JPS62107854A - Method and apparatus for insert casting and insert-casting thereof - Google Patents

Abstract

PURPOSE:To obtain an insert-casting product having substantial strength with an easy operation by subjecting a material to be insert-cast to plating while oscillating a plating liquid then subjecting the material to be insert-cast with an Al alloy. CONSTITUTION:The material 9 such as Al alloy, iron or steel, or Ti alloy to be insert-cast is subjected to a pretreatment and is then immersed into a hot dip coating liquid 4 of Al solder, Sn-Zn alloy, etc., in a bath tank 5 of a solder melting furnace 2 of a plating device 1. A diaphragm plate 8 which is fixed at one end to an oscillation horn 7 of an ultrasonic device 3 and is branched to two parts is disposed in proximity to the material 9 in the above- mentioned liquid 4 and the liquid 4 is oscillated by the plate 8 to remove the oxide from the surface of the material 9 and to form the uniform plating layer thereon. The material 9 subjected to the plating is subjected to insert casting by the Al alloy in succession thereof. The insert-casting material and the material 9 to be insert-cast are thoroughly welded by the above-mentioned, by which the insert-casting product having the substantial strength is obtd.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to casting aluminum alloys, FRM, steel, T1 alloys, Co alloys, etc. into aluminum alloys.

[Prior art]

Aluminum alloy castings have the great advantage of being lightweight and high productivity through die casting, molten metal casting, low pressure casting, etc. However, they are inferior to iron castings in terms of strength, wear resistance, etc., so their application is limited. has its limits.

For this reason, high-strength materials such as iron-based materials are cast in the necessary parts, but in the case of simply casting 1. For example, when iron-based materials are cast with aluminum alloy gold, The iron-aluminum alloy boundary is not welded.

[Problem that the invention seeks to solve]

However, the strength of the cast product was insufficient because the interface was not welded.

Therefore, Alfine treatment is available as a method for diffusion bonding iron and aluminum by eliminating the unwelded portions, but the treatment operation is time-consuming and involves an increase in cost and weight.

[Means for solving problems]

The present invention relates to aluminum alloy, FRM, steel, Ti alloy,
The wave channel filling material, such as Ni alloy or Co alloy, is pretreated by washing with water, degreasing, pickling, and drying.Secondly, the wave channel filling material is immersed in a plating solution, and the wave channel filling material is placed in the same plating solution. Plating is applied to the material surrounding the wave channel by vibrating a diaphragm installed nearby. Subsequently, this corrugated material is covered with a casting material made of an aluminum alloy.

[Effect]

Then, by vibrating the plating solution, oxides on the surface of the wave channel surrounding material are removed and a uniform plating layer is formed. By casting the corrugated material with a casting material made of aluminum alloy through this plating layer, the casting material and the corrugated material are completely welded and the two are diffusion bonded.

Therefore, the cast material and the corrugated material are firmly joined, and a cast product with sufficient strength can be obtained.

Further, since it is only necessary to vibrate the plating solution, the manufacturing operation is easy and the cost is low.

〔Example〕

Two aspects of the present invention will be described in detail below.

Embodiment 1゜2'7'4Is A2024S A corrugated material is formed from an aluminum alloy material. Next, this corrugated material is washed with water, degreased, washed with water, pickled, and washed with water using a pretreatment device.

Washing and drying, that is, pretreatment, are performed in the order of drying.

Subsequently, plating is performed in a plating apparatus 1 shown in FIG. The solder melting furnace 2 consists of a bathtub 5 that holds a plating solution 4 at the top and a heating section (electric heating coil) installed at the bottom of the bathtub 5 to heat the bathtub 5. )6. The ultrasonic oscillator 3 has one end of a bifurcated diaphragm 8 fixed to the oscillation horn 7, and the other end of the diaphragm 8 fixed to the oscillation horn 7.
! ! Soak in water at 4°C. In addition, the wave path surrounding material 9 is
The diaphragm 8 is inserted between two diaphragms 811r) and the diaphragm 8 is inserted between the two diaphragms 8 and 0.
．． They are located with a spacing of 1&I.

Then, plating is performed on the wave path surrounding material 9 under the secondary conditions.

1. Plating bath components: Molten aluminum solder [eutectic Z, -51 alloy (95 Z9-5 At) melting point: 380°C] 2. Ultrasonic vibration conditions: oscillation Frequency 18KHz
.

Shaking width: 20 um, application time: 2 to 3 seconds 3, Plating bath temperature: 400 to 420°C 4 Plating film thickness: 50 pm 5 Plating time: 7 minutes And Z? l A wave channel filling material 9 plated with 5At alloy was placed in a mold (two sets) of a casting device (not shown), and hot water of AC4B aluminum alloy was poured as a casting material and gravity casting was carried out to form a taper 7 shaft 10 as shown in FIG. This tapered shaft 10 has a main body 11 made of AC4B.
and a wave-covered material 8.

Comparative Example A wave-lined material was formed using JIS A2024S material, and after the ninth stage was subjected to no treatment, ZN plating, SN plating, Kanigen plating, and molten aluminum solder plating, it was cast with AC4B aluminum alloy to form a tapered shaft (Example 1) was formed.

The table below shows the results of examining the welding conditions of Example 1 and Comparative Example and the presence or absence of melting loss of the corrugated material.

In this method, welding is insufficient even in this state.

As is clear from this table, the welding condition of Example 1 was better than that of the conventional method, and there was no melting loss of the wave surrounding material.

In addition, a 100x microscopic micrograph (Fig. 3) of the boundary between the wave-filled material 8 and the main body 11 of Example 1 and the wave-filled material of a comparative example cast without treatment and without preheating are shown. Comparing the 100x magnification micrograph (Fig. 4) of the boundary with the main body, it is found that in Example 1, in which aluminum solder plating was performed while applying ultrasonic vibration, there was an unwelded part between the wave-filled material and the main body. On the other hand, it is clear that the comparative example has an unwelded part between the two and is weak in terms of strength.

Furthermore, molten aluminum soldering is carried out while applying ultrasonic vibration to the corrugated material, thereby completely removing the oxide film layer on the surface of the corrugated material and forming a uniform eutectic layer of aluminum-aluminum solder. This eutectic layer has a low melting point, easily melts in the cast aluminum alloy molten metal, and becomes integrated with the molten metal.

Example 2 A wear ring of a diesel piston with a wear ring was used as a wave filling material, and it was melt-plated with ZN-5At solder in the same manner as in Example 1, and then placed in a mold as a casting material. A certain AC8A aluminum alloy was poured to form a piston. The casting temperature is 700°C. Note 7
The wear ring is an ADC10 aluminum alloy with 51sNa powder dispersed in it. 100 at the boundary between the wear-resistant ring and the piston body 13 cast from AC8A aluminum alloy.
According to the microscopic micrograph (Fig. 5) K.

There is no unwelded part between the wear resistant IV and the piston body 13,
Both are completely welded together.

Example 3 A cylinder liner was formed from an ADC10 aluminum alloy in which Si and N4 powders were dispersed, and Z
, aluminum solder plated with -5At alloy.

Next, this cylinder liner was set in a mold, molten aluminum alloy was injected, and a cylinder block body was cast to form a cylinder block in which the cylinder liner was cast into the cylinder block body.

The boundary between the cylinder block body and the cylinder liner was completely welded.

Example 4 The roof member that forms the ignition surface of the combustion chamber of the cylinder head is made of FRM with high thermal fatigue strength (i.e., all JISA6061 aluminum alloy is made of Trinox and contains long carbon fibers)
2. Next, aluminum solder plating was performed in the same manner as in Example 1, the conor roof member was set in the mold, aluminum alloy as the casting material was poured, and the cylinder hend body was cast, as shown in Fig. 13. In this manner, the cylinder head body 31 was cast around the roof member 32 to form the cylinder head 33.

In this case as well, there was no unwelded portion between the roof member and the cylinder hend body, and the two were completely welded.

Example 5 After pretreatment of SuS630 steel and MASICf4 3.0φ wire, the ultrasonic plating apparatus shown in Example 1 was used.
"IIs Z 3281 Aluminum solder plated with Alumitsu AM350, which is aluminum solder. After preheating this steel wire 14 to 300°C, it was set in the mold 19 shown in Fig. 6, and heated to 700°C, which is a casting material.
AC4B aluminum alloy 20 was poured to produce a casting. Note that 2] is a support for holding the steel wire 14 within the mold 19. From this casting, a JI Hair Table No. 84 tensile test piece (Figure 6, 2-dot horizontal line) 15 was cut out with the steel wire 14 as the center.
A tensile test was conducted. The dimensions of the tensile test piece 150 are the parallel part φ7 x 32 ax (gauge length 25 mm) and the chunk part M12. The PL5 screw eliminates the effect of chucking on the casting material during the tensile test.

The plating conditions and tensile test results are shown in the table below.

Casting test piece manufacturing conditions and tensile test results The test results show that a uniform plating layer can be obtained by plating aluminum solder on iron-based casting materials while applying ultrasonic vibrations1. The material (AC4B) was completely welded at the boundary, as shown in the 100x micrograph of FIG. In addition, FIG. 7 shows the 4th test piece shown in the table above.

However, the comparative material (which was not subjected to ultrasonic vibration plating)
As shown in the 100x microscopic micrograph of FIG. 8, many unwelded parts remain at the interface between the wave-filled material and the cast-filled material.

Example 6 A 4.0φ MASIC steel 16 was plated with aluminum solder under the same conditions as the test piece 4 of Example 4.

After preheating to 300°C, it was placed in a mold and ADCIO aluminum alloy was cast using a non-porous die casting method.

Connecting front 1 for automobile engine shown in Fig. 9
7 was molded.

This connecting rod 17 showed an approximately 50% increase in strength compared to the case where MASIC steel was not cast. Sho MAS
The IC steel and ADC10 material were completely joined via aluminum solder.

Example 7 A cam 18 of an internal combustion engine was formed from an iron-based sintered alloy as shown in FIG. Ta. Continuing,
After preheating the aluminum solder-plated cam 18 to 300°C, it is set in a mold for casting a camshaft of an internal combustion engine.
ADC10 fulminium alloy was poured into the mold and cast by a die casting method, and the cam 18 was cast through the shaft 19.

The cam 18 and one shaft were completely connected to each other through aluminum solder.

Example 8 A wear ring 21 for a diesel engine made of Niresist cast iron was plated with aluminum solder in the same manner as the Gallo 4 test piece of Example 5. After preheating this wear ring to 300°C, it was placed in a mold and subjected to gravity. Injected with ADCIO aluminum alloy by casting.

A piston 22 for a diesel engine shown in FIG. 12 was molded.

The wear-resistant ring and the ADC10 aluminum alloy were completely bonded via aluminum solder.

Example 9 S! After a cylinder liner was formed from an ADC10 aluminum alloy in which xN+ powder was dispersed, it was pretreated in the same manner as in Example 1, and pure zinc was plated on the cylinder liner while applying ultrasonic vibration. The plating conditions at this time were as follows.

1. Plating bath components: Pure zinc2. Plating bath temperature: 440-450℃3. Plating film thickness.
...50pm4, ultrasonic vibration conditions ...oscillation frequency 18KHz.

With an imaging width of 20 μm and an application time of 2 to 3 seconds, a galvanized cylinder lychee is inserted into the mold, aluminum alloy (ADCIO alloy) hot water is poured into the mold, and the cylinder liner 34 shown in FIG. 14 is inserted. A cast cylinder block 35 was formed.

The boundary between the cylinder litchi and the cylinder block was completely welded.

Example 10 A cam for an internal combustion engine was formed from an iron-based sintered alloy in the same manner as in Example 6, and pretreatment was performed in the same manner as in Example 8.

Next, pure zinc plating was performed. Next, set the cam to 300
After preheating to °C, ADCIO aluminum alloy was poured into a mold, and a camshaft with a cam encased therein was cast by die-casting.

When we examined the interface between the cam and camshaft, we found that they were completely welded together.

The bath temperature for the zinc plating was 500° C., the plating time was 5 minutes, and the ultrasonic vibration application time was 5 seconds.

In the above embodiment, the ultrasonic vibration frequency is 18 KHz, but in the present invention, it may be in the range of 1 to 100 KHz, and particularly preferably 1 to 100 KHz. IKHz
If the number of repetitions is less than that, the number of repetitions per unit time will be small and the oxide film formed on the surface of the material to be plated cannot be removed.
Plating is not done completely, the plating tends to peel off, and a uniform plating layer cannot be formed.

Furthermore, if the frequency exceeds 1000 KHz, the plating solution will not be able to follow the vibration of the diaphragm, and the metal parts will peel off from the surface of the diaphragm.
Causes cavitation and damages the diaphragm.

In addition, the plating film thickness was 50 μm in the above example.

100/J m, but in the present invention, 5
It is preferably 300 pm or more, particularly 30 pm to 1
100p is preferred and it is less than 5 μm.

Welding to the aluminum alloy during casting is incomplete.

Moreover, since the casting material and the leaded filling material are completely welded together at a thickness of 300 .mu.m or less, there is no need to plate the material over 300 .mu.m.

Furthermore, although the amplitude of the diaphragm was set to 20 μm in the above embodiment, it is preferably in the range of 5 pm or more and 35 /J m or less.

If the thickness is less than 5 μm, sufficient energy cannot be applied to the plating solution, and oxides formed on the surface of the leaded surrounding material cannot be removed, and a uniform plating layer cannot be obtained. If it exceeds 35 pm, the liquid cannot follow the movement of the diaphragm, causing cavitation and damaging the diaphragm.

In addition, in the above embodiment, the distance between the diaphragm and the plating surface of the leaded surrounding material was 0.1M, but in the present invention, the distance was 0.5M.
It is sufficient that the plating solution is filled between the diaphragm and the leaded surrounding material at a depth of less than m. In addition.

If it exceeds 0.5u, the wave force applied to the plating solution due to the vibration of the diaphragm will not be sufficiently transmitted to the leaded surrounding material, making it impossible to obtain a uniform and strong plating layer.

Furthermore, in the above examples, ZN-
Although At alloy and pure zinc were used, aluminum solder 5AL-BQZ or 5A specified in JIS Z3281 was used.
It can be applied anywhere as long as it is compatible with L-CRZ. In addition, cadmium-silver alloy [Cd:95
%, Ag: 5ch (weight)], tin-zinc alloy (Su
:85 section.

Z, :15%, (wt%)] etc. may be used.

Furthermore, in the above embodiments, leaded surrounding materials include aluminum alloy, stainless steel, high-strength steel, cast iron, and FRM (
Aluminum alloys with carbon long fibers,) 2 iron-based sintered alloys were used, but steel (including Sf7V SfA, heat-resistant steel)
, a titanium alloy, a nickel alloy, a cobalt alloy, an aluminum alloy, or a zinc alloy as a matrix can be used.

Furthermore, in the above embodiment, the throat to the cylinder.

In addition to forming internal combustion engine components such as cylinder broncs, camshafts, pistons, and connecting rods, we also manufacture rocker arms, crankshafts 2, automobile suspension parts (such as suspension arms), differential gear carriers, disc brake calipers, and various other parts. It can be used to make automobile components such as gears.

In more detail, for example, the opening 7 arm consists of a tip 37 made of iron-based sintered alloy and a rocker arm main body 36 made of aluminum alloy, as shown in FIG. Yes, this chip 37
The outer surface of the rocker arm body 36 is plated with a ZN-At alloy or the like while applying ultrasonic vibration, and then the rocker arm body 36 is cast.

In addition, in the case of a suspension arm, the steel wire is entirely cast in the longitudinal direction, the bushing at the attachment part to the vehicle body and the joint member to the wheel side are cast, and the outer surface of the steel wire is plated by the method of the present invention. Furthermore, a suspension arm is manufactured by plating the joint surfaces of the steel outer cylinder of the bushing and the joint member by the method of the present invention, and casting these three members in an aluminum alloy.

In the case of a differential gear carrier, the mounting bush to the vehicle body is reinforced using the method of the present invention in the same manner as the suspension arm, and steel wire, FRM, etc. are reinforced by casting using the method of the present invention.

In the case of a gear, a ring-shaped FRM is plated by the method of the present invention, and then the FRM is cast in an aluminum alloy to produce a gear material. Next, the FRM is cut to form teeth.

In addition, in the present invention, the plated wave-filled material is cast with a cast material; examples of the four-wheeled two-way casting method include sand mold casting, mold gravity casting, low-pressure casting, die casting, molten metal forging, etc. This method is also possible.

In the above embodiment, when the wave-filled material before being cast is an iron-based material, it is preheated, but it is not necessary to preheat it, and the preheating temperature may be 400°C or less. Furthermore, it is only necessary to select whether or not to preheat as appropriate depending on the material of the wave-covering material.
4. In the above embodiments, plating is performed while applying ultrasonic vibration to the plating solution. At this time, the distance between the wave surrounding material and the diaphragm is set to 0.
For 1 u, it is sufficient that the distance between the two is 0.5 w or less and that there is a plating antinode between the two. 0.5
If it is less than ax, the vibration applied to the metal plate 10 by the diaphragm is reflected by the wave-filled material, and this reflected wave is further given vibration energy by the diaphragm and reaches the surface of the wave-filled material as a large energy. , remove the oxides on the surface of the wave-covered material and use a material that can obtain a uniform plating layer. If it exceeds 0.5 vl, the wave reflected by the wave surrounding material will be attenuated, and even if this attenuated reflected wave is excited by the diaphragm, the vibration wave will not have enough vibration energy, so the wave surrounding material will be attenuated. The removal of surface oxides from the material is insufficient, making it impossible to obtain a uniform plating layer, resulting in unwelded areas between the cast material and the wave-filled material.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a sectional view showing a plating apparatus according to Embodiment 1 of the present invention;
Fig. 2 is a tapered shaft manufactured by the casting method described in Example 1, and Fig. 3 is a microscopic photograph of the boundary between the wave-filled material and the casting material of the casting product produced by the method of the present invention in Example 1. 100 times).

Figure 4 is a microscopic photograph of the boundary between the wave-filled material and the cast material of a comparison example in which the wave-filled material was cast without plating (i.e., the untreated material without preheating in the comparative example table). (100 magnification), FIG.
6 is a cross-sectional view of the mold 19 of Example 5, FIG. The figure shows steel wire 14 and aluminum alloy 2 of Ii 6 test piece of Example 5.
Micrograph of the boundary with 0 (100x magnification).

FIG. 9 is a sectional view of a connecting rod for an engine as an exception, and FIG. 10 is a perspective view showing the cam 18 of the example.
FIG. 11 is a sectional view showing the camshaft of the example daughter,
Fig. 2 is a sectional view of a piston according to an embodiment, Fig. 13 is a sectional view of a cylinder head of an embodiment 4, Fig. 14 is a sectional view of an engine including a cylinder block of an embodiment type, and Fig. 15 is a sectional view of an engine according to the present invention. FIG. 2 is a front view of a rocker arm of an internal combustion engine to which the invention is applied.

1: Plating equipment, 4: Plating @ solution, 8: Vibration plate 9: Casting material Fig. 1 Fig. 2 Fig. 6 Fig. 7 Fig. 8 Fig. 10 Fig. 11 Fig. 14 Fig. Procedure amendment document import (issued) January 70, 1986

Claims (1)

[Claims] 1) After pre-treating the casting material, the casting material is immersed in a plating solution, and a diaphragm placed in the plating solution and close to the casting material is placed in the plating solution. Casting method characterized by plating the cast material while vibrating, and then casting the same plated cast material with an aluminum alloy 2) Before pre-treating the cast material A processing device, a plating device for plating the cast material while applying vibration to the plating solution using a diaphragm, a plating device that holds the plated cast material in a mold, and pours aluminum alloy into the mold. 3) Vibrations are applied to the cast material and the plating solution to form the cast material on the surface of the cast material. A casting product characterized by a casting material made of an aluminum alloy that is diffusion bonded to the casting material through a plating layer.