JPWO2007141854A1 - Mold repair method, heat-resistant inorganic repair material, mold, molded product and product - Google Patents

Abstract

The method for repairing a molding die of the present invention is a heat-resistant inorganic material in which a heat-resistant inorganic repair material 140 containing an inorganic binder, inorganic particles, and metal particles is filled in a crack H generated on the molding surface of the molding die 110. In this order, the repair material filling step, the inorganic binder curing step for heating the heat resistant inorganic repair material 140 to cure the inorganic binder, and the metal particle melting step for heating the heat resistant inorganic repair material 140 to melt the metal particles Including. For this reason, according to the method for repairing a molding die of the present invention, the inside of the crack H generated on the molding surface of the molding die 110 is filled with the heat-resistant inorganic repair material 140. No burr or sashimi Q on the surface. Moreover, since burrs and waste meat Q do not adhere to the surface of the molded product Pa, when the molded product Pa is taken out from the molding die 110, the molding die 110 and the molded product Pa are not damaged.

Description

  The present invention relates to a method for repairing a molding die, a heat-resistant inorganic repair material, a molding die, a molded product, and a product.

  FIG. 13 is a diagram schematically showing a molding die 1010 used for aluminum die casting. 13A is a cross-sectional view of the molding die 1010, FIG. 13B is a perspective view of the moving die 1020 in the molding die 1010, and FIG. 13C is a fixed die in the molding die 1010. FIG. 11 is a perspective view of a mold 1030. In FIG. 13, the gates, runners, etc. for pouring molten aluminum into the cavity S are omitted. FIG. 14 is a view showing a molded product P manufactured using the molding die 1010. 14A is a perspective view of the molded product P, and FIG. 14B is a cross-sectional view of the molded product P.

  The molding die 1010 includes a moving die 1020 and a fixed die 1030 as shown in FIG. Molding is performed by pouring molten aluminum into a cavity S formed between the moving mold 1020 and the fixed mold 130. And if shaping | molding is performed normally, as shown in FIG. 14, the molded product P with the favorable surface state will be manufactured.

  By the way, when molding is performed many times using such a molding die 1010, cracks, pinholes, surface roughness, etc. (hereinafter referred to as this specification) are formed on the surface of the molding die 1010 (particularly, the corner near the gate). These are collectively referred to as “cracks”). Then, due to the cracks, a molded product with burrs and meat on the surface is manufactured.

  15-17 is a figure which shows typically a mode that the molded product Px with a burr | flash and sacrificial meat is manufactured. FIG. 15A is a cross-sectional view showing a molding die 1010 in which cracks have occurred on the molding surface, and FIG. 15B is an enlarged cross-sectional view showing portions indicated by reference signs A to F in FIG. It is. FIG. 16A is a perspective view of a molded product Px with burrs and fillet, and FIG. 16B is a cross-sectional view of the molded product Px with burrs and fillet. FIG. 17A is an enlarged cross-sectional view of the portion indicated by reference signs A to F in FIG. 16B, and FIG. 17B is an enlarged view of the portion indicated by reference sign F ′ in FIG. It is sectional drawing shown.

  That is, if molding is performed many times using the molding die 1010, cracks as indicated by reference signs A to F in FIG. 15 may occur on the surface of the molding die 1010. Then, due to this, a molded product Px having a burr and waste meat Q on the surface as shown by reference signs A to F in FIGS. 16 and 17 is manufactured.

The molded product Px with such burrs and burrs Q may be defective. In that case, the burrs and burrs Q on the surface of the molded products Px must be scraped off with endless paper or the like. Therefore, there is a problem that it takes time and cost.
Further, if there are burrs and waste meat Q in the molded product Px, there is a problem that when the molded product Px is taken out from the molded mold 1010, the molded product or the molded mold is damaged.

  In addition, these problems are not problems seen only in the molding die used for aluminum die casting, but the molding die used for die casting of other metals, the molding die used for low pressure casting, and the molding used for gravity casting. This is a problem commonly seen in the case of a mold, a mold used for glass molding, a mold used for rubber molding, a mold used for resin molding, and the like.

  Therefore, conventionally, there has been disclosed a first mold repair method capable of solving the above-described problems (for example, see Patent Document 1). In this first molding die repair method, both the repair portion of the molding die and the repair material are heated to, for example, 1400 ° C. or more to form a molten pool in the repair portion, and this is cooled. Thereby, the crack which generate | occur | produced on the surface of a shaping die can be plugged up, and the above problems can be solved.

  However, in the first method for repairing the molding die, there is a problem that the shape accuracy of the molding die surface deteriorates because the molding die itself needs to be melted. Moreover, in the repair method of a 1st shaping | molding die, there exists a problem that it is not easy to planarize the swelling part formed after plugging up a crack. Furthermore, in the first method for repairing the molding die, it is easy to close the surface portion (for example, a portion of 1 to 2 mm from the surface) inside the crack, while the bottom portion inside the crack is closed. Since this is not easy, there is a problem that repair of the cooling pipe portion in the molding die is not easy when a crack reaches the cooling piping of the molding die, for example.

  Therefore, a cracking mold repair putty (for example, refer to Patent Document 2) containing a binder made of epoxy resin or the like and inorganic particles made of alumina or the like is filled in a crack generated on the molding surface of the mold. (Hereinafter, referred to as a second molding die repair method).

JP-A-3-433 Japanese Patent Laid-Open No. 10-244588

  However, since the second molding die repair method described above uses an organic binder made of an epoxy resin or the like as a binder, this method is used in a severe temperature environment (high temperature environment and temperature difference) as in a die casting molding die. When used in a mold that is exposed to a large thermal cycle environment), the organic binder deteriorates due to the severe temperature environment, and the putty tends to peel off from the inside of the crack, and the molding surface in the mold There is a problem that it is not easy to maintain the quality.

  Therefore, the present invention has been made to solve the above-described problems, and does not deteriorate the shape accuracy of the molding die surface, and it is easy to flatten the swelled portion formed after the crack is closed. It is also possible to provide a method for repairing a molding die that can easily close the bottom portion inside the crack and can maintain the quality of the molding surface of the molding die even when exposed to a severe temperature environment. With the goal. It is another object of the present invention to provide a heat-resistant inorganic repair material that can be applied to such a molding die repair method. It is another object of the present invention to provide a molding die repaired by such a molding die repair method and various molded products manufactured using such a molding die. Furthermore, it aims at providing the various products repaired using such a heat resistant inorganic repair material.

(1) In the method for repairing a molding die of the present invention, a melting point lower than the melting point of the inorganic binder, the inorganic particles, and the metal material constituting the molding die is provided inside the crack generated on the molding surface of the molding die. A heat-resistant inorganic repair material filling step for filling a heat-resistant inorganic repair material containing metal particles made of a metal material having, an inorganic binder curing step for curing the inorganic binder by heating the heat-resistant inorganic repair material, and And a metal particle melting step of heating the heat-resistant inorganic repair material to melt the metal particles in this order.

  For this reason, according to the method for repairing a molding die of the present invention, the inside of the crack generated on the molding surface of the molding die is filled with a heat-resistant inorganic repair material. The surface of the molded product produced in this way will not be burred or dumped. In addition, since the surface of the molded product is free from burrs and waste, the molded product and the molding die are not damaged when the molded product is taken out from the molding die.

  Further, according to the method for repairing a molding die of the present invention, it is not necessary to melt the molding die itself, so that the shape accuracy of the molding die surface does not deteriorate due to this.

  Further, according to the method for repairing a molding die of the present invention, even if a raised portion of the heat-resistant inorganic repair material is formed on the surface of the molding die, this raised portion can be easily obtained using a file or endless paper. It can be flattened.

  Further, according to the method of repairing a molding die of the present invention, if a heat-resistant inorganic repair material having a relatively low viscosity is selected as the heat-resistant inorganic repair material, the heat-resistant inorganic repair material can be easily obtained up to the bottom portion inside the crack. Therefore, the bottom portion inside the crack can be easily closed.

Furthermore, according to the method for repairing a molding die of the present invention, since a heat-resistant inorganic repair material containing an inorganic binder is used instead of containing an organic binder, even if it is exposed to a severe temperature environment. The binder is not deteriorated and the heat-resistant inorganic repair material is not easily peeled off from the inside of the crack.
Moreover, according to the repair method of the molding die of the present invention, the metal particles are melted and solidified through the metal particle melting step, thereby increasing the strength of the heat-resistant inorganic repair material and increasing the surface smoothness. Therefore, it becomes difficult to peel off the heat-resistant inorganic repair material from the inside of the crack.
As a result, the quality of the molding surface of the molding die can be maintained even when exposed to a severe temperature environment.

  Therefore, the molding die repair method of the present invention does not deteriorate the shape accuracy of the molding die surface, it is easy to flatten the raised portion formed after closing the crack, and inside the crack It is easy to close the bottom portion, and this is a method for repairing a molding die capable of maintaining the quality of the molding surface of the molding die even when exposed to a severe temperature environment.

In the molding die repair method of the present invention, any of a moving die, a fixed die, and a core can be selected as a molding die to be repaired.
In the molding die repair method of the present invention, either a molding die having an extrusion pin or a molding die having no extrusion pin can be selected as a molding die to be repaired.

  When a crack occurs on the molding surface of a molding die without an extrusion pin, it may be impossible to take out the molding product from the molding die due to the presence of burrs and fillet on the molding product. When the method for repairing a molding die of the present invention is applied to such a molding die without an extrusion pin, such a serious problem is solved.

  On the other hand, when a crack occurs on the molding surface of a molding die having an extrusion pin, it may be difficult to take out the molding product from the molding die due to the presence of burrs and fillets on the molding product. In such a case, the molded product can be removed from the molding die by the extrusion pin. However, when the molded product is taken out from the molding die, the molded product or the molding die may be damaged. When the method for repairing a molding die of the present invention is applied to a molding die having such an extrusion pin, such a problem is solved.

(2) In the method for repairing a molding die of the present invention, the metal particle melting step is performed by heating the heat-resistant inorganic repair material near the surface among the heat-resistant inorganic repair materials filled in the cracks. It is preferable.

  By adopting such a method, on the surface side inside the crack, the metal particles are melted and solidified through the metal particle melting step, thereby increasing the strength of the heat-resistant inorganic repair material and heat-resistant inorganic repair material. The effect of improving the surface smoothness is obtained. In addition, on the bottom side inside the crack, the metal particles are not melted and solidified even after the metal particle melting step, so that the heat-resistant inorganic repair material and the molding die are well bonded by the adhesive force of the inorganic binder. The effect of doing is obtained. As a result, even when exposed to a severe temperature environment, the heat-resistant inorganic repair material is more difficult to peel off from the inside of the crack.

(3) In the method for repairing a molding die of the present invention, heat-resistant inorganic repair is performed by heating the entire molding die, heating a heat-resistant inorganic repair material with an oxygen burner, or performing electric discharge machining in the air. Of course, it is possible to heat the material, but it is preferable to heat the heat-resistant inorganic repair material by performing electric discharge machining in an inert gas atmosphere.

  By setting it as such a method, it becomes possible to heat efficiently only the heat resistant inorganic repair material of the surface vicinity among the heat resistant inorganic repair materials with which the inside of the crack was filled. Further, by adopting such a method, the metal particles are not oxidized during the metal particle melting step, thereby preventing the occurrence of a situation in which the strength of the heat-resistant inorganic repair material is reduced. It becomes possible. Further, by adopting such a method, the surface of the molding die is not oxidized during the metal particle melting step, and the occurrence of a situation in which the quality of the molding die is deteriorated due to this is prevented. It becomes possible. Furthermore, by adopting such a method, the adjustment of the heating temperature is facilitated, and appropriate conditions (only the heat-resistant inorganic repair material near the surface of the heat-resistant inorganic repair material is melted, the molding die is not melted) It is possible to carry out the metal particle melting step under conditions such as.

(4) In the repair method of the shaping die of this invention, it is preferable that the said metal particle consists of aluminum or aluminum alloy.

  By adopting such a method, it becomes possible to increase the difference between the melting point of the metal material (for example, hot die steel) constituting the molding die and the melting point of the metal particles. Only the metal particles can be melted without melting the molding die.

(5) In the method for repairing a molding die of the present invention, the inorganic particles are preferably ceramic particles.

  Ceramic particles are resistant to high temperatures and are resistant to temperature changes. Therefore, the ceramic particles are suitable for repairing molds that are exposed to severe temperature environments such as die casting molds. can do. In addition, since ceramic particles have high mechanical strength, the mechanical strength of the heat-resistant inorganic repair material after curing is also high, so that the quality of the molding surface in the molding die can be maintained even when exposed to harsh temperature environments. Is possible.

  As the ceramic particles, ceramic particles made of aluminum oxide, silicon oxide, zirconium oxide, chromium oxide or the like can be preferably used. As the ceramic particles, ceramic particles made of an appropriate material can be appropriately selected and used in view of the molding die material, molding conditions, crack size, depth, shape, and the like.

(6) In the method for repairing a molding die of the present invention, the inorganic particles are preferably other metal particles made of a metal material having a melting point higher than that of the metal material constituting the metal particles.

  By adopting such a method, it becomes possible to melt only metal particles without melting other metal particles in the metal particle melting step, so other heat-resistant inorganic repair materials after the metal particle melting step can be used. Therefore, the strength of the heat-resistant inorganic repair material is not lowered. As a result, it can be suitably used for repairing a molding die that is exposed to a severe temperature environment such as a die casting molding die.

Other metal particles include tungsten, tungsten alloy, molybdenum, molybdenum alloy, tantalum, tantalum alloy, gold, gold alloy, platinum, platinum alloy, iridium, iridium alloy, osmium, osmium alloy with high melting point and excellent chemical stability. The metal particle which consists of etc. can be used suitably.
Further, as other metal particles, metal particles made of a metal material (for example, a steel material) constituting a molding die, or metal particles made of a highly conductive metal material (copper, silver, nickel, etc.). Can also be suitably used.

(7) In the method for repairing a molding die of the present invention, the inorganic binder is preferably a phosphate-based or silicate-based inorganic binder.

  Phosphate-based or silicate-based inorganic binders have high chemical stability and thermal stability. By using the above method, chemical stability of the heat-resistant inorganic repair material after curing is achieved. It is possible to increase the thermal stability, and it is possible to prevent the heat-resistant inorganic repair material from being easily peeled off from the inside of the crack even if exposed to a severe temperature environment. Even when exposed to a temperature environment, the quality of the molding surface of the molding die can be maintained. In addition, since phosphate-based or silicate-based inorganic binders are easy to handle and inexpensive, it is possible to repair a molding die at low cost.

  In the method for repairing a molding die of the present invention, the inorganic binder is more preferably a silicate inorganic binder.

  By setting it as such a method, compared with a phosphate type inorganic binder, it becomes possible to suppress alteration of a metal particle.

  In the molding die repair method of the present invention, the heat-resistant inorganic repair material is preferably a one-component heat-curable inorganic repair material.

  By setting it as such a method, since it becomes unnecessary to mix a some liquid before filling a heat resistant inorganic repair material, the workability | operativity at the time of filling a heat resistant inorganic repair material inside a crack improves.

  Moreover, in the repair method of the shaping die of this invention, it is preferable that the said inorganic binder is a thermosetting inorganic binder.

  By setting it as such a method, after filling the inside of a crack with a heat resistant inorganic repair material, it becomes possible to implement an inorganic binder hardening process only by heating a shaping die as it is. As heating conditions, relatively mild conditions (for example, room temperature to 200 ° C.) can be selected.

(8) In the repair method of the molding die of this invention, it is preferable that the said heat resistant inorganic repair material further contains an inorganic fiber.

  By adopting such a method, since the inorganic fibers are entangled with the inorganic particles in the heat-resistant inorganic repair material, the connection between the inorganic particles is strengthened, so that the inorganic particles are removed from the heat-resistant inorganic repair material filled in the cracks. It becomes difficult to peel. Moreover, since the inorganic particles and the inorganic fibers are appropriately dispersed in the heat-resistant inorganic repair material, the toughness of the cured heat-resistant inorganic repair material can be increased. As a result, according to the method for repairing a molding die of the present invention, it is possible to maintain the quality of the molding surface in the molding die even when exposed to a severe temperature environment.

  The material, length, thickness, shape and amount of addition of the inorganic fiber are appropriate in view of the size, depth or shape of the crack, the size or shape of the inorganic particles contained in the heat-resistant inorganic repair material to be filled, etc. These can be appropriately selected and used.

(9) In the repair method of the molding die of this invention, it is preferable that the said inorganic fiber is carbon fiber.

  By setting it as such a method, since it becomes possible to make the electroconductivity of a heat resistant inorganic repair material high, workability | operativity improves when performing a metal particle fusion process by electrical discharge machining.

  As the carbon fiber, besides a normal carbon fiber, a carbon nanotube or a carbon nanofiber can be preferably used.

(10) In the repair method of the molding die of this invention, it is also preferable that the said inorganic fiber is a ceramic fiber.

  Since it becomes possible to make oxidation resistance high by setting it as such a method, when performing a metal particle melting process, it says that a heat resistant inorganic repair material deteriorates resulting from oxidation of an inorganic fiber. Nothing will happen.

  As the ceramic fiber, a ceramic fiber made of aluminum oxide, silicon oxide, zirconium oxide, chromium oxide or the like can be preferably used.

(11) In the repair method of the molding die of this invention, it is also preferable that the said inorganic fiber is glass fiber.

  Also by adopting such a method, it becomes possible to increase the oxidation resistance, and therefore, when performing the metal particle melting step, the heat-resistant inorganic repair material deteriorates due to the oxidation of the inorganic fibers. This is no longer the case.

  As glass fiber, quartz glass fiber and other glass fibers can be preferably used.

  In addition, in the repair method of the shaping die of this invention, SiC fiber and other inorganic fibers can also be used as inorganic fiber.

(12) In the method for repairing a molding die of the present invention, before performing the heat-resistant inorganic repair material filling step, in addition to the heat-resistant inorganic repair material, the heat-resistant inorganic repair material contains an inorganic binder and inorganic particles. Prepare other heat-resistant inorganic repair material having a viscosity lower than the viscosity of the inorganic repair material, in the heat-resistant inorganic repair material filling step, inside the crack generated on the molding surface of the molding die, The other heat-resistant inorganic repair material and the heat-resistant inorganic repair material are preferably filled in this order.

  By setting it as such a method, since the bottom part in the inside of a crack will be filled with the other heat resistant inorganic repair material which has a viscosity lower than the viscosity of a heat resistant inorganic repair material, in the inside of a crack It is possible to sufficiently close the bottom portion.

  In addition, the surface side portion inside the crack is filled with a heat-resistant inorganic repair material having sufficiently high mechanical strength and sufficiently high surface smoothness, so that the heat-resistant inorganic repair material is cracked during molding. No more being peeled off from inside.

  From the viewpoint of sufficiently closing the bottom portion inside the crack, the average particle size of the inorganic particles contained in the other heat-resistant inorganic repair material is the average of the inorganic particles contained in the heat-resistant inorganic repair material. It is preferable to be smaller than the particle size.

  In the method for repairing the molding die of the present invention, prior to performing the heat-resistant inorganic repair material filling step, the step of washing the inside of the crack to be filled with the heat-resistant inorganic repair material with an organic solvent It is preferable to carry out.

  When the molding die is a molding die for rubber molding or a molding die for resin molding, prior to performing the heat-resistant inorganic repair material filling step, cracks to be filled with the heat-resistant inorganic repair material By performing the step of washing the inside with an organic solvent, it is possible to remove rubber or resin that may be present inside the crack. For this reason, the adhesiveness of a shaping die and a heat resistant inorganic repair material improves.

  Further, in the method for repairing a molding die of the present invention, prior to performing the heat resistant inorganic repair material filling step, the inside of the crack to be filled with the heat resistant inorganic repair material is washed with a strong alkaline aqueous solution. It is also preferable to perform the step and the step of washing the inside of the crack to be filled with the heat-resistant inorganic repair material with an organic solvent.

  When the mold is a die casting mold, a low pressure casting mold, a gravity casting mold or a glass molding mold, a heat resistant inorganic repair material filling process is performed. Prior to performing, the glass and oil component or metal that may be present inside the crack by performing a step of washing the inside of the crack with a strong alkaline aqueous solution and a step of washing the inside of the crack with an organic solvent. And oil and fat components can be removed. For this reason, the adhesiveness of a shaping die and a heat resistant inorganic repair material improves.

(13) In the molding die repair method of the present invention, the molding die is preferably a die for die casting.

  In the repair method of the molding die of the present invention, a die for die casting molding, a molding die for low pressure casting molding, a molding die for gravity casting molding, a molding die for glass molding, a rubber molding die It can be applied to all molding dies and molding dies for resin molding, especially when the molding dies are die casting dies, heat resistance, cold cycle resistance, mechanical strength It has an excellent effect in terms of durability. The reason for this is that, in a molding die for die casting molding, molding is performed under conditions of extremely large temperature differences and pressure differences, so that cracks are likely to occur in the molding die.

(14) The heat-resistant inorganic repair material of the present invention is characterized by containing an inorganic binder, inorganic particles, and metal particles.

  For this reason, according to the heat resistant inorganic repair material of this invention, it becomes possible to implement the repair method of the shaping die as described in said (1) by using the heat resistant inorganic repair material of this invention.

  Therefore, in the heat resistant inorganic repair material of the present invention, it is preferable to use metal particles made of a metal material having a melting point lower than the melting point of the metal material constituting the molding die.

(15) In the heat resistant inorganic repair material of this invention, it is preferable that the said metal particle consists of aluminum or aluminum alloy.

  For this reason, according to the heat resistant inorganic repair material of this invention, it becomes possible to implement the molding die repair method as described in said (4) by using the heat resistant inorganic repair material of this invention.

(16) In the heat resistant inorganic repair material of this invention, it is preferable that the said inorganic particle is a ceramic particle.

  For this reason, according to the heat resistant inorganic repair material of this invention, it becomes possible to implement the repair method of the shaping die as described in said (5) by using the heat resistant inorganic repair material of this invention.

(17) In the heat resistant inorganic repair material of this invention, it is preferable that the said inorganic particle is another metal particle which consists of a metal material which has melting | fusing point higher than melting | fusing point of the metal material which comprises the said metal particle.

  For this reason, according to the heat resistant inorganic repair material of this invention, it becomes possible to implement the molding die repair method as described in said (6) by using the heat resistant inorganic repair material of this invention.

(18) In the heat resistant inorganic repair material of this invention, it is preferable that the said inorganic binder is a phosphate type or silicate type inorganic binder.

  For this reason, according to the heat resistant inorganic repair material of this invention, it becomes possible to implement the molding die repair method as described in said (7) by using the heat resistant inorganic repair material of this invention.

(19) In the heat resistant inorganic repair material of this invention, it is preferable that the said heat resistant inorganic repair material further contains an inorganic fiber.

  For this reason, according to the heat resistant inorganic repair material of this invention, it becomes possible to implement the molding die repair method as described in said (8) by using the heat resistant inorganic repair material of this invention.

(20) In the heat resistant inorganic repair material of this invention, it is preferable that the said inorganic fiber is a carbon fiber.

  For this reason, according to the heat resistant inorganic repair material of this invention, it becomes possible to implement the molding die repair method as described in said (9) by using the heat resistant inorganic repair material of this invention.

(21) In the heat resistant inorganic repair material of this invention, it is preferable that the said inorganic fiber is a ceramic fiber.

  For this reason, according to the heat resistant inorganic repair material of this invention, it becomes possible to implement the molding die repair method as described in said (10) by using the heat resistant inorganic repair material of this invention.

(22) In the heat resistant inorganic repair material of this invention, it is preferable that the said inorganic fiber is glass fiber.

  For this reason, according to the heat resistant inorganic repair material of this invention, it becomes possible to implement the repair method of the shaping die as described in said (11) by using the heat resistant inorganic repair material of this invention.

  In addition, the suitable characteristic of the heat resistant inorganic repair material demonstrated with the repair method (the repair method of the shaping die in any one of said (1)-(13)) of the shaping die of this invention is the feature of this invention. The present invention is also applicable to a heat-resistant inorganic repair material (the heat-resistant inorganic repair material described in any one of (14) to (22) above).

  The heat-resistant inorganic repair material of the present invention (the heat-resistant inorganic repair material described in any one of (14) to (22) above) is used in the molding die repair method of the present invention as described above. In addition, it can also be used for repairing a product used in a severe temperature environment when a crack occurs in the product.

(23) The molding die of the present invention is a molding die repaired by the molding die repair method of the present invention.

  For this reason, since the molding die of the present invention is a molding die in which the inside of the crack is filled with a heat-resistant inorganic repair material, it is possible to produce a high-quality molded product free from burrs and sagging on the surface. . Further, due to this, by using the molding die of the present invention, the molded product and the molding die are not damaged when the molded product is taken out from the molding die.

(24) The molded product of the present invention is a molded product manufactured using the molding die of the present invention.

  For this reason, since the molded product of the present invention is a molded product manufactured using the excellent molding die as described above, it becomes a molded product with high quality and low manufacturing cost.

  Examples of such molded products include aluminum, zinc, magnesium, brass, etc., when the mold is a die casting mold, a low pressure casting mold, or a gravity casting mold. Various metal products are exemplified. When the molding die is a molding die for glass molding, various glass products are exemplified. When the molding die is a molding die for rubber molding, various rubber products are exemplified. In the case where the molding die is a molding die for resin molding, various resin products are exemplified.

(25) The product of the present invention is a product repaired using the heat-resistant inorganic repair material of the present invention.

  For this reason, the product of this invention turns into a product which can be used conveniently also in a severe temperature environment. Examples of the product of the present invention include an internal combustion engine, a rocket engine, a gas turbine, a rocket structure, and various boilers.

It is a figure which shows typically the repair method of the shaping die concerning Embodiment 1. FIG. It is a figure which shows typically the repair method of the shaping die concerning Embodiment 1. FIG. It is a figure which shows typically the inside of the crack H after a metal particle melting process (embodiment 1). It is a figure which shows the electron micrograph of the heat resistant inorganic repair material 140 before and behind a metal particle melting process (Embodiment 1). It is a figure which shows the molded product Pa manufactured with the shaping die 110. FIG. It is a figure which shows typically the inside of the crack H after a metal particle melting process (embodiment 2). It is a figure which shows the electron micrograph of the heat resistant inorganic repair material 240 after a metal particle melting process (embodiment 2). It is a figure which shows typically the inside of the crack H after a metal particle melting process (Embodiment 3). It is a figure which shows the electron micrograph of the heat resistant inorganic repair material 340 after a metal particle melting process (Embodiment 3). It is a figure which shows typically the inside of the crack H after a metal particle melting process (Embodiment 4). It is a figure which shows typically the inside of the crack H after a metal particle melting process (Embodiment 5). It is a figure which shows typically the inside of the crack H after a metal particle melting process (Embodiment 6). It is a figure which shows typically the shaping die 1010 used for aluminum die-casting shaping | molding. It is a figure which shows the molded product P manufactured using the molding die 1010. FIG. It is a figure which shows typically a mode that the molded product Px with a burr | flash and sacrificial meat is manufactured. It is a figure which shows typically a mode that the molded product Px with a burr | flash and sacrificial meat is manufactured. It is a figure which shows typically a mode that the molded product Px with a burr | flash and sacrificial meat is manufactured.

  Hereinafter, a repair method for a molding die, a heat-resistant inorganic repair material, a molding die, a molded product, and a product of the present invention will be described based on the embodiments shown in the drawings.

Embodiment 1
The method for repairing a molding die according to the first embodiment is a method for repairing a molding die for repairing a molding die for aluminum die casting.

  1 and 2 are diagrams schematically showing a molding die repair method according to the first embodiment. FIG. 1A is a cross-sectional view showing a repaired molding die 110, and FIG. 1B is an enlarged cross-sectional view showing portions indicated by reference signs A to F in FIG. FIG. 2A to FIG. 2E are enlarged views showing each step in the molding die repair method according to the first embodiment.

  FIG. 3 is a diagram schematically showing the inside of the crack H after the metal particle melting step. FIG. 4 is a view showing electron micrographs of the heat-resistant inorganic repair material 140 before and after the metal particle melting step. FIG. 4A is the one before the metal particle melting step, and FIG. 4B is the one after the metal particle melting step. FIG. 5 is a view showing a molded product Pa manufactured by the molding die 110. FIG. 5A is a perspective view of the molded product Pa, and FIG. 5B is a cross-sectional view of the molded product Pa.

  As shown in FIG. 1, the method for repairing a molding die according to the first embodiment is a crack that may occur on the molding surface of a molding die 110 (moving die 120 and fixed die 130) for aluminum die casting. This is a method for repairing a molding die that repairs the molding die 100 by filling H (see reference signs A to F) with a heat-resistant inorganic repair material 140. The molding die repair method according to Embodiment 1 includes the following steps (P1) to (P7).

(P1) Heat-resistant inorganic repair material preparation step First, a heat-resistant inorganic adhesive containing an inorganic binder 150 and inorganic particles 160 made of ceramic particles dispersed in the inorganic binder 150 is prepared. As the heat-resistant inorganic adhesive, Aron Ceramic C manufactured by Toagosei Co., Ltd., which is a silicate-based one-component heat-curable inorganic adhesive, was used. Next, 1 g of metal particles 170 made of aluminum having an average particle diameter of 30 μm is added to 8 g of this heat-resistant inorganic adhesive, thereby producing a heat-resistant inorganic repair material 140.

(P2) Cleaning Step with Strong Alkaline Aqueous Solution Next, aluminum Al (FIG. 2A) that may be present inside the crack H generated on the molding surface of the molding die (moving die 120 or fixed die 130). In order to remove the reference H.), the inside of the crack H is washed with a strong alkaline aqueous solution. For example, a potassium hydroxide aqueous solution is used as the strong alkaline aqueous solution.

(P3) Cleaning Step with Organic Solvent Next, the inside of the crack H is cleaned with an organic solvent in order to remove oil and fat components (not shown) that may be present inside the crack H. As the organic solvent, for example, acetone is used. FIG. 2B shows the inside of the crack H when the cleaning process with the organic solvent is completed.

(P4) Heat-resistant inorganic repair material filling step Next, as shown in FIG. 2 (c), the heat-resistant inorganic repair material 140 is filled into the crack H.

(P5) Inorganic Binder Curing Step Next, the heat-resistant inorganic repair material 140 is heated by allowing the molding die to stand in a dryer at 150 ° C. to cure the inorganic binder 150 and thus the heat-resistant inorganic repair material 140. (See FIG. 4A.)

(P6) Metal particle melting step Next, the metal particles 170 are melted by heating the heat-resistant inorganic repair material 140 in the vicinity of the surface of the heat-resistant inorganic repair material 140 filled in the crack H, and then heat-resistant. By stopping the heating of the inorganic repair material 140, the molten metal (aluminum) is solidified (see FIG. 2D). The heat resistant inorganic repair material 140 is heated using an argon discharge welder.

As a result, on the surface side of the internal cracks H, as shown in FIG. 3, reference numeral G ₁ and 4 of the metal particles 170 are agglomerated by melting and solidification through metal particles melting step (see FIG. 2 (d) (See (b).) On the other hand, within the bottom of the crack H is not the metal particles 170 is melted even after the metal particles melting process, there remains the metal particles (code G ₂ references FIG 2 (d). ).

(P7) Flattening Step Next, as shown in FIG. 2E, the raised portion of the heat-resistant inorganic repair material 140 is flattened. The raised portion is flattened using, for example, a file.

  Through the above steps, the molding die repair method according to Embodiment 1 is completed.

  Therefore, according to the method for repairing a molding die according to the first embodiment, the inside of the crack H generated on the molding surface of the molding die 110 is filled with the heat-resistant inorganic repair material 140. As shown in FIG. 5, the surface of the molded product Pa manufactured using the molding die 110 is free from burrs and sacrificial meat. In addition, since the surface of the molded product Pa is free from burrs and waste, the molded product Pa and the molding die 110 are not damaged when the molded product Pa is taken out from the molding die 110.

  Further, according to the method for repairing the molding die according to the first embodiment, it is not necessary to melt the molding die 110 itself, so that the shape accuracy of the molding die surface is not deteriorated due to this.

  Further, according to the method for repairing a molding die according to the first embodiment, even if a raised portion of the heat-resistant inorganic repair material 140 is formed on the surface of the molding die 110, the raised portion is made of a file or endless paper. And can be easily flattened.

  Further, according to the molding die repair method according to the first embodiment, since the heat-resistant inorganic repair material 140 having a relatively low viscosity is selected as the heat-resistant inorganic repair material, the heat resistance is easily achieved up to the bottom portion inside the crack H. The inorganic repair material 140 can be filled, and the bottom portion inside the crack H can be easily closed.

Furthermore, according to the method for repairing the molding die according to the first embodiment, since the heat-resistant inorganic repair material 140 containing the inorganic binder 150 is used instead of containing the organic binder, it is exposed to a severe temperature environment. Even if it is done, the binder is not deteriorated and the heat-resistant inorganic repair material 140 is not easily peeled off from the inside of the crack H.
Moreover, according to the molding die repair method according to the first embodiment, the metal particles 170 are melted and solidified through the metal particle melting step, thereby increasing the strength of the heat-resistant inorganic repair material 140 and the surface smoothness. Therefore, it is difficult for the heat-resistant inorganic repair material 140 to peel off from the inside of the crack H.
As a result, according to the molding die repair method according to the first embodiment, it is possible to maintain the quality of the molding surface of the molding die 110 even when exposed to a severe temperature environment.

  Therefore, in the molding die repair method according to the first embodiment, the shape accuracy of the surface of the molding die 110 is not deteriorated, and it is easy to flatten the raised portion formed after closing the crack H, It is easy to close the bottom portion inside the crack H, and this is a method for repairing a molding die capable of maintaining the quality of the molding surface of the molding die 110 even when exposed to a severe temperature environment.

  Moreover, according to the repair method of the molding die concerning Embodiment 1, since it is supposed to heat the heat resistant inorganic repair material 140 using an argon discharge welding machine, the heat resistant inorganic repair with which the inside of the crack H was filled was carried out. It becomes possible to heat the heat-resistant inorganic repair material 140 near the surface of the material 140, and the following effects are obtained.

  That is, on the surface side inside the crack H, the metal particles 170 are melted and solidified through the metal particle melting step, whereby the strength of the heat resistant inorganic repair material 140 is increased and the surface smoothness of the heat resistant inorganic repair material 140 is increased. The effect of improving the degree is obtained. Further, on the bottom side inside the crack H, the metal particles 170 are not melted and solidified even after the metal particle melting step, so that the heat-resistant inorganic repair material 140 and the molding die 110 are bonded by the adhesive force of the inorganic binder 150. Can be effectively bonded. As a result, even if exposed to a severe temperature environment, the heat-resistant inorganic repair material 140 is more difficult to peel off from the inside of the crack H.

  Moreover, it becomes possible to efficiently heat only the heat-resistant inorganic repair material 140 in the vicinity of the surface of the heat-resistant inorganic repair material 140 filled in the crack H. In addition, the metal particles 170 are not oxidized during the metal particle melting step, and it is possible to prevent the occurrence of a situation in which the strength of the heat-resistant inorganic repair material 140 is reduced due to this. In addition, the surface of the molding die is not oxidized during the metal particle melting step, and it is possible to prevent the occurrence of a situation in which the quality of the molding die 110 deteriorates due to this. Furthermore, adjustment of the heating temperature is facilitated, and under appropriate conditions (conditions such as melting only the heat-resistant inorganic repair material near the surface of the heat-resistant inorganic repair material 140, or not melting the molding die 110). It becomes possible to carry out the metal particle melting step.

  Further, according to the method for repairing a molding die according to the first embodiment, since metal particles made of aluminum are used as the metal particles 170, the metal material constituting the molding die 110 (in this case, hot die steel) SKD61.) And the melting point of the metal material constituting the metal particles (in this case, aluminum) can be increased, so that the metal mold 110 is not melted in the metal particle melting step. Only the particles 170 can be melted.

  In the repair method of the molding die according to the first embodiment, the average particle diameter of the inorganic particles 160 and the viscosity of the heat-resistant inorganic repair material 140 are appropriately adjusted according to the size, depth, or shape of the crack H. Thus, it is possible to appropriately repair various cracks. That is, when the crack H is a crack having an elongated shape, it is preferable to use the heat-resistant inorganic repair material 140 containing the inorganic particles 160 having a relatively small particle diameter and having a relatively low viscosity. On the other hand, when the crack H is a crack having a wide shape, it is preferable to use the heat-resistant inorganic repair material 140 containing the inorganic particles 160 having a relatively large particle diameter and having a relatively high viscosity.

  Moreover, according to the repair method of the molding die concerning Embodiment 1, since the heat resistant inorganic repair material containing the silicate type inorganic binder is used as the heat resistant inorganic repair material 140, the heat resistance after curing is increased. It is possible to increase the chemical stability and thermal stability of the heat-resistant inorganic repair material, and the heat-resistant inorganic repair material 140 is easily peeled off from the inside of the crack H even when exposed to a severe temperature environment. As a result, the quality of the molding surface of the molding die 110 can be maintained. In addition, the molding die 110 can be repaired at a low cost.

  Moreover, according to the molding die repair method according to the first embodiment, since the one-component heat-curable inorganic repair material is used as the heat-resistant inorganic repair material 140, before filling the heat-resistant inorganic repair material. It is not necessary to mix a plurality of liquids, and workability when filling the heat resistant inorganic repair material inside the crack H is improved.

  In addition, according to the molding die repair method according to the first embodiment, since the heat-resistant inorganic repair material 140 containing a thermosetting inorganic binder is used, the heat-resistant inorganic repair material 140 is filled in the crack H. After that, the inorganic binder curing step can be carried out simply by heating the molding die 110 as it is. As heating conditions, relatively mild conditions (for example, room temperature to 200 ° C.) can be selected.

  In the molding die repair method according to the first embodiment, as described above, prior to performing the heat-resistant inorganic repair material filling step (P4), the crack H to be filled with the heat-resistant inorganic repair material 140 is formed. Since the process of cleaning the interior with a strong alkaline aqueous solution (P2) and the process of cleaning the interior of the crack H to be filled with the heat resistant inorganic repair material 140 with an organic solvent (P3) are performed, Aluminum Al and fat components that may be present inside can be removed. For this reason, the adhesiveness between the molding die 110 and the heat-resistant inorganic repair material 140 is improved.

  As shown in FIGS. 1 to 4, the molding die 110 according to the first embodiment is a molding die that has been repaired by the above-described repairing method.

  For this reason, since the molding die 110 according to the first embodiment is a molding die in which the inside of the crack H is filled with the heat-resistant inorganic repair material 140, a high-quality molded product Pa having no burrs and no meat on the surface. Can be manufactured. Further, due to this, by using the molding die 110 according to the first embodiment, the molded product Pa and the molding die 110 are not damaged when the molding product Pa is taken out from the molding die 110. .

  The molded product Pa according to the first embodiment is a molded product manufactured using the molding die 110 according to the first embodiment.

  For this reason, since the molded product Pa according to the first embodiment is a molded product manufactured using the excellent molding die 110 as described above, it is a molded product with high quality and low manufacturing cost.

[Embodiment 2]
The molding die repair method according to the second embodiment is a molding die repair method in which a molding die is repaired using a heat-resistant inorganic repair material 240 containing inorganic fibers 280 made of carbon fibers.

  FIG. 6 is a diagram schematically showing the inside of the crack H after the metal particle melting step. FIG. 7 is a view showing an electron micrograph of the heat-resistant inorganic repair material 240 after the metal particle melting step.

The molding die repair method according to the second embodiment is a molding die repair method that is similar to the molding die repair method according to the first embodiment, but the composition of the heat-resistant inorganic repair material is the same as that of the first embodiment. This is different from the method of repairing such a mold.
That is, the molding die repair method according to the second embodiment further includes inorganic fibers 280 made of carbon fibers in addition to the inorganic binder 250, the inorganic particles 260, and the metal particles 270, as shown in FIGS. The heat resistant inorganic repair material 240 is used.

  For this reason, according to the method for repairing a molding die according to the second embodiment, in addition to the inorganic binder 250, the inorganic particles 260, and the metal particles 270, the heat-resistant inorganic repair material 240 further containing inorganic fibers 280 is used. For this reason, the inorganic fibers 280 are entangled with the inorganic particles 260 in the heat resistant inorganic repair material 240, thereby strengthening the connection between the inorganic particles 260, and the inorganic particles 260 are peeled off from the heat resistant inorganic repair material 240 filled in the cracks H. It becomes difficult to do. In addition, since the inorganic particles 260, the metal particles 270, and the inorganic fibers 280 are appropriately dispersed in the heat-resistant inorganic repair material 240, the toughness of the cured heat-resistant inorganic repair material can be increased. As a result, according to the molding die repair method according to the second embodiment, it is possible to maintain the quality of the molding surface in the molding die even when exposed to a severe temperature environment.

  In addition, according to the method for repairing a molding die according to the second embodiment, the heat-resistant inorganic repair material 240 contains inorganic fibers 280 made of carbon fibers, so that the conductivity of the heat-resistant inorganic repair material 240 can be increased. Since it becomes possible, the effect that workability | operativity improves when performing a metal particle fusion process by electrical discharge machining is also acquired.

  The molding die repair method according to the second embodiment is the same method as the molding die repair method according to the first embodiment except that a heat-resistant inorganic repair material further containing inorganic fibers is used. Of the effects of the molding die repair method according to the first embodiment, the corresponding effects are provided as they are.

[Embodiment 3]
The molding die repair method according to Embodiment 3 is a molding die repair method in which a molding die is repaired using a heat-resistant inorganic repair material 340 containing inorganic fibers 380 made of ceramic fibers.

  FIG. 8 is a diagram schematically showing the inside of the crack H after the metal particle melting step. FIG. 9 is an electron micrograph of the heat resistant inorganic repair material 340 after the metal particle melting step.

The molding die repair method according to the third embodiment is a molding die repair method that is similar to the molding die repair method according to the second embodiment, but the type of inorganic fiber is the molding die according to the second embodiment. It is different from the mold repair method.
That is, the method for repairing a molding die according to Embodiment 3 uses inorganic fibers 380 made of ceramic fibers as shown in FIGS.

  As described above, the method for repairing the molding die according to the third embodiment is different from the method for repairing the molding die according to the second embodiment, but the method for repairing the molding die according to the second embodiment is different. Since the heat resistant inorganic repair material containing an inorganic fiber is used similarly to the case, it has the applicable effect as it is among the effects which the molding die repair method which concerns on Embodiment 2 has.

  That is, according to the method for repairing a molding die according to Embodiment 3, in addition to the inorganic binder 350, the inorganic particles 360, and the metal particles 370, the heat-resistant inorganic repair material 340 that further includes inorganic fibers 380 is used. In addition, the inorganic fibers 380 are entangled with the inorganic particles 360 in the heat-resistant inorganic repair material 340, whereby the connection between the inorganic particles 360 is strengthened, and the inorganic particles 360 are peeled off from the heat-resistant inorganic repair material 340 filled in the crack H. It becomes difficult. Further, since the inorganic particles 360, the metal particles 370, and the inorganic fibers 380 are appropriately dispersed in the heat resistant inorganic repair material 340, the toughness of the cured heat resistant inorganic repair material can be increased. As a result, according to the method for repairing a molding die according to the third embodiment, it is possible to maintain the quality of the molding surface in the molding die even when exposed to a severe temperature environment.

  Moreover, according to the method for repairing a molding die according to the third embodiment, since the heat-resistant inorganic repair material 340 contains inorganic fibers 380 made of ceramic fibers, the following effects are also obtained.

  That is, according to the method for repairing a molding die according to the third embodiment, it is possible to increase the oxidation resistance. Therefore, when performing the metal particle melting step, heat resistance is caused due to oxidation of inorganic fibers. The functional inorganic repair material will not deteriorate. Moreover, since it becomes possible to make the electroconductivity of the heat resistant inorganic repair material 340 high, workability | operativity improves when performing a metal particle melting process by electrical discharge machining.

[Embodiment 4]
The molding die repair method according to the fourth embodiment is a molding die repair method in which a molding die is repaired using a heat-resistant inorganic repair material 440 containing inorganic fibers 480 made of glass fibers.

  FIG. 10 is a diagram schematically showing the inside of the crack H after the metal particle melting step.

The molding die repair method according to the fourth embodiment is a molding die repair method that is similar to the molding die repair method according to the third embodiment, but the type of inorganic fiber is the molding die according to the third embodiment. It is different from the mold repair method.
That is, the method for repairing a molding die according to the fourth embodiment uses inorganic fibers 480 made of glass fibers as shown in FIG.

  As described above, the method for repairing the molding die according to the fourth embodiment differs from the method for repairing the molding die according to the third embodiment in the type of the inorganic fiber, but the method for repairing the molding die according to the third embodiment is different. Since the heat resistant inorganic repair material containing an inorganic fiber is used similarly to the case, it has the applicable effect as it is among the effects which the molding die repair method according to Embodiment 3 has.

  That is, according to the method for repairing a molding die according to Embodiment 4, in addition to the inorganic binder 450, the inorganic particles 460, and the metal particles 470, the heat-resistant inorganic repair material 440 further containing inorganic fibers 480 is used. In addition, the inorganic fibers 480 are entangled with the inorganic particles 460 in the heat-resistant inorganic repair material 440, so that the bonds between the inorganic particles 460 are strengthened, and the inorganic particles 460 are separated from the heat-resistant inorganic repair material 440 filled in the cracks H. It becomes difficult. Further, since the inorganic particles 460, the metal particles 470, and the inorganic fibers 480 are appropriately dispersed in the heat resistant inorganic repair material 440, the toughness of the cured heat resistant inorganic repair material can be increased. As a result, according to the molding die repair method according to the fourth embodiment, it is possible to maintain the quality of the molding surface of the molding die even when exposed to a severe temperature environment.

  In addition, according to the method for repairing a molding die according to the fourth embodiment, since the heat-resistant inorganic repair material 440 contains inorganic fibers 480 made of glass fibers, it becomes possible to increase the oxidation resistance and to melt the metal particles. When performing the process, the heat-resistant inorganic repair material is not deteriorated due to the oxidation of the inorganic fibers. Moreover, since it becomes possible to make the electroconductivity of the heat resistant inorganic repair material 440 high, workability | operativity improves when performing a metal particle melting process by electrical discharge machining.

[Embodiment 5]
The molding die repair method according to Embodiment 5 is a molding die repair method in which a molding die is repaired using a heat-resistant inorganic repair material 540 containing other metal particles 570 as inorganic particles.

  FIG. 11 is a diagram schematically showing the inside of the crack H after the metal particle melting step.

The molding die repair method according to the fifth embodiment is a molding die repair method that is similar to the molding die repair method according to the first embodiment, but the type of inorganic particles is the molding die according to the first embodiment. It is different from the mold repair method.
That is, in the method for repairing a molding die according to Embodiment 5, the melting point of the metal material (aluminum) constituting the metal particles 570 instead of the inorganic particles 160 made of ceramic particles as the inorganic particles, as shown in FIG. Another metal particle 560 made of a metal material (molybdenum) having a higher melting point is used.

  For this reason, according to the molding die repair method according to the fifth embodiment, it is possible to melt only the metal particles 570 without melting the other metal particles 560 in the metal particle melting step. In the heat-resistant inorganic repair material 540 after the process, other metal particles 560 are present in a particle state, and the strength of the heat-resistant inorganic repair material 540 is not lowered. As a result, it can be suitably used for repairing a molding die that is exposed to a severe temperature environment such as a die casting molding die.

  The method for repairing the molding die according to the fifth embodiment is the same as the method for repairing the molding die according to the first embodiment except that other metal particles 560 are used as the inorganic particles. Among the effects possessed by the method for repairing a molding die according to the above, the corresponding effects are maintained as they are.

[Embodiment 6]
In addition to the heat resistant inorganic repair material 640, the molding die repair method according to the sixth embodiment includes an inorganic binder 652 and inorganic particles 662, and has other heat resistance that is lower than the viscosity of the heat resistant inorganic repair material 640. This is a method for repairing a molding die in which the molding die is repaired using a functional inorganic repair material 642.

  FIG. 12 is a diagram schematically showing the inside of the crack H after the metal particle melting step.

The molding die repair method according to the sixth embodiment is a molding die repair method that is similar to the molding die repair method according to the first embodiment, but the heat-resistant inorganic repair material filling step is the first embodiment. This is different from the method of repairing such a mold.
That is, in the molding die repair method according to the sixth embodiment, the other heat-resistant inorganic repair material 642 and heat-resistant inorganic repair material 640 are filled in the crack H in this order.

  For this reason, according to the method for repairing a molding die according to the sixth embodiment, as shown in FIG. 12, the bottom portion inside the crack H is filled with another heat-resistant inorganic repair material 642 having a low viscosity. Therefore, the bottom portion inside the crack H can be sufficiently blocked. Further, the surface side portion inside the crack H is filled with the heat-resistant inorganic repair material 640 having a sufficiently high mechanical strength and a sufficiently high surface smoothness, so that the heat-resistant inorganic repair material 640 is formed during molding. Will not peel off from the inside of the crack H.

  In the method for repairing the molding die according to the sixth embodiment, in order to sufficiently close the bottom portion inside the crack H, the average particle diameter of the inorganic particles 662 contained in the other heat-resistant inorganic repair material 642 is heat-resistant. Smaller than the average particle diameter of the inorganic particles 660 contained in the conductive inorganic repair material 640.

  The method for repairing a molding die according to Embodiment 6 relates to Embodiment 1 except that the inside of the crack H is filled with other heat-resistant inorganic repair material 642 and heat-resistant inorganic repair material 640 in this order. Since it is the same method as the method for repairing the molding die, it has the corresponding effect as it is among the effects of the method for repairing the molding die according to the first embodiment.

  As mentioned above, although the repair method of the molding die of this invention, the heat resistant inorganic repair material, the molding die, the molded product, and the product were demonstrated based on said each embodiment, this invention is limited to each said embodiment. However, the present invention can be implemented in various modes without departing from the gist thereof, and for example, the following modifications are possible.

(1) In Embodiments 1 to 6, a silicate inorganic binder is used as the inorganic binder, but the present invention is not limited to this. Instead of the silicate inorganic binder, a phosphate or other inorganic binder can also be used.

(2) In Embodiments 1 to 6, metal particles made of aluminum are used as the metal particles, but the present invention is not limited to this. Metal particles made of an aluminum alloy or other metal material can also be used.

(3) In Embodiment 5 described above, other metal particles made of molybdenum are used as the other metal particles, but the present invention is not limited to this. Metal particles made of tungsten, tungsten alloy, molybdenum alloy, tantalum, tantalum alloy, gold, gold alloy, platinum, platinum alloy, iridium, iridium alloy, osmium, osmium alloy, or other metal materials can also be used.

(4) In the said Embodiment 2-4, although carbon fiber, ceramic fiber, or glass fiber is used as inorganic fiber, this invention is not limited to this. Instead of these fibers, SiC fibers, metal fibers, or the like can be used.

(5) In each of the above embodiments, the case where the method for repairing a molding die of the present invention is applied to a molding die for die casting for aluminum casting is shown, but the present invention is limited to this. It is not a thing. The method for repairing a molding die of the present invention can also be applied to a molding die for die casting or other die casting. The molding die repair method of the present invention includes a molding die for low-pressure casting molding, a molding die for gravity casting molding, a molding die for glass product molding, a molding die for rubber product molding, and a resin. The present invention can also be applied to a molding die for product molding and other molding die for product molding.

(6) In each of the above embodiments, the heat-resistant inorganic repair material of the present invention is used to repair a molding die, but the present invention is not limited to this. The heat-resistant inorganic repair material of the present invention can also be used to repair products used in severe temperature environments such as internal combustion engines, rocket engines, gas turbines, rocket structures, and various boilers.

Explanation of symbols

110 ... molding die, 120 ... moving die, 130 ... fixed die, 140,240,340,440,540,640 ... heat resistant inorganic repair material, 150,250,350,450,550,650,652 ... Inorganic binder, 160, 260, 360, 460, 560, 660, 662 ... inorganic particles, 170, 270, 370, 470, 570, 670 ... metal particles, 280, 380, 480 ... inorganic fibers, 560 ... other metal particles 642 ... Other heat-resistant inorganic repair materials, H ... cracks, P, Pa ... molded products

Claims (25)

Heat resistant inorganic repair containing metal particles made of a metal material having a melting point lower than the melting point of the metal material constituting the molding die inside the crack generated on the molding surface of the molding die A heat-resistant inorganic repair material filling process for filling the material,
An inorganic binder curing step of curing the inorganic binder by heating the heat-resistant inorganic repair material;
A method of repairing a molding die, comprising a metal particle melting step of heating the heat-resistant inorganic repair material to melt the metal particles in this order. In the repair method of the molding die of Claim 1,
A method for repairing a molding die, wherein the metal particle melting step is performed by heating a heat-resistant inorganic repair material in the vicinity of a surface of the heat-resistant inorganic repair material filled in the crack. In the repair method of the shaping die according to claim 1 or 2,
A method for repairing a molding die, characterized by heating a heat-resistant inorganic repair material by performing electric discharge machining in an inert gas atmosphere. In the repair method of the molding die in any one of Claims 1-3,
The method for repairing a molding die, wherein the metal particles are made of aluminum or an aluminum alloy. In the repair method of the molding die in any one of Claims 1-4,
The method for repairing a molding die, wherein the inorganic particles are ceramic particles. In the repair method of the molding die in any one of Claims 1-4,
The method for repairing a molding die, wherein the inorganic particles are other metal particles made of a metal material having a melting point higher than that of the metal material constituting the metal particles. In the repair method of the molding die in any one of Claims 1-6,
The method for repairing a molding die, wherein the inorganic binder is a phosphate-based or silicate-based inorganic binder. In the repair method of the molding die in any one of Claims 1-7,
The heat-resistant inorganic repair material further contains inorganic fibers, and is a method for repairing a molding die. In the repair method of the shaping die according to claim 8,
The said inorganic fiber is carbon fiber, The repair method of the shaping die characterized by the above-mentioned. In the repair method of the shaping die according to claim 8,
The method for repairing a molding die, wherein the inorganic fiber is a ceramic fiber. In the repair method of the shaping die according to claim 8,
The said inorganic fiber is glass fiber, The repair method of the shaping die characterized by the above-mentioned. In the repair method of the shaping die in any one of Claims 1-11,
Before carrying out the heat-resistant inorganic repair material filling step, in addition to the heat-resistant inorganic repair material, other heat resistance containing an inorganic binder and inorganic particles and having a viscosity lower than the viscosity of the heat-resistant inorganic repair material Prepare inorganic repair materials,
In the heat-resistant inorganic repair material filling step, the other heat-resistant inorganic repair material and the heat-resistant inorganic repair material are filled in this order into the cracks generated on the molding surface of the molding die. Repair method for molds. In the repair method of the molding die in any one of Claims 1-12,
The method for repairing a molding die, wherein the molding die is a die for die casting.   A heat-resistant inorganic repair material comprising an inorganic binder, inorganic particles, and metal particles. In the heat resistant inorganic repair material according to claim 14,
The heat-resistant inorganic repair material, wherein the metal particles are made of aluminum or an aluminum alloy. In the heat resistant inorganic repair material according to claim 14 or 15,
The heat-resistant inorganic repair material, wherein the inorganic particles are ceramic particles. In the heat resistant inorganic repair material according to claim 14 or 15,
The heat-resistant inorganic repair material, wherein the inorganic particles are other metal particles made of a metal material having a melting point higher than that of the metal material constituting the metal particles. In the heat-resistant inorganic repair material in any one of Claims 14-17,
The heat-resistant inorganic repair material, wherein the inorganic binder is a phosphate-based or silicate-based inorganic binder. In the heat-resistant inorganic repair material in any one of Claims 14-18,
The heat-resistant inorganic repair material further includes inorganic fibers. In the heat-resistant inorganic repair material according to claim 19,
The heat-resistant inorganic repair material, wherein the inorganic fiber is a carbon fiber. In the heat-resistant inorganic repair material according to claim 19,
The heat-resistant inorganic repair material, wherein the inorganic fiber is a ceramic fiber. In the heat-resistant inorganic repair material according to claim 19,
The heat-resistant inorganic repair material, wherein the inorganic fiber is a glass fiber.   A molding die repaired by the molding die repair method according to claim 1.   A molded product produced using the molding die according to claim 23.   The product repaired using the heat-resistant inorganic repair material in any one of Claims 14-22.