US20110056646A1 - Method for producing cast molded parts as well as cast molded parts produced according to the method - Google Patents

Method for producing cast molded parts as well as cast molded parts produced according to the method Download PDF

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Publication number
US20110056646A1
US20110056646A1 US12/735,895 US73589509A US2011056646A1 US 20110056646 A1 US20110056646 A1 US 20110056646A1 US 73589509 A US73589509 A US 73589509A US 2011056646 A1 US2011056646 A1 US 2011056646A1
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United States
Prior art keywords
recited
cast
cast molded
molded part
copper alloy
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Abandoned
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US12/735,895
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English (en)
Inventor
Thomas Helmenkamp
Dirk Rode
Markus Niemann
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KME Special Products GmbH and Co KG
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KME Germany GmbH
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Filing date
Publication date
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Assigned to KME GERMANY AG & CO. KG reassignment KME GERMANY AG & CO. KG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HELMENKAMP, THOMAS, NIEMANN, MARKUS, RODE, DIRK
Publication of US20110056646A1 publication Critical patent/US20110056646A1/en
Assigned to KME GERMANY AG & CO. KG reassignment KME GERMANY AG & CO. KG MERGER (SEE DOCUMENT FOR DETAILS). Assignors: KME GERMANY AG
Assigned to KME GERMANY GMBH & CO. KG reassignment KME GERMANY GMBH & CO. KG CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: KME GERMANY AG & CO. KG
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
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/04—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
    • B22D11/059—Mould materials or platings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/06—Permanent moulds for shaped castings
    • B22C9/061—Materials which make up the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
    • B22D11/0637—Accessories therefor
    • B22D11/0648—Casting surfaces
    • B22D11/066—Side dams
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C9/00—Alloys based on copper
    • C22C9/06—Alloys based on copper with nickel or cobalt as the next major constituent
    • 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
    • C22F1/08—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of copper or alloys based thereon

Definitions

  • the present invention relates to a method for producing cast molded parts from a copper alloy containing silicon, nickel, chromium and zirconium as well as intermetallic primary phases. Furthermore, the present invention relates to cast molded parts produced according to this method.
  • the material In order to avoid premature wear of the side edges of the blocks due to mechanical stressing, which leads to the formation of gaps between the blocks and then to the penetration of the molten mass into this gap, the material must exhibit not only high hardness and tensile strength but also a small grain size.
  • optimum fatigue behavior of the material is of the most decisive significance, which will ensure that the thermal stresses arising during cooling of the blocks after they leave the casting line do not lead to cracking of the blocks at the corners of the T groove incorporated for the accommodation of the steel band. If such cracks caused by thermal shock do appear, the respective form block will fall out of the chain after even a short period of time and molten metal is able to run uncontrollably from the casting form cavity and damage parts of the installation. An exchange of the faulty block requires the system to be stopped and the casting operation to be interrupted.
  • the zirconium-containing, curable CuNiSiCr alloy described in EP 0 346 645 B1 is extremely suitable for blocks in side dams of twin-belt casting systems.
  • the addition of chromium increases the conductivity of the material.
  • the Fe addition restricts the increase in grain size during the solutionizing treatment without adversely affecting the other properties of the material.
  • intermetallic primary phases occur in the structure of the chromium- and zirconium-containing material, which crystallize in hypoeutectic manner, i.e., with an inhomogeneous distribution, during the solidification of the melt.
  • these CrSi-containing and NiZr-containing phases already occur in the cast round ingots that are used as starting material for the production of blocks for the side dams of twin-belt casting systems.
  • the molten material is usually formed while still warm, employing conventional deformation processes such as extrusion, forging or rolling, and subsequently solutionized and cured; in the process, the eutectic, inhomogeneous distribution of the intermetallic primary phases of the casting state are more or less destroyed, and the primary phases are aligned in the form of bands in the main deformation direction.
  • conventional deformation processes such as extrusion, forging or rolling, and subsequently solutionized and cured; in the process, the eutectic, inhomogeneous distribution of the intermetallic primary phases of the casting state are more or less destroyed, and the primary phases are aligned in the form of bands in the main deformation direction.
  • the present invention is based on the objective of optimizing a method for producing cast molded parts, in particular for producing blocks for side dams of twin-band casting systems, such that the wear of the casting surfaces coming into contact with molten metal sets in later and progresses more slowly, so that a cast metal band featuring a perfect surface quality is able to be produced over a longer period of production using the cast molded parts. Furthermore, a cast molded part having improved properties is to be provided.
  • the invention provides a method for producing cast molded parts made from a copper alloy containing at least one alloy element from each of the groups a) and b), group a) including nickel and cobalt, and group b) including chromium, zirconium, beryllium and silicon, as well as intermetallic primary phases, a cast ingot being ironed by hot deformation in only one direction, at a ratio of at least 4:1; an angle of 90° ⁇ 10° relative to the ironing direction of the cast ingot being selected for a casting surface, which comes into contact with the molten metal, of a cast molded part that is produced from the ironed cast ingot.
  • FIG. 1 is a micrograph of a cast round ingot which can be used as a starting material for the production of cast molded parts of side dams of a twin-belt casting system.
  • FIG. 2 shows the distribution of the intermetallic primary phases of a cast ingot that already underwent hot deformation, and thus the micrograph in the region of the casting surface of a later cast component.
  • FIG. 3 shows a micrograph perpendicular to the casting surface and thus perpendicular to the micrograph of FIG. 2 .
  • the objective underlying the present invention is achieved in that selective hot deformation is used to orient the intermetallic primary phases included in the copper alloy in such a way that a casting surface, which comes into contact with the molten metal, of a cast molded part that is produced from the ironed cast ingot is selected to be at an angle of 90° ⁇ 10°, i.e., essentially perpendicular, to the ironing direction of the cast ingot.
  • Essentially perpendicular as used in the following text means an angle of 90 ⁇ 10° relative to the ironing direction of the cast ingot. Perpendicular denotes an angle of 90°.
  • the essential aspect in this procedure is that the hot shaping of the cast ingot not only produces the fine-grained structure recrystallization of the originally coarse-grained casting structure, but also a distinct fiber orientation featuring a reduction in size and an alignment of the intermetallic primary phases in line with these fibers.
  • the fiber orientation has fine and evenly distributed primary phases, which in the framework of the present invention is achieved in that the ironing by hot forming takes place in only a single direction, the cast ingot being ironed at a ratio of at least 4:1, preferably more than 7:1.
  • the hot forming may be performed employing methods such as forging or hot rolling.
  • a sweeping overall deformation of at least 4:1 or preferably of at least 7:1, in different directions does not lead to the fiber flow aimed for according to the present invention.
  • the intermetallic primary phases in the casting surface essentially manifest themselves only in the form of evenly distributed dots. It is considered useful if the quantitative proportion of the intermetallic primary phases, cut in a micrograph, between the casting surface and the sides of the ironed casting ingot standing perpendicular to the casting surface is set to be greater than 1.5:1. This means that at least 50% more intermetallic primary phases are cut in the casting surface, or in a plane running essentially perpendicular to the ironing direction, than in a side or plane perpendicular to the casting surface.
  • the cast molded part produced according to the method of the present invention has a fiber flow that causes the intermetallic primary phases to be arranged in fibers or bands as well.
  • there are bands of intermetallic primary phases in the casting surface whose length corresponds to maximally 30% of the length of a band of an intermetallic primary phase that runs essentially or precisely perpendicular to the casting surface.
  • the cast molded part according to the present invention is made of a curable copper alloy, which for this purpose contains alloy components which precipitate as intermetallic phases.
  • the curable copper alloy preferably contains nickel, which may be at least partially replaced by cobalt.
  • the alloy contains at least one of the following alloy elements: chromium, zirconium, beryllium, silicon.
  • the finished cast molded part is characterized by excellent material properties tailored to the specific application case, i.e., especially by a tensile strength of at least 600 MPa at a room temperature of 20° C., and a tensile strength of at least 350 MPa at a temperature of 500° C.
  • the electric conductivity preferably amounts to at least 45%.
  • the cured copper alloy is to feature a grain size of maximally 130 ⁇ m measured according to ASTM E 112.
  • the U.S. ASTM E 112 standard (American Society for Testing and Materials) is a standard testing method for determining the average grain size.
  • FIG. 1 shows a micrograph of a cast round ingot, which is used as starting material for the production of cast molded parts of side dams of a twin-belt casting system. It involves the typical cast structure of a CuNiSiCrZr alloy having CrSi-containing or NiZr-containing intermetallic primary phases in a eutectic arrangement. Subsequently, deformation methods such as extrusion, forging or rolling are used to deform the material in order to adjust a fine-grained structure and to achieve the required hardness and electrical conductivity; then, the material is subjected to a solutionizing treatment and cured, so that a change occurs in the eutectic, inhomogeneous distribution of the intermetallic primary phases.
  • deformation methods such as extrusion, forging or rolling are used to deform the material in order to adjust a fine-grained structure and to achieve the required hardness and electrical conductivity; then, the material is subjected to a solutionizing treatment and cured, so that a change occurs
  • FIG. 2 shows the distribution of the intermetallic primary phases of a cast ingot that already underwent hot deformation, and thus the micrograph in the region of the casting surface of a later cast component. It can be seen quite clearly that the intermetallic primary phases are very fine and evenly distributed. The fiber orientation, or the orientation of the intermetallic primary phases, runs perpendicular to the casting surface, so that the cut primary phases appear as dots in this figure.
  • the number of cut primary phases is approximately 1.7 as high as in FIG. 3 , which shows a micrograph perpendicular to the casting surface and thus perpendicular to the micrograph of FIG. 2 . While the phase bands are discernible only in rudimentary form in FIG. 2 and have a maximum length of approximately 100 ⁇ m, a much higher number of primary phase bands can be seen in FIG. 3 , the phase band lengths ranging from 100 to 400 ⁇ m, and partially amounting to more than 400 ⁇ m.
  • the following table illustrates the mechanical properties and the fatigue resistance of cast molded parts made from CuNiSiCrZr alloys according to the method of the present invention.
  • Exemplary embodiment A is based on an alloy having the following composition in weight-%:
  • This alloy was smelted in an induction crucible furnace and cast in the form of a round ingot using an extrusion method.
  • the round ingot was preheaded in a forging press within a temperature range between 950° C. and 750° C. and then shaped into a cuboid.
  • the cuboid was subsequently forged into a plate in the longitudinal direction.
  • This blocked plate was then rolled to its final dimensions in a hot rolling mill between 950° C. and 800° C.
  • the overall deformation ratio R in the longitudinal direction based on the preheaded length and ending with the completely rolled plate length, amounted to 5.3:1.
  • the plate was subsequently solution-annealed and cured.
  • the cooling following the curing was performed in a kiln at a defined cooling rate. Subsequently, the plate was sawed into horizontal strips, and these strips were then used to produce cast molded parts, also referred to as dam blocks, having the dimensions of 70 mm ⁇ 50 mm ⁇ 40 mm.
  • the cast molded parts having dimensions of 60 mm ⁇ 50 mm ⁇ 40 mm or 50 mm ⁇ 50 mm ⁇ 40 mm may be obtained in the same manner as well.
  • the casting surfaces of the cast molded parts in essence come to lie exactly perpendicular to the longitudinal direction of the plate, and thus preferably in essence also exactly perpendicular to the ironing direction of the deformed cast ingot or the fiber alignment.
  • the table reproduces the mechanical/technical properties and also the fatigue resistance of formed molded parts thus produced, in comparison with cast molded parts whose fibers lie parallel to the casting surface and which have not been subjected to a preferred deformation at a ratio of at least 4:1.
  • the cast molded parts produced according to the present invention having an alignment of the intermetallic phases that runs perpendicular to the casting surface, exhibit a fatigue resistance that is 17% higher than that of cast molded parts whose fiber position runs parallel to the casting surface.
  • This alloy too, was smelted in an induction crucible furnace and cast in the form of a round ingot using an extrusion method. Then, the round ingot was rolled into a plate on a hot rolling mill between 950° C. and 800° C.
  • the overall deformation ratio R in the longitudinal direction relative to the starting length of the cast ingot amounts to 7.4:1, and thus corresponds to the preferred specification according to the present invention of at least 7:1.
  • Table 1 once again reproduces the hardness properties of the cast molded parts having primary phases that run perpendicular to the ironing direction, in comparison with cast molded parts whose intermetallic primary phases run parallel to the casting direction.
  • the cast molded parts produced according to the present invention and shown in exemplary embodiment B exhibit a fatigue resistance that is even 26% higher in comparison with cast molded parts having a fiber alignment parallel to the casting surface, the mechanical properties being approximately equal.
  • the exemplary embodiments illustrate that the cast molded parts produced according to the present invention provide a fatigue behavior of the casting surface that it 17 to 26% better than comparable cast molded parts having a fiber and phase alignment parallel to the casting surface or having no preferred orientation.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Continuous Casting (AREA)
  • Forging (AREA)
US12/735,895 2008-03-19 2009-03-19 Method for producing cast molded parts as well as cast molded parts produced according to the method Abandoned US20110056646A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102008015096A DE102008015096A1 (de) 2008-03-19 2008-03-19 Verfahren zur Herstellung von Gießformteilen sowie nach dem Verfahren hergestellte Gießformteile
DE102008015096.7 2008-03-19
PCT/DE2009/000359 WO2009115081A1 (de) 2008-03-19 2009-03-19 Verfahren zur herstellung von giessformteilen sowie nach dem verfahren hergestellte giessformteile

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US20110056646A1 true US20110056646A1 (en) 2011-03-10

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US12/735,895 Abandoned US20110056646A1 (en) 2008-03-19 2009-03-19 Method for producing cast molded parts as well as cast molded parts produced according to the method

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US (1) US20110056646A1 (zh)
EP (1) EP2280794A1 (zh)
JP (1) JP5328886B2 (zh)
CN (1) CN101945719B (zh)
CA (1) CA2718808C (zh)
DE (1) DE102008015096A1 (zh)
RU (1) RU2492961C2 (zh)
WO (1) WO2009115081A1 (zh)

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5736040A (ja) * 1980-08-11 1982-02-26 Chuetsu Gokin Chuko Kk Sekishutsukokagatarenzokuchuzoyoigatazairyo
US4415374A (en) * 1982-03-30 1983-11-15 International Telephone And Telegraph Corporation Fine grained metal composition
US5069270A (en) * 1988-06-14 1991-12-03 Km-Kabel Metall Ag Continuous casting mold
JPH0987815A (ja) * 1995-09-22 1997-03-31 Mitsubishi Materials Corp 製鋼連続鋳造用銅合金モールド素材の製造方法およびそれにより製造されたモールド
US6565681B1 (en) * 1994-08-06 2003-05-20 Km-Kabelmetal Aktiengesellschaft Age-hardenable copper alloy casting molds
US20030159763A1 (en) * 2002-02-15 2003-08-28 Thomas Helmenkamp Age-hardenable copper alloy
US6668907B1 (en) * 1999-06-23 2003-12-30 Vacuumschmelze Gmbh Casting wheel produced by centrifugal casting
US20050230014A1 (en) * 2004-04-14 2005-10-20 Masahiko Ishida Copper alloy and method of manufacturing the same

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5370923A (en) * 1976-12-06 1978-06-23 Kobe Steel Ltd Mold in copper alloy for steel continuous casting
LU82346A1 (fr) * 1980-04-08 1981-12-02 Liege Usines Cuivre Zinc Perfectionnements aux blocs de rive pour la coulee continue de barres de cuivre
JP2738130B2 (ja) * 1990-05-25 1998-04-08 三菱マテリアル株式会社 高冷却能を有する高強度Ｃｕ合金製連続鋳造鋳型材およびその製造法
JPH04210438A (ja) * 1990-12-13 1992-07-31 Mitsubishi Materials Corp 高強度Ｃｕ　合金製連続鋳造鋳型材
TW590822B (en) * 2001-11-21 2004-06-11 Km Europa Metal Ag Casting-roller for a two-roller-casting equipment and its manufacturing method
DE10156925A1 (de) * 2001-11-21 2003-05-28 Km Europa Metal Ag Aushärtbare Kupferlegierung als Werkstoff zur Herstellung von Giessformen
DE10227034A1 (de) * 2002-06-17 2003-12-24 Km Europa Metal Ag Kupfer-Gießform
CN100425717C (zh) * 2006-08-16 2008-10-15 苏州有色金属加工研究院 引线框架用铜合金及其制造方法

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5736040A (ja) * 1980-08-11 1982-02-26 Chuetsu Gokin Chuko Kk Sekishutsukokagatarenzokuchuzoyoigatazairyo
US4415374A (en) * 1982-03-30 1983-11-15 International Telephone And Telegraph Corporation Fine grained metal composition
US5069270A (en) * 1988-06-14 1991-12-03 Km-Kabel Metall Ag Continuous casting mold
US6565681B1 (en) * 1994-08-06 2003-05-20 Km-Kabelmetal Aktiengesellschaft Age-hardenable copper alloy casting molds
JPH0987815A (ja) * 1995-09-22 1997-03-31 Mitsubishi Materials Corp 製鋼連続鋳造用銅合金モールド素材の製造方法およびそれにより製造されたモールド
US6668907B1 (en) * 1999-06-23 2003-12-30 Vacuumschmelze Gmbh Casting wheel produced by centrifugal casting
US20030159763A1 (en) * 2002-02-15 2003-08-28 Thomas Helmenkamp Age-hardenable copper alloy
US20050230014A1 (en) * 2004-04-14 2005-10-20 Masahiko Ishida Copper alloy and method of manufacturing the same

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JP2011518668A (ja) 2011-06-30
CA2718808A1 (en) 2009-09-24
WO2009115081A1 (de) 2009-09-24
CN101945719A (zh) 2011-01-12
EP2280794A1 (de) 2011-02-09
JP5328886B2 (ja) 2013-10-30
RU2010142458A (ru) 2012-04-27
CN101945719B (zh) 2013-03-13
CA2718808C (en) 2015-05-26
DE102008015096A1 (de) 2009-09-24
RU2492961C2 (ru) 2013-09-20

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