JP5264188B2 - Mold release agent for mold casting - Google Patents
Mold release agent for mold casting Download PDFInfo
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- JP5264188B2 JP5264188B2 JP2008002212A JP2008002212A JP5264188B2 JP 5264188 B2 JP5264188 B2 JP 5264188B2 JP 2008002212 A JP2008002212 A JP 2008002212A JP 2008002212 A JP2008002212 A JP 2008002212A JP 5264188 B2 JP5264188 B2 JP 5264188B2
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Abstract
Description
この発明は、アルミニウムの金型鋳造の内、スクイズダイキャストなどのように、溶湯を射出することにより行う、速度が遅く、溶湯が冷え易い鋳造方法に好適に使用することができる離型剤に関するものである。 TECHNICAL FIELD The present invention relates to a mold release agent that can be suitably used for a casting method that is performed by injecting a molten metal, such as squeeze die casting, among aluminum mold castings, that is slow and easy to cool. Is.
溶湯の射出速度が遅い（低速鋳込み）金型鋳造法は、鋳造品へのガスの巻き込みがなく、高強度の鋳造品を得ることができる。従って、このような鋳造品は、自動車の軽量化指向に伴うアルミニウム部品の製造に広く採用されている。
従来、金型鋳造の際に用いられる離型剤は、黒鉛が主流であったが、黒色で周囲を汚損するので好ましくなく、タルク、雲母、ろう石などの天然鉱物、あるいは窒化硼素、ＰＴＦＥ（ポリテトラフルオロエチレン）等の白色または淡色系の離型剤が多く用いられている。
これらの離型剤粒子は、カルボキシメチルセルロース（ＣＭＣ）等の分散剤を含む水中に懸濁させた塗料の形態で加熱された鋳型に塗布し皮膜を形成するものである。本出願人は、比表面積が４０ｍ２／ｇ以上の多孔質合成珪酸化合物からなる離型剤粒子を水中に懸濁させたものを既に提案した（特許文献４、５）。
Conventionally, a mold release agent used for mold casting has been mainly graphite, but it is not preferable because it is black and fouls the surroundings. Natural minerals such as talc, mica and wax stone, boron nitride, PTFE ( White or light-colored release agents such as polytetrafluoroethylene are often used.
These release agent particles are applied to a heated mold in the form of a paint suspended in water containing a dispersant such as carboxymethyl cellulose (CMC) to form a film. The present applicant has already proposed a product obtained by suspending release agent particles made of a porous synthetic silicate compound having a specific surface area of 40 m 2 / g or more in water (Patent Documents 4 and 5).
前記の金型鋳造法は、金型内に溶湯を完全に充填する前に溶湯温度が下ると、湯回りが悪くなり、湯じわ、湯境、あるいは欠肉などの品質上の欠陥を起こし易いという欠点が潜在している。従来の離型剤は熱伝導性がよいため、鋳造欠陥が比較的発生し難い単純な形状の小形部品用としては好適であったが、大形で複雑な形状の部品あるいは薄肉の部品などの場合には、湯回り不良による品質欠陥が発生し易いという問題点があった。この発明は、以上のような事情に鑑み、低速鋳込みの鋳造法において品質欠陥を起こさない離型剤を提供することを目的とするものである。
詳細には、上記特許文献２〜５に開示された目的と同様の白色または淡色系の水系離型剤を提供するものである。
In the mold casting method described above, when the temperature of the molten metal is lowered before the molten metal is completely filled in the mold, the temperature of the molten metal becomes worse, and quality defects such as hot water, hot water boundary, or undercutting occur. It has the disadvantage of being easy. Conventional mold release agents have good thermal conductivity, so they were suitable for small parts with simple shapes, where casting defects are relatively unlikely to occur, but large, complex parts, thin parts, etc. In such a case, there is a problem that a quality defect is likely to occur due to poor hot water. In view of the circumstances as described above, an object of the present invention is to provide a release agent that does not cause a quality defect in a low-speed casting method.
More specifically, the present invention provides a white or light-colored water-based mold release agent similar to the object disclosed in Patent Documents 2 to 5.
上記の課題を解決するために、この発明の金型鋳造用離型剤は、分散剤を含む水中に懸濁させる離型剤粒子として、モース硬度が３〜４の金属塩化合物からなる離型剤粒子を懸濁させたことを特徴とする金型鋳造用離型剤を提供するものである。
なお、金属塩化合物としては、硫酸バリウム、炭酸ストロンチウム、炭酸カルシウムのうち少なくとも１種を用いる。これらの化合物は、従来技術において提案されている上記のタルク、雲母、ろう石などの天然鉱物、あるいは窒化硼素、ＰＴＦＥ、合成珪酸化合物、その他ワックスと無機化合物の組合せなどとは相違し、離型剤用原料として本発明者らが新たに着目し、本発明を完成したものである。
また、本発明の他の態様においては、離型剤粒子の懸濁液中に、さらにイソフタル酸ナトリウムを添加することにより、潤滑剤としての効果を向上させることができる。
In order to solve the above-described problems, the mold casting release agent of the present invention is a release agent particle made of a metal salt compound having a Mohs hardness of 3 to 4 as release agent particles suspended in water containing a dispersant. The present invention provides a mold casting release agent characterized by suspending agent particles.
In addition, as a metal salt compound, at least 1 sort (s) is used among barium sulfate, strontium carbonate, and calcium carbonate. These compounds differ from the above-mentioned natural minerals such as talc, mica, and wax that have been proposed in the prior art, or boron nitride, PTFE, synthetic silicate compounds, and other combinations of waxes and inorganic compounds. The inventors of the present invention have newly paid attention as an agent raw material, and the present invention has been completed.
In another embodiment of the present invention, the effect as a lubricant can be improved by further adding sodium isophthalate to the suspension of release agent particles.
本発明の離型剤は、金型内に充填するアルミニウム溶湯に対する金型内面の保護効果に優れるため、低速射出鋳造に適用すれば、湯回りや湯流れ性がよくなり、複雑な形状の高品質アルミ鋳物を生産することが可能となる。 The mold release agent of the present invention is excellent in the effect of protecting the inner surface of the mold against the molten aluminum filled in the mold. It becomes possible to produce quality aluminum castings.
以下に、好ましい実施の形態を挙げて本発明を更に詳しく説明する。
上記のモース硬度は、主として鉱物に対する硬さの尺度であり、１〜１０までの整数値で標準物質を定め、その標準物質と試料を比較して、ひっかいた時の傷の付き難さを指標として標記するものである。すなわち、本発明においてモース硬度３〜４とは、モース硬度３の方解石およびモース硬度４の蛍石を標準物質として用い、方解石でひっかいても傷付かないが、蛍石でひっかくと傷が付くような硬さの物質を意味する。
このように、モース硬度によって特定した金属塩化合物粒子を含有する金型鋳造用離型剤を金型内に塗布・皮膜化させ鋳造を行うと、ワークを離型する際に金型内面を傷付けることがない。
Hereinafter, the present invention will be described in more detail with reference to preferred embodiments.
The Mohs hardness is mainly a measure of hardness against minerals. A standard substance is defined by an integer value from 1 to 10, and the standard substance and the sample are compared to indicate the difficulty of scratching when scratched. As shown below. That is, in the present invention, the Mohs hardness 3 to 4 uses calcite with a Mohs hardness of 3 and fluorite with a Mohs hardness of 4 as a standard substance, and even if scratched with calcite, it will not be scratched, but it will be scratched with fluorite. Means a material with high hardness.
Thus, when the mold casting release agent containing the metal salt compound particles specified by the Mohs hardness is applied and formed into a film in the mold and cast, the inner surface of the mold is damaged when the workpiece is released. There is nothing.
離型剤中の金属塩化合物の使用量は、配合するその他の固形分材料との兼ね合いで変化させるが、調合時の配合量は３〜２５質量％、好ましく５〜２０質量％、特に好ましくは７〜１５質量％の範囲である。調合時の配合量が３質量％未満であると金属塩化合物粒子の含有量が少なく、後述のように、調合時の組成物を後に希釈して使用するのが一般的であるから、金型の内面を保護する効果を有する皮膜を形成することができない。また、調合時の組成物が希薄であると、それを大量に貯留する必要があり、現場管理上不都合である。更に、金属塩化合物の濃度が高過ぎても、あるいは低過ぎても、粒子の沈殿や凝集が起こり、調合液を希釈して使用する場合に均一に分散し難くなる。
用いる金属塩化合物粒子の大きさは、レーザー光学式粒度分布測定装置を用いて測定した平均粒子径（Ｄ５０）が０.１〜１μｍ、好ましくは０.３〜０.７μｍ、特に好ましくは０.５μｍ程度である。
The amount of the metal salt compound used in the release agent is changed in consideration of the other solid material to be blended, but the blending amount at the time of blending is 3 to 25% by mass, preferably 5 to 20% by mass, particularly preferably. It is in the range of 7 to 15% by mass. If the blending amount is less than 3% by mass, the content of the metal salt compound particles is small, and as described later, it is common to dilute and use the composition at the time of blending, as described later. A film having the effect of protecting the inner surface of the film cannot be formed. Moreover, when the composition at the time of preparation is dilute, it is necessary to store a large amount thereof, which is inconvenient in field management. Furthermore, even when the concentration of the metal salt compound is too high or too low, precipitation or aggregation of particles occurs, and it becomes difficult to uniformly disperse the preparation liquid after diluting it.
As for the size of the metal salt compound particles used, the average particle diameter (D 50 ) measured using a laser optical particle size distribution measuring device is 0.1 to 1 μm, preferably 0.3 to 0.7 μm, particularly preferably 0. It is about .5 μm.
モース硬度が３〜４の金属塩化合物の例としては、硫酸バリウム［ＢａＳO４］（モース硬度：３.０）、炭酸ストロンチウム［ＳｒＣＯ３］（モース硬度：３.５）、炭酸カルシウム［ＣａＣＯ３］（モース硬度：３.０）などが挙げられる。実際には、これらの少なくとも１種あるいは２種以上を併用する。なお、これらの金属塩化合物の内、特に好ましいものは、胃腸のX線検査の造影剤として使用される硫酸バリウムである。 Examples of metal salt compounds having a Mohs hardness of 3-4 include barium sulfate [BaSO 4 ] (Mohs hardness: 3.0), strontium carbonate [SrCO 3 ] (Mohs hardness: 3.5), calcium carbonate [CaCO 3 ] (Mohs' hardness: 3.0). In practice, at least one or two or more of these are used in combination. Among these metal salt compounds, barium sulfate used as a contrast agent for gastrointestinal X-ray examination is particularly preferable.
この発明の離型剤の内、モース硬度が上記のように特定される金属塩化合物を単独で用いる場合には、離型剤の潤滑性は比較的低いが金型内面を保護する効果が高いため、鋳造品が単純な形状の場合に適している。鋳造品が複雑な形状の場合には、前記金属塩化合物のみからなる離型剤に、さらにイソフタル酸ナトリウムを、調合時の配合量として５〜１５質量％添加することによって、鋳造用離型剤としての潤滑性を向上させることができる。配合量が５質量％未満では添加効果が発揮されず、逆に１５質量％を超えてもそれ以上の添加効果は認められない。
なお、従来から知られているタルク、窒化硼素、弗化黒鉛などの固体潤滑剤粒子を添加して潤滑性を向上させることも可能である。なお、固体潤滑剤粒子のうち黒鉛は黒色であるから、用いる場合は少量にすることが好ましい。
Among the release agents of this invention, when a metal salt compound whose Mohs hardness is specified as described above is used alone, the release agent has a relatively low lubricity but a high effect of protecting the mold inner surface. Therefore, it is suitable when the cast product has a simple shape. When the cast product has a complicated shape, a mold release agent for casting is obtained by adding 5 to 15% by mass of sodium isophthalate as a compounding amount at the time of preparation to the mold release agent composed of only the metal salt compound. As a result, the lubricity can be improved. If the blending amount is less than 5% by mass, the effect of addition is not exhibited. Conversely, if the amount exceeds 15% by mass, no further effect of addition is recognized.
In addition, it is possible to improve lubricity by adding solid lubricant particles such as talc, boron nitride, and fluorinated graphite which are conventionally known. In addition, since graphite is black among solid lubricant particles, when using it, it is preferable to make it small.
鋳造物品の形状や寸法によって、金型面への離型剤塗膜の接着性が必要な場合には、懸濁液中にさらに水ガラス、コロイド状シリカなどの無機系材料やエマルジョン、樹脂などの有機系材料を適宜添加することができる。その添加量は固形分として約２〜１５質量％程度の範囲が好ましい。 Depending on the shape and dimensions of the cast article, if adhesiveness of the release agent coating to the mold surface is required, inorganic materials such as water glass and colloidal silica, emulsions, resins, etc. in the suspension These organic materials can be added as appropriate. The addition amount is preferably in the range of about 2 to 15% by mass as the solid content.
なお、この発明の離型剤懸濁液は、上記のとおり、調合（懸濁液製造）時には固形分の濃度を高くし（固形分として２０〜３０質量％程度）、残部は溶媒として水を添加して調製し、保存する。後刻の使用時に、金型の寸法、形状、塗布条件などに合わせて、適宜の濃度に離型剤懸濁液を希釈して金型面に塗布する。例えば、固形分として０.１〜１０質量％程度に水で希釈して用いるのが一般的である。 In addition, as above-mentioned, the mold release agent suspension of this invention makes the density | concentration of solid content high at the time of preparation (suspension manufacture) (about 20-30 mass% as solid content), and the remainder uses water as a solvent. Add to prepare and store. At the time of later use, the release agent suspension is diluted to an appropriate concentration and applied to the mold surface according to the dimensions, shape, application conditions, etc. of the mold. For example, the solid content is generally diluted with water to about 0.1 to 10% by mass.
以下に、実施例によりこの発明をさらに詳細に説明するが、この発明はそれらの実施例に限定されるものではない。 Hereinafter, the present invention will be described in more detail with reference to examples, but the present invention is not limited to these examples.
〔実施例１〕
ここではまず、離型剤粒子の金属塩化合物の状態について説明する。
分散剤として２質量％のＣＭＣを水に溶解した液に、表１に示すような平均粒子径（Ｄ５０）が０.５μｍ程度の各種の無機粉体２０質量％を、凝集塊が生じないように徐々に添加し、十分に撹拌して離型剤試料を調製した。その後離型剤試料を金型に塗布する前に、全固形分が２.０質量％になるように水で希釈した。なお、用いた無機粉体材料とそのモース硬度値を表１に示す。表中のタルクおよび雲母は、従来離型剤として使用される無機粉体であり、硫酸バリウム、炭酸ストロンチウムおよび炭酸カルシウムはこの発明において離型剤としての新規な用途を提案する金属塩化合物である。
[Example 1]
Here, first, the state of the metal salt compound of the release agent particles will be described.
Aggregates are not formed in a solution in which 2% by mass of CMC as a dispersant is dissolved in water and 20% by mass of various inorganic powders having an average particle diameter (D 50 ) of about 0.5 μm as shown in Table 1. The release agent sample was prepared by gradually adding and stirring well. Thereafter, before the release agent sample was applied to the mold, it was diluted with water so that the total solid content was 2.0% by mass. The inorganic powder material used and its Mohs hardness value are shown in Table 1. Talc and mica in the table are inorganic powders conventionally used as mold release agents, and barium sulfate, strontium carbonate, and calcium carbonate are metal salt compounds that propose novel uses as mold release agents in the present invention. .
また、表２に示すように、無機粉体の全量を１００質量部とする各材料の配合量を、上記ＣＭＣ水溶液に添加して離型剤試料を調製し、更に水で希釈して得た離型剤組成物を塗布して形成した皮膜について、離型抵抗および金型温度の最高値を測定した。 Moreover, as shown in Table 2, the release agent sample was prepared by adding the compounding amount of each material in which the total amount of the inorganic powder was 100 parts by mass to the CMC aqueous solution, and further diluted with water. With respect to the film formed by applying the release agent composition, the maximum values of the mold release resistance and the mold temperature were measured.
それぞれの評価方法は、以下のとおりである。
〔離型抵抗〕
２００℃に加熱した２００×２００ｍｍの金属製平板（材質：ＳＫＤ６１）上に離型剤組成物をスプレー塗布し、皮膜化させた。皮膜の乾燥時の厚みは約１μｍであった。
その皮膜上にφ１００ｍｍ（外径）、高さ５０ｍｍ、厚さ１ｍｍの金属製丸型枠（材質：ＳＫＤ６１）を置き、その中に６８０℃に加熱したアルミニウム合金（ＡＣ４Ｃ）の溶湯１００ｃｍ３を注ぎ入れ、４０秒後に１０ｋｇの錘を載せ、丸型枠を金属平板上で移動させた。その時の必要荷重をロードセルで測定し、単位面積（丸型枠内の接触面積：７５ｃｍ２）当たりの荷重を算出した。この離型抵抗値が低いものほど、潤滑性に優れる離型剤皮膜が得られたと判断する。
Each evaluation method is as follows.
(Release resistance)
The release agent composition was spray-coated on a 200 × 200 mm metal flat plate (material: SKD61) heated to 200 ° C. to form a film. The thickness of the film when dried was about 1 μm.
A metal round frame (material: SKD61) having a diameter of 100 mm (outer diameter), a height of 50 mm, and a thickness of 1 mm is placed on the coating, and 100 cm 3 of a molten aluminum alloy (AC4C) heated to 680 ° C. is poured therein. After 40 seconds, a 10 kg weight was placed, and the round frame was moved on the metal flat plate. The required load at that time was measured with a load cell, and the load per unit area (contact area in the round frame: 75 cm 2 ) was calculated. It is judged that the lower the release resistance value is, the more excellent release agent film is obtained.
〔金型温度〕
前記離型抵抗の評価治具を用いる。但し、金属製平板には熱電対が埋め込まれており、金属製平板の温度変化の状態を確認できるようにした。２００℃に加熱した金属製平板上に前記離型剤組成物をスプレー塗布し皮膜を形成した。皮膜形成部分の上に金属製丸型枠を載せ、その枠内に６８０℃の溶融アルミニウム合金を流し込む。流し込み時から１分間の平板温度変化状態を観察し、最高到達温度を記録した。この評価で、温度が高い場合は、アルミニウム溶湯の熱が金型側に移動したと見なし、実際の鋳造評価においては湯廻りの悪い離型剤皮膜と見なされる。一方、温度が低い場合は、離型剤皮膜による熱伝播が悪く湯廻りの良い離型剤皮膜と見なした。
[Mold temperature]
The mold release resistance evaluation jig is used. However, a thermocouple was embedded in the metal flat plate so that the temperature change state of the metal flat plate could be confirmed. The release agent composition was spray-coated on a metal flat plate heated to 200 ° C. to form a film. A metal round frame is placed on the film forming portion, and a molten aluminum alloy at 680 ° C. is poured into the frame. The state of plate temperature change for 1 minute from the time of pouring was observed, and the maximum temperature reached was recorded. In this evaluation, when the temperature is high, it is considered that the heat of the molten aluminum has moved to the mold side, and in the actual casting evaluation, it is regarded as a release agent film with poor hot water circulation. On the other hand, when the temperature was low, it was regarded as a release agent film with poor heat propagation due to the release agent film and good hot water circulation.
表２に示す評価結果では、従来から知られている比較試料であるタルク、雲母（試料番号１、２）を含め、本発明試料の９点（試料番号３〜１１）について、採用したいずれの評価においても離型抵抗は９ｋｇｆ／ｃｍ２以下であった。 In the evaluation results shown in Table 2, any of the 9 samples (sample numbers 3 to 11) of the present invention, including talc and mica (sample numbers 1 and 2), which are conventionally known comparative samples, were adopted. Also in the evaluation, the mold release resistance was 9 kgf / cm 2 or less.
〔実施例２〕
次に、さらに潤滑特性を向上させるための方策として、本発明の金属塩化合物からなる離型剤組成物にイソフタル酸ナトリウムを添加した場合の試験結果を示す。用いた金属塩化合物は、実施例１と同様に、硫酸バリウム、炭酸ストロンチウム、炭酸カルシウムの３種である。
実施例１と同様の方法で、表３に示す配合組成で離型剤試料を調製した。また、実施例１と同様の評価によって離型抵抗および金型温度（最高値）を測定した。
評価結果を表３に示す。
[Example 2]
Next, a test result when sodium isophthalate is added to the release agent composition comprising the metal salt compound of the present invention will be shown as a measure for further improving the lubrication characteristics. As in Example 1, the metal salt compounds used were three kinds of barium sulfate, strontium carbonate, and calcium carbonate.
In the same manner as in Example 1, a release agent sample was prepared with the composition shown in Table 3. Further, the mold release resistance and the mold temperature (maximum value) were measured by the same evaluation as in Example 1.
The evaluation results are shown in Table 3.
硫酸バリウムに、更にイソフタル酸ナトリウムを添加した試料番号２１〜２３の離型剤では、離型抵抗値が減少し、イソフタル酸ナトリウムの添加量が多いものほど、低い抵抗値を示した（試料番号２１）。この傾向は、金属塩化合物が炭酸ストロンチウムおよび炭酸カルシウムの場合でも同様の結果となった。 In the release agents of sample numbers 21 to 23, in which sodium isophthalate was further added to barium sulfate, the release resistance value decreased, and the higher the amount of sodium isophthalate added, the lower the resistance value (sample number). 21). This tendency was the same even when the metal salt compound was strontium carbonate and calcium carbonate.
この発明の金属塩化合物からなる離型剤組成物は、金型内に充填されるアルミニウム溶湯に対する金型内面の保護効果に優れるため、低速射出鋳造に適用され、湯回り、湯流れ性がよく、アルミニウムの金型鋳造の内、スクイズダイキャストなどのように、溶湯を射出する速度が遅く、溶湯が冷え易い鋳造方法に好適に使用することができる。 The mold release agent composition comprising the metal salt compound of the present invention is excellent in the effect of protecting the inner surface of the mold against the molten aluminum filled in the mold, and thus is applied to low-speed injection casting and has good hot water flow and hot water flow. Of aluminum mold casting, it can be suitably used for casting methods such as squeeze die-casting where the molten metal is injected at a low speed and the molten metal is easily cooled.
Claims (4)
Before using a mold release agent, after diluting with water so that total solid content may be 0.1-10 mass%, it apply | coats to a metal mold | die surface, It is any one of Claim 1 to 3 characterized by the above-mentioned. The mold release agent for mold casting as described.
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