EP3147046B1 - Moule en sable, dispositif de moulage composé d'une base de masselotte insérable et du moule en sable et procédé permettant d'obtenir le dispositif de moulage - Google Patents

Moule en sable, dispositif de moulage composé d'une base de masselotte insérable et du moule en sable et procédé permettant d'obtenir le dispositif de moulage Download PDF

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Publication number
EP3147046B1
EP3147046B1 EP14745172.8A EP14745172A EP3147046B1 EP 3147046 B1 EP3147046 B1 EP 3147046B1 EP 14745172 A EP14745172 A EP 14745172A EP 3147046 B1 EP3147046 B1 EP 3147046B1
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EP
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Prior art keywords
riser
cavity
riser base
mould
base
Prior art date
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Active
Application number
EP14745172.8A
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German (de)
English (en)
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EP3147046A1 (fr
Inventor
Julián IZAGA
Jaime PRAT
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 GmbH
Casa Maristas Azterlan
Original Assignee
ASK CHEMICALS ESPANA SA
Casa Maristas Azterlan
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Application filed by ASK CHEMICALS ESPANA SA, Casa Maristas Azterlan filed Critical ASK CHEMICALS ESPANA SA
Priority to PT147451728T priority Critical patent/PT3147046T/pt
Publication of EP3147046A1 publication Critical patent/EP3147046A1/fr
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Classifications

    • 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
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives
    • 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
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings

Definitions

  • the present invention relates to methods and devices for casting in sand moulds and, more specifically, to the feeding systems for casting moulds.
  • moulds are used (generally made of sand) which comprise:
  • Figure 1 shows, in outline, the elements constituting a casting mould.
  • a correctly designed feeding system must be capable of counteracting contractions occuring during the cooling of the metal in liquid state.
  • the solidification or change in state takes place in two stages:
  • the response of the feeding system is that which corresponds to the sum of the two mentioned contractions, since once the metal has finished solidifying the feed devices are not capable of adding metal.
  • the feeding systems in other words, risers and mini risers, can occupy two perfectly distinct positions in the moulds:
  • the riser base can fulfil its function, in other words, so that during the liquid interval there is communication between the part and the riser, it is essential that in the first place the part solidifies, next the riser base and finally, the riser itself.
  • This sequence of solidification is what guarantees that contraction defects (shrinkage) do not occur in the part, making the part unusable.
  • the match plate that is used to obtain the interior configuration of the sand mould generates the cavity of the part to be manufactured and the riser base, in such a way that the sand mould obtained is a replica of the shaes of the pattern plate and the cavity of the riser base. Therefore, the cavity forming the riser base is made of the same material as the rest of the mould, generally silica sand, bound using different systems.
  • riser bases present a greater size which has a significant effect on net/gross performance.
  • An object of the present invention is a sand mould for the casting of metal parts configured to receive the incorporation of an insertable riser base, provided to receive molten metal from a feeding riser.
  • the mould comprises a main cavity which can be filled with molten metal to obtain a cast part and at least one auxiliary cavity with an (interior) geometry that allows the insertion of said riser base, the auxiliary cavity being disposed in respect to the main cavity in such a way that when the riser base is inserted into the auxiliary cavity, the interior cavity of the riser base puts said main cavity of the mould in communication with a feeding riser.
  • the insertable riser base which is as such not part of the invention, is obtained independently from the mould, for example by manual moulding or blowing with an exterior geometry having variable shapes and sizes. These shapes will be preferably simple, for example prismatic, truncated pyramidal, cylindrical or semi-spherical.
  • the riser bases that will act as inserts may be manufactured outside of the casting plant, as occurs for example with risers, mini risers or sleeves.
  • the sand mould is made of silica sand.
  • silica sand is to be understood as pure silica sand in addition to other sands which contain usual sand components other than silica such as iron, feldspar, gypsum, etc.
  • the mould is obtained by means of moulding tools, for example a pattern plate that configures the main cavity and one or several auxiliary cavities having geometries in correspondence with the shape of the insertable riser bases manufactured for this express purpose.
  • the exterior geometry will preferably be prismatic, truncated pyramidal, cylindrical or semi-spherical.
  • the riser bases are incorporated into the mould at the time of proceeding to prepare the mould for the casting of the parts, in other words, by means of the match plate the main cavity is generated and the auxiliary cavity or cavities of the mould (depending on the necessary number of risers) and next the riser bases are introduced as if they were cores.
  • the interior cavity must fulfil the criterion of the thermal module, in such a way that the last parts of the liquid metal must be found in the feeding system, to add the metal that the part requires during its contraction.
  • the join between the feeder (riser, mini riser, etc.) and the main cavity of the mould (part) is achieved by means of an insert or detachable part (riser base) foreign to the mould that has been disposed in the auxiliary space or cavity made in the mould itself to act as the riser base.
  • the riser base comprises an insulating or exothermic composition.
  • This composition may comprise hollow microspheres of aluminium silicate and a binder, preferably cold box curing binders, the hollow microspheres presenting an alumina content of equal to or less than 38 % in weight, and preferably of 20 to 38 %.
  • any type of solid or liquid resin can be used which is polymerised by means of the corresponding catalyser.
  • the hot or cold boxy system can be used, in addition to self-curing techniques.
  • the composition may comprise non-fibrous fillers, selected from the group made up of oxidable metals, oxidants capable of oxidising said oxidable metals and inorganic fluorinated fluxes.
  • oxidable metals aluminium magnesium and silicon may be used, preferably aluminium.
  • alkaline or alkaline earth metal salts may be resorted to, for example, nitrates, chlorates and permanganates of alkaline and alkaline earth metals.
  • Metal oxides may also be resorted to, for example Iron and manganese oxides, preferably iron oxide.
  • inorganic fluorinated fluxes cryolite, aluminium and potassium tetrafluoride and aluminium and potassium hexafluoride, preferably cryolite.
  • the hollow microspheres of aluminium silicate present preferably a grain diameter of up to 3 mm and more preferably a grain diameter of less than 1 mm and a wall thickness of approximately 10 % of the diameter of the microsphere.
  • a further object of the invention is a moulding device made up of a sand mould according to the present invention and a riser base, and wherein said riser base is inserted into said sand mould.
  • the riser base presents an exterior geometry that allows the insertion of the riser base into the aforesaid auxiliary cavity and comprises an interior cavity that communicates said main cavity of the mould with a feeding riser, when the riser base is inserted into the auxiliary cavity of the mould.
  • the auxiliary cavity can present a shape and configuration complementary to the exterior geometry of the riser base, so that the base fits into the cavity. It is also possible for the riser base to comprise elements designed to fit into a part of the auxiliary cavity.
  • the auxiliary cavity is disposed (in the mould) in such a way that, when the riser base is inserted into the auxiliary cavity of the mould, the interior of the riser base is in communication with the main cavity of the mould (part) to allow passage of the molten metal in the interior cavity to the main cavity.
  • the auxiliary cavity may be adjacent to the main cavity and even form a single cavity to facilitate the formation of the mould, in this last case, once the riser base is inserted the main cavity is formed and remains communicated with the interior cavity of the riser base.
  • an object of the invention is a method for obtaining a moulding device for casting cast parts which comprises the following steps:
  • the riser base presents an insulating or exothermal composition.
  • This composition may comprise hollow aluminium silicate microspheres and a binder, the hollow microspheres presenting an alumina content of equal to or less than 38 % in weight and preferably of 20 to 38 %.
  • any type of resin can be used, either solid or liquid, which is polymerised by means of the corresponding catalyser.
  • the hot or cold boxy system can be used, in addition to self-curing techniques.
  • a cold box curing binder is used.
  • the composition may comprise non-fibrous fillers, selected from the group formed by oxidable metals, oxidants and inorganic fluorinated fluxes.
  • oxidable metals aluminium magnesium and silicon may be used, preferably aluminium.
  • alkaline or alkaline earth metal salts may be resorted to, for example, nitrates, chlorates and permanganates of alkaline and alkaline earth metals.
  • Metal oxides may also be resorted to, for example iron and manganese oxides, preferably iron oxide.
  • inorganic fluorinated fluxes cryolite aluminium-potassium tetrafluoride and aluminium-potassium hexafluoride may be used, preferably cryolite.
  • the hollow microspheres of aluminium silicate present preferably a grain diameter of up to 3 mm and more preferably a grain diameter of less than 1 mm and a wall thickness of approximately 10 % of the diameter of the microsphere.
  • the formulation inherent to this invention may contain optional fillers in non-fibrous form, selected from the group of oxidable metals, oxidants and inorganic fluorinated fluxes.
  • the formulations described above are used, which are moulded manually or by blowing, polymerising the resin used by means of the appropriate catalyser, obtaining as a result a block with a shape that is more or less prismatic (or truncated pyramidal or cylindrical or semi-spherical) which contains the shape of the previously designed riser base.
  • the dimensional precision obtained by these methods is far greater than that obtained by traditional moulding methods, allowing these riser bases to be considered as precision elements, and for this reason, they can be coupled to the sand mould very easily, possibly even reaching the level of automation.
  • the new process is based on the use of insertable riser bases (inserts), which are housed in the cavities which have been made expressly in the mould using moulding tools.
  • the cavity provided in the mould can present various shapes and dimensions (prismatic, truncated pyramidal, semi-spherical, etc.), said cavity, belongs to the mould and is constituted by the same system or mass as the rest of the mould.
  • said cavity belongs to the mould and is constituted by the same system or mass as the rest of the mould.
  • the insert of the object is placed or disposed, in the form of a core, which consists of the following particularities or characteristics:
  • Figure 1 represents a casting mould (1) which comprises a main cavity (2) corresponding to the part to be manufactured and which has been formed by the moulding tool (3).
  • the filling system (4) has been configured and the feed devices (5).
  • the filling system (4) communicates the exterior of the mould (1) with the main cavity (2) and is made up of the feeding riser, the distribution channels and the joins or attacks on the part.
  • the feeding systemfeeding system (5) is responsible for feeding the part, in other words, for offsetting the contractions that occur in the liquid-solid change. It is frequent to use mini risers with insulating and/or exothermal properties.
  • Figure 2 represents two common shapes of feed devices (in this case mini risers).
  • the feed device (5) When the feed device (5) is situated on the top part of the part it is referred to as “on top” and in this case the “riser base” is not used.
  • the feed when the feed is on the side, it is essential to use cavities for the bases of the riser (6).
  • the cavity corresponding to the riser base (6) is one more part of the mould and, for this reason, these cavities are formed by the moulding tools (3) themselves, with the same moulding material as the mould assembly (1).
  • Figure 3 presents a moulding tool (3) or match plate used to obtain the main cavity (2) and the cavity that forms the base of the riser (6).
  • Figure 4 represents an insertable riser base (7).
  • the insertable riser base (7) is an element obtained independently from the casting mould (1) and comprises an interior cavity (8) which can house molten metal for feeding the main cavity (2).
  • a casting mould (1) has also been represented which comprises a main cavity (2) that reproduces the shape of the part to be obtained and an auxiliary cavity (9).
  • the exterior geometry of the insertable riser base (7) is similar to the geometry of the auxiliary cavity (9), in such a way that the riser base (7) can easily be inserted into the auxiliary cavity (9).
  • Figure 5 represents an insertable riser base (7) housed in the auxiliary cavity (9) of the mould (1) and a riser or mini riser (10) on the insertable riser base (7).
  • the interior cavity (8) is left in direct communication with the main cavity (2) of the mould (1) and with the riser, in such a way that the molten metal contained in the riser feeds the main cavity (2) of the mould (1).
  • the metal of the part, of the riser base and of the mini riser forms a unit, which from the thermal point of view must keep the corresponding relation.
  • the material constituting the insertable riser base (7) is similar to or the same as that of the mini riser (10), as in both cases they must present insulating and/or exothermal characteristics, this material being different to that of the mould (1). It is observed that the riser base (7) is an insert in the mould (1), which fulfils the same function as those traditional riser base cavities made of the same mixture (silica sand) as the mould and obtained along with the cavity of the party.
  • Figures 6A and 6B help to visualise what actually happens in manufacturing cast components.
  • Figure 6A shows a riser base according to the usual techniques.
  • the size of the "riser base” is very large, if compared with the diameter of the riser itself. This disproportion is related to the thermal and physical characteristics of the material of the mould and of the riser. It is very obvious that the size of the "riser base” penalises performance, while at the same time it is possible to appreciate the enormous disproportion existing between it and the feeder itself.
  • the replacement of the cavity of the "riser base” with a riser base having a similar material to that of the mini riser allows the modification of the solidification models of the feed environment.
  • the invention is not limited to the specific embodiments described herein, and also encompass, for example, variants that may be embodied by the average person skilled in the art (for example, with regards to the choice of materials, dimensions, components, configuration, etc.), within the scope of that inferred from the claims.

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

Claims (14)

  1. Moule en sable (1) pour couler des pièces métalliques, configuré pour recevoir l'incorporation d'une base de masselotte insérable (7) dotée d'une cavité intérieure (8) configurée pour recevoir du métal fondu provenant d'une masselotte d'alimentation (10), caractérisé en ce qu'il comprend une cavité principale (2) qui peut être remplie de métal fondu pour que soit obtenue une pièce coulée et, au moins, une cavité auxiliaire (9) ayant une géométrie qui permet l'insertion de ladite base de masselotte (7), la cavité auxiliaire (9) étant disposée par rapport à la cavité principale (2) de telle sorte que, lorsque la base de masselotte (7) est insérée dans la cavité auxiliaire (9), la cavité intérieure (8) de la base de masselotte (7) mette ladite cavité principale (2) du moule (1) en communication avec une masselotte d'alimentation (10), et en ce que le moule en sable (1) est fait de sable de silice.
  2. Moule en sable selon la revendication 1, dans lequel la géométrie intérieure de la cavité auxiliaire est prismatique, en pyramide tronquée, cylindrique ou semi-sphérique.
  3. Dispositif de moulage formé d'un moule en sable (1) selon l'une quelconque des revendications 1 et 2 et d'une base de masselotte (7) insérée dans la cavité auxiliaire (9) dudit moule en sable (1), la base de masselotte (7) comprenant une cavité intérieure (8) configurée pour loger du métal fondu pour alimenter la cavité principale (2) du moule en sable (1) quand la base de masselotte (7) est insérée dans la cavité auxiliaire (9) du moule en sable (1), dans lequel ladite cavité intérieure (8) fait communiquer ladite cavité principale (2) du moule (1) avec une masselotte d'alimentation (10) quand la base de masselotte (7) est insérée dans la cavité auxiliaire (9), ladite base de masselotte (7) comprenant une composition isolante ou exothermique.
  4. Dispositif de moulage selon la revendication 3, dans lequel la composition isolante ou exothermique de ladite base de masselotte (7) comprend des microsphères creuses en silicate d'aluminium et un liant, les microsphères creuses ayant une teneur en alumine égale ou inférieure à 38 % en poids.
  5. Dispositif de moulage selon la revendication 4, dans lequel les microsphères creuses ont une teneur en alumine de 20 à 38 %.
  6. Dispositif de moulage selon l'une quelconque des revendications 4 et 5, dans lequel la composition isolante ou exothermique de ladite base de masselotte (7) comprend des charges non fibreuses choisies dans le groupe constitué par les métaux oxydables, les oxydants et les fondants fluorés inorganiques.
  7. Dispositif de moulage selon l'une quelconque des revendications 4 à 6, dans lequel la composition isolante ou exothermique de ladite base de masselotte (7) comprend des liants de durcissement en boîte froide ou chaude.
  8. Dispositif de moulage selon l'une quelconque des revendications 3 à 7, dans lequel la géométrie extérieure de ladite base de masselotte (7) est prismatique, en pyramide tronquée, cylindrique ou semi-sphérique.
  9. Méthode pour obtenir un dispositif de moulage pour couler des pièces coulées, caractérisé en ce qu'il comprend les étapes suivantes :
    - obtention d'un moule (1) en sable de silice qui comprend une cavité principale (2) qui peut être remplie de métal fondu pour que soit obtenue une pièce coulée et au moins une cavité auxiliaire (9) qui présente une géométrie qui est configurée pour permettre l'insertion d'une base de masselotte (7) ;
    - obtention d'une base de masselotte (7) ayant une composition en matériau isolant et/ou exothermique, qui comprend une cavité intérieure (8) pour recevoir un métal fondu depuis une masselotte d'alimentation (10) et une géométrie extérieure qui permet l'insertion d'une base de masselotte (7) dans ladite cavité auxiliaire (9) du moule (1) ;
    - insertion de la base de masselotte (7) dans la cavité auxiliaire (9) du moule (1), de telle façon que la cavité intérieure (8) de la base de masselotte (7) soit en communication avec la cavité principale (2) du moule (1) ;
    - le placement d'une masselotte d'alimentation (10) sur la base de masselotte (7), de telle façon que l'intérieur de la masselotte (7) soit en communication avec la cavité intérieure (8) de la base de masselotte (7).
  10. Méthode selon la revendication 9, dans lequel la base de masselotte comprend une composition isolante ou exothermique qui comprend des microsphères creuses en un silicate d'aluminium et un liant, les microsphères creuses ayant une teneur en alumine égale ou inférieure à 38 % en poids.
  11. Méthode selon la revendication 10, dans lequel le silicate d'aluminium a une teneur en alumine de 20 à 38 %.
  12. Méthode selon l'une quelconque des revendications 10 et 11, dans lequel la base de masselotte comprend des charges non fibreuses, choisies dans le groupe formé par les métaux oxydables, les oxydants et les fondants fluorés inorganiques.
  13. Méthode selon l'une quelconque des revendications 10 à 12, dans lequel la composition isolante et/ou exothermique comprend des liants de durcissement en boîte froide ou chaude.
  14. Méthode selon l'une quelconque des revendications 9 à 13, dans lequel la géométrie extérieure de la base de masselotte et la géométrie intérieure de la cavité auxiliaire du moule ont une forme prismatique, en pyramide tronquée, cylindrique ou semi-sphérique.
EP14745172.8A 2014-05-19 2014-05-19 Moule en sable, dispositif de moulage composé d'une base de masselotte insérable et du moule en sable et procédé permettant d'obtenir le dispositif de moulage Active EP3147046B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PT147451728T PT3147046T (pt) 2014-05-19 2014-05-19 Molde de areia, dispositivo de moldação que consiste numa base do massalote inserível e o molde de areia e o método para produzir o dispositivo de moldação

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/ES2014/070411 WO2015177384A1 (fr) 2014-05-19 2014-05-19 Base de masselotte insérable, moule en sable, dispositif de moulage composé de la base de masselotte insérable et du moule en sable, et procédé permettant d'obtenir le dispositif de moulage

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Publication Number Publication Date
EP3147046A1 EP3147046A1 (fr) 2017-03-29
EP3147046B1 true EP3147046B1 (fr) 2020-02-12

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Country Status (8)

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US (1) US20170080483A1 (fr)
EP (1) EP3147046B1 (fr)
CN (1) CN107073562A (fr)
CA (1) CA2951268A1 (fr)
ES (1) ES2802262T3 (fr)
PT (1) PT3147046T (fr)
RU (1) RU2016145110A (fr)
WO (1) WO2015177384A1 (fr)

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CN105983663B (zh) * 2016-06-29 2018-07-27 马鞍山奥特佳机电有限公司 冒口带有保温套的汽车空调压缩机动、静盘浇注装置
CN113458338B (zh) * 2021-06-30 2022-07-05 洛阳航辉新材料有限公司 一种钛合金铸造用冒口的制备方法
TWI823196B (zh) * 2021-11-26 2023-11-21 財團法人金屬工業研究發展中心 自動生成冒口之系統與方法

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CN203281809U (zh) * 2013-05-09 2013-11-13 江苏力源金河铸造有限公司 一种铸件冒口结构

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Publication number Publication date
EP3147046A1 (fr) 2017-03-29
CA2951268A1 (fr) 2015-11-26
US20170080483A1 (en) 2017-03-23
WO2015177384A1 (fr) 2015-11-26
CN107073562A (zh) 2017-08-18
PT3147046T (pt) 2020-06-17
RU2016145110A (ru) 2018-05-17
ES2802262T3 (es) 2021-01-18

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