US20090120538A1 - Aluminum die cast product and method for manufacturing same - Google Patents

Aluminum die cast product and method for manufacturing same Download PDF

Info

Publication number
US20090120538A1
US20090120538A1 US12/155,170 US15517008A US2009120538A1 US 20090120538 A1 US20090120538 A1 US 20090120538A1 US 15517008 A US15517008 A US 15517008A US 2009120538 A1 US2009120538 A1 US 2009120538A1
Authority
US
United States
Prior art keywords
aluminum die
cooling medium
die cast
cast product
core pin
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
Application number
US12/155,170
Other languages
English (en)
Inventor
Masafumi Hamasaki
Kazuhiko Inoguchi
Masaya Hatanaka
Masaki Kawasaki
Shinji Saho
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.)
Mitsubishi Heavy Industries Ltd
Original Assignee
Mitsubishi Heavy Industries Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Mitsubishi Heavy Industries Ltd filed Critical Mitsubishi Heavy Industries Ltd
Assigned to MITSUBISHI HEAVY INDUSTRIES, LTD. reassignment MITSUBISHI HEAVY INDUSTRIES, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HAMASAKI, MASAFUMI, HATANAKA, MASAYA, INOGUCHI, KAZUHIKO, KAWASAKI, MASAKI, SAHO, SHINJI
Publication of US20090120538A1 publication Critical patent/US20090120538A1/en
Abandoned legal-status Critical Current

Links

Images

Classifications

    • 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/002—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working by rapid cooling or quenching; cooling agents used therefor
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon

Definitions

  • the present invention relates to an aluminum die cast product that can be advantageously used, e.g., for a pressure container that requires high airtightness, as in a compressor housing, and to a method for manufacturing the aluminum die cast product.
  • a solidification shrinkage space is known to occur in aluminum die cast products as a result of solidification shrinkage of a melt injected into a die during die cast molding.
  • a volume shrinkage of about 6% occurs during solidification.
  • Shrinkage cavities occur due to inclusion of such shrinkage spaces in the product, and the shrinkage cavities become casting defects. Shrinkage cavities tend to expand to a wide range where the cast portion has a large thickness or a low cooling rate.
  • the cooling rate of a portion located close to the surface (casting surface) that is in contact with a die is generally high and, therefore, a region with a small number of defects that is called a chill layer is formed at the casting surface.
  • a region with a small number of defects that is called a chill layer is formed at the casting surface.
  • shrinkage cavities occurring due to solidification shrinkage are formed therein. In most cases, the shrinkage cavities are formed via three-dimensional expansion.
  • a port hole for taking in and discharging a cooling gas and a screw hole for attaching a fitting serving to connect a pipe to the port hole are provided in a thick portion that is thicker than other portions of the housing.
  • Cast holes obtained by die casting using core pins usually serve as rough holes for the port hole and screw hole, and because the dimensional accuracy of as-cast products is low, machining is typically performed with a cutting allowance of about 0.5 mm.
  • the shrinkage cavity defects sometimes appear inside, as described hereinabove.
  • the shrinkage cavity defects are exposed on the cut surface after the cutting, thereby creating a risk of the inside and outside of the housing, or the port hole and screw hole being linked to each other. This can cause pressure leak or cooling gas leak and becomes an important reason for the decrease in the product yield.
  • a local pressurization method and a local cooling method are known as methods for inhibiting the occurrence of shrinkage cavity defects in the thick portions, and it has been empirically established that the occurrence of shrinkage cavity defects can be inhibited by intensifying local cooling.
  • a core pin for die casting a cast holes has been suggested (see, for example, Japanese Unexamined Patent Application, Publication No. Hei 9-323149), the pin having a configuration in which a cooling water path is formed by fitting a cooling water pipe into the core pin body and cooling water is forced to flow in the cooling water path, and a process of casting a rough hole for a bolt hole provided in a cylinder block has been described as an example.
  • the present invention was created with the foregoing in view, and it is an object of the present invention to provide an aluminum die cast product, e.g., a pressure vessel that requires high airtightness, in which pressure leak or gas leak ratio can be reduced and the product yield can be increased and also to provide a method for manufacturing the product.
  • an aluminum die cast product e.g., a pressure vessel that requires high airtightness, in which pressure leak or gas leak ratio can be reduced and the product yield can be increased and also to provide a method for manufacturing the product.
  • the aluminum die cast product and method for manufacture thereof in accordance with the present invention utilize the following means to resolve the above-described problems.
  • the aluminum die cast product in accordance with the present invention is an aluminum die cast product in which a cast hole is formed by a core pin in a thick portion that is made thicker than other portions, wherein a chill layer with a secondary dendrite arm spacing of at least 5.5 ⁇ m or less is provided at the surface of the cast hole.
  • a chill layer can be formed in which shrinkage cavity defects that cause pressure leak or gas leak do not appear on the casting surface.
  • a chill layer with a secondary dendrite arm spacing of at least 5.5 ⁇ m or less is provided at the surface of cast holes in the aluminum die cast product in which cast holes are formed by core pins. Therefore, where the cast holes serve as rough holes, the shrinkage cavity defects are not exposed on the surface thereof and the occurrence of pressure leak or gas leak via the cast holes can be reliably inhibited. Therefore, when a pressure vessel or the like is manufactured, the yield thereof can be greatly increased.
  • the secondary dendrite arm spacing is a distance between the centers of the adjacent secondary dendrite arms and represented by an average value of secondary dendrite arm spacing in a portion where four or more secondary dendrite arms are continuously arranged side by side. More specifically, a portion in which four or more secondary dendrite arms are arranged side by side is selected, a total of n (n is 4 or more) spacings l of secondary dendrite arm spacings are measured, and l/(n ⁇ 1) is found. The measurements are performed in three or more locations and an arithmetical average of the results is found.
  • the aluminum die cast product in accordance with the present invention is the above-described aluminum die cast product in which a thickness of a chill layer with a secondary dendrite arm spacing of at least 5.5 ⁇ m or less is made larger than a cutting allowance of the cast hole that is set in advance.
  • the thickness of the chill layer with a secondary dendrite arm spacing of at least 5.5 ⁇ m or less is made larger than a cutting allowance of the cast hole that is set in advance. Therefore, even when the cast hole is machined as a rough hole by cutting, the machining surface thereof can be confined within a range of the chill layer with a secondary dendrite arm spacing of at least 5.5 ⁇ m or less in which the shrinkage cavity defects have not occurred. Therefore, the shrinkage cavity defects are not exposed on the cutting surface, and the occurrence of pressure leak or gas leak directly from the cast hole portion or via a screw hole, or the like, adjacent to the cast hole portion can be reliably inhibited.
  • the aluminum die cast product in accordance with the present invention is the above-described aluminum die cast product in which the chill layer with a secondary dendrite arm spacing of at least 5.5 ⁇ m or less remains after cutting performed with the aforementioned cutting allowance.
  • the chill layer with a secondary dendrite arm spacing of at least 5.5 ⁇ m or less remains after cutting performed with the cutting allowance, the chill layer in which no shrinkage cavity defects have occurred remains at the cast hole surface in the product after cutting. Therefore, the exposure of shrinkage cavity defects on the cutting surface can be reliably prevented and the occurrence of pressure leak or gas leak directly from the cast hole portion or via a screw hole, or the like, adjacent to the cast hole portion can be reliably inhibited.
  • the aluminum die cast product in accordance with the present invention is any of the above-described aluminum die cast products in which the thickness of the chill layer with a secondary dendrite arm spacing of at least 5.5 ⁇ m or less is at least 0.5 mm or more.
  • the thickness of the chill layer with a secondary dendrite arm spacing of at least 5.5 ⁇ m or less is at least 0.5 mm or more, the thickness of the chill layer with a secondary dendrite arm spacing of at least 5.5 ⁇ m or less can be made larger than the cutting allowance of aluminum die cast products that is generally set to 0.5 mm or less.
  • the chill layer in which no shrinkage cavity defects have occurred can be reliably left at the surface of cast hole after cutting. Therefore, the shrinkage cavity defects are not exposed on the cutting surface and the occurrence of pressure leak or gas leak directly from the cast hole portion or via a screw hole, or the like, adjacent to the cast hole portion can be reliably inhibited.
  • the aluminum die cast product in accordance with the present invention is any of the above-described aluminum die cast products in which the aluminum die cast product is a pressure vessel.
  • the aluminum die cast product is a pressure vessel
  • a pressure vessel can be obtained in which no internal fluid leak occurs from the cast hole via the shrinkage cavity defects. Therefore, when an aluminum die cast pressure vessel is manufactured, the yield thereof can be greatly increased and a high-quality pressure vessel can be obtained at a low cost.
  • the aluminum die cast product in accordance with the present invention is the above-described aluminum die cast product in which the pressure vessel is a compressor housing.
  • the pressure vessel is a compressor housing
  • the method for manufacturing an aluminum die cast product in accordance with the present invention is a method for manufacturing an aluminum die cast product in which a cast hole is formed by a core pin in a thick portion that is made thicker than other portions, wherein a chill layer with a secondary dendrite arm spacing of at least 5.5 ⁇ m or less is formed to a thickness equal to, or larger than a predetermined thickness at the cast hole surface by passing a flow of a cooling medium through the core pin and locally cooling the cast hole.
  • the temperature gradient during melt solidification shrinkage can be increased. Therefore, the growth of dendrites can be inhibited and the chill layer with a secondary dendrite arm spacing of at least 5.5 ⁇ m or less can be formed to a thickness equal to, or larger than a predetermined thickness at the cast hole surface.
  • the chill layer with a secondary dendrite arm spacing of at least 5.5 ⁇ m or less can be formed to a thickness equal to, or larger than a predetermined thickness at the cast hole surface.
  • the method for manufacturing an aluminum die cast product in accordance with the present invention is the above-described method for manufacturing an aluminum die cast product in which a core pin with a double-pipe structure in which a central pipe is inserted into a hollow core pin body is used as the core pin, the cooling medium is supplied from the central pipe to a distal end portion of the core pin, the cooling medium is forced to flow into a cooling medium channel between the central pipe and the pin body, and the cast hole is locally cooled.
  • the cooling medium is supplied from the central pipe to a distal end portion of the core pin, and the cooling medium is forced to flow into a cooling medium channel between the central pipe and the pin body, a uniform cooling medium flow channel is formed along the entire periphery, the flow rate of the cooling medium can be stabilized, and local cooling of the cast hole can be performed uniformly.
  • the chill layer with a secondary dendrite arm spacing of at least 5.5 ⁇ m or less can be reliably formed to a thickness equal to, or larger than a predetermined thickness at the cast hole surface with uniformity over the entire periphery. Therefore, the quality of the aluminum die cast product obtained by casting can be stabilized and the yield thereof can be increased.
  • the method for manufacturing an aluminum die cast product in accordance with the present invention is the above-described method for manufacturing an aluminum die cast product, wherein the cooling medium is caused to flow at a flow rate of 12 cc/s or more.
  • the cooling medium is caused to flow at a flow rate of 12 cc/s or more, the temperature gradient during melt solidification shrinkage is sufficiently increased and the dendrite growth is inhibited.
  • the chill layer with a secondary dendrite arm spacing of at least 5.5 ⁇ m or less can be reliably formed to a thickness equal to, or larger than a predetermined thickness at the cast hole surface.
  • the method for manufacturing an aluminum die cast product in accordance with the present invention is the above-described method for manufacturing an aluminum die cast product, wherein a core pin of a partition plate structure in which a partition plate arranged along a pin axial direction is inserted into a hollow core pin body is used as the core pin, the cooling medium is supplied from one of cooling medium channels partitioned by the partition plate, the cooling medium is caused to flow into the other cooling medium channel, and the cast hole is locally cooled.
  • the cooling medium is supplied from one of cooling medium channels partitioned by the partition plate, and the cooling medium is caused to flow into the other cooling medium channel, a uniform cooling medium flow channel can be formed, the flow rate of the cooling medium can be stabilized, and the cooling performance can be improved.
  • the chill layer with a secondary dendrite arm spacing of at least 5.5 ⁇ m or less can be reliably formed to a thickness equal to, or larger than a predetermined thickness at the cast hole surface. Therefore, the quality of the aluminum die cast product obtained by casting can be stabilized and the yield thereof can be increased.
  • the method for manufacturing an aluminum die cast product in accordance with the present invention is any of the above-described methods for manufacturing an aluminum die cast product, wherein the flow of the cooling medium is initiated simultaneously with, or immediately prior to the completion of melt injection.
  • the chill layer with a secondary dendrite arm spacing of at least 5.5 ⁇ m or less can be reliably formed to a thickness equal to, or larger than a predetermined thickness at the cast hole surface.
  • the chill layer with a secondary dendrite arm spacing of at least 5.5 ⁇ m or less can be reliably formed to a thickness equal to, or larger than a predetermined thickness at the cast hole surface.
  • the cast hole serves as a rough hole
  • the shrinkage cavity defects are not exposed on the surface thereof and the occurrence of pressure leak or gas leak via the cast hole can be reliably inhibited. Therefore, when a pressure vessel or the like is manufactured, the yield thereof can be greatly increased and high-quality aluminum die cast products can be manufactured at a low cost.
  • FIG. 1 is a perspective view illustrating the external appearance of a compressor housing that is an aluminum die cast product of one embodiment of the present invention.
  • FIG. 2 is a cross-sectional view along arrows Y-Y of the compressor housing shown in FIG. 1 .
  • FIG. 3 is a partial simplified cross-sectional view illustrating a die casting state of the compressor housing shown in FIG. 1 .
  • FIG. 4 is a cross-sectional view illustrating an example of a core pin employed for die casting of the compressor housing shown in FIG. 1 .
  • FIG. 5 is a cross-sectional view illustrating another example of a core pin employed for die casting of the compressor housing shown in FIG. 1 .
  • FIG. 6 is a conceptual diagram illustrating solidification shrinkage of the melt in the case of a small temperature gradient during die cooling.
  • FIG. 7 is a conceptual diagram illustrating solidification shrinkage of the melt in the case of a large temperature gradient during die cooling.
  • FIG. 8 illustrates observations performed with an optical microscope for DAS measurements.
  • FIG. 9 is a graph illustrating the relationship between a cooling water flow rate V (cc/s) and a thickness t (mm) of the region free of shrinkage cavity defects.
  • FIG. 10 is a graph illustrating the relationship between a depth d (mm) from the casting surface in which shrinkage cavity is observed and DAS ( ⁇ m).
  • FIG. 1 is a perspective view of a compressor housing 1 of one embodiment of the present invention.
  • FIG. 2 is a cross-sectional view along arrows Y-Y in FIG. 1 .
  • the compressor housing 1 which is a pressure vessel requiring airtightness, is explained as an example of an aluminum die cast product, but the aluminum die cast product in accordance with the present invention is not limited thereto.
  • the compressor housing 1 constitutes the outer shell of the compressor, and a compression mechanism (not shown in the figure) is contained inside thereof.
  • the compression mechanism compresses a low-pressure cooling gas sucked in via a port hole 2 from the outside of the compression housing 1 and discharges the resultant high-pressure cooling gas to the outside via a port hole (not shown in the figure) provided in the compression housing 1 .
  • the compression housing 1 forms a compressor accommodation space that covers and seals the outer periphery of the compression mechanism so as to prevent leak to the outside as the cooling gas is taken in, compressed, and discharged, and the compression housing acts as a pressure vessel.
  • the aforementioned port hole 2 is provided so as to pass through the compression housing 1 , as shown in FIG. 2 , and a cooling medium pipe (not shown in the figure) is connected to the port hole 2 .
  • a thick portion 4 that is thicker than other portions is provided in the outer peripheral portion of the compression housing 1 , and the port hole 2 is provided together with a screw hole 3 for attaching a fitting for connecting the cooling medium pipe in this thick portion 4 .
  • the screw hole 3 is not necessarily provided and may be omitted.
  • the compression housing 1 is produced from an aluminum alloy in order to reduce weight and is manufactured by die casting.
  • the rough holes of the port hole 2 and screw hole 3 are formed as cast holes 2 A and 3 A with core pins during die casting and then finished by machining to predetermined dimensions after die casting.
  • FIG. 3 is a schematic sectional view illustrating a state in which the cast holes 2 A and 3 A for the port hole 2 and screw hole 3 are die cast with core pins 5 and 6 .
  • a molding space 9 of the thick portion 4 for molding the cast holes 2 A and 3 A is formed by a fixed die 7 and a movable die 8 .
  • the core pins 5 and 6 for molding the cast holes 2 A and 3 A are introduced from the side of the fixed die 7 into the molding space 9 and disposed therein.
  • the molding space 9 is filled with a melt, thereby molding the cast holes 2 A and 3 A serving as rough holes for the port hole and screw hole 3 with the core pins 5 and 6 .
  • the thick portion 4 where the port hole 2 and screw hole 3 are provided is thicker than other portions, and during die casting, a solidification shrinkage space is produced by solidification shrinkage of the melt and shrinkage cavity defects easily appear therein.
  • the shrinkage cavity defects can be exposed on the cutting surface and the inside and outside of the compressor housing 1 or the port hole 2 and screw hole 3 can be lined together via the shrinkage cavity defects. As mentioned hereinabove, this can result in a leak of pressure or cooling medium gas from inside the compressor housing 1 to the outside.
  • the chill layer 2 B in which no shrinkage cavity defects have appeared is formed to a thickness above a predetermined thickness at the casting surface, and when the cutting is performed with a predetermined cutting allowance, no shrinkage cavity defects are exposed on the cutting surface. Furthermore, locally cooling the cast holes with the core pins would be also effective for forming the chill layer 2 B in which no shrinkage cavity defects have occurred to a thickness exceeding the cutting allowance. From among the core pins 5 and 6 , the core pin 6 for the screw hole 3 has a small pin diameter, and providing a cooling medium flow channel inside thereof is difficult.
  • a flow channel for the cooling medium (water) is provided inside the core pin 5 with a comparatively large diameter that serves to mold the port hole 2 , local cooling capacity with the core pin 5 is enhanced, and a region (chill layer 2 B) where no shrinkage cavity defects occur is made thicker.
  • FIG. 4 shows a configuration of the core pin 5 provided with a flow channel for a cooling medium (water) inside thereof.
  • the core pin 5 is a core pin 5 of a double pipe structure composed of a hollow pin body 5 A, a holder 5 C connected via a thread 5 B to the upper portion of the pin body 5 A, a plug 5 D screwed into the end portion of the holder 5 C, a central pipe 5 E having one end thereof held in an up-down partition portion within the holder 5 C and another end opened at the distant end portion inside the hollow pin body 5 A, a cooling medium flow channel 5 F formed between the hollow pin body 5 A and the central pipe 5 E and serving to pass the cooling medium (water) therethrough, a cooling medium supply pipe 5 G connected to a space in the upper portion inside the holder 5 C, and a cooling medium discharge pipe 5 H connected to a space in the lower portion inside the holder 5 C.
  • the cooling medium (water) can flow at a preset flow rate from a water supply device 10 via the cooling medium supply
  • the core pin 5 can be replaced with a core pin 50 shown in FIG. 5 .
  • the core pin 50 has a partition plate structure in which the central pipe 5 E of the core pin 5 is replaced with a partition plate 50 E, one of the flow channels partitioned by the partition plate 50 is a cooling medium supply channel 50 I and the other flow channel is a cooling medium discharge channel 50 J.
  • Other components are identical to those of the core pin 5 and assigned with identical symbols. The explanation thereof is omitted.
  • a method for forming the chill layer 2 B with a thickness above a predetermined value in which no shrinkage cavity defects have occurred at the surface of the cast hole 2 A serving as a rough hole for the port hole 2 by using the core pin 5 or 50 and a configuration of the compressor housing 1 provided with the chill layer 2 B will be described below.
  • the relationship between the temperature gradient and growth of dendrite arms during solidification shrinkage of the melt that is shown in FIG. 6 and FIG. 7 will be explained.
  • the solidification of melt proceeds while the melt is supplied from a liquid phase side so as to compensate for the volume shrinkage that accompanies solidification between the dendrite arms 20 extending from the solid phase side.
  • the growth of dendrite arms 20 can be inhibited by increasing the cooling capacity of the die and increasing the temperature gradient G.
  • the temperature gradient G can be represented by the following formula:
  • T L stands for a liquidus temperature
  • T S a solidus temperature
  • L a length of dendrite arms 20 .
  • the dendrite arms 20 grow and the length L thereof increases to L 1 .
  • the temperature gradient G is small (the case shown in FIG. 6 )
  • the dendrite arms 20 grow and the length L thereof increases to L 1 .
  • by increasing the temperature gradient G it is possible to inhibit the growth of dendrite arms 20 and make the length L thereof as short as L 2 (L 1 >L 2 ).
  • the spacing between the secondary dendrite arms 21 can be decreased by increasing the temperature gradient G.
  • the DAS can be easily checked by using an optical microscope after completion of solidification.
  • the DAS is a distance between the centers of adjacent secondary dendrite arms and is taken as an average value of secondary dendrite arm spacing in a portion where four or more of secondary dendrite arms are arranged continuously side by side. More specifically, a portion where four or more of secondary dendrite arms are arranged continuously side by side is selected, a total of n (n is 4 or more) secondary dendrite arm spacings l are measured, and a value of l/(n ⁇ 1) is found. The measurements are preformed in three or more places and an arithmetical average of the results is found.
  • the temperature gradient G can be increased by increasing the cooling capacity of the mold. Therefore, apparently the DAS can be decreased and the thickness of the region (chill layer 2 B) where no shrinkage cavities have occurred can be increased by increasing the flow rate of the cooling medium that cools the mold, thereby raising the cooling rate of the mold, and inhibiting the growth of dendrite arms 20 during solidification. Accordingly, the following test was performed.
  • the core pin 5 shown in FIG. 4 was used, the cast holes 2 A and 3 A for the port hole 2 and screw hole 3 were die cast with the core pins 5 and 6 (see FIG. 3 ), while varying the flow rate V (cc/s) of the cooling medium (water), the DAS ( ⁇ m) in a location at a predetermined depth from the casting surface (surface of cast product) was measured by a linear intercept method, and the thickness t (mm) of the region (chill layer 2 B) without the shrinkage cavity defects was measured.
  • the measurement results are shown in Table 1.
  • the casting conditions in the above-described process were as follows: melt temperature 665° C., die temperature 200° C., injection rate 0.2 m/s (low rate) and 2.3 m/s (high rate). These casting conditions are identical to a melt temperature of 640-690° C. and mold temperature of 150-300° C. that are typical molding conditions for casting the aluminum die cast housing 1 .
  • the conditions relating to the flow of cooling medium (water) the flow of cooling medium (water) was initiated simultaneously with the completion of injection and the flow passage time was 3 sec.
  • the test results were analyzed and the relationship between the flow rate V (cc/s) of the cooling medium (water) and the thickness t (mm) of the region without shrinkage cavity defects was plotted as shown in FIG. 9 .
  • a thick solid line in FIG. 9 connects the minimum values of the thickness t (mm) of the region without shrinkage cavities obtained at each flow rate V (cc/s) of cooling water.
  • FIG. 10 a graph representing the relationship between the depth d (mm) from the casting surface (surface of cast product) where shrinkage cavities are observed and DAS ( ⁇ m) is shown in FIG. 10 , the region shown by thick solid lines in FIG. 10 indicates a region in which the depth d (mm) from the casting surface (surface of cast product) where shrinkage cavities are observed, that is, the thickness of the region without shrinkage cavities assumes a minimum value (t min ) in the molded products obtained at various flow rates V (cc/s) of cooling water shown by broken lines. This region could be considered as a threshold (5.5-6.9 ⁇ m) of DAS at which shrinkage cavities were observed, and it was made clear that the condition for DAS at which no shrinkage cavities occur was 5.5 ⁇ m or less.
  • the chill layer 2 B with a DAS of 5.5 ⁇ m or less was formed to a thickness more than a machining allowance in cutting after die casting at the surface of cast hole 2 A for the port hole 2 cast with the core pin 5 .
  • the cutting allowance has a usual value of 0.5 mm
  • the chill layer 2 B with a DAS of 5.5 ⁇ m or less was formed to a thickness of 0.5 mm or more, and the chill layer 2 B with a DAS of 5.5 ⁇ m or less remained on the cut surface after cutting.
  • the flow of the cooling medium in the core pins 5 , 50 is initiated during die casting at the same time as the melt injection is completed, but performing the two actions simultaneously is not necessary.
  • the cooling medium can be caused to flow immediately before the completion of melt injection, for example, from about 1 s before the completion of injection.
  • the cooling medium may be caused to flow before the completion of injection, provided that no such adverse effect is produced.
  • the present invention is not limited to this application and can be applied to a wide variety of aluminum die cast products such as other pressure vessels, aluminum cylinder blocks for engines, and transmission cases. In these cases, the leak of fluid sealed inside the product also can be reliably eliminated.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
US12/155,170 2006-12-20 2008-05-30 Aluminum die cast product and method for manufacturing same Abandoned US20090120538A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP2006-342909 2006-12-20
JP2006342909A JP4043502B1 (ja) 2006-12-20 2006-12-20 アルミダイカスト製品およびその製造方法
PCT/JP2007/068935 WO2008075491A1 (ja) 2006-12-20 2007-09-28 アルミダイカスト製品およびその製造方法

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
PCT/JP2007/068935 Continuation WO2008075491A1 (ja) 2006-12-20 2007-09-28 アルミダイカスト製品およびその製造方法

Publications (1)

Publication Number Publication Date
US20090120538A1 true US20090120538A1 (en) 2009-05-14

Family

ID=39124532

Family Applications (1)

Application Number Title Priority Date Filing Date
US12/155,170 Abandoned US20090120538A1 (en) 2006-12-20 2008-05-30 Aluminum die cast product and method for manufacturing same

Country Status (6)

Country Link
US (1) US20090120538A1 (de)
EP (1) EP2095895B1 (de)
JP (1) JP4043502B1 (de)
CN (1) CN101432087B (de)
CA (1) CA2631229A1 (de)
WO (1) WO2008075491A1 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10410682B2 (en) * 2018-01-19 2019-09-10 Nidec Corporation Disk drive housing

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP5020889B2 (ja) * 2008-05-26 2012-09-05 株式会社豊田中央研究所 Ａｌ合金ダイカスト鋳物およびその製造方法
CN105057630A (zh) * 2015-07-31 2015-11-18 安徽得力汽车部件有限公司 一种针对铝压铸类零件充氧压铸成型工艺

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5211778A (en) * 1990-03-27 1993-05-18 Atsugi Unista Corporation Method for forming aluminum-silicon alloy
US20030026726A1 (en) * 2001-07-17 2003-02-06 Sumitomo Electric Industries, Ltd. Wear resistant aluminum alloy elongate body, manufacturing method thereof and piston for car air conditioner
US20070158000A1 (en) * 2004-11-01 2007-07-12 Motoharu Tanizawa Pressure vessel, compressor and process for casting cylinder block

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH09277014A (ja) * 1996-04-10 1997-10-28 Hitachi Metals Ltd 樹脂中子を用いた軽合金ダイカスト製造法及び中空状軽合金ダイカスト鋳造品
JP3748622B2 (ja) 1996-06-03 2006-02-22 本田技研工業株式会社 鋳造用金型の鋳抜ピン構造
JP2004223610A (ja) 2003-01-21 2004-08-12 Kyosan Hirota ダイカスト製品の製造方法およびその製造装置
JP2004225134A (ja) * 2003-01-24 2004-08-12 Showa Keigokin Kk ディーゼルエンジンシリンダーヘッド用アルミニウム合金材料及びその製造方法並びにディーゼルエンジン
JP2004330273A (ja) * 2003-05-09 2004-11-25 Sanden Corp ピストンの鋳造方法
CN1254328C (zh) * 2003-05-16 2006-05-03 西北工业大学 铝合金薄壁件金属型铸造用焓变涂料
JP4290024B2 (ja) * 2004-01-26 2009-07-01 古河スカイ株式会社 耐熱強度に優れたターボチャージャー用アルミニウム合金鋳物製コンプレッサーインペラー

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5211778A (en) * 1990-03-27 1993-05-18 Atsugi Unista Corporation Method for forming aluminum-silicon alloy
US20030026726A1 (en) * 2001-07-17 2003-02-06 Sumitomo Electric Industries, Ltd. Wear resistant aluminum alloy elongate body, manufacturing method thereof and piston for car air conditioner
US20070158000A1 (en) * 2004-11-01 2007-07-12 Motoharu Tanizawa Pressure vessel, compressor and process for casting cylinder block

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10410682B2 (en) * 2018-01-19 2019-09-10 Nidec Corporation Disk drive housing

Also Published As

Publication number Publication date
EP2095895A1 (de) 2009-09-02
EP2095895A4 (de) 2011-12-28
CN101432087B (zh) 2010-12-29
JP4043502B1 (ja) 2008-02-06
CA2631229A1 (en) 2008-06-20
WO2008075491A1 (ja) 2008-06-26
CN101432087A (zh) 2009-05-13
JP2008149369A (ja) 2008-07-03
EP2095895B1 (de) 2013-03-06

Similar Documents

Publication Publication Date Title
CN109158536B (zh) 一种预防汽车球铁转向器壳体铸件泄漏的铸造工艺
US5732671A (en) Method and apparatus for manufacturing cylinder blocks
US20090120538A1 (en) Aluminum die cast product and method for manufacturing same
CN106077575A (zh) 一种铝合金车轮低压铸造模具
KR100567696B1 (ko) 다이캐스트 제품을 제조하기 위한 장치 및 방법
JP4224024B2 (ja) アルミニウム合金の真空ダイカスト鋳造方法および鋳造装置並びにアルミニウム合金製品
CN205702388U (zh) 一种铝合金车轮低压铸造模具
US20160114386A1 (en) Method for manufacturing cylinder block
US10898948B2 (en) Method of manufacturing metal castings
JP2004243327A (ja) 真空ダイカスト用金型のシール性確認方法
US10596622B1 (en) Slides and expendable cores for high pressure die cast closed deck engine block
JP2004322138A (ja) ダイカスト鋳造における新規低圧鋳造法
CN114632920B (zh) 一种基于AlSi10MnMg合金制备的新能源汽车动力电池壳体及模具
US20050173091A1 (en) Method and apparatus for manufacturing strong thin-walled castings
US3118225A (en) Method of casting
US20020060059A1 (en) Aluminum alloy for high pressure die-casting, subordinate frame for automobile, and high pressure die-casting method
US2452855A (en) Mold for making castings
JP2020006375A (ja) 鋳造用金型装置および低圧鋳造方法
JP2762563B2 (ja) 金型およびその製造方法
KR20220036140A (ko) 슬라이드 코어와 코어 홀더 사이의 이형제 및 냉각수 배출이 가능한 다이캐스팅 가동금형
JP2003136193A (ja) シリンダブロック鋳造用ボアピン
JP3095333B2 (ja) シリンダブロック鋳造用金型装置
JP7430952B1 (ja) 冷却装置及び冷却方法
JP2002239683A (ja) 鋳抜きピンの冷却方法
JP2006159255A (ja) 鋳造方法及び鋳造装置

Legal Events

Date Code Title Description
AS Assignment

Owner name: MITSUBISHI HEAVY INDUSTRIES, LTD., JAPAN

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:HAMASAKI, MASAFUMI;INOGUCHI, KAZUHIKO;HATANAKA, MASAYA;AND OTHERS;REEL/FRAME:021090/0349

Effective date: 20080507

STCB Information on status: application discontinuation

Free format text: ABANDONED -- AFTER EXAMINER'S ANSWER OR BOARD OF APPEALS DECISION