EP1721689B1 - Verfahren zur herstellung eines gussteils - Google Patents
Verfahren zur herstellung eines gussteils Download PDFInfo
- Publication number
- EP1721689B1 EP1721689B1 EP05710586A EP05710586A EP1721689B1 EP 1721689 B1 EP1721689 B1 EP 1721689B1 EP 05710586 A EP05710586 A EP 05710586A EP 05710586 A EP05710586 A EP 05710586A EP 1721689 B1 EP1721689 B1 EP 1721689B1
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- European Patent Office
- Prior art keywords
- mold
- mixture
- casting process
- cast article
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- 238000000034 method Methods 0.000 title claims abstract description 54
- 239000000203 mixture Substances 0.000 claims abstract description 51
- 238000005266 casting Methods 0.000 claims abstract description 50
- 229910052751 metal Inorganic materials 0.000 claims abstract description 48
- 239000002184 metal Substances 0.000 claims abstract description 48
- 239000008187 granular material Substances 0.000 claims abstract description 43
- 238000010438 heat treatment Methods 0.000 claims abstract description 27
- 238000000465 moulding Methods 0.000 claims abstract description 19
- 239000003232 water-soluble binding agent Substances 0.000 claims abstract description 16
- 238000001816 cooling Methods 0.000 claims abstract description 14
- 239000006260 foam Substances 0.000 claims abstract description 11
- 230000013011 mating Effects 0.000 claims abstract description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 8
- 238000003756 stirring Methods 0.000 claims abstract description 4
- 238000001704 evaporation Methods 0.000 claims abstract description 3
- 238000002156 mixing Methods 0.000 claims abstract description 3
- 239000004576 sand Substances 0.000 claims description 39
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 8
- 229910000838 Al alloy Inorganic materials 0.000 claims description 6
- 239000004372 Polyvinyl alcohol Substances 0.000 claims description 6
- 229920002472 Starch Polymers 0.000 claims description 6
- 239000008107 starch Substances 0.000 claims description 6
- 235000019698 starch Nutrition 0.000 claims description 6
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 4
- 229910000881 Cu alloy Inorganic materials 0.000 claims description 3
- 229910000861 Mg alloy Inorganic materials 0.000 claims description 3
- 238000004064 recycling Methods 0.000 claims description 2
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 claims 1
- 229910000831 Steel Inorganic materials 0.000 claims 1
- 229910045601 alloy Inorganic materials 0.000 claims 1
- 239000000956 alloy Substances 0.000 claims 1
- 229910052742 iron Inorganic materials 0.000 claims 1
- 239000010959 steel Substances 0.000 claims 1
- 239000007789 gas Substances 0.000 abstract description 8
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 43
- 229920005989 resin Polymers 0.000 description 10
- 239000011347 resin Substances 0.000 description 10
- 239000011230 binding agent Substances 0.000 description 9
- 239000000463 material Substances 0.000 description 9
- 238000010112 shell-mould casting Methods 0.000 description 5
- 206010044565 Tremor Diseases 0.000 description 4
- 229910001092 metal group alloy Inorganic materials 0.000 description 4
- 239000011435 rock Substances 0.000 description 4
- 239000000377 silicon dioxide Substances 0.000 description 4
- KRKNYBCHXYNGOX-UHFFFAOYSA-N citric acid Chemical compound OC(=O)CC(O)(C(O)=O)CC(O)=O KRKNYBCHXYNGOX-UHFFFAOYSA-N 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 235000019645 odor Nutrition 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- IMROMDMJAWUWLK-UHFFFAOYSA-N Ethenol Chemical compound OC=C IMROMDMJAWUWLK-UHFFFAOYSA-N 0.000 description 2
- 230000001877 deodorizing effect Effects 0.000 description 2
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 2
- 239000004088 foaming agent Substances 0.000 description 2
- 238000003801 milling Methods 0.000 description 2
- 239000003110 molding sand Substances 0.000 description 2
- 229910052863 mullite Inorganic materials 0.000 description 2
- 229910052609 olivine Inorganic materials 0.000 description 2
- 239000010450 olivine Substances 0.000 description 2
- 229920001568 phenolic resin Polymers 0.000 description 2
- 229910052845 zircon Inorganic materials 0.000 description 2
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 description 2
- GGAUUQHSCNMCAU-ZXZARUISSA-N (2s,3r)-butane-1,2,3,4-tetracarboxylic acid Chemical compound OC(=O)C[C@H](C(O)=O)[C@H](C(O)=O)CC(O)=O GGAUUQHSCNMCAU-ZXZARUISSA-N 0.000 description 1
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 1
- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical compound [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 description 1
- 229910001018 Cast iron Inorganic materials 0.000 description 1
- 229910001208 Crucible steel Inorganic materials 0.000 description 1
- 229920001353 Dextrin Polymers 0.000 description 1
- 239000004375 Dextrin Substances 0.000 description 1
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
- 244000048199 Hibiscus mutabilis Species 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 125000000129 anionic group Chemical group 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 239000007767 bonding agent Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 239000003431 cross linking reagent Substances 0.000 description 1
- 235000019425 dextrin Nutrition 0.000 description 1
- 238000004512 die casting Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- SLGWESQGEUXWJQ-UHFFFAOYSA-N formaldehyde;phenol Chemical compound O=C.OC1=CC=CC=C1 SLGWESQGEUXWJQ-UHFFFAOYSA-N 0.000 description 1
- 231100001261 hazardous Toxicity 0.000 description 1
- 238000005058 metal casting Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910021652 non-ferrous alloy Inorganic materials 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 229910021653 sulphate ion Inorganic materials 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 239000008256 whipped cream Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
- B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives
- B22C1/10—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives for influencing the hardening tendency of the mould material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
- B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
- B22C1/18—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents
- B22C1/186—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents contaming ammonium or metal silicates, silica sols
- B22C1/188—Alkali metal silicates
-
- 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
- B22C9/10—Cores; Manufacture or installation of cores
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
- B22D29/001—Removing cores
- B22D29/005—Removing cores by vibrating or hammering
Definitions
- This invention relates to a casting process, more particularly, to a casting process that is capable of substituting for the conventional shell mold process and capable of readily removing a mold.
- a shell mold process is known as disclosed in Japanese Patent Early-Publication No. 5-261478 .
- the shell mold process employs a binder that includes a phenol-formaldehyde resin. Molding sand that is coated with such a binder is charged into a heated mold using a blowing introducing process. The coating binder of the charged molding sand is then hardened by the heat transferred from the mold.
- a core mold that is poured and molded has a higher hardness. This needs a core-knockout process to apply greater impact forces to the core mold to collapse or crush it to remove it from a cast article.
- the cast article should be sufficiently cooled before it is heat treated. As much as 70-80% of the sand grains can be removed from the cast article when the relatively high impact forces of not less than 1MPa at an operating frequency as high as 10Hz or more are applied for 10 seconds or more. Consequently, the resulting collapsed or crushed core mold causes the residues of its sand grains (core-sand grains) or crushed rocks to remain in the cast article during the heat treatment of it and the following processes. Therefore, the process of removing the residues may be needed once again. To recycle and use recovered residues of the collapsed core mold from the cast article, a roasting process is generally required to achieve this purpose.
- the binder In the shell mold process, the binder generates volatile gases when it is to be hardened by the heat transferred from the mold.
- the volatile gases involve unpleasant odors.
- the phenol-formaldehyde, phenol, and ammonium gases impose a biohazard for humans.
- a pourable foundry molding compositions which comprise refractory filler material, water, a bonding agent and a foaming agent selected from the class of anionic alcohol sulphate foaming agents such that it produces a foam structure in the composition of an inherently limited life ensuring dispersion of the foam shortly after pouring.
- GB 1 361 027 and CH 470 922 disclose casting molds using a self-hardening material.
- an aggregate granular material means that it comprises one or more of silica, zircon, sand, olivine sand, chromite sand, mullite, artificial sand, and so forth.
- the term "after a molten metal is solidified" or "the solidified molten metal” refers to the molten metal being solidified and hardened.
- the temperatures at which the molten metal can be solidified and hardened are various, and depend on the kinds of the processes and the materials of the molten metal.
- the term “during a cooling process of a cast article” refers to the period to cool the cast article to lower the temperature until the cast article is cooled enough to cause no deformation of it when it is removed from the completed mold.
- the term “during a cooling process of the cast article” refers to the period to cool the cast article lower than about the 520 deg. C used for a typical solution treatment, but higher than the conventional cooling range from 70 deg. C to 111 deg. C, such as the period to cool the cast article at temperatures down to 300 deg. C.
- One aspect of the present invention provides a casting process.
- the process comprises the steps of:
- the mold that is cast in the hardened mixture is a core mold.
- a mating mold i.e., a master mold, may be a metal mold or a sand mold.
- a complete mold refers to an assembly that is assembled from the master mold with at least one molding mold, i.e., the core mold.
- Such an assembly refers to a mold for which the molten metal can be poured.
- the complete mold may include any element required for the pouring process, as well as the master mold and the core mold.
- the casting process of the present invention may further comprise the steps of returning the aggregate granular material, and recovering the returned aggregate granular material.
- the returned and recovered aggregate granular material is preferably recycled and used for molding a mold.
- the steps of returning and recovering the aggregate granular material are mechanical recovering processes.
- the cast article may be cast in an aluminum alloy, a magnesium alloy, a copper alloy, and so forth.
- the heat treatment may be the T6 treatment or the T7 treatment.
- the step of removing the completed mold from the cast article is to shake the completed mold.
- it includes impact forces of less than 1MPa at an operating frequency at less than 30Hz being applied in the completed mold for less than 30 seconds, within from 5 to 20 minutes after the molten metal is poured.
- Fig. 1 is a flowchart that schematically shows the steps of the casting process of the present invention. The principles of the casting process of the present invention will now be described in line with the flowchart of Fig. 1 .
- a first step one or more kind of aggregate granular material, one or more kind of a water-soluble binder, and water are mixed to form a mixture of the aggregate granular material.
- the resulting mixture is then stirred to cause it to foam (the first or preparing step 1).
- the foamed mixture obtained in the first step is charged into a molding space.
- the moisture within the charged mixture is then evaporated to harden the charged mixture to mold a mold with the hardened mixture, i.e., the aggregate granular material (the second or molding step 2).
- a third step at least one mold (a core mold) that is cast in the hardened mixture is assembled with a mating mold (a master mold) to form a completed mold (the third or assembling step 3).
- a molten metal is poured into the completed mold (the fourth or pouring step 4).
- the core mold is removed ("core out") from a cast article that is composed of the solidified molten metal to disassemble the completed mold during a process of cooling the cast article after the molten metal is solidified (the fifth or disassembling step 5).
- a heat treatment is applied to the cast article (the sixth or heat treatment step 6).
- the resulting completed cast article is thus produced.
- the aggregate granular material comprises one or more materials made of silica, zircon, sand, olivine sand, chromite sand, mullite, artificial sand, and so forth.
- a desirable water-soluble binder has water-solubility at room temperature.
- the water-soluble binder having the water-solubility at room temperature can be formed into the aggregate granular material without heating. This can save the energy and time required for heating the binder and the aggregate granular material that would otherwise be required.
- This advantage of the present invention is significantly contrasted with the prior-art production of coated sand in the conventional shell molding process.
- a suitable water-soluble binder is a polyvinyl alcohol or its derivative, or a starch or its derivative, or both. Because the water-soluble binder can be readily evaporated or dissolved, the core mold can be readily removed from the cast article in which the molten metal has been solidified in the fifth disassembling step 5.
- the aggregate granular material preferably contains the water-soluble binder from 0.1 to 5.0 wt% based on the total weight of the aggregate granular material.
- One or more kind of the water-soluble binder and one or more kind of the aggregate granular material and water are mixed to form a mixture of the aggregate granular material.
- the mixture of the aggregate granular material is stirred to cause it to foam and thus it is formed as a whipped cream mixture.
- the foamed mixture is charged into the molding space, and the moisture within the charged mixture is then evaporated to harden the charged mixture to mold a core mold.
- This core mold has a hollow structure due to the foam within the aggregate granular material.
- the hollow core mold has a porosity of 3 to 60 %. For example, if the hollow core mold is about 40 mm in thickness, more than 50% of a water-soluble binder is aggregated in the surface layer between the surface of the core mold and a depth of 10 mm therefrom.
- the distribution of the foam in the aggregate granular material and the moisture content of the binder are concentrated at the center portion of the core mold. After the moisture is evaporated, the center portion of the core mold has thus a low density of the charged aggregate granular material.
- the master mold may be a metal mold or a sand mold that is composed of, e.g., the aggregate granular material.
- the master mold is a metal mold
- the casting process is a low-pressure casting. If the master mold is a metal mold, the casting process of the present invention is not limited to the low-pressure casting, but may be applied to a back-pressure casting, a die-casting, or a gravitational casting for casting the metal mold and so forth.
- the embodiment employs, without limitation, an aluminum alloy as the molten metal to be poured into the completed mold.
- an aluminum alloy as the molten metal to be poured into the completed mold.
- other materials including a light metal alloy or a nonferrous alloy (e.g., a magnesium alloy or a copper alloy) may be used.
- a cast iron, a cast steel, or an iron metal alloy may be used. If the iron metal alloy is used as the molten metal, a mold wash or a facing material may be desirably applied on the core mold.
- the core mold is removed from the cast article during the periods for a process to cool the cast article or the period to cool the cast article and lower the temperature until the cast article is cooled enough to cause no deformation of it when it is removed from the completed mold.
- the material of the molten metal in the fourth or pouring step 4 is an aluminum alloy
- the term "during the periods of a cooling process of the cast article” refers to the period to cool the cast article lower than about the 520 °C used in the solution treatment, but higher than the conventional cooling range from 70 to 111°C, such as the period to cool the cast article at a temperatures down to 300 °C.
- the heat treatment is the T6 treatment or the T7 treatment and so forth.
- the heat treatment step 6 of the casting process of the present invention may be followed by additional steps, if needed.
- the additional steps include a step 7 of returning the used aggregate granular material (i.e., the core-sand grains) or crushed rocks, a step 8 of milling the crushed rocks, and a step 9 of mechanically recovering the returned sand grains.
- the returned and recovered sand grains can be recycled and used for molding a new core mold.
- the prior-art shell molding process needs heating elements for the production of the resin-coated sand and needs deodorizing equipment for removing the hazardous gases due to heating the resin.
- the preparing step 1 needs neither a heating element nor deodorizing equipment.
- Two whipped and creamy mixtures, A and B, that are prepared in the preparing step 1, are separately pressure-charged into a respective cavity (not shown) in the corresponding metal mold (not shown), which is maintained at a temperature of 250 °C, and held for a period of one minute.
- the moisture content within the respective mixture is evaporated to harden the mixture such that a respective core mold is removed from a respective cavity of the corresponding metal mold (the molding step 2).
- the core mold is assembled with the mating mold to form the completed mold (the assembling step 3).
- the respective core mold and the corresponding master metal mold of a low-pressure molding machine are assembled to form the completed mold so that it is ready and waiting for the pouring step.
- the molten metal is poured into the respective completed mold (the pouring step 4).
- a molten metal of an aluminum metal alloy AC4C having a temperature of 720 °C is poured from beneath into the respective completed mold using the low-pressure molding machine (not shown). With the temperature of 720 °C of the molten metal, the binder can be volatilized or dissolved such that the respective core molds can be readily removed from the corresponding cast article in the following step.
- the respective core mold is removed from the corresponding cast article during the periods of a cooling process of the cast article after the molten metal is solidified (the removing step 5).
- the prior-art shell mold process needs a process to apply a greater impact to the core mold to collapse it to remove it from the cast article that has been sufficiently cooled.
- the core mold does not need either significant cooling nor a following step to apply a high impact force on it to remove it from the cast article. Accordingly, the core mold can be easily removed from the cast article such as by means of weak shakings, described below.
- the cast article that is composed of the solidified molten metal is removed from the completed mold 10 minutes after the pouring is completed.
- the weak shakings or the impact forces of less than 1MPa at an operating frequency of 20Hz are applied to the cast article having a temperature of 350°C for less than 20 seconds to remove sand particles such that the core mold is completely removed from the cast article.
- the weak shakings or the impact forces of less than 1MPa at an operating frequency of less than 30 Hz are continued in periods of less than 30 seconds, within from 5 to 20 minutes after said molten metal is poured.
- the core mold can be also completely removed from the cast article.
- the cast article is heat-treated (the heat treatment step 6) after its pouring gate and casting fines are removed.
- the pouring gate and casting fines of the cast article are removed before the heat treatment step, they may be removed after the heat treatment step.
- the heat treatment step 6 of this embodiment may be followed by the returning step 7, the milling step 8, and the mechanical recovery step 110, as shown in Fig. 1 .
- the used aggregate grains or crushed rocks are salvaged or returned from just the core mold and thus the salvaged and recovered aggregate grains may be readily recycled and used for molding a new mold.
- Fig. 2 shows a comparative flowchart of the prior-art casting processes based on the shell molding process as disclosed in Japanese Patent Early-Publication No. 5-261478 .
- the prior-art process of Fig. 2 employs resin-coated sand.
- the resin-coated sand is prepared and commercially delivered from a manufacturer that differs from a castings industry maker. Therefore, a step 11 of preparing the coated-sand is typically carried out at a site that differs from casting facilities. This causes difficulties in recycling and using the used resin-coated resin for molding a mold, even if the used resin coated resin may be successfully salvaged and recovered. This contrasts with the casting process of the present invention.
- the castings industry maker heats the commercially available resin-coated sand to mold a core mold (as shown in a step 12), and assembles it with another mold into a completed mold (as shown in a step 13). Then the molten metal is poured into the completed mold (as shown in a step 14). The core mold is then removed or shaken out from the cast article with a furnace for removing sand (as shown in a step 15). After the cast article is sufficiently cooled (as shown in a step 16) the molded sand should be completely shaken out by using the knockout process (as shown in a step 17).
- the cast article is then subjected to the heat treatment (as shown in a step 18).
- the core sand that includes sand clots is returned (as shown in a step 19).
- the returned sand is milled (as shown in a step 20), roasted (as shown in a step 21), and mechanically recovered (as shown in a step 22) by a company that produces resin-coated sand.
- a company mostly does the production away from the job site of the returning step 19.
- the number of processes in the casting process of the present invention as shown in Fig. 1 is lower than the number of the prior-art processes as shown in Fig. 2 .
- the removing step 5 of the inventive casting process of the present invention can be readily carried out with a means for removing the sand such as a means using weaker shakings, since the inventive casting process employs the collapse-prone core molds.
- the prior-art casting process as shown in Fig. 2 needs the removing step 15 for removing the sand by means of the furnace for removing sand, the cooling step 16 for sufficiently cooling the cast article, and the knockout process 17.
- the inventive casting process needs no roasting process 21 for returning and recovering the used sand as in the prior-art casting process.
- Fig. 3 is a graphic representation of the relationships between the temperatures of the cast article and the periods during the step 5 to remove a completed mold from the cast article and the process 6 to apply the heat treatment to the cast article of the embodiment of the present invention.
- Fig. 4 is also a graphic representation similar to Fig. 3 , but for the corresponding steps of the prior-art process.
- the prior-art process there is a sufficient cooling of the cast article (the step 16 of Fig. 2 ) followed by removing the sand with a knockout process (the step 17 of Fig. 2 ).
- the cast article is then re-heated to subject it to the T6 treatment.
- the prior-art process thus needs the time to cool the cast article, the time to re-heat the cast article to subject it to the heat treatment, and consumes energy.
- the molten metal having a temperature of 720°C is poured into the completed mold.
- the cast article that is composed of the solidified molten metal is then removed from the completed mold followed by the core mold being removed from the cast article.
- the cast article needs no greater impact force to be applied to it after it is sufficiently cooled.
- the cast article thus can be immediately subjected to the heat treatment. This causes a reduction of the time to cool the cast article, the time to re-heat it for the heat treatment, the consumption of energy, and the number of processes. When consuming energy, it is not necessary to cool the cast article at temperatures down to 100 °C, or even to cool the cast article to a temperature down to 300 °C.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Mold Materials And Core Materials (AREA)
- Glass Compositions (AREA)
Claims (13)
- Gießverfahren mit den folgenden Schritten:- Mischen einer oder mehrerer Arten eines gekörnten Aggregatmaterials, einer oder mehrerer Arten eines wasserlöslichen Binders, und von Wasser, um ein Gemenge des gekörnten Aggregatmaterials zu bilden, und Rühren des Gemenges, um es zum Schäumen zu bringen,- Einbringen des geschäumten Gemenges in einen Formraum und Verdampfen der Feuchtigkeit in dem eingebrachten Gemenge zum Aushärten des eingebrachten Gemenges, um eine Gießform mit dem ausgehärteten Gemenge zu formen,- Zusammenbauen mindestens einer Gießform, die aus dem ausgehärteten Gemenge geformt ist, und der dazu passenden Gießform, um eine fertige Gießform zu bilden,- Gießen von Metallschmelze in die fertige Gießform,- Entfernen der fertigen Gießform von dem aus der verfestigten Metallschmelze bestehenden Gussstück während eines Abkühlvorgangs des Gussstücks, nachdem sich die Metallschmelze verfestigt hat, und- Anwenden einer Wärmebehandlung an dem Gussstück,dadurch gekennzeichnet, dass eine oder mehrere Art(en) des wasserlöslichen Binders entweder ein Polyvinylalkohol oder dessen Derivat, oder mindestens eine Stärke oder deren Derivat ist/sind.
- Gießverfahren nach Anspruch 1,
wobei die mindestens eine Gießform, die aus dem ausgehärteten Gemenge gegossen ist, und die dazu passende Gießform eine Mutterform ist. - Gießverfahren nach Anspruch 2,
wobei die Mutterform eine Metallform ist. - Gießverfahren nach Anspruch 2,
wobei die Mutterform eine Sandform ist. - Gießverfahren nach einem der vorangehenden Ansprüche, ferner mit den Schritten des Zurückführens des gekörnten Aggregatmaterials und des Zurückgewinnens des zurückgeführten gekörnten Aggregatmaterials.
- Gießverfahren nach Anspruch 5,
ferner mit den Schritten des Recycelns und des Verwendens des zurückgeführten und zurückgewonnenen gekörnten Aggregatmaterials zum Formen einer Gießform. - Gießverfahren nach Anspruch 5 oder 6,
wobei die Schritte des Zurückführens und Zurückgewinnens des gekörnten Aggregatmaterials mechanische Rückgewinnungsverfahren sind. - Gießverfahren nach einem der vorangehenden Ansprüche,
wobei das Gussstück aus einer Aluminiumlegierung oder einer Magnesiumlegierung gegossen ist. - Gießverfahren nach Anspruch 8,
wobei die Wärmebehandlung eine T6-Behandlung oder eine T7-Behandlung ist. - Gießverfahren nach einem der Ansprüche 1-7,
wobei das Gussstück aus Gusseisen, Gussstahl oder einer Eisenlegierung gegossen ist. - Gießverfahren nach einem der Ansprüche 1-7,
wobei das Gussstück aus einer Kupferlegierung gegossen ist. - Gießverfahren nach einem der Ansprüche 1-7,
wobei der Schritt des Entfernens der fertiggestellten Gießform von dem Gussstück darin besteht, Rüttelvorgänge in der Gießform anzuwenden. - Gießverfahren nach einem der Ansprüche 1-7,
wobei der Schritt des Anwendens von Rüttelvorgängen in der Gießform das Anwenden von Stoßkräften von weniger als 1 MPa auf die Gießform bei einer Betriebsfrequenz von weniger als 30 Hz für weniger als 30 Sekunden innerhalb von 5 bis 20 Minuten nach dem Vergießen der Metallschmelze umfasst.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2004049428 | 2004-02-25 | ||
PCT/JP2005/002893 WO2005080023A1 (ja) | 2004-02-25 | 2005-02-23 | 鋳物の製造方法 |
Publications (3)
Publication Number | Publication Date |
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EP1721689A1 EP1721689A1 (de) | 2006-11-15 |
EP1721689A4 EP1721689A4 (de) | 2007-05-02 |
EP1721689B1 true EP1721689B1 (de) | 2011-05-18 |
Family
ID=34879546
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Application Number | Title | Priority Date | Filing Date |
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EP05710586A Active EP1721689B1 (de) | 2004-02-25 | 2005-02-23 | Verfahren zur herstellung eines gussteils |
Country Status (7)
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---|---|
US (1) | US20070137825A1 (de) |
EP (1) | EP1721689B1 (de) |
JP (1) | JP3948490B2 (de) |
CN (1) | CN1921969B (de) |
AT (1) | ATE509714T1 (de) |
TW (1) | TW200533436A (de) |
WO (1) | WO2005080023A1 (de) |
Families Citing this family (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11501911B2 (en) * | 2007-04-05 | 2022-11-15 | Grant A. MacLennan | Method of forming a cast inductor apparatus |
DE102007042506B4 (de) * | 2007-09-07 | 2010-06-17 | Norbert Gatzweiler | Verfahren zur Abschreckung von Aluminiumbauteilen |
JP5024733B2 (ja) * | 2008-10-15 | 2012-09-12 | 新東工業株式会社 | 鋳包まれた砂中子の砂落し方法 |
CN101956121B (zh) * | 2010-10-13 | 2013-03-13 | 江苏万恒铸业有限公司 | 高压临氢不锈钢阀门铸件制造工艺 |
US10371686B2 (en) | 2012-11-15 | 2019-08-06 | Heraeus EIectro-Nite International N.V. | Detection device for molten metal |
MX2015006148A (es) * | 2012-11-19 | 2015-10-22 | Sintokogio Ltd | Arena para molde de fundicion, metodo de fabricacion para molde de fundicion hecho de arena, y nucleo para fundicion de metales. |
CN103601465B (zh) * | 2013-11-06 | 2015-04-29 | 安庆帝雅艺术品有限公司 | 一种铜器填充材料 |
AT517384A1 (de) * | 2015-06-15 | 2017-01-15 | Fill Gmbh | Verfahren zur Herstellung eines gegossenen Werkstückes |
CN109641265B (zh) * | 2016-08-31 | 2021-06-11 | 旭有机材株式会社 | 铸模的制造方法 |
AT520370B1 (de) | 2017-09-07 | 2020-08-15 | Fill Gmbh | Verfahren zur Herstellung eines gegossenen Werkstückes |
DE102017131255A1 (de) | 2017-12-22 | 2019-06-27 | HÜTTENES-ALBERTUS Chemische Werke Gesellschaft mit beschränkter Haftung | Verfahren zur Herstellung eines metallischen Gussstücks oder eines ausgehärteten Formteils unter Verwendung aliphatischer Polymere umfassend Hydroxygruppen |
JP7309405B2 (ja) * | 2018-03-30 | 2023-07-18 | 株式会社巴川製紙所 | 鋳型用砂型資材及び鋳型用の中子及び砂型材の製造方法 |
TWI789125B (zh) * | 2021-11-19 | 2023-01-01 | 財團法人金屬工業研究發展中心 | 低壓鑄造金屬發泡系統及中間發泡裝置 |
Family Cites Families (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CH470922A (de) * | 1965-07-23 | 1969-04-15 | Tsnii T I Mash | Flüssiges selbsthärtendes Gemisch für Gussformen und Formkerne |
GB1193952A (en) * | 1966-06-02 | 1970-06-03 | British Cast Iron Res Ass | Foundry Moulding Materials |
FR2096863B1 (de) * | 1970-07-07 | 1973-02-02 | Ctre Tech Ind Fonderie | |
NO142944L (de) * | 1975-08-14 | 1900-01-01 | ||
JPS57115942A (en) * | 1981-01-06 | 1982-07-19 | Sintokogio Ltd | Method for forming mold |
JPS5832540A (ja) * | 1981-08-21 | 1983-02-25 | Sintokogio Ltd | ダイカスト用中子の製造方法 |
JPH05261478A (ja) * | 1992-03-19 | 1993-10-12 | Ube Ind Ltd | 崩壊性砂中子の製造方法 |
-
2005
- 2005-02-23 JP JP2006510291A patent/JP3948490B2/ja active Active
- 2005-02-23 AT AT05710586T patent/ATE509714T1/de not_active IP Right Cessation
- 2005-02-23 CN CN200580005550.1A patent/CN1921969B/zh active Active
- 2005-02-23 EP EP05710586A patent/EP1721689B1/de active Active
- 2005-02-23 US US10/590,354 patent/US20070137825A1/en not_active Abandoned
- 2005-02-23 TW TW094105370A patent/TW200533436A/zh unknown
- 2005-02-23 WO PCT/JP2005/002893 patent/WO2005080023A1/ja active Application Filing
Also Published As
Publication number | Publication date |
---|---|
EP1721689A4 (de) | 2007-05-02 |
CN1921969B (zh) | 2015-03-18 |
JP3948490B2 (ja) | 2007-07-25 |
WO2005080023A1 (ja) | 2005-09-01 |
EP1721689A1 (de) | 2006-11-15 |
CN1921969A (zh) | 2007-02-28 |
TW200533436A (en) | 2005-10-16 |
ATE509714T1 (de) | 2011-06-15 |
JPWO2005080023A1 (ja) | 2007-10-25 |
US20070137825A1 (en) | 2007-06-21 |
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