US3848847A - Casting method for aluminum or aluminum alloys and a mold therefor - Google Patents

Casting method for aluminum or aluminum alloys and a mold therefor Download PDF

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Publication number
US3848847A
US3848847A US00375390A US37539073A US3848847A US 3848847 A US3848847 A US 3848847A US 00375390 A US00375390 A US 00375390A US 37539073 A US37539073 A US 37539073A US 3848847 A US3848847 A US 3848847A
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United States
Prior art keywords
mold
aluminum
metal
layer
carbide
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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.)
Expired - Lifetime
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US00375390A
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English (en)
Inventor
N Komatsu
T Arai
M Mizutani
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Toyota Central R&D Labs Inc
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Toyota Central R&D Labs Inc
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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
    • B22C3/00—Selection of compositions for coating the surfaces of moulds, cores, or patterns
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal

Definitions

  • ABSTRACT A method of casting aluminum or aluminum alloys characterized by utilizing a mold of ferrous or ferrous alloy members having at least a portion of the mold surface provided with a carbide layer of at least one metal selected from the Group V, Subgroup a of the periodic table.
  • the metal carbide layer' can be a vanadium carbide, a niobium carbide, or a tantalum carbide, which layer is preferably a diffusion layer on the ferrous alloy mold member having a thickness in the range of 2 to 100 microns.
  • the present invention is directed to a method of casting aluminum alloys, a mold used in casting, and a method of preparing the mold.
  • the present invention is directed to a method of castingaluminum oraluminum alloy to obtain castings with high dimensional accuracy, smooth casting surfaces and high quality by utilizing a mold having mold surfaces which obviate adhesion of the aluminum to the mold surface and'reduce wear of the ,mold surfaces.
  • the mold is formed of mold members of a ferrous metal as the base material and have a portion of the surface which is in contact with the molten aluminum or aluminum alloy formed with a metal carbide layer of at least one metal selected from Group V, Subgroup a of the-periodic table.
  • the metal carbide layer is preferably formed by a diffusion process comprising heating the mold member made of a ferrous metal containing carbon and subjecting the surface to be provided with the metal carbide layer to a powdery treating material,
  • FIG. 1 is a cross-sectional view of a mold utilized for aluminum die casting in accordance with the present invention
  • p FIG. 2 is a photomicrograph showing a niobium carbide layer formed on vthe surface of a core pin of a mold in accordance with the present invention
  • the movable die 2 has ejection pins 3 and a core pin 4.
  • the dies 1 and 2 each have surfaces which coact to form a gate 5 to a mold cavity formed by the two die members 1 and 2.
  • the fixed die 1 is provided with a sprue 6.
  • Prior art molds having a configuration of the mold illustrated in FIG. 1 were formed of steel alloys such as a quenched and tempered tool steel.
  • the areas around and near the gate 5 were subjected to wear or erosion due to the fast flow speed of the molten aluminum during casting operation.
  • Also projecting parts-such as a core pin head 41 of core pin 4 and the projection 11 in the fixed die I have a poor heat conduction and were subjected to both erosion and adhesion of the molten aluminum during casting.
  • the heads 31 of the ejection pins 3 were subjected to wear when pushing or removing the casting from the separated die members I and 2.
  • the present invention provides a metal carbide layer at least on those portions of the mold surface which are subjected to erosion, corrosion or wear -If desired, the entire mold surface can be provided with the metal carbide layer.
  • the carbide layer is a metal carbide of at least one metal selected from Group V, Subgroup a of the periodic table, and includes such metals as vanadium, niobium and/or tantalum. These metals form carbide layers of vanadium carbide (VC), niobium carbide (NbC) and tantalum carbide (TaC) respectively.
  • VC vanadium carbide
  • NbC niobium carbide
  • TaC tantalum carbide
  • Each of these metal carbides has great hardness, (hv: 3,000) and. high wear resistance during aluminum casting. Therefore, a mold for casting aluminum or aluminum alloy having a surface area provided with the abovementioned metal carbide layer has excellent durability. Thus, it is possible, to obtain a high quality casting of aluminum or aluminum alloy both efficiently
  • the mold members such as thedies l and 2 are formed of a ferrous metal containing carbon such as carbon steel or tool steel.
  • the metal carbide layer of the present invention adds the properties of high corrosion resistance and high wear resistance.
  • the metal carbide layer may be formed on either a portion of the mold surface or the entire mold surface by various methods.
  • An example is a diffusion method 'which includes'keeping a treating material containing the metal in contact withthe mold surface at a high temperature to form a diffusion layer by diffusion of the metal into the mold surface.
  • the carbide layers could also be formed by spraying.
  • the spraying method of providing the carbide layer the metal carbide layer is only bonded to the base metal of the mold by a mechanical bond.
  • the mold provided with a carbide layer by a method of spraying will not be suited for use as a casting mold since the carbide layer will easily peel off especially from thermal shock which occurs due to repeated heating and cooling during use of the mold.
  • the diffusion method of applying the metal carbide layer With the diffusion method of applying the metal carbide layer, a metallic bonding is obtained between the layer and the substrate of ferrous metal. Due to the metallic bonding, the layer-does not easily peel off the substrate even when subjected to repeated stresses due to the difierent coefficients of thermal expansion for the base metal of the mold and the metal carbide layer.
  • the diffusion method for preparing the mold surfaces may include any method such as a pack method which uses a powdery treating material, a gaseous method which treats the surface in a gaseous atmosphere, a fused salt method which treats the surfacein a high temperature fused salt or an electrolytic method which electrolytically treats the surface while in a fused salt.
  • either the entire surface or portions of the surface may be treated.
  • the surface 'to be treated is contacted with a powdery treating material consisting of a powder of the metal and a fluoroborate such as potassium tetrafluoroborate either by being packed in the material or having the treatment material spread over the specific part of the mold surface to be treated.
  • a powdery treating material consisting of a powder of the metal and a fluoroborate such as potassium tetrafluoroborate either by being packed in the material or having the treatment material spread over the specific part of the mold surface to be treated.
  • the entire arrangement is heated with the fluoroborate which activates the metal and the metal in the material diffuses into the surface and acts with the carbon in the base metal to form the metal carbide layer.
  • a bath of fused boric acid or borate' such as sodium borate, i.e., borax, containing the metal element is prepared and the mold'member is then inserted into the fused bath for a period of time to obtain the diffusion of the metal into the surface layer.
  • an electrolytic treatment of the mold member i'nthe fused bath can be utilized by making the mold member a cathode and such a treatment enables the obtaining of the metal carbide layer in a shorter period of time.
  • the thickness of the carbide layer formed on the mold surface maybe between 2 to 3 microns toabout 100 microns;
  • the carbide, layer with a thickness of less than 2 microns will have insufficient corrosionresistance and wear resistance and the life of the mold may be shortened.
  • a carbide layer with a thickness greater than 100 microns will have less resistance to thermal shock and will easily peeloff of the mold.
  • the treated pin was subjected to a tempering in charcoal powder at 550C. for a period of 1 hour.
  • the carbide layer 51 had a Vickers hardness of 2600 and the base metal had a Rockwell hardness" (Scale C) of 45. Thus, the carbide layer was found to be extremely hard,
  • EXAMPLE 2 A core pin for gravity casting having a diameter of 23 mm and a length of 180 mm and a spool core for die casting having a diameter of 80 mm and a length of 80 mm were made from an annealed alloy tool steel (81(1) 61) and a metal carbide layer was formed thereon by l the same method as inExample 1.
  • the core pin and provement comprising using a casting mold having portions of the surface of the mold members forming the least one metal selected from Group V, Subgroup aof the periodic table. t I I
  • the present invention is described in more detail by the following examples:
  • mold cavity provided with a metal carbide layer of at spool core were assembled into their separate mold and an aluminum alloy was cast.
  • the pin for the gravity casting was still usable even after 3,000 shots.
  • aluminum adhesion appeared only after 2,000 shots and the adhered aluminum was easily removed by brushing the core in the mold to make the core usable.
  • a'conventional core pin for gravitycasting and aspool core for die casting made from annealed alloy tool steel (SKD 61) could not be used after the 1,000 shot, respectively, due to the adhesion of aluminum,
  • EXAMPLE 3 A core pin having dimensions of approximately 80 X 120 X 170 mm and having a cavity was made from an I annealed alloy tool steel (SKDGI). It was treated by The .core pin was made from an annealed alloy tool steel (Japanese lndustrial Standard SKD 61). The core pi'n was provided with the layer of metal carbide by being immersed in a bath of fused borax (Na B O which was mixed with 20 percent ferroniobium powder (containing 63 percent niobium and 6 percent tantalum) for a period of 8 hours at a temperature of 950C. 4
  • fused borax Na B O which was mixed with 20 percent ferroniobium powder (containing 63 percent niobium and 6 percent tantalum) for a period of 8 hours at a temperature of 950C. 4
  • Example 2 A part of the core pin was cut off and the surface layer was examined just as in Example 1 by a microscope, X-ray microanalyzer and X-ray diffraction. As a result of the examination, the layer had a thickness of approximately 12 microns and was a vanadium carbide (VC) layer containing almost no iron.
  • VC vanadium carbide
  • a core pin formed by the above treatment was assembled in the mold, and the casting operation was performed. As a result of the casting, there was no aluminum adhesion on the core pin of the present invention up to 5,000 shots.
  • a conventional core pin made from conventional quenched and tempered alloy tool steel (SKD 61) had adhesion of aluminum on the projected portions of the mold surface after the 2,000th shot.
  • the test confirmed the durability of the mold having a vanadium carbide layer as being superior to the conventional core pin just'as the niobium carbide layer proved to be superior to the conventionalv mold.
  • EXAMPLE 4 A fixed die and a movable die suchas dies 1' and 2 of the mold shown in FIG. 1 were made from an annealed alloy tool steel (SKD 6l Using the same method as in Example 3, thedies 1 and 2 were packed cellent durability and a casting method requiring very the adhesion of aluminum, and also has excellent wear resistance due to the hardness of the metal carbide layer, the present invention produces a mold with exlittle repair work and which casting method produces castings with smooth surfaces.
  • SBD 6l annealed alloy tool steel
  • a mold for casting aluminum or aluminum alloys comprising at least two mold members having mold surfaces coacting to form a cavity for receiving the molten aluminum or aluminum alloy, each of said mold members being of a ferrous metal, the improvement comprising at least a: portion of the mold surface of at least one mold member being a metal carbide layer of in two iron cases with each case containing a powdery treatment material consisting of 80 percent ferrovanadium and 20 percent potassium tetrafluoroborate.
  • a powdery treatment material consisting of 80 percent ferrovanadium and 20 percent potassium tetrafluoroborate.
  • Each case was heated for 6 hours at 1.,000C. in an electric furnace. At the end ofthe 6 hour period, the cases were taken out of the furnace and cooled in air.
  • the surfaces of dies 1 and 2 each had a vanadium carbide (VC) layer.
  • the carbide layer which was both dense and uniform, was approximately 11 microns in thickness.
  • the present invention relates to a mold for use in a method of casting aluminum or aluminum alloy which mold is made of ferrous basemetal and has a portion or the entire mold surface provided with a metal carbide layer with the metal selected from Group V, Subgroup a of the periodic table. Since the metal carbide layer formed on the mold surface has excellent corrosion resistance to molten aluminum, serves to reduce at least one metal being selected from Group V, Subgroup a of the periodic table.
  • the metal carbide is a niobium carbide.
  • mold members include at least one core. pin having a surface layer of said metal carbide.
  • a method of casting molten aluminum or aluminum alloys comprising providing a casting mold formed of atleast two mold members of a ferrous alloy having surfaces coacting to form a mold cavity, pouring the molten aluminum or aluminum alloys into the mold cavity, and allowing the molten metal to solidify, the improvement comprising using a casting mold having a portion of the surface. of the mold members forming the mold cavity provided with a metal carbide layer of at least one metal selected from Group V, Subgroup a of the periodic table.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Chemical Vapour Deposition (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
US00375390A 1972-07-11 1973-07-02 Casting method for aluminum or aluminum alloys and a mold therefor Expired - Lifetime US3848847A (en)

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JP6976772A JPS5318970B2 (sk) 1972-07-11 1972-07-11

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US (1) US3848847A (sk)
JP (1) JPS5318970B2 (sk)
CA (1) CA1001823A (sk)
FR (1) FR2194504B1 (sk)
GB (1) GB1407729A (sk)

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4027716A (en) * 1974-03-11 1977-06-07 Metallgesellschaft Aktiengesellschaft Method for preparing a continuous casting belt
US4197902A (en) * 1976-07-31 1980-04-15 Kabel-Und Metallwerke Gutehoffnungshuette Ag Molds for continuous casting of metals
US5318091A (en) * 1991-11-22 1994-06-07 Borgo-Nova Spa Die coating
US5337800A (en) * 1992-09-09 1994-08-16 Cook Arnold J Reactive coating
US5445514A (en) * 1993-09-22 1995-08-29 Heitz; Lance A. Refractory material coated metal surfaces adapted for continuous molding of concrete blocks
US20060151139A1 (en) * 2002-10-30 2006-07-13 Hiroaki Koyama Mold for casting and method for manufacture thereof
US20090224443A1 (en) * 2008-03-05 2009-09-10 Rundquist Victor F Niobium as a protective barrier in molten metals
US8574336B2 (en) 2010-04-09 2013-11-05 Southwire Company Ultrasonic degassing of molten metals
US8652397B2 (en) 2010-04-09 2014-02-18 Southwire Company Ultrasonic device with integrated gas delivery system
US9528167B2 (en) 2013-11-18 2016-12-27 Southwire Company, Llc Ultrasonic probes with gas outlets for degassing of molten metals
US10233515B1 (en) 2015-08-14 2019-03-19 Southwire Company, Llc Metal treatment station for use with ultrasonic degassing system
US20190111467A1 (en) * 2016-06-16 2019-04-18 Mitsubishi Electric Corporation Semiconductor-mounting heat dissipation base plate and production method therefor

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5778370A (en) * 1980-11-04 1982-05-17 Hitachi Ltd Power converter
JP2687055B2 (ja) * 1991-06-11 1997-12-08 トヨタ自動車株式会社 ダイカスト用金型

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB489266A (en) * 1937-12-31 1938-07-22 Joseph Beckett Improvements in forming castings from metals of high melting points
GB836421A (en) * 1956-07-10 1960-06-01 Airtron Inc Method of making high frequency power dissipating terminations
US3666531A (en) * 1970-07-16 1972-05-30 Nalco Chemical Co Metal casting process
US3680626A (en) * 1969-04-15 1972-08-01 Toyota Motor Co Ltd Corrosion-resistant surface coating for use in the casting of aluminum and aluminum alloys

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS4911129A (sk) * 1972-05-31 1974-01-31

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB489266A (en) * 1937-12-31 1938-07-22 Joseph Beckett Improvements in forming castings from metals of high melting points
GB836421A (en) * 1956-07-10 1960-06-01 Airtron Inc Method of making high frequency power dissipating terminations
US3680626A (en) * 1969-04-15 1972-08-01 Toyota Motor Co Ltd Corrosion-resistant surface coating for use in the casting of aluminum and aluminum alloys
US3666531A (en) * 1970-07-16 1972-05-30 Nalco Chemical Co Metal casting process

Cited By (22)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4027716A (en) * 1974-03-11 1977-06-07 Metallgesellschaft Aktiengesellschaft Method for preparing a continuous casting belt
US4197902A (en) * 1976-07-31 1980-04-15 Kabel-Und Metallwerke Gutehoffnungshuette Ag Molds for continuous casting of metals
US5318091A (en) * 1991-11-22 1994-06-07 Borgo-Nova Spa Die coating
US5337800A (en) * 1992-09-09 1994-08-16 Cook Arnold J Reactive coating
US5445514A (en) * 1993-09-22 1995-08-29 Heitz; Lance A. Refractory material coated metal surfaces adapted for continuous molding of concrete blocks
US20060151139A1 (en) * 2002-10-30 2006-07-13 Hiroaki Koyama Mold for casting and method for manufacture thereof
US7497243B2 (en) * 2002-10-30 2009-03-03 Honda Motor Co., Ltd. Mold for casting and method for manufacture thereof
US8844897B2 (en) * 2008-03-05 2014-09-30 Southwire Company, Llc Niobium as a protective barrier in molten metals
US20090224443A1 (en) * 2008-03-05 2009-09-10 Rundquist Victor F Niobium as a protective barrier in molten metals
EP2452763A1 (en) * 2008-03-05 2012-05-16 Southwire Company Graphite die with protective niobium layer and associated die-casting method
US9327347B2 (en) 2008-03-05 2016-05-03 Southwire Company, Llc Niobium as a protective barrier in molten metals
US8652397B2 (en) 2010-04-09 2014-02-18 Southwire Company Ultrasonic device with integrated gas delivery system
US8574336B2 (en) 2010-04-09 2013-11-05 Southwire Company Ultrasonic degassing of molten metals
US9382598B2 (en) 2010-04-09 2016-07-05 Southwire Company, Llc Ultrasonic device with integrated gas delivery system
US9617617B2 (en) 2010-04-09 2017-04-11 Southwire Company, Llc Ultrasonic degassing of molten metals
US10640846B2 (en) 2010-04-09 2020-05-05 Southwire Company, Llc Ultrasonic degassing of molten metals
US9528167B2 (en) 2013-11-18 2016-12-27 Southwire Company, Llc Ultrasonic probes with gas outlets for degassing of molten metals
US10316387B2 (en) 2013-11-18 2019-06-11 Southwire Company, Llc Ultrasonic probes with gas outlets for degassing of molten metals
US10233515B1 (en) 2015-08-14 2019-03-19 Southwire Company, Llc Metal treatment station for use with ultrasonic degassing system
US20190111467A1 (en) * 2016-06-16 2019-04-18 Mitsubishi Electric Corporation Semiconductor-mounting heat dissipation base plate and production method therefor
US10898946B2 (en) * 2016-06-16 2021-01-26 Mitsubishi Electric Corporation Semiconductor-mounting heat dissipation base plate and production method therefor
US11484936B2 (en) 2016-06-16 2022-11-01 Mitsubishi Electric Corporation Semiconductor-mounting heat dissipation base plate and production method therefor

Also Published As

Publication number Publication date
JPS4928526A (sk) 1974-03-14
CA1001823A (en) 1976-12-21
DE2335185B2 (de) 1975-08-21
GB1407729A (en) 1975-09-24
FR2194504B1 (sk) 1977-02-18
FR2194504A1 (sk) 1974-03-01
JPS5318970B2 (sk) 1978-06-17
DE2335185A1 (de) 1974-01-24

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