WO2006021082B1 - Apparatus for metal foam casting and methods therefor - Google Patents
Apparatus for metal foam casting and methods thereforInfo
- Publication number
- WO2006021082B1 WO2006021082B1 PCT/CA2005/001278 CA2005001278W WO2006021082B1 WO 2006021082 B1 WO2006021082 B1 WO 2006021082B1 CA 2005001278 W CA2005001278 W CA 2005001278W WO 2006021082 B1 WO2006021082 B1 WO 2006021082B1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- molten metal
- mould
- gas injection
- crucible
- injection nozzle
- Prior art date
Links
Classifications
-
- 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
- B22D18/06—Vacuum casting, i.e. making use of vacuum to fill the mould
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D25/00—Special casting characterised by the nature of the product
- B22D25/005—Casting metal foams
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Continuous Casting (AREA)
- Manufacture And Refinement Of Metals (AREA)
Abstract
An apparatus for casting a metal foam article comprises a crucible for containing the molten metal, a gas injection nozzle located above the level of the molten metal when at the neutral level, and a mould having a mould cavity of the shape of the article. The apparatus includes a means for raising the level of the molten metal above the gas injection nozzle for generating the foam. A method for casting the foam article comprises maintaining the level of the molten metal below the gas injection nozzle until foaming is desired, raising the level of the molten metal above the gas injection nozzle and injecting a gas into the molten metal for generating the metal foam. The method also comprises directing the foam into the mould and cooling the foam to form the foam article. The apparatus may be constructed of separable modules thereby allowing the process to be tailored to meet specific requirements.
Claims
1. An apparatus for casting a metal foam article from a foam of a molten metal, the apparatus comprising:
- a crucible for containing a molten metal;
- at least one mould, wherein the mould includes at least one mould cavity having the shape of said article and at least one opening for fluid communication between said crucible and said cavity;
- at least one gas injection nozzle, connected to a gas supply3 the gas injection nozzle being positioned below said mould cavity opening; and
- a flow generating means for causing said molten metal to flow from the crucible to the mould, whereby the molten metal level in said crucible is varied from a first level below the gas injection nozzle to a second level above the gas injection nozzle.
2. The apparatus of claim 1 wherein said flow generating means comprises a pressurizing means, a vacuum meansj a pump, a displacement means, gravity, or any combination thereof.
3. The apparatus of claim 2 wherein said crucible comprises a first chamber and a second chamber, wherein:
- said first and second chambers are in fluid communication with each other whereby molten metal flows between said chambers;
- said flow generating means is provided in the first chamber; and,
■ said mould and said gas injection nozzle are provided on the second chamber.
4. The apparatus of claim 3 wherein said first chamber is provided with a filling port for introducing molten metal into the first chamber,
5. The apparatus of claim 3 further including a molten metal reservoir in fluid communication with said first chamber.
6. The apparatus of claim 5 wherein said reservoir extends vertically higher than the height of the mould cavity.
24 21501411.1
7. The apparatus of claim 6 wherein said reservoir includes a monitoring means for monitoring the level of molten metal contained therein.
8. The apparatus of claim 7 wherein said monitoring means is connected to a processor and wherein said processor controls the gas supply for said gas injection nozzle.
9. The apparatus of claim 3 wherein said second chamber includes a guide for guiding molten metal or metal foam into said mould cavity.
10. The apparatus of claim 2 wherein said pressurizing means includes a pressurized gas supply.
11. The apparatus of claim 3 wherein at least one of said chambers is provided with a mixer for stirring the molten metal.
12. The apparatus of claim 1 further including a riser tube provided in said crucible and extending through the molten metal contained in the crucible, the riser tube having an upper end opening into said mould cavity and a lower end proximal to the bottom of the crucible.
13. The apparatus of claim 12 wherein the bottom of said crucible is concavely shaped.
14. The apparatus of claim 12 wherein said pressurizing means includes a pressurized gas supply.
15. The apparatus of claim 3 wherein one or more of said crucible, first chamber, second chamber, and mould are releasably connected to each other.
16. A method of casting a metal foam article from a foam of a molten metal comprising: a) providing a crucible containing said molten metal; b) providing at least one mould having a mould cavity having the shape of said article, the mould cavity having an opening into said crucible for fluid communication therewith; c) providing at least one gas injection nozzle below said mould cavity opening; d) maintaining the level of the molten metal below said gas injection nozzle; e) raising the level of the molten metal above the gas injection nozzle;
21501411,1 25 f) injecting gas through said gas injection nozzle to generate a foam of said molten metal; g) directing said foam into said mould cavity;. h) filling said mould cavity with said foam and allowing said foam to cool; i) returning the level of said molten metal level to below the gas injection nozzle; j) removing said formed article from the mould cavity.
17, The method of claim 16 wherein said gas injection is ceased when said molten metal level is below the gas injection nozzle.
18 , The method of claim 16 wherein said step (e) includes filling said mould cavity with the molten metal.
19, The method of claim 16 wherein said step (e) comprises establishing a pressure within the crucible, said pressure being sufficient to cause the level of the molten metal to rise above the gas injection nozzle and flow into and fill said mould cavity.
20, An apparatus for casting a metal foam article from a foam of a molten metal, the apparatus comprising:
- a crucible for containing a molten metal;
- at least one mould, wherein the mould includes at least one mould cavity having the shape of said article and an opening for fluid communication between said crucible and said cavity;
- at least one gas injection nozzle, connected to a gas supply; and
- a flow generating means for causing said molten metal to flow from the crucible to the mould; wherein said crucible and mould are releasably connected together,
21 , The apparatus of claim 20 wherein said flow generating means comprises a pressurizing means, a vacuum means, a pump, a displacement means, gravity, or any combination thereof.
22, The apparatus of claim 21 wherein said crucible comprises a first chamber and a second chamber, wherein:
21501411,1 26 - said first and second chambers are in fluid communication with each other whereby molten metal flows between said chambers;
- said flow generating means is provided in the first chamber; and,
- said mould and said gas injection nozzle are provided on the second chamber.
23. The apparatus of claim 22 wherein said mould is releasably connected to said second chamber.
24. The apparatus of claim 23 wherein said first and second chambers are releasably connected together.
25. The apparatus of claim 24 wherein said mould is fluidly connected to said second chamber through a conduit.
26. The apparatus of claim 24 wherein said first and second chambers are fluidly connected through a conduit.
27. The apparatus of claim 20 wherein said mould includes multiple cavities.
28. The apparatus of claim 22 wherein said apparatus includes multiple gas injection nozzles.
29. The apparatus of claim 20 wherein said flow generating means maintains the level of molten meal between a first level below the gas injection nozzle and a second level above the gas injection nozzle.
21501411.1 27
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US60355404P | 2004-08-24 | 2004-08-24 | |
| US60/603,554 | 2004-08-24 | ||
| US70228605P | 2005-07-26 | 2005-07-26 | |
| US60/702,286 | 2005-07-26 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| WO2006021082A1 WO2006021082A1 (en) | 2006-03-02 |
| WO2006021082B1 true WO2006021082B1 (en) | 2006-05-04 |
Family
ID=35967140
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/CA2005/001278 WO2006021082A1 (en) | 2004-08-24 | 2005-08-24 | Apparatus for metal foam casting and methods therefor |
Country Status (1)
| Country | Link |
|---|---|
| WO (1) | WO2006021082A1 (en) |
Families Citing this family (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102006045267A1 (en) * | 2006-09-22 | 2008-03-27 | Kurtz Gmbh | Casting device for producing open-pored foam structures made of metal, metal alloys, plastic or ceramic with or without closed outer shell |
| US7699092B2 (en) | 2007-06-18 | 2010-04-20 | Husky Injection Molding Systems Ltd. | Metal-molding system and process for making foamed alloy |
| HU227545B1 (en) * | 2008-12-04 | 2011-08-29 | Bay Zoltan Alkalmazott Kutatasi Koezalapitvany | Method for producing metal foam |
| EP2502688A1 (en) * | 2011-03-23 | 2012-09-26 | ADMATIS Kft. | Apparatus and method for the production of particle-stabilized, closed-cell, shaped metal foam products with a metal foam injector |
| WO2013144881A2 (en) | 2012-03-27 | 2013-10-03 | Universidade Do Minho | Light-weight metallic structure and respective production method |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AT406027B (en) * | 1996-04-19 | 2000-01-25 | Leichtmetallguss Kokillenbau W | METHOD FOR PRODUCING MOLDED PARTS FROM METAL FOAM |
| AT411768B (en) * | 2002-09-09 | 2004-05-25 | Huette Klein Reichenbach Gmbh | METHOD AND DEVICE FOR PRODUCING FLOWABLE METAL FOAM |
| US6881241B2 (en) * | 2002-11-18 | 2005-04-19 | General Motors Corporation | Method for manufacturing closed-wall cellular metal |
-
2005
- 2005-08-24 WO PCT/CA2005/001278 patent/WO2006021082A1/en active Application Filing
Also Published As
| Publication number | Publication date |
|---|---|
| WO2006021082A1 (en) | 2006-03-02 |
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