting, preferably in die-casting technology; as cavity placeholder in the production of castings in mold or gravity casting; as cavity placeholder in the production of plastic parts by the injection molding technology.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Mold Materials And Core Materials (AREA)

Abstract

Les noyaux introduits dans un moule pour le moulage sous pression de pièces en métal afin que les cavités ménagées dans les pièces ne soient pas remplies de métal fondu lors du remplissage des moules, sont soumis à de sévères exigences concernant leur stabilité de forme, leur stabilité mécanique et thermique ainsi que leur possibilité de démoulage. C'est pourquoi les noyaux selon l'invention sont des noyaux à base de sel, pouvant être fabriqués par mise en forme et compression d'un mélange de matériau de noyau constitué d'au moins un sel, d'au moins un liant et éventuellement d'agents auxiliaires comme des adjuvants, des agents mouillants et des catalyseurs. Le sel, le liant et les agents auxiliaires éventuellement utilisés sont inorganiques, ces matériaux de noyau sont solubles dans l'eau, les éléments sont mis en forme et comprimés par décochage ou compactage, et les noyaux comprimés sont stabilisés par un infiltrat.
EP11726376.4A 2010-06-02 2011-06-01 Noyaux de sel stabilisés par un infiltrat Withdrawn EP2576100A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102010029656 2010-06-02
PCT/EP2011/059153 WO2011151420A1 (fr) 2010-06-02 2011-06-01 Noyaux de sel stabilisés par un infiltrat

Publications (1)

Publication Number Publication Date
EP2576100A1 true EP2576100A1 (fr) 2013-04-10

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP11726376.4A Withdrawn EP2576100A1 (fr) 2010-06-02 2011-06-01 Noyaux de sel stabilisés par un infiltrat

Country Status (6)

Country Link
US (1) US20130068129A1 (fr)
EP (1) EP2576100A1 (fr)
BR (1) BR112012030752A2 (fr)
DE (1) DE102011076905A1 (fr)
MX (1) MX339426B (fr)
WO (1) WO2011151420A1 (fr)

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DE102011077714A1 (de) * 2011-06-17 2012-12-20 E.G.O. Elektro-Gerätebau GmbH Gusskern für ein Gießverfahren und Verfahren zum Entfernen eines Gusskerns
DE102012108079B3 (de) * 2012-08-31 2013-11-14 Hochschule Aalen Verfahren zur Herstellung hohler Salzkerne
DE102012110592A1 (de) * 2012-11-06 2014-05-08 Martinrea Honsel Germany Gmbh Verfahren zum Herstellen eines Zylinderkurbelgehäuses und Gießformanordnung für ein Zylinderkurbelgehäuse
WO2015011232A1 (fr) * 2013-07-24 2015-01-29 Emil Müller GmbH Noyaux de sel et procédés de fabrication additive pour réaliser des noyaux de sel
DE102014214528A1 (de) 2013-07-24 2015-01-29 Emil Müller GmbH Salzkerne und generative Fertigungsverfahren zur Herstellung von Salzkernen
DE102015209762A1 (de) * 2015-05-28 2016-12-01 Bayerische Motoren Werke Aktiengesellschaft Verfahren zur Herstellung von SMC-Hohlbauteilen
DE102016221033A1 (de) * 2015-10-26 2017-04-27 Emil Müller GmbH Salzkerne und Verfahren zur Herstellung von Salzkernen
DE102018121847A1 (de) * 2018-09-07 2020-03-12 Hengst Se Verfahren zum Metall-Druckgießen mit verlorenem Kern
DE102019131676A1 (de) 2019-11-22 2021-05-27 HÜTTENES-ALBERTUS Chemische Werke Gesellschaft mit beschränkter Haftung Kerne für den Druckguss
DE102021200812A1 (de) 2021-01-29 2022-08-04 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung eingetragener Verein Verfahren zur Herstellung von Formelementen für Tauch- und Laminierverfahren, Kernen oder Modellen, die zum Abbilden von Hinterschneidungen in Metall-, Keramik-, Kunststoff- oder Compositebauteilen einsetzbar sind

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Also Published As

Publication number Publication date
DE102011076905A1 (de) 2011-12-08
MX2012013912A (es) 2013-04-03
MX339426B (es) 2016-05-25
BR112012030752A2 (pt) 2016-11-08
US20130068129A1 (en) 2013-03-21
WO2011151420A1 (fr) 2011-12-08

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