US20100326617A1 - Intermediate stalk, method of producing the same, and low-pressure die-casting apparatus - Google Patents

Intermediate stalk, method of producing the same, and low-pressure die-casting apparatus Download PDF

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Publication number
US20100326617A1
US20100326617A1 US12/677,065 US67706509A US2010326617A1 US 20100326617 A1 US20100326617 A1 US 20100326617A1 US 67706509 A US67706509 A US 67706509A US 2010326617 A1 US2010326617 A1 US 2010326617A1
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US
United States
Prior art keywords
refractory material
covering material
intermediate stalk
metal covering
precast refractory
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
US12/677,065
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English (en)
Inventor
Shigeru Nakama
Norihiro Kihara
Munehiko Fukase
Yoshiyuki Ito
Hirotaka Ide
Kohei Fujita
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.)
Nichias Corp
Toyota Motor Corp
Original Assignee
Nichias Corp
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 Nichias Corp filed Critical Nichias Corp
Assigned to TOYOTA JIDOSHA KABUSHIKI KAISHA, NICHIAS CORPORATION reassignment TOYOTA JIDOSHA KABUSHIKI KAISHA ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FUJITA, KOHEI, IDE, HIROTAKA, ITO, YOSHIYUKI, FUKASE, MUNEHIKO, KIHARA, NORIHIRO, NAKAMA, SHIGERU
Publication of US20100326617A1 publication Critical patent/US20100326617A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D18/00—Pressure casting; Vacuum casting
    • B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould

Definitions

  • the present invention relates to an intermediate stalk for a low-pressure die-casting apparatus used to produce an aluminum casting or the like, and a method of producing the same.
  • the intermediate stalk 103 used for the low-pressure die-casting apparatus 100 must withstand a molten metal temperature of 600 to 700° C. and make it unnecessary to provide an external heating system, for example.
  • an intermediate stalk in which the inner side of a metal covering material 113 is lined with a refractory heat insulator 123 has been known.
  • JP-A-2006-272448 discloses the intermediate stalk 103 in which the inner side of the metal covering material 113 is lined with the refractory heat insulator 123 , and an inorganic material 133 that adjusts and absorbs the difference in thermal expansion between the covering material 113 and the refractory heat insulator 123 is interposed between the covering material 113 and the refractory heat insulator 123 , and also discloses the low-pressure die-casting apparatus 100 including the intermediate stalk 103 .
  • the intermediate stalk 103 and the low-pressure die-casting apparatus 100 have advantages in that radiation of heat from the intermediate stalk 103 is suppressed so that a decrease in temperature of the molten metal is prevented; cracks that may occur in the refractory heat insulator 123 due to the difference in thermal expansion between the covering material 113 and the refractory heat insulator 123 can be prevented by providing the inorganic material 133 that adjusts and absorbs the difference in thermal expansion between the covering material 113 and the refractory heat insulator 123 ; and an opening that may be formed between the covering material 113 and the refractory heat insulator 123 due to the difference in thermal expansion is closed by utilizing a thermally expansible sheet that expands due to heating as the inorganic material 133 so that a deterioration in heat insulation effect is prevented, for example.
  • water contained in the refractory heat insulator consists of a residue of water used during lining when producing the refractory heat insulator and water absorbed by the refractory heat insulator during storage.
  • An object of the present invention is to provide an intermediate stalk that allows water to be sufficiently released from a refractory material during heating, does not explode, does not produce cracks in the refractory material due to the difference in coefficient of thermal expansion between the refractory material and a metal covering material, and allows easy replacement of the refractory material, a method of producing the same, and a low-pressure die-casting apparatus.
  • the present invention provides an intermediate stalk that is used for a low-pressure die-casting apparatus, the intermediate stalk comprising a metal covering material, and a precast refractory material that is removably fitted into the metal covering material, an air release opening being formed between the metal covering material and the precast refractory material when viewed from above.
  • the present invention also provides a low-pressure die-casting apparatus comprising the above intermediate stalk.
  • the present invention further provides a method of producing an intermediate stalk that is used for a low-pressure die-casting apparatus, the method comprising fitting a precast refractory material into a metal covering material, the precast refractory material being formed in advance so that an air release opening is formed between the metal covering material and the precast refractory material when viewed from above in a state in which the precast refractory material is fitted into the metal covering material.
  • the production method, the production apparatus, and the like can be conveniently determined so that the degree of freedom of production increases. Moreover, since the intermediate stalk can be substantially produced by merely fitting the precast refractory material into the metal covering material, the production cost can be reduced.
  • FIG. 1 is a cross-sectional view showing an intermediate stalk according to one embodiment of the present invention
  • FIG. 2 is a plan view of the intermediate stalk shown in FIG. 1
  • FIG. 3 is a view showing an example of a method of securing a precast refractory material in the intermediate stalk
  • (A) is a plan view showing another embodiment of an area enclosed by a two-dot chain line in FIG. 2
  • (B) is a front view of (A)
  • (C) is a front view showing an area secured by a securing plate
  • (D) is a plan view of (C)
  • FIG. 4 is a view illustrative of a method of producing an intermediate stalk according to the present invention
  • FIG. 5 is a schematic view showing a low-pressure die-casting apparatus according to the present invention
  • FIG. 6 is a schematic view showing a related-art low-pressure die-casting apparatus.
  • FIG. 1 is a cross-sectional view showing the intermediate stalk according to this embodiment.
  • FIG. 2 is a plan view of the intermediate stalk shown in FIG. 1 .
  • FIG. 3 is a view showing an example of a method of securing a precast refractory material in the intermediate stalk, wherein (A) is a plan view showing another embodiment of an area enclosed by a two-dot chain line in FIG. 2 , (B) is a front view of (A), (C) is a front view showing an area secured by a securing plate, and (D) is a plan view of (C).
  • FIG. 4 is a view illustrative of a method of producing the intermediate stalk according to the present invention.
  • FIG. 5 is a schematic view showing a low-pressure die-casting apparatus.
  • An intermediate stalk 10 is used for a low-pressure die-casting apparatus.
  • the intermediate stalk 10 includes a metal covering material 2 that is in the shape of a relatively shallow holding bath and has an upper opening 27 having a large opening size and a lower opening 28 that has an opening size smaller than that of the upper opening 27 , and a precast refractory material 1 that has almost the same shape as the covering material 2 and is removably fitted into the metal covering material 2 .
  • An intermediate stalk has been normally produced using a metal covering material as a molding box since the inner side of the metal covering material is lined with a refractory material. This poses limitations on the production conditions.
  • the intermediate stalk according to the present invention is not produced using the metal covering material as a molding box, the production method, the production apparatus, and the like can be conveniently determined so that the degree of freedom of production increases. Moreover, since it is unnecessary to replace the refractory material for maintenance purposes, a problem in which the metal covering material is damaged due to replacement does not occur.
  • the material for the metal covering material 2 is not particularly limited.
  • the metal covering material 2 may be formed of cast iron.
  • the shape of the metal covering material 2 is not particularly limited. It is preferable that a flat horizontal section 21 that supports the precast refractory material 1 be provided around the lower opening. The placement stability of the precast refractory material 1 having a flat horizontal bottom can be improved by providing the flat horizontal section 21 around the lower opening.
  • the precast refractory material 1 is removably fitted into the metal covering material 2 .
  • the precast refractory material 1 may be arbitrarily fitted into the metal covering material 2 insofar as an air release opening 3 is formed between the covering material 2 and the precast refractory material 1 when viewed from above.
  • the intermediate stalk 10 according to the present invention is configured so that the precast refractory material 1 is supported at the bottom. Specifically, a flat horizontal bottom 11 is formed at the bottom of the precast refractory material 1 around the opening of the metal covering material 2 .
  • the flat horizontal bottom 11 of the precast refractory material 1 is disposed on the flat horizontal section 21 of the metal covering material 2 through a packing material 4 .
  • a situation in which molten metal leaks through the opening between the precast refractory material 1 and the metal covering material 2 can be prevented by providing the packing material 4 in the area where the precast refractory material 1 is supported by (comes in contact with) the metal covering material 2 .
  • the packing material may be a sheet material that contains 20 to 40 mass % of ceramics fibers, 40 to 70 mass % of unfired vermiculite, and 5 to 20 mass % of an organic binder, for example.
  • the density of such a thermally expansible sheet is preferably 500 to 800 kg/cm 3 , and particularly preferably 600 to 700 kg/cm 3 .
  • the precast refractory material 1 may be fitted into the metal covering material 2 so that part of the outer side surface (outer circumferential surface) of the precast refractory material 1 is supported by part of the inner side surface (inner circumferential surface) of the metal covering material 2 (e.g., almost the lower half of the outer side surface of the precast refractory material 1 is supported by almost the lower half of the inner side surface of the metal covering material 2 ). Since an opening through which the air is released upward is formed even if part of the outer side surface of the precast refractory material 1 comes in contact with part of the inner side surface of the metal covering material 2 , release of water from the refractory material during heating is not hindered.
  • the air release opening 3 is formed between the covering material 2 and the precast refractory material 1 when viewed from above. This means that the opening 3 is observed between the metal covering material 2 and the precast refractory material 1 when observing the intermediate stalk 10 from above, as shown in FIG. 2 . Since the air release opening 3 is formed between the covering material 2 and the precast refractory material 1 when viewed from above, water is sufficiently released from the refractory material during heating, an explosion does not occur, cracks do not occur in the refractory material due to the difference in coefficient of thermal expansion between the refractory material and the metal covering material, and the refractory material can be easily replaced.
  • the width of the opening 3 is 0.5 mm or more, preferably 1.0 mm or more, and particularly preferably 2.0 mm or more.
  • the upper limit of the width of the opening 3 is not particularly limited, but is about 5 mm since the placement stability of the precast refractory material 1 decreases if the width of the opening 3 is too large.
  • the opening 3 need not be formed between the metal covering material 2 and the precast refractory material 1 over the entire circumference of the intermediate stalk 10 , or may be formed between the metal covering material 2 and the precast refractory material 1 over the entire circumference of the intermediate stalk 10 . It is preferable that the opening 3 be formed between the metal covering material 2 and the precast refractory material 1 over the entire circumference of the intermediate stalk 10 from the viewpoint of ease of design and the placement stability of the precast refractory material 1 .
  • the opening 3 formed between the metal covering material 2 and the precast refractory material 1 may be connected to an internal opening 3 a that is formed between an inner circumferential surface 25 of the metal covering material 2 and an outer circumferential surface 15 of the precast refractory material 1 .
  • the opening 3 formed between the metal covering material 2 and the precast refractory material 1 is connected to an opening formed between almost the upper half of the inner side surface of metal covering material 2 and almost the upper half of the outer side surface of the precast refractory material 1 .
  • the precast refractory material 1 may be formed using a known insulating material.
  • the precast refractory material 1 may be formed using an unshaped refractory material.
  • the unshaped refractory material include a material obtained by adding an alumina cement binder and water to calcium silicate or silica (main component) and kneading the mixture, a paste material obtained by adding mica, carbon, a silicon carbide powder, or a silicon nitride powder (non-wettability improver) to inorganic fibers and an alumina powder, adding a silica or alumina-based inorganic binder, a thickener, and water to the mixture, and kneading the mixture, and the like.
  • a heat insulator may be formed on the outer circumferential surface of the precast refractory material 1 .
  • the heat insulating properties of the intermediate stalk can be improved by forming the heat insulator on the outer circumferential surface of the precast refractory material 1 (i.e., lining the precast refractory material 1 with the heat insulator) so that a problem due to a decrease in temperature of molten metal can be prevented.
  • the heat insulator also functions as a sealing material that prevents leakage of molten metal due to cracks formed in the precast refractory material 1 .
  • the heat insulator examples include inorganic fiber aggregates (e.g., inorganic fiber felt and blanket) and the like.
  • examples of the inorganic fibers include ceramic fibers, silica fibers, alumina fibers, and the like. Even if the heat insulator is formed on the outer circumferential surface of the precast refractory material 1 , the air release opening 3 is formed between the covering material 2 and the precast refractory material 1 provided with the heat insulator when viewed from above.
  • the internal opening 3 a may be formed between the inner circumferential surface 25 of the metal covering material 2 and the outer circumferential surface of the heat insulator formed on the precast refractory material 1 .
  • the intermediate stalk 10 according to the present invention may have a structure in which a thermally expansible sheet that has flexibility and expands due to heating is provided in part of the area (particularly the lower half) between the metal covering material 2 and the precast refractory material 1 . This improves the placement stability of the precast refractory material 1 .
  • the thermally expansible sheet starts to expand at 300 to 400° C., for example, and expands in the thickness direction.
  • the expansion coefficient is 2, and preferably 2 to 4 in the thickness direction.
  • reference numeral 5 indicates a grip of the metal covering material 2 .
  • the four corners or two diagonal corners of the precast refractory material 1 fitted into the metal covering material 2 may be secured using a securing plate.
  • This enables the precast refractory material 1 to be stably secured.
  • a securing method using the securing plate is described below with reference to FIG. 3 .
  • the corner of the upper end of the intermediate stalk 10 is provided with a depression 6 that is approximately in the shape of a triangle when viewed from above and has a given dimension in the depth direction.
  • the depression 6 includes a depression 61 formed in the metal covering material 2 , and a depression 62 formed in the precast refractory material 1 .
  • a bolt hole 7 is formed in the depression 61 formed in the metal covering material 2 ( FIG.
  • a securing plate 8 that is fitted into the depression 6 is provided.
  • the securing plate 8 has a through-hole that receives a flush bolt 9 and is formed at a position opposite to the bolt hole 7 after installation ( FIG. 3(B) ).
  • the precast refractory material 1 is strongly secured on the metal covering material 2 due to repulsion of the flexible packing material 4 provided at the bottom ( FIGS. 3(C) and 3(D) ).
  • the intermediate stalk 10 according to the present invention is produced by fitting the precast refractory material 1 into the metal covering material 2 , the precast refractory material 1 being formed in advance so that the air release opening 3 is formed between the metal covering material 2 and the precast refractory material 1 when viewed from above in a state in which the precast refractory material 1 is fitted into the metal covering material 2 .
  • the precast refractory material 1 is produced using an unshaped refractory material described with regard to the intermediate stalk 10 according to the present invention. Since the precast refractory material 1 is not produced using the metal covering material 2 as a molding box, the production method, the production apparatus, and the like can be conveniently determined so that the degree of freedom of production increases.
  • the metal covering material 2 and the refractory material are integrally formed (e.g., related-art intermediate stalk)
  • the metal covering material 2 since the metal covering material 2 is oxidized and deformed when the heating temperature during production is increased, it is necessary to employ a low heating temperature. In this case, since water remaining in the refractory material may vaporize or shrinkage due to heating may occur during actual use, the refractory material may break.
  • a low-pressure die-casting apparatus 20 includes the intermediate stalk 10 .
  • the low-pressure die-casting apparatus 20 according to the present invention includes a molten metal container 31 (crucible) that contains molten metal 32 , a furnace cover 36 that seals the molten metal container, a stalk tube 34 that is disposed at the center of the furnace cover 36 so that the stalk tube 34 passes through the furnace cover 36 and the lower opening of the stalk tube 34 is positioned in the molten metal 32 , the intermediate stalk 10 that is disposed so that the upper opening of the stalk tube 34 communicates with the bottom opening of the intermediate stalk 10 , and a die 35 that is disposed over the intermediate stalk 10 .
  • FIG. 5 shows the structure of the low-pressure die-casting apparatus that causes the molten metal to move upward and to be supplied to the die
  • the low-pressure die-casting apparatus may have a structure in which the pressure inside the die 35 is reduced to suck up the molten metal, or a structure in which the molten metal is caused to move upward at a positive pressure while reducing the pressure inside the die 35 , for example.
  • the low-pressure die-casting apparatus 20 is configured so that the air release opening is formed between the covering material and the precast refractory material when viewed from above, water is sufficiently released from the refractory material during heating, an explosion does not occur, cracks do not occur in the refractory material due to the difference in coefficient of thermal expansion between the refractory material and the metal covering material, and the refractory material can be easily replaced. Moreover, since it is unnecessary to replace the refractory material for maintenance purposes, a problem in which the metallic covering material is damaged due to replacement does not occur.
  • a ceramic fiber sheet material (packing material) containing unfired vermiculite and provided with a hole having the same shape as the bottom opening of a covering material was disposed at the bottom of a covering material formed of cast iron and having a shape shown in FIGS. 1 and 2 .
  • the precast refractory material produced by the above method was disposed inside the covering material on which the packing material was disposed, and a securing plate was attached to each of two diagonal corners over the covering material to obtain an intermediate stalk.
  • the intermediate stalk had an opening (width: 3 mm) between the covering material and the precast refractory material over the entire circumference of the intermediate stalk when viewed from above.
  • a ceramic fiber sheet material containing unfired vermiculite was bonded to the entire inner circumference of a covering material formed of cast iron and having a shape shown in FIGS. 1 and 2 using an organic adhesive.
  • a core for forming the inner surface (inner lining material) of an intermediate stalk was disposed inside the covering material.
  • the mortar used in Example 1 was injected between the covering material and the core, and cured and hardened overnight at a temperature of 25° C. and a relative humidity of 80%. After removing the core, the product was dried at 110° C. for 24 hours. The resulting intermediate stalk did not have an opening between the covering material and the lining material when viewed from above.
  • the inside of the intermediate stalk was rapidly heated using a gas burner until the temperature of the atmosphere inside the intermediate stalk reached 900° C. as a simulation of actual use of a low-pressure die-casting apparatus.
  • White smoke due to the organic adhesive was produced from the intermediate stalk obtained in Comparative Example 1.
  • the state of the refractory material after heating was visually inspected. Cracks that are considered to be caused by the difference in thermal expansion and removal of the refractory material due to explosion were observed.
  • no abnormalities were observed during and after heating.
  • the intermediate stalk and the low-pressure die-casting apparatus according to the present invention allow water to be sufficiently released from the refractory material during heating, do not explode, and do not produce cracks in the refractory material due to the difference in coefficient of thermal expansion between the refractory material and the metal covering material
  • the intermediate stalk and the low-pressure die-casting apparatus according to the present invention may be suitably used to produce an aluminum casting or the like.
  • the production method, the production apparatus, and the like can be conveniently determined so that the degree of freedom of production increases.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Furnace Housings, Linings, Walls, And Ceilings (AREA)
  • Incineration Of Waste (AREA)
  • Building Environments (AREA)
US12/677,065 2008-07-11 2009-06-12 Intermediate stalk, method of producing the same, and low-pressure die-casting apparatus Abandoned US20100326617A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP2008-181216 2008-07-11
JP2008181216A JP5255934B2 (ja) 2008-07-11 2008-07-11 中間ストーク、その製造方法及び低圧鋳造装置
PCT/JP2009/061155 WO2010004848A1 (ja) 2008-07-11 2009-06-12 中間ストーク、その製造方法及び低圧鋳造装置

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US20100326617A1 true US20100326617A1 (en) 2010-12-30

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US12/677,065 Abandoned US20100326617A1 (en) 2008-07-11 2009-06-12 Intermediate stalk, method of producing the same, and low-pressure die-casting apparatus

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US (1) US20100326617A1 (ja)
EP (1) EP2181784A4 (ja)
JP (1) JP5255934B2 (ja)
CN (1) CN101801563B (ja)
WO (1) WO2010004848A1 (ja)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11597007B2 (en) 2019-05-22 2023-03-07 Honda Motor Co., Ltd. Low-pressure casting device

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE202017007133U1 (de) * 2017-05-03 2019-09-03 EKW Gesellschaft mit beschränkter Haftung Gießdüse mit auswechselbarer Krone

Citations (5)

* Cited by examiner, † Cited by third party
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US3019496A (en) * 1958-10-27 1962-02-06 Bethlehem Steel Corp Vacuum casting apparatus
US3430289A (en) * 1965-11-01 1969-03-04 Toho Zinc Co Ltd Apparatus for preparing high purity fine powder of low-melting metals
US4345743A (en) * 1980-10-10 1982-08-24 Alcan Research And Development Limited Means and method for containing flowing or standing molten metal
US5011049A (en) * 1989-04-17 1991-04-30 General Electric Company Molten metal transfer tube
US5558801A (en) * 1993-06-01 1996-09-24 Nichias Corporation Casting stalk

Family Cites Families (10)

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JPS63132762A (ja) * 1986-11-21 1988-06-04 Ngk Insulators Ltd 低圧鋳造用スト−ク
JPH0447856U (ja) * 1990-08-27 1992-04-23
JPH0577023A (ja) * 1991-09-18 1993-03-30 Tokyo Yogyo Co Ltd 低圧鋳造用セラミツクスストーク
JP2565327Y2 (ja) * 1992-03-24 1998-03-18 株式会社クボタ 低圧鋳造装置における給湯路の湯口部材
JP3339141B2 (ja) * 1993-11-05 2002-10-28 日立金属株式会社 セラミックス製ストーク
DE19639358A1 (de) * 1996-09-25 1998-03-26 Bayer Ag Steigrohr für Leichtmetallschmelzen
JP3549430B2 (ja) * 1999-03-23 2004-08-04 ニチアス株式会社 低圧鋳造装置
JP2005296959A (ja) * 2004-04-06 2005-10-27 Hitachi Metals Ltd 低圧鋳造用ストーク
JP4421506B2 (ja) 2005-03-30 2010-02-24 ニチアス株式会社 中間ストークの製造方法
CN2822829Y (zh) * 2005-06-29 2006-10-04 冷星培 低压铸造机升液管

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3019496A (en) * 1958-10-27 1962-02-06 Bethlehem Steel Corp Vacuum casting apparatus
US3430289A (en) * 1965-11-01 1969-03-04 Toho Zinc Co Ltd Apparatus for preparing high purity fine powder of low-melting metals
US4345743A (en) * 1980-10-10 1982-08-24 Alcan Research And Development Limited Means and method for containing flowing or standing molten metal
US5011049A (en) * 1989-04-17 1991-04-30 General Electric Company Molten metal transfer tube
US5558801A (en) * 1993-06-01 1996-09-24 Nichias Corporation Casting stalk

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11597007B2 (en) 2019-05-22 2023-03-07 Honda Motor Co., Ltd. Low-pressure casting device

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JP5255934B2 (ja) 2013-08-07
CN101801563A (zh) 2010-08-11
JP2010017743A (ja) 2010-01-28
WO2010004848A1 (ja) 2010-01-14
CN101801563B (zh) 2011-11-09
EP2181784A1 (en) 2010-05-05
EP2181784A4 (en) 2013-03-13

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