US20080190583A1 - Chill Mould for the Casting of Light Metal Casting Materials, and the Use of Such a Mould, as Well as of a Cast Iron Material - Google Patents
Chill Mould for the Casting of Light Metal Casting Materials, and the Use of Such a Mould, as Well as of a Cast Iron Material Download PDFInfo
- Publication number
- US20080190583A1 US20080190583A1 US11/815,191 US81519106A US2008190583A1 US 20080190583 A1 US20080190583 A1 US 20080190583A1 US 81519106 A US81519106 A US 81519106A US 2008190583 A1 US2008190583 A1 US 2008190583A1
- Authority
- US
- United States
- Prior art keywords
- casting
- mould
- cast iron
- light metal
- expansion
- 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
Links
- 239000000463 material Substances 0.000 title claims abstract description 76
- 238000005266 casting Methods 0.000 title claims abstract description 55
- 229910001018 Cast iron Inorganic materials 0.000 title claims abstract description 35
- 238000005058 metal casting Methods 0.000 title claims abstract description 27
- 238000007528 sand casting Methods 0.000 claims abstract description 8
- 239000000470 constituent Substances 0.000 claims abstract description 5
- 229910052759 nickel Inorganic materials 0.000 claims description 16
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 15
- 229910052748 manganese Inorganic materials 0.000 claims description 15
- 229910052782 aluminium Inorganic materials 0.000 claims description 9
- 238000004519 manufacturing process Methods 0.000 claims description 9
- 238000000034 method Methods 0.000 claims description 8
- 229910045601 alloy Inorganic materials 0.000 claims description 7
- 239000000956 alloy Substances 0.000 claims description 7
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 6
- 229910052742 iron Inorganic materials 0.000 claims description 6
- 229910052710 silicon Inorganic materials 0.000 claims description 6
- 239000012535 impurity Substances 0.000 claims description 4
- 229910052804 chromium Inorganic materials 0.000 claims description 3
- 229910052802 copper Inorganic materials 0.000 claims description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 22
- 239000011572 manganese Substances 0.000 description 14
- 229910001369 Brass Inorganic materials 0.000 description 7
- 239000010951 brass Substances 0.000 description 7
- 238000007711 solidification Methods 0.000 description 7
- 230000008023 solidification Effects 0.000 description 7
- 238000002485 combustion reaction Methods 0.000 description 6
- 239000000155 melt Substances 0.000 description 6
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 4
- 229910000838 Al alloy Inorganic materials 0.000 description 3
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 3
- 238000001816 cooling Methods 0.000 description 3
- 230000007547 defect Effects 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 239000011777 magnesium Substances 0.000 description 3
- 239000010703 silicon Substances 0.000 description 3
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 229910052749 magnesium Inorganic materials 0.000 description 2
- 229910001092 metal group alloy Inorganic materials 0.000 description 2
- 239000004576 sand Substances 0.000 description 2
- 229910000967 As alloy Inorganic materials 0.000 description 1
- 229910001060 Gray iron Inorganic materials 0.000 description 1
- 229910000861 Mg alloy Inorganic materials 0.000 description 1
- 238000005275 alloying Methods 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- -1 for example Inorganic materials 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 229910001120 nichrome Inorganic materials 0.000 description 1
- 239000002244 precipitate Substances 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/06—Permanent moulds for shaped castings
- B22C9/061—Materials which make up the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/0009—Cylinders, pistons
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
- B22D21/002—Castings of light metals
Definitions
- the invention relates to a chill mould for the casting of light metal casting materials.
- the invention likewise relates to the use of such a mould.
- the principle is known of using chill moulds in casting moulds, in particular in sand casting moulds, in order specifically to cool more substantially a cast material cast into the casting mould, in particular a light metal casting material, such as an aluminum or magnesium material, in the contact area between the casting material and the chill mould, than the sand mould is capable of doing (Stephan Hasse, Ernst Brunhuber: “Giesserei Lexikon” [Casting Plant Encyclopaedia], page 735, 18 th edition, 2001). In this way, a specifically directed solidification of the casting material is achieved, taking as a basis the areas of the casting material coming in contact with the chill mould. In addition to this, the accelerated cooling achieved by the use of chill moulds allows a microstructure of the solidified casting to be obtained which is improved in respect of its mechanical properties, in particular denser, in the area cooled by the chill mould.
- Chill moulds are accordingly usually used in such sections of the casting mould which form areas of the casting which is to be formed at which particularly high demands are placed on the microstructure properties. This applies in particular to the technical casting manufacture of engine blocks or cylinder heads of combustion engines from a light metal alloy.
- a typical example for the sector of casting moulds, in which chill moulds are used for local improvement of the microstructure, is the cylinder chambers of combustion engines.
- the running surfaces of the cylinder chambers are subjected to heavy loads when in operation, so that high demands are placed in particular on their wear resistance properties, their toughness and their strength.
- chill moulds are manufactured from cast iron material. In terms of casting technology, they can be manufactured in a simple and economical manner. In practice, however, cast iron chill moulds have proved to be problematic with the casting of light metal casting materials, such as aluminum or magnesium melts, due to the lower thermal coefficient of expansion of the cast iron in comparison with the light metal casting material. During casting, the chill mould which comes in contact with the light metal melt heats up and its thermal coefficient of expansion expands accordingly. If the temperature drops during the subsequent solidification process, the chill mould shrinks again back to its initial volume.
- light metal casting materials such as aluminum or magnesium melts
- a disadvantage of the known brass moulds is their high price and their unfavorable wear behavior. Their handling is also unwieldy, since brass moulds cannot be held with magnets, for example. With automatic manufacturing techniques in particular, this makes it difficult to provide casting moulds which are equipped with brass moulds. In order to avoid the adherence of the cast material to the mould, and to obtain an optimum surface quality, it is also necessary in practice, as a rule, for the surface of the mould to be provided with a sizing. This procedure also leads to a complication of the manufacturing process, which inevitably incurs additional costs.
- the invention in one embodiment, features a chill mould capable of being manufactured economically, which possesses optimized properties of use and at the same time makes optimized casting results possible.
- the invention features a new application possibility for an inherently known casting material.
- this object is resolved in that it is manufactured from an Ni and/or Mn alloyed cast iron material, of which the Ni content and/or Mn content is dimensioned in such a way that the thermal coefficient of expansion of the chill mould is adjusted to the thermal coefficient of expansion of the light metal casting material which is to be cast in each case.
- a chill mould provided in accordance with the invention can be used preferably as a constituent part of a sand casting mould for the casting of a cylinder block from a light metal casting material.
- the invention takes advantage of the possibility of alloying cast iron in such a way that its thermal coefficient of expansion corresponds with the thermal coefficient of expansion of the light metal melt which is to be cast in each case.
- Appropriately alloyed cast iron is already inherently known.
- a cast iron material is already described which has a thermal coefficient of expansion of between 16.0 ⁇ 10 ⁇ 6 and 21.0 ⁇ 10 ⁇ 6 K ⁇ 1 at temperatures lying between 20° C. and 100° C. This corresponds, for example, to the thermal coefficient of expansion of typical cast aluminum alloys in the temperature range concerned.
- such cast iron materials have only be used for structural components which are cast into or shrunk onto light metal elements, or compressed with them.
- a typical example of use for the alloy known from DE 27 19 456 A1 is in the manufacture of ring grooves, used as sealing elements in light metal pistons for combustion engines.
- the deviation between the thermal coefficient of expansion of the particular iron cast material used for the chill mould and the thermal coefficient of expansion of the particular light metal casting material is restricted to a maximum range of ⁇ 0.4 ⁇ 10 ⁇ 6 /K.
- the invention it is both possible to add only nickel or only manganese to the cast iron material, as well as to provide both these elements as alloy constituents.
- the decisive factor is that the thermal coefficient of expansion of the chill mould is adjusted to the thermal coefficient of expansion of the casting material.
- Chill moulds according to the invention are particularly well-suited for use when casting aluminum alloys, since the thermal coefficient of expansion of the mould material can be adjusted particularly well to that of the aluminum alloys.
- the chill moulds can, however, also be used in the casting of other light metal alloys, such as, for example, magnesium alloys.
- chill moulds according to the invention are well-suited for use in sand casting moulds for the casting of a cylinder block made of a light metal casting material.
- chill moulds which are formed in accordance with the invention can serve in particular to form the cylinder cavities of a cast cylinder block for combustion engines. This is the case regardless of whether the cavities themselves serve as cylinder running surfaces or whether additional cylinder liners are provided.
- the cavity inner walls of the cavity themselves serve as the cylinder running surfaces
- the cavity inner walls can be coated in an inherently known manner with a material, such as nickel or silicon, in order to increase their wear resistance.
- a material such as nickel or silicon
- the chill moulds according to the invention reliably guarantee that the desired precipitations of Si occur in the area of the cylinder running surfaces thanks to an accelerated solidification induced in a controlled manner by means of the chill moulds.
- machining of the running surfaces to be carried out in order to expose the precipitated silicon in a likewise inherently known manner.
- the cast iron material can have a nickel fraction of 0.1 to 13.0% by weight.
- the adjustment of the thermal coefficient of expansion can be realized in a particularly simple manner. Higher Ni contents cause increased expansion of the cast iron on heating, while with lower Ni contents, which are combined with likewise small quantities of Mn, if present, adjust smaller thermal coefficients of expansion.
- Thermal coefficients of expansion of the chill moulds according to the invention which are particularly well adjusted to the thermal expansion behavior of aluminum based melts are produced if the content of Ni is more than 6.00% by weight, in particular at least 6.5% by weight.
- the range for the nickel contents can be limited upwards, at which the effects used by the invention occur particularly reliably, in setting the upper limit for this range at a maximum 8.00% by weight, preferably less than 8.00% by weight.
- the cast iron material may also have a manganese fraction for adjusting the thermal coefficient of expansion, which lies in the range from 0.1 to 19.0% by weight.
- a manganese fraction for adjusting the thermal coefficient of expansion, which lies in the range from 0.1 to 19.0% by weight.
- Mn contents lead to a displacement of the thermal coefficient of expansion towards higher values, while lower Mn fractions, with at the same time low or non-existent Ni fractions, cause a lower expansion of the cast iron on heating.
- the contents of Mn lie in the range from 4 to 12% by weight, in order to guarantee an optimum adjustment to the expansion behavior of Al melts.
- the cast iron material can also, in an inherently known manner, as well as iron and unavoidable impurities, contain the following elements (in % by weight):
- the solution to the object referred to heretofore lies in the fact that this material, in addition to iron and unavoidable impurities, containing (in % by weight) C: 1.5-4.0%, Si: 0.5-4.0%, Cu: 0.3-7.0%, Cr: ⁇ 2.0%, Al: 0.3-8.0%, Ti: 0.01-0.5%, 0.5%, as well as at least one element from the group Ni, Mn, with the proviso that the content of Ni amounts to: 0.1-13.0% and the content of Mn to: 0.1-19.0%, is used to manufacture a chill mould for casting light metal casting materials.
- the invention is explained in greater detail hereinafter on the basis of an exemplary embodiment represented in a drawing.
- the single figure shows a cast cylinder block 1 with a chill mould 2 inserted in it, in a cross-section.
- FIG. 1 a finished solidified cylinder block 1 is represented, cast in an inherently known manner in a sand casting mould, not shown, of a multi-cylinder combustion engine, in a cross-section through one of the cylinder chambers. After solidification and cooling, the sand casting mould was removed from the cylinder block 1 , being destroyed in the process.
- This casting material possesses a thermal coefficient of expansion of 19.4 ⁇ 10 ⁇ 6 / K.
- the chill mould 2 was manufactured from a commercial GGL-NiCr 20-2 cast iron alloy known under the name “Ni-Resist”. By choosing the Mn and Ni contents, the chill moulds have a thermal coefficient of expansion which lies in the range from 20° C. to 200° C. 18.7 ⁇ 10 ⁇ 6 / K. This thermal coefficient of expansion lies so close to the coefficient of expansion of 19.4 ⁇ 10 ⁇ 6 / K of the AlSil7Cu4Mg alloy from which the engine block is cast that the chill moulds, on heating and cooling, behave in essentially the same manner as the Al casting material. As a consequence, only minimal stresses occur in the contact area between the casting part and the chill mould in each case, and an optimum casting result is achieved.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Cylinder Crankcases Of Internal Combustion Engines (AREA)
- Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Treatment Of Steel In Its Molten State (AREA)
- Dental Prosthetics (AREA)
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE102005004481A DE102005004481B3 (de) | 2005-01-31 | 2005-01-31 | Kühlkokille zum Vergießen von Leichtmetall-Gusswerkstoffen und Verwendung einer solchen Kokille sowie eines Gusseisenwerkstoffs |
| DE102005004481.6 | 2005-01-31 | ||
| PCT/EP2006/000701 WO2006081983A1 (de) | 2005-01-31 | 2006-01-27 | KÜHLKOKILLE ZUM VERGIEßEN VON LEICHTMETALL-GUSSWERKSTOFFEN UND VERWENDUNG EINER SOLCHEN KOKILLE SOWIE EINES GUSSEISENWERKSTOFFS |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| US20080190583A1 true US20080190583A1 (en) | 2008-08-14 |
Family
ID=36143452
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US11/815,191 Abandoned US20080190583A1 (en) | 2005-01-31 | 2006-01-27 | Chill Mould for the Casting of Light Metal Casting Materials, and the Use of Such a Mould, as Well as of a Cast Iron Material |
Country Status (15)
Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102015225588A1 (de) | 2015-12-17 | 2017-06-22 | Volkswagen Aktiengesellschaft | Gießverfahren und Kühleinsatz zur Herstellung eines Gussteiles |
| CN107090565A (zh) * | 2017-06-08 | 2017-08-25 | 含山县朝霞铸造有限公司 | 耐高温耐磨铸铁及其铸造方法 |
| CN107354373A (zh) * | 2017-06-29 | 2017-11-17 | 太仓市钧胜轧辊有限公司 | 一种用于制备轧辊的高强度铁基合金材料 |
| CN107287496A (zh) * | 2017-07-20 | 2017-10-24 | 马鞍山市万鑫铸造有限公司 | 基于奥氏体基体的高强韧球墨铸铁及其制造工艺 |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4129309A (en) * | 1976-06-18 | 1978-12-12 | Mahle Gmbh | Austenitic cast iron |
| US5931213A (en) * | 1995-09-11 | 1999-08-03 | Vaw Alucast Gmbh | Method of casting an engine block of aluminum |
Family Cites Families (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS51105921A (ja) * | 1975-03-14 | 1976-09-20 | Mitsubishi Motors Corp | Shirindaburotsukuchuzoho |
| DE2719456C2 (de) * | 1977-04-30 | 1984-09-13 | Mahle Gmbh, 7000 Stuttgart | Austenitisches Gußeisen |
| JPS5672151A (en) * | 1979-11-17 | 1981-06-16 | Toyo Chuko Kk | Pseudo flaky graphite cast iron for glass molding metal mold |
| JPS61252912A (ja) * | 1985-04-30 | 1986-11-10 | Mazda Motor Corp | エンジンのクランクシヤフト軸受構造 |
| JPS63153239A (ja) * | 1986-12-17 | 1988-06-25 | Yaskawa Electric Mfg Co Ltd | 回転電機の回転軸 |
| CH672604A5 (enrdf_load_stackoverflow) * | 1987-04-22 | 1989-12-15 | Sulzer Ag | |
| JP2602838B2 (ja) * | 1987-07-31 | 1997-04-23 | 日立金属株式会社 | 高熱膨張鋳鉄 |
| SU1507532A1 (ru) * | 1987-10-13 | 1989-09-15 | Научно-исследовательский институт автотракторных материалов | Способ изготовлени отливок поршн из алюминиевого сплава с чугунной вставкой |
| JP2832970B2 (ja) * | 1989-01-18 | 1998-12-09 | 三菱自動車工業株式会社 | シリンダブロックの鋳造方法 |
| SU1811976A1 (en) * | 1989-05-29 | 1993-04-30 | Dn Selskokhoz I | Method for producing castings from chilled cast iron |
| JPH03134132A (ja) * | 1989-10-19 | 1991-06-07 | Yamaha Motor Co Ltd | 高熱膨張係数を有する鋳鉄材 |
| JPH0760399A (ja) * | 1993-08-27 | 1995-03-07 | Toyota Motor Corp | 鋳造用金型構造 |
| DE4431713C2 (de) * | 1994-09-06 | 2001-03-15 | Audi Ag | Vorrichtung zum Herstellen von Gußstücken |
| JP2002283003A (ja) * | 2001-03-22 | 2002-10-02 | Toyota Industries Corp | 鋳造方法および鋳造用金型装置 |
| DE10242559A1 (de) * | 2002-09-13 | 2004-03-25 | Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. | Kühlkörper zur Beeinflussung der Abkühlung bei Gussteilen |
-
2005
- 2005-01-31 DE DE102005004481A patent/DE102005004481B3/de not_active Expired - Fee Related
-
2006
- 2006-01-27 CA CA002595833A patent/CA2595833A1/en not_active Abandoned
- 2006-01-27 DE DE502006004855T patent/DE502006004855D1/de active Active
- 2006-01-27 EP EP06706440A patent/EP1841554B1/de not_active Not-in-force
- 2006-01-27 ES ES06706440T patent/ES2330965T3/es active Active
- 2006-01-27 PL PL06706440T patent/PL1841554T3/pl unknown
- 2006-01-27 WO PCT/EP2006/000701 patent/WO2006081983A1/de active Application Filing
- 2006-01-27 AU AU2006210029A patent/AU2006210029B2/en not_active Ceased
- 2006-01-27 UA UAA200708774A patent/UA87349C2/ru unknown
- 2006-01-27 RU RU2007132745/02A patent/RU2422243C2/ru not_active IP Right Cessation
- 2006-01-27 AT AT06706440T patent/ATE442924T1/de not_active IP Right Cessation
- 2006-01-27 JP JP2007552581A patent/JP2008528292A/ja active Pending
- 2006-01-27 MX MX2007009008A patent/MX2007009008A/es active IP Right Grant
- 2006-01-27 US US11/815,191 patent/US20080190583A1/en not_active Abandoned
- 2006-01-27 CN CNB2006800064064A patent/CN100513007C/zh not_active Expired - Fee Related
- 2006-01-27 BR BRPI0606754-9A patent/BRPI0606754A2/pt not_active IP Right Cessation
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4129309A (en) * | 1976-06-18 | 1978-12-12 | Mahle Gmbh | Austenitic cast iron |
| US5931213A (en) * | 1995-09-11 | 1999-08-03 | Vaw Alucast Gmbh | Method of casting an engine block of aluminum |
Also Published As
| Publication number | Publication date |
|---|---|
| MX2007009008A (es) | 2007-09-14 |
| CN100513007C (zh) | 2009-07-15 |
| BRPI0606754A2 (pt) | 2009-07-14 |
| JP2008528292A (ja) | 2008-07-31 |
| RU2007132745A (ru) | 2009-03-10 |
| EP1841554B1 (de) | 2009-09-16 |
| CN101128276A (zh) | 2008-02-20 |
| AU2006210029B2 (en) | 2010-02-18 |
| WO2006081983A1 (de) | 2006-08-10 |
| PL1841554T3 (pl) | 2010-01-29 |
| CA2595833A1 (en) | 2006-08-10 |
| UA87349C2 (ru) | 2009-07-10 |
| AU2006210029A1 (en) | 2006-08-10 |
| RU2422243C2 (ru) | 2011-06-27 |
| ATE442924T1 (de) | 2009-10-15 |
| EP1841554A1 (de) | 2007-10-10 |
| DE102005004481B3 (de) | 2006-06-14 |
| ES2330965T3 (es) | 2009-12-17 |
| DE502006004855D1 (de) | 2009-10-29 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| AS | Assignment |
Owner name: HYDRO ALUMINIUM DEUTSCHLAND GMBH, GERMANY Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:TRUMPER, JURGEN;SMETAN, HERBERT;REEL/FRAME:020543/0661 Effective date: 20071022 |
|
| STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |