EP2581149B1 - Verfahren zur herstellung eines metallteiles - Google Patents

Verfahren zur herstellung eines metallteiles Download PDF

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Publication number
EP2581149B1
EP2581149B1 EP10754535.2A EP10754535A EP2581149B1 EP 2581149 B1 EP2581149 B1 EP 2581149B1 EP 10754535 A EP10754535 A EP 10754535A EP 2581149 B1 EP2581149 B1 EP 2581149B1
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EP
European Patent Office
Prior art keywords
insulating
metal
molten metal
casting
model
Prior art date
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Active
Application number
EP10754535.2A
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English (en)
French (fr)
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EP2581149A1 (de
Inventor
Santiago Prat Urreiztieta
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.)
ASK CHEMICALS ESPANA SA
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ASK CHEMICALS ESPANA SA
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C23/00—Tools; Devices not mentioned before for moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C25/00—Foundry moulding plants
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • B22C9/088—Feeder heads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould

Definitions

  • the invention is comprised among the methods of casting metal parts in sand molds, and it specifically relates to a method which allows supplying insulating and/or exothermic material in areas of the sand mold which will be in contact with the molten metal and in which a greater insulation or heat supply is required.
  • the production of cast metal parts comprises pouring a molten metal into a mold, the solidification of the metal and demolding of the part formed by means of eliminating or destroying the mold.
  • a casting box in which the portion of the corresponding model is placed is used to produce each half sand mold, the rest being filled with a mixture of agglomerated sand and its catalyst.
  • the volume of molten metals is reduced during solidification. For this reason, when casting metals it is common to use risers arranged outside the part to offset the shrinkage which occurs during solidification. To improve the feed effect and in order for the volume of the feed riser to be kept at a minimum, the feed riser is normally surrounded with an exothermic and/or thermal insulating sleeve for the purpose of keeping the metal of the riser in the molten state for the longest possible time.
  • the metal Since the riser is surrounded by the exothermic and/or insulating sleeve, the metal will be in a liquid state for a longer time period as it solidifies and the metal shrinks in the rest of the part, thus allowing the feed of the molten metal to offset the shrinkage and thus reduce the formation of shrinkage cavities to a minimum.
  • the mold will need more or less risers, and each of them will be surrounded by an exothermic and/or insulating sleeve. Therefore, before pouring the molten metal into the mold, the sleeves will have had to have been placed in their respective risers, considerably increasing the work cycle.
  • the risering areas are defined in the sand mold by the model itself in which, in addition to the geometry of the part to be produced, the risering areas outside the part are shaped. These risering areas must be covered before casting with the corresponding insulating and/or exothermic sleeves.
  • padding is typically used, which consists of producing in the sand mold a flaring of the constrained area or the area which is difficult for the liquid metal to access, in order to produce an excess of metal which assures complete filling of that area of the cavity.
  • the foundryman generally manufactures the sand molds and the sleeves come from a manufacturer that specializes in sleeves, such that the foundryman does not control the materials and the composition of the sleeves, which involves certain risks because there is a series of materials that are frequently used today in manufacturing sleeves, the use of which under current European laws is restricted because during handling or after casting they can produce emissions or particles that are hazardous to the health.
  • DE 21 00 097 A1 discloses methods of making sand molds for metal casting whereby a model of the part to be cast as well as a model of a riser having the desired outer diameter of the riser are placed in a mold which are thereafter filled with sand. Once the molds are filled with sand the riser model is removed and a further model is installed. The space left is then filled with an insulating material.
  • the object of the invention is a method of producing metal parts by casting a molten metal into a sand mold which allows applying an insulating or exothermic material in areas of the mold which require a greater insulation or heat supply by exothermic reaction, such as risering areas or internal areas of the mold and all this during a process of manufacturing the sand mold.
  • This allows, "in situ", making the sleeves which are to surround the risers and supplying insulating or exothermic material in areas which are difficult to feed that do not allow feeding the rest of the part before it solidifies.
  • the method object of the invention comprises the following steps:
  • the insulating or exothermic mixture is arranged in contact with the model in some areas in which it is required that the molten metal cast in step e) remains in the liquid state for a longer time period than the rest of the molten metal that is going to shape the part, such that, once the model is removed in step d), the insulating or exothermic mixture delays the solidification of the molten metal cast in step e) in the areas in which the mentioned mixture has been arranged.
  • an insulating or exothermic mixture will depend on the thermal characteristics of the metal which is going to be melted, on the dimensions of the part, on its geometry and on other variants, for example, if the part is a non-ferritic metal part with low melting point, the mixture used could be an insulating mixture.
  • the insulating or exothermic mixture will be deposited in contact with the model in that constrained area before pouring the molding sand so that when casting the molten metal, said metal in the mentioned constrained area will remain in the liquid state for a longer time period than the rest of the metal that is going to shape the part and can therefore feed other areas.
  • an auxiliary part can be placed around the mentioned riser such that after pouring the molding sand, the mentioned auxiliary part is removed, a gap being shaped between the molding sand and the model, into which the insulating or exothermic mixture forming the sleeve once it is cured will be poured.
  • the auxiliary part used for surrounding the riser can be a bush with a circular section which must be able to be extracted, i.e., separated from the riser easily in order to form the aforementioned gap.
  • the insulating or exothermic mixture can be a non-fibrous mixture, such as those described in patents EP 1543897 and EP 0265112 , such that the molding sand and the mentioned insulating or exothermic mixtures which will shape the mold can be located in independent tanks. These input materials fall into a hopper and from there into a continuous or batch mixer in which they will be mixed with the corresponding resins and catalysts coming from other tanks. The molding sand along with the resins and catalysts are poured into the casting box. The insulating or exothermic materials which are already mixed with the resins and catalysts are also poured into the casting box in the location corresponding to them.
  • Figure 1 shows a casting box (3), namely the upper box, inside which a model (4) has been arranged for shaping a cavity (5), which will define the shape of the metal part (1), and at least one riser (11). Furthermore, the corresponding model for shaping the casting channel or sprue (10) also has been placed in this upper casting box (3).
  • Figure 1 shows areas (41, 42) which, due to their configuration, are areas in which it is required that the metal which will be cast in the cavity (5) remains in the liquid state for a longer time period than the rest of the metal which is going to shape the part (1).
  • the area (41) corresponds to a riser (11) which will be formed once the molten metal is cast, and the area (42) is an area with difficult access for the molten metal to reach it.
  • the risers are used to offset the shrinkage occurring during the solidification of the metals, such that feeding molten metal from the riser (11) into the cavity (5) allows the complete filling thereof and thus the production of quality parts.
  • the method object of the invention allows supplying an insulating or exothermic mixture (7) in contact with the model (4) in the areas (41, 42) so that the molten metal cast into the cavity (5) remains in the liquid state in the areas (41, 42) for a longer time period than the rest of the metal which will shape the part (1).
  • Figure 2 shows that in the area (42), which is an area that is difficult to feed that does not allow feeding the rest of the part, there has been deposited the insulating or exothermic mixture (7), which allows delaying the solidification of the metal cast in that the area (42).
  • This mixture (7) will be arranged in the area (42) before pouring the molding sand (6) into the casting box (3).
  • an auxiliary part (8) has been placed around the same, in this case the auxiliary part (8) being a bush with a circular section due to the shape of the riser.
  • the bush is extracted such that a gap (9) is created between the molding sand (6) and the area (41).
  • the gap (9) is filled with the insulating or exothermic mixture (7) in order to allow that the solidification of the molten metal in the area (41) once it is cast in the cavity (5) is delayed.
  • Figure 8 shows the complete sand mold (2), with the upper and lower portions, in which there has been defined a cavity corresponding with the final shape of the metal part (1) to be produced.
  • the cavity of the sand mold (2) has been filled with molten metal through the sprue (10).
  • the molten metal will remain in the liquid state for a longer time period than the rest of the metal in order to completely fill the entire cavity and in order for the metal to reach areas which are difficult to feed, such as the area (42), for example.
  • FIG 9 schematically shows an industrial installation for producing metal parts according to the invention.
  • the installation depicted has three tanks (12) or hoppers with the materials involved in the process.
  • the sand for shaping the sand mold (2) is in one of these tanks (12)
  • the insulating mixture is in another tank (12)
  • the exothermic mixture is in another one.
  • the suitable amount is dispensed from each tank (12) into a distribution hopper (14) which pours it into a mixer (13).
  • the resins and the catalysts coming from the tanks (15) enter the continuous or batch mixer (13). Once the mixtures, whether the mixed molding sand (6) or the mixed insulating or exothermic mixture (7), are produced, they are deposited by gravity in the casting boxes (3) in the location corresponding to them.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Claims (6)

  1. Verfahren zur Herstellung eines Metallteiles (1) durch Gießen einer Metallschmelze in eine Sandform (2), umfassend:
    a) Einbringen eines Modells (4) in einen Gießkasten (3) zum Ausbilden eines Hohlraums (5), der die Form des Metallteiles (1) und von mindestens einem Speiser (11) definieren wird,
    b) Einfüllen eines Formsandes (6) in den Gießkasten (3) nach Schritt a) zum Ausbilden der Sandform (2),
    c) Einfüllen eines isolierenden oder exothermen Gemisches (7) in einigen Bereichen (41, 42) in den Gießkasten (3) nach Schritt a), um das Erstarren einer Metallschmelze in den Bereichen (41, 42) zu verzögern,
    d) Entfernen des Modells (4) zum Ausbilden des erwähnten Hohlraums (5),
    e) Gießen einer Metallschmelze in den erwähnten Hohlraum (5),
    f) Entnehmen des nach dem Erstarren der Metallschmelze gebildeten Teiles (1),
    dadurch gekennzeichnet, dass nach Schritt a) ein zusätzliches Teil (8) um den Bereich (41) herum so angebracht wird, dass nach Schritt b) das erwähnte zusätzliche Teil (8) entfernt wird, wobei ein Spalt (9) zwischen dem Formsand (6) und dem Modell (4) gebildet wird, in den das isolierende oder exotherme Gemisch (7) von Schritt c) eingefüllt wird.
  2. Verfahren zur Herstellung eines Metallteiles (1) nach Anspruch 1, dadurch gekennzeichnet, dass das zusätzliche Teil (8) eine Hülse mit einem kreisförmigen Querschnitt ist.
  3. Verfahren zur Herstellung eines Metallteiles (1) nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass das isolierende oder exotherme Gemisch (7) ein nichtfasriges Gemisch ist.
  4. Verfahren zur Herstellung eines Metallteiles (1) nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass das isolierende oder exotherme Gemisch (7) in Kontakt ist mit der Metallschmelze in einem Bereich (41), der den Speiser (11) bildet, um Wärme oder Wärmedämmung bereitzustellen.
  5. Verfahren zur Herstellung eines Metallteiles (1) nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass das isolierende oder exotherme Gemisch (7) in Kontakt mit einem Teil der Metallschmelze in einem Bereich mit erschwerter Zugänglichkeit (42) des Teiles (1), der eine Wärmezuführung oder Wärmedämmung erfordert, angeordnet ist.
  6. Verfahren zur Herstellung eines Metallteiles nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass sich der Formsand (6) und das isolierende oder exotherme Gemisch (7), die die Sandform (2) bilden, in voneinander unabhängigen Tanks (12) befinden, die einen Mischer (13) speisen, in welchem sie mit agglomerierenden Harzen gemischt werden, sodass sie durch Schwerkraft in den Gießkasten (3) gelangen.
EP10754535.2A 2010-06-08 2010-06-08 Verfahren zur herstellung eines metallteiles Active EP2581149B1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/ES2010/070377 WO2011154561A1 (es) 2010-06-08 2010-06-08 Procedimiento de obtencion de una pieza metalica

Publications (2)

Publication Number Publication Date
EP2581149A1 EP2581149A1 (de) 2013-04-17
EP2581149B1 true EP2581149B1 (de) 2018-01-03

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EP10754535.2A Active EP2581149B1 (de) 2010-06-08 2010-06-08 Verfahren zur herstellung eines metallteiles

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US (1) US20130139994A1 (de)
EP (1) EP2581149B1 (de)
ES (1) ES2663280T3 (de)
WO (1) WO2011154561A1 (de)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP5347077B1 (ja) * 2013-03-19 2013-11-20 テクノメタル株式会社 砂型鋳造方法
CN107584077A (zh) * 2016-07-06 2018-01-16 科华控股股份有限公司 一种使用发热块打通冒口补缩通道的工艺结构

Family Cites Families (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3273211A (en) * 1963-11-29 1966-09-20 Archer Daniels Midland Co Process of molding exothermic compositions
GB1240301A (en) * 1968-10-03 1971-07-21 Foseco Int Production of metal castings
DE2128428A1 (de) * 1971-06-08 1973-01-04 Huettenes Albertus Steigeraufsatz
US4190369A (en) * 1976-10-13 1980-02-26 National Engineering Company Method and apparatus for making molds
AU1869583A (en) * 1983-09-05 1985-03-14 Aikoh Co. Ltd. Heat-retaining of blind riser and an agent thereof
JPS6146345A (ja) * 1984-08-08 1986-03-06 Kobe Steel Ltd Ｍｇ合金鋳造用の押湯部保温スリ−ブの防燃処理法
GB8624598D0 (en) 1986-10-14 1986-11-19 Foseco Int Feeder sleeves
ES2134729B1 (es) * 1996-07-18 2000-05-16 Kemen Recupac Sa Mejoras introducidas en objeto solicitud patente invencion española n. 9601607 por "procedimiento para fabricacion manguitos exactos y otros elementos de mazarotaje y alimentacion para moldes de fundicion, incluyendo la formulacion para obtencion de dichos manguitos y elementos".
JP3239209B2 (ja) * 1997-05-22 2001-12-17 正光 三木 鋳物用発熱体の製造方法
US6286585B1 (en) * 2000-03-21 2001-09-11 Ashland Inc. Sleeve mixes containing stabilized microspheres and their use in making riser sleeves
PT1543897E (pt) 2002-09-09 2007-09-12 Iberia Ashland Chem Sa ''manga, respectivo método de fabrico e mistura para a sua produção''
DE102005011644A1 (de) * 2005-03-14 2006-09-21 AS Lüngen GmbH & Co. KG Exotherme und isolierende Speisereinsätze mit hoher Gasdurchlässigkeit

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Publication number Publication date
ES2663280T3 (es) 2018-04-11
US20130139994A1 (en) 2013-06-06
EP2581149A1 (de) 2013-04-17
WO2011154561A1 (es) 2011-12-15

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