JPS61115658A - Casting method - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed Description of the Invention] Aluminum alloy castings have the great advantage of being lightweight and having high productivity through die casting, molten metal forging, low-pressure casting, etc., but on the other hand, they have the same strength and wear resistance as iron castings. Because it is inferior, its application is limited.

For this reason, iron-based materials are poured into the necessary parts, but when simply cast, the iron-aluminum boundary is not welded.

Alphine processing is a method for diffusion bonding iron and aluminum by eliminating this unwelded part, but the operation is time-consuming and increases cost and weight.

By the way, in recent years, wear-resistant aluminum alloys and various aluminum-based composite materials have been developed.

Some materials have appeared that surpass iron-based materials in terms of wear resistance and strength.

The present invention provides a method of casting an aluminum material having such special characteristics with an ordinary aluminum alloy having good castability and machinability.

In the case of aluminum-aluminum castings, there are also unwelded areas at the interface. One of the causes of this unwelded portion is the presence of an oxide film layer on the surface of the cast material.

If the presence of unwelded parts does not pose a problem, such castings are acceptable; for example, pistons.

Cylinder heads, cylinder liners, and other items that require uniform heat transfer require aluminum-aluminum diffusion bonding. In order to achieve aluminum-to-aluminum diffusion bonding, the present invention has investigated various surface treatments for the cast material, and as a result, we have developed molten aluminum solder (95Z) using ultrasonic energy.
It has been found that diffusion bonding can be easily achieved by applying n-5Al) plating. The method of aluminum solder plating is shown below.

[Ultrasonic fused aluminum solder plating method] (1) Ultrasonic oscillator - frequency 18KHz, output.

Time variable (manufactured by Shimada Rika Kogyo, ultrasonic soldering equipment) (2) Aluminum solder composition: Eutectic W Zn-5A
1 alloy (melting point: 580°C) (6) Ultrasonic application time: 22 to 5 seconds In Fig. 1, the ultrasonic oscillation horn 1 of the ultrasonic oscillation device
is fixed to one end of the diaphragm 2, and the other end of the diaphragm 2 is immersed in a solder solution 4 in a solder melting furnace 3.

Then, the wave surrounding material 5 was immersed in the solder solution 4, the ultrasonic oscillator was activated to vibrate the diaphragm 2, and molten aluminum solder plating was performed using ultrasonic energy.

Note that the device conditions are as described above.

Next, the plated wave-filled material described above is cast, and any method such as gravity casting, low-pressure casting, die-casting, molten metal forging, or high-pressure casting can be used. An example is shown below. [Example 1] As shown in FIG. 2, a part of a tapered shaft 7 made of AC14B was made of wave-filled material (A2024S) 6.

JIS A2[)24S material was cast using mold gravity casting.

Figure 6 shows a cross-sectional view of the cast-in part.

・-) (Figure 6(a) shows the case where the surface of the wave-covered material 6 is coated with the ultrasonic melted aluminum solder plating of the present invention. Figure 5(b) is the penetrant inspection photograph when no aluminum solder plating is applied.
This is a 0x border micrograph (xioo).

The difference between the two is obvious, and by applying aluminum solder plating, it is possible to make diffusion bonding all over the cylinder without welding the unwelded parts.

[Example 2] ADC1 with 5t3N< powder dispersed in the wear ring 8 of Bistono with a wear ring for diesel engines as a wave filling material
After applying aluminum solder plating using 0 alloy, the piston body 9 was inserted into a mold, and the piston body 9 was cast by gravity casting.

FIG. 4 shows a microscopic structure photograph (X10[]) of the boundary between the wear-resistant ring 8 and the piston body 9. In this case as well, there is no unwelded portion between the two materials.

The material of the piston body is AC8A, and the casting temperature is 700°.
C. Preheating of the wear ring is not performed.

[Example 3] ADC10 alloy in which Si3N4 powder was dispersed was used for the cylinder liner of an aluminum alloy cylinder block, and the outer periphery of the cylinder liner was plated with aluminum solder.

It was inserted into a mold and the cylinder block body was cast using die casting. In this case as well, there was no unwelded portion between the liner and the cylinder block body.

[Example 4] FRM with high thermal fatigue strength was used on the contact surface of the combustion chamber of an aluminum alloy cylinder head (after applying aluminum solder plating to its outer periphery, it was inserted into a mold and the cylinder head body was heated to low pressure). Cast by casting.

In this case as well, there was no unwelded portion between the combustion chamber and the syringe head body.

[Comparative example]

Example 10 The method of the present invention was compared with the conventional method, and the results shown in the table were obtained, from which it is clear that the method of the present invention is superior.

As is clear from the above, in the aluminum-aluminum casting method of the present invention, by applying molten aluminum solder plating to the surface of the corrugated material using ultrasonic energy, diffusion bonding of both materials can be easily achieved.

Molten aluminum solder plating using ultrasonic energy removes the oxide layer on the surface of the wave-covered material.

Form a eutectic layer of full aluminum solder. This eutectic layer has a low melting point and is easily melted and integrated with cast aluminum molten metal.

[Brief explanation of drawings]

FIG. 1 is a front view showing an apparatus for carrying out the method of the present invention. FIG. 2 is a front view of the tapered shaft formed in Example 1, and FIG. 3 is a penetrant inspection photograph and a boundary micrograph (
100 times), and Figure 4 is a microscopic photograph of the boundary area of Example 2 (1
00 times). 1: Ultrasonic transmitting horn, 2: Vibration plate. Yaa IT ￥1 1 ゝ、enter ■、
Continuing from page 1 Inventor Tadao Yamashita 1, Miyako Seisakusho, Uzumasa Tatsumi-cho, Ukyo-ku, Kyoto Mitsubishi Motors Corporation, Kyo 1, Mitsubishi Motors Corporation Kogyo Co., Ltd. Kyo Procedures Amendment (Method) March 29, 1985

Claims (1)

[Claims] When producing aluminum castings by casting a cast material made of aluminum alloy or aluminum-based composite material, an aluminum solder layer is formed while applying ultrasonic energy to the surface of the material, and then the cast material is cast. Casting method characterized by