EP2823916A1 - Composite casting - Google Patents

Composite casting Download PDF

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Publication number
EP2823916A1
EP2823916A1 EP13175828.6A EP13175828A EP2823916A1 EP 2823916 A1 EP2823916 A1 EP 2823916A1 EP 13175828 A EP13175828 A EP 13175828A EP 2823916 A1 EP2823916 A1 EP 2823916A1
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EP
European Patent Office
Prior art keywords
insert
producing
casting
composite casting
composite
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EP13175828.6A
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German (de)
French (fr)
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EP2823916B1 (en
Inventor
Sabine Tunzini
Thomas Baginski
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.)
GF Casting Solutions Herzogenburg Iron GmbH
GF Casting Solutions Kunshan Co Ltd
GF Casting Solutions Leipzig GmbH
Fondium Mettmann GmbH
Fondium Singen GmbH
Original Assignee
Georg Fischer Eisenguss GmbH
Georg Fischer Automotive Kunshan Co Ltd
Georg Fischer Automobilguss GmbH Germany
Georg Fischer GmbH
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Application filed by Georg Fischer Eisenguss GmbH, Georg Fischer Automotive Kunshan Co Ltd, Georg Fischer Automobilguss GmbH Germany, Georg Fischer GmbH filed Critical Georg Fischer Eisenguss GmbH
Priority to EP13175828.6A priority Critical patent/EP2823916B1/en
Publication of EP2823916A1 publication Critical patent/EP2823916A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/04—Casting in, on, or around objects which form part of the product for joining parts

Definitions

  • the invention relates to a method for producing a composite casting comprising an insert and casting material, wherein the insert is materially connected to the casting material.
  • the DE 10 2006 041 901 A1 discloses a method for producing metal composite parts from steel and / or cast iron.
  • the einzug manende part which is made of steel or cast iron, coated by flux.
  • the coating aims at a reduction, that is to say that during the pouring, the oxide skin of the casting is dissolved and washed away, as a result of which the casting material can form a metallurgical bond.
  • the DE 10 2011 053 858 B3 discloses a method of using a pourable component in a lost mold, wherein a coating agent is applied to a surface of the inflowing component.
  • the coating agent forms a separation-active surface, which prevents adhesion of the material to the component and corrosion before casting with casting material.
  • the DE 100 43 105 B4 discloses a method of forming a tough, resilient and / or at least substantially defect free bond between an insert and a cast metal material having a melting point below that of the feedstock.
  • the insert is coated with a thin layer of a metallic material derived from the group of silver, antimony, bismuth, chromium, gold, lead, magnesium, silicon, tin, titanium and zinc. This is followed by casting of the casting material against the coated surface of the insert.
  • the thermal expansion coefficient of the coating is greater than that of the insert and less than that of the casting material.
  • the coated insert is also maintained at a temperature of at least 100 ° C for a period of at least 5 minutes.
  • Object of the present invention is to provide a method and a corresponding composite casting, which achieved over the prior art, an improved bond between an insert and casting material, and ensures economic production.
  • the sheathing or embedding of the insert is formed by an exothermic material which ignites due to the contact with the inflowing casting material or by reaching the ignition temperature. This energy is released and released to the environment, resulting in a reduced temperature gradient between the solidifying melt and the insert.
  • Exothermic materials are in addition to the use in welding (Thermitsch Stammsgemische) in exothermic feeders in the foundry used. Upon contact of the melt with the exothermic mass, a combustion reaction is triggered, which ensures in the feeder that there is the last solidifying melt and so that the changing volume during solidification in the casting can be compensated.
  • welding Thermitschweissgemische
  • a combustion reaction is triggered, which ensures in the feeder that there is the last solidifying melt and so that the changing volume during solidification in the casting can be compensated.
  • such a known material causing an exothermic reaction is used as a sheath for the inflowing insert.
  • the material ignites.
  • the insert is heated from both sides, which prevents rapid solidification of the casting material in the border region to the insert, since the insert loses its quenching effect for the casting material.
  • the temperature gradient between casting material and insert is minimized. This, in turn, promotes carbon diffusion between the casting material and the insert, whereby a cohesive or metallurgical bond can be produced.
  • the insert is preferably made of steel, copper, bronze, brass, aluminum or an aluminum alloy.
  • the process or the composite casting is versatile due to the wide choice of materials.
  • the exothermic material preferably has an easily oxidizable metal, in particular aluminum and / or magnesium.
  • the exothermic material has an oxidizing agent for the readily oxidizable metal, in particular iron (III) oxide.
  • the backfill material used is preferably an oxide, in particular SiO 2 .
  • the backfill material serves as a filling material, which is mixed with the other substances such as aluminum and / or magnesium and an oxidizing agent.
  • the exothermic material preferably comprises a binder which serves the cohesion of the exothermic material.
  • the preferred binder is an alkali silicate in use.
  • a preferred embodiment is that a cast iron is used as the casting material, preferably GJS, GJL and / or GJV.
  • a cast iron is used as the casting material, preferably GJS, GJL and / or GJV.
  • a high strength and elongation at break can be achieved at designated locations in the cast component, or additional, positive properties for a subsequent further treatment can be given to the composite cast component.
  • an aluminum alloy is used as the casting material, thereby, for example, aluminum components can be combined with various metallic materials, whereby the advantage of the weight reduction can be used by the light aluminum.
  • the inventive method is used with lost molds.
  • an insert which has a sufficient thickness or wall thickness, which makes it possible to subject the insert after the casting process nor a heat treatment or welding process.
  • Methods which are known from the prior art allow only the pouring of a steel part, which is very thin-walled, in order to counteract the rapid solidification and the impeded carbon diffusion by the contact of the room temperature-controlled steel part with the casting material something.
  • a hollow body is used as an insert.
  • the cavity fills with the casting material and connects cohesively with the insert.
  • the outer surface of the insert is coated with the exothermic material or embedded in the material.
  • the mass Due to the exothermic reaction of the mass after contact with the melt, the mass also gives off heat to the insert, resulting in a unified temperature gradient between the solidifying melt and the insert.
  • the insert can also be unilaterally, or in hollow execution from the inside with the exothermic material in combination.
  • the exothermic material can be easily removed and the outer surface or inner surface of the insert emerges.
  • Post-processing is then possible, but in some cases not necessary because the dimensional accuracy and the surface finish are already of good quality.
  • the inventive method is economically highly interesting. Furthermore, these methods provide extended possibilities to after-treat the cast component, such as e.g. Welding or heat treatment (even partially on the insert).
  • Such composite castings produced by the method according to the invention are particularly suitable for general mechanical engineering, construction machinery and vehicle construction. It can thereby different materials economically combined with each other and the preferred properties of the individual materials are combined with each other, without the problem of insufficient connection of the materials by early solidification of the casting material occurs.
  • Fig. 1 shows a partial section of a mold in which a composite casting 1 was shed.
  • the casting material 2 flows into the mold 5 formed by the mold in which an insert 3 is inserted in order to enter into a cohesive or metallurgical bond with the cast material 2.
  • GJS preferably GJS, GJL or GJV
  • the exothermic material 4 this ignites, whereby heat is released to the environment.
  • the insert is thereby heated and the temperature gradient between the solidifying melt and the insert is reduced.
  • the carbon diffusion between casting material 2, which directly touches the insert 3, and the insert 3 is driven forward.
  • a cohesive or metallurgical connection at the direct contact points between insert 3 and casting material 2 is achieved.
  • the exothermic material 4 can be easily removed from the insert 3.
  • the area covered by the exothermic material 4 / n of the insert 3 is free of casting material, thus a reworking of the surface of the insert is not necessarily necessary, which in turn makes the inventive method economically very interesting.
  • FIG. 2-4 Another embodiment is by the Fig. 2-4 demonstrated.
  • insert 3 a cylindrical steel tube made of a high-carbon steel with wall thicknesses of 5 mm is used and molded into exothermic material 4 with a defined wall thickness.
  • This steel pipe 3 with surrounding exothermic material 4 is inserted into the mold 5 to be cast as from Fig. 2 seen.
  • the closed mold 5 is filled with melt 2 for producing a GJS, wherein the interior of the steel pipe 3 is flowed through by melt 2 and a part of the exothermic material 4 has direct melt contact. After the ignition temperature of the exothermic material 4 is reached, this gives off heat to the environment and the steel pipe 3. This is greatly heated and the temperature gradient between steel pipe 3 and solidifying melt 2 is reduced.

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

Abstract

Verfahren zur Herstellung eines Verbundgussteils enthaltend ein Einlegeteil und Gussmaterial, wobei das Einlegeteil stoffschlüssig mit dem Gussmaterial verbunden ist und das Verfahren folgende Schritte umfasst: Herstellen des Einlegeteils, Ummanteln bzw. Einbetten des Einlegeteils, Einlegen des ummantelten/eingebetteten Einlegeteils in die Giessform, Füllen der Form mit Schmelze, wobei die Ummantelung/Einbettung des Einlegeteils durch ein exothermes Material gebildet wird, das sich durch die Kontaktierung mit dem einfliessenden Gussmaterials oder durch Erreichen der Zündtemperatur der exothermen Masse entzündet wodurch der Temperaturgradient zwischen erstarrender Schmelze und dem Einlegeteil verringert wird.A method for producing a composite casting comprising an insert and cast material, wherein the insert is materially bonded to the cast material and the method comprises the steps of: Making the insert, Wrapping or embedding the insert, Inserting the coated / embedded insert into the mold, Filling the mold with melt, wherein the sheath / embedding of the insert is formed by an exothermic material which ignites by contacting with the inflowing casting material or by reaching the ignition temperature of the exothermic mass whereby the temperature gradient between solidifying melt and the insert is reduced.

Description

Die Erfindung betrifft ein Verfahren zur Herstellung eines Verbundgussteils enthaltend ein Einlegeteil und Gussmaterial, wobei das Einlegeteil stoffschlüssig mit dem Gussmaterial verbunden ist.The invention relates to a method for producing a composite casting comprising an insert and casting material, wherein the insert is materially connected to the casting material.

Die Herstellung von Verbundgussteilen ermöglicht eine Kombination der bevorzugten Eigenschaften der Materialien an den entsprechenden Stellen. So können Bauteile entsprechend ihren Anforderungen und Einsatzgebieten aufgrund der Materialkombination optimal zusammengestellt werden. Das bedingt aber einer stoffschlüssigen bzw. metallurgischen Verbindung zwischen den Materialien. Beim Eingiessen von Stahlteilen in Gusseisen oder Aluminiumlegierungen tritt häufig das Problem der unzureichenden Verbindung zwischen eingegossenem Stahlteil und umschliessenden bzw. eingegossenem Werkstoff auf. Durch das frühe Erstarren der Schmelze aufgrund des Kontakts mit dem raumtemperierten Einlegeteil, wird ein metallurgisches bzw. stoffschlüssiges Verbinden zwischen Gusswerkstoff und Stahlteil behindert, wodurch Spalten zwischen den Verbundpartnern entstehen können.The production of composite castings allows a combination of the preferred properties of the materials in the appropriate locations. So components can be optimally assembled according to their requirements and applications due to the combination of materials. However, this requires a cohesive or metallurgical connection between the materials. When pouring steel parts into cast iron or aluminum alloys, the problem often arises of insufficient connection between cast-in steel part and enclosing or cast-in material. The early solidification of the melt due to the contact with the space-tempered insert, a metallurgical or cohesive bonding between the casting material and steel part is hindered, which can cause gaps between the composite partners.

Die DE 10 2006 041 901 A1 offenbart ein Verfahren zur Herstellung von metallischen Verbundteilen aus Stahl und/oder Gusseisen. In diesem Verfahren wird das einzugiessende Teil, welches aus Stahl oder Gusseisen hergestellt ist, mittels Flussmittel beschichtet. Die Beschichtung zielt darauf ab, dass es zu einer Reduktion, das heisst, dass es beim Eingiessen zum Auflösen und Wegschwemmen der Oxidhaut des Eingussteils kommt, wodurch der Gusswerkstoff eine metallurgische Bindung eingehen kann.The DE 10 2006 041 901 A1 discloses a method for producing metal composite parts from steel and / or cast iron. In this process, the einzugießende part, which is made of steel or cast iron, coated by flux. The coating aims at a reduction, that is to say that during the pouring, the oxide skin of the casting is dissolved and washed away, as a result of which the casting material can form a metallurgical bond.

Die DE 10 2011 053 858 B3 offenbart ein Verfahren zur Anwendung eines eingiessbaren Bauteils in einer verlorenen Giessform, wobei auf einer Oberfläche des einzugiessenden Bauteils ein Beschichtungsmittel aufgebracht wird. Das Beschichtungsmittel bildet eine trennaktive Oberfläche, welches ein Anhaften vom Material am Bauteil sowie das Korrodieren vor dem Umgiessen mit Gussmaterial verhindert.The DE 10 2011 053 858 B3 discloses a method of using a pourable component in a lost mold, wherein a coating agent is applied to a surface of the inflowing component. The coating agent forms a separation-active surface, which prevents adhesion of the material to the component and corrosion before casting with casting material.

Die DE 100 43 105 B4 offenbart ein Verfahren zur Bildung einer zähfesten, belastbaren und/oder zumindest im wesentlichen mängelfreien Verbindung zwischen einem Einsatz und einem Gussmetallmaterial mit Schmelzpunkt unter jenem des Einsatzmaterials. Der Einsatz wird mit einer dünnen Schicht eines metallischen Materials das aus der Gruppe Silber, Antimon, Wismut, Chrom, Gold, Blei, Magnesium, Silizium, Zinn, Titan und Zink stammt, beschichtet. Darauf erfolgt das Giessen des Gussmaterials gegen die beschichtete Oberfläche des Einsatzes. Der Wärmeausdehnungskoeffizient der Beschichtung ist grösser als der des Einsatzes und geringer als der des Gussmaterials. Der beschichtete Einsatz wird zudem auf eine Temperatur von mindestens 100°C während einem Zeitraum von mindestens 5 Minuten gehalten. Durch dieses Verfahren soll ein Teil der Beschichtung sich auflösen und dem Gussmetallmaterial geopfert werden, während ein Teil dieser Beschichtung als Diffusionsbarriere zwischen Einsatz und Gussmaterial bleibt, was eine hoch zähe Bindung zwischen Einsatz und Gussmaterial erzielen soll.The DE 100 43 105 B4 discloses a method of forming a tough, resilient and / or at least substantially defect free bond between an insert and a cast metal material having a melting point below that of the feedstock. The insert is coated with a thin layer of a metallic material derived from the group of silver, antimony, bismuth, chromium, gold, lead, magnesium, silicon, tin, titanium and zinc. This is followed by casting of the casting material against the coated surface of the insert. The thermal expansion coefficient of the coating is greater than that of the insert and less than that of the casting material. The coated insert is also maintained at a temperature of at least 100 ° C for a period of at least 5 minutes. By this method, a part of the coating is intended to dissolve and be sacrificed to the cast metal material, while a portion of this coating remains as a diffusion barrier between insert and casting material, which is to achieve a highly tough bond between insert and casting material.

Aufgabe der vorliegenden Erfindung ist es, ein Verfahren und ein entsprechendes Verbundgussteil zu schaffen, welches gegenüber dem Stand der Technik eine verbesserte Bindung zwischen einem Einlegeteil und Gussmaterial erzielt, sowie eine wirtschaftliche Herstellung gewährleistet.Object of the present invention is to provide a method and a corresponding composite casting, which achieved over the prior art, an improved bond between an insert and casting material, and ensures economic production.

Diese Aufgabe wird erfindungsgemäss dadurch gelöst, dass die Ummantelung bzw. Einbettung des Einlegeteils durch ein exothermes Material gebildet wird, welches sich durch die Kontaktierung mit dem einfließenden Gussmaterials oder durch Erreichen der Zündtemperatur entzündet. Dabei wird Energie freigesetzt und an die Umgebung abgegeben, wodurch es zu einem verringert Temperaturgradienten zwischen der erstarrenden Schmelze und dem Einlegeteil kommt.This object is achieved according to the invention in that the sheathing or embedding of the insert is formed by an exothermic material which ignites due to the contact with the inflowing casting material or by reaching the ignition temperature. This energy is released and released to the environment, resulting in a reduced temperature gradient between the solidifying melt and the insert.

Das erfindungsgemässe Verfahren umfasst folgende Schritte:

  • Herstellen des Einlegeteils,
  • Ummanteln bzw. Einbetten des Einlegeteils mittels exothermen Material,
  • Einlegen des ummantelten/eingebetteten Einlegeteils in die Giessform,
  • Füllen der Form mit Schmelze.
The method according to the invention comprises the following steps:
  • Making the insert,
  • Wrapping or embedding the insert by means of exothermic material,
  • Inserting the coated / embedded insert into the mold,
  • Filling the mold with melt.

Exotherme Materialien werden neben dem Einsatz beim Schweissen (Thermitschweissgemische) auch in exothermen Speisern in der Giesserei eingesetzt. Bei der Berührung der Schmelze mit der exothermen Masse wird eine Verbrennungsreaktion ausgelöst, welche im Speiser gewährleistet, dass sich dort die zuletzt erstarrende Schmelze befindet und sodass das verändernde Volumen während der Erstarrung im Gussteil ausgeglichen werden kann. Solche Materialien sind aus dem Stand der Technik bekannt, die EP 1 050 354 A1 , EP 0 888 199 B1 und DE 196 42 838 A1 offenbaren solche.Exothermic materials are in addition to the use in welding (Thermitschweissgemische) in exothermic feeders in the foundry used. Upon contact of the melt with the exothermic mass, a combustion reaction is triggered, which ensures in the feeder that there is the last solidifying melt and so that the changing volume during solidification in the casting can be compensated. Such materials are known in the art, which EP 1 050 354 A1 . EP 0 888 199 B1 and DE 196 42 838 A1 reveal such.

In der vorliegenden Erfindung wird ein solch bekanntes Material das eine exotherme Reaktion verursacht, als Ummantelung bzw. Einbettung für das einzugiessende Einlegeteil eingesetzt. Durch die Berührung des exothermen Materials mit dem flüssigen Gussmaterialoder durch Erreichen der Zündtemperatur der exothermen Masse entzündet sich das Material. Dadurch wird das Einlegeteil von beiden Seiten aufgeheizt, was ein rasches Erstarren des Gussmaterials im Grenzbereich zum Einlegeteil verhindert, da das Einlegeteil seine Abschreckwirkung für das Gussmaterial verliert. Der Temperaturgradient zwischen Gussmaterial und Einlegeteil wird minimiert. Das wiederum treibt die Kohlenstoffdiffusion zwischen Gussmaterial und Einlegeteil voran, wodurch eine stoffschlüssige bzw. metallurgische Verbindung erzeugt werden kann.In the present invention, such a known material causing an exothermic reaction is used as a sheath for the inflowing insert. By contacting the exothermic material with the liquid casting material or by reaching the ignition temperature of the exothermic mass, the material ignites. As a result, the insert is heated from both sides, which prevents rapid solidification of the casting material in the border region to the insert, since the insert loses its quenching effect for the casting material. The temperature gradient between casting material and insert is minimized. This, in turn, promotes carbon diffusion between the casting material and the insert, whereby a cohesive or metallurgical bond can be produced.

Das Einlegeteil ist vorzugsweise aus Stahl, Kupfer, Bronze, Messing, Aluminium oder einer Aluminiumlegierung hergestellt. Das Verfahren bzw. das Verbundgussteil ist durch die breite Materialauswahl vielseitig einsetzbar.The insert is preferably made of steel, copper, bronze, brass, aluminum or an aluminum alloy. The process or the composite casting is versatile due to the wide choice of materials.

Vorzugsweise weist das exotherme Material ein leicht oxidierbares Metall insbesondere Aluminium und/oder Magnesium auf.The exothermic material preferably has an easily oxidizable metal, in particular aluminum and / or magnesium.

Zudem ist es Vorteilhaft, dass das exotherme Material ein Oxidationsmittel für das leicht oxidierbare Metall aufweist insbesondere Eisen(III)-oxid.In addition, it is advantageous that the exothermic material has an oxidizing agent for the readily oxidizable metal, in particular iron (III) oxide.

Als Hinterfüllstoff wird vorzugsweise ein Oxid eingesetzt, insbesondere SiO2. Der Hinterfüllstoff dient als Füllmaterial, welcher mit den weiteren Stoffen wie Aluminium und/oder Magnesium sowie einem Oxidationsmittel vermengt wird.The backfill material used is preferably an oxide, in particular SiO 2 . The backfill material serves as a filling material, which is mixed with the other substances such as aluminum and / or magnesium and an oxidizing agent.

Das exotherme Material weist vorzugsweise ein Bindemittel auf, welches dem Zusammenhalt des exothermen Materials dient. Als bevorzugtes Bindemittel ist ein Alkalisilicat im Einsatz.The exothermic material preferably comprises a binder which serves the cohesion of the exothermic material. The preferred binder is an alkali silicate in use.

Eine bevorzugte Ausgestaltung besteht darin, dass als Gussmaterial ein Gusseisen eingesetzt wird, vorzugsweise GJS, GJL und/oder GJV. Durch das eingegossene Einlegeteil kann an dafür vorgesehenen Stellen im Gussbauteil eine hohe Festigkeit und Bruchdehnung erreicht werden, bzw. zusätzliche, positive Eigenschaften für eine nachfolgende Weiterbehandlung dem Verbundgussbauteil gegeben werden.A preferred embodiment is that a cast iron is used as the casting material, preferably GJS, GJL and / or GJV. Through the cast-in insert, a high strength and elongation at break can be achieved at designated locations in the cast component, or additional, positive properties for a subsequent further treatment can be given to the composite cast component.

Bei Verbundgussteilen, die durch Verfahren hergestellt wurden, die aus dem Stand der Technik bekannt sind, sind die Verbindungen zwischen Gussmaterial und Einlegeteil meist ungenügend. Verbundgussteile die durch das erfindungsgemäss Verfahren hergestellt wurden, weisen eine verbesserte stoffschlüssige Verbindung zwischen den Materialien auf.In composite castings produced by methods known in the art, the connections between the cast material and the insert are usually insufficient. Composite castings which have been produced by the method according to the invention have an improved cohesive connection between the materials.

Der Einsatz solcher hergestellten Verbundgussteile bietet eine gute Alternative Stahlguss- bzw. Stahlschweisskonstruktionen mit dem Vorteil der bekannten Gusseisenlegierungen und deren Herstellungsverfahren zu substituieren.The use of such manufactured composite castings offers a good alternative to substituting cast steel or steel welded constructions with the advantage of the known cast iron alloys and their method of manufacture.

Als bevorzugte Ausführungsform wird als Gussmaterial eine Aluminiumlegierung eingesetzt, dadurch können bspw. Aluminiumbauteile mit verschiedenen metallischen Materialien kombiniert werden, wodurch der Vorteil der Gewichtsreduktion durch das leichte Aluminium genutzt werden kann.As a preferred embodiment, an aluminum alloy is used as the casting material, thereby, for example, aluminum components can be combined with various metallic materials, whereby the advantage of the weight reduction can be used by the light aluminum.

Vorzugsweise wird das erfindungsgemässe Verfahren mit verlorenen Giessformen angewandt.Preferably, the inventive method is used with lost molds.

Durch dieses Verfahren besteht die Möglichkeit ein Einlegeteil einzusetzen, welches eine genügende Dicke bzw. Wandstärke aufweist, die es ermöglicht, das Einlegeteil nach dem Giessverfahren noch einem Wärmebehandlungs- bzw. Schweissverfahren zu unterziehen. Verfahren, die aus den Stand der Technik bekannt sind, ermöglichen nur das Eingiessen eines Stahlteils, welches sehr dünnwandig ist, um dem raschen Erstarren und der behinderten Kohlenstoffdiffusion durch den Kontakt des raumtemperierten Stahlteils mit dem Gussmaterials etwas entgegen zu halten. Vorzugsweise wird ein Hohlkörper als Einlegeteil eingesetzt. Der Hohlraum füllt sich mit dem Gussmaterial und verbindet sich stoffschlüssig mit dem Einlegeteil. Die äussere Oberfläche des Einlegeteils ist mit dem exothermen Material ummantelt bzw. in das Material eingebettet. Durch die exotherme Reaktion der Masse nach der Berührung mit der Schmelze, gibt die Masse Wärme auch an das Einlegeteil ab, wodurch es zu einem vereinheitlichtem Temperaturgradienten zwischen der erstarrenden Schmelze und dem Einlegeteil kommt. Das Einlegeteil kann auch einseitig, oder bei hohler Ausführung von innen mit dem exothermen Material in Verbindung stehen.By this method, it is possible to use an insert, which has a sufficient thickness or wall thickness, which makes it possible to subject the insert after the casting process nor a heat treatment or welding process. Methods which are known from the prior art, allow only the pouring of a steel part, which is very thin-walled, in order to counteract the rapid solidification and the impeded carbon diffusion by the contact of the room temperature-controlled steel part with the casting material something. Preferably, a hollow body is used as an insert. The cavity fills with the casting material and connects cohesively with the insert. The outer surface of the insert is coated with the exothermic material or embedded in the material. Due to the exothermic reaction of the mass after contact with the melt, the mass also gives off heat to the insert, resulting in a unified temperature gradient between the solidifying melt and the insert. The insert can also be unilaterally, or in hollow execution from the inside with the exothermic material in combination.

Nach dem Giessvorgang und dem Entformen kann das exotherme Material leicht entfernt werden und die äussere Oberfläche oder die innere Fläche des Einlegeteils tritt zum Vorschein. Ein Nachbearbeiten ist anschliessend möglich, aber in manchen Fällen auch nicht von Nöten da die Massgenauigkeit und die Oberflächenbeschaffenheit bereits von guter Qualität sind. Auch durch das mögliche Einsparen von weiteren Bearbeitungsschritten ist das erfindungsgemässe Verfahren wirtschaftlich hoch interessant. Weiterhin ergeben sich durch diese Verfahren erweiterte Möglichkeiten das Gussbauteil nachzubehandeln, wie z.B. Schweissen oder Wärmebehandeln (auch nur partiell am Einlegeteil).After the casting and demolding, the exothermic material can be easily removed and the outer surface or inner surface of the insert emerges. Post-processing is then possible, but in some cases not necessary because the dimensional accuracy and the surface finish are already of good quality. Also by the possible savings of further processing steps, the inventive method is economically highly interesting. Furthermore, these methods provide extended possibilities to after-treat the cast component, such as e.g. Welding or heat treatment (even partially on the insert).

Solche Verbundgussteile hergestellt nach dem erfindungsgemässen Verfahren eignen sich insbesondre für den allgemeinen Maschinenbau, für Baumaschinen und den Fahrzeugbau. Es können dadurch unterschiedliche Materialien auch bei hohen Stückzahlen wirtschaftlich miteinander verbunden und die bevorzugten Eigenschaften der einzelnen Materialien miteinander kombiniert werden, ohne dass die Problematik einer ungenügenden Verbindung der Materialien durch frühes Erstarren des Gussmaterials auftritt.Such composite castings produced by the method according to the invention are particularly suitable for general mechanical engineering, construction machinery and vehicle construction. It can thereby different materials economically combined with each other and the preferred properties of the individual materials are combined with each other, without the problem of insufficient connection of the materials by early solidification of the casting material occurs.

Ausführungsbeispiele der Erfindung werden anhand der Figuren beschrieben, wobei sich die Erfindung nicht nur auf die Ausführungsbeispiele beschränkt. Es zeigt:

Fig. 1
einen Teilschnitt einer Giessform mit eingesetztem ummantelten Einlegeteil,
Fig. 2
eine fotographische Abbildung eines mit exothermem Material ummantelten Stahlrohrs,
Fig. 3
ein Schliffbild durch einen Ausschnitt des Verbundgussteils und
Fig.4
ein Ausschnitt eines Verbundgussbauteil mit eingegossenem Stahlteil
Embodiments of the invention will be described with reference to the figures, wherein the invention is not limited to the embodiments. It shows:
Fig. 1
a partial section of a mold with inserted jacketed insert,
Fig. 2
a photographic image of a steel tube encased with exothermic material,
Fig. 3
a microsection through a section of the composite casting and
Figure 4
a section of a composite cast component with cast steel part

Fig. 1 zeigt einen Teilschnitt einer Gussform in der ein Verbundgussteil 1 vergossen wurde. Das Gussmaterial 2 fliesst in die vom Formmaterial 5 gebildete Giessform in welcher ein Einlegeteil 3 eingelegt ist, um mit dem Gussmaterial 2 eine stoffschlüssige bzw. metallurgische Verbindung einzugehen. Das Gussmaterial 2 vorzugsweise GJS, GJL oder GJV fliesst in die vom Formmaterial 5 gebildete Giessform. An den Stellen an denen das Gussmaterial 2 das exotherme Material 4 berührt, entzündet sich dieses, wodurch Wärme an die Umgebung abgegeben wird. Das Einlegeteil wird dadurch erwärmt und der Temperaturgradient zwischen erstarrender Schmelze und dem Einlegeteil verringert. Zudem wird die Kohlenstoffdiffusion zwischen Gussmaterial 2, welches das Einlegeteil 3 direkt berührt, und dem Einlegeteil 3 vorangetrieben. Damit wird eine stoffschlüssige bzw. metallurgische Verbindung an den direkten Berührungsstellen zwischen Einlegeteil 3 und Gussmaterial 2 erzielt. Nach dem Ausformen kann das exotherme Material 4 leicht vom Einlegeteil 3 entfernt werden. Die von dem exothermen Material 4 abgedeckte Fläche/n des Einlegeteils 3 ist frei von Gussmaterial, somit ist eine Nachbearbeitung der Oberfläche des Einlegeteils nicht zwangsläufig notwendig, was das erfindungsgemässe Verfahren wiederum wirtschaftlich sehr interessant macht. Fig. 1 shows a partial section of a mold in which a composite casting 1 was shed. The casting material 2 flows into the mold 5 formed by the mold in which an insert 3 is inserted in order to enter into a cohesive or metallurgical bond with the cast material 2. The casting material 2, preferably GJS, GJL or GJV, flows into the casting mold formed by the molding material 5. At the points where the casting material 2 touches the exothermic material 4, this ignites, whereby heat is released to the environment. The insert is thereby heated and the temperature gradient between the solidifying melt and the insert is reduced. In addition, the carbon diffusion between casting material 2, which directly touches the insert 3, and the insert 3 is driven forward. Thus, a cohesive or metallurgical connection at the direct contact points between insert 3 and casting material 2 is achieved. After molding, the exothermic material 4 can be easily removed from the insert 3. The area covered by the exothermic material 4 / n of the insert 3 is free of casting material, thus a reworking of the surface of the insert is not necessarily necessary, which in turn makes the inventive method economically very interesting.

Ein weiteres Ausführungsbeispiel ist durch die Fig. 2-4 aufgezeigt. Als Einlegeteil 3 wird ein zylindrisches Stahlrohr aus einem hochgekohlten Stahl mit Wanddicken von 5 mm verwendet und in exothermes Material 4 mit definierter Wandstärke eingeformt. Dieses Stahlrohr 3 mit umgebendem exothermen Material 4 wird in die zu giessende Form 5 eingelegt wie aus Fig. 2 ersichtlich. Die geschlossene Giessform 5 wird mit Schmelze 2 zur Herstellung eines GJS gefüllt, wobei der Innenraum des Stahlrohres 3 von Schmelze 2 durchflossen wird und ein Teil des exothermen Materials 4 direkten Schmelzekontakt hat. Nachdem die Zündtemperatur des exothermen Materials 4 erreicht ist, gibt dieses Wärme an die Umgebung und das Stahlrohr 3 ab. Dieses wird dadurch stark erwärmt und der Temperaturgradient zwischen Stahlrohr 3 und erstarrender Schmelze 2 wird verkleinert. Dies wirkt sich begünstigend auf die Gefügeausbildung und auf die Kohlenstoffdiffusion zwischen dem Gussmaterial 2 und dem Stahlrohr 2, welches aufgrund der Konzentrationsunterschiede vonstatten geht, aus. Durch die Einlagerung der Kohlenstoffatome in den Zwischengitterplätzen des Stahls wird die Schmelztemperatur herabgesetzt und die Rohrwand des Stahlrohrs 3 löst sich an. Bereiche des Stahls werden aufgekohlt und quasi durch Guss ersetzt. Somit erfolgt ein nahtloser Übergang vom Guss 2 und Stahl 3 was in Fig. 3 abgebildet ist. In Fig. 4 ist ein Ausschnitt des Bauteils mit eingegossenem Stahlrohr 3 dargestellt.Another embodiment is by the Fig. 2-4 demonstrated. As insert 3, a cylindrical steel tube made of a high-carbon steel with wall thicknesses of 5 mm is used and molded into exothermic material 4 with a defined wall thickness. This steel pipe 3 with surrounding exothermic material 4 is inserted into the mold 5 to be cast as from Fig. 2 seen. The closed mold 5 is filled with melt 2 for producing a GJS, wherein the interior of the steel pipe 3 is flowed through by melt 2 and a part of the exothermic material 4 has direct melt contact. After the ignition temperature of the exothermic material 4 is reached, this gives off heat to the environment and the steel pipe 3. This is greatly heated and the temperature gradient between steel pipe 3 and solidifying melt 2 is reduced. This has a favorable effect on the structure formation and the carbon diffusion between the casting material 2 and the steel pipe 2, which is due to the concentration differences take place from. Due to the incorporation of the carbon atoms in the interstices of the steel, the melting temperature is lowered and the tube wall of the steel pipe 3 dissolves. Areas of the steel are carburized and replaced by castings. Thus, a seamless transition from the casting 2 and steel 3 takes place in Fig. 3 is shown. In Fig. 4 is a section of the component with cast steel pipe 3 shown.

BezugszeichenlisteLIST OF REFERENCE NUMBERS

11
VerbundgussteilComposite casting
22
Gussmaterialcast material
33
Einlegeteil / StahlrohrInsert / steel tube
44
Exothermes MaterialExothermic material
55
Giessform aus FormmaterialCasting mold made of molding material

Claims (13)

Verfahren zur Herstellung eines Verbundgussteils enthaltend ein Einlegeteil und Gussmaterial, wobei das Einlegeteil stoffschlüssig mit dem Gussmaterial verbunden ist und das Verfahren folgende Schritte umfasst: Herstellen des Einlegeteils, Ummanteln bzw. Einbetten des Einlegeteils, Einlegen des ummantelten/eingebetteten Einlegeteils in die Giessform, Füllen der Form mit Schmelze,
dadurch gekennzeichnet, dass die Ummantelung/Einbettung des Einlegeteils durch ein exothermes Material gebildet wird, das sich durch die Kontaktierung mit dem einfliessenden Gussmaterials oder durch Erreichen der Zündtemperatur der exothermen Masse entzündet wodurch der Temperaturgradient zwischen erstarrender Schmelze und dem Einlegeteil verringert wird. A method for producing a composite casting comprising an insert and cast material, wherein the insert is materially bonded to the cast material and the method comprises the steps of Making the insert, Wrapping or embedding the insert, Inserting the coated / embedded insert into the mold, Filling the mold with melt,
characterized in that the sheathing / embedding of the insert is formed by an exothermic material which ignites by contacting with the inflowing casting material or by reaching the ignition temperature of the exothermic mass whereby the temperature gradient between solidifying melt and the insert is reduced. Verfahren zur Herstellung eines Verbundgussteils nach Anspruch 1, dadurch gekennzeichnet, dass das Einlegeteil aus Stahl, Kupfer, Bronze, Messing, Aluminium oder einer Aluminiumlegierung besteht.Method for producing a composite casting according to claim 1, characterized in that the insert consists of steel, copper, bronze, brass, aluminum or an aluminum alloy. Verfahren zur Herstellung eines Verbundgussteils nach einem der Ansprüche 1 oder 2, dadurch gekennzeichnet, dass das exotherme Material ein leicht oxidierbares Metall insbesondere Aluminium und/oder Magnesium aufweist.Method for producing a composite casting according to one of claims 1 or 2, characterized in that the exothermic material comprises an easily oxidizable metal, in particular aluminum and / or magnesium. Verfahren zur Herstellung eines Verbundgussteils nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass das exotherme Material ein Oxidationsmittel für das leicht oxidierbare Metall aufweist, insbesondere Eisen(III)-oxidA method for producing a composite casting according to any one of the preceding claims, characterized in that the exothermic material comprises an oxidizing agent for the easily oxidizable metal, in particular iron (III) oxide Verfahren zur Herstellung eines Verbundgussteils nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass das exotherme Material einen Hinterfüllstoff aufweist vorzugsweise ein Oxid.Method for producing a composite casting according to one of the preceding claims, characterized in that the exothermic material comprises a backfill material, preferably an oxide. Verfahren zur Herstellung eines Verbundgussteils nach Anspruch 5, dadurch gekennzeichnet, dass das Oxid vorzugsweise SiO2 ist.A method for producing a composite casting according to claim 5, characterized in that the oxide is preferably SiO 2 . Verfahren zur Herstellung eines Verbundgussteils nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass das exotherme Material ein Bindemittel aufweist, vorzugsweise Alkalisilicat.A method for producing a composite casting according to any one of the preceding claims, characterized in that the exothermic material comprises a binder, preferably alkali silicate. Verfahren zur Herstellung eines Verbundgussteils nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass das Gussmaterial ein Gusseisen ist, insbesondere GJS, GJL und/oder GJVMethod for producing a composite casting according to one of the preceding claims, characterized in that the casting material is a cast iron, in particular GJS, GJL and / or GJV Verfahren zur Herstellung eines Verbundgussteils nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass das Gussmaterial eine Aluminiumlegierung ist.Method for producing a composite casting according to one of the preceding claims, characterized in that the casting material is an aluminum alloy. Verfahren zur Herstellung eines Verbundgussteils nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass die Giessform eine verlorene Giessform ist.Method for producing a composite casting according to one of the preceding claims, characterized in that the casting mold is a lost casting mold. Verfahren zur Herstellung eines Verbundgussteils nach einem der
vorangehenden Ansprüche, dadurch gekennzeichnet, dass das Verbundgussteil zumindest am Einlegeteil einer Wärmebehandlung bzw. einem Schweissverfahren unterzogen werden kannProcess for producing a composite casting according to one of
previous claims, characterized in that the composite casting at least at the insert part of a heat treatment or a welding process can be subjected Verfahren zur Herstellung eines Verbundgussteils nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass das Einlegeteil ein Hohlkörper oder ein Freiformteil ist.Method for producing a composite casting according to one of the preceding claims, characterized in that the insert is a hollow body or a free-form part. Verbundgussteil enthalten ein Einlegeteil und ein Gussmaterial, hergestellt
nach dem Verfahren nach einem der vorangehenden Ansprüche, dadurch gekennzeichnet, dass das Einlegeteil mit dem Gussmaterial stoffschlüssig verbunden ist.Composite casting include an insert and a cast material made
according to the method according to one of the preceding claims, characterized in that the insert is materially connected to the casting material.
EP13175828.6A 2013-07-10 2013-07-10 Method of manufacturing a composite casting Active EP2823916B1 (en)

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CN108262466A (en) * 2017-12-13 2018-07-10 浙江灿根智能科技有限公司 A kind of bi-metal casting process
DE102016104351B4 (en) 2016-03-10 2018-08-23 Knorr-Bremse Systeme für Nutzfahrzeuge GmbH Cast iron brake caliper of a disc brake and method of making a caliper
CN114029450A (en) * 2021-11-10 2022-02-11 北京星航机电装备有限公司 Light alloy casting embedded pipeline assembly and preparation method thereof and casting method of light alloy part with embedded pipeline

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