EP3941662B1 - Method for transporting a melt and method for casting a melt - Google Patents

Description

The invention relates to a method for transporting melt and a method for casting melt.

The DE 10 2007 011 253 A1 discloses a casting device with a melt container for metallic materials. An injector, which has an opening for discharging the melt, is arranged on the underside of the melt container. Furthermore, a closing device is formed, which is used to close the opening.

More such casting devices with an injector are from EP 3 274 113 B1 and from the DE 10 2009 004 613 A1 known. Also, in one Master's thesis "Classification and characterization of process-related casting defects in an innovative permanent mold casting process", published in February 2014 Such a casting device with an injector and a casting method that can be carried out with it were disclosed at the Montanuniversität Leoben.

The ones from the DE 10 2007 011 253 A1 known pouring device has the disadvantage that the closing device can become dirty, as a result of which its tightness can no longer be guaranteed after some use. The casting device or the casting method also has the disadvantage that the flow behavior or the flow rate of the melt during casting can only be inadequately controlled by the described design of the closing device. The casting device or the casting method also has the disadvantage that due to the positioning of the closing device above the lance, the melt impacts the mold at a great height, which can damage the mold. In addition, the large drop height can cause turbulence and thus oxide inclusions in the casting. This all leads to the production of inferior castings.

More casting devices are from JP H10 314920A , the JP 2000 042723 A , the EP 1 428 599 A1 , the DE 10 78 743 B , the U.S. 6,332,357 B1 and the U.S. 3,767,090 A known. The JP H11 33696 A discloses another casting device.

The object of the present invention was to overcome the disadvantages of the prior art and to provide a method by means of which improved cast workpieces can be produced.

This object is solved by a method according to the claims.

A melt transport device is provided for carrying out the method. The melt transport device comprises a melt container in which a melt receiving space is formed and a spout which is coupled to the melt container, the spout having a spout opening which is flow-connected to the receiving space. A gas valve is arranged in the melt container, which is flow-connected to the melt receiving space and which is designed for the regulated entry of gas into the melt receiving space. In particular, it can be provided that the gas valve is arranged above a maximum filling level.

Furthermore, in a first embodiment of the invention it is provided that a siphon is formed in the spout, which has a reservoir which is arranged between the melt receiving space and the spout opening, the reservoir having an overflow level, a siphon wall being formed which has a siphon wall lower edge , wherein the siphon wall protrudes into the reservoir in such a way that a lower edge of the siphon wall is arranged at a lower level than the overflow level. In particular, it can be provided that the highest point of the lower edge of the siphon wall is arranged at a lower level than the lowest point of the overflow level.

In other words, the siphon wall is designed such that it protrudes into the reservoir in such a way that when the reservoir is filled with melt up to an overflow level, the melt receiving space is sealed gas-tight to the outside of a melt container.

The overflow level in the sense of this document is the level from which the melt can flow out of the reservoir and subsequently out of the pouring opening due to the influence of gravity.

Alternatively or additionally, a second embodiment of the invention provides for a sieve to be arranged in the spout, which has a mesh size between 0.05 mm and 10 mm.

A pouring channel in the area of the sieve or in the area of the siphon can have a diameter between 5 mm and 200 mm, in particular between 10 mm and 100 mm, preferably between 20mm and 80mm. Thus, despite a large diameter of the pouring channel, and thus a high flow rate that can be achieved, the melt can be prevented from escaping by means of the negative pressure in the melt receiving space.

The embodiment variants according to the invention both have the surprising advantage that no mechanical closure is required to prevent the melt from escaping, which is arranged in the area of the melt, but rather that a negative pressure can be applied in the melt receiving space, which prevents the melt from escaping from the melt transport device can. Adequate leakage protection can thus be achieved at all times, since there is no mechanical seal in the area of the melt that could cause contamination. In addition, in the embodiment of the melt transport device according to the invention, in contrast to the exemplary embodiments known from the prior art, the fall height of the melt can be kept as low as possible, which enables the melt to be poured into a mold in a calm manner. In addition, the outflow rate or the outflow behavior of the melt can be precisely controlled by means of the gas valve.

Both embodiment variants according to the invention are based on the same inventive principle. This inventive principle is that the ambient pressure, in particular the atmospheric pressure, acts on a first melt surface on the part of the pouring opening and in the melt receiving space of the melt container a melt receiving space internal pressure acts on a second melt surface, the melt space internal pressure being lower than the ambient pressure. The internal pressure in the melt space can therefore also be referred to as negative pressure. As a result of this negative pressure, the level of the second melt surface can be kept higher than the level of the first melt surface, as a result of which the melt can be prevented from escaping from the melt receiving space.

In the first embodiment variant according to the invention, an actual fill level can be kept higher than the overflow level of the reservoir as a result of the negative pressure. If the negative pressure ceases and the pressure between the internal pressure of the melt receiving space and the ambient pressure is equalized, the melt would run off over the overflow level of the reservoir until the actual filling quantity level is the same as the overflow level of the reservoir. The pressure difference between the ambient pressure and the internal melt receiving space pressure determines the height of the column of melt above the overflow level of the reservoir.

In the second embodiment of the invention, the pressure difference between the ambient pressure and the internal pressure of the melt receiving space also determines the height of the column of melt, with the first melt surface being formed directly on the screen.

In a melt transport device, as in the DE 10 2007 011 253 A1 is described, the melt runs out of the spout even when a negative pressure is applied in the melt receiving space. This is due to the fact that the spout opening or spout channel in the spout must have a minimum diameter of around 20 mm to ensure an effective flow volume. If a negative pressure were now applied in the melt receiving space in such an embodiment variant, the above-described physical effect of the counter-pressure on the first melt surface could indeed be used purely theoretically. In reality, however, the surface tension of the melt is too low, so that due to the large pouring opening, a local melt drop forms and drips off. Air can get into the discharge channel as a result of these melt drops dripping off, as a result of which the physical operating principle of the back pressure is destroyed and the melt sooner or later runs out of the melt receiving space.

Only through the two embodiments according to the invention can a stable first melt surface be achieved through which the described physical effect of the negative pressure in the melt receiving space can be used.

In the first embodiment, in which a siphon is formed, the effect of the stable first melt surface is achieved in that the first melt surface is aligned horizontally through the siphon and the ambient pressure can act on the first melt surface from above. Thus, the first melt surface is maintained by the action of gravity and is not disturbed.

In the second embodiment, the use of the screen results in the formation of individual small openings, each of which has the required mesh size. The atmospheric ambient pressure thus acts on each of these individual small openings, with the surface tension of the melt being large enough on the individual small openings of the sieve to prevent a drop from forming, which can drip off. Thus, the melt can be successfully prevented from escaping from the melt transport device solely by means of the screen and even without the presence of the additional siphon.

Of course, it is also conceivable that an additional sieve is arranged elsewhere in the spout channel, for example to be able to filter out impurities.

When using a sieve as a leak guard, the mesh size of the sieve is selected in such a way that the surface tension of a melt to be received in the melt receiving space, together with the atmospheric counter-pressure, prevents the formation of a drippable drop. Based on current knowledge, this is the case with a mesh size between 0.05mm and 10mm, depending on the type of melt. The claimed mesh size was therefore chosen as structural equivalence for the aspect of the invention. However, if a mesh size outside of these limits for a composition that has not yet been examined is also based on the same aspect of the invention, such an embodiment variant is also covered by the patent claims. The mesh size to be selected depends on the viscosity properties and the surface tension of the melt.

A screen within the meaning of this document can be a screen, which is formed from a metallic material, as in the DE 20 2006 002 897 U1 or in the EP2270248A2 is described. The screen can also be made of a ceramic material, as described in US Pat DE 2848005 A1 is described, be formed.

The screen within the meaning of this document can have a lattice structure, through which the mesh size is formed in a regular pattern. As an alternative to this, the sieve can also be formed by a porous structure, such as a sponge-like structure.

Furthermore, it can be expedient if the maximum filling level is between 20 mm and 3000 mm, in particular between 100 mm and 2000 mm, preferably between 300 mm and 1000 mm above the overflow level. Particularly in the case of a melt transport device designed in this way, good leakage protection of the melt can be achieved by means of the negative pressure that can be achieved in the melt receiving space.

Furthermore, it can be provided that the spout is designed as a lance and the siphon and/or the sieve is arranged on an underside of the lance. Such an embodiment variant has the advantage that the height of fall of the melt into the mold can be kept as low as possible, whereby on the one hand a settled casting can be achieved and on the other hand washing out of molding sand can be prevented as far as possible. Such a lance can be inserted directly into the mold, for example.

In addition, it can be provided that the sieve is arranged in the spout in such a way that the top side of the sieve faces the melt receiving space and the bottom side of the sieve faces the spout opening or forms the end of the spout opening, with the bottom side of the sieve lying in a horizontal plane. In particular with such an arrangement of the screen, the formation of drops can be effectively prevented, as a result of which good functionality of the melt transport device can be achieved. With such an arrangement of the sieve, the formation of drops is prevented in particular by the fact that a drop located at an individual sieve opening remains centrally at this sieve opening and is not shifted laterally to the sieve opening by gravity, where it would combine with another droplet from another sieve opening.

Also advantageous is an embodiment according to which it can be provided that the sieve has a mesh size between 0.1 mm and 2 mm, in particular between 0.3 mm and 1.5 mm, preferably between 0.4 mm and 0.8 mm. Mesh sizes in the specified range in particular can serve as well as possible to prevent droplets from forming on the screen. The mesh size in the sense of this document is the distance between the walls delimiting the screen opening.

According to one development, it is possible for a magnetic element to be arranged on the spout, which is designed to apply a magnetic field to the melt flowing in the spout. This measure allows a magnetic force to be applied to the melt, which allows a force to be applied to the melt. In this way, for example, the melt can be slowed down as it flows out.

Furthermore, it can be expedient if the magnetic element is designed as an electromagnet which has a coil which at least partially surrounds the spout. It is particularly advantageous if the magnetic force is generated by means of an electromagnet. This brings with it the advantage that the magnetic field is selectively applied and removed again can be. In addition, the effective direction of the magnetic field can be influenced by means of an electromagnet.

Provision can also be made for direct current to be applied to the electromagnet.

As an alternative to this, it can be provided that the electromagnet is acted upon by alternating current.

Furthermore, it can be provided that the melt comprises aluminum or an aluminum alloy. Since aluminum is paramagnetic, a magnetic effect on the melt can be achieved with this material.

In addition, it can be provided that the gas valve is designed as a valve block that includes at least two individual valves. The gas supply into the melt receiving space can be precisely controlled, in particular by means of a valve block with several individual valves, as a result of which the melt can be discharged precisely.

Furthermore, it can be provided that the valve block comprises at least four individual valves, with at least two of the individual valves having different characteristic data from one another, with the individual valves being coupled to an electronic digital computer, by which they are controlled, with the individual valves being opened independently of one another individually or also simultaneously so that different flow rates can be set. As a result, the accuracy of the gas introduction into the melt receiving space can be further improved.

Furthermore, it can be expedient if the valve block comprises between 8 and 20 individual valves, in particular between 11 and 15 individual valves, of different sizes. The advantage here is that with such a number of individual valves, the flow rate can be adjusted as steplessly as possible and, moreover, the valve block can still have a manageable size or the complexity and also the maintenance intensity can be kept within limits due to the limited number of individual valves can.

Furthermore, it can be provided that the individual valves are designed in the form of slide valves. The advantage here is that such slide valves have an exact switching behavior and thus the air flow rate can be set exactly using slide valves.

In addition, it can be provided that the individual valves are designed in the form of digitally controlled valves. The advantage here is that digitally controlled valves can be controlled directly by the electronic digital computer and can therefore have very short switching times or reaction times.

According to a special embodiment, it is possible for a second melt receiving space to be formed in the melt container, which is flow-connected to the spout. This measure allows two different melts, such as two different alloys, to be received in the individual receiving spaces and to be mixed with one another in the spout or to be poured out at different times.

According to an advantageous development, it can be provided that the spout has a coupling in the area of the spout opening, by means of which the spout can be coupled to a casting mold and/or a melting furnace. Such a coupling has the advantage that a clean connection can be established between the melt transport device and the mold or the melting furnace, as a result of which contamination of the melt transport device by the melt can be prevented as far as possible.

In particular, it can be advantageous if the spout has two or more spout openings, by means of which several molds can be filled at the same time.

Furthermore, of course, it can also be provided that a single mold is filled using a plurality of pouring openings. Thus, the melt can flow from the plurality of pouring openings into the mold cavity of the mold at the same time. As a result, on the one hand, the filling speed can be increased and, on the other hand, a uniform and steady inflow of the melt into the mold cavity of the casting mold can be achieved.

Furthermore, it can be provided that a closable drain opening is formed at the lowest point of the reservoir. The residual melt remaining in the reservoir can be drained through such a drain opening after the casting process. This can prevent the residual melt in the reservoir from solidifying, which would damage the melt transport device.

Furthermore, it can be provided that a heating device is formed, which is arranged in the area of the spout and/or in the area of the melt receiving space. The heating device has the advantage that the melt can be kept warm in the melt transport device, so that unwanted solidification of the melt in the melt transport device can be prevented.

Furthermore, it can be provided that a filling level sensor is formed, which is used to detect the filling quantity actual level. Such a sensor has the advantage that the filling process can be precisely controlled.

The filling level sensor can, for example, be arranged outside the melt container, with a window that is permeable for the waves of the filling level sensor being able to be formed in the melt container. In particular, it can be provided that the filling level sensor is designed as a radar probe. As an alternative to this, it is also conceivable for the level sensor to be in the form of some other non-contact sensor.

Furthermore, it can be provided that the melt transport device comprises a weighing device, such as a weighing cell, for determining the filling volume in the melt receiving space. The weighing cell can be arranged, for example, on the suspension of the melt container.

Furthermore, it can be provided that a pressure detection means is formed, which is used to detect the internal pressure in the melt receiving space.

All sensors and valves can be coupled to a central processing unit, by means of which the casting process can be controlled.

• eine Schmelzetransportvorrichtung, insbesondere eine Schmelzetransportvorrichtung nach einem der vorhergehenden Ansprüche;
• eine Gussform;
• ein Grundgestell zur Aufnahme der Gussform.

Outside the scope of the invention, a casting device is formed. The casting device includes:

• a melt transport device, in particular a melt transport device according to one of the preceding claims;
• a mold;
• a base frame to hold the mold.

Furthermore, it can be provided that the base frame includes a rotation device, by means of which the mold can be rotated about an axis of rotation. This brings the benefit that the melt can be introduced into the center of the mold by means of the melt transport device and can be distributed in the mold by rotating it.

In addition, it can be provided that the casting device is designed as a low-pressure casting device or as a counter-pressure casting device, with a riser tube being designed as a flow connection element between a receiving space of a furnace and a mold cavity of the casting mold, with the casting mold having a first sprue and a second sprue, with the riser tube opens into the first sprue and the second sprue is designed for pouring in a melt by means of the melt transport device. This design makes it possible to introduce two different melts with a different composition into the mold.

Furthermore, it can be provided that the casting device also has a squeeze-casting function. This means that when the melt is filled into the cavity, the volume of the melt can be compressed in a further step by applying pressure to one or more areas in the cavity. For example, it is advantageous if pins are pressed hydraulically into the melt volume. It can also be advantageous if larger areas of the tool parts forming the cavity are used to apply pressure. For example, a tool part that is moved to remove the cast part can also be used relative to a second tool part for squeezing, ie for pressure build-up.

• bereitstellen der Schmelzetransportvorrichtung;
• befüllen des Schmelzeaufnahmeraumes der Schmelzetransportvorrichtung, wobei während dem Befüllen des Schmelzeaufnahmeraumes das Gasventil geöffnet ist;
• beenden des Befüllvorganges und verschließen des Gasventiles, wenn im Schmelzeaufnahmeraum ein Füllmengenistniveau gleich mit einem Füllmengensollniveau ist;
• transportieren der Schmelzetransportvorrichtung von einer Befüllposition zu einer Gießposition, wobei während des Transportes der Schmelzetransportvorrichtung im Schmelzeaufnahmeraum ein Unterdruck anliegt, wobei ein Auslaufen der Schmelze aus der Ausgussöffnung durch den Unterdruck in Zusammenwirken mit dem Umgebungsdruck unterbunden wird.

According to the invention, a method for transporting melt in a melt transport device is provided. The process comprises the process steps:

• providing the melt transport device;
• filling the melt receiving space of the melt transport device, the gas valve being open during the filling of the melt receiving space;
• ending the filling process and closing the gas valve when an actual filling quantity level in the melt receiving space is equal to a nominal filling quantity level;
• transporting the melt transport device from a filling position to a casting position, with a negative pressure being present in the melt receiving space during the transport of the melt transport device, with the melt being prevented from escaping from the pouring opening by the negative pressure in conjunction with the ambient pressure.

The method according to the invention has the advantage that the melt can be transported easily, with the melt transport device having a simple structure.

According to the invention, it is also provided that when filling the melt receiving space of the melt transport device, first a melt of a first composition is picked up and then a melt of a second composition is picked up, the melt of the second composition having different physical or chemical properties to the melt of the first composition, in particular a higher one density. This has the advantage that different melts with a different composition can be received in the melt receiving space of the melt transport device. As a result, the different melts can be cast separately from one another in terms of time, and castings with locally different properties can thus be cast.

Furthermore, it can be provided that after the filling of the melt receiving space of the melt transport device, the melt remains in the melt receiving space for a predetermined period of time, with the melt settling in the melt receiving space, with a melt of a first composition and a melt of a second composition being formed in a layer in the melt receiving space, wherein the melt of the second composition has different physical properties to the melt of the first composition, in particular a higher density. This measure allows homogeneous melts to be separated, so that the different melts can be cast separately from one another in terms of time, and castings with locally different properties can thus be cast.

Furthermore, it can be provided that the melt transport device is rotated so that the settling process is accelerated under the action of the centrifugal force.

Also advantageous is an embodiment according to which it can be provided that when the melt transport device is provided, the melt receiving space is filled with an inert gas, in particular with nitrogen. By this measure, a reaction of the melt received in the melt receiving space with the gas can be avoided, as a result of which, for example, slag formation can be suppressed as far as possible. Nitrogen in particular is easy to produce and has no harmful effects on the body Environment at the outflow. As an alternative to nitrogen, it is also possible to use argon as the inert gas.

According to one development, it is possible for the melt receiving space to be evacuated by means of a vacuum pump in order to fill the melt receiving space of the melt transport device, as a result of which the melt is drawn into the melt receiving space. This brings with it the advantage that the melt can be actively drawn into the melt receiving space, as a result of which the melt can be drawn into the receiving space from a lower-lying melting furnace. A further advantage here is that the necessary pressure for holding the melt column is already generated in the melt receiving space, which means that the melt level in the melt receiving space does not drop when the melt transport device is lifted out of the melting furnace.

Furthermore, it can be expedient if, in order to fill the melt receiving space of the melt transport device, the pouring opening is coupled to a melting furnace by means of a coupling. Such a coupling has the advantage that a clean connection can be established between the melt transport device and the mold or the melting furnace, as a result of which contamination of the melt transport device by the melt can be prevented as far as possible.

In addition, it can be provided that for filling the melt receiving space of the melt transport device, the discharge opening is coupled to the riser pipe of a low-pressure furnace by means of a coupling, the melt being pressed into the melt receiving space by means of the low-pressure furnace. This measure allows the melt receiving space to be easily filled with melt.

Provision can furthermore be made for the pouring opening to be immersed in a melting furnace in order to fill the melt receiving space of the melt transport device.

According to a special embodiment, it is possible that, in order to fill the melt receiving space of the melt transport device, the discharge opening is coupled to a melting furnace by means of the coupling, which has a furnace filling level that is higher than the nominal filling quantity level, and that the filling process is carried out by controlled venting of gas from the Melt receiving space takes place. This brings with it the advantage that the melt can be brought from the melting furnace into the melt receiving space by the action of gravity without the need for an additional energy application means.

• bereitstellen der Schmelzetransportvorrichtung mit im Schmelzeaufnahmeraum aufgenommener Schmelze, wobei im Schmelzeaufnahmeraum ein Unterdruck anliegt und ein Auslaufen der Schmelze aus der Ausgussöffnung durch den Unterdruck in Zusammenwirken mit dem Umgebungsdruck unterbunden wird;
• ablassen der Schmelze aus der Schmelzetransportvorrichtung durch öffnen des Gasventiles zum kontrollierten einbringen von Gas in den Schmelzeaufnahmeraum und verringern des Unterdruckes im Schmelzeaufnahmeraum, wodurch die Schmelze schwerkraftbedingt aus der Ausgussöffnung in eine Gussform strömt.

According to the invention, a method for casting melt by means of a melt transport device is provided. The process comprises the process steps:

• providing the melt transport device with the melt accommodated in the melt receiving space, a negative pressure being present in the melt receiving space and the melt being prevented from escaping from the pouring opening by the negative pressure in conjunction with the ambient pressure;
• draining the melt from the melt transport device by opening the gas valve for the controlled introduction of gas into the melt receiving space and reducing the negative pressure in the melt receiving space, whereby the melt flows out of the pouring opening into a mold due to gravity.

The method according to the invention brings with it the advantage that the melt can be discharged from the melt transport device in an exactly metered manner, as a result of which it is possible to produce high-quality cast workpieces. In addition, the melt can leak under the action of gravity.

In particular, it can be advantageous if, after the melt has been drained, the melt remaining in the reservoir of the siphon is blown out by a gas pressure surge. This brings with it the advantage that the residual melt cannot solidify in the reservoir, as a result of which damage to the melt transport device can be prevented. For this purpose, for example, a compressed air nozzle can be arranged in the pouring channel. Furthermore, it is also conceivable for a large volume of gas to be introduced into the melt receiving space in a short time, so that the melt in the reservoir can be blown out.

Furthermore, it can be provided that when gas is introduced into the melt receiving space in a controlled manner, an inert gas is introduced into the melt receiving space.

In addition, it can be provided that in the case of a gas valve, which is designed as a valve block with several individual valves, the regulation takes place by means of the electronic digital computer, the regulation taking place on the basis of a mathematical model of the melt transport device, the mathematical model of the melt transport device the characteristic data of all individual valves of the valve block are stored. This brings with it the advantage that the gas supply into the melt receiving space can be precisely controlled. According to a further development, it is possible for the individual valves of the valve block to be brought only into the open state or into the closed state in order to regulate the flow rate of the air, and therefore assume exclusively binary states. The advantage here is that this measure means that the flow rates of compressed air in the individual valves are known exactly. Thus, the current flow rate of compressed air can be precisely controlled at any time.

Furthermore, it can be expedient if the individual valves are subjected to an increased overvoltage during the opening process in order to shorten the switching time and are then kept in the open state by being subjected to a lower switching voltage. The advantage here is that the switching times of the individual valves can be shortened as a result of this measure, and highly precise control is thus made possible.

Also advantageous is an embodiment according to which it can be provided that while the melt is being discharged from the melt transport device, a magnetic field is applied to the melt flowing in the spout by means of the magnetic element. This has the advantage that the melt can be slowed down while it is being drained.

According to the invention it is also provided that when the melt is poured into the mold cavity of the casting mold, first a melt of a first composition is poured in and then a second melt of a second composition is poured in. As a result, the finished workpiece can have locally different properties.

In addition, it can be provided that the two melts of different composition are accommodated in layers in the melt receiving space of the melt transport device.

Alternatively, it is conceivable that the first melt of the first composition is introduced into the mold cavity of the mold by means of a riser pipe of a low-pressure casting device or a counter-pressure casting device and that the second melt of the second composition is introduced into the mold cavity of the mold by means of the melt transport device is introduced. This brings with it the advantage that no layering of the melt is necessary in the melt transport device and a workpiece with locally different properties can nevertheless be produced.

Alternatively, it is of course also conceivable that the first melt of the first composition is introduced into the mold cavity of the mold by means of the melt transport device and that the second melt of the second composition is introduced into the mold cavity of the mold by means of the riser pipe of the low-pressure casting device or the counter-pressure casting device. This brings with it the advantage that no layering of the melt is necessary in the melt transport device and a workpiece with locally different properties can nevertheless be produced.

Furthermore, it can be provided that the casting mold is designed to produce a brake disc, with the casting mold being rotated about its axis of rotation while the mold cavity is being filled with melt, so that the first melt of the first composition reaches the disc part of the brake disc and the second melt the second Composition gets into the hub part of the brake disc. Brake discs produced in this way can be adapted to local requirements. For example, the brake disc can have high strength in the disc part and good machinability in the hub part.

In addition, it can be provided that the first melt is an aluminum melt which has a solids content, in particular a silicon carbide content, of between 1% by volume and 40% by volume, in particular between 5% by volume and 35% by volume, preferably between 15% by volume. and 30% by volume. In particular, a melt formed in this way is surprisingly well suited for use in the production of a brake disk.

In particular, it can be provided that the particle sizes of the silicon carbide are between 3 μm and 25 μm, in particular between 4 μm and 20 μm, preferably between 5 μm and 17 μm.

In an alternative embodiment, it can also be provided that the solids content is an aluminum oxide content of between 1% by volume and 40% by volume, in particular between 5% by volume. and 35% by volume, preferably between 15% by volume and 30% by volume. In particular, a melt formed in this way is surprisingly well suited for use in the production of a brake disc.

In particular, it can be provided that the particle sizes of the aluminum oxide are between 3 μm and 25 μm, in particular between 4 μm and 20 μm, preferably between 10 μm and 15 μm.

The melt transport device can also be moved in the operating state and can therefore be moved or transported between different positions. Thus, the melt transport device can also be brought into different orientations or tilted. However, the melt transport device is functional in only one operational orientation, the operational orientation. In particular, a vertical alignment of the melt transport device is seen as the main operational orientation. As already mentioned, however, the operating orientation can still be present even if the melt transport device is tilted by a maximum permissible tilting angle from its vertical alignment.

Orientation references chosen in this document, such as above or below, refer to a melt transport device oriented in its primary operating orientation as shown in the individual figures.

For the purposes of this document, negative pressure is an absolute pressure that is lower than the ambient pressure of the melt transport device. Normally, the melt transport device is set up in a production hall and the ambient pressure corresponds to atmospheric pressure. The atmospheric pressure depends on the ambient conditions and the installation site. In particular, the absolute atmospheric pressure can assume a standard pressure of 1013.25 mbar. Furthermore, it is also conceivable that the melt transport device is operated in a hermetically sealed space and the ambient pressure of the melt transport device is increased or decreased compared to atmospheric pressure.

The overflow level in the sense of this document is that melt level up to which the melt would flow freely out of the melt receiving space in the absence of negative pressure in the melt receiving space.

Furthermore, it is also conceivable that the gas valve is formed in that a piston is coupled to the melt receiving space. Furthermore, it is also conceivable that at least one of the walls delimiting the melt receiving space is designed as a piston.

By moving the piston, the entry of gas into the melt receiving space can be regulated.

Furthermore, it is also conceivable that the mold is designed in such a way that there is a depression in the mold, which is used to accommodate that partial area of the spout which is arranged below the overflow level and also has its shape. As a result, the drop height of the melt at the beginning of the casting process can be kept as low as possible.

For a better understanding of the invention, it is explained in more detail with reference to the following figures.

Fig. 1

eine schematische Schnittdarstellung eines ersten Ausführungsbeispiels einer Schmelzetransportvorrichtung mit einem Siphon;

Fig. 2

eine schematische Schnittdarstellung eines zweiten Ausführungsbeispiels einer Schmelzetransportvorrichtung mit einem Sieb;

Fig. 3

einzelne Verfahrensschritte eines Füllvorganges zum Füllen eines Schmelzeauf-nahmeraumes mit Schmelze;

Fig. 4

einzelne Verfahrensschritte eines alternativen Füllvorganges zum Füllen eines Schmelzeaufnahmeraumes mit Schmelze;

Fig. 5

eine schematische Darstellung eines Eingießvorganges;

Fig. 6

eine schematische Darstellung eines weiteren alternativen Füllvorganges zum Füllen eines Schmelzeaufnahmeraumes mit Schmelze;

Fig. 7

eine schematische Schnittdarstellung eines weiteren Ausführungsbeispiels einer Schmelzetransportvorrichtung mit einer Ablassöffnung;

Fig. 8

eine schematische Schnittdarstellung eines weiteren Ausführungsbeispiels einer Schmelzetransportvorrichtung mit einer Heizvorrichtung;

Fig. 9

eine schematische Schnittdarstellung eines weiteren Ausführungsbeispiels einer Schmelzetransportvorrichtung mit mehreren Ausgussöffnungen;

Fig. 10

eine schematische Schnittdarstellung eines ersten Ausführungsbeispiels einer Schmelzetransportvorrichtung mit einem Siphon und Spritzschutz;

Fig. 11

eine schematische Darstellung eines weiteren alternativen Füllvorganges zum Füllen eines Schmelzeaufnahmeraumes mit Schmelze unter Verwendung eines Niederdruckofens;

Fig. 12

eine schematische Darstellung eines Eingießvorganges in mehrere Gussformen gleichzeitig;

Fig. 13

eine schematische Schnittdarstellung eines weiteren Ausführungsbeispiels einer Schmelzetransportvorrichtung mit mehreren Aufnahmeräumen;

Fig. 14

eine schematische Schnittdarstellung eines weiteren Ausführungsbeispiels einer Schmelzetransportvorrichtung mit einer Lanze;

Fig. 15

eine schematische Schnittdarstellung eines weiteren Ausführungsbeispiels einer Schmelzetransportvorrichtung mit einem Kolben;

Fig. 16

ein Ausführungsbeispiel einer Gießvorrichtung.

They each show in a greatly simplified, schematic representation:

1

a schematic sectional view of a first embodiment of a melt transport device with a siphon;

2

a schematic sectional view of a second embodiment of a melt transport device with a screen;

3

individual process steps of a filling process for filling a melt receiving space with melt;

4

Individual method steps of an alternative filling process for filling a melt receiving space with melt;

figure 5

a schematic representation of a pouring process;

6

a schematic representation of a further alternative filling process for filling a melt receiving space with melt;

7

a schematic sectional view of a further embodiment of a melt transport device with a discharge opening;

8

a schematic sectional view of a further embodiment of a melt transport device with a heating device;

9

a schematic sectional view of a further exemplary embodiment of a melt transport device with a plurality of pouring openings;

10

a schematic sectional view of a first embodiment of a melt transport device with a siphon and splash guard;

11

a schematic representation of a further alternative filling process for filling a melt receiving space with melt using a low-pressure furnace;

12

a schematic representation of a pouring process in several molds at the same time;

13

a schematic sectional view of a further exemplary embodiment of a melt transport device with a plurality of receiving spaces;

14

a schematic sectional view of a further embodiment of a melt transport device with a lance;

15

a schematic sectional view of another embodiment of a melt transport device with a piston;

16

an embodiment of a casting device.

As an introduction, it should be noted that in the differently described embodiments, the same parts are provided with the same reference numbers or the same component designations, it being possible for the disclosures contained throughout the description to be applied to the same parts with the same reference numbers or the same component designations. The position information selected in the description, such as top, bottom, side, etc., is related to the figure directly described and shown and these position information are to be transferred to the new position in the event of a change of position.

1 shows a first embodiment of a melt transport device 1, which is used to transport melt 2.

The melt transport device 1 has a melt container 3 in which a melt receiving space 4 is formed, which serves to receive the melt 2 .

Furthermore, the melt transport device 1 comprises a spout 5 which is coupled to the melt container 3 . The spout 5 can be designed as an integral part of the melt container 3 . Furthermore, it is also conceivable that the spout 5 is designed as a separate component which is coupled to the melt container 3 . The spout 5 has a spout opening 6 through which the melt 2 contained in the melt container 3 can flow out of the melt transport device 1 and into a mold.

The pouring opening 6 can have a circular cross section. Furthermore, it is also conceivable that the pouring opening 6 has a square cross section. In addition, it is also conceivable for the pouring opening 6 to have a rectangular cross section, in which case, in particular, a longitudinal extent of the pouring opening 6 which runs normal to the section plane can have a large extent. For example, the length of the spout opening 6 can be up to 2000 mm, in particular up to 500 mm. This is particularly advantageous in the case of elongated cast workpieces, such as cylinder blocks or cylinder heads.

Of course, this elongated extension of the pouring opening 6 can also be advantageous in the other variants.

Furthermore, a gas valve 7 is formed, which is flow-connected to the melt receiving space 4 and which is designed to regulate the entry of gas into the melt receiving space 4 . The gas valve 7 is arranged above a maximum filling level 8 so that no melt 2 can flow into the gas valve 7 . The maximum fill level is selected so that when the melt container 3 is filled with melt 2 up to the maximum fill level 8 , a gas-filled space remains in the melt receiving space 4 , in which a pressure can be set using the gas valve 7 .

Furthermore, a pressure detection means 9 can be provided, by means of which an internal pressure in the melt receiving space 4 can be detected. The gas pressure in the melt receiving space 4 can thus be adjusted in a targeted manner by the gas valve 7 .

As from the embodiment according to 1 further evident, it can be provided that the melt transport device 1 has a filling level sensor 10 which serves to detect an actual filling quantity level 11 . The actual filling quantity level 11 can thus be continuously recorded and compared with a nominal filling quantity level 12 .

How out 1 further evident, it can be provided that the melt transport device 1 has a siphon 13 which has a reservoir 14 which is arranged between the melt receiving space 4 and the pouring opening 6 . A siphon wall 15 is also formed, which protrudes into the reservoir 14 in such a way that when the reservoir 14 is filled with melt up to an overflow level 17, the melt receiving space 4 is sealed gas-tight with respect to an outside 16 of the melt container. The siphon 13 in the spout 5 is designed in such a way that the reservoir 14 has the overflow level 17 , the siphon wall 15 being designed in such a way that it has a lower edge 41 of the siphon wall. The siphon wall 15 protrudes into the reservoir 14 in such a way that a lower edge 41 of the siphon wall is arranged at a lower level than the overflow level 17.

In 1 the melt container 3 is shown partially filled with the melt 2 . How out 1 As can be seen, the structure described results in a first melt surface 18 which is arranged on the outside 16 of the melt container or is assigned to it. Furthermore, a second melt surface 19 is formed, which is arranged in the melt receiving space 4 of the melt container 3 . The second melt surface 19 corresponds to the actual fill quantity level 11. The ambient pressure of the melt container 3 acts on the first melt surface 18. The internal pressure of the melt receiving space 4 acts on the second melt surface 19.

For the transport of the melt container 3, it can be advantageous if, as in 1 shown, the first melt surface 18 is slightly below the overflow level 17. As a result, spilling of the melt 2 can be avoided in the best possible way. This difference in level can be achieved, for example, by reducing the pressure in the melt receiving space 4 . As an alternative to this, the melt container 3 can be shaken or slightly tilted directly after filling in order to achieve this level difference immediately after the melt container 3 has been filled. Of course, it is also possible for the melt container 3 to be manipulated while the level of the first melt surface 18 is the same as the overflow level 17 .

How out 1 as can also be seen, provision can be made for the spout 5 to be in the form of a lance 20 and for the siphon 13 to be arranged on the underside of the lance 20 .

In the embodiment after 1 For example, the siphon 13 can comprise a container 21 which is open at the top and which is coupled to the spout 5 by means of struts 22 . In this embodiment, an upper edge of the container 21 defines the overflow level 17 at the same time 1 If gas is admitted into the melt receiving space 4 by means of the gas valve 7, the second melt surface 19 lowers, as a result of which the melt 2 located in the melt receiving space 4 runs through a pouring channel 23 into the reservoir 14, whereby the first melt surface 18 rises. The first melt surface 18 rises here until the melt 2 runs out over the overflow level 17 .

Furthermore, it can also be provided that the container 21 , which is open at the top, is arranged on the spout 5 so that it can be changed.

In the 2 a further and optionally independent embodiment of the melt transport device 1 is shown, with the same reference numerals or component designations as in the previous one being used for the same parts 1 be used. To avoid unnecessary repetition, reference is made to the detailed description in the foregoing 1 pointed out or referred to.

The embodiment after 2 basically has a similar structure to the exemplary embodiment 1 on, but instead of the siphon 13 a sieve 24 is arranged in the spout 5. The sieve 24 can also be arranged on the spout 5 so that it can be changed.

The sieve 24 or its possible structure is also in 2 shown in detail. As can be seen from this detailed view, the sieve 24 has a mesh size of 25. The mesh size 25 results from the spacing of the individual screen bars 48 from one another. A large number of screen openings 49 are formed by the individual screen bars 48 .

Furthermore, the screen 24 has a top side 26 of the screen, which faces the melt receiving space 4 , and a bottom side 27 of the screen, which faces the outside 16 of the melt container. In this exemplary embodiment, the first melt surface 18 is formed on the underside 27 of the screen.

In the embodiment after 2 the sieve 24 is arranged directly on the pouring opening 6 . Of course, the sieve 24 can also be arranged within the pouring channel 23 at a distance from the pouring opening 6 .

How out 2 As can also be seen, it can be provided that the gas valve 7 is designed as a valve block 28 which has a plurality of individual valves 29 . In particular, it can be provided that the individual valves 29 of the valve block 28 are configured in a parallel connection to one another. The individual valves 29 formed in the valve block 28 can have a different flow rate from one another, as a result of which different flow rates can be set in the valve block 28 by selectively switching the individual valves 29 . In particular, it can be provided that some of the individual valves 29 have the same characteristic data and that some of the individual valves 29 have different characteristic data from one another.

The design of a valve block 28 can be chosen independently of the design of a screen 24 or a siphon 13 .

In the Figures 3a to 3c a further and possibly independent embodiment of the melt transport device 1 is shown, with the same reference numerals or component designations as in the preceding ones being used for the same parts figures 1 and 2 be used. To avoid unnecessary repetition, reference is made to the detailed description in the foregoing figures 1 and 2 pointed out or referred to.

In the Figures 3a to 3c a possible filling process for filling the melt receiving space 4 with melt 2 is shown schematically.

How out Figure 3a As can be seen, it can be provided that the melt 2 is provided in a melting furnace 30 and that the melt container 3 is positioned above the melting furnace 30 .

How out Figure 3b As can be seen, the melt container 3 can at least partially dip into the melt 2 arranged in the melting furnace 30 in a further method step, so that the pouring opening 6 dips below the furnace fill level 32 of the melt 2 in the melting furnace 30 . If the gas valve 7 is now open or is already open during immersion, the melt 2 can flow into the melt receiving space 4 of the melt container 3 via the pouring opening 6 . This position of the melt container 3 can also be referred to as the filling position 31 .

When the nominal fill level 12 in the melt receiving space 4 is reached, the gas valve 7 can be closed and the melt container 3, as in 3c can be seen to be raised again in order to be transported to its casting position.

If the gas flowing out of the melt receiving space 4 can pass through the gas valve 7 without pressure, the actual filling quantity level 11 will adapt to the furnace filling level 32 when the melt container 3 is filled. When the gas valve 7 is then closed and the melt container 3 is raised, the actual filling quantity level 11 will drop until the negative pressure in the melt receiving space 4 is sufficiently great to keep the melt 2 at the same level as a result of the pressure difference between the interior pressure in the melt receiving space 4 and the ambient pressure.

In the Figures 4a and 4b a further and possibly independent embodiment of the melt transport device 1 is shown, with the same reference numerals or component designations as in the preceding ones being used for the same parts Figures 1 to 3 be used. To avoid unnecessary repetition, reference is made to the detailed description in the foregoing Figures 1 to 3 pointed out or referred to.

In the Figures 4a and 4b an alternative method for filling the melt receiving space 4 with melt 2 is shown.

How from the Figures 4a and 4b As can be seen, it can be provided that the melt container 3 only dips so far into the melting furnace 30 that the pouring opening 6 is below the filling level 32 in the furnace.

In order to reach the filling level target level 12 in the melt receiving space 4, the melt receiving space 4 can be evacuated by means of a vacuum pump 33, whereby the Melt 2 is drawn into the melt receiving space 4. The gas valve 7 can then be closed in order to keep the actual filling quantity level 11 in the melt receiving space 4 during transport of the melt transport device 1 at a constant level.

Since the melt receiving space 4 before the melt container 3 is lifted, as is shown in Figure 4b is shown, is already evacuated by the vacuum pump 33, the filling quantity actual level 11 in the melt receiving space 4 will drop only slightly when it is raised.

In the figure 5 a further and possibly independent embodiment of the melt transport device 1 is shown, with the same reference numerals or component designations as in the preceding ones being used for the same parts Figures 1 to 4 be used. To avoid unnecessary repetition, reference is made to the detailed description in the foregoing Figures 1 to 4 pointed out or referred to.

How out figure 5 As can be seen, after the filling process with melt 2 , the melt container 3 can be brought into its pouring position 34 , in which the pouring opening 6 is connected to a mold 35 or introduced into the mold 35 . The gas valve 7 can then be opened in order to allow gas to flow into the melt receiving space 4 in a targeted manner and to lower the actual filling quantity level 11 . This process allows the melt 2 to be introduced from the melt receiving space 4 into a mold cavity 36 of the casting mold 35 .

In the figure 6 a further and possibly independent embodiment of the melt transport device 1 is shown, with the same reference numerals or component designations as in the preceding ones being used for the same parts Figures 1 to 5 be used. To avoid unnecessary repetition, reference is made to the detailed description in the foregoing Figures 1 to 5 pointed out or referred to.

6 shows another variant of filling the melt receiving space 4 with melt 2.

How out 6 As can be seen, it can be provided that a coupling 37 is arranged on the spout 5, which is used to couple the spout 5 to the melting furnace 30. In particular, it can be provided in such an embodiment variant that the furnace fill level 32 is located higher than the nominal fill quantity level 12. Thus, after successful establishment of a flow connection between the melt container 3 and the melt furnace 30 by means of the coupling 37, the melt 2 can be let in from the melt furnace 30 into the melt receiving space 4 under the influence of gravity. In this case, the gas valve 7 can be used to regulate the filling quantities or the filling speed of the melt 2 in the melt receiving space 4 .

If the melt container 3, as in 6 shown, has a coupling 37, this coupling 37 can also be used to establish a flow connection between the melt container 3 and the mold 35 at the same time.

In the figure 7 a further and possibly independent embodiment of the melt transport device 1 is shown, with the same reference numerals or component designations as in the preceding ones being used for the same parts Figures 1 to 6 be used. To avoid unnecessary repetition, reference is made to the detailed description in the foregoing Figures 1 to 6 pointed out or referred to.

7 shows a further exemplary embodiment of the melt transport device 1, in particular of the spout 5. As shown in FIG 7 As can be seen, it can be provided that a drain opening 38 is provided at the bottom of the reservoir 14, which is used to drain a residual melt that remains in the reservoir 14 due to the structural conditions. The drain opening 38 can have a mechanical closure, by means of which the residual melt remaining in the reservoir 14 can be drained.

In the figure 8 a further and possibly independent embodiment of the melt transport device 1 is shown, with the same reference numerals or component designations as in the preceding ones being used for the same parts Figures 1 to 7 be used. To avoid unnecessary repetition, reference is made to the detailed description in the foregoing Figures 1 to 7 pointed out or referred to.

How out 8 As can be seen, provision can be made for the siphon 13 to be formed directly adjacent to the spout channel 23 of the spout 5 as a closed channel, with the reservoir 14 being formed by a depression. The pouring opening 6 can be designed, for example, as a vertical opening.

In an embodiment of the spout 5 as shown in 8 is shown, it can be provided that the residual melt remaining in the reservoir 14 after the casting process is blown out of the reservoir 14 by a blast of compressed air. For this purpose, for example, a compressed air nozzle can be arranged in the pouring channel 23 . Furthermore, it is also conceivable for a large volume of gas to be introduced into the melt receiving space 4 in a short time, so that the melt 2 in the reservoir 14 can be blown out.

How out 8 further evident, it can be provided that a heating device 39 is arranged in the spout 5, which is used to keep the melt 2 warm. The heating device 39 can of course also be placed elsewhere in the melt transport device 1 . Of course, the heating device 39 can be implemented in all variants of the melt transport device 1 .

In the figure 9 a further and possibly independent embodiment of the melt transport device 1 is shown, with the same reference numerals or component designations as in the preceding ones being used for the same parts Figures 1 to 8 be used. To avoid unnecessary repetition, reference is made to the detailed description in the foregoing Figures 1 to 8 pointed out or referred to.

In the figure 9 a further and possibly independent embodiment of the melt transport device 1 is shown, with the same reference numerals or component designations as in the preceding ones being used for the same parts Figures 1 to 8 be used. To avoid unnecessary repetition, reference is made to the detailed description in the foregoing Figures 1 to 8 pointed out or referred to.

How out 9 As can be seen, provision can be made for the spout 5 to have a plurality of spout openings 6 . The individual spout openings 6 can be arranged on the spout 5 distributed over the circumference, for example. in 9 illustrated embodiment, four spout openings 6 are formed distributed over the circumference. How out 9 As can be seen, it can be provided that in such an embodiment a central reservoir 14 is formed, which has, for example, a single circumferential siphon wall 15, wherein the individual pouring openings 6 can each be flow-connected to the reservoir 14 by means of a flow channel 40. How out 9 further evident, it can be provided that the individual pouring openings 6 all have the same clear width.

Thus, individual casting molds 35 can be connected to each of the pouring openings 6, with the casting molds 35 being able to be filled evenly.

In an alternative embodiment variant, not shown, it can also be provided that the individual pouring openings 6 have a different clear width, which means that different casting molds 35 connected to the individual pouring openings 6 can be filled at different filling speeds.

How out 9 further evident, it can be provided that the individual pouring openings 6 have the same overflow level 17 . In order to ensure the functionality of the siphon 13, it must be provided that a siphon wall lower edge 41 is arranged lower than the lowest overflow level 17.

How out 9 as can also be seen, it can be provided that a magnetic element 42 is formed which, for example, comprises a coil 43 . If the coil 43 is supplied with current, in addition to the negative pressure in the melt container 3, a braking effect can be achieved when the melt 2 flows out, as a result of which the melt 2 can be equalized or calmed down during casting.

In the figure 10 a further and possibly independent embodiment of the melt transport device 1 is shown, with the same reference numerals or component designations as in the preceding ones being used for the same parts Figures 1 to 9 be used. To avoid unnecessary repetition, reference is made to the detailed description in the foregoing Figures 1 to 9 pointed out or referred to.

10 shows a further exemplary embodiment of the melt transport device 1, the basic structure of which is the same as that exemplary embodiment 1 can be. How out 10 As can be seen, it can be provided that a deflection element 44 is formed, which serves as a splash guard or for guiding the melt 2 . In particular, the deflection element 44 can be designed in such a way that the melt 2 is deflected downwards.

In the figure 11 a further and possibly independent embodiment of the melt transport device 1 is shown, again with the same reference numerals for the same parts or component designations as in the previous ones Figures 1 to 10 be used. To avoid unnecessary repetition, reference is made to the detailed description in the foregoing Figures 1 to 10 pointed out or referred to.

How out 11 As can be seen, it can be provided that the melt transport device 1 is filled by means of a low-pressure furnace 45 known to those skilled in the art. In this case, a riser pipe 46 of the low-pressure furnace 45 can be coupled directly to the discharge opening 6 in order to create a flow connection between the riser pipe 46 and the melt receiving space 4 . If the gas valve 7 is now opened during the filling process, the melt 2 in the riser pipe 46 can be pushed upwards by the function of the low-pressure furnace 45 until the melt receiving space 4 is filled with melt 2 up to its desired fill quantity level 12 .

In such an embodiment variant, it can also be provided that in the area of the coupling 37 between the riser pipe 46 and the pouring opening 6, a vent (not shown) is formed, which can be activated so that the melt in the riser pipe can be removed again after the end of the filling process and before decoupling can flow back into the low-pressure furnace 45. Furthermore, it is of course also conceivable that the area of the pouring opening 6 and the riser pipe 46 are formed obliquely, so that the melt 2 can flow back into the low-pressure furnace 45 when it is uncoupled.

In the figure 12 a further and possibly independent embodiment of the melt transport device 1 is shown, with the same reference numerals or component designations as in the preceding ones being used for the same parts Figures 1 to 11 be used. To avoid unnecessary repetition, reference is made to the detailed description in the foregoing Figures 1 to 11 pointed out or referred to.

12 shows a further exemplary embodiment of the melt transport device 1. As shown in FIG 12 As can be seen, it can be provided that several casting molds 35 can be coupled to the melt transport device 1 and can be filled by it at the same time. In particular, it can be provided that the individual casting molds 35 can be filled with the melt transport device 1 in a rising pour. For this purpose, it can be provided that a sprue is formed in the lower mold half of the individual molds 35 . In this case, the sprue can be coupled to the pouring opening 6 of the melt transport device 1 .

In the figure 13 a further and possibly independent embodiment of the melt transport device 1 is shown, with the same reference numerals or component designations as in the preceding ones being used for the same parts Figures 1 to 12 be used. To avoid unnecessary repetition, reference is made to the detailed description in the foregoing Figures 1 to 12 pointed out or referred to.

How out 13 As can be seen, it can be provided that the melt transport device 1 does not have a single melt receiving space 4, but that several melt receiving spaces 4 can be formed, which serve to receive different melts. Thus, for example, different alloys can be accommodated in the individual melt accommodation spaces 4 . It is also conceivable that the individual melt receiving spaces 4 are each flow-coupled to a common reservoir 14 , as a result of which the melts received in the different melt receiving spaces 4 can be poured out through the common pouring opening 6 .

Furthermore, it can be provided that each of the melt receiving spaces 4 has its own gas valve 7 so that the melt 2 located in the different melt receiving spaces 4 can be conveyed into the reservoir 14 independently of one another. It is thus conceivable, for example, that the melts 2 located in the individual melt receiving spaces 4 are discharged simultaneously into the reservoir 14 so that they mix there to form a desired alloy.

Furthermore, it is also conceivable that the melts 2 located in the individual melt receiving spaces 4 are not discharged into the reservoir 14 at the same time but rather with a time delay. In this way it can be achieved that the workpiece produced in the casting mold 35 has, for example, a different layering of different alloys. It is also conceivable, for example, for melt 2 from a first melt receiving space 4 to be drained first, then melt 2 from a second melt receiving space 4 to be mixed in, and then only melt 2 from the second melt receiving space 4 to be drained into reservoir 14. In this way, a different composition or a layering of different alloys in the workpiece can be achieved, with a uniform transition from a first alloy to a second alloy being able to be achieved.

In the figure 14 a further and possibly independent embodiment of the melt transport device 1 is shown, with the same reference numerals or component designations as in the preceding ones being used for the same parts Figures 1 to 13 be used. To avoid unnecessary repetition, reference is made to the detailed description in the foregoing Figures 1 to 13 pointed out or referred to.

How out 14 As can be seen, provision can be made for the siphon 13 to be arranged on the underside of the spout 5 designed as a lance 20 . The siphon 13 or the spout 5 can be shaped in such a way that the spout opening 6 is formed on the underside of the lance 20 . Such an embodiment variant of the melt transport device 1 is particularly advantageous when the drop height of the melt 2 into the mold 35 is to be as small as possible. This can be the case, for example, when the mold cavity 36 is formed by molding sand 47 in the casting mold 35 , for example. In such an embodiment variant, the pouring opening 6 can be brought as close as possible to the surface of the molding sand 47 in order to keep the drop height of the melt 2 as low as possible and thus to prevent the molding sand 47 from being washed out. With increasing melt level in the mold 35, the melt transport device 1 can also be raised. Here, the lance 20 can always be kept slightly above the level of the melt in the mold 35 .

In a further exemplary embodiment, it is also conceivable that the lance 20 always dips slightly into the melt 2 in the mold 35 while the mold 35 is being filled with melt 2, as a result of which a particularly smooth casting process can be achieved.

Of course, the casting process described can also be carried out with a melt transport device 1 which has a screen 24 instead of the siphon 13 .

In the figure 15 a further and possibly independent embodiment of the melt transport device 1 is shown, with the same reference numerals or component designations as in the preceding ones being used for the same parts Figures 1 to 14 be used. To avoid unnecessary repetition, reference is made to the detailed description in the foregoing Figures 1 to 14 pointed out or referred to.

How out 15 As can be seen, it can be provided that one of the walls of the melt receiving space 4 is designed in the form of a displaceable piston 50 . Such a piston 50 can have a seal 51 by means of which the melt receiving space 4 is sealed off from the outside 16 of the melt container.

By moving the piston 50, the volume of the melt receiving space 4 can be changed. As a result, the melt 2 can be drawn into the melt receiving space 4 or discharged from it again during casting.

16 shows a first exemplary embodiment of a casting device 52 with a base frame 53 and a mold 35 arranged on the base frame 53.

How out 16 As can be seen, it can be provided that the base frame 53 comprises a rotation device 54 by means of which the mold 35 can be rotated about an axis of rotation 60 .

In the 16 The casting device 52 shown is designed as a low-pressure casting device, which has a riser pipe 55 as a flow connection element between a receiving space 56 of a furnace 57 and the mold cavity 36 of the casting mold 35 .

How out 16 further evident, it can be provided that the casting mold 35 has a first sprue 58 and a second sprue 59 . In particular, it can be provided that the riser pipe 55 opens into the first sprue 58 and the second sprue 59 is designed for pouring in a melt by means of the melt transport device 1 .

In particular, how from 16 As can be seen, it can be provided that the casting mold 35 is designed for casting a brake disk 61 which has a disk part 62 and a hub part 63 . In particular, it can be provided that by means of the casting device 52 after 16 a first melt 2 is applied by means of the first sprue 58 into the mold cavity 36 of the casting mold 35, with the casting mold 35 being rotated about the axis of rotation 60 by means of the rotation device 54, so that the first melt 2 is injected into the disk part 62 of the brake disk 61 under the action of centrifugal force is pressed. Then, before the first melt 2 solidifies, the second melt can be introduced into the mold cavity 36 by means of the melt transport device 1 via the second sprue 59, so that the second melt 2 is received in the hub part 63 and during solidification of the melt 2 an integral connection with the first melt 2 is produced. Thus, the brake disk 61 can have different strength properties in the disk part 62 and in the hub part 63 and still have a good connection between the disk part 62 and the hub part 63 .

The exemplary embodiments show possible variants, whereby it should be noted at this point that the invention is not limited to the specifically illustrated variants of the same, but rather that various combinations of the individual variants with one another are also possible and this possibility of variation is based on the teaching on technical action through the present invention in skills of the specialist working in this technical field.

The scope of protection is determined by the claims. However, the description and drawings should be used to interpret the claims. Individual features or combinations of features from the different exemplary embodiments shown and described can represent independent inventive solutions. The task on which the independent inventive solutions are based can be found in the description.

All information on value ranges in the present description is to be understood in such a way that it also includes any and all sub-ranges, e.g. the information 1 to 10 is to be understood in such a way that all sub-ranges, starting from the lower limit 1 and the upper limit 10, are also included , i.e. all subranges start with a lower limit of 1 or greater and end with an upper limit of 10 or less, e.g. 1 to 1.7, or 3.2 to 8.1, or 5.5 to 10.

Finally, for the sake of clarity, it should be pointed out that some elements are shown not to scale and/or enlarged and/or reduced in size for a better understanding of the structure. <b>List of Reference Signs</b> 1 melt transport device 31 filling position 2 melt 32 oven level 3 melt tank 33 vacuum pump 4 melt receiving space 34 casting position 5 spout 35 mold 6 spout opening 36 mold cavity 7 gas valve 37 coupling 8th filling level maximum 38 drain hole 9 pressure sensing means 39 heating device 10 level sensor 40 flow channel 11 Actual fill level 41 bottom edge of the siphon wall 12 filling level target level 42 magnetic element 13 siphon 43 Kitchen sink 14 reservoir 44 deflection element 15 siphon wall 45 low pressure furnace 16 Melt tank exterior 46 riser 17 overflow level 47 molding sand 18 first melt surface 48 sieve bar 19 second melt surface 49 sieve opening 20 lance 50 Pistons 21 container 51 poetry 22 strut 52 casting device 23 spout 53 base frame 24 Sieve 54 rotation device 25 mesh size 55 riser 26 screen top 56 recording room 27 sieve bottom 57 Oven 28 valve block 58 first pour 29 single valve 59 second pour 30 melting furnace 60 axis of rotation 61 brake disc 62 disc part 63 hub part

Claims (17)

1. A method for transporting melt (2) in a melt transport device (1), comprising the method steps:

   - providing the melt transport device (1) comprising a melt container (3) in which a melt receiving space (4) is formed and a spout (5) which is coupled to the melt container (3), wherein the spout (5) has a spout orifice (6) which is flow-connected to the melt receiving space (4), wherein a gas valve (7) is formed which is flow-connected to the melt receiving space (4), and which is formed for controlling the gas entry into the melt receiving space (4), and wherein

   a) a siphon (13) is formed in the spout (5), which siphon (13) has a reservoir (14) arranged between the melt receiving space (4) and the spout orifice (6), wherein the reservoir (14) has an overflow level (17), wherein a siphon wall (15) is formed having a siphon wall lower edge (41), wherein the siphon wall (15) projects into the reservoir (14) such that a siphon wall lower edge (41) is located at a lower level than the overflow level (17) of the reservoir (14),
   and/or

   b) a sieve (24) is arranged in the spout (5), which sieve (24) has a mesh width (25) between 0.05 mm and 10 mm;

   - filling the melt receiving space (4) of the melt transport device (1), wherein the gas valve (7) is open during the filling of the melt receiving space (4);

   - terminating the filling operation and closing the gas valve (7) when an actual fill quantity level (11) in the melt receiving space (4) is equal to a target fill quantity level (12);

   - transporting the melt transport device (1) from a filling position (31) to a casting position (34), wherein a negative pressure is present in the melt receiving space (4) during the transport of the melt transport device (1), wherein a leakage of the melt (2) from the spout orifice (6) is prevented by the negative pressure in cooperation with the ambient pressure,

   characterized in that when the melt receiving space (4) of the melt transport device (1) is filled, first a melt (2) of a first composition is received and subsequently a melt (2) of a second composition is received, wherein the melt (2) of the second composition has different physical or chemical properties to the melt (2) of the first composition.
2. The method according to claim 1, characterized in that after filling the melt receiving space (4) of the melt transport device (1), the melt (2) stays in the melt receiving space (4) for a predetermined period of time, wherein the melt (2) settles in the melt receiving space (4), wherein a melt (2) of a first composition and a melt (2) of a second composition form in a stratification in the melt receiving space (4), wherein the melt (2) of the second composition has different physical or chemical properties, in particular a higher density, than the melt (2) of the first composition.
3. The method according to any one of claims 1 to 2, characterized in that, when the melt transport device (1) is provided, the melt receiving space (4) is filled with an inert gas, in particular with nitrogen.
4. The method according to one of the claims 1 to 3, characterized in that for filling the melt receiving space (4) of the melt transport device (1), the melt receiving space (4) is evacuated by means of a vacuum pump (33), whereby the melt (2) is drawn into the melt receiving space (4).
5. The method according to one of the claims 1 to 4, characterized in that for filling the melt receiving space (4) of the melt transport device (1), the spout orifice (6) is coupled to a melt furnace by means of a coupling (37).
6. The method according to one of the claims 1 to 5, characterized in that for filling the melt receiving space (4) of the melt transport device (1), the spout orifice (6) is coupled by means of a coupling (37) to the riser tube (46) of a low-pressure furnace (45), wherein the melt (2) is pressed into the melt receiving space (4) by means of the low-pressure furnace (45).
7. The method according to one of claims 1 to 6, characterized in that for filling the melt receiving space (4) of the melt transport device (1), the spout orifice (6) is immersed in a melt furnace (30).
8. The method according to one of claims 1 to 7, characterized in that for filling the melt receiving space (4) of the melt transport device (1), the spout orifice (6) is coupled by means of the coupling (37) to a melt furnace (30) which has a furnace fill level (32) which is higher than the target fill quantity level (12), and that the filling process is effected by controlled discharge of gas from the melt receiving space (4).
9. A method for casting melt (2) by means of a melt transport device (1) comprising the method steps:

   - providing the melt transport device (1) comprising a melt container (3) in which a melt receiving space (4) is formed and a spout (5) which is coupled to the melt container (3), wherein the spout (5) has a spout orifice (6) which is flow-connected to the melt receiving space (4), wherein a gas valve (7) is formed which is flow-connected to the melt receiving space (4), and which is formed for controlling the gas entry into the melt receiving space (4), and wherein

   a) a siphon (13) is formed in the spout (5), which siphon (13) has a reservoir (14) arranged between the melt receiving space (4) and the spout orifice (6), wherein the reservoir (14) has an overflow level (17), wherein a siphon wall (15) is formed having a siphon wall lower edge (41), wherein the siphon wall (15) projects into the reservoir (14) such that a siphon wall lower edge (41) is located at a lower level than the overflow level (17) of the reservoir (14),
   and/or

   b) a sieve (24) is arranged in the spout (5), which sieve (24) has a mesh width (25) between 0.05 mm and 10 mm, wherein melt (2) is received in the melt receiving space (4), wherein a negative pressure is present in the melt receiving space (4) and a leakage of the melt (2) from the spout orifice (6) is prevented by the negative pressure in cooperation with the ambient pressure;

   - discharging the melt (2) from the melt transport device (1) by opening the gas valve (7) for the controlled introduction of gas into the melt receiving space (4) and reducing the negative pressure in the melt receiving space (4), as a result of which the melt (2) flows due to gravity out of the spout orifice (6) into a casting mold (35),

   characterized in that
   when casting the melt into the mold cavity (36) of the mold (35), first a melt (2) of a first composition is cast in and then a second melt (2) of a second composition is cast in.
10. The method according to claim 9, characterized in that after termination of the discharge of the melt (2), the melt (2) remaining in the reservoir (14) of the siphon (13) is blown out by means of a gas blast.
11. The method according to claim 9 or 10, characterized in that during the controlled insertion of gas into the melt receiving space (4), an inert gas is introduced into the melt receiving space (4).
12. The method according to one of claims 9 to 11, characterized in that, in the case of a gas valve (7) which is configured as a valve block (28) with a plurality of individual valves (29), the control is carried out by means of the electronic digital computer, wherein the control is carried out on the basis of a mathematical model of the melt transport device (1), wherein the characteristic data of all the individual valves (29) of the valve block (28) are stored in the mathematical model of the melt transport device (1).
13. The method according to one of claims 9 to 12, characterized in that during the discharge of the melt (2) from the melt transport device (1), a magnetic field is applied by means of the magnetic element (42) to the melt (2) flowing in the spout (5).
14. The method according to one of claims 9 to 13, characterized in that the two melts (2) of different compositions are received being stratified in the melt receiving space (4) of the melt transport device (1).
15. The method according to one of claims 9 to 14, characterized in that the first melt (2) of the first composition is introduced into the mold cavity (36) of the mold (35) by means of a riser tube (55) of a low-pressure casting device or a counter-pressure casting device, and that the second melt (2) of the second composition is introduced into the mold cavity (36) of the mold (35) by means of the melt transport device (1).
16. The method according to one of claims 9 to 15, characterized in that the mold (35) is configured for producing a brake disc (61), wherein the mold (35) is rotated about its axis of rotation (60) during the filling of the mold cavity (36) with melt, such that the first melt (2) of the first composition enters the disc part (62) of the brake disc (61) and the second melt (2) of the second composition enters the hub part (63) of the brake disc (61).
17. The method according to claim 16, characterized in that the first melt (2) is an aluminum melt which has a solid content, in particular a silicon carbide content, of between 1 vol.-% and 40 vol.-%, in particular between 5 vol.-% and 35 vol.-%, preferably between 15 vol.-% and 30 vol.-%.

Images