US20020179280A1 - Diecasting method and device for carrying out the same - Google Patents

Diecasting method and device for carrying out the same Download PDF

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Publication number
US20020179280A1
US20020179280A1 US09/937,281 US93728101A US2002179280A1 US 20020179280 A1 US20020179280 A1 US 20020179280A1 US 93728101 A US93728101 A US 93728101A US 2002179280 A1 US2002179280 A1 US 2002179280A1
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United States
Prior art keywords
casting
casting chamber
melt
chamber
suspension
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Abandoned
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US09/937,281
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English (en)
Inventor
Gerhard Peleschka
Evgueni Sterling
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RITTER ALUMINUM GIESSEREI GmbH
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RITTER ALUMINUM GIESSEREI GmbH
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Assigned to RITTER ALUMINUM GIESSEREI GMBH reassignment RITTER ALUMINUM GIESSEREI GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: PELESCHKA, GERHARD, STERLING, EVGUENI
Publication of US20020179280A1 publication Critical patent/US20020179280A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/007—Semi-solid pressure die casting
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/12—Making non-ferrous alloys by processing in a semi-solid state, e.g. holding the alloy in the solid-liquid phase

Definitions

  • the invention relates to a die casting method for producing cast parts from a semi-solidified alloy melt, whereby the alloy melt is transformed into a semi-solidified state by stimulating the crystallization process, then introduced into a casting chamber, and the cast parts are produced under pressure. Furthermore, the invention relates to a device for carrying out the method.
  • thermodynamic state of the metal plays a decisive role in the various treatment processes.
  • the effects connected therewith can be exploited not only for facilitating the deformation process, but employed also for substantially influencing the morphology of the resulting crystalline forms and the properties of the cast part.
  • the alloy loses its strength as the temperature rises, which is of basic importance for shaping process, and the capability for plastic deformability is obtained at the same time as a property dependent upon the structure.
  • the alloy melt is in the semi-solidified state. Said state is therefore referred to as the “metallic suspension”, which is employed as the preliminary material for the novel die casting method.
  • the invention is dealing with the phenomenological behavior of the crystallizing liquids and their rheological properties, and exploits the same for the production of cast parts from the semi-solidified state.
  • a method for producing cast parts from the semi-solidified state of the melt is known from EP 0 841 406 A1.
  • This patent describes a multi-stage process, the objective of which is to produce the parts from the semi-solidified alloys on a vertical die casting machine.
  • the transport of the preliminary material into the casting chamber takes place following a nucleus formation phase in the superheated melt followed by a subsequent granulation process.
  • a vibrator device was employed for that purpose, by which the formation of nuclei in the crystallizing melt is stimulated.
  • the semi-solidified preliminary material was heated in a controlled manner. After the casting chamber was communicatively linked up with the container for the preliminary material, the latter was pressed into the die casting mold.
  • EP 0 733 421 A1 discloses another casting process in which the casting chamber is filled with the help of a casting plunger after the predetermined volume of the melt has been metered in.
  • the preset volume of the melt is transformed into a state of suspension by additional cooling and mixing in the electromagnetic field, and subsequently pressed into the die casting mold.
  • the inventors addressed the problem of achieving an enhanced homogeneity of the structure as compared to the products obtained in the prior art, whereby the amount of resulting column-shaped crystals or transcrystallites and the amount of coaxial or globular crystals were used as the quality yardstick.
  • the experimental results showed that the enhanced isotropy of the cast parts can be demonstrated by the type of crystalline shapes obtained, and that particularly high strength values and a very good tenacity behavior can be proven in this way.
  • the goal of the present invention is a die casting method by which a homogeneous state of the suspension of the preliminary material is reliably assured. Said preliminary material is then filled under pressure into a pressure chamber while it is in said state of suspension.
  • a further goal consists in that the preliminary material is produced from an exogenous metallic suspension.
  • the goal is to develop a continuous casting process, whereby all stages of the method can take place in a closed casting system. It is possible with the novel die casting method to produce from the metallic suspension cast parts exhibiting an excellent quality.
  • the aforementioned problems are solved according to the invention with a method of the type specified above in that the preset volume of the melt is put into rotation outside of the casting chamber in a closed processing container, and a homogeneous metallic suspension of the exogenous type is produced in this process, from which a cast part is then produced after the suspension has been filled into the casting chamber.
  • the casting chamber remains in the communicatively linked-up condition throughout the duration of the method and the entire method, which is comprised of individual steps, is devised in the form of a closed casting system.
  • a special feature of distinction of the method as defined by the invention is the way in which the metallic suspension is prepared.
  • the preset volume of the melt is transformed into the suspension state by external cooling, which provides the suspension with an endogenous nature
  • a basically different approach has been selected in connection with the present invention in that an exogenous suspension is produced abruptly.
  • the core of such an approach is the rapid and uniform cooling of the melt, which is possible only by introducing additional micro-heat processes into the preset volume of the melt.
  • a powder produced from the same alloy as the volume of the melt is used as coolant in order to be able to obtain the required cooling effect in the shortest possible time.
  • the cooling effect lies in a reduction of the excess superheating temperature, whereby the following two crystallization processes, which take place in parallel, occur:
  • the melt is cooled from the interior up to the preset temperature, or at least to the temperature of the liquid state, and crystallization nuclei are developed by the additional cooling. Said crystallization nuclei determine the morphology of the structure. Their uniform distribution in the forming metallic suspension is of primary importance in order to assure that the same conditions of crystallization exist throughout the volume of the suspension.
  • the cooling powder is introduced into the melt under pressure, for which purpose air, argon or nitrogen are employed as carrier gas.
  • a special design of the treatment container is required for producing metallic suspension following conditioning.
  • a treatment container is a closed space whose outlet opening can be sealed with a stopper bar.
  • the treatment container is placed in an electromagnetic field and the melt filling is set in motion in said closed space and maintained there until the conditioning process is completed.
  • Such range of suspension is characteristic of the entire material volume in the proposed process. From the outset, the forces acting on the metal melt in the form of the electromagnetic field are required in order to shear off the solidifying material within a narrow solidification range and to set the entire volume of the suspension into a motion at which the suspension retains its capability of flowing over a longer period of time while producing the homogeneity desired for the quality of the cast part.
  • a formation of hollow, partially liquid rotating bodies takes place in the course of said process.
  • the suspension flows to the walls of the treatment container and is maintained in the state of motion until the required casting temperature and casting homogeneity have been reached.
  • K coefficient of gravitation
  • the inventors were successful also in obtaining an experimental equation according to which the homogeneity measure of metallic suspensions is determined by a coefficient of homogeneity (X) whose lower efficient limit for aluminum alloys comes to the value 3.8 ⁇ 10 8 A 2 /s.
  • the coefficient of homogeneity can be determined based on the following relation:
  • N the number of rotation on the free surface of the partly liquid, rotating body
  • H the strength of the magnetic field
  • R the average wall thickness of the partly liquid, rotating body.
  • the special design of the treatment container permits converting the preset volume of the melt into a metallic suspension under constant technological conditions. Such a suspension exits from the treatment container as a homogeneous suspension material by way of the outlet opening and then flows into the casting chamber.
  • a particularly preferred embodiment of the invention is characterized by a transport chamber specially provided for transporting the suspension.
  • Said transport chamber communicatively connects the treatment container and the casting chamber; it is equipped with a transport plunger, and it can be mounted on the vertically arranged casting chamber either at a right or at an acute angle.
  • the transport plunger has the two following functions:
  • the plunger is designed for that purpose in such a way that its frontal contour is a continuation of the inner contour of the casting chamber, so that when the casting plunger is moving, no interference occurs within the zone of the filling opening from the side of the transport plunger.
  • FIG. 1 is a schematic representation of a die casting device as defined by the invention, with which cast parts can be produced from a homogeneous metallic suspension of the exogenous type;
  • FIG. 2 is a cutout “A” of FIG. 1 within the area of the mouth of the transport chamber 6 feeding into the casting chamber 7 .
  • a treatment container 1 that is equipped with a stopper bar 2 and a pipeline 3 for admitting cooling powder. Furthermore, by means of a melt line 4 , the container is connected with the furnace 5 for keeping the melt hot, and connected with the vertically arranged casting chamber 7 by means of a transport chamber 6 .
  • the treatment container 1 is inserted in an electromagnetic agitating device 8 which, as an integrating system is comprised of an induction and control unit in the form of a closed component of the die casting machine.
  • the diagram shows that the transport chamber 6 is mounted on the casting chamber 7 at an acute angle. However, it is possible also to link up the structural elements at a right angle and to provide them with the transport plunger 9 .
  • Such a transport plunger not only frees the transport chamber 8 of metal residues but also seals the filling opening 10 in the casting chamber 7 .
  • the casting chamber is aligned in the usual manner with a casting plunger 11 .
  • An electromagnetic field permitting a stirring motion of the melt is generated in the induction unit with a control system (not shown in the diagram).
  • the melt 12 is subsequently conveyed by way of a melt line 4 from the furnace 5 keeping the melt hot, into the treatment container 1 , which is located in the induction coil 8 .
  • the preset volume of the melt is set in motion, notably in a closed space because the outlet opening of the treatment container is tightly sealed by the stopper bar 2 .
  • the melt flows to the walls of the container and forms a liquid, hollow rotating body (according to the drawing, the rotating body has a conical shape).
  • a coefficient of gravitation “K” is generated in this process on the free surface of the rotating body whose value is determined by the velocity with which the different liquid layers are displaced against one another.
  • the cooling powder is admitted into the melt under pressure, notably according to a pulsating regimen.
  • the exogenous metallic suspension, which is abruptly produced in the treatment container 1 is a result of the three following merging processes:
  • the first process is part of the heat exchange process, in which the powder material extracts the excess heat from the superheated melt. This produces a number of cooled areas of the suspension where the temperature is below the liquid level.
  • the second process is connected with the way in which the powder is introduced into the melt.
  • the powder particles do not remain on the inner surface of the liquid, rotating bodies, but penetrate the melt very deeply and act as efficient inner heat absorbers, which causes an exogenous metallic suspension to be simultaneously produced throughout the entire volume of the melt.
  • elastic oscillations develop in the liquid metal by which the formation of new nuclei of crystallization in the preset volume of the melt is stimulated even more by a micro-cavitation effect.
  • the third process is the constant rotational motion of the preset volume of the melt that takes place in the course of and parallel with the two processes specified above.
  • the suspension is drained from the treatment container 1 by pulling out the stopper bar 2 , and the suspension is received in the transport chamber 6 .
  • the suspension either may be set in motion, or it may directly flow from the treatment container 1 , which has no bearing on the quality of the suspension, but an influence on the draining time.
  • the metallic suspension produced in such a manner has a high potential of kinetic energy, it flows very rapidly towards the transport chamber 6 in the direction of the casting chamber 7 , which starts to fill by way of the filling opening 10 .
  • the casting plunger 11 is synchronously displaced downwards in order to permit the filling level to rise.
  • the transport chamber is equipped with the transport plunger 9 . After the filling operation has been completed, the transport plunger 9 is pushed forward and closes the filling opening 10 and thereby seals the casting chamber 7 .
  • the transport plunger 9 is designed in this connection in such a way that its frontal contour is a continuation of the inner contour of the casting chamber 7 .
  • the metallic suspension present in the casting chamber fills the pressure chamber by means of acceleration of the plunger, so that a cast part is produced from the semi-solidified preliminary material.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture Of Metal Powder And Suspensions Thereof (AREA)
  • Extrusion Of Metal (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Manufacture And Refinement Of Metals (AREA)
US09/937,281 2000-01-24 2001-01-04 Diecasting method and device for carrying out the same Abandoned US20020179280A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10002670A DE10002670C2 (de) 2000-01-24 2000-01-24 Druckgießverfahren und Vorrichtung zu seiner Durchführung
DE10002670.2 2000-01-24

Publications (1)

Publication Number Publication Date
US20020179280A1 true US20020179280A1 (en) 2002-12-05

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US09/937,281 Abandoned US20020179280A1 (en) 2000-01-24 2001-01-04 Diecasting method and device for carrying out the same

Country Status (7)

Country Link
US (1) US20020179280A1 (ja)
EP (1) EP1120471A1 (ja)
JP (1) JP2003520683A (ja)
KR (1) KR20010113858A (ja)
AU (1) AU3166101A (ja)
DE (1) DE10002670C2 (ja)
WO (1) WO2001055464A1 (ja)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030094258A1 (en) * 2001-11-22 2003-05-22 Demag Ergotech Gmbh Apparatus and method for casting metallic materials
US20040003912A1 (en) * 2002-03-13 2004-01-08 Evgenij Sterling Method and apparatus for preparing a metal or metal-alloy product for a casting process
US20050103461A1 (en) * 2003-11-19 2005-05-19 Tht Presses, Inc. Process for generating a semi-solid slurry
US20050167073A1 (en) * 2004-02-04 2005-08-04 Chun Pyo HONG Rheoforming apparatus
US20090304542A1 (en) * 2005-05-04 2009-12-10 Evgenij Sterling Method for the production of pigs,and pigs
AU2004242667B2 (en) * 2003-06-03 2011-04-07 Dong Keun Go Die casting machine and casting method by thereof machine

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6908590B2 (en) * 2002-03-19 2005-06-21 Spx Corporation Aluminum alloy

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6365015A (ja) * 1986-09-05 1988-03-23 Kubota Ltd 金属溶湯への脱酸剤添加方法
JP2955863B2 (ja) * 1989-04-14 1999-10-04 新日本製鐵株式会社 金属の鋳造方法
EP0733421B1 (en) * 1995-03-22 2000-09-06 Hitachi Metals, Ltd. Die casting method
JPH08290257A (ja) * 1995-04-20 1996-11-05 Mitsubishi Heavy Ind Ltd 耐摩耗性アルミニウム合金鋳物及びその製造法
WO1997021509A1 (en) * 1995-12-12 1997-06-19 Thixomat, Inc. Apparatus for processing semisolid thixotropic metallic slurries
CA2220357A1 (en) * 1996-11-08 1998-05-08 Ube Industries, Ltd. Method of shaping semisolid metals
EP1004374B1 (de) * 1998-11-25 2002-02-13 Ritter Aluminium Giesserei Gmbh Druckgiessverfahren zur Herstellung von Gussstücken aus Legierungen mit thixotropen Eigenschaften sowie Vorrichtung zur Duchführung des Verfahrens
DE19918229C2 (de) * 1999-04-22 2002-07-18 Daimler Chrysler Ag Verfahren zum Herstellen von Rohlingen für Zylinderlaufbüchsen

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030094258A1 (en) * 2001-11-22 2003-05-22 Demag Ergotech Gmbh Apparatus and method for casting metallic materials
US20040003912A1 (en) * 2002-03-13 2004-01-08 Evgenij Sterling Method and apparatus for preparing a metal or metal-alloy product for a casting process
US6988529B2 (en) * 2002-03-13 2006-01-24 Evgenij Sterling Method and apparatus for preparing a metal or metal-alloy product for a casting process
AU2004242667B2 (en) * 2003-06-03 2011-04-07 Dong Keun Go Die casting machine and casting method by thereof machine
AU2004242667A8 (en) * 2003-06-03 2011-08-04 Dong Keun Go Die casting machine and casting method by thereof machine
US20050103461A1 (en) * 2003-11-19 2005-05-19 Tht Presses, Inc. Process for generating a semi-solid slurry
US20050167073A1 (en) * 2004-02-04 2005-08-04 Chun Pyo HONG Rheoforming apparatus
US20090304542A1 (en) * 2005-05-04 2009-12-10 Evgenij Sterling Method for the production of pigs,and pigs
US8459330B2 (en) * 2005-05-04 2013-06-11 Evgenij Sterling Method for the production of pigs, and pigs

Also Published As

Publication number Publication date
AU3166101A (en) 2001-08-07
WO2001055464A1 (de) 2001-08-02
EP1120471A1 (de) 2001-08-01
DE10002670C2 (de) 2003-03-20
KR20010113858A (ko) 2001-12-28
DE10002670A1 (de) 2001-08-02
JP2003520683A (ja) 2003-07-08

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Owner name: RITTER ALUMINUM GIESSEREI GMBH, GERMANY

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:PELESCHKA, GERHARD;STERLING, EVGUENI;REEL/FRAME:012292/0964

Effective date: 20010918

STCB Information on status: application discontinuation

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