JP2010125470A - Method of manufacturing internally cast article - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To increase joining strength of an internally cast portion of an internally cast article obtained by joining different metallic materials. <P>SOLUTION: Semi-solidified slurry 36a-36d is placed at depressions 32a-32c of a die 22 constituting a metal mold device 20 and metallic hollow pipes 12a-12c are mounted at mounting parts 34a-34c. While clamping is carried out to form a cavity 30, the semi-solidified slurry 36a-36d is pressed by slurry pressing parts 38a-38c formed at a punch 24. As a result, the semi-solidified slurry 36a-36d starts flowing toward the respective ends of the metallic hollow pipes 12a-12c. The fluidized semi-solidified slurry 36a-36d surrounds the respective ends of the metallic hollow pipes 12a-12c, and accordingly flow resistance increases. The pressing force of the semi-solidified slurry 36a-36d to the respective ends becomes large, and large friction force is generated between the respective ends and the semi-solidified slurry 36a-36d. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for producing a cast product in which a semi-solid slurry is solidified to obtain a cast product in which the solidified product casts a part of a workpiece.

  A so-called cast-in is known as one of the techniques for joining different metal materials having different compositions to obtain a joined molded product. According to this method, after a work (casting material) is accommodated in a mold, the molten metal is filled and solidified in accordance with casting. The molten metal is solidified according to the shape of the cavity of the mold and is joined to the workpiece at this time.

  However, when performing cast-in, it is not easy to increase the bonding strength between the cast-in material (metal melt) and the workpiece. In Patent Document 1, it is presumed that this is because an oxide film or the like is present at the bonding interface between the workpiece and the molten metal, and the molten metal at the solid-liquid coexistence temperature is used for casting. Attempts to remove the oxide film on the surface of the workpiece by pressing to the surface.

Japanese Patent Laid-Open No. 10-99961

  The molten metal in a solid-liquid coexistence state is unlikely to flow. For this reason, when the molten metal is filled into the mold by injection, the molten metal tends to solidify during the flow in the mold. If solidification progresses to such an extent that the flow stops, a so-called filling failure occurs in which the molten metal does not reach a part of the mold. In other words, in this case, it is not easy to efficiently obtain a cast product.

  This inconvenience is particularly noticeable when manufacturing a large shape. In this case, the flow distance in the mold is increased, and a large amount of molten metal needs to be filled.

  The present invention has been made to solve the above-described problems, and provides a method for producing a cast product that can efficiently obtain a cast product having a high joint strength between the cast product and the cast product. For the purpose.

In order to achieve the above object, a method for producing a cast product according to the present invention includes a step of accommodating one or more semi-solid slurry and two or more workpieces in a mold,
Forming each of the semi-solid slurry into a shape corresponding to the shape of the cavity by performing mold clamping, and flowing to each cast casting part of the workpiece;
Solidifying the semi-solid slurry;
Have
The to-be-casting part is cast by the semi-solid slurry that has flowed to the to-be-casting part.

  In the present invention, the semi-solid slurry is pressed against the workpiece at the time of stamping, whereby the semi-solid slurry is brought into sliding contact with the part to be cast of the workpiece. Along with this sliding contact, the frictional force between the semi-solidified slurry and the cast-in part is increased, and as a result, the passive state (oxide film) existing on the surface of the semi-solidified slurry is destroyed and the internal slurry flows out. To do.

  This slurry has no oxide film. For this reason, the wettability with respect to a to-be-casting part is favorable. That is, according to the present invention, the cast-out part of the workpiece is wetted well by the slurry, and the solidified product and the workpiece are firmly joined together as the slurry becomes a solidified product in this state. In other words, a cast product with excellent bonding strength can be obtained even if different metal materials are used.

  Moreover, in the present invention, the molten metal in the coexisting state of solid and liquid does not solidify during the flow as in the case of injection molding, and no filling failure occurs. Therefore, even when producing a large-sized cast product, the cast product can be produced efficiently.

  The semi-solid slurry may be disposed between the workpieces to perform mold clamping, or may be disposed on the workpiece to perform mold clamping.

  According to the present invention, the flow resistance of the semi-solidified slurry is increased by the cast portion of the workpiece. For this reason, the frictional force between the semi-solidified slurry and the cast-in part is increased. As a result, the oxide film on the surface of the semi-solidified slurry is destroyed and the internal slurry flows out.

  Since this slurry has no oxide film, the slurry wets the cast-in part of the work well. Therefore, it is possible to obtain a cast product in which the solidified product obtained by cooling and solidifying the semi-solid slurry and the cast-in part of the workpiece are firmly joined to each other.

  DESCRIPTION OF EMBODIMENTS Hereinafter, preferred embodiments of a method for manufacturing a cast product according to the present invention will be described in detail with reference to the accompanying drawings.

  First, an overall schematic plan sectional view of the cast product 10 is shown in FIG. This cast product 10 is interposed between three metal hollow tubes 12a to 12c each filled with a sand core and adjacent ones of the metal hollow tubes 12a to 12c. It has connecting members 14a to 14c and is used as a subframe constituting an automobile body.

  The connecting members 14a to 14c connect the ends of the metal hollow tubes 12a and 12b, the ends of the metal hollow tubes 12b and 12c, and the ends of the metal hollow tubes 12a and 12c, respectively. . In the present embodiment, the metal hollow tubes 12a to 12c are the same type of metal material, the connecting members 14a to 14c are the same type, and the metal hollow tubes 12a to 12c are a different type of metal material. is there. Examples of the materials of the metal hollow tubes 12a to 12c and the connecting members 14a to 14c include aluminum alloy A5052 and AC4CH (both JIS), but are not particularly limited thereto.

  The metal hollow tubes 12a and 12c extend in a direction substantially orthogonal to the extending direction of the metal hollow tube 12b and are arranged substantially parallel to each other. For this reason, the connecting member 14c that connects the ends of the metal hollow tubes 12a and 12c is significantly longer than the remaining connecting members 14a and 14b. Hereinafter, the connecting member 14c may be referred to as a bridge member 14c.

  Here, FIG. 2 shows a longitudinal sectional view from the direction of arrow A in FIG. As can be seen from FIG. 2, the end of the metal hollow tube 12b is embedded in the connecting member 14b. This embedding is realized by casting as described later. Although illustration is omitted, the end portions of the metal hollow tubes 12a and 12b are cast into the connecting member 14a. Similarly, the end portions of the metal hollow tube 12c are cast into the connecting member 14b. Yes. Further, the other end portions of the metal hollow tubes 12a and 12c are cast in the horizontal portion of the bridge member 14c. As can be understood from the above, in the cast product 10, any one of the metal hollow tubes 12a to 12c is interposed between the adjacent ones of the connecting members 14a to 14c.

  This cast product 10 can be produced by a mold apparatus 20 whose main parts of the front and rear schematic vertical sections are shown in FIGS. 3 and 4 respectively.

  The mold apparatus 20 includes a die 22 and a punch 24 as a mold. As shown in FIGS. 3 to 5, the die 22 and the punch 24 are formed with recesses 26 and 28. When the mold is clamped, the spaces formed by the recesses 26 and 28 are combined. A cavity 30 having a shape corresponding to the shape of the cast product 10 is defined (see FIGS. 6 and 7).

  As shown in FIGS. 3 to 5, depressions 32 a to 32 c constituting the concave portion 26 are formed in a predetermined portion of the die 22, and the placement portions 34 a to 34 a are disposed between adjacent ones of the depressions 32 a to 32 c. 34c is protrudingly formed. In the depressions 32a to 32c, semiconsolidated slurries 36a to 36d having a substantially conical shape are disposed. On the placement portions 34a to 34c, the metal hollow tubes 12a to 12c are placed. Is done. For this reason, as shown in FIG. 5, any one of the metal hollow tubes 12a to 12c is interposed between the adjacent ones in the semi-solid slurry 36a to 36d. In FIG. 5, the approximate arrangement positions of the semi-solid slurry 36 a to 36 d and the metal hollow tubes 12 a to 12 c are indicated by phantom lines.

  The punch 24 (see FIGS. 3 and 4) can approach or separate from the die 22 under the action of a lifting mechanism (not shown). That is, when the punch 24 approaches the die 22 by the lifting mechanism, the mold is clamped, and the cavity 30 (see FIGS. 6 and 7) is formed accordingly.

  The punch 24 (see FIGS. 3 and 4) is formed with slurry pressing portions 38a to 38c for pressing the semi-solid slurry 36a to 36d. Among these, the slurry pressing portions 38a and 38b press the semi-solid slurry 36a and 36b, respectively (see FIG. 3), and the remaining slurry pressing portion 38c simultaneously presses the two semi-solid slurry 36c and 36d (FIG. 4). reference).

  The punch 24 is formed with work seal portions 40a to 40c for sealing the metal hollow tubes 12a to 12c (see FIG. 3). Each of the work seal portions 40a to 40c individually seals each of the metal hollow tubes 12a to 12c. Further, the semi-solid slurry is prevented from flowing into the metal hollow tubes 12a to 12c.

  The method for manufacturing the cast product 10 according to the present embodiment is performed as follows in the mold apparatus 20 configured as described above.

  First, after the metal hollow tubes 12a to 12c are placed on the placement portions 34a to 34c, the semi-solid slurry 36a to 36d is placed on each of the depressions 32a to 32c. Of course, after placing the semi-solid slurry 36a-36d in each of the depressions 32a-32c, the metal hollow tubes 12a-12c may be placed on each of the placement portions 34a-34c.

  As described above, the metal hollow tubes 12a to 12c may be selected from, for example, those made of A5052, and the semi-solid slurry 36a to 36d may be selected from, for example, AC4CH. In addition, on the surfaces of the semi-solidified slurries 36a to 36d, there are so-called passive oxide films formed by oxidizing the surfaces with oxygen in the atmosphere.

  Next, the punch 24 is lowered under the action of the lifting mechanism. Along with this lowering, the slurry pressing portions 38a to 38c come into contact with the semi-solid slurry 36a to 36d, thereby applying a pressing force to the semi-solid slurry 36a to 36d. As a result, the semi-solidified slurries 36a to 36d are crushed and start to flow. In this case, since the metal hollow tubes 12a to 12c are interposed between adjacent ones in the semi-solid slurry 36a to 36d, the semi-solid slurry 36a to 36d is contained in the metal hollow tubes 12a to 12c. Flow toward the edge of the adjacent ones.

  When the punch 24 is further lowered, the metal hollow tubes 12a to 12c are sealed by the work seal portions 40a to 40c. In some cases, together with this seal, the metal hollow tubes 12a to 12c may be formed corresponding to the shapes of the work seal portions 40a to 40c and the mounting protrusion (cavity 30).

  When the punch 24 is lowered and the mold is clamped, a cavity 30 is formed (see FIGS. 6 and 7). At this time, as shown in FIG. 6, the semi-solid slurry 36a surrounds one end of each of the metal hollow tubes 12a and 12b, and the semi-solid slurry 36b includes the other end of the metal hollow tube 12b and the middle metal. The end of the empty tube 12c is surrounded. Similarly, the semi-solid slurry 36c, 36d surrounds the other end of the metal hollow tubes 12a, 12c.

  During this surrounding, the flow of the semi-solid slurry 36a to 36d is hindered by the end portions of the metal hollow tubes 12a to 12c. Accordingly, the flow resistance of the semi-solid slurry 36a to 36d increases.

  As the flow resistance of the semi-solid slurry 36a to 36d increases, the pressing force with which the semi-solid slurry 36a to 36d presses each end of the metal hollow tubes 12a to 12c increases. As a result, the frictional force between the semi-solid slurry 36a to 36d and the end portions of the metal hollow tubes 12a to 12c increases, and the oxide film present on the surface of the semi-solid slurry 36a to 36d is received by this friction force. Is destroyed.

  In other words, in the present embodiment, the semi-solid slurry 36a to 36d is subjected to frictional resistance from each end of the metal hollow tubes 12a to 12c, and the surface layer is destroyed. leak. This slurry is not oxidized and therefore has good wettability to other metal materials.

  The slurry having good wettability comes into contact with each end of the metal hollow tubes 12a to 12c. That is, each end is wet and adhered by the slurry. If the slurry is cooled and solidified in this state to form the connecting members 14a and 14b, the end portions and the connecting members 14a and 14b are joined to each other while avoiding the formation of an oxide film between the end portions and the slurry. As a result, a cast product 10 as a joint-molded product is obtained.

  At the same time, the crushed and molded semi-solid slurry 36c and 36d are joined and cooled and solidified to form a bridge member 14c. Of course, for the reason described above, the bonding strength between the bridge member 14c and the metal hollow tubes 12a and 12c is also increased.

  In the cast product 10 obtained in this way, the bonding strength between adjacent metal hollow tubes 12a to 12c and any of the connecting members 14a to 14c interposed therebetween is high. As understood from the above, it is avoided that an oxide film intervenes between the metal hollow tubes 12a to 12c and the connecting members 14a to 14c.

  As described above, according to the present embodiment, the semi-solid slurry 36a to 36d is flowed to surround the respective ends of the metal hollow tubes 12a to 12c, thereby the flow resistance of the semi-solid slurry 36a to 36d. Since the oxide film on the surfaces of the semi-solidified slurries 36a to 36d is destroyed by raising the level, it becomes possible to firmly bond dissimilar metal materials.

  And when using the semi-solid slurry 36a-36d, the filling defect induced when performing injection molding using the molten metal in a solid-liquid coexistence state is avoided. For this reason, even the large cast product 10 can be efficiently manufactured.

  In this embodiment, the metal hollow tubes 12a to 12c are not molded. However, depending on the shape of the cast product 10, the metal hollow tube 12a is simultaneously formed with the crushing and molding of the semi-solid slurry. ~ 12c may be molded simultaneously.

  Of course, a metal hollow tube may be interposed between the semi-solid slurry 36c, 36d and the like.

  Further, in this embodiment, the semi-solid slurry 36a to 36d is interposed between the metal hollow tubes 12a to 12c, but the semi-solid slurry 36a to 36d is placed on the metal hollow tubes 12a to 12c. The mold may be clamped to cause the semi-solid slurry 36a to 36d to flow from above the metal hollow tubes 12a to 12c to the cast-in part.

  Furthermore, in this embodiment, four semi-solid slurries 36a to 36d are used, but the number of semi-solid slurries may be set according to the shape of the cast product, and in some cases even one. It is enough.

  When a plurality of semi-solid slurry is used, the semi-solid slurries may be different metals.

  Furthermore, in the above-described embodiment, an example in which a subframe is obtained as a mold is illustrated, but it goes without saying that the mold is not particularly limited to this. Of course, the work casted by the semi-solid slurry (material to be cast) is not particularly limited to the metal hollow tube. For example, various shaped bodies such as solid columnar members and castings are adopted. be able to.

It is the whole outline plane sectional view of the cast product manufactured by the manufacturing method of the cast product which concerns on this Embodiment. It is a principal part expanded longitudinal cross-sectional view of the cast product of FIG. It is a schematic longitudinal cross-sectional view of the front surface of the shaping | molding die which comprises a metal mold apparatus. It is a schematic longitudinal cross-sectional view of the rear surface of the shaping | molding die which comprises a metal mold apparatus. FIG. 4 is an overall schematic plan view of a die constituting the mold apparatus of FIG. 3. It is a schematic longitudinal cross-sectional view of the front surface of a shaping | molding die when the mold apparatus of FIG. 3 is clamped. It is a schematic longitudinal cross-sectional view of the rear surface of a shaping | molding die when the mold apparatus of FIG. 3 is clamped.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Casting goods 12a-12c ... Metal hollow tubes 14a-14c ... Connecting member 20 ... Mold apparatus 22 ... Die 24 ... Punch 30 ... Cavity 32a-32c ... Depression 34a-34c ... Mounting part 36a-36d ... Semi-solid slurry 38a-38c ... Slurry pressing part 40a-40c ... Work seal part

Claims (3)

Containing one or more semi-solid slurry and two or more workpieces in a mold;
Forming each of the semi-solid slurry into a shape corresponding to the shape of the cavity by performing mold clamping, and flowing to each cast casting part of the workpiece;
Solidifying the semi-solid slurry;
Have
A method for producing a cast product, wherein the cast product part is cast with the semi-solid slurry flowing to the cast part.   The manufacturing method according to claim 1, wherein the mold clamping is performed by placing the semi-solid slurry between the workpieces.   The manufacturing method according to claim 1, wherein the semi-solid slurry is placed on the workpiece and the mold clamping is performed.

Images