JPH11151569A - Method for integrally casting plural metallic materials and integral cast product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an integral casting method of plural metallic materials for integrally forming metal needing the different characteristics of wear resistance, heat resistance, etc., from a base body metal on the surface layer of the base body metal, and also provided an integral cast product. SOLUTION: A cast product forming part is formed in a mold 25 and also, plural cast product forming parts S1, S2 are formed by interposing a partition body at a prescribed position. Plural molten metallic materials K1, K2 are poured into plural cast product forming parts and also, the partition body 30 is melted and a fused metallic layer K3 is formed to integrally form plural metallic materials. By this method, plural metal can accurately and integrally be cast at the prescribed position.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a casting technique for integrally forming a plurality of metal materials, and more particularly to a method and a method for integrally casting a plurality of metal materials which can integrate a plurality of different metal materials at predetermined positions. Related to castings.

[0002]

2. Description of the Related Art For example, a cylinder block of an engine is cast from an aluminum casting. As shown in FIG. 8, in the cylinder block 10, a wear-resistant cylinder liner 5 is press-fitted into a bore 3A of the cylinder 3 opened at the top of the casting body at the time of casting or post-processing. . This is because it must withstand intense high-temperature and high-speed friction with the piston.

The cylinder block 10 is made lighter by a hypoeutectic aluminum alloy. On the other hand, the cylinder liner 5 press-fitted into the bore 3A is made of iron. However, there is a problem that adhesion between the two metals is emphasized. Furthermore, the cylinder liners 5 require a sufficient distance L between the cylinder liners 5, and the cylinder block 10 is inevitably long and large, and thus cannot be reduced in weight. That said, the cylinder block 1 together with the body
If it is formed of a hypereutectic aluminum alloy even up to 0, there is a problem that it becomes hard and it becomes difficult to form a screw or the like, thereby lowering the processing efficiency and causing a crack or chipping, thereby affecting the production cost.

[0004] A base metal plate in a brake pad of a disc brake and a brake shoe (friction piece) adhered to the base metal plate are joined by bonding or welding.
According to this fixing means, in addition to the casting process of the base metal plate,
A step of forming the brake shoe and a step of joining it to the base metal plate are required, which complicates the manufacturing process and affects production costs.

Further, a wear-resistant spring which has a surface layer having high wear resistance formed on the surface of a base metal plate, and which can reduce wear even when repeatedly receiving a load of spring pressure by pressing a coil spring end face against the surface layer. Receiving members are known. As a method of forming a surface layer having high wear resistance on the surface of the base metal plate, a method of performing electroplating or a step of bonding another material is performed, but it takes time to manufacture and increases the production cost. .

[0006]

SUMMARY OF THE INVENTION The present invention has been developed in view of the above-mentioned problems such as press-fitting of a cylinder liner into a cylinder block. It is an object of the present invention to provide an integrated casting method capable of integrating a plurality of different metal materials at predetermined positions, for example, by integrally forming a metal required to have different properties from a base metal such as a property, and a casting thereof. I do.

[0007]

According to a first aspect of the present invention, there is provided a method for integrally casting a plurality of metallic materials, the method comprising: Forming a molded part, pouring a plurality of molten metal materials into a plurality of molded parts, respectively, forming a casting, melting the partition body, and fusing the divided body part with a plurality of molten metal materials. A metal layer is formed, and the plurality of metal materials are integrally formed.

According to a second aspect of the present invention, in the method for integrally casting a plurality of metal materials according to the first aspect, the molded part is a vanishing model.

According to a third aspect of the present invention, in the method for integrally casting a plurality of metal materials according to the first aspect, the molded product is a space in a mold or a sand mold.

[0010] Claim 4 is Claim 1, 2 or 3
In the above-described method for integrally casting a plurality of metal materials, the partition body is a resinous film-like body that can be eliminated.

[0011] Claim 5 is Claim 1, 2 or 3
In the integrated casting method of a plurality of metal materials described above, the partition body is a metal material.

According to a sixth aspect of the present invention, an integrated casting of a plurality of metal materials is manufactured by the method of integrally casting a plurality of metal materials according to any one of the first to fifth aspects. , To form an integral casting.

According to a seventh aspect of the present invention, there is provided an integrated casting of a plurality of metal materials according to the sixth aspect, wherein a base portion is formed of a hypoeutectic aluminum alloy, and a sliding portion is provided. Is formed of a wear-resistant alloy such as a hypereutectic aluminum alloy or a copper alloy.

[0014]

According to the first aspect of the present invention, a molded product portion is formed in a mold, and a partition member is interposed at a predetermined position of the molded product portion to form a plurality of molded product portions. Pour molten metal material. As a result, first, different molten metal materials are first filled in the plurality of cast molded portions, and the different molten metal materials on both sides melt the partition plate separating the cast molded portions. As a result, a fusion metal layer of a plurality of different metal materials is formed at the part of the partition body, and an integrated casting made of different molten metal materials integrated at the predetermined position accurately via the fusion metal layer is formed.

According to a second aspect of the present invention, the casting method of the first aspect can be carried out using a vanishing model.

According to the third aspect, the casting method of the first aspect can be carried out by using a mold and a sand mold.

According to a fourth aspect of the present invention, in the first aspect,
In the casting method of 2 or 3, since the partition body was made of a resin-made film having a fugitive property, the molten metal was filled into the casting molding while separating a plurality of molten metal materials for a certain period of time, and then the partition body was melted and melted. Disappears to form a fused metal layer, and accurately integrates a plurality of metal materials at predetermined positions.

According to a fifth aspect, the first aspect,
In the casting method of 2 or 3, since the partition body is made of a metal material, the molten metal is filled in a casting molding portion while separating a plurality of molten metal materials for a certain period of time, and then the partition body is melted to form a plurality of molten metal materials. To form a fused metal layer, and integrate a plurality of metal materials accurately at predetermined positions.

Further, according to the present invention, an integrated casting in which a plurality of metal materials are fused at predetermined positions is obtained, and the base metal has a surface layer different from the base metal such as abrasion resistance and heat resistance. A plurality of different metal materials are integrated at a predetermined position, for example, by integrally forming a metal requiring characteristics.

Further, according to the present invention, the base portion is formed of a lightweight and soft hypoeutectic aluminum alloy, and the sliding portion is formed of a hypereutectic aluminum alloy or a copper alloy having high wear resistance. It is formed of metal, and these are integrally formed at a predetermined position accurately through a fusion metal layer.The main body is lightweight, compact, has good workability, and the sliding portion is formed of an alloy having high wear resistance. Can be easily manufactured and provided at a low cost.

[0021]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of an embodiment of a method for integrally casting a plurality of metallic materials according to the present invention. FIG. 1 shows, as a first embodiment, a method of manufacturing a cylinder block using a vanishing model.

First, a mold 25 is formed in a frame 20 by sand 23. This mold 25 has two runners 2
5A and 25B, the vane cups 25C and 25D and the vanishing model 27 as the first molded part S1 and the vanishing model 29 as the second molded part S2 are stored.
As shown in FIGS. 1 and 2, the disappearance models 27 and 29 are made of a foamed body for the body (foamed body made of synthetic resin) 27A to be the cylinder block 50 and a foamed foam for the bore to be the cylinder liner 53. Body (foam molded article made of synthetic resin) 2
9A. In addition, the main body foam molded body 27A shows an example in which the cylinder block 50 is a closed deck type, the upper part 27B serving as a water jacket is closed, and a hollow part 27C formed by a sand core is formed.

Between the two types of disappearing models 27 and 29, a vanishing resin film 30 serving as a partition is interposed to separate the two disappearing models 27 and 29. Note that a coating layer A is formed on the surfaces of the two types of disappearance models 27 and 29 that are in contact with the sand 23. In addition, a vinyl sheet 40 is placed on the upper surface of the sand 23, and a wire mesh plate 43 for deaeration and a space S3 are formed on the bottom 20A in the frame 20, and the space S3 is a vacuum pump disposed outside. Connected to P, vanishing models 27, 29
The gas generated when the gas disappears is sucked and exhausted.

According to the first embodiment, a method of integrally casting a plurality of metal materials is performed as follows. First, as shown in FIG.
Then, molten hypoeutectic aluminum alloy (metal material) K1 is poured from gate cup 25C, and molten hypereutectic aluminum alloy (metal material) K2 is poured from other gate cup 25D. . Thus, the poured hypoeutectic aluminum alloy (metal material) K1 and the hypereutectic aluminum alloy (metal material) K2 are replaced with the foaming body for body 27A and the foaming body for bore portion 29A, The side in contact with the sand 23 is cooled and solidified by the endothermic action of the sand, and a cast of a predetermined shape is formed by each metal.

Next, the melted hypoeutectic aluminum alloy (metal material) K1 and the hypereutectic aluminum alloy (metal material) K2 on both sides that are melted contact each other at the portion of the vanishable resin film 30 which is a partition. However, since this resin film 30 has a time difference required for melting and is slowly melted, it is maintained without being occupied by any molten metal material. The entire film-like body 30 disappears, and a fusion metal layer K3 of both molten metal materials is formed on the joint surface.

Therefore, the hypoeutectic aluminum alloy (metal material) K1 and the hypereutectic aluminum alloy (metal material) K2 are
The cylinder block 50 and the cylinder liner 53 are formed of different metal materials, and the resin film 30 is formed.
Are precisely fused at a predetermined position where the metal alloy layer is disposed to form a fusion metal layer K3, and a solidly fused integrally cast product is cast. Thereafter, the surface of the cylinder liner portion 53 of the hypereutectic aluminum alloy (metal material) K2 is polished to obtain a finished product.

In the first embodiment according to the present invention, instead of the hypereutectic aluminum alloy (metal material) K2 of the cylinder liner 53, a copper alloy or another different alloy is used instead of the intermetallic compound layer. K4 may be formed. For example,
CuAl _{2 for} copper and aluminum, FeAl _{3 for} iron and aluminum, NiAl _{3 for} nickel and aluminum, Al ₃ T for titanium and aluminum
An intermetallic compound such as i can be formed. CuAl ₂ above
Since the intermetallic compound layer K4 such as shown in FIG. 3 is formed at an intermediate portion between the two metals, as shown in FIG.
The intermediate intermetallic compound layer K4 is cut and polished to be exposed as a surface layer, and as shown in FIG. 4B, the wear-resistant intermetallic compound layer K4 is exposed.

By using the intermetallic compound layer K4 as a surface layer, the surface of the hypoeutectic aluminum alloy (metal material) K1 of the cylinder block 50 is formed as a cylinder liner 53 with a hypoeutectic aluminum alloy and copper or the like. The intermetallic compound (metal material) K4 is integrally formed.

According to the first embodiment of the present invention,
The following effects are obtained. First, the cylinder block is formed of a lightweight and soft hypoeutectic aluminum alloy, and the cylinder liner is formed of a metal such as a hypereutectic aluminum alloy having high wear resistance, and these are integrally formed with a fusion metal layer interposed therebetween. Therefore, a lightweight, compact, highly workable cylinder block with high wear resistance can be manufactured at low cost. That is, a linerless cylinder block made of a closed deck type aluminum alloy can be manufactured easily at low cost.

Further, the intermetallic compound layer K4 is formed by changing the hypereutectic aluminum alloy (metal material) K2 of the cylinder liner portion 53 to a copper alloy or another different alloy to form an intermetallic compound. It is cut and polished to be exposed on the surface, and can be effectively used as a surface layer of a wear-resistant alloy compound. As a result, a cylinder block that is lightweight, compact, has good workability, and has high wear resistance can be easily manufactured at low cost.

Further, the method for integrally casting a plurality of metal materials according to the present invention may be as in the second embodiment shown in FIG. In the second embodiment, in the first embodiment in which the cylinder block 50 integrated with the cylinder liner portion 53 is cast, casting is performed by a mold 250 instead of the disappearing model casting. In the mold 250, two runners 25A and 25B for pouring two different metal materials, and two types of cast molding parts S1 and S2 separated by a cylindrical partition body 300 of an aluminum alloy. Is formed. An aluminum alloy cylindrical partitioning body 300 is arranged at a predetermined position in a mold 250 by a baseboard 301, and is provided with a cylinder block 50.
And the portion to be the cylinder liner 53 are accurately separated from each other. Then, the two kinds of molten metal materials K1 and K2 are poured into the respective cast molding portions S1 and S2, and the aluminum alloy partition 300 is melted to form a fusion metal layer K3. The two types of metal materials K1 and K2 are integrally formed accurately at the position of.
Other configurations are the same as those in the first embodiment, and the same reference numerals are given and the description is omitted.

According to the second embodiment, a method of integrally casting a plurality of metal materials is performed as follows. First, as shown in FIG. 5, a runner 25A is formed in a casting molding portion S1.
The molten hypoeutectic aluminum alloy (metallic material) K1 is poured from the other runner 25B and the cast molding portion S
The molten hypereutectic aluminum alloy (metal material) K2 is poured. Thus, first, a cast of the hypoeutectic aluminum alloy (metal material) K1 and the hypereutectic aluminum alloy (metal material) K2 injected into each of the molded parts S1 and S2 is formed.

Next, the thin partition body 300 of the aluminum alloy is
Since it is interposed between the two molded parts S1 and S2, it is melted by the different hypoeutectic aluminum alloy (metal material) K1 and hypereutectic aluminum alloy (metal material) K2 on both sides and fused metal layer K3 Is formed.

Therefore, the hypoeutectic aluminum alloy (metal material) K
1 and a hypereutectic aluminum alloy (metal material) K2 are integrally cast as a cylinder block 50 and a cylinder liner 53, and a fusion metal layer K3 is formed at the partition 300.
Is formed and is fused firmly to form an integral casting of the cylinder block 50 and the cylinder liner portion 53.

In the above embodiment, the partition 30
0 is thin and melts to form a fusion metal layer K3 of the hypoeutectic aluminum alloy (metal material) K1 and the hypereutectic aluminum alloy (metal material) K2, but this is not necessarily limited to this. Absent. For example, when the partition 300 is thick, one surface of the partition 300 melts to form a fusion metal layer with the hypoeutectic aluminum alloy (metal material) K1, and the other surface of the partition 300 melts. To form a fusion metal layer with a hypereutectic aluminum alloy (metal material) K2 and a hypoeutectic aluminum alloy (metal material) K1 and a hypereutectic aluminum alloy (metal material) K2
Form a fused metal layer K3 integrated with the partition body 300 left.

According to the second embodiment of the present invention,
The following effects are obtained. First, the cylinder block 50 is formed of a lightweight and soft hypoeutectic aluminum alloy K1, and the cylinder liner 53 is formed of a hypereutectic aluminum alloy K having high wear resistance.
2, and these are integrally formed via the fusion metal layer K3. Therefore, a cylinder block that is lightweight, compact, has good workability, and has high wear resistance can be easily and inexpensively manufactured.

Also in this embodiment, similarly to the first embodiment, the hypereutectic aluminum alloy (metal material) K2 of the cylinder liner 53 is changed to a copper alloy or another different alloy. By forming an intermetallic compound,
The intermetallic compound layer can be exposed on the surface and used as a surface layer of an abrasion-resistant intermetallic alloy compound.

The method for integrally casting a plurality of metal materials according to the present invention is not limited to the above embodiments, and it is needless to say that the design can be freely changed within the scope of the present invention. For example,
In each of the above embodiments, the number of molded parts is two.
It may be provided with three or more cast molding parts.
Further, in the first embodiment, the vanishing model may be paper or wax in addition to the foamed resin material. In the second embodiment, die casting is used, but sand casting may be used instead. In addition, the partition body may be made of heat-resistant paper or a metal material other than an aluminum plate as long as the partition body has vanishing or fusible properties, in addition to the vanishing resin.

The casting manufactured by the method for integrally casting a plurality of metal materials according to the present invention is not limited to the above embodiment. For example, as shown in FIG. 6, a brake pad in which the pad 63 of the disc brake and the brake shoe portion 65 are integrated may be manufactured by the above-described casting method. This makes it possible to easily and inexpensively manufacture a casting in which the base metal plate and the brake shoe portion (friction piece) of the brake pad of the disc brake are integrated. Further, a product is obtained in which the joining of the base metal plate and the brake shoe is complete, and there is no risk of peeling due to vibration or heat generated during the braking operation.

Also, as shown in FIG.
A surface layer 75 having high wear resistance is formed on the surface of the coil spring, and the end face of the coil spring 80 is pressed against the surface layer 75 to reduce wear even when repeatedly receiving the load of the spring pressure. It may be manufactured by a method. This allows
A casting in which the surface layer 75 having high wear resistance is integrated with the surface of the base metal plate 70 can be easily and inexpensively manufactured.

[0041]

As described above in detail, according to the first to third aspects, a fusion metal layer of a plurality of different metal materials is formed at the partition portion, and integrated at a predetermined position accurately via the fusion metal layer. An integrated casting made of different molten metal materials is easily formed.

According to the fourth and fifth aspects of the present invention, in the casting method of the first to fourth aspects, since the partition body is made of a resinous film or a metal material which can be eliminated, a plurality of molten metal materials are used for a certain period of time. The molten metal is filled into the molded part while separating,
Then, since the partition body can be melted to form a fusion metal layer, a plurality of metal materials can be accurately integrated at predetermined positions.

According to the sixth aspect of the present invention, an integrated casting in which a plurality of metal materials are fused at predetermined positions is obtained, and the surface of the base metal differs from the base metal such as abrasion resistance and heat resistance. A plurality of different metal materials are integrated at a predetermined position, for example, by integrally forming a metal requiring characteristics.

According to the present invention, the cylinder block portion is made of a lightweight and soft hypoeutectic aluminum alloy, and the cylinder liner portion is a hyper-eutectic aluminum alloy or copper alloy having high wear resistance. The body is lightweight and compact, has good workability, and the cylinder liner is made of an alloy with high wear resistance. It is formed.

[Brief description of the drawings]

FIG. 1 is a view showing a first embodiment of the present invention, and is a cross-sectional view of an apparatus for integrally casting a plurality of metal materials.

FIG. 2 is a view showing a first embodiment of the present invention, and is a cross-sectional view of a cylinder block.

FIG. 3 is a diagram showing the first embodiment of the present invention, and is a characteristic diagram of a compound state of aluminum and copper.

FIG. 4 is a view showing the first embodiment of the present invention, and is a cross-sectional view of a compound of aluminum and copper.

FIG. 5 is a view showing a second embodiment of the present invention, and is a cross-sectional view of an integrated casting apparatus for a composite metal material.

FIG. 6 is a view showing a third embodiment of the present invention, and is a cross-sectional view of a brake pad.

FIG. 7 is a view showing a fourth embodiment of the present invention, and is a cross-sectional view of a wear-resistant spring receiving member.

FIG. 8 is a view showing a conventional example, and is a perspective view of a cylinder block.

[Explanation of symbols]

Reference Signs List 20 frame 25 mold 25A, 25B pouring spout 25C, 25D spout cup 27, 29 vanishing model 27A foam molded body for main body 29A foam molded body for bore portion 30 partition body (foamable resin film-like body) 300 partition body ( Aluminum alloy cylinder) 40 Vinyl sheet 43 Wire mesh plate 50 Cylinder block 53 Cylinder liner 63 Disc brake pad 65 Brake shoe 70 Base metal plate 75 Surface layer K1 Hypoeutectic aluminum alloy K2 Hypereutectic aluminum alloy K3 Fusion metal Layer S1 First molding part S2 Second molding part P Vacuum pump

Claims (7)

[Claims] 1. A plurality of molded parts are formed in a mold with a partition body separating the molded parts separated from each other, and a plurality of molten metal materials are poured into the plurality of molded parts, respectively. While forming a casting, the partition body is melted to form a fusion metal layer made of a plurality of molten metal materials on the partition body portion, and the plurality of metal materials are formed integrally with each other. One-piece casting method. 2. The method according to claim 1, wherein the casting is a vanishing model. 3. The method according to claim 1, wherein the cast molding is a space in a mold or a sand mold. 4. The method according to claim 1, wherein the partition is a film made of a resin that can be eliminated. 5. The method according to claim 1, wherein the partition is made of a metal material. 6. A method for producing a monolithic product, wherein the production process is performed by the method for integrally casting a plurality of metal materials according to any one of claims 1 to 5, wherein the plurality of metal materials are fused at predetermined positions to form an integral casting. An integrated casting of a plurality of metal materials. 7. A base part is formed of a hypoeutectic aluminum alloy, and a sliding part is formed of a wear-resistant alloy such as a hypereutectic aluminum alloy or a copper alloy. An integral casting of a plurality of metallic materials according to claim 6.