EP3456437B1 - Procédé de fabrication d'un corps moulé en un matériau métallique pourvu de pores remplis de gaz coulé sous pression avec un procédé à chambre chaude - Google Patents

Procédé de fabrication d'un corps moulé en un matériau métallique pourvu de pores remplis de gaz coulé sous pression avec un procédé à chambre chaude Download PDF

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Publication number
EP3456437B1
EP3456437B1 EP17191916.0A EP17191916A EP3456437B1 EP 3456437 B1 EP3456437 B1 EP 3456437B1 EP 17191916 A EP17191916 A EP 17191916A EP 3456437 B1 EP3456437 B1 EP 3456437B1
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EP
European Patent Office
Prior art keywords
casting
mold cavity
molded body
melt
metallic material
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Application number
EP17191916.0A
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German (de)
English (en)
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EP3456437A1 (fr
Inventor
Paul Jens
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.)
Hzd Druckguss Havelland GmbH
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Hzd Druckguss Havelland GmbH
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Priority to EP17191916.0A priority Critical patent/EP3456437B1/fr
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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
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/02—Hot chamber machines, i.e. with heated press chamber in which metal is melted
    • B22D17/04—Plunger machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/32—Controlling equipment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002—Castings of light metals
    • B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • B22D25/005—Casting metal foams

Definitions

  • the invention relates to a method for producing a shaped body with gas-filled pores from a metallic material by means of hot chamber pressure casting.
  • Die-casting processes are used to produce moldings using a die-casting machine.
  • the cold chamber and hot chamber methods are known.
  • the die-casting machine and the furnace for providing the melt of the metallic material are always arranged separately.
  • the required amount of melt is dosed into the mold chamber of the die casting mold manually or automatically using a dosing furnace or scooping device.
  • the hot chamber process the melt is pressed into a warm die casting mold with a mold cavity.
  • a construction is provided that connects the furnace with the die-casting mold and is often called a casting vessel.
  • the die casting machine and holding furnace form one unit.
  • the document discloses the cold chamber method DE 10 2013 103 672 A1 a method for die-casting molded bodies having pores filled with gas from a die-cast alloy.
  • the liquid die-cast alloy is pressed together with the gas into a mold cavity which has a negative shape of the molded body.
  • the gas and the die-cast alloy are enclosed together in a casting cylinder without prior mixing.
  • a casting piston is advanced into the casting cylinder at such a high speed that the gas and the liquid die-cast alloy mix by the time they enter the mold cavity at the latest.
  • the casting piston is to be advanced in the casting cylinder at a speed selected in such a way that a turbulent flow of gas and liquid die-casting alloy is formed in the casting cylinder.
  • a pore-free die casting process and a device for carrying out the process are known.
  • Various measures are proposed to reduce pore formation in a die-casting hot chamber process. This includes, for example, flushing the mold cavity with a reactive gas.
  • the mold cavity is intended to be filled by a gooseneck and a mouthpiece, whereby in order to reduce the formation of pores, it is provided that non-reactive gas from the gooseneck and the mouthpiece is displaced by the casting material.
  • the object of the invention is to provide a method for producing a molded body with gas-filled pores from a metallic material by means of hot chamber pressure casting, which method enables molded bodies with a modified pore structure to be produced.
  • a method for producing a molded body with gas-filled pores from a metallic material by means of hot chamber pressure die casting in which a pressure die with a mold cavity is provided which has a negative shape of a molded body to be produced.
  • the mold cavity is filled with a melt of a metallic material, the mold cavity being filled up to the end of the mold via a gate which is arranged between the mold cavity and a casting chamber. After the metallic material has solidified in the mold cavity, the molded body is removed from the die-casting mold.
  • the formation of a pore structure with gas-filled pores in the molded body is promoted and supported by the production of the molded body in the mold cavity free of a holding pressure phase or with a shortened holding pressure phase that is shorter than a solidification time of the melt in the gate.
  • a molded body with a closed pore structure is produced, in which the pores are gas-filled, in particular in the form of air pockets.
  • a closed-cell metal foam can be produced from which the shaped body is then formed.
  • Omitting or shortening the holding pressure phase customary in hot chamber die casting supports and promotes the formation of the gas-filled pores in a targeted manner in such a way that they enlarge.
  • the method proposed here specifically reinforces such casting defects in order to form the pore structure. Since the holding pressure phase is omitted or significantly shortened, the compression of the air inclusions is reduced or omitted, whereby the formation of the pore structure is promoted. If the holding pressure phase is used after filling the mold cavity, this can be shortened so that it ends in the gate before the melt solidifies. As a result, the briefly strongly compressed gas pores can partially relax again and press part of the poured melt back into the gate back into the casting chamber.
  • the previously applied casting pressure can remain at the same level as in an immediately preceding time segment of the filling.
  • the casting pressure is only maintained for a short time in order to then reduce it completely.
  • the shortened holding pressure phase can extend over a period of approximately 0.01 s to approximately 0.6 s.
  • the shortened holding pressure phase can extend over a period of approximately 0.1 s to approximately 0.3 s.
  • the gas-filled pores of the pore structure can be produced with the same pore size.
  • a majority of the pores (> 50%) can have a pore size of about 0.0mm to about 5mm
  • the gas-filled pores of the pore structure can be produced in accordance with a uniform pore distribution.
  • a zinc alloy, a magnesium alloy or an aluminum alloy can be used as the metallic material.
  • the zinc alloy ZnAl 4 Cu 1 can be processed.
  • the melt is free of turbulent flows in a first phase and, in a second phase, which follows the first phase, is introduced into the mold cavity with partial formation of turbulent flows.
  • the pore structure can be produced so as to completely cover a body volume of the shaped body.
  • Fig. 1 shows a schematic representation of an arrangement for hot chamber die casting.
  • a casting chamber 1 is arranged in a melting furnace 2.
  • a die casting mold 3 has a mold cavity 4 which is formed with a negative mold of a molded body 5 to be produced.
  • the melt of the metallic material for example a zinc melt, runs through filling bores 6 into the mold cavity 4.
  • the melt flows into the die casting mold 3 via risers 8 and nozzles 9.
  • the melt flows into the mold cavity 4 via distributors, channels and gates.
  • Fig. 1a shows the arrangement before the start of the casting process, the die casting mold 3 being open. According to Fig. 2 the die 3 is then closed to form the mold cavity 4, and the melt is introduced into the mold cavity 4. After solidification, the shaped body 5 can according to FIG Figure 1c demolded and ejected.
  • Fig. 2 shows a graphical representation for pressure and velocity curves of the casting piston.
  • the filling of the mold cavity 4 is usually divided into three phases.
  • a first phase the melt is slowly conveyed through distributors and channels until shortly before the gate in order to reduce turbulence (duration, for example, 0.5 to 1.0 s).
  • a second phase the mold cavity 4 is filled as quickly as possible in order to achieve complete mold filling with as little cold flow as possible (for example 5 to 50 ms).
  • the metallic material can no longer flow and the casting piston 7 stops abruptly.
  • This is known as a form filling (FFE).
  • Casting gases such as air, outgassing melt and / or evaporating Release agents are pressed together by the high, specific casting pressure and experience an enormous reduction in volume.
  • the specific casting pressure is, for example, 250 to 450 bar and is achieved by reducing the hydraulic system pressure from, for example, 100 to 150 bar.
  • the casting piston 7 remains under full casting pressure for, for example, 0.3 to 1.0 s. This time is called the holding pressure time (tN).
  • tN holding pressure time
  • the melt experiences a change in density, for example from 6.3 to 6.7 g / cm 3 in the case of a zinc melt, for example ZnAl 4 Cu 1 . This is accompanied by volume deficits, shrinkage porosity and / or the formation of cavities.
  • melt is replenished to a certain extent and the resulting shrinkage porosity is reduced.
  • the gate of the shaped body 5 has completely solidified, no further feeding is possible.
  • the remaining shrinkage porosity which takes place mainly in thick-walled, ultimately solidifying areas, cannot be compensated.
  • the holding pressure phase acts with full machine system pressure at least until the gate has completely solidified (see pressure curve I in Fig. 2 ).
  • the shaped body is produced by deliberately setting the holding pressure time (too) short so that the The holding pressure phase is specifically canceled as soon as the machine system pressure is generally full for a short time.
  • the time at which the holding pressure phase is interrupted can vary slightly depending on the cast part, but is usually always shortly before or shortly after the FFE is reached (see pressure curve II in Fig. 2 ).
  • the foam structure (pore structure) of the molded body achieved in this way generally has a relatively uniform size and distribution of pores.
  • the high flow velocity of the second phase creates a turbulent flow.
  • the casting gases are finely distributed and evenly mixed with the melt.
  • Due to the missing or almost missing holding pressure time the pores are not compressed at all or are compressed only very briefly.
  • the internal pressure of the pores is much closer to atmospheric pressure than to the specific casting pressure, which is why the pores take up a relatively large volume and thus form a foam structure.
  • the absolute amount of air (measured in grams) in a conventional die-cast part and in a die-cast part produced using the method described here is identical. Only the internal pressure of the pores or their degree of compression and thus their volume are different.
  • Fig. 3 shows moldings produced by means of hot chamber die casting in cross section for comparison (above: conventional method; below: method without / with a shortened holding pressure phase).
  • the short pressure impulse of the full machine system pressure ensures that the melt, for example a zinc melt, is pressed once hard against the shaping contour. This achieves good imaging accuracy and filling of thin areas.

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

Claims (7)

  1. Procédé de fabrication d'un corps moulé (5) pourvu de pores remplis de gaz en un matériau métallique au moyen d'un moulage sous pression à chambre chaude, comportant les étapes suivantes :
    - fourniture d'un moule de moulage sous pression (3) pourvu d'une cavité de moule (4) qui a une forme négative d'un corps moulé (5) à fabriquer ;
    - remplissage de la cavité de moule (4) avec une masse fondue d'un matériau métallique, la cavité de moule (4) étant remplie jusqu'à la fin de remplissage du moule par l'intermédiaire d'une ouverture, qui est disposée entre la cavité de moule (4) et un corps moulé (1), et la masse fondue étant amenée dans une première phase sans écoulement turbulent juste avant l'ouverture et étant introduite dans une deuxième phase, qui suit la première phase, avec formation partielle d'écoulements turbulents dans la cavité de moule (4) ;
    - solidification du matériau métallique dans la cavité de moule (4) ; et
    - démoulage du corps moulé (5) du moule de moulage sous pression (3) ;
    la formation d'une structure de pores pourvue de pores remplis de gaz dans le corps moulé (5) étant favorisée en ce que la fabrication du corps moulé (5) dans la cavité de moule (4) est exécutée sans phase de pression de maintien ou avec une phase de pression de maintien raccourcie qui est plus courte qu'un temps de solidification de la masse fondue dans l'ouverture.
  2. Procédé selon la revendication 1, caractérisé en ce que la phase de pression de maintien raccourcie s'étend sur une période d'environ 0,01 s à environ 0,6 s.
  3. Procédé selon la revendication 2, caractérisé en ce que la phase de pression de maintien raccourcie s'étend sur une période d'environ 0,1 s à environ 0,3 s.
  4. Procédé selon au moins l'une des revendications précédentes, caractérisé en ce que les pores remplis de gaz de la structure de pores sont fabriqués en ayant la même taille de pores.
  5. Procédé selon au moins l'une des revendications précédentes, caractérisé en ce que le corps moulé (1) est complètement rempli de matière fondue avant que la cavité de moule (4) ne commence à se remplir.
  6. Procédé selon au moins l'une des revendications précédentes, caractérisé en ce qu'un alliage de zinc, un alliage de magnésium ou un alliage d'aluminium est utilisé comme matériau métallique.
  7. Procédé selon au moins l'une des revendications précédentes, caractérisé en ce que la structure de pores est fabriquée en capturant complètement un volume corporel du corps moulé (5).
EP17191916.0A 2017-09-19 2017-09-19 Procédé de fabrication d'un corps moulé en un matériau métallique pourvu de pores remplis de gaz coulé sous pression avec un procédé à chambre chaude Active EP3456437B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP17191916.0A EP3456437B1 (fr) 2017-09-19 2017-09-19 Procédé de fabrication d'un corps moulé en un matériau métallique pourvu de pores remplis de gaz coulé sous pression avec un procédé à chambre chaude

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP17191916.0A EP3456437B1 (fr) 2017-09-19 2017-09-19 Procédé de fabrication d'un corps moulé en un matériau métallique pourvu de pores remplis de gaz coulé sous pression avec un procédé à chambre chaude

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EP3456437A1 EP3456437A1 (fr) 2019-03-20
EP3456437B1 true EP3456437B1 (fr) 2021-03-10

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EP17191916.0A Active EP3456437B1 (fr) 2017-09-19 2017-09-19 Procédé de fabrication d'un corps moulé en un matériau métallique pourvu de pores remplis de gaz coulé sous pression avec un procédé à chambre chaude

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Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4085791A (en) * 1976-01-26 1978-04-25 International Lead Zinc Research Organization, Inc. Method of pore-free die casting
DE102006010084B3 (de) * 2006-02-24 2007-05-03 Oskar Frech Gmbh + Co. Kg Beheizbare Dosiereinrichtung für eine Warmkammer-Druckgießmaschine
DE102013103672A1 (de) 2013-04-11 2014-10-30 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Poren-Druckguss

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
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