WO2007135995A1 - 鋳造用塩中子の製造方法及び鋳造用塩中子 - Google Patents
鋳造用塩中子の製造方法及び鋳造用塩中子 Download PDFInfo
- Publication number
- WO2007135995A1 WO2007135995A1 PCT/JP2007/060239 JP2007060239W WO2007135995A1 WO 2007135995 A1 WO2007135995 A1 WO 2007135995A1 JP 2007060239 W JP2007060239 W JP 2007060239W WO 2007135995 A1 WO2007135995 A1 WO 2007135995A1
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- WO
- WIPO (PCT)
- Prior art keywords
- salt
- core
- salt core
- forging
- mold
- Prior art date
Links
- 150000003839 salts Chemical group 0.000 title claims abstract description 192
- 238000004519 manufacturing process Methods 0.000 title claims description 30
- 238000005266 casting Methods 0.000 title description 3
- 239000007788 liquid Substances 0.000 claims abstract description 35
- 238000010438 heat treatment Methods 0.000 claims abstract description 11
- XAEFZNCEHLXOMS-UHFFFAOYSA-M potassium benzoate Chemical compound [K+].[O-]C(=O)C1=CC=CC=C1 XAEFZNCEHLXOMS-UHFFFAOYSA-M 0.000 claims abstract description 10
- 159000000000 sodium salts Chemical class 0.000 claims abstract description 10
- 239000000155 melt Substances 0.000 claims abstract description 7
- 229910052751 metal Inorganic materials 0.000 claims description 61
- 239000002184 metal Substances 0.000 claims description 61
- 238000005242 forging Methods 0.000 claims description 52
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 40
- 239000007790 solid phase Substances 0.000 claims description 17
- 239000007791 liquid phase Substances 0.000 claims description 14
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 claims description 12
- 229910001414 potassium ion Inorganic materials 0.000 claims description 12
- 150000001768 cations Chemical class 0.000 claims description 10
- 150000001450 anions Chemical class 0.000 claims description 9
- 238000000465 moulding Methods 0.000 claims description 8
- NPYPAHLBTDXSSS-UHFFFAOYSA-N Potassium ion Chemical compound [K+] NPYPAHLBTDXSSS-UHFFFAOYSA-N 0.000 claims description 5
- 238000001816 cooling Methods 0.000 claims description 5
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 claims description 3
- FKNQFGJONOIPTF-UHFFFAOYSA-N Sodium cation Chemical compound [Na+] FKNQFGJONOIPTF-UHFFFAOYSA-N 0.000 claims description 3
- 238000011049 filling Methods 0.000 claims description 3
- 229910001415 sodium ion Inorganic materials 0.000 claims description 3
- 238000007711 solidification Methods 0.000 abstract description 19
- 230000008023 solidification Effects 0.000 abstract description 18
- 238000004512 die casting Methods 0.000 abstract description 12
- 238000002844 melting Methods 0.000 abstract description 10
- 230000008018 melting Effects 0.000 abstract description 10
- 230000003247 decreasing effect Effects 0.000 abstract 1
- 239000000498 cooling water Substances 0.000 description 42
- 238000005452 bending Methods 0.000 description 36
- 239000007787 solid Substances 0.000 description 24
- 238000000034 method Methods 0.000 description 23
- 238000012360 testing method Methods 0.000 description 22
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 18
- 238000003756 stirring Methods 0.000 description 16
- BWHMMNNQKKPAPP-UHFFFAOYSA-L potassium carbonate Chemical compound [K+].[K+].[O-]C([O-])=O BWHMMNNQKKPAPP-UHFFFAOYSA-L 0.000 description 14
- 239000011734 sodium Substances 0.000 description 14
- 238000005259 measurement Methods 0.000 description 13
- 238000002347 injection Methods 0.000 description 12
- 239000007924 injection Substances 0.000 description 12
- 239000000203 mixture Substances 0.000 description 12
- 238000004891 communication Methods 0.000 description 10
- 230000013011 mating Effects 0.000 description 9
- 229910000029 sodium carbonate Inorganic materials 0.000 description 9
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 8
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 8
- 229910000027 potassium carbonate Inorganic materials 0.000 description 7
- 229910052708 sodium Inorganic materials 0.000 description 7
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 6
- WCUXLLCKKVVCTQ-UHFFFAOYSA-M Potassium chloride Chemical compound [Cl-].[K+] WCUXLLCKKVVCTQ-UHFFFAOYSA-M 0.000 description 6
- 239000000243 solution Substances 0.000 description 6
- 229910052782 aluminium Inorganic materials 0.000 description 5
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 5
- 238000004090 dissolution Methods 0.000 description 5
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 4
- 238000005345 coagulation Methods 0.000 description 4
- 230000015271 coagulation Effects 0.000 description 4
- 239000013078 crystal Substances 0.000 description 4
- 238000010586 diagram Methods 0.000 description 4
- 238000009826 distribution Methods 0.000 description 4
- 238000001746 injection moulding Methods 0.000 description 4
- 150000002500 ions Chemical class 0.000 description 4
- 239000011591 potassium Substances 0.000 description 4
- 229910052700 potassium Inorganic materials 0.000 description 4
- 229910000838 Al alloy Inorganic materials 0.000 description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 230000005484 gravity Effects 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 239000001103 potassium chloride Substances 0.000 description 3
- 235000011164 potassium chloride Nutrition 0.000 description 3
- NLKNQRATVPKPDG-UHFFFAOYSA-M potassium iodide Chemical compound [K+].[I-] NLKNQRATVPKPDG-UHFFFAOYSA-M 0.000 description 3
- FVAUCKIRQBBSSJ-UHFFFAOYSA-M sodium iodide Chemical compound [Na+].[I-] FVAUCKIRQBBSSJ-UHFFFAOYSA-M 0.000 description 3
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- 239000006243 Fine Thermal Substances 0.000 description 2
- CSNNHWWHGAXBCP-UHFFFAOYSA-L Magnesium sulfate Chemical compound [Mg+2].[O-][S+2]([O-])([O-])[O-] CSNNHWWHGAXBCP-UHFFFAOYSA-L 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 229910002091 carbon monoxide Inorganic materials 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 230000008602 contraction Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000011010 flushing procedure Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 238000010587 phase diagram Methods 0.000 description 2
- IOLCXVTUBQKXJR-UHFFFAOYSA-M potassium bromide Chemical compound [K+].[Br-] IOLCXVTUBQKXJR-UHFFFAOYSA-M 0.000 description 2
- FGIUAXJPYTZDNR-UHFFFAOYSA-N potassium nitrate Chemical compound [K+].[O-][N+]([O-])=O FGIUAXJPYTZDNR-UHFFFAOYSA-N 0.000 description 2
- 238000001878 scanning electron micrograph Methods 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- JHJLBTNAGRQEKS-UHFFFAOYSA-M sodium bromide Chemical compound [Na+].[Br-] JHJLBTNAGRQEKS-UHFFFAOYSA-M 0.000 description 2
- 239000011780 sodium chloride Substances 0.000 description 2
- VWDWKYIASSYTQR-UHFFFAOYSA-N sodium nitrate Chemical compound [Na+].[O-][N+]([O-])=O VWDWKYIASSYTQR-UHFFFAOYSA-N 0.000 description 2
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 1
- 235000010585 Ammi visnaga Nutrition 0.000 description 1
- 244000153158 Ammi visnaga Species 0.000 description 1
- UXVMQQNJUSDDNG-UHFFFAOYSA-L Calcium chloride Chemical compound [Cl-].[Cl-].[Ca+2] UXVMQQNJUSDDNG-UHFFFAOYSA-L 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 206010053567 Coagulopathies Diseases 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- PMZURENOXWZQFD-UHFFFAOYSA-L Sodium Sulfate Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=O PMZURENOXWZQFD-UHFFFAOYSA-L 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- AYJRCSIUFZENHW-DEQYMQKBSA-L barium(2+);oxomethanediolate Chemical compound [Ba+2].[O-][14C]([O-])=O AYJRCSIUFZENHW-DEQYMQKBSA-L 0.000 description 1
- 235000015895 biscuits Nutrition 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 230000035602 clotting Effects 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000005496 eutectics Effects 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- 239000010437 gem Substances 0.000 description 1
- 229910001751 gemstone Inorganic materials 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- INHCSSUBVCNVSK-UHFFFAOYSA-L lithium sulfate Inorganic materials [Li+].[Li+].[O-]S([O-])(=O)=O INHCSSUBVCNVSK-UHFFFAOYSA-L 0.000 description 1
- 229910052943 magnesium sulfate Inorganic materials 0.000 description 1
- 235000019341 magnesium sulphate Nutrition 0.000 description 1
- 238000010907 mechanical stirring Methods 0.000 description 1
- 238000001000 micrograph Methods 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000012071 phase Substances 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- 239000004323 potassium nitrate Substances 0.000 description 1
- 235000010333 potassium nitrate Nutrition 0.000 description 1
- OTYBMLCTZGSZBG-UHFFFAOYSA-L potassium sulfate Chemical compound [K+].[K+].[O-]S([O-])(=O)=O OTYBMLCTZGSZBG-UHFFFAOYSA-L 0.000 description 1
- 229910052939 potassium sulfate Inorganic materials 0.000 description 1
- 235000011151 potassium sulphates Nutrition 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 239000012744 reinforcing agent Substances 0.000 description 1
- 239000011833 salt mixture Substances 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 235000009518 sodium iodide Nutrition 0.000 description 1
- 239000004317 sodium nitrate Substances 0.000 description 1
- 235000010344 sodium nitrate Nutrition 0.000 description 1
- 229910052938 sodium sulfate Inorganic materials 0.000 description 1
- 235000011152 sodium sulphate Nutrition 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- RBTVSNLYYIMMKS-UHFFFAOYSA-N tert-butyl 3-aminoazetidine-1-carboxylate;hydrochloride Chemical compound Cl.CC(C)(C)OC(=O)N1CC(N)C1 RBTVSNLYYIMMKS-UHFFFAOYSA-N 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/10—Cores; Manufacture or installation of cores
- B22C9/105—Salt cores
-
- 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
Definitions
- the present invention relates to a method for producing a water-soluble salt core for forging and a salt core for forging.
- forging aluminum die casting is a technique for producing a structure having a desired shape by injecting a molten aluminum alloy into a mold at high speed and high pressure, as is well known.
- a core is used when forming a forged product having a hollow structure such as a water cooling water jacket such as a cylinder block of an internal combustion engine.
- the core used in such a case is strong enough to withstand high pressure and high temperature because the molten metal injected at high speed from the gate receives a large impact and the forging pressure is high until solidification is completed. Is required.
- the core is removed from the forged product after forging.
- Salt cores as described above include, for example, sodium carbonate (Na 2 CO 3), potassium salt (KC1), and
- the present invention has been made in order to solve the above-described problems, and has a water-soluble forging salt made of a salt forging formed by melting a salt such as sodium or strength sodium.
- the purpose is to allow the core to be manufactured more easily.
- the method for producing a forging salt core comprises heating a mixed salt containing at least a potassium salt and a sodium salt so that the solid phase and the liquid phase coexist in a solid-liquid coexisting state.
- the first step of forming the molten metal, the second step of putting the molten metal in the solid-liquid coexistence state into the core mold, and the third step of solidifying the molten metal inside the mold to form the salt core for forging It is intended to have at least. Therefore, when the mold is filled, a part of the molten metal is solidified.
- the forging core according to the present invention forms a melt in a solid-liquid coexistence state in which a solid phase and a liquid phase coexist by heating a mixed salt containing at least a potassium salt and a sodium salt.
- the molten metal coexisting with the solid and liquid is put into a mold for core molding, and the molten metal is solidified inside the mold.
- the salt core for forging is, for example, a core for forming a water jacket for water cooling of an engine cylinder.
- forging is performed using a molten metal in a coexisting state of solid and liquid, so that it has water solubility comprising a salt forging formed by melting a salt such as sodium or potassium.
- a salt forging formed by melting a salt such as sodium or potassium.
- FIG. 1 is a perspective view of a cylinder block when forged using a salt core for forging according to the present invention.
- FIG. 2 is a metallographic microscope (optical microscope) photograph showing the state of the solidified structure of salt core 2.
- FIG. 3 is a characteristic diagram showing the temperature dependence of the solid phase ratio of a semi-solid state molten metal.
- Fig. 4 shows a mixture salt with a high salt content and melted and solidified without stirring. It is the scanning electron micrograph of the solidification structure when letting it go.
- FIG. 5 is a scanning electron micrograph of a solidified structure when a mixed salt having a composition containing a large amount of carbonate is melt-molded and solidified without stirring.
- FIG. 6A is a graph showing the bending strength of bending test specimens of sample numbers 1 to 9.
- FIG. 6B is a graph showing the bending strength of the bending test pieces of sample numbers 10 to 12.
- FIG. 6C is a graph showing the bending strength of the bending test pieces of sample numbers 13 to 17.
- FIG. 7A is a graph showing the bending strength of bending test specimens of sample numbers 18 to 23.
- FIG. 7B is a graph showing the bending strength of the bending test specimens of sample numbers 24-27.
- FIG. 8 is a characteristic diagram (phase diagram) showing the relationship between the cation ratio of potassium ions and the anion ratio of carbonate ions and the liquidus temperature.
- FIG. 9A is a configuration diagram showing the state of a test piece used for bending strength measurement.
- FIG. 9B is a cross-sectional view showing a part of a test piece used for bending strength measurement.
- FIG. 10 is an explanatory diagram for explaining bending strength measurement.
- FIG. 11 is a photograph for explaining the measurement points of the pressure in the cavity at the time of injection molding of the salt core.
- FIG. 12 is an explanatory view showing the measurement result of the pressure in the cavity at the time of injection molding of the salt core.
- FIG. 13 is a perspective view of another cylinder block when forged using the forged salt core according to the present invention.
- FIG. 14 is a photograph of salt core 1302 shown in FIG.
- FIG. 1 is a perspective view of a cylinder block when forged using a salt core for forging according to the present invention, and is a partially broken view.
- reference numeral 1 denotes an engine cylinder block made of an aluminum alloy, which is forged using a salt core 2 as a forged salt core according to the present invention.
- This cylinder block 1 is a part of a water-cooled four-cycle four-cylinder engine for motorcycles, and is formed into a predetermined shape by a die casting method. ing.
- a cylinder body 4 having four cylinder bores 3 and a cylinder bore 3 and an upper crankcase 5 extending downward from the lower end of the cylinder body 4 are integrally formed.
- the upper crankcase 5 has a lower crankcase (not shown) attached to a lower end portion thereof, and supports a crankshaft (not shown) rotatably through a bearing together with the lower crankcase.
- the cylinder body 4 is of a so-called closed deck type, and a water jacket 6 is formed inside using a salt core 2.
- the water jacket 6 includes a cooling water passage forming portion 7, a cooling water inlet 8, a main cooling water passage 9, and a communication passage 10.
- the cooling water passage forming portion 7 projects from one side of the cylinder body 4 and extends in the direction in which the cylinder bores 3 are arranged.
- the cooling water inlet 8 is formed in the cooling water passage forming portion 7.
- the main cooling water passage 9 communicates with a cooling water distribution passage (not shown) formed inside the cooling water passage forming portion 7 and is formed so as to cover all the cylinder bores 3.
- the communication passage 10 extends upward from the main cooling water passage 9 in FIG. 1 and opens to the mating surface 4a of the upper end of the cylinder body 4 with the cylinder head shown in FIG.
- the water jacket 6 described above supplies the cooling water flowing from the cooling water inlet 8 to the main cooling water passage 9 around the cylinder bore through the cooling water distribution passage, and this cooling water is further supplied from the main cooling water passage 9. It is configured to lead to a cooling water passage in a cylinder head (not shown) through the communication passage 10.
- the cylinder body 4 has the same structure as that of the cylinder body 4 except that the communication path 10 of the water jacket 6 opens at the mating surface 4a at the upper end to which the cylinder head is connected. It will be covered with the ceiling wall (the wall that forms the mating surface 4a), and it will be a closed deck type configuration.
- the salt core 2 for forming the water jacket 6 is formed in a shape in which the respective parts of the water jacket 6 are integrally connected.
- the cylinder body 4 is drawn in a partially broken state so that the shape of the salt core 2 (the shape of the water jacket 6) can be easily understood.
- the salt core (salt core for fabrication) 2 uses a plurality of salts such as sodium carbonate, salt sodium, and salt potassium, and coexists with solid-liquid such as semi-solidification. For example, da Formed to form the shape of a water jacket 6 by the cast casting method!
- the salt core 2 heats a mixed salt containing at least a potassium salt and a sodium salt to form a solid-liquid coexisting molten state in which a solid phase and a liquid phase coexist.
- the method for producing the salt core 2 will be described in detail below.
- the salt core 2 can also be formed by using other fabrication methods such as a gravity fabrication method in addition to the die casting fabrication method.
- a molten metal is made by heating and melting a mixture composed of a plurality of salts described later.
- the temperature of the molten metal is lowered to a semi-solid state (solid-liquid coexistence), and the molten metal in a semi-solid state is injected into a salt core mold by high pressure to be solidified and taken out from the mold after solidification.
- the salt core 2 includes a passage forming portion 2a that forms a cooling water inlet 8 and a cooling water distribution passage, and an annular portion 2b that surrounds the four cylinder bores 3.
- the plurality of convex portions 2c protruding upward from the annular portion 2b are all integrally formed.
- the communication passage 10 of the water jacket 6 is formed by these convex portions 2c.
- the salt core 2 is supported at a predetermined position in a mold (not shown) by a skirting board (not shown) at the time of forging, and is heated by hot water or steam after forging. Dissolve and remove.
- the salt core 2 can be performed by immersing the cylinder block 1 in a dissolution tank (not shown) in which a powerful solution such as hydrochloric acid and warm water is stored.
- a powerful solution such as hydrochloric acid and warm water is stored.
- the passage forming portion 2a in the salt core 2 and the convex portion 2c exposed on the mating surface 4a come into contact with the solution and dissolve.
- This dissolved part gradually expands and finally all the parts dissolve.
- hot water or steam may be blown with pressure from the hole in order to promote dissolution of the salt core 2 remaining in the water jacket 6.
- a baseboard can be inserted in place of the convex portion 2c at the portion where the convex portion 2c is formed.
- salt core 2 contains potassium carbonate and sodium carbonate. When dissolved in water, it becomes alkaline. Thus, in the alkaline state, there is a problem that the cylinder block 1 which is a forged aluminum is corroded. against this problem, cylinder block corrosion can be prevented by adding hydrochloric acid and controlling the pH close to 7.
- the salt core 2 is produced by pouring (injecting) the molten metal into the mold without pouring (injecting) the molten metal at a high pressure as in the die casting method (gravity forging method).
- the salt core 2 in this embodiment is mixed with sodium carbonate, potassium carbonate, sodium chloride salt, and potassium chloride, and heated until they are melted to prepare a molten salt of the mixed salt.
- the above salt When the above salt is mixed so that X 100) is 67 mol%, it dissolves at 647 ° C.
- the above mixed salt can be dissolved in an alumina crucible and dissolved in an electric furnace. .
- the crucible was taken out of the electric furnace and air-cooled.
- the cooling rate was 0.3 to 1.2 ° C per second.
- the mixed salt in the crucible was stirred with an alumina stirrer at a rotation speed of 3 revolutions per second, and poured into the mold when the temperature of the molten salt was 638 ° C.
- the molten salt melt is 6 38 ° C, it is in a semi-solid state where the solid phase and the liquid phase coexist. Put the molten metal in this state into a salt core mold and solidify it. Take out from.
- the mixed salt is heated to a liquid phase only, and then cooled to form a solid-liquid coexisting molten metal.
- the present invention is not limited to this. It is also possible to obtain a semi-solid state by heating the mixed salt to a temperature at which it becomes semi-solid.
- the strength (bending strength) of the salt core 2 thus obtained was as high as 21.4-24. 6 MPa.
- the solidification structure of the salt core 2 was composed of fine crystal grain forces as shown in the metal micrograph in Fig. 2.
- the solid phase ratio depends on the temperature dependence of the solid phase ratio when the solid-liquid coexistence temperature range is about 60 ° C and the solid phase ratio is 0-40%. Therefore, it is easy to obtain a molten salt mixture in a uniform solid-liquid coexistence state. Thus, according to the manufacturing method in this example, strict temperature control and isothermal holding are not performed. Even salt core 2 can be manufactured.
- the temperature range in which the entire temperature of the molten metal becomes a solid phase changes to the liquid phase, in other words, the temperature range in which the solid-liquid coexistence state is maintained.
- a mixed salt having a composition of 10 mol% of CO 2 ] Z ([CO 2 —] + [CI—]) X 100) is melt-molded and stirred.
- stirring is not necessary, but stirring may be performed. This is because the temperature distribution in the mixed salt in the solid-liquid coexistence state can be lowered by stirring, and a mixed salt having a uniform solid phase ratio can be easily obtained.
- the solid phase particles in the mixed salt in the solid-liquid coexisting state can be made into fine-spheroids by stirring, so that moldability is improved. When molding the core with a high solid phase ratio, it is better to stir. In the case of mechanical stirring, the stirrer has good corrosion resistance against molten salt, and ceramics can be used.
- the amount of solidification shrinkage that occurs during the solidification process can be suppressed. Therefore, the shrinkage nest and microporosity generated in the salt core are fine. It becomes possible to suppress thermal cracks. In addition, since the amount of coagulation shrinkage can be suppressed, it becomes possible to mold the mold as accurately as possible. When fabricated from a completely melted state as in the past, the amount of solidification shrinkage is large, and many shrinkage, microporosity and fine thermal cracks are generated. For this reason, It comes to be.
- the solidification shrinkage of the core to be molded is larger than the shrinkage of the mold, so when trying to mold a cylindrical annular core such as a water jacket of a cylinder, In some cases, shrinkage nests, microporosity, fine thermal cracks may occur, and in some cases, the salt core may break in the mold.
- the use of a semi-solid molten metal as described above can reduce the solidification shrinkage rate, so that a cylindrical annular core such as a water jacket can be formed.
- the salt does not oxidize, and even if the above-described stirring is performed in the atmosphere, the stirring of the molten metal that does not involve the oxidization in the molten metal is easy. You can do it for hours.
- an annular shape is formed in a semi-solid state, an oxide film is not formed at the joint junction on the opposite side of the molten metal that is divided into two in the circumferential direction from the gate. Therefore, there is no separation at the joint after forming with cold shut ( C0 ld shut)
- a force that is cooled from the melted state to the semi-solidified region to form a solid-liquid coexistence state is not limited to this.
- the mixed salt of the solid phase may be heated to a semi-molten region to be in a solid-liquid coexistence state.
- a solid powdery salt (mixed salt) may be added to the molten salt so as to be in a solid-liquid coexistence state.
- a molten salt may be added to a preheated solid salt (mixed salt) to make it coexist in a solid-liquid state.
- Molar component ratio YCO 2 ( [CO 2 —] / ([CO 2 —] + [C1—]) X 100) to 67 mol%
- the mixed salt is formed only from potassium ion, sodium ion, chlorine ion, and carbonate ion.
- Table 1 also shows the measurement results of the bending strength (maximum bending load) of the prepared specimen
- Table 2 shows the measurement results of the bending strength (maximum bending strength) of the prepared specimen. It also shows. Tables 1 and 2 are the same except that the measurement results are represented differently. These bending load and bending strength states are shown as bar graphs in Figures 6A to 6C, 7A, and 7B. The concentration of each ion was measured by an analysis method established in the general rules for ion chromatograph analysis of JIS standard K0127.
- FIG. 8 shows the relationship between the cation ratio of potassium ions and the anion ratio of carbonate ions and the melting temperature (liquidus temperature) (phase diagram of Na-KC to CO system). In Figure 8, it is shown in Table 1.
- Liquid phase temperature of KC1 liquid phase temperature of Na CO in the case of K + 0mol%, Cl—0mol%, Na + 0
- the eutectic line is indicated by a bold line.
- a high bending strength is obtained as a result of the test. Also, within the region where XK + is 0-40 mol% and YCO is 50-70 mol%! / Especially, high 1 and bending strength are obtained. [0037] Next, measurement of the bending strength will be described. To measure the bending strength, prepare a prismatic test piece with a predetermined size, apply a load to the test piece, and determine the bending load from the maximum load required for fracture. First, preparation of a test piece will be described. A rod-shaped test piece 901 as shown in FIGS. 9A and 9B is formed using a predetermined mold. The mold used is made of chrome molybdenum steel such as SCM440H, for example.
- 9A also shows a portion 902 of the hot water used for filling the mold with the semi-solid molten metal, the portion 902 is cut out for measuring the bending strength.
- 9A shows a side view
- FIG. 9B shows a cross-sectional view at the position bb in FIG. 9A.
- the dimensions shown in the figure are design values for the mold.
- the bending strength of the rod-shaped test piece 901 produced as described above is first measured with a space of 50 mm open at the center of the test piece 901.
- the test piece 901 is supported by the two support parts 1001.
- a load is applied to the test piece 901 by two load portions 1002 having an interval of 10 mm at an intermediate position between the two support portions 1001.
- the load held on the test piece 901 was gradually increased, and the load when the test piece 901 was broken was defined as the bending load shown in Table 1.
- H is the load direction in the cross section of the specimen.
- B represents the length perpendicular to the load direction in the cross section of the test piece, and
- L is the distance from the support portion 1011, which is the fulcrum, to the load portion 1002 to which the load is applied.
- it is formed by pouring the molten metal in the coexisting state of the solid and liquid into the above mold, but it is difficult to form a shape that has no wrinkles or sink marks and exactly matches the dimensions of the mold.
- the strength is estimated to be as low as 0 to 20%.
- a specimen that has been fractured at a bending load of 1200 N has a bending strength of lOMPa. It can be considered stronger than the ideal test strip with strength.
- the crucible is a dense alumina made of the same material as the Tamman tube. Use a pot.
- a predetermined amount of mixed salt consisting of sodium carbonate, potassium carbonate, sodium chloride salt, and potassium chloride is placed in a heating furnace and heated. In order to protect the crucible, the temperature is gradually raised to the target temperature over about 14 hours.
- the target temperature is 10-30 ° C higher than the liquidus temperature corresponding to the molar component ratio of the mixed salt, and is maintained at that temperature after reaching the target temperature.
- the temperature of the mold and the injection sleeve is about 180 to 220 ° C.
- the mold should be capable of heating to a mold temperature of about 250 ° C.
- the forged injection pressure is as high as about 120MPa and the nest can be crushed.
- the molten salt of the mixed salt melted in the crucible is drawn up with a handle.
- the handle is heated to about 500-600 ° C by heating means such as a burner.
- the molten metal is pumped up from the crucible with the handle, the molten metal is gradually deprived of heat by the handle and the temperature becomes lower than the liquidus temperature, so that it becomes a solid-liquid coexistence state.
- the molten metal is shaken and stirred in the moving handle and the primary crystals are precipitated in granular form.
- the molten salt in the mixed salt is in a solid-liquid coexistence state in the handle of the process of transporting and pouring the molten metal into the crucible force injection sleeve.
- the solidified core is removed from the mold. It is advisable to put a push pin and a return pin in the fixed mold so that the material can be released well when the mold opens.
- the salt cores taken out are gradually cooled, and the cooled salt cores may be stored in a dry container.
- test piece for which this strength measurement was performed was almost in the shape of a rectangular parallelepiped, as in FIGS. 9A and 9B.
- the liquidus temperature of the mixed salt is 630 ° C.
- the mixed salt contained in the crucible was dissolved by gradually raising the temperature until the liquidus temperature exceeded 630 ° C over 14 hours, and the molten metal temperature was maintained at 640 to 660 ° C.
- the temperature control was performed automatically.
- the sleeve temperature and mold temperature were 180-220 ° C.
- the gate portion 1101 and the inner portion 1102 shown in FIG. As shown in the injection curve of 12, both were about 60MPa.
- the solid line shows the measurement result in the portion 1101
- the wavy line shows the measurement result in the portion 1102.
- the measured pressure was maintained at a constant level of about 60 MPa from the start of injection to just before the end of solidification (about 5 seconds before) when the mold was opened, and it dropped rapidly at the time of mold opening. Actually, the measured pressure gradually decreases as shown in Fig. 12. This is thought to be because the salt core solidifies the surface force and transmits pressure.
- the molten metal has good thermal conductivity and the solidification time is short. In many cases, the intermediate part solidifies before the end of the mold, and the end of the mold It may not be possible to replenish the melt sufficiently.
- molten salt has a low thermal conductivity and takes about three times as long as aluminum to solidify. Therefore, as shown in Fig. 12, almost constant pressure is applied to the entire cavity until mold opening. It is possible to continue. In this way, the same pressure is always applied to the cavity until the mold is opened, or the pressure applied to the cavity is gradually changed by the same amount of change until the mold is opened. It is the condition to obtain high strength at a uniform pressure.
- the salt core in this embodiment is formed by solidifying molten salt, the surface state of the mold is reflected in the surface state of the salt core, and a smooth surface is obtained. For this reason, in the forged product using the salt core according to the present example, the portion in contact with the salt core is formed in a state having high smoothness.
- a force using a mixed salt of sodium carbonate, potassium carbonate, sodium chloride salt, and potassium chloride is not limited to this.
- potassium carbonate, sodium chloride salt, and potassium salt may be mixed, and sodium carbonate, sodium salt, and potassium salt may be mixed.
- the salt may be mixed. Further, these may contain ceramics for reinforcement, other reinforcing agents, and the like.
- FIG. 13 is a perspective view of a cylinder block in the case of forging using the forging salt core according to the present invention, and is a partially broken view.
- FIG. 1301 what is indicated by reference numeral 1301 is an engine cylinder block made of an aluminum alloy forged using a salt core 1302 as a forged salt core according to the present invention.
- the salt core 1302 is manufactured in the same manner as the salt core 2 shown in FIG.
- This cylinder block 1301 is a part of a water-cooled four-cycle single-cylinder engine for a motorcycle, and is formed into a predetermined shape by a die casting method.
- the cylinder block 1301 shown in FIG. 13 is also configured with a cylinder body 1304 having a cylinder bore 1303 and a cylinder bore 1303.
- a crankcase is attached to the lower part of the cylinder body 1304, and the crankshaft is rotatably supported via a bearing.
- the cylinder body 1304 is of a so-called closed deck type, and is formed inside the force of the water jacket 1306 using a salt core 1302.
- the water jacket 130 6 includes a cooling water passage forming portion (not shown), a cooling water inlet (not shown), and a main cooling water passage 130. 9, It is constituted including the communication path 1310.
- the cooling water passage forming portion projects from one side of the cylinder body 1304.
- the cooling water inlet is formed in the cooling water passage forming portion.
- the main cooling water passage 1309 communicates with a cooling water supply passage (not shown) formed inside the cooling water passage forming portion and is formed so as to cover the periphery of the cylinder bore 1303. Further, the communication passage 1310 extends upward from the main cooling water passage 1309 in FIG. 13 and opens at a mating surface 1304 a with the cylinder head (not shown) at the upper end of the cylinder body 1304.
- the above-described water jacket 1306 supplies the cooling water flowing from the cooling water inlet (not shown) to the main cooling water passage 1309 around the cylinder bore through the cooling water supply passage, and further, this cooling water is supplied to the main cooling water.
- the water passage 1309 is led to the cooling water passage in the cylinder head (not shown) through the communication passage 1310.
- the cylinder body 1304 has the communication passage 1310 of the water jacket 1306 opened on the mating surface 1304a of the upper end to which the cylinder head is connected. It will be covered with the ceiling wall (the wall that forms the mating surface 1304a), and it will have a closed deck configuration.
- the salt core 1302 for forming the water jacket 1306 is formed in a shape in which the respective parts of the water jacket 1306 are integrally connected.
- Reference numeral 1311 denotes a camshaft drive chain passage
- reference numeral 1312 denotes a chain tensioner mounting hole.
- the salt core 1302 shown in FIG. 13 uses a plurality of salts such as sodium carbonate, salt sodium, and salt potassium as in the salt core 2 described above.
- the water jacket 1306 is formed in the shape of a die-cast forging method in which the forging is performed in the coexistence of solid-liquid such as solidification.
- the salt core 1302 can also be formed by using other forging methods such as a gravity forging method in addition to the die casting method.
- a molten metal is made by heating and melting a mixture of a plurality of salts described later. Next, lower the temperature of this molten metal This is done by solidifying (solid-liquid coexistence), injecting the molten metal in a semi-solid state into a salt core mold at high pressure and solidifying it, and then extracting the mold force after solidification.
- the salt core 1302 includes a cooling water passage forming portion (not shown) that forms a cooling water inlet and a cooling water supply passage, and an annular portion that surrounds the cylinder bore 1303. 13 02b and a plurality of convex portions 1302a protruding upward from the annular portion 1302b are all formed integrally. A communication passage 1310 of the water jacket 1306 is formed by these convex portions 1302a.
- the salt core 1302 is supported at a predetermined position in a mold (not shown) by a skirting board (not shown in FIG. 13) at the time of forging. Dissolve with steam and remove.
- the salt core 1302 can be removed after fabrication by immersing the cylinder block 1301 in a dissolution tank (not shown) in which a solution composed of hydrochloric acid and warm water is stored. .
- a dissolution tank (not shown) in which a solution composed of hydrochloric acid and warm water is stored.
- the cooling water inlet of the cooling water passage forming portion (not shown) in the salt core 1302 and the convex portion 1302a exposed on the mating surface 1304a contact the solution. And dissolve. This dissolved part gradually expands and finally all the parts are dissolved.
- hot water or steam may be blown with a hole force or pressure in order to promote dissolution of the salt core 1302 remaining in the water jacket 1306.
- a baseboard can be inserted in place of the convex portion 1302a at a portion where the convex portion 1302a is formed.
- the annular salt core 1302 can be easily formed.
- the baseboard region shown in the photograph of FIG. 14 is a region protruding above the mating surface 1304a of FIG.
- the overflow, gate, runner, and biscuit portions shown in the photograph in FIG. 14 are formed at the stage where the salt core 1302 is manufactured, but at the stage where the salt core 1302 is used to manufacture the cylinder block 1301. Deleted.
- the present invention is suitably used as a core in the fabrication of aluminum die castings and the like.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Mold Materials And Core Materials (AREA)
Description
Claims
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/301,073 US20090205801A1 (en) | 2006-05-18 | 2007-05-18 | Method of manufacturing expendable salt core for casting and expendable salt core for casting |
EP07743674A EP2022577A4 (en) | 2006-05-18 | 2007-05-18 | SALT CORE FOR CASTING AND METHOD FOR PRODUCING THE SAME |
JP2008516667A JP4685933B2 (ja) | 2006-05-18 | 2007-05-18 | 鋳造用塩中子の製造方法及び鋳造用塩中子 |
Applications Claiming Priority (2)
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JP2006138879 | 2006-05-18 | ||
JP2006-138879 | 2006-05-18 |
Publications (1)
Publication Number | Publication Date |
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WO2007135995A1 true WO2007135995A1 (ja) | 2007-11-29 |
Family
ID=38723306
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PCT/JP2007/060239 WO2007135995A1 (ja) | 2006-05-18 | 2007-05-18 | 鋳造用塩中子の製造方法及び鋳造用塩中子 |
Country Status (4)
Country | Link |
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US (1) | US20090205801A1 (ja) |
EP (1) | EP2022577A4 (ja) |
JP (1) | JP4685933B2 (ja) |
WO (1) | WO2007135995A1 (ja) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2009136650A1 (ja) * | 2008-05-09 | 2009-11-12 | ヤマハ発動機株式会社 | 鋳造用塩中子の製造方法 |
WO2010126135A1 (ja) * | 2009-05-01 | 2010-11-04 | 国立大学法人東北大学 | 鋳造用塩中子の製造方法 |
CN108237206A (zh) * | 2018-02-28 | 2018-07-03 | 厦门格欧博新材料科技有限公司 | 一种盐芯成型设备 |
Families Citing this family (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP2586546A1 (de) * | 2011-10-31 | 2013-05-01 | Bühler AG | Verfahren zur Herstellung von Salzkernen |
EP2647451A1 (de) | 2012-04-04 | 2013-10-09 | Bühler AG | Verfahren zur Herstellung von Salzkernen |
ITMI20120950A1 (it) | 2012-06-01 | 2013-12-02 | Flavio Mancini | Metodo e impianto per ottenere getti pressofusi in leghe leggere con anime non metalliche |
DE102012022390B3 (de) * | 2012-11-15 | 2014-04-03 | Audi Ag | Verfahren zur kalten Herstellung eines Salzkerns für das Druckgießen |
KR101637638B1 (ko) * | 2014-02-18 | 2016-07-07 | 현대자동차주식회사 | 주조제품 및 그 제조방법 |
KR102176149B1 (ko) * | 2018-12-04 | 2020-11-09 | 한국생산기술연구원 | 용융형 중자를 이용하여 중공 구조를 갖는 중공 휠을 제조하는 방법 |
CN114951556A (zh) * | 2022-05-31 | 2022-08-30 | 西北橡胶塑料研究设计院有限公司 | 一种用于模压成型工艺的低成本水溶性芯材的制备方法 |
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US5303761A (en) * | 1993-03-05 | 1994-04-19 | Puget Corporation | Die casting using casting salt cores |
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- 2007-05-18 WO PCT/JP2007/060239 patent/WO2007135995A1/ja active Application Filing
- 2007-05-18 EP EP07743674A patent/EP2022577A4/en not_active Withdrawn
- 2007-05-18 US US12/301,073 patent/US20090205801A1/en not_active Abandoned
- 2007-05-18 JP JP2008516667A patent/JP4685933B2/ja not_active Expired - Fee Related
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US3963818A (en) | 1971-10-29 | 1976-06-15 | Toyo Kogyo Co., Ltd. | Water soluble core for pressure die casting and process for making the same |
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Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2009136650A1 (ja) * | 2008-05-09 | 2009-11-12 | ヤマハ発動機株式会社 | 鋳造用塩中子の製造方法 |
EP2277644A1 (en) * | 2008-05-09 | 2011-01-26 | Yamaha Hatsudoki Kabushiki Kaisha | Process for producing salt core for casting |
EP2277644A4 (en) * | 2008-05-09 | 2013-07-10 | Yamaha Motor Co Ltd | PROCESS FOR PRODUCING A CASTING SALT CORE |
US8574476B2 (en) | 2008-05-09 | 2013-11-05 | Buhler Ag | Method of manufacturing expendable salt core for casting |
JP5363468B2 (ja) * | 2008-05-09 | 2013-12-11 | ビューラー・アクチエンゲゼルシャフト | 鋳造用塩中子の製造方法 |
WO2010126135A1 (ja) * | 2009-05-01 | 2010-11-04 | 国立大学法人東北大学 | 鋳造用塩中子の製造方法 |
JP2010279951A (ja) * | 2009-05-01 | 2010-12-16 | Tohoku Univ | 鋳造用塩中子の製造方法 |
CN108237206A (zh) * | 2018-02-28 | 2018-07-03 | 厦门格欧博新材料科技有限公司 | 一种盐芯成型设备 |
Also Published As
Publication number | Publication date |
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US20090205801A1 (en) | 2009-08-20 |
JPWO2007135995A1 (ja) | 2009-10-01 |
EP2022577A1 (en) | 2009-02-11 |
EP2022577A4 (en) | 2013-03-20 |
JP4685933B2 (ja) | 2011-05-18 |
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