EP1166922A1 - Vacuum die-casting method for producing castings of non-ferrous alloys - Google Patents
Vacuum die-casting method for producing castings of non-ferrous alloys Download PDFInfo
- Publication number
- EP1166922A1 EP1166922A1 EP01112949A EP01112949A EP1166922A1 EP 1166922 A1 EP1166922 A1 EP 1166922A1 EP 01112949 A EP01112949 A EP 01112949A EP 01112949 A EP01112949 A EP 01112949A EP 1166922 A1 EP1166922 A1 EP 1166922A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- die
- ladle
- gas
- holding furnace
- air
- Prior art date
- Legal status (The legal status 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 status listed.)
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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
- B22D39/00—Equipment for supplying molten metal in rations
- B22D39/02—Equipment for supplying molten metal in rations having means for controlling the amount of molten metal by volume
- B22D39/026—Equipment for supplying molten metal in rations having means for controlling the amount of molten metal by volume using a ladler
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/14—Machines with evacuated die cavity
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/30—Accessories for supplying molten metal, e.g. in rations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D41/00—Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like
- B22D41/005—Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like with heating or cooling means
Definitions
- the present invention relates to a vacuum die-casting method for producing castings of nonferrous alloys.
- More and more assembly-line vehicles use chassis and body components made of light alloy.
- the methods currently used to manufacture car chassis made of light material are forging, vacuum die-casting, and thixoforming.
- Forged parts have a satisfactory grain structure and are suitable particularly for considerable lengths.
- the die-casting process consists in keeping the molten material in a holding furnace, subsequently transferring a specific quantity thereof into an injector for compression inside a die, and finally cooling the resulting casting.
- Thixoforming lies, in terms of technical method, between forging and die-casting.
- vacuum die-casting has slight advantages regarding component weight and greater freedom of configuration.
- the die-casting process is much more advantageous if it relates to the production of large batches meant for high-volume assembly lines.
- the die-cast parts are castings which are welded and/or are required, in various forms, to have plastic deformation properties, whereas parts obtained with the standard die-casting process are characterized by high porosity, high value of gas inclusions, poor weldability and low expansion value.
- Die-cast parts must have specific elongation properties, and since there are no nondestructive elongation tests for materials, if the testing of one casting determines that the parts do not comply with quality requirements it is necessary to discard the entire batch.
- the aim of the present invention is to provide a vacuum die-casting method which solves, or substantially reduces, the problems of conventional pressure die-casting methods.
- an object of the present invention is to obtain thin-walled and/or thick-walled castings which are free from gases and/or porosities, can be welded and/or have high expansion values, and L-shaped and pressure-tight castings.
- Another object of the invention is to provide a die-casting method for obtaining castings which preserves the qualities of the light material used.
- Another object of the present invention is to provide a die-casting method which is flexible in terms of the type of nonferrous alloy used.
- Another object of the invention is to provide a die-casting method which is characterized by a high degree of reliability, in terms of quality requirements of the resulting castings.
- a vacuum die-casting method for producing castings of nonferrous alloys comprising the steps of:
- an apparatus particularly for performing a vacuum die-casting method according to the invention is generally designated by the reference numeral 10.
- the method consists of a first step, in which the light material, usually a nonferrous aluminum alloy, is kept in a molten state in a holding furnace designated by the reference numeral 11.
- the holding furnace 11 comprises a section 12 for filling with the material and a section 13 for withdrawal of the material in a liquid state.
- the material in the molten state is filtered.
- the material in the molten state is subjected to a degassing step by means of a rotor which is installed inside the furnace 11, with a cover 14 of the section 12 in the closed configuration.
- the withdrawal section 13 is a region in which the material is in a quiescent state, free from gas bubbles and filtered and therefore has an optimum degree of purity for the subsequent operations.
- the material While it is inside the furnace 11, the material is protected against contact with the air, in the regions not occupied by the containment walls, by an atmosphere of a protective gas having a higher relative density than air.
- a preset amount of molten material is then poured from the withdrawal section 13, by means of a ladle 15, into a cylindrical chamber 16 of an injector which is generally designated by the reference numeral 17.
- the ladle 15 enters the withdrawal section 13 only after being held proximate to the holding furnace 11 for a period required and sufficient to reach a given operating temperature, so as to avoid affecting the temperature of the molten material that is drawn.
- the ladle 15 enters the filling section 12 at an angle which depends on the amount of molten material that it must draw; the inclination, particularly the height of the lowest edge of the ladle, determines the height of the free surface of the drawn material.
- the ladle 15 moves at a tipping rate which determines a constant filling rate of the cylindrical chamber 16 and a constant speed of the molten material, so as to minimize turbulence inside the cylindrical chamber 16.
- the material is protected against contact with air, in the regions not occupied by the containment means, by an atmosphere of a protective gas which has a greater relative density than air; advantageously, the protective gas is nitrogen, which has no environmental impact and is available at low cost as a residue of smelting.
- the protective gas is thus contained in the holding furnace 11.
- the ladle 15 During withdrawal from the withdrawal section 13, the ladle 15, before making contact with the liquid material, enters the protective gas atmosphere.
- the withdrawal method is such that the ladle 15 in any case contains an upper layer of protective gas even when it conveys the maximum possible quantity of liquid material.
- the ladle in fact enters the section 13 at an angle and straightens after withdrawal, leaving an upper volume available for carrying the gas 22, while the lower volume is filled with material 23 in the liquid state.
- the inside of the cylindrical chamber 16 is filled with protective gas, so that even during the filling of such chamber the liquid material never makes contact with the air, avoiding the danger of forming inclusions which are dangerous for the quality of the casting.
- the apparatus 10 is provided with valves 20 for introducing nitrogen and, at the dies 18 and injectors 17, with valves 21 for generating a vacuum.
- the casting Since the casting has no porosities, it has a greater mechanical strength than an equal casting performed with known methods.
- thermal treatments (which entail additional costs and longer times) are no longer required in order to attain strength values which cannot be achieved in known processes.
- the materials and the dimensions may be any according to requirements.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacture And Refinement Of Metals (AREA)
- Continuous Casting (AREA)
- Manufacture Of Alloys Or Alloy Compounds (AREA)
- Forging (AREA)
Abstract
Description
- The present invention relates to a vacuum die-casting method for producing castings of nonferrous alloys.
- In recent years the use of light alloys to manufacture structural elements and/or components has been growing.
- More and more assembly-line vehicles use chassis and body components made of light alloy.
- The methods currently used to manufacture car chassis made of light material are forging, vacuum die-casting, and thixoforming.
- Forged parts have a satisfactory grain structure and are suitable particularly for considerable lengths.
- The die-casting process consists in keeping the molten material in a holding furnace, subsequently transferring a specific quantity thereof into an injector for compression inside a die, and finally cooling the resulting casting.
- In vacuum die-casting, a vacuum is produced before the molten material is inserted in the die; the filigree-like structure type of the casting, with thicknesses of 4 to 8 mm, often requires wings and reinforcements in order to support the loads.
- Thixoforming lies, in terms of technical method, between forging and die-casting.
- With respect to forging and thixoforming, vacuum die-casting has slight advantages regarding component weight and greater freedom of configuration.
- In terms of apparatus maintenance and amortization costs, the die-casting process is much more advantageous if it relates to the production of large batches meant for high-volume assembly lines.
- However, the standard die-casting process is scarcely suited for the manufacture of car chassis or body components owing to its brittle fracture behavior and porosity.
- Currently it is not possible to provide Al-Mg alloy castings, since the result are castings full of porosities.
- In possible applications for the manufacture of car chassis, body components et cetera, the die-cast parts are castings which are welded and/or are required, in various forms, to have plastic deformation properties, whereas parts obtained with the standard die-casting process are characterized by high porosity, high value of gas inclusions, poor weldability and low expansion value.
- Die-cast parts must have specific elongation properties, and since there are no nondestructive elongation tests for materials, if the testing of one casting determines that the parts do not comply with quality requirements it is necessary to discard the entire batch.
- This explains the high degree of reliability that the process is required to have and cannot be ensured by the current method.
- The aim of the present invention is to provide a vacuum die-casting method which solves, or substantially reduces, the problems of conventional pressure die-casting methods.
- Within this aim, an object of the present invention is to obtain thin-walled and/or thick-walled castings which are free from gases and/or porosities, can be welded and/or have high expansion values, and L-shaped and pressure-tight castings.
- Another object of the invention is to provide a die-casting method for obtaining castings which preserves the qualities of the light material used.
- Another object of the present invention is to provide a die-casting method which is flexible in terms of the type of nonferrous alloy used.
- Another object of the invention is to provide a die-casting method which is characterized by a high degree of reliability, in terms of quality requirements of the resulting castings.
- This aim and these and other objects which will become better apparent hereinafter are achieved by a vacuum die-casting method for producing castings of nonferrous alloys, comprising the steps of:
- keeping a material of nonferrous alloy in a molten state in a holding furnace;
- transferring a preset amount of said material from the furnace to a die, at injectors;
- compressing the material in the die and allowing it to cool,
- Further characteristics and advantages of the present invention will become better apparent from the following detailed description of a preferred but not exclusive embodiment thereof, illustrated only by way of non-limitative example in the accompanying drawings, wherein:
- Figure 1 is a view of an apparatus for performing a die-casting method according to the invention;
- Figures 2 and 3 are schematic views of two steps of the operation of a component of the apparatus.
-
- With particular reference to Figure 1, an apparatus particularly for performing a vacuum die-casting method according to the invention is generally designated by the reference numeral 10.
- The method consists of a first step, in which the light material, usually a nonferrous aluminum alloy, is kept in a molten state in a holding furnace designated by the
reference numeral 11. - The
holding furnace 11 comprises asection 12 for filling with the material and asection 13 for withdrawal of the material in a liquid state. - During transfer from the
filling section 12 to thewithdrawal section 13, the material in the molten state is filtered. - During holding in the
filling section 12, the material in the molten state is subjected to a degassing step by means of a rotor which is installed inside thefurnace 11, with acover 14 of thesection 12 in the closed configuration. - The
withdrawal section 13 is a region in which the material is in a quiescent state, free from gas bubbles and filtered and therefore has an optimum degree of purity for the subsequent operations. - While it is inside the
furnace 11, the material is protected against contact with the air, in the regions not occupied by the containment walls, by an atmosphere of a protective gas having a higher relative density than air. - A preset amount of molten material is then poured from the
withdrawal section 13, by means of aladle 15, into acylindrical chamber 16 of an injector which is generally designated by thereference numeral 17. - The
ladle 15 enters thewithdrawal section 13 only after being held proximate to theholding furnace 11 for a period required and sufficient to reach a given operating temperature, so as to avoid affecting the temperature of the molten material that is drawn. - The
ladle 15 enters thefilling section 12 at an angle which depends on the amount of molten material that it must draw; the inclination, particularly the height of the lowest edge of the ladle, determines the height of the free surface of the drawn material. - Also in this case, while the material is inside the
ladle 15, it is protected against contact with air in the regions not occupied by the containment walls by an atmosphere of a protective gas having a higher relative density than air. - During the transfer of the molten material from the
ladle 15 to thecylindrical chamber 16, theladle 15 moves at a tipping rate which determines a constant filling rate of thecylindrical chamber 16 and a constant speed of the molten material, so as to minimize turbulence inside thecylindrical chamber 16. - In this manner it is possible to minimize the number of gas inclusions in the casting.
- Once the filling step has ended, the injection of the molten material into dies, generally designated by the
reference numeral 18, begins. - While the
piston 19 of theinjector 17 pushes the molten material contained in thecylindrical chamber 16, vacuum is produced inside saidcylindrical chamber 16 and inside thedies 18. - In order to take into account shrinkage of the casting by a percentage which depends on the type of alloy used, there is also a step for topping up the liquid material.
- As mentioned, during the various processing and transfer steps the material is protected against contact with air, in the regions not occupied by the containment means, by an atmosphere of a protective gas which has a greater relative density than air; advantageously, the protective gas is nitrogen, which has no environmental impact and is available at low cost as a residue of smelting.
- The protective gas is thus contained in the
holding furnace 11. - During withdrawal from the
withdrawal section 13, theladle 15, before making contact with the liquid material, enters the protective gas atmosphere. - The withdrawal method is such that the
ladle 15 in any case contains an upper layer of protective gas even when it conveys the maximum possible quantity of liquid material. - As shown in Figures 2 and 3, the ladle in fact enters the
section 13 at an angle and straightens after withdrawal, leaving an upper volume available for carrying thegas 22, while the lower volume is filled withmaterial 23 in the liquid state. - Also the inside of the
cylindrical chamber 16 is filled with protective gas, so that even during the filling of such chamber the liquid material never makes contact with the air, avoiding the danger of forming inclusions which are dangerous for the quality of the casting. - At the
holding furnace 11 and at theinjectors 17, the apparatus 10 is provided withvalves 20 for introducing nitrogen and, at thedies 18 andinjectors 17, withvalves 21 for generating a vacuum. - In practice it has been observed that the present invention has achieved the intended aim and objects.
- In particular, it is evident that the various steps of the method absolutely avoid contact with air, which would contaminate the material, oxidizing it, and the continuous degassing step allows the castings to be absolutely pure.
- It is thus possible to obtain thin-walled and/or thick-walled castings, castings which are free from gas and/or porosities, are weldable and/or have high expansion values, and L-shaped and pressure-tight castings.
- Since the casting has no porosities, it has a greater mechanical strength than an equal casting performed with known methods.
- Accordingly, thermal treatments (which entail additional costs and longer times) are no longer required in order to attain strength values which cannot be achieved in known processes.
- Moreover, for an equal required strength it is possible to reduce the thicknesses of the castings, with a consequent cost saving and an increase in manufacturing possibilities in the field of vehicle bodies.
- Another particularly important fact is that it is possible to provide Al-Mg castings, which currently cannot be obtained due to the limitations linked to known technologies, which produce castings full of porosities.
- The actual reliability of the process, which also takes into account the metallurgical properties of the materials used in order to optimize results, is further ensured.
- The present invention is susceptible of numerous modifications and variations, all of which are within the scope of the inventive concept.
- The technical details may be replaced with other technically equivalent elements.
- The materials and the dimensions may be any according to requirements.
- The disclosures in Italian Patent Application No. PD2000A000166 from which this application claims priority are incorporated herein by reference.
- Where technical features mentioned in any claim are followed by reference signs, those reference signs have been included for the sole purpose of increasing the intelligibility of the claims and accordingly, such reference signs do not have any limiting effect on the interpretation of each element identified by way of example by such reference signs.
Claims (9)
- A vacuum die-casting method for producing castings of nonferrous alloys, comprising the steps of:keeping a material of nonferrous alloy in a molten state in a holding furnace;transferring a preset amount of said material from the furnace to a die, at injectors;compressing the material in the die and allowing it to cool,
- The method according to claim 1, further comprising the step of degassing continuously during holding, by means of a rotor, the material contained in a withdrawal section of the holding furnace.
- The method according to claim 2, comprising the step of filtering the molten material during transfer from a section for filling with the material in the solid state to the withdrawal section, said sections being comprised within the holding furnace.
- The method according to claim 1, comprising the step of transferring a preset amount of material into said die by means of a ladle, with adjustment of the amount of material withdrawn by tipping the ladle.
- The method according to claim 4, further comprising the step of heating said ladle at the holding furnace before withdrawing the material.
- The method according to claim 4, characterized in that the molten material is poured into the injectors by means of said ladle with an adjustable tipping rate.
- The method according to claim 1, comprising the step of producing a vacuum inside the injectors and the die after the injector filling step.
- The method according to claim 1, comprising the step of using nitrogen as a protective gas.
- An apparatus for performing a method according to claim 1.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
IT2000PD000166A IT1317349B1 (en) | 2000-06-20 | 2000-06-20 | PERFECTED PROCESS OF VACUUM DIE CASTING FOR THE PRODUCTION OF CASTINGS IN NON-FERROUS ALLOYS. |
ITPD000166 | 2000-06-20 |
Publications (1)
Publication Number | Publication Date |
---|---|
EP1166922A1 true EP1166922A1 (en) | 2002-01-02 |
Family
ID=11452014
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP01112949A Withdrawn EP1166922A1 (en) | 2000-06-20 | 2001-06-06 | Vacuum die-casting method for producing castings of non-ferrous alloys |
Country Status (6)
Country | Link |
---|---|
US (1) | US20010052402A1 (en) |
EP (1) | EP1166922A1 (en) |
JP (1) | JP2002018565A (en) |
BR (1) | BR0102440A (en) |
CA (1) | CA2350286A1 (en) |
IT (1) | IT1317349B1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN105127398A (en) * | 2015-09-09 | 2015-12-09 | 东莞市隆盛压铸设备有限公司 | Multi-station full-automatic feeding device |
CN109465422A (en) * | 2018-12-07 | 2019-03-15 | 蚌埠隆华压铸机有限公司 | A kind of charging gear of horizontal cold room die casting machine for aluminum alloy |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
KR100842004B1 (en) | 2007-05-07 | 2008-06-27 | 주식회사 임동 | Goods making device using a melting aluminum alloy and controlling method for the same |
CN103448199B (en) * | 2013-08-30 | 2015-11-25 | 苏州橙石铸造有限公司 | A kind of die casting machine with L shape frame |
CN108772555B (en) * | 2018-06-25 | 2020-01-03 | 溧阳市联华机械制造有限公司 | Explosion-proof device of vacuum suction casting chamber and control method thereof |
CN110026538B (en) * | 2019-04-28 | 2021-04-23 | 易平 | Accurate quantitative soup taking mechanism |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE742181C (en) * | 1939-02-25 | 1943-11-24 | Hahn & Kolb | Device for transferring easily oxidizable metals into the pressure chamber of press casting machines |
US5782287A (en) * | 1995-06-08 | 1998-07-21 | Toshiba Kikai Kabushiki Kaisha | Method of controlling vacuum in vacuum die-casting and vacuum control system for carrying out the same |
JPH10291068A (en) * | 1997-04-17 | 1998-11-04 | Hitachi Metals Ltd | Method for restraining waving of liquid surface |
US5913353A (en) * | 1994-09-26 | 1999-06-22 | Ford Global Technologies, Inc. | Process for casting light metals |
DE19847700A1 (en) * | 1998-10-16 | 2000-04-20 | Abb Patent Gmbh | Metal casting process comprises determining a weight force of an empty and/or charged ladle to control the movement of the casting robot |
-
2000
- 2000-06-20 IT IT2000PD000166A patent/IT1317349B1/en active
-
2001
- 2001-06-01 JP JP2001166816A patent/JP2002018565A/en active Pending
- 2001-06-06 EP EP01112949A patent/EP1166922A1/en not_active Withdrawn
- 2001-06-12 CA CA002350286A patent/CA2350286A1/en not_active Abandoned
- 2001-06-12 US US09/878,215 patent/US20010052402A1/en not_active Abandoned
- 2001-06-19 BR BR0102440-0A patent/BR0102440A/en not_active Application Discontinuation
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE742181C (en) * | 1939-02-25 | 1943-11-24 | Hahn & Kolb | Device for transferring easily oxidizable metals into the pressure chamber of press casting machines |
US5913353A (en) * | 1994-09-26 | 1999-06-22 | Ford Global Technologies, Inc. | Process for casting light metals |
US5782287A (en) * | 1995-06-08 | 1998-07-21 | Toshiba Kikai Kabushiki Kaisha | Method of controlling vacuum in vacuum die-casting and vacuum control system for carrying out the same |
JPH10291068A (en) * | 1997-04-17 | 1998-11-04 | Hitachi Metals Ltd | Method for restraining waving of liquid surface |
DE19847700A1 (en) * | 1998-10-16 | 2000-04-20 | Abb Patent Gmbh | Metal casting process comprises determining a weight force of an empty and/or charged ladle to control the movement of the casting robot |
Non-Patent Citations (1)
Title |
---|
PATENT ABSTRACTS OF JAPAN vol. 1999, no. 02 26 February 1999 (1999-02-26) * |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN105127398A (en) * | 2015-09-09 | 2015-12-09 | 东莞市隆盛压铸设备有限公司 | Multi-station full-automatic feeding device |
CN109465422A (en) * | 2018-12-07 | 2019-03-15 | 蚌埠隆华压铸机有限公司 | A kind of charging gear of horizontal cold room die casting machine for aluminum alloy |
Also Published As
Publication number | Publication date |
---|---|
IT1317349B1 (en) | 2003-06-16 |
ITPD20000166A1 (en) | 2001-12-20 |
JP2002018565A (en) | 2002-01-22 |
BR0102440A (en) | 2002-02-19 |
US20010052402A1 (en) | 2001-12-20 |
ITPD20000166A0 (en) | 2000-06-20 |
CA2350286A1 (en) | 2001-12-20 |
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