EP1183120B2 - Giesswerkzeug und verfahren zur herstellung eines bauteils - Google Patents

Giesswerkzeug und verfahren zur herstellung eines bauteils Download PDF

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Publication number
EP1183120B2
EP1183120B2 EP00920651A EP00920651A EP1183120B2 EP 1183120 B2 EP1183120 B2 EP 1183120B2 EP 00920651 A EP00920651 A EP 00920651A EP 00920651 A EP00920651 A EP 00920651A EP 1183120 B2 EP1183120 B2 EP 1183120B2
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EP
European Patent Office
Prior art keywords
insert
casting
die
metal
filling
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.)
Expired - Lifetime
Application number
EP00920651A
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German (de)
English (en)
French (fr)
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EP1183120A1 (de
EP1183120B1 (de
Inventor
Tilmann Haug
Steffen Rauscher
Kolja Rebstock
Michael Scheydecker
Markus Walters
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Mercedes Benz Group AG
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DaimlerChrysler AG
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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
    • 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
    • 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 method for producing a component according to claims 1 and 6.
  • a generic method is known from DE 197 10 671 C2. This shows a method in which a porous sacrificial body made of a ceramic material (insert) is inserted in a defined position in a casting mold and infiltrated under pressure with a molten metal (casting metal). The infiltration of the insert with the casting metal creates a metal-ceramic composite (reinforcing element) at the location of the insert. Thereafter, the molded component is heated so that a reaction between the ceramic material and the cast metal takes place within the reinforcing element, resulting in a composite material of ceramic and intermetallic material phases, which exceeds the reinforcing element in terms of wear resistance and rigidity.
  • the heating of the component however, can be realized only with high technical complexity and high production costs, in particular for local reinforcements. Furthermore, due to the process, due to bending stresses, damage to the insert during infiltration may occur.
  • JP 60130460 A describes a method for producing a composite component, which is produced by centrifugal casting.
  • a core of ceramic fibers is placed in a centrifugal casting tool and supported by holding elements.
  • the holding elements direct the flow of a casting metal past the core, so that after solidification a layered tube is formed which contains the core of ceramic fibers and is made of metal on the surfaces.
  • a method of this kind is not suitable for the infiltration of porous ceramic Insert parts, as there is no sufficient pressure on the insert.
  • the object of the present invention is therefore to provide a casting tool and a further improved method of the type mentioned above, so that light metal components with improved mechanical strength, in particular improved creep resistance are simple and inexpensive to produce.
  • the solution of the problem consists in a device (casting tool) with the features of claim 1 and a method according to claim 6.
  • the inventive device according to claim 1 is characterized in that fixing elements are mounted in the casting tool, which position the insert position defined, wherein the insert is positioned freely in the space of the casting tool and is held by pins and / or lugs and / or edges and of all sides an isostatic infiltration is possible.
  • the Fixleriata are designed so that the bending moments acting on the insert are minimized. This is done according to the invention so that forces acting on the insert by the fixing elements are compensated by collinear forces. That is, the lines of force of opposite forces lie on a straight line.
  • the insert is positioned in a mold cavity such that it does not lie directly in the flow of propagation of a cast metal. In order to realize this, shielding elements are used.
  • these shielding elements are components of the mold cavity contour, such as edges or walls, which are predetermined by the component geometry.
  • additional fixing elements so that they shield the flow of the casting metal relative to the insert. Together, the fixing and the shield prevent damage to the ceramic insert and thus reduce the reject rate in a mass production of reinforced light metal components.
  • the endg′′ige fixation of the insert takes place when closing the casting tool.
  • the insert is positioned freely in the space of the mold cavity
  • the fixation is carried out according to the invention by fixing.
  • the infiltration of the insert takes place after complete filling of the mold cavity evenly from all sides, that is isostatic. Isostatic infiltration has the advantage that the bending moments acting on the insert are minimized
  • the insert with holes and to position pins that are located on the fixed side or the movable side or on a slide in an exact fit. This is advantageous if the construction of the component to be produced locally does not allow any fixing elements in the mold cavity, which are imaged in the component as cavities
  • the cross-section of a casting piston which carries the casting metal is usually larger than the cross-section of the opening of the mold cavity (gate): this results in an acceleration of the casting metal as it enters the mold cavity at a constant speed of the casting piston.
  • the speed of the cast metal in the region of the insert should not be greater than eight times the maximum G deskkotben für. Therefore, the cross section of the Ariiteses should not be less than about one-eighth of the cross-section of the casting piston
  • 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 curb casing and / or in the crankcase bottom 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 expansion coefficient 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 applying the device according to the invention, a component in the form of a heat sink with low expansion coefficient and simultaneously high thermal conductivity produced.
  • the customary in standard die casting division of the casting process in three phases, flow, Medhub and re-densification is applied in modified form according to the method of claim 6 in the invention
  • the three phases are defined by the speed of the casting piston as a function of the degree of filling of the casting tool with the casting metal.
  • the degree of filling of the mold cavity at the onset of the filling stroke depends on the position of the insert in the component and can be between 10% and 90%; in practice, a degree of filling of the mold cavity at the beginning of the mold cavity Filling strokes between 50% and 80% particularly well proven.
  • the use of fibers in composites generally causes an increase in the ductility of a composite material. This is because the fibers absorb the energy of cracks and thus the composite material has a higher resistance to breakage.
  • the connection between the fiber and the matrix is particularly important. It has been found that in the method according to the invention by metal fibers in particular based on iron, chromium, aluminum and yttrium particularly high fracture resistance can be achieved.
  • the most favorable thickness of the fibers is in a range between 20 .mu.m and 200 .mu.m, in particular between 35 .mu.m and 50 .mu.m.
  • the speed of the casting piston is dependent on the degree of filling of the casting tool a significant parameter of the method according to the invention. It has been found that the speed of the casting piston during the flow between 0.1 m / s and 2 m / s is beneficial In this interval, the speed of the casting piston during the flow increase, if this is appropriate for the filling process. According to the invention, the speed of the casting piston during the filling stroke is between 1 m / s and 5 m
  • the filling stroke should be carried out with the highest possible speed at the specified interval.
  • the optimum speeds in the described intervals must be determined separately for each component geometry.
  • the pressure of the re-compression results from the velocity of the casting piston during the filling stroke and from the casting piston during the Grehubs.
  • the filling stroke sets in later than in the conventional die-casting, the maximum pressure achieved during the Nachverêtns is accordingly lower than in the conventional die-casting. It is generally between 600 bar and 1200 bar, in most cases between 700 bar and 900 bar, with a good infiltration as high pressure is desirable.
  • the temperature of the cast metal is in the inventive method, in particular when using aluminum or magnesium alloys between 700 and 740 ° 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, thus remains liquid and no solidification sets in, through which the pores of the insert could be blocked. If the casting metal consists of an aluminum alloy, this absorbs hydrogen from the air at temperatures above 740 ° C, which damages the quality of the component to be cast. For this reason, the temperature of the casting metal is between 700 ° C and 740 ° C.
  • the insert is provided according to the invention to preheat the insert at a temperature between 600 ° C and 700 ° C.
  • This preheating temperature is particularly advantageous, which is between 600 ° C and 700 ° C, since thus a possible chemical reaction between the casting metal and the insert is excluded and at the same time a solidification of the casting metal is delayed.
  • the preheating of the insert can be done in an electrically heated chamber furnace, which is useful in the manufacture of components in small numbers. As part of a series production, however, a continuous furnace is particularly suitable. As a result, a continuous provision of the required inserts for production is ensured and also a constant temperature of the inserts is adjustable. In the further course of the process chain, the inserts can be picked up by a casting robot and inserted into the casting tool. This saves time compared to a manual insert and ensures a precise positioning of the insert in the casting mold.
  • the insert is particularly well infiltrated by the casting metal, if it has a porosity between 30% and 80% in particular at a porosity of 50% is a very good infiltration feasible with the insert has a comparatively high strength
  • the optimum pore diameter of the insert is between 1 .mu.m and 100 .mu.m, preferably at 20 microns.
  • Figure 1 shows a Prinzipdarsteltung a casting machine 12 which is suitable for the process according to the invention with a casting tool 1, which comprises a casting 2, a gate 3 with a defined cross section and a mold cavity 4 with a device for positioning of the insert 5 by fixing elements 7. Furthermore, the casting tool 1 consists of two parts which touch each other in the casting-ready state in a parting plane 15. One of these parts is a fixed side 16, which remains stationary with respect to the casting machine 12 when opening the casting tool 1, the other part consists of a movable side 17 which moves when opening the casting tool 1 with respect to the casting machine 12 in the arrow direction
  • the casting tool is attached to a casting machine 12, which comprises a casting piston 11 of defined diameter, through which the casting metal 13 is pressed at a defined speed in the casting 2 and in the further course through the gate 3 in the mold cavity 4 of the casting mold 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 can reach all areas of the mold cavity 4 unhindered. Due to its kinetic energy, the cast metal 13 exerts a force on the insert part 5, which can lead to bending moments that can rise above the strength of the insert part 5. For this reason, according to the invention, the insert 5 is protected by shielding elements 6 from the cast metal 13, so that the casting metal 13, the insert part 5 laterally flows around the force on the insert 5 is thus reduced
  • the shielding element 6 is designed in the form of a wall of the mold cavity 4. To further reduce the forces acting on the insert 5 forces, it is necessary that the fixing of the insert 5 is effected so that the forces acting through the fixing forces cause the lowest possible bending moments, which is achieved according to the invention, by essentially by the fixing on the insert. 5 occurring force counteracts a kolüneäre force, that is, both forces are on a straight line.
  • a rectangular insert 5 is fixed from below by a shielding element 6, which in this example is in the form of an edge 10.
  • the fixing takes place, taking into account the collinearity of the forces also by an edge 10.
  • the horizontal fixation of the insert is made by pins. 9
  • annular insert 5 is shown, which is slid in the fixed side 16 of the casting tool 1 on a pin 9 and by further pins 9, which are mounted in the movable side 17, to the wall 18 of the mold cavity 4 of the fixed side 16 is pressed.
  • the casting run 2 is located directly under the insert, when the casting metal 13 enters the mold cavity 4 it is guided past the insert 5 by the shielding element 6
  • FIG. 4 A further embodiment according to the invention is shown in FIG. 4, in which the parting plane of the fixed side 16 is shown.
  • a cylindrical insert 5 is mounted on two conical slides 14.
  • the slides are mounted either on the fixed side 16 or the movable side 17 and can be so far out of the mold cavity 4 drive out that the component can be removed from the mold.
  • the movable and the fixed side touch positively in the parting plane 15 and can be separated for removal of the component.
  • the shielding element 6 is located below the insert 5 and is in this example designed in two parts, wherein one part is in the fixed side 16, the other part in the movable side 17.
  • the principle of the embodiment shown in Figure 4 is suitable for a Bushing in a Zylinderkurbefgehause represent as a reinforcing element. It is possible to use only a slider on which the insert is placed over its entire length.
  • annular insert 5 is shown for the inventive method, which is positioned in the fixed side 16.
  • the mold cavity 4 of the fixed side 16 and the insert 5 are designed congruent, so that within the production tolerances no margin exists
  • the liquid casting metal is however, able to penetrate small gaps (> 0.1 mm).
  • the guarantee of tolerances ⁇ 0.1 mm is possible with porous ceramic inserts only with great effort, this is especially true when one considers that the mold cavity has on the surfaces facing the parting plane 29 slopes for demolding of the component Accordingly, a spread of Casting metal between the surfaces 29 and the insert 5 (which would lead to lead moments) under the conditions mentioned in principle possible. This spread prevents the edge 10 of the movable side 17, at the same time this edge 10 acts as a fixing.
  • the insert is positioned so that the plane facing the parting surface 29 of the mold cavity 4 serves as a shielding element 6
  • FIG. 6 a sectional view of the mold cavity 4 is shown for the inventive method in which a bored insert 5 is placed on pins 9, which are fixed in the fixed side 16 of the casting tool. Further pins 9 are fixed in the movable side 17 and fix the insert 5 while maintaining the collinearity of the forces acting on the insert 5 forces.
  • a fixing of the insert 5 according to FIG. 6 is expedient if, due to specifications of the component geometry, no outer fixing elements are permissible at specific locations.
  • the pins 9 on the movable side 17 shown in FIG. 5 could also be designed according to the invention by edges or noses.
  • the supply line is filled at a low velocity of the casting piston vV (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 cast metal at a higher speed of the casting piston vF (1 m / s-5 m / s) (FIG. 7 b).
  • FIG. 7 b FIG.
  • FIG. 7c shows the speed of the casting piston 11 vG as a function of the path sG traveled by the casting piston.
  • the first path of the flow sV is carried out at the low speed vV up to the degree of filling of the mold cavity 26, which is shown in Figure 7a, followed by the acceleration of the casting plunger 11 to the speed vF, over the path of the filling stroke sF to the complete filling of Mold cavity is maintained ( Figure 7b).
  • the casting piston 11 is braked abruptly (recompression), the speed drops to vN, wherein the casting plunger 11 for recompression of the casting metal moves only slightly sN.
  • the insert In this phase of the recompression, the insert is infiltrated with the cast metal, resulting in the movement of the plunger 11 sN.
  • 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-dimensionally crosslinked and has an open pore system which is completely filled by the infiltrated casting metal, the metallic material phase 28.
  • the metal present in the interpenetration structure is identical to the solidified cast metal represented by the component and continuously connected to it in a transition layer. Both material phases together form a dense and pore-free penetration structure.
  • the resulting powder now had a bulk density of 0.942 g / cm3.
  • a powder with the o.g. Composition mixed in a radial rotor mixer for 5 minutes at stage II.
  • the powder subsequently had a bulk density of 1.315 g / cm 3.
  • the dried green body was heated in a tunnel oven with access of air in 60 min at 100 ° C and heated at this temperature for 90 min, then followed by further temperature ramps, in 300 min to 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 body at the 1150 ° C were annealed 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. 2. Pressure infiltration
  • 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 mold and fixed according to the invention. Thereafter, the casting mold was closed and the mold cavity for molding the entire component with aluminum or an aluminum alloy.
  • aluminum or an aluminum alloy for example, 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 Zuhattezeit the casting tool was about 10 s to 40 s.
  • an aluminum die casting member having a reinforcing member made of titanium oxide and aluminum having a flexural strength of 400 MPa, a thermal conductivity of about 60 W / mK and a density of about 3.1 g / cm 3 was 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 surround 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 casting metal, but is so low that no reaction takes place with the ceramic insert Particularly in the case of aluminum as a filling metal, 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 produced. 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 can be controlled to result in a gradient, wherein the ceramic-metal composite of the reinforcing element steplessly in the intermetallic-ceramic composite material
  • a porous ceramic insert was made using AIN 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 reinforced the upper portion of the heat sink, thereby adjusting the coefficient of expansion between the electronic substrate and Heat sink is created at the same time high thermal conductivity.
  • a porous ceramic insert was produced using TiO 2 as ceramic powder and infiltrated under the same conditions with a magnesium alloy (AZ 91).
  • a porous ceramic insert was produced analogously to Example 1 using TiO 2 as ceramic powder.
  • 30% by volume (based on the total powder volume) of carbon reinforcing fibers in the form of short fibers with a length of 3 to 15 mm were added to the mixture porous ceramic insert was infiltrated with aluminum under the same conditions.
  • 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 element.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
EP00920651A 1999-04-16 2000-04-01 Giesswerkzeug und verfahren zur herstellung eines bauteils Expired - Lifetime EP1183120B2 (de)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
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)

Publication Number Publication Date
EP1183120A1 EP1183120A1 (de) 2002-03-06
EP1183120B1 EP1183120B1 (de) 2003-05-28
EP1183120B2 true EP1183120B2 (de) 2006-08-16

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EP00920651A Expired - Lifetime EP1183120B2 (de) 1999-04-16 2000-04-01 Giesswerkzeug und verfahren zur herstellung eines bauteils

Country Status (6)

Country Link
US (1) US6648055B1 (ja)
EP (1) EP1183120B2 (ja)
JP (1) JP3420572B2 (ja)
DE (2) DE19917175A1 (ja)
ES (1) ES2197088T3 (ja)
WO (1) WO2000062959A1 (ja)

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JP3420572B2 (ja) 2003-06-23
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DE19917175A1 (de) 2000-10-19
WO2000062959A1 (de) 2000-10-26
ES2197088T3 (es) 2004-01-01
JP2002542035A (ja) 2002-12-10
US6648055B1 (en) 2003-11-18
EP1183120B1 (de) 2003-05-28

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