EP1356131B1 - Method for the production of metallic foam and metal bodies produced according to said method - Google Patents

Method for the production of metallic foam and metal bodies produced according to said method Download PDF

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Publication number
EP1356131B1
EP1356131B1 EP02708278A EP02708278A EP1356131B1 EP 1356131 B1 EP1356131 B1 EP 1356131B1 EP 02708278 A EP02708278 A EP 02708278A EP 02708278 A EP02708278 A EP 02708278A EP 1356131 B1 EP1356131 B1 EP 1356131B1
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EP
European Patent Office
Prior art keywords
metal
foam
mold
foaming agent
mould cavity
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EP02708278A
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German (de)
French (fr)
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EP1356131A2 (en
Inventor
Benno Niedermann
Wilfried Knott
Manfred Recksik
Andreas Weier
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Buehler Druckguss AG
Evonik Operations GmbH
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Buehler Druckguss AG
Goldschmidt GmbH
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Publication of EP1356131A2 publication Critical patent/EP1356131A2/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • B22D25/005—Casting metal foams
    • 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
    • C22C1/08—Alloys with open or closed pores
    • 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
    • C22C1/08—Alloys with open or closed pores
    • C22C1/083—Foaming process in molten metal other than by powder metallurgy
    • C22C1/087—Foaming process in molten metal other than by powder metallurgy after casting in solidified or solidifying metal to make porous metals

Definitions

  • the invention relates to a method for the production of metal foam in a metal die casting machine, in particular of Metal foam made of aluminum materials and one after this Method produced metal body, for example, a component from such an aluminum material.
  • foamed metallic materials manufacture. These are characterized by lightweight construction, Stiffness, compressive strength, improved mechanical and acoustic Damping u. a. out.
  • casting cores are made Aluminum foam with an aluminum material cast or such inserted as molded parts in a component. Shell and core or Molding are made separately and then together connected. This has in addition to the high production costs as well a low production quality result.
  • foamable aluminum semi-finished products is atomized Aluminum powder to which a blowing agent is added. So for example, according to DE-A-197 44 300 a from a powder mixture pressed body in a heated, closed Vessel at temperatures above the decomposition temperature the blowing agent and / or the melting temperature of the metal is heated.
  • the powder is compacted and the resulting molded part is placed in the photograph2020 area of a component and foamed by heating up to 650 ° C. It can the "shell" is subject to impermissible deformations or the Foaming process is uneven.
  • JP-A-03017236 are metallic Article with cavities generated by the fact that gases in one Molten metal are dissolved and the foaming process by sudden pressure reduction is initiated. By cooling the melt is stabilized foam.
  • W.Thiele Filler-containing Aiuminium sponge - a compressible Casting material for the absorption of impact energy. in: metal 28, 1974, Issue 1, p. 39 to 42 describes the preparation of Foamed aluminum.
  • the desired cavities are in size, Shape and position in the form of a loose bed of easily compressible inorganic lightweight materials, such as blown Clay minerals, expanded clay, glass foam balls or hollow corundum balls etc. specified.
  • the lightweight packing is in brought a mold. The remaining spaces of the Fill are filled up with metal.
  • the aluminum sponge thus obtained is relatively poor mechanical load and contains the material of the bed.
  • DE-B-11 64 103 and DE-B-1 164 102 relate to a process for producing metal foam bodies.
  • a solid substance which decomposes on heating with formation of gas, with a molten Metal mixed in such a way that the solid substance is wetted by the metal.
  • a molten Metal mixed in such a way that the solid substance is wetted by the metal.
  • powdery Titanium hydride of a molten aluminum alloy and magnesium added at a temperature of 600 ° C.
  • the thus formed closed foam is then in a Mold poured to cool and solidify.
  • GB-A-892934 relates to the preparation of complex structures with foamed metal core and closed non-porous Surface, the execution of the method described from the filling of the metal-blowing agent mixture into the mold depends on the start of the foaming process.
  • DE-C-198 32 794 describes a process for the preparation of a Hollow profile filled with metal foam.
  • This method includes the steps of pressing the hollow profile from a Envelope material with an extrusion press, which is an extrusion die with a die and a mandrel, feeding the metal foam of a foam material through a supply channel to the hollow profile formed in the mandrel.
  • WO 92/21457 describes the Production of aluminum foam such that gas under the Surface of a molten metal is injected, wherein Abrasives serve as stabilizers.
  • EP-B-0 666 784 describes a method of molding a Particle stabilized metal foam, in particular an aluminum alloy by forming a composite of a metal matrix and finely divided solid stabilizing particles the solidus temperature of the metal matrix is heated, and gas bubbles in the molten metal compound below Surface are drained, thereby stabilized liquid foam on the surface of the molten metal composite train.
  • Characteristic is a molding of the metal foam by pressing the stabilized liquid foam in a mold and with a print that is only sufficient the liquid foam takes the shape of the mold without the Cells of the foam are significantly compressed and subsequent Cool and solidify the foam to a molded To receive the subject.
  • the foam is here by means of a movable plate pressed into the mold. A first moving one Plate pushes the liquid foam into the mold and molded Foam article is formed a smooth surface. A second moving plate gets into the foam inside the mold pressed to form smooth interior surfaces on the foam article.
  • the shaping can also be done by means of roles.
  • EP-A-0 804 982 Another method for the production of moldings made of metal foam teaches EP-A-0 804 982.
  • the Foaming in a heated chamber outside one Mold wherein the volume of the introduced into the chamber powder metallurgical starting material for the metal foam in its foamed with the entire foaming phase the volume of a filling of the mold substantially equivalent. All in the chamber located metal foam is pressed into the mold, in which a frothing with the remaining foaming capacity is continued until complete filling of the mold.
  • the mold is one Sand or ceramic form, the metal foam is used as semi-finished in introduced the chamber and only after foaming for Example pressed by means of a piston in the mold. At the Pushing the foam into the mold shears it. Form is not intended to be inhomogeneous with a foam of itself Structure filled.
  • DE-A-19 501 508 discloses a process for the preparation a cavity profile with reduced weight and increased Stiffness, for example, a component for the chassis of a Motor vehicle. This is made of die-cast aluminum and in whose cavities is a core of aluminum foam. The integrated foam core is made by powder metallurgy and then on the inner wall of a G mantechnikmaschinees fixed and using Druckg intelligentmaschine Cast metal.
  • the dissolution or blowing of propellant gases in molten metal is not suitable for the production of near net shape components, as a System consisting of melt with occluded gas bubbles not is sufficiently stable in time to be processed in shaping tools to become.
  • the solution to the above problem consists in a first Embodiment in a method for producing metal foam by adding a blowing agent to a molten metal, which is characterized in that the molten metal in introduces the mold cavity of a metal die casting machine and with a gas-releasing, solid at room temperature Foaming agent foams.
  • light metal foams for example, aluminum or aluminum alloys as integral foams, d. H. with closed outer skin, targeted as a gradient material and close to the final contour in one step by a casting process in a commercial die casting machine based on the use of solid, gas-releasing propellant, for example a metal hydride, in particular a light metal hydride.
  • solid, gas-releasing propellant for example a metal hydride, in particular a light metal hydride.
  • liquid or mushy metal is forced under high pressure into a mold which constitutes the mold cavity.
  • the metal is injected directly from the melting chamber with up to about 10 7 Pa in the mold, in accordance with the invention preferred cold chamber method, for example, for materials of Al and Mg alloys, the melt is only in a cold intermediate chamber and from there with more than 10 8 Pa pressed into the mold.
  • the casting performance of the hot chamber process is higher, but also the wear of the system.
  • the advantages of die casting are the good material strength, the clean surface, the high dimensional accuracy, the low wall thickness required, the possibility of complex casting design and the high operating speed. These advantages can be further improved by negative pressure (vacuum) in the mold.
  • Advantageously used here are available on the market, real-time controlled die casting machines.
  • the process sequence preferred according to the invention comprises Fill the required volume of molten metal in the Filling or casting chamber and their introduction into a mold cavity adding the blowing agent to the molten metal.
  • molten metal and propellants are in a preferred embodiment brought together in the mold cavity, wherein the Form volume defined filled with the melt-blowing agent mixture respectively is underfilled.
  • the blowing agent not directly in the mold cavity, but in a Golfoder Casting chamber brought into contact with the molten metal and The mixture is then introduced into the mold cavity.
  • the foaming itself takes place in the mold cavity, the one represents closed form. This can, however, as in die-casting or the like usual via risers for venting feature. Thereafter, the ejection of the substantially foamed Metal body.
  • the propellant is directly in the filling or casting chamber or in the mold cavity to the molten metal added, each integral in one operation foamed metal body are produced.
  • a smooth surface whose formation is well reproducible is. Due to the possible spray filling are different Wall thicknesses are easily adjustable. The walls are closed on all sides, clean, dense and homogeneous. An aftertreatment is usually not required. Inside are the manufactured ones Metal body increasingly porous and have a density gradient on.
  • the propellant should be in terms of its decomposition temperature on the melting temperature of the casting material (molten metal) be coordinated.
  • the decomposition may only above start from 100 ° C and should not be higher than about 150 ° C above be the melting temperature.
  • the metal content in the produced Metal body in the range of 5 to 95 vol .-% or wt .-%, depending on the volume or the thickness of the metal body, where a lower volume to surface ratio for higher Filling degree speaks.
  • the "shot” took place before foaming; the foaming process Expired in situ in the mold cavity. It was fast in the cold form foamed.
  • the component had a mass of only about 40% compared to conventional diecasting parts.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Powder Metallurgy (AREA)
  • Superconductors And Manufacturing Methods Therefor (AREA)

Abstract

The invention relates to a method for producing metallic foam and metal body produced according to said method. The aim of the invention is to produce a method which produces a metallic foam by adding a foaming agent to the metal melt, characterised in that the metal melt is introduced into the mould cavity in a metallic die casting machine and foamed by means of a gas-releasing foam-foaming agent which is solid at room temperature.

Description

Die Erfindung betrifft ein Verfahren zur Herstellung von Metallschaum in einer Metall-Druckgießmaschine, insbesondere von Metallschaum aus Aluminiumwerkstoffen sowie einen nach diesem Verfahren hergestellten Metallkörper, zum Beispiel ein Bauteil aus einem solchen Aluminiumwerkstoff.The invention relates to a method for the production of metal foam in a metal die casting machine, in particular of Metal foam made of aluminum materials and one after this Method produced metal body, for example, a component from such an aluminum material.

Es ist bekannt, Bauteile aus geschäumten metallischen Werkstoffen herzustellen. Diese zeichnen sich durch leichte Bauweise, Steifigkeit, Druckfestigkeit, verbesserte mechanische und akustische Dämpfung u. a. aus. So werden zum Beispiel Gießkerne aus Aluminiumschaum mit einem Aluminiumwerkstoff umgossen oder solche als Formteile in ein Bauteil eingelegt. Hülle und Kern bzw. Formteil werden getrennt hergestellt und anschließend miteinander verbunden. Dies hat neben dem hohen Fertigungsaufwand auch eine geringe Fertigungsqualität zur Folge.It is known components of foamed metallic materials manufacture. These are characterized by lightweight construction, Stiffness, compressive strength, improved mechanical and acoustic Damping u. a. out. For example, casting cores are made Aluminum foam with an aluminum material cast or such inserted as molded parts in a component. Shell and core or Molding are made separately and then together connected. This has in addition to the high production costs as well a low production quality result.

Die Basis von schaumfähigen Aluminiumhalbzeugen ist verdüstes Aluminiumpulver, welchem ein Treibmittel zugemischt wird. So wird zum Beispiel nach der DE-A-197 44 300 ein aus einer Pulvermischung gepresster Körper in einem beheizbaren, geschlossenen Gefäß auf Temperaturen oberhalb der Zersetzungstemperatur des Treibmittels und/oder der Schmelztemperatur des Metalls erwärmt.The basis of foamable aluminum semi-finished products is atomized Aluminum powder to which a blowing agent is added. So For example, according to DE-A-197 44 300 a from a powder mixture pressed body in a heated, closed Vessel at temperatures above the decomposition temperature the blowing agent and / or the melting temperature of the metal is heated.

Das Pulver wird verdichtet und das so entstandene Formteil wird in den auszuschäumenden Bereich eines Bauteils eingelegt und durch eine Erwärmung auf bis zu 650 °C geschäumt. Dabei kann die "Hülle" unzulässigen Verformungen unterliegen oder der Schäumvorgang erfolgt ungleichmäßig.The powder is compacted and the resulting molded part is placed in the auszuschäumenden area of a component and foamed by heating up to 650 ° C. It can the "shell" is subject to impermissible deformations or the Foaming process is uneven.

Möglich ist ebenso ein Sintern metallischer Hohlkugeln oder eine Infiltration von Metallschmelzen in Kerne bzw. Füllkörper, die nach Erstarrung der Schmelze entfernt werden.Also possible is sintering metallic hollow spheres or an infiltration of metal melts into cores or packing, which are removed after solidification of the melt.

Nach einem Verfahren gemäss der JP-A-03017236 werden metallische Artikel mit Hohlräumen dadurch erzeugt, dass Gase in einer Metallschmelze gelöst werden und der Aufschäumvorgang durch plötzliche Druckverringerung eingeleitet wird. Durch Abkühlen der Schmelze wird der Schaum stabilisiert.According to a method according to JP-A-03017236 are metallic Article with cavities generated by the fact that gases in one Molten metal are dissolved and the foaming process by sudden pressure reduction is initiated. By cooling the melt is stabilized foam.

Der Lehre der JP-A-09241780 folgend, wird metallischer Schaum unter kontrollierter Freisetzung von Treibgasen gewonnen, indem ein Metall zunächst bei Temperaturen unterhalb der Zersetzungstemperatur des verwendeten Treibmittels geschmolzen wird. Durch anschließendes Dispergieren des Treibmittels im geschmolzenen Metall und Erhitzen der Matrix über die dann zur Freisetzung von Treibgasen benötigte Temperatur etabliert sich ein Metallschaum.Following the teaching of JP-A-09241780, metallic foam obtained under controlled release of propellant gases by a metal initially at temperatures below the decomposition temperature the blowing agent used is melted. By then dispersing the blowing agent in the molten state Metal and then heat the matrix over to release The temperature required for propellant gases establishes a metal foam.

W.Thiele: Füllstoffhaltiger Aiuminiumschwamm - ein kompressibler Gußwerkstoff zur Absorption von Stoßenergie. in: Metall 28, 1974, Heft 1, S. 39 bis 42 beschreibt die Herstellung von Schaumaluminium. Die angestrebten Hohlräume werden in Größe, Gestalt und Lage in Form einer losen Schüttung aus leicht komprimierbaren anorganischen Leichtstoffen, wie zum Beispiel geblähte Tonmineralien, Blähton, Glasschaumkugeln oder Hohlkorundkugeln usw. vorgegeben. Die Leichtstoffschüttung wird in eine Gießform gebracht. Die verbleibenden Zwischenräume der Schüttung werden mit Metall aufgefüllt. Der so erhaltene Aluminiumschwamm ist relativ schlecht mechanisch belastbar und enthält das Material der Schüttung. W.Thiele: Filler-containing Aiuminium sponge - a compressible Casting material for the absorption of impact energy. in: metal 28, 1974, Issue 1, p. 39 to 42 describes the preparation of Foamed aluminum. The desired cavities are in size, Shape and position in the form of a loose bed of easily compressible inorganic lightweight materials, such as blown Clay minerals, expanded clay, glass foam balls or hollow corundum balls etc. specified. The lightweight packing is in brought a mold. The remaining spaces of the Fill are filled up with metal. The aluminum sponge thus obtained is relatively poor mechanical load and contains the material of the bed.

DE-B-11 64 103 und DE-B-1 164 102 betriffen ein Verfahren zur Herstellung von Metallschaumkörpern. Bei diesem Verfahren wird ein fester Stoff, der sich bei Erhitzung unter Gasbildung zersetzt, mit einem geschmolzenen Metall in der Weise gemischt, dass der feste Stoff durch das Metall benetzt wird. So wird beispielsweise pulverförmiges Titanhydrid einer geschmolzenen Legierung aus Aluminium und Magnesium bei einer Temperatur von 600 °C zugesetzt. Der so gebildete geschlossene Schaum wird anschließend in eine Form gegossen um dort abzukühlen und zu erstarren. Auch hier wird offensichtlich nicht in einem geschlossenen System, sondern in einem offenen System gearbeitet.DE-B-11 64 103 and DE-B-1 164 102 relate to a process for producing metal foam bodies. In this process, a solid substance, which decomposes on heating with formation of gas, with a molten Metal mixed in such a way that the solid substance is wetted by the metal. For example, powdery Titanium hydride of a molten aluminum alloy and magnesium added at a temperature of 600 ° C. The thus formed closed foam is then in a Mold poured to cool and solidify. Here too Obviously not in a closed system, but worked in an open system.

GB-A-892934 betrifft die Herstellung von komplexen Strukturen mit geschäumtem Metallkern und geschlossener nicht poröser Oberfläche, wobei die Ausführung des beschriebenen Verfahrens von dem Einfüllen der Metall-Treibmittelmischung in die Form vor dem Start des Aufschäumprozesses abhängt.GB-A-892934 relates to the preparation of complex structures with foamed metal core and closed non-porous Surface, the execution of the method described from the filling of the metal-blowing agent mixture into the mold depends on the start of the foaming process.

DE-C-198 32 794 beschreibt ein Verfahren zur Herstellung eines Hohlprofils, das mit Metallschaum gefüllt ist. Dieses Verfahren umfasst die Schritte des Pressens des Hohlprofils aus einem Hüllwerkstoff mit einer Strangpresse, die ein Strangpresswerkzeug mit einer Matrize und einem Dorn aufweist, des Zuführens des Metallschaums aus einem Schaumwerkstoff durch einen Zufuhrkanal zu dem Hohlprofil, der in dem Dorn ausgebildet ist.DE-C-198 32 794 describes a process for the preparation of a Hollow profile filled with metal foam. This method includes the steps of pressing the hollow profile from a Envelope material with an extrusion press, which is an extrusion die with a die and a mandrel, feeding the metal foam of a foam material through a supply channel to the hollow profile formed in the mandrel.

Vorbekannt ist das Gießen von Metallteilen mit verlorenem Schaum gemäss EP-B-0 461 052. Die WO 92/21457 beschreibt die Herstellung von Aluminiumschaum dergestalt, dass Gas unter die Oberfläche eines geschmolzenen Metalls eingeblasen wird, wobei Abrasivstoffe als Stabilisatoren dienen.Previously known is the casting of metal parts with lost Foam according to EP-B-0 461 052. WO 92/21457 describes the Production of aluminum foam such that gas under the Surface of a molten metal is injected, wherein Abrasives serve as stabilizers.

Die EP-B-0 666 784 beschreibt ein Verfahren zum Formgießen eines mittels Teilchen stabilisierten Metallschaums, insbesondere eine Aluminiumlegierung, indem ein Verbund aus einer Metallmatrix und fein verteilten festen Stabilisierungsteilchen über die Solidustemperatur der Metallmatrix erwärmt wird, und Gasblasen in den geschmolzenen Metallverbund unterhalb dessen Oberfläche abgelassen werden, um dadurch einen stabilisierten flüssigen Schaum an der Oberfläche des geschmolzenen Metallverbundes auszubilden. Kennzeichnend ist ein Formgießen des Metallschaumes durch Pressen des stabilisierten flüssigen Schaumes in eine Form und mit einem Druck, der nur ausreicht, dass der flüssige Schaum die Gestalt der Form annimmt, ohne dass die Zellen des Schaums wesentlich komprimiert werden und nachfolgendes Kühlen und Verfestigen des Schaums, um einen geformten Gegenstand zu erhalten. Der Schaum wird hierbei mittels einer beweglichen Platte in die Form gedrückt. Eine erste bewegliche Platte drückt den flüssigen Schaum in die Form und am geformten Schaumgegenstand wird eine glatte Oberfläche ausgebildet. Eine zweite bewegliche Platte wird in den Schaum innerhalb der Form gedrückt, um am Schaumgegenstand glatte Innenflächen auszubilden. Die Formgebung kann aber auch mittels Rollen erfolgen.EP-B-0 666 784 describes a method of molding a Particle stabilized metal foam, in particular an aluminum alloy by forming a composite of a metal matrix and finely divided solid stabilizing particles the solidus temperature of the metal matrix is heated, and gas bubbles in the molten metal compound below Surface are drained, thereby stabilized liquid foam on the surface of the molten metal composite train. Characteristic is a molding of the metal foam by pressing the stabilized liquid foam in a mold and with a print that is only sufficient the liquid foam takes the shape of the mold without the Cells of the foam are significantly compressed and subsequent Cool and solidify the foam to a molded To receive the subject. The foam is here by means of a movable plate pressed into the mold. A first moving one Plate pushes the liquid foam into the mold and molded Foam article is formed a smooth surface. A second moving plate gets into the foam inside the mold pressed to form smooth interior surfaces on the foam article. The shaping can also be done by means of roles.

Ein weiteres Verfahren zur Herstellung von Formteilen aus Metallschaum lehrt die EP-A-0 804 982. Hierbei erfolgt das Aufschäumen in einer beheizbaren Kammer außerhalb einer Gussform, wobei das Volumen des in die Kammer eingebrachten pulvermetallurgischen Ausgangsmaterials für den Metallschaum in seiner mit der gesamten Schäumkapazität aufgeschäumten Phase dem Volumen einer Füllung der Gussform im Wesentlichen entspricht. Aller in der Kammer befindliche Metallschaum wird in die Gussform gedrückt, in der ein Aufschäumen mit der restlichen Schäumkapazität fortgesetzt wird, bis zum vollständigen Ausfüllen der Gussform. Die Gussform ist eine Sand- oder Keramikform, der Metallschaum wird als Halbzeug in die Kammer eingebracht und erst nach dem Aufschäumen zum Beispiel mittels eines Kolbens in die Gussform gedrückt. Beim Drücken des Schaumes in die Form wird dieser geschert. Die Form wird nicht mit einem Schaum von an sich gewollt inhomogener Struktur gefüllt.Another method for the production of moldings made of metal foam teaches EP-A-0 804 982. In this case, the Foaming in a heated chamber outside one Mold, wherein the volume of the introduced into the chamber powder metallurgical starting material for the metal foam in its foamed with the entire foaming phase the volume of a filling of the mold substantially equivalent. All in the chamber located metal foam is pressed into the mold, in which a frothing with the remaining foaming capacity is continued until complete filling of the mold. The mold is one Sand or ceramic form, the metal foam is used as semi-finished in introduced the chamber and only after foaming for Example pressed by means of a piston in the mold. At the Pushing the foam into the mold shears it. Form is not intended to be inhomogeneous with a foam of itself Structure filled.

Die DE-A-19 501 508 offenbart ein Verfahren zur Herstellung eines Hohlraumprofils mit reduziertem Gewicht und erhöhter Steifigkeit, zum Beispiel ein Bauteil für das Fahrwerk eines Kraftfahrzeuges. Dieses besteht aus Aluminiumdruckguss und in dessen Hohlräumen befindet sich ein Kern aus Aluminiumschaum. Der integrierte Schaumkern wird auf pulvermetallurgischem Weg hergestellt und anschließend an der Innenwand eines Gießwerkzeuges fixiert und mittels Druckgießverfahren mit Metall umgossen.DE-A-19 501 508 discloses a process for the preparation a cavity profile with reduced weight and increased Stiffness, for example, a component for the chassis of a Motor vehicle. This is made of die-cast aluminum and in whose cavities is a core of aluminum foam. The integrated foam core is made by powder metallurgy and then on the inner wall of a Gießwerkzeuges fixed and using Druckgießverfahren with Cast metal.

Das Lösen bzw. Einblasen von Treibgasen in Metallschmelzen ist nicht zur Herstellung endkonturnaher Bauteile geeignet, da ein System, bestehend aus Schmelze mit okkludierten Gasblasen nicht ausreichend zeitstabil ist, um in formgebenden Werkzeugen verarbeitet zu werden.The dissolution or blowing of propellant gases in molten metal is not suitable for the production of near net shape components, as a System consisting of melt with occluded gas bubbles not is sufficiently stable in time to be processed in shaping tools to become.

Es ist daher Aufgabe der Erfindung, ein einfaches und für die Massenfertigung taugliches Verfahren zur Herstellung von Metallschaum bereit zu stellen, welches mit geringem Aufwand die Herstellung von endkonturnahen Metallkörpern gestattet.It is therefore an object of the invention, a simple and for the Mass production suitable process for the production of metal foam to provide, which with little effort the Production of near-net shape metal bodies allowed.

Die Lösung der vorgenannten Aufgabe besteht in einer ersten Ausführungsform in einem Verfahren zur Herstellung von Metallschaum durch Zugabe eines Treibmittels zu einer Metallschmelze, das dadurch gekennzeichnet ist, dass man die Metallschmelze in den Formhohlraum einer Metall-Druckgießmaschine einbringt und mit einem gasabspaltenden, bei Raumtemperatur festen Treibmittel ausschäumt. The solution to the above problem consists in a first Embodiment in a method for producing metal foam by adding a blowing agent to a molten metal, which is characterized in that the molten metal in introduces the mold cavity of a metal die casting machine and with a gas-releasing, solid at room temperature Foaming agent foams.

Überraschend wurde gefunden, dass sich insbesondere Leichtmetallschäume zum Beispiel aus Aluminium oder Aluminiumlegierungen als Integralschäume, d. h. mit geschlossener Außenhaut, gezielt als Gradientenwerkstoff und endkonturnah in einem Schritt durch einen Gießvorgang in einer handelsüblichen Druckgießmaschine herstellen lassen, beruhend auf der Verwendung fester, gasabspaltender Treibmittel, zum Beispiel eines Metallhydrids, insbesondere eines Leichtmetallhydrids.Surprisingly, it was found that in particular light metal foams for example, aluminum or aluminum alloys as integral foams, d. H. with closed outer skin, targeted as a gradient material and close to the final contour in one step by a casting process in a commercial die casting machine based on the use of solid, gas-releasing propellant, for example a metal hydride, in particular a light metal hydride.

Beim Druckgießen im Sinne der vorliegenden Erfindung wird flüssiges oder breiiges Metall mit hohem Druck in eine Form gedrückt, die den Formhohlraum darstellt. Beim Warmkammer-Verfahren wird das Metall direkt aus dem Schmelzraum mit bis ca. 107 Pa in die Form gespritzt, beim erfindungsgemäß bevorzugten Kaltkammer-Verfahren, zum Beispiel für Werkstoffe aus Al- und Mg-Legierungen wird die Schmelze erst in eine kalte Zwischenkammer und von dort mit mehr als 108 Pa in die Form gepresst. Die Gießleistung des Warmkammer-Verfahrens ist höher, allerdings auch die Abnutzung der Anlage. Die Vorzüge des Druckgusses liegen in der guten Werkstoff-Festigkeit, der sauberen Oberfläche, der hohen Maßgenauigkeit, den geringen erforderlichen Wanddicken, der Möglichkeit komplexer Gussstückgestaltung und der hohen Arbeitsgeschwindigkeit. Diese Vorteile können durch Unterdruck (Vakuum) in der Kokille weiter verbessert werden. Vorteilhaft einsetzbar sind hierbei am Markt erhältliche, echtzeitgeregelte Druckgießmaschinen.In die casting according to the present invention, liquid or mushy metal is forced under high pressure into a mold which constitutes the mold cavity. In the hot chamber process, the metal is injected directly from the melting chamber with up to about 10 7 Pa in the mold, in accordance with the invention preferred cold chamber method, for example, for materials of Al and Mg alloys, the melt is only in a cold intermediate chamber and from there with more than 10 8 Pa pressed into the mold. The casting performance of the hot chamber process is higher, but also the wear of the system. The advantages of die casting are the good material strength, the clean surface, the high dimensional accuracy, the low wall thickness required, the possibility of complex casting design and the high operating speed. These advantages can be further improved by negative pressure (vacuum) in the mold. Advantageously used here are available on the market, real-time controlled die casting machines.

Der erfindungsgemäß bevorzugte Verfahrensablauf umfasst das Einfüllen des erforderlichen Volumens an Metallschmelze in die Füll- bzw. Gießkammer und deren Einbringen in einen Formhohlraum unter Zugabe des Treibmittels zu der Metallschmelze. Metallschmelze und Treibmittel werden in einer bevorzugten Ausführungsform in dem Formhohlraum zusammengebracht, wobei die Form volumendefiniert mit dem Schmelze-Treibmittelgemisch gefüllt respektive unterfüllt wird.The process sequence preferred according to the invention comprises Fill the required volume of molten metal in the Filling or casting chamber and their introduction into a mold cavity adding the blowing agent to the molten metal. molten metal and propellants are in a preferred embodiment brought together in the mold cavity, wherein the Form volume defined filled with the melt-blowing agent mixture respectively is underfilled.

In einer weiteren bevorzugten Ausführungsform wird das Treibmittel nicht direkt in den Formhohlraum, sondern in einer Fülloder Gießkammer mit der Metallschmelze in Kontakt gebracht und das Gemisch anschließend in den Formhohlraum eingebracht.In a further preferred embodiment, the blowing agent not directly in the mold cavity, but in a Fülloder Casting chamber brought into contact with the molten metal and The mixture is then introduced into the mold cavity.

Das Einbringen des Treibmittels in die Füll- oder Gießkammer einerseits und/oder den Formhohlraum andererseits kann vor, während und/oder nach dem Einbringen der Metallschmelze in die jeweilige Kammer erfolgen. Beim Zusammenbringen von Metallschmelze und Treibmittel ist ein spezieller Mischvorgang nicht erforderlich. Vielmehr erfolgt die Durchmischung beim erfindungsgemäßen Verfahren durch das in der Druckgießmaschine mit hoher Geschwindigkeit erfolgende Einbringen der Metallschmelze in die Formkammer, und zwar unabhängig vom Zeitpunkt der Zugabe des Treibmittels zur Metallschmelze.The introduction of the propellant in the filling or casting chamber on the one hand and / or the mold cavity on the other hand, during and / or after the introduction of the molten metal into the respective chamber done. When bringing together molten metal and propellant is not a special mixing process required. Rather, the mixing takes place in the inventive Method by in the die-casting machine with high speed introduction of the molten metal into the mold chamber, regardless of the time of addition the blowing agent to the molten metal.

Von Bedeutung für die vorliegende Erfindung ist jedoch, dass die Ausschäumung bedingt durch die Gasabspaltung des Treibmittels im Wesentlichen erst im Formhohlraum erfolgt.Of importance for the present invention, however, is that the foaming due to the gas separation of the Propellant essentially takes place only in the mold cavity.

Das Ausschäumen selbst erfolgt in dem Formhohlraum, der eine geschlossene Form darstellt. Diese kann jedoch, wie beim Druckgießen oder dergleichen üblich über Steigkanäle zur Entlüftung verfügen. Danach erfolgt das Ausstoßen des im Wesentlichen geschäumten Metallkörpers.The foaming itself takes place in the mold cavity, the one represents closed form. This can, however, as in die-casting or the like usual via risers for venting feature. Thereafter, the ejection of the substantially foamed Metal body.

In einer weiteren Ausgestaltung wird das Treibmittel direkt in der Füll- oder Gießkammer oder in der Formkavität zur Metallschmelze hinzugegeben, wobei jeweils in einem Arbeitsgang integral geschäumte Metallkörper hergestellt werden. Diese weisen eine glatte Oberfläche auf, deren Bildung gut reproduzierbar ist. Infolge der möglichen Sprühfüllung sind unterschiedliche Wandstärken gut einstellbar. Die Wandungen sind allseitig geschlossen, sauber, dicht und homogen. Eine Nachbehandlung ist in der Regel nicht erforderlich. Nach innen sind die hergestellten Metallkörper zunehmend porös und weisen einen Dichtegradienten auf.In a further embodiment, the propellant is directly in the filling or casting chamber or in the mold cavity to the molten metal added, each integral in one operation foamed metal body are produced. These wise a smooth surface, whose formation is well reproducible is. Due to the possible spray filling are different Wall thicknesses are easily adjustable. The walls are closed on all sides, clean, dense and homogeneous. An aftertreatment is usually not required. Inside are the manufactured ones Metal body increasingly porous and have a density gradient on.

Das Treibmittel sollte hinsichtlich seiner Zersetzungstemperatur auf die Schmelztemperatur des Gießwerkstoffes (Metallschmelze) abgestimmt sein. Die Zersetzung darf erst oberhalb von 100 °C beginnen und sollte nicht höher als ca. 150 °C oberhalb der Schmelztemperatur sein.The propellant should be in terms of its decomposition temperature on the melting temperature of the casting material (molten metal) be coordinated. The decomposition may only above start from 100 ° C and should not be higher than about 150 ° C above be the melting temperature.

Bezogen auf Vollmaterial kann der Metallanteil im hergestellten Metallkörper im Bereich von 5 bis 95 Vol.- oder Gew.-% liegen, in Abhängigkeit vom Volumen oder der Dicke des Metallkörpers, wobei ein niedrigeres Verhältnis Volumen zu Oberfläche für höhere Füllgrade spricht.Based on solid material, the metal content in the produced Metal body in the range of 5 to 95 vol .-% or wt .-%, depending on the volume or the thickness of the metal body, where a lower volume to surface ratio for higher Filling degree speaks.

Die Erfindung wird nachfolgend in einem Ausführungsbeispiel näher beschrieben.The invention will be closer in one embodiment described.

Ausführungsbeispiel:Embodiment:

In einer handelsüblichen Druckgießmaschine, z. B. einer Druckgiessmaschine der Baureihe Evolution der Bühler Druckguss AG, sollte ein Fahrzeugteil aus einem Aluminiumwerkstoff als integral geschäumter Metallkörper hergestellt werden. Hierzu wurde eine Gießkammer der Druckgießmaschine mit einer entsprechenden Menge an Metallschmelze gefüllt. In die geschlossene Gießkammer wurde als Treibmittel Magnesiumhydrid in Pulverform dem flüssigen Metall zugegeben. Nahezu gleichzeitig begann ein schnelles Einschieben des Gemisches aus Treibmittel und Metallschmelze in dem Formhohlraum. Der Formhohlraum wurde volumendefiniert unterfüllt. Durch die entstehenden Turbulenzen erfolgte eine gute Durchmischung in dem Formhohlraum und das Ausschäumen. Das Metall erstarrte an den Formwänden und bildete eine dichte und homogene Wandung des Metallkörpers aus, wobei sowohl die Wandstärken als auch die Porösität und deren Gradient durch Variation von Verfahrensparametern einstellbar waren.In a commercial die casting machine, z. B. a die casting machine of the Bühler Druckguss AG Evolution series, should a vehicle part made of an aluminum material as integral foamed metal body are produced. For this was a casting chamber of the die casting machine with a corresponding Amount of molten metal filled. In the closed Casting chamber was used as blowing agent magnesium hydride in powder form added to the liquid metal. Almost at the same time one started rapid insertion of the mixture of propellant and molten metal in the mold cavity. The mold cavity was volume defined underfilled. Due to the resulting turbulence took place a good mixing in the mold cavity and the Foaming. The metal froze on the mold walls, forming a dense and homogeneous wall of the metal body, wherein both the wall thicknesses and the porosity and its gradient were adjustable by varying process parameters.

Der "Schuss" erfolgte vor der Schaumbildung; der Schäumungsprozess lief in situ in dem Formhohlraum ab. Es wurde schnell in die kalte Form geschäumt. Das Bauteil wies eine Masse von nur ca. 40% gegenüber konventionellen Druckgießteilen auf.The "shot" took place before foaming; the foaming process Expired in situ in the mold cavity. It was fast in the cold form foamed. The component had a mass of only about 40% compared to conventional diecasting parts.

Der gemäss dem Beispiel hergestellte Metallkörper aus einem Aluminiumwerkstoff wies zwar eine geringere Dichte als Magnesium auf, aber etwa dessen Verwindungssteifigkeit.The metal body produced according to the example of one Although aluminum material had a lower density than magnesium but about its torsional rigidity.

Claims (6)

  1. A method for producing metallic foam by adding a foaming agent to a metal melt, characterised in that the metal melt is introduced to the mould cavity of a metalic die-casting machine and foamed with a gas-releasing foaming agent, solid at room temperature.
  2. The method as claimed in Claim 1, characterised in that the mould cavity is filled or underfilled by volume and foaming takes place in an unheated mould cavity.
  3. The method as claimed in Claim 1 or 2, characterised in that the foaming agent is brought into concact in a filing or casting chamber with the metal melt and the mixture is then introduced to the mould cavity.
  4. The method as claimed in Claim 1 or 2, characterised in that the foaming agent is introduced to the mould cavity.
  5. The method as claimed in Claim 4, characterised in that the foaming agent is introduced to the mould cavity before, after and/or while the metal melt is being introduced.
  6. The method as claimed in any one of Claims 1 to 5, characterised in that a metal melt of light metal, in particular aluminium or an aluminium alloy is used.
EP02708278A 2001-02-01 2002-01-12 Method for the production of metallic foam and metal bodies produced according to said method Expired - Lifetime EP1356131B1 (en)

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DE10104339A DE10104339A1 (en) 2001-02-01 2001-02-01 Process for the production of metal foam and metal body produced thereafter
DE10104339 2001-02-01
PCT/EP2002/000245 WO2002060621A2 (en) 2001-02-01 2002-01-12 Method for the production of metallic foam and metal bodies produced according to said method

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DE10104339A1 (en) 2002-08-08
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AU2002242664A1 (en) 2002-08-12
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