JPH07232262A - Production of intake manifold - Google Patents

Abstract

PURPOSE:To prevent the joining defect at the joining part between a part made of Al casting and part made of Al extruded material so as to prevent leakage from the joined part. CONSTITUTION:A zinc spraying layer is formed on the outer circumferential surface of both ends of a branch tube 3 made of Al extruded material. One end of the branch tube 3 is placed to a sand mold 11 for a plenum chamber casting, the other end part is placed to a sand mold 12 for a mounting flange casting. By high frequency induction heating method, the branch tube 3 made of Al extruded material is heated to 350-500 deg.C. Under this state, Al molten metal is poured in each sand mold 11, 12, one end of the branch tube 3 is cast in to the cylindrical outward project/ing part of the plenum chamber and at the same time the other end is cast in to the cylindrical projecting part of the mounting flange for a cylinder head.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing an intake manifold, which comprises an aluminum casting part and an aluminum extruded profile part connected to the aluminum part, and is used, for example, in an automobile engine.

In this specification, the term "aluminum" includes aluminum alloy in addition to pure aluminum.

[0003]

2. Description of the Related Art As an intake manifold for an automobile engine, which comprises an aluminum casting component and an aluminum extrusion profile component connected thereto, for example, an aluminum casting plenum chamber and an aluminum casting cylinder head mounting flange. And a plurality of branch pipes made of extruded aluminum having one end connected to a plenum chamber and the other end connected to a mounting flange. Then, such an intake manifold, after arranging both ends of the aluminum extruded shape branch pipe in the plenum chamber casting mold and the mounting flange casting mold, the molten aluminum is poured into the mold to branch the pipe. Manufactured by casting both ends with a plenum chamber and a flange (Jpn.
No. 2).

[0004]

However, in the conventional method, since the oxide film is formed on the surface of the branch pipe made of the aluminum extruded profile, the plenum chamber and the mounting flange are not formed in the manufactured intake manifold. There is a problem in that a joint failure occurs with the branch pipe and leakage occurs from the joint portion.

An object of the present invention is to provide a method for manufacturing an intake manifold that solves the above problems.

[0006]

SUMMARY OF THE INVENTION A method of manufacturing an intake manifold according to the present invention is directed to an intake manifold comprising an aluminum casting part and an aluminum extruded profile part connected thereto, and an aluminum extruded profile part being used as a mold. When the molten aluminum is poured into the mold and the aluminum extruded profile parts are made by casting with aluminum cast parts, the connection part of the aluminum extruded profile parts with the aluminum cast parts A zinc sprayed layer was formed on the surface of the aluminum alloy in an active and clean state immediately after extrusion, a sand mold was used as a mold, and an aluminum extruded profile part was formed by a high frequency induction heating method.
It is characterized in that it is heated to 0 to 500 ° C. and that molten aluminum is poured into the mold in this state.

In the above, the zinc sprayed layer has a function of firmly joining the aluminum extruded profile part and the aluminum cast part in the manufactured intake manifold. The thickness of the zinc sprayed layer is preferably 10 to 100 μm. If it is less than 10 μm, the joint strength between the aluminum extruded shape component and the aluminum casting component may not be sufficiently large, and if it exceeds 100 μm, the cost becomes high and the effect of improving the joint strength even if the thickness is further increased. Because it will not change.

When the aluminum extruded profile part is heated to 350 to 500 ° C. by the high frequency induction heating method and the molten aluminum is poured into the mold in this state, the aluminum extruded profile part and the aluminum cast part are produced. The temperature of the zinc sprayed layer formed on the connection part also becomes the above temperature, and the temperature of the molten aluminum (JIS AC2B, AC4C
Etc., the wettability between the zinc sprayed layer and the molten aluminum is improved, and the aluminum casting component after casting and the aluminum extrusion profiled component are firmly joined. It will be. However, if the heating temperature is lower than 350 ° C., such an effect cannot be obtained, and if it exceeds 500 ° C., the zinc sprayed layer may melt. Therefore, the heating temperature should be in the range of 350 to 500 ° C, but it is preferable to heat in the range of 400 to 450 ° C.

[0009]

[Operation] An intake manifold composed of an aluminum casting part and an aluminum extrusion profile part connected to the intake manifold is placed in the mold and then the molten aluminum is poured into the mold to extrude the aluminum. When manufacturing shaped parts made by casting aluminum cast parts, the zinc sprayed layer is active and clean immediately after extrusion on the surface of the connection part of the aluminum extruded parts with the aluminum cast parts. By forming, the oxide film is not formed on the part where the zinc sprayed layer is formed in the aluminum extruded profile part, and the zinc sprayed layer firmly adheres to the aluminum extruded profile part. Will be there. Moreover, when the aluminum extruded profile parts are placed in the mold and then the molten aluminum is poured into the mold to cast the aluminum extruded profile parts with the aluminum cast parts, the aluminum cast parts and the zinc sprayed layer And is firmly bonded. Therefore, in the manufactured intake manifold, the aluminum extruded profile part and the aluminum cast part are firmly joined via the zinc sprayed layer.

When a sand mold is used as the mold, only the aluminum extruded profile parts can be heated to a desired temperature by the high frequency induction heating method.

When the aluminum extruded profile part is heated to 350 to 500 ° C. by the high frequency induction heating method, the temperature of the zinc sprayed layer formed at the connection portion of the aluminum extruded profile part with the aluminum cast part is increased. Also becomes the above temperature and approaches the temperature of the aluminum molten metal, the wettability between the zinc sprayed layer and the aluminum molten metal is improved, and the joining between the aluminum casting component after casting and the aluminum extruded profile component becomes firm. Done.

[0012]

Embodiments of the present invention will be described below with reference to the drawings.

1 and 2 show an example of an intake manifold for an automobile engine manufactured by the present invention.

In FIG. 1, an intake manifold (1) comprises a tubular aluminum casting plenum chamber (2) having one end open and the other end closed, and a plurality of pipes each having one end connected to the plenum chamber (2). The aluminum extruded profiled branch pipe (3) and the other end of all the branch pipes (3) are connected together to a flange (4) for mounting on a cylinder head made of cast aluminum.

A throttle body mounting flange (5) is integrally formed at the open end of the plenum chamber (2). A throttle body including a throttle valve (not shown) is attached to the throttle body mounting flange, and an air supply pipe from an air cleaner is connected to the throttle body. Plenum chamber (2)
The same number of holes (6) as the branch pipes (3) are formed on the peripheral wall of the, and a cylindrical outward protrusion (7) is integrally formed around each hole (6). One end of the branch pipe (3) is surrounded by the protrusion (7).

The other end of the branch pipe (3) is connected to a cylinder head of an engine (not shown) via a flange (4). The flange (4) has the same number of holes (not shown) as the branch pipe (3), and cylindrical projections (8) are integrally formed around each hole. ) Surrounds the other end of the branch pipe (3). Further, an insertion port (9) of the fuel injection device is formed in a portion of the flange (4) above each tubular projection (8).

The plenum chamber (2) and the flange (4) for mounting on the cylinder head are, for example, JIS A
It is cast from C2B, AC4C, etc.

As shown in FIG. 2, the outer peripheral surface of the end of the branch pipe (3) on the side of the plenum chamber (2) which is surrounded by the cylindrical outer protruding portion (7) is 10 to 100 μm. A zinc sprayed layer (10) having a thickness of 1 is formed over a predetermined length. Although not shown in the drawings, the outer peripheral surface of the end of the flange (4) that is surrounded by the tubular projection (8) is also
A zinc sprayed layer having a thickness of 10 to 100 μm is formed over a predetermined length. The branch pipe (3) is, for example, JI
It is made by bending an extruded pipe made of S A6063 alloy into a U-shape, and the zinc sprayed layer (10) is formed during extrusion molding of the pipe when it is in an active and clean state immediately after extrusion. It is a thing.

Next, a method of manufacturing the intake manifold (1) will be described with reference to FIG.

First, an extruded pipe having a zinc sprayed layer (10) of a predetermined thickness and a predetermined length on the outer peripheral surfaces of both ends is bent and branched into a U shape when it is in an active and clean state immediately after extrusion. Make a tube (3). Also, sand mold for plenum chamber casting
Prepare (11) and sand mold (12) for flange mounting for mounting on cylinder head. Both sand molds (11) (12) are
It consists of a) (12a) and lower molds (11b) (12b). Next, one end of each branch pipe (3) is interposed between the upper and lower molds (11a) and (11b) of the plenum chamber casting sand mold (11), and the other end is attached to the cylinder head. It is interposed between the upper and lower molds (12a) and (12b) of (12).

Both sand molds (11) (12) and branch pipe (3)
Is placed in the high frequency induction coil (13). The high frequency induction coil (13) is formed of a hollow copper tube (14), and cooling water is circulated in the high frequency induction coil (13) in order to prevent overheating of itself.

In such a state, a high frequency current is supplied from the high frequency power supply (15) to the high frequency induction coil (13) while circulating cooling water in the hollow copper tube (14) forming the high frequency induction coil (13). . Then, an induced current is generated in the branch pipe (3), and Joule heat of the induced current heats the branch pipe (3). The heating temperature of the branch pipe (3) at this time is 350-
The temperature is set to 500 ° C, preferably 400 to 450 ° C. After that, molten aluminum is poured from the sprue (not shown) of each sand mold (11) (12), and one end of the branch pipe (3) is cast by the cylindrical outward projection (7) of the plenum chamber (2). Along with the rounding, the other end is cast around by the cylindrical protruding portion (8) of the flange (4). Thus, the intake manifold (1) is manufactured.

[0023]

As described above, according to the method for manufacturing the intake manifold of the present invention, the aluminum extruded profile part and the aluminum cast part can be firmly joined together via the zinc sprayed layer. Further, since the sand mold is used as the mold, only the aluminum extruded profile parts can be accurately heated to the desired temperature by the high frequency induction heating method. As a result, when the aluminum extruded profile part is heated to 350 to 500 ° C. by the high frequency induction heating method, the temperature of the zinc sprayed layer formed at the connection part of the aluminum extruded part part with the aluminum cast part is also the above temperature. And approach the temperature of the molten aluminum.
The wettability between the zinc sprayed layer and the molten aluminum is improved, and the aluminum casting component after casting and the aluminum extruded component member are firmly joined. Therefore, it is possible to prevent the occurrence of joint failure at the joint between the aluminum casting component and the aluminum extruded profile component, and to prevent leakage from this joint.

[Brief description of drawings]

FIG. 1 is a perspective view showing an example of an intake manifold manufactured by the method of the present invention.

FIG. 2 is an enlarged cross-sectional view of a portion of a cylindrical outward protrusion in the plenum chamber of the intake manifold.

FIG. 3 is a diagram showing a method for manufacturing an intake manifold.

[Explanation of symbols]

(1) Intake manifold (2) Plenum chamber (3) Branch pipe (4) Cylinder head mounting flange (10) Zinc sprayed layer (11) Plenum chamber sand casting mold (12) Cylinder head mounting flange casting Sand mold

Continuation of front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display area F02M 35/10 F02M 35/10 301 P

Claims (1)

[Claims] 1. An intake manifold comprising an aluminum casting part and an aluminum extrusion profile part connected to the aluminum manifold part is placed in a mold, and then an aluminum melt is poured into the mold. When manufacturing aluminum extruded shape parts by casting with aluminum cast parts, on the surface of the connection part of the aluminum extruded shape parts with the aluminum cast parts, zinc in an active and clean state immediately after extrusion A sprayed layer is formed in advance, a sand mold is used as a mold, and the aluminum extruded profile parts are 350 to 350
A method for manufacturing an intake manifold, which comprises heating to 500 ° C. and pouring molten aluminum into a mold in this state.