US20070272387A1 - Method for Manufacturing Castings by Using a Lost-Foam Pattern Casting Method - Google Patents

Method for Manufacturing Castings by Using a Lost-Foam Pattern Casting Method Download PDF

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Publication number
US20070272387A1
US20070272387A1 US11/793,609 US79360905A US2007272387A1 US 20070272387 A1 US20070272387 A1 US 20070272387A1 US 79360905 A US79360905 A US 79360905A US 2007272387 A1 US2007272387 A1 US 2007272387A1
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United States
Prior art keywords
mold
molten metal
pressure
castings
pattern
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Abandoned
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US11/793,609
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English (en)
Inventor
Ryoji Hirukawa
Tatsuhiko Kato
Masahito Goka
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sintokogio Ltd
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Sintokogio Ltd
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Filing date
Publication date
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Assigned to SINTOKOGIO, LTD. reassignment SINTOKOGIO, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GOKA, MASAHITO, HIRUKAWA, RYOJI, KATO, TATSUHIKO
Publication of US20070272387A1 publication Critical patent/US20070272387A1/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
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/20—Measures not previously mentioned for influencing the grain structure or texture; Selection of compositions therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02—Lost patterns
    • B22C7/023—Patterns made from expanded plastic materials
    • B22C7/026—Patterns made from expanded plastic materials by assembling preformed parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • B22C9/046—Use of patterns which are eliminated by the liquid metal in the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/09—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure
    • B22D27/13—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure making use of gas pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/15—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using vacuum

Definitions

  • These inventions relate to a method for manufacturing cast iron, such as gray cast iron or ductile cast iron. Particularly, they provide a method for manufacturing castings with improved quality and increased production efficiency by using a foam pattern.
  • the method for manufacturing the castings by using a foam pattern For the method for manufacturing the castings by using a foam pattern, first the portion of the product of the pattern made from foamed resin is coated with a mold wash. Next, patterns for a runner, a sprue, a pouring cup and a feeder are formed by foaming resin and then coating them with the mold wash. Then these foam patterns are assembled and are buried in molding sand.
  • molten metal is poured in the pouring cup, since the foamed resin patterns has decomposed and then gas is generated by the heat of the molten metal, the molten metal can flow into the pattern made from the foamed resin through the runner and the gate. The molten metal can decompose the patterns made from the foamed resin by its heat and generate gas. Accordingly, the space for the pattern is filled with the molten metal. Then, as the molten metal in the space of the pattern is solidified, the castings can be manufactured.
  • the method that uses foundry sand that includes a binder, such as a fran resin is called a “full mold casting.”
  • the method that uses molding sand that does not include any binder is called a “lost-foam casting.”
  • the method for manufacturing castings by using a foam pattern is used to manufacture water pipes and other items, since the cost of equipment for this method is low.
  • lost-foam casting which uses molding sand that does not include any binder, is used, since there is less waste sand than in other methods, it is advantageous in this point.
  • shrinkage is caused to appear on the castings. Accordingly, the shrinkage must be reduced by adding a feeder in the mold.
  • the first purpose of these inventions is to provide a method for manufacturing castings which have no defect, such as a shrinkage, a cold shot or blow hole and which have good quality. Namely, for the method for manufacturing castings by using a foam pattern, this purpose is achieved by dropping the temperature of the molten metal without decreasing the fluidity of the molten metal in the mold.
  • the second purpose of these inventions is to provide a method for manufacturing castings with high productivity. This purpose is achieved by decreasing the time for cooling the foundry product after pouring the molten metal in the mold, by reusing the molding sand, by increasing the recovery of the molten metal, and by increasing the productivity of the mold.
  • a method for manufacturing a castings by using a foam pattern wherein the method uses dry sand and a foamed pattern as a lost pattern, the method comprising: a step for pouring molten metal into a mold, wherein the molten metal has a temperature range from 1250 to 1330° C., and a step for pressure reduction in a mold.
  • the molten metal is poured into the mold at a low temperature so that it is formed in a semi-solid state, which means a state wherein a solid and liquid state coexist. Consequently, it becomes possible to reduce the shrinkage of the castings caused by the solidification shrinkage while cooling. Further, it is accomplished by reducing the pressure in the mold. Consequently, since the gas caused by the decomposition of the foamed pattern is suctioned from the mold, no blow holes can affect the castings. Further, the fluidity of the molten metal in the mold can be increased. Thus, it becomes possible to prevent the blow holes or the cold shut from being generated in the castings, and to provide a method for manufacturing them with a high quality.
  • the step for reducing the pressure in the mold is accomplished by decreasing the pressure in a ventilator channel. It is disposed at a lower part of the mold and is provided with holes connecting with the sand in the mold.
  • the invention of claim 3 is comprised of:
  • the method of claim 2 wherein after the step for reducing the pressure in the mold, it further comprises a step for increasing the pressure in the mold, wherein the step is achieved by increasing the pressure in the ventilator channel.
  • the vacuum pressure of 0.03 Mpa to 0.05 Mpa to the ventilator channel as the step for decreasing the pressure in the mold, the gas caused by the decomposition of the foamed pattern is best suctioned from the mold while the molten metal is being poured.
  • no gas bubbles affect the foundry product, and so the fluidity of the molten metal in the mold can be improved.
  • invention of claim 5 is comprised of:
  • the material of the foamed pattern is a PMMA (polymethylmethacrylate), and wherein the material has its volume increased by 40-50 times, by being foamed.
  • the rigidity of the foamed pattern can be increased so as to withstand a load applied to a mold. Further, it is possible to make a foamed pattern generating less gas caused by the decomposition and less residue and to manufacture high quality castings.
  • invention of claim 10 is comprised of:
  • any of claims 1 - 9 wherein the foamed pattern that includes a runner, a gate, and a portion of a product, is integrally made, or separately formed, and then is assembled by adhering them.
  • the temperature of a molten metal while pouring it into a mold affects the quality and the costs of manufacturing castings.
  • the temperature of the molten metal while pouring it into a mold is high, namely, about 1,450° C.
  • the temperature of molten metal affects the shrinkage of foundry products when the molten metal is solidified, affects the fluidity of the molten metal in the mold, affects the degree of the decomposition of a foamed pattern, and affects the electrical power required to melt the metal.
  • the shrinkage in castings becomes greater than otherwise when the molten metal is solidified.
  • a feeder is disposed at the castings to prevent the surface sink. If molten metal which is in a half-solidified state, namely, in a semi-solid state, is poured into the mold, the thermal shrinkage of castings substantially equals that of its expansion. This expansion is caused by graphite deposition during solidification. Thus, since these effects cancel each other out, it is possible to prevent the shrinkage.
  • the semi-solid state is defined as the state in which cementite that is in a liquid state and martensite that is in a solid state are mixed, at the step when the state of the cast iron changes from a liquid state to a solid state.
  • the molten metal that is in the semi-solid state is poured into the mold, it is not necessary to heat the molten metal up to the temperature that is used in the conventional manufacturing process. Thus, the electrical power necessary for heating can be reduced.
  • the analyses while pouring the molten metal were made by using a device that simulates the runner portion of the actual mold.
  • the device is provided with a metal pipe having a wall made from a refractory material, and with a foamed resin (a foamed pattern) in the hollow part of the pipe.
  • the molten metal is poured through the pipe.
  • the molten metal that goes through the pipe falls into a tank of water disposed under the outlet port of the pipe.
  • the analyses were made to evaluate whether the molten was formed in the semi-solid state at the outlet port of the pipe (this location corresponds to the gate of the mold) by metallographic observation of samples (test pieces) that solidified in the tank of water.
  • Table 1 shoes the results of the analyses of the poured molten metal.
  • FIG. 2 shows a photomicrograph of the metallographic structure of the test piece.
  • the mark “ ⁇ ” in Table 1 denotes that the molten metal formed in a semi-solid state.
  • the mark “x” in Table 1 denotes that the molten metal did not form in a semi-solid state.
  • deformed fittings made from ductile cast iron were experimentally manufactured by varying the manufacturing conditions. Two types of the deformed fittings were experimentally manufactured. One was a straight duct-type deformed fitting having a nominal diameter of 8 inches and a thickness of 3.5 mm, as shown in FIG. 3 (weight of 5.5 Kg/one). The other was a straight duct-type deformed fitting having a nominal diameter of 10 inches and thickness of 5 mm, as shown in FIG. 3 (weight of 11 Kg/one).
  • the deformed fittings were manufactured by varying the temperature of the molten metal that was poured into the mold from 1,230 to 1,400° C. Further, while pouring the molten metal into the mold, two types of pressure conditions were applied. Namely, in one case, while pouring the molten metal into the mold, the pressure in the mold was decreased. In the other case, it was not decreased.
  • the foamed pattern having a shape of a deformed fitting, which pattern is used to form the mold, is made by foaming a polymethylmethacrylate resin (PMMA).
  • PMMA polymethylmethacrylate resin
  • the foamed pattern were to be made by increasing the ratio of the volume of the resin after foaming compared to before foaming too much, since the density and the rigidity of the pattern would also be reduced too much, the foamed pattern would become deformable. Consequently, it would become difficult to manufacture castings having a high dimensional accuracy.
  • it is desirable to set the volume of the resin after foaming to be 40-50 times greater than that before foaming.
  • the surface layer of the foamed pattern is formed by coating it with a mold wash (facing material).
  • a mold wash facing material
  • This mold wash is used to prevent the sand from reacting to the molten metal, to improve the rigidity of the foamed pattern, and to reinforce it.
  • a mold wash having a strength of more than 15 Kg/cm 2 .
  • the concentration of the mold wash affects the quantity of the blow holes generated in the castings. It is desirable to set the concentration of the mold wash at about 70 Baume.
  • the foamed patterns When the foamed patterns are made, it is possible to independently form the portion of the product of the pattern, the patterns of the runner portion, the gate portion, the portion for pouring the molten metal, and the portion for pressurizing the portion of the product. It is also possible to integrally make all parts of the foamed pattern, such as the patterns of castings, the runner, the gate, pouring cup, and feeder. Then the foamed patterns are coated with the mold wash. It is also possible to independently form the patterns of all portions, to assemble them by adhering them together, and then to coat them with the mold wash.
  • Thera Beads 400 (a brand name), which is molding sand made from artificial ceramics, is used as the sand for the mold. Since the sand does not include a binder, and since there is less waste foundry sand generated from fractures than by other methods, it can be reused as the sand. Thus, this sand has an advantage in this point.
  • the molten metal is poured into the mold.
  • the material of the molten metal is FCD45 (spheroidal graphite cast iron).
  • the steps after pouring the molten metal into the mold differ from those in the method of manufacturing it without reducing the pressure or not. Namely, as shown in FIG. 4 , in the method for manufacturing the deformed fitting while reducing the pressure, the step for decreasing the pressure in the mold is accomplished by decreasing the pressure in a ventilator channel ( 2 ), which is disposed at the lower part of the mold ( 1 ), at the same time that the molten metal is poured into the mold containing the foamed pattern.
  • the ventilator channel ( 2 ) has a plurality of holes ( 3 ) to contact with the foundry sand in the mold.
  • One end of the ventilatory channel ( 2 ) is connected to a device (not shown in the Figs.) named a vacuum pump.
  • the pressure in the ventilator channel ( 2 ) is decreased by the device for decompression, the air in the foundry sand and the gas caused by the decomposition of the foamed pattern made from a resin are drawn through voids between the sand.
  • the suction of the decomposition gas it is desirable to continue decreasing the pressure in the ventilator channel ( 2 ) until the molten metal poured into the mold can be solidified. Further, to avoid directly drawing out the sand, but to draw out all the decomposition gas, it is desirable to set the pressure in the mold within the range of 0.03 Mpa to 0.05 Mpa.
  • the ventilator channel ( 2 ) is disposed at the lower portion of the mold.
  • the location of the ventilator channel ( 2 ) is not limited to this configuration. It can also be disposed at the sides or upper portion of the mold. Further, a flask having a plurality of vent holes can be used. Such a flask is disposed at the periphery of the mold. It is also possible to decompress the outside the flask.
  • the ventilator channel ( 2 ) is disposed at the lower portion of the mold, then when the molten metal is poured into it while the pressure in the ventilator channel ( 2 ) is being decreased, the molten metal is drawn downward. Thus, it is less likely that the molten metal will swash in the mold, and so the surface of the molten metal in the mold will gradually and stably ascend. Thus, the molten metal can be prevented from possibly including air or gas bubbles.
  • Table 2 shows the results of the trial manufacture of a straight duct-type deformed fitting having a nominal diameter of 8 inches and a thickness of 3.5 mm and a straight duct-type deformed fitting having a nominal diameter of 10 inches and a thickness of 5 mm.
  • deformed fittings are manufactured by varying the temperature of the molten metal and the pressure in the ventilator channel ( 2 ).
  • the marks of “ ⁇ ”, “ ⁇ ”, and “x” in Table 2 denote the results of the evaluation for foundry products produced by the deformed fittings.
  • the mark “ ⁇ ” means that the product produced by the deformed fittings has no defects, such as a cold shut caused by the fluidity of the molten metal or blow holes caused by including the decomposition gas caused by foam pattern, and has a high quality.
  • the mark “ ⁇ ” means that while there are not any problems with the fluidity of the molten metal, the castings has blow holes in it.
  • the mark “x” means that there are also some problems with the fluidity of the molten metal.
  • FIG. 5 shows the measurements of the strength of the castings shown in Table 2. They can be manufactured by decompressing or not decompressing the mold while the molten metal is being poured.
  • the deformed fittings were trial manufactured by causing the castings to cool by further raising the pressure of the mold after lowering it.
  • the steps for manufacturing castings by applying a step for compressing a mold after a step for decompressing it are substantially similar to those applying only a step for decompressing a mold, except for one step. Namely, the step for compressing the ventilator channel ( 2 ) in the mold after reducing the pressure in it while pouring the molten metal is applied to the method for manufacturing castings, instead of the step for just reducing the pressure in the ventilator channel ( 2 ).
  • the decompression of the mold is achieved by reducing the pressure in the ventilator channel ( 2 ) disposed at the lower portion of the mold ( 1 ). The decompression is continued until all the molten metal has been poured into the mold. After pouring the molten metal, the pressure in the ventilator channel ( 2 ) is increased to above the atmospheric pressure. By increasing the pressure in the ventilator channel ( 2 ), room-temperature air is fed in the voids between the sand from the ventilator channel ( 2 ). And then, an air flow is formed. It becomes possible to increase cooling rate of the castings by that flow of air.
  • the ventilator channel ( 2 ) may be compressed until the temperature of the castings drop down sufficiently. It may also be compressed until the temperature of the castings drop down to below the temperature of ferrite-pearlite transformation, and then the pressure in the ventilator channel ( 2 ) may be reduce to the atmospheric pressure. By this method, the cooling rate of castings can be effectively increased. Further, wasted use of the energy necessary to compress the ventilator channel ( 2 ) can be reduced.
  • FIG. 1 shows a device used for analyzing molten metal being poured to clarify which temperature causes the metal to be in a semi-solid state in the mold.
  • FIG. 2 shows a photomicrograph of the metallographic structure of the test piece that is made by the analysis of the molten metal being poured to clarify which temperature of the molten metal causes the metal to be in the semi-solid state.
  • FIG. 3 shows a photograph of a deformed fitting. It is trial manufactured cast iron.
  • FIG. 4 shows the constitution of the device for compressing or decompressing the mold.
  • FIG. 5 shows the measurements of the strength of the castings which are manufactured by decompressing or not decompressing the mold while pouring the molten metal.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
US11/793,609 2004-12-24 2005-12-12 Method for Manufacturing Castings by Using a Lost-Foam Pattern Casting Method Abandoned US20070272387A1 (en)

Applications Claiming Priority (3)

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JP2004-372907 2004-12-24
JP2004372907A JP2006175494A (ja) 2004-12-24 2004-12-24 ダクタイル鋳鉄のフェライト地鋳物の製造方法
PCT/JP2005/022786 WO2006067991A1 (ja) 2004-12-24 2005-12-12 ダクタイル鋳鉄のフェライト地鋳物の製造方法

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102012209805A1 (de) * 2012-06-12 2013-12-12 Bayerische Motoren Werke Aktiengesellschaft Kühlvorrichtung und Verfahren zur Kühlung eines während eines Lost Foam Gießverfahrens hergestellten Bauteils
US9556498B2 (en) 2011-10-07 2017-01-31 Akebono Brake Industry Co., Ltd. Method for producing spheroidal graphite cast iron and vehicle component using said spheroidal graphite cast iron
US9862022B2 (en) * 2014-08-18 2018-01-09 Kobe Steel, Ltd Casting method using lost foam
US10099274B2 (en) * 2014-11-19 2018-10-16 Kobe Steel, Ltd. Evaporative pattern casting method

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103695758A (zh) * 2013-12-23 2014-04-02 哈尔滨东安汽车动力股份有限公司 一种全激冷凸轮轴生产方法
JP6991908B2 (ja) * 2018-03-22 2022-01-13 株式会社栗本鐵工所 筒状体

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4457352A (en) * 1980-03-14 1984-07-03 Scheffer Karl D System and process for the abatement of casting pollution, reclaiming resin bonded sand, and/or recovering a low BTU fuel from castings
US4877078A (en) * 1988-01-29 1989-10-31 Wittmoser A Pattern for use in lost pattern foundry process
US6453976B1 (en) * 1999-10-29 2002-09-24 Hitchiner Manufacturing Co., Inc. Lost foam countergravity casting
US20040045638A1 (en) * 2000-12-14 2004-03-11 Michel Garat Safety component moulded in a1-si alloy

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH05277699A (ja) * 1992-04-02 1993-10-26 Hitachi Metals Ltd 薄肉鋳物の鋳造方法
JPH08112664A (ja) * 1994-08-25 1996-05-07 Hitachi Metals Ltd 注湯方法および注湯装置

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4457352A (en) * 1980-03-14 1984-07-03 Scheffer Karl D System and process for the abatement of casting pollution, reclaiming resin bonded sand, and/or recovering a low BTU fuel from castings
US4877078A (en) * 1988-01-29 1989-10-31 Wittmoser A Pattern for use in lost pattern foundry process
US6453976B1 (en) * 1999-10-29 2002-09-24 Hitchiner Manufacturing Co., Inc. Lost foam countergravity casting
US20040045638A1 (en) * 2000-12-14 2004-03-11 Michel Garat Safety component moulded in a1-si alloy

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9556498B2 (en) 2011-10-07 2017-01-31 Akebono Brake Industry Co., Ltd. Method for producing spheroidal graphite cast iron and vehicle component using said spheroidal graphite cast iron
DE102012209805A1 (de) * 2012-06-12 2013-12-12 Bayerische Motoren Werke Aktiengesellschaft Kühlvorrichtung und Verfahren zur Kühlung eines während eines Lost Foam Gießverfahrens hergestellten Bauteils
US9862022B2 (en) * 2014-08-18 2018-01-09 Kobe Steel, Ltd Casting method using lost foam
US10099274B2 (en) * 2014-11-19 2018-10-16 Kobe Steel, Ltd. Evaporative pattern casting method

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JP2006175494A (ja) 2006-07-06

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