JPWO2004058434A1 - Vacuum die casting product and method for manufacturing the same - Google Patents
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- 238000000034 method Methods 0.000 title claims description 13
- 238000004519 manufacturing process Methods 0.000 title claims description 9
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- 229910000838 Al alloy Inorganic materials 0.000 claims abstract description 22
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- 238000004090 dissolution Methods 0.000 claims abstract description 6
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- 238000002347 injection Methods 0.000 claims description 29
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- 239000006082 mold release agent Substances 0.000 claims description 11
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- 230000000052 comparative effect Effects 0.000 description 16
- 238000010438 heat treatment Methods 0.000 description 15
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- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
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- CWQXQMHSOZUFJS-UHFFFAOYSA-N molybdenum disulfide Chemical compound S=[Mo]=S CWQXQMHSOZUFJS-UHFFFAOYSA-N 0.000 description 1
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- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
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- 229910052725 zinc Inorganic materials 0.000 description 1
Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/14—Machines with evacuated die cavity
Abstract
アルミニウム合金の真空ダイカスト鋳造品であって、真空ダイカスト鋳造品の気泡中に残存するガスは、鋳造品の溶解により放出させた後にガスクロマトグラフィにより測定した場合、Ｈ２ガスがＣＯ２ガスより少ない組成を有する真空ダイカスト鋳造品。An aluminum alloy vacuum die cast product, wherein the gas remaining in the bubbles of the vacuum die cast product has a composition in which H2 gas is less than CO2 gas when measured by gas chromatography after being released by dissolution of the cast product. Vacuum die casting product.
Description
発明の分野
本発明は、機械的強度に優れたアルミニウム合金の真空ダイカスト鋳造品及びその製造方法に関し、特に高強度及び高靭性を有する輸送機器用に好適なアルミニウム合金の真空ダイカスト鋳造品及びその製造方法に関する。FIELD OF THE INVENTION The present invention relates to an aluminum alloy vacuum die cast product having excellent mechanical strength and a method for producing the same, and particularly to an aluminum alloy vacuum die cast product suitable for use in transportation equipment having high strength and high toughness and the production thereof. Regarding the method.
ダイカスト鋳造法は高速・高圧で金型内へ溶融金属を充填することにより鋳造品を製造する技術であり、他の鋳造法に比べて寸法精度が高く、鋳肌が美しく、生産性が高いという利点がある。しかしながら溶湯の高速充填により周囲のガスを溶湯中に巻き込んでしまい、鋳造品の内部にガスが充填された多量の気泡や、ガスと金属との反応によりできた酸化物等の介在物が存在するという問題がある。これらの欠陥は鋳造品の機械的強度を低下させるだけでなく、特にガスが充填された気泡は、熱処理や溶接時に内部ガスの膨張によりブリスターとなり、機械的強度を著しく低下させる。従って、ダイカスト鋳造品の構造用部材としての用途は限られていた。
ダイカスト鋳造品に内在するガスには、大気成分の他、プランジャ用の潤滑剤や金型キャビティ用の離型剤の燃焼ガス等も含まれる。これらのガスの巻き込みを低減するため、金型キャビティ内を減圧して鋳造する真空ダイカスト法が実用化されている。
キャビティ内を減圧して溶湯を射出スリーブ内に装填する真空ダイカスト装置として、例えば特開平６−１２６４１５号は、固定プラテンに取り付けられた固定型と、固定型とともにキャビティを形成する可動型と、キャビティに連通する射出スリーブと、射出スリーブ内を前後進するプランジャと、射出スリーブの下方にあって溶湯を収容する保持炉と、一端が射出スリーブの給湯口に連結し、他端が保持炉内の溶湯に没入する給湯管と、キャビティ内を真空状態に減圧して保持炉内の溶湯を給湯管を介して射出スリーブ内に装填する減圧手段とを有する真空ダイカスト装置を開示している。
しかしながらこの真空ダイカスト装置を用いた真空ダイカスト法でも、内在する残存ガスを減らせても、皆無にすることは不可能である。それは、（１）金型キャビティを完全に真空状態にするのは工業的に困難であり、また（２）離型剤及び潤滑剤から発生するガスを完全に除去することも困難であるという理由による。
特にアルミニウムダイカストの場合、その機械的特性を向上させるには、（ａ）溶湯に溶解した水素が凝固時に排出されて、鋳造品に気孔が形成されるのを防止すること、（ｂ）水素による脆化を防ぐため、溶湯から水素を除去すること、（ｃ）酸化物等の介在物の生成を抑制するため、酸素を除去すること等が重要である。特に酸化膜や介在物がアルミニウム鋳造品中に存在する場合、それらの端部周辺は大きな切欠係数を持つので、応力集中により亀裂の原因になり、鋳造品の靱性を大きく低下させる。
従来アルミニウム合金のダイカストには、シリコーン系エマルジョン型の離型剤が用いられている。シリコーン系エマルジョン型の離型剤は水を媒体とし、変成シリコーンオイルを乳化剤により乳化させたものである。しかしエマルジョン型の離型剤では、鋳造品に残存するガスの総量が多いのみならず、残存ガスのうち３０％超がＨ２、Ｃ２Ｈ６、ＣＨ４等であることが分かった。特にＣＯ２ガスよりＨ２ガスが多いので、熱処理や溶接時に鋳造品が脆化するという問題があった。
これは以下の理由によると考えられる。すなわち、金型キャビティは３００℃程度であるので、水性離型剤を使用しても水分はほとんど蒸発するが、大量に塗布するため可動型と固定型のあわせ面にも相当量の離型剤が付着する。あわせ面の表面温度は低いので、離型剤中の水分は蒸発しきらずに残留する。このため、型締め後に減圧しても可動型と固定型の隙間から離型剤がキャビティ内に吸い込まれ、蒸発し続ける。入れ子の奥の可動部分に水性離型剤が付着しても同様の現象が起きる。これによりキャビティ内の真空度が低下しないばかりか、水素ガスの発生量が多くなる。
ガスの巻き込みは金型キャビティの表面近くで起こりやすいので、ガスを含有する気孔は鋳造品の表面近傍にあることが多い。このようなガス含有気孔を有する鋳造品に対して熱処理とか溶接を行うと、気孔中のガスが膨張し、気孔はいわゆるブリスターとなって鋳造品表面から突出した膨れとなる。ブリスターは負荷がかかったときに亀裂や破断の起点となるおそれがある。
気孔に封止されたガスが水素の場合、熱処理や溶接の際に鋳造品に吸蔵され、鋳造品の劣化の原因となる。従って、真空ダイカストの際にガスの巻き込みを低減するだけでなく、巻き込まれたガスのうち水素の割合を低減することも必要であることが分かった。
発明の目的
従って本発明の目的は、ガスが残留する気泡が少ないのみならず、気泡内ガス中の水素の割合も少なく、もって輸送用機器の足回り部品や車体構成部品等に好適な真空ダイカスト鋳造品を提供することである。
本発明のもう一つの目的は、かかる真空ダイカスト鋳造品を確実に製造する方法を提供することである。The die-casting method is a technology that manufactures cast products by filling molten metal into the mold at high speed and high pressure, and has high dimensional accuracy, beautiful casting surface, and high productivity compared to other casting methods. There are advantages. However, the surrounding gas is entrained in the molten metal by high-speed filling of the molten metal, and there are a large amount of bubbles filled with the gas inside the casting and inclusions such as oxides formed by the reaction between the gas and the metal. There is a problem. These defects not only lower the mechanical strength of the cast product, but especially the gas-filled bubbles become blisters due to the expansion of the internal gas during heat treatment and welding, and significantly reduce the mechanical strength. Therefore, the use as a structural member of a die cast product has been limited.
In addition to atmospheric components, the gas inherent in the die cast product includes a lubricant for the plunger, a combustion gas for the mold release agent for the mold cavity, and the like. In order to reduce the entrainment of these gases, a vacuum die casting method in which the inside of the mold cavity is reduced in pressure and cast has been put into practical use.
As a vacuum die casting apparatus that decompresses the inside of a cavity and loads molten metal into an injection sleeve, for example, Japanese Patent Laid-Open No. 6-126415 discloses a fixed mold attached to a fixed platen, a movable mold that forms a cavity together with the fixed mold, and a cavity An injection sleeve that communicates with the injection sleeve, a plunger that moves back and forth in the injection sleeve, a holding furnace that is below the injection sleeve and contains the molten metal, one end connected to the hot water inlet of the injection sleeve, and the other end in the holding furnace There is disclosed a vacuum die casting apparatus having a hot water supply pipe immersed in the molten metal and a pressure reducing means for reducing the pressure in the cavity to a vacuum state and loading the molten metal in the holding furnace into the injection sleeve through the hot water supply pipe.
However, even with the vacuum die casting method using this vacuum die casting apparatus, it is impossible to completely eliminate the residual gas even if it is reduced. This is because (1) it is industrially difficult to make the mold cavity completely vacuum, and (2) it is also difficult to completely remove the gas generated from the mold release agent and lubricant. by.
In particular, in the case of aluminum die casting, in order to improve the mechanical properties, (a) preventing hydrogen dissolved in the molten metal from being discharged during solidification and forming pores in the cast product; (b) due to hydrogen In order to prevent embrittlement, it is important to remove hydrogen from the molten metal, and (c) remove oxygen to suppress the formation of inclusions such as oxides. In particular, when an oxide film and inclusions are present in an aluminum cast product, the periphery of the end portion has a large notch coefficient, which causes a crack due to stress concentration and greatly reduces the toughness of the cast product.
Conventionally, silicone-based emulsion mold release agents have been used for die casting of aluminum alloys. The silicone emulsion type release agent is obtained by emulsifying a modified silicone oil with an emulsifier using water as a medium. However, it was found that not only the total amount of gas remaining in the cast product is large in the emulsion type mold release agent, but also more than 30% of the remaining gas is H 2 , C 2 H 6 , CH 4, and the like. In particular, since CO 2 H 2 gas is higher than the gas, there is a problem that casting becomes brittle during heat treatment or welding.
This is considered to be due to the following reason. That is, since the mold cavity is about 300 ° C., even if an aqueous mold release agent is used, the water is almost evaporated. Adheres. Since the surface temperature of the mating surfaces is low, the moisture in the release agent remains without being evaporated. For this reason, even if the pressure is reduced after mold clamping, the release agent is sucked into the cavity from the gap between the movable mold and the fixed mold, and continues to evaporate. The same phenomenon occurs even if an aqueous release agent adheres to the movable part at the back of the nest. This not only reduces the degree of vacuum in the cavity, but also increases the amount of hydrogen gas generated.
Since gas entrainment tends to occur near the surface of the mold cavity, the gas-containing pores are often near the surface of the casting. When heat treatment or welding is performed on a cast product having such gas-containing pores, the gas in the pores expands, and the pores become so-called blisters and become blisters protruding from the surface of the cast product. Blisters can be the starting point for cracks and breaks when loaded.
When the gas sealed in the pores is hydrogen, the cast product is occluded during heat treatment or welding, which causes deterioration of the cast product. Accordingly, it has been found that it is necessary not only to reduce gas entrainment during vacuum die casting, but also to reduce the proportion of hydrogen in the entrained gas.
Accordingly, an object of the present invention is to provide not only a small number of bubbles in which gas remains, but also a small proportion of hydrogen in the gas in the bubbles, and hence vacuum die casting suitable for undercarriage parts of transportation equipment and vehicle body components. It is to provide castings.
Another object of the present invention is to provide a method for reliably producing such a vacuum die cast product.
上記目的に鑑み鋭意研究の結果、真空ダイカストの際に溶湯に巻き込まれるガスの発生量が少ないのみならず、水素ガスの発生量も少ない離型剤を使用することにより、熱処理や溶接をしてもブリスターの発生や水素脆性の問題が起こらない真空ダイカスト鋳造品が得られることを発見し、本発明に想到した。
すなわち、本発明のアルミニウム合金の真空ダイカスト鋳造品は、気泡中に残存するガスが、鋳造品の溶解により放出させた後にガスクロマトグラフィにより測定した場合、Ｈ２ガスがＣＯ２ガスより少ない組成を有することを特徴とする。
真空ダイカスト鋳造品に残存するガスの総量の５０％以上はＣＯ２ガスであるのが好ましい。残存ガスの総量はいずれの箇所でも２０ｃｍ３／１００ｇ以下であるのが好ましく、鋳造品全体の平均として１０ｃｍ３／１００ｇ以下であるのが好ましい。
残存ガスのうちＣＯ２ガスは鋳造品全体の平均として９ｃｍ３／１００ｇ以下であるのが好ましい。またＨ２ガス、ＣＨ４ガス及びＣ２Ｈ６ガスの合計量は鋳造品全体の平均として５ｃｍ３／１００ｇ以下であるのが好ましい。
残存ガスのうちＨ２ガスの割合は１５％以下であるのが好ましく、１０％以下であるのがより好ましい。またＣＨ４ガス、Ｃ２Ｈ６ガス及びＣＯガスの合計量は鋳造品全体の平均として２０％以下であるのが好ましい。
本発明の真空ダイカスト鋳造品は輸送用機器の足回り部品又は車体構成部品に使用するのが好ましい。
本発明の真空ダイカスト鋳造品の製造方法は、金型キャビティ内を減圧することによりアルミニウム合金溶湯を射出スリーブ内に装填した後、射出スリーブに嵌合するプランジャを前進して射出スリーブ内の溶湯をキャビティ内に充填するもので、真空ダイカスト鋳造品の気泡中に残存するガスが、鋳造品の溶解により放出させた後にガスクロマトグラフィにより測定した場合、Ｈ２ガスがＣＯ２ガスより少ない組成を有するように、離型剤として実質的に水分を含まない化学合成油を金型キャビティに塗布した後鋳造を行うことを特徴とする。
化学合成油はシリコーンオイルを７０質量％以上含み、かつ動粘度が２００×１０−２ｍ２／ｓ以下であるのが好ましい。また射出スリーブ内に実質的に水分を含まない潤滑剤を塗布するのが好ましい。As a result of diligent research in view of the above purpose, heat treatment and welding are performed by using a release agent that not only generates a small amount of gas to be caught in the molten metal during vacuum die casting but also generates a small amount of hydrogen gas. In addition, it was discovered that a vacuum die-cast product free from blistering and hydrogen embrittlement problems can be obtained, and the present invention has been conceived.
That is, the vacuum die cast product of the aluminum alloy of the present invention has a composition in which H 2 gas is less than CO 2 gas when the gas remaining in the bubbles is measured by gas chromatography after being released by dissolution of the cast product. It is characterized by that.
50% or more of the total amount of gas remaining in the vacuum die cast product is preferably CO 2 gas. It is preferably at 20 cm 3/100 g or less in total amount any point of the residual gas, preferably at 10 cm 3/100 g or less as an average of the entire casting.
CO 2 gas of the residual gas is preferably not less 9cm 3/100 g or less as an average of the entire casting. The H 2 gas, the total amount of CH 4 gas and C 2 H 6 gas is preferably at 5 cm 3/100 g or less as an average of the entire casting.
The proportion of H 2 gas in the residual gas is preferably 15% or less, and more preferably 10% or less. Further, the total amount of CH 4 gas, C 2 H 6 gas and CO gas is preferably 20% or less as an average of the entire cast product.
The vacuum die cast product of the present invention is preferably used for an undercarriage part or a vehicle body component part of a transportation device.
In the manufacturing method of the vacuum die casting product of the present invention, after the molten aluminum alloy is loaded into the injection sleeve by reducing the pressure inside the mold cavity, the plunger fitted to the injection sleeve is advanced to move the molten metal in the injection sleeve. intended to be filled into the cavity, the gas remaining in the bubble of the vacuum die casting article, when measured by gas chromatography after were released by the dissolution of the casting, so that H 2 gas has a composition less than the CO 2 gas Further, it is characterized in that a chemical synthetic oil substantially free of moisture as a release agent is applied to the mold cavity and then cast.
The chemically synthesized oil preferably contains 70% by mass or more of silicone oil and has a kinematic viscosity of 200 × 10 −2 m 2 / s or less. Further, it is preferable to apply a lubricant substantially free of moisture in the injection sleeve.
図１は本発明に用いる真空ダイカスト鋳造装置（型開きした状態）の一例を示す概略断面図であり、
図２は図１の真空ダイカスト鋳造装置を型締めし、射出スリーブ内にアルミニウム合金溶湯を装入した状態を示す概略断面図であり、
図３は型締めした真空ダイカスト鋳造装置のプランジャを射出スリーブ内に押し込んで、アルミニウム合金溶湯を金型キャビティ内に注入した状態を示す概略断面図であり、
図４は給湯開始から射出完了までのキャビティ内の真空度を示すグラフであり、
図５は本発明の真空ダイカスト鋳造品の一例を示す概略斜視図であり、
図６は真空状の引け巣を有する真空ダイカスト鋳造品の金属組織を示す顕微鏡写真であり、
図７はガスが残存するボイドを有する真空ダイカスト鋳造品の金属組織を示す顕微鏡写真であり、
図８はガスが残存するボイドが熱処理によりブリスターとなった状態を示す顕微鏡写真である。FIG. 1 is a schematic cross-sectional view showing an example of a vacuum die casting apparatus (a state where the mold is opened) used in the present invention.
FIG. 2 is a schematic cross-sectional view showing a state in which the vacuum die casting apparatus of FIG. 1 is clamped and the molten aluminum alloy is charged into the injection sleeve,
FIG. 3 is a schematic cross-sectional view showing a state in which the plunger of the clamped vacuum die casting apparatus is pushed into the injection sleeve and the molten aluminum alloy is injected into the mold cavity.
FIG. 4 is a graph showing the degree of vacuum in the cavity from the start of hot water supply to the completion of injection,
FIG. 5 is a schematic perspective view showing an example of a vacuum die cast product of the present invention,
FIG. 6 is a photomicrograph showing the metallographic structure of a vacuum die cast product having a vacuum-like shrinkage nest,
FIG. 7 is a photomicrograph showing the metallographic structure of a vacuum die cast product having voids in which gas remains,
FIG. 8 is a photomicrograph showing a state in which the voids in which the gas remains are blistered by heat treatment.
［１］真空ダイカスト鋳造品
真空ダイカスト鋳造品中の残存ガスの総量は鋳造方案だけでなく、鋳造品の形状にも依存する。例えば単純な平板形状等にすれば残存ガスの総量を低減できるが、複雑な形状が求められるダイカスト鋳造品では残存ガスの総量だけで鋳造方案が最適であったかどうかを判定することは難しい。従って、残存ガスの総量だけでなく残存ガス中のＣＯ２ガス及びＨ２ガスの割合が真空ダイカスト鋳造品の良否を判定する上で重要である。
離型剤及び潤滑剤の熱分解により発生した残存ガスの総量及び組成は鋳造品の気泡に残存するガスを取り出した後でなければ測定できないが、残存ガスを完全に取り出すには鋳造品を溶解しなければならない。しかしながら、アルミニウム合金の溶湯は酸素や水蒸気と反応して、酸化アルミニウムを生成し、酸素を消費するとともに水蒸気を還元して水素ガスにすると考えられるので、鋳造品の溶解により取り出した残存ガスの総量及び組成は、鋳造品中に存在していたガスの総量及び組成と完全に一致する訳ではない。従って本明細書において単に「残存ガスの総量及び組成」という場合、特に断りがなければ、鋳造品の溶解により取り出した残存ガスの総量及び組成を表すものとする。
具体的には、４×１０−３ｋＰａに減圧したＡｒ雰囲気で鋳造品を７００℃で溶解させ、発生したガスを５０ｍｌ／ｍｉｎの流量のＡｒキャリアガスにより、ガスクロマトグラフィ分析装置（ＧＣ−８ＡＩＴ、島津製作所（株）製）の並列分流カラムに流し入れ、ガスクロマトグラフィ分析をした。分析時間は１５秒である。残存ガスの総量及び組成は、特に断りがなければ上記条件で測定したものである。
残存ガスは鋳造品に均一に含まれるのではなく、部位により異なる。具体的には、鋳造品のうち湯口近傍部分では残存ガスの総量が少なく、かつ残存ガスのうちのＣＯ２ガスの割合が高いが、湯口から最も遠い部分（真空ポンプ側）では残存ガスの総量が多く、かつ残存ガスのうちのＣＯ２ガスの割合が低い傾向がある。従って、湯口近傍部分、湯口から最も遠い部分及び途中の部分における３〜１０箇所から試験片をサンプリングし、各試験片について残存ガスの量及び組成を測定し、各部分の測定値及びそれらの平均値を求める必要がある。
残存ガスの総量については、最も多い湯口近傍部分では２０ｃｍ３／１００ｇ以下であるのが好ましく、また鋳造品全体の平均として１０ｃｍ３／１００ｇ以下であるのが好ましい。残存ガスの総量がこれらの上限値を超えると、鋳造品の熱処理や溶接時にブリスターが発生し、外観不良を起こすのみならず、機械的強度の低下を引き起こす。残存ガスの総量は平均で８．０ｃｍ３／１００ｇ以下であるのがより好ましい。なお、ガス量は、ガスの種類に関係なく、特に断りがなければ標準状態（２０℃、１気圧）における量として表す。
ＣＯ２ガスの量の上限も、鋳造品全体の平均として９ｃｍ３／１００ｇであるのが好ましい。ＣＯ２ガスの量の下限は限定的ではないが、多くの場合鋳造品全体の平均として２．５ｃｍ３程度であるのが好ましい。ＣＯガスは、ダイカストのような高速充填の場合、１０μｍ以下と非常に細かい気泡になって鋳造品内に分散する。このような気泡は球形のため切欠係数が非常に小さく、応力集中も非常に小さい。
その他のガス（ＣＨ４、Ｃ２Ｈ６及びＨ２）の合計量は、鋳造品全体の平均として５ｃｍ３／１００ｇ以下であるのが好ましい。Ｎ２ガスは不活性であるが、ブリスターの発生を防止するために、鋳造品全体の平均として７ｃｍ３／１００ｇ以下であるのが好ましく、１ｃｍ３／１００ｇ以下であるのがより好ましい。Ｎ２ガスが７ｃｍ３／１００ｇ超であると、金型キャビティの減圧が不十分である。
残存ガスの組成としては、Ｈ２ガスがＣＯ２ガスより少ないことが必要である。残存ガスの総量の５０％以上がＣＯ２ガスであるのが好ましい。これらの条件を満たすことにより、気泡中のガスの大部分が不活性であるために、熱処理や溶接時に鋳造品が脆化することはない。
Ｈ２が局部的にも平均的にも１５％超では水素脆性による鋳造品の機械的強度の低下が激しいので、残存ガスの総量に対するＨ２の割合は１５％以下であるのが好ましく、１０％以下であるのがより好ましい。また離型剤の分解生成物であるＣＨ４、Ｃ２Ｈ６及びＣＯについては、残存ガスの総量を低減して安定した機械的強度を得るために、できるだけ少ない方が好ましい。具体的には、ＣＨ４、Ｃ２Ｈ６及びＣＯの合計量は残存ガスの総量に対して２０％以下の範囲であるのが好ましい。
［２］真空ダイカスト鋳造法
（１）離型剤
本発明では、ガス発生源である離型剤として実質的に水分を含まない化学合成油を使用する。この非水系離型剤は従来の水性エマルジョン型の離型剤に比べて、塗布量を著しく低減できるので、得られる真空ダイカスト鋳造品の残存ガス量を低減することができる。
実質的に水分を含まない化学合成油として、例えばシリコーンオイルを７０質量％以上含み、残部はポリオレフィンやパラフィンであるのが好ましい。シリコーンオイルとしては、ジメチルシリコーンオイル、α−オレフィン変性シリコーンオイル、α−メチルスチリルシリコーンオイル、メチルフェニルシリコーンオイル、アルキルアリール変性シリコーンオイル、メチルハイドロジェンシリコーンオイル等が好ましい。またポリオレフィンとしては、低分子量のポリエチレン、ポリプロピレン、ポリブテン−１、ポリ ４−メチルペンテン−１等が挙げられる。ポリオレフィンは、必要に応じて、酸化反応により分子量を低減させるとともに、シリコーンオイルとの相溶性を向上させるのが好ましい。これらの成分は炭素量が多いため、分解により発生するガス中でＣＯ２ガスの割合が多くなる。
金型キャビティ表面への噴霧を考慮して、化学合成油の４０℃での動粘度は２００×１０−６ｍ２／ｓ（２００ｃＳｔ）以下、好ましくは１００×１０−６ｍ２／ｓ（１００ｃＳｔ）以下、より好ましくは５０×１０−６ｍ２／ｓ（５０ｃＳｔ）以下である。本明細書に記載の動粘度は、田中科学機器製作所（株）のＡＫＶ−２０１を用いて、ＪＩＳ Ｋ ２２８３に基づき測定したものである。動粘度が２００×１０−６ｍ２／ｓを超えると、離型剤として金型キャビティ表面に薄く均一に塗布できず、単位面積あたりの塗布量が増える。その結果、溶湯により揮発するガスの総量が１０ｃｍ３／１００ｇを超えてしまう。また上記範囲内の動粘度を有する離型剤を使用すれば、可動型と固定型のあわせ面に塗布された離型剤が型締めの際に可動型と固定型の隙間を塞ぎ、外部雰囲気がキャビティ内に侵入するのを防止し、金型キャビティ内の真空度を高める役割を果たす。
化学合成油への添加剤として、界面活性剤、防腐剤、防錆剤、潤滑剤、粘度調節剤等が挙げられる。これらの添加剤の量は、化学合成油の機能を損なわないように、化学合成油全体に対して３質量％以下とするのが好ましい。
離型剤を金型キャビティの表面に薄く均一に塗布するために、離型剤を噴霧するのが好ましい。そのため、黒鉛、雲母、タルク、カオリン、窒化ホウ素、フッ化黒鉛等の粉体を使用しないか、もしくは噴霧するのを妨げない程度の粒径及び添加量とするのが好ましい。
（２）潤滑剤
スリーブとプランジャの潤滑性を保つため、実質的に水分を含まない粉体潤滑剤を用いるのが好ましい。例えば、ＰｂＯ等の金属酸化物、二硫化モリブデン、二硫化タングステン等の硫化物、セラミックス、黒鉛、高分子化合物等を、ワックスやパラフィンに適量添加し、０．１〜２ｍｍ程度の粒状粉体にしたものが好ましい。
（３）アルミニウム合金
本発明に使用し得るアルミニウム合金は特に限定的でなく、Ａｌ−Ｓｉ−Ｃｕ、Ａｌ−Ｓｉ−Ｍｇ、Ａｌ−Ｍｇ等のアルミニウム合金、例えばＡＤＣ３、ＡＤＣ５、ＡＤＣ１０、ＡＤＣ１２等が挙げられる。例えば、質量基準で５〜２０％のＳｉ、１％以下のＭｇ、１０％以下のＣｕ、１％以下のＴｉ、１％以下のＦｅ、１％以下のＭｎ、残部Ａｌ及び不可避不純物からなるアルミニウム合金、又は２％以下のＳｉ、１％以下のＭｇ、１０％以下のＣｕ、１％以下のＴｉ、１％以下のＦｅ、１％以下のＭｎ、残部Ａｌ及び不可避不純物からなるアルミニウム合金が使用可能である。
アルミニウム合金溶湯に溶存する水素は、脱ガス処理により０．２ｃｍ３／１００ｇ以下に減少させることができる。アルミニウム合金溶湯中の酸素及び炭素の量は０．１ｃｍ３／１００ｇ以下である。
（４）真空ダイカスト装置及び金型キャビティの減圧
金型キャビティの減圧が十分であれば、鋳造品中の残存ガスに窒素はほとんど含まれない。従って、金型キャビティの減圧度は以下にするのが好ましい。
真空ダイカスト装置は、金型キャビティ内を減圧することにより保持炉内の溶湯を射出スリーブ内に装填する機構を具備するものが好ましい。具体的には、図１〜３に例示する真空ダイカスト装置１０が好ましい。
真空ダイカスト装置１０は、固定プラテン１６ａに取り付けられた固定型１６ｃと、可動プラテン１６ｂに取り付けられた可動型１６ｄと、固定型１６ｃ及び可動型１６ｄにより形成されたキャビティ１６に連通するように固定型１６ｃに取り付けられた射出スリーブ１１と、射出スリーブ１１内を前後進するプランジャ１２と、射出スリーブ１１の下方でアルミニウム合金溶湯Ｍを収容する保持炉１３と、一端が射出スリーブ１１に形成した給湯口１１ａに連通し、他端１４ａが保持炉１３内の溶湯Ｍに没入する給湯管１４と、キャビティ１６に連通するカットオフバルブ１８ａと、パイプ１８ｂを介してキャビティ１６に連通し、キャビティ１６内を真空状態に減圧して保持炉１３内の溶湯Ｍを射出スリーブ１１内に吸引する真空ポンプ１８とを有する。
保持炉１３は昇降台１５上に載置されており、昇降台１５を上下することにより溶湯Ｍの湯面が一定に保たれる。給湯管１４は、溶湯Ｍとの反応を防止するために内面にＢＮコーティングを施したセラミック製であり、下端１４ａはオリフィス状である。給湯管１４の外周はヒータ（図示せず）で包囲されており、給湯管１４を溶湯Ｍの温度近くに保持している。
図１に示すように、真空ダイカスト装置１０は、金型キャビティ１６に水分を含まない化学合成油からなる離型剤を塗布する装置２０と、スリーブ１１に非水系潤滑剤を塗布する装置３０を有する。離型剤の塗布装置２０はアーム２２の先端に離型剤を噴霧するノズル２１を具備し、可動型１６ｄが固定型１６ｃから開いた状態で金型キャビティ１６の表面に離型剤を噴霧する。離型剤の１サイクルごとの使用量は金型キャビティ１６の表面積に対して好ましくは０．３〜５０ｇ／ｍ２であり、より好ましくは１．０〜２５ｇ／ｍ２である。潤滑剤の噴出装置３０は、型開きされた時にスリーブ１１の金型キャビティ側開口部から粉体潤滑剤３１を噴霧するノズル３２を有する。潤滑剤の１サイクルごとの使用量はスリーブ１１の内周面積に対して好ましくは０．３〜３０ｇ／ｍ２であり、より好ましくは０．５〜２０ｇ／ｍ２である。
図４に示すように、可動型１６ｄと固定型１６ｃを閉じた状態で、キャビティ１６内を真空状態に減圧（例えば５０ｋＰａ以下、好ましくは２０ｋＰａ以下、より好ましくは１０ｋＰａ以下、特に５ｋＰａ以下）にする。キャビティ１６内の減圧により射出スリーブ１１内も減圧になり、保持炉１３内の溶湯Ｍは給湯管１４を介して射出スリーブ１１内に装填される（図２）。２〜１０秒間でキャビティ１６内を排気した後、プランジャ１２をスリーブ１１内に押し込み、溶湯Ｍをキャビティ１６内に充填する（図３）。射出後プランジャ１２を後退させるとともに、可動型１６ｄを固定型１６ｃから離隔させ、キャビティ１６から凝固した鋳造品を取り出す。
真空ダイカスト装置１０により溶湯Ｍを大気と接触させずに鋳造できるので、溶湯Ｍの酸化やガスの巻き込みが低減される。真空ダイカスト鋳造の終了後、再度開いた固定型１６ｃ及び可動型１６ｄのキャビティ表面に離型剤を噴霧するとともに、スリーブ１１の内面に潤滑剤を噴霧する。この操作を繰り返すことにより、所望の数の真空ダイカスト鋳造品を作製する。
［３］用途
本発明の真空ダイカスト鋳造法により得られた鋳造品は、残存ガス量が少ないのみならず、熱処理や溶接時に脆化の原因となる水素ガスの割合が少ないので、熱処理や溶接によりブリスターが発生するおそれが少なく、かつ機械的強度の低下もない。また本発明の真空ダイカスト鋳造品は靱性低下の大きな要因である酸化物や介在物が少ない。従って、高強度及び高靭性が要求される輸送機器用の足回り部品や車体構成部品等に使用できる。
本発明を以下の実施例によりさらに詳細に説明するが、本発明はそれらに限定されるものではない。[1] Vacuum die casting product The total amount of residual gas in the vacuum die casting product depends not only on the casting method but also on the shape of the casting product. For example, a simple flat plate shape or the like can reduce the total amount of residual gas, but it is difficult to determine whether or not the casting method is optimal only with the total amount of residual gas in a die-cast product that requires a complicated shape. Therefore, not only the total amount of residual gas but also the proportion of CO 2 gas and H 2 gas in the residual gas is important in determining the quality of the vacuum die cast product.
The total amount and composition of the residual gas generated by the thermal decomposition of the mold release agent and lubricant can be measured only after the gas remaining in the bubbles of the cast product is taken out, but the cast product must be dissolved to completely remove the residual gas. Must. However, the molten aluminum alloy reacts with oxygen and water vapor to produce aluminum oxide, which consumes oxygen and reduces water vapor to hydrogen gas, so the total amount of residual gas extracted by melting the casting And the composition does not exactly match the total amount and composition of gas present in the casting. Accordingly, in the present specification, the term “total amount and composition of residual gas” refers to the total amount and composition of residual gas taken out by dissolution of a cast product unless otherwise specified.
Specifically, the cast product was dissolved at 700 ° C. in an Ar atmosphere decompressed to 4 × 10 −3 kPa, and the generated gas was analyzed by a gas chromatography analyzer (GC-8AIT, The sample was poured into a parallel diversion column manufactured by Shimadzu Corporation and subjected to gas chromatography analysis. The analysis time is 15 seconds. The total amount and composition of the residual gas are measured under the above conditions unless otherwise specified.
The residual gas is not uniformly contained in the casting, but varies depending on the part. Specifically, the total amount of residual gas is small in the vicinity of the sprue of the cast product, and the ratio of CO 2 gas in the residual gas is high, but the total amount of residual gas in the portion farthest from the spout (vacuum pump side). And the ratio of CO 2 gas in the residual gas tends to be low. Therefore, the test piece is sampled from 3 to 10 locations in the vicinity of the gate, the portion farthest from the gate, and the middle portion, and the amount and composition of the residual gas are measured for each test piece. It is necessary to find a value.
The total amount of residual gas is preferably equal to or less than 20 cm 3/100 g is the most common sprue portion near and preferably at 10 cm 3/100 g or less as an average of the entire casting. If the total amount of residual gas exceeds these upper limit values, blisters are generated during heat treatment or welding of the cast product, causing not only a poor appearance but also a decrease in mechanical strength. The total amount of residual gas is more preferably at most 8.0 cm 3/100 g on average. The gas amount is expressed as the amount in a standard state (20 ° C., 1 atm) unless otherwise specified regardless of the type of gas.
The upper limit of the amount of CO 2 gas is also preferably a 9cm 3/100 g as an average of the entire casting. The lower limit of the amount of CO 2 gas is not limited, but in many cases, it is preferably about 2.5 cm 3 as an average of the entire cast product. In the case of high-speed filling such as die casting, CO gas becomes very fine bubbles of 10 μm or less and is dispersed in the cast product. Since these bubbles are spherical, the notch coefficient is very small and the stress concentration is very small.
The total amount of other gases (CH 4, C 2 H 6 and H 2) is preferably in the range 5 cm 3/100 g or less as an average of the entire casting. Although N 2 gas is inert, in order to prevent occurrence of blisters, preferably at 7 cm 3/100 g or less as an average of the entire casting, and more preferably not more than 1 cm 3/100 g. When N 2 gas is at 7 cm 3/100 g greater vacuum of the mold cavity is insufficient.
As the composition of the residual gas, it is necessary that the H 2 gas is less than the CO 2 gas. It is preferable that 50% or more of the total amount of residual gas is CO 2 gas. By satisfying these conditions, most of the gas in the bubbles is inactive, so that the cast product does not become brittle during heat treatment or welding.
If H 2 exceeds 15% both locally and on average, the mechanical strength of the cast product is drastically reduced due to hydrogen embrittlement. Therefore, the ratio of H 2 to the total amount of residual gas is preferably 15% or less. % Or less is more preferable. Further, CH 4 , C 2 H 6 and CO, which are decomposition products of the release agent, are preferably as small as possible in order to reduce the total amount of residual gas and obtain a stable mechanical strength. Specifically, the total amount of CH 4 , C 2 H 6 and CO is preferably in the range of 20% or less with respect to the total amount of residual gas.
[2] Vacuum die casting method (1) Release agent In the present invention, a chemically synthesized oil substantially free of moisture is used as a release agent which is a gas generation source. Since this non-aqueous release agent can significantly reduce the coating amount as compared with the conventional aqueous emulsion release agent, the residual gas amount of the obtained vacuum die cast product can be reduced.
As a chemically synthetic oil substantially free of moisture, it is preferable that, for example, 70% by mass or more of silicone oil is contained and the balance is polyolefin or paraffin. As the silicone oil, dimethyl silicone oil, α-olefin-modified silicone oil, α-methylstyryl silicone oil, methylphenyl silicone oil, alkylaryl-modified silicone oil, methylhydrogen silicone oil and the like are preferable. Examples of the polyolefin include low molecular weight polyethylene, polypropylene, polybutene-1, and poly-4-methylpentene-1. If necessary, the polyolefin preferably has a molecular weight reduced by an oxidation reaction and an improved compatibility with silicone oil. Since these components have a large amount of carbon, the proportion of CO 2 gas in the gas generated by decomposition increases.
Considering spraying onto the mold cavity surface, the kinematic viscosity of chemically synthesized oil at 40 ° C. is 200 × 10 −6 m 2 / s (200 cSt) or less, preferably 100 × 10 −6 m 2 / s (100 cSt). ) Or less, more preferably 50 × 10 −6 m 2 / s (50 cSt) or less. The kinematic viscosity described in this specification is measured based on JIS K 2283 using AKV-201 of Tanaka Scientific Instruments Co., Ltd. When the kinematic viscosity exceeds 200 × 10 −6 m 2 / s, it cannot be applied thinly and uniformly as a mold release agent on the mold cavity surface, and the coating amount per unit area increases. As a result, the total amount of gas volatilized exceeds the 10 cm 3/100 g by melt. If a release agent having a kinematic viscosity within the above range is used, the release agent applied to the mating surface of the movable mold and the stationary mold closes the gap between the movable mold and the fixed mold when clamping, and the external atmosphere Prevents the intrusion into the cavity and increases the degree of vacuum in the mold cavity.
Examples of additives to chemically synthesized oils include surfactants, preservatives, rust inhibitors, lubricants, viscosity modifiers, and the like. The amount of these additives is preferably 3% by mass or less based on the entire chemically synthesized oil so as not to impair the function of the chemically synthesized oil.
In order to apply the release agent thinly and uniformly to the surface of the mold cavity, it is preferable to spray the release agent. Therefore, it is preferable not to use powders such as graphite, mica, talc, kaolin, boron nitride, and graphite fluoride, or to have a particle size and an addition amount that do not hinder spraying.
(2) Lubricant In order to maintain the lubricity of the sleeve and the plunger, it is preferable to use a powder lubricant that does not substantially contain moisture. For example, metal oxides such as PbO, sulfides such as molybdenum disulfide and tungsten disulfide, ceramics, graphite, polymer compounds, etc. are added in appropriate amounts to wax and paraffin to form granular powder of about 0.1 to 2 mm. Is preferred.
(3) Aluminum alloy The aluminum alloy that can be used in the present invention is not particularly limited, and aluminum alloys such as Al-Si-Cu, Al-Si-Mg, and Al-Mg, such as ADC3, ADC5, ADC10, ADC12, etc. Can be mentioned. For example, aluminum consisting of 5 to 20% Si, 1% or less Mg, 10% or less Cu, 1% or less Ti, 1% or less Fe, 1% or less Mn, the balance Al and inevitable impurities on a mass basis Alloy or aluminum alloy consisting of 2% or less Si, 1% or less Mg, 10% or less Cu, 1% or less Ti, 1% or less Fe, 1% or less Mn, balance Al and inevitable impurities Is possible.
Hydrogen dissolved in the molten aluminum alloy can be reduced to below 0.2 cm 3/100 g by degassing. Oxygen and the amount of carbon in the aluminum alloy melt is less than 0.1 cm 3/100 g.
(4) Decompression of vacuum die casting apparatus and mold cavity If the depressurization of the mold cavity is sufficient, the residual gas in the cast product contains almost no nitrogen. Therefore, the pressure reduction degree of the mold cavity is preferably set to the following.
The vacuum die casting apparatus preferably includes a mechanism for loading the molten metal in the holding furnace into the injection sleeve by reducing the pressure in the mold cavity. Specifically, the vacuum die casting apparatus 10 illustrated in FIGS.
The vacuum die casting apparatus 10 includes a fixed die 16c attached to the fixed platen 16a, a movable die 16d attached to the movable platen 16b, and a fixed die so as to communicate with the cavity 16 formed by the fixed die 16c and the movable die 16d. An injection sleeve 11 attached to 16 c, a plunger 12 that moves forward and backward in the injection sleeve 11, a holding furnace 13 that houses the molten aluminum alloy M below the injection sleeve 11, and a hot water inlet that is formed at one end of the injection sleeve 11 11a, and the other end 14a communicates with the cavity 16 via the hot water pipe 14 into which the molten metal M in the holding furnace 13 is immersed, the cut-off valve 18a communicated with the cavity 16, and the pipe 18b. A vacuum pump for reducing the pressure to a vacuum state and sucking the molten metal M in the holding furnace 13 into the injection sleeve 11 And a 8.
The holding furnace 13 is placed on the lifting platform 15, and the molten metal M surface is kept constant by moving the lifting platform 15 up and down. The hot water supply pipe 14 is made of ceramic whose inner surface is coated with BN in order to prevent reaction with the molten metal M, and the lower end 14a has an orifice shape. The outer periphery of the hot water supply pipe 14 is surrounded by a heater (not shown), and the hot water supply pipe 14 is held near the temperature of the molten metal M.
As shown in FIG. 1, the vacuum die casting apparatus 10 includes a device 20 for applying a mold release agent made of chemically synthesized oil not containing moisture to a mold cavity 16 and a device 30 for applying a non-aqueous lubricant to the sleeve 11. Have. The release agent coating device 20 includes a nozzle 21 for spraying the release agent at the tip of the arm 22, and sprays the release agent onto the surface of the mold cavity 16 with the movable die 16 d opened from the fixed die 16 c. . The amount of the release agent used per cycle is preferably 0.3 to 50 g / m 2 , more preferably 1.0 to 25 g / m 2 with respect to the surface area of the mold cavity 16. The lubricant ejection device 30 has a nozzle 32 that sprays the powder lubricant 31 from the mold cavity side opening of the sleeve 11 when the mold is opened. The amount of each cycle of the lubricant is preferably the inner circumferential area of the sleeve 11 is 0.3 to 30 g / m 2, more preferably from 0.5 to 20 g / m 2.
As shown in FIG. 4, with the movable die 16d and the fixed die 16c closed, the inside of the cavity 16 is evacuated to a reduced pressure (eg, 50 kPa or less, preferably 20 kPa or less, more preferably 10 kPa or less, especially 5 kPa or less). . Due to the reduced pressure in the cavity 16, the inside of the injection sleeve 11 is also reduced in pressure, and the molten metal M in the holding furnace 13 is loaded into the injection sleeve 11 through the hot water supply pipe 14 (FIG. 2). After the cavity 16 is evacuated in 2 to 10 seconds, the plunger 12 is pushed into the sleeve 11 to fill the cavity 16 with the molten metal M (FIG. 3). After the injection, the plunger 12 is retracted and the movable die 16d is separated from the fixed die 16c, and the solidified casting is taken out from the cavity 16.
Since the molten metal M can be cast without being brought into contact with the atmosphere by the vacuum die casting apparatus 10, oxidation of the molten metal M and gas entrainment are reduced. After completion of the vacuum die casting, the release agent is sprayed on the cavity surfaces of the fixed mold 16c and the movable mold 16d which are opened again, and the lubricant is sprayed on the inner surface of the sleeve 11. By repeating this operation, a desired number of vacuum die cast products are produced.
[3] Applications The cast product obtained by the vacuum die casting method of the present invention not only has a small amount of residual gas, but also has a small proportion of hydrogen gas that causes embrittlement during heat treatment and welding. There is little risk of blistering and there is no decrease in mechanical strength. Further, the vacuum die cast product of the present invention has few oxides and inclusions which are a major factor in reducing toughness. Therefore, it can be used for undercarriage parts and body components for transportation equipment that require high strength and high toughness.
The present invention will be described in more detail with reference to the following examples, but the present invention is not limited thereto.
図１〜３に示す構造を有する１０００トンのダイカスト装置を使用し、質量基準で９．３％のＳｉ、０．５％のＭｇ、０．９％のＦｅ、０．１％のＭｎ、０．０５％のＣｕ、０．０７％のＮｉ及び０．２％のＺｎを含有するアルミニウム合金（ＡＳＴＭ Ｂ８５のＡ３６０）を真空ダイカスト鋳造して、図５に示すスノーモービル用の座席部品４０を作製した。ダイカスト鋳造した溶湯の鋳込み温度は６７０℃であり、溶湯のゲート速度は高速時に２０〜４０ｍ／秒であった。
離型剤は、２２０℃で溶融したアタクチックポリプロピレンに空気を吹き込んで酸化反応させたものを１００℃まで冷却し、シリコーンオイル［Ｗａｃｋｅｒ−Ｃｈｅｍｉｅ ＧＭＢＨ製Ｗａｃｋｅｒ ＴＮ］を完全に攪拌混合したものである。この混合物に少量の殺菌剤を加えた。各成分の添加量は、シリコーンオイルが８５質量％、アタクチックポリプロピレンが１４．９質量％、殺菌剤が０．１質量％であった。この離型剤の４０℃での動粘度は５ｘ１０−６ｍ２／ｓ〜１．０ｘ１０−４ｍ２／ｓ（５〜１００ｃＳｔ）であった。この離型剤を１サイクル当たり２．５ｇ／ｍ２の割合で金型キャビティ１６の表面に噴霧した。
粉体潤滑剤として、タルク、天然黒鉛及び合成ワックスを含有するアストロルブＧＷ−２３（花野商事株式会社製）を、１サイクル当たり１．５ｇ／ｍ２の量でスリーブ１１の内周面に噴霧した。
図４に示す減圧条件で得られた真空ダイカスト鋳造品を金型から取りだし、鋳造品の湯口近傍部分Ｐ１、バルブ１８ａ近傍部分Ｐ２及び中央部分Ｐ３を切り出して試験片とし、各試験片を４×１０−３ｋＰａに減圧した真空チャンバ内のＡｒ雰囲気中で７００℃で溶解させ、発生したガスを５０ｍｌ／ｍｉｎの流量のＡｒキャリアガスにより、ガスクロマトグラフィ分析装置（ＧＣ−８ＡＩＴ、島津製作所（株）製）の並列分流カラムに流し入れ、ガスの総量及び組成を１５秒間ガスクロマトグラフィーにより測定した。湯口近傍部分Ｐ１及びバルブ近傍部分Ｐ２における残存ガスの総量（標準状態）及び組成、並びに残存ガスの総量（標準状態）及び組成の平均値Ｐａを表１に示す。
同様に製造した真空ダイカスト鋳造品の湯口近傍部分Ｐ１から切り出した幅６．５ｍｍ、厚さ３ｍｍ及び長さ１００ｍｍの板状の試験片に対して、ＪＩＳ規格（ＪＩＳ Ｚ ２２４１）に従って引張り強さ、０．２％耐力及び伸びを、標点距離を２５ｍｍとして測定した。結果を表２に示す。
比較例１
離型剤としてシリコーンオイルエマルジョン［商品名ＴＳＭ６３５２、ＧＥ東芝シリコーン（株）製］を用いた以外実施例１と同様にして、真空ダイカスト鋳造を行なった。このシリコーンオイルエマルジョンは、１５質量％の変性シリコーンオイル、２．０質量％の乳化ポリプロピレン、０．３質量％のエトキシ化アルコール乳化剤、２．０質量％の腐食防止剤、残部水からなる組成を有していた。このシリコーンオイルエマルジョンをさらに水で４０倍に希釈し、金型キャビティの表面に１サイクル当たり３００ｇ／ｍ２の割合で噴霧した。
得られた鋳造品の湯口近傍部分Ｐ１から切り出した試験片に対して、実施例１と同じ測定を行った。結果を表１及び２に示す。比較例１の鋳造品に残存するガスは、８．８ｃｍ３／１００ｇと実施例１より多かっただけでなく、Ｈ２ガス、Ｃ２Ｈ６ガス及びＣＨ４ガスを多量に含有する組成を有していた。これは水性離型剤を使用したためであると考えられる。比較例１の鋳造品の機械的強度は実施例１の鋳造品と比較して低かった。Using a 1000 ton die casting apparatus having the structure shown in FIGS. 1-3, 9.3% Si, 0.5% Mg, 0.9% Fe, 0.1% Mn, 0 The aluminum alloy (ASTM B85 A360) containing 0.05% Cu, 0.07% Ni and 0.2% Zn is vacuum die cast to produce the seat component 40 for a snowmobile shown in FIG. did. The casting temperature of the melt cast by die casting was 670 ° C., and the gate speed of the melt was 20 to 40 m / sec at high speed.
The mold release agent is an atactic polypropylene melted at 220 ° C., blown with air and cooled to 100 ° C., and completely stirred and mixed with silicone oil [Wacker TN manufactured by Wacker-Chemie GMBH]. . A small amount of fungicide was added to this mixture. The amount of each component added was 85% by mass for silicone oil, 14.9% by mass for atactic polypropylene, and 0.1% by mass for bactericides. Kinematic viscosity at 40 ° C. The release agent was 5x10 -6 m 2 /s~1.0x10 -4 m 2 / s (5~100cSt). This release agent was sprayed on the surface of the mold cavity 16 at a rate of 2.5 g / m 2 per cycle.
Astrorub GW-23 (manufactured by Hanano Corporation) containing talc, natural graphite and synthetic wax as a powder lubricant was sprayed on the inner peripheral surface of the sleeve 11 in an amount of 1.5 g / m 2 per cycle. .
The vacuum die cast product obtained under the decompression condition shown in FIG. 4 is taken out from the mold, and the vicinity of the gate P 1 , the vicinity of the valve 18a P 2 and the central part P 3 of the casting are cut out to form test pieces. Was dissolved at 700 ° C. in an Ar atmosphere in a vacuum chamber depressurized to 4 × 10 −3 kPa, and the generated gas was analyzed by a gas chromatography analyzer (GC-8AIT, Shimadzu Corporation) using an Ar carrier gas having a flow rate of 50 ml / min. The total amount and composition of the gas were measured by gas chromatography for 15 seconds. Table 1 shows the total amount (standard state) and composition of residual gas, and the total amount (standard state) and composition average Pa of residual gas in the vicinity of the gate P 1 and the portion near the valve P 2 .
Produced as in width 6.5mm cut from the sprue portion near P 1 of the vacuum die casting products were, to the plate-like test piece having a thickness of 3mm and length 100 mm, tensile strength according to JIS standards (JIS Z 2241) 0.2% proof stress and elongation were measured with a gauge distance of 25 mm. The results are shown in Table 2.
Comparative Example 1
Vacuum die casting was performed in the same manner as in Example 1 except that a silicone oil emulsion [trade name TSM6352, manufactured by GE Toshiba Silicone Co., Ltd.] was used as a release agent. This silicone oil emulsion has a composition comprising 15% by weight modified silicone oil, 2.0% by weight emulsified polypropylene, 0.3% by weight ethoxylated alcohol emulsifier, 2.0% by weight corrosion inhibitor and the balance water. Had. This silicone oil emulsion was further diluted 40 times with water and sprayed onto the surface of the mold cavity at a rate of 300 g / m 2 per cycle.
On specimens cut out from the sprue portion near P 1 of the resulting castings were subjected to the same measurements as in Example 1. The results are shown in Tables 1 and 2. Gas remaining in the casting of Comparative Example 1, 8.8 cm 3/100 g and not only was greater than in Example 1, H 2 gas, C 2 H 6 gas and CH 4 have a composition large amount containing gas Was. This is probably because an aqueous release agent was used. The mechanical strength of the cast product of Comparative Example 1 was lower than that of the cast product of Example 1.
残存ガス量を比較例１とほぼ同じになるように増やすために化学合成油系離型剤の使用量を４．５ｇ／ｍ２と多くした以外実施例１と同様にして、真空ダイカスト鋳造品を作製し、残存ガスの組成と鋳造品の機械的強度との関係を調べた。湯口近傍部分Ｐ１から切り出した試験片における残存ガス量は７．７ｃｍ３／１００ｇであった。実施例１と同様にして測定した残存ガス組成及び機械的強度を表１及び２に示す。表１及び２から、残存ガス量が比較例１とほぼ同程度であるにもかかわらず、比較例１より明らかに機械的強度が向上していることが分かる。A vacuum die cast product in the same manner as in Example 1, except that the amount of the chemically synthesized oil-based mold release agent was increased to 4.5 g / m 2 in order to increase the residual gas amount to be substantially the same as in Comparative Example 1. The relationship between the composition of the residual gas and the mechanical strength of the cast product was investigated. Remaining gas amount in a test piece cut from the sprue portion near P 1 was 7.7 cm 3/100 g. The residual gas composition and the mechanical strength measured in the same manner as in Example 1 are shown in Tables 1 and 2. From Tables 1 and 2, it can be seen that the mechanical strength is clearly improved compared to Comparative Example 1 even though the amount of residual gas is almost the same as that of Comparative Example 1.
実施例１より複雑な形状の真空ダイカスト鋳造品を作製し、実施例１と同じ方法で残存ガスの総量及び組成を測定した。結果を表１に示す。残存ガスの総量は７．１ｃｍ３／１００ｇに抑えられ、かつＨ２ガスがＣＯ２ガスより少なかった。なお実施例１と異なり残存ガスのほとんとがＮ２であったが、これは、金型キャビティが実施例１より複雑形状であったために、キャビティ中の真空度が２５ｋＰａ程度であり、排気が必ずしも十分ではなかったためと考えられる。
比較例２
溶湯をスリーブ内に供給してから減圧する従来の真空ダイカスト鋳造法により、実施例１と同一形状の真空ダイカスト鋳造品を製造し、残存ガスの総量及び組成並びに機械的性質を測定した。先ず実施例１と同じアルミニウム合金溶湯を射出スリーブ内に直接注湯し、射出スリーブを気密状態にした後不活性ガス及び実施例１で用いたのと同じ離型剤を供給し、射出スリーブ内を以下に減圧した。その後プランジャを前進させ、溶湯を金型キャビティ内に充填した。サイクルタイムは実施例１と同じであった。
得られた真空ダイカスト鋳造品の湯口近傍部分Ｐ１での残存ガスの総量及び組成並びに機械的強度を実施例１と同様に測定した。結果を表１及び２に示す。比較例２ではスリーブ内に注湯してから金型キャビティ内を減圧したために、減圧時間は短かった。そのためスリーブ内が十分に排気されず、Ｎ２やＨ２の量が増えていることが分かる。残存ガス量は２１．７５ｃｍ３／１００ｇであった。比較例２の鋳造品の機械的強度は非常に低かった。
Comparative Example 2
A vacuum die casting product having the same shape as in Example 1 was manufactured by a conventional vacuum die casting method in which the molten metal was supplied into the sleeve and then depressurized, and the total amount and composition of residual gas and mechanical properties were measured. First, the same molten aluminum alloy as in Example 1 was poured directly into the injection sleeve, and after the injection sleeve was made airtight, an inert gas and the same release agent used in Example 1 were supplied, Was reduced in pressure below. Thereafter, the plunger was advanced to fill the mold cavity with molten metal. The cycle time was the same as in Example 1.
The obtained total amount and composition and the mechanical strength of the residual gas in the sprue portion near P 1 of the vacuum die casting products were measured in the same manner as in Example 1 were. The results are shown in Tables 1 and 2. In Comparative Example 2, since the mold cavity was decompressed after pouring into the sleeve, the decompression time was short. Therefore, it can be seen that the inside of the sleeve is not exhausted sufficiently and the amount of N 2 and H 2 is increased. Residual gas amount was 21.75cm 3 / 100g. The mechanical strength of the casting of Comparative Example 2 was very low.
実施例１で作製した真空ダイカスト鋳造品を大気雰囲気の５００℃の熱処理炉内に４時間載置した後、６０℃の温水に投入し、溶体化処理（Ｔ６処理）を施した。次いで鋳造品に１５０℃で２時間の時効処理を施した。このようにして熱処理した鋳造品の表面にはブリスターが発生していなかった。これは、引け巣内部がほとんど真空であるために、引け巣が熱処理により膨張しなかったためであると考えられる。
熱処理した鋳造品から試験片を切り出し、鋳造品内部のボイドを調べた。図６は鋳造品の金属組織を示す顕微鏡写真であり、図６中央の濃色部分がボイドである。ほとんどのボイドはアルミニウム合金溶湯の凝固収縮の際にできた引け巣であった。引け巣はなめらかな形状を有し、かつほとんど真空状態であるために、機械的強度の低下の原因にはならないことが分かる。
熱処理によるブリスターの発生の有無を調べるため、熱処理による鋳造品の体積膨張率を測定した。結果を表３に示す。熱処理後の体積膨張率が小さいことから、ブリスターとなる残存ガスを含有する気泡が少ないことが分かる。また実施例１の鋳造品を溶接したもブリスターの発生は認められなかった。これらの結果から、実施例１の鋳造品は強度のばらつきが著しく小さいことが分かる。
比較例３
比較例１の鋳造品に対して実施例４と同様に熱処理を行い、ブリスターの有無及び体積膨張率を測定した。結果を表３に示す。またこの鋳造品の金属組織を図７に示す。図７から、ほとんどのボイドが残存ガスを含有し、ほぼ粒状であることが分かる。そのため、図８に示すように、熱処理後の鋳造品にはブリスターが認められた。このような鋳造品は、輸送用機器の足回り部品又は車体構成部品のような激しい振動を受ける条件下で使用するのに必要な機械的強度を有さない。また比較例１の鋳造品に溶接を行うと、ブリスターが発生した。
比較例４
比較例２の鋳造品に対して実施例４と同様に熱処理を行い、ブリスターの有無及び体積膨張率の測定を行った。結果を表３に示す。比較例４では比較例３より多くブリスターが発生した。
A test piece was cut out from the heat-treated casting, and the void inside the casting was examined. FIG. 6 is a photomicrograph showing the metallographic structure of the cast product, and the dark colored portion in the center of FIG. 6 is a void. Most of the voids were shrinkage cavities formed during solidification shrinkage of the molten aluminum alloy. It can be seen that the shrinkage nest has a smooth shape and is almost in a vacuum state, so that it does not cause a decrease in mechanical strength.
In order to investigate whether or not blisters were generated by heat treatment, the volume expansion coefficient of the cast product by heat treatment was measured. The results are shown in Table 3. From the fact that the volume expansion coefficient after the heat treatment is small, it can be seen that there are few bubbles containing residual gas that becomes blisters. In addition, no blistering was observed when the cast of Example 1 was welded. From these results, it can be seen that the casting of Example 1 has extremely small variation in strength.
Comparative Example 3
The cast product of Comparative Example 1 was heat-treated in the same manner as in Example 4, and the presence or absence of blisters and the volume expansion coefficient were measured. The results are shown in Table 3. The metal structure of this cast product is shown in FIG. It can be seen from FIG. 7 that most voids contain residual gas and are almost granular. Therefore, as shown in FIG. 8, blisters were observed in the cast product after the heat treatment. Such castings do not have the mechanical strength necessary for use under conditions subject to severe vibrations such as undercarriage parts of transport equipment or vehicle body components. Moreover, when welding was performed on the cast product of Comparative Example 1, blisters were generated.
Comparative Example 4
The cast product of Comparative Example 2 was heat-treated in the same manner as in Example 4, and the presence or absence of blisters and the volume expansion coefficient were measured. The results are shown in Table 3. In Comparative Example 4, more blisters were generated than in Comparative Example 3.
以上詳細に説明したように、本発明により、残存ガス量が少ないのみならず、残存ガス中の水素量が低減したアルミニウム合金の真空ダイカスト鋳造品を得ることができる。このような真空ダイカスト鋳造品は、高強度及び高靭性が要求される輸送機器用の足回り部品や車体構成部品等に好適である。 As described above in detail, according to the present invention, it is possible to obtain a vacuum die cast product of an aluminum alloy in which not only the residual gas amount is small but also the hydrogen amount in the residual gas is reduced. Such a vacuum die cast product is suitable for undercarriage parts for transportation equipment and body component parts that require high strength and high toughness.
Claims (13)
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2002371961 | 2002-12-24 | ||
| JP2002371961 | 2002-12-24 | ||
| PCT/JP2003/016541 WO2004058434A1 (en) | 2002-12-24 | 2003-12-24 | Vacuum die casting and method for production thereof |
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| JPWO2004058434A1 true JPWO2004058434A1 (en) | 2006-04-27 |
| JP4518256B2 JP4518256B2 (en) | 2010-08-04 |
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| JP (1) | JP4518256B2 (en) |
| CN (1) | CN1322951C (en) |
| AU (1) | AU2003292610A1 (en) |
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| JP5238553B2 (en) * | 2009-03-06 | 2013-07-17 | トヨタ自動車株式会社 | Gas analyzer |
| CN102126009A (en) * | 2011-03-01 | 2011-07-20 | 宁波旭升机械有限公司 | Die casting manufacturing process of aluminum alloy pump head |
| CN103212688A (en) * | 2013-04-08 | 2013-07-24 | 杭州友阳电器有限公司 | Die-casting manufacturing method for electric appliance joint |
| DE102013223311A1 (en) | 2013-11-15 | 2015-05-21 | Bayerische Motoren Werke Aktiengesellschaft | Maintenance station for casting tools and method for servicing a casting tool |
| CN111531146B (en) * | 2020-05-14 | 2021-06-29 | 深圳市协力达精密科技有限公司 | Aluminum alloy die-casting release agent and preparation system and method thereof |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH02117992A (en) * | 1988-10-27 | 1990-05-02 | Kawasaki Steel Corp | Oil lubricating mold release agent |
| JPH0924454A (en) * | 1995-07-11 | 1997-01-28 | Toyota Motor Corp | Casting device |
| JPH09241784A (en) * | 1996-03-05 | 1997-09-16 | Hitachi Metals Ltd | Die cast product |
| JP2003164954A (en) * | 2001-11-30 | 2003-06-10 | Nissan Motor Co Ltd | Device and method for die casting |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CA2188906C (en) * | 1995-10-27 | 2006-06-06 | Onofre Costilla-Vela | Method and apparatus for preheating molds for aluminum castings |
| DE19810032A1 (en) * | 1998-03-09 | 1999-09-16 | Acheson Ind Inc | Method and device for preparing the mold walls of a mold for primary shaping or shaping for the next molding cycle, spray element with centrifugal atomization and air guidance and use of such a spray element for spraying essentially solvent-free mold wall treatment agents |
| JP2003010958A (en) * | 2001-06-28 | 2003-01-15 | Mitsui Mining & Smelting Co Ltd | Mold for die cast molding, die cast molding method, and molded product |
| JP2003136211A (en) * | 2001-10-26 | 2003-05-14 | Nippon Achison Kk | Apply method |
-
2003
- 2003-12-24 AU AU2003292610A patent/AU2003292610A1/en not_active Abandoned
- 2003-12-24 WO PCT/JP2003/016541 patent/WO2004058434A1/en active Application Filing
- 2003-12-24 JP JP2004562905A patent/JP4518256B2/en not_active Expired - Lifetime
- 2003-12-24 CN CNB2003801073866A patent/CN1322951C/en not_active Expired - Fee Related
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH02117992A (en) * | 1988-10-27 | 1990-05-02 | Kawasaki Steel Corp | Oil lubricating mold release agent |
| JPH0924454A (en) * | 1995-07-11 | 1997-01-28 | Toyota Motor Corp | Casting device |
| JPH09241784A (en) * | 1996-03-05 | 1997-09-16 | Hitachi Metals Ltd | Die cast product |
| JP2003164954A (en) * | 2001-11-30 | 2003-06-10 | Nissan Motor Co Ltd | Device and method for die casting |
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| CN1732058A (en) | 2006-02-08 |
| JP4518256B2 (en) | 2010-08-04 |
| AU2003292610A1 (en) | 2004-07-22 |
| CN1322951C (en) | 2007-06-27 |
| WO2004058434A1 (en) | 2004-07-15 |
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