KR20030065775A - Method for casting metallic ingot for plastic working, apparatus for producing the same, members for plastic working, mehtod for producing the same - Google Patents

Abstract

The present invention has a problem of providing a method for efficiently producing an ingot of a metal having a more dense structure, and a plastic working member having sufficient mechanical properties. The solution means can be opened and closed by an opening and closing operation. In the casting method of the metal which has a spout in the upper part and a cooling member serves as the bottom part, and the metal molten metal supplied from the spout is cooled with a cooling member, and a ingot is obtained. ,

Opening before opening and closing on the condition that the cooling member of the mold is above a predetermined allowable lower limit temperature,

Cooling of the cooling member is started to satisfy the initial cooling condition that the temperature when the molten metal injected into the mold contacts the surface of the mold in the mold is not lower than the allowable lower limit temperature.

After the molten metal is filled in the mold, the pressure in the mold is continued without closing the opening and closing.

The molten metal is closed by the opening and closing before the solidification of the molten metal in the mold reaches near the pouring hole and becomes impossible before closing, where the opening and closing of the pouring hole becomes impossible.

After the closing, the cooling to the cooling member is stopped when a predetermined cooling termination condition is achieved,

Based on the predetermined ingot drawing condition after cooling stop, the casting method of the metal ingot for plastic processing which removes the cooling member from the mold main body and draws out the ingot, and by applying plastic processing to the obtained ingot at a processing rate of a predetermined ratio or more It is characterized by being solved by the manufacturing method of the plastic processing member used as a plastic processing member.

Description

METHOD FOR CASTING METALLIC INGOT FOR PLASTIC WORKING, APPARATUS FOR PRODUCING THE SAME, MEMBERS FOR PLASTIC WORKING, MEHTOD FOR PRODUCING THE SAME}

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to plastic processing, in particular, forging metal ingots, and more particularly, to plastic processing members used in cold forging such as aluminum, annual cutting, closed forging, and the like. As a metal, it can be applied also to nonferrous metals, such as aluminum, zinc, and magnesium (including an alloy each), and other steels, but aluminum, zinc, and magnesium are especially suitable.

In aluminum forging, an example of a plastic processing member, an extruded rod or a continuous casting rod cut into pieces of the required length and thickness is generally used. (Au, July 1995, issue 33, pp. 33-34) (Keikinjokutsu Shinaru Co., Ltd., issued July 28, 1995.) In addition, a rolled sheet is punched to form an original.

In the case of extruded rods, aluminum baths are cast continuously to be billets, extruded after homogenization treatment, round rods, shaped cross-section rods, and hollow rods. After the process, the material is cut to length or thickness.

In the case of using a continuous casting rod, the aluminum molten metal is continuously cast into a thin diameter rod, and then subjected to heat treatment to cut the outer circumferential surface, and then cut into a predetermined length and thickness. Moreover, a mold release cross section bar and a hollow bar are cut | disconnected to predetermined length. When punching a rolled sheet, first, an aluminum molten metal is continuously cast and used as a rolling material, and after heating, it is hot rolled to form a rolled sheet. Thereafter, the punching machine is punched to a predetermined outer diameter to form a material.

In addition, there is a method of obtaining a punching material by using a direct rolling method of obtaining a plate by continuous casting directly from the molten metal.

The forging material obtained by the above method has a cutting surface, a cutting surface, or a plastic working surface, and the entire surface is not a casting surface. In other words, the ingot itself is not made of a forged material.

Other methods of obtaining ingots include mold gravity casting, diecast casting, low pressure or high pressure casting. These casting methods are obtained by pouring aluminum molten metal into a casting machine to form an ingot and then cutting a hot water ball, a hot water, or the like to obtain a raw material.

The casting forging method, which is studied by the Japan Aluminum and Light Metals Association Aluminum Forging Committee, is a method of obtaining the forging preform that is optimal for mold filling and defect reduction of each part by controlling the solidification rate of the molten metal. Although it can be said to be an improvement method of cast casting, in order to forge the ingot obtained by this method, it is necessary to cut a molten metal, a pressure bath, etc. (refer to above-mentioned "Aru" page 42).

Apart from these, a so-called one-way solidification method is known for casting steel (Japanese Patent Laid-Open No. 56-50776). In addition, unidirectional coagulation as a test apparatus is known in aluminium alloys (Japan, Magazine No. 49, No. 9 (1977), P539-544). In the casting by the one-way solidification, a casting body having good internal quality can be obtained. However, if the upper surface of the molten metal is an open free surface, the meniscus portion in contact with the side wall of the mold becomes a large curved surface, and the casting body is an outer peripheral surface. It was not possible to form a face at right angles. In addition, it is difficult to constantly control the amount of pouring, a large unevenness of the weight of the finished material, an overload during forging, stop the forging machine, or a large dimensional nonuniformity of the forging product.

In order to solve the above-mentioned drawback of casting by one-way solidification, the present inventors proposed a casting method and apparatus by one-way solidification as disclosed in Japanese Patent Application Laid-open No. Hei 8-155627.

In today's world, plastic working is more precise. In order to do so, it is required that the ingot used for plastic processing be more dense and more uniform in structure, and further improve the mechanical strength of the final product.

However, in the case of using a casting apparatus that performs a casting process in a casting cycle of the conventional method, the molten metal injected into the mold is mainly cooled until the cooling plate main body starts to cool until cold water starts to be cooled. The casting structure becomes rough due to the delay in speed. In addition, since cooling is started after the pouring is completed, it is difficult to obtain a sufficiently dense structure. Moreover, the cycle time used for casting cannot be shortened and casting efficiency is bad.

Moreover, in the metal structure of a metal ingot, when DAS is large and crystal grain diameter becomes large, the mechanical characteristics, such as tensile strength, 0.2 strength, and elongation, tend to weaken generally. Therefore, in the case of a metal ingot manufactured by solidification from a conventional one direction, a difference occurs in the size of the DAS between the opening and closing side and the cooling member side, and as a result, a difference occurs in the mechanical properties as it is. Even in one case, nonuniformity was likely to occur in the mechanical properties.

The present invention has been proposed in view of the above, and an object thereof is to provide a method for efficiently producing an ingot having a denser structure, and to provide a member for plastic working with sufficient mechanical properties.

1 is a schematic configuration diagram of a casting apparatus according to the present invention.

2 is a time chart showing the flow of the casting process in relation to the temperature of the cold plate.

3 is a functional block diagram showing an example of a casting control device.

FIG. 4 is a view showing an ingot, a single block, and a short member in Example 1. FIG.

5 is a view showing the shape of the tensile test piece, (a) is a front view, (b) is a side view.

FIG. 6 is a view showing an ingot, a short body, and a short member in Example 2. FIG.

FIG. 7 is a view showing an ingot and a rolling member in Example 3. FIG.

FIG. 8 is a view showing an ingot and a cup-shaped forging member in Example 4. FIG.

<Description of the code>

1: forging device 2: cooling plate

3: mold body 4: mold

5: molten metal 5 ', 111a, 121a, 131a, 141a: ingot

7: spout 8: before opening and closing

9: opening and closing electric lifting mechanism 12: spray nozzle

16: on-off valve 17: solenoid valve

18: temperature detection means 19: casting control means

111b, 121b: Single body 121c: Short member

131b: rolling member 141b: cup-shaped forging member

141p: inner cup bottom 141q: outer cup bottom

1) According to a first aspect of the present invention, a molten metal is supplied from a spout by using a mold having a spout which can be opened and closed by opening and closing at the top and a cooling member also serving as a bottom portion. In the method of casting a metal that is cooled to obtain an ingot,

Opening before opening and closing on the condition that the cooling member of the mold is above a predetermined allowable lower limit temperature,

The cooling of the cooling member is started to satisfy the initial cooling condition that the temperature when the molten metal injected into the mold contacts the surface of the mold of the cooling member is not lower than the allowable lower limit temperature.

After the metal melts in the mold, the hot water in the mold continues without closing before opening and closing.

The molten metal is closed by the opening and closing before the molten metal coagulation in the mold reaches near the pouring hole and becomes incapable of closing before the opening and closing of the pouring hole becomes impossible.

After the closing charge, cooling to the cooling member is stopped when a predetermined cooling end condition is achieved,

A method of casting a metal ingot for plastic working, characterized in that the cooling member is removed from the mold main body to take out the ingot based on the predetermined ingot drawing condition after cooling stop.

2) A second invention for solving the above problems is a method for producing a plastic processing member, characterized in that the plastic processing is applied to the ingot obtained by the method 1) at a processing rate equal to or more than a predetermined ratio to form a plastic processing member. .

3) The third invention for solving the above problems,

The processing rate of the predetermined ratio or more is a method for producing a member for plastic working as described in 2), which is achieved by one or more plastic working on the ingot.

4) The 4th invention for solving the said subject is a manufacturing method of the plastic processing member as described in 2) or 3) whose predetermined ratio is 25%.

5) The fifth invention for solving the above problems is a method for producing a member for plastic working according to any one of 2) to 4), wherein the plastic working is a partial plastic working for an ingot.

6) In the sixth invention for solving the above problems, the plastic working is for plastic working according to any one of 2) to 5), wherein the plastic working is a plastic working for a part including at least an opening and closing front side of the ingot. It is a manufacturing method of a member.

7) In the seventh method for solving the above problems, the plastic working is carried out by forging (cold, hot), short fermentation, rolling, extrusion, rolling, rotary forging (electric). It is a manufacturing method of the member for plastic working as described in any one of 2) -6) which is either.

8) The eighth invention for solving the above problems is a mold having a spout which can be opened and closed by opening and closing the upper portion and cooling means for cooling the mold having the bottom portion and the cooling member of the mold; A metal casting apparatus having a casting control means for collectively performing opening control and cooling control by a cooling means and detachment control of a cooling member and a mold body.

The casting control means,

A pre-opening control means for opening the opening and closing before starting the pouring to the mold, as a requirement that the cooling member is equal to or higher than a predetermined lower limit temperature;

After the start of pouring by the pre-opening control means, the cooling means is controlled so as to satisfy the initial cooling condition that the temperature when the molten metal injected into the mold contacts the surface of the mold of the convex member is not lower than the allowable lower limit temperature. Initial cooling control means,

Normal cooling control means for controlling the cooling means after the molten metal injected into the mold has completely covered the mold inner surface of the cooling member to perform normal cooling of the cooling member;

Pre-closure control means for closing the pouring hole by the opening and closing and stopping the pressurization into the mold before the solidification of the molten metal in the mold reaches near the pouring hole and becomes impossible to close before the opening and closing of the pouring hole becomes impossible.

Cooling stop control means for stopping cooling to the cooling member by stopping control to the cooling means by the normal cooling control procedure on the basis that the predetermined cooling termination condition is achieved after the closing charge by the closing control means; ,

After the cooling stops, predetermined removal conditions for the ingot are achieved, and the cooling member is detached from the mold body so as to take out the ingot from the mold. After the ingot is taken out, the detachable control means for mounting the cooling member to the mold body again to form the mold is provided. It is a manufacturing apparatus for casting a metal for plastic working, characterized in that provided.

9) The 9th invention for solving the said subject is a manufacturing apparatus which casts the metal ingot for plastic working described in 8) characterized by the air vent hole formed in the mold.

10) According to a tenth aspect of the present invention, a metal molten metal charged from an opening and closing state is cooled by using an occluded mold in which an end face before opening and closing forms part of the mold inner surface and a cooling member forms part. It is a plastic processing member characterized in that plastic processing is applied to a ingot solidified by forced cooling by a member at a processing rate of a predetermined ratio or more.

11) The eleventh invention for solving the above problems is a member for plastic working according to 10), wherein the ingot is a cabinet in which the ingot is solidified by the method described in 1).

12) The twelfth invention for solving the above problems is a member for plastic working according to 10) or 11), wherein the ingot is subjected to plastic working according to any one of 2) to 7).

13) The thirteenth invention for solving the above problems is the plastic working member according to any one of 10) to 12), which is an intermediate processed product.

14) The 14th invention for solving the said subject is a plastic processing member as described in any one of 10) -12) which is a final processing product.

15) The fifteenth invention for solving the above problems is the plastic working member according to any one of 10) to 14), wherein the metal is aluminum or an aluminum alloy.

16) The sixteenth invention for solving the above-mentioned problems is any one of 10) to 15) in which the DAS of the metal structure in the opening and closing side is 1.1 to 10.0 times the DAS of the metal structure on the cooling member side of the ingot. The plastic processing member described in the above paragraph.

17) According to a seventeenth invention for solving the above-mentioned problems, the crystal grain diameter of the metal structure in the opening and closing side is 1.05 to 7 times the crystal grain diameter of the metal structure on the cooling member side of the ingot. The plastic processing member described in any one of items).

18) According to an eighteenth aspect of the present invention, the second phase outgoing particle diameter of the plastic working member is 10 or more in which the ratio of the particle diameter before opening and closing to the particle diameter on the cooling member side is 1.2 or more. The plastic processing member according to any one of items 1 to 17).

19) The nineteenth invention for solving the above-mentioned problems is characterized in that the ingot is ingot which is poured downward from the spout and the growth direction of the crystal is approximately upward. Plastic processing member.

20) The twentieth invention for solving the above problems is the plastic working member according to any one of 10) to 19), which is in an annealed state.

21) The twenty-first invention for solving the above problems is a member for plastic working according to any one of items 10) to 20), wherein the surface is barrel-polished.

22) The twenty-second invention for solving the above problems is a member for plastic working according to any one of items 10) to 21), wherein the surface is shot blasted.

Next, based on an accompanying drawing, embodiment of the metal casting method and casting apparatus which concerns on this invention is described.

1 is a schematic configuration diagram of a casting apparatus 1 which is an example of the casting apparatus of the present invention. The casting apparatus 1 illustrated here is a metal ingot used as a raw material in plastic processing, such as cold forging, hot forging, closed forging, rolling, extrusion, rolling, etc. In order to manufacture various kinds of castings (members for plastic processing, metal ingots), steel may be used as a raw material of the castings, but it is particularly suitable to apply nonferrous metals such as aluminum, zinc, magnesium, and respective alloys. A closed mold 4 is formed by a cooling plate 2 and a mold main body 3, which are plate-shaped cooling members, and a molten metal bath 5 is prepared in the upper part of the mold main body 3 in preparation for the molten metal 5 from a melting furnace or the like. (Iii) (6) and opening and closing the pouring port 7 communicating with the molten metal bath 6 and the mold main body 3 by the opening and closing 8 to open and close the molten water tank 6 The molten metal 5 is supplied to the mold 4 or the supply is stopped. Further, the opening and closing before 8 moves up and down by the opening and closing electric lifting mechanism 9 to close the pouring hole 7 or open the pouring hole 7. In this example, the mold body and the molten metal bath are integrated, but it is also possible to have a separately divided configuration. When making the space in a mold into a complicated shape, it is preferable to divide a molten metal bath and a mold main body separately, and to divide a mold main body.

The spout 7 has a tapered shape in which the lower end thereof has a constant inner diameter while the upper end thereof gradually increases inward. The elevation angle of this tapered portion is 15 ° to 75 °, preferably 30 ° to 60 °. In this embodiment, what is comprised by the silicon carbide is applied as a mold body. In addition, the pouring port 7 is not limited to the site | part which becomes the center of the upper wall of a mold, You may change the position according to a ingot shape and a use. For example, when the spout is inconvenient to remain as a trace in the final product of plastic working, the remaining part (for example, a part removed by cutting or the like) can be selected and set.

Examples of the material for the opening 8 include calcium silicate (CaSiO ₃ ), calcium oxide (CaO), silicon dioxide (SiO ₂ ), aluminum oxide (Al ₂ O ₃ ), magnesium oxide (MgO), and the like. It is preferable to apply nonmetals with high mechanical strength in addition to refractory and thermal resistance, such as heat-insulating refractory composed of main components, silicon carbide, tri-silicon nitride, or mixtures thereof, but are not reactive with iron, cast steel, or molten metal. It is also possible to apply metal materials with very low reactivity.

The upper lid 10 is disposed on the upper portion of the molten metal bath 6 as described above to prevent cooling from the upper surface of the molten metal 5, and the side surface of the molten water tank 6 by the electric furnace 11. Is heated to maintain the molten metal at a predetermined temperature.

In addition, a cooling case 13 for accommodating and fixing the spray nozzle 12 is attached to the lower portion of the cooling plate 2, and the cooling case 13 and the cooling plate (by the cooling plate elevating mechanism 14). When 2) rises, the cooling plate 2 closes the lower opening of the mold main body 3 to form a clogging mold 4, and conversely, when the cooling case 13 descends, the casting ingot 5 The cooling plate 2 on which '' is placed is isolated from the mold main body 3 and the ingot 5 'can be taken out.

The cooling plate 2 is molded from a metal having excellent fire resistance such as iron, copper, aluminum, and high thermal conductivity, or a high fire conductivity such as graphite, silicon carbide, and trisilicon tetranitride.

As the material of the mold main body 3, it is judged integrally from the raw materials of the casting to be manufactured, the wettability with the molten metal, the use temperature, the corrosion resistance, and the like, and the calcium silicate (CaSiO ₃ ), the calcium oxide (CaO), 2 Insulating refractories mainly composed of silicon oxide (SiO ₂ ), aluminum oxide (Al ₂ O ₃ ), magnesium oxide (MgO), or trisilicon tetranitride containing silicon nitride, trisilicon nitride, boron nitride, silicon carbide, Graphite, boron nitride, titanium dioxide, zirconium oxide and aluminum nitride alone or mixed refractories thereof, and metals such as iron and copper can be appropriately selected. In addition, although not shown in the drawing, it is preferable to provide an air passage for releasing the air in the mold interior space to the outside at the time of pouring in the appropriate place of the mold body.

Moreover, what is necessary is just to apply a mold release agent to the cooling plate 2 beforehand so that generation | occurrence | production of the "blow" mentioned above may be prevented. Moreover, making the surface of the cooling plate 2 into the rough surface by shot blast is also effective in preventing generation of "blow".

From the spray nozzle 12, a cooling medium such as subcooled water below 0 ° C. containing 0.5 or more sodium chloride, subcooled mixed water below 0 ° C. containing ethylene glycol, oil, or the like is ejected to form a cooling plate (2). It is flushed to the lower surface of the, and the cooling plate 2 is forcibly cooled. In the following description, the cooling medium injected from the spray nozzle 12 is simply referred to as cooling water. An on-off valve 16 is provided in the middle of the water supply pipe 15 for supplying the coolant to the spray nozzle 12. The solenoid valve 17 of the on / off valve 16 is turned on and off to cool the spray nozzle 12. ) Or stop.

In the cooling plate 2, a thermocouple is provided as the temperature detecting means 18 for detecting the temperature, and the temperature information of the cooling plate is obtained to obtain the temperature in the casting step. It is used to determine various conditions. In addition, the position where the tip of the thermocouple is inserted into the cooling plate 2 and the number of thermocouples may be appropriately determined according to the necessary determination conditions by the process control of the casting process, but in the present embodiment, it is injected into the mold 4. The temperature of the last place (one place) where the molten metal 5 completely covers the surface of the cooling plate 2 can be detected as the representative temperature of the cooling plate 2. As in the present embodiment, when the spout 7 is formed in the center upper portion of the mold body 3 to form a cylindrical ingot, if the upper surface of the cooling plate 2 is approximately horizontal, it is injected from the spout 7 The molten metal 5 falling on the cooling plate 2 is blown around to every corner, and may be anywhere on the circumference which becomes the outermost edge in the mold 4 (refer FIG. 1). The buried position is also appropriately determined.

Thus, the casting apparatus 1 according to the present embodiment is to automatically control the whole process of molten metal injection, cooling, and ingot extraction by the casting control means 19. The casting process control is performed based on the temperature information of the cooling plate 2 by the temperature detecting means 18 and the time-up of the timer. Specifically, the casting process control is performed by the timing shown in FIG. Perform a cycle. In addition, the casting method is not limited to automatic control by the casting control means 19, but may be performed by an artificial control device in accordance with an appropriate control timing.

The casting process shown in this embodiment is a case where it is performed on condition of the following. As the molten metal, an aluminum alloy (JIS 22218 alloy) dissolved in a melting furnace was used, and the cooling plate was made of a copper plate, a mold, a molten water bath, and commercially available fire-resistant insulating material (manufactured by Isolite Co., Ltd. Used. The temperature in the molten water bath is 720 ° C, the height of the hot water in the molten water bath is 50 mm, the amount of cooling water is 5 (liters / min), the diameter of the pouring port is 8 mm, and the plate thickness of the cooling plate is 12 mm. The thermocouple was positioned at a tip 2 mm below the surface of the cooling plate around the circumference of the circular region serving as the mold inner surface with a diameter of 1 mm of an aluminel-chromel sized coupler. The shape of the material to be cast is 63 mm x 10 mm thick, and the casting cycle is about 12 seconds.

At the start of the casting cycle, first, the casting control means 19 sends a cold plate rising command to the cold plate elevating mechanism 14 on the condition that drawing out of the ingot by the ingot extracting device is completed, thereby providing a cold plate. (2) is attached to the lower part of the mold main body 3, and the mold 4 is comprised. In addition to the first condition that the cooling plate 2 is in an elevated state (the state in which the mold 4 is configured), the second condition that the temperature of the cooling plate 2 is equal to or larger than the allowable lower limit temperature TC is also satisfied. If there is, the casting control means 19 sends an open battery command to the opening / closing elevating mechanism 9, and the opening / closing elevating mechanism 9 received the command raises the pouring hole 7 by opening and closing the opening 8 before. The molten metal 5 is poured into the mold 4 to start. In addition, the casting control means 19 sets the time for determining the precondition for closing (for example, TM1 = 5 seconds) as the open battery command is sent.

Thus, as a necessary condition for starting the pouring, the temperature of the cooling plate 2 may change depending on the allowable lower limit temperature TC (for example, TC = 100 ° C.) and the environmental conditions at the time of casting, the melt component, and the like. When the metal capacity 5 comes into contact with the cooling plate 2 and solidifies, when it is poured on the cooling plate 2 lower than the allowable lower limit temperature TC, blow defects may occur. Because it is thrown away. In addition, as in the present embodiment, after the casting cycle is started by sending a cold plate rising command to the cold plate elevating mechanism 14, before the opening and closing 8 is actually opened, the molten metal 5 is supplied into the pouring 4. If there is a slight time lug (about 1 to 2 seconds) beforehand, the temperature of the cooling plate 2 may be lowered in the meantime, so that the temperature is higher than the allowable lower limit temperature TC (for example, TC It is more preferable that it is 10 degreeC-20 degreeC or more, and it is preferable to set to TO = 150 degreeC in this embodiment.

Based on the temperature information from the temperature detecting means 18, the temperature of the cooling plate 2 becomes T1 (e.g., T1 = 155 deg. C) after the pouring of the mold 4 is started as described above. When the control means 19 detects, the solenoid valve 17 is turned on to open the on-off valve 916, and cooling water is supplied to the spray nozzle 12 from the water supply pipe 15.

The timing at which cooling starts is not particularly limited, but at least the temperature at which the molten metal 5 injected into the mold 4 contacts the mold inner surface of the cooling plate 2 is not lower than the allowable lower limit temperature TC. If it meets the initial cooling conditions. In other words, if the timing at which cooling starts (timing for opening / closing the opening / closing valve 16) is too early, the surface of the mold inside of the cooling plate 2 to which the molten metal 5 injected into the mold 4 is not reached. This is because the temperature of the site may be lower than the allowable lower limit temperature, and blow defects occur when the molten metal 5 comes into contact with the site lower than the allowable lower limit temperature TC.

In addition, when obtaining the ingot 5 'of the magnitude | size shown by this embodiment, the molten metal 5 quickly spreads to the mold inner surface of the cooling plate 2, and the temperature detection means 918 makes it possible. When the temperature of the part to be detected rises to T1 ° C, the molten metal 5 can be regarded as having reached the corresponding point. Therefore, by employing this at the timing of cooling start, the initial cooling conditions are satisfied and the blow defects are eliminated. It was supposed to prevent the occurrence. In addition, by setting an appropriate cooling start timing empirically obtained based on the actual device structure, for example, starting cooling after a predetermined time has elapsed from the pre-opening control before opening and closing 8, even if the initial cooling condition is satisfied. do.

The coolant timing determination that satisfies the initial cooling conditions is not limited to the above-mentioned ones. For example, the first condition that "before opening and closing 8 is before opening" and "the temperature of the cooling plate 2 are more than TC And the third condition that "the increase in temperature of the cooling plate 2 is zero (zero) or positive" is satisfied. The third condition is to determine that the slope of the temperature change characteristic curve of the cooling plate 2 obtained by detecting the temperature of the cooling plate 2 in a short period is zero or positive, for example, the temperature. The derivative of the data can be computed and provided to the decision. If the differential value of the temperature data is zero or positive, it can be assumed that the cooling plate 2 is converted from the molten metal 2 injected into the mold 4 to the temperature rise. Therefore, if this third condition is used, it can be determined whether the molten metal is in contact with the temperature detection part or in a state in which the molten metal is in contact within a very short time. When the temperature change is unstable (e.g., when a fine motion that cannot be determined that the temperature has risen steadily) continues, the limit value is set in increments to increase the temperature and increase the temperature. If this limit is exceeded, it may be determined that the third condition is satisfied. The first condition (before opening and closing 8 state before opening) and the second condition (the temperature of cooling plate 2 being above TC) are determined in order to improve control reliability. Usually, there is no problem even if it is excluded from determination conditions.

In addition, when the size of the mold is large, it may take a relatively long time before the molten metal spreads to the entire surface of the cooling plate, and in the meantime, a control is performed to prevent cooling of the molten metal injected into the mold. If the cooling conditions are satisfied, the cooling rate may be delayed. In such a case, the spray nozzles are divided into two parts according to the mold size, and only the parts touched by the molten metal injected from the spout are cooled, and the parts (cooling plate surface) not covered with the molten metal yet. Controlling the sequential expansion of the cooling area to a portion covered with the molten metal while the temperature is not lower than the allowable lower limit temperature allows the cooling plate to be cooled while satisfying the initial cooling conditions. As the cooling control that satisfies the initial cooling conditions in the case of adopting such a control, the cooling start timing judgment of each part may be such that the temperature of each part reaches the predetermined temperature as described above, and the slope of the temperature change is zero. Or you may employ | adopt a well. Of course, an appropriate cooling start timing obtained based on the actual device structure may be set and controlled by a timer or the like.

In addition, when using a cooling member of a complicated shape whose thickness from the receiving surface to which the cooling water touches to the surface of the mold is not uniform, the cooling plate 2 having almost constant thickness is used. The flow of the molten metal varies depending on the shape, and the time required for each part of the mold inner surface of the cooling member to be covered by the molten metal is also different. In this case, the metal molten metal is cooled from the portion covered by the molten metal. The cooling control may be performed so as to satisfy the initial cooling condition that the temperature of the part where the molten metal has not yet reached is not lower than the lower limit temperature. In either case, if the surface inside the mold of the cooling plate (or cooling member) is covered with the entire molten metal, the flail of the initial cooling conditions is eliminated, and thus normal cooling can be performed.

After the cooling of the cooling plate 2 is started as described above, if the timer for preconditioning for closing (TM1) is timed up by a predetermined time (for example, 5 seconds), the casting control means 19 The closing battery command is sent to the opening / closing elevating mechanism 9, and the pouring port 4 is blocked by the opening and closing before 8. The criterion for determining the pre-closing condition is not limited to the time display, but at least the solidification of the molten metal 5 in the mold 4 reaches the vicinity of the spout 7 and is determined by the pre-opening and closing 8. It is necessary to close before the pouring port becomes incapable of closing. Even so, if the inside of the mold 4 is filled by the molten metal 5 and immediately closed, the pressure is applied (pressure acts on the mold 4 by the molten metal 5 in the molten metal bath 6). Since the molten metal (5) solidifies in the mold (4) to compensate for the deficiency of the insufficient volume), the pouring hole (7) is opened to the position where it becomes impossible before closing. It is desirable to put it. Therefore, it is not limited to electric closing by timer control like this embodiment, and it is before closing that the temperature drying means provided in the vicinity of the pouring port of the mold 4 reaches the predetermined temperature near the solidification temperature of the metal capacity. It may be detected as a state before the incapable state and closed control before closing.

On the other hand, when the temperature of the cooling plate 2 reaches T2 (for example, T2 = 70 ° C) which is a predetermined temperature, the casting control means 19 sets the cooling end condition determination timer TM2, When the timer for determining the cooling end condition time-outs for a predetermined time (for example, 4 seconds), the casting control means 19 turns off the solenoid valve 17 to close the opening / closing valve 16, and the water supply pipe ( The cooling water supply to the spray nozzle 12 from 15) is stopped. The temperature of the cooling plate 2 is T2, which is not limited to the time before the pre-closing condition determination timer used for controlling the opening and closing 8 is timed up, and the detection temperature for the timer set condition determination is not limited. When T2 is set at a relatively low temperature, the cooling plate 2 may become T2 after the opening and closing 8 is closed. Considering the possibility that the temperature T2 for determining the timer set condition is detected early due to some unexpected error, and the timer for cooling end condition determination times up when the opening before opening and closing 8 is opened. It is preferable to apply the determination of the cooling end condition even before the opening and closing 8 is already closed.

As described above, the temperature information of the cooling plate 2 and the timekeeping by the timer are used in combination with the determination of the cooling end condition. When the temperature of the cooling plate 2 receiving the cooling water drops to a certain degree, the temperature change is slow. (See Fig. 2), it becomes difficult to detect subtle temperature changes, so that the error in the determination of the cooling end condition is large, and the cooling ends in a state in which cooling is insufficient, or, on the contrary, the cycle time is unnecessarily lengthened or overheated. Is likely. Therefore, the temperature of the cooling plate 2 is detected at a time point before the temperature decrease gradient becomes gentle and the detection error becomes large, and then the supply of the cooling water is stopped after a certain period of time determined according to the structure of the actual device. It was made to let. In addition, as long as the temperature detection means for determining the cooling end condition can detect the temperature change of the cooling plate 2 with extremely high accuracy, the cooling end condition may be set as the cooling termination condition if the temperature of the cooling plate 2 reaches a predetermined temperature. The cooling time optimum for the actual device structure may be obtained in advance, and the timer control may be performed such that the cooling end condition is set after the predetermined time elapses from the start of cooling.

When the forced cooling by the cooling water is finished, the temperature of the cooling plate 2 starts to rise again by the heat of retention of the ingot 5 ', for example, the temperature of the cooling plate 2 is T3 (e.g., When the casting control means 19 detects that T3 = 160 ° C, based on the temperature degree from the temperature detecting means 18, the ingot drawing condition is achieved, and the cold plate lifting mechanism 14 receives the cold plate hardening instruction. The cold plate 2 in the state where the ingot 5 'is placed is separated from the mold main body 3 and lowered, and the ingot 5' is drawn out by operating the ingot drawing device, not shown. In addition, the ingot withdrawal conditions are not limited to the case where the detection temperature of the cooling plate 2 reaches T3, and the ingot withdrawal conditions may be achieved after a predetermined time elapses from the stop of the cooling water. As described above, when the ingot 5 'is pulled out and the ingot drawing device stops, the casting control means 19 which receives the signal of the effect immediately sends a cooling plate rising command to the cold plate lifting mechanism 14, The give cycle starts.

As described above, according to the metal casting method according to the present embodiment, solidification in the mold proceeds sequentially while the molten metal is injected into the mold, and the cooling rate of each part in the ingot is a conventional method. It is much faster than cooling by, and segregation of solute is reduced. In addition, since the opening and closing is not closed until immediately before the closing becomes impossible, the ingot is formed into a dense structure by the squeezing effect, and the amount of casting defects can be suppressed.

As described above, according to the casting method of the metal according to the present embodiment, since the cooling control is performed on the cooling plate 2 so as to satisfy the initial cooling conditions without waiting for the mold to be filled with the molten metal, the cast product The advantage is that the casting cycle can be shortened after preventing blow defects from occurring. For example, in the conventional method, a casting cycle requiring 16 seconds can be shortened to 12 seconds.

In addition, after eliminating flail under the initial cooling conditions, normal cooling is performed. Therefore, solidification proceeds sequentially while injecting molten metal into the mold, thereby cooling each part in the ingot 5 '. The speed is much faster than the cooling by the conventional method, and segregation of the solute is reduced. In addition, since the opening and closing is not closed until immediately before the closing is impossible, the ingot 5 'has a dense structure and can suppress the amount of casting defects.

The state which performed the etching process with respect to the cut surface at the time of cut | disconnecting the short cylindrical ingot of 63 mm in diameter and 10 mm in thickness which were cast by the casting apparatus 1 which performs the above-mentioned casting process lengthwise from the surface containing an axis | shaft was observed. . The concentration segregation of the solutes seen in the above-mentioned conventional method was not generated, and no etching pattern was recognized. Further, a 20% caustic soda solution was used as the chemical treatment solution for etching, and the immersion time was set to 3 minutes at a liquid temperature of 50 ° C.

As a result of observing the microstructure of the ingot, the defects occurring near the spout were less than 0.5 micropores of 200 µm or more in 100 mm2 and less than 5 in the size of 50 to 200 µm.

In this way, the quality of the ingot prepared by the casting step shown in the present embodiment is significantly improved than the quality of the ingot cast by the conventional method.

Next, the detailed control function of the casting control means 18 which performs comprehensive control for realizing the above-mentioned casting process is demonstrated based on the functional block diagram shown in FIG.

The casting control means 19, on the basis of the temperature information from the temperature detection means 18, the cooling water for cooling the opening and closing before and after the lifting mechanism 9 for raising and lowering the opening and closing 8, and the cooling plate (2). The solenoid valve 17 which opens and closes the opening / closing valve 16 which opens and closes the water supply pipe 15 supplied to the spray nozzle 12, and the cooling plate lifting mechanism which raises and lowers the cooling plate 2 with the cooling case 13 ( 14). In addition, in the structure of the casting apparatus 1, the spray nozzle 12 cooperates with the water supply pipe 15 and the opening / closing valve 16 to implement a function as a cooling means, and supply / stop of cooling water is performed by a solenoid valve ( By the control of 17), in the casting control means 19 according to the present embodiment, the activation and disabling of the cooling means is realized only by the control of the solenoid valve 17. In addition, the casting control means 19 performs the lift control on the cold plate lifting mechanism 14 by receiving the ingot drawing completion signal from the ingot drawing device 20.

The pre-opening control means 21 receiving the temperature information of the temperature detecting means 18 has the first condition that the temperature TO of the cooling plate 2 is equal to or higher than the allowable lower limit temperature TC, and the cooling plate elevating mechanism 14 has a cooling plate ( 2) When the pouring start conditions are achieved, both of the second conditions, which are in the elevated state, are achieved, and when the pouring start conditions are achieved, the pre-opening command is sent to the opening / closing elevating mechanism 9 before opening and closing. (8) is raised and the molten metal 5 is injected into the mold 4 from the opened pouring mouth 7. In addition, when the apparatus structure with a time lug is made from the start of a cold plate rise until actually the metal molten metal 5 is injected into the mold 4 like this embodiment, the temperature TO of the cold plate 2 is simply TC. It is insufficient alone, and the entire portion of the mold inner surface of the cooling plate 2 is lower than TO until the molten metal 5 is actually injected into the mold 4 and the temperature of the cooling plate 2 starts to rise. In order to avoid this, it is preferable to set the determination condition at a temperature sufficiently higher than TC (for example, TO ≧ 150 ° C.).

As described above, after the pouring by the pre-opening control means 21 starts, the temperature when the molten metal 5 injected into the mold 4 contacts the mold inner surface of the cooling plate 2 is allowed. In order to satisfy the initial cooling condition not to be lower than the lower limit temperature TC, the initial cooling control means 21 controls the normal cooling means 23 so that there is no heat to open the solenoid valve 17. That is, the initial cooling control means 22 included in the casting control means 19 does not directly control the cooling means so as to satisfy the initial cooling conditions, but controls the normal cooling control means 23 so as not to start the cooling control. As a result, the molten metal 5 does not come into contact with the cooling plate 2 at a temperature lower than the allowable lower limit temperature, so that blow defects do not occur.

Then, it is assumed that the molten metal 5 injected into the mold 4 covers the entire mold inner surface of the cooling plate 2 so that the temperature information of the temperature detecting means 18 reaches T1 = 500 ° C. If the initial cooling control means 22 determines, the solenoid valve 17 is turned on by the normal cooling means 23, the opening-closing valve 16 is opened, cooling water is injected from the spray nozzle 12, and cooling is carried out. Cooling to the plate 2 is started. In addition, in the state where the initial cooling control means 22 suppresses the start of cooling by the normal cooling control means 23 in order to satisfy the initial cooling conditions, the condition for determining that the flaw of the initial cooling conditions is removed is As described above, it is not limited to the case where the temperature of the cooling plate 2 reaches a predetermined temperature, and the increase in the temperature change of the cooling plate 2 may be changed to zero or positive, and based on the actual device structure. May be shifted to normal cooling based on the predetermined timing set (e.g., elapse of a predetermined time from before opening).

On the other hand, the pre-opening control means 21 sends an open battery command to the opening / closing elevating mechanism 9, and also sends a signal to the pre-closing control means 24, indicating that it has been opened. 24) sets a pre-closing control timer TM1 for a predetermined time (for example, 5 seconds), and the time counted by the pre-closing control timer is a molten metal in the mold 4. (7) Informing the immediate vicinity of the inability to close before the opening and closing of the pouring port 7 by the opening and closing 8 is impossible. Therefore, when the control timer for closing time-ups, the pre-closing control means 24 sends a closing battery command to the elevating mechanism 9 before opening and closing, and closes the pouring port 7 by the opening and closing 8 before the mold 4 Stop the pressure on the inside.

Immediately after the opening and closing 8 is closed as described above, solidification in the mold 4 is completed to form the ingot 5 ', but the cooling of the cooling plate 2 by the cooling water is completed by the predetermined cooling. Continue until the condition is achieved. As the cooling end condition, as described above, the predetermined predetermined time elapses after the temperature of the cooling plate 2 reaches a predetermined temperature T2 (for example, T2 = 70 ° C). Therefore, the cooling stop control means 25 which detects that the temperature of the cooling plate 2 has reached T2 sets the cooling end condition determination timer TM2, and the cooling end condition determination timer is set for a predetermined time (e.g., For example, if the time is up by 4 seconds, the normal cooling control means 23 instructs cooling stop, and the normal cooling control means 23 closes the solenoid valve 17 to force the cooling to the cooling plate 2. Stop.

As described above, the cooling stop control means 25 which has instructed the normal cooling control means 23 to stop the cooling also sends a signal to the detachment control means 26 to indicate that the cooling is stopped, and the detachment control means 26 having received this signal. ) Detects that the temperature of the cooling plate 2 determined as the ingot drawing condition is T3 (e.g., T3 = 160 ° C) on the basis of the temperature information from the temperature detecting means 18. Sending a descending command to the sphere 14, the cooling plate (2) is lowered and separated from the mold body (3) so that the cold plate lifting mechanism (14) received the command can draw out the ingot (5 ') from the mold, The ingot 5 'is drawn out by the ingot extractor 20. FIG.

In addition, when the withdrawal of the ingot 5 'is finished, the ingot takeout device 20 sends a signal indicating that the ingot is taken out to the control means 26, and the detachable control means 26 receiving the signal cools down. The rising command is sent to the plate lifting mechanism 14, and the cooling plate 2 is mounted on the lower part of the mold main body 3 to perform a new casting cycle. In addition, in accordance with the start of a new casting cycle, the detachable control means 26 receives a completion signal of the cooling plate rising from the cold plate lifting mechanism 14, and signals that the cooling plate is raised to the control means 21 before opening. However, without receiving the completion signal from the cold plate elevating mechanism 14, the detachable control means 26 sends a rising command to the cold plate elevating mechanism 14, so that the cold plate 2 is the mold body ( After sufficient time has elapsed for mounting to the bottom of 3), the pre-opening control means 21 may send a signal indicating that the cooling plate 2 is raised.

In the embodiment of the casting control means 19 described above, the initial cooling control means 22 is to perform the control not to perform the cabinet to the cooling plate 2 so as to meet the initial cooling conditions, but by the initial cooling control means Control is not limited to this.

The casting control means of another embodiment is provided with three temperature detecting means and three cooling means in the cooling plate 2.

For example, the first temperature detecting means is provided at a portion where the molten metal 5 injected from the pouring hole 7 is hardest to reach in the mold of the cooling plate 2. The second temperature detecting means is provided in a portion where the molten metal 5 is likely to be worn out rather than in one portion, and the third temperature detecting means is provided in a portion where the molten metal is most easily reached, such as directly under the pouring hole 7. . The first temperature detecting means cools the area where the representative temperature can be detected by the first cooling means, and the second temperature detecting means cools the area where the representative temperature can be detected by the second cooling means. The region where the representative temperature can be detected by the temperature detecting means is cooled by the third cooling means 17c.

In this way, a casting apparatus including a plurality of temperature detecting means and a plurality of cooling means may be employed.

In the production method of the present invention, ingots 5 'in which the lower surface on the side of the cooling plate 2 and the upper surface on the side before the opening and closing 8 can be obtained in accordance with the shape of the space in the mold, the ingot is a mold. By changing the shape of the inner space, it can be formed into any shape, and the upper and lower surfaces may not be parallel, and may be a three-dimensionally heterogeneous structure composed of a flat surface and a curved surface or a curved surface. In the case of being three-dimensionally deformed, the coagulation interface is not limited to a horizontal flat plane. However, in this case, it is preferable that the coagulation interface does not form a closed loop and maintains one direction.

In the thus-manufactured cast body (ingot) 5 ', since the solidification interface always maintains one direction and forms one-way solidification without forming a closed loop, the internal quality of the cast body (ingot), ingot piping, and pinhole is increased. It becomes a favorable thing without defects, such as the rolling of an oxide. In addition, since the upper part of the mold space is occluded by the upper wall constituting the mold inner space and the front end surface of the mold opening and closing 8, the amount of pouring is always constant without measuring the molten metal. A large curved surface is not formed in the meniscus, and there is no fear that a large unevenness occurs in the size and weight of the ingot 5 '.

This ingot 5 'was made of aluminum or an aluminum alloy, and the DAS and crystal grain diameter of the metal structure were observed using a polarizing microscope (magnification x40 to x100). In addition, the measurement of DAS is published in "Light Metals (1988), Vol. 38, No. 1, p54, and the measurement of the crystallite diameter in accordance with the "dendrite arm spacing measurement procedure" described in "Light Metals (1983), Vol. 33, No. 2, p111 ", and it carried out based on the" metal structure ".

Regarding the DAS, a remarkable tendency of increasing from the cooling plate 2 (bottom surface B) toward the front 8 (top surface T) side before and after opening and closing was observed under the above-described unidirectional crystal growth. When the DAS on the bottom surface B side is represented by d1 and the DAS on the top surface T side is represented by d2, the forced cooling results in d1 &lt; d2. However, if d2 &lt; 1.1d1, the tendency of d2 to increase is small, the effects of unidirectionality, crystal growth are almost insignificant, and casting defects are also included. On the other hand, if d2> 10.0d1, the increase of d2 is excessive and it is not realistic from the industrial production of ingot. Therefore, it is preferable to exist in the range of d2 = 1.1d1-10.0d1. More preferably, it is d2 = 1.1d1-5.0d1. Moreover, in order to raise the effect of unidirectional crystal growth, it is preferable that DAS in the bottom surface B side is 40 micrometers or less. By forced cooling in this way, it is possible to produce a healthy ingot in which casting defects such as microporosity of more than 200 µm and microshrinkage cage are within 100 square mm, and within 10 joint defects of 50 to 200 µm.

In addition, in the metal composition of the ingot, the crystal grain diameter of the crystal forming the equiaxed crystal structure is increased from the bottom surface B to the top surface under the unidirectional crystal growth as described above. A remarkable trend was recognized. When the crystal grain diameter of the bottom surface B side is represented by d1 'and the crystal grain diameter of the top surface T side is represented by d2', it becomes d1 '<d2' by forced cooling. However, if d2 '&lt; 1.05d1', the tendency of d2 'to increase is small, so that there is little effect of unidirectional crystal growth, and the conditions in which casting defects are increased are included. On the other hand, if d2 '> 7.0d1, the increase of d2' is excessive, and it is not realistic in industrial production of ingot. Therefore, it is preferable to exist in the range of d2 '= 1.05d1'-7.0d1'. More preferably, it is d2 '= 1.05d1'-5.0d1'. In addition, in order to enhance the effect of unidirectional crystal growth, it is preferable that the crystal grain diameter d1 'on the bottom surface B side is 100 µm or less on average.

In this embodiment, as described above, ingots of various shapes are produced by using a casting apparatus (one-direction solidification casting apparatus) in which the molten metal is solidified sequentially in one direction, and the plastic ingot is further subjected to plastic processing. This improves the mechanical properties, especially before the opening and closing, to eliminate unevenness and to make the mechanical properties uniform as a whole.

In the production method of the present invention, the obtained ingot is subjected to plastic working at a processing rate of a predetermined ratio or more to form a plastic working member, and a processing rate of a predetermined ratio or more is preferably achieved by at least one plastic working on the ingot.

Moreover, it is preferable that firing ratio is 25% (more preferably 50%).

Moreover, it is preferable that plastic processing is partial plastic processing with respect to an ingot. In particular, the plastic working is preferably a plastic working on a portion of the ingot including at least the opening side.

In addition, the process which gives a target shape and a characteristic using the plastic deformation of a material here is named generically, and it is called plastic processing. For example, forging (cold, hot), short roll processing, rolling, extrusion, rolling, rotary forging (electric processing) and the like. In addition, the processing rate K of the plastic working is (deformed height) ÷ (initial height) x 100% in the case of rough working, for example, and in the case of extrusion, the (cross-sectional area subjected to deformation) ÷ (initial cross section X 100%.

The plastic processing member manufactured by the above method uses an occluded mold whose end surface before opening and closing forms part of the mold inner surface and part of the cooling member, while forcibly filling the molten metal charged from the opening and closing with the cooling member. A plastic working member is applied to a cooled and solidified ingot at a processing rate of a predetermined ratio or more, and therefore, it is preferable because it can obtain good mechanical properties.

In the plastic processing member manufactured by the above method, the ingot is opened before opening and closing on the condition that the cooling member of the mold is above a predetermined allowable lower limit temperature to start pouring into the mold, and the cooling member in the molten metal injected into the mold. Start cooling of the cooling member so as to meet the initial cooling condition that the temperature at the time of contact with the mold inner surface is not lower than the allowable lower limit temperature, and after closing the opening and closing even after the metal molten metal is filled in the mold, The molten iron in the mold is continued and the molten iron in the mold reaches near the pouring hole and the pouring hole is closed before opening and closing. On the basis that the cooling of the cooling member is stopped when the cooling end condition is achieved, and the predetermined ingot drawing condition is achieved after cooling stop, That each member of a solidified by cooling in a manner so as to draw the ingot mold body separated from the ingot, and the plastic working member as claimed, it is preferable because get good mechanical properties.

The plastic working member produced by the above method is preferable because the ingot is a plastic working member characterized by being subjected to plastic working and good mechanical properties can be obtained.

The plastic working member produced by the above method is preferable because the plastic working member becomes a plastic working member which is an intermediate processing product, and good mechanical properties can be obtained.

The plastic processing member manufactured by the above method is preferable because the plastic processing member becomes a small-phase processing member which is a final processed product, and good mechanical properties can be obtained.

The plastic processing member manufactured by the above method is preferable because the metal becomes an aluminum or aluminum alloy plastic processing member and a good mechanical property can be obtained.

The plastic processing member manufactured by the above method becomes a plastic processing member having a DAS of 1.1 to 10.0 times that of the metal structure in the opening and closing side with respect to the DAS of the metal structure on the cooling member side of the ingot, thereby obtaining good mechanical properties. It is preferable because it is. The plastic working member produced by the above method is a plastic working member having a crystal grain diameter of 1.05 to 7 times the metal grain in the opening and closing side with respect to the crystal grain diameter of the metal structure on the cooling member side of the ingot. It is preferable because mechanical properties can be obtained.

The plastic processing member manufactured by the above method has a plastic processing member having a ratio of the second phase crystallized particle diameter of the plastic processing member to a particle diameter on the front side of the opening and closing to a particle diameter on the cooling member side of 1.2 or more. This is preferable because good mechanical properties can be obtained.

The plastic processing member manufactured by the above method is an ingot in which the ingot is poured downward from the spout, and the growth direction of the crystal is approximately an upward plastic processing member. It is preferable because good mechanical properties can be obtained.

It is preferable that the obtained plastic working member is further subjected to an annealing process because of its good mechanical strength characteristics.

The resultant plastic processing member is preferably barrel-polished on the projection surface because of good surface condition.

The resulting plastic working member is preferably short blasted because it improves the surface state.

Specific examples are shown and described below.

(Example 1)

The JIS2218 alloy molten metal was melted by another melting apparatus (not shown), and the molten metal was poured into a one-way solidification casting apparatus similar to the configuration shown in Figs. 1 and 3, where one side was 72 mm and a thickness of 20 mm. Ingot 111a (FIG. 4 (a)) was poured. Casting conditions were as showing in the column of Example 1 of Table 1. Moreover, Al-5 mass% Ti-1 mass% B was added to the alloy molten metal after a solvent, and the molten alloy alloy after addition was provided for casting. The addition amount was made into the amount which added Ti amount becomes 0.01 mass%, and refinement | miniaturization of the crystal grain was aimed at by this addition. The chemical composition of the molten alloy provided in the forging was as shown in Table 2.

Casting condition Item unit Example 1 Example 2 Example 3 Example 4 1. Alloy 2218 6061 6061 Al-Si Alloy 2.The temperature of the molten water bath contents ℃ 720 750 750 700 3. The level difference between the upper inner surface of the mold and the molten water surface of the molten metal bath Mm 150 100 100 200 4. Cooling plate temperature before pouring ℃ 150 150 150 150 5. Cooling water amount 1 / min 7 8 7 8 6.diameter of molten metal inlet Mm 12 10 10 10 7.Ambient temperature in electric furnace ℃ 750 780 780 720 8. Upper temperature of upper mold and side mold ℃ 680 700 700 680 9. Casting Process 1) Pouring 2) Cold Plate 3) Cold Plate 4) Cold Plate 5) Material Extraction After 10 seconds, the water is shut off before opening and closing.When water is started at 500 ℃, cooling is completed at 30 ℃. After 10 seconds, the water is shut off before opening and closing.When water is started at 500 ℃, cooling is completed at 30 ℃. 9 seconds later, closed before opening and closing, water cooled at 500 ° C, water cooled at 30 ° C, cooled down at 200 ° C After 12 seconds, the water is shut off before opening and closing.When water is started at 500 ℃, cooling is completed at 30 ℃.

2218 alloy chemical composition (mass%) Si Cu Mg Ni Fe Ti 0.38 4.1 1.53 1.80 0.23 0.010

The ingot 111a is subjected to a homogenization treatment by maintaining at 505 ° C. for 8 hours, and thereafter a monoblock 111b having a width of 40 mm, a length of 65 mm, and a thickness of 20 mm from the ingot 111 a (FIG. 4). (b)) was cut out. At this time, the thickness direction of the single-piece body 111b is the same direction as the solidification direction of the ingot 111a, and the upper surface of the thickness direction corresponds to the top surface T of the ingot 111a, and the lower surface corresponds to the bottom surface B, respectively. .

The monolayer 111b was heated to 420 ° C. in a heating furnace, and short-stacked under the conditions shown in Table 3 using a 400-ton mechanical press, thereby removing the short-circuit member 111c (Fig. 4 (c)). Created. Short cutting was performed in the direction of thinning the width of 40 mm, as indicated by the arrow Y1 in Fig. 4 (b), and the processing rate (coating rate) K was set at 25,50,70%.

Short processing condition One Type of press 400ton mechanical press (crank press) 2 Type of mold Top and bottom planes are also parallel 3 Mold temperature 200 ℃ -220 ℃ 4 Lubricants Water soluble graphite lubricant, sprayed onto mold 5 Work temperature 400 ℃ ~ 430 ℃ 6 Fermentation rate Adjust the punch bottom dead center position (slide)

After the short cutting process, an artificial aging treatment (T6 treatment) was performed on the short extending member 111c. That is, as the T6 treatment condition, a solution treatment for performing water hardening after holding at 505 ° C for 4 hours and then returning at 190 ° C for 8 hours was performed. The tensile test piece 111d (FIG. 5) of the shape as shown in FIG. 5 was cut out from the extending member 111c after this T6 process in order to investigate a mechanical characteristic. The shape of this tensile test piece 111d conforms to the dimensional standard of 0.113 in. Of nominal diameter in "E8-99, Fig8" of ASTM standard. The sampling position of the tensile test piece 111d is the X, Y, and Z positions of the single member 111c, as shown in Fig. 4C, where X is near the top surface T of the ingot 111a, Y is intermediate, and Z is shown. Corresponds to the vicinity of the bottom surface B, respectively. Thus, the 1st ingot 111a (single body 111b) is short-circuited at 25% processing rate, and the tensile test piece 111d (FIG. 5) is respectively carried out from the X, Y, and Z positions of the short-circuit member 111c. The second ingot 111a (single 111b) was shortened at 50% cutting rate, and the tensile test piece 111d was taken out from the X, Y, and Z positions of the extending member 111c, respectively. The third ingot 111a (single 111b) is short-cut at a processing rate of 75%, and the tensile test pieces 111d are taken out from the X, Y, and Z positions of the single-length member 111c, respectively, and tensioned. Provided for the test.

The tensile test was carried out using an autograph manufactured by Shimatsu Seisakusho, and the tensile test speed was performed at 1 mm / minute. The evaluation items are three items, a tensile strength of 0.2% and elongation.

(Comparative Example 1)

The tensile test piece for comparison with Example 1 was created as follows. In other words, in the same alloy molten metal as in Example 1 and the same casting method, the same ingot was cast and homogenized under the same heat treatment conditions, and then the same monolith was cut.

Then, the T6 treatment was carried out under the same conditions as in Example 1, with the short sheet not subjected to the short cut and the 10% short cut, and the tensile test piece was cut from the member subjected to the T6.

In addition, 10% of short-cutting was performed in the same manner as in Example 1, and the sampling position of the tensile test piece was from the same position as the X, Y, and Z positions in Fig. 4 (c), and the top surface T and bottom of the ingot. The relationship with surface B corresponds to Example 1. FIG. In addition, the shape of the tensile test piece, the tensile test method and the evaluation items are the same as in Example 1.

Table 4 is a table which shows the various data of tensile strength-0.2% yield strength and elongation of the tensile test result in Example 1. From the tensile test results, the tensile strength, 0.2% yield strength, elongation rate together with the elongation rate of 25% or more, the improvement is remarkable, especially the angular characteristic at the top surface X position becomes a desirable value, and the improvement is high. It has a roughness of 50% or more, which almost coincides with the characteristics of the top face T and the bottom face B which has a more desirable value than the center.

Tensile test results (Example 1, Comparative Example 1) Example 1 Comparative Example 1 Fermentation rate (K%) 25 50 75 0 10 Strength (MPa) Place X Top side 372 380 381 314 330 Y center 381 384 385 360 365 Z Bottom surface 382 381 382 382 380 0.2% yield strength (MPa) Place X Top side 246 246 247 243 245 Y center 245 249 248 247 249 Z Bottom surface 246 247 248 248 247 kidney(%) Place X Top side 12.8 16.7 18.0 5.8 7.2 Y center 13.9 16.9 17.1 7.3 8.6 Z Bottom surface 15.6 17.6 18.5 10.0 11.2

(Example 2)

In Example 1 mentioned above, single-line processing was performed once, but in Example 2, single-line processing is divided into multiple times.

The JIS6061 alloy molten metal was melted by another melting apparatus (not shown), and the molten metal was poured into a one-way solidification casting apparatus similar to the configuration shown in Figs. 1 and 3, where one side was 80 mm and a thickness of 30 mm. Ingot 121a and FIG. 6 (a) were poured. Casting conditions were as shown in Example 2 of Table 1. Moreover, Al-5 mass% Ti-1 mass% B was added to the alloy molten metal after a solvent, and the molten alloy after addition was provided for casting. The addition amount was made into the amount which added Ti amount becomes 0.01 mass%, and refinement | miniaturization of the crystal grain was aimed at by this addition. The chemical composition of the molten alloy provided in the forging was as shown in Table 5.

6061 Alloy Chemical Composition (mass%) Si Cu Mg Ni Fe Ti 0.55 0.24 1.12 0.25 0.22 0.011

In addition, the DAS and crystal grain diameters of the surface portion of the ingot bottom surface, the central portion, and the final solidification surface side of the surface passing through the center axis of the ingot and passing through the half of the side in contact with the cooling plate were measured. The ratio with each bottom surface was included and the result was as having shown in Table 1, Table 2. The DAS is measured by drawing five straight lines parallel to the cooling surface on a metallographic photograph with a magnification of 78 times and displaying the DAS average value μm obtained from the number of intersection points of the dendrites (intersection method). In addition, the crystal grain diameter was determined from the number of intersections of the five straight lines drawn in the random orientation of the polarization microscope with the boundary of the crystal and the distance of the straight line traversing the crystal.

Ingot location DAS (μm) Ratio of DAS to lower part Periphery Top 29.2 1.36 center 27.5 1.29 bottom 21.4 1.00 Middle section Top 32.4 1.64 center 26.9 1.36 bottom 19.7 1.00 center Top 34.4 1.62 center 27.3 1.28 bottom 21.3 1.00

Ingot location Grain size (㎛) Ratio of crystal grain diameter to lower part Periphery Top 113 1.19 center 108 1.14 bottom 95 1.00 Middle section Top 122 1.31 center 117 1.26 bottom 93 1.00 center Top 129 1.32 center 118 1.20 bottom 98 1.00

The ingot 121a is subjected to a homogenization treatment by maintaining at 540 ° C. for 6 hours, and thereafter a single body 121b having a width of 50 mm, a length of 80 mm, and a thickness of 30 mm from the ingot 121 a (FIG. 6). (b)) was cut out. At this time, the thickness direction of the unit body 121b is the same direction as the solidification direction of the ingot 121a, and the upper surface in the thickness direction corresponds to the top surface T of the ingot 121a, and the lower surface corresponds to the bottom surface B, respectively. have.

The short body 121b was subjected to short-cutting (coating) by cold or hot to prepare a short-body member 121c (Fig. 6 (c)). As indicated by the arrow Y2 in Fig. 6 (b), the short cut was divided into two in the direction of thinning the width of 50 mm, and the cold short cut was 25% and the hot short cut was 50 in the second short cut. A percent machining rate K was obtained.

25% of short-lived was carried out as follows. That is, after the metal soap film was formed as a lubricating film on the single body 121b, it was placed at 15% by 400 ton press. Then, after performing annealing treatment for 4 hours at 360 degreeC by the heating furnace, the metal soap skin film was formed again, 10% of mounting was performed by the press, and it was set as 25% in total.

50% of short-lives were performed as follows. In other words, the single-plate body 121b is heated to 420 ° C. by a heating furnace, and is subjected to 25% of the short-breaking conditions shown in Table 3 after cooling to room temperature in the middle and reheating up to 420 ° C. It was carried out twice each and made 50%.

After the short cutting process, an artificial aging treatment (T6 treatment) was performed on the short extending member 121c. That is, as a T6 process, the solution treatment which hold | maintains 540 degreeC * 4 hours was performed, and then the return process of 170 degreeC * 8 hours maintenance was performed. Tensile test pieces Tensile test pieces were obtained in the same manner as in Example 1 in order to examine the mechanical properties from the new member 121c after the T6 treatment, and were used for the test. The testing machine, test method, evaluation item, etc. are the same as that of Example 1.

In Example 2 mentioned above, since the processing rate of 25% or 50% was obtained by the 2nd single body, in Example 2A, the monolith of the same shape was cut | disconnected from the ingot obtained on the same conditions as Example 2, After providing to a process and making it a single member and heating a single object at 420 degreeC, it mounted to (1) 25% (2) 50% at once. The tensile test piece was extract | collected from this extending | stretching member, it used for the tension test, and it compared with Example 2. Other conditions are the same as in Example 2.

Table 8 is a table which shows various data of the tensile strength, 0.2% yield strength, and elongation which are the test results of Examples 2 and 2A. According to this result, it is understood that equivalent mechanical characteristics can be obtained even when single-circuit single or two-circuit single.

Tensile test results (Examples 2 and 2A) Example 2 Example 2A Total deferment rate (K%) 25 50 25 50 Processing Cold Hot Cold Hot Short Processing Process 15% Short ↓ Annealing ↓ 10% Short 25% short ↓ room temperature heating ↓ 25% short Up to 25% Up to 50% Strength (MPa) Place X Top side 347 351 346 351 Y center 355 358 354 357 Z Bottom surface 354 354 355 353 0.2% yield strength (MPa) Place X Top side 313 315 313 314 Y center 318 318 312 314 Z Bottom surface 315 316 314 316 kidney(%) Place X Top side 15.2 18.3 15.4 18.2 Y center 15.1 13.7 15.1 18.8 Z Bottom surface 15.2 18.8 15.1 18.9

(Example 3)

In the third embodiment, rolling processing is carried out in a plurality of times as plastic working. First, the same JIS6061 alloy molten metal as in Example 2 was dissolved in another dissolution facility (not shown), and the molten metal was poured into a one-way solidification casting apparatus similar to the configuration shown in FIGS. 1 and 3 to form a long side of 80 mm and a short side. (Iv) 50 mm and 30 mm thick ingot 131a (Fig. 7 (a)) was injected. Casting conditions were as showing in the column of Example 3 of Table 1. The chemical composition of the molten alloy provided in the casting was as shown in Table 5.

The ingot 131a was subjected to a homogenization treatment by holding at 550 ° C. for 6 hours, and then rolled. In addition, the thickness direction of this ingot 131a is the same direction as the solidification direction of the ingot 131a, and the upper surface of a thickness direction corresponds to the top surface T, and the lower surface corresponds to the bottom surface B, respectively.

Rolling uses a two-stage rolling mill. The roll was preheated before rolling to be 150 ° C, and the ingot 131a was preheated at 400 ° C in the heating furnace. Pressurization at the time of rolling is performed in the direction of thinning 30 mm in thickness, as shown by the arrow Y3 of FIG. 7 (a), and adjusts the rolling direction to the ingot longitudinal direction, and the processing rate (rolling down ratio) Five rollings were repeatedly performed until K reached 25%. Each rolling reduction gave 5%, 1.5 mm, with respect to the raw material. Rolling was performed by lubrication-free.

The obtained rolling member 31b was subjected to T6 treatment according to the method of Example 2, and tensile test pieces were taken in parallel in the rolling direction from the positions of X, Y, and Z in FIG. The testing machine, test method, evaluation item, etc. are the same as that of Example 1.

In Example 3 mentioned above, since the processing rate of 25% was obtained by 5 times of rolling, as Example 3A, the processing rate of 25% was obtained by one single body, and both were compared, ie, Example 3 and The ingot obtained under the same conditions was heated to 400 ° C., then placed at 25%, and a tensile test piece was taken from the single member, and subjected to a tensile test. Other conditions are the same as in Example 3.

In Comparative Example 3, the tensile test piece was moved along the longitudinal direction of the ingot 131a from the positions of X, Y, and Z of the ingot 131a (FIG. 7 (a)) before performing the plastic working such as rolling or short stature. It was taken out and provided to the tensile test. Various other conditions are the same as in Example 3.

Table 9 is a table which shows the various data of the tensile strength, 0.2% yield strength, and elongation which are the test results of Examples 3 and 3A and the comparative example 3. According to this result, even by five rolling and one single body, equivalent mechanical properties were obtained, and apparent improvement was observed as compared with Comparative Example 3 in which the processing rate was 0% (before baking).

Tensile test results (Examples 3 and 3A and Comparative Example 3) Example 3 Example 3A Comparative Example 3 Total processing rate (K%) Rolling reduction 25% Fermentation rate 25% 0 Manufacturing process 5 consecutive rollings every 5% Up to 25% Strength (MPa) Place X Top side 347 345 340 Y center 352 353 347 Z Bottom surface 354 353 348 0.2% yield strength (MPa) Place X Top side 313 312 301 Y center 315 314 303 Z Bottom surface 315 314 304 kidney(%) Place X Top side 15.0 15.1 14.1 Y center 15.1 15.0 13.9 Z Bottom surface 15.0 15.0 13.8

(Example 4)

In Example 4, hot forging is performed as plastic working. First, the Al-Si-Cu-Mg alloy molten metal is dissolved in another melting facility (not shown), and the molten metal is poured into a one-way solidification casting apparatus and poured into it, and a columnar shape having a diameter of 110 mm Ø-thickness 50 mm is formed. Ingot 141a (FIG. 8 (a)) was obtained. Casting conditions were as showing in the column of Example 4 of Table 1. In addition, the thickness direction of this ingot 141a is the same direction as the solidification direction. The chemical composition of the molten alloy provided in the casting was as shown in Table 10.

Al-Si-Cu-Mg alloy (mass%) Si Cu Mg Fe 13.1 3.1 0.38 0.21

The ingot 141a was subjected to homogenization treatment by holding at 490 ° C for 8 hours. Subsequently, the bottom surface B of the ingot 141a is the upper surface, the top surface T is the lower surface, and the die is introduced into the die, and the punch is pressed from the upper side as shown in Fig. 8 (b). Forging was carried out to obtain a cup-shaped forging member 141b. The forging was hot forging and was performed under the conditions shown in Table 11. Further, the processing rate K was adjusted to 25, 50, 75% by adjusting the punch bottom dead center position and varying the bottom thickness h (Fig. 8 (b)) of the cup-shaped forging member 141b.

Cup Forging Condition One Type of press 800ton mechanical press 2 Mold temperature 200 ℃ -220 ℃ 3 Type of lubricant Water Soluble Graphite Lubricant 4 Work temperature Heated to 400-430 ℃ 5 Machining rate K (%) The punch bottom dead center position (slide amount) was adjusted to 25, 50, 75%.

Forging was back extrusion, and the lubricating oil was spray-coated to a punch and dice | dies, and it performed. After the forging, T6 treatment (solventization: 490 ° C × 4 hours, return: 170 ° C × 10 hours) was performed, and tensile test pieces were taken from the positions X, Y. Z in FIG. 8 (b) and subjected to tensile testing. The testing machine, test method, evaluation item, etc. are the same as that of Example 1.

Moreover, about the cup-shaped forging member 141b of working ratio K = 50%, the sample for microscope observation was taken. As shown in Fig. 8 (b), the sampling position is 1 mm inside, 3 mm inside, 3 mm inside, 3 mm inside, 1 mm inside from the bottom of the cup 141q, and 5 mm inside the cup inner bottom 141p. I made a point. After the polishing finish, the sample for microscopic observation was measured for the second phase crystal grains by an image processing apparatus. Here, the second phase crystal grain particles are eutectic silicon and primary silicon. As the image analysis processing device, Nikon Corporation Cosmozone R500 was used. The microscope observation ratio was performed 800 times with respect to the process silicon particle diameter, and 200 times with respect to the ultrafine silicon particle diameter.

The particle diameter was taken as the diameter when the area of one particle was replaced by a circle, that is, the equivalent circular diameter (Haywood diameter), and was obtained as the average particle diameter of the particles present in the observation field. For the average particle diameters of each of the process silicon and the ultrafine silicon, a ratio at each site was taken based on the measured value within 1 mm from the bottom surface 141P in the cup.

(Comparative Example 4)

In Example 4 described above, hot forging was performed at a processing rate of 25% or more. As Comparative Example 4, hot forging was performed at processing rates of 0% and 10%, and both were compared. In other words, ingots having a processing rate of 0% obtained under the same conditions as those of Example 4 and cup-shaped forging members having a processing rate of 10% that were hot forged under the conditions of Table 9 were subjected to T6 treatment for each work. Tensile test pieces were taken. The same conditions as in Example 4 except that the processing rate was changed.

(Comparative Example 5)

In Example 4, the ingot was obtained by unidirectional solidification casting, but as Comparative Example 5, the ingot was produced by the continuous casting method disclosed, for example, in Japanese Patent Application Laid-Open No. 54-42847, and both were compared. . That is, 115 mol of continuous casting rods were melted using the same molten metal as in Example 4. As the continuous casting method, the gas pressure hot saw casting method disclosed by Japanese Patent Application Laid-Open No. 54-42847 was used, and the casting conditions thereof were as shown in Table 12.

Casting condition of gas pressure hot top casting method One Cold bath temperature 730 ℃ 2 Cooling water amount 40 liters / minute 3 Casting speed 180 mm / min 4 Type of lubricant Castor Oil 5 Amount of lubricant 1 ㏄ / min 6 Type of gas air 7 Gas flow rate 0.5 liters / minute 8 Header 10 mm

After the homogeneous treatment, the obtained continuous casting rod (bar) was peeled to 110 mm, and cut into rounded pieces with a thickness of 50 mm. Thereafter, the steel sheet was hot forged at a processing rate of 50% to obtain a cup-shaped member shown in Fig. 8B. After the cup member was subjected to T6 treatment, a tensile test piece was obtained, and a sample for microscopic observation was taken. The homogenization treatment conditions, forging conditions, T6 condition, tensile test piece shape, tensile test method, and sample preparation procedure for microscopic observation were the same as in Example 4. The sampling position of the microscopic observation sample, the shape measurement method of the second phase particles, and the like are also the same as those in the fourth embodiment.

Table 13 is a table which shows various data of the tensile strength, 0.2% yield strength, and elongation of the tensile test result in Example 4, the comparative example 4, and the comparative example 5. From this table, in Comparative Example 4 in which the processing rates were 0 and 10%, the mechanical properties (tensile strength, 0.2% yield strength, elongation) of the top surface T and the center were obviously low with respect to the bottom surface B, but the processing rate was 25% or more. In the fourth embodiment, the mechanical properties of the top face T and the center side are greatly improved, and are roughly in agreement with the characteristics of the top face T, the center together, and the bottom face B at a processing rate of 50% or more.

Tensile test results (Example 4, Comparative Examples 4 and 5) Example 4 Comparative Example 4 Comparative Example 5 Fermentation rate (K%) 25 50 75 0 10 50 Strength (MPa) Place X Top side 385 305 403 365 370 392 Y center 393 398 402 377 385 394 Z Bottom surface 401 402 405 388 392 401 0.2% yield strength (MPa) Place X Top side 324 328 329 314 317 327 Y center 329 328 328 322 327 327 Z Bottom surface 329 330 329 327 326 328 kidney(%) Place X Top side 4.8 6.9 7.8 4.1 3.9 7.2 Y center 5.3 7.4 8.2 4.0 4.2 7.8 Z Bottom surface 6.3 7.9 8.2 4.5 4.7 7.3

In the case of tensile strength, when the work rate K reaches 75%, the strength up is no longer seen or the work rate is alleviated. However, the elongation tends to improve even when the work rate K reaches 75%. In particular, the improvement effect is observed on the top surface T side.

On the other hand, the mechanical properties of the cup-shaped member having a machining ratio K of 50% obtained from the continuous casting rod of Comparative Example 5 were almost identical to the values of the machining ratio K of 50% of Example 4.

Table 14 and Table 15 are tables showing the shape measurement results of the second phase crystal grains, Table 14 shows the results of Example 4, and Table 15 shows the results of Comparative Example 5. In Table 14, with respect to the shape of the second phase particles of the cup-shaped forging member 141b obtained in Example 4, the process silicon particle diameter is gradually increasing from the inner bottom surface 141p toward the outer bottom surface 141q. The value of "1 mm inside from cup outer bottom surface 41q" when the particle diameter of 1 mm inside from "cup inner bottom surface 41P" was 1 was 2.67.

Regarding the second phase particles of the cup obtained in Example 4 Type of Second Phase Particles Process silicon Ultra Silicon About the second phase particle Average particle diameter Ratio of average particle diameter to inner surface of cup Number of particles in 0.307mm2 Average particle diameter Ratio of Average Particle Diameter to Inner Cup Μm dog Μm Observation place 1mm inside from the inner surface 1.8 1.00 18 9.7 1.00 3mm inside from the inner surface 2.2 1.22 22 11.8 1.22 center 3.9 2.17 28 13.8 1.42 3 mm from the bottom 4.6 2.56 40 14.7 1.52 1 mm from the bottom outside 4.8 2.67 42 15.2 1.57

Regarding the second phase particles of the cup obtained in Comparative Example 5 Type of Second Phase Particles Process silicon Ultra Silicon For the second phase particles Average particle diameter Ratio of average particle diameter to inner surface of cup Number of particles in 0.307mm2 Average particle diameter Ratio of Average Particle Diameter to Inner Cup Μm dog Μm Observation place 1mm inside from the inner surface 2.5 1.00 44 13.6 1.00 3mm inside from the inner surface 2.3 0.92 40 13.9 1.02 center 2.5 1.00 48 14.0 1.03 3 mm from the bottom 2.4 0.96 37 14.1 1.04 1 mm from the bottom outside 2.5 1.00 44 13.9 1.02

In addition, the number of particles present in 0.307 square meters of ultra-silicon increases from the inner bottom surface 141p toward the outer bottom surface 141q, and the average particle diameter also increases, and the value is 1 from the cup inner bottom surface 141p. The value of "the inside of 1 mm from cup outer bottom surface 141q" when the particle diameter of the inside of mm was set to 1 was 1.57.

In addition, in Table 15, the 2nd phase crystal grain of the cup-shaped member obtained by the comparative example 5 showed the substantially same value in any part with process silicon and ultrafine silicon. In addition, about the number of particles which exist in 0.307 square millimeters of ultra-silicon, almost the same value was shown in any site | part.

In each of Example 4 and Comparative Example 5 provided with the above second phase crystallized particles, wear resistance evaluation of two points of "1 mm inside from the inner bottom surface" and "1 mm inside from the outer bottom surface" of the cup. Done.

Abrasion resistance test apparatus and test conditions are as follows.

(1) Testing equipment Takachiho Seiki Abrasion Tester TRI-S500

(2) Test type Pin, on-disk method

(3) Disc material FC230

(4) Clean SF-GF2 (temperature 80 degreeC) made from lubricant oil

(5) Pressing load 5 kgf

(6) sliding speed 0.25m / s

(7) Sliding time 60 minutes

(8) Shape of the pin ø7.98 mm x h20 mm

The evaluation items were abrasion amount and hardness, and each test piece was taken from the above two point positions of the cup-like member which was the same as that of the tensile test piece. The pin of the test piece for abrasion amount was cut in the column shape so that the axis might become the same as the thickness direction of a cup bottom part. The heat treatment is the end of T6 treatment.

Moreover, the hardness test piece was extract | collected from the site | part adjacent to the abrasion amount test piece, and hardness measurement was performed using the Rockwell hardness tester. The scale of hardness used Rockwell B scale (HRB).

Table 16 is a table which shows the result of the abrasion resistance evaluation test in Example 4 and the comparative example 5. In the drawing, in Comparative Example 5, the amount of wear did not change with the inner bottom face and the outer bottom face. On the other hand, in Example 4, although the amount of abrasion at the "inside 1 mm from the inner surface of the cup" was almost the same as that of Comparative Example 5, the amount of abrasion at the "inside 1 mm from the outer surface" was significantly smaller, and was 1 mm from the inner surface. It was about 50% of inside, and it turned out that wear resistance improves. In addition, the hardness (HRB) of the test piece was the same level with Comparative Example 5 and Example 4.

Pin Hardness and Wear Example 4 Comparative Example 5 Hardness Wear Hardness Wear HRB Μm HRB Μm Observation place 1mm inside from the inner surface 80 78 79 78 1 mm from the bottom outside 79 41 79 76

The outer bottom surface of the cup-shaped forging member 141b in Example 4 is excellent in wear resistance.The process silicon particle diameter and the ultra-fine silicon particle diameter are ingots even after the cup is forged by forging the ingot obtained by the one-way solidification casting method. It was estimated that the wear resistance was improved because of its roughness and size at the outer bottom surface of the cup corresponding to the top surface T side.

The difference between the various characteristics of the cup-shaped forging member 141b of Example 4 and the cup-shaped member in Comparative Example 5 is basically the cup-shaped forging member 141b of Example 4 as described above. On the basis of the ingot, the capturing method of the cooling member side and the front / opening side is commonly used, and the material obtained by roundly cutting the continuous casting rod, which is the basis of the cup-shaped member of Comparative Example 5, was originally equally determined at both ends thereof. Because it has an organization, it can be said that the capturing method of one side and the other side is caused by the nonexistence.

In each of the embodiments of the present invention, the second phase crystal grain diameter (process silicon particle diameter, ultra-fine silicon particle diameter) was examined for the plastic processing member manufactured by performing plastic working on the ingot by the one-way solidification casting method. In the plastic processing member, the ratio of the particle diameter before opening and closing to the particle diameter on the cooling member side was 1.2 or more.

When plastic processing is performed on the ingot by the one-way solidification casting method having such a feature, and the member is formed in a predetermined shape, the member is manufactured in such a way that the strength is high at a certain part and wear resistance is excellent at a part. It becomes possible. For example, in the case of the cup shape described above, it is possible to secure strength at the inner bottom surface which is not related to wear resistance and to secure both strength and wear resistance at the outer bottom surface where wear resistance is required.

For example, in the case of a lightweight and highly rigid internal piston engine utilizing the characteristics of recent aluminum alloys, high thermal conductivity and abrasion resistance are required for the performance of the piston as a whole. Abrasion resistance, low thermal expansion, and thermal shock resistance are required for the head portion and the ring groove portion, while the piston skirt portion and the pin boss portion, in which the deformation amount is increased by plastic working, have high moldability, machinability, and high fatigue strength characteristics in use. Required. By the way, when the opening and closing front side of the ingot is pressed downward, and the center of the cooling member side of the upper surface is pressed, the opening and closing front side extends to the ring groove portion, and the piston head portion and the ring groove portion can be formed at the opening and closing side with remarkable wear resistance. The piston skirt or pin boss portion can be formed on the cooling member side. The piston head portion and the ring groove portion formed in this way can secure wear resistance along with the strength, and the piston skirt portion and the pin boss portion can ensure high quality and strong strength. In this way, when the plastic working member of the present invention is used, even if the required characteristic differs from site to site, the requirements can be met.

As described above, in the embodiment of the present invention, the ingot 5 '(111a, 121a, 131a, 141a) obtained by the one-way solidification casting method is subjected to plastic working to obtain a plastic working member, so that the mechanical distance from the saw surface is increased. The characteristics can be remarkably improved, and even the member manufactured from the ingot by the one-way solidification casting method can raise the strength of the whole member and at the same time, the nonuniformity of the strength can be made uniform.

In addition, the ingot 5 'according to the one-way solidification casting method of the present invention is excellent in terms of internal quality and small in size and weight, so that it can be used as a high-value product, but it has a predetermined plastic working rate. In addition, since the strength of the whole member was raised and the unevenness of the strength was also made uniform, it was possible to greatly use as a structural member requiring strength.

In each of the above embodiments, the plastic working has been described as short cutting, rolling and hot forging, but the present invention provides other processing such as cold forging, rolling processing, rotary forging (electric processing), extrusion, and the like. The plastic deformation of the material can be used to apply the overall plasticity to give the desired shape and properties.

The plastic working member may be obtained by performing plastic working on the ingot, or the plastic working member may be a final processed product, or may be a intermediate processed product that requires some further processing.

Moreover, although the pressing direction at the time of plastic processing was demonstrated as the width direction and the thickness direction, the same effect can be exhibited even if this direction is arbitrary directions.

Moreover, although plastic processing was performed to the whole ingot, you may carry out partially.

For example, in the one-way solidification casting method, mold release ingots can be produced by pouring, but it is not necessary to plasticize the entirety of the release ingots, and the plastic processing may be performed at a processing rate of 25% or more in part. In that case, it is preferable to apply plastic processing at the process rate of 25% or more to the site | part including the opening and closing at least of the required place, and the processing rate of other places becomes less than 25%.

In particular, in the case where the ingot is large and the product to be obtained is large, it is sufficient to apply at least 25% of short-cutting to the part including at least before and after opening by forging. Accordingly, it is possible to make the plastic processing material, which is impossible to forge, into a shape close to the forging die shape by partially deforming the ingot. In addition, this partial plastic working (short processing) can improve the partial mechanical properties of the material. By turning the partial extension member to die forging in the next process, machining process, etc., it is possible to prevent nonuniformity in the mechanical properties of the part required by the product.

In this way, by partial plastic working,

① As the ingot, it is possible to make the required minimum input volume.

② Therefore, the amount of burr after forging can be minimized. Forging yield is better than cutting from a round bar and using a cutting blank material.

(3) Since the load on the mold can be made smaller than that of using a cutting blank material, the mold life is long and contributes to cost reduction. You can get a Merit back.

Representative examples of the parts used to remove the non-uniformity of the mechanical properties by applying the plastic processing member, in particular, more than 25% of the plastic working as described above are as follows, but it is natural that many other uses.

First, the parts of the wheel circumference of the car include an upper arm, a lower arm, a torsion rod, an ABS pump housing, and the like.

Next, as the engine circumference component of the automobile, a connecting rod, a GDI body, an internal combustion engine piston, and the like can be given. For motorcycles, cushion arms, brackets, fork bottom bridges, etc. may be mentioned. Moreover, gear crank etc. are mentioned as automobile parts.

At the time of manufacturing these parts, it is appropriately selected that the whole is subjected to plastic processing of 25% or more, or 25% or more, in part forging or partial shortening.

As described above, according to the metal casting method of the present invention, since the cooling member is cooled to satisfy the initial cooling conditions without waiting for the mold to be filled with the molten metal, blow defects are generated in the casting. Can be prevented and then the casting cycle can be shortened. In addition, since the cooling is performed after the flail is removed by the initial cooling conditions, solidification in the mold proceeds sequentially while the molten metal is injected into the medium, and the cooling rate of each part in the ingot is This is much faster than cooling by the conventional method, and segregation of solutes is reduced. In addition, since the opening and closing until just before the closing becomes impossible, the ingot becomes a dense structure by the squeezing effect, and the amount of casting defects can be suppressed.

In the present invention, the ingot obtained by unidirectional crystal growth from the cooling member toward the front opening and closing direction is subjected to plastic processing to obtain a plastic processing member, so that the mechanical properties separated from the opening can be remarkably improved, and the unidirectional crystal Even in the case of a plastic processing member by growth, the strength of the entire member can be increased, and the nonuniformity of the strength can be evened.

The member for plastic processing by unidirectional crystal growth of the present invention is excellent in internal quality and small in size and weight nonuniformity, so that it can be utilized as a product with high usability, and improves the strength of the whole material. Since the uniformity of strength was also made uniform, it could be greatly utilized as a structural member requiring strength.

Claims (22)

In the method of casting a metal having a spout which can be opened and closed by opening and closing at the top and using a mold whose cooling member also serves as a bottom part, the molten metal supplied from the spout is cooled by the cooling member to obtain an ingot. Opening before opening and closing on the condition that the cooling member of the mold is above a predetermined allowable lower limit temperature, The cooling of the cooling member is started to satisfy the initial cooling condition that the temperature when the molten metal injected into the mold contacts the surface of the mold of the cooling member is not lower than the allowable lower limit temperature. After the metal melts in the mold, the hot water in the mold continues without closing before opening and closing. The molten metal is closed by the opening and closing before the molten metal coagulation in the mold reaches near the pouring hole and becomes incapable of closing before the opening and closing of the pouring hole becomes impossible. After the closing charge, cooling to the cooling member is stopped when a predetermined cooling end condition is achieved, A method of casting a metal ingot for plastic working, characterized in that the cooling member is removed from the mold main body to take out the ingot based on the predetermined ingot drawing condition after cooling stop. A process for producing a member for plastic working, characterized in that the plastic working is applied to the ingot obtained by the method of claim 1 at a processing rate of a predetermined ratio or more to form a plastic working member. The method of manufacturing a member for plastic working according to claim 2, wherein a processing rate of a predetermined ratio or more is achieved by at least one plastic working on the ingot. The method for manufacturing a member for plastic working according to claim 2 or 3, wherein the predetermined ratio is 25%. The method for producing a member for plastic working according to any one of claims 2 to 4, wherein the plastic working is a partial plastic working for the ingot. The process for producing a member for plastic working according to any one of claims 2 to 5, wherein the plastic working is plastic working for a portion of the ingot including at least an opening and closing front side. 7. The plastic working according to any one of claims 2 to 6, wherein the plastic working is forging (cold or hot), short rolling processing, rolling, extrusion, rolling processing, rotary forging (electric processing). The manufacturing method of the member for plastic working which is made. Cooling control and cooling by means of a mold having a spout which can be opened and closed by opening and closing at the same time, and a cooling member serving as a bottom portion, cooling means for cooling the cooling member of the mold, opening and closing control and cooling means of the pouring hole before opening and closing. In the metal casting apparatus provided with the casting control means which performs the detachable control of a member and a mold main body collectively, The casting control means, A pre-opening control means for opening the opening and closing before starting the pouring to the mold, as a requirement that the cooling member is equal to or higher than the predetermined lower limit temperature; After the start of pouring by the pre-opening control means, the cooling means is controlled so as to satisfy the initial cooling condition that the temperature when the molten metal injected into the mold contacts the surface of the mold of the cooling member is not lower than the allowable lower limit temperature. Initial cooling control means, Normal cooling control means for controlling the cooling means after the molten metal injected into the mold has completely covered the mold inner surface of the cooling member to perform normal cooling of the cooling member; Pre-closure control means for closing the pouring port by stopping before and after the solidification of the molten metal in the mold reaches near the pouring hole and becomes impossible to close before the opening of the pouring hole becomes impossible. Cooling stop control means for stopping cooling to the cooling member by stopping control to the cooling means by the normal cooling control means on the basis that a predetermined cooling end condition is achieved after the closing charge by the closed control means; , After the cooling stops, predetermined removal conditions for the ingot are achieved, and the cooling member is detached from the mold body so as to take out the ingot from the mold, and after removing the ingot, the cooling member is mounted on the mold body again to remove the control means. Manufacturing apparatus for casting a metal for plastic working, characterized in that provided. The manufacturing apparatus for casting a metal ingot for plastic working according to claim 8, wherein an air vent hole is formed in the mold. The end face before opening and closing constitutes a part of the mold inner surface, and the occlusion mold in which the cooling member constitutes a part is used to process the metal molten metal charged from the opening and closing before and after the forced cooling by the cooling member to a solidified ingot. Plastic processing member characterized in that the plastic processing at a rate applied. The plastic processing member according to claim 10, wherein the ingot is an ingot that is cooled and solidified by the method described in claim 1. The plastic processing member according to claim 10 or 11, wherein the ingot is subjected to the plastic working according to any one of claims 2 to 7. The plastic processing member according to any one of claims 10 to 12, wherein the plastic processing member is an intermediate processed product. The plastic processing member according to any one of claims 10 to 12, wherein the plastic processing member is a final processed product. The plastic processing member according to any one of claims 10 to 14, wherein the metal is aluminum or an aluminum alloy. The plastic processing member according to any one of claims 10 to 15, wherein the DAS of the metal structure at the opening and closing side of the ingot relative to the DAS of the metal structure at the cooling member side is 1.1 to 10.0 times. 17. The plastic working according to any one of claims 10 to 16, wherein the crystal grain diameter of the metal structure at the opening and closing side is 1.05 to 7 times the crystal grain diameter of the metal structure at the cooling member side of the ingot. absence. The plastic processing member according to any one of claims 10 to 17, wherein the ratio of the second phase-purified particle diameter of the plastic working member to the particle diameter on the cooling member side is 1.2 or more. 19. The plastic working member according to any one of claims 10 to 18, wherein the ingot is an ingot that is poured downward from the spout and the growth direction of the crystal is approximately upward. The plastic processing member according to any one of claims 10 to 19, which is in an annealed state. The plastic processing member according to any one of claims 10 to 20, wherein the surface is barrel-polished. The plastic processing member according to any one of claims 10 to 21, wherein the surface is shot blasted.