WO2006063696A1 - Hochisolierende und feuerfeste beschichtungsmassen für giessformen - Google Patents
Hochisolierende und feuerfeste beschichtungsmassen für giessformen Download PDFInfo
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- WO2006063696A1 WO2006063696A1 PCT/EP2005/012917 EP2005012917W WO2006063696A1 WO 2006063696 A1 WO2006063696 A1 WO 2006063696A1 EP 2005012917 W EP2005012917 W EP 2005012917W WO 2006063696 A1 WO2006063696 A1 WO 2006063696A1
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- sizing composition
- weight
- casting
- composition according
- sizing
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B3/00—General-purpose turning-machines or devices, e.g. centre lathes with feed rod and lead screw; Sets of turning-machines
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- 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
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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
- B22D13/00—Centrifugal casting; Casting by using centrifugal force
- B22D13/10—Accessories for centrifugal casting apparatus, e.g. moulds, linings therefor, means for feeding molten metal, cleansing moulds, removing castings
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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
- B22D13/00—Centrifugal casting; Casting by using centrifugal force
- B22D13/10—Accessories for centrifugal casting apparatus, e.g. moulds, linings therefor, means for feeding molten metal, cleansing moulds, removing castings
- B22D13/101—Moulds
- B22D13/102—Linings for moulds
Definitions
- the present invention relates to coating compositions or sizing compositions comprising a solvent component and a solid component, the solid component comprising metakaolinite and pyrophyllite, which can be applied to molds, casting molds comprising these sizing compositions and the use thereof, in particular in centrifugal casting and large-casting processes.
- Casting transforms molten bath materials into geometrically determined objects with specific workpiece properties.
- Most products of the iron and steel industry as well as the materials of the non-ferrous metal industry go through casting processes for the first shaping.
- a prerequisite for the production of castings is, among other things, the production of partly very complicated casting molds for receiving the melt.
- the molds are subdivided into lost molds, which usually consist of a mineral, refractory, granular base material with a binder and often still other additives, for example, to achieve good Gussoberfietzen, and destroyed after each casting, and permanent molds, each with a large Number of castings can be made.
- the refractory, granular ground substance used is predominantly washed, classified quartz sand, in certain cases also chromite, zircon and olivine sand.
- moldings based on fireclay, magnesite, sillimanite, corundum and others are used.
- the binders for the molding sands may be inorganic or organic in nature.
- Lost molds are predominantly made from bentonite-bonded molded materials for smaller molds or resin-bonded molded materials for larger molds, which must be mechanically compacted to achieve sufficient stability.
- a method for producing casting molds and cores from resin-bonded foundry sand comprises, for example, the production of a basic mold or foundry core from the molding sand and the application of a refractory inorganic constituent, also called sizing, to at least those surfaces 5 of the basic mold / Core core, which come into contact with the cast metal.
- the purpose of the mold coatings is to influence the molding surface, to improve the casting appearance, to metallurgically influence the casting and / or to avoid casting defects. Further, these coatings have the function of chemically isolating the mold from the liquid metal during casting, thereby eliminating any adhesion
- the sizing ensures a thermal separation of mold and casting. If this function is not fulfilled, e.g. subjected a metal mold in the course of successive casting operations such thermal stresses that it is prematurely destroyed. Heat transfer can be used selectively to cool down the casting
- the mold is coated with an insulating size in the form of a single-layer or multi-layer coating.
- the commonly used sizing agents contain as base materials e.g. Tone, Quartz,
- Diatomaceous earth Diatomaceous earth, cristobalite, tridymite, aluminum silicate, zirconium silicate, mica, chamotte and also
- centrifugal cast iron tubes There are currently 3 different processes for making centrifugal cast iron tubes: One method uses a powder sizing based on inoculant and graphite, sometimes with aluminum. This size is distributed by means of a cut and filled with the powder sizing tube by rotating in the rotating mold. Another method uses a finished, water-based finish with the zirconium silicate, aluminum silicate, and / or alumina refractories. This size is sprayed from a pressure vessel with a spray lance with spray or flood nozzle in one or more passes on the hot rotating mold. Another method employs a prepared water base of fillers consisting of calcined diatomaceous earth (such as the commercial products Celite, Dicalite) with bentonite and water.
- calcined diatomaceous earth such as the commercial products Celite, Dicalite
- Centrifugal castings which are nowadays used essentially, are based on kieselguhr.
- the rotational movement of the mold in centrifugal casting and the post-processing of the casting often lead to a part of the sizing passes into the environment.
- Dust forms of diatomaceous earth, calcined diatomaceous earth and products resulting from the burning of kieselguhr, such as e.g. Cristobalite-containing fine dust, are now classified as silicosis and also as carcinogenic. This creates a high risk potential for employees at the workplaces. Therefore, there is a great need for another highly insulating and at the same time refractory coating material for mold coatings.
- EP-B-0 806 258 describes a method for producing an insulating coating for metal molds for casting ferrous metals, wherein at least one base coat is applied to the surface of the mold, and wherein a top coat on the
- Base coat is applied, wherein the top coat contains metakaolin and is completely or partially renewed during each casting process.
- FR-A-2,829,048 describes a sizing composition comprising water, metakaolin, activated sodium or calcium bentonite, neutralized copra fatty acid, an ethoxylated fatty alcohol and ethoxylated nonylphenol. The drawing of the tubes from the mold with such a composition often proves to be extremely difficult.
- One aspect of the present invention relates to casting compositions (coating compositions) for casting molds comprising a solvent component and a solid component, the solid component comprising as the main constituent a mixture of metakaolinite and pyrophyllite.
- this sizing composition contains less than 5 weight percent, more preferably less than 3 weight percent, even more preferably less than 1 weight percent, based on all ingredients of the sizing composition, and most preferably no diatomaceous earth.
- the solid component of the sizing composition of the invention comprises a mixture of metakaolinite and pyrophyllite in the ratio of 1: 3 to 20: 1, preferably 1: 1 to 14: 1, more preferably 1: 1 to 10: 1, even more preferably 2 : 1 to 6: 1, and most preferably in the ratio of 2: 1 to 5: 1.
- a further preferred embodiment of the size composition according to the invention further comprises at least one further constituent selected from bentonite and hectorite.
- the sizing agent of the invention may further comprise binders, wetting agents, defoamers, pigments, dyes and biocides.
- Another aspect of the present invention relates to casting molds comprising a topcoat on at least a portion of the surfaces of the molds which come into contact with the cast metal prepared by applying and drying a sizing composition of the invention.
- the topcoat according to the invention is on a basecoat and optionally on further basecoat-free surface parts of the casting mold applied, wherein in a preferred embodiment, the base coat was also obtained from a ScMichtezusammen agent invention.
- Another aspect of the present invention relates to spin casting and large casting processes which use molds having at least one topcoat obtained from a sizing composition of the present invention.
- Another aspect of the present invention relates to a method of making a casting mold.
- a layer of a sizing composition according to the invention is applied and dried on at least one surface part or on the entire surface of the casting mold, which come into contact with the casting metal, to produce a topcoat.
- at least one layer of a base coat is first applied to the surface of the casting mold or to portions of the surface thereof, and the size composition for the production of the top coat is then applied to this base coat and optionally other parts of the surface of the casting mold and dried.
- a size composition according to the invention is also used for the production of the basecoat, wherein the composition of the size composition for the production of the basecoat may be the same or different from that of the size composition for the production of the topcoat.
- zirconium silicate-containing sizes are used for basecoats, which, if appropriate, also form an additional protection of the casting base form through an increased penetration tendency into the substrate.
- the casting molds according to the invention are used for the production of pipes, cylinder liners, engine and engine components, machine beds and turbines.
- the present invention is based on the surprising finding that the sizing compositions according to the invention which comprise a solid component are known as
- Main component include a mixture of metakaolinite and pyrophyllite, lead to similar good and better casting results as sizing compositions, its solid component contains kieselguhr as the main constituent.
- Advantages of the size according to the invention compared with kieselguhr-containing sizing in centrifugal casting are in particular health, safety and labeling effects.
- metakaolinite and pyrophyllite the high risk potential described for kieselguhr is unknown.
- materials containing kieselguhr may under certain circumstances have to be labeled as hazardous to health and that kieselguhr, which is eg brushed off or buffed from castings, must in future only be disposed of as hazardous waste.
- the mixture according to the invention also has the advantage that it is refractory and inert due to its chemical composition.
- a metakaolinite / pyrophyllite mixture leads to excellent properties compared to zirconium sizings and also pure pyrophyllite coatings due to the reactivity of metakaolinite with pyrophyllite and the refractoriness and fine granularity (impregnation of the sand cavities) of the metakaolinite.
- the high insulating values of pyrophyllite / Metakaolinitgemisches cause very good protection against so-called leaf ribs, which are often found in quartz sand by the thermal expansion of the quartz sand (quartz crack) and the insufficient thermal strengths, especially in polyurethane cold box cores.
- Kaolinite is a trikline two-layer clay mineral and the main constituent of kaolins.
- the dewatering of kaolinite leads to metakaolinite depending on particle size, degree of order, duration of heating and partial pressure of water vapor.
- Kaolinite cleaves the water from its hydroxyl groups at about 450 ° C and above.
- metalakaolinite is meant in the context of the present invention a material obtained from natural kaolin, from which in a preferred embodiment substantially all impurities have been removed and which is heated at a temperature in the range of 750-950 ° C was to substantially completely, preferably completely, remove the constitutional water.
- Suitable metakaolinite materials are e.g. commercially available under the product name Satintone from Engelhard Corporation, Iseli, USA.
- metakaolinite having a BET specific surface area of at least 10 m 2 / g, preferably at least 25 m 2 / g, measured according to DIN 66131 is used in the present invention.
- the metakaolinite should have a loss on ignition of less than 3% by weight, preferably less than 1% by weight, measured according to DIN 38414.
- Preferred metakaolinite materials have an uncompressed bulk density of 100-300 g / l, preferably 150-200 g / l, measured according to DIN 53194.
- the metakaolinite has a high specific surface area, expressed in oil absorption, measured according to DIN 53109, between 50 and 120%, preferably between 85 and 120%.
- the metakaolinite powder preferably has a grain size of 0.05 to 20 ⁇ m, more preferably 0.1 to 10 ⁇ m, and has an average grain size in the range of preferably 1 to 5 ⁇ m.
- pyrophyllite used in the present invention in admixture with metakaolinite, in the following description is meant a material obtained from natural pyrophyllite-containing ores of various mining areas.
- the pyrophyllite material used has a pyrophyllite content of at least 40%, preferably at least 50%, and more preferably at least 60%.
- roseki agalmatolith and the oracle called “wonderstone” with more than 90% pyrophyllite can be used.
- Many of the commercially available pyrophyllite materials can be used in the present invention.
- the pyrophyllite material used may, if desired, be previously purified by conventional purification techniques to remove any accompanying minerals and contaminants.
- the pyrophyllite raw material is prepared prior to use.
- a preferred treatment is the grinding of the raw material on special mills, resulting in. Pyrophyllite leads with a platelet-shaped structure.
- Another treatment method is a "shaving off" of pyrophyllite platelets from pyrophyllite raw materials. By usual separation methods, such as sieving, air classification, etc.,. If necessary, the recycled pyrophyllite material can be classified. If necessary, unwanted accompanying minerals can be separated as well.
- the platelets of the processed pyrophyllite preferably have a microscopic size of 10-100 microns and a thickness of 1-10 microns.
- a pyrophyllite form useful in the invention is the Pyrax RG series, eg Pyrax RG 140 and Pyrax RG 200, commercially available from RTVanderbilt Company Inc., Norwalk, USA.
- a particularly preferred Pyrophyllitform has a Mohs hardness of 1-2, a density of 2.8-2.9 g / cm 3, and a PCE (ASTM C-24) of 27-28 at.
- PCE ASTM C-24
- the pyrophyllite to be used has an aspect (length-to-thickness ratio) of at least 5, preferably 10-30.
- a pyrophyllite having an uncompressed bulk density of 300-600 g / l, preferably 300-400 g / l, measured according to DIN 53194 is used.
- the preferred pyrophyllite material has a tamped density of 800-1800 kg / m 3 , preferably 900-1550 kg / m 3 (DIN 55943).
- the preferred pyrophyllite material has a particle size of 5-600 ⁇ m, preferably 10-300 ⁇ m, more preferably 10-200 ⁇ m.
- the preferred pyrophyllite material has a shrinkage of not more than 2%, preferably not more than 1%.
- the pyrophyllite is used in hydrated form, ie the naturally occurring water of hydration is not removed by heating or annealing the pyrophyllite material prior to use.
- the sizing composition of the present invention comprises a solid component whose main component consists of a mixture of metakaolinite and pyrophyllite.
- metakaolinite to pyrophyllite is in the ratio of preferably 1: 3 to 20: 1, preferably 1: 1 to 14: 1, more preferably 1: 1 to 10: 1, even more preferably 2: 1 to 6: 1, and most preferably in the ratio of 2: 1 to 5: 1, before.
- the sizing composition of the invention preferably contains less than 5% by weight, more preferably less than 2% by weight, even more preferably less than 1% by weight, and most preferably not diatomaceous earth.
- the solid component additionally comprises bentonite, hectorite or a mixture thereof.
- the content of bentonite, hectorite or a mixture thereof is usually 0.1-10% by weight, preferably 0.1-5% by weight, and more preferably 0.3-3% by weight, based on all components the composition.
- the sizing composition according to the present invention may further optionally further comprise other commonly used two-layer silicates and three-layer silicates, such as e.g. Attapulgite, serpentine, kaolin, smectite, such as saponite, montmorillonite, beidellite and
- Nontronite, vermiculite, ulite and mica in smaller quantities, eg 0.5-4.0% by weight, preferably 1.0-2.0 wt .-%, contained.
- the sizing composition according to the invention may optionally contain one or more further components, e.g. Binders, wetting agents, defoamers, pigments, dyes and biocides.
- Binders e.g. Binders, wetting agents, defoamers, pigments, dyes and biocides.
- a binder is to allow binding of the ingredients of the sizing composition, including metakaolinite and pyrophyllite, after drying the sizing applied to a casting mold.
- the binder preferably cures irreversibly and thus results in an abrasion-resistant coating on the casting mold.
- the abrasion resistance is of great importance for the finished coating, since the coating can be damaged in the absence of abrasion resistance.
- the binder should not be softened by atmospheric moisture, in preferred embodiments curing of the binder is carried out in a manner known per se. For example, in acrylate systems, curing may be accomplished using free radical generators which form, for example, under the irradiation of UV light.
- the binder consists of a dispersion of an alkyd resin, which is soluble in both water and in lower alcohols, such as ethanol, propanol and isopropanol.
- alkyd resins are unmodified water-dispersible alkyd resins based on a natural oil or its fatty acids with polyalcohols, as described, for example, in US Pat. No. 3,442,835, or isocyanate-modified alkyd resins, as described, for example, in US Pat. No. 3,639,315, which are preferred, or epoxy urethane. modified alkyd resins according to DE 43 08 188.
- binders are polyvinyl alcohols and polyvinyl acetate copolymers.
- the binders are preferably used in an amount of 0.1-5% by weight, more preferably 0.5-2% by weight, based on all the components of the sizing composition.
- Suitable wetting agents are preferably anionic and non-anionic surfactants of medium and high polarity (HSB value of 7 and higher) known to the person skilled in the art.
- An example of a wetting agent that can be used in the present invention is disodium dioctylsulfosuccinate.
- the wetting agents are preferably used in an amount of 0.01-1% by weight, more preferably 0.05-0.3% by weight, based on all the components of the sizing composition.
- Defoamers or antifoam agents are used to prevent foaming in the preparation of the sizing composition of the present invention and in applying it. Foaming on application of the sizing composition can result in uneven layer thickness and holes in the coating.
- defoamers for example, silicone or mineral oil can be used.
- defoamers are used in an amount of 0.01-1 wt%, more preferably 0.05-0.3 wt%.
- pigments and dyes may be used in the sizing composition of the present invention. These are optionally added to provide a different contrast, e.g. between different layers, or to achieve a greater separation effect of the sizing of the casting. Examples of pigments are red and yellow iron oxide and graphite. Examples of dyes are commercial grades such as the Luconyl color series from BASF. The dyes and pigments are usually used in an amount of 0.01-10% by weight, preferably 0.1-5% by weight.
- Sizing compositions whose solvent component consists mainly of water, so-called water sizing, are usually added biocides to prevent bacterial attack and thus to avoid a negative impact on the rheology and the binding force of the binding agents.
- biocides to be used are formaldehyde, 2-methyl-4-isothiazolin-3-one (MIT), 5-chloro-2-methyl-4-isothiazolin-3-one (CIT) and 1,2-benzisothiazolin-3 on (BIT).
- MIT, BIT or a mixture thereof are used.
- the biocides are usually used in an amount of 0.01-0.5 wt% or 10-1000 ppm, preferably 50-500 ppm.
- the solvent component of the sizing composition according to the invention comprises water or one or more volatile, preferably aliphatic alcohols or mixtures of alcohol (s) and water and optionally as further component one or more organic, volatile solvents which differ from the above alcohols.
- Sizing compositions whose solvent consists mainly of water are commonly called water sizing, sizing composition whose solvent consists mainly of alcohol or alcohol mixtures, called Alcohol Sizing.
- the solvent component comprises 0-100% by weight, preferably 20-80% by weight, more preferably 60-40% by weight, water, and as further component 0-100% by weight, preferably 40-60% by weight, of one or more volatile alcohols, based on all components of the solvent component.
- the invention is useful for both pure water sizing and pure alcohol sizing, as well as water / alcohol mixtures and water sizing which can be diluted with alcohol.
- preferred alcohols are aliphatic C 1 -C 5 -AlkOhOIe.
- preferred C 1 -C 8 alcohols are methanol, ethanol, n-propanol and isopropanol.
- volatile alcohols are ethanol, isopropanol and mixtures thereof.
- further organic volatile solvents may be used, preferably in small amounts. Examples include alkyl acetates such as ethyl acetate and butyl acetate, and ketones such as acetone and methyl ethyl ketone.
- a sizing composition of the invention comprises 10-40% by weight of metakaolinite, 5-20% by weight of pyrophyllite and 10-85% by weight of water, based on all components of the composition.
- a further preferred embodiment of a sizing composition according to the invention comprises the following constituents: 15-40% by weight of metakaolinite, 7-20% by weight of pyrophyllite, 0.1-5% by weight of bentonite, hectorite or a mixture thereof, 0.5% 2% by weight of binder, 0.01-0.5% by weight of biocide and 10-78% by weight of water. It is also possible to prepare sizing compositions whose solvent component initially consists only of water.
- a sizing composition according to the invention is prepared by a majority of the total amount of the solvent component, preferably the total amount of the solvent component, for example, the total amount of water submitted, and here clay minerals such as bentonite and hectorite by using a high shear stirrer (eg 400-2000 U / min) digested become.
- a high shear stirrer eg 400-2000 U / min
- the refractory components for example, first metakaolinite, then pyrophyllite, pigments and dyes are stirred until a homogeneous mixture is formed.
- the order of addition plays no role or only a minor role, which can then be easily determined by a person skilled in the art.
- wetting agents, anti-foaming agents, biocides and binders are stirred in.
- a size composition according to the invention can be prepared and sold as ready-to-use formulated coating material, for example as a ready-to-use size.
- the size of the present invention may be prepared and sold in concentrated form, in the latter case, to provide a ready-to-use size, the appropriate amount of solvent component necessary to adjust the required viscosity and density characteristics of the size must be added.
- the solid component may be present as a powdery solid mixture in a separate container.
- liquid components to be used such as binders, wetting agents, defoamers, pigments, dyes and biocides
- the solvent component can either comprise the optionally additionally used components, for example in a common container, or it can be present in a separate container separately from further optional components.
- a size according to the invention preferably comprises a solids content of 20-80% by weight, preferably 30-70% by weight, based on all constituents of the size.
- a sizing composition according to the invention whose solvent component initially consists only of water.
- a volatile alcohol or alcohol mixture preferably ethanol, propanol, isopropanol and mixtures thereof, in preferably amounts of 40 to 200 wt .-%, based on. the water-based sizing
- a ready-to-use alcohol sizing can be made from this water-based sizing.
- the solids content of an alcohol sizing agent according to the invention is preferably 20-60% by weight, more preferably 30-40% by weight.
- sizing compositions according to the invention used to coat molds and cores in foundry technology have a viscosity of 12-25 s, more preferably 14-16 s (determined according to DIN 53211, outlet cup 4 mm, Ford cup).
- the size compositions according to the invention can be used for coating casting molds.
- the term "mold” includes all types of bodies necessary to make a casting, such as cores, molds and molds.
- the use of the size compositions according to the invention also includes partial coating of casting molds. Preferably, the surfaces of a mold are coated, which come into contact with the casting metal.
- the sizing compositions are suitable for all conceivable applications where coating of molds with sizing is desired.
- sand cores may be mentioned which are PUR cold box, water glass CO 2 , MF resole, resole CO 2 , furan resin, phenolic or water glass / ester bonded.
- a method for coating a casting mold with a size composition according to the invention comprises the steps:
- the size in several passes i. Layers, wherein the applied sizing layer is usually partially or completely dried before applying the next sizing layer. As a rule, 2-5 layers are applied.
- the sizing composition is usually applied only once, whereby a priming layer can be applied at critical points beforehand. Light (casting up to 2 tons) and medium casting (up to 2-1 tons) are generally not primed.
- the application of a primer coating, if desired, to the foundry mold can be accomplished by any conventional method of application in the art.
- the base coats may contain as base materials, for example, clays, talc, quartz, mica, zirconium silicate, magnesite, aluminum silicate, and chamotte. These raw materials are the functional part of the base coat. They cover the mold surface, close the sand pores against the penetration of the casting metal and serve, inter alia, as a thermal insulation against the mold. Commonly used application methods are dipping, flooding, spraying and brushing.
- the basecoat may also be a sizing composition of the present invention.
- the basecoat has a dry film thickness of at least 0.1 mm, preferably at least 0.2 mm, more preferably at least 0.45 mm, and most preferably in the range from 0.3 mm to 1.5 mm.
- a primer coating both water-based and alcohol-based sizing can be used.
- a size composition according to the invention for the production of a topcoat can be carried out by means of all application methods conventional in the art. Examples of preferred application methods are dipping, flooding, spraying and brushing. Conventional application methods are e.g. in "Formstoffe und Form Kunststoff", Eckart Flemming and Werner Tilch, Wiley VCH, 1993, ISBN 3-527-30920-9.
- the optionally containing a base coat mold is immersed in a container with a ready-to-use, sizing composition according to the invention for about 2 seconds to 2 minutes.
- the time taken to drain the excess sizing composition after dipping depends on the flow behavior of the sizing composition used. After a sufficient expiration time, the coated casting mold is subjected to drying.
- the size is filled in the diluted state in a pressure vessel.
- the sizing can be pressed into a spray gun via the overpressure to be set, where it is sprayed with the aid of separately adjustable atomizing air.
- spraying it is preferable to ensure that the gun is set so that the pressure for the size composition and the atomizing air are adjusted so that the sprayed coating is still wet. the shape or the core, but results in a uniform order.
- the application of the size composition according to the invention can take place in one or more layers. When applying several layers, each individual layer can be completely or partially dried after application.
- the drying method it is possible to employ any drying methods conventional in the art, such as air drying, dehumidified air drying, microwave or infrared radiation drying, convection oven drying, and the like.
- the coated mold at 100-250 ° C, more preferably at 120-18O 0 C, in a convection oven dried.
- the sizing composition according to the invention is preferably dried by burning off the alcohol or alcohol mixture.
- the coated casting mold is additionally heated by the heat of combustion.
- the coated casting mold is dried in the air without further treatment.
- the dried size may optionally be further cured. All known curing methods can be used. Added hardeners can be activated by heat or electromagnetic radiation. Water or alcohol sizing can be e.g. dry at temperatures below 100 ° C. For curing certain binders, e.g. of phenolic resins, temperatures of about 140-160 ° C are needed. Depending on the temperature used, drying and curing of the size can be carried out in one step or in separate steps. Also conceivable would be radical and ionic curing processes. , ,
- the dry film thickness of the topcoat obtained from the size composition of the present invention is at least 0.1 mm, preferably at least 0.2 mm, more preferably at least 0.3 mm, even more preferably at least 0.45 mm, most preferably at least 0.55 mm, and most preferably in a range of 0.3 mm to 1.5 mm.
- the dry film thickness is in this case the layer thickness of the dried sizing, which was obtained by drying the sizing composition by substantially 'complete removal of the solvent component, and optionally followed by curing.
- the dry layer thickness of the base coat and the top coat are preferably determined by measurement with the wet film thickness comb.
- the comb can determine the layer thickness by scraping the sizing off at the end marks of the comb until the surface is revealed. On the markings of the teeth you can then read off the layer thickness.
- Casting molds with a dried size according to the invention are preferably used in centrifugal casting and large-casting processes.
- the basic principles of these casting methods are described, for example, in Stefan Hasse, "G manegaleikon”, Schiele & Schön, Berlin, 1997.
- a dormant permanent shape for example made of sand, steel or cast iron, generally under the influence of gravity, with the liquid casting metal
- the cast metal is filled into a tubular or annular mold rotating about its axis, in which it is subjected to centrifugal force to form cans, rings and tubes (eg pressure pipes made of cast iron, pipes etc.)
- the rotationally symmetric cavity is created by the centrifugal force, which is maintained until solidification of the casting
- the wall thickness is determined by the amount of metal supplied preferably applied by dipping or flooding the casting mold in a dip or flood basin.
- top coats having a dry film thickness of 0.3-1.5 mm are preferably produced from the size composition according to the invention.
- a top coat having a dry film thickness in the range of 0.3-1.2 mm is prepared from the size composition of the invention.
- Molds comprising a top coat made from the size compositions of the present invention are used, inter alia, to make pipes, cylinder liners, engine and engine components, machine beds, turbines, and general machine components.
- the centrifugal casting size used in the following examples contained the following constituents (% by weight):
- Satintone Plus metakaolinite, particle size 2.0 ⁇ m; manufactured by Engelhard Cooperation, Iseli, USA
- Pyrax RG 140 Pyropyllite with a particle size of approx. 80 ⁇ m; made by R.T.Vanderbilt Company here, Norwalk, USA
- Bentone EW Bentone EW; manufactured by Elementis Specialties Inc., NJ 08520 Hightstown, USA
- the centrifuged casting size was prepared as follows: The total amount of water is initially charged and the bentonite and hectorite are digested for at least 15 minutes using a high shear stirrer Ekato (1000 rpm, toothed disk with d / D4O3). Subsequently, the refractory components metakaolinite and pyrophyllite are added and stirred for at least 15 minutes until a homogeneous mixture is formed. Finally, the biocide was added. The viscosity was 9.6 seconds with DIN 6 cups or 33 seconds with DIN 4 cups. Water-dilutable casting molds
- the water-dilutable casting mixture used in the examples below contained the following constituents (% by weight):
- Satintone W metakaolinite, bulk density (loose) approx. 300 g / l, particle size approx. 1.5 ⁇ m; manufactured by Engelhard Cooperation, Iseli, USA
- Pyrax RG 140 Pyropyllite with a particle size of approx. 80 ⁇ m; prepared by
- Bentonite Green Bond; manufactured by Südchemie AG, 80333 Munich, Germany
- Wetting agent common wetting agent from Henkel AG, 40589 Dusseldorf, Germany
- Defoamer conventional defoamer from Henkel AG, 40589 Dusseldorf, Germany
- Binder solution Polyviol, Wacker-Chemie GmbH, 81737 Kunststoff,
- the mold casting size was prepared by the method described above for the spin finish size.
- the density of the size produced was 1.3-1.4 g / cm 3 and the viscosity according to Brookfield 2-5 Pa-s.
- the alcohol-reducible molding slip used in the examples below contained the following components (% by weight):
- Pyrax RG 140 Pyropyllite with a particle size of approx. 80 ⁇ m; prepared by
- Wetting agent conventional wetting agent from Henkel AG, Dusseldorf, Dusseldorf, Germany
- Iron Oxide Iron Oxide Yellow, Bayer AG, 51368 Leverkusen, Germany
- Binder solution Necowel, ASK GmbH, 40721 Hilden, Germany
- the mold casting size was prepared by the method described above for the spin finish size.
- the finished size had a spindle density of 8O 0 Be.
- Example 1 Spin casting method using the above centrifugal casting size
- Viscosity 9.6 seconds with DIN 6 cup; 33 seconds with DIN 4 cup
- 15 l (20 kg) of sizing are further diluted with 5 l of water to a density of 37 ° Be and a viscosity of 13.2 s (DIN 4 cup).
- the mold preheated to about 200 ° C. was coated by applying the finishing composition according to the invention with a finishing pressure of 0.9 bar using a Düker atomizer lance at a feed rate of 500 mm / s.
- the dry layer thickness is 0.65 mm.
- the sizing dried by the heat of the mold during the spraying process.
- a topcoat with a useful surface was obtained.
- the centrifugal casting showed a good drawing behavior of the tube.
- the metallurgical investigations showed the desired graphite formation in gray cast iron (Fe 5 C, Si) and the correct hardness range of the gray cast iron, indicating a sufficient insulating effect of the size.
- Example 3 PUCB core for V-engine
- a PUCB (Polyurethane Cold Box) core for a V-engine was treated with the above-mentioned water-dilutable casting.
- For the core was a 100% no-bake
- Altsandregenerat means a self-hardening process, whereby for example furan resin with
- Paratoluene sulfonic acid is cured.
- the sand of these cores or forms is regenerated, i. made reusable by a rubbing process, in this example the sand was used for the gas curing (amine) PUCB process).
- 100 parts by weight of the cast molding size was diluted with 5 parts by weight of water.
- Viscosity > 25 s (DIN 4 cup)
- the sizing was applied to the core by flooding.
- the flow behavior of the size was good and the wet layer thickness was 250 ⁇ m.
- the core was dried in a chamber oven with circulating air at 160-180 ° C. The coverage of the dried size for this core was at the lower limit. The casting result was perfect.
- Example 3 Similar to Example 3, the above-mentioned water-dilutable casting mixture was applied to an untreated Kuranraumkern from furan resin. For processing consistency, 100 parts by weight of the size was diluted with 20 parts by weight of water.
- No-bake forms were treated with the above-mentioned, alcohol-thinnable casting molds.
- no-bake shapes were flooded.
- the odor load on the flood system was significantly lower compared to conventional pyrophyllite / isopropanol sizes.
- the wet layer thickness was 250-300 ⁇ m.
- the forms could be completely dried by burning off the alcohol even in about 30 cm deep pockets and showed good abrasion resistance. Dry cracks or blisters were not observed.
- the casting results showed no abnormalities compared to pyrophyllite / isopropanol sizes.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Mold Materials And Core Materials (AREA)
- Fireproofing Substances (AREA)
- Paints Or Removers (AREA)
- Insulated Conductors (AREA)
- Organic Insulating Materials (AREA)
- Polymers With Sulfur, Phosphorus Or Metals In The Main Chain (AREA)
Abstract
Description
Claims
Priority Applications (11)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP05813959A EP1841556B1 (de) | 2004-12-16 | 2005-12-02 | Hochisolierende und feuerfeste beschichtungsmassen für giessformen |
BRPI0519332-0A BRPI0519332B1 (pt) | 2004-12-16 | 2005-12-02 | Composição de goma, molde de fundição, processos de fundição, método para produção do referido molde e uso deste |
US11/792,936 US8088208B2 (en) | 2004-12-16 | 2005-12-02 | Highly insulating and fireproof coating materials for casting moulds |
DE502005006851T DE502005006851D1 (de) | 2004-12-16 | 2005-12-02 | Hochisolierende und feuerfeste beschichtungsmassen für giessformen |
CA2591394A CA2591394C (en) | 2004-12-16 | 2005-12-02 | Highly insulating and fireproof coating material for casting moulds |
JP2007545884A JP4918497B2 (ja) | 2004-12-16 | 2005-12-02 | 鋳造鋳型用高断熱性及び不燃性コーティング材料 |
KR1020077015171A KR101285020B1 (ko) | 2004-12-16 | 2005-12-02 | 사이징 조성물, 캐스팅 몰드, 캐스팅 몰드의 생산 방법, 및 캐스팅 몰드의 용도 |
MX2007007231A MX2007007231A (es) | 2004-12-16 | 2005-12-02 | Materiales de recubrimiento termicamente aislantes y resistentes al fuego para moldes de fundicion. |
PL05813959T PL1841556T3 (pl) | 2004-12-16 | 2005-12-02 | Dobrze izolujące i ogniotrwałe masy powłokowe do form odlewniczych |
AU2005315901A AU2005315901B2 (en) | 2004-12-16 | 2005-12-02 | Highly insulating and fireproof coating material for casting moulds |
NO20073394A NO20073394L (no) | 2004-12-16 | 2007-07-02 | Svaert ikke-ledende og brannsikkert beleggingsmateriale for stopeformer |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102004060649.8 | 2004-12-16 | ||
DE102004060649A DE102004060649A1 (de) | 2004-12-16 | 2004-12-16 | Hochisolierende und feuerfeste Beschichtungsmassen für Gießformen |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2006063696A1 true WO2006063696A1 (de) | 2006-06-22 |
Family
ID=35892547
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/EP2005/012917 WO2006063696A1 (de) | 2004-12-16 | 2005-12-02 | Hochisolierende und feuerfeste beschichtungsmassen für giessformen |
Country Status (19)
Country | Link |
---|---|
US (1) | US8088208B2 (de) |
EP (1) | EP1841556B1 (de) |
JP (1) | JP4918497B2 (de) |
KR (1) | KR101285020B1 (de) |
CN (1) | CN100493790C (de) |
AT (1) | ATE424955T1 (de) |
AU (1) | AU2005315901B2 (de) |
BR (1) | BRPI0519332B1 (de) |
CA (1) | CA2591394C (de) |
DE (2) | DE102004060649A1 (de) |
ES (1) | ES2323323T3 (de) |
MX (1) | MX2007007231A (de) |
NO (1) | NO20073394L (de) |
PL (1) | PL1841556T3 (de) |
PT (1) | PT1841556E (de) |
RU (1) | RU2398651C2 (de) |
UA (1) | UA88342C2 (de) |
WO (1) | WO2006063696A1 (de) |
ZA (1) | ZA200704399B (de) |
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WO2007082646A1 (de) * | 2006-01-17 | 2007-07-26 | Ashland-Südchemie-Kernfest GmbH | Impfmittelhaltige flüssigschlichte auf wasserbasis |
WO2008135247A1 (de) * | 2007-05-02 | 2008-11-13 | Ashland-Südchemie-Kernfest GmbH | Beschichtungsmassen für giessformen und kerne zur vermeidung von reaktionsgasfehlern |
WO2013044904A1 (de) * | 2011-09-30 | 2013-04-04 | Ask Chemicals Gmbh | Beschichtungsmassen für anorganische giessformen und kerne und deren verwendung und verfahren zum schlichten |
CN108559316A (zh) * | 2018-05-03 | 2018-09-21 | 佛山市三水万瑞达环保科技有限公司 | 一种钢结构防火涂料及其制备方法 |
WO2019224070A1 (de) | 2018-05-25 | 2019-11-28 | Ask Chemicals Gmbh | SCHLICHTEZUSAMMENSETZUNG, VERFAHREN ZUR BESCHICHTUNG EINER GIEßFORM UND VERWENDUNG DER SCHLICHTEZUSAMMENSETZUNG ZUR BESCHICHTUNG EINER GIEßFORM |
WO2020212433A1 (en) | 2019-04-16 | 2020-10-22 | Ask Chemicals Gmbh | Coating composition, method for coating a casting mold, use of the coating composition for coating a casting mold, and casting mold |
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CN102310159B (zh) * | 2010-12-11 | 2013-05-29 | 中国一拖集团有限公司 | 一种铸铁冷芯盒砂芯用水基粉状浸涂涂料 |
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US10035182B2 (en) | 2013-12-09 | 2018-07-31 | United Technologies Corporation | Method of fabricating an investment casting mold and slurry therefor |
US9827608B2 (en) * | 2013-12-09 | 2017-11-28 | United Technologies Corporation | Method of fabricating an investment casting mold and slurry therefor |
CN103861994B (zh) * | 2013-12-23 | 2016-03-02 | 宁波钰烯阴极保护材料有限责任公司 | 用于生产高硅铸铁管状阳极的涂料及其制备方法 |
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JP7356394B2 (ja) | 2020-04-10 | 2023-10-04 | ユシロ化学工業株式会社 | ダイカスト用水性離型剤 |
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2004
- 2004-12-16 DE DE102004060649A patent/DE102004060649A1/de not_active Ceased
-
2005
- 2005-02-12 UA UAA200707942A patent/UA88342C2/uk unknown
- 2005-12-02 PL PL05813959T patent/PL1841556T3/pl unknown
- 2005-12-02 WO PCT/EP2005/012917 patent/WO2006063696A1/de active Application Filing
- 2005-12-02 PT PT05813959T patent/PT1841556E/pt unknown
- 2005-12-02 CA CA2591394A patent/CA2591394C/en not_active Expired - Fee Related
- 2005-12-02 AT AT05813959T patent/ATE424955T1/de active
- 2005-12-02 MX MX2007007231A patent/MX2007007231A/es active IP Right Grant
- 2005-12-02 RU RU2007126820/02A patent/RU2398651C2/ru not_active IP Right Cessation
- 2005-12-02 EP EP05813959A patent/EP1841556B1/de active Active
- 2005-12-02 ES ES05813959T patent/ES2323323T3/es active Active
- 2005-12-02 CN CNB2005800431783A patent/CN100493790C/zh not_active Expired - Fee Related
- 2005-12-02 DE DE502005006851T patent/DE502005006851D1/de active Active
- 2005-12-02 BR BRPI0519332-0A patent/BRPI0519332B1/pt not_active IP Right Cessation
- 2005-12-02 JP JP2007545884A patent/JP4918497B2/ja not_active Expired - Fee Related
- 2005-12-02 US US11/792,936 patent/US8088208B2/en not_active Expired - Fee Related
- 2005-12-02 KR KR1020077015171A patent/KR101285020B1/ko not_active IP Right Cessation
- 2005-12-02 AU AU2005315901A patent/AU2005315901B2/en not_active Ceased
-
2007
- 2007-05-29 ZA ZA200704399A patent/ZA200704399B/xx unknown
- 2007-07-02 NO NO20073394A patent/NO20073394L/no not_active Application Discontinuation
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Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2007082646A1 (de) * | 2006-01-17 | 2007-07-26 | Ashland-Südchemie-Kernfest GmbH | Impfmittelhaltige flüssigschlichte auf wasserbasis |
WO2008135247A1 (de) * | 2007-05-02 | 2008-11-13 | Ashland-Südchemie-Kernfest GmbH | Beschichtungsmassen für giessformen und kerne zur vermeidung von reaktionsgasfehlern |
WO2013044904A1 (de) * | 2011-09-30 | 2013-04-04 | Ask Chemicals Gmbh | Beschichtungsmassen für anorganische giessformen und kerne und deren verwendung und verfahren zum schlichten |
CN108559316A (zh) * | 2018-05-03 | 2018-09-21 | 佛山市三水万瑞达环保科技有限公司 | 一种钢结构防火涂料及其制备方法 |
WO2019224070A1 (de) | 2018-05-25 | 2019-11-28 | Ask Chemicals Gmbh | SCHLICHTEZUSAMMENSETZUNG, VERFAHREN ZUR BESCHICHTUNG EINER GIEßFORM UND VERWENDUNG DER SCHLICHTEZUSAMMENSETZUNG ZUR BESCHICHTUNG EINER GIEßFORM |
EP4147804A1 (de) | 2018-05-25 | 2023-03-15 | ASK Chemicals GmbH | Schlichtezusammensetzung, verfahren zur beschichtung einer giessform und verwendung der schlichtezusammensetzung zur beschichtung einer giessform |
WO2020212433A1 (en) | 2019-04-16 | 2020-10-22 | Ask Chemicals Gmbh | Coating composition, method for coating a casting mold, use of the coating composition for coating a casting mold, and casting mold |
DE102019002802A1 (de) * | 2019-04-16 | 2020-10-22 | Ask Chemicals Gmbh | Schlichtezusammensetzung, Verfahren zur Beschichtung einer Gießform, Verwendung der Schlichtezusammensetzung zur Beschichtung einer Gießform und Gießform |
Also Published As
Publication number | Publication date |
---|---|
BRPI0519332A2 (pt) | 2009-01-20 |
EP1841556A1 (de) | 2007-10-10 |
PL1841556T3 (pl) | 2009-08-31 |
CA2591394A1 (en) | 2006-06-22 |
US8088208B2 (en) | 2012-01-03 |
MX2007007231A (es) | 2007-08-14 |
PT1841556E (pt) | 2009-06-15 |
ES2323323T3 (es) | 2009-07-13 |
JP2008523991A (ja) | 2008-07-10 |
KR20070086891A (ko) | 2007-08-27 |
NO20073394L (no) | 2007-09-07 |
CN100493790C (zh) | 2009-06-03 |
ATE424955T1 (de) | 2009-03-15 |
CN101080298A (zh) | 2007-11-28 |
ZA200704399B (en) | 2008-06-25 |
EP1841556B1 (de) | 2009-03-11 |
CA2591394C (en) | 2013-02-19 |
AU2005315901A1 (en) | 2006-06-22 |
US20090014145A1 (en) | 2009-01-15 |
AU2005315901B2 (en) | 2011-06-02 |
BRPI0519332B1 (pt) | 2018-06-12 |
KR101285020B1 (ko) | 2013-07-10 |
DE102004060649A1 (de) | 2006-06-29 |
DE502005006851D1 (de) | 2009-04-23 |
RU2007126820A (ru) | 2009-01-27 |
RU2398651C2 (ru) | 2010-09-10 |
JP4918497B2 (ja) | 2012-04-18 |
UA88342C2 (uk) | 2009-10-12 |
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