EP1604756B1 - method for producing metallic reticular structures - Google Patents

method for producing metallic reticular structures Download PDF

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Publication number
EP1604756B1
EP1604756B1 EP05011668A EP05011668A EP1604756B1 EP 1604756 B1 EP1604756 B1 EP 1604756B1 EP 05011668 A EP05011668 A EP 05011668A EP 05011668 A EP05011668 A EP 05011668A EP 1604756 B1 EP1604756 B1 EP 1604756B1
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EP
European Patent Office
Prior art keywords
cuvette
lattice elements
metal
structures
vessel
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EP05011668A
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German (de)
French (fr)
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EP1604756A2 (en
EP1604756A3 (en
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Dieter Dr. Girlich
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mpore GmbH
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Individual
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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
    • B22D25/00—Special casting characterised by the nature of the product
    • B22D25/005—Casting metal foams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02—Lost patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02—Lost patterns
    • B22C7/023—Patterns made from expanded plastic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • B22C9/043—Removing the consumable pattern

Definitions

  • the invention relates to a method for producing metallic lattice structures in the form of open-pore foam.
  • Reticular structures made of metal and other materials have a wide range of applications due to their properties.
  • these structures may be used as low weight components, accumulator plates, electrochemical anodes and cathodes, filters and mixers for fluids, catalyst, gas absorbers, heat exchangers and many other applications.
  • U.S. Patent 3,616,841 discloses a method of making a foam material having a predetermined reticulated structure. This process involves the preparation of a self-supporting reticulated polyurethane foam; the preparation of a refractory mass by filling the voids of the polyurethane foam with an aqueous molding suspension and setting this suspension; heating the refractory mass to a temperature of about 120 ° C (250 ° F) for a period of two hours for drying; generating voids in the refractory molding material by raising the temperature of the refractory molding material to 650-850 ° C to volatilize all of the foam; introducing into the refractory molding compound a molten substance consisting of metals or metal alloys, the amount of substance sufficient to fill the cavities previously occupied by the reticulated structure were; and solidifying the molten substance by reducing the temperature to below the melting point of the substance; and washing out the material forming the refractory molding compound.
  • DE 199 39 155 discloses a method for producing metallic lattice structures in which a reticulated foam pre-structure is inserted into a hinged container, the foam pre-structure is infiltrated with a refractory material and the refractory material is then solidified. Subsequently, the solidified refractory material is removed from the hinged container, the foam pre-structure removed from the refractory material and the resulting, preheated body is inserted into a heat-resistant container. This body is infiltrated with a molten metal and removed from the heat-resistant container after the molten metal solidifies. Subsequently, the refractory material is removed from the body, as a result of which a reticular metal structure is obtained.
  • One advantage of this method is, inter alia, that bonding of the foam pre-structure to the sprue system and the sprue is no longer necessary as compared to said US Pat. No. 3,616,841. As a result, not only the material and time consumption in the production of the mold is significantly reduced, but also an automated production of reticular metallic structures possible.
  • the object of the invention is therefore to eliminate the disadvantages of the prior art.
  • a method for the production of metallic lattice structures is to be specified, which allows a lower use of materials and a faster production of such structures and consequently a series production.
  • the pre-structure by planar or separate thermal compression of the pre-structure such that it has from the outside inwardly increasing pores and thus a graded structure in the region of the compression, and for the production of metallic lattice structures although in basically known to use a reticulated preform, preferably a PU foam structure, but to thicken their webs previously by one or more times coating, by means of one or more different organic materials.
  • a reticulated preform preferably a PU foam structure
  • the inflow of the metal is facilitated.
  • the mechanical properties of the structure can thus be influenced in a targeted manner, wherein it is essential that the reproducibility of the characteristic values be sustainably improved compared with the prior art.
  • the thickness of the webs of the PU foam structure is adapted to the respective requirements determined by the intended use of the metal grid structure.
  • the coating of the webs of the pre-structure by means of liquid and / or solid materials is provided, for.
  • the use of powder prevents sticking of the structure and ensures a uniformly thick layer, especially since no membranes (cell skins) form between the webs.
  • the Vor Siemens is inserted in register in a frame and filled with molding material so that it is not completely covered, but rather a boundary of 2 to 5 mm remains free.
  • the remaining cavities are filled with sand and pressed.
  • the sheathing of the pre-structure is carried out with a ceramic slurry, wherein the sheath is optionally repeated to produce a stable layer.
  • the embedded molding can be refinished beforehand if necessary, such. B. by milling and drilling to produce knobs or other geometric shapes of solid material in the structure, or through holes to pour by means of core pins pipes in the structure.
  • the incorporation of continuous, but also non-continuous holes, grooves or the like in the cast-in pre-structure is carried out according to the invention at a distance of at least two pores to each other. This process step has the consequence that the density of the material and consequent its stability can be increased application specific; At the same time there is a sustained improvement in thermal conductivity.
  • the diameters of the recesses are optimized according to the strength requirements of the material
  • An essential further process step is the thermal removal of the preliminary structure by melting and / or burnout, for this purpose, the solidified structure-ceramic composite is taken out of the frame and placed in a cuvette whose bottom is filled with loose refractory material, preferably foundry sand. Alternatively, it is also possible to dry and burn out the molded part without cuvette by means of infrared or microwaves.
  • the cuvette comprises a molding sand / ceramic stencil for the runners; In addition, it has insulation to prevent premature cooling of the molded part.
  • the cuvette consists of a pressed molding sand / ceramic composite, wherein the molding sand is recyclable and also the use of molding material is reduced to the necessary volume.
  • the cuvette with the molding is placed for this purpose in a pressure-resistant container, filled with liquid metal, the container is closed and evacuated to degas the molding and the melt. By aerating the container, the melt is pressed into the molding.
  • the crucible is located in the container, the cuvette is connected by a tube to the melt.
  • the molding is removed from the cuvette.
  • the solidification can be done directionally over the cast metal parts.
  • the preliminary structure can also be produced by pouring granular mineral substances or granular organic substances with a mineral coating.
  • granular structures preferably in spherical pellets
  • PU foam structures usually pore sizes of max. 5 ppi, which corresponds to an average pore diameter of 8 to 10 mm, can be produced, can be realized with this pore sizes in the range of 1 to 3 cm.
  • the pellets are glued together over a large area, so that it is certain that only the cavities between the pellets are used as a pouring channel.
  • a coating of the pre-structure thus created is not provided and also not necessary because the desired ceramic coating is already present.
  • the other method steps according to the invention are retained.
  • the structure created in this way offers itself as a versatile lightweight construction material.

Abstract

The method for producing reticulated metal structures involves thickening of elements of reticulated foam structures by organic coatings, filling of the resultant structure with a fire-resistant compound, and removal of the foam structure by application of heat before casting operations.

Description

Die Erfindung betrifft ein Verfahren zur Herstellung metallischer Gitterstrukturen in Form offenporigen Schaums.The invention relates to a method for producing metallic lattice structures in the form of open-pore foam.

Retikuläre Strukturen aus Metall und anderen Materialien besitzen aufgrund ihrer Eigenschaften ein breites Anwendungsgebiet. Beispielsweise können diese Strukturen als Bauteile mit niedrigem Gewicht, Akkumulatorenplatten, elektrochemische Anoden und Kathoden, Filter und Mischer für Fluide, Katalysator, Gasabsorber, Wärmeüberträger und für zahlreiche weitere Anwendungen verwendet werden.Reticular structures made of metal and other materials have a wide range of applications due to their properties. For example, these structures may be used as low weight components, accumulator plates, electrochemical anodes and cathodes, filters and mixers for fluids, catalyst, gas absorbers, heat exchangers and many other applications.

Verfahren zur Herstellung retikulärer metallischer Strukturen sind seit längerem bekannt, wobei diese Verfahren in der Regel einer industriellen Anwendung aufgrund schwieriger Handhabbarkeit der eingesetzten Materialien, komplizierter Verfahrensschritte und hohem Zeitaufwand nicht genügen.Processes for producing reticular metallic structures have been known for some time, but these processes generally do not suffice for industrial application because of the difficulty of handling the materials used, the complicated process steps and the high expenditure of time.

Beispielsweise offenbart das US-Patent 3.616.841 ein Verfahren zur Herstellung eines Schaummaterials mit einer vorbestimmten retikulierten Struktur. Dieses Verfahren umfaßt die Herstellung eines selbsttragenden retikulierten Polyurethanschaums; die Herstellung einer feuerfesten Masse, indem die Hohlräume des Polyurethanschaums mit einer wässerigen Formstoffsuspension gefüllt werden und diese Suspension abbindet; das Erhitzen der feuerfesten Masse auf eine Temperatur von etwa 120 °C (250 °F) über einen Zeitraum von zwei Stunden zum Trocknen; das Erzeugen von Hohlräumen in der feuerfesten Formmasse, indem die Temperatur der feuerfesten Formmasse auf 650 bis 850 °C erhöht wird, um den gesamten Schaum zu verflüchtigen; das Einbringen einer geschmolzenen Substanz, die aus Metallen oder Metallegierungen besteht, in die feuerfeste Formmasse, wobei die Menge der Substanz ausreicht, um die Hohlräume zu füllen, die zuvor von der retikulierten Struktur eingenommen wurden; und das Verfestigen der geschmolzenen Substanz, in dem die Temperatur so verringert wird, daß sie unter dem Schmelzpunkt der Substanz liegt; und das Auswaschen des Materials, das die feuerfeste Formmasse bildet.For example, U.S. Patent 3,616,841 discloses a method of making a foam material having a predetermined reticulated structure. This process involves the preparation of a self-supporting reticulated polyurethane foam; the preparation of a refractory mass by filling the voids of the polyurethane foam with an aqueous molding suspension and setting this suspension; heating the refractory mass to a temperature of about 120 ° C (250 ° F) for a period of two hours for drying; generating voids in the refractory molding material by raising the temperature of the refractory molding material to 650-850 ° C to volatilize all of the foam; introducing into the refractory molding compound a molten substance consisting of metals or metal alloys, the amount of substance sufficient to fill the cavities previously occupied by the reticulated structure were; and solidifying the molten substance by reducing the temperature to below the melting point of the substance; and washing out the material forming the refractory molding compound.

Dieses Verfahren erscheint jedoch für eine industrielle Anwendung, insbesondere für eine automatisierte Herstellung retikulärer metallischer Strukturen aus folgenden Gründen nicht sonderlich gut geeignet: Die Schaumstruktur bestimmt die technischen Parameter des Endproduktes, so daß die statistische Schwankungsbreite möglichst gering sein muß, um das Erreichen der technischen Parameter des Endproduktes zu gewährleisten. Überdies ist es notwendig, um die verzweigten Hohlräume der feuerfesten Formmasse mit einem geschmolzenen Metall zu füllen, die Formmasse auf Temperaturen zu erwärmen, die über der Schmelztemperatur der verwendeten Substanz liegen. Das führt dazu, daß das Metall nur sehr langsam erstarrt, wodurch das erstarrte Metall eine grobkörnige Gefügestruktur erhält, die eine geringere Festigkeit der Struktur zur Folge hat. Zur Lösung dieses Problems schlägt US 3.616.841 verschiedene Kühlmethoden wie beispielsweise Besprühen mit Wasser oder Luft vor. Der Kühleffekt wird jedoch erheblich abgeschwächt, da die Formmasse den Wärmefluß behindert. Auch die Herstellung massiver Metallbereiche gemeinsam mit der Gitterstruktur ist mit dem Problem der sehr langsam erfolgenden Abkühlung verbunden. Die angegebenen Verfahrensschritte lassen eine gelenkte Erstarrung des Metalls, um eine lunkerfreie und feinkörnige Gefügestruktur zu erhalten, kaum bzw. nicht zu. Überdies führt die langsam verlaufende Erstarrung des Metalls zu langen Prozeßzeiten, die einer automatisierten Fertigung ebenfalls entgegenstehen.However, this method does not appear to be particularly well suited for industrial use, in particular for the automated production of reticular metallic structures, for the following reasons: The foam structure determines the technical parameters of the end product, so that the statistical fluctuation range must be as low as possible to achieve the technical parameters of the final product. Moreover, in order to fill the branched cavities of the refractory molding compound with a molten metal, it is necessary to heat the molding compound to temperatures above the melting temperature of the substance used. As a result, the metal solidifies only very slowly, as a result of which the solidified metal acquires a coarse-grained microstructure, which results in a lower strength of the structure. To solve this problem, US 3,616,841 proposes various cooling methods such as spraying with water or air. However, the cooling effect is significantly reduced, since the molding material hinders the heat flow. The production of solid metal areas together with the grid structure is associated with the problem of very slow cooling. The specified process steps hardly allow a controlled solidification of the metal in order to obtain a void-free and fine-grained microstructure. Moreover, the slow solidification of the metal leads to long process times, which also preclude automated production.

DE 199 39 155 offenbart ein Verfahren zur Herstellung metallischer Gitterstrukturen, bei dem eine retikulierte Schaum-Vorstruktur in einen aufklappbaren Behälter eingesetzt wird, die Schaum-Vorstruktur mit einem feuerfesten Material infiltriert und das feuerfeste Material dann verfestigt wird. Anschließend wird das verfestigte feuerfeste Material aus dem aufklappbaren Behälter entnommen, die Schaum-Vorstruktur aus dem feuerfesten Material entfernt und der resultierende, vorgewärmte Körper in einen hitzebeständigen Behälter eingesetzt. Dieser Körper wird mit einer Metallschmelze infiltriert und nach dem Erstarren der Metallschmelze aus dem hitzebeständigen Behälter entnommen. Im Anschluß daran wird das feuerfeste Material aus dem Körper entfernt, wodurch im Ergebnis eine retikuläre Metallstruktur erhalten wird.DE 199 39 155 discloses a method for producing metallic lattice structures in which a reticulated foam pre-structure is inserted into a hinged container, the foam pre-structure is infiltrated with a refractory material and the refractory material is then solidified. Subsequently, the solidified refractory material is removed from the hinged container, the foam pre-structure removed from the refractory material and the resulting, preheated body is inserted into a heat-resistant container. This body is infiltrated with a molten metal and removed from the heat-resistant container after the molten metal solidifies. Subsequently, the refractory material is removed from the body, as a result of which a reticular metal structure is obtained.

Vorteil dieses Verfahrens ist unter anderem, daß im Vergleich zu dem genannten US-Patent Nr. 3.616.841 ein Verkleben der Schaum-Vorstruktur mit dem Eingußsystem und dem Eingußtrichter nicht mehr nötig ist. Dadurch wird nicht nur der Material- und Zeitverbrauch bei der Herstellung der Gußform deutlich gesenkt, sondern auch eine automatisierte Herstellung von retikulären metallischen Strukturen möglich.One advantage of this method is, inter alia, that bonding of the foam pre-structure to the sprue system and the sprue is no longer necessary as compared to said US Pat. No. 3,616,841. As a result, not only the material and time consumption in the production of the mold is significantly reduced, but also an automated production of reticular metallic structures possible.

Auch wenn das in DE 199 39 155 offenbarte Verfahren eine deutliche Vereinfachung der Herstellung von retikulären metallischen Strukturen bietet, ist nicht zu übersehen, daß der Material- und Zeitaufwand noch immer vergleichsweise hoch ist, so daß zwar eine automatisierte Fertigung möglich, eine Serienfertigung derartiger Strukturen aber noch immer einem - im Vergleich zur Serienfertigung vergleichbarer Erzeugnisse - hohen Aufwand verbunden ist. Insbesondere die große Menge an Formstoff, die getrocknet, gebrannt und nicht in den Prozeß zurückgeführt werden kann, stellt einen nicht zu kompensierenden Kostenfaktor dar. Die isolierende Wirkung des Formstoffes erfordert lange Prozeßzeiten. Eine Produktion unter Marktbedingungen ist so nicht möglich.Even if the process disclosed in DE 199 39 155 offers a clear simplification of the production of reticular metallic structures, it is not to be overlooked that the material and time expenditure is still comparatively high, so that an automated production is possible, a series production of such structures But still one - in comparison to the mass production of comparable products - high effort is connected. In particular, the large amount of molding material, which can be dried, fired and can not be returned to the process, represents an incalculable cost factor. The insulating effect of the molding material requires long processing times. A production under market conditions is not possible.

Aufgabe der Erfindung ist es daher, die Nachteile des Standes der Technik zu beseitigen. Es soll insbesondere ein Verfahren zur Herstellung metallischer Gitterstrukturen angegeben werden, das einen geringeren Materialeinsatz und eine schnellere Fertigung derartiger Strukturen und daraus folgend eine Serienfertigung ermöglicht.The object of the invention is therefore to eliminate the disadvantages of the prior art. In particular, a method for the production of metallic lattice structures is to be specified, which allows a lower use of materials and a faster production of such structures and consequently a series production.

Diese Aufgabe wird durch die Merkmale des Anspruchs 1 gelöst. Zweckmäßige Ausgestaltungen ergeben sich aus den Merkmalen der Ansprüche 2 bis 11.This object is solved by the features of claim 1. Advantageous embodiments emerge from the features of claims 2 to 11.

Nach Maßgabe der Erfindung ist zunächst vorgesehen, daß durch flächiges oder separates thermisches Verpressen der Vorstruktur derart, daß sie von au-ßen nach innen größer werdende Poren und damit einen gradierten Aufbau im Bereich der Verpressung aufweist, und für die Herstellung metallischer Gitterstrukturen zwar gleichfalls in grundsätzlich bekannter Weise eine retikulierte Vorstruktur, bevorzugt eine PU-Schaumstruktur, zu verwenden, aber deren Stege zuvor durch ein- oder mehrmaliges Beschichten, mittels eines oder mehrerer verschiedener organischer Materialien, zu verdicken. Überraschenderweise wurde nämlich gefunden, daß somit, gepaart mit den sonstigen erfindungsgemäßen Verfahrensschritten, das Einfließen des Metalls erleichtert wird. Gleichzeitig können so die mechanischen Eigenschaften der Struktur gezielt beeinflußt werden, wobei wesentlich ist, daß die Reproduzierbarkeit der Kennwerte gegenüber dem Stand der Technik nachhaltig verbessert ist.According to the invention, it is initially provided that by planar or separate thermal compression of the pre-structure such that it has from the outside inwardly increasing pores and thus a graded structure in the region of the compression, and for the production of metallic lattice structures although in basically known to use a reticulated preform, preferably a PU foam structure, but to thicken their webs previously by one or more times coating, by means of one or more different organic materials. Surprisingly, it was found that, thus, coupled with the other method steps according to the invention, the inflow of the metal is facilitated. At the same time, the mechanical properties of the structure can thus be influenced in a targeted manner, wherein it is essential that the reproducibility of the characteristic values be sustainably improved compared with the prior art.

Durch Änderung der Rezeptur und/oder der Prozeßführung wird die Dicke der Stege der PU-Schaumsstruktur den jeweiligen, vom Verwendungszweck der Metallgitterstruktur bestimmen Anforderungen angepaßt. Erfindungsgemäß ist das Beschichten der Stege der Vorstruktur mittels flüssigen und/oder festen Materialien vorgesehen, z. B. durch Eintauchen der Vorstruktur in flüssiges Wachs und anschließendem Beschichten mit Wachspulver (das eine andere Schmelztemperatur hat) oder einem Polymerpulver, etwa Polystyrol- oder Polyamidpulver, die auch einen geringen Anteil Kleber, bevorzugt 5 Vol.%, implizieren können. Namentlich der Einsatz von Pulver verhindert ein Verkleben der Struktur und sichert eine gleichmäßig dicke Schicht zumal sich keine Membranen (Zellhäute) zwischen den Stegen ausbilden.By changing the recipe and / or the process control, the thickness of the webs of the PU foam structure is adapted to the respective requirements determined by the intended use of the metal grid structure. According to the invention, the coating of the webs of the pre-structure by means of liquid and / or solid materials is provided, for. Example by immersion of the preliminary structure in liquid wax and subsequent coating with wax powder (which has a different melting temperature) or a polymer powder, such as polystyrene or polyamide powder, which may also imply a small amount of adhesive, preferably 5 vol.%. In particular, the use of powder prevents sticking of the structure and ensures a uniformly thick layer, especially since no membranes (cell skins) form between the webs.

Nachdem derart die Vorstruktur erzeugt wurde, wird sie für den Gießvorgang in einem Formstoff fixiert.After the preliminary structure has been produced in this way, it is fixed in a molding material for the casting process.

Hierbei wird die Vorstruktur paßgenau in einen Rahmen eingelegt und mit Formstoff so ausgegossen, daß sie nicht vollständig umhüllt ist, sondern vielmehr eine Berandung von 2 bis 5 mm frei bleibt. Die verbleibenden Hohlräume werden mit Sand gefüllt und verpreßt. Die Umhüllung der Vorstruktur erfolgt mit einem Keramikschlicker, wobei die Umhüllung gegebenenfalls wiederholt wird, um eine stabile Schicht zu erzeugen. Das eingebettete Formteil kann zuvor bei Bedarf nachgearbeitet werden, so z. B. durch Fräsen und Bohren, um Noppen oder andere geometrische Gebilde aus festem Material in der Struktur zu erzeugen, oder durch Durchbohrungen, um mittels Kernstifte Rohre in die Struktur einzugießen. Die Einarbeitung von durchgängigen, aber auch nichtdurchgängigen Bohrungen, Rillen oder dergleichen in die eingegossene Vorstruktur erfolgt erfindungsgemäß in einem Abstand von wenigstens zwei Poren zueinander. Dieser Verfahrensschritt hat zur Folge, daß die Dichte des Werkstoffes und daraus folgend seine Stabilität anwendungsspezifisch erhöht werden kann; gleichzeitig ergibt sich eine nachhaltig verbesserte Wärmeleitfähigkeit. Die Durchmesser der Aussparungen werden entsprechend den Festigkeitsanforderungen an den Werksstoff optimiert.Here, the Vorstruktur is inserted in register in a frame and filled with molding material so that it is not completely covered, but rather a boundary of 2 to 5 mm remains free. The remaining cavities are filled with sand and pressed. The sheathing of the pre-structure is carried out with a ceramic slurry, wherein the sheath is optionally repeated to produce a stable layer. The embedded molding can be refinished beforehand if necessary, such. B. by milling and drilling to produce knobs or other geometric shapes of solid material in the structure, or through holes to pour by means of core pins pipes in the structure. The incorporation of continuous, but also non-continuous holes, grooves or the like in the cast-in pre-structure is carried out according to the invention at a distance of at least two pores to each other. This process step has the consequence that the density of the material and consequent its stability can be increased application specific; At the same time there is a sustained improvement in thermal conductivity. The diameters of the recesses are optimized according to the strength requirements of the material.

Ein wesentlicher weiterer Verfahrensschritt ist die thermische Entfernung der Vorstruktur durch Ausschmelzen und/oder Ausbrennen, hierfür wird der verfestigte Struktur-Keramikverbund aus dem Rahmen herausgenommen und in eine Küvette, deren Boden mit losem feuerfesten Material, vorzugsweise Gießereisand, gefüllt ist, eingebracht. Alternativ ist es auch möglich das Formteil ohne Küvette mittels Infrarot oder Mikrowellen zu trocknen und auszubrennen.An essential further process step is the thermal removal of the preliminary structure by melting and / or burnout, for this purpose, the solidified structure-ceramic composite is taken out of the frame and placed in a cuvette whose bottom is filled with loose refractory material, preferably foundry sand. Alternatively, it is also possible to dry and burn out the molded part without cuvette by means of infrared or microwaves.

Die Küvette umfaßt eine Schablone aus Formsand/Keramik für die Gießkanäle; zudem besitzt sie eine Isolierung, um ein vorzeitiges Auskühlen des Formteiles zu verhindern. Vorzugsweise besteht die Küvette aus einem gepreßten Formsand/Keramikverbund, wobei der Formsand recycelbar und zudem die Verwendung von Formstoff auf das notwendige Volumen reduziert ist.The cuvette comprises a molding sand / ceramic stencil for the runners; In addition, it has insulation to prevent premature cooling of the molded part. Preferably, the cuvette consists of a pressed molding sand / ceramic composite, wherein the molding sand is recyclable and also the use of molding material is reduced to the necessary volume.

Diesen Verfahrensschritten schließt sich das Gießen und Gutformen an. Die Küvette mit dem Formteil wird hierzu in einen druckfesten Behälter eingebracht, mit flüssigem Metall gefüllt, der Behälter geschlossen und evakuiert, um das Formteil und die Schmelze zu entgasen. Durch Belüften des Behälters wird die Schmelze in das Formteil gepreßt. Der Schmelztiegel befindet sich im Behälter, die Küvette ist durch ein Rohr mit der Schmelze verbunden.These process steps are followed by casting and molding. The cuvette with the molding is placed for this purpose in a pressure-resistant container, filled with liquid metal, the container is closed and evacuated to degas the molding and the melt. By aerating the container, the melt is pressed into the molding. The crucible is located in the container, the cuvette is connected by a tube to the melt.

Nach dem Gießen und dem Erstarren der äußersten Metallschicht wird das Formteil aus der Küvette entnommen. Die Erstarrung kann gerichtet über die angegossenen Metallteile erfolgen.After casting and solidification of the outermost metal layer, the molding is removed from the cuvette. The solidification can be done directionally over the cast metal parts.

Grundsätzlich kann die Vorstruktur auch durch Schüttung granularer mineralischer Stoffe oder granularer organischer Stoffe mit einem mineralischen Überzug erzeugt werden. Durch solche granularen Strukturen, bevorzugt in kugelförmigen Pellets, ist es möglich, die Porengrößen der Gitterstruktur wesentlich zu erweitern. Während mit PU-Schaumstrukturen üblicherweise Porengrößen von max. 5 ppi, das entspricht einen mittleren Porendurchmesser von 8 bis 10 mm, erzeugt werden können, lassen sich hiermit Porengrößen im Bereich von 1 bis 3 cm realisieren. Hierzu sind die Pellets großflächig miteinander zu verkleben, damit sicher ist, daß als Gießkanal nur die Hohlräume zwischen den Pellets genutzt werden. Eine Beschichtung der damit geschaffenen Vorstruktur ist nicht vorgesehen und auch nicht notwendig, da der gewünschte keramische Überzug bereits vorhanden ist. Die sonstigen erfindungsgemäßen Verfahrensschritte werden beibehalten. Die so erzeugte Struktur bietet sich als vielfältiger Leichtbauwerkstoff an.In principle, the preliminary structure can also be produced by pouring granular mineral substances or granular organic substances with a mineral coating. By such granular structures, preferably in spherical pellets, it is possible to significantly expand the pore sizes of the lattice structure. While with PU foam structures usually pore sizes of max. 5 ppi, which corresponds to an average pore diameter of 8 to 10 mm, can be produced, can be realized with this pore sizes in the range of 1 to 3 cm. For this purpose, the pellets are glued together over a large area, so that it is certain that only the cavities between the pellets are used as a pouring channel. A coating of the pre-structure thus created is not provided and also not necessary because the desired ceramic coating is already present. The other method steps according to the invention are retained. The structure created in this way offers itself as a versatile lightweight construction material.

Nachfolgend wird die Erfindung anhand von Ausführungsbeispielen näher erläutert. Dabei zeigen

  • Fig. 1 in schematischer Darstellung einen Ausschnitt der beschriebenen retikulierten Vorstruktur, ausgeführt als PU-Schaumstruktur 1 (Vorstruktur) mit den Stegen 2;
  • Fig. 2 die PU-Schaumstruktur 1 mit der Beschichtung 3, die sich bevorzugt aus zwei Schichten, nämlich einer Schicht, die aus flüssigem Wachs erzeugt ist, und einer Polymerschicht, zusammensetzt;
  • Fig. 3 die mit dem Formstoff 4 (Keramikschlicker) umhüllte PU-Schaumstruktur 1, die so in beschriebener Weise bearbeitet werden kann;
  • Fig. 4 in Draufsicht die mögliche Form (kreisförmig, oval) von Pellets 7, die aus granularen mineralischen Stoffen oder granularen organischen Stoffen mit einem mineralischen Überzug bestehen, und durch Schüttung und Verklebung zusammengefügt sind, wobei sich die so erzeugte Vorstruktur gegenüber der PU-Schaumstruktur 1 durch wesentlich vergrößerte Poren auszeichnet;
  • Fig. 5 den gebrannten Formstoff/Formteil 5 und die Poren 6, die durch das thermische Entfernen der Stege entstanden sind;
  • Fig. 6 das Formteil 5, das in die Küvette 8 eingebracht ist;
  • Fig. 7 die Küvette 8, die ihrerseits in den druckfesten Behälter 9 eingebracht ist.
The invention will be explained in more detail by means of exemplary embodiments. Show
  • Figure 1 shows a schematic representation of a section of the described reticulated Vorstruktur, executed as PU foam structure 1 (Vorstruktur) with the webs 2.
  • 2 shows the PU foam structure 1 with the coating 3, which is preferably composed of two layers, namely a layer which is produced from liquid wax, and a polymer layer;
  • FIG. 3 shows the PU foam structure 1 encased in the molding material 4 (ceramic slip), which can be processed in the manner described; FIG.
  • 4 shows in plan view the possible shape (circular, oval) of pellets 7, which consist of granular mineral substances or granular organic substances with a mineral coating, and are joined together by pouring and bonding, wherein the preliminary structure thus produced is opposite to the PU Foam structure 1 characterized by significantly enlarged pores;
  • 5 shows the fired molding material / molded part 5 and the pores 6, which are formed by the thermal removal of the webs;
  • 6 shows the molded part 5, which is introduced into the cuvette 8;
  • Fig. 7, the cuvette 8, which in turn is introduced into the pressure-resistant container 9.

Liste der verwendeten BezugszeichenList of reference numbers used

11
PU-Schaumstruktur (Vorstruktur)PU foam structure (pre-structure)
22
Stegweb
33
Beschichtungcoating
44
Formstoffmolding
55
gebrannter Formstoff/Formteilburned molding material / molding
66
Porepore
77
Pelletpellet
88th
Küvettecuvette
99
Behältercontainer

Claims (11)

  1. Method to produce metallic lattice structures using a reticulated structure, preferably a reticulated foam structure, wherein the pouring channels formed by such structures are stabilised with organic materials before filling of the metal, characterised in that it comprises the steps
    (a) planar or separate thermal moulding of the pre-structure such that it displays pores which become larger from the outside to the inside and thus a graduated structure in the area of moulding;
    (b) thickening of the lattice elements of the reticulated structure through single or multiple coating with an organic material or different, and in this case preferably two organic materials;
    (c) placing of the coated structure into a correspondingly shaped vessel which is open to the top and pouring out of the structure with a refractory mass;
    (d) provision of continuous and/or discontinuous holes, grooves or the like in the cast pre-structure at a distance of at least two pores from each other;
    (e) removal of the solidified structure/ceramic composite from the vessel and placing in a cuvette whose base is filled with loose refractory material;
    (f) elimination of the pre-structure through thermal conversion in a furnace;
    (g) placing of the cuvette into a pressure-resistant vessel;
    (h) placing of a foundry template of moulding sand or ceramic onto the cuvette and the upper surface of the ceramic body, such that the edges of the ceramic body remain free as pouring channels and the pouring template forms insulation to the cuvette in order to avoid premature solidifying of the metal to be poured in;
    (i) filling in of the metal/closing of the pressure-resistant vessel;
    (j) evacuation of the pressure-resistant vessel to degas the metal and spaceholder; and
    (k) reaerating of the vessel, removal of the cuvette and cooling of the same.
  2. Method to produce metallic lattice structures according to Claim 1, characterised in that the organic material serving to coat the lattice elements is liquid wax.
  3. Method according to Claim 1, characterised in that the organic material serving to coat the lattice elements is a wax powder.
  4. Method according to Claim 1, characterised in that the organic material serving to coat the lattice elements is polystyrene powder.
  5. Method according to Claim 1, characterised in that the organic material serving to coat the lattice elements is polyamide powder.
  6. Method according to Claims 1, 4 and 5, characterised in that the polystyrene/polyamide implicates a small, preferably 5% proportion of gluten.
  7. Method according to Claims 1 to 6, characterised in that in case of multiple coating of the lattice elements of the reticulated structure the individual coatings are applied at different temperatures in the range from 40 to 80 °C.
  8. Method according to Claims 1 to 7, characterised in that the multiple coating of the lattice elements is performed with two wax modifications which display different melting temperatures.
  9. Method according to Claims 1 to 7, characterised in that the multiple coating of the lattice elements is produced with a wax layer and a powder layer.
  10. Method according to Claim 1, characterised in that the loose refractory material used in step (e) is foundry sand.
  11. Method according to Claim 1, characterised in that filled granular mineral materials or granular organic materials with a mineral coating are used as the pre-structure.
EP05011668A 2004-06-02 2005-05-31 method for producing metallic reticular structures Not-in-force EP1604756B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL05011668T PL1604756T3 (en) 2004-06-02 2005-05-31 method for producing metallic reticular structures

Applications Claiming Priority (2)

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DE102004026959A DE102004026959B3 (en) 2004-06-02 2004-06-02 Process for producing metallic lattice structures
DE102004026959 2004-06-02

Publications (3)

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EP1604756A2 EP1604756A2 (en) 2005-12-14
EP1604756A3 EP1604756A3 (en) 2005-12-28
EP1604756B1 true EP1604756B1 (en) 2007-03-21

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AT (1) ATE357302T1 (en)
DE (2) DE102004026959B3 (en)
ES (1) ES2285604T3 (en)
PL (1) PL1604756T3 (en)

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US8875395B2 (en) 2009-10-29 2014-11-04 Universiteit Gent Manufacturing heat exchanger from porous medium and conduits

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DE102014118177A1 (en) 2013-12-19 2015-06-25 Mayser Gmbh & Co. Kg Process for producing metallic moldings, metallic moldings and method for forming a component with a heat exchanger
DE102014118178A1 (en) 2013-12-19 2015-06-25 Mayser Gmbh & Co. Kg Method for producing a metallic structure
US9789534B2 (en) 2015-01-20 2017-10-17 United Technologies Corporation Investment technique for solid mold casting of reticulated metal foams
US9789536B2 (en) 2015-01-20 2017-10-17 United Technologies Corporation Dual investment technique for solid mold casting of reticulated metal foams
US9737930B2 (en) 2015-01-20 2017-08-22 United Technologies Corporation Dual investment shelled solid mold casting of reticulated metal foams
US10035174B2 (en) 2015-02-09 2018-07-31 United Technologies Corporation Open-cell reticulated foam
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Also Published As

Publication number Publication date
EP1604756A2 (en) 2005-12-14
ATE357302T1 (en) 2007-04-15
EP1604756A3 (en) 2005-12-28
DE102004026959B3 (en) 2006-02-16
DE502005000489D1 (en) 2007-05-03
PL1604756T3 (en) 2007-08-31
ES2285604T3 (en) 2007-11-16

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