US20040261969A1 - Method for producing castings, molding sand and its use for carrying out said method - Google Patents
Method for producing castings, molding sand and its use for carrying out said method Download PDFInfo
- Publication number
- US20040261969A1 US20040261969A1 US10/489,485 US48948504A US2004261969A1 US 20040261969 A1 US20040261969 A1 US 20040261969A1 US 48948504 A US48948504 A US 48948504A US 2004261969 A1 US2004261969 A1 US 2004261969A1
- Authority
- US
- United States
- Prior art keywords
- casting
- mould
- mould material
- basic
- binding agent
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
- B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives
- B22C1/08—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives for decreasing shrinkage of the mould, e.g. for investment casting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
- B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
- B22C1/18—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/10—Cores; Manufacture or installation of cores
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/12—Treating moulds or cores, e.g. drying, hardening
Definitions
- the invention relates to a method for the manufacture of castings from a molten metal, in particular molten light metal, such as molten aluminium.
- the invention relates to a moulding material and its use for the manufacture of casting mould parts, which are used for the casting of molten metal, in particular molten light metal, such as molten aluminium.
- Such casting mould parts may, for example, be casting cores, through which cavities are formed in the interior of the castings to be produced.
- the casting mould parts according to the invention can be structural elements from which a multi-part casting mould can be composed, by means of which the external shape of the casting to be manufactured is determined.
- the manufacture of structural components made of metal by casting technology requires casting mould parts by means of which, on the one hand, the inner shape and, on the other, the outer shape of the workpieces which are to be cast are determined.
- Such casting mould parts can accordingly be casting cores, by means of which cavities are formed in the interior of the casting which is to be created, or casting mould elements from which a multi-part casting mould is assembled, which determines the outer shape of the casting which is to be created.
- mould material systems are used, as a rule, which are composed of a basic mould material and a binding agent. These two components are mixed with each other, shaped, and processed in a suitable hardening process to form a compact body.
- a basic mould material quartz sand is usually used, which in the majority of applications is bonded with an organic binding agent.
- quartz sand as a basic material for the manufacture of casting mould parts has proved its value in many respects in particular in the sector of the casting of light metal materials.
- quartz sand can be obtained economically and is characterised by easy processing qualities and good quality in the imaging of the mould elements of the casting which is to be produced in each case.
- the mould material used for the manufacture of the casting mould parts must have high strength and high dimensional consistency, which will still be maintained under the loads incurred during the manufacture of the casting mould and the casting of the melt.
- the moulding material should be easy to remove after the casting. This becomes particularly important if casting cores are used which form complex shaped interiors in the casting.
- the mould materials should be capable of being regenerated after use in such a way that the highest possible quota of reuse can be achieved with the basic mould material.
- This can be achieved in a known manner by the use of inorganic binding agents, which release low emissions during the manufacture of the mould parts and, after the end of the casting process, can be incinerated almost free of any residue under the effect of sufficiently high temperatures.
- a further problem with the casting of complexly shaped castings making use of casting mould parts manufactured by conventional means lies in the fact that the sand can only be removed from the casting with difficulty after cooling.
- the casting is usually subjected to shaking or knocking, which causes the disintegration of the casting cores on the inside of the casting and of the mould parts adhering to the outside of the casting, and is intended to promote the pouring out of the mould material particles obtained.
- These mechanical methods for the removal of the mould parts do, however, incur the risk of damage to the casting; for example, especially with filigree-shaped or thin-walled components, crack formation may occur.
- the casting should be heated sufficiently for the binding agent to be combusted until the basic mould material alone remain, and can then be easily removed out of and from the casting as pourable material.
- the expenditure required in terms of apparatus for this is considerable.
- the temperatures required for the combustion of the binding agent are so high that the heating will inevitably also cause a change in the properties of the metallic castings.
- the object of the invention was to provide a method with which high-quality complex-shaped castings can be manufactured, and with which, after the end of the casting process, the casting mould parts can also be removed out of and from the casting in a simple manner and without any risk.
- a mould material is also intended to be provided with which mould parts can be manufactured which are suitable for the production of high-quality complex-shaped castings, and which, after the termination of the casting process, can be removed out of and from the casting in a simple manner and without any risk.
- a mould material for the manufacture of casting mould parts for the casting of molten metal in particular of molten light metal, consisting of a pourable mixture of basic mould material, inert in relation to the molten metal, and a binding agent mixed with the basic mould material, wherein the thermal expansion behaviour of the basic mould material and binding agent are adjusted to one another in such a way that the coefficient of thermal expansion of the molten metal lies above the coefficient of thermal expansion of the casting mould part manufactured from the mould material.
- the invention is based on the understanding that, by the selection of a suitable mould material, casting mould parts can be produced which combine in an optimum manner the properties required for the simple, reliable, and environmentally-friendly manufacture of high-quality and dimensionally-stable castings.
- Mould material according to the invention provides an optimum combination of the properties which are a precondition for the manufacture of a high-quality casting with, at the same time, a simple way of manufacture.
- the mould material according to the invention contains a basic material which is present in a grain form, or comparable particle form, and which as such is pourable, which, during the heating which inevitably arises during the casting, shows considerably less thermal expansion in relation to conventionally used quartz sand.
- the basic mould material accordingly guarantees, even with low material thicknesses, high dimensional stability in the manufacture of complex shaped castings.
- the basic material which is pourable in the unbound state, is mixed with a binding agent which has a different expansion behaviour on heating from the basic material. Because of the different thermal expansion between the basic mould material and the binding agent, the application of heat from the casting heat leads to the release of the binding agent from the grains of the basic mould material. As a result, the binding agent accordingly bursts the mould part, when it expands more strongly than the basic material, in such a way that the mould part loses its solid shape and can be easily removed out of and from the casting.
- the expansion behaviour of the basic mould material can be established in such a way that the change of volume which is inherent in the heating process breaks the binding with the binding agent and the basic material is again pourable.
- An essential factor is that, inherently with the heating, the core or mould component breaks up, so that, after the casting has cooled, it has disintegrated into loose individual parts which are easily removable.
- the invention has a particularly favourable effect with the casting of components made from molten aluminium. Aluminium exhibits a high coefficient of thermal expansion, with the result that, in the course of the casting and solidifying of the melt, sufficiently high forces are exerted on the mould parts in contact with the cast part that the mould part concerned will be certain to break into smaller fragments. This proves to be particularly favourable if the mould part is a core mould.
- a further property which is favourable for the invention of the mould material constituted and used according to the invention is that the binding agent and the basic mould material are adjusted to one another in such a way that, with the casting mould parts produced from the mould material, the particles of the basic material are thermally stable and are not elastically bonded by the binding agent.
- the casting mould part which is produced from a basic mould material constituted in this manner behaves throughout the entire temperature interval run through during the casting of the molten metal in a brittle manner, as a result of which the disintegration of the mould parts wanted according to the invention is promoted.
- the binding agent of the mould is for preference selected in such a way that it does not disintegrate due to the effect of heat. In this way the situation is avoided in which volumes are released in the core which could lead to a compliance of the mould concerned, which is undesirable according to the invention.
- a further advantageous embodiment of the invention is that the particles of the basic mould material exhibit an essentially round, spherical shape.
- the spherical shape of the basic mould material and the prevalence of point contacts between the basic moulding material particles, associated with this promotes the self-acting disintegration of the mould parts as a consequence of the mechanical forces which arise during the casting and solidification of the melt.
- a basic mould material which fulfils this requirement particularly well is synthetically manufactured mullite.
- a further advantageous embodiment of the invention makes provision for the basic mould material to contain at least a part of aluminium oxide sand (mullite), for preference substituting for more than 50% or more than 70% of the quartz sand.
- Mullite exhibits a round grain shape and a density comparable to quartz sand.
- the mould materials manufactured from mullite are considerably easier to process than, for example, known ZrO 2 sands.
- the round spherical shape of the mullite particles leads in practice to simplified processability of the mould materials manufactured from such basic mould materials, and therefore inherently to a reduced wear on the tools and machines used for the manufacture of the mould parts.
- a mould material with high mullite content has high dimensional stability during the manufacture of complex shaped castings even with low material thickness.
- mould material composed according to the invention is particularly well-suited for the manufacture of casting cores. These can be removed after casting without the risk of damage to the finished castings.
- binding agent and basic material are, in addition to this, for preference adjusted to one another in such a way that a casting mould part produced from the mould material has a low thermal conductivity.
- This property has the effect that, after the casting of the molten metal, the temperature difference between the cast material and the mould part remains large, so that the risk of premature disintegration of the mould part induced by thermal or chemical means is reduced to a minimum.
- the disintegration of the mould cores is enhanced by the fact that the constituents of the mould material are matched to one another in such a way that basic mould material and binding agent expand differently when heated, with the result that the bindings between them break under the heating which occurs with the casting of the melt.
- the invention can be realised in a manner particularly well-suited to practice in that a mould material is processed which is formed from a mixture of a basic substance which is present in a grain or comparable particle form, and as such is pourable, and an inorganic binding agent.
- mould materials have proved to be particularly well-suited which are mixed from a binding agent based on water glass and a basic mould material composed according to the invention.
- An essential consideration in this situation, however, is that the expansion behaviour of the components mixed with one another differs in a sufficient manner.
- the basic mould material and binding agent expand differently.
- the binding agent becomes detached from the grains of the basic mould material. This causes the binding agent, if it expands stronger than the basic substance, to burst the mould part in such a way that it loses its solid shape and disintegrates into fragments. These can be easily shaken out of or from the casting without the risk of mechanical damage.
- the casting mould part is also manufactured by way of a mould material mixture composed in accordance with the invention being shot in a known manner into the core box of a core moulding machine.
- the mould material is then hardened, for example in the manner described in DE 196 32 293 A1, in that an low pressure is imposed on the hollow mould of the core box, heated to a temperature of 100° C. to 160° C., and the core mould is heated over a period from 20 to 30 seconds by the core box.
- the casting mould part becomes so solid that it can be removed from the core box and can be placed into a heating device, such as a microwave furnace, arranged outside the core moulding box.
- a heating device such as a microwave furnace
- this heating device it is heated at an adequate thermal output until a sufficient volume of water has been drawn from it for complete hardening.
- the removal of water can also be effected by sufficient heating of the core box itself, or by hot air gassing. These measures can in each case be combined with heating applied outside the core box. It is likewise possible for the removal of water to be effected by microwave heating taking effect directly on the core mould when still located in the core box.
- the respective mould part can be sprayed with binding fluid in order to increase the core surface hardness.
- the mould parts treated in this way exhibit increased stability with likewise increased abrasion resistance, so that they can be stored without any problem and meet the highest demands on dimensional stability. This proves to be particularly favourable with regard to optimised quality of the casting which is to be produced if a water glass binding agent is used.
- Two recesses 3 , 4 are formed in the underside 2 of the camshaft core 1 , spaced at a distance from one another in the longitudinal direction, by means of which in each case the shape of the pillow blocks of the cylinder head which is to be manufactured, intended for the bearing of the camshaft is determined.
- the length A of the branches 5 , 6 is many times larger than its diameter B.
- the length C of the main section 7 of the oil channel core 8 is many times larger than its diameter D.
- the oil channel core 8 has been manufactured in an inherently known manner in a conventional shoot-moulding machine from a mould material according to the invention, manufactured by mixing a basic mould material consisting of a mullite sand and quartz sand with a water glass binder. Due to the proportion of mullite sand, it is guaranteed that the oil channel core 8 expands uniformly and consequently in a manner which can be distinctly predetermined, also under the heat rising in the course of the casting of the cylinder head to be manufactured, up to more than 573° C.
- the casting cores 1 , 8 are only insignificantly deformed because of the features of the basic mould material and the binding agents being adjusted to one another in accordance with the invention.
- the low thermal expansion of the basic mould material thus supports the reliable process attainment of the dimensional requirements of the casting.
- the fragments into which the respective casting core 1 , 8 self-actingly disintegrates, as a result of the effect of the casting heat and due to the different thermal expansion behaviour of the basic mould material and the binding agent, are emptied out of the casting and reprocessed.
- the respective casting core 1 , 8 is subjected to high mechanical stresses due to the substantially higher solid body contraction of the cast metal in comparison with the casting cores 1 , 8 .
- the reprocessing of the fragments of the casting core can include gentle breaking into grainy particles.
- the grainy particles thus obtained can then be subjected to a metal separation process and dust extraction, in order to produce the state required for their reuse.
- the casting mould parts recycled to grainy material are then again used as basic material for mould material composed in accordance with the invention.
- mould materials are used in the manner according to the invention, consisting of basic mould material such as synthetic mullite, mixed with water glass binding agent, then no emissions worth mentioning are incurred during the manufacture of the casting mould parts.
- basic mould material such as synthetic mullite, mixed with water glass binding agent.
- mullite or a comparabl inert refractory material is used as a basic substance for the mould material system according to the invention, then a further advantage of the invention is realised in the chemical resistance of the basic mould material in relation to binding agents and melt. This property ensures that, with the method according to the invention, a casting is obtained of which the surface is entirely free of residual sand adherence after the emptying of the fragments of the mould cores and mould parts, without additional cleaning measures.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Mold Materials And Core Materials (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Powder Metallurgy (AREA)
Applications Claiming Priority (7)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE10145417A DE10145417A1 (de) | 2001-09-14 | 2001-09-14 | Formgrundstoff, Formstoff und Formteil für eine Giessform |
DE101-45-417.1 | 2001-09-14 | ||
DE102-09-183.8 | 2002-03-04 | ||
DE102-09-224.9 | 2002-03-04 | ||
DE10209183A DE10209183A1 (de) | 2002-03-04 | 2002-03-04 | Formstoff für die Herstellung von Gießformteilen |
DE10209224A DE10209224A1 (de) | 2002-03-04 | 2002-03-04 | Verfahren zum Herstellen von Gußstücken |
PCT/EP2002/010301 WO2003024642A1 (de) | 2001-09-14 | 2002-09-13 | Verfahren zum herstellen von gussstücken, formsand und seine verwendung für die durchführung des verfahrens |
Publications (1)
Publication Number | Publication Date |
---|---|
US20040261969A1 true US20040261969A1 (en) | 2004-12-30 |
Family
ID=27214603
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/489,485 Abandoned US20040261969A1 (en) | 2001-09-14 | 2002-09-13 | Method for producing castings, molding sand and its use for carrying out said method |
Country Status (14)
Country | Link |
---|---|
US (1) | US20040261969A1 (es) |
EP (1) | EP1425121B1 (es) |
JP (1) | JP2005502473A (es) |
KR (1) | KR20040070330A (es) |
CN (1) | CN1298456C (es) |
AT (1) | ATE323563T1 (es) |
BR (1) | BR0212534A (es) |
CA (1) | CA2461797A1 (es) |
DE (1) | DE50206490D1 (es) |
ES (1) | ES2262845T3 (es) |
HU (1) | HUP0401547A2 (es) |
MX (1) | MXPA04002424A (es) |
PL (1) | PL367736A1 (es) |
WO (1) | WO2003024642A1 (es) |
Families Citing this family (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE10321106A1 (de) * | 2003-05-09 | 2004-12-23 | Hydro Aluminium Deutschland Gmbh | Formstoff, Formteil und Verfahren zur Herstellung von Formteilen für eine Gießform |
EP3576337A1 (en) | 2005-09-30 | 2019-12-04 | Apple Inc. | Synchronization channel for scalable wireless mobile communication networks |
CN1319669C (zh) * | 2005-12-20 | 2007-06-06 | 金啸海 | 一种用于铸造的型砂及其制备方法 |
EP2216112A1 (de) * | 2009-02-10 | 2010-08-11 | Siemens Aktiengesellschaft | Nickel-Basis-Gussbauteil mit einem Ausgleichskörper und Verfahren zum Herstellen des Nickel-Basis-Gussbauteils |
RU2635598C2 (ru) * | 2013-09-04 | 2017-11-14 | Немак, С.А.Б. Де К.В. | Способ извлечения из формы для литья литой заготовки, отлитой из лёгкого сплава |
DE102014110826A1 (de) * | 2014-07-30 | 2016-02-04 | Fritz Winter Eisengiesserei Gmbh & Co. Kg | Verfahren zum Gießen von Gussteilen |
KR101663084B1 (ko) * | 2016-03-18 | 2016-10-06 | 박성제 | 정밀 주조를 통해 거푸집을 용이하게 제거할 수 있는 수도꼭지 제조 방법 |
CN111822677A (zh) * | 2019-04-11 | 2020-10-27 | 上海航天精密机械研究所 | 一种基于复合铸型的轻金属铸造方法 |
DE102020208692A1 (de) | 2020-07-10 | 2022-01-13 | Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung eingetragener Verein | Verfahren zur Herstellung und Entfernung eines Gießkerns sowie zur Verwendung des Gießkerns |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5612393A (en) * | 1993-12-24 | 1997-03-18 | Nissan Motor Co., Ltd. | Casting core composition |
US6371194B1 (en) * | 1996-08-09 | 2002-04-16 | Vaw Aluminium Ag | Method for producing core preforms and recycling core sand for a foundry |
Family Cites Families (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS544817A (en) * | 1977-06-15 | 1979-01-13 | Hitachi Ltd | Selffhardening casting sand |
JPS5584251A (en) * | 1978-12-22 | 1980-06-25 | Hitachi Ltd | Casting method |
WO1986000033A1 (en) * | 1984-06-12 | 1986-01-03 | MIKROVA^oGSAPPLIKATION AB | A method and a plant of manufacturing cores |
GB9308363D0 (en) * | 1993-04-22 | 1993-06-09 | Foseco Int | Refractory compositions for use in the casting of metals |
JPH07164102A (ja) * | 1993-12-13 | 1995-06-27 | Mazda Motor Corp | 鋳造用砂鋳型およびその製造方法 |
JP3186005B2 (ja) * | 1993-12-24 | 2001-07-11 | 愛知機械工業株式会社 | 鋳造用中子 |
CN1041064C (zh) * | 1994-07-05 | 1998-12-09 | 江苏理工大学 | 一种再生砂制备有机酯水玻璃自硬砂的方法 |
CN1071159C (zh) * | 1995-11-08 | 2001-09-19 | 花王株式会社 | 砂型用粘结剂、型砂组合物和砂型的制造方法 |
DE19632293C2 (de) * | 1996-08-09 | 1999-06-10 | Thomas Prof Dr In Steinhaeuser | Verfahren zur Herstellung von Kernformlingen für die Gießereitechnik |
-
2002
- 2002-09-13 MX MXPA04002424A patent/MXPA04002424A/es active IP Right Grant
- 2002-09-13 CA CA002461797A patent/CA2461797A1/en not_active Abandoned
- 2002-09-13 CN CNB02820431XA patent/CN1298456C/zh not_active Expired - Fee Related
- 2002-09-13 KR KR10-2004-7003845A patent/KR20040070330A/ko not_active Application Discontinuation
- 2002-09-13 PL PL02367736A patent/PL367736A1/xx unknown
- 2002-09-13 JP JP2003528331A patent/JP2005502473A/ja active Pending
- 2002-09-13 DE DE50206490T patent/DE50206490D1/de not_active Expired - Fee Related
- 2002-09-13 HU HU0401547A patent/HUP0401547A2/hu unknown
- 2002-09-13 BR BR0212534-0A patent/BR0212534A/pt not_active IP Right Cessation
- 2002-09-13 EP EP02772298A patent/EP1425121B1/de not_active Expired - Lifetime
- 2002-09-13 AT AT02772298T patent/ATE323563T1/de not_active IP Right Cessation
- 2002-09-13 ES ES02772298T patent/ES2262845T3/es not_active Expired - Lifetime
- 2002-09-13 US US10/489,485 patent/US20040261969A1/en not_active Abandoned
- 2002-09-13 WO PCT/EP2002/010301 patent/WO2003024642A1/de active IP Right Grant
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5612393A (en) * | 1993-12-24 | 1997-03-18 | Nissan Motor Co., Ltd. | Casting core composition |
US6371194B1 (en) * | 1996-08-09 | 2002-04-16 | Vaw Aluminium Ag | Method for producing core preforms and recycling core sand for a foundry |
Also Published As
Publication number | Publication date |
---|---|
WO2003024642A1 (de) | 2003-03-27 |
CN1298456C (zh) | 2007-02-07 |
EP1425121A1 (de) | 2004-06-09 |
JP2005502473A (ja) | 2005-01-27 |
BR0212534A (pt) | 2004-10-19 |
ES2262845T3 (es) | 2006-12-01 |
EP1425121B1 (de) | 2006-04-19 |
PL367736A1 (en) | 2005-03-07 |
DE50206490D1 (de) | 2006-05-24 |
HUP0401547A2 (hu) | 2005-08-29 |
ATE323563T1 (de) | 2006-05-15 |
CA2461797A1 (en) | 2003-03-27 |
MXPA04002424A (es) | 2005-04-11 |
CN1599651A (zh) | 2005-03-23 |
KR20040070330A (ko) | 2004-08-07 |
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Owner name: HYDRO ALUMINIUM MANDI & BERGER GMBH, AUSTRALIA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:STAUDER, BERNHARD;GINTNER, WALTER;REEL/FRAME:015757/0314 Effective date: 20040603 |
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STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |