WO2015194550A1 - 鋳型の製造方法及び鋳型 - Google Patents
鋳型の製造方法及び鋳型 Download PDFInfo
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- WO2015194550A1 WO2015194550A1 PCT/JP2015/067303 JP2015067303W WO2015194550A1 WO 2015194550 A1 WO2015194550 A1 WO 2015194550A1 JP 2015067303 W JP2015067303 W JP 2015067303W WO 2015194550 A1 WO2015194550 A1 WO 2015194550A1
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- WIPO (PCT)
- Prior art keywords
- mold
- molding material
- material mixture
- carbonate
- water glass
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
- B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
- B22C1/18—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents
- B22C1/186—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents contaming ammonium or metal silicates, silica sols
- B22C1/188—Alkali metal silicates
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
- B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives
- B22C1/10—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives for influencing the hardening tendency of the mould material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/12—Treating moulds or cores, e.g. drying, hardening
- B22C9/123—Gas-hardening
Definitions
- the present invention relates to a mold manufacturing method and a mold, and more particularly to a casting mold manufacturing method using a dry or wet molding material mixture at room temperature and a mold obtained by such a method. .
- the present invention has been made in the background of such circumstances, the problem to be solved is to improve the moisture resistance of the mold using an inorganic binder made of water glass. Another object of the present invention is to provide a mold obtained by such a production method.
- the present invention can be suitably implemented in various aspects as listed below, and each aspect described below is adopted in any combination. Is possible. It should be noted that aspects or technical features of the present invention are not limited to those described below, and can be recognized based on the inventive concept that can be grasped from the description of the entire specification. Should be understood.
- a molding material mixture containing at least (a) a refractory aggregate, (b) a binder containing water glass as an essential component, and (c) carbonate and / or borate A method for producing a mold, wherein the mold is cured by filling and holding in a mold heated to a temperature of 120 ° C. to 200 ° C.
- a molding material mixture containing at least (a) a refractory aggregate, (b) a binder containing water glass as an essential component, and (c) carbonate and / or borate A method for producing a mold, wherein the mold is solidified or cured by filling and holding in a heated mold, followed by secondary firing at a temperature of 120 ° C.
- the borate is sodium tetraborate, potassium tetraborate, lithium tetraborate, ammonium tetraborate, calcium tetraborate, strontium tetraborate, silver tetraborate, sodium metaborate, metaborate Said aspect (1), characterized in that it is at least one of potassium, lithium metaborate, ammonium metaborate, calcium metaborate, silver metaborate, copper metaborate, lead metaborate, and magnesium metaborate Thru
- a molding material mixture containing at least (a) a refractory aggregate, (b) a binder containing water glass as an essential component, and (c) carbonate and / or borate.
- a mold produced by solidifying or curing by filling in a heated mold and holding it, followed by secondary firing at a temperature of 120 ° C. to 200 ° C. .
- water glass is used as a binder, and the aqueous solution is applied to a refractory aggregate to mold a mold.
- a refractory aggregate is formed by a refractory aggregates to form a molding material mixture and mold making, while at a high temperature of 120 ° C. to 200 ° C.
- a mold excellent in moisture resistance could be advantageously provided, and a decrease in mold strength during moisture absorption can be effectively suppressed.
- characteristics such as the long-term storage of the molding material mixture and the mold can be advantageously exhibited.
- the molding material mixture used in the present invention is, here, in a dry state when it is less than 0.5% by mass, or when the moisture content is 0.5% by mass or more, depending on the amount of moisture contained therein. Is classified as wet.
- the molding material mixture is used as coated sand in which the binder is coated with a refractory aggregate together with carbonate and / or borate.
- this dry molding material mixture itself is not sticky, water glass (coating layer) on the aggregate surface is dissolved by aeration of water vapor or the like to obtain a wet molding material mixture. It can be solidified or cured by heat drying.
- the wet molding material mixture is in the form of sticky sand containing moisture, and the wet molding material mixture in such a state is molded and dried by heating to solidify or It can be cured.
- the refractory aggregate constituting such a molding material mixture is a refractory substance that functions as a base material (casting sand) of a mold, and various fire resistances conventionally used for molds.
- Any granular material can be used. Specifically, silica sand, recycled silica sand, special sand such as alumina sand, olivine sand, zircon sand, chromite sand, ferrochrome slag, ferronickel slag Slag particles such as converter slag, porous particles such as alumina particles and mullite particles, and regenerated particles thereof; alumina balls, magnesia clinker and the like.
- refractory aggregates may be fresh sand, or reclaimed sand or recovered sand that has been used once or a plurality of times as a casting sand for casting molds. Even mixed sand made by adding new sand to sand or recovered sand and mixing them can be used.
- Such a refractory aggregate generally has a particle size of about 40 to 80 in AFS index, and preferably has a particle size of about 60 or less in order to facilitate the ventilation and drying of water vapor during mold molding. As a thing, it will be used.
- the water glass used as the binder is a soluble silicate compound, for example, sodium silicate, potassium silicate, sodium metasilicate, potassium metasilicate, lithium silicate. , Ammonium silicate, colloidal silica, alkyl silicate, and the like.
- the resulting molding material mixture is difficult to block and has good moldability. Soda) is advantageously used.
- Such sodium silicates are usually classified and used as No. 1 to No. 5 depending on the molar ratio of SiO 2 / Na 2 O. Specifically, sodium silicate No. 1 has a SiO2 / Na2O molar ratio of 2.0 to 2.3, and sodium silicate No.
- sodium silicate No. 2 has a SiO2 / Na2O molar ratio of 2.4.
- sodium silicate No. 3 has a SiO2 / Na2O molar ratio of 3.0 to 3.3.
- sodium silicate No. 4 has a SiO2 / Na2O molar ratio of 3.3 to 3.5
- sodium silicate No. 5 has a SiO2 / Na2O molar ratio of 3.6 to 3 .8.
- sodium silicate Nos. 1 to 3 are also defined in JIS K1408. These sodium silicates may be used alone or in combination, and the molar ratio of SiO2 / Na2O can be adjusted by mixing additives such as sodium hydroxide. Is possible.
- sodium silicate used as a caking additive has a molar ratio of SiO2 / Na2O of 1.5. Is preferably in the range of -4.0, and more preferably in the range of 1.8-3.0.
- a molar ratio outside the range of the sodium silicate classification described above can be formed and used.
- the dry state unlike the wet state, a process of venting water vapor is required at the time of molding the mold. At that time, if water glass with a lower molar ratio is used, there is a lot of alkali, so the caking of the sand grain surface Since the agent can be easily dissolved in water vapor and the binder of the entire sand can be dissolved without unevenness, the moldability is improved. Therefore, it can be said that in the dry molding material mixture, the molar ratio of SiO 2 / Na 2 O is more preferably in the range of 2.0 to 2.5 lower than that of the wet state. For these reasons, in the present invention, it is desirable to use water glasses having different molar ratios in the dry and wet conditions without uniquely defining the molar ratio.
- the water glass aqueous solution used in the present invention means a water glass in a state dissolved in water, and can be used in the state of a stock solution as purchased on the market, and water is added to such a stock solution. Thus, it can be used even in a diluted state.
- a solid content obtained by removing a volatile substance such as water or a solvent from such an aqueous solution of water glass is referred to as a non-volatile content, and this corresponds to the above-described soluble silicate compound such as sodium silicate. .
- the water glass concentration in water glass aqueous solution becomes so deep that the ratio of such a non volatile matter (solid content) is high.
- the non-volatile content of the aqueous water glass solution used in the present invention corresponds to the ratio excluding the amount of water in the stock solution when it is composed of the stock solution, while the stock solution is water.
- the ratio excluding the amount of water in the stock solution and the amount of water used for dilution corresponds to the nonvolatile content of the aqueous water glass solution used. Will be.
- the non-volatile content in the water glass aqueous solution is set to an appropriate ratio depending on the type of the water glass and the like, but is preferably contained in a ratio of 20 to 45% by mass. It is desirable.
- the water glass component corresponding to this non-volatile content is uniformly and uniformly applied to the refractory aggregate when mixed (kneaded) with the refractory aggregate.
- a mold having high bending strength and high hardness when scratching the surface can be advantageously formed.
- the heating temperature is increased in order to dry the molding material mixture in the dry state. It is necessary to lengthen the heating time, which causes problems such as energy loss. Moreover, in the case of a wet state, the problem that the molding time becomes long is caused. Furthermore, if the proportion of non-volatile components in the water glass aqueous solution becomes too high, it becomes difficult to uniformly coat the surface of the refractory aggregate with the water glass component in the dry state. Increasingly, it also causes problems in improving the mold characteristics.
- the water glass aqueous solution is preferably used at a ratio of 0.1 to 2.5 parts by mass in terms of solid content when considered as only a non-volatile content with respect to 100 parts by mass of the refractory aggregate.
- a ratio of 0.2 to 2.0 parts by mass is particularly advantageously employed, and a water glass coating layer is formed on the surface of the refractory aggregate.
- 10 g of a sample is weighed and accommodated in an aluminum foil dish (length: 90 mm, width: 90 mm, height: 15 mm) as a sample dish, and 180 ⁇ After being placed on a heating plate maintained at 1 ° C.
- Solid content (%) [mass after drying (g) / mass before drying (g)] ⁇ 100 If the amount of the water glass aqueous solution used is too small, it becomes difficult to form an effective coating layer of water glass on the surface of the refractory aggregate, and the molding material mixture is sufficiently solidified or cured.
- the above-mentioned binder used as an essential component in the present invention is combined with at least one of carbonate and borate and is contained in the molding material mixture.
- carbonate examples include zinc carbonate, iron carbonate, manganese carbonate, copper carbonate, etc., but zinc carbonate is more preferably used.
- sodium tetraborate and potassium metaborate are more preferably used.
- These carbonates and borates may be used alone or in combination with a plurality of types.
- a molding material mixture formed by blending these carbonates and borates is used, filled in a mold heated to a temperature of 120 ° C. to 200 ° C. and held, or in a heated mold It is possible to advantageously improve the moisture resistance strength of the obtained mold for the first time by solidifying or hardening by filling and holding, followed by secondary firing at a temperature of 120 ° C. to 200 ° C. It becomes.
- the amount is preferably about 1 to 50 parts by mass, more preferably 1 to 20 parts by mass, and particularly preferably 2 to 10 parts by mass.
- the amount used is 1 part by mass or more, and if the amount added is increased, it depends on the binder. It is desirable that the amount be 50 parts by mass or less because there is a risk of causing a problem such as a decrease in physical strength due to obstruction of bonding.
- these carbonates and / or borates are combined with a caking additive containing water glass as an essential component and mixed with a predetermined refractory aggregate, thereby forming.
- a material mixture is formed, various known techniques that allow uniform mixing of these three components can be appropriately employed to form such a molding material mixture.
- carbonate and / or borate is refractory.
- a method of adding the binder to the synthetic aggregate and mixing the binder with the aggregate to uniformly knead or mix the whole is adopted.
- the carbonate and / or borate used in the present invention is in the form of a solid powder, the latter method of premixing with the refractory aggregate is advantageously employed.
- the molding material mixture prepared as described above can contain various known additives as required.
- the additive that can be added as necessary include solid oxides, salts, carbohydrates, and surfactants.
- the moisture resistance of the molding material mixture can be advantageously improved by containing a solid oxide or a salt.
- the solid oxide for example, use of oxides of silicon, zinc, magnesium, aluminum, calcium, lead, and boron is effective.
- metal oxides such as zinc oxide and aluminum oxide.
- silicon oxide precipitated silicic acid and exothermic silicic acid are preferably used.
- the salt there are silicofluoride, silicate, phosphate, etc. Among them, use of phosphate is desirable.
- oligosaccharides polysaccharides, cellulose, starch, and dextrin as carbohydrates.
- an anionic surfactant having a sulfate group, a sulfonate group, or a phosphate group as the surfactant.
- These solid oxides, salts, and the like are 0.5 to 5 parts by mass in total with respect to 100 parts by mass of water glass in terms of solids when considered as only the non-volatile content of the water glass aqueous solution. Among these, 1 to 3 parts by mass is more preferable.
- a coupling agent that strengthens the bond between the refractory aggregate and water glass (binder).
- a coupling agent that strengthens the bond between the refractory aggregate and water glass (binder).
- silane coupling agent, zircon coupling agent, titanium cup A ring agent or the like can be used.
- a lubricant that contributes to improving the fluidity of the molding material mixture.
- waxes such as paraffin wax, synthetic polyethylene wax, and montan wax; stearic acid amide, oleic acid amide, erucic acid amide, etc.
- Fatty acid amides such as methylene bis stearic acid amide and ethylene bis stearic acid amide; stearic acid, stearyl alcohol, metal stearate, lead stearate, zinc stearate, calcium stearate, magnesium stearate, stearic acid Monoglycerides, stearyl stearate, hydrogenated oils and the like can be used.
- release agents paraffin, wax, light oil, machine oil, spindle oil, insulating oil, waste oil, vegetable oil, fatty acid ester, organic acid, fine graphite particles, mica, meteorite, fluorine release agent, silicone release agent An agent or the like can also be used.
- these other additives are preferably 0.001 to 5 parts by mass with respect to 100 parts by mass of water glass in terms of solid content when considered as only the nonvolatile content of the water glass aqueous solution, More preferred is 0.01 to 3 parts by mass.
- the molding material mixture according to the present invention when manufacturing the molding material mixture according to the present invention as described above, it may be a dry molding material mixture or a wet molding material mixture.
- the heated refractory aggregate is combined with a caking additive and carbonate and / or borate, and kneaded or mixed with additives as necessary.
- a caking additive and carbonate and / or borate By mixing and mixing uniformly, the surface of such a refractory aggregate is covered with a binder, and the water glass aqueous solution that is a binder component of such a binder is evaporated by transpiration.
- a technique for obtaining a dry molding material mixture having fluidity at room temperature will be employed.
- the water vapor of the aqueous water glass solution is evaporated in the presence of carbonate and / or borate. It is necessary to be carried out quickly before the solidification or hardening of the steel. Therefore, in the present invention, the water glass aqueous solution is added (mixed) to the refractory aggregate within 5 minutes. More preferably within 3 minutes, Skip moisture, it is desirable to molding material mixtures Inuitai.
- the refractory aggregate is preheated, A method of kneading or mixing the binder is used.
- the water glass aqueous solution is kneaded or mixed with the preheated refractory aggregate so that the water in the water glass aqueous solution is evaporated very quickly by the heat of the refractory aggregate. Therefore, the moisture content of the resulting molding material mixture can be effectively reduced, and a dry powder having room temperature fluidity can be advantageously obtained. .
- the preheating temperature of the refractory aggregate is appropriately selected according to the water content of the water glass aqueous solution and the blending amount thereof, and is generally about 100 to 150 ° C., more preferably It is desirable to heat the refractory aggregate to a temperature of about 100 to 120 ° C. If the preheating temperature is too low, it is not possible to effectively evaporate moisture, and it takes time to dry. Therefore, it is desirable to set the temperature to 100 ° C. or higher. If the temperature becomes too high, the hardening of the water glass progresses when the resulting molding compound mixture is cooled, and in addition, the formation of composite particles progresses, so there is a problem with the function as the molding compound mixture, particularly physical properties such as strength. It is because it comes to produce.
- the molding material mixture according to the present invention obtained in this way is manufactured as a product whose moisture content is adjusted to less than 0.5% by mass, preferably 0.3% by mass or less, in the dry state.
- the filling property of the mold for molding the mold into the molding cavity is further improved, and also in the mold molded using such a molding material mixture, This is because excellent properties are imparted.
- the molding material mixture according to the present invention has a moisture content of 0.5% by mass or more, preferably 0.5 to 5.0% by mass, more preferably 1.0 to 3.0% by mass. In this way, the wet sand is prevented from drying and blocking with blow air when filling the mold during mold making, and the wet molding material mixture is kept wet.
- the wet molding material mixture may be in a wet state at the time of mold production, for example, a dry molding material mixture may be used by adding water before use to form a wet molding material mixture. May be. It is desirable that the mold is in a dry state except when the mold is manufactured because it is excellent in transportability and long-term storage.
- the amount of water added at this time is preferably 1 to 5 parts by mass of water with respect to 100 parts by mass of the dry molding material mixture.
- the target mold is prepared as follows. While filling the mold cavity of the mold to be fed, the mold is heated to a temperature of 120-200 ° C. and held until the filled molding material mixture is dried in the mold. . By heating and holding in such a mold, the filled molding material mixture is solidified or cured.
- the molding material mixture constituting the filling phase is wet. Are joined together to form an integral mold-shaped molding material mixture aggregate (bonded product).
- the water glass which is the main component of the binder, is usually solidified by evaporating to dryness of water, and is cured when an oxide or salt is added as a curing agent.
- the carbonate and / or borate is added as a curing agent, the filling phase is hardened, but it may be simply solidified. There is no problem.
- the molding compound mixture in a wet state is dried by evaporation to dryness of water and solidified or cured by being held for a certain period of time in a mold that has been preheated to 120 to 200 ° C. It is done.
- 120 to 200 ° C preferably 130 to 180 ° C, more preferably 140 to 160 ° C, and further preferably 145 to 160 ° C is employed.
- the moisture resistance strength can be improved and the drying of the molding material mixture can be advantageously carried out.
- a molding material mixture obtained by combining carbonate and / or borate with water glass and uniformly blending with refractory aggregate is held in a mold heated to 120 ° C. to 200 ° C.
- the reason for giving the effect of improving moisture resistance will be discussed below.
- a wet molding material mixture is used to dry and solidify at a temperature of less than 120 ° C.
- the water glass contains water and is easily dissolved again.
- the water in water glass is evaporated by heating at 120 ° C. or higher, it becomes difficult to re-dissolve to some extent.
- the molding material mixture contains a large amount of alkali, so it will inevitably re-dissolve under high temperature and high humidity.
- the carbonate when carbonate is added as an additive, the carbonate is thermally decomposed at around 120 ° C. to generate CO 2 soot, so that the alkali present in the vicinity of the carbonate is neutralized. Thus, it is considered that re-dissolution can be prevented and moisture resistance strength can be improved.
- borate when borate is added as an additive, it is heated to 120 ° C. or more, and moisture is evaporated. At the same time, tetraborate ions or metaborate ions are chelated between OH bonds of water glass. Will come to form. Thus, it is considered that the OH of the water glass is blocked, thereby preventing remelting and improving the moisture resistance strength.
- a dry molding material mixture is used and filled in a molding cavity of the molding die that gives the target mold. Then, water vapor is blown in and allowed to pass through the filling phase of the molding material mixture, while being held in a mold heated to a temperature of 30 ° C. or higher and lower than 120 ° C. until it is dried. By heating and holding in this mold, the filled molding material mixture is solidified or cured. Thereafter, secondary baking is generally performed in a thermostatic chamber heated to 120 ° C. to 200 ° C. for about 0.2 to 2 hours, preferably 0.5 to 1 hour. In addition, the time from the molding by such a mold to the secondary firing is not particularly limited, but it is preferably within 24 hours in order to stabilize the physical properties of the mold, and within 2 hours. Is more desirable.
- a molding material mixture obtained by combining water glass with carbonates and / or borates and uniformly blended with the refractory aggregate is held in a heated mold and molded.
- the reason why the effect of improving moisture resistance can be realized by performing secondary firing at a temperature of 200 ° C. will be discussed below.
- the water glass contains water and is easily re-dissolved.
- the molded mold is subjected to secondary firing in a constant temperature bath at 120 ° C. to 200 ° C., preferably 130 ° C. to 180 ° C., more preferably 140 ° C.
- the moisture resistance strength can be improved by the effect of adding carbonate or borate as an additive.
- the effect of adding the carbonate or borate is the same as that in the first method for producing a mold, and the description thereof will be omitted.
- the temperature of water vapor that is blown through the vent of such a mold and allows the inside of the filling phase of the molding material mixture to pass through is generally about 80 to 150 ° C., more preferably about 95 to 120 ° C.
- the pressure of water vapor to be ventilated according to the present invention a gauge pressure value of about 0.01 to 0.3 MPa, more preferably about 0.01 to 0.1 MPa is advantageously employed.
- the pressure for allowing the water vapor to pass is about the above-mentioned gauge pressure
- the water vapor can be uniformly supplied to the mold formed in the mold.
- the water vapor passage time and the mold drying time are short, and the molding speed can be shortened.
- such a gauge pressure has an advantage that molding is possible even when the air permeability of the molding material mixture is poor.
- the gauge pressure is too high, squeezing occurs in the vicinity of the vent, and if it is too low, there is a possibility that the whole does not vent and the molding material mixture cannot be sufficiently moistened.
- a method of venting water vapor as described above a method is adopted in which water vapor is blown from a vent provided in the mold and the inside of the molding material mixture (phase) filled in the molding cavity of the mold is vented. Furthermore, as the aeration time, water vapor is supplied to the surface of the filled molding material mixture to sufficiently wet the water glass as the binding material on the surface, thereby bonding (bonding) the molding material mixture to each other.
- the time to be obtained is appropriately selected depending on the size of the mold, the number of vents, and the like. Generally, a ventilation time of about 2 seconds to about 60 seconds is adopted. If the water vapor passage time is too short, it will be difficult to sufficiently wet the surface of the molding material mixture. If the air passage time is too long, the binder on the surface of the molding material mixture will dissolve and flow out. By doing so, in addition to the possibility of causing a spot on the mold, etc., the molding time also becomes longer.
- the improvement of water vapor permeability in the molding material mixture filled in the mold is further enhanced by venting water vapor while sucking the atmosphere in the mold from the exhaust port of the mold. Is possible.
- it is also effective to put the molding material mixture phase filled in the mold in a reduced pressure state in advance when such water vapor flows.
- it is important for the manufacture of complex shaped cores and the like to appropriately set the positions of the vent and the exhaust port and optimize the length of the flow path in the water vapor filling phase. In some cases, it is also effective to use a plurality of vents and exhausts and perform simulation of water vapor ventilation.
- a mold such as a mold or a wooden mold, which is filled with the dry molding material mixture, is desirably preliminarily kept warm by heating, and is held in the heated mold for a certain period of time.
- the molding material mixture moistened with water vapor is dried, and the solidification or curing of the molding material mixture can proceed advantageously.
- a temperature of about 30 to 120.degree. C., preferably about 50 to 110.degree. C., more preferably about 60 to 100.degree. If this heat retention temperature is increased, it becomes difficult for steam to pass to the surface of the mold, and the strength decreases, and if the temperature is too low, it takes time to dry the molded mold. The resin adheres to the mold surface, and it becomes easy to cause a stain.
- the dry molding material mixture to be filled in the mold is advantageously preheated.
- the mold strength of the resulting mold can be increased more advantageously by filling the molding die with the molding material mixture heated to a temperature of 30 ° C. or higher.
- the heating temperature of such a molding material mixture is preferably about 30 to 100 ° C., and in particular, a molding material mixture heated to a temperature of about 40 to 80 ° C. is advantageously used.
- the second method it is also possible to use a wet molding material mixture instead of a dry one.
- the step of blowing water vapor after the molding material mixture is filled in the molding cavity of the molding mold which gives the target mold is not necessary, and the wet molding material mixture is dried until 30%. It will be held in a mold heated to a temperature not lower than 120 ° C and lower than 120 ° C. Thereafter, secondary firing is performed in a thermostatic chamber heated to 120 ° C. to 200 ° C., thereby obtaining a target mold.
- the wet molding material mixture when the wet molding material mixture is held in a heated mold (in the dry state, water vapor is used).
- a method of blowing dry air, heated dry air, superheated steam, or nitrogen gas to allow the filling phase of the moist molding composition mixture to be actively dried and then let the filling phase aerate. Is going to be adopted.
- dry air, heated dry air, superheated steam or nitrogen gas it can be quickly dried to the inside of the filling phase of the molding material mixture, and the solidification or curing of the filling phase can be further advantageously promoted.
- the curing rate can be advantageously increased, and the properties such as the bending strength of the obtained mold can be advantageously enhanced, and it can also contribute to shortening the molding time of the mold.
- aeration is performed by hot air such as heated dry air or superheated steam.
- a predetermined gas such as a reactive gas such as carbon dioxide (carbon dioxide) or ester, or an inert gas such as nitrogen or argon is vented. It is also possible to further solidify or harden the caking material by neutralizing the caking material by aeration of these gases. Note that these gases may be ventilated at the same time as the vapor or dry air is ventilated.
- CS1 -Production Example 1 (CS1) of wet molding material mixture- As fireproof aggregate, Lunamos # 50 (trade name: manufactured by Kao Corporation), which is commercially available artificial sand for casting, is prepared, and commercially available sodium silicate No. 3 (trade name: trade name: A water glass aqueous solution prepared by diluting a SiO2 / Na2O molar ratio (3.0) manufactured by Fuji Chemical Co., Ltd. with water to a non-volatile content (a ratio obtained by removing the water content from the water glass aqueous solution) of 25.6% was prepared. .
- CS10 Dry Molding Material Mixture- Zinc carbonate in Production Example 8 was replaced with sodium tetraborate decahydrate, and this sodium tetraborate decahydrate was added at a ratio of 5 parts when the solid content of the water glass aqueous solution was 100 parts. Except that, CS10 was obtained according to the same procedure as in Production Example 8 above.
- the moisture ratios of the wet molding material mixtures CS1 to CS7 obtained above are 1.2% to 1.5%, respectively, and the moisture ratios of the dry molding material mixtures CS8 to CS11 are respectively It was 0.01% to 0.15%.
- Example 1 Mold Temperature Control, No Secondary Firing, Humidity> -Mold making 1 (Example 1)- After filling CS1 having a temperature of 20 ° C. obtained in Production Example 1 of the above molding material mixture into a mold heated to 120 ° C. with a gauge pressure of 0.3 MPa, the inside of the mold For 1 minute and 30 seconds, and then blowing hot air at a temperature of 300 ° C. for 1 minute under a gauge pressure of 0.03 MPa, filling the molding material mixture into the mold and holding for a total of 3 minutes. By curing CS1, a mold (Example 1) used as a test piece [10 mm ⁇ 10 mm ⁇ 80 mm] was produced.
- Example 2 -Mold making 2 (Examples 2 to 3)-
- molds (Examples 2 to 3) were prepared in the same manner as in Example 1 except that CS1 at a temperature of 20 ° C was filled in a mold heated to 150 ° C or 200 ° C. did.
- Example 4 -Mold making 3 (Examples 4 to 8)-
- each of the molds (Examples 4 to 8) was prepared in the same manner as in Example 1 except that CS1 was replaced with CS2 to CS6 and filled in molds heated to 150 ° C., respectively. Produced.
- Example 1 a mold (Comparative Example 1) was produced in the same manner as in Example 1 except that CS1 was replaced with CS7 and the mold was heated to 150 ° C.
- Example 1 a mold (Comparative Examples 2 to 4) was used in the same manner as in Example 1 except that CS1, CS5, or CS7 was used as the molding material mixture, and each was filled in a mold heated to 100 ° C. Was made.
- the bending strength after 24 hours of moisture absorption is higher than the bending strength after molding. This is because the curing proceeds for 24 hours after molding, so that the bending strength when time passes after molding is slightly higher than the bending strength after molding. This is because deterioration due to moisture absorption was suppressed in a state where the bending strength was increased later, and the bending strength after 24 hours of moisture absorption was higher.
- test pieces were subjected to secondary firing for 30 minutes in a thermostatic bath kept at 120 ° C., 150 ° C. or 200 ° C. within 2 hours after molding, respectively, to obtain a mold (Example 9). To 11) were produced.
- molds (Examples 12 to 13) were produced in the same manner as in Example 9 except that CS8 was replaced with CS9 to 10 and the temperature for secondary firing was 150 ° C.
- Example 9 a mold (Comparative Example 5) was produced in the same manner as in Example 9 except that the temperature for secondary firing was set to 100 ° C.
- Example 9 a mold (Comparative Example 6) was produced in the same manner as in Example 9 except that secondary firing was not performed.
- Example 9 a mold (Comparative Example 7) was produced according to the same method as in Example 9 except that CS8 was replaced with CS11 and the secondary firing temperature was 150 ° C.
- Example 9 a mold (Comparative Example 8) was produced in the same manner as in Example 9 except that CS8 was replaced with CS11 and secondary firing was not performed.
- test pieces were subjected to secondary firing for 30 minutes in a thermostat kept at 150 ° C. to produce molds (Examples 14 to 15).
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Abstract
Description
(2)(a)耐火性骨材と、(b)水ガラスを必須成分とする粘結材と、(c)炭酸塩及び/又はホウ酸塩とを少なくとも含む成形材料混合物を用い、これを、加熱された成形型内に充填して、保持することにより、固化乃至は硬化せしめた後、120℃~200℃の温度で二次焼成することを特徴とする鋳型の製造方法。
(3)前記成形型が、30℃以上120℃未満の温度に加熱されていることを特徴とする前記態様(2)に記載の鋳型の製造方法。
(4)前記成形型の保持中に、該成形型内に熱風または過熱水蒸気が通気せしめられることを特徴とする前記態様(1)乃至前記態様(3)の何れか1つに記載の鋳型の製造方法。
(5)前記炭酸塩及び/又はホウ酸塩が、前記水ガラスの100質量部に対して1~50質量部の割合で用いられていることを特徴とする前記態様(1)乃至前記態様(4)の何れか1つに記載の鋳型の製造方法。
(6)前記水ガラスが、ケイ酸ナトリウムを主成分とするものであることを特徴とする前記態様(1)乃至前記態様(5)の何れか1つに記載の鋳型の製造方法。
(7)前記ケイ酸ナトリウムのSiO2 /Na2 Oのモル比が、1.5~4.0であることを特徴とする前記態様(6)に記載の鋳型の製造方法。
(8)前記炭酸塩が、炭酸亜鉛、炭酸鉄、炭酸マンガン、及び炭酸銅のうちの少なくとも何れか一つであることを特徴とする前記態様(1)乃至前記態様(7)の何れか1つに記載の鋳型の製造方法。
(9)前記ホウ酸塩が、四ホウ酸ナトリウム、四ホウ酸カリウム、四ホウ酸リチウム、四ホウ酸アンモニウム、四ホウ酸カルシウム、四ホウ酸ストロンチウム、四ホウ酸銀、メタホウ酸ナトリウム、メタホウ酸カリウム、メタホウ酸リチウム、メタホウ酸アンモニウム、メタホウ酸カルシウム、メタホウ酸銀、メタホウ酸銅、メタホウ酸鉛、及びメタホウ酸マグネシウムのうちの少なくとも何れか一つであることを特徴とする前記態様(1)乃至前記態様(8)の何れか1つに記載の鋳型の製造方法。
(10)前記成形材料混合物が、湿態のものである前記態様(1)乃至前記態様(9)の何れか1つに記載の鋳型の製造方法。
(11)前記成形材料混合物が乾態のものであり、この乾態の成形材料混合物を前記成形型内に充填した後、その充填相内に水蒸気が通気せしめられる前記態様(1)乃至前記態様(9)の何れか1つに記載の鋳型の製造方法。
(12)(a)耐火性骨材と、(b)水ガラスを必須成分とする粘結材と、(c)炭酸塩及び/又はホウ酸塩とを少なくとも含む成形材料混合物を用い、これを、120℃~200℃の温度に加熱された成形型内に充填して、保持することにより、硬化せしめることによって、製造してなることを特徴とする鋳型。
(13)(a)耐火性骨材と、(b)水ガラスを必須成分とする粘結材と、(c)炭酸塩及び/又はホウ酸塩とを少なくとも含む成形材料混合物を用い、これを、加熱された成形型内に充填して、保持することにより、固化乃至は硬化せしめた後、120℃~200℃の温度で二次焼成することによって、製造してなることを特徴とする鋳型。
固形分(%)=[乾燥後の質量(g)/乾燥前の質量(g)]×100
なお、この水ガラス水溶液の使用量が少なくなり過ぎると、耐火性骨材の表面に、水ガラスの有効な被覆層が形成され難くなって、成形材料混合物の固化乃至は硬化が充分に行なわれ難くなるからであり、また水ガラス水溶液の使用量が多くなり過ぎても、耐火性骨材の表面に余分に水ガラス水溶液が付着して、均一な被覆層が形成され難くなると共に、金属を鋳込んだ後の中子の砂落としも、難しくなるからである。
各CSを用いて得られた試験片について、その破壊荷重を、測定器(高千穂精機株式会社製:デジタル鋳物砂強度試験機)を用いて測定して、この測定された破壊荷重を用いて、抗折強度を、下記の式により算出した。なお、抗折強度は、成形後(1時間後)の冷間で測定を行った。
抗折強度=1.5×LW/ab2
[但し、L:支点間距離(cm)、W:破壊荷重(kgf)、a:試験片の幅(cm)、b:試験片の厚み(cm)]
得られた試験片を、30℃、湿度80%の恒温恒湿槽の中に入れて、24時間保持した後、恒温恒湿槽から取り出して、10分以内に、前述した試験法に従って、抗折強度を測定した。
耐火性骨材として、市販の鋳造用人工砂であるルナモス#50(商品名:花王株式会社製)を準備すると共に、粘結材のバインダー成分として、市販のケイ酸ナトリウム3号(商品名:富士化学株式会社製、SiO2/Na2Oモル比:3.0)を水で希釈して、不揮発分(水ガラス水溶液から水分量を除いた割合)を25.6%とした水ガラス水溶液を準備した。
製造例1における炭酸亜鉛を、水ガラス水溶液の固形分を100部とした場合の3部の割合で添加すること以外は、上記製造例1と同様の手順に従って、CS2を得た。
製造例1における炭酸亜鉛を、水ガラス水溶液の固形分を100部とした場合の10部の割合で添加すること以外は、上記製造例1と同様の手順に従って、CS3を得た。
製造例1における炭酸亜鉛を、炭酸鉄(II)に代えて、この炭酸鉄(II)を、水ガラス水溶液の固形分を100部とした場合の5部の割合で添加すること以外は、上記製造例1と同様の手順に従って、CS4を得た。
製造例1における炭酸亜鉛を、四ホウ酸ナトリウム十水和物に代えて、この四ホウ酸ナトリウム十水和物を、水ガラス水溶液の固形分を100部とした場合の5部の割合で添加すること以外は、上記製造例1と同様の手順に従って、CS5を得た。
製造例1における炭酸亜鉛を、メタホウ酸カリウムに代えて、このメタホウ酸カリウムを、水ガラス水溶液の固形分を100部とした場合の5部の割合で添加すること以外は、上記製造例1と同様の手順に従って、CS6を得た。
製造例1において添加剤として用いた炭酸亜鉛を添加しないこと以外は、上記製造例1と同様の手順に従って、CS7を得た。
耐火性骨材として、市販の鋳造用人工砂であるルナモス#50(商品名:花王株式会社製)を準備すると共に、粘結材のバインダー成分として、市販のケイ酸ナトリウム3号(商品名:富士化学株式会社製、SiO2/Na2Oモル比:3.0)に水酸化ナトリウムを添加することで、モル比を2.3とし、そして水で希釈して、不揮発分(水ガラス水溶液から水分量を除いた割合)を25.6%とした水ガラス水溶液を準備した。
製造例7における炭酸亜鉛を、炭酸鉄(II)に代えて、この炭酸鉄(II)を、水ガラス水溶液の固形分を100部とした場合の5部の割合で添加すること以外は、上記製造例8と同様の手順に従って、CS9を得た。
製造例8における炭酸亜鉛を、四ホウ酸ナトリウム十水和物に代えて、この四ホウ酸ナトリウム十水和物を、水ガラス水溶液の固形分を100部とした場合の5部の割合で添加すること以外は、上記製造例8と同様の手順に従って、CS10を得た。
製造例8において添加剤として用いた炭酸亜鉛を添加しないこと以外は、上記製造例8同様の手順に従って、CS11を得た。
-鋳型の造型1(実施例1)-
上記の成形材料混合物の製造例1にて得られた、20℃の温度のCS1を、120℃に加熱した成形型内に、0.3MPaのゲージ圧力にて吹き込んで充填した後、成形型内で1分30秒間保持し、その後0.03MPaのゲージ圧力の下で、温度:300℃の熱風を1分間吹き込み、成形型内に成形材料混合物を充填してからトータルで3分間保持することで、CS1を硬化させることにより、試験片[10mm×10mm×80mm]として用いられる鋳型(実施例1)を作製した。
実施例1において、20℃の温度のCS1を、150℃又は200℃に加熱した成形型内に充填したこと以外は、実施例1と同じ方法により、それぞれ鋳型(実施例2~3)を作製した。
実施例1において、CS1をCS2~CS6に代えて、それぞれ150℃に加熱した成形型内に充填したこと以外は、実施例1と同様な方法に従って、それぞれ、鋳型(実施例4~8)を作製した。
実施例1において、CS1をCS7に代えて、150℃に加熱した成形型内に充填したこと以外は、実施例1と同じ方法に従って、鋳型(比較例1)を作製した。
実施例1において、成形材料混合物として、CS1、CS5又はCS7を用い、それぞれ100℃に加熱した成形型内に充填したこと以外は、実施例1と同じ方法に従って、鋳型(比較例2~4)を作製した。
-鋳型の造型6(実施例9~11)-
上記の成形材料混合物の製造例8にて得られた、20℃の温度のCS8を、100℃に加熱した成形型内に、0.3MPaのゲージ圧力にて吹き込んで充填した後、更に0.04MPaのゲージ圧力の下の温度100℃の水蒸気と、0.2MPaのゲージ圧力の下の窒素ガスとを、20秒間同時に吹き込み、成形型内に充填した成形材料混合物相に、通気せしめた。次いで、そのような水蒸気の通気が終了した後、0.03MPaのゲージ圧力の下で温度:300℃の熱風を2分40秒間吹き込み、成形型内に成形材料混合物を充填してからトータルで3分間保持することで、CS8を硬化させることにより、試験片[10mm×10mm×80mm]として用いられる鋳型を取り出した。
実施例9において、CS8をCS9~10に代えて、二次焼成の温度を150℃にしたこと以外は、実施例9と同じ方法に従って、鋳型(実施例12~13)を作製した。
実施例9において、二次焼成の温度を100℃にしたこと以外は、実施例9と同じ方法に従って、鋳型(比較例5)を作製した。
実施例9において、二次焼成を行わなかったこと以外は、実施例9と同じ方法に従って、鋳型(比較例6)を作製した。
実施例9において、CS8をCS11に代えて、二次焼成の温度を150℃にしたこと以外は、実施例9と同じ方法に従って、鋳型(比較例7)を作製した。
実施例9において、CS8をCS11に代えて、二次焼成を行わなかったこと以外は、実施例9と同じ方法に従って、鋳型(比較例8)を作製した。
-鋳型の造型12(実施例14~15)-
上記の成形材料混合物の製造例1,5にて得られた、20℃の温度のCS1、CS5を、それぞれ100℃に加熱した成形型内に、0.3MPaのゲージ圧力にて吹き込んで、充填した後、成形型内で1分30秒間保持し、その後0.03MPaのゲージ圧力の下の温度300℃の熱風を1分30秒間吹き込み、成形型内に成形材料混合物を充填してからトータルで3分間保持することで、CS1、CS5を硬化させることにより、それぞれ、試験片[10mm×10mm×80mm]として用いられる鋳型を取り出した。
実施例14において、CS1をCS7に代えたこと以外は、実施例14と同じ方法に従って、鋳型(比較例9)を作製した。
Claims (13)
- (a)耐火性骨材と、(b)水ガラスを必須成分とする粘結材と、(c)炭酸塩及び/又はホウ酸塩とを少なくとも含む成形材料混合物を用い、これを、120℃~200℃の温度に加熱された成形型内に充填して、保持することにより、硬化せしめることを特徴とする鋳型の製造方法。
- (a)耐火性骨材と、(b)水ガラスを必須成分とする粘結材と、(c)炭酸塩及び/又はホウ酸塩とを少なくとも含む成形材料混合物を用い、これを、加熱された成形型内に充填して、保持することにより、固化乃至は硬化せしめた後、120℃~200℃の温度で二次焼成することを特徴とする鋳型の製造方法。
- 前記成形型が、30℃以上120℃未満の温度に加熱されていることを特徴とする請求項2に記載の鋳型の製造方法。
- 前記成形型の保持中に、該成形型内に熱風または過熱水蒸気が通気せしめられることを特徴とする請求項1乃至請求項3の何れか1項に記載の鋳型の製造方法。
- 前記炭酸塩及び/又はホウ酸塩が、前記水ガラスの100質量部に対して1~50質量部の割合で用いられていることを特徴とする請求項1乃至請求項4の何れか1項に記載の鋳型の製造方法。
- 前記水ガラスが、ケイ酸ナトリウムを主成分とするものであることを特徴とする請求項1乃至請求項5の何れか1項に記載の鋳型の製造方法。
- 前記ケイ酸ナトリウムのSiO2 /Na2 Oのモル比が、1.5~4.0であることを特徴とする請求項6に記載の鋳型の製造方法。
- 前記炭酸塩が、炭酸亜鉛、炭酸鉄、炭酸マンガン、及び炭酸銅のうちの少なくとも何れか一つであることを特徴とする請求項1乃至請求項7の何れか1項に記載の鋳型の製造方法。
- 前記ホウ酸塩が、四ホウ酸ナトリウム、四ホウ酸カリウム、四ホウ酸リチウム、四ホウ酸アンモニウム、四ホウ酸カルシウム、四ホウ酸ストロンチウム、四ホウ酸銀、メタホウ酸ナトリウム、メタホウ酸カリウム、メタホウ酸リチウム、メタホウ酸アンモニウム、メタホウ酸カルシウム、メタホウ酸銀、メタホウ酸銅、メタホウ酸鉛、及びメタホウ酸マグネシウムのうちの少なくとも何れか一つであることを特徴とする請求項1乃至請求項8の何れか1項に記載の鋳型の製造方法。
- 前記成形材料混合物が、湿態のものである請求項1乃至請求項9の何れか1項に記載の鋳型の製造方法。
- 前記成形材料混合物が乾態のものであり、この乾態の成形材料混合物を前記成形型内に充填した後、その充填相内に水蒸気が通気せしめられる請求項1乃至請求項9の何れか1項に記載の鋳型の製造方法。
- (a)耐火性骨材と、(b)水ガラスを必須成分とする粘結材と、(c)炭酸塩及び/又はホウ酸塩とを少なくとも含む成形材料混合物を用い、これを、120℃~200℃の温度に加熱された成形型内に充填して、保持することにより、硬化せしめることによって、製造してなることを特徴とする鋳型。
- (a)耐火性骨材と、(b)水ガラスを必須成分とする粘結材と、(c)炭酸塩及び/又はホウ酸塩とを少なくとも含む成形材料混合物を用い、これを、加熱された成形型内に充填して、保持することにより、固化乃至は硬化せしめた後、120℃~200℃の温度で二次焼成することによって、製造してなることを特徴とする鋳型。
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WO2018097178A1 (ja) * | 2016-11-22 | 2018-05-31 | 旭有機材株式会社 | コーテッドサンド及びその製造方法並びにこれを用いた鋳型の製造方法 |
WO2018097180A1 (ja) * | 2016-11-22 | 2018-05-31 | 旭有機材株式会社 | コーテッドサンド及びその製造方法並びにこれを用いた鋳型の製造方法 |
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