EP1183120B1 - Giesswerkzeug und verfahren zur herstellung eines bauteils - Google Patents
Giesswerkzeug und verfahren zur herstellung eines bauteils Download PDFInfo
- Publication number
- EP1183120B1 EP1183120B1 EP00920651A EP00920651A EP1183120B1 EP 1183120 B1 EP1183120 B1 EP 1183120B1 EP 00920651 A EP00920651 A EP 00920651A EP 00920651 A EP00920651 A EP 00920651A EP 1183120 B1 EP1183120 B1 EP 1183120B1
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- EP
- European Patent Office
- Prior art keywords
- casting
- insert
- casting tool
- accordance
- metal
- 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
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/10—Alloys containing non-metals
- C22C1/1005—Pretreatment of the non-metallic additives
- C22C1/1015—Pretreatment of the non-metallic additives by preparing or treating a non-metallic additive preform
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/14—Casting in, on, or around objects which form part of the product the objects being filamentary or particulate in form
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/10—Alloys containing non-metals
- C22C1/1036—Alloys containing non-metals starting from a melt
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
- C22C47/02—Pretreatment of the fibres or filaments
- C22C47/06—Pretreatment of the fibres or filaments by forming the fibres or filaments into a preformed structure, e.g. using a temporary binder to form a mat-like element
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
- C22C47/08—Making alloys containing metallic or non-metallic fibres or filaments by contacting the fibres or filaments with molten metal, e.g. by infiltrating the fibres or filaments placed in a mould
Definitions
- the present invention relates to a casting tool and a Process for producing a component according to the patent claims 1 and 10.
- a generic method is known from DE 197 10 671 C2 known. This results in a method in which a porous sacrificial body made of a ceramic material (insert) inserted in a casting tool position defined and under Pressure with a molten metal (casting metal) is infiltrated. By infiltration of the insert with the casting metal At the location of the insert, a metal-ceramic composite material is produced (Reinforcing member). Subsequently, the heated component, so that within the reinforcing element a reaction between the ceramic material and the casting metal takes place, from which a composite material ceramic and intermetallic material phases results, in terms of wear resistance and rigidity Reinforcement element still surpasses. Heating the component however, especially with local reinforcements only with high technical complexity and high production costs to realize. Furthermore, it may be due to the process due to Bending stresses to damage the insert during the infiltration come.
- JP 60130460 A describes a method for the production a composite component produced by centrifugal casting becomes.
- a core of ceramic fibers is in a centrifugal casting tool inserted and by holding elements supported.
- the holding elements direct the flow of a cast metal past the core, so that after solidification one layered tube is formed, which is the core of ceramic Contains fibers and on the surfaces of metal consists.
- a method of this kind is not suitable for infiltration of porous ceramic inserts, since there is no sufficient pressure on the insert.
- the object of the present invention is therefore to a casting tool and a further improved method of to provide the above-mentioned type, so that light metal components with improved mechanical strength, in particular improved creep resistance easy and inexpensive can be produced.
- the solution of the problem consists in a device (casting tool) with the features of claim 1 and a method according to claim 10.
- the device according to the invention according to claim 1 is characterized in that fixing elements in the casting tool are attached, which position the insert position defined.
- the fixing elements are designed so that the Bending moments that act on the insert are minimized. This is done according to the invention so that by the fixing Forces acting on the insert by collinear Forces are compensated. That is, the lines of force of opposite Forces are on a straight line.
- the fixing elements according to the invention is the insert in a mold cavity positioned so that it is not directly in the Spreading current of a cast metal is. To realize this, Shielding elements are used. Ideally these shielding elements components of the mold cavity contour, such as As edges or walls, by the component geometry are predetermined. However, it is also possible additional fixing so that they shape the flow of cast metal Shield against the insert. Prevent together the fixing and the shielding a damage of the ceramic insert and thus reduce the Committee rate in a series production of reinforced Light metal components (claim 1).
- the insert is preferably in one with respect to a casting machine fixed side of the casting tool as it is so no movement when closing the casting tool learns by which it could be moved in its position. If the geometry of the component and / or the geometry of the casting tool it is possible, it is possible, the insert in a movable side of the casting tool or on a Position slide. Furthermore, it is possible several To position inserts in the casting tool, the in the fixed side and / or the moving side and / or can be on a slider (claim 2).
- the insert on a wall of the Positioning mold cavity. It is important that the Insert fit exactly the surface of the casting mold wall. Ideally, it is the casting tool wall around a flat surface (claim 3).
- the final fixation of the insert takes place during Close the casting tool.
- the insert with holes to provide and on pins, which are on the firm side or the moving side or on a slider to be positioned precisely. This is an advantage if the Construction of the component to be produced locally no fixing elements in the mold cavity allowed in the component as Cavities are shown (claim 7).
- the cross section of a casting piston conveying the casting metal is usually larger than the cross section of the opening of the mold cavity (bleed). This results in an acceleration of the casting metal entering the mold cavity at constant speed of the casting piston.
- the speed of the To keep casting metal low So it turned out in practice that the speed of the cast metal in the range of the insert should not be greater than eight times the maximum casting piston speed. Therefore, should the cross-section of the gate is not less than about one Eighth of the cross section of the casting piston amount (claim 8th).
- For local reinforcement of light metal components using the device according to the invention are in particular components of internal combustion engines and transmissions.
- the flexural strength, the modulus of elasticity, the expansion coefficient and the wear resistance may be mentioned.
- Local reinforcements for example, with cylinder liners inserted in the cylinder crankcase, find particular application.
- wear resistance is of importance, on the other hand, the rigidity of the liner. This is particularly important at low cylinder spacing that is narrow web width, since it comes here without reinforcement to an unwanted bulge of the bushing, which leads to a gap between the cylinder and bush, can escape unburned through the fuel (blow-by effect).
- Another application of local reinforcements are basic bearing areas of a crankshaft (eg in the cylinder crankcase and / or in the crankcase lower part and / or in the bearing cap) as well as bearing areas in the gearbox housing.
- the increased rigidity of the reinforcing element and the lower coefficient of expansion and the higher creep resistance compared to the unreinforced light metal can be exploited. Due to the good wear resistance of the reinforcing elements, it is conceivable that they could replace the bearing shells in the bearing block.
- Other mechanically loaded components or functional elements that can be reinforced by reinforcing elements are, for example, connecting rods, turbocharger blades or sliding blocks on a transmission shift fork.
- brake disks can be reinforced in the region of the friction ring, wherein the advantage over the light metal increased wear resistance of the reinforcing element is utilized. Furthermore, by selective choice of the starting composition of the insert by application of the device according to the invention, a component in the form of a heat sink with low expansion coefficient at the same time high thermal conductivity can be produced (claim 9).
- the standard in the die-casting division of the casting process in three phases, supply, filling stroke and recompression, is in inventive method according to claim 10 in modified Form applied.
- the three phases are by the speed of the casting piston depending on the degree of filling the casting tool defined with the casting metal.
- the casting plunger slowly to move until the casting metal reaches the mold cavity (Flow) and then accelerate the casting piston (Filling stroke). But is there a porous insert in the Mold cavity, then it is advantageous, the casting piston only then to accelerate, if the insert already with the Casting metal is surrounded. This will damage the Inserted avoided and lowered the reject rate.
- the properties of the reinforcing element are different Requirements, thus it is in the sense of Invention useful, different for different applications ceramic raw powders as precursors of the insert consulted. Is z.
- ceramic raw powders as precursors of the insert consulted. Is z.
- titanium carbide or to use silicon carbide as raw powder.
- silicon carbide or the aluminum nitride is suitable ceramic raw powder.
- the mechanical ones Properties such as strength, modulus of elasticity, creep resistance or wear resistance considering the Raw material costs for the mode of action of the reinforcing element significant. According to these criteria find raw powder like Titanium oxide, spinel, mullite, aluminum silicates or clay minerals Use (claim 12).
- Fibers in composites generally works an increase in the ductility of a composite material. This is because the fibers absorb the energy of cracks and thus the composite material a higher Breaking resistance has. Here is the connection between especially important to the fiber and the matrix. It turned out that in the inventive method Metal fibers, in particular based on iron, chromium, Aluminum and yttrium achieved particularly high breaking resistance become. The most favorable thickness of the fibers lies in one area between 20 ⁇ m and 200 ⁇ m, in particular between 35 ⁇ m and 50 microns (claim 13).
- the speed of the casting piston is dependent on the Filling degree of the casting tool is an authoritative parameter of the inventive method. It turned out that the speed of the plunger during the flow between 0.1 m / s and 2 m / s is advantageous. In this interval can the speed of the casting piston during the Increase flow, if appropriate for the filling process is.
- the speed of the plunger during the filling stroke is according to the invention between 1 m / s and 5 m / s, so that a low speed in the forerun at a low speed linked during the filling stroke.
- the optimal Speeds depend on the geometry of each Mold cavity from and are therefore casting tool specific. in the general care should be taken in the lead the least possible Casting piston speed of the specified interval which guarantee a faultless representation of the component.
- the filling stroke should be as fast as possible take place at the specified interval.
- the optimal Speeds must be in the described intervals be determined separately for each component geometry (claim 14).
- the pressure of the recompression results from the speed of the casting piston during the filling stroke and from the G mankolbenweg during the filling stroke.
- the maximum pressure achieved during the re-compaction is accordingly lower than in the conventional die casting. He is generally in between 600 bar and 1200 bar, in most cases between 700 bar and 900 bar, whereby for a good infiltration a highest possible pressure is sought (claim 15).
- the temperature of the cast metal is in the inventive Especially when using aluminum or magnesium alloys between 680 ° C and 780 ° C.
- the temperature should be as high as possible so that during the filling of the mold cavity and in particular during the Infiltration of the insert the casting metal remains so hot that its temperature is above the liquidus temperature therefore remains liquid and does not set through which the pores of the insert are clogged could.
- the cast metal made of an aluminum alloy this decreases at temperature above 740 ° C hydrogen from the Air on what the quality of the component to be cast from it harm. For this reason, the optimum temperature of the Cast metal between 700 ° C and 740 ° C (claim 16).
- the insert at Preheat a temperature between 500 ° C and 800 ° C. Especially advantageous is a preheating temperature between 600 ° C and 700 ° C, there is thus a possible chemical reaction excluded between the casting metal and the insert is and at the same time a solidification of the casting metal is delayed (claim 17).
- the preheating of the insert can be done in an electrically heated Chamber furnace done, resulting in the production of components in small numbers is appropriate.
- a continuous furnace is particularly suitable for mass production. This will provide a continuous delivery the required inserts for production guaranteed
- a constant temperature of the inserts is adjustable (Claim 18).
- the inserts can be picked up by a casting robot and are inserted into the casting tool. This saves Time versus manual insertion and ensures Precise positioning of the insert in the casting mold (Claim 19).
- This Metals have a low density and are for potting in a die-casting well suited (claim 20).
- the insert is particularly well infiltrated by the cast metal, if it has a porosity between 30% and 80% especially at a porosity of 50% is a very good infiltration feasible with the insert a has comparatively high strength.
- the optimal pore diameter of the insert is between 1 .mu.m and 100 .mu.m preferably at 20 microns (claim 21).
- FIG. 1 shows a schematic diagram of a casting machine 12 with a casting tool 1, a casting run 2, a gate 3 with defined cross section and a mold cavity 4 with a device for positioning the insert 5 by fixing elements 7. Furthermore, there is the casting tool 1 of two parts, which are ready for casting in touch a parting line 15. One of these parts is a solid Page 16, with respect to the casting machine 12 when opening the casting tool 1 remains stationary, the other part is made from a movable side 17, which opens when the Casting tool 1 with respect to the casting machine 12 in the arrow direction emotional.
- the casting tool is attached to a casting machine 12, the a casting piston 11 of defined diameter comprises, through the casting metal 13 at a defined speed in the run 2 and in the further course through the gate 3 is pressed into the mold cavity 4 of the casting tool 1.
- the casting metal 13 For optimal filling of the casting tool 1 with the Casting metal 13, it is necessary that the casting metal 13 all Regions of the mold cavity 4 can reach unhindered. Due to its kinetic energy, the casting metal 13 exerts a Force on the insert 5, which lead to bending moments can, which can exceed the strength of the insert 5. For this reason, according to the invention, the insert 5 Protected by shielding 6 before the casting metal 13, so that the casting metal 13, the insert part 5 flows laterally. The Force on the insert 5 is thus reduced.
- the shielding element 6 in the form of a wall of the Mold cavity 4 is formed.
- the Fixation of the insert 5 is done so that the through Fixation acting forces lowest possible bending moments cause what is achieved according to the invention, by substantially through the fixing elements on the insert 5 occurring force counteracts a collinear force, the means, both forces lie on a straight line.
- FIG. 3 in another example, an annular one is shown Inserting part 5 shown in the fixed side 16 of the casting tool 1 is pushed onto a pin 9 and through more pins 9, which are mounted in the movable side 17 are, on the wall 18 of the mold cavity 4 of the fixed side 16th is pressed.
- the casting 2 is located directly below the Insertion, upon entry of the casting metal 13 in the mold cavity 4, this is done by the shielding element 6 on the insert 5 passed by.
- FIG 4 Another embodiment of the invention is shown in FIG 4, in which the parting plane of the fixed side 16 is shown.
- a cylindrical insert 5 is on two conical Sliders 14 attached.
- the sliders are either on the fixed side 16 or the movable side 17 and fixed can be so far out of the mold cavity 4 drive out that the component can be removed from the mold.
- the mobile and the fixed Side touch form fit in the parting plane 15th and can be separated to demould the component.
- the Shielding element 6 is located below the insert 5 and is configured in two parts in this example, wherein the one part in the fixed page 16, the other part in the movable side 17 is located.
- the principle of the one shown in FIG Embodiment is suitable for a liner in a cylinder crankcase as a reinforcing element display. It is possible to use only one slider, on the insert over its entire length is put on.
- an annular insert 5 is shown in FIG the fixed side 16 is positioned.
- the mold cavity 4 of fixed side 16 and the insert 5 are designed congruent so that within the manufacturing tolerances no leeway exist.
- the liquid casting metal is able to small column (> 0.1 mm) to penetrate.
- the warranty of tolerances ⁇ 0.1 mm is for porous ceramic Insert parts only with great effort possible, this is especially true then, taking into account that the mold cavity at the plane facing the parting plane 29 slopes to Removal of the component has. Accordingly, there is a spread of cast metal between the surfaces 29 and the insert 5 (which would lead to bending moments) among the mentioned Conditions possible in principle. This spread prevents the edge 10 of the movable side 17, simultaneously this edge 10 acts as a fixing element. In FIG. 5, this is Insert positioned so that facing the parting plane Surface 29 of the mold cavity 4 serves as a shielding element 6.
- FIG. 6 shows a sectional view of the mold cavity 4, in which a provided with holes insert 5 Pins 9 is placed in the fixed side 16 of the casting tool are attached. Further pins 9 are in the movable Page 17 attached and fix the insert 5 while maintaining the collinearity of the insert 5 acting forces. A fixation of the insert 5 according to FIG 6 is useful if by specifications of the component geometry in certain places, no external fixing elements allowed are.
- the pins 9 shown in Figure 5 on the movable Page 17 could according to the invention by edges or Noses be designed. Further, it is possible to use the mold cavity 4 so that the mold cavity wall 18 of the movable Page 17 is applied directly to the insert 5 and this fixes.
- the shielding element 6 is in this example mounted below the insert 5 so that it not touched.
- the supply line is filled at a low velocity of the casting piston V V (0.1 m / s-1.5 m / s) so far that the insert part 5 is already encapsulated with casting metal.
- the degree of filling 26 of the mold cavity 4 is for example about 80% ( Figure 7a).
- the casting piston 11 is accelerated during the filling stroke and the mold cavity is filled to 100% with casting metal at a higher speed of the casting piston V F (1 m / s - 5 m / s) (FIG. 7 b).
- FIG. 7 b FIG.
- FIG. 7 c shows the speed of the casting piston 11 v G as a function of the distance s G traveled by the casting piston.
- the first path of the advance s V takes place at the low speed v V up to the degree of filling of the mold cavity 26, which is shown in Figure 7a.
- the acceleration of the casting piston 11 to the speed v F which is maintained over the path of the Gresets s F to complete filling of the mold cavity ( Figure 7b).
- the casting piston 11 is braked abruptly (recompression), the speed drops to v N , with the casting plunger 11 for recompression of the cast metal moves only slightly s N.
- the insert part is infiltrated with the cast metal, which leads to the movement of the casting piston 11 s N.
- the degree of filling 26 at the beginning of the filling stroke depends on the position of the insert 5 in the mold cavity 4 and on the geometry of the component and is between 10% and 90%. The least stress would experience the insert 5, if no acceleration would take place during the Grehubs. In this case, however, an optimal filling of the mold cavity 4 with the casting metal 13 could not be guaranteed.
- the optimum filling of the mold cavity 4 and the mechanical loading of the insert 5 are two criteria that are directly but counteracted by the speed of the cast metal 13 during the Grehubs. In order to meet both criteria, in practice, a degree of filling has proven that is between 50% and 80%.
- FIG. 8 shows an enlarged schematic representation of a Penetration structure of the reinforcing element 25.
- the ceramic Material phase 27 of the reinforcing element 25 is three-dimensional networked and has an open pore system, that through the infiltrated casting metal, the metallic material phase 28, completely filled out. That in the interpenetration structure present metal is solidified with the Casting metal, which was represented by the component, identical and with this in a transitional layer continuously connected. Both material phases together form a dense and pore-free penetration structure.
- the resulting powder now had a bulk density of 0.942 g / cm 3 .
- a powder having the above-mentioned composition was mixed for 5 minutes at stage II in a star rotor mixer.
- the powder subsequently had a bulk density of 1.315 g / cm 3 .
- the dried green body was heated in a tunnel oven with air in 60 min at 100 ° C and heated at this temperature for 90 min, then followed by further temperature ramps, in 300 min at 400 ° C and in more 60 minutes at 550 ° C. At this point, further heating of the green body up to 1150 ° C is possible, which contributes to increasing its strength.
- the cooled green body treated at a temperature of 550 ° C subsequently exhibited a compressive strength of about 15 MPa, a flexural strength of 3 MPa, and a porosity of about 45%.
- Green bodies annealed at 1150 ° C for 1 h showed a flexural strength of 30 MPa and a porosity of 35%.
- Green bodies which have been produced and processed by the process described are referred to below as inserts.
- the porous ceramic insert 5 was preheated to a temperature of 500 ° C to prevent premature cooling of the cast metal by the insert. Subsequently, it was inserted in a defined position in a casting tool and fixed according to the invention. Thereafter, the mold was closed and the mold cavity for molding the entire component with aluminum or aluminum alloy poured.
- aluminum or aluminum alloy poured.
- 99.9% pure aluminum or all aluminum alloys suitable for die casting can be used for this purpose (for example GD 226 or GD 231).
- the tool was tempered during the casting process to 300 ° C.
- the specific pressure of the cast metal was between 600 and 800 bar, the temperature was about 680 to 750 ° C. The pressure was built up during the filling stroke after a 60% filling of the casting tool.
- the duration of the filling of the casting tool was 100 ms at a piston speed of about 0.2 m / s (flow) to 1.8 m / s (filling stroke).
- the closing time of the casting tool was about 10 s to 40 s.
- an aluminum die casting member having a reinforcing member of titanium oxide and aluminum having a bending strength of 400 MPa, a thermal conductivity of about 60 W / mK and a density of about 3.1 g / cm 3 is obtained .
- the insert When pouring the casting tool, the insert is infiltrated with the aluminum alloy AlSi9Cu3 (GD226) and at the same time the remaining intermediate areas in the casting tool, which have no insert part, are poured out with the metal.
- a component to be manufactured can be adapted in a favorable manner to its respective intended use.
- the remaining empty areas of the die, which enclose the later crankcase, then represent the intermediate areas.
- the pouring of the casting tool or the infiltration of the insert takes place at a filling temperature which is above the liquidus temperature of the cast metal, but is so low that no reaction takes place with the ceramic insert.
- the filling temperature is below 750 ° C.
- the resulting brake disk can be heated after filling in the region of the friction surfaces of the later friction ring in a conventional manner at or above a reaction temperature at which an intermetallic-ceramic composite material is formed. The heating thus takes place selectively with respect to the brake disk. It can be done by induction or by laser heating.
- the energy input may be controlled to result in a gradient whereby the ceramic-metal composite of the reinforcing element steplessly merges into the intermetallic-ceramic composite.
- Example 1 Analogously to Example 1 was a porous ceramic insert made using AlN as a ceramic powder and infiltrated with aluminum under the same conditions.
- the die casting tool provided a heat sink for power electronics
- the ceramic matrix reinforces the upper area of the heat sink, causing an adjustment of the expansion coefficient between electronic substrate and heat sink is created at the same time high thermal conductivity.
- Example 2 Analogous to Example 2 was a porous ceramic insert prepared using SiC as raw powder and infiltrated with aluminum under the same conditions.
- a porous ceramic insert was prepared using TiO 2 as a ceramic powder and infiltrated under the same conditions with a magnesium alloy (AZ 91).
- a porous ceramic insert was produced using TiO 2 as a ceramic powder.
- 30% by volume (based on the total powder volume) of carbon reinforcing fibers in the form of short fibers having a length of 3 to 15 mm were added to the mixture.
- the porous ceramic insert was infiltrated with aluminum under the same conditions.
- a porous ceramic insert was produced using TiO 2 as a ceramic powder.
- the insert was cold isostatically pressed in the form of a cylinder and infiltrated with aluminum under the same conditions.
- the resulting component is a cylinder crankcase with a cylinder liner represented by a reinforcing member.
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- Crystallography & Structural Chemistry (AREA)
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- Cylinder Crankcases Of Internal Combustion Engines (AREA)
Description
Weitere mechanisch belastete Bauteile oder Funktionselemente, die durch Verstärkungselemente verstärkt werden können, sind beispielsweise Pleuel, Turboladerschaufeln oder Gleitsteine auf einer Getriebeschaltgabel. Ferner können Bremsscheiben im Bereich des Reibringes verstärkt werden, wobei die gegenüber dem Leichtmetall erhöhte Verschleißbeständigkeit des Verstärkungselementes ausgenutzt wird.
Des weiteren kann durch gezielte Wahl der Ausgangszusammensetzung des Einlegeteils durch Anwendung der erfindungsgemäßen Vorrichtung ein Bauteil in Form eines Kühlkörpers mit geringem Ausdehnungskoeffizienten bei gleichzeitig hoher Wärmeleitfähigkeit hergestellt werden (Anspruch 9).
- Fig. 1
- in einem ersten Beispiel eine Prinzipdarstellung einer Druckgußmaschine mit einer Schnittansicht eines Gießwerkzeuges, mit einem Einlegeteil und einem Gießkolben,
- Fig. 2
- in einem zweiten Beispiel eine vergrößerte Schnittansicht eines Gießwerkzeugdetails, mit einem in diesem angeordneten Einlegeteil, Fixierelementen und Abschirmelement,
- Fig. 3
- in einem dritten Beispiel eine vergrößerte Schnittansicht eines Gießwerkzeugdetails, mit einem Einlegeteil, Fixierelementen und Abschirmelement,
- Fig. 4
- in einem vierten Beispiel eine vergrößerte Schnittansicht eines Gießwerkzeugdetails, in der ein Abschirmelement und ein Einlegeteil, das auf einem Schieber des Gießwerkzeugs positioniert ist, gezeigt ist,
- Fig. 5
- in einem fünften Beispiel eine vergrößerte Schnittzeichnung eines Gießwerkzeugdetails mit einem ringförmigen Einlegeteil und Fixirelementen,
- Fig. 6
- in einem sechsten Beispiel eine vergrößerte Schnittzeichnung eines Gießwerkzeugdetails, mit einem Einlegeteil, in dem sich Bohrungen befinden und das auf Fixierelemente des Gießwerkzeuges aufgesteckt ist,
- Fig. 7a, 7b und 7c
- einen schematischen Verlauf der Befüllung eines Formhohlraums mit einem Gießmetall,
- Fig. 8
- ein Durchdringungsgefüge mit einer metallischen Materialphase und einer keramischen Materialphase.
Der konventionelle Druckgußvorgang ist zeitlich in drei Phasen unterteilt. In einer ersten Phase bewegt sich der Gießkolben 11 (vgl. Figur 1) mit einer konstanten Geschwindigkeit soweit, daß der Gießlauf 2 des Gießwerkzeuges 1 mit Gießmetall 13 gefüllt wird (Vorlauf). In einer zweiten Phase, dem Füllhub, wird der Gießkolben 11 beschleunigt und der Formhohlraum 4 mit Gießmetall 13 befüllt. In einer dritten Phase wird der Gießkolben 11 schlagartig abgebremst, da das gesamte Gießwerkzeug 1 mit Gießmetall 13 gefüllt ist, wobei gleichzeitig ein Druck auf das Gießmetall 13 im Gießwerkzeug 1 aufgebaut wird, der bis zu 1200 bar betragen kann (Nachverdichten). Durch das Nachverdichten wird einer Schrumpfung des Bauteils durch eine Erstarrung des Gießmetalls 13 entgegengewirkt, gleichzeitig wird in dem erfindungsgemäßen Verfahren der Druck des Gießmetalls 13 zur Infiltration des Einlegeteils 5 genutzt.
Die Geschwindigkeit des Gießmetalls 13 während des Füllhubs kann je nach Auslegung des Gießwerkzeuges 1 bis zu zehn mal so hoch sein wie die Geschwindigkeit im Vorlauf. Die Füllhubgeschwindigkeit beträgt im Anschnitt 3 üblicherweise zwischen 30 m/s und 50 m/s. Allgemein wird die Geschwindigkeit des Gießmetalls im Anschnitt vA mit folgender Formel berechnet:
Der Füllgrad 26 zu Beginn des Füllhubs ist abhängig von der Position des Einlegeteils 5 im Formhohlraum 4 und von der Geometrie des Bauteils und beträgt zwischen 10 % und 90 %. Die geringste Belastung würde das Einlegeteil 5 erfahren, wenn keine Beschleunigung während des Füllhubs stattfinden würde. Hierbei könnte jedoch eine optimale Befüllung des Formhohlraums 4 mit dem Gießmetall 13 nicht gewährleistet werden. Die optimale Befüllung des Formhohlraums 4 und die mechanische Belastung des Einlegeteils 5 sind zwei Kriterien, die direkt aber gegenläufig von der Geschwindigkeit des Gießmetalls 13 während des Füllhubs beeinflußt werden. Um beide Kriterien erfüllen zu können, hat sich in der Praxis ein Füllgrad bewährt, der zwischen 50 % und 80 % liegt.
Der abgekühlte Grünkörper, der bei einer Temperatur von 550° C behandelt wurde wies anschließend eine Druckfestigkeit von ca. 15 MPa, eine Biegefestigkeit von 3 MPa und eine Porosität von etwa 45 % auf. Grünkörper, die bei 1150° C 1 h geglüht wurden, zeigten eine Biegefestigkeit von 30 MPa und eine Porosität von 35 %. Grünkörper, die nach dem beschriebene Verfahren hergestellt und bearbeitet wurden werden im folgenden Einlegeteile genannt.
Das Ausgießen des Gießwerkzeuges bzw. die Infiltration des Einlegeteils erfolgt bei einer Befüllungstemperatur, die oberhalb der Liquidustemperatur des Gießmetalls liegt, aber so niedrig ist, daß keine Reaktion mit dem keramischen Einlegeteil stattfindet. Insbesondere bei Aluminium als befüllendes Metall liegt die Befüllungstemperatur unterhalb 750°C. Bei der Bremsscheibenherstellung kann die resultierende Bremsscheibe nach dem Befüllen im Bereich der Reibflächen des späteren Reibrings in an sich bekannter Weise auf oder oberhalb einer Reaktionstemperatur erhitzt, werden, bei der ein Intermetallic-Keramik-Verbundwerkstoff entsteht. Die Erhitzung erfolgt bezüglich der Bremsscheibe also selektiv. Sie kann durch Induktions- oder durch Laserbeheizung erfolgen. Der Energieeintrag kann so gesteuert werden, daß ein Gradient resultiert, wobei der Keramik-Metall-Verbundwerkstoff des Verstärkungselement stufenlos in den Intermetallic-Keramik-Verbundwerkstoff übergeht.
Claims (21)
- Gießwerkzeug (1) mit einer Fixierung und einem Einlegeteil (5) zur Herstellung eines durch das Einlegeteil (5) lokal verstärkten Bauteils, wobei das Gießwerkzeug (1) Abschirmelemente (6) umfaßt, mittels welcher das Einlegeteil während des Gießvorgangs vom Hauptausbreitungsstrom eines Gießmetalls (13) abgeschirmt ist,
dadurch gekennzeichnet, daßdas Einlegeteil (5) ein poröses keramisches Einlegeteil (5) ist,das eine Porosität zwischen 30 % und 80 % aufweist undzur Infiltration mit einem Gießmetall (13) geeignet ist,und das Gießwerkzeug (1) ein Druckgießwerkzeug ist, dasFixierelemente (7, 8, 9, 10) zur Positionierung des Einlegeteils (5) aufweist, durch die auf das Einlegeteil (5) wirkende Kräfte durch entsprechende kollineare Kräfte ausgleichbar sind. - Gießwerkzeug (1) nach Anspruch 1
dadurch gekennzeichnet, daß
das Einlegeteil in einer festen Seite des Gießwerkzeugs (16) und/oder in einer beweglichen Seite des Gießwerkzeugs (17) und/oder auf einem Schieber des Gießwerkzeugs (14) positioniert ist. - Gießwerkzeug (1) nach Anspruch 1 oder 2,
dadurch gekennzeichnet, daß
das Einlegeteil (5) paßgenau an einer Wand (18) eines Formhohlraums (4) anliegt. - Gießwerkzeug (1) nach einem der Ansprüche 1 bis 3,
dadurch gekennzeichnet, daß
die endgültige Positionierung und Fixierung des Einlegeteils (5) im Gießwerkzeug (1) beim Schließen des Gießwerkzuegs (1) erfolgt. - Gießwerkzeug (1) nach einem der Ansprüche 1 bis 4,
dadurch gekennzeichnet, daß
der Übergang zwischen dem Einlegeteil (5) und der diesem benachbarten Wand (18) des Formhohlraums (4) durch Kanten eines korrospondierenden Teils des Gießwerkzeugs und/oder durch einen Schieber (14) gegenüber dem Gießmetall abdichtbar ist. - Gießwerkzeug (1) nach Anspruch 1 oder 2,
dadurch gekennzeichnet, daß
das Einlegeteil (5) frei im Raum des Gießwerkzeuges (1) positioniert ist und durch Stifte (9) und/oder Nasen (8) und/oder Kanten (10) gehalten ist und von allen Seiten eine isostatische Infiltration ermöglicht ist. - Gießwerkzeug (1) nach einem der Ansprüche 1 bis 6,
dadurch gekennzeichnet, daß
das Einlegeteil (5) mit Bohrungen (19) versehen ist und auf Stifte (9) des Gießwerkzeugs (1) aufsetzbar ist. - Gießwerkzeug (1) nach einem der Ansprüche 1 bis 7,
dadurch gekennzeichnet, daß
das Gießwerkzeug (1) einen Anschnitt (3) mit einer definierten Querschnittsfläche zur Befüllung eines Formhohlraums (4) umfaßt und daß die Querschnittsfläche so groß gewählt wird, daß die Geschwindigkeit des Gießmetalls (13) gegenüber der Geschwindigkeit eines Gießkolbens (11) beim Eintritt in den Formhohlraum (4) weniger als das Achtfache beträgt. - Gießwerkzeug (1) nach einem der vorhergehenden Ansprüche,
dadurch gekennzeichnet, daß
das Bauteil ein Funktionsbauteil im Verbrennungsmotor, im Getriebe eines Automobils oder eine Bremsscheibe, oder ein Kühlkörper ist. - Verfahren zur Herstellung eines Bauteils mit einem lokalen Verstärkungselement (25) aus einem Metall-Keramik-Verbund-Material umfassend folgende Schritte:lokale Positionierung eines Einlegeteils (5) in einem Gießwerkzeug (1), das einen Gießlauf (2), einen Anschnitt (3) und einen Formhohlraum (4) aufweist,befüllen des Gießwerkzeuges (1) mit einem Gießmetall (13) zur Darstellung des lokalen Verstärkungselementes (25)das Einlegeteil (5) aus keramischen Vorprodukten hergestellt wird und eine Porosität zwischen 30 % und 80 % aufweist,die Befüllung des Gießwerkzeuges durch einen Gießkolben erfolgt,ein Vorlauf die Befüllung des Gießlaufs (2) und die Befüllung von mindestens 10 % des Formhohlraums (4) mit dem Gießmetall (13) umfaßt und daßdie Geschwindigkeit des Gießkolbens (11) während des Vorlaufs geringer ist als während eines Füllhubs,das Einlegeteil (5) bei erhöhtem Druck zur Darstellung des Verstärkungselementes (25) mit dem Gießmetall infiltriert wird.
- Verfahren nach Anspruch 10,
dadurch gekennzeichnet, daß
das lokale Verstärkungselement (25) des Bauteils aus einer keramischen Materialphase (27) und einer metallischen Materialphase (28) besteht, wobei jede Materialphase ein eigenes dreidimensionales Gerüst aufweist und beide Materialphasen zusammen in Form eines Durchdringungsgefüges vorliegen. - Verfahren nach Anspruch 10 oder 11,
dadurch gekennzeichnet, daß
das Rohpulver des keramischen Vorprodukts entweder aus einzelnen der folgenden Bestandteile oder Mischungen hieraus besteht: TiO2, SiO2, TiC, SiC, Spinell, Mullit, Aluminiumsilikate Tonmineralien. - Verfahren nach einem der Ansprüche 10 bis 12,
dadurch gekennzeichnet, daß
daß dem keramischen Vorprodukt zur Herstellung des Einlegeteils (5) keramische, metallische, mineralische oder Kohlenstoff-Fasern in Form von Lang- oder Kurzfasern, Filzen oder Geweben beigegeben werden. - Verfahren nach einem der Ansprüche 10 bis 13,
dadurch gekennzeichnet, daß
die Geschwindigkeit des Gießkolbens (11) während des Vorlaufs zwischen 0,1 m/s und 2 m/s beträgt und während des Füllhubs zwischen 1 m/s und 5 m/s beträgt. - Verfahren nach einem der Ansprüche 10 bis 14
dadurch gekennzeichnet, daß
der Maximaldruck auf das Gießmetall zwischen 600 bar und 1200 bar, insbesondere zwischen 700 bar und 900 bar liegt. - Verfahren nach einem der Ansprüche 10 bis 15,
dadurch gekennzeichnet, daß
die Temperatur des Gießmetalls für Aluminium- oder Magnesiumlegierungen (13) zwischen 680 und 780°C, vorzugsweise zwischen 700°C und 740°C beträgt. - Verfahren nach einem der Ansprüche 10 bis 16,
dadurch gekennzeichnet, daß
das Einlegeteil (5) auf eine Temperatur zwischen 500 °C und 800°C insbesondere zwischen 600°C und 700°C vorgeheizt wird. - Verfahren nach Anspruch 17,
dadurch gekennzeichnet, daß
das Vorheizen des Einlegeteils in einem Kammerofen oder in einem Durchlaufofen erfolgt. - Verfahren nach einem der vorhergehenden Ansprüche,
dadurch gekennzeichnet, daß
das Einlegen des Einlegeteils (5) in das Gießwerkzeug (1) mit Hilfe eines Gießroboters erfolgt. - Verfahren nach einem der vorhergehenden Ansprüche,
dadurch gekennzeichnet, daß
das Gießmetall (13) aus Aluminium oder aus Magnesium oder aus einer Aluminium-Legierung oder einer Magnesium-Legierung besteht. - Verfahren nach einem der vorhergehenden Ansprüche,
dadurch gekennzeichnet, daß
der Porendurchmesser des Einlegeteils zwischen 1 µm und 100 µm beträgt.
Applications Claiming Priority (3)
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DE19917175 | 1999-04-16 | ||
DE19917175A DE19917175A1 (de) | 1999-04-16 | 1999-04-16 | Verfahren zum Herstellen eines Bauteiles und Bauteil |
PCT/EP2000/002935 WO2000062959A1 (de) | 1999-04-16 | 2000-04-01 | Giesswerkzeug und verfahren zur herstellung eines bauteils |
Publications (3)
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EP1183120A1 EP1183120A1 (de) | 2002-03-06 |
EP1183120B1 true EP1183120B1 (de) | 2003-05-28 |
EP1183120B2 EP1183120B2 (de) | 2006-08-16 |
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ID=7904759
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EP00920651A Expired - Lifetime EP1183120B2 (de) | 1999-04-16 | 2000-04-01 | Giesswerkzeug und verfahren zur herstellung eines bauteils |
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Country | Link |
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US (1) | US6648055B1 (de) |
EP (1) | EP1183120B2 (de) |
JP (1) | JP3420572B2 (de) |
DE (2) | DE19917175A1 (de) |
ES (1) | ES2197088T3 (de) |
WO (1) | WO2000062959A1 (de) |
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-
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- 1999-04-16 DE DE19917175A patent/DE19917175A1/de not_active Ceased
-
2000
- 2000-04-01 DE DE50002369T patent/DE50002369D1/de not_active Expired - Lifetime
- 2000-04-01 JP JP2000612086A patent/JP3420572B2/ja not_active Expired - Fee Related
- 2000-04-01 EP EP00920651A patent/EP1183120B2/de not_active Expired - Lifetime
- 2000-04-01 WO PCT/EP2000/002935 patent/WO2000062959A1/de active IP Right Grant
- 2000-04-01 US US09/958,947 patent/US6648055B1/en not_active Expired - Fee Related
- 2000-04-01 ES ES00920651T patent/ES2197088T3/es not_active Expired - Lifetime
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102005043193A1 (de) * | 2005-09-09 | 2007-03-15 | Ks Aluminium-Technologie Ag | Zylinderkurbelgehäuse für Kraftfahrzeuge |
CN107824764A (zh) * | 2017-10-26 | 2018-03-23 | 洛阳西格马炉业股份有限公司 | 一种金属包覆陶瓷碎片型新材料的制备方法 |
CN107824764B (zh) * | 2017-10-26 | 2019-09-27 | 洛阳西格马炉业股份有限公司 | 一种金属包覆陶瓷碎片型材料的制备方法 |
Also Published As
Publication number | Publication date |
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JP3420572B2 (ja) | 2003-06-23 |
WO2000062959A1 (de) | 2000-10-26 |
US6648055B1 (en) | 2003-11-18 |
DE50002369D1 (de) | 2003-07-10 |
EP1183120A1 (de) | 2002-03-06 |
EP1183120B2 (de) | 2006-08-16 |
JP2002542035A (ja) | 2002-12-10 |
ES2197088T3 (es) | 2004-01-01 |
DE19917175A1 (de) | 2000-10-19 |
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