WO2012026898A1 - Mould coating method - Google Patents

Mould coating method Download PDF

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Publication number
WO2012026898A1
WO2012026898A1 PCT/TR2010/000234 TR2010000234W WO2012026898A1 WO 2012026898 A1 WO2012026898 A1 WO 2012026898A1 TR 2010000234 W TR2010000234 W TR 2010000234W WO 2012026898 A1 WO2012026898 A1 WO 2012026898A1
Authority
WO
WIPO (PCT)
Prior art keywords
mould
moulding
coating
aluminium
tantalum
Prior art date
Application number
PCT/TR2010/000234
Other languages
French (fr)
Inventor
Omer Demirkurt
Kemal Demirkurt
Original Assignee
Deka Kaynak Ve Motorlu Sporlar Merkezi San.Ve Tic.Ltd.Sti.
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 Deka Kaynak Ve Motorlu Sporlar Merkezi San.Ve Tic.Ltd.Sti. filed Critical Deka Kaynak Ve Motorlu Sporlar Merkezi San.Ve Tic.Ltd.Sti.
Publication of WO2012026898A1 publication Critical patent/WO2012026898A1/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C27/00—Alloys based on rhenium or a refractory metal not mentioned in groups C22C14/00 or C22C16/00
    • C22C27/06—Alloys based on chromium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/56—Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium

Definitions

  • the invention relates to the mould coating method, in which all of the mould, core, and bench-mould connection pieces and etc. mould pieces are coated by using coating powders in order to prevent the aluminium that is molten in high temperatures from causing damage on the moulding by being welded, soldered on mould surface.
  • Rim production with Low Pressure Casting Method is based on filling of the aluminium alloy molten at 750°C - 800°C into mould with the help of pressure and solidification via cooling by force.
  • Soldering is defined as the molten aluminium causing damage on the mould via "welding", adhering on it.
  • soldering mechanism There are two different formation types of the soldering mechanism: 1 ) Chemical/metallurgical reaction between the aluminium molten at high temperature and the mould, and
  • the invention is formed by being inspired from the prior art and aims to solve above said problems.
  • the purpose of the invention is to prevent reaction of the moulds with the molten liquid aluminium by coating of the moulds in order to eliminate the soldering problem occurring in the productions made with aluminium casting method.
  • Another purpose of the invention is to prevent reaction of the moulds with the molten liquid aluminium by coating of the moulds in order to eliminate the soldering problem after determination of the coatings having high abrasion resistance and thermal shock resistance.
  • Another purpose of the invention is to reduce bench stoppage.
  • Another purpose of the invention is to increase usage of capacity.
  • Another purpose of the invention is to increase production efficiency. Another purpose of the invention is to provide reduction of the unit cost per finished product. ,
  • the invention relates to mould coating method, in which all of the mould, core, and bench-mould connection pieces and etc. moulding are coated by using coating powder in aluminium alloy casting method in order to prevent the aluminium that is molten in high temperatures from causing damage on the moulding by being welded, soldered on mould surface.
  • Figure 1 - is the flow scheme showing the operation steps of mould coating method.
  • the invention is the mould coating method, in which the moulding (10) is coated by using coating powder (31 ) in aluminium alloy casting method in order to prevent the aluminium that is molten in high temperatures from causing damage - on the moulding (10) by being welded, soldered on all mould, core, and bench- mould connection pieces and etc. moulding (10) surfaces, and it is characterized in that; it comprises the operation steps of:
  • moulding (10) coming from the customer are made. Afterwards, moulding (10) is taken into sandblasting. In order to provide good adherence of coating, all surfaces to be coated are sanded. After sandblasting operation, the moulding (10) is taken into coating cabinet and via the coating device (30) controlled coating is applied with the coating powder (31 ) mixture which is prepared in accordance with the operation medium of the surface to be coated. The piece determined to have reached the appropriate coating thickness as a result of measurement is taken to the waiting area for shipment.
  • soldering-free casting can be made up to 5000 items according to the mould design and model.
  • pottage operation is renewed on coating.
  • Pottage is the refractor based sodium silicate solution preventing the applied and casted piece from adhering on these surfaces and also helping directional solidification of the liquid metal.
  • deformed coatings as a result of being damaged are removed from the surface. Since there is no abrasion in the mould, the same moulding (10) is made ready for use by coating operation.
  • the invention is the coating powder (31 ) used in mould coating in aluminium alloy casting method, wherein moulding (10) is coated in order to prevent the aluminium that, is molten in high temperatures from causing damage on the moulding (10) by being welded, soldered on all mould, core, and bench-mould connection pieces and etc. moulding (10) surfaces, and it comprises chrome, nickel, tungsten, tantalum and cobalt metals.
  • Coating powder (31 ) comprises chrome, nickel, tungsten, tantalum, and cobalt metals in the ratio by mass of;

Abstract

The invention is the coating powder (31) used in mould coating in aluminium alloy casting method, wherein moulding (10) is coated in order to prevent the aluminium that is molten in high temperatures from causing damage on the moulding (10) by being welded, soldered on all mould, core, and bench-mould connection pieces and etc. moulding (10) surfaces, and it comprises chrome, nickel, tungsten, tantalum and cobalt metals.

Description

DESCRIPTION
MOULD COATING METHOD The Related Art
The invention relates to the mould coating method, in which all of the mould, core, and bench-mould connection pieces and etc. mould pieces are coated by using coating powders in order to prevent the aluminium that is molten in high temperatures from causing damage on the moulding by being welded, soldered on mould surface.
The Prior Art In basic mould casting methods, filling of the material into the mould is ensured via gravity. In low pressure casting, liquid metal is filled into mould from bottom to top via low pressure. Advantage of this method against conventional casting methods is: the liquid metal filling into the mould from a chamber being cleaner than the liquid metal open to atmosphere. In this way, while gas pores and oxidation are minimized, mechanical properties are improved.
The most important and fundamental two inputs of rim production conducted by using Conventional Low Pressure Casting Method are: "aluminium alloy and mould". Rim production with Low Pressure Casting Method is based on filling of the aluminium alloy molten at 750°C - 800°C into mould with the help of pressure and solidification via cooling by force.
One of the significant problems causing increase of wastage and scrap and loss of efficiency and labour is "soldering". Soldering is defined as the molten aluminium causing damage on the mould via "welding", adhering on it.
There are two different formation types of the soldering mechanism: 1 ) Chemical/metallurgical reaction between the aluminium molten at high temperature and the mould, and
2) Mechanical interaction at low temperature.
At the sub-cores, chemical/metallurgical reactions are encountered between the aluminium molten at high temperature and the mould. In the applications, it is determined that the soldering problem occurs after the 50th-100th pieces after starting of the casting of mould.
Said problems directly affect the finished product quality and cause them to be wastage and scrap. As a result of these problems, production is halted and levelling operations are applied on the relevant areas on the mould. If levelling operations are inadequate, the cavitations formed are filled via welding.
Swellings occur at the welded areas. Therefore, adequate efficiency is not obtained from welding operation. After a certain number of usages, the mould becomes useless. Efficiency losses occur in production due to soldering problem. Moreover, the unit costs per finished product increase as a result of production of extra moulds. Direct and indirect costs occur.
As a result, above said drawbacks and the inadequacy of the prior solutions about the subject have necessitated improvement in the related technical field.
Purpose of the Invention
The invention is formed by being inspired from the prior art and aims to solve above said problems.
The purpose of the invention is to prevent reaction of the moulds with the molten liquid aluminium by coating of the moulds in order to eliminate the soldering problem occurring in the productions made with aluminium casting method.
Another purpose of the invention is to prevent reaction of the moulds with the molten liquid aluminium by coating of the moulds in order to eliminate the soldering problem after determination of the coatings having high abrasion resistance and thermal shock resistance.
Another purpose of the invention is to reduce bench stoppage.
Another purpose of the invention is to increase usage of capacity.
Another purpose of the invention is to increase production efficiency. Another purpose of the invention is to provide reduction of the unit cost per finished product. ,
In order to achieve above said purposes, the invention relates to mould coating method, in which all of the mould, core, and bench-mould connection pieces and etc. moulding are coated by using coating powder in aluminium alloy casting method in order to prevent the aluminium that is molten in high temperatures from causing damage on the moulding by being welded, soldered on mould surface. The structural and characteristic features of the invention and all advantages will be understood better in detailed descriptions with the figures given below and with reference to the figures, and therefore, the assessment should be made taking into account said figures and detailed explanations. Figures for Better Understanding of the Invention
Figure 1 - is the flow scheme showing the operation steps of mould coating method.
Description of the Parts References
10. Moulding
1 1. Sandblasted moulding
12. Coated moulding
20. Sandblasting device
30. Coating device
31. Coating powder Drawings do not have to be scaled and details not necessary for understanding the present invention may be neglected. Moreover, components which are at least widely equal or which have at least widely equal functions are shown with the same number.
Detailed Description of the Invention In this detailed description, the operation steps of the mould coating method applied by using coating powder (31) on all mould, core, and bench-mould connection pieces and etc. moulding (10), which is the subject of the invention, are disclosed.
The invention is the mould coating method, in which the moulding (10) is coated by using coating powder (31 ) in aluminium alloy casting method in order to prevent the aluminium that is molten in high temperatures from causing damage - on the moulding (10) by being welded, soldered on all mould, core, and bench- mould connection pieces and etc. moulding (10) surfaces, and it is characterized in that; it comprises the operation steps of:
- visual examination of moulding (10), getting the moulding (10) into sandblasting process and thus sandblasting of all surfaces to be coated via sandblasting device (20), and
coating of the moulding (10) by coating powder (31 ) formed of chrome, nickel, tungsten, tantalum, and cobalt metals.
First of all, visual examination of mould, core, and bench-mould connection pieces etc. moulding (10) coming from the customer are made. Afterwards, moulding (10) is taken into sandblasting. In order to provide good adherence of coating, all surfaces to be coated are sanded. After sandblasting operation, the moulding (10) is taken into coating cabinet and via the coating device (30) controlled coating is applied with the coating powder (31 ) mixture which is prepared in accordance with the operation medium of the surface to be coated. The piece determined to have reached the appropriate coating thickness as a result of measurement is taken to the waiting area for shipment.
In the mould coating method, as a result of digital monitoring of number of productions, it is determined that soldering-free casting can be made up to 5000 items according to the mould design and model. After 5000 items, pottage operation is renewed on coating. Pottage is the refractor based sodium silicate solution preventing the applied and casted piece from adhering on these surfaces and also helping directional solidification of the liquid metal. In the ' operation made during removal of the remaining pottage from the surface, deformed coatings as a result of being damaged are removed from the surface. Since there is no abrasion in the mould, the same moulding (10) is made ready for use by coating operation.
The invention is the coating powder (31 ) used in mould coating in aluminium alloy casting method, wherein moulding (10) is coated in order to prevent the aluminium that, is molten in high temperatures from causing damage on the moulding (10) by being welded, soldered on all mould, core, and bench-mould connection pieces and etc. moulding (10) surfaces, and it comprises chrome, nickel, tungsten, tantalum and cobalt metals.
Coating powder (31 ) comprises chrome, nickel, tungsten, tantalum, and cobalt metals in the ratio by mass of;
65% - 85% Chrome (Cr)
18% - 39% Nickel (Ni)
1 % - 15% Tungsten (W)
0.007% - 0.980% Tantalum (Ta)
0.1 % - 0.93% Cobalt (Co).

Claims

1. The invention is the coating powder (31 ) used in mould coating in aluminium alloy casting method, wherein moulding (10) is coated in order to prevent the aluminium that is molten in high temperatures from causing damage on the moulding (10) by being welded, soldered on all mould, core, and bench- mould connection pieces and etc. moulding (10) surfaces, and it is characterized in that; it comprises chrome, nickel, tungsten, tantalum and cobalt metals. '
2. Coating powder (31 ) according to Claim 1 , and it is characterized in that; said powder (31 ) comprises below given metals by mass;
65%'to 85% Chrome (Cr)
- 18% to 39% Nickel (Ni)
1 % to 15% Tungsten (W)
0.007% to 0.980% Tantalum (Ta)
0.1 % to 0.93% Cobalt (Co).
3. The invention is the mould coating method, in which the moulding (10) is coated by using coating powder (31 ) in aluminium alloy casting method in order to prevent the aluminium that is molten in high temperatures from causing damage on the moulding (10) by being welded, soldered on all mould, core, and bench-mould connection pieces and etc. moulding (10) surfaces, and it is characterized in that; it comprises the operation steps of:
visual examination of moulding (10),
getting the moulding (10) into sandblasting process and thus sandblasting of all surfaces to be coated via sandblasting device (20), and
- coating of the moulding (10) by coating powder (31 ) formed of chrome, nickel, tungsten, tantalum, and cobalt metals. Mould coating method according to Claim 3, and it is characterized said coating powder (31 ) comprises below given metals by mass;
65% to 85% Chrome (Cr)
18% to 39% Nickel (Ni)
1 % to 15% Tungsten (W)
0.007% to 0.980% Tantalum (Ta)
0.1 % to 0.93% Cobalt (Co) .
PCT/TR2010/000234 2010-08-27 2010-12-01 Mould coating method WO2012026898A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
TR2010/07176A TR201007176A2 (en) 2010-08-27 2010-08-27 Mold coating method.
TR2010/07176 2010-08-27

Publications (1)

Publication Number Publication Date
WO2012026898A1 true WO2012026898A1 (en) 2012-03-01

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WO (1) WO2012026898A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015089534A3 (en) * 2013-12-20 2015-08-13 Plansee Se Coating material containing chromium

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1989003264A1 (en) * 1987-10-16 1989-04-20 Avco Corporation High temperature metal alloy mixtures for filling holes and repairing damages in superalloy bodies
EP0353843A1 (en) * 1988-07-14 1990-02-07 ROLLS-ROYCE plc Powder alloy mix and superalloy article repair method
JPH08229632A (en) * 1995-02-23 1996-09-10 Asahi Tec Corp Method for coating copper alloy casting mold
US5628814A (en) * 1994-12-28 1997-05-13 General Electric Company Coated nickel-base superalloy article and powder and method useful in its preparation
WO2002050323A2 (en) * 2000-12-15 2002-06-27 Rolls-Royce Corporation Nickel diffusion braze alloy and method for repair of superalloys
EP1797981A2 (en) * 2005-12-19 2007-06-20 General Electric Company Environmentally resistant disk
EP1859880A1 (en) * 2006-05-24 2007-11-28 United Technologies Corporation Nickel alloy for repairs

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1989003264A1 (en) * 1987-10-16 1989-04-20 Avco Corporation High temperature metal alloy mixtures for filling holes and repairing damages in superalloy bodies
EP0353843A1 (en) * 1988-07-14 1990-02-07 ROLLS-ROYCE plc Powder alloy mix and superalloy article repair method
US5628814A (en) * 1994-12-28 1997-05-13 General Electric Company Coated nickel-base superalloy article and powder and method useful in its preparation
JPH08229632A (en) * 1995-02-23 1996-09-10 Asahi Tec Corp Method for coating copper alloy casting mold
WO2002050323A2 (en) * 2000-12-15 2002-06-27 Rolls-Royce Corporation Nickel diffusion braze alloy and method for repair of superalloys
EP1797981A2 (en) * 2005-12-19 2007-06-20 General Electric Company Environmentally resistant disk
EP1859880A1 (en) * 2006-05-24 2007-11-28 United Technologies Corporation Nickel alloy for repairs

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015089534A3 (en) * 2013-12-20 2015-08-13 Plansee Se Coating material containing chromium
CN106133191A (en) * 2013-12-20 2016-11-16 攀时奥地利公司 Painting cloth material containing chromium
US10837088B2 (en) 2013-12-20 2020-11-17 Plansee Se Coating material

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Publication number Publication date
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