WO2017013590A1 - Process for the production of objects in aluminium, aluminium alloys, light alloys, brass, bronze and the like - Google Patents

Process for the production of objects in aluminium, aluminium alloys, light alloys, brass, bronze and the like Download PDF

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Publication number
WO2017013590A1
WO2017013590A1 PCT/IB2016/054307 IB2016054307W WO2017013590A1 WO 2017013590 A1 WO2017013590 A1 WO 2017013590A1 IB 2016054307 W IB2016054307 W IB 2016054307W WO 2017013590 A1 WO2017013590 A1 WO 2017013590A1
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WO
WIPO (PCT)
Prior art keywords
cavity
mould
liquid metal
compacting
process according
Prior art date
Application number
PCT/IB2016/054307
Other languages
French (fr)
Inventor
Claudio Frulla
Carlo CONTRI
Original Assignee
Hydromec S.R.L.
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 Hydromec S.R.L. filed Critical Hydromec S.R.L.
Priority to EP16751659.0A priority Critical patent/EP3325189B1/en
Publication of WO2017013590A1 publication Critical patent/WO2017013590A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D18/00—Pressure casting; Vacuum casting
    • B22D18/02—Pressure casting making use of mechanical pressure devices, e.g. cast-forging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C23/00—Tools; Devices not mentioned before for moulding
    • B22C23/02—Devices for coating moulds or cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D18/00—Pressure casting; Vacuum casting
    • B22D18/08—Controlling, supervising, e.g. for safety reasons

Definitions

  • This invention relates to a process for the production of objects in aluminium, aluminium alloys, light alloys, brass, bronze and the like.
  • MI2006A0004166 describes a process for the production of objects in aluminium by means of an apparatus comprising a lower mould and an upper mould that, coupled together, define the shape of the piece and delimit an area for the containment of a metered quantity of liquid metal.
  • the liquid metal is inserted between the moulds by means of a feed duct connected to a furnace and coming from below, so that the liquid metal is inserted directly into the mould cavity.
  • This apparatus is provided, in correspondence of the upper mould, with a shutter element for closing the feed duct of the liquid metal and a compacting plug suitable to realise a forging of the material when this is still in the semi-liquid or semi-solid state.
  • the mould is closed by the descent of the upper mould and the compacting plug in the retracted position towards the top by a predetermined amount and with the shutter in raised position.
  • the liquid metal is then inserted until the mould cavity is completely filled.
  • the descent of the shutter is then commanded to close the feed duct and, once this duct is closed, the descent of the compacting plug is commanded, which performs the forging of the material .
  • the purpose of this invention is to resolve the problems of the known art, taking into account the needs of the field.
  • the purpose of this invention is to provide a process for the production of objects in aluminium, aluminium alloys, light alloys, brass, bronze and the like that allows accumulating the material necessary for forging while keeping it liquid, without there being residual air in the mould cavity and in particular in metal accumulation area.
  • the purpose of this invention is to provide a process for the production of objects in aluminium, aluminium alloys, light alloys, brass, bronze and the like that allows reducing the solidification times of the metal.
  • a further object purpose of the invention is to provide a process that allows producing objects in a much shorter time, thus contributing to a significant reduction of production costs.
  • a still further purpose of the invention is to provide a production process that allows obtaining a product with high mechanical characteristics, which can provide the greatest assurances of reliability and safety, and low weight, so as to be highly competitive even from a purely economic point of view.
  • Figure 1 represents a step of the production process according to this invention, with the upper mould spaced from the lower mould (machine open) ;
  • Figure 2 represents the closing step of the upper mould, by means, of lowering it;
  • Figure 3 represents the closing step of the moulds, by means of lowering the containment ring;
  • Figure 4 represents the step of beginning the filling of the mould cavity
  • Figure 5 represents the step of filling the entire mould cavity and simultaneously the retraction (partial ascent) of the compacting plug for the accumulation of a quantity of liquid metal necessary for forging;
  • FIG. 6 represents the closing step of the feed duct of the liquid metal, by means of lowering the shutter element
  • Figure 7 represents the step of depressurising the furnace with consequent emptying of the feed duct
  • Figure 8 represents the forging step of the material, by means of lowering the compacting plug
  • Figure 9 represents the opening step of the machine with the forged piece anchored to the upper mould
  • FIG. 10 represents the -step of extracting the forged piece
  • Figure 11 represents the lubrication step of the upper mould, and the shutter element.
  • the apparatus for the realisation of the process for the production of objects in aluminium, aluminium alloy, light alloys, brass, bronze and the like comprises a lower press platen 1 that supports a lower mould 3 suitable to define at least partially a lower imprint 5, and an upper press platen 2 that supports an upper mould 4 suitable to define at least partially an upper imprint 6.
  • a central vertical axis X For the apparatus is defined a central vertical axis X.
  • the upper mould 4 is translatable towards and away from the lower mould 3.
  • a mould cavity 70, enclosed in a surface, is defined between an upper mould 4 and a lower mould 3.
  • an insertion duct 10 of liquid metal that has a communication opening 11 with the lower imprint 5.
  • the insertion duct 10 is in communication with a furnace (not shown) for the liquid metal.
  • the furnace is of the pressurised type.
  • the liquid metal is thus inserted between the moulds by means of the duct 10 coming from below, so that the liquid metal is inserted directly into the mould cavity.
  • the insertion channel 10 extends through the lower press platen and along its extension are provided the usual heating means for maintaining the metal in the liquid state.
  • This apparatus is provided, in correspondence of the upper mould 4, with a shutter element 30 for closing the feed duct 10 of the liquid metal and a compacting plug 20 suitable to realise a forging of the material when this is still in the semi-liquid or semi-solid state.
  • the compacting plug 20 is the only element that performs the compaction of the liquid metal.
  • the shutter element 30, the compacting plug 20 and the insertion duct 10 are coaxial and provided with movement independent of each other.
  • the shutter 30 is translatable, along the direction defined by the duct, through thrust means.
  • the thrust means comprise a piston 31, movable in a chamber 32 defined in the compacting 20 so as to be able to have an independent movement between the shutter 30 and the compacting plug 20.
  • the compacting plug 20 can be of the mechanical type, for example a cylinder or equivalent element, or of the pneumatic type, for example an air jet.
  • the compacting plug 20 defines at least a portion of the imprint of the moulded and forged part: in fact, the plug 20 causes the translation of a part of the surface which defines the imprint of the piece so as to create a high pressure and thus achieve the forging of the material that is still in the semi-solid or semi- liquid state.
  • the compacting plug 20 defines at least a portion of the upper imprint 6 or the lower imprint 5 of the moulded and forged piece, and thus at least a portion of the outer profile or of the inner profile of the piece.
  • the forged piece P may comprise a plurality of portions, at least one of which is destined to rise to originate the final piece PF, and any other portions PS destined to be removed in subsequent machining s steps (swarf) .
  • Figure 10 shows an example of a forged piece P: it is a piece comprising a plurality of taps (that represent the finished piece PF) joined by a portion of swarf PS destined to be removed.
  • the shutter element 30 defines at least a portion of the imprint of moulded and forged piece, for example the inner walls of the hole that is formed in the piece forged by . the shutter element 30.
  • the apparatus is provided, on shutter 30 or on the upper mould 4, with at least one level sensor 40, which has the function of stopping the ascent of the liquid metal.
  • the level sensor 40 is suitable to program the time and pressure of filling of the liquid metal in the mould cavity.
  • the level sensor 40 is suitable to command the ascent of the compacting plug 20 for the accumulation of a quantity of liquid metal necessary for forging (as shown in Figure 5) .
  • the apparatus is provided., in correspondence of the upper mould 4, with a containment ring 50 suitable to act to ensure the closure of the sliders 13 of the lower mould 3 during the forging step of the semi-solid or semi-liquid material.
  • the containment ring 50 is provided with a movement independent from the upper press platen 2.
  • the sliders 13 slide in the longitudinal direction with respect to the lower press platen 1, in closing/opening the mould cavity 70.
  • the moulding apparatus comprises a plurality of air vents in communication with the mould cavity 70, so as to allow the escape of air during the insertion step of the fluid metal.
  • Figure 2 illustrates the closing step of the upper mould 4 on the lower mould 3 and the sliders 13 (which approach the central axis X) , with the compacting plug 20 completely lowered and the shutter element 30 completely raised. Between the upper mould 4, the lower mould 3 (and the sliders 13) , the compacting plug 20 and the shutter element 30 a mould cavity 70 is defined for the containment of a metered quantity of liquid metal.
  • a depression is created in the mould cavity 70 is provided a depression, in such a way as to eliminate air residues that could affect the moulding of the piece.
  • the step of filling the mould cavity 70 takes place in low pressure, so as to . facilitate the entrance of the liquid metal into the mould.
  • An accumulation cavity 71, enclosed in a surface, is defined as a portion of the mould cavity 70, and is formed as a result of an expansion of the mould cavity 70, only in a very specific stage of the process (configuration of Figure 5) .
  • the accumulation cavity 71 is obtained through the retraction of the compacting plug 20 and/or of the shutter element 30.
  • the ascent of the compacting plug 20 and/or of the shutter element 30 is commanded until a programmed position and a programmed speed is reached.
  • the raising of the compacting plug 20 and/or of the shutter element 30 determines a temporary expansion of the mould cavity 70, and in particular determines the formation of an accumulation cavity 71 (feedhead type) suitable precisely for accumulating the material (liquid metal) necessary for the forging step as it remains liquid longer.
  • the accumulation cavity 71 (or feedhead) is defined in correspondence of the head of the compacting plug 20 and/or of the shutter element 30 ( Figure 5) .
  • the accumulation cavity 71 is defined between the walls of the upper mould and the head of the compacting plug 20 and/or of the shutter element 30.
  • the speed of raising of the compacting plug 20 and/or of the shutter element 30 is a function of the input speed of the liquid metal of the mould cavity 70. Therefore, the filling of the accumulation cavity 71 takes place concurrently with the formation , of the accumulation cavity 71 itself.
  • the fluid metal is inserted in such a way as to integrally fill the mould cavity 70 and the accumulation cavity 71.
  • the feed pressure of the liquid metal from the furnace is maintained until the shutter element 30 has completely closed the communication opening 11 of the duct 10.
  • the sensor 40 gives a signal for the actuation of the shutter element 30 (descent) towards the closing of the opening 11.
  • the liquid metal remains under pressure until the closing of the insertion opening port 11 of the duct 10. Note that the shutter 30 closes the insertion duct 10 when the material is still under pressure from the furnace.
  • the compacting plug 20 is actuated that (descending) moves, completely or even only partially, the liquid metal accumulated in the accumulation cavity 71 to compensate for the volumetric shrinkage of the piece during moulding and to perform the compacting and forging of the metal.
  • the accumulation cavity 71 has been completely, or at least partly, occupied by the compacting plug 20 itself ( Figure 8) .
  • the application of high pressure in the semi-solid state of the metal allows a considerable reduction of the solidification times and a considerable increase in the mechanical characteristics of the piece to be produced.
  • the forging step is carried out with speed and pressure programmable for the semi-solid state of the material in the cavity, and that the pressure is maintained until the end of solidification.
  • the containment ring 50 remains closed at a predetermined pressure to prevent the sectors 13 (sliders) from opening as a result of the high pressure exerted.
  • the upper mould 4 is opened ( Figure 9) , following the opening order of the containment ring opening 50, then the sliders 13 (which move away from the central axis X) and finally the upper press platen 2. As shown in Figure. 9, the piece P is anchored to the upper mould: at this point, the piece is extracted from the apparatus.,
  • a layer of material suitable to facilitate the detachment of the forged piece (or release agent) , is applied on the lower mould 3, the sliders 13 and on the upper mould 4.
  • both the compacting plug 20 and the shutter element 30 are lubricated and, in particular, graphite oil is applied.
  • Figure 11 illustrates a lubrication device 90 (for example, rotating) that, simultaneously with the application of the release agent on the upper imprint 6, lubricates both the compacting plug 20 and the shutter element 30.
  • the compacting plug 20 is fully retracted upwards and the shutter element 30 is fully extracted (i.e., lowered) . So, at the end of the cycle, after extracting the forged piece, between the shutter 30 fully extracted and the compacting plug 20 fully retracted, the rotating lubrication system 90, which lubricates the two elements in a single pass, goes into operation.
  • the purpose of this invention is also an apparatus 1 for the production of objects in aluminium, aluminium alloys, light alloys, brass, bronze and the like, comprising:
  • the mould cavity 70 is predefined by the lower mould 3 and the upper mould 4, and the compacting plug 20 is an element separate from the moulds 3,4 and is the only element that performs the forging of the metal when this is still in the semi-liquid or semi-solid state.
  • the mould cavity 70 is predefined by the lower mould 3 and the upper mould 4 : as can be seen in Figure 2, once the closing step of the upper mould 4 on the lower mould 3 (and possibly of the sliders 13 that approach the central axis X) is completed, the mould cavity 70 is substantially defined. In fact, as can be seen in Figures 5, 6 and 8 the movement of the compacting plug 20 and/or of the shutter element 30 is independent from the upper mould 4 (or the lower mould 3) , which remains stationary in the closed position .
  • the compacting plug 20 and/or the shutter element 30 are retracted without there being any movement of the upper mould 4 (or the lower mould 3) , which remains stationary in the closed position.
  • the mould cavity 70 is filled slowly and at low pressure, and high pressure is applied in the solidification step: this allows reducing solidification times in connection with the high pressure.
  • the process for the production of objects in aluminium, aluminium alloys, light alloys, brass, bronze and the like allows obtaining different types of products, such as wheels, wheel hubs, wheel axles, safety tips for shoes, winches, taps, and so on.
  • the process for the production of objects in aluminium, aluminium alloys, light alloys, brass, bronze and the like allows obtaining several finished pieces using a single moulding cycle.
  • a technician in the field to satisfy contingent requirements, may make modifications, adaptations and replacements of members with others functionally equivalent, without departing from the scope of the following claims.
  • Each of the characteristics described as belonging to a possible form of embodiment can be achieved independently from the other embodiments described.

Abstract

A process for moulding and forging objects in aluminium, aluminium alloys, light alloys, brass, bronze and the like comprises the steps of inserting in a mould cavity (70) liquid metal coming from a feed duct (10) until the total filling of the cavity (70); forming an accumulation cavity (71) of the mould cavity (70), and accumulating further liquid metal in the accumulation cavity (71), then closing the communication with the duct (10); compacting the material in the semi-solid state by compression of at least a portion of the surface of cavity (70); maintaining closure and pressure for a predetermined period of time; opening ' the moulds and removing the piece.

Description

"Process for the production of objects in aluminium, aluminium alloys , light alloys , brass , bronze and the like"
DESCRIPTION
[0001] This invention relates to a process for the production of objects in aluminium, aluminium alloys, light alloys, brass, bronze and the like.
[0002] A previous patent application, MI2006A000416, describes a process for the production of objects in aluminium by means of an apparatus comprising a lower mould and an upper mould that, coupled together, define the shape of the piece and delimit an area for the containment of a metered quantity of liquid metal. In this apparatus, the liquid metal is inserted between the moulds by means of a feed duct connected to a furnace and coming from below, so that the liquid metal is inserted directly into the mould cavity. This apparatus is provided, in correspondence of the upper mould, with a shutter element for closing the feed duct of the liquid metal and a compacting plug suitable to realise a forging of the material when this is still in the semi-liquid or semi-solid state. At the beginning of the moulding cycle, the mould is closed by the descent of the upper mould and the compacting plug in the retracted position towards the top by a predetermined amount and with the shutter in raised position. The liquid metal is then inserted until the mould cavity is completely filled. The descent of the shutter is then commanded to close the feed duct and, once this duct is closed, the descent of the compacting plug is commanded, which performs the forging of the material .
[0003] The moulding process described in that patent application, which is shown to be valid from many respects, is susceptible of improvements as regards the dosage of the liquid metal in the mould cavity.
[0004] The purpose of this invention is to resolve the problems of the known art, taking into account the needs of the field.
[ [0005] In particular, the purpose of this invention is to provide a process for the production of objects in aluminium, aluminium alloys, light alloys, brass, bronze and the like that allows accumulating the material necessary for forging while keeping it liquid, without there being residual air in the mould cavity and in particular in metal accumulation area.
[0006] Furthermore, the purpose of this invention is to provide a process for the production of objects in aluminium, aluminium alloys, light alloys, brass, bronze and the like that allows reducing the solidification times of the metal. [0007] A further object purpose of the invention is to provide a process that allows producing objects in a much shorter time, thus contributing to a significant reduction of production costs.
[0008] A still further purpose of the invention is to provide a production process that allows obtaining a product with high mechanical characteristics, which can provide the greatest assurances of reliability and safety, and low weight, so as to be highly competitive even from a purely economic point of view.
[0009] This purpose is achieved with a process for the production of objects in aluminium, aluminium alloys, light alloys, ' brass, bronze and the like according to claim 1, and by the related equipment according. to claim 11. The dependent claims describe preferred embodiments of the invention.
[0010] The characteristics and advantages of the production process according to the invention will be evident from the following description of several preferred embodiments, provided by way of non-limiting example, with reference to the accompanying figures, in which:
[0011] - Figure 1 represents a step of the production process according to this invention, with the upper mould spaced from the lower mould (machine open) ;
[0012] - Figure 2 represents the closing step of the upper mould, by means, of lowering it;
[0013] - Figure 3 represents the closing step of the moulds, by means of lowering the containment ring;
[0014] - Figure 4 represents the step of beginning the filling of the mould cavity;
[0015] - Figure 5 represents the step of filling the entire mould cavity and simultaneously the retraction (partial ascent) of the compacting plug for the accumulation of a quantity of liquid metal necessary for forging;
[0016] - Figure 6 represents the closing step of the feed duct of the liquid metal, by means of lowering the shutter element;
[0017] - Figure 7 represents the step of depressurising the furnace with consequent emptying of the feed duct;
[0018] - Figure 8 represents the forging step of the material, by means of lowering the compacting plug;
[0019] - Figure 9 represents the opening step of the machine with the forged piece anchored to the upper mould;
[0020] - Figure 10 represents the -step of extracting the forged piece;
[0021] - Figure 11 represents the lubrication step of the upper mould, and the shutter element.
[0022] With reference to the figures, and in particular Figure 1, the apparatus for the realisation of the process for the production of objects in aluminium, aluminium alloy, light alloys, brass, bronze and the like according to the invention, comprises a lower press platen 1 that supports a lower mould 3 suitable to define at least partially a lower imprint 5, and an upper press platen 2 that supports an upper mould 4 suitable to define at least partially an upper imprint 6. For the apparatus is defined a central vertical axis X.
[0023] The lower mould 3 and the upper mould 4, once coupled, at least partially define the shape of the piece to be moulded and forged and delimit an area for the containment of a metered quantity of liquid metal. The upper mould 4 is translatable towards and away from the lower mould 3.
[0024] A mould cavity 70, enclosed in a surface, is defined between an upper mould 4 and a lower mould 3.
[0025] In correspondence of the lower mould 3 is provided an insertion duct 10 of liquid metal that has a communication opening 11 with the lower imprint 5. The insertion duct 10 is in communication with a furnace (not shown) for the liquid metal. Preferably, the furnace is of the pressurised type. The liquid metal is thus inserted between the moulds by means of the duct 10 coming from below, so that the liquid metal is inserted directly into the mould cavity. [0026] Preferably, the insertion channel 10 extends through the lower press platen and along its extension are provided the usual heating means for maintaining the metal in the liquid state.
[0027] This apparatus is provided, in correspondence of the upper mould 4, with a shutter element 30 for closing the feed duct 10 of the liquid metal and a compacting plug 20 suitable to realise a forging of the material when this is still in the semi-liquid or semi-solid state. Note that the compacting plug 20 is the only element that performs the compaction of the liquid metal.
[0028] Advantageously, the shutter element 30, the compacting plug 20 and the insertion duct 10 are coaxial and provided with movement independent of each other.
[0029] The shutter 30 is translatable, along the direction defined by the duct, through thrust means. In an embodiment example, the thrust means comprise a piston 31, movable in a chamber 32 defined in the compacting 20 so as to be able to have an independent movement between the shutter 30 and the compacting plug 20.
[0030] The compacting plug 20 can be of the mechanical type, for example a cylinder or equivalent element, or of the pneumatic type, for example an air jet.
[0031] Preferably, the compacting plug 20 defines at least a portion of the imprint of the moulded and forged part: in fact, the plug 20 causes the translation of a part of the surface which defines the imprint of the piece so as to create a high pressure and thus achieve the forging of the material that is still in the semi-solid or semi- liquid state.
[0032] It is clear that, depending on the shape of the forged piece or of its position inside the apparatus, the compacting plug 20 defines at least a portion of the upper imprint 6 or the lower imprint 5 of the moulded and forged piece, and thus at least a portion of the outer profile or of the inner profile of the piece.
[0033] The forged piece P may comprise a plurality of portions, at least one of which is destined to rise to originate the final piece PF, and any other portions PS destined to be removed in subsequent machinings steps (swarf) .
[0034] Figure 10 shows an example of a forged piece P: it is a piece comprising a plurality of taps (that represent the finished piece PF) joined by a portion of swarf PS destined to be removed.
[0035] Therefore, the apparatus and the production process described here allow obtaining several finished parts by means of a single moulding cycle.
[0036] Preferably, but not limitingly, also the shutter element 30 defines at least a portion of the imprint of moulded and forged piece, for example the inner walls of the hole that is formed in the piece forged by . the shutter element 30.
[0037] The apparatus is provided, on shutter 30 or on the upper mould 4, with at least one level sensor 40, which has the function of stopping the ascent of the liquid metal. In particular, the level sensor 40 is suitable to program the time and pressure of filling of the liquid metal in the mould cavity.
[0038] In addition, the level sensor 40 is suitable to command the ascent of the compacting plug 20 for the accumulation of a quantity of liquid metal necessary for forging (as shown in Figure 5) .
[0039] Advantageously, in the case in which the lower mould 3 includes a plurality of sectors or sliders 13, the apparatus is provided., in correspondence of the upper mould 4, with a containment ring 50 suitable to act to ensure the closure of the sliders 13 of the lower mould 3 during the forging step of the semi-solid or semi-liquid material. The containment ring 50 is provided with a movement independent from the upper press platen 2. In addition, the sliders 13 slide in the longitudinal direction with respect to the lower press platen 1, in closing/opening the mould cavity 70.
[0040] Preferably, the moulding apparatus comprises a plurality of air vents in communication with the mould cavity 70, so as to allow the escape of air during the insertion step of the fluid metal.
[0041] The accompanying figures show several steps of the moulding and forging process according to this invention.
[0042] Figure 2 illustrates the closing step of the upper mould 4 on the lower mould 3 and the sliders 13 (which approach the central axis X) , with the compacting plug 20 completely lowered and the shutter element 30 completely raised. Between the upper mould 4, the lower mould 3 (and the sliders 13) , the compacting plug 20 and the shutter element 30 a mould cavity 70 is defined for the containment of a metered quantity of liquid metal.
[0043] Subsequently, as shown in ' Figure 3, the lowering of the containment ring 50 completes the closure of the moulds 3,13,4, and in particular locks them in position, and counteracts the thrust during forging.
[0044] Prior to the insertion of the liquid metal, a depression is created in the mould cavity 70 is provided a depression, in such a way as to eliminate air residues that could affect the moulding of the piece.
[0045] In addition, the step of filling the mould cavity 70 takes place in low pressure, so as to . facilitate the entrance of the liquid metal into the mould.
[0046] At this point (Figure 4), the insertion of the liquid metal through the insertion duct 10 and the filling of the mould cavity 70 takes place until the level sensor 40 is reached.
[0047] When the liquid metal reaches the level sensor 40 (Figure 5) , a furnace pressure and speed is commanded to complete the filling of the mould cavity 70.
[0048] The insertion of the metal thus takes place until the mould cavity 70 is completely filled. Before the closing of the feed duct 10, there is the step of realising at least one accumulation cavity 71 and thus the accumulation of additional liquid metal inside of this accumulation cavity 71.
[0049] An accumulation cavity 71, enclosed in a surface, is defined as a portion of the mould cavity 70, and is formed as a result of an expansion of the mould cavity 70, only in a very specific stage of the process (configuration of Figure 5) .
[0050] In particular, the accumulation cavity 71 is obtained through the retraction of the compacting plug 20 and/or of the shutter element 30.
[0051] In fact, as visible in Figure 5, the ascent of the compacting plug 20 and/or of the shutter element 30 is commanded until a programmed position and a programmed speed is reached. The raising of the compacting plug 20 and/or of the shutter element 30 determines a temporary expansion of the mould cavity 70, and in particular determines the formation of an accumulation cavity 71 (feedhead type) suitable precisely for accumulating the material (liquid metal) necessary for the forging step as it remains liquid longer.
[0052] Preferably, the accumulation cavity 71 (or feedhead) is defined in correspondence of the head of the compacting plug 20 and/or of the shutter element 30 (Figure 5) . In particular, the accumulation cavity 71 is defined between the walls of the upper mould and the head of the compacting plug 20 and/or of the shutter element 30.
[0053] Concurrently with the formation of the accumulation cavity 71, the liquid metal continues to flow from the feed duct 10 and thus determines the filling of the accumulation cavity 71.
[0054] The speed of raising of the compacting plug 20 and/or of the shutter element 30 is a function of the input speed of the liquid metal of the mould cavity 70. Therefore, the filling of the accumulation cavity 71 takes place concurrently with the formation , of the accumulation cavity 71 itself.
[0055] This results in the insertion (a kind of loading) of the liquid metal necessary for the forging step inside the accumulation cavity 71, as in a sort of syringe. [0056] In addition, the depression present in the mould cavity 70 prevents the remainder of air residues in the accumulation area of the liquid metal necessary precisely for the forging step.
[0057] The fluid metal is inserted in such a way as to integrally fill the mould cavity 70 and the accumulation cavity 71. The feed pressure of the liquid metal from the furnace is maintained until the shutter element 30 has completely closed the communication opening 11 of the duct 10. The sensor 40 gives a signal for the actuation of the shutter element 30 (descent) towards the closing of the opening 11. To ensure the dosage, the liquid metal remains under pressure until the closing of the insertion opening port 11 of the duct 10. Note that the shutter 30 closes the insertion duct 10 when the material is still under pressure from the furnace.
[0058] Note that, even after the shutter element 30 is lowered to closed duct 10, there is still an accumulation cavity 71 (feedhead type) filled with liquid metal.
[0059] Once the communication opening 11 of the duct 10 is closed, the furnace feeding the liquid metal is depressurised and the liquid metal returns down from the duct into the furnace (Figure 7) .
[0060] Then the compacting plug 20 is actuated that (descending) moves, completely or even only partially, the liquid metal accumulated in the accumulation cavity 71 to compensate for the volumetric shrinkage of the piece during moulding and to perform the compacting and forging of the metal. At the end of the descent of the compacting plug 20, the accumulation cavity 71 has been completely, or at least partly, occupied by the compacting plug 20 itself (Figure 8) .
[0061] Advantageously, the application of high pressure in the semi-solid state of the metal allows a considerable reduction of the solidification times and a considerable increase in the mechanical characteristics of the piece to be produced.
[0062] Note then that the forging step is carried out with speed and pressure programmable for the semi-solid state of the material in the cavity, and that the pressure is maintained until the end of solidification.
[0063] Advantageously, during the forging step (Figure 8), the containment ring 50 remains closed at a predetermined pressure to prevent the sectors 13 (sliders) from opening as a result of the high pressure exerted.
[0064] Once the compacting plug 20 has maintained the forging position for the required solidification time, the upper mould 4 is opened (Figure 9) , following the opening order of the containment ring opening 50, then the sliders 13 (which move away from the central axis X) and finally the upper press platen 2. As shown in Figure. 9, the piece P is anchored to the upper mould: at this point, the piece is extracted from the apparatus.,
[0065] Advantageously, before starting a new production cycle, a layer of material, suitable to facilitate the detachment of the forged piece (or release agent) , is applied on the lower mould 3, the sliders 13 and on the upper mould 4.
[0066] Advantageously, before starting a new production cycle, both the compacting plug 20 and the shutter element 30 are lubricated and, in particular, graphite oil is applied.
[0067] Figure 11 illustrates a lubrication device 90 (for example, rotating) that, simultaneously with the application of the release agent on the upper imprint 6, lubricates both the compacting plug 20 and the shutter element 30. Preferably, in the lubrication step through the device 90, the compacting plug 20 is fully retracted upwards and the shutter element 30 is fully extracted (i.e., lowered) . So, at the end of the cycle, after extracting the forged piece, between the shutter 30 fully extracted and the compacting plug 20 fully retracted, the rotating lubrication system 90, which lubricates the two elements in a single pass, goes into operation.
[0068] The purpose of this invention is also an apparatus 1 for the production of objects in aluminium, aluminium alloys, light alloys, brass, bronze and the like, comprising:
[0069] - a lower press platen 1 that supports a lower mould 3 suitable to define at least partially a lower imprint 5, and an upper press platen 2 that supports an upper mould 4 suitable to define at least partially an upper imprint 6;
[0070] - a shutter element 30 to close an insertion duct 10 of the molten metal;
[0071] - a compacting plug '20, translatable independently from the shutter 30, suitable to forge the molten metal;
[0072] wherein the shutter element 30, the compacting plug 20 and the insertion duct 10 are coaxial, and
[0073] wherein the mould cavity 70 is predefined by the lower mould 3 and the upper mould 4, and the compacting plug 20 is an element separate from the moulds 3,4 and is the only element that performs the forging of the metal when this is still in the semi-liquid or semi-solid state.
[0074] In the apparatus 1, the mould cavity 70 is predefined by the lower mould 3 and the upper mould 4 : as can be seen in Figure 2, once the closing step of the upper mould 4 on the lower mould 3 (and possibly of the sliders 13 that approach the central axis X) is completed, the mould cavity 70 is substantially defined. In fact, as can be seen in Figures 5, 6 and 8 the movement of the compacting plug 20 and/or of the shutter element 30 is independent from the upper mould 4 (or the lower mould 3) , which remains stationary in the closed position .
[0075] Furthermore, during the step of realising the accumulation cavity 71 and thus a further accumulation liquid metal, the compacting plug 20 and/or the shutter element 30 are retracted without there being any movement of the upper mould 4 (or the lower mould 3) , which remains stationary in the closed position.
[0076] Innovatively, according to the process for the production of objects in aluminium, aluminium alloys, light alloys, brass, bronze and the like according to this .invention, there is provided a step of forming an accumulation cavity, 71 and thus a further accumulation liquid metal, necessary for the forging and compacting step, inside of this accumulation cavity 71. In particular, the realisation step of the accumulation cavity 71 provides for the retraction of the compacting plug and/or of the shutter element so as to form the accumulation cavity. In this way it is possible to accumulate the liquid metal necessary to the forging step, and avoid residual air remaining in the metal accumulation area.
[0077] Advantageously, according to the production process described above, the mould cavity 70 is filled slowly and at low pressure, and high pressure is applied in the solidification step: this allows reducing solidification times in connection with the high pressure.
[0078] Advantageously, according to the above-described production process, it is possible to provide a moulding and forging process that allows producing objects in a much shorter time, thus contributing to a significant reduction of production costs.
[0079] Advantageously, according to the production process described above, it is possible to obtain forged pieces that are significantly light and with high mechanical characteristics, and therefore highly competitive even from a purely economic point of view.
[0080] Advantageously, the process for the production of objects in aluminium, aluminium alloys, light alloys, brass, bronze and the like allows obtaining different types of products, such as wheels, wheel hubs, wheel axles, safety tips for shoes, winches, taps, and so on.
[0081] Advantageously, the process for the production of objects in aluminium, aluminium alloys, light alloys, brass, bronze and the like allows obtaining several finished pieces using a single moulding cycle. [0082] To the forms of embodiment of the moulding and forging process according to the invention, a technician in the field, to satisfy contingent requirements, may make modifications, adaptations and replacements of members with others functionally equivalent, without departing from the scope of the following claims. Each of the characteristics described as belonging to a possible form of embodiment can be achieved independently from the other embodiments described.

Claims

Claims
1. Process for the production of objects in aluminium, aluminium alloys, light alloys, brass, bronze and the like comprising the steps of:
inserting into a mould cavity (70) , enclosed in a surface defined between an upper mould (4) and a lower mould (3) , liquid metal coming from a feed duct (10) until the mould cavity (70) is totally filled;
- forming at least one accumulation cavity (71) of the mould cavity (70) , and accumulating further liquid metal in the accumulation cavity (71);
- subsequently closing the communication with said feed duct (10);
compacting the material in semi-solid state by compression of at least a portion of the surface of said mould cavity (70) ;
- maintaining closure and pressure for a predetermined period of time;
- opening the moulds (3,4) and removing the piece.
2. Process according to claim 1, wherein the step of forming at least one accumulation cavity (71) requires expanding the mould cavity (70) .
3. Process according to claim 1 or 2, wherein the step of forming at least one accumulation ' cavity (71) requires retracting a compacting plug (20) suitable to compact the material and/or a shutter element (30) suitable to c'lose the communication with said feed duct (10) .
4. Process according to claim 3, wherein the retraction speed of the compacting plug (20) and/or of the shutter element (30) is a function of the input speed of the liquid metal of the mould cavity (70) in such a way that the filling of the accumulation cavity (71) occurs simultaneously with the formation of the accumulation cavity (71) itself.
5. Process according to claim 3 or 4, wherein, before the step of inserting the liquid metal in the mould cavity (70), there is the step of closing the moulds (3,4,13) in which the compacting plug (20) is fully lowered and the shutter member (30) is completely lifted.
6. Process according to claim 5, wherein, after the step of closing of the moulds (3,4,13), there is the step of lowering a containment ring (50) to lock the moulds (3,4,13) .
7. Process according to claim 6, wherein, during the step of compacting the material, the containment ring (50) remains lowered to lock the moulds (3,4,13).
8. Process according to any of the preceding claims, wherein, before the step of inserting the liquid metal in the mould cavity (70), there is the step of creating a depression in the mould cavity (70) .
9. Process according to any of the preceding claims, wherein, during the insertion step, the liquid metal is pressurised until the closure of the insertion duct (10) .
10. Process according to any of the preceding claims, wherein, before starting a new production cycle, there is the step of applying a layer of material on the moulds (3,4,13) to facilitate detachment of the piece forged.
11. Process according to any of claims 2 to 10> wherein, before starting a new production cycle, there is the step of lubricating both the compacting plug (20) and the shutter element (30) .
12. Apparatus (1) for the production of objects in aluminium, aluminium alloys, light alloys, brass, bronze and the like comprising:
- a lower press platen (1) that supports a lower mould (3) suitable to define at least partially a lower imprint (5), and an upper press platen (2) that supports an upper mould (4) suitable to define at least partially an upper imprint ( 6) ;
- a shutter element (30) to close an insertion duct (10) of the molten metal;
- a compacting plug (20) , translatable independently from the shutter (30), suitable to forge the molten metal;
wherein the shutter element (30) , the compacting plug (20) and the insertion duct (10) are coaxial, and wherein the mould cavity (70) is predefined by the lower mould (3) and the upper mould (4), and the compacting plug (20) is an element separate from the moulds (3,4) and is the only element that performs the forging of the metal when this is still in the semi-liquid or semi-solid state .
13. Apparatus (1) according to claim 12, comprising a lubrication device (90), preferably rotating, that simultaneously with the application of the release agent on the upper imprint (6), lubricates both the compacting plug (20) and the shutter element (30) .
PCT/IB2016/054307 2015-07-22 2016-07-20 Process for the production of objects in aluminium, aluminium alloys, light alloys, brass, bronze and the like WO2017013590A1 (en)

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