EP2744612B1 - Procédé de production de moulages à moules perdus - Google Patents

Procédé de production de moulages à moules perdus Download PDF

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Publication number
EP2744612B1
EP2744612B1 EP12772821.0A EP12772821A EP2744612B1 EP 2744612 B1 EP2744612 B1 EP 2744612B1 EP 12772821 A EP12772821 A EP 12772821A EP 2744612 B1 EP2744612 B1 EP 2744612B1
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EP
European Patent Office
Prior art keywords
temperature
liquid
mould
ceramic
castings
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
Application number
EP12772821.0A
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German (de)
English (en)
Other versions
EP2744612A2 (fr
Inventor
Edward CZEKAJ
Aleksander Karwinski
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Instytut Odlewnictwa
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Instytut Odlewnictwa
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Publication of EP2744612A2 publication Critical patent/EP2744612A2/fr
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • 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
    • 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
    • B22D27/045—Directionally solidified castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D30/00—Cooling castings, not restricted to casting processes covered by a single main group

Definitions

  • This invention relates to a method for producing investment castings, preferably in ceramic moulds, from alloys based on aluminium, magnesium, copper, zinc and iron.
  • the ceramic moulds used in investment casting are characterised by low thermal conductivity and therefore the time of the liquid metal solidification is relatively long. As a result of the slow solidification, a coarse-grain structure is formed, which is the cause of reduced mechanical properties of the casting.
  • a directional solidification of the metal should be provided.
  • a method to produce investment castings according to patent specification DE-OS 3629079 consists in this that it uses ceramic moulds with "pockets" made in the selected parts of mould. Before pouring of mould with liquid metal, these pockets are filled with steel shot. Because of the heat capacity of the steel shot considerably higher than the heat capacity of the aluminium alloy, an intense heat transfer from the liquid metal is thereby provided, which allows making castings with the areas of directional solidification.
  • a fluid coolant is used, preferably in liquid state, at varying degrees of overheating, wherein the boiling point is lower than the temperature of the metal poured.
  • the liquid coolant should have an appropriate viscosity, and it is a mixture of substances characterised by different boiling points.
  • a composition comprising wax, glycol, ester and / or oil is given. Due to the flammability of the components of the coolant, the process is carried out in a closed container under inert gas atmosphere.
  • ceramic moulds poured with aluminium alloy are cooled in an oil bath, which has a high flash point and low viscosity.
  • the ceramic foundry mould filled with liquid metal is kept at a pressure of at least 20 MPa for the time of about 300 seconds, and then it is introduced into a liquid coolant at a temperature of -100°C, or lower. It is advantageous to subject the solidifying metal to the effect of ultrasounds, or to another alternative treatment.
  • a method for producing investment castings according to the invention in ceramic moulds, from alloys based on Al, Mg, Cu, Zn and Fe is characterised in that the ceramic mould is baked at a temperature of 800-1000°C for 2-4 hours, is cooled next to a temperature in the range of 20-950°C, and is held at this temperature for 10-40 minutes, and after a lapse of this time, the said mould is poured with liquid alloy overheated by 50 to 200°C above the initial melting point, and after a lapse of 10-100 seconds, it is immersed at a fixed or variable speed in a liquid cooling medium, the said liquid cooling medium being a 1 -99 volume percent aqueous solution of liquid polymer at a temperature in the range of 15-85°C.
  • the liquid polymer is a polymer of the PAG, or PVP, or ACR type.
  • the ceramic moulds made from the aluminosilicate or high alumina refractories, especially based on synthetic sand, for example Molochite, are used.
  • Liquid polymers are solutions, suspensions or alloys of polymers, which belong to a particular group of liquids characterised by a measurable shape stability, reveal some characteristics of a solid body, and are characterised by a measurable elasticity. They represent polymolecular carbon and hydrogen compounds, containing also oxygen, nitrogen, phosphorus and sulphur, as well as modifiers, inhibitors and other additives. Liquid polymers exhibit non-Newtonian fluid properties at high shear rates, which means that their flow curves are not straight lines.
  • the applied cooling medium has nearly 2-times higher specific heat than the quenching oils, owing to which the temperature increase of the medium will be for a given batch weight reduced by approximately one half.
  • the aqueous solution of liquid polymers penetrating through the ceramic mould walls forms in contact with molten metal a thin separating polymer coating, which enables making castings with excellent surface quality.
  • the outer surfaces of castings are not contaminated with oil or wax, and therefore they do not require degreasing or other cleaning processes.
  • the residues of the cooling medium that can remain on castings when the said medium occurs in high concentrations in the cooling bath are not carbonised, but fully decompose at high temperatures to form water vapour and carbon oxides.
  • the cooling rate depends on the type of the polymer, on its concentration, and on the temperature of the aqueous solution.
  • the applied cooling medium is non-flammable and environmentally friendly. Due to these characteristics, for the implementation of the method according to the present invention, no sealed space is required but a sucking-off installation is sufficient, since larger amounts of smoke can arise only in the case of the premature removal of moulds from the cooling medium.
  • Ceramic moulds made of aluminosilicate or high-alumina refractories are characterised by stable properties during changes in temperature. Higher temperature of the ceramic mould favours alloy castability, and thus enables making thin wall or ultra-thin wall castings.
  • Castings made by the method according to the invention have very good quality of the outer surface, characterised by a low degree of roughness, by glossy appearance, and by absence of defects of the gas microporosity type.
  • the directional solidification provides good internal compactness, measured by density.
  • the castings are characterised by high homogeneity of the macro- and microstructure in the wall cross-sections, the thicknesses of which are not greater than 2-3 times.
  • Their structure is more refined with respect to similar castings solidifying according to the traditional methods of the investment casting process, in particular, the average values of the secondary dendrite arm spacing are reduced, and in eutectic alloys a fine-grain eutectic is formed. All these factors affect the increase of strength parameters R m and R p0.2 and ductility A 5 in the tensile test, while the magnitude of these parameters depends on the alloy type and cooling conditions.
  • a ceramic mould for a pilot conical casting of 020 x 030 x 100 mm is made of quartz flour and silica sand with SiO 2 content above 90 weight percent, with a binder of the LUDOX ® PX30 type in the form of an aqueous solution of colloidal silica containing 20 to 40 weight percent of SiO 2 .
  • the mould is baked at a temperature of 800-850°C for 2 hours. Then it is slowly cooled to a temperature of 750°C, held at this temperature for 15 minutes, and next poured with an aluminium alloy, which is a hypoeutectic EN AC-AlSi7Mg0,6 silumin at a temperature of 700-720°C.
  • the ceramic mould poured with liquid alloy is after 10 seconds immersed at a speed of 7.5 mm/s in a 20 volume percent aqueous solution of the liquid polymeric quenching agent such as Aqua-Quench 260 at a temperature of 20°C.
  • a ceramic mould for a tapered casting as in Example 1, wherein the said mould is made of an aluminosilicate material in the form of a synthetic filler under the trade name of Molochite and the LUDOX ® PX30 binder, and wherein the said mould is baked at 900°C for 2 hours, and then cooled to room temperature. After preheating the said mould to a temperature of 300°C, it is held at this temperature for 15 minutes and poured with liquid cast MgAl9Zn1 magnesium alloy at a temperature of 690-710°C.
  • the mould poured with molten metal is immersed at a constant speed of 7.5 mm/s in a 20 volume percent aqueous solution of the liquid POLIHARTENOL-E8 polymer at a temperature of 20°C.
  • the mould shell does not show any signs of adherence to the outer surface of the casting.
  • the casting is compact, free from any external and internal porosity, while its density is close to the theoretical one typical for an alloy of a given chemical composition.
  • the casting When hit with a metal tool, the casting produces a clear metallic sound, typical for gravity die castings.
  • the outer surface of the sample has a low surface roughness and is slightly glossy.
  • a ceramic mould of a conical shape based on Molochite as a filler and with the LUDOX ® PX30 binder is baked at a temperature of 950°C for 3 hours and then cooled to a temperature of 700°C, held at this temperature for 20 minutes and poured at a temperature of 1450°C with liquid chromium-molybdenum cast iron, containing in weight percent: 3.35 C, 0.53 Si, 92 Mn, 9.5 Cr, 0.14 Ni, 1.53 Mo, rest Fe.
  • the mould with liquid cast iron is immersed at a speed of 5 mm/s in an aqueous solution of the liquid THERMISOL QZS 700 polymer at a concentration of 19.14 volume percent and at a temperature of 50°C.
  • the accelerated crystallisation and cooling favour the spheroidisation of primary and eutectic carbides in a ferritic matrix.
  • a ceramic mould made of aluminosilicate filler called Molochite and the LUDOX ® PX30 binder based on colloidal silica is baked for 3 hours at 900°C. Then the mould is cooled to room temperature and then heated to 400°C. The mould is held at this temperature for 30 minutes and poured with the liquid AC-AlSi7Mg0.3 alloy at a temperature of 710-740°C. After 15 seconds, the mould poured with the liquid alloy is immersed at an average speed of about 5 mm/s in a tank filled with a polymer coolant, which is a 20 percent aqueous solution of POLIHARTENOL-E8 at room temperature.
  • a polymer coolant which is a 20 percent aqueous solution of POLIHARTENOL-E8 at room temperature.
  • the microstructure of the resulting casting is more refined than the microstruc-ture of casting solidifying in a self-supported ceramic mould at a temperature of 400°C.
  • the overall quality of the outer surface of casting has been very good in both cases: it has low surface roughness, and is bright and glossy.
  • the casting made by the method according to the invention is more compact, with no internal defects and, compared with the casting made by a traditional technique, depending on wall thickness, has a higher density of from 0.01 to 0.04 g/cm 3 .
  • Faster crystallisation has reduced the ⁇ A l dendrites of the aluminium solid solution; particularly visible is the effect of undercooling-related modification of the ( ⁇ Al + ⁇ Si ) eutectic.
  • the DAS or SDAS parameters i.e. the interdendritic spacing of I- and II-order, better correlate with the solidification rate than the grain size.
  • the average dendrite arm spacing is 40 pm.
  • Three ceramic moulds based on Molochite with the LUDOX ® PX30 type binder are baked at a temperature of 900°C for 2.5 hours and then are cooled to 500°C, held at this temperature for 15 minutes and are next poured with liquid copper alloy of the BA1044, B555, or M059 type, according to PN-91/H-87026, overheated by 100-150°C above the initial melting point.
  • the mould is immersed at a speed of 8.5 mm/s in a polymer coolant based on POLIHARTENOL-E8, at a concentration of 15-25 volume percent H 2 O, at a temperature of 35°C.
  • the outer surface of copper alloy castings is characterised by low surface roughness and is glossy, especially in the case of BA1044 aluminium bronze. Rapid directional solidification of copper alloy castings reduces in the microstructure both the grain size and SDAS. For example, in B555 alloy, these distances were reduced: from 33 ⁇ m - for castings made by the method according to the invention, to 26 ⁇ m for castings undergoing free cooling in a self-supported molochite mould at a temperature of about 500°C. Cooling conditions had a significant effect on the hardness of copper alloy castings, and while HV of the BA1044 alloy in a self-supported mould was 232 units, it increased to 253 in casting solidifying directionally in the mould placed in a liquid polymer medium.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Mold Materials And Core Materials (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Claims (1)

  1. Méthode de fabrication de pièces moulées de précision dans des moules céramiques, lesdites pièces étant réalisées en alliage sur matrice d'Al, Mg, Cu, Zn et Fe, caractérisée en ce que le moule céramique est recuit à une température comprise entre 800 et 1000°C pendant 2 à 4 heures, puis le moule est refroidi jusqu'à une température comprise entre 20 et 950°C et maintenu à cette température pendant 10 à 40 minutes, puis rempli d'alliage liquide surchauffé de 50 à 200°C au-delà du point de fusion initial, et ensuite, après 10 à 100 secondes, immergé à une vitesse constante ou variable dans un milieu liquide constitué d'une solution aqueuse à 1-99 pourcent en volume de polymère liquide de type PAG ou PVP ou ACR, ayant une température comprise entre 15 et 85°C.
EP12772821.0A 2011-08-19 2012-08-10 Procédé de production de moulages à moules perdus Not-in-force EP2744612B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
PL396030A PL216825B1 (pl) 2011-08-19 2011-08-19 Sposób wytwarzania odlewów precyzyjnych
PCT/PL2012/000068 WO2013028086A2 (fr) 2011-08-19 2012-08-10 Procédé de production de moulages à moules perdus

Publications (2)

Publication Number Publication Date
EP2744612A2 EP2744612A2 (fr) 2014-06-25
EP2744612B1 true EP2744612B1 (fr) 2015-10-21

Family

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EP12772821.0A Not-in-force EP2744612B1 (fr) 2011-08-19 2012-08-10 Procédé de production de moulages à moules perdus

Country Status (7)

Country Link
US (1) US20140190653A1 (fr)
EP (1) EP2744612B1 (fr)
JP (1) JP2014525839A (fr)
PL (1) PL216825B1 (fr)
RU (1) RU2579841C2 (fr)
UA (1) UA109823C2 (fr)
WO (1) WO2013028086A2 (fr)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102018221750A1 (de) * 2018-12-14 2020-06-18 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Verfahren und Gussform zum Herstellen von Metallgusswerkstücken
CN115815574A (zh) * 2022-12-07 2023-03-21 中国航发动力股份有限公司 一种高温合金薄壁空心铸件的浇注方法

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SU977108A1 (ru) * 1981-04-07 1982-11-30 Предприятие П/Я М-5671 Способ изготовлени отливок направленным затвердеванием
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Also Published As

Publication number Publication date
PL396030A1 (pl) 2013-03-04
WO2013028086A2 (fr) 2013-02-28
UA109823C2 (uk) 2015-10-12
EP2744612A2 (fr) 2014-06-25
WO2013028086A3 (fr) 2013-04-18
RU2014104995A (ru) 2015-09-27
PL216825B1 (pl) 2014-05-30
WO2013028086A4 (fr) 2013-06-13
RU2579841C2 (ru) 2016-04-10
US20140190653A1 (en) 2014-07-10
JP2014525839A (ja) 2014-10-02

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