WO2007104469A1 - Moule ou ébauche, mélange de matériau de moulage pour fonderie et procédé de réalisation associé - Google Patents

Moule ou ébauche, mélange de matériau de moulage pour fonderie et procédé de réalisation associé Download PDF

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Publication number
WO2007104469A1
WO2007104469A1 PCT/EP2007/002008 EP2007002008W WO2007104469A1 WO 2007104469 A1 WO2007104469 A1 WO 2007104469A1 EP 2007002008 W EP2007002008 W EP 2007002008W WO 2007104469 A1 WO2007104469 A1 WO 2007104469A1
Authority
WO
WIPO (PCT)
Prior art keywords
binder
molding
sand
mold
alumina
Prior art date
Application number
PCT/EP2007/002008
Other languages
German (de)
English (en)
Inventor
Martin Weith
Original Assignee
Minelco Gmbh
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Minelco Gmbh filed Critical Minelco Gmbh
Publication of WO2007104469A1 publication Critical patent/WO2007104469A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
    • B22D29/001—Removing cores
    • B22D29/002—Removing cores by leaching, washing or dissolving
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
    • B22C1/18—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents
    • B22C1/186—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents contaming ammonium or metal silicates, silica sols
    • B22C1/188—Alkali metal silicates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/12—Treating moulds or cores, e.g. drying, hardening
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
    • B22D29/001—Removing cores
    • B22D29/005—Removing cores by vibrating or hammering

Definitions

  • the invention relates to molds or foundries for foundry purposes, a foundry-molding material mixture consisting of molding sand, binder and aggregates and a process for its preparation.
  • Foundry-molding mixtures are known in many forms. Basically, a distinction must be made between clay-bound foundry sand, sand mixtures with inorganic or organic binders, and binderless molding sands with physical bonding.
  • the requirements of the foundry-molding mixtures are very diverse and include properties such as flowability of the molding material mixture, solidification behavior, achievable ultimate strength, separability or mold release.
  • WO 2006/024540 describes a molding material mixture for the production of casting molds for metal processing, in which a free-flowing, refractory molding base material and a water glass-based binder are used.
  • a particulate metal oxide selected from a group consisting of silica, alumina, titania or zinc oxide, more preferably synthetic amorphous silica.
  • Molded materials of spherical form and / or organic additives are used to improve the surface quality of the casting.
  • the strength of the molded article in a moist environment should be improved by intensively combining the surface of the particulate metal oxide with a strongly alkaline water glass phase in the binder.
  • DE-OS-1508634 (Diamond Shamrock Corp.) discloses a binder for raw materials for the production of self-hardening casting molds and casting cores.
  • the setting time is shortened by the addition of potassium hydroxide.
  • the setting is too fast, there is a risk that the surface of the core moldings will not have the required smoothness.
  • the finished green form is chemically or thermally solidified, for example by esterification during drying for one hour at 200 0 C. This process is tedious and consuming and therefore not suitable for rapid, mechanical core production.
  • a surfactant is added to the binder, which may consist of a surfactant such as silicone oil or a silicone emulsion.
  • a surfactant such as silicone oil or a silicone emulsion.
  • the invention has for its object to provide a mold or a molding for foundry purposes, a foundry-molding material mixture and a method for producing a mold or a molded article using the foundry-molding mixture, which overcomes the disadvantages of the prior art and a machine, fast clocked mold and core production allows.
  • a cast product made using the new mold or molding should be easily demoldable.
  • the molding material mixture should have good disintegration properties after the intended use and the spent molding sand can be easily processed with low emission.
  • the solution according to the invention of this complex task consists, on the one hand, of providing a new foundry molding material mixture and of the one with it producible new form or new forms according to claims 1-9. For optimum results, a new method of making the mold or blanks and the production of castings having claims 10-14 has been developed.
  • aluminum oxide is suitable as a supplement to a foundry-molding material mixture when it covers the sand or quartz particles of the molding material after being dried through and dried as an opaque layer.
  • the alumina in a certain amount based on the binder and in a certain particle size based on the average diameter of the sand or quartz grains to use.
  • alumina significantly improves the flowability and the solidification behavior of the molding material mixture. This will be explained in more detail by means of subsequent comparative experiments. Furthermore, it was surprising that the molding / core or the mold had particularly good disintegration properties after their intended use. For example, it has been observed that the core contacted with water immediately disintegrates and can be fully processed as a homogeneous suspension.
  • Forming surface with the liquid metal plays a role, on the other hand, a opposite effect was observed during demolding or reprocessing of the molding sand.
  • good wetting conditions are important; on the other hand, this sometimes leads to problems during demoulding, since with the removal of the casting, parts of the mold or of the molded article are also entrained in the form of fine sand particles.
  • in a poor wetting behavior of the molding sand already in the state of mixing with the partially liquid binder adverse effects that led to poor reusability of the spent molding material mixture (segregation, inhomogeneities, etc.).
  • an aluminum oxide with 99.9% purity was first added directly to a molding material mixture as an oxide and homogeneously distributed. It was found that homogenous distributions in common molding sands with mean particle sizes between 75 and 250 micrometers could only be obtained by repeated and lengthy mixing processes. In order to be able to effectively use above all established systems, which are designed for the use of liquid binders in the form of resins, alcohols, oils or inorganic suspensions, the oxide was first added to the binder, homogeneously dispersed and then added to the molding material via established methods. It was found that
  • AI 2 O 3 binder dispersions despite the relatively high density (about 4 g / cm 3 ) of the AI 2 O 3 particles over several days no tendency to segregation.
  • Al 2 O 3 - Particles with a particle size of over 200 microns were obtained unstable dispersions.
  • Al 2 O 3 particles with less than 1 micron average particle size the viscosity of the dispersion increased significantly, which made subsequent distribution of the dispersion in the molding sand more difficult and necessitated longer stirring times.
  • the AI 2 O 3 concentration ranged from 10% to 85% (by weight, all subsequent concentrations as well).
  • Flowability relates to the flow behavior of the molding material mixture while it is being filled into the mold. It is influenced by the cohesion of the molding material mixture components with each other and the adhesion of the molding material to the wall of the mold. Particularly in the field of dry molding mixtures, in which the ratio of foundry sand to binders and aggregates can be in the range of 3 to 1 - 2, the properties of the aggregates are clearly evident.
  • the ratio of foundry sand to binders and aggregates can be in the range of 3 to 1 - 2
  • the properties of the aggregates are clearly evident.
  • different mixtures of foundry sand and aluminum oxide were homogenized in a stirred mixer. The mean grain size of the molding sand was 0.32 mm; the size of the alumina particles was 1, 5-2.5 microns; also in the following experiments.
  • the mixture was compacted in a cylindrical, vertically extended form.
  • the upright mold was then pulled vertically upward with constant force, while a stationary die fixed the compacted mixture in place so that the mold was pulled upwards from the mix.
  • the time t1 was determined, which was needed to completely remove the cylinder.
  • the time t2 at which the mixture broke up the cylindrical shape by its own weight and crumbled into a cone was determined.
  • the inclination angle alpha of the conical flanks of the resulting cone was determined.
  • Dry sand trials showed breakage of the mold during withdrawal of the cylinder.
  • the cylinder then accelerated upward without resistance and triggered the timing t1.
  • the alumina causes at a high content of the total mixture earlier breaking of the molding and a flatter angle of the cone flanks.
  • the additionally added water glass binder enhances the cohesive forces between the particles of the molding material mixture.
  • the breaking up of the molding occurred at comparable height of exposed form. This means that the significantly lower value for t1 and t2 can be explained by a higher take-off speed and a reduced adhesion to the mold wall with an aluminum oxide content of 40%.
  • Hardening behavior and separability The solidification behavior describes the ability of a molding mixture to fill a mold while arranging its particles in the closest possible way. Separability or releasability relates to the interactions between the molding material mixture and the mold. If too strong adhesion forces occur, parts of the molded article can adhere to the mold during demoulding and break out of the molding.
  • a foundry sand binder mixture with a binder content of 2.5% and a varied alumina content of 10% and 40% and 80% in the binder (percent by weight based on the binder) was injected via a core shooter into a mold until sufficient green strength pre-dried and removed. After examining the greenware for defects, these microwells were completely dried into ready-to-use molds and finally evaluated.
  • the mold is a rectangular test specimen whose one side is smooth and whose other side has profiles and undercuts with increasing fineness. Each 10 molds were made. The relative density was calculated after complete drying considering the different density of the alumina and the sand.
  • the blend without additive shows the occurrence of defects in the fine profiling during drying, while this is not the case with the mixtures according to the invention.
  • In the drying behavior of the mixture according to the invention shows a better resistance of the molding material mixture against thermal effects.
  • molding mixtures according to the invention based on quartz sand were prepared according to Table 3 and dried under different conditions and tested for their profile fidelity.
  • the improved resistance to thermal effects was confirmed.
  • the inventors assume that the free spaces in the molding material mixture, due to the Al 2 O 3 particles which space the quartz sand grains apart, allow the unhindered transfer of the solvent into the gas phase during drying.
  • a dried in a drying oven at 60 0 C within 48 hours molding had too high final weight and showed in the microscopic examination bulky, coated with a glassy layer throughout binder bridges and had clearly set during drying.
  • a impinged at 80 0 C internal temperature immediately after the wandering of 5000 watt microwave, explosively dried molding showed on microscopic examination a foam-like solidified water glass phase by the A ⁇ Os particles around and had spread over the mold out. From the observations of extremely slow and explosive drying, the inventors recognized that drying at medium speed proceeds well over rough evaporation sites. Especially on freshly generated fracture surfaces and / or breaklines drying apparently takes place preferably on the Al 2 ⁇ 3 particles, wherein the resulting gas is passed through spaces between the particles in the free inter-granular spaces and is led out through the free inter-granular spaces from the molding.
  • this process is directed so that the Al 2 O 3 particles are held as a porous, closed area, packed layer over the binder on the single quartz sand grain.
  • porous binder bridges are formed, which connect the quartz sand grains together.
  • a test series with varied oxide content in the binder showed that with oxide contents from 10%, oxide particle coverage could be observed, while at 80% to 90%, the increasing concentration in the total mixture resulted in more and more particle-coated sand grains. Preference was given to working with contents of 40% to 60%, particularly preferably 50% of oxide.
  • the castings produced showed a significantly smoother surface compared to the standard castings after demoulding.
  • the number of average adherent grains per square centimeter dropped from 47 to 49 to 0.4 to 0.5.
  • the adhesion force of the individual grains to the metal surface was extremely low, so that cleaning could be carried out by means of compressed air or ultrasound instead of the usual sandblasting. This opens up the possibility of the final cleaning of the castings with methods such.
  • the fine profiles were formed exactly in the manner given in the shaping manner.
  • binder bridges between the quartz grains, characterized by a framework of Al 2 O 3 particles, binder as adhesion-promoting phase and pores along the Al 2 O 3 particle interstices, represent optimum predetermined breaking points Provide vibration after casting the improved decorability.
  • the barking out time for binders based on water glass was additionally lowered. This can be explained by an additional weakening of the adhesion-promoting phase of the binder bridges by dissolving with water.
  • the coring time was 20% lower compared to industrial products of the same particle size distribution.
  • the improved barking time on freshly milled Al 2 O 3 particles is attributed to a reduced bond strength of the binder on the fresh fracture surfaces of the particles and a more soluble scaffold of the irregularly comminuted particles.
  • Al 2 O 3 particles had pores of 0.1 microns to a maximum of 2.5 microns. The inventors believe that these micropores have such a high capillarity that the added
  • milled oxides oxides which have been adjusted in their morphology by grinding, crushing, crushing, blasting, impact milling, vibratory milling, etc., during production are referred to as milled oxides. It was found that even with ground aluminum oxides with a purity of 90%, the advantages according to the invention could be achieved.
  • the finely ground aluminum oxides especially in the limits of 100-200 microns, preferably immediately after the grinding must be added to the binder and used, otherwise there is a risk of dissolution or aluminate formation in the case of prolonged storage.
  • the aluminate formation takes place by direct transition of the aluminum from the oxidic surface into the solution in the form of a negatively charged complex.
  • the aluminum is kept in solution in the complex, spreads by diffusion, and tends to agglomerate and flocculate with longer residence time of the solution. This is especially at elevated temperatures as they can occur anywhere in foundry.
  • the agglomeration and flocculation causes inhomogeneously altered Flow properties of the binder and makes use of the binder mixture impossible.
  • the foundry molding material mixture according to the invention consists of molding sand, binder, aggregates and aluminum oxide as an emulsion-free and thus emission-free additive. It results in an improved flowability and resistance to thermal effects of the molding material mixture, a significantly reduced number of adhering grains on the finished casting, a reduced adhesive force of adhering grains on the casting and a significantly shortened Entkemungszeit.
  • the inventive method for producing a foundry molding mixture provides that the alumina with a purity of> 90% and a particle size of 1-200 microns is added directly to the binder and processed.
  • the proportion may be between 10 and 85%, based on the amount of binder.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Mold Materials And Core Materials (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

L'invention concerne un moule ou une ébauche pour fonderie, constitués par du sable de fonderie, des liants et des produits additionnels, le sable de fonderie étant du sable siliceux et de l'oxyde d'aluminium étant mélangé au liant. La granulométrie du sable siliceux va de 0,05 à 5 mm, la granulométrie de l'oxyde d'aluminium va de 1 à 200 micromètres, le liant comportant l'oxyde d'aluminium est disposé sur la surface du sable siliceux comme couche de couverture. La phase verre soluble contenue dans le liant est rassemblée en angle sur les surfaces de contact des grains de silice et elle présente une structure microporeuse dans les interfaces. Le procédé de l'invention destiné à la production d'un moule ou d'une ébauche consiste à ajouter au liant et à mélanger de manière homogène le sable siliceux susmentionné et l'oxyde d'aluminium à raison de 10 à 85 % en poids du liant. Le mélange d'oxyde et de liant est alors mélangé au sable de fonderie puis enfermé et solidifié sous pression dans un châssis, le rapport du mélange liant/oxyde au sable de fonderie étant maintenu entre 1 et 10 à 90. Le séchage du liant liquide est réalisé de manière à créer des ponts de liant microporeux entre les grains de silice individuels.
PCT/EP2007/002008 2006-03-10 2007-03-08 Moule ou ébauche, mélange de matériau de moulage pour fonderie et procédé de réalisation associé WO2007104469A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102006011530.9 2006-03-10
DE102006011530A DE102006011530A1 (de) 2006-03-10 2006-03-10 Form oder Formling, Gießerei-Formstoffgemisch und Verfahren zu seiner Herstellung

Publications (1)

Publication Number Publication Date
WO2007104469A1 true WO2007104469A1 (fr) 2007-09-20

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PCT/EP2007/002008 WO2007104469A1 (fr) 2006-03-10 2007-03-08 Moule ou ébauche, mélange de matériau de moulage pour fonderie et procédé de réalisation associé

Country Status (7)

Country Link
EP (1) EP1832357B1 (fr)
AT (1) ATE460243T1 (fr)
DE (2) DE102006011530A1 (fr)
ES (1) ES2342733T3 (fr)
PL (1) PL1832357T3 (fr)
SI (1) SI1832357T1 (fr)
WO (1) WO2007104469A1 (fr)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102007012660B4 (de) * 2007-03-16 2009-09-24 Chemex Gmbh Kern-Hülle-Partikel zur Verwendung als Füllstoff für Speisermassen
DE102014004914A1 (de) * 2013-08-26 2015-02-26 Gebrüder Dorfner GmbH & Co. Kaolin- und Kristallquarzsand-Werke KG Gießform oder einen Gießformkern aus beschichtetem Formsand für Metallguss

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SU1163958A1 (ru) * 1982-10-22 1985-06-30 Институт проблем литья АН УССР Состав дл изготовлени литейный форм и стержней
DE4020506A1 (de) * 1989-06-30 1991-01-10 Okazaki Minerals & Refining Co Gussform-material
JPH0663683A (ja) * 1992-08-18 1994-03-08 Mitsubishi Heavy Ind Ltd 鋳型の製造方法
WO1998029208A1 (fr) * 1996-12-18 1998-07-09 Dti Industri Procede pour preparer des particules enrobees d'une couche de verre soluble et articles contenant des particules ainsi enrobees
EP1095719A2 (fr) * 1999-10-26 2001-05-02 VAW Aluminium AG Liant, sable à noyaux et leur procédé de fabrication
US20020029862A1 (en) * 1996-08-09 2002-03-14 Vaw Motor Gmbh Method for producing core preforms and recycling core sand for a foundry
US6361610B1 (en) * 1999-03-23 2002-03-26 Forward Technology Industries Method for cleaning or decoring a casting
WO2006024540A2 (fr) * 2004-09-02 2006-03-09 AS Lüngen GmbH Melange de matieres de moulage pour produire des moules pour le travail des metaux

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT8024122A0 (it) * 1979-08-20 1980-08-12 Gen Electric Forme di fonderia, composizioni di trattamento e relativi metodi di preparazione.
DE10216464B4 (de) * 2002-04-12 2004-04-15 Deutsches Zentrum für Luft- und Raumfahrt e.V. Silica gebundene Kernwerkstoffe, Verfahren zu deren Herstellung und deren Verwendung

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SU1163958A1 (ru) * 1982-10-22 1985-06-30 Институт проблем литья АН УССР Состав дл изготовлени литейный форм и стержней
DE4020506A1 (de) * 1989-06-30 1991-01-10 Okazaki Minerals & Refining Co Gussform-material
JPH0663683A (ja) * 1992-08-18 1994-03-08 Mitsubishi Heavy Ind Ltd 鋳型の製造方法
US20020029862A1 (en) * 1996-08-09 2002-03-14 Vaw Motor Gmbh Method for producing core preforms and recycling core sand for a foundry
WO1998029208A1 (fr) * 1996-12-18 1998-07-09 Dti Industri Procede pour preparer des particules enrobees d'une couche de verre soluble et articles contenant des particules ainsi enrobees
US6361610B1 (en) * 1999-03-23 2002-03-26 Forward Technology Industries Method for cleaning or decoring a casting
EP1095719A2 (fr) * 1999-10-26 2001-05-02 VAW Aluminium AG Liant, sable à noyaux et leur procédé de fabrication
WO2006024540A2 (fr) * 2004-09-02 2006-03-09 AS Lüngen GmbH Melange de matieres de moulage pour produire des moules pour le travail des metaux

Non-Patent Citations (4)

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Title
"Self hardenable mould material - contg. silica sand, water glass and titanium oxide based waste paint ash", DERWENT, 18 November 1977 (1977-11-18), XP002366407 *
"Self-hardenable mould prodn. - using water glass as caking agent and blast furnace slag", DERWENT, 26 March 1976 (1976-03-26), XP002366408 *
DATABASE WPI Week 1986, Derwent World Patents Index; AN 1986-019218, XP002441668, L.I. BUTENKO, V.P. GAVRILYUK, A.A. PASHCHENKO: "Mixt. for prep. of casting moulds and cores - contains quartz, sand, water glass, carbonate, and specified aluminous slag" *
UNBEKANNT: "AWB - the binder system for a clean foundry", USEPA MEETING 26TH OF OCTOBER 2005 RALEIGH/DURHAM, October 2005 (2005-10-01), XP002441666, Retrieved from the Internet <URL:www.epa.gov/ttn/atw/ifoundry/binders/minelco10-26-05.pdf> [retrieved on 20070709] *

Also Published As

Publication number Publication date
ATE460243T1 (de) 2010-03-15
EP1832357B1 (fr) 2010-03-10
DE102006011530A1 (de) 2007-09-13
ES2342733T3 (es) 2010-07-13
DE502007003051D1 (de) 2010-04-22
SI1832357T1 (sl) 2010-07-30
PL1832357T3 (pl) 2010-08-31
EP1832357A1 (fr) 2007-09-12

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