JP2005059081A - High strength water-soluble core and its manufacturing method - Google Patents
High strength water-soluble core and its manufacturing method Download PDFInfo
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- 238000004519 manufacturing process Methods 0.000 title claims description 13
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 77
- 239000011230 binding agent Substances 0.000 claims abstract description 60
- 239000004576 sand Substances 0.000 claims abstract description 56
- 229910017053 inorganic salt Inorganic materials 0.000 claims abstract description 47
- 239000011256 inorganic filler Substances 0.000 claims abstract description 31
- 229910003475 inorganic filler Inorganic materials 0.000 claims abstract description 31
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 23
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 claims abstract description 12
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims abstract description 12
- NJLLQSBAHIKGKF-UHFFFAOYSA-N dipotassium dioxido(oxo)titanium Chemical compound [K+].[K+].[O-][Ti]([O-])=O NJLLQSBAHIKGKF-UHFFFAOYSA-N 0.000 claims abstract description 11
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 11
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 7
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims abstract description 7
- 229910010271 silicon carbide Inorganic materials 0.000 claims abstract description 7
- 229910052845 zircon Inorganic materials 0.000 claims abstract description 7
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 claims abstract description 7
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 claims abstract description 6
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims abstract description 6
- 239000000395 magnesium oxide Substances 0.000 claims abstract description 6
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims abstract description 6
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims abstract description 6
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 claims abstract description 6
- 239000011787 zinc oxide Substances 0.000 claims abstract description 6
- CSNNHWWHGAXBCP-UHFFFAOYSA-L Magnesium sulfate Chemical group [Mg+2].[O-][S+2]([O-])([O-])[O-] CSNNHWWHGAXBCP-UHFFFAOYSA-L 0.000 claims description 62
- 229910052943 magnesium sulfate Inorganic materials 0.000 claims description 31
- 235000019341 magnesium sulphate Nutrition 0.000 claims description 31
- 238000005266 casting Methods 0.000 claims description 24
- 239000011734 sodium Substances 0.000 claims description 21
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 claims description 18
- 238000000034 method Methods 0.000 claims description 17
- 238000000465 moulding Methods 0.000 claims description 13
- 239000002245 particle Substances 0.000 claims description 11
- 229910000029 sodium carbonate Inorganic materials 0.000 claims description 9
- 229910000838 Al alloy Inorganic materials 0.000 claims description 7
- 239000007864 aqueous solution Substances 0.000 claims description 5
- 239000000843 powder Substances 0.000 claims description 5
- BHPQYMZQTOCNFJ-UHFFFAOYSA-N Calcium cation Chemical compound [Ca+2] BHPQYMZQTOCNFJ-UHFFFAOYSA-N 0.000 claims description 4
- JLVVSXFLKOJNIY-UHFFFAOYSA-N Magnesium ion Chemical compound [Mg+2] JLVVSXFLKOJNIY-UHFFFAOYSA-N 0.000 claims description 4
- FKNQFGJONOIPTF-UHFFFAOYSA-N Sodium cation Chemical compound [Na+] FKNQFGJONOIPTF-UHFFFAOYSA-N 0.000 claims description 4
- 150000001450 anions Chemical class 0.000 claims description 4
- 239000011575 calcium Substances 0.000 claims description 4
- 229910001424 calcium ion Inorganic materials 0.000 claims description 4
- 150000001768 cations Chemical group 0.000 claims description 4
- 239000011777 magnesium Substances 0.000 claims description 4
- 229910001425 magnesium ion Inorganic materials 0.000 claims description 4
- 229910001415 sodium ion Inorganic materials 0.000 claims description 4
- PMZURENOXWZQFD-UHFFFAOYSA-L Sodium Sulfate Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=O PMZURENOXWZQFD-UHFFFAOYSA-L 0.000 claims description 3
- 229910021538 borax Inorganic materials 0.000 claims description 3
- 239000000463 material Substances 0.000 claims description 3
- 150000003839 salts Chemical class 0.000 claims description 3
- 229910052938 sodium sulfate Inorganic materials 0.000 claims description 3
- 235000011152 sodium sulphate Nutrition 0.000 claims description 3
- 235000010339 sodium tetraborate Nutrition 0.000 claims description 3
- 238000009210 therapy by ultrasound Methods 0.000 claims description 3
- BSVBQGMMJUBVOD-UHFFFAOYSA-N trisodium borate Chemical compound [Na+].[Na+].[Na+].[O-]B([O-])[O-] BSVBQGMMJUBVOD-UHFFFAOYSA-N 0.000 claims description 3
- 238000004898 kneading Methods 0.000 claims description 2
- 238000002156 mixing Methods 0.000 claims description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims 1
- CHWRSCGUEQEHOH-UHFFFAOYSA-N potassium oxide Chemical compound [O-2].[K+].[K+] CHWRSCGUEQEHOH-UHFFFAOYSA-N 0.000 claims 1
- 229910001950 potassium oxide Inorganic materials 0.000 claims 1
- 239000010936 titanium Substances 0.000 claims 1
- 229910052719 titanium Inorganic materials 0.000 claims 1
- 239000003110 molding sand Substances 0.000 abstract description 3
- 230000000052 comparative effect Effects 0.000 description 15
- 238000005452 bending Methods 0.000 description 12
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 8
- UQGFMSUEHSUPRD-UHFFFAOYSA-N disodium;3,7-dioxido-2,4,6,8,9-pentaoxa-1,3,5,7-tetraborabicyclo[3.3.1]nonane Chemical compound [Na+].[Na+].O1B([O-])OB2OB([O-])OB1O2 UQGFMSUEHSUPRD-UHFFFAOYSA-N 0.000 description 5
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 4
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 4
- 229910052863 mullite Inorganic materials 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- 238000004090 dissolution Methods 0.000 description 3
- 239000000945 filler Substances 0.000 description 3
- 229910002804 graphite Inorganic materials 0.000 description 3
- 239000010439 graphite Substances 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 238000005495 investment casting Methods 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 239000011246 composite particle Substances 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 239000010954 inorganic particle Substances 0.000 description 2
- 239000011780 sodium chloride Substances 0.000 description 2
- UXJVHYYUORGLGW-UHFFFAOYSA-L S(=O)(=O)([O-])[O-].[Mg+2].B([O-])(O)O.B(O)(O)O.B(O)(O)O.B(O)(O)O.[Na+] Chemical compound S(=O)(=O)([O-])[O-].[Mg+2].B([O-])(O)O.B(O)(O)O.B(O)(O)O.B(O)(O)O.[Na+] UXJVHYYUORGLGW-UHFFFAOYSA-L 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 239000002826 coolant Substances 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000007849 furan resin Substances 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- INHCSSUBVCNVSK-UHFFFAOYSA-L lithium sulfate Inorganic materials [Li+].[Li+].[O-]S([O-])(=O)=O INHCSSUBVCNVSK-UHFFFAOYSA-L 0.000 description 1
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 1
- 239000001095 magnesium carbonate Substances 0.000 description 1
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910003465 moissanite Inorganic materials 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 239000011295 pitch Substances 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 238000004904 shortening Methods 0.000 description 1
- RPACBEVZENYWOL-XFULWGLBSA-M sodium;(2r)-2-[6-(4-chlorophenoxy)hexyl]oxirane-2-carboxylate Chemical compound [Na+].C=1C=C(Cl)C=CC=1OCCCCCC[C@]1(C(=O)[O-])CO1 RPACBEVZENYWOL-XFULWGLBSA-M 0.000 description 1
- RBTVSNLYYIMMKS-UHFFFAOYSA-N tert-butyl 3-aminoazetidine-1-carboxylate;hydrochloride Chemical compound Cl.CC(C)(C)OC(=O)N1CC(N)C1 RBTVSNLYYIMMKS-UHFFFAOYSA-N 0.000 description 1
Landscapes
- Mold Materials And Core Materials (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
Description
本発明は、砂落しの容易性の目安となる水溶性を低下させずに、高温強度を向上させた水溶性中子、及びその製造方法に関する。 The present invention relates to a water-soluble core having improved high-temperature strength without reducing water solubility, which is a measure of ease of sand removal, and a method for producing the same.
鋳型に溶湯を圧入し、急冷凝固させて鋳物を製造することができる。このような、精密鋳造技術においては、機械部品等の精密鋳造品の内部に空間を設けるために、中子が広く利用されている。例えば、アルミ合金を使ったシリンダの内部空間、エグゾースト内部の冷却媒体通路の作製に中子は不可欠なものである。 A casting can be manufactured by press-fitting molten metal into a mold and rapidly solidifying it. In such precision casting technology, a core is widely used to provide a space inside a precision casting such as a machine part. For example, the core is indispensable for the production of the internal space of the cylinder using aluminum alloy and the cooling medium passage inside the exhaust.
中子の強度を増加させるためには、樹脂、無機塩等のバインダが使用されている。特に、中子バインダとして無機塩を用いることにより、鋳造時のガス発生量を低減させ、鋳造後は中子砂落しを水で行うことのできる水溶性中子が考えられている。しかしながら、実用化・量産化は困難であるとされている。その理由は、バインダの結合力がないため、必要な中子強度を得ることが困難なことによる。 In order to increase the strength of the core, a binder such as a resin or an inorganic salt is used. In particular, by using an inorganic salt as a core binder, a water-soluble core that can reduce the amount of gas generated during casting and can perform core sand removal with water after casting is considered. However, practical use and mass production are considered difficult. The reason is that it is difficult to obtain the necessary core strength because there is no binding force of the binder.
即ち、中子用鋳物砂に無機塩等のバインダを添加する場合、
１）バインダ量を増加すれば、中子強度が向上する。
２）バインダは、水に溶かして（飽和濃度にして）鋳物砂に添加する。よって、バインダ量の増加は、水の量の増加となる。
３）水の増加は、鋳物砂の流動性低下となり、中子型への鋳物砂の充填性を阻害する。
That is, when adding a binder such as an inorganic salt to the core foundry sand,
1) If the amount of the binder is increased, the core strength is improved.
2) The binder is dissolved in water (saturated concentration) and added to the foundry sand. Therefore, an increase in the amount of binder results in an increase in the amount of water.
3) The increase in water results in a decrease in the fluidity of the foundry sand and hinders the filling property of the foundry sand into the core mold.
このように、鋳物砂に、バインダだけの添加だと、中子強度と鋳物砂の流動性を両立させることができない。そこで、バインダ量を増加させずに、中子強度を向上させる技術が必要となっている。 Thus, if only the binder is added to the foundry sand, the core strength and the fluidity of the foundry sand cannot be made compatible. Therefore, a technique for improving the core strength without increasing the binder amount is required.
下記特許文献１には、流動性、充填性、成形性の改善を目的として、無機粒子に黒鉛をバインダで被覆してなる無機複合粒子であって、黒鉛の被覆量が無機粒子１００重量部に対して０．１〜５０重量部であり、かつ黒鉛に対するバインダの重量比が０．００２〜２である無機複合粒子からなる鋳物用砂の発明が開示されている。しかし、用いられているバインダは、フェノール樹脂、フラン樹脂、ピッチであり、本発明のように、水溶性中子を得るものではない。 The following Patent Document 1 discloses inorganic composite particles obtained by coating inorganic particles with graphite for the purpose of improving fluidity, filling properties, and moldability, and the coating amount of graphite is 100 parts by weight of inorganic particles. On the other hand, there is disclosed an invention of a sand for casting made of inorganic composite particles having a weight ratio of 0.1 to 50 parts by weight and a binder to graphite of 0.002 to 2. However, the binder used is phenol resin, furan resin, or pitch, and does not obtain a water-soluble core as in the present invention.
また、下記特許文献２には、鋳造時に有機バインダより分解ガスが発生することを解消することを目的として、鋳物砂に対して無機材料を成分とするバインダを用いることが開示されている。具体的には、バインダとして硫酸カルシウムと硫酸マグネシウムを成分とする構成とし、硫酸カルシウムと硫酸マグネシウムの混合比率は、硫酸カルシウムを３５〜９５％とし、残部を硫酸マグネシウムとしている。しかしながら、この方法では、中子強度、特に高温での強度が充分ではなく、造型後、鋳造までの間に、中子形状が崩れてしまい、設計通りの鋳物が得られないという問題がある。 Patent Document 2 below discloses the use of a binder containing an inorganic material as a component with respect to foundry sand for the purpose of eliminating the generation of decomposition gas from the organic binder during casting. Specifically, the binder is composed of calcium sulfate and magnesium sulfate as components, and the mixing ratio of calcium sulfate and magnesium sulfate is 35 to 95% for calcium sulfate and the remainder is magnesium sulfate. However, this method has a problem that the core strength, particularly the strength at high temperature, is not sufficient, and the core shape collapses between molding and casting, and a casting as designed cannot be obtained.
一方、水溶性中子バインダとしては、硫酸マグネシウム（ＭｇＳＯ4）が知られている。しかながら、硫酸マグネシウム（ＭｇＳＯ4）水溶液は、以下の欠点を有している。
１）粘着力が弱く、中子強度が充分ではない。
２）バインダ必要量が多くなり（水の量も増加する）、鋳物砂の流動性が悪化し、中子造型時にブロー充填性が不十分である。
On the other hand, magnesium sulfate (MgSO 4 ) is known as a water-soluble core binder. However, the magnesium sulfate (MgSO 4 ) aqueous solution has the following drawbacks.
1) Adhesive strength is weak and core strength is not sufficient.
2) The required amount of binder increases (the amount of water also increases), the fluidity of the foundry sand deteriorates, and the blow filling property is insufficient during core molding.
そこで、下記特許文献３には、塩化ナトリウムを基材とし、これに硫酸リチウム２〜４０％、硫酸マグネシウム２〜２０％等を加えた水溶性中子バインダが開示されている。又、下記特許文献４には、硫酸カルシウムと硫酸マグネシウムから成る水溶性中子バインダが開示されている。しかしながら、これら特許文献３及び４に開示された水溶性中子バインダを用いても強度は十分ではなかった。
上記問題に鑑み、本発明は、砂落しの容易性の目安となる水溶性を低下させずに、高温強度を向上させた水溶性中子及びその製造方法を提供し、水溶性中子を実用性のあるものとすることを目的とする。 In view of the above problems, the present invention provides a water-soluble core with improved high-temperature strength without reducing water-solubility, which is a measure of ease of sand removal, and a method for producing the same. The purpose is to have a sex.
本発明者らは、多数の化合物について検討した結果、特定のフィラーのみがバインダとして水溶性無機塩と共存でき、砂落しの容易性の目安となる水溶性を有するとともに、中子強度、特に高温強度、充填性等を満たすことを見出し本発明に到達した。 As a result of studying a large number of compounds, the present inventors have found that only a specific filler can coexist with a water-soluble inorganic salt as a binder, has water solubility that is a measure of ease of sand removal, and has core strength, particularly high temperature. The inventors have found that the strength, filling property, and the like are satisfied, and have reached the present invention.
即ち、第１に、本発明は、水溶性中子の発明であり、鋳物砂粒子の表面が水溶性無機塩バインダで被覆された水溶性中子において、該水溶性無機塩バインダに、珪砂（珪粉）、アルミナ、チタン酸カリウム、炭化珪素、珪酸ジルコン、繊維状チタン酸カリウム、酸化チタン、酸化亜鉛、酸化鉄、酸化マグネシウムから選択される無機フィラーの１種以上が添加されていることを特徴とする。 That is, first, the present invention is an invention of a water-soluble core. In the water-soluble core in which the surface of the casting sand particle is coated with a water-soluble inorganic salt binder, the water-soluble inorganic salt binder is coated with silica sand ( Silica powder), alumina, potassium titanate, silicon carbide, zircon silicate, fibrous potassium titanate, titanium oxide, zinc oxide, iron oxide, magnesium oxide, one or more inorganic fillers are added. Features.
本発明の水溶性中子は、流動性、充填性と水溶性が低下することなく、高温強度が向上している。水溶性中子の高温強度が向上することで、造型された中子のハンドリングに優れるという実用性が生じる。 The water-soluble core of the present invention has improved high-temperature strength without lowering fluidity, fillability and water solubility. Improvement in the high-temperature strength of the water-soluble core results in practicality that it is excellent in handling of the molded core.
本発明で用いられる水溶性無機塩としては、マグネシウムイオン（Ｍｇ2+）、ナトリウムイオン（Ｎａ+）、カルシウムイオン（Ｃａ2+）から選択されるカチオンと、ＳＯ4 2-、ＣＯ3 2-、ＨＣＯ3 2-、Ｂ4Ｏ7 -から選択されるアニオンとの組み合わせからなる水溶性無機塩の１種以上であることが好ましい。その中でも、硫酸マグネシウム（ＭｇＳＯ4）が好ましい。又、水溶性無機塩として、硫酸マグネシウム（ＭｇＳＯ4）０〜１００重量％と、炭酸ナトリウム（Ｎａ2ＣＯ3）、４ホウ酸ナトリウム（Ｎａ2Ｂ4Ｏ7）、硫酸ナトリウム（Ｎａ2ＳＯ4）から選択される１種以上１００〜０重量％から混合系も好ましい。 Examples of the water-soluble inorganic salt used in the present invention include a cation selected from magnesium ion (Mg 2+ ), sodium ion (Na + ), and calcium ion (Ca 2+ ), SO 4 2− , CO 3 2−. , HCO 3 2-, B 4 O 7 - is preferably at least one water-soluble inorganic salt comprising a combination of anion selected from. Among these, magnesium sulfate (MgSO 4 ) is preferable. As water-soluble inorganic salts, magnesium sulfate (MgSO 4 ) 0 to 100% by weight, sodium carbonate (Na 2 CO 3 ), sodium borate (Na 2 B 4 O 7 ), sodium sulfate (Na 2 SO 4) A mixed system is also preferred from 1 to 100% by weight selected from 1).
無機塩バインダと特定の無機フィラーを併用することによって、中子の高温強度が向上する理由は以下のことと考えられる。水溶性中子の鋳物砂に無機塩バインダのみを添加した場合は、鋳物砂の表面に無機塩バインダが被覆され、鋳物砂間の結合力は、鋳物砂間の接点に存在する無機塩バインダ量に依存している。この場合、多量のバインダを添加しても、接点以外の表面に被覆されたバインダは結合に寄与しない。例えば、水溶性無機塩として、硫酸マグネシウム（ＭｇＳＯ4）単味から成るバインダは、造型直後（約１００℃〜１６０℃）の温間強度及び鋳造時（約２００℃〜７００℃）での高温強度が低い。これは、硫酸マグネシウム（ＭｇＳＯ4）結晶が、加熱により、粘性化して低強度化するためと考えられる。これに対して、本発明のように、水溶性無機塩に特定のフィラーを添加することによって、表面が水溶性無機塩バインダで被覆された鋳物砂粒子同士の接点において、これら特定のフィラーが存在することで、鋳物砂粒子同士の接点が破壊されることを防止するためと考えられる。 The reason why the high temperature strength of the core is improved by using the inorganic salt binder and the specific inorganic filler in combination is considered as follows. When only an inorganic salt binder is added to the water-soluble core foundry sand, the surface of the foundry sand is coated with the inorganic salt binder, and the bonding strength between the foundry sands is the amount of inorganic salt binder present at the contact points between the foundry sands. Depends on. In this case, even if a large amount of binder is added, the binder coated on the surface other than the contact does not contribute to the bonding. For example, as a water-soluble inorganic salt, a binder consisting of magnesium sulfate (MgSO 4 ) has a warm strength immediately after molding (about 100 ° C. to 160 ° C.) and a high temperature strength at the time of casting (about 200 ° C. to 700 ° C.). Is low. This is presumably because magnesium sulfate (MgSO 4 ) crystals become viscous and lower in strength by heating. On the other hand, by adding specific fillers to the water-soluble inorganic salt as in the present invention, these specific fillers are present at the contact points between the molding sand particles whose surfaces are coated with the water-soluble inorganic salt binder. This is considered to prevent breakage of the contacts between the foundry sand particles.
本発明の水溶性中子では、鋳物砂に対する前記無機塩バインダ添加量が０．８〜１０重量％であり、前記無機フィラー添加量が０．２〜１０重量％であることが好ましい。無機塩バインダ添加量と無機フィラー添加量がこの範囲を外れると、両者を併用する本発明の効果が減少する。 In the water-soluble core of the present invention, the inorganic salt binder is preferably added in an amount of 0.8 to 10% by weight and the inorganic filler is added in an amount of 0.2 to 10% by weight relative to the foundry sand. When the addition amount of the inorganic salt binder and the addition amount of the inorganic filler are out of this range, the effect of the present invention using both of them decreases.
第２に、本発明は、高強度水溶性中子の製造方法の発明であり、鋳物砂粒子と、無機塩バインダの水溶液とを配合・混練し、得られた混練物を中子型で造型する造型工程を含む水溶性中子の製造方法において、水溶性無機塩バインダに、珪砂（珪粉）、アルミナ、チタン酸カリウム、炭化珪素、珪酸ジルコン、繊維状チタン酸カリウム、酸化チタン、酸化亜鉛、酸化鉄、酸化マグネシウムから選択される無機フィラーの１種以上が添加されていることを特徴とする。 2ndly, this invention is invention of the manufacturing method of a high intensity | strength water-soluble core, mix | blends and knead | mixes a casting sand particle and the aqueous solution of an inorganic salt binder, and shape | molds the obtained kneaded material by a core type | mold. In a method for producing a water-soluble core including a molding step, silica-sand (silica powder), alumina, potassium titanate, silicon carbide, zircon silicate, fibrous potassium titanate, titanium oxide, and zinc oxide are added to the water-soluble inorganic salt binder. One or more inorganic fillers selected from iron oxide and magnesium oxide are added.
本発明の方法により、高温強度と、砂落しの容易性の目安となる水溶性を兼ね備えた水溶性中子を製造することが出来る。
好ましい水溶性無機塩の種類、各成分の量比等は上記第１の発明と同様である。
By the method of the present invention, it is possible to produce a water-soluble core having both high-temperature strength and water-solubility that is a measure of ease of sand removal.
The preferable kind of water-soluble inorganic salt, the ratio of each component, and the like are the same as in the first invention.
本発明の方法において、無機フィラーを水に溶解する際には、即溶解性の無機フィラーや僅かな力を加える程度で溶解する無機フィラーの場合は、溶解自体は容易である。本発明で用いられる幾つかの無機フィラーについては、水への溶解時に、超音波処理することは溶解時間を短縮させる上で効果的であり、好ましい。 In the method of the present invention, when the inorganic filler is dissolved in water, the dissolution itself is easy in the case of an inorganic filler that is immediately soluble or an inorganic filler that dissolves with a slight force. For some inorganic fillers used in the present invention, ultrasonic treatment at the time of dissolution in water is effective in shortening the dissolution time and is preferable.
第３に、本発明は、アルミ合金の鋳造方法の発明であり、中子造型工程、鋳造工程、及び砂落し工程を含むアルミ合金鋳造方法において、中子造型工程で請求項１乃至４のいずれかに記載の水溶性中子を用いることを特徴とする。本発明により、例えば、アルミ合金シリンダ等の精密鋳造品を製造することが出来る。
本発明のアルミ合金鋳造方法において、砂落しを効率的に行うためには、砂落し工程で、超音波処理を用いて前記水溶性中子を水に溶解することが好ましい。
3rdly, this invention is invention of the casting method of an aluminum alloy, In the aluminum alloy casting method including a core molding process, a casting process, and a sand removal process, it is any one of Claims 1 thru | or 4 in a core molding process. A water-soluble core as described above is used. According to the present invention, for example, a precision casting such as an aluminum alloy cylinder can be manufactured.
In the aluminum alloy casting method of the present invention, in order to perform sand removal efficiently, it is preferable to dissolve the water-soluble core in water using ultrasonic treatment in the sand removal process.
本発明のように、水溶性無機塩バインダに、珪砂（珪粉）、アルミナ、チタン酸カリウム、炭化珪素、珪酸ジルコン、繊維状チタン酸カリウム、酸化チタン、酸化亜鉛、酸化鉄、酸化マグネシウムから選択される無機フィラーの１種以上を添加することで、高温強度と、砂落しの容易性の目安となる水可溶性を併せ持つ水溶性中子が得られる。 As in the present invention, the water-soluble inorganic salt binder is selected from silica sand (silica powder), alumina, potassium titanate, silicon carbide, zircon silicate, fibrous potassium titanate, titanium oxide, zinc oxide, iron oxide and magnesium oxide. By adding one or more inorganic fillers, a water-soluble core having both high-temperature strength and water-solubility that is a measure for ease of sand removal can be obtained.
特に水溶性無機塩として、マグネシウムイオン（Ｍｇ2+）、ナトリウムイオン（Ｎａ+）、カルシウムイオン（Ｃａ2+）から選択されるカチオンと、ＳＯ4 2-、ＣＯ3 2-、ＨＣＯ3 2-、Ｂ4Ｏ7 -から選択されるアニオンとの組み合わせからなる水溶性無機塩の１種以上を用いる水溶性中子バインダを用いることで、十分な中子強度と水可溶性を併せ持つ水溶性中子を得ることができる。また、この水溶性中子を用いることで、鋳造時に型崩れせず、鋳造後の砂落しが容易な鋳造を行うことができる。 In particular, as a water-soluble inorganic salt, a cation selected from magnesium ion (Mg 2+ ), sodium ion (Na + ), and calcium ion (Ca 2+ ), SO 4 2− , CO 3 2− , HCO 3 2− , B 4 O 7 - the use of water-soluble core binder using one or more water-soluble inorganic salt comprising a combination of anion selected from water-soluble core having both adequate core strength and water-soluble Can be obtained. Further, by using this water-soluble core, it is possible to perform casting that does not lose its shape during casting and can easily drop sand after casting.
本発明で用いられる鋳物砂粒子は、従来知られたものを用いることができる。具体的には、ＳｉＣ，アルミナ，ムライト，シリカ，ジルコン等を用いることが好ましい。これらは、優れた強度，低熱膨張率を有するとともに入手が比較的容易であり、強度，寸法精度等に優れた水溶性中子を製造することができる。
鋳物砂に対する無機塩バインダ添加量の合計量は０．８〜１０重量％であることが好ましく、４〜７重量％であることがより好ましい。
As the foundry sand particles used in the present invention, those conventionally known can be used. Specifically, it is preferable to use SiC, alumina, mullite, silica, zircon or the like. These have excellent strength and low thermal expansion coefficient and are relatively easily available, and can produce a water-soluble core excellent in strength, dimensional accuracy, and the like.
The total amount of the inorganic salt binder added to the foundry sand is preferably 0.8 to 10% by weight, and more preferably 4 to 7% by weight.
本発明で用いられる特定の無機フィラーは、表面が無機塩バインダで被覆された鋳物砂粒子の接点付近に存在して、鋳物砂粒子の結合力を高めるものである。その平均粒径は、数μｍ〜数１０μｍ程度が鋳物砂の接点付近に存在するのに好ましい。
これら、鋳物砂粒子：無機塩バインダ：無機フィラーの量比としては、１００：４〜７：１〜７であることが中子強度と鋳物砂の流動性（充填性）を両立させることから好ましい。
The specific inorganic filler used in the present invention is present near the contact point of the foundry sand particles whose surface is coated with the inorganic salt binder, and enhances the binding force of the foundry sand particles. The average particle size is preferably about several μm to several tens of μm in the vicinity of the contact point of the foundry sand.
The amount ratio of these foundry sand particles: inorganic salt binder: inorganic filler is preferably 100: 4 to 7: 1 to 7 because both the core strength and the fluidity (fillability) of the foundry sand are compatible. .
以下、本発明を実施例及び比較例により説明する。
（実施例１〜１０）
［配合］
鋳物砂としてムライト系人工砂に、無機塩バインダとして硫酸マグネシウム（ＭｇＳＯ4）を水に溶かした水溶液に、下記表１に記載の各種無機フィラーを添加し、１２０分間、混練して、硫酸マグネシウム（ＭｇＳＯ4）含有量を２．５％とし、各種無機フィラーの含有量を０．１〜２．５％とした。なお、他の水溶性無機塩、例えばＮａ塩は併用しなかった。
［中子造型］
断面１０ｍｍ×１０ｍｍ（Ｈ）、長さ６０ｍｍの中子形状を有する金型に、上記配合物を手込めした。上記金型を、恒温炉にて、１５０℃で３０分間放置して乾燥した（ＪＩＳによる）。同様に丸棒を造型した。
［中子強度測定］
中子をｌ（５０ｍｍ）間の支点に置き、中心部へ上部よりＰ（ｋｇｆ）加圧した。下記式より、抗折強度σ（ｋｇｆ／ｍ2）を求めた。
σ ＝ ３／２ × ｌ／ａ・Ｈ2 × Ｐ
表１に、上記ＪＩＳによって造型された中子、丸棒に造型された中子の抗折強度σ（冷間強度、ｋｇｆ／ｍ2）、ＪＩＳによって造型された中子を４００℃で１分間加熱した場合の抗折強度σ（高温強度、ｋｇｆ／ｍ2）の結果を示す。同時に、砂落しの容易性の目安となる、７００℃で１時間加熱した場合での水可溶性の結果と充填性の結果を示す。
Hereinafter, the present invention will be described with reference to examples and comparative examples.
(Examples 1 to 10)
[Combination]
Various inorganic fillers listed in Table 1 below are added to an aqueous solution in which magnesium sulfate (MgSO 4 ) is dissolved in water as mullite artificial sand as casting sand, and kneaded for 120 minutes. The MgSO 4 ) content was 2.5%, and the contents of various inorganic fillers were 0.1 to 2.5%. Other water-soluble inorganic salts such as Na salt were not used in combination.
[Core molding]
The above composition was prepared in a mold having a core shape having a cross section of 10 mm × 10 mm (H) and a length of 60 mm. The mold was left to dry at 150 ° C. for 30 minutes in a constant temperature oven (according to JIS). Similarly, a round bar was formed.
[Core strength measurement]
The core was placed on a fulcrum between 1 (50 mm), and P (kgf) was pressurized from the top to the center. The bending strength σ (kgf / m 2 ) was determined from the following formula.
σ = 3/2 × l / a · H 2 × P
Table 1 shows the bending strength σ (cold strength, kgf / m 2 ) of the core formed by the above JIS and the core formed by a round bar, and the core formed by JIS at 400 ° C. for 1 minute. The results of the bending strength σ (high temperature strength, kgf / m 2 ) when heated are shown. At the same time, the results of water-solubility and filling properties when heated at 700 ° C. for 1 hour, which is a measure of ease of sand removal, are shown.
（比較例１）
無機塩バインダとして硫酸マグネシウム（ＭｇＳＯ4）のみを用いた他は、実施例１と同様の中子を成型し、強度等を測定した。
（比較例２〜９）
無機フィラーとして表１に記載のものを用いた他は、実施例１と同様の中子を成型し、強度等を測定した。
(Comparative Example 1)
A core similar to that of Example 1 was molded except that only magnesium sulfate (MgSO 4 ) was used as the inorganic salt binder, and the strength and the like were measured.
(Comparative Examples 2-9)
A core similar to that of Example 1 was molded and the strength and the like were measured except that the inorganic fillers listed in Table 1 were used.
表１の結果より、無機バインダに特定の無機フィラーを併用する本発明の実施例１〜１０では、いずれも砂落しの容易性の目安となる水可溶性に優れているとともに、その多くは高温での中子の抗折強度σが向上していることが分かる。これに対して、無機バインダとして硫酸マグネシウム（ＭｇＳＯ4）のみを用いた比較例１や、無機バインダに本発明以外の無機フィラーを併用する比較例２〜９では、高温での中子の抗折強度σに改善されたものが見られるもの、比較例１以外は水に不溶であり、砂落しが出来ないことが分かる。即ち、本発明の実施例１〜１０の中子はいずれも高温強度と水可溶性の両者に優れていることが分る。 From the results of Table 1, in Examples 1 to 10 of the present invention in which a specific inorganic filler is used in combination with an inorganic binder, all are excellent in water solubility, which is a measure of ease of sand removal, and many of them are at high temperatures. It can be seen that the bending strength σ of the core is improved. On the other hand, in Comparative Example 1 using only magnesium sulfate (MgSO 4 ) as an inorganic binder and Comparative Examples 2 to 9 using an inorganic filler other than the present invention in combination with the inorganic binder, the core is bent at a high temperature. It can be seen that those with improved strength σ are seen, and those other than Comparative Example 1 are insoluble in water and cannot be removed. That is, it can be seen that the cores of Examples 1 to 10 of the present invention are excellent in both high temperature strength and water solubility.
（実施例１１〜１３）
鋳物砂としてムライト系人工砂に、無機塩バインダとして硫酸マグネシウム（ＭｇＳＯ4）と４ホウ酸ナトリウム（Ｎａ2Ｂ4Ｏ7）を併用して水に溶かした水溶液に、下記表２に記載の各種無機フィラーを添加し、１２０分間、混練して、硫酸マグネシウム（ＭｇＳＯ4）含有量を２．０％又は２．５％とし、４ホウ酸ナトリウム（Ｎａ2Ｂ4Ｏ7）含有量を２．０％とし、各種無機フィラーの含有量を２．４〜２．５％とした。
実施例１と同様の中子を成型し、強度等を測定した。表２に、上記ＪＩＳによって造型された中子、丸棒に造型された中子の抗折強度σ（冷間強度、ｋｇｆ／ｍ2）、上記ＪＩＳによって造型された中子の温間抗折強度σ（ｋｇｆ／ｍ2）、ＪＩＳによって造型された中子を４００℃で１分間加熱した場合の抗折強度σ（高温強度、ｋｇｆ／ｍ2）の結果を示す。同時に、砂落しの容易性の目安となる、７００℃で１時間加熱した場合での水可溶性の結果と充填性の結果を示す。
(Examples 11 to 13)
Various types of water as described in Table 2 below were prepared by using mullite artificial sand as casting sand and magnesium sulfate (MgSO 4 ) and sodium tetraborate (Na 2 B 4 O 7 ) as an inorganic salt binder. An inorganic filler is added and kneaded for 120 minutes to obtain a magnesium sulfate (MgSO 4 ) content of 2.0% or 2.5%, and a sodium tetraborate (Na 2 B 4 O 7 ) content of 2. The content of various inorganic fillers was 2.4 to 2.5%.
The core similar to Example 1 was shape | molded and intensity | strength etc. were measured. Table 2 shows the bending strength σ (cold strength, kgf / m 2 ) of the core formed by the above JIS and the core formed by the round bar, and the warm bending of the core formed by the above JIS. strength σ (kgf / m 2), shows a flexural strength sigma (high-temperature strength, kgf / m 2) of the results obtained by heating for 1 minute at 400 ° C. the molding has been the core by JIS. At the same time, the results of water-solubility and filling properties when heated at 700 ° C. for 1 hour, which is a measure of ease of sand removal, are shown.
（比較例１０、１１）
無機塩バインダとして硫酸マグネシウム（ＭｇＳＯ4）と４ホウ酸ナトリウム（Ｎａ2Ｂ4Ｏ7）を併用し、無機フィラーを添加しなかった他は、実施例１と同様の中子を成型し、強度等を測定した。
（比較例１２）
無機フィラーとして表２に記載の塩化ナトリウムを用いた他は、実施例１と同様の中子を成型し、強度等を測定した。
(Comparative Examples 10 and 11)
The same core as in Example 1 was molded, except that magnesium sulfate (MgSO 4 ) and sodium tetraborate (Na 2 B 4 O 7 ) were used in combination as the inorganic salt binder, and no inorganic filler was added. Etc. were measured.
(Comparative Example 12)
A core similar to that of Example 1 was molded and the strength and the like were measured except that sodium chloride shown in Table 2 was used as the inorganic filler.
表２の結果より、無機塩バインダとして硫酸マグネシウム（ＭｇＳＯ4）と４ホウ酸ナトリウム（Ｎａ2Ｂ4Ｏ7）を併用する実施例１１〜１３は、硫酸マグネシウム（ＭｇＳＯ4）のみを用いる比較例１と比べて、冷間強度及び高温強度が大幅に向上している。又、硫酸マグネシウム（ＭｇＳＯ4）と４ホウ酸ナトリウム（Ｎａ2Ｂ4Ｏ7）を併用する無機バインダに特定の無機フィラーを併用する本発明の実施例１１〜１３では、いずれも砂落しの容易性の目安となる水可溶性に優れているとともに、高温での中子の抗折強度σが向上していることが分かる。これに対して、無機バインダとして硫酸マグネシウム（ＭｇＳＯ4）と４ホウ酸ナトリウム（Ｎａ2Ｂ4Ｏ7）を併用するのみの比較例１０と１１や、無機バインダに本発明以外の無機フィラーを併用する比較例１２では、高温での中子の抗折強度σに改善が見られるもの、比較例１２は水に不溶であり、砂落しが出来ないことが分かる。即ち、本発明の実施例１１〜１３の中子はいずれも高温強度と水可溶性の両者に優れていることが分る。 From the results of Table 2, Examples 11-13 used in combination with sodium tetraborate magnesium sulfate (MgSO 4) (Na 2 B 4 O 7) as an inorganic salt binder, comparative examples using only magnesium sulfate (MgSO 4) Compared to 1, cold strength and high temperature strength are significantly improved. In Examples 11 to 13 of the present invention in which a specific inorganic filler is used in combination with an inorganic binder using both magnesium sulfate (MgSO 4 ) and sodium tetraborate (Na 2 B 4 O 7 ), sand removal is easy. It can be seen that the water-solubility that is a measure of the property is excellent, and the bending strength σ of the core at high temperature is improved. On the other hand, Comparative Examples 10 and 11 in which only magnesium sulfate (MgSO 4 ) and sodium tetraborate (Na 2 B 4 O 7 ) are used in combination as inorganic binders, and inorganic fillers other than the present invention are used in combination with inorganic binders. It can be seen that Comparative Example 12 shows improvement in the bending strength σ of the core at a high temperature, and Comparative Example 12 is insoluble in water and cannot remove sand. That is, it can be seen that the cores of Examples 11 to 13 of the present invention are excellent in both high temperature strength and water solubility.
（実施例１４〜１８）
鋳物砂としてムライト系人工砂に、無機塩バインダとして硫酸マグネシウム（ＭｇＳＯ4）と炭酸ナトリウム（Ｎａ2ＣＯ3）を併用して水に溶かした水溶液に、下記表３に記載の各種無機フィラーを添加し、１２０分間、混練して、硫酸マグネシウム（ＭｇＳＯ4）含有量を２．０％又は２．５％とし、炭酸ナトリウム（Ｎａ2ＣＯ3）含有量を２．０％とし、各種無機フィラーの含有量を０．１〜２．５％とした。
(Examples 14 to 18)
Various inorganic fillers listed in Table 3 below are added to an aqueous solution in which magnesium sulfate (MgSO 4 ) and sodium carbonate (Na 2 CO 3 ) are used in combination with mullite artificial sand as casting sand and magnesium carbonate (Na 2 CO 3 ) as inorganic salt binder. And kneading for 120 minutes, the magnesium sulfate (MgSO 4 ) content is 2.0% or 2.5%, the sodium carbonate (Na 2 CO 3 ) content is 2.0%, The content was set to 0.1 to 2.5%.
実施例１と同様の中子を成型し、強度等を測定した。表３に、上記ＪＩＳによって造型された中子、丸棒に造型された中子の抗折強度σ（冷間強度、ｋｇｆ／ｍ2）、上記ＪＩＳによって造型された中子の温間抗折強度σ（ｋｇｆ／ｍ2）、ＪＩＳによって造型された中子を４００℃で１分間加熱した場合の抗折強度σ（高温強度、ｋｇｆ／ｍ2）の結果を示す。同時に、砂落しの容易性の目安となる、７００℃で１時間加熱した場合での水可溶性の結果と充填性の結果を示す。 The core similar to Example 1 was shape | molded and intensity | strength etc. were measured. Table 3 shows the bending strength σ (cold strength, kgf / m 2 ) of the core formed by the above JIS and the core formed by a round bar, and the warm bending of the core formed by the above JIS. strength σ (kgf / m 2), shows a flexural strength sigma (high-temperature strength, kgf / m 2) of the results obtained by heating for 1 minute at 400 ° C. the molding has been the core by JIS. At the same time, the results of water-solubility and filling properties when heated at 700 ° C. for 1 hour, which is a measure of ease of sand removal, are shown.
（比較例１３、１４）
無機塩バインダとして硫酸マグネシウム（ＭｇＳＯ4）と炭酸ナトリウム（Ｎａ2ＣＯ3）を併用し、無機フィラーを添加しなかった他は、実施例１と同様の中子を成型し、強度等を測定した。
(Comparative Examples 13 and 14)
A core similar to that of Example 1 was molded and the strength and the like were measured, except that magnesium sulfate (MgSO 4 ) and sodium carbonate (Na 2 CO 3 ) were used in combination as the inorganic salt binder and no inorganic filler was added. .
表３の結果より、無機塩バインダとして硫酸マグネシウム（ＭｇＳＯ4）と炭酸ナトリウム（Ｎａ2ＣＯ3）を併用する実施例１４〜１８は、硫酸マグネシウム（ＭｇＳＯ4）のみを用いる比較例１と比べて、冷間強度及び高温強度が大幅に向上している。又、硫酸マグネシウム（ＭｇＳＯ4）と炭酸ナトリウム（Ｎａ2ＣＯ3）を併用する無機バインダに特定の無機フィラーを併用する本発明の実施例１４〜１８では、いずれも砂落しの容易性の目安となる水可溶性に優れているとともに、高温での中子の抗折強度σが向上していることが分かる。これに対して、無機バインダとして硫酸マグネシウム（ＭｇＳＯ4）と炭酸ナトリウム（Ｎａ2ＣＯ3）を併用するのみの比較例１３と１４では、高温での中子の抗折強度σの改善も見られないことが分かる。即ち、本発明の実施例１４〜１８の中子はいずれも高温強度と水可溶性の両者に優れていることが分る。 From the results of Table 3, Examples 14 to 18 used in combination with magnesium sulfate (MgSO 4) and sodium carbonate (Na 2 CO 3) as the inorganic salt binder, as compared with Comparative Example 1 using only magnesium sulfate (MgSO 4) The cold strength and high temperature strength are greatly improved. In Examples 14 to 18 of the present invention in which a specific inorganic filler is used in combination with an inorganic binder using magnesium sulfate (MgSO 4 ) and sodium carbonate (Na 2 CO 3 ), It is understood that the water bending solubility σ of the core at high temperature is improved as well as excellent water solubility. On the other hand, in Comparative Examples 13 and 14 in which only magnesium sulfate (MgSO 4 ) and sodium carbonate (Na 2 CO 3 ) are used in combination as the inorganic binder, improvement in the bending strength σ of the core at high temperature is also seen. I understand that there is no. That is, it can be seen that the cores of Examples 14 to 18 of the present invention are excellent in both high temperature strength and water solubility.
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| WO2007036563A1 (en) * | 2005-09-30 | 2007-04-05 | Ceramtec Ag Innovative Ceramic Engineering | Core and a method for the production thereof |
| JP2011041973A (en) * | 2009-08-24 | 2011-03-03 | Daito Kogyo Kk | Method for molding water soluble mold |
| DE102010038455A1 (en) | 2010-07-27 | 2012-02-02 | Federal-Mogul Nürnberg GmbH | Preparing water-soluble salt cores for forming hollow molds in casting processes, comprises adding a metal powder to salt cores and heating the salt cores by magnetic induction to remove moisture |
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