US20110056644A1 - Casting mold for magnesium alloy and method of casting magnesium alloy - Google Patents

Casting mold for magnesium alloy and method of casting magnesium alloy Download PDF

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Publication number
US20110056644A1
US20110056644A1 US12/934,441 US93444109A US2011056644A1 US 20110056644 A1 US20110056644 A1 US 20110056644A1 US 93444109 A US93444109 A US 93444109A US 2011056644 A1 US2011056644 A1 US 2011056644A1
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United States
Prior art keywords
mold
casting
mold assembly
magnesium alloys
network
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Abandoned
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US12/934,441
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English (en)
Inventor
Masayuki Takashima
Susumu Yonezawa
Yoshiaki Arata
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Individual
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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
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002—Castings of light metals
    • B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes

Definitions

  • the present invention relates generally to a mold assembly for magnesium alloys and a casting method for magnesium alloys, and more particularly to a mold assembly for magnesium alloys and a casting method for magnesium alloys, which make sure of the fluidity of a molten magnesium alloy.
  • Magnesium is practically the lightest metal, and has increasing applications, partly because it is better in specific strength and specific rigidity than steels and aluminum, and partly because it is improved in terms of electromagnetic shield capability, machinability, vibration absorption capability, denting resistance, and recyclability.
  • Magnesium alloys in particular are now increasingly used, and in mounting demand, as materials for parts in the car and personal digital assistant fields.
  • the solidified magnesium alloy clogs up a molten alloy flow space, rendering it difficult to allow the molten alloy to gain access to the whole cavity of the mold.
  • JP(A) 2002-129272 shows that the metallic mold is heated at 200° C. to implement casting while the fluidity of the molten alloy is ensured.
  • Patent Publication 1 JP(A) 2002-129272
  • the object of the present invention is to provide a mold assembly for magnesium alloys which makes sure of the fluidity of a molten magnesium alloy while the production cost of casting equipment and the energy cost added up by heating are kept low and casting method for magnesium alloys using the mold assembly.
  • the present invention is embodied as follows.
  • the mold assembly for magnesium alloys comprises a mold and/or a core formed of an air permeable material.
  • the air permeable material is any one or any combination of a network, a sheet having multiple holes, and cloth.
  • the network, the sheet or the cloth is any one or any combination of a metal, a chemical fiber, and a ceramic material.
  • the network, the sheet, and the cloth has flexibility.
  • the air permeable blank mold and/or core are formed of any one or any combination of a network, a sheet having multiple holes, and cloth.
  • the mold and/or the core of the mold assembly for magnesium alloys are formed of an air permeable material so that there can be a decrease in the apparent thermal conductance between a molten alloy and the mold assembly for magnesium alloys.
  • the decrease in the apparent thermal conductance prevents the molten alloy from solidification momentarily upon contact with the mold assembly for magnesium alloys, making sure of the fluidity of the molten alloy and letting the molten alloy gain access to the whole mold assembly for magnesium alloys.
  • the air permeable material is any one or any combination of a network, a sheet having multiple holes, and cloth. Under the influences of a low latent heat of fusion per unit volume and surface tension of the molten magnesium alloy, the molten alloy solidifies upon contact with the mold assembly for magnesium alloys without going out of the network, the holes and the interstices, and between fibers, etc.
  • the air permeable material is formed of any one or any combination of a network, a sheet having multiple holes, and cloth. Therefore, there is no need of providing another air vents in the mold assembly for magnesium alloys.
  • the network, sheet or cloth material best-suited for casting may be chosen in consideration of the composition of magnesium alloys, the size and shape of castings, etc.
  • the network, the sheet, and the cloth is flexible so that the mold assembly for magnesium alloys can easily be produced.
  • the shape of the mold assembly for magnesium alloys can be so varied easily that the shape of a magnesium alloy casting can be varied easily too.
  • the mold and/or the core of the mold assembly for magnesium alloys are formed of an air permeable material so that there can be a decrease in the apparent thermal conductance between a molten alloy and the mold assembly for magnesium alloys.
  • the decrease in the apparent thermal conductance prevents the molten alloy from solidification momentarily upon contact with the mold assembly for magnesium alloys, making sure of the fluidity of the molten alloy and letting the molten alloy gain access to the whole mold assembly for magnesium alloys.
  • the air permeable material is any one or any combination of a network, a sheet having multiple holes, and cloth.
  • the molten alloy solidifies upon contact with the mold assembly for magnesium alloys without going out of the network, the holes and the interstices, and between fibers, etc.
  • the air permeable material is formed of any one or any combination of a network, a sheet having multiple holes, and cloth. Therefore, there is no need of providing another air vents in the mold assembly for magnesium alloys.
  • FIG. 1 is a sectional view showing the process of casting a columnar magnesium alloy casting.
  • FIG. 2 is a sectional view showing the process of casting a hollow, spherical magnesium alloy casting.
  • the object of the present invention the fluidity of a molten magnesium alloy is ensured while the production cost of casting equipment and energy cost added by heating are kept low—is accomplished by the mold assembly for magnesium alloys wherein the mold and/or the core are formed of an air permeable material, and the casting method for magnesium alloys using that mold assembly.
  • FIG. 1 is a sectional view showing the process of casting a columnar magnesium alloy casting.
  • the magnesium alloy used here is AZ91D.
  • a mold assembly 1 for magnesium alloys is built up of a network formed of an air permeable material.
  • the network has a line diameter of 0.30 mm and a mesh of 20.
  • the mold assembly 1 is constructed of a top mold 11 and a bottom mold 12 .
  • a molten magnesium alloy 3 melted in a crucible 4 is cast into a space defined between the top mold 11 and the bottom mold 12 .
  • the molten alloy is at a temperature of 560° C. to 800° C.
  • the upper mold 11 , and the bottom mold 12 is constructed of an air permeable network so that there is a decrease in the apparent thermal conductance between a molten magnesium alloy 3 and the upper mold 11 and the bottom mold 12 .
  • the decrease in the apparent thermal conductance makes sure of the fluidity of the molten alloy 3 without solidification momentarily upon contact with the top mold 11 and the bottom mold 12 ; so the molten alloy 3 gains access to all over the space defined between the top mold 11 and the bottom mold 12 (see FIG. 1( c )).
  • FIG. 2 is a sectional view showing the process of casting a hollow, spherical magnesium alloy casting.
  • the magnesium alloy used here is again AZ91D, as used in FIG. 1 .
  • a mold assembly 1 for magnesium alloys, and a core 2 is built up of a network formed of an air permeable material.
  • the network has a line diameter of 0.30 mm and a mesh of 20.
  • the mold assembly 1 is constructed of a top mold 11 and a bottom mold 12 .
  • a molten magnesium alloy 3 melted in a crucible 4 is cast into a space defined between the top mold 11 , the bottom mold 12 and the core 2 .
  • the molten alloy 3 is at a temperature of 560° C. to 800° C.
  • the upper mold 11 , the bottom mold 12 , and the core 2 is made up of an air permeable network so that there is a decrease in the apparent thermal conductance between the upper mold 11 , the bottom mold 12 and the core 2 .
  • the decrease in the apparent thermal conductance makes sure of the fluidity of the molten alloy 3 without solidification momentarily upon contact with the top mold 11 , the bottom mold 12 and the core 2 ; so the molten alloy 3 gains access to all over the space defined between the top mold 11 , the bottom mold 12 and the core 2 (see FIG. 2( c )).
  • top mold 11 and the bottom mold 12 are released off to obtain a hollow, spherical magnesium alloy casting 31 (see FIG. 2( d )).
  • the core 2 is within the magnesium alloy casting 31 ; so the ensuing casting is a magnesium alloy/stainless composite one.
  • the mold assembly 1 , and the core 2 is made up of a network; so the molten alloy 3 takes hold of fluidity without application of heat to the mold assembly 1 , and the core 2 .
  • the molten magnesium alloy 3 in contact with the mold assembly 1 and/or the core 2 solidifies without going out of the network under the influences of the low latent heat per unit volume of the molten magnesium alloy 3 and surface tension.
  • the mold assembly 1 for magnesium alloys, and the core 2 is constructed of a network; so there is no need of providing another air vents in the mold assembly 1 and the core 2 .
  • the molten alloy could then gain access even to details or thin sites where the molten alloy is apt to lose fluidity.
  • the network is used as the air permeable material in the foresaid examples, it is to be noted that the present invention is by no means limited to them. For instance, use may be made of a sheet having multiple holes (punching metal), cloth or a network, or any combination of a sheet having multiple holes (punching metal) and cloth or a network.
  • the decrease in the apparent thermal conductance makes sure of the fluidity of the molten alloy 3 ; so the molten alloy 3 gains access to all over the mold assembly 1 and the core 2 without solidification momentarily upon contact with the mold assembly 1 and the core 2 .
  • magnesium alloys having added to them a suitable element or elements selected from the group consisting of aluminum, zinc, manganese, rare earths, heavy rare earths, yttrium, calcium, strontium, silver, silicon, zirconium, beryllium, nickel, iron, copper, cobalt, sodium, potassium, and barium.
  • the network may have been woven in the form of plain weaving, diagonal weaving, stranded weaving, herringbone weaving, satin weaving, plain tatami weaving, diagonal tatami weaving, reversed tatami weaving, extension weaving, chain-like longitudinal tri-weaving, cord weaving (cord fabric), etc.
  • the network having a mesh of 20 is used in the aforesaid examples, it is to be noted that the mesh used may be chosen from the range of 1.5 to 3,600.
  • the line diameter may be chosen from the range of 0.02 mm to 6
  • the network best-suited for casting may be sorted out in consideration of the composition of magnesium alloys, the size and shape of castings, etc.
  • sheet thickness, the shape of holes having influences on air permeability, and aperture may be set at any desired values.
  • air permeable woven and unwoven fabrics may be used.
  • the woven fabrics may have been woven by any desired weaving processes, and the unwoven fabrics may have been made by any desired processes, with any desired fiber diameter.
  • prepregs made of air permeable carbon fibers may be used.
  • the network is formed of stainless steel; however, the present invention is in no way limited to it.
  • the network may be formed of metals such as an aluminum alloy, nickel, monel metal, brass, red brass, phosphor bronze, copper, silver, gold, iron, titanium, nichrome, hastelloy, and inconel; heat-resistant chemical fibers such as PBO, carbon fibers, and metal meta-aramides; and ceramic materials such as carbon, mullite, alumina, and zirconia, which may be used alone or in combination of two or more.
  • the sheet having multiple holes, and the cloth may be formed of the above described metals, chemical fibers and ceramic materials as mentioned above, which may be used alone or in combination of two or more.
  • the network, sheet or cloth material best-suited for casting may be picked up in consideration of the composition of magnesium alloys, the size and shape of castings, etc.
  • the network, the sheet, and the cloth may have flexibility.
  • the present invention may also be applied to continuous casting.
  • the mold assembly, and continuous casting rolls and belts of continuous casting equipment are each made of an air permeable material.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Mold Materials And Core Materials (AREA)
  • Forging (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
US12/934,441 2008-03-26 2009-03-18 Casting mold for magnesium alloy and method of casting magnesium alloy Abandoned US20110056644A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP2008080509A JP4748426B2 (ja) 2008-03-26 2008-03-26 マグネシウム合金用鋳型及びマグネシウム合金鋳造方法
JP2008-080509 2008-03-26
PCT/JP2009/056034 WO2009119701A1 (ja) 2008-03-26 2009-03-18 マグネシウム合金用鋳型及びマグネシウム合金鋳造方法

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US20110056644A1 true US20110056644A1 (en) 2011-03-10

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US12/934,441 Abandoned US20110056644A1 (en) 2008-03-26 2009-03-18 Casting mold for magnesium alloy and method of casting magnesium alloy

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US (1) US20110056644A1 (de)
EP (1) EP2263817A4 (de)
JP (1) JP4748426B2 (de)
CN (1) CN101977710A (de)
WO (1) WO2009119701A1 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10129375B1 (en) 2017-05-11 2018-11-13 Microsoft Technology Licensing, Llc Thin section interlock geometry for molding plastic

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106366531B (zh) * 2016-08-31 2018-10-02 广州经济技术开发区卜威工业有限公司 车架用复合材料及其制备方法
CN109746395B (zh) * 2019-03-06 2020-03-17 西安交通大学 一种易于脱芯的砂芯结构

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5684153A (en) * 1979-12-12 1981-07-09 Nissan Motor Co Ltd Manufacture of cast article having hollow part
US20070012417A1 (en) * 2005-07-12 2007-01-18 Chu Men G Method of unidirectional solidification of castings and associated apparatus

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
BE570320A (de) * 1957-08-16
JPS56160852A (en) * 1980-05-13 1981-12-10 Toshiba Corp Production of metallic mold
JPS61115643A (ja) * 1984-11-12 1986-06-03 Kao Corp 鋳物の製造方法
JP2763970B2 (ja) * 1991-05-09 1998-06-11 株式会社神戸製鋼所 セラミックシェル鋳型の製造方法
JPH1133674A (ja) * 1997-07-16 1999-02-09 Honda Motor Co Ltd 三次元網目構造を持つ多孔質鋳物の製造方法
JP3072088B1 (ja) * 1998-02-23 2000-07-31 花王株式会社 パルプモ―ルド成形品の製造方法
JP2002129272A (ja) 2000-10-31 2002-05-09 Ahresty Corp ダイカスト用マグネシウム合金
DE10357618B4 (de) * 2003-12-10 2008-01-24 Bender, Wilfried, Dr. Verfahren zum Herstellen eines Gussteils aus einer Metallschmelze

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5684153A (en) * 1979-12-12 1981-07-09 Nissan Motor Co Ltd Manufacture of cast article having hollow part
US20070012417A1 (en) * 2005-07-12 2007-01-18 Chu Men G Method of unidirectional solidification of castings and associated apparatus

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10129375B1 (en) 2017-05-11 2018-11-13 Microsoft Technology Licensing, Llc Thin section interlock geometry for molding plastic

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Publication number Publication date
CN101977710A (zh) 2011-02-16
EP2263817A1 (de) 2010-12-22
JP4748426B2 (ja) 2011-08-17
EP2263817A4 (de) 2013-05-15
JP2009233690A (ja) 2009-10-15
WO2009119701A1 (ja) 2009-10-01

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