WO2009151139A1 - 半溶融または半凝固状態の鉄系合金の鋳造方法および鋳造用金型 - Google Patents
半溶融または半凝固状態の鉄系合金の鋳造方法および鋳造用金型 Download PDFInfo
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- WO2009151139A1 WO2009151139A1 PCT/JP2009/060878 JP2009060878W WO2009151139A1 WO 2009151139 A1 WO2009151139 A1 WO 2009151139A1 JP 2009060878 W JP2009060878 W JP 2009060878W WO 2009151139 A1 WO2009151139 A1 WO 2009151139A1
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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
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/2007—Methods or apparatus for cleaning or lubricating moulds
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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
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/007—Semi-solid pressure die casting
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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
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/2015—Means for forcing the molten metal into the die
- B22D17/2038—Heating, cooling or lubricating the injection unit
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S164/00—Metal founding
- Y10S164/90—Rheo-casting
Definitions
- the present invention relates to a method of casting a semi-molten or semi-solidified iron-based alloy and a casting mold used for such casting.
- Patent Document 2 after apply
- Patent Document 3 a coating material in which powders such as oxides and fiber materials such as potassium titanate are dispersed in water containing sodium silicate is applied and dried on the surface of the casting mold, and curing heat treatment is performed.
- a technique for improving the durability of the mold and the releasability of the casting is disclosed.
- JP 2004-114151 A Japanese Patent Laid-Open No. 2001-232443 Japanese Patent Application Laid-Open No. 07-303933
- the temperature of the cast iron in the semi-molten state is lower than the melting point of the cast iron, for example, about 1200 to 1270 ° C. in the case of C: 2.0% cast iron, which is much higher than the melting point of the aluminum alloy or the magnesium alloy. High temperature.
- the mold material is mostly mold steel represented by SKD61. Under these circumstances, the mold is exposed to an environment in which wear, seizure with a workpiece, cracking due to thermal shock at the time of contact, melting into cast iron, etc. are very likely to occur. In fact, ordinary die casting molds for low alloys can withstand the production of more than 10,000 molded products, but the current semi-molten cast iron die casting molds are about 1000 even if the techniques of Patent Documents 1 to 3 are used. Durability corresponding to the number of manufactured products is the limit. Thus, semi-molten cast iron die casting molds are desired to have a short life and improve durability.
- the present invention provides high-temperature wear on the inner surface of a mold, formed metal in thixocasting (semi-melt molding) and rheocasting (semi-solid molding) of an iron-based alloy (such as hypoeutectic cast iron). It is an object of the present invention to provide a semi-molten or semi-solid state iron-based alloy casting method and casting mold in which seizure, erosion, and the like are prevented from occurring, and releasability is good and durability is improved.
- the present inventor has extensively studied the coating material (release agent) applied to the mold. As a result, it has been found that the lubricating mold release agent described below is highly effective in improving the durability of a mold for casting an iron-based alloy in a semi-molten or semi-solid state.
- the present invention has been made on the basis of the above findings, and the gist thereof is as follows.
- (1) A method of casting a semi-molten or semi-solidified iron-based alloy, in which a part or all of the inner surface of the mold is coated with molybdenum disulfide, graphite, tungsten disulfide, boron nitride, oxidation
- a part or the entire surface of the base material of the mold is coated with one or more coatings of any one of metal or cermet spraying, metal plating, or metal nitride or metal carbonitride deposition,
- the solvent of the lubricant release agent is a synthetic ester oil, silicone oil, polyglycol, polyacryl, polyglycol or polyacrylic aqueous solution, or an aqueous solution obtained by adding a surfactant to the aqueous solution.
- a casting mold used for semi-molten casting or semi-solid casting of an iron-based alloy, and a part or all of the inner surface thereof has molybdenum disulfide, graphite, tungsten disulfide, boron nitride, A casting mold to which a lubricating mold release agent in which particles composed of one or more of chromium oxide and boron oxide are dispersed in a solvent is applied.
- a part or the whole surface of the base material of the casting mold is covered with one or more coatings of metal or cermet spraying, metal plating, or metal nitride or metal carbonitride vapor deposition.
- the solvent of the lubricant release agent is a synthetic ester oil, silicone oil, polyglycol, polyacryl, polyglycol or polyacrylic aqueous solution, or an aqueous solution obtained by adding a surfactant to the aqueous solution.
- the durability of the mold is improved by the present invention, and about 1 to 20,000 or more molded products can be manufactured without correcting or repairing with one mold.
- the effect is exhibited only by applying the lubricant release agent between shots, it is possible to reduce the time for maintenance and replacement of the mold and to improve the manufacturing efficiency. Therefore, these can stabilize the quality of the iron-based alloy molded product and reduce the manufacturing cost.
- FIG. 1 is a cross-sectional view showing an example of a mold for forming an iron-based alloy applied to the present invention.
- reference numeral 1 is a mold
- reference numeral 2 is a plunger
- reference numeral 3 is an injection port
- reference numeral 4 is a gate
- reference numeral 5 is a cavity filled with a molded product
- reference numeral 6 is a mold frame.
- the mold 1 is housed in a mold frame 6 and has a structure that can be opened and closed at a dividing section 7.
- the iron-based alloy molding material is heated to a semi-molten or semi-solid state, then charged into the injection port 3, filled in the cavity 5 through the gate 4 with the plunger 2, Immediately after that, the mold 1 opens at the dividing surface 7 and the molded product is taken out.
- the material of the mold base material is a mold steel represented by SKD61, high speed tool steel, Cr heat resistant steel, Ni—Cr heat resistant steel, heat resistant cast steel, cemented carbide, Inconel 718 and other Ni alloys, copper and Be Copper and copper alloys such as Cr—Zr copper are preferred.
- a lubricating mold release agent having seizure resistance, lubricity, and heat shielding properties against an iron-based alloy is applied to part or all of the inner surface constituted by the injection port 3 and the cavity 5 of the mold 1.
- Materials suitable for the lubricating mold release agent applied to the inner surface of the mold and the characteristics thereof are as follows. a) Particles composed of one or more of molybdenum disulfide, graphite, tungsten disulfide, boron nitride, chromium oxide and boron oxide having a particle diameter of 2 to 200 ⁇ m dispersed in a solvent. These particles act as fillers, lubricants, and mold release agents among the components of the lubricant mold release agent, alleviate the thermal shock caused by the contact of the semi-molten molding material to the inner surface of the mold, and semi-melt. Contributes to the reduction of friction and wear due to the flow of the material, and the improvement of mold release after molding.
- the above materials have a solid lubrication effect, that is, a friction / wear reduction effect, without oxidizing or decomposing in a short time up to the temperature of the semi-molten or semi-solidified region of iron-based alloys (mostly 1100 ° C to 1400 ° C). Demonstrate.
- the particle size is smaller than 2 ⁇ m, it does not uniformly disperse in the solvent, and not only can not exhibit a role of forming a stable coating film as a filler, and also has an insufficient thermal shock mitigating action.
- the particle size is larger than 200 ⁇ m, it precipitates in the solvent and is not uniformly dispersed.
- a coating film becomes non-uniform
- heterogenous or surface roughness increases, and the shape precision of a molded article will fall.
- synthetic ester oils having a kinematic viscosity of 5 ⁇ 10 ⁇ 6 to 5 ⁇ 10 ⁇ 4 m 2 / s, silicone oil, polyglycol, polyacryl, polyglycol or an aqueous solution of polyacryl, Or the aqueous solution which added surfactant to the said aqueous solution.
- Oil and water systems can be used as the solvent material, but in oil systems, mineral oil has a high molding temperature of iron-based alloys, and there is a risk of ignition, so it has a high flash point and less evaporation materials.
- Synthetic ester oils such as polyol esters
- silicone oils are suitable.
- polyglycol or polyacryl is suitable, having a suitable viscosity alone or in the form of an aqueous solution, and having a property of evaporating stably without being bumped when exposed to high temperatures.
- the kinematic viscosity in the present invention is a value measured at 40 ° C.
- the type and amount of the surfactant are not particularly limited, but from the viewpoint of enhancing the dispersibility of the solid particles, a nonionic surfactant (for example, naphthalene sulfone) is used. Acid salt, etc.) is preferred, and the amount added is preferably about 0.1 mass% with respect to water.
- the particles described in a) above are dispersed in the solvent described in b) to form a lubricant release agent.
- the blending amount of the particles in the solvent varies depending on the particle diameter and the viscosity of the solvent, but can be blended in a wide range of 1 to 90 vol%.
- the film thickness of the coating applied with the lubricant release agent thus blended varies depending on the particle diameter, but is preferably 5 ⁇ m to 150 ⁇ m.
- the lubricant release agent can be applied to the inner surface of the mold by spraying or brushing in a short time between shots of die casting.
- the next molding can be performed without problems in a semi-dry state of several seconds to several tens of seconds due to the residual heat of die casting.
- the solvent b) evaporates stably even at a high temperature during the semi-molten forming of an iron-based alloy, there is no problem that causes danger in the work, and there is no deterioration in the quality of the molded product.
- bubbles are formed in the coating film at the time of evaporation at a high temperature, a further effect can be exhibited in mitigating thermal shock to the inner surface of the mold.
- the above lubricant release agent has excellent seizure resistance with the iron-based alloy that is the molding material, lubrication characteristics, and heat shielding properties to alleviate thermal shock to the mold base material, and is excellent in combination with mold release properties. Demonstrate the characteristics. Therefore, when any one of these materials is used, a mold having a durability sufficient to produce at least 10,000 to 20,000 non-defective products can be obtained in the semi-melting or semi-solid forming of an iron-based alloy.
- a preferred example of applying a lubricant release agent to the inner surface of the mold according to the present invention will be described based on a cross-sectional view of a mold for forming an iron-based alloy shown in FIG.
- the mold part to which the lubricant releasing agent is applied is the whole or a part of the inner surface of the injection port 3, the gate 4 and the cavity 5.
- the injection port aims at improving the lubrication of the sliding surface between the plunger 2 and the injection port 3 and improving the lubrication between the molding material and the gate 4. 3 and the inner surface of the gate 4 are also effective.
- the purpose when it is to prevent wear of the mold, it may be applied only to the inner surface of the injection port 3 and the gate 4.
- the effect of reducing the molding pressure is also exhibited.
- the mold may be applied directly without any surface treatment, but metal or cermet spraying / plating / vapor deposition is applied to the inner surface of the mold for the purpose of wear resistance and thermal shock mitigation.
- a lubricated release agent may be applied to the finished surface. Usually, these surface treatments may be applied to the entire surface of 3 to 5 or only partially.
- the lubricating mold release agent of the present invention exhibits a lubricating effect and a mold releasing effect on the inner surface of the mold in any case.
- FIG. 2 is a schematic diagram showing a cross section of the coating layer of the lubricant release agent applied to the inner surface of the mold of the present invention.
- FIG. 3 is a schematic diagram showing a cross section of a lubricant release agent coating layer applied on the surface of the surface treatment layer 8 of either metal or cermet spraying / plating / deposition on the inner surface of the mold of the present invention.
- FIG. When applied between molding shots and in a semi-dry state, the cross-sectional structure of the lubricant release agent is in a form in which particles 10 are dispersed in a solvent or a semi-dried or semi-solidified layer 9 as shown in the figure. ing.
- the semi-dried or semi-solidified layer 9 is porous due to the action of the solvent vapor being dissipated by the residual heat at the time of molding. Therefore, the thermal shock mitigating effect is improved, and the fluid 10 is easily flowed and spread by pressure receiving and shearing from the molding material during molding, and the lubricating effect of the particles 10 is also improved.
- a lubricating effect and a thermal shock mitigating effect are efficiently acted on a wide area of the inner surface of the mold with a small amount of a lubricating release agent.
- Example 1 The evaluation apparatus shown in FIG. 4 was used to evaluate the wear resistance and seizure resistance to the iron-based material during the heat of the application surface of various lubricant release agents.
- the apparatus was a pin-on-disk system, and the lubricant release agent to be evaluated was applied to the surface of the disk 12 by spraying.
- the film thickness of the lubricant release agent coating layer 13 after coating was 20 to 120 ⁇ m.
- the shape of the disk base material was ⁇ 50 ⁇ thickness 10 mm, and the disk material used was mold steel SKD61, heat-resistant steel SCH22, Ni alloy Inconel 718, and Be copper.
- the test conditions were a rotational speed of 500 r / m, a sliding speed between the pin and the disk of 0.92 m / s, a pressing force of the pin of 980 N, and an ambient temperature of 400 ° C.
- Table 1 shows the results of evaluating the various lubricant release agent materials according to the present invention by comparing the wear resistance and seizure resistance with other materials by the above method.
- Table 2 shows the configuration of the lubricating release agent used for the evaluation.
- the wear resistance was evaluated by removing the disc after 30 minutes of operation, observing the cross section of the sliding surface with the pin, and measuring the thickness reduction amount of the most worn portion.
- the seizure resistance was evaluated by visual observation and cross-sectional observation of the presence or absence of transfer of the pin tip material on the disk surface after the test. Thus, as a result of evaluation, it was confirmed that the mold of the present invention has excellent performance in terms of wear resistance and seizure resistance.
- Example 2 Next, a lubricating mold release agent was applied to an actual die casting molding test mold to form a mold according to the present invention, and then cast molding in a semi-molten state of an iron-based alloy was performed.
- the shape of the prototype molded product is shown in FIG.
- the molded product shown in the figure has a step-like shape for the purpose of evaluating the formability of the iron-based alloy material, that is, the flow characteristics into the cavity, and the thickness is increased from the thickest part to 25 mm and 15 mm in order. 10 mm, 5 mm, 2.5 mm, and 1 mm.
- Table 3 shows the results of evaluation of shape moldability and mold durability by casting an iron-based alloy in a semi-molten state using the mold according to the present invention under various conditions.
- the material of the iron-based alloy used is cast iron consisting of C: 2.4% by mass, Si: 1% and other impurities.
- the shape of the material is a cylinder with a diameter of 50 mm and a height of 50 mm, the preheating temperature of the molding material is 1250 ° C., the temperature is raised from room temperature to the preheating temperature within 15 minutes, and the holding time is 3 minutes or more and 5 minutes or less. did.
- the mold was preheated and kept warm with an electric heater, and the mold temperature before molding was adjusted to 250 to 300 ° C. on the inner surface of the cavity.
- a plurality of devices for preheating the above materials were installed and molding was started.
- the actual one-shot die casting is completed in 1 to 2 seconds, but the idle time from taking out the molded product to inserting the next material into the mold is about 30 seconds to 5 minutes.
- the lubricant release agent was applied to the inside of the mold by air spray 15 to 30 seconds before the start of the next shot.
- the coating thickness of the lubricant release agent was 20 to 150 ⁇ m when dried.
- the shape moldability was evaluated by the inflow thickness of the stepped portion of the molded product.
- the mold durability was determined by visually observing the wear state inside the mold after molding with a certain number of shots.
- the mold of the present invention coated with the lubricating release agent exhibits excellent performance in terms of wear resistance and seizure resistance, and can be molded 10,000 to 20,000 times without replacement. It was confirmed that the shape moldability was improved by reducing the friction with the material to be molded.
- the die for semi-molten or semi-solid casting of the iron-based alloy of the present invention can be widely applied in die-cast molding from the semi-molten or semi-solid state of the iron-based alloy and improves the durable life of the die.
- This has the effect of preventing seizure between the material and the mold and promoting releasability, thereby reducing molding costs, improving productivity, improving the quality and shape accuracy of molded products, etc. Contribute greatly.
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Abstract
Description
本願は、2008年6月13日に、日本に出願された特願2008-155991号に基づき優先権を主張し、その内容をここに援用する。
特に、特許文献1では、金型の表面にガス浸硫窒化処理を施すことによってダイカストまたは射出成形に供するマグネシウムの溶湯に対して金型の表面の濡れ性を低くして焼き付き防止及び被成形物の離型性を向上させる技術が開示されている。
また、特許文献2では、ダイカスト金型の表面にフッ化物、ホウ化物、炭化物、炭酸塩等の粒子や油脂類、有機金属からなる被膜剤を塗布後、乾燥して気孔を有する被膜とする方法が開示されている。
さらに、特許文献3では、鋳造用金型表面に、酸化物などの粉末とチタン酸カリウムなどの繊維材料を、珪酸ナトリウムを含む水に分散させた被覆材を塗布乾燥し、キュアリングの熱処理をして被覆することによって金型の耐久性と鋳造品の離型性を向上させる技術が開示されている。
(1)半溶融または半凝固状態の鉄系合金を鋳造する方法であって、金型の内表面の一部又は全部の最表面に、二硫化モリブテン、グラファイト、二硫化タングステン、窒化ホウ素、酸化クロム、酸化ホウ素のうちの1種又は2種以上で構成された粒子を溶媒に分散させた潤滑離型剤を塗布した後に、前記金型を用いて鋳造する、半溶融または半凝固状態の鉄系合金の鋳造方法。
(2)前記金型の母材表面の一部又は全面を、金属もしくはサーメットの溶射、金属のめっき、または金属窒化物もしくは金属炭窒化物の蒸着のいずれか1種以上の被膜で被覆し、該被覆面上に前記潤滑離型剤を塗布する、(1)に記載の半溶融または半凝固状態の鉄系合金の鋳造方法。
(3)前記潤滑離型剤の溶媒が、合成エステル油、シリコーン油、ポリグリコール、ポリアクリル、ポリグリコールもしくはポリアクリルの水溶液、又は前記水溶液に界面活性剤を添加した水溶液である、(1)または(2)に記載の半溶融または半凝固状態の鉄系合金の鋳造方法。
(4)鉄系合金の半溶融鋳造または半凝固鋳造に用いる鋳造用金型であって、その内表面の一部又は全部の最表面に、二硫化モリブテン、グラファイト、二硫化タングステン、窒化ホウ素、酸化クロム、酸化ホウ素のうちの1種又は2種以上で構成された粒子を溶媒に分散させた潤滑離型剤が塗布されている鋳造用金型。
(5)この鋳造用金型の母材表面の一部又は全面が、金属もしくはサーメットの溶射、金属のめっき、または金属窒化物もしくは金属炭窒化物の蒸着のいずれか1種以上の被膜で被覆され、該被覆面上に前記潤滑離型剤が塗布されている、(4)に記載の鋳造用金型。
(6)前記潤滑離型剤の溶媒が、合成エステル油、シリコーン油、ポリグリコール、ポリアクリル、ポリグリコールもしくはポリアクリルの水溶液、又は前記水溶液に界面活性剤を添加した水溶液である、(4)または(5)に記載の鋳造用金型。
図1は、本発明に適用される鉄系合金の成形用の金型の例を示す断面図である。図中、符号1は金型、符号2はプランジャ、符号3は射出口、符号4はゲート、符号5は成形品が充填されるキャビティ、符号6は金型枠である。金型1は金型枠6に内装されており、分断面7で開閉できる構造になっている。
a)粒子径2~200μmの二硫化モリブテン、グラファイト、二硫化タングステン、窒化ホウ素、酸化クロム、酸化ホウ素のうちの1種あるいは複数種で構成された粒子を溶媒に分散させたもの。
これらの粒子は、潤滑離型剤の成分のなかで充填剤、潤滑剤かつ離型剤として作用し、金型内表面への半溶融の成形素材の接触による熱衝撃を緩和し、また半溶融素材の流動による摩擦・摩耗の低減、成型終了後の離型性の向上に寄与する。上記の材質は、鉄系合金の半溶融あるいは半凝固の領域の温度(多くは1100℃~1400℃)まで、短時間で酸化や分解することなく、固体潤滑作用すなわち摩擦・摩耗の低減作用を発揮する。粒子径は2μmより小さい場合は、溶媒に均一に分散せず、また充填剤として安定な塗布膜を形成する役割を発揮できないばかりか、熱衝撃の緩和作用も不充分である。
一方、200μmよりも粒径が大きい場合、溶媒中に沈殿してしまい、やはり均一に分散しない。また、局部的に凝集した場合は、塗布膜の厚みが不均一になったり、表面粗さが増大したりして成形品の形状精度が低下してしまう。
b)潤滑離型剤の溶媒としては、動粘度5×10-6~5×10-4m2/sの合成エステル油、シリコーン油、ポリグリコール、ポリアクリル、ポリグリコールもしくはポリアクリルの水溶液、又は前記水溶液に界面活性剤を添加した水溶液。
溶媒の材質としては、油系と水系を用いることが出来るが、油系では、鉱物油は、鉄系合金の成形温度が高く、発火の危険が伴うため、引火点が高く、蒸発原料も少ない合成エステル油(ポリオールエステルなど)あるいはシリコーン油が適している。また、水系では、ポリグリコールまたはポリアクリルが適しており、単独あるいは水溶液の形で適度な粘度を持ち、また高温にさらされたときに突沸しないで安定に蒸発する特性を有する。粘度は5×10-6m2/sより小さい場合は金型内表面への粘着力が弱く、また蒸発が早すぎて安定的に塗布することができない。また5×10-4m2/sよりも高粘度の場合は、上記a)に記述した粒子を均一に分散させることが困難であり、かつ塗布時に膜厚の不均一や垂れなどが起こり、金型への適用が出来ない。なお、本発明における動粘度は、40℃で測定した値とする。また、上記動粘度の範囲とするため、水溶液とする場合には、合成エステル油、シリコーン油、ポリグリコール、ポリアクリル、ポリグリコールもしくはポリアクリルを70質量%以上の濃度とすることが好ましい。さらに、この水溶液に界面活性剤を添加する場合、界面活性剤の種類や添加量は特に限定されないが、固体粒子の分散性を高めるという観点からは、ノニオン系の界面活性剤(例えば、ナフタレンスルホン酸塩など)が好ましく、その添加量は、水に対して0.1質量%程度とすることが好ましい。
上記a)に記述した粒子をb)に記述した溶媒に分散させて潤滑離型剤を形成する。粒子の溶媒への配合量は粒子径、溶媒の粘度によって変わるが、1~90体積%の広い範囲で配合させることが出来る。このように配合した潤滑離型剤を塗布した被膜の膜厚は、粒子径によって変わるが、5μm~150μmが好適である。潤滑離型剤はダイカスト成形のショット間に短時間で金型内表面にスプレーや刷毛塗り等によって塗布できる。塗布後乾燥しても良いが、多くの場合、ダイカスト成形の余熱により数秒~数十秒の半乾燥状態で次の成形を問題無く行うことが出来る。前述のように、上記b)の溶媒は鉄系合金の半溶融成形時の高温でも安定して蒸発するため、作業に危険を伴うような支障が無く、成形品の品質劣化も無い。さらに高温での蒸発時に塗布膜内に気泡を形成するため、金型内表面への熱衝撃緩和に更なる効果を発揮することができる。
上記潤滑離型剤は、被成形材である鉄系合金との耐焼付き性、潤滑特性、金型母材への熱衝撃を緩和する熱遮蔽性に優れており、離型性と併せて優れた特性を発揮する。よって、これらのいずれかの材質を用いると、鉄系合金の半溶融あるいは半凝固成形において、少なくとも連続1~2万個の良品製造が可能な程度の耐久性を有する金型が得られる。
図4に示す評価装置を用いて、種々の潤滑離型剤の塗布面の熱間での鉄系材料に対する耐摩耗性および耐焼き付き性を評価した。装置はピン-オン-ディスク方式であり、評価すべき潤滑離型剤はディスク12の表面にスプレーにより塗布した。塗布後の潤滑離型剤の塗布層13の膜厚は20~120μmであった。ディスク母材の形状はφ50×厚み10mmとし、ディスクの材質は試験条件によって金型鋼SKD61、耐熱鋼SCH22、Ni合金インコネル718、Be銅を用いた。ピン11の形状はφ5×長さ20mmとし、ピン材質はSKD61の焼入れ品で硬さがHRC=48~50のものを用いた。なお、本試験は鋳鉄等の鉄系合金成形材と金型表面の摩耗および焼付き特性を評価する目的で行ったものであるが、摩耗試験を促進させる目的で、ピン材質に鋳鉄よりも強度および硬度の高い金型鋼を用いた。また、鋳鉄も金型鋼も同じ鉄系材料であるため、一般に焼付き特性も同様の評価が可能である。
試験条件は、回転数500r/m、ピンとディスクの摺動速度は0.92m/s、ピンの押し付け荷重は980N、雰囲気温度を400℃とした。
次に、実際のダイカスト成型用試験金型に潤滑離型剤を塗布して本発明の金型の態様としたうえで、鉄系合金の半溶融状態での鋳造成形を行った。試作成形品の形状を図5に示す。図に示す成形品は、鉄系合金材料の形状成形性すなわちキャビティへ内の流動特性を評価する目的で、階段状の形状となっており、最も厚みの厚い部分から順に厚みを、25mm、15mm、10mm、5mm、2.5mm、1mmとした。
上記の素材を予熱する装置を複数台設置し、成形を開始した。実際の1ショットのダイカスト成形は1~2秒で完了するが、成形品の取り出しから次の素材の金型内への装入までのアイドル時間は、30秒~5分程度である。潤滑離型剤の金型内部への塗布は、次のショット開始の15~30秒前にエアスプレーで行った。潤滑離型剤の塗布膜厚は乾燥時で20~150μmであった。
形状成形性の評価は、成形品の階段状の部分の流入厚みで評価した。また金型耐久性は、一定ショット数の成形の後の金型内部の摩耗状態を目視で観察した。かくして評価の結果、潤滑離型剤を塗布した本発明の金型は、耐摩耗性、耐焼付き性において、いずれも優れた性能を示し、交換することなく10000~20000回の成形を行うことが可能となり、かつ被成形材との摩擦低減により形状成形性も改善されることが確認された。
2 プランジャ
3 射出口
4 ゲート
5 キャビティ
6 金型枠
7 金型分断面
8 表面処理層
9 溶媒あるいはその半乾燥または半固化した層
10 粒子
11 ピン
12 ディスク
13 潤滑離型剤塗布層
Claims (6)
- 半溶融または半凝固状態の鉄系合金を鋳造する方法であって、
金型の内表面の一部又は全部の最表面に、二硫化モリブテン、グラファイト、二硫化タングステン、窒化ホウ素、酸化クロム、酸化ホウ素のうちの1種又は2種以上で構成された粒子を溶媒に分散させた潤滑離型剤を塗布した後に、前記金型を用いて鋳造する
ことを特徴とする半溶融または半凝固状態の鉄系合金の鋳造方法。 - 前記金型の母材表面の一部又は全面を、金属もしくはサーメットの溶射、金属のめっき、または金属窒化物もしくは金属炭窒化物の蒸着のいずれか1種以上の被膜で被覆し、該被覆面上に前記潤滑離型剤を塗布した
ことを特徴とする請求項1に記載の半溶融または半凝固状態の鉄系合金の鋳造方法。 - 前記潤滑離型剤の溶媒が、合成エステル油、シリコーン油、ポリグリコール、ポリアクリル、ポリグリコールもしくはポリアクリルの水溶液、又は前記水溶液に界面活性剤を添加した水溶液であることを特徴とする、請求項1または2に記載の半溶融または半凝固状態の鉄系合金の鋳造方法。
- 鉄系合金の半溶融鋳造または半凝固鋳造に用いる鋳造用金型であって、
その内表面の一部又は全部の最表面に、二硫化モリブテン、グラファイト、二硫化タングステン、窒化ホウ素、酸化クロム、酸化ホウ素のうちの1種又は2種以上で構成された粒子を溶媒に分散させた潤滑離型剤が塗布されている
ことを特徴とする鋳造用金型。 - この鋳造用金型の母材表面の一部又は全面が、金属もしくはサーメットの溶射、金属のめっき、または金属窒化物もしくは金属炭窒化物の蒸着のいずれか1種以上の被膜で被覆され、該被覆面上に前記潤滑離型剤が塗布されている
ことを特徴とする請求項4に記載の鋳造用金型。 - 前記潤滑離型剤の溶媒が、合成エステル油、シリコーン油、ポリグリコール、ポリアクリル、ポリグリコールもしくはポリアクリルの水溶液、又は前記水溶液に界面活性剤を添加した水溶液である
ことを特徴とする請求項4または5に記載の鋳造用金型。
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CA2727044A CA2727044C (en) | 2008-06-13 | 2009-06-15 | Method of casting semi-liquid or semi-solid iron-based alloy and die for casting |
BRPI0915067A BRPI0915067A2 (pt) | 2008-06-13 | 2009-06-15 | método de fundição de liga à base de ferro semilíquida ou semissólida e molde para fundição |
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US12/737,123 US9022093B2 (en) | 2008-06-13 | 2009-06-15 | Method of casting semi-liquid or semi-solid iron-based alloy and die for casting |
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EP2301689A1 (en) | 2011-03-30 |
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CA2727044C (en) | 2013-02-12 |
JP2009297754A (ja) | 2009-12-24 |
JP4452310B2 (ja) | 2010-04-21 |
BRPI0915067A2 (pt) | 2015-10-27 |
US9022093B2 (en) | 2015-05-05 |
KR101286842B1 (ko) | 2013-07-17 |
US20110088864A1 (en) | 2011-04-21 |
EP2301689B1 (en) | 2019-11-06 |
CN102056689B (zh) | 2016-08-17 |
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