DESCRIPTION
"Pattern for obtaining a casting by the lost foam casting technique and method for manufacturing such pattern"
This invention relates to a pattern of expanded material for use in the manufacture of a casting using the "LOST FOAM" casting technique.
In accordance with a further aspect the invention also relates to a method for manufacturing a pattern of expanded material for use in the manufacture of a casting through the lost foam casting technique.
As is known, the lost foam casting process is currently used to manufacture castings, that is parts of complex shape or having a plurality of cavities manufactured through a fusion process. In fact, in comparison with more conventional casting techniques the special feature of the lost foam process lies in the use of polymer foam patterns to manufacture the casting. In fact the production of a metal casting depends on the manufacture of a corresponding pattern made of polyurethane foam through an injection moulding technique. It should be pointed out that the pattern of expanded material must be a faithful copy of the metal casting which has to be produced.
Once the pattern has been completed it is covered with a refractory paint, which is generally water-based, dried and then placed in a casting box to be covered with refractory sand which is suitably vibrated and compacted. The molten metal is then poured onto the foam pattern causing thermal degradation of the expanded material of which the pattern is made and filling the volume of the pattern with tlae cast metal. Ultimately a perfect replica in metal of the pattern of expanded material is obtained.
One strength of the lost foam technique lies in the possibility of producing even very complex patterixs in a simplified way, including patterns incorporating openings, ducts and the like such as, for example, the pattern, for an engine head block to which reference will be made b»elow in the description for the sake of simplicity.
The manufacture of complex patterns of expanded material is rendered more advantageous by the possibility of subcϋividing the pattern into several layers, which can be joined together by adhesive bonding before sand casting is carried out. This technique of manufacturing a complicated pattern through joining several parts or layers of expanded material is particularly advantageous where the pattern whiclx has to be produced provides for the presence of one or more internal ducts.
In connection with patterns of expanded material manufactured through joining several parts or laye-trs adhesively bonded together it must be pointed out that trae adhesive inserted along the edges of the parts gives rise to the formation of bonding edges along the joint lines when the parts which have to be adhesively bonded are joined together by force.
Generally the presence of bonding edges corresponding to the aforesaid joint lines does not cause any problems in casting of the metal material which has to be obtained, as these artre dimensional defects which do not interfere with trie structure and function of the part.
There are however situations in which the dimensional variations due to the presence of the aforesaid bonding edges corresponding to the joints cannot be toleratecl, because it is necessary to comply with the design geometiry and dimensions. This for example occurs in the case of car engine head blocks in which the geometry and dimensions of the inlet ducts have to be complied with. In fact any imperfections, even small ones, in the aforesaid inlet ducts could have an effect on the fluid dynamic behaviour of ttαe air drawn into the combustion chamber, with adverse repercussions on the engine's performance.
In this context it is obvious that machining of the patteum
to remove ttie bonding edges from the pattern of expanded material or machining of the metal casting to remove the marks left by the latter on the finished piece is a possibility, although an onerous one, in the case of easily accessible joint lines, but it is substantially impossi-ole within an inLet duct.
In the light of the above it is obvious that there is a strong need to be able to have a pattern of expanded material incorporating one or more ducts which are free of dimensional defects due to the presence of adhesion bonding edges.
At the present time manufacturers of castings of this t^pe have decided to tolerate the presence of the aforesaid imperfections both in the pattern of expanded material and in the metal casting obtained at the end of the lost foam process, wtiile benefiting from the advantages a.nd simplification deriving from the lost foam casting technique.
The problem underlying this invention is that of devising and providing a pattern for obtaining a casting within which there is a diαct, using the lost foam casting technique, -the said pattern having structural and functioxial characteristics such as to satisfy the abovementioined requirement, while at the same time overcoming -the
disadvantages mentioned.
This problem is .resolved by a pattern according to ClarLm 1 used for obtaining a casting within which there is a d/uct, using the lost foam casting technique.
According to another aspect the invention further relates to a method according to Claim 17 for the production of a pattern incorporating a duct which is used to obtarLn a casting through tlie lost foam casting technique.
Other features and the advantages of the pattern accor*ding to the present invention will become clear from the following detailed description which is given with reference to the appended drawings which are provided purely by wa.y of non-limiting example and in which:
Figure 1 shows a simplified perspective view in partial cross-section of a pattern according to the invention,
- Figure 2 shows a perspective view of the pattern, in Figure 1 in a different condition of use,
- Figure 3 shows a perspective partly exploded vie-w of the pattern in Figure 1, and
- Figures 4 and 4a relate to the stage of moulding a layer of the pattern in Figure 1.
With reference to the appended figures, 1 indicates as a whole a pattern of expanded material for obtaining a casting within which there are a plurality of ducts.
In the example in the figure, pattern 1 compr±ses an exact reproduction in expanded material of the head block of a diesel engine incorporating a plurality of internal ducts, among which may be recognised the inlet ducts, identified in the figure by 2. Inlet ducts 2 present in the pattern are open at both ends so as to form a through path through the said mass of expanded material.
Head block pattern 1 is intended to be used four obtaining a metal casting, in the example the aluminium head block of a diesel engine, through the lost foam casting technique.
Pattern 1 therefore comprises a mass of expanded material having a shape and dimensions corresponding to those of the aluminium casting which is to be obtained- In greater detail, and in accordance with the lost foam casting procedure, pattern 1 is designed to be:
- coated with a refractory paint, which is preferably water-based,
- dried, and
— placed in a casting box (not illustrated) in which it is covered with refractory sand, suitably vibrated and compacted, to receive the cast molten metal, in the example aluminium.
The cast metal is poured into the casting box through suitable casting channels so that it can reach the expanded material of pattern 1 within the refractory sand. Contact between the molten metal and the expanded materia.1 gives rise to thermal degradation of the expanded material of patteirn 1 and progressive replacement of the expanded material with cast molten metal. After the metal has solidified the metal casting is obtained.
The expanded material in pattern 1 is a polymer foam, preferably a polystyrene, a polymethylmethacrylate or polyalkylene carbonate.
In th.e case where the aluminium casting which has to be obtained has some structural complexity, pattern 1 may comprise several parts or layers adhesively bonded together. In the example in the figure, pattern 1 comprises a. central layer Ia and two opposing peripheral layers Ib above and below connected together by adhesive bonding. In Figure 1 the dividing planes between the layers are shown loy dashed lines , while Figure 3 shows the pattern according to the invention with the layers partly exploded.
In accordance wittα an advantageous feature, pattern 1 comprises a shaped, insert 3, preferably of refractory- material, for each άnlet duct 2, that is a material capable of withstanding contact with the molten metal. Each shaped insert 3 is embedded, within the mass of expanded material to form a corresponding duct within the expanded mass.
Each shaped insert 3 projects from the mass of expanded material of pattern 1 with at least one end portion 4 forming an appendix portion through which the insert can be handled, as will be better described in the remainder of the description.
The portion of each shaped insert 3 which is embedded within the mass of expanded material has a shape and dimensions which match those of the corresponding duct which it is desired to obtain in pattern 1 of expanded material and, as a consequence, also in the aluminium casting.
In the case illustrated, inserts 3 are mostly embedded within central layer Ia of pattern 1. Consequently inlet ducts 2 present in pattern 1 lie completely within central layer Ia with tlie exception of a negligible part. Advantageously this makes it possible to obtain inlet ducts 2 which are free from imperfections due to the presence of bonding edges. In this respect it is worth pointing out that
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the bonding edge formed along inlet ducts 2 along the j oint lines between central layer Ia and upper layer Ib is wholly negl igible, in that it gives rise to a c ircumferential ring located in a position of the inlet duct which is intended to receive the sealing rings or the seats of the valves in the engine head block .
The presence of the shaped members of inert material thexrefore makes it possible to form the inlet ducts in such a way that they comply with the geome try and dimensions required by the design specifications , and are free from any geometrical anomalies giving rise to the fluid dynamic turbulence phenomena mentioned with reference to the patterns of expanded material in the known art .
As indicated above , shaped inserts 2 are preferably made of a refractory material , that is a material which does not deteriorate or dissolve following contact with the molten metal .
A r-efractory material which may be used is for example friable silica sand, with the possible addition of a binding agent . Phenol or f uran resins or the like which burn and/or vaporise at the temperatures reached by the molten metal may be used for example as the binder .
It Is also possible to use a water-soluble material , for
example a material based on urea, for shaped inserts 3. In this case it is desirable that the surface of th.e refractory material be treated with a paint or other product: capable of rendering the shaped insert non-soluble, at least on the surface, so as to prevent the shaped inserts from dissolving following contact with the molten metal.
Shaped inserts 3 may be removed from pattern IL before the latter is inserted into the casting box (as shown in Figure 2) or may be left within pattern 1 of expanded material in order to be removed from the aluminium casting after it has cooled.
Removal of the shaped inserts from pattern 1 of expanded material, obviously without damaging it, or from the metal casting, may be effected by conventional technicjues such as breaking, -vibration, shot blasting, dissolution in water or other suitable liquid.
In the case where the shaped inserts are removed from the pattern before the molten metal is cast it is not necessary that the shaped inserts should be of a refractory material or that tlxe same should be surface treated so as to become insoluble-
The method of manufacturing pattern 1 substantially provides for the following operational stages:
- providing a mould 5 formed from two half -moulds defining between them a cavity 6 corresponding to the shape and dimensions of the shaped model which has to be oϊotained,
- positioning shaped inserts 3 of refractory material within cavity 6 in mould 5 , each shaped insert 3 having- a shape and dimensions matching those of the duct which has to be obtained in pattern 1,
- blowing the expandable plastics material into mould 5 in such a way as to obtain a mass of expanded material having the shape and dimensions of the pattern which has to be obtained and incorporating the shaped inserts 3 of refractorry material embedded within it .
In accordance with what has been described albove, shaped inserts 3 of refractory material are positioned and/or held in posit dL on within the mould through their end portions 4 forming sn appendix portion through which the Lnsert may be manipulated .
In the case in which shaped inserts 3 are .removed from pattern 1 and do not therefore have to come into contact with the molten metal , these may be manufactured of non- refractory material . In this case it is desirat>le to use a material , such as for example a water-soluble resin, which is capable of withstanding the inj ection moul-ding process used to produce the pattern of expanded material .
As may be appreciated from what has been described, the pattern of expanded material and the method according to the invention make it possible to satisfy the abovementioned requirement and at the same time overcome the disadvantages mentioned in the introductory part of this description.
In fact, problems associated with the geometrical abnormalities brought about through the presence of bonding edges corresponding to the joints between several layers are wholly overcome in the pattern of exrpanded material according to the invention in that all the ducts in respect of which design geometrical and/or dimensional tolerances have to be complied with are obtained throαigh the presence of shaped members of refractory material whose dimensions and shapes can be easily determined with maximum accuracy.
Naturally, the principle of the invention remaining the same, the forms of embodiment and details of construction may be varied widely with respect to those described and illustrated, which have been given purely by way of example, without thereby departing from the scope of the invention.