US20090050289A1 - Vaccuum Die-Casting Method - Google Patents
Vaccuum Die-Casting Method Download PDFInfo
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- US20090050289A1 US20090050289A1 US11/791,677 US79167705A US2009050289A1 US 20090050289 A1 US20090050289 A1 US 20090050289A1 US 79167705 A US79167705 A US 79167705A US 2009050289 A1 US2009050289 A1 US 2009050289A1
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- vacuum
- casting
- casting chamber
- phase
- carried out
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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
- B22D17/14—Machines with evacuated die cavity
-
- 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
- B22D17/02—Hot chamber machines, i.e. with heated press chamber in which metal is melted
- B22D17/04—Plunger machines
Definitions
- the invention relates to a vacuum die-casting method according to the preambles of the first and eighteenth claims.
- Die-casting under vacuum has already been used for some times for producing workpieces from metal and metal alloys in particular alloys of metals Al, Mg, Zn, and Cu.
- die-casting under vacuum a high quality of material of work-pieces is achieved as less air and gases is included in the material.
- workpieces from, e.g., aluminum, which later are subjected to heat treatment or welding one can hardly do without vacuum.
- EP-OS O 051 310 discloses a process which is known in the industry under the name Vacural ⁇ (a registered trademark of Machinenfabric Müiller-Weingart AG). This and similar later processes are carried out with a tightly closed casting chamber connected with a heat maintaining furnace by a suction pipe. Metal is aspirated into the casting chamber and is metered out by vacuum which is produced in the mold and is precisely controlled.
- the vacuum system for such a process consists essentially of a buffer vessel the vacuum in which is produced by a vacuum pump. Sometimes, the vacuum pump is directly connected, sometimes a central vacuum system is used. Further, such vacuum systems also contain interposed valves and filters and pressure measuring tools.
- Publication DE-0S 196 45 104 describes a technology which permits to obtain a higher vacuum in the mold cavity when the cavity is connected in succession with two different vacuum buffer vessels, without the need to connect the vessels with each other. This method permits to increase the stability of the process and monitory the process by end pressures of the vessels.
- the vacuum is generated with a deaeration valve secured on the mold. Only after the casting piston passes past the filing opening during the first casting phase and, thus, breaks the connection to atmosphere, the mold can be put under vacuum.
- the process time which remains after the passing of the piston past the deaeration opening, is generally not sufficient to establish pressure balance between the mold cavity and the buffer vessel or to efficiently evacuate the mold cavity with vacuum pumps.
- the achieved vacuum is adversely affected by the cross-section of the deaeration valve itself and of the connection channels which extend in the mold from the mold cavity to the deaeration valve.
- constriction in the mold itself can negatively influence the vacuum still further. Leaks, in particular between the casting piston and the casting chamber, result in worse and fluctuating vacuum values. The leaks vary greatly with wear of the piston and the casting chamber and depend from the temperature.
- an object of the invention is to provide an improved die-casting method with which larger deaeration cross-sections are possible so that a higher vacuum is achieved.
- the requirements to the piston and the mold with regard to vacuum-tightness should be reduced.
- the metering precision during filling of the casting chamber with metal or metal alloy should be increased.
- This object is achieved with a method of die-casting of metal alloys which form a cast mass under application of vacuum. It comprises the steps of:
- a hot-chamber die-casting method wherein a vacuum system is provided with at least two vacuum conduits, and which includes the steps of:
- the new method according to claim 1 or claim 18 has at least two vacuum phases in the total casting cycle, in which vacuum is produced.
- the first phase the atmosphere through the casting chamber is exhausted. This permits to use connections which have much larger cross-sections. Contrary to exhaust through the mold or the mold valve, noticeably better conductance in the vacuum system and, thereby, a better end pressure are achieved. At that, the better conductance permits to reduce the time of the first phase. Because the greater conductance permits to achieve a better vacuum sooner, it is possible, in comparison with the method according to EP-OS 0 051 310, to tolerate, at a much greater degree, the leaks in the mold and along the piston.
- the casting chamber which is closable according to the invention, enables to carry out the metal metering with high precision independent from vacuum.
- a second phase the vacuum is generated through the mold, whereby the achieved end pressure is improved.
- This phase takes place when the cavity with the metal melt is separated from the conduit to the vacuum system of the first phase. This can take place as a result of displacement of the casting piston or closing of a valve in the conduit.
- this method can be improved.
- a vacuum system with a buffer vessel for a vacuum phase it is possible to achieve such low pressures in the mold that closing of the deaeration valve is possible before the metal reaches the valve.
- an improved end pressure is achieved when the space behind the casting piston is likewise evacuated during the first and/or the second phase.
- this can be achieved when the space behind the piston forms a whole with a hood which closes the chamber or is connected therewith.
- a casting chamber, which is closed with a hood has a further advantage consisting in that after the hood is closed, vacuum generation can be started immediately with the first phase, while the piston has not yet closed the filling opening. Thereby, the process time can be reduced, while the piston can have a high speed during the first casting phase. In addition, more time remains for carrying out the second phase.
- no use is made of a closable hood.
- the separation of the casting chamber cavity from atmosphere takes place, while the piston closes the filling opening.
- the casting chamber is connected with the conduit of the first vacuum phase by a further big-dimensioned opening.
- the first vacuum phase is produced before the piston closes the second opening.
- the piston can have one or several sealing rings. This embodiment can be incorporated in existing plants without any substantial expenses.
- the sealing and separation of the casting chamber from the atmosphere take place while the two mold halves are assembled together, i.e., the mold is closed. Thereby, the number of the necessary components and openings in the casting chamber is reduced.
- the sealing and separation of the casting chamber cavity from the atmosphere can in other embodiments take place, while the casting chamber is connected with the mold. Thereby, it is possible then to separate the casting chamber and the mold from each other and to fill the casting chamber in this condition of the assembly. After filling, the mold is connected with the casting chamber. This can e.g., take place at sides of the mold with a movable ram, slide, or piston at the chamber end or in cast-in channel. Alternatively, e.g., a vertical or pivotal casting chamber can be formed, as is conventional in many “squeeze casting” plants.
- the sealing and separation of the casting chamber cavity from the atmosphere takes place with a movable cover that closes the filling opening.
- This embodiment can be rapidly closed and is particularly advantageous when metal is metered through the filling opening into the casting chamber through the pouring spout.
- the pouring spout or a connection tube between the pouring spout and the casting chamber is likewise formed movable. The combination of a metering furnace with the pouring spout is actually a most recommended metering system for most of foundries.
- the casting chamber cavity and the atmosphere are separated from each other by a (heated) closable metering pot.
- the metering pot serves as a storage vessel for a to-be-metered cast mass.
- the casting chamber can, thus, be filed with metal before, during, or after vacuumization or feeding of protective or reaction gases.
- the metering pot itself is filled through a closable opening (cover, tube, metering piston . . . ) and can itself be vacuumized or subjected to action of protective or reaction gases.
- the first conduit to the vacuum system can be connected, otherwise as descried above, to a casting chamber cover or directly to the casting chamber, also to the cast-in channel or a connected therewith, big-dimensioned channel in the mold.
- An additional valve must be mounted at the admission point in the mold in order to prevent penetration of the metal in the conduit.
- the inventive method can be used in a hot-chamber die-casting process.
- a casting ladle (gooseneck) is immersed in metal in a heat maintaining furnace. It includes, in addition to a casting chamber, a gooseneck-shaped channel which is connected with a mold via an intermediate piece and a mouthpiece.
- This unit (gooseneck, intermediate piece, mouthpiece) in a broad sense can be seen as analogue of the casting chamber cavity in the cold-chamber process.
- a first vacuum phase can be introduced, so that the already described invention is usable in hot-chamber die-casting process.
- With large cross-sections it is possible to produce vacuum so rapidly that it can take place shortly before the charging process. Thereby, it is prevented that metal is aspirated into the mold cavity by the produced vacuum already before the charging process itself.
- the method according to the present invention can advantageously be used for metal alloys which primarily contain aluminum because it is with this metal, the presence of large shares of air in the structure makes further processing (e.g., welding) more difficult if not impossible.
- FIG. 1 a cross-sectional view of a die-casting machine suitable for carrying out the method
- FIG. 2 a cross-sectional view of the casting chamber.
- the sections a through c show different phases of the process;
- FIG. 3 an embodiment of a vacuum system with several buffer vessels
- FIG. 4 an embodiment with a direct connection to the casting chamber (separation from atmosphere with the casting piston);
- FIG. 5 an embodiment with a metering spout and a closing mechanism on the filling opening
- FIG. 6 an embodiment with a closable metering pot
- FIG. 7 an embodiment of a hot-chamber die-casting.
- FIG. 1 shows a basic embodiment of a die-casting machine suitable for carrying out the inventive method.
- a mold 21 is clamped between two plates 22 .
- a to-be-finished workpiece is obtained by solidification of metal or metal alloy in the mold cavity 10 .
- a piston 3 which presses a mass of liquid metal 8 into the mold cavity as a result of its linear movement, is displaceable in a casting chamber 6 .
- the casting chamber is provided with a filing opening 4 through which the liquid metal is fed before the first vacuum phase.
- a hood 7 vacuum-tightly seals the casting chamber from outside.
- the cavity within the hood is connected by a port 11 and a first conduit 12 , in which the a valve 13 is located, with a vacuum system 20 .
- the vacuum system can be formed by an arrangement of vacuum pumps and/or buffer vessels. Vacuum is introduced over the first conduit during the first vacuum phase. A second conduit 15 is connected with a valve 16 that connects a deaeration valve 14 , which is mounted on the mold with the vacuum system 20 . Over the second conduit, the vacuum is introduced during the second vacuum phase.
- FIG. 2 a shows the first step during which metal in form of a cast mass 8 is fed into the casting chamber 6 .
- the hood 7 is pulled back, releasing the filling opening 4 .
- the hood 7 is pushed forward and vacuum-tightly closes the casting chamber cavity 5 at the piston side, the sealing is effected with a circumferential seal 2 provided on the piston rod 1 .
- the vacuum system generates, over the port 11 , vacuum which corresponds to the first vacuum phase.
- This port can have a large conductance because practically there are no spacial limitations. Thereby, the mold cavity and the casting chamber are effectively and rapidly evacuated.
- the piston 3 is pushed forward so that at the end, the filling opening 4 is closed. Thereby, the volume above the cast mass is separated from the cavity beneath the hood 7 and, therefore, from the vacuum conduit means 11 .
- the mold is evacuated via the valve 14 and the second conduit 15 in accordance with the second vacuum phase. This phase ends when the valve 14 is closed.
- valves 13 , 14 and 16 The phases can be explained with reference to the positions of valves 13 , 14 and 16 .
- the valves are closed.
- the first vacuum phase takes place.
- the filling opening becomes closed, and the vales 14 and 15 open (in most cases, the valve 14 is already open), and the second vacuum phase takes place.
- the valves 14 and 16 are closed. There, most of the aeration valves are closed by the metal itself.
- the separation of the first conduit is carried out only by closing the valve 13 , which permits to simplify the construction.
- the second vacuum phase can be carried out, independent on the position of the piston.
- a further embodiment is associated with filing of the casting chamber with metal. This need not necessarily take place before the first vacuum phase. It is conceivable to use a vacuum phase for metering of the cast mass, with the metal being aspirated into the casting chamber by vacuum, e.g., through a riser.
- the metering of the cast mass should not take place in the first vacuum phase but takes place in subsequent vacuum phases. Thereby, the reaction of the cast mass with gases in the casting chamber can be reduced, as those are reduced during the vacuum phase before filling.
- protective or reaction gases are fed into the casting chamber and/or the mold cavity.
- reactions of the cast mass with gases are prevented, e.g., oxidation of the cast mass surface is prevented to a great extent.
- gases can be fed which purposefully react with the cast mass and improve the properties of the material.
- the valve 13 can remain open. With this system, particularly low end pressure in the mold can be achieved, so that it is possible to close the deaeration valve 14 before metal reaches it.
- the sealing of the casting chamber against atmosphere is effected not by linear displacement of the hood as in FIG. 2 .
- the hood is formed as a part rotatable about the axis of the casting chamber 6 and the piston rod 1 .
- the filling opening becomes closes as a result of this rotation.
- FIG. 3 A suitable embodiment of a vacuum system 20 is shown in FIG. 3 .
- the first conduit 12 which is used in the first vacuum phase
- the second conduit 15 which is used in the second vacuum phase
- the vessels are evacuated by vacuum pumps.
- FIG. 4 shows an embodiment in which the casting chamber cavity 5 is sealed against atmosphere by the piston 3 .
- FIG. 4 a shows a process step after the liquid metal 8 has filled the casting chamber 6 .
- the casting chamber cavity 5 becomes sealed against atmosphere, and the first vacuum phase can be introduced through the port 42 of the first conduit 12 into the casting chamber 6 .
- FIG. 4 b shows the first vacuum phase.
- the valve 13 in the first conduit becomes closed or the piston passes past the port 42
- the second vacuum phase can be introduced through the deaeration valve 14 and the second conduit 15 .
- FIG. 4 c While retaining vacuum, the metal fills the mold cavity 10 under the action of the piston 3 , a shown in FIG. 4 a.
- a connection can be formed on the cast channel 41 or be realized in a form of a channel connectable herewith.
- the cast channel 41 has, as a rule, a large cross-section in the direction of the casting chamber cavity 5 .
- This connection naturally is, closed with additional valve (analogous to the deaeration valve 14 ), so that no metal can penetrate in the first vacuum conduit 12 . After this valve or the valve 13 is closed, the second vacuum phase can be introduced.
- FIG. 5 shows an embodiment in which the filling opening 4 of the casting chamber 6 can be closed with a lid 53 , and the metal 8 is metered into the casting chamber 6 over a movable pouring spout 51 .
- FIG. 5 shows the process during metering of the metal. After the casting chamber 6 is filled with the metal 8 , the pouring spout 51 is lifted off the filling opening 4 vertically upward, so that the lid 53 can pivot beneath the pouring spout 51 and can be lowered onto a lid seat 52 after a short vertical movement. This seals the filling opening 4 , and the first vacuum phase can be introduced through the first conduit 12 .
- the vertical movement of the pouring spout 51 and the rotational movement of the lid prevents the sealing surface between the lid and the lid seat from contact with the hot metal and its contamination.
- the seal 54 is preferably mounted on the underside of the lid 53 .
- a drain metal sheet 55 is mounted above the lid 53 .
- a short movable feed tube 58 can be provided, which is displaced downwardly during metering to bridge the distance between the outlet of the pouring spout 51 and the filling opening 4 . Thereby, sidewise flow of the metal or its splashing is prevented.
- the cavity behind the piston is likewise connected, in the embodiment shown in FIG. 5 , by a connection 57 with the first vacuum conduit 12 .
- FIG. 6 represent a solution that contemplates filling of the casting chamber 6 with metal 8 using the metering pot 61 .
- the metering pot simultaneously provides for separation of the casting chamber cavity 5 from atmosphere.
- the metering pot is filled with metal in the first step ( FIG. 6 a ).
- the first vacuum phase can already be introduced at a very early point in time ( FIG. 6 b ). This takes place in this embodiment over the first vacuum phase conduit 12 .
- the metering pot cavity 63 can be brought to a certain underpressure. By pulling the plug 62 , the metal is metered into the casting chamber 6 through the filling opening 4 . An eventually occurring (positive) pressure difference between the metering pot cavity 63 and the casting chamber cavity 5 would accelerate the metering process.
- a further vacuum phase is introduced.
- FIG. 6 a shows a modification of the metering pot 61 with a closable lid 64 .
- the lid can be open after the plug 62 reliably closes the through-opening. It makes sense to wait with opening of the lid until the piston 3 passes past the filling opening 4 in order not to jeopardize the tightness of the casting chamber cavity 5 by a possible leakage at the plug 62 . Then, the metering pot 61 is filled again with the cast mass 8 by an arbitrary point in time. In case, e.g., the metering pot cavity 63 is under a protective gas, the metering pot 61 can be filled through a closable tube or a metering piston instead through a closable lid 64 .
- a closable metering tube or a metering piston can be excused.
- FIG. 7 An embodiment for a hot-chamber method is shown in FIG. 7 .
- the casting ladle (gooseneck) 74 is immersed in metal that fills a heat maintaining furnace 71 .
- the casting ladle 74 has a casting chamber 73 having a filing opening 72 that connects the casting chamber 72 with the metal bath in the heat maintaining furnace.
- the casting ladle has also a gooseneck-shaped channel that connects the casting ladle through an intermediate piece 75 and a mouthpiece (heated) 76 with the mold 21 .
- FIG. 7 a shows an initial position in which the piston 3 is in its initial position and the metal in the casting ladle 74 is at the same level as in the heat maintaining furnace 71 .
- a second step the piston 3 closes the filling opening 72 so that no metal can flow.
- the conduit 12 can introduce a first vacuum phase ( FIG. 1 b ).
- an additional valve (piston) 77 becomes closed, so that no metal can flow in the first conduit 12 to the vacuum system.
- a second vacuum phase can be introduced over the conventional deaeration valve and the second conduit 15 .
- FIG. 7 c the piston 3 advances the metal further into the mold over the intermediate piece 75 and the mouthpiece 76 .
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Abstract
The invention relates to an improved vacuum die-casting, in particular for metals and metal alloys which contain Al, Mg, Zn, and Cu. In order to improve the quality of the components, it is proposed to produce vacuum in the mold cavity and the casting chamber cavity in several phases of the die-casting process. The use of the new method is contemplated for both cold-chamber and hot-chamber die-casting.
Description
- The invention relates to a vacuum die-casting method according to the preambles of the first and eighteenth claims.
- Die-casting under vacuum has already been used for some times for producing workpieces from metal and metal alloys in particular alloys of metals Al, Mg, Zn, and Cu. By die-casting under vacuum, a high quality of material of work-pieces is achieved as less air and gases is included in the material. For workpieces from, e.g., aluminum, which later are subjected to heat treatment or welding, one can hardly do without vacuum.
- In addition, die-casting under vacuum not only possible with use of liquid alloys, but can also be used with other different particular processes. As examples, one can name here: processes in which semi-liquid or doughy materials are used as a cast mass (usually called thixo casting or rheocasting), processes in which the cast mass consists of a material combination (composition) of liquid or semi-liquid metals and non-metal inclusions (MMC), and processes in which liquid material infiltrates a head piece.
- Publication EP-OS O 051 310 discloses a process which is known in the industry under the name Vacural© (a registered trademark of Machinenfabric Müiller-Weingarten AG). This and similar later processes are carried out with a tightly closed casting chamber connected with a heat maintaining furnace by a suction pipe. Metal is aspirated into the casting chamber and is metered out by vacuum which is produced in the mold and is precisely controlled.
- The vacuum system for such a process consists essentially of a buffer vessel the vacuum in which is produced by a vacuum pump. Sometimes, the vacuum pump is directly connected, sometimes a central vacuum system is used. Further, such vacuum systems also contain interposed valves and filters and pressure measuring tools.
- Publication DE-0S 196 45 104 describes a technology which permits to obtain a higher vacuum in the mold cavity when the cavity is connected in succession with two different vacuum buffer vessels, without the need to connect the vessels with each other. This method permits to increase the stability of the process and monitory the process by end pressures of the vessels.
- In the simplest form of the vacuum die-casting, the vacuum is generated with a deaeration valve secured on the mold. Only after the casting piston passes past the filing opening during the first casting phase and, thus, breaks the connection to atmosphere, the mold can be put under vacuum. The process time, which remains after the passing of the piston past the deaeration opening, is generally not sufficient to establish pressure balance between the mold cavity and the buffer vessel or to efficiently evacuate the mold cavity with vacuum pumps. Further, the achieved vacuum is adversely affected by the cross-section of the deaeration valve itself and of the connection channels which extend in the mold from the mold cavity to the deaeration valve. Also, constriction in the mold itself can negatively influence the vacuum still further. Leaks, in particular between the casting piston and the casting chamber, result in worse and fluctuating vacuum values. The leaks vary greatly with wear of the piston and the casting chamber and depend from the temperature.
- In the process according to EP-0S 051 310, these drawbacks are partially eliminated by applying vacuum already during filling of metal and, thus, more time is available for achieving a lower vacuum. Nevertheless, the metering precision is greatly influenced by the vacuum value, temperature and viscosity of the melt, and condition of the openings through which metal flows. Also, an expensive control is not able to completely overcome difficulties associated with metering.
- In addition, this process requires an expensive and careful sealing of the mold and piston because they remain longer under vacuum then at a conventional vacuum die-casting, and leaks have a greater influence.
- Accordingly, an object of the invention is to provide an improved die-casting method with which larger deaeration cross-sections are possible so that a higher vacuum is achieved. The requirements to the piston and the mold with regard to vacuum-tightness should be reduced. The metering precision during filling of the casting chamber with metal or metal alloy should be increased.
- This object is achieved with a method of die-casting of metal alloys which form a cast mass under application of vacuum. It comprises the steps of:
-
- a filling the casting chamber (6) with the cast mass (8),
- b sealing a casting chamber cavity (5) against atmosphere, whereby the steps a and b can be exchanged, and is characterized in that after sealing and separating the casting chamber cavity (5) from atmosphere, a first vacuum phase is carried out, and a second or further vacuum phases are carried out after separation of the casting chamber cavity (5) from a first conduit to a vacuum system (12).
- Further claims disclose further embodiments.
- The object is also achieved with a hot-chamber die-casting method wherein a vacuum system is provided with at least two vacuum conduits, and which includes the steps of:
-
- 1. Displacing a casting piston so that a filling opening (72) is closed; 2. Producing vacuum in a casting ladle (74), an intermediate piece (75), a mouthpiece (76) and a mold cavity via a first vacuum conduit (12), characterized in that 3) a first vacuum phase is carried out after the casting piston passes past the filling opening (12); 4) thereafter, the connection with the first vacuum conduit (12) is broken; and 5) finally, a second vacuum phase is carried out.
- The new method according to
claim 1 orclaim 18 has at least two vacuum phases in the total casting cycle, in which vacuum is produced. In the first phase, the atmosphere through the casting chamber is exhausted. This permits to use connections which have much larger cross-sections. Contrary to exhaust through the mold or the mold valve, noticeably better conductance in the vacuum system and, thereby, a better end pressure are achieved. At that, the better conductance permits to reduce the time of the first phase. Because the greater conductance permits to achieve a better vacuum sooner, it is possible, in comparison with the method according to EP-OS 0 051 310, to tolerate, at a much greater degree, the leaks in the mold and along the piston. The casting chamber, which is closable according to the invention, enables to carry out the metal metering with high precision independent from vacuum. - According to the invention, in a second phase, the vacuum is generated through the mold, whereby the achieved end pressure is improved. This phase takes place when the cavity with the metal melt is separated from the conduit to the vacuum system of the first phase. This can take place as a result of displacement of the casting piston or closing of a valve in the conduit.
- With a low end pressure in the mold, the amount of gases confined in the structure of the produced component is reduced. High metal pressures, which were required up to now, can, therefore, be reduced because the remaining residual gas must be compressed to a lesser degree to achieve the same quality of the structure. The method enables to improve the quality of the component at die-casting of metal and metal alloys.
- In further embodiments, this method can be improved. By using a vacuum system with a buffer vessel for a vacuum phase, it is possible to achieve such low pressures in the mold that closing of the deaeration valve is possible before the metal reaches the valve.
- According to a further embodiment, an improved end pressure is achieved when the space behind the casting piston is likewise evacuated during the first and/or the second phase. In one of the embodiments, this can be achieved when the space behind the piston forms a whole with a hood which closes the chamber or is connected therewith. A casting chamber, which is closed with a hood has a further advantage consisting in that after the hood is closed, vacuum generation can be started immediately with the first phase, while the piston has not yet closed the filling opening. Thereby, the process time can be reduced, while the piston can have a high speed during the first casting phase. In addition, more time remains for carrying out the second phase.
- In yet another embodiment, no use is made of a closable hood. The separation of the casting chamber cavity from atmosphere takes place, while the piston closes the filling opening. The casting chamber is connected with the conduit of the first vacuum phase by a further big-dimensioned opening. The first vacuum phase is produced before the piston closes the second opening. The piston can have one or several sealing rings. This embodiment can be incorporated in existing plants without any substantial expenses.
- Alternatively, in one of the embodiments, the sealing and separation of the casting chamber from the atmosphere take place while the two mold halves are assembled together, i.e., the mold is closed. Thereby, the number of the necessary components and openings in the casting chamber is reduced.
- The sealing and separation of the casting chamber cavity from the atmosphere can in other embodiments take place, while the casting chamber is connected with the mold. Thereby, it is possible then to separate the casting chamber and the mold from each other and to fill the casting chamber in this condition of the assembly. After filling, the mold is connected with the casting chamber. This can e.g., take place at sides of the mold with a movable ram, slide, or piston at the chamber end or in cast-in channel. Alternatively, e.g., a vertical or pivotal casting chamber can be formed, as is conventional in many “squeeze casting” plants.
- Further, the sealing and separation of the casting chamber cavity from the atmosphere takes place with a movable cover that closes the filling opening. This embodiment can be rapidly closed and is particularly advantageous when metal is metered through the filling opening into the casting chamber through the pouring spout. The pouring spout or a connection tube between the pouring spout and the casting chamber is likewise formed movable. The combination of a metering furnace with the pouring spout is actually a most recommended metering system for most of foundries.
- In one of the embodiments in which the metering pot is mounted on the filling opening, the casting chamber cavity and the atmosphere are separated from each other by a (heated) closable metering pot. Here, the metering pot serves as a storage vessel for a to-be-metered cast mass. Thereby, the metering process is made independent from the remainder of the casting process. The casting chamber can, thus, be filed with metal before, during, or after vacuumization or feeding of protective or reaction gases. The metering pot itself is filled through a closable opening (cover, tube, metering piston . . . ) and can itself be vacuumized or subjected to action of protective or reaction gases.
- Independent of the used method, in order to separate the casting chamber cavity from the atmosphere, the first conduit to the vacuum system can be connected, otherwise as descried above, to a casting chamber cover or directly to the casting chamber, also to the cast-in channel or a connected therewith, big-dimensioned channel in the mold. An additional valve must be mounted at the admission point in the mold in order to prevent penetration of the metal in the conduit.
- According to a further embodiment, the inventive method can be used in a hot-chamber die-casting process. With this process, mostly, magnesium, zinc, or lead-based metal alloys are cast. Hear, a casting ladle (gooseneck) is immersed in metal in a heat maintaining furnace. It includes, in addition to a casting chamber, a gooseneck-shaped channel which is connected with a mold via an intermediate piece and a mouthpiece. This unit (gooseneck, intermediate piece, mouthpiece) in a broad sense can be seen as analogue of the casting chamber cavity in the cold-chamber process. By a connection to this unit, a first vacuum phase can be introduced, so that the already described invention is usable in hot-chamber die-casting process. With large cross-sections, it is possible to produce vacuum so rapidly that it can take place shortly before the charging process. Thereby, it is prevented that metal is aspirated into the mold cavity by the produced vacuum already before the charging process itself.
- The method according to the present invention can advantageously be used for metal alloys which primarily contain aluminum because it is with this metal, the presence of large shares of air in the structure makes further processing (e.g., welding) more difficult if not impossible.
- The invention will be explained in detail based on the following description and drawings.
-
FIG. 1 a cross-sectional view of a die-casting machine suitable for carrying out the method; -
FIG. 2 a cross-sectional view of the casting chamber. The sections a through c show different phases of the process; -
FIG. 3 an embodiment of a vacuum system with several buffer vessels; -
FIG. 4 an embodiment with a direct connection to the casting chamber (separation from atmosphere with the casting piston); -
FIG. 5 an embodiment with a metering spout and a closing mechanism on the filling opening; -
FIG. 6 an embodiment with a closable metering pot; and -
FIG. 7 an embodiment of a hot-chamber die-casting. -
FIG. 1 shows a basic embodiment of a die-casting machine suitable for carrying out the inventive method. Amold 21 is clamped between twoplates 22. A to-be-finished workpiece is obtained by solidification of metal or metal alloy in themold cavity 10. Apiston 3, which presses a mass ofliquid metal 8 into the mold cavity as a result of its linear movement, is displaceable in acasting chamber 6. The casting chamber is provided with afiling opening 4 through which the liquid metal is fed before the first vacuum phase. Ahood 7 vacuum-tightly seals the casting chamber from outside. The cavity within the hood is connected by aport 11 and afirst conduit 12, in which the avalve 13 is located, with avacuum system 20. The vacuum system can be formed by an arrangement of vacuum pumps and/or buffer vessels. Vacuum is introduced over the first conduit during the first vacuum phase. Asecond conduit 15 is connected with avalve 16 that connects adeaeration valve 14, which is mounted on the mold with thevacuum system 20. Over the second conduit, the vacuum is introduced during the second vacuum phase. - The method with two vacuum phases will be explained in detail with reference to
FIG. 2 .FIG. 2 a shows the first step during which metal in form of acast mass 8 is fed into thecasting chamber 6. In this step, thehood 7 is pulled back, releasing the fillingopening 4. In the next step inFIG. 2 b, thehood 7 is pushed forward and vacuum-tightly closes thecasting chamber cavity 5 at the piston side, the sealing is effected with acircumferential seal 2 provided on thepiston rod 1. Only then, the vacuum system generates, over theport 11, vacuum which corresponds to the first vacuum phase. This port can have a large conductance because practically there are no spacial limitations. Thereby, the mold cavity and the casting chamber are effectively and rapidly evacuated. Between the second and third steps, thepiston 3 is pushed forward so that at the end, the fillingopening 4 is closed. Thereby, the volume above the cast mass is separated from the cavity beneath thehood 7 and, therefore, from the vacuum conduit means 11. In the third step, the mold is evacuated via thevalve 14 and thesecond conduit 15 in accordance with the second vacuum phase. This phase ends when thevalve 14 is closed. - The phases can be explained with reference to the positions of
valves hood 7 is pushed forward, the casting chamber becomes sealed against the atmosphere, and thevalve 13 opens, the first vacuum phase takes place. After the displacement of the piston, the filling opening becomes closed, and thevales valve 14 is already open), and the second vacuum phase takes place. When the mold is filled with metal, thevalves - In a simplified embodiment, the separation of the first conduit is carried out only by closing the
valve 13, which permits to simplify the construction. After closing, the second vacuum phase can be carried out, independent on the position of the piston. - A further embodiment is associated with filing of the casting chamber with metal. This need not necessarily take place before the first vacuum phase. It is conceivable to use a vacuum phase for metering of the cast mass, with the metal being aspirated into the casting chamber by vacuum, e.g., through a riser.
- The metering of the cast mass should not take place in the first vacuum phase but takes place in subsequent vacuum phases. Thereby, the reaction of the cast mass with gases in the casting chamber can be reduced, as those are reduced during the vacuum phase before filling.
- In an advantageous embodiment, instead of one vacuum phase, protective or reaction gases are fed into the casting chamber and/or the mold cavity. As a result, reactions of the cast mass with gases are prevented, e.g., oxidation of the cast mass surface is prevented to a great extent. Also, gases can be fed which purposefully react with the cast mass and improve the properties of the material.
- In an advantageous embodiment, after the first vacuum phase, no aeration of the cavity within the hood takes place. The vacuum during one or several further vacuum phases can remain. Therefore, the leaks along the piston are less critical, and possible leaks do not lead to a dramatic deterioration of vacuum.
- The
valve 13 can remain open. With this system, particularly low end pressure in the mold can be achieved, so that it is possible to close thedeaeration valve 14 before metal reaches it. - In a further embodiment, the sealing of the casting chamber against atmosphere is effected not by linear displacement of the hood as in
FIG. 2 . Rather, in this embodiment, the hood is formed as a part rotatable about the axis of thecasting chamber 6 and thepiston rod 1. The filling opening becomes closes as a result of this rotation. Such a hood proved to be advantageous, having a shorter length and a shorter closing time. - A suitable embodiment of a
vacuum system 20 is shown inFIG. 3 . Thefirst conduit 12, which is used in the first vacuum phase, and thesecond conduit 15, which is used in the second vacuum phase, are connected, respectively, withvacuum buffer vessels common pump 19 with which the vessels can be evacuated independently from each other in accordance with switching of thevalve 23. - Advantageously, a separate vacuum buffer vessel is provided for each phase.
FIG. 4 shows an embodiment in which thecasting chamber cavity 5 is sealed against atmosphere by thepiston 3.FIG. 4 a shows a process step after theliquid metal 8 has filled thecasting chamber 6. After thepiston 3 passed past the fillingopening 4, the castingchamber cavity 5 becomes sealed against atmosphere, and the first vacuum phase can be introduced through theport 42 of thefirst conduit 12 into thecasting chamber 6. This step is shown inFIG. 4 b. When thevalve 13 in the first conduit becomes closed or the piston passes past theport 42, the second vacuum phase can be introduced through thedeaeration valve 14 and thesecond conduit 15. This condition is shown inFIG. 4 c. While retaining vacuum, the metal fills themold cavity 10 under the action of thepiston 3, a shown inFIG. 4 a. - Alternatively to the
port 42, a connection can be formed on thecast channel 41 or be realized in a form of a channel connectable herewith. Thecast channel 41 has, as a rule, a large cross-section in the direction of thecasting chamber cavity 5. This connection, naturally is, closed with additional valve (analogous to the deaeration valve 14), so that no metal can penetrate in thefirst vacuum conduit 12. After this valve or thevalve 13 is closed, the second vacuum phase can be introduced. -
FIG. 5 shows an embodiment in which thefilling opening 4 of thecasting chamber 6 can be closed with alid 53, and themetal 8 is metered into thecasting chamber 6 over a movable pouringspout 51.FIG. 5 shows the process during metering of the metal. After thecasting chamber 6 is filled with themetal 8, the pouringspout 51 is lifted off the fillingopening 4 vertically upward, so that thelid 53 can pivot beneath the pouringspout 51 and can be lowered onto alid seat 52 after a short vertical movement. This seals the fillingopening 4, and the first vacuum phase can be introduced through thefirst conduit 12. - The vertical movement of the pouring
spout 51 and the rotational movement of the lid prevents the sealing surface between the lid and the lid seat from contact with the hot metal and its contamination. Theseal 54 is preferably mounted on the underside of thelid 53. In order to eventually collect the draining metal, adrain metal sheet 55 is mounted above thelid 53. - Alternatively to movement of the pouring
spout 51, a shortmovable feed tube 58 can be provided, which is displaced downwardly during metering to bridge the distance between the outlet of the pouringspout 51 and the fillingopening 4. Thereby, sidewise flow of the metal or its splashing is prevented. - The cavity behind the piston is likewise connected, in the embodiment shown in
FIG. 5 , by aconnection 57 with thefirst vacuum conduit 12. - The embodiment of
FIG. 6 represent a solution that contemplates filling of thecasting chamber 6 withmetal 8 using themetering pot 61. The metering pot simultaneously provides for separation of thecasting chamber cavity 5 from atmosphere. - The metering pot is filled with metal in the first step (
FIG. 6 a). After themold 21 is closed, the first vacuum phase can already be introduced at a very early point in time (FIG. 6 b). This takes place in this embodiment over the firstvacuum phase conduit 12. Independent therefrom, alternatively, themetering pot cavity 63 can be brought to a certain underpressure. By pulling theplug 62, the metal is metered into thecasting chamber 6 through the fillingopening 4. An eventually occurring (positive) pressure difference between themetering pot cavity 63 and thecasting chamber cavity 5 would accelerate the metering process. After filling with metal and closing the valve (13) in the first conduit, immediately thereafter a further vacuum phase is introduced. -
FIG. 6 a shows a modification of themetering pot 61 with aclosable lid 64. The lid can be open after theplug 62 reliably closes the through-opening. It makes sense to wait with opening of the lid until thepiston 3 passes past the fillingopening 4 in order not to jeopardize the tightness of thecasting chamber cavity 5 by a possible leakage at theplug 62. Then, themetering pot 61 is filled again with thecast mass 8 by an arbitrary point in time. In case, e.g., themetering pot cavity 63 is under a protective gas, themetering pot 61 can be filled through a closable tube or a metering piston instead through aclosable lid 64. - In another embodiment, instead of a metering pot, a closable metering tube or a metering piston can be excused.
- An embodiment for a hot-chamber method is shown in
FIG. 7 . As it is conventional with the use of the hot-chamber method, the casting ladle (gooseneck) 74 is immersed in metal that fills aheat maintaining furnace 71. The castingladle 74 has a castingchamber 73 having afiling opening 72 that connects the castingchamber 72 with the metal bath in the heat maintaining furnace. The casting ladle has also a gooseneck-shaped channel that connects the casting ladle through anintermediate piece 75 and a mouthpiece (heated) 76 with themold 21.FIG. 7 a shows an initial position in which thepiston 3 is in its initial position and the metal in the castingladle 74 is at the same level as in theheat maintaining furnace 71. In a second step, thepiston 3 closes the fillingopening 72 so that no metal can flow. At this time, theconduit 12 can introduce a first vacuum phase (FIG. 1 b). Before the metal raises up to theintermediate piece 75, an additional valve (piston) 77 becomes closed, so that no metal can flow in thefirst conduit 12 to the vacuum system. By this time, a second vacuum phase can be introduced over the conventional deaeration valve and thesecond conduit 15. This step is shown inFIG. 7 c. In the lastFIG. 7 d, thepiston 3 advances the metal further into the mold over theintermediate piece 75 and themouthpiece 76.
Claims (21)
1. A method of die-casting of metal, metal alloys, which form a cast mass, under application of vacuum, comprising the steps of:
a: filling the casting chamber (6) with the cast mass (8),
b: sealing a casting chamber cavity (5) against atmosphere, whereby the steps a and b can be exchanged,
characterized in that
after sealing and separating the casting chamber cavity (5) from atmosphere, a first vacuum phase is carried out,
a second or further vacuum phases are carried out after separation of the casting chamber cavity (5) from a first conduit to vacuum system (12).
2. A die-casting method according to claim 1 , wherein sealing and separation of the casting chamber cavity (5) from atmosphere takes place by closing the mold (21).
3. A method according to claim 1 , characterized in that sealing and separation of the casting chamber cavity (5) from atmosphere is carried out by connecting the casting chamber (6) with the mold.
4. A method according to claim 1 characterized in that the sealing and separation of the casting chamber (5) is carried out by closing a filling opening (4) with a casting piston (3).
5. A method according to claim 1 , characterized in that separation of the casting chamber cavity (5) from atmosphere is carried out with a cover closable from outside.
6. A method according to claim 5 , characterized in that sealing of the casting chamber cavity (5) is carried out by a linear movement of a hood (7).
7. A method according to claim 5 , characterized in that sealing of the casting chamber cavity (5) is carried out by a linear movement of a hood (7).
8. A method according to claim 1 , characterized in that metering of the cast mass (8) takes place before carrying out the first vacuum phase.
9. A method according to claim 1 , characterized in that metering of the cast mass (8) takes place during or by means of a vacuum phase.
10. A method according to claim 1 , characterized in that metering of the cast mass (8) takes place after carrying out a preceding vacuum phase.
11. A method according to claim 1 , characterized in that instead of a vacuum phase, protective or reaction gases are fed into the casting chamber and/or a mold cavity or such a phase is interposed.
12. A method according to claim 1 , characterized in that the filling opening (4) is closed by displacement of the piston.
13. A method according to claim 1 , characterized in that separation of the casting chamber cavity (5) from the first conduit to the vacuum system (12) is carried out by closing a valve (13).
14. A method according to claim 1 , characterized in that separation of the casting chamber cavity (5) from the first conduit to the vacuum system (12) is carried out by displacement of the casting piston (3).
15. A method according to claim 1 , characterized in that vacuum, which remains behind the casting piston (3) after the first vacuum phase, remains in at least one further phase.
16. A method according to claim 1 , characterized in that vacuum, which is necessary for several vacuum phases, is produced with a respective buffer vessel (17, 18).
17. A method according to claim 16 , characterized in that the buffer vessels (17, 18) are evacuated by a common arrangement of vacuum pumps (19).
18. A hot-chamber die-casting method, wherein a vacuum system is provided with at least two vacuum conduits, including the steps of:
1. Displacing a casting piston so that a filing opening (72) is closed
2. Producing vacuum in a casting ladle (74), an intermediate piece (75), a mouthpiece (76) and a mold cavity via a first vacuum conduit (12)
characterized in that
3. a first vacuum phase is carried out after the casting piston passes past the filling opening (3)
4. thereafter, the connection with the first vacuum conduit (12) is broken
5. finally, a second vacuum phase is carried out.
19. A hot-chamber die-casting method according to claim 18 , characterized in that an additional valve (77) prevents penetration of metal in the first conduit (12).
20. A hot-chamber die-casting method according to claim 19 , characterized in that the additional valve (77) is provided on the intermediate piece (75) located between the casting ladder (74) and the mouthpiece (76).
21. A method according to claim 17 , characterized in that cast mass (8) contains aluminum as a major component.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102004057324A DE102004057324A1 (en) | 2004-11-27 | 2004-11-27 | Vacuum die casting process |
DE102004057324.7 | 2004-11-27 | ||
PCT/EP2005/012503 WO2006056410A1 (en) | 2004-11-27 | 2005-11-23 | Vacuum die-casting method |
Publications (1)
Publication Number | Publication Date |
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US20090050289A1 true US20090050289A1 (en) | 2009-02-26 |
Family
ID=35825345
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/791,677 Abandoned US20090050289A1 (en) | 2004-11-27 | 2005-11-23 | Vaccuum Die-Casting Method |
Country Status (4)
Country | Link |
---|---|
US (1) | US20090050289A1 (en) |
EP (1) | EP1819465B1 (en) |
DE (1) | DE102004057324A1 (en) |
WO (1) | WO2006056410A1 (en) |
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Also Published As
Publication number | Publication date |
---|---|
WO2006056410A1 (en) | 2006-06-01 |
DE102004057324A1 (en) | 2006-06-01 |
EP1819465A1 (en) | 2007-08-22 |
EP1819465B1 (en) | 2013-02-27 |
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