FR3143393A1 - METHOD FOR MANUFACTURING HOLLOW METAL PARTS BY MOLDING, WITHOUT CORE - Google Patents
METHOD FOR MANUFACTURING HOLLOW METAL PARTS BY MOLDING, WITHOUT CORE Download PDFInfo
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- FR3143393A1 FR3143393A1 FR2213453A FR2213453A FR3143393A1 FR 3143393 A1 FR3143393 A1 FR 3143393A1 FR 2213453 A FR2213453 A FR 2213453A FR 2213453 A FR2213453 A FR 2213453A FR 3143393 A1 FR3143393 A1 FR 3143393A1
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Classifications
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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
- B22D23/00—Casting processes not provided for in groups B22D1/00Â -Â B22D21/00
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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
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
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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
- B22D25/02—Special casting characterised by the nature of the product by its peculiarity of shape; of works of art
-
- 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
- B22D25/06—Special casting characterised by the nature of the product by its physical properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/20—Measures not previously mentioned for influencing the grain structure or texture; Selection of compositions therefor
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
TITRE : PROCEDE DE FABRICATION PAR MOULAGE, SANS NOYAU, DE PIECES METALLIQUES CREUSES DOMAINE DE LâINVENTION La prĂ©sente invention concerne un procĂ©dĂ© de fabrication par moulage, sans noyau, de piĂšces mĂ©talliques creuses. Lâinvention concerne Ă©galement des piĂšces mĂ©talliques obtenues selon le procĂ©dĂ© de lâinvention. (Figure 1) .TITLE: METHOD FOR MANUFACTURING HOLLOW METAL PARTS BY MOLDING, WITHOUT CORE, FIELD OF THE INVENTION The present invention relates to a process for manufacturing by molding, without core, hollow metal parts. The invention also relates to metal parts obtained according to the process of the invention. (Figure 1) .
Description
La prĂ©sente invention concerne un procĂ©dĂ© de fabrication par moulage, sans noyau, de piĂšces mĂ©talliques creuses. Lâinvention concerne Ă©galement des piĂšces mĂ©talliques obtenues selon le procĂ©dĂ© de lâinvention.The present invention relates to a method of manufacturing hollow metal parts by molding, without a core. The invention also relates to metal parts obtained according to the process of the invention.
La fonderie regroupe les procĂ©dĂ©s de formage des mĂ©taux, en Ă©tat pur ou sous forme dâalliage, impliquant un moule dans lequel un mĂ©tal fondu est coulĂ© pour donner, aprĂšs solidification, une piĂšce mĂ©tallique. Une multitude de procĂ©dĂ©s ont Ă©tĂ© dĂ©veloppĂ©s au cours des derniers siĂšcles, capables de produire des piĂšces mĂ©talliques trĂšs diverses.The foundry brings together the processes of forming metals, in pure state or in the form of an alloy, involving a mold into which a molten metal is poured to give, after solidification, a metal part. A multitude of processes have been developed over the last centuries, capable of producing very diverse metal parts.
Des piÚces métalliques creuses ayant une coque de faible épaisseur, par exemple inférieure à 2 mm, sont particuliÚrement demandées. Ces piÚces ont un poids inférieur à une piÚce pleine à dimensions extérieure et à métal identiques, ou à une piÚce creuse ayant une coque plus épaisse. Il existe en particulier un réel besoin de pouvoir disposer de piÚces dont la faible épaisseur est homogÚne, variable et évolutive.Hollow metal parts having a thin shell, for example less than 2 mm, are particularly in demand. These parts weigh less than a solid part with identical external dimensions and metal, or a hollow part with a thicker shell. In particular, there is a real need to be able to have parts whose low thickness is uniform, variable and scalable.
Le brevet FR 2 646 824 B1, par exemple, divulgue la fabrication dâun chĂąssis de motocyclette creuse en une piĂšce. Le procĂ©dĂ© utilise un noyau pour rĂ©aliser le caractĂšre Ă©vidĂ© de la piĂšce. Cependant, lâutilisation dâun noyau, qui doit ĂȘtre conçu est fabriquĂ© au prĂ©alable, est contraignant.Patent FR 2 646 824 B1, for example, discloses the manufacture of a one-piece hollow motorcycle chassis. The process uses a core to achieve the hollowed-out character of the part. However, the use of a core, which must be designed and manufactured beforehand, is restrictive.
Une mĂ©thode de fabrication de piĂšces mĂ©talliques creuses sans utilisation dâun noyau consiste Ă verser un mĂ©tal fondu dans un moule. Une peau de mĂ©tal solidifiĂ© se forme en quelques secondes sur la surface du moule, puis le moule est basculĂ© afin dâĂ©liminer le mĂ©tal liquide en excĂšs.One method of making hollow metal parts without the use of a core is to pour molten metal into a mold. A skin of solidified metal forms in a few seconds on the surface of the mold, then the mold is tilted to remove the excess liquid metal.
Dans ce procĂ©dĂ©, dit «coulĂ©e au renversé», le fait dâĂ©vider le moule par basculement a pour rĂ©sultat que le mĂ©tal reste plus longtemps en contact avec une partie du moule, Ă savoir la partie sur laquelle le mĂ©tal coule aprĂšs basculement, ce qui conduit Ă une coque asymĂ©trique, plus Ă©paisse dâun cĂŽtĂ© par rapport Ă un autre cĂŽtĂ©.In this process, called " reverse casting ", the fact of hollowing out the mold by tilting results in the metal remaining in contact for longer with part of the mold, namely the part on which the metal flows after tilting, this which leads to an asymmetrical shell, thicker on one side compared to another side.
Des procĂ©dĂ©s existants ne satisfont pas le besoin de fournir des procĂ©dĂ©s de fabrication par moulage, sans noyaux, de piĂšces mĂ©talliques creuses ayant une coque de faible Ă©paisseur contrĂŽlĂ©e, (< 2 mm) en particulier comprise entre 0,2 mm et 2 mm, , et fait dâun mĂ©tal ou alliage ayant point de fusion supĂ©rieur Ă 180°C.Existing processes do not satisfy the need to provide manufacturing processes by molding, without cores, of hollow metal parts having a shell of controlled low thickness, (< 2 mm) in particular between 0.2 mm and 2 mm, and made of a metal or alloy having a melting point greater than 180°C.
Il existe donc un besoin de fournir des nouveaux procĂ©dĂ©s permettant la fabrication par moulage de piĂšces ne pouvant pas ĂȘtre obtenues par des procĂ©dĂ©s existants de moulage.There is therefore a need to provide new processes allowing the manufacturing by molding of parts that cannot be obtained by existing molding processes.
Dans ce contexte, un premier but de lâinvention est la mise Ă disposition dâun procĂ©dĂ© de fabrication par moulage, sans noyaux, de piĂšces mĂ©talliques creuses ayant une coque de faible Ă©paisseur,i.e.infĂ©rieure Ă 2 mm et supĂ©rieure Ă 0,2 mm. Un deuxiĂšme but de lâinvention est la mise Ă disposition dâun procĂ©dĂ© de fabrication par moulage de piĂšces mĂ©talliques, permettant de maitriser lâĂ©paisseur de coque de la piĂšce Ă former. Un autre but de lâinvention est de pouvoir mettre en Ćuvre le procĂ©dĂ© avec des mĂ©taux ou des alliages mĂ©talliques de point de fusion supĂ©rieur Ă 180°C, notamment supĂ©rieur Ă 320°C. Un autre but de lâinvention est la mise Ă disposition de nouvelles piĂšces mĂ©talliques creuses.In this context, a first aim of the invention is to provide a method of manufacturing by molding, without cores, hollow metal parts having a thin shell, ie less than 2 mm and greater than 0.2 mm. A second aim of the invention is to provide a method of manufacturing by molding metal parts, making it possible to control the shell thickness of the part to be formed. Another aim of the invention is to be able to implement the process with metals or metal alloys with a melting point greater than 180°C, in particular greater than 320°C. Another aim of the invention is to provide new hollow metal parts.
Unpremier objetde la prĂ©sente invention est un procĂ©dĂ© de fabrication dâune piĂšce mĂ©tallique creuse, ledit procĂ©dĂ© comprenant au moins les Ă©tapes suivantes :
- uneĂ©tape 1dâinjection dâune masse liquide initiale de mĂ©tal fondu dans un moule, depuis un contenant comprenant ledit mĂ©tal fondu, pour obtenir un moule comprenant du mĂ©tal fondu ;
- uneĂ©tape 2de solidification partielle dudit mĂ©tal fondu au sein du moule pendant un temps suffisant pour former une coque mĂ©tallique solidifiĂ©e en contact avec les parois du moule prĂ©sentant une tempĂ©rature infĂ©rieure Ă la tempĂ©rature dusolidusdudit mĂ©tal fondu, et maintenir en phase liquide la partie restante de la masse liquide initiale dudit mĂ©tal fondu contenue Ă lâintĂ©rieur de la coque mĂ©tallique solidifiĂ©e, pour obtenir une partie solide constituĂ©e de la coque mĂ©tallique solidifiĂ©e, et une phase liquide constituĂ©e de la partie restante de la masse liquide initiale dudit mĂ©tal fondu ;
- uneétape 3de soustraction de la susdite phase liquide, ladite étape de soustraction étant effectuée sans basculement du moule ; et
- uneétape 4de récupération de la piÚce métallique creuse sous forme de coque métallique solidifiée,
- a step 1 of injecting an initial liquid mass of molten metal into a mold, from a container comprising said molten metal, to obtain a mold comprising molten metal;
- a step 2 of partial solidification of said molten metal within the mold for a time sufficient to form a solidified metal shell in contact with the walls of the mold having a temperature lower than the solidus temperature of said molten metal, and maintain the part in the liquid phase remaining of the initial liquid mass of said molten metal contained inside the solidified metal shell, to obtain a solid part consisting of the solidified metal shell, and a liquid phase consisting of the remaining part of the initial liquid mass of said molten metal;
- a step 3 of subtracting the above liquid phase, said subtraction step being carried out without tilting the mold; And
- a step 4 of recovering the hollow metal part in the form of a solidified metal shell,
dans lequel le métal a un point de fusion supérieur à 180°C, en particulier supérieur à 320°C, et dans lequel la piÚce métallique creuse est formée en absence de noyau,in which the metal has a melting point greater than 180°C, in particular greater than 320°C, and in which the hollow metal part is formed in the absence of a core,
ledit procĂ©dĂ© ayant une mise au mille de 1 :1 Ă 1,2 :1, de prĂ©fĂ©rence dâenviron 1:1, en particulier de 1:1.said method having a target setting of 1:1 to 1.2:1, preferably about 1:1, particularly 1:1.
Lors de la mise en Ćuvre du procĂ©dĂ© de lâinvention, un mĂ©tal fondu, Ă lâĂ©tat liquide, est injectĂ© dans un moule. Lors du sĂ©jour dans le moule, une partie du mĂ©tal initialement fondu se solidifie contre la paroi intĂ©rieure du moule, ou lâempreinte, pour former une coque de mĂ©tal solidifiĂ©e. Cette coque solidifiĂ©e est dĂ©limitĂ©e Ă lâextĂ©rieur par le moule, et Ă lâintĂ©rieur par du mĂ©tal liquide, non encore solidifiĂ©.During the implementation of the process of the invention, a molten metal, in liquid state, is injected into a mold. While in the mold, part of the initially molten metal solidifies against the interior wall of the mold, or the cavity, to form a solidified metal shell. This solidified shell is delimited on the outside by the mold, and on the inside by liquid metal, not yet solidified.
Le moule est ensuite vidangĂ© du mĂ©tal encore liquide,i.e.non encore solidifiĂ©, qui se trouve Ă lâintĂ©rieur de la coque, formant ainsi une piĂšce mĂ©tallique creuse.The mold is then drained of the still liquid metal, ie not yet solidified, which is inside the shell, thus forming a hollow metal part.
Les Inventeurs ont trouvĂ© que le procĂ©dĂ© selon lâinvention permet la fabrication dâune grande variĂ©tĂ© de piĂšces creuses, dont par exemple des piĂšces ayant une coque de faible Ă©paisseur,i.e.infĂ©rieure Ă 2 mm et supĂ©rieure Ă 0,2 mm. GrĂące Ă une vidange sans basculement du moule, le procĂ©dĂ© nâest pas tributaire dâune solidification non voulue du mĂ©tal, ladite solidification Ă©tant complĂštement maitrisĂ©e.The inventors have found that the process according to the invention allows the manufacture of a wide variety of hollow parts, including for example parts having a thin shell, ie less than 2 mm and greater than 0.2 mm. Thanks to emptying without tilting the mold, the process is not dependent on unwanted solidification of the metal, said solidification being completely controlled.
Par «piĂšce mĂ©tallique creuse» on entend donc une piĂšce mĂ©tallique sous la forme dâune coque qui entoure, ou qui partiellement entoure, une partie vide. A titre dâexemple, parmi les piĂšces sous forme dâune coque qui partiellement entoure une partie vide, on peut citer des piĂšces telles que des gobelets, des coupelles, des bols et des bouteilles.By â hollow metal part â we therefore mean a metal part in the form of a shell which surrounds, or which partially surrounds, an empty part. By way of example, among the parts in the form of a shell which partially surrounds an empty part, we can cite parts such as cups, cups, bowls and bottles.
Par «solidification partielle du mĂ©tal fondu» on entend que la solidification est suffisante pour former la coque solide, tout en laissant une partie du mĂ©tal en Ă©tat liquide pour permettre dâobtenir la partie creuse de la piĂšce aprĂšs soustraction, ou vidange, dudit mĂ©tal en Ă©tat liquide.By â partial solidification of the molten metal â we mean that the solidification is sufficient to form the solid shell, while leaving part of the metal in a liquid state to make it possible to obtain the hollow part of the part after subtraction, or emptying, of said metal. in liquid state.
Par« partie solide »on entend une phase solide au sens mĂ©tallurgique ou thermodynamique. Ainsi la partie solide peut ĂȘtre composĂ©e de plusieurs phases solides, ce qui est le cas par exemples des alliages Al-Si.By âsolid partâ we mean a solid phase in the metallurgical or thermodynamic sense. Thus the solid part can be composed of several solid phases, which is the case for example with Al-Si alloys.
Par «sans basculement du moule» il faut entendre que la soustraction du mĂ©tal encore liquide se fait sans basculement (i.e.sans rotation autour dâun axe) du moule, ce qui est habituel dans un procĂ©dĂ© de «coulĂ©e au renversé». Pour ce faire, le moule est vidangĂ© par des techniques exposĂ©es ci-aprĂšs. Cela Ă©tant, il est entendu que lâabsence de basculement du moule, nâempĂȘche pas de pourvoir translater lâintĂ©gralitĂ© du moule au-dessus dâun four ou dâune poche afin de rĂ©ceptionner la vidange.By â without tilting the mold â it is meant that the subtraction of the still liquid metal is done without tilting ( ie without rotation around an axis) of the mold, which is usual in a â reverse casting â process. To do this, the mold is drained using the techniques explained below. That being said, it is understood that the absence of tilting of the mold does not prevent the ability to translate the entire mold above an oven or a ladle in order to receive the drain.
Par «mĂ©tal» on entend, au sens de la prĂ©sente invention, soit un mĂ©tal unique, soit un alliage mĂ©tallique comprenant ledit mĂ©tal. Parmi ces alliages mĂ©talliques, on peut citer un alliage eutectique ou proche de lâeutectique, sinon un alliage Ă faible intervalle de solidification (i.e.avec des tempĂ©ratures de liquidus et de solidus trĂšs proches).By â metal â is meant, within the meaning of the present invention, either a single metal, or a metal alloy comprising said metal. Among these metal alloys, we can cite an alloy that is eutectic or close to the eutectic, otherwise an alloy with a short solidification interval ( ie with very close liquidus and solidus temperatures).
On entend par «mĂ©tal unique» un mĂ©tal qui nâest pas en mĂ©lange avec un autre Ă©lĂ©ment, comme un autre mĂ©tal. Il sâagit dâun mĂ©tal dit «pur», ayant une puretĂ© supĂ©rieure Ă 98%, en particulier supĂ©rieure Ă 99%.By â single metal â we mean a metal which is not mixed with another element, such as another metal. It is a so-called â pure â metal, having a purity greater than 98%, in particular greater than 99%.
Parmi les mĂ©taux (purs) utilisables dans la piĂšce et le procĂ©dĂ© de lâinvention on peut citer, Ă titre dâexemple : lâaluminium (Al), le plomb (Pb), lâĂ©tain (Sn), le cuivre (Cu), le zinc (Zn), le fer (Fe), le nickel (Ni) et le magnĂ©sium (Mg).Among the (pure) metals usable in the part and the process of the invention we can cite, by way of example: aluminum (Al), lead (Pb), tin (Sn), copper ( Cu), zinc (Zn), iron (Fe), nickel (Ni) and magnesium (Mg).
Parmi les alliages eutectiques utilisables dans la piĂšce et le procĂ©dĂ© de lâinvention on peut citer, Ă titre dâexemple : AlSi12, ZnAl5, AlCu33, AlMg32, MgZn37, CuMn37, CuSi16, SnPb38, de la fonte eutectique.Among the eutectic alloys that can be used in the part and the process of the invention we can cite, by way of example: AlSi12, ZnAl5, AlCu33, AlMg32, MgZn37, CuMn37, CuSi16, SnPb38, eutectic cast iron.
Parmi les alliages Ă faible intervalle de solidification utilisables dans la piĂšce et le procĂ©dĂ© de lâinvention on peut citer, Ă titre dâexemple : AlSi10, AlSi2, de la fonte relativement proche de lâeutectique Fe-C, ou de lâacier Ă trĂšs faible intervalle de solidification.Among the alloys with a short solidification interval which can be used in the part and the process of the invention we can cite, by way of example: AlSi10, AlSi2, cast iron relatively close to the Fe-C eutectic, or the steel with very short solidification interval.
Par «un point de fusion supĂ©rieur Ă 180°C» on entend en particulier un point de fusion supĂ©rieur Ă 200°C, supĂ©rieur Ă 320°C, supĂ©rieur Ă 500°C et notamment supĂ©rieur Ă 660°C. Le point de fusion est en particulier compris de 180°C Ă 1750°C. Par «de 180°C Ă 1750°C» on entend Ă©galement les gammes suivantes : de 200°C Ă 1750°C, de 320°C Ă 1750°C, de 400°C Ă 1750°C, de 500°C Ă 1750°C, de 600°C Ă 1750°C, de 660°C Ă 1750°C, de 700°C Ă 1750°C, de 800°C Ă 1750°C, de 900°C Ă 1750°C, de 1000°C Ă 1750°C, de 1100°C Ă 1750°C, de 1200°C Ă 1750°C, de 1300°C Ă 1750°C, de 1400°C Ă 1750°C, de 1500°C Ă 1750°C, de 180°C Ă 1600°C, de 180°C Ă 1400°C, de 180°C Ă 1200°C, de 180°C Ă 1000°C, de 180°C Ă 800°C, de 200°C Ă 1600°C, de 200°C Ă 1400°C, de 200°C Ă 1200°C, de 200°C Ă 1000°C, de 200°C Ă 800°C, de 320°C Ă 1600°C, de 320°C Ă 1400°C, de 320°C Ă 1200°C, de 320°C Ă 1000°C, de 320°C Ă 800°C, de 500°C Ă 1400°C, de 500°C Ă 1200°C, de 500°C Ă 1000°C, de 500°C Ă 800°C, de 660°C Ă 1400°C, de 660°C Ă 1200°C, de 660°C Ă 1000°C, de 660°C Ă 800°C.By â a melting point greater than 180°C â is meant in particular a melting point greater than 200°C, greater than 320°C, greater than 500°C and in particular greater than 660°C. The melting point is in particular between 180°C and 1750°C. By â from 180°C to 1750°C â we also mean the following ranges: from 200°C to 1750°C, from 320°C to 1750°C, from 400°C to 1750°C, from 500°C to 1750°C, from 600°C to 1750°C, from 660°C to 1750°C, from 700°C to 1750°C, from 800°C to 1750°C, from 900°C to 1750°C, from 1000°C to 1750°C, from 1100°C to 1750°C, from 1200°C to 1750°C, from 1300°C to 1750°C, from 1400°C to 1750°C, from 1500°C to 1750 °C, from 180°C to 1600°C, from 180°C to 1400°C, from 180°C to 1200°C, from 180°C to 1000°C, from 180°C to 800°C, from 200 °C to 1600°C, from 200°C to 1400°C, from 200°C to 1200°C, from 200°C to 1000°C, from 200°C to 800°C, from 320°C to 1600° C, from 320°C to 1400°C, from 320°C to 1200°C, from 320°C to 1000°C, from 320°C to 800°C, from 500°C to 1400°C, from 500° C to 1200°C, from 500°C to 1000°C, from 500°C to 800°C, from 660°C to 1400°C, from 660°C to 1200°C, from 660°C to 1000°C , from 660°C to 800°C.
Il est entendu que le point de fusion peut correspondre au point de fusion dâun mĂ©tal pur, ou au liquidus dâun alliage. Dans ce qui prĂ©cĂšde et ce qui suit, lâexpression «point de fusion» se rapporte Ă la fois aux mĂ©taux purs et aux alliages ; auquel cas il faut entendre «le liquidus».It is understood that the melting point can correspond to the melting point of a pure metal, or to the liquidus of an alloy. In the above and what follows, the expression " melting point " refers to both pure metals and alloys; in which case we must understand â the liquidus â.
En gĂ©nĂ©ral en fonderie, la «mise au mille» dĂ©signe le rapport de la masse de la grappe de coulĂ©e sur la masse de la piĂšce brute parachevĂ©e. La grappe de coulĂ©e correspond Ă la piĂšce sortie du moule avec lâensemble de ses artifices de coulĂ©e adhĂ©rents (systĂšme de remplissage, de masselottage, dâĂ©vents, bavures). La mise au mille est donc souvent supĂ©rieure Ă 1, et rarement Ă©gale Ă 1.In general in foundries, the â thousand point â designates the ratio of the mass of the casting cluster to the mass of the finished raw part. The casting sprue corresponds to the part taken out of the mold with all of its adhering casting devices (filling system, weighting system, vents, burrs). The bullseye bet is therefore often greater than 1, and rarely equal to 1.
Dans le cas du prĂ©sent procĂ©dĂ©, le ratio qui est obtenu est de 1:1, ou proche de 1:1, ce qui est exceptionnelvis-Ă -visdes procĂ©dĂ©s conventionnels de fonderie. Effectivement, le procĂ©dĂ© permet dâobtenir une piĂšce brute en sortie du moule sans ou quasiment sans artifice de coulĂ©e adhĂ©rent, supprimant ou limitant fortement ainsi le parachĂšvement. Cela est rendu possible car le volume de mĂ©tal liquide initialement injectĂ© dans le moule nâest pas totalement solidifiĂ©.In the case of the present process, the ratio which is obtained is 1:1, or close to 1:1, which is exceptional compared to conventional foundry processes. Indeed, the process makes it possible to obtain a raw part coming out of the mold without or almost without adhering casting artifice, thus eliminating or strongly limiting the completion. This is made possible because the volume of liquid metal initially injected into the mold is not completely solidified.
Par «proche de 1:1» on entend de 1:1 Ă 1,2:1. Par «1:1 Ă 1,2:1» on entend Ă©galement les gammes suivantes : « 1:1 Ă 1,01:1 », « 1:1 Ă 1,02 :1 », « 1:1 Ă 1,03:1 », « 1:1 Ă 1,04:1 », « 1:1 Ă 1,05:1 », « 1:1 Ă 1,06:1 », « 1:1 Ă 1,07:1 », « 1:1 Ă 1,08:1 », « 1:1 Ă 1,09:1 », « 1:1 Ă 1,10:1 », « 1:1 Ă 1,11 :1 », « 1:1 Ă 1,12 :1 », « 1:1 Ă 1,13:1 », « 1:1 Ă 1,14:1 », « 1:1 Ă 1,15:1 », « 1:1 Ă 1,16:1 », « 1:1 Ă 1,17:1 », « 1:1 Ă 1,18:1 », « 1:1 Ă 1,19:1 ».By â close to 1:1 â we mean from 1:1 to 1.2:1. By â 1:1 to 1.2:1 â we also mean the following ranges: â1:1 to 1.01:1â, â1:1 to 1.02:1â, â1:1 to 1, 03:1", "1:1 to 1.04:1", "1:1 to 1.05:1", "1:1 to 1.06:1", "1:1 to 1.07: 1", "1:1 to 1.08:1", "1:1 to 1.09:1", "1:1 to 1.10:1", "1:1 to 1.11:1" , â1:1 to 1.12:1â, â1:1 to 1.13:1â, â1:1 to 1.14:1â, â1:1 to 1.15:1â, â 1:1 to 1.16:1â, â1:1 to 1.17:1â, â1:1 to 1.18:1â, â1:1 to 1.19:1â.
LâĂ©tape 1dâinjection dâune masse liquide de mĂ©tal fondu dans un moule peut ĂȘtre effectuĂ©e par plusieurs techniques. Lâinjection peut ĂȘtre rĂ©alisĂ© par gravitĂ©, au moyen dâun godet manuel ou automatique, voire dâune goulotte de transvasement. Lâinjection du mĂ©tal fondu dans lâempreinte peut aussi ĂȘtre rĂ©alisĂ©e via une buse dâinjection ou une chemise avec piston dâinjection ; le procĂ©dĂ© est alors adaptĂ© Ă un moulage avec machine de basse pression ou presse Ă injecter sous pression notamment Ă chambre chaude. Step 1 of injecting a liquid mass of molten metal into a mold can be carried out by several techniques. Injection can be carried out by gravity, using a manual or automatic bucket, or even a transfer chute. The injection of molten metal into the cavity can also be carried out via an injection nozzle or a liner with an injection piston; the process is then adapted to molding with a low pressure machine or pressure injection press, particularly in a hot chamber.
LâĂ©tape 2de solidification permet de former une coque, ou peau, de mĂ©tal, solidifiĂ©e contre la paroi intĂ©rieure du moule. Le temps de maintien du mĂ©tal en fusion dans le moule dĂ©pend de plusieurs paramĂštres, dont par exemple la diffĂ©rence de matĂ©riaux et de tempĂ©ratures initiales entre le moule et le mĂ©tal en fusion. Le temps de maintien dĂ©pend Ă©galement de lâĂ©paisseur de la coque Ă fabriquer. En gĂ©nĂ©ral, un temps de quelques secondes Ă quelques minutes est suffisant pour obtenir une coque de faible Ă©paisseur, i.e.infĂ©rieure Ă 2 mm et supĂ©rieure Ă 0,2 mm. Stage 2 of solidification makes it possible to form a shell, or skin, of metal, solidified against the interior wall of the mold. The time the molten metal is held in the mold depends on several parameters, including for example the difference in materials and initial temperatures between the mold and the molten metal. The holding time also depends on the thickness of the shell to be manufactured. In general, a time of a few seconds to a few minutes is sufficient to obtain a thin shell , ie less than 2 mm and greater than 0.2 mm.
LâĂ©tape 3de soustraction peut sâeffectuer par la gravitĂ© ; le mĂ©tal liquide sort par une ouverture dans le bas du moule, initialement obstruĂ©e par une quenouille, un bouchon, une trappe, ou autre dispositif chauffant ou isolant thermiquement, ou autre dispositif (e.g.systĂšme Ă induction). Elle peut Ă©galement ĂȘtre facilitĂ©e par la poussĂ©e dâun gaz sous pression en partie supĂ©rieure du moule.Subtraction step 3 can be carried out by gravity; the liquid metal exits through an opening in the bottom of the mold, initially obstructed by a stopper, a stopper, a trapdoor, or other heating or thermally insulating device, or other device ( eg induction system). It can also be facilitated by pushing a pressurized gas into the upper part of the mold.
LâĂ©tape 4de rĂ©cupĂ©ration de la piĂšce mĂ©tallique creuse peut ĂȘtre effectuĂ©e par des mĂ©thodes connues de dĂ©moulage. Le dĂ©moulage peut par exemple ĂȘtre effectuĂ© par retournement du moule. En prĂ©alable, une grille peut ĂȘtre placĂ©e sur le dessus du moule pour Ă©viter que la piĂšce chute du moule, se casse ou se dĂ©forme. AprĂšs retournement du moule, la piĂšce Ă©jectĂ©e se trouve alors sur ladite grille. Step 4 of recovering the hollow metal part can be carried out by known demolding methods. Demolding can for example be carried out by turning the mold over. Beforehand, a grid can be placed on top of the mold to prevent the part from falling from the mold, breaking or deforming. After turning the mold over, the ejected part is then on said grid.
Selon un mode de rĂ©alisation particulier, lâinvention concerne un procĂ©dĂ© de fabrication tel que dĂ©fini ci-dessus pour la production dâune piĂšce mĂ©tallique creuse ayant une Ă©paisseur de 0,2 mm Ă 2 mm.According to a particular embodiment, the invention relates to a manufacturing process as defined above for the production of a hollow metal part having a thickness of 0.2 mm to 2 mm.
Selon un mode de rĂ©alisation particulier, lâinvention concerne un procĂ©dĂ© de fabrication tel que dĂ©fini ci-dessus pour la production dâune piĂšce mĂ©tallique creuse constituĂ©e dâune coque mĂ©tallique qui entoure, partiellement ou totalement une partie vide,According to a particular embodiment, the invention relates to a manufacturing process as defined above for the production of a hollow metal part consisting of a metal shell which partially or completely surrounds an empty part,
dans laquelle la dite coque métallique a :
- une surface extérieure lisse,
- une surface intérieure cristallographique.
- a smooth exterior surface,
- a crystallographic interior surface.
Ainsi, le procĂ©dĂ© selon lâinvention peut ĂȘtre mis en Ćuvre de diffĂ©rentes façons :Thus, the method according to the invention can be implemented in different ways:
Dans le cas de la verse du mĂ©tal liquide par gravitĂ©, un moule fixe doit possĂ©der au minimum une entrĂ©e supĂ©rieure pour recevoir le mĂ©tal et une sortie infĂ©rieure pour Ă©vacuer lâalliage en surplus encore liquide aprĂšs formation dâune peau solidifiĂ©e. Il est donc ouvert sur la partie haute du moule pour assurer son remplissage, et il possĂšde au minimum un orifice dans la partie basse du moule, bouchĂ© par un bouchon, une quenouille ou autre systĂšme dâobturation qui pourra ĂȘtre ouvert lors de la vidange du moule.In the case of pouring liquid metal by gravity, a fixed mold must have at least one upper inlet to receive the metal and a lower outlet to evacuate the excess alloy that is still liquid after the formation of a solidified skin. It is therefore open on the upper part of the mold to ensure its filling, and it has at least one orifice in the lower part of the mold, blocked by a plug, a stopper or other closing system which can be opened during emptying of the mold.
En gĂ©nĂ©ral, le dispositif dâobturation de lâorifice de vidange est prĂ©chauffĂ© et/ou constituĂ© de matĂ©riaux isolants thermiques. En dessous du moule, une poche de coulĂ©e ou un four permet de recueillir le surplus dâalliage en fusion.In general, the device for closing the drain port is preheated and/or made of thermal insulating materials. Below the mold, a ladle or an oven collects the excess molten alloy.
Le procédé de moulage par gravité est illustré par la
Pendant les courtes phases de remplissage et de vidange, lâalliage liquide prĂ©sent dans lâempreinte se solidifie contre les parois du moule. Cela peut conduire Ă des variations dâĂ©paisseur de la coque solidifiĂ©e par endroits ; notamment souvent lâĂ©paisseur solidifiĂ©e est plus fine en haut du moule et plus Ă©paisse en partie basse du moule. Pour gĂ©rer au mieux lâĂ©paisseur de la coque solidifiĂ©e, plusieurs paramĂštres du procĂ©dĂ© peuvent ĂȘtre utilisĂ©s : lâĂ©paisseur du moule (surtout avec un moule mĂ©tallique), lâintroduction de refroidisseurs (en acier ou fonte, ou carbure de silicium, ou graphite par exemple) dans un moule en sable ou dâartifices de refroidissement dans un moule mĂ©tallique, la prĂ©chauffe ou chauffe non homogĂšne du moule mĂ©tallique (en gĂ©nĂ©ral tempĂ©rature du moule plus chaude en partie basse), lâutilisation de poteyages diffĂ©rents sur lâempreinte du moule mĂ©tallique (poteyages isolants et conducteurs), lâemploi de diffĂ©rents sables (plus ou moins conducteurs thermiques) et/ou adjuvants dans la composition du moule en sable.During the short filling and emptying phases, the liquid alloy present in the cavity solidifies against the walls of the mold. This can lead to variations in the thickness of the solidified shell in places; in particular often the solidified thickness is thinner at the top of the mold and thicker at the bottom of the mold. To best manage the thickness of the solidified shell, several process parameters can be used: the thickness of the mold (especially with a metal mold), the introduction of coolers (made of steel or cast iron, or silicon carbide, or graphite for example) in a sand mold or cooling devices in a metal mold, the preheating or non-homogeneous heating of the metal mold (generally hotter mold temperature in the lower part), the use of different coatings on the the footprint of the metal mold (insulating and conductive coatings), the use of different sands (more or less thermal conductors) and/or adjuvants in the composition of the sand mold.
Dans la majoritĂ© des cas, la position du trou de vidange correspond Ă la partie la plus basse de la piĂšce dans le moule. GĂ©nĂ©ralement, ce trou est situĂ© sous le moule ; mais dans certains cas il peut ĂȘtre localisĂ© sur un cĂŽtĂ© bas du moule. Pour certaines gĂ©omĂ©tries particuliĂšres de piĂšces, il peut ĂȘtre possible dâassocier une lĂ©gĂšre inclinaison du moule lors de la vidange pour faciliter au mieux lâĂ©vacuation totale du bain mĂ©tallique rĂ©siduel liquide encore prĂ©sent dans lâempreinte.In the majority of cases, the position of the drain hole corresponds to the lowest part of the part in the mold. Generally, this hole is located under the mold; but in certain cases it can be located on a lower side of the mold. For certain particular part geometries, it may be possible to combine a slight inclination of the mold during emptying to best facilitate the total evacuation of the liquid residual metal bath still present in the cavity.
La basse pression est un dispositif technique consistant Ă apporter un gaz inerte pour le mĂ©tal du type azote, argon ou autre, dans la chambre hermĂ©tique du four contenant le mĂ©tal en fusion. La pression du gaz sur la surface du bain permet de faire monter le mĂ©tal en fusion dans une buse dâinjection qui alimente lâempreinte du moule. En gĂ©nĂ©ral, le moule est placĂ© au-dessus du four de basse pression et le mĂ©tal rentre dans lâempreinte par sa partie infĂ©rieure ou par un cĂŽtĂ©.Low pressure is a technical device consisting of bringing an inert gas for the metal such as nitrogen, argon or other, into the hermetic chamber of the furnace containing the molten metal. The gas pressure on the surface of the bath causes the molten metal to rise into an injection nozzle which feeds the mold cavity. In general, the mold is placed above the low pressure furnace and the metal enters the cavity from its lower part or from one side.
Dans le cas dâune coulĂ©e basse pression, le moule est Ă©quipĂ© dâune entrĂ©e dans le bas du moule servant Ă lâinjection du mĂ©tal. Cette entrĂ©e fait Ă©galement office de vidange du surplus de mĂ©tal qui retourne directement dans le four via la buse dâinjection. Un dispositif dâappel dâair, ou autre gaz, peut ĂȘtre amĂ©nagĂ© afin de faciliter lâĂ©vacuation du mĂ©tal en fusion. Une fois que les tempĂ©ratures du moule et de du mĂ©tal sont opĂ©rationnelles, la matiĂšre en fusion est injectĂ©e par le bas du moule, puis mise sous pression pendant la solidification, cela sous atmosphĂšre contrĂŽlĂ©e (azote, argon ou autre).In the case of low pressure casting, the mold is equipped with an inlet at the bottom of the mold used for metal injection. This inlet also serves as a drain for excess metal which returns directly to the oven via the injection nozzle. A device for drawing air, or another gas, can be fitted to facilitate the evacuation of the molten metal. Once the temperatures of the mold and the metal are operational, the molten material is injected through the bottom of the mold, then put under pressure during solidification, this under a controlled atmosphere (nitrogen, argon or other).
Cette technique permet de maitriser la vitesse de remplissage et de vidange du moule, et grĂące au gaz neutre limite la formation de peaux dâoxyde avec les mĂ©taux oxydables, dont par exemple lâalumine avec les alliages dâaluminium.This technique makes it possible to control the speed of filling and emptying of the mold, and thanks to the neutral gas limits the formation of oxide skins with oxidizable metals, including for example alumina with aluminum alloys.
Ce mode de rĂ©alisation du procĂ©dĂ© de lâinvention est illustrĂ© par les Figures 2 et 3.This embodiment of the method of the invention is illustrated in Figures 2 and 3.
3- Procédé de moulage par injection sous pression3- Pressure injection molding process
Dans le cas dâune coulĂ©e sous pression, le moule possĂšde une entrĂ©e, qui peut Ă©galement faire office de sortie. Un dispositif dâappel dâair ou de gaz neutre pour faciliter lâĂ©vacuation de du mĂ©tal liquide peut Ă©galement ĂȘtre mis en place. Dâautre part, le conduit dâentrĂ©e du mĂ©tal dans lâempreinte peut ĂȘtre distinct de celui de vidange. Une fois que les tempĂ©ratures du moule et du mĂ©tal sont opĂ©rationnelles, le mĂ©tal en fusion est injectĂ© par un piston ou un gaz dans le moule, sous pression (de 5 Ă 5 000 bars). Lâinjection peut aussi se faire sous atmosphĂšre contrĂŽlĂ©e de gaz neutre (azote, argon ou autre). Le procĂ©dĂ© de moulage par injection sous pression est trĂšs compatible avec des systĂšmes dâinjection sous pression dits Ă chambre chaude, oĂč le mĂ©tal liquide vidangĂ© peut revenir directement dans la chambre dâinjection, utilisant un piston dâinjection pilotĂ© par vĂ©rin hydraulique ou rĂ©alisant lâinjection par pression de gaz dans la chambre. Moins facile de mise en Ćuvre, le procĂ©dĂ© sous pression Ă chambre froide peut ĂȘtre aussi utilisĂ©, notamment dans le cas oĂč la vidange du surplus de mĂ©tal liquide sâeffectue par un conduit diffĂ©rent de celui dâinjection.In the case of die casting, the mold has an inlet, which can also act as an outlet. An air or neutral gas inlet device to facilitate the evacuation of liquid metal can also be installed. On the other hand, the metal entry conduit into the cavity can be separate from the drain conduit. Once the temperatures of the mold and the metal are operational, the molten metal is injected by a piston or a gas into the mold, under pressure (5 to 5,000 bars). The injection can also be done under a controlled atmosphere of neutral gas (nitrogen, argon or other). The pressure injection molding process is very compatible with so-called hot chamber pressure injection systems, where the drained liquid metal can return directly to the injection chamber, using an injection piston controlled by a hydraulic cylinder or carrying out the injection by gas pressure in the chamber. Less easy to implement, the cold room pressure process can also be used, particularly in the case where the excess liquid metal is drained through a conduit different from the injection conduit.
Ce mode de rĂ©alisation du procĂ©dĂ© de lâinvention est illustrĂ© par les Figures 8 Ă 14.This embodiment of the method of the invention is illustrated in Figures 8 to 14.
Selon un mode de rĂ©alisation particulier, la prĂ©sente invention concerne le procĂ©dĂ© de fabrication tel que dĂ©fini ci-dessus, dans lequel lâĂ©tape 1 dâinjection est effectuĂ©e par gravitĂ©, ladite Ă©tape 1 dâinjection Ă©tant effectuĂ©e par versement du mĂ©tal liquide par une ouverture dans la partie haute du moule.According to a particular embodiment, the present invention relates to the manufacturing process as defined above, in which injection step 1 is carried out by gravity, said injection step 1 being carried out by pouring the liquid metal through an opening in the upper part of the mold.
Par «partie haute du moule», on entend la partie apicale du moule, Ă savoir la partie qui est la plus Ă©loignĂ©e du sol.By â upper part of the mold â, we mean the apical part of the mold, namely the part which is furthest from the ground.
Selon un autre mode de rĂ©alisation particulier, la prĂ©sente invention concerne le procĂ©dĂ© de fabrication tel que dĂ©fini ci-dessus, dans lequel lâĂ©tape 1 dâinjection est effectuĂ©e par injection avec un procĂ©dĂ© de basse pression, ladite Ă©tape 1 dâinjection Ă©tant effectuĂ©e par application dâune pression de gaz dans le contenant comprenant le mĂ©tal liquide, permettant de pousser ledit mĂ©tal liquide dans le moule, Ă travers un orifice situĂ© dans le bas dudit moule.According to another particular embodiment, the present invention relates to the manufacturing process as defined above, in which injection step 1 is carried out by injection with a low pressure process, said injection step 1 being carried out by applying a gas pressure in the container comprising the liquid metal, making it possible to push said liquid metal into the mold, through an orifice located in the bottom of said mold.
Parmi les gaz utilisables dans lâĂ©tape 1 dâinjection on peut citer, Ă titre dâexemple : lâair, lâazote, lâargon. Il est entendu que dans le cas de lâutilisation dâun mĂ©tal oxydable, tel que les alliages dâaluminium, un gaz inerte comme lâazote ou lâargon est prĂ©fĂ©rĂ© afin dâĂ©viter la formation de peaux dâalumine.Among the gases that can be used in injection stage 1, we can cite, for example: air, nitrogen, argon. It is understood that in the case of using an oxidizable metal, such as aluminum alloys, an inert gas such as nitrogen or argon is preferred in order to avoid the formation of alumina skins.
Par «le bas du moule», on entend la partie basale du moule, Ă savoir la partie qui est la plus proche du sol.By â the bottom of the mold â, we mean the basal part of the mold, namely the part which is closest to the ground.
Selon un autre mode de rĂ©alisation particulier, la prĂ©sente invention concerne le procĂ©dĂ© de fabrication tel que dĂ©fini ci-dessus, dans lequel lâĂ©tape 1 dâinjection est effectuĂ©e par injection sous pression, ladite Ă©tape 1 dâinjection Ă©tant effectuĂ©e par injection du mĂ©tal liquide Ă lâaide dâun piston ou dâun gaz.According to another particular embodiment, the present invention relates to the manufacturing process as defined above, in which injection step 1 is carried out by injection under pressure, said injection step 1 being carried out by injection of the liquid metal using a piston or gas.
Selon un autre mode de rĂ©alisation particulier, la prĂ©sente invention concerne le procĂ©dĂ© de fabrication tel que dĂ©fini ci-dessus, dans lequel lâĂ©tape 1 dâinjection est effectuĂ©e par injection sous pression Ă chambre chaude, ladite Ă©tape 1 dâinjection Ă©tant effectuĂ©e par injection du mĂ©tal liquide Ă lâaide dâun piston ou dâun gaz.According to another particular embodiment, the present invention relates to the manufacturing process as defined above, in which injection step 1 is carried out by injection under pressure in a hot chamber, said injection step 1 being carried out by injection of liquid metal using a piston or a gas.
Selon un autre mode de rĂ©alisation particulier, la prĂ©sente invention concerne le procĂ©dĂ© de fabrication tel que dĂ©fini ci-dessus, dans lequel lâĂ©tape 1 dâinjection est effectuĂ©e par injection sous pression Ă chambre froide, ladite Ă©tape 1 dâinjection Ă©tant effectuĂ©e par injection du mĂ©tal liquide Ă lâaide dâun piston ou dâun gaz.According to another particular embodiment, the present invention relates to the manufacturing process as defined above, in which injection step 1 is carried out by injection under pressure in a cold room, said injection step 1 being carried out by injection of liquid metal using a piston or a gas.
A noter quâau regard de ces deux modes de rĂ©alisation particuliers. Les valeurs des pressions dâinjection sont nettement diffĂ©rentes (sous pression Ă chambre chaude : par gaz 5 Ă 110 bars et par piston hydraulique 100 Ă 400 bars ; sous pression Ă chambre froide : par piston 250 Ă 5000 bars ; basse pression : 1,5 bars). En gĂ©nĂ©ral, le plan de joint principal du moule est horizontal en basse pression et vertical en moulage sous pression. En basse pression, le moule peut ĂȘtre en sable ou en mĂ©tal ; en sous pression le moule est uniquement en mĂ©tal. La sous pression permet des temps de cycle beaucoup plus courts et une plus grande prĂ©cision gĂ©omĂ©trique que la basse pression. Lâarchitecture du dispositif dâinjection est aussi assez diffĂ©rente entre ces procĂ©dĂ©s.Note that with regard to these two particular embodiments. The injection pressure values are clearly different (under hot chamber pressure: by gas 5 to 110 bars and by hydraulic piston 100 to 400 bars; under cold chamber pressure: by piston 250 to 5000 bars; low pressure: 1. 5 bar). In general, the main parting plane of the mold is horizontal in low pressure and vertical in die casting. At low pressure, the mold can be made of sand or metal; under pressure the mold is only made of metal. Under pressure allows much shorter cycle times and greater geometric precision than low pressure. The architecture of the injection device is also quite different between these processes.
Selon un autre mode de rĂ©alisation particulier, la prĂ©sente invention concerne le procĂ©dĂ© de fabrication tel que dĂ©fini ci-dessus, dans lequel lâĂ©tape 4 de dĂ©moulage est effectuĂ©e par retournement du moule. Le retournement du moule permet Ă la coque de sortir du moule par gravitĂ©. Un exemple de ce mode de rĂ©alisation est schĂ©matisĂ© dans la Figure 4C.According to another particular embodiment, the present invention relates to the manufacturing process as defined above, in which step 4 of demolding is carried out by inversion of the mold. Flipping the mold allows the shell to come out of the mold by gravity. An example of this embodiment is shown schematically in Figure 4C.
Selon un autre mode de rĂ©alisation particulier, la prĂ©sente invention concerne le procĂ©dĂ© de fabrication tel que dĂ©fini ci-dessus, dans lequel le moule prĂ©sente une ouverture dans le bas du moule, laquelle ouverture est obstruĂ©e, lors de lâĂ©tape 1 dâinjection et lors de lâĂ©tape 2 de solidification, par un dispositif de fermeture, notamment un bouchon, une quenouille ou une trappe, lâĂ©tape 3 de soustraction Ă©tant initiĂ©e par une libĂ©ration de ladite ouverture, par enlĂšvement dudit dispositif de fermeture.According to another particular embodiment, the present invention relates to the manufacturing process as defined above, in which the mold has an opening in the bottom of the mold, which opening is obstructed, during injection step 1 and during step 2 of solidification, by a closing device, in particular a stopper, a stopper or a trap door, step 3 of subtraction being initiated by releasing said opening, by removing said closing device.
Ce mode de réalisation est illustré par les Figures 1A et 1B. A noter que dans un mode de réalisation particulier, ledit dispositif de fermeture (bouchon, une quenouille ou trappe) est soit préchauffé, soit chauffant, soit isolant thermique.This embodiment is illustrated in Figures 1A and 1B. Note that in a particular embodiment, said closure device (cap, stopper or trapdoor) is either preheated, heated, or thermally insulating.
Selon un autre mode de réalisation particulier, la présente invention concerne le procédé de fabrication tel que défini ci-dessus,According to another particular embodiment, the present invention relates to the manufacturing process as defined above,
dans lequel le moule prĂ©sente des moyens dâappel dâair ou de gaz dans le haut du moule, lesdits moyens dâappel dâair ou de gaz Ă©tant fermĂ©s lors de lâĂ©tape 1 dâinjection et lors de lâĂ©tape 2 de solidification,in which the mold has means for drawing air or gas into the top of the mold, said means for drawing air or gas being closed during injection step 1 and during step 2 solidification,
dans lequel lâĂ©tape 3 de soustraction est favorisĂ©e ou rendue possible par lâouverture desdits moyens dâappel dâair ou de gaz entrainant un appel dâair ou de gaz, notamment dâazote ou dâargon, sous pression, en particulier Ă une pression Ă©gale ou supĂ©rieure Ă la pression atmosphĂ©rique.in which step 3 of subtraction is favored or made possible by the opening of said means for drawing air or gas resulting in a draw of air or gas, in particular nitrogen or argon, under pressure, in particular at a pressure equal to or greater than atmospheric pressure.
Avantageusement lesdits moyens dâappel dâair ou de gaz sont une trappe ou bouchon en matĂ©riau trĂšs isolant thermique, ou en matĂ©riau chauffĂ© ou prĂ©chauffĂ©, Ă©vitant localement la solidification ; ou filtre(s) Ă air mĂ©tallique(s) ou rĂ©fractaire(s) chauffĂ©(s) ; voire Ă©lĂ©ment de perçage de la fine peau solidifiĂ©e Ă cet endroit.Advantageously, said air or gas intake means are a hatch or plug made of highly thermally insulating material, or of heated or preheated material, locally avoiding solidification; or heated metallic or refractory air filter(s); or even an element for piercing the thin solidified skin at this location.
Lesdits moyens dâappel dâair ou de gaz sont dits fermĂ©s lorsque lâair ou le gaz ne peut pas pĂ©nĂ©trer Ă lâintĂ©rieur du moule.Said means of drawing air or gas are said to be closed when air or gas cannot penetrate inside the mold.
Lesdits moyens dâappel dâair ou de gaz sont dits ouverts lorsque lâair ou le gaz peut pĂ©nĂ©trer Ă lâintĂ©rieur du moule.Said means of drawing air or gas are said to be open when air or gas can penetrate inside the mold.
Dans ce mode de rĂ©alisation, les moyens dâappel ou de gaz, notamment un bouchon ou une trappe, sont constituĂ©s dâun matĂ©riau isolant, et/ou en matĂ©riau chauffĂ© ou prĂ©chauffĂ©, afin dâĂ©viter la solidification du mĂ©tal contre la partie dudit dispositif en contact avec ledit mĂ©tal.In this embodiment, the call or gas means, in particular a plug or a trapdoor, are made of an insulating material, and/or of heated or preheated material, in order to avoid the solidification of the metal against the part of said device in contact with said metal.
De cette façon, lorsque les moyens sont ĂŽtĂ©s, une ouverture est prĂ©sente dans la coque formĂ©e Ă lâissue de lâĂ©tape 2 de solidification. Cette solution nâest toutefois utilisĂ©e en gĂ©nĂ©ral que pour la basse pression et la sous pression.In this way, when the means are removed, an opening is present in the shell formed at the end of step 2 of solidification. However, this solution is generally only used for low pressure and under pressure.
Selon un autre mode de réalisation particulier, la présente invention concerne le procédé de fabrication tel que défini ci-dessus, dans lequel le point de fusion du métal est supérieur à 180°C, et est notamment compris de 180°C à 1750°C.According to another particular embodiment, the present invention relates to the manufacturing process as defined above, in which the melting point of the metal is greater than 180°C, and is in particular from 180°C to 1750°C. .
Selon un autre mode de réalisation particulier, la présente invention concerne le procédé de fabrication tel que défini ci-dessus, dans lequel le point de fusion du métal est supérieur à 320°C, et est notamment compris de 320°C à 1750°C.According to another particular embodiment, the present invention relates to the manufacturing process as defined above, in which the melting point of the metal is greater than 320°C, and is in particular from 320°C to 1750°C. .
Selon un autre mode de réalisation particulier, la présente invention concerne le procédé de fabrication tel que défini ci-dessus, dans lequel le point de fusion du métal est supérieur à 500°C, et est notamment compris de 500°C à 1750°C.According to another particular embodiment, the present invention relates to the manufacturing process as defined above, in which the melting point of the metal is greater than 500°C, and is in particular between 500°C and 1750°C. .
Selon un autre mode de réalisation particulier, la présente invention concerne le procédé de fabrication tel que défini ci-dessus, dans lequel le point de fusion du métal est supérieur à 660°C, et est notamment compris de 660 à 1750°C.According to another particular embodiment, the present invention relates to the manufacturing process as defined above, in which the melting point of the metal is greater than 660°C, and is in particular from 660 to 1750°C.
Selon un autre mode de rĂ©alisation particulier, la prĂ©sente invention concerne le procĂ©dĂ© tel que dĂ©fini ci-dessus, dans lequel le mĂ©tal est lâaluminium pur ou alliĂ©. En particulier, la prĂ©sente invention concerne le procĂ©dĂ© tel que dĂ©fini ci-dessus, dans lequel le mĂ©tal est lâaluminium pur. En particulier, la prĂ©sente invention concerne Ă©galement le procĂ©dĂ© tel que dĂ©fini ci-dessus, dans lequel le mĂ©tal est lâaluminium alliĂ©.According to another particular embodiment, the present invention relates to the process as defined above, in which the metal is pure or alloyed aluminum. In particular, the present invention relates to the process as defined above, in which the metal is pure aluminum. In particular, the present invention also relates to the process as defined above, in which the metal is alloyed aluminum.
Selon un autre mode de rĂ©alisation particulier, la prĂ©sente invention concerne le procĂ©dĂ© tel que dĂ©fini ci-dessus, dans lequel le mĂ©tal est lâalliage eutectique AlSi12.According to another particular embodiment, the present invention relates to the process as defined above, in which the metal is the eutectic alloy AlSi12.
Selon un autre mode de rĂ©alisation particulier, la prĂ©sente invention concerne le procĂ©dĂ© tel que dĂ©fini ci-dessus, dans lequel le moule est constituĂ© de fonte, dâaluminium, dâacier, dâalliage mĂ©tallique, et est notamment constituĂ© dâalliage dâaluminium, ou dâalliage de cuivre.According to another particular embodiment, the present invention relates to the process as defined above, in which the mold is made of cast iron, aluminum, steel, metal alloy, and is in particular made of alloy aluminum, or copper alloy.
Il est Ă©galement possible dâutiliser dâautres matĂ©riaux constituant le moule, comme par exemple : du sable, du plĂątre rĂ©fractaire, de la cĂ©ramique, ou du graphite. Le matĂ©riau qui constitue le moule doit ĂȘtre compatible avec le mĂ©tal utilisĂ© dans la prĂ©paration des piĂšces creuses. Ainsi, si le procĂ©dĂ© sert Ă prĂ©parer une piĂšce en aluminium, dont le point de fusion se situe vers 660°C, il est prĂ©fĂ©rable de choisir un moule constituĂ© dâun matĂ©riau ayant un point de fusion supĂ©rieur Ă 660°C, comme, par exemple, un moule en acier ou en sable, afin de limiter la dĂ©gradation du moule. Pour la fabrication dâune piĂšce en acier de haut point de fusion (tempĂ©rature de coulĂ©e comprise entre 1550°C et 1750°C), un moule en sable ou en alliage ferreux est prĂ©fĂ©rablement utilisĂ©.It is also possible to use other materials constituting the mold, such as: sand, refractory plaster, ceramic, or graphite. The material which constitutes the mold must be compatible with the metal used in the preparation of the hollow parts. Thus, if the process is used to prepare an aluminum part, the melting point of which is around 660°C, it is preferable to choose a mold made of a material having a melting point greater than 660°C, such as, for example, a steel or sand mold, in order to limit degradation of the mold. For the manufacture of a steel part with a high melting point (casting temperature between 1550°C and 1750°C), a sand or ferrous alloy mold is preferably used.
Le procĂ©dĂ© selon lâinvention permet la fabrication de piĂšces comprenant une coque de faible Ă©paisseur. Le procĂ©dĂ© permet Ă©galement de contrĂŽler localement lâĂ©paisseur de la coque solidifiĂ©e. Pour ce faire, il est possible dâutiliser un moule dâĂ©paisseur variable. La coque solidifiĂ©e sera plus Ă©paisse aux endroits oĂč la paroi du moule est plus Ă©paisse.The process according to the invention allows the manufacture of parts comprising a thin shell. The process also makes it possible to locally control the thickness of the solidified shell. To do this, it is possible to use a mold of varying thickness. The solidified shell will be thicker in places where the mold wall is thicker.
LâĂ©paisseur de la coque solidifiĂ©e peut Ă©galement ĂȘtre contrĂŽlĂ©e par la chauffe locale du moule et/ou les poteyages dĂ©posĂ©s dans le moule. Ainsi, la coque solidifiĂ©e sera moins Ă©paisse aux endroits en contact avec les parties surchauffĂ©es du moule, ou en contact avec les parties de lâempreinte revĂȘtues de poteyage isolant thermique.The thickness of the solidified shell can also be controlled by local heating of the mold and/or the coatings deposited in the mold. Thus, the solidified shell will be thinner in the places in contact with the overheated parts of the mold, or in contact with the parts of the impression coated with thermal insulating coating.
Selon un autre mode de rĂ©alisation particulier, la prĂ©sente invention concerne le procĂ©dĂ© tel que dĂ©fini ci-dessus, dans lequel le moule est un moule dâĂ©paisseur variable. Ce mode de rĂ©alisation permet en particulier de mieux contrĂŽler la cartographie thermique du moule et donc de mieux maitriser les Ă©paisseurs des piĂšces mĂ©talliques moulĂ©es.According to another particular embodiment, the present invention relates to the process as defined above, in which the mold is a mold of variable thickness. This embodiment makes it possible in particular to better control the thermal mapping of the mold and therefore to better control the thicknesses of the molded metal parts.
Selon un autre mode de réalisation particulier, la présente invention concerne le procédé tel que défini ci-dessus, dans lequel le moule est localement chauffé ou refroidi à une température différente de celle du reste du moule. Cette température est dépendante de la géométrie de la piÚce et du moule, ainsi que de la nature des matériaux utilisés (moule et métal coulé).According to another particular embodiment, the present invention relates to the process as defined above, in which the mold is locally heated or cooled to a temperature different from that of the rest of the mold. This temperature depends on the geometry of the part and the mold, as well as the nature of the materials used (mold and cast metal).
Dans certains cas, ce mode de rĂ©alisation permet une meilleure maĂźtrise de lâĂ©paisseur (variable ou uniforme) des piĂšces mĂ©talliques. De mĂȘme, lâutilisation de diffĂ©rents poteyages et/ou une variation dâĂ©paisseur du moule et/ou lâintĂ©gration dâun joint thermique dans le moule (lames dâair ou matĂ©riau isolant incrustĂ©) et/ou un dispositif de refroidissement (circulation dâun fluide ou incrustation dâun matĂ©riau conducteur thermique) peuvent permettre Ă©galement de mieux gĂ©rer lâĂ©paisseur de la coque solidifiĂ©e.In certain cases, this embodiment allows better control of the thickness (variable or uniform) of the metal parts. Likewise, the use of different coatings and/or a variation in mold thickness and/or the integration of a thermal seal in the mold (air blades or inlaid insulating material) and/or a cooling device (circulation of a fluid or incrustation of a thermally conductive material) can also make it possible to better manage the thickness of the solidified shell.
Selon un autre mode de rĂ©alisation particulier, la prĂ©sente invention concerne le procĂ©dĂ© tel que dĂ©fini ci-dessus, dans lequel le moule est revĂȘtu dâun revĂȘtement de poteyage.According to another particular embodiment, the present invention relates to the process as defined above, in which the mold is coated with a coating of clay.
Le «revĂȘtement de poteyage» est un revĂȘtement apposĂ© sur, ou contre, la face intĂ©rieure du moule (empreinte), câest-Ă -dire la face qui sera en contact avec le mĂ©tal fondu. Le revĂȘtement de poteyage permet de faciliter le dĂ©moulage, de limiter les interactions chimiques moule-alliage et les chocs thermiques, ainsi que de participer au contrĂŽle de la solidification. Un revĂȘtement de poteyage est utilisĂ© dans le cas de lâutilisation dâun moule mĂ©tallique, et est constituĂ© dâun matĂ©riau isolant- ou conducteur thermique. Le revĂȘtement de poteyage a notamment une Ă©paisseur comprise de 0,2 Ă 0,5 mm. Par « de 0,2 Ă 0,5 mm » on entend Ă©galement les gammes suivantes : de 0,3 Ă 0,5 mm, de 0,4 Ă 0,5 mm, de 0,2 Ă 0,4 mm, de 0,2 Ă 0,3 mm, de 0,3 Ă 0,4 mm.The â poteyage coating â is a coating applied to, or against, the interior face of the mold (impression), that is to say the face which will be in contact with the molten metal. The bonding coating facilitates demoulding, limits chemical mold-alloy interactions and thermal shock, as well as helps control solidification. A bonding coating is used in the case of using a metal mold, and is made of an insulating or thermally conductive material. The poteyage coating notably has a thickness of 0.2 to 0.5 mm. By âfrom 0.2 to 0.5 mmâ we also mean the following ranges: from 0.3 to 0.5 mm, from 0.4 to 0.5 mm, from 0.2 to 0.4 mm, from 0.2 to 0.3 mm, 0.3 to 0.4 mm.
Sur ce point, il convient de noter quâun revĂȘtement, souvent appelĂ© « couche », peut Ă©galement ĂȘtre appliquĂ© sur lâempreinte dâun moule en sable. En gĂ©nĂ©ral, son rĂŽle consiste Ă amĂ©liorer lâĂ©tat de surface de la piĂšce moulĂ©e (attĂ©nuation de la granulomĂ©trie du sable), voire parfois Ă accĂ©lĂ©rer localement et en surface la solidification du mĂ©tal coulĂ©. La composition courante correspond Ă une farine rĂ©fractaire (zircon, graphite, âŠ) en suspension dans un liquide (eau, alcool) qui est Ă©vaporĂ© aprĂšs lâapplication (au pistolet, pinceau ou au trempĂ©). Lorsquâune grande conductivitĂ© thermique est recherchĂ©e pour ce dĂ©pĂŽt de surface, la couche peut contenir de la poudre dâaluminium.On this point, it should be noted that a coating, often called a "coat", can also be applied to the impression of a sand mold. In general, its role consists of improving the surface condition of the molded part (attenuation of the grain size of the sand), or sometimes even accelerating the solidification of the cast metal locally and on the surface. The common composition corresponds to a refractory flour (zircon, graphite, etc.) suspended in a liquid (water, alcohol) which is evaporated after application (by spray gun, brush or dipping). When high thermal conductivity is desired for this surface deposit, the layer may contain aluminum powder.
Selon un autre mode de rĂ©alisation particulier, la prĂ©sente invention concerne le procĂ©dĂ© tel que dĂ©fini ci-dessus, dans lequel le matĂ©riau de poteyage est un matĂ©riau isolant thermique, en particulier choisi parmi le talc, le kaolin, le blanc dâEspagne et le blanc de Meudon. A noter que lâĂ©paisseur de ce type de matĂ©riau poteyage sur lâempreinte du moule est souvent comprise de 0,3 mm Ă 0,5 mm.According to another particular embodiment, the present invention relates to the process as defined above, in which the coating material is a thermal insulating material, in particular chosen from talc, kaolin, Spanish white and white from Meudon. Note that the thickness of this type of plastering material on the mold cavity is often between 0.3 mm and 0.5 mm.
Selon un autre mode de rĂ©alisation particulier, la prĂ©sente invention concerne le procĂ©dĂ© tel que dĂ©fini ci-dessus, dans lequel le matĂ©riau de poteyage est un matĂ©riau conducteur thermique, en particulier le graphite colloĂŻdal. A noter que lâĂ©paisseur de ce type de matĂ©riau de poteyage sur lâempreinte du moule est souvent de lâordre de 0,2 Ă 0,3 mm.According to another particular embodiment, the present invention relates to the process as defined above, in which the coating material is a thermally conductive material, in particular colloidal graphite. Note that the thickness of this type of plastering material on the mold cavity is often of the order of 0.2 to 0.3 mm.
Selon un autre mode de rĂ©alisation particulier, la prĂ©sente invention concerne le procĂ©dĂ© tel que dĂ©fini ci-dessus, dans lequel, au dĂ©but de lâĂ©tape 1 dâinjection, le moule est Ă une tempĂ©rature supĂ©rieure Ă la tempĂ©rature ambiante. Le moule est notamment chauffĂ© lorsquâun moule constituĂ© dâun matĂ©riau mĂ©tallique est utilisĂ©. Il nâest cependant pas nĂ©cessaire de chauffer le moule si ledit moule est un moule en sable.According to another particular embodiment, the present invention relates to the process as defined above, in which, at the start of injection step 1, the mold is at a temperature higher than ambient temperature. The mold is heated in particular when a mold made of a metallic material is used. However, it is not necessary to heat the mold if said mold is a sand mold.
Par «tempĂ©rature ambiante» on entend une tempĂ©rature comprise de 15°C Ă 30°C, en particulier comprise de 20 Ă 25°C.By â room temperature â we mean a temperature between 15°C and 30°C, in particular between 20 and 25°C.
Le chauffage du moule permet de recevoir le mĂ©tal en fusion, tout en limitant les risques de dĂ©gradation du moule mĂ©tallique,e.g.rupture par choc thermique, fissuration due Ă la fatigue thermique. De plus, le prĂ©chauffage du moule Ă©vite une solidification prĂ©maturĂ©e du mĂ©tal versĂ© conduisant Ă un remplissage incomplet du moule, appelĂ© «malvenue».Heating the mold allows the molten metal to be received, while limiting the risks of degradation of the metal mold, eg rupture by thermal shock, cracking due to thermal fatigue. In addition, preheating the mold prevents premature solidification of the poured metal leading to incomplete filling of the mold, called â unwelcome â.
Les tempĂ©ratures de lâalliage et du moule peuvent ĂȘtre mesurĂ©es par thermocouples ou capteurs optiques.Alloy and mold temperatures can be measured by thermocouples or optical sensors.
Selon un autre mode de rĂ©alisation particulier, la prĂ©sente invention concerne le procĂ©dĂ© tel que dĂ©fini ci-dessus, dans lequel, lors de lâĂ©tape 1 dâinjection, le moule est Ă une tempĂ©rature telle que la diffĂ©rence entre la tempĂ©rature du moule et la tempĂ©rature de la masse de mĂ©tal fondu est comprise de 50°C Ă 1750°C.According to another particular embodiment, the present invention relates to the process as defined above, in which, during injection step 1, the mold is at a temperature such that the difference between the temperature of the mold and the temperature of the mass of molten metal is between 50°C and 1750°C.
Selon ce mode de rĂ©alisation, il faut entendre que la tempĂ©rature du moule est infĂ©rieure de 50°C Ă 1750°C Ă la tempĂ©rature de la masse de mĂ©tal fondu (appelĂ©e couramment « tempĂ©rature de coulĂ©e »). Sur ce point, il faut bien diffĂ©rencier la tempĂ©rature de coulĂ©e (tempĂ©rature de verse du mĂ©tal fondu dans le moule) du point de fusion dudit mĂ©tal (tempĂ©rature de liquidus). LâĂ©cart entre ces deux tempĂ©ratures ( tempĂ©rature de coulĂ©e et tempĂ©rature de liquidus) est appelĂ© «la surchauffe» dans le vocabulaire mĂ©tier des fondeurs.According to this embodiment, it should be understood that the temperature of the mold is 50°C to 1750°C lower than the temperature of the mass of molten metal (commonly called âcasting temperatureâ). On this point, it is necessary to differentiate between the casting temperature (pouring temperature of the molten metal into the mold) and the melting point of said metal (liquidus temperature). The difference between these two temperatures (casting temperature and liquidus temperature) is called â overheating â in the professional vocabulary of foundries.
Aux fins dâinformation :
- en moulage au sable oĂč le moule est Ă tempĂ©rature ambiante, la surchauffe est couramment comprise de 50°C Ă 200°C pour une coulĂ©e par gravitĂ©, et est trĂšs souvent comprise de 100°C Ă 150°C ;
- en moulage avec une coquille mĂ©tallique et coulĂ©e par gravitĂ©, la surchauffe pour un alliage coulĂ© dâaluminium est souvent comprise de 50°C Ă 100°C et la tempĂ©rature du moule est de lâordre de 350°C ; et
- en moulage sous pression, il est parfois possible dâavoir une surchauffe nulle (tempĂ©rature dâinjection du mĂ©tal fondu dans le moule mĂ©tallique Ă©gale Ă la tempĂ©rature de liquidus du mĂ©tal fondu), ou comprise entre 0°C et 150°C, ou plus rarement nĂ©gative (câest-Ă -dire avec une tempĂ©rature dâinjection du mĂ©tal fondu comprise entre la tempĂ©rature de liquidus et celle de solidus du mĂ©tal fondu).
- in sand casting where the mold is at room temperature, the overheating is commonly between 50°C and 200°C for gravity casting, and is very often between 100°C and 150°C;
- in casting with a metal shell and gravity casting, the overheating for a cast aluminum alloy is often between 50°C and 100°C and the mold temperature is of the order of 350°C; And
- in die casting, it is sometimes possible to have zero superheat (injection temperature of the molten metal into the metal mold equal to the liquidus temperature of the molten metal), or between 0°C and 150°C, or more rarely negative (that is to say with an injection temperature of the molten metal between the liquidus temperature and that of solidus of the molten metal).
Suite aux expĂ©rimentations, les inventeurs ont de façon inattendue constatĂ© que la surchauffe avec le procĂ©dĂ© innovant selon lâinvention peut ĂȘtre plus faible que celle utilisĂ©e couramment dans les procĂ©dĂ©s conventionnels de fonderie, alors quâen gĂ©nĂ©ral il est attendu quâune piĂšce fine nĂ©cessite une surchauffe Ă©levĂ©e. Cela permet des Ă©conomies dâĂ©nergie et dâamĂ©liorer la durĂ©e de vie du moule mĂ©tallique.Following the experiments, the inventors unexpectedly noted that the overheating with the innovative process according to the invention can be lower than that commonly used in conventional foundry processes, while in general it is expected that a thin part requires high superheat. This saves energy and improves the life of the metal mold.
Par « de 50°C Ă 1750°C » on entend Ă©galement les gammes suivantes : de 50 Ă 75°C, de 75 Ă 100°C, de 100 Ă 200°C, de 200 Ă 300°C, de 300 Ă 400°C, de 400 Ă 500°C, de 500 Ă 600°C, de 600 Ă 700°C, de 700 Ă 800°C, de 800 Ă 900°C, de 900 Ă 1000°C, de 1000 Ă 1100°C, de 1100 Ă 1200°C, de 1200 Ă 1300°C, de 1300 Ă 1400 °C, de 1400 Ă 1500°C, de 1500 Ă 1600°C, de 1600 Ă 1700°C, de 1700 Ă 1750°C.By âfrom 50°C to 1750°Câ we also mean the following ranges: from 50 to 75°C, from 75 to 100°C, from 100 to 200°C, from 200 to 300°C, from 300 to 400 °C, from 400 to 500°C, from 500 to 600°C, from 600 to 700°C, from 700 to 800°C, from 800 to 900°C, from 900 to 1000°C, from 1000 to 1100° C, from 1100 to 1200°C, from 1200 to 1300°C, from 1300 to 1400°C, from 1400 to 1500°C, from 1500 to 1600°C, from 1600 to 1700°C, from 1700 to 1750°C .
A titre dâexemple pour les valeurs thĂ©oriques en moulage coquille classique : dans le cas oĂč le mĂ©tal Ă couler par gravitĂ© est lâaluminium pur, le moule mĂ©tallique est prĂ©fĂ©rablement chauffĂ© Ă une tempĂ©rature dâenviron 350°C, le point de fusion de lâaluminium pur Ă©tant dâenviron 660°C et la surchauffe souvent choisie dâenviron 75°C, la tempĂ©rature du moule est dans ce cas infĂ©rieure dâenviron 385°C Ă la tempĂ©rature de coulĂ©e du mĂ©tal fondu. Ces valeurs correspondent aux tempĂ©ratures couramment utilisĂ©es en moulage dit « en coquille » (cĂ d en moule mĂ©tallique avec coulĂ©e par gravitĂ©).As an example for the theoretical values in conventional shell casting: in the case where the metal to be cast by gravity is pure aluminum, the metal mold is preferably heated to a temperature of approximately 350°C, the melting point pure aluminum being around 660°C and the superheat often chosen around 75°C, the temperature of the mold is in this case around 385°C lower than the casting temperature of the molten metal. These values correspond to the temperatures commonly used in so-called âshellâ molding (i.e. in a metal mold with gravity casting).
A titre dâexemple pratique non limitatif, correspondant Ă la rĂ©alisation illustrĂ©e en
Au regard de cette
Ces cinq paramĂštres permettent dâinfluer sur les Ă©tapes du procĂ©dĂ© selon lâinvention afin dâassurer la qualitĂ© de la piĂšce moulĂ©e, notamment dans le cas prĂ©sentĂ© en
Selon un mode de rĂ©alisation particulier, la prĂ©sente invention concerne le procĂ©dĂ© tel que dĂ©fini ci-dessus, dans lequel ledit mĂ©tal est aluminium ou un alliage dâaluminium, en particulier AlSi12,According to a particular embodiment, the present invention relates to the process as defined above, in which said metal is aluminum or an aluminum alloy, in particular AlSi12,
dans lequel lâĂ©tape 1 dâinjection est effectuĂ©e par gravitĂ©, ladite Ă©tape 1 dâinjection Ă©tant effectuĂ©e par versement du mĂ©tal liquide par une ouverture dans la partie haute du moule,in which injection step 1 is carried out by gravity, said injection step 1 being carried out by pouring the liquid metal through an opening in the upper part of the mold,
dans lequel le moule prĂ©sente une ouverture dans lebasdu moule, laquelle ouverture est obstruĂ©e, lors de lâĂ©tape 1 dâinjection et lors de lâĂ©tape 2 de solidification, par un dispositif de fermeture, notamment un bouchon, une quenouille ou une trappe, lâĂ©tape 3 de soustraction Ă©tant initiĂ© par une libĂ©ration de ladite ouverture, par enlĂšvement dudit dispositif de fermeture.in which the mold has an opening in the bottom of the mold, which opening is obstructed, during step 1 of injection and during step 2 of solidification, by a closing device, in particular a plug, a stopper or a trap door, step 3 of subtraction being initiated by releasing said opening, by removing said closing device.
Avantageusement dans ce mode de réalisation(
Avantageusement dans ce mode de rĂ©alisation le temps dâattente avant vidange dans le moule est de 10 secondes Ă une minute.Advantageously in this embodiment the waiting time before emptying into the mold is 10 seconds to one minute.
Avantageusement dans ce mode de réalisation le temps de durée de vidange est de 11 à 18 secondes.Advantageously in this embodiment the draining duration time is 11 to 18 seconds.
Selon un autre mode de réalisation particulier, la présente invention concerne le procédé tel que défini ci-dessus, dans lequel ladite température du moule supérieure à la température ambiante est :
- soit atteinte par une Ă©tape 0 de prĂ©chauffage du moule, avant lâĂ©tape 1 de versement,
- soit le rĂ©sultat dâune production prĂ©cĂ©dente.
- is achieved by a step 0 of preheating the mold, before step 1 of pouring,
- or the result of a previous production.
Le prĂ©chauffage du moule peut ĂȘtre effectuĂ©, Ă titre dâexemple par utilisation de brĂ»leurs Ă gaz, ou de dispositifs Ă©lectriques de chauffe.Preheating the mold can be carried out, for example by using gas burners or electric heating devices.
AprĂšs une premiĂšre production, il est possible que le moule ait dĂ©jĂ la tempĂ©rature souhaitĂ©e. Dans ce cas, le moule peut ĂȘtre utilisĂ© sans chauffage supplĂ©mentaire. Cette caractĂ©ristique est particuliĂšrement intĂ©ressante et recherchĂ©e dans le cas dâune production de multiples piĂšces en sĂ©rie.After initial production, it is possible that the mold already has the desired temperature. In this case, the mold can be used without additional heating. This characteristic is particularly interesting and sought after in the case of mass production of multiple parts.
Selon un autre mode de rĂ©alisation particulier, la prĂ©sente invention concerne le procĂ©dĂ© tel que dĂ©fini ci-dessus, dans lequel le mĂ©tal fondu, injectĂ© lors de lâĂ©tape 1 dâinjection, est Ă une tempĂ©rature Ă©gale ou supĂ©rieure au point de fusion dudit mĂ©tal,According to another particular embodiment, the present invention relates to the process as defined above, in which the molten metal, injected during injection step 1, is at a temperature equal to or greater than the melting point of said metal,
ladite tempĂ©rature, nommĂ©e «tempĂ©rature de coulĂ©e/dâinjection», Ă©tant Ă©gale ou supĂ©rieure de 0°C Ă 200°C par rapport audit point de fusion.said temperature, called â casting/injection temperature â, being equal to or greater than 0°C to 200°C relative to said melting point.
La surchauffe au-dessus du point de fusion est dĂ©pendante de la gĂ©omĂ©trie de la piĂšce Ă mouler, la nature de lâalliage et celle du moule. Le choix de la tempĂ©rature Ă laquelle le mĂ©tal est chauffĂ© relĂšve du savoir-faire de lâhomme de lâart.Overheating above the melting point depends on the geometry of the part to be molded, the nature of the alloy and that of the mold. The choice of the temperature to which the metal is heated falls within the know-how of those skilled in the art.
Par «de 0°C Ă 200°C» on entend Ă©galement les gammes suivantes : de 0°C Ă 150°C, de 0°C Ă 100°C, de 0°C Ă 50°C, de 50°C Ă 100°C, de 50°C Ă 150°C, de 50°C Ă 200°C, de 100°C Ă 200°C, de 150°C Ă 200°C, de 100°C Ă 150°C.By â from 0°C to 200°C â we also mean the following ranges: from 0°C to 150°C, from 0°C to 100°C, from 0°C to 50°C, from 50°C to 100°C, from 50°C to 150°C, from 50°C to 200°C, from 100°C to 200°C, from 150°C to 200°C, from 100°C to 150°C.
A titre dâexemple en moulage coquille classique, pour un alliage AlSi12 coulĂ© par gravitĂ© dans le moule mĂ©tallique, la diffĂ©rence entre la tempĂ©rature de coulĂ©e et le liquidus (appelĂ©e « surchauffe ») est souvent comprise de 50°C Ă 100°C.As an example in classic shell casting, for an AlSi12 alloy cast by gravity in the metal mold, the difference between the casting temperature and the liquidus (called âoverheatingâ) is often between 50°C and 100°C.
Le liquidus dudit alliage Ă©tant de 580°C (solidus 575°C) ( cf NFA 57.703), lâalliage est donc chauffĂ© Ă une tempĂ©rature comprise de 630 Ă 680°C,e.g.souvent Ă une tempĂ©rature dâenviron 650°C.The liquidus of said alloy being 580°C (solidus 575°C) (see NFA 57.703), the alloy is therefore heated to a temperature of between 630 and 680°C, eg often to a temperature of approximately 650°C.
Pour la mise en Ćuvre de la prĂ©sente invention, notamment lâobtention dâĂ©paisseur faible de coque solidifiĂ©e et le temps nĂ©cessaire pour effectuer la vidange, des surchauffes supĂ©rieures peuvent ĂȘtre employĂ©es,e.g.comprise de 100 Ă 200°C.For the implementation of the present invention, in particular the obtaining of low thickness of solidified shell and the time necessary to carry out the emptying, higher superheats can be used, eg between 100 and 200°C.
La prĂ©sente invention concerne Ă©galement un procĂ©dĂ© de fabrication en sĂ©rie dâau moins deux piĂšces mĂ©talliques, ledit procĂ©dĂ© comprenant au moins :
- la fabrication dâune premiĂšre piĂšce mĂ©tallique selon le procĂ©dĂ© de fabrication tel que dĂ©fini ci-dessus, et
- la fabrication dâune deuxiĂšme piĂšce mĂ©tallique, selon le procĂ©dĂ© de fabrication tel que dĂ©fini ci-dessus, dans lequel le mĂ©tal utilisĂ© versĂ© dans lâĂ©tape 1 de versement est le mĂ©tal soustrait lors de lâĂ©tape 3 de soustraction de la fabrication de la premiĂšre piĂšce.
- manufacturing a first metal part according to the manufacturing process as defined above, and
- the manufacture of a second metal part, according to the manufacturing process as defined above, in which the metal used poured in step 1 of pouring is the metal subtracted during step 3 of subtraction of the manufacture of the first piece.
Dans ce mode de rĂ©alisation, aprĂšs la premiĂšre production, il nâest plus nĂ©cessaire de chauffer le moule. Les coulĂ©es successives dans le moule mĂ©tallique entretiennent le moule chaud. Le procĂ©dĂ© de production en sĂ©rie est un procĂ©dĂ© relativement Ă©conomique (limitation des consommations Ă©nergĂ©tiques). LâĂ©paisseur du moule et la tempĂ©rature de prĂ©chauffage permettent donc de dissiper suffisamment la chaleur pour solidifier la peau dâalliage, mais assurent aussi de conserver le moule mĂ©tallique suffisamment chaud pour couler les piĂšces suivantes sans avoir Ă rĂ©chauffer le moule, par une autorĂ©gulation thermique du moule : la chaleur apportĂ©e au moule par chaque piĂšce produite correspond alors substantiellement Ă la chaleur Ă©changĂ©e par le moule avec son milieu extĂ©rieur pendant le temps de cycle.In this embodiment, after the first production, it is no longer necessary to heat the mold. The successive pours into the metal mold keep the mold hot. The mass production process is a relatively economical process (limiting energy consumption). The thickness of the mold and the preheating temperature therefore make it possible to dissipate the heat sufficiently to solidify the alloy skin, but also ensure that the metal mold is kept hot enough to cast the following parts without having to reheat the mold, through self-regulation. thermal of the mold: the heat brought to the mold by each part produced then corresponds substantially to the heat exchanged by the mold with its external environment during the cycle time.
Une autre solution consiste à vidanger le moule directement au-dessus du four de fusion-maintien, permettant ainsi de limiter le refroidissement du métal récupéré encore liquide pour son réemploi, et donc limitant les dépenses énergétiques des moyens de fusion, ces solutions étant non exhaustives.Another solution consists of emptying the mold directly above the melting-holding furnace, thus making it possible to limit the cooling of the recovered metal which is still liquid for its reuse, and therefore limiting the energy expenditure of the melting means, these solutions being non-exhaustive. .
Toutefois, dans certains cas particuliers de piĂšces, un dispositif de refroidissement ou de chauffe locale peut aussi ĂȘtre installĂ© sur le moule.However, in certain specific cases of parts, a local cooling or heating device can also be installed on the mold.
A titre dâexemple, pour la coulĂ©e, dâun alliage dâaluminium, un ordre de grandeur de lâĂ©paisseur du moule est donnĂ© par la formule de Jander :As an example, for the casting of an aluminum alloy, an order of magnitude of the thickness of the mold is given by the Jander formula:
Pour dimensionner lâĂ©paisseur de la coque solidifiĂ©e de façon plus optimale, un logiciel de simulation numĂ©rique de fonderie peut ĂȘtre utilisĂ© (jumeau numĂ©rique du procĂ©dĂ© de moulage). Garder une empreinte pleine dâalliage en fusion avant la vidange du moule facilite le maintien Ă une tempĂ©rature Ă©levĂ©e du moule en service.To dimension the thickness of the solidified shell more optimally, digital foundry simulation software can be used (digital twin of the casting process). Keeping a cavity full of molten alloy before draining the mold makes it easier to maintain a high mold temperature in service.
Ce procĂ©dĂ© permet Ă©galement une production en continu avec une cadence Ă©levĂ©e. La cadence dĂ©pend de plusieurs paramĂštres dont la gĂ©omĂ©trie de la piĂšce et ses dimensions, ainsi que de la nature de lâalliage coulĂ© et du matĂ©riau du moule.This process also allows continuous production at a high rate. The rate depends on several parameters including the geometry of the part and its dimensions, as well as the nature of the alloy cast and the material of the mold.
A titre indicatif, pour des piĂšces de petite Ă moyenne taille avec alliage dâaluminium coulĂ© et moule mĂ©tallique le temps de cycle peut ĂȘtre de quelques secondes Ă 5 minutes.As an indication, for small to medium sized parts with cast aluminum alloy and metal mold the cycle time can be from a few seconds to 5 minutes.
Le procĂ©dĂ© selon la prĂ©sente invention est moins onĂ©reux, moins Ă©nergivore et moins polluant que les procĂ©dĂ©s conventionnels. Cela est le rĂ©sultat de lâabsence de noyau dans le procĂ©dĂ© de lâinvention et de la mise au mille trĂšs faible,e.g.proche de 1 :1.The process according to the present invention is less expensive, less energy intensive and less polluting than conventional processes. This is the result of the absence of a core in the process of the invention and the very low focus, eg close to 1:1.
UndeuxiĂšme objetde la prĂ©sente invention concerne une piĂšce mĂ©tallique creuse susceptible dâĂȘtre obtenue par le procĂ©dĂ© tel que dĂ©fini ci-dessus.A second object of the present invention relates to a hollow metal part capable of being obtained by the process as defined above.
Le prĂ©sent procĂ©dĂ© permet dâobtenir des piĂšces mĂ©talliques creuses trĂšs variĂ©es. Selon la piĂšce Ă produire, lâhomme de lâart est en mesure de choisir parmi les diffĂ©rentes options de procĂ©dĂ© exposĂ©es dans la prĂ©sente demande.This process makes it possible to obtain a wide variety of hollow metal parts. Depending on the part to be produced, those skilled in the art are able to choose from the different process options set out in this application.
Les caractĂ©ristiques du procĂ©dĂ©, Ă savoir lâabsence dâun noyau et la formation dâune coque solidifiĂ©e de mĂ©tal contre la paroi intĂ©rieure du moule, confĂšrent aux piĂšces mĂ©talliques moulĂ©es des surfaces extĂ©rieures et surtout intĂ©rieures de structure spĂ©cifique par rapport aux piĂšces produites par les techniques conventionnelles.The characteristics of the process, namely the absence of a core and the formation of a solidified shell of metal against the interior wall of the mold, give the molded metal parts exterior and especially interior surfaces of specific structure compared to the parts produced by conventional techniques.
Effectivement, les piÚces produites ont une surface extérieure lisse et une surface intérieure cristallographique.Indeed, the parts produced have a smooth exterior surface and a crystallographic interior surface.
Par «surface extĂ©rieure lisse» on entend une surface correspondant Ă la forme complĂ©mentaire de la gĂ©omĂ©trie de la surface intĂ©rieure du moule (empreinte). La surface extĂ©rieure de la piĂšce produite est cependant lĂ©gĂšrement diminuĂ©e par le retrait linĂ©aire, i.e. la contraction du mĂ©tal solidifiĂ© entre la tempĂ©rature du solidus et la tempĂ©rature ambiante.By â smooth exterior surface â we mean a surface corresponding to the shape complementary to the geometry of the interior surface of the mold (cavity). The exterior surface of the part produced is, however, slightly reduced by linear shrinkage, ie the contraction of the solidified metal between the solidus temperature and the ambient temperature.
La surface lisse est donc dĂ©pourvue dâartifices cristallographiques, nâest pas rugueuse et ne possĂšde pas une topologie accidentĂ©e (pas de relief prononcĂ© dĂ» aux cristaux de solidification).The smooth surface is therefore devoid of crystallographic features, is not rough and does not have an uneven topology (no pronounced relief due to solidification crystals).
Par «surface intĂ©rieure cristallographique» on entend une surface non lisse, rugueuse et prĂ©sentant un relief chaotique. La topologie de la surface cristallographique prĂ©sente des reliefs correspondant aux cristaux formĂ©s lors de la solidification, e.g. cristaux dendritiques, cristaux polyĂ©driques, cellules eutectiques.By â crystallographic interior surface â we mean a surface that is not smooth, rough and has chaotic relief. The topology of the crystallographic surface presents reliefs corresponding to the crystals formed during solidification, eg dendritic crystals, polyhedral crystals, eutectic cells.
Ainsi, une coque métallique obtenue par le procédé de la présente invention, présente donc en relief sur sa surface intérieure des structures dendritiques, colonnaires et/ou équiaxes, et des facettes eutectiques pour les alliages hypoeutectiques.Thus, a metal shell obtained by the process of the present invention therefore presents in relief on its interior surface dendritic, columnar and/or equiaxed structures, and eutectic facets for hypoeutectic alloys.
Par exemple, une piĂšce produite avec lâalliage eutectique AlSi12, prĂ©sentera sur la surface intĂ©rieure des cristaux dendritiques riche en aluminium, des cristaux polyĂ©driques riches en silicium, et majoritairement des cellules eutectiques.For example, a part produced with the eutectic alloy AlSi12 will present on the interior surface dendritic crystals rich in aluminum, polyhedral crystals rich in silicon, and mainly eutectic cells.
La taille de ces différents cristaux est liée à la vitesse de solidification du métal ; plus la vitesse élevée plus les grains de cristaux sont fins.The size of these different crystals is linked to the speed of solidification of the metal; the higher the speed, the finer the crystal grains.
Les piĂšces produites selon le procĂ©dĂ© de lâinvention peuvent Ă©galement avoir une Ă©paisseur trĂšs faible, homogĂšne et contrĂŽlable par rapport aux piĂšces produits par des techniques existantes.The parts produced according to the process of the invention can also have a very low, homogeneous and controllable thickness compared to parts produced by existing techniques.
Par exemple lors de la mise en Ćuvre dâun procĂ©dĂ© dit «de coulĂ©e au renversé», pendant le basculement du moule pour la vidange, une partie de lâempreinte du moule est plus longtemps en contact avec le mĂ©tal versĂ© que le reste de lâempreinte. Le rĂ©sultat est une piĂšce non-symĂ©trique et dâĂ©paisseur non-homogĂšne.For example when implementing a so-called â reverse casting â process, during the tilting of the mold for emptying, part of the mold cavity is in contact with the poured metal for longer than the rest of the mold. the imprint. The result is a non-symmetrical part with a non-homogeneous thickness.
Pour certaines typologies de piĂšces produites, une Ă©paisseur de coque solidifiĂ©e infĂ©rieure Ă 2 mm peut ĂȘtre obtenue sur la totalitĂ© de la piĂšce ; cela mĂȘme avec une coulĂ©e, une solidification et une vidange effectuĂ©es par gravitĂ©.For certain types of parts produced, a solidified shell thickness of less than 2 mm can be obtained over the entire part; this even with pouring, solidification and emptying carried out by gravity.
Dans la mesure oĂč la coque est dâĂ©paisseur variable, ladite coque nâest manifestement pas fine sur toute sa surface. La phrase ci-haut correspond donc Ă un mode de rĂ©alisation prĂ©fĂ©rĂ©e de lâinvention qui portein finesur des piĂšces fines.Since the shell is of variable thickness, said shell is clearly not thin over its entire surface. The sentence above therefore corresponds to a preferred embodiment of the invention which ultimately relates to fine parts.
Les inventeurs ont mis au point un procĂ©dĂ© innovant permettant la mise en Ćuvre dâun procĂ©dĂ© de «coulĂ©e vidangĂ©e» avec des mĂ©taux detempĂ©raturede fusion supĂ©rieure Ă 180°C (en particulier supĂ©rieure Ă 320°C), sans basculement du moule lors de la vidange.The inventors have developed an innovative process allowing the implementation of a â drained casting â process with metals with a melting temperature greater than 180°C (in particular greater than 320°C), without tilting the mold during of the drain.
La mise en Ćuvre de ce procĂ©dĂ© a donc permis de disposer de piĂšces mĂ©talliques creuses ayant une surface intĂ©rieure cristallographique ainsi quâune trĂšs faible Ă©paisseur, impossibles Ă obtenir avec les procĂ©dĂ©s conventionnels de fabrication connus de lâart antĂ©rieur tels que le moulage, lâusinage, la dĂ©formation plastique. La prĂ©sence de cette surface intĂ©rieure cristallographique est intĂ©ressante pour certaines applications, notamment dans le transfert de chaleur (Ă©changeurs thermiques), la rĂ©flexion lumineuse (dĂ©coration, luminaires), la rugositĂ© (piĂšces anti-dĂ©rapantes),etc.The implementation of this process therefore made it possible to have hollow metal parts having a crystallographic interior surface as well as a very low thickness, impossible to obtain with conventional manufacturing processes known from the prior art such as molding, machining, plastic deformation. The presence of this crystallographic interior surface is interesting for certain applications, notably in heat transfer (heat exchangers), light reflection (decoration, lighting), roughness (anti-slip parts), etc.
Unautre objetde la présente invention concerne une piÚce métallique creuse comprenant: Another object of the present invention relates to a hollow metal part comprising:
- une surface extérieur lisse- a smooth exterior surface
- une surface intérieure cristallographique et- a crystallographic interior surface and
- une Ă©paisseur moyenne homogĂšne,- a uniform average thickness,
Selon un mode de rĂ©alisation particulier, lâinvention concerne une piĂšce mĂ©tallique creuse telle que dĂ©fini ci-dessus dans laquelle le mĂ©tal de ladite piĂšce mĂ©tallique a un point de fusion supĂ©rieur Ă 180°C, en particulier supĂ©rieur Ă 320°CAccording to a particular embodiment, the invention relates to a hollow metal part as defined above in which the metal of said metal part has a melting point greater than 180°C, in particular greater than 320°C
Selon un mode de rĂ©alisation particulier, lâinvention concerne une piĂšce mĂ©tallique creuse telle que dĂ©fini ci-dessus dans laquelle lâĂ©paisseur moyenne homogĂšne est de 0,2 mm Ă 2 mm.According to a particular embodiment, the invention relates to a hollow metal part as defined above in which the uniform average thickness is 0.2 mm to 2 mm.
Selon un mode de rĂ©alisation particulier, lâinvention concerne une piĂšce mĂ©tallique creuse telle que dĂ©fini ci-dessus, dans laquelle la topologie de ladite surface intĂ©rieure cristallographique comprend des reliefs correspondant aux cristaux formĂ©s lors de la solidification, en particulier des reliefs correspondant aux cristaux dendritiques ou aux cristaux polyĂ©driques ou aux cellules eutectiques.According to a particular embodiment, the invention relates to a hollow metal part as defined above, in which the topology of said crystallographic interior surface comprises reliefs corresponding to the crystals formed during solidification, in particular reliefs corresponding to the crystals dendritic or polyhedral crystals or eutectic cells.
Selon un mode de rĂ©alisation particulier, lâinvention concerne une piĂšce mĂ©tallique creuseAccording to a particular embodiment, the invention relates to a hollow metal part
comprenant:including:
- une surface extérieur lisse comprenant des grains métallurgiques,- a smooth exterior surface comprising metallurgical grains,
- une surface intérieure cristallographique et- a crystallographic interior surface and
- une Ă©paisseur moyenne homogĂšne, en particulier de 0,2 mm Ă 2 mm,- a uniform average thickness, in particular from 0.2 mm to 2 mm,
ladite piĂšce mĂ©tallique est constituĂ©e dâun mĂ©tal ayant un point de fusion supĂ©rieur Ă 180°C, en particulier supĂ©rieur Ă 320°C,said metal part consists of a metal having a melting point greater than 180°C, in particular greater than 320°C,
dans laquelle la topologie de ladite surface intérieure cristallographique comprend des reliefs correspondant aux cristaux métallurgiques, en particulier des reliefs correspondant aux cristaux dendritiques ou aux cristaux polyédriques ou aux cellules eutectiques.in which the topology of said crystallographic interior surface comprises reliefs corresponding to metallurgical crystals, in particular reliefs corresponding to dendritic crystals or polyhedral crystals or eutectic cells.
Les cristaux mĂ©tallurgiques sont les cristaux formĂ©s librement lors de la solidification du mĂ©tal fondu Ă partir duquel la piĂšce est fabriquĂ©e, par exemple sans contrainte dâune surface appliquĂ©e.Metallurgical crystals are the crystals formed freely during the solidification of the molten metal from which the part is made, for example without constraint from an applied surface.
Les grains mĂ©tallurgiques sont des cristaux de solidification formĂ©s en contact dâune surface lors de la solidification.Metallurgical grains are solidification crystals formed in contact with a surface during solidification.
Selon un mode de rĂ©alisation particulier, lâinvention concerne une piĂšce mĂ©tallique creuse telle que dĂ©fini ci-dessus, dans laquelle ladite piĂšce mĂ©tallique creuse comprend en relief sur sa surface intĂ©rieure cristallographique des structures choisies parmi des structures dendritiques, des structures colonnaires, des structures Ă©quiaxes et des structures de facettes eutectiques ou un mĂ©lange ou une association de ces structures.According to a particular embodiment, the invention relates to a hollow metal part as defined above, in which said hollow metal part comprises in relief on its crystallographic interior surface structures chosen from dendritic structures, columnar structures, structures equiaxed and eutectic facet structures or a mixture or association of these structures.
Par « association de ces structures » on entend par exemple des cristaux dendritiques constituĂ©s de colonnes.By âassociation of these structuresâ we mean, for example, dendritic crystals made up of columns.
Etats de surface du produit :Surface conditions of the product:
Selon le procĂ©dĂ© innovant de fabrication de lâinvention, la piĂšce moulĂ©e prĂ©sente deux types dâĂ©tat de surface.According to the innovative manufacturing process of the invention, the molded part has two types of surface condition.
Les surfaces du produit en contact direct avec les Ă©lĂ©ments moulants (empreinte du moule, broches) sont « lisses ». Ces surfaces « lisses » sont principalement extĂ©rieures ; leur rugositĂ© est relativement faible car reprĂ©sentative de lâĂ©tat de surface de lâintĂ©rieur du moule.The surfaces of the product in direct contact with the molding elements (mold cavity, pins) are âsmoothâ. These âsmoothâ surfaces are mainly exterior; their roughness is relatively low because it represents the surface condition of the interior of the mold.
Les surfaces du produit qui ne sont pas directement en contact avec les Ă©lĂ©ments moulants, gĂ©nĂ©ralement les surfaces intĂ©rieures du produit, sont appelĂ©es « cristallographiques ». Ces surfaces « cristallographiques » sont chaotiques, câest-Ă -dire de rugositĂ© importante, car reprĂ©sentatives de la morphologie des phases solides dĂ©veloppĂ©es pendant la solidification et de lâĂ©coulement du mĂ©tal fondu lors de la vidange.Product surfaces that are not directly in contact with the molding elements, generally the interior surfaces of the product, are called âcrystallographicâ. These âcrystallographicâ surfaces are chaotic, that is to say of significant roughness, because they represent the morphology of the solid phases developed during solidification and the flow of the molten metal during emptying.
Visuellement, il est possible dâidentifier ces diffĂ©rentes surfaces sur le produitĂ lâĆil nu,Ă lâaide dâimages comparatives de rĂ©fĂ©rence de microscopie optique ou de microscopie Ă©lectronique Ă balayage.Visually, it is possible to identify these different surfaces on the product with the naked eye, using comparative reference images from optical microscopy or scanning electron microscopy.
Le profil de ces surfaces est mesurable via un rugosimÚtre ou des clichés métallographiques :The profile of these surfaces can be measured using a roughness meter or metallographic plates:
Dans un mode de rĂ©alisation particulier, lâinvention concerne une piĂšce mĂ©tallique creuse telle que dĂ©fini ci-dessus dans laquelle la taille des grains mĂ©tallurgiques de la surface extĂ©rieure lisse est infĂ©rieure Ă celle des cristaux sur la surface intĂ©rieure cristallographique.In a particular embodiment, the invention relates to a hollow metal part as defined above in which the size of the metallurgical grains of the smooth exterior surface is smaller than that of the crystals on the crystallographic interior surface.
Avantageusement la piĂšce mĂ©tallurgique creuse comprend une augmentation de la taille des cristaux dans lâĂ©paisseur de la surface extĂ©rieure lisse Ă la surface intĂ©rieure cristallographique.Advantageously, the hollow metallurgical part includes an increase in the size of the crystals in the thickness of the smooth exterior surface to the crystallographic interior surface.
Taille des grains métallurgiques :Metallurgical grain size:
Le refroidissement rapide du mĂ©tal fondu en contact direct avec le moule gĂ©nĂšre une faible taille des cristaux primaires de solidification (cristaux dendritiques, polyĂ©driques, ⊠selon la nature du mĂ©tal fondu). A lâinverse, au voisinage des surfaces « cristallographiques », oĂč le temps de solidification est plus long, la taille de ces cristaux primaires de solidification est plus grossiĂšre.The rapid cooling of the molten metal in direct contact with the mold generates a small size of the primary solidification crystals (dendritic, polyhedral crystals, etc. depending on the nature of the molten metal). Conversely, in the vicinity of âcrystallographicâ surfaces, where the solidification time is longer, the size of these primary solidification crystals is coarser.
Par observation mĂ©tallographique, sur Ă©chantillon coupĂ© et poli, il est possible de percevoir cette Ă©volution de taille de grain et dâen effectuer la mesure (mesure de DAS, analyse dâimage).By metallographic observation, on a cut and polished sample, it is possible to perceive this evolution of grain size and measure it (SAR measurement, image analysis).
Selon un mode de rĂ©alisation particulier, la prĂ©sente invention concerne une piĂšce mĂ©tallique creuse constituĂ© dâune coque mĂ©tallique qui entoure, ou qui partiellement entoure une partie vide,According to a particular embodiment, the present invention relates to a hollow metal part consisting of a metal shell which surrounds, or which partially surrounds an empty part,
dans laquelle la dite coque métallique a :
- une surface extérieure lisse,
- une surface intérieure cristallographique,
- a smooth exterior surface,
- a crystallographic interior surface,
dans laquelle le métal de la dite coque métallique a un point de fusion supérieur à 180°C, en particulier supérieur à 320°C.in which the metal of said metal shell has a melting point greater than 180°C, in particular greater than 320°C.
Selon un mode de réalisation particulier, la présente invention concerne la piÚce métallique, telle que définie ci-dessus, ayant une épaisseur inférieure ou égale à 2 mm, en particulier de 0,2 mm à 2 mm, sur au moins une partie de la piÚce ou la totalité de la piÚce.According to a particular embodiment, the present invention relates to the metal part, as defined above, having a thickness less than or equal to 2 mm, in particular from 0.2 mm to 2 mm, over at least part of the room or the entire room.
Selon un mode de réalisation particulier, la présente invention concerne la piÚce métallique telle que définie ci-dessus, dans laquelle le métal est un métal pur ou un alliage dudit métal, alliage type eutectique préférable.According to a particular embodiment, the present invention relates to the metal part as defined above, in which the metal is a pure metal or an alloy of said metal, a preferable eutectic type alloy.
Selon un autre mode de rĂ©alisation particulier, la prĂ©sente invention concerne la piĂšce mĂ©tallique telle que dĂ©finie ci-dessus, dans laquelle le mĂ©tal est lâaluminium.According to another particular embodiment, the present invention relates to the metal part as defined above, in which the metal is aluminum.
Selon un autre mode de rĂ©alisation particulier, la prĂ©sente invention concerne la piĂšce mĂ©tallique telle que dĂ©finie ci-dessus, dans laquelle le mĂ©tal est lâalliage eutectique AlSi12.According to another particular embodiment, the present invention relates to the metal part as defined above, in which the metal is the eutectic alloy AlSi12.
Unautre objetde la prĂ©sente invention concerne un assemblage comprenant un, deux ou plusieurs piĂšces mĂ©talliques creuses telles quâobtenues selon le procĂ©dĂ© ci-dessus ou selon lâinvention telle que dĂ©fini ci-dessus. Another object of the present invention relates to an assembly comprising one, two or more hollow metal parts as obtained according to the method above or according to the invention as defined above.
A titre dâexemple, un cadre de vĂ©lo a Ă©tĂ© conçu comme exemplifiĂ© dans la
Les Exemples et Figures suivants illustrent lâinvention, sans en limiter la portĂ©e.The following Examples and Figures illustrate the invention, without limiting its scope.
LaFigure 1A reprĂ©sente un moule ouvert vidangĂ© par ouverture de trappe/bouchon ou autre dispositif.101reprĂ©sente le moule (mĂ©tallique, ou en sable, ou en plĂątre rĂ©fractaire, ou en cĂ©ramique, ou en graphite),102reprĂ©sente le remplissage du moule avec le mĂ©tal/alliage mĂ©tallique en fusion,103reprĂ©sente un dispositif de trappe/bouchon (matĂ©riau isolant thermique ou mĂ©tallique, chauffĂ© ou prĂ©chauffĂ© selon besoin) ou autre dispositif placĂ© sous le moule ou sur le cĂŽtĂ© le moule dans certaines applications,104reprĂ©sente la vidange du bain mĂ©tallique en fusion,107reprĂ©sente une coque mĂ©tallique solidifiĂ©e,108reprĂ©sente la surface intĂ©rieure de la coque de mĂ©tal/alliage solidifiĂ©, laquelle surface intĂ©rieure est sous la forme dâune surface cristallographique dont lâĂ©tat de surface dĂ©pend du type dâalliage mĂ©tallique coulĂ©,109reprĂ©sente la surface extĂ©rieure de la coque de mĂ©tal/alliage solidifiĂ©, laquelle surface extĂ©rieure est complĂ©mentaire Ă la gĂ©omĂ©trie de lâempreinte du moule. ThereFigure 1A represents an open mold drained by opening a trapdoor/plug or other device.101represents the mold (metallic, or sand, or refractory plaster, or ceramic, or graphite),102represents the filling of the mold with the molten metal/metal alloy,103represents a trapdoor/plug device (thermal insulating or metallic material, heated or preheated as needed) or other device placed under the mold or on the side of the mold in certain applications,104represents the emptying of the molten metal bath,107represents a solidified metal shell,108represents the interior surface of the solidified metal/alloy shell, which interior surface is in the form of a crystallographic surface whose surface condition depends on the type of metal alloy cast,109represents the exterior surface of the solidified metal/alloy shell, which exterior surface is complementary to the geometry of the mold cavity.
LaFigure 1B reprĂ©sente un moule ouvert vidangĂ© par une quenouille supĂ©rieure.101reprĂ©sente le moule (mĂ©tallique, ou en sable, ou en plĂątre rĂ©fractaire, ou en cĂ©ramique, ou en graphite),102reprĂ©sente le remplissage du moule avec le mĂ©tal/alliage mĂ©tallique en fusion,105reprĂ©sente une quenouille supĂ©rieure (matĂ©riau rĂ©fractaire ou tube mĂ©tallique avec poteyage isolant, chauffĂ© ou prĂ©chauffĂ© si besoin),106reprĂ©sente le retrait de la quenouille vers le haut pour permettre la vidange du bain,104reprĂ©sente le vidange du bain mĂ©tallique encore en fusion,107une coque mĂ©tallique solidifiĂ©e,108reprĂ©sente la surface intĂ©rieure de la coque de mĂ©tal/alliage solidifiĂ©, laquelle surface intĂ©rieure est sous la forme dâune surface cristallographique dont lâĂ©tat de surface dĂ©pend du type dâalliage mĂ©tallique coulĂ©,109reprĂ©sente la surface extĂ©rieure de la coque de mĂ©tal/alliage solidifiĂ©, laquelle surface extĂ©rieure est complĂ©mentaire Ă la gĂ©omĂ©trie de lâempreinte du moule. ThereFigure 1B shows an open mold drained by an upper stopper.101represents the mold (metallic, or sand, or refractory plaster, or ceramic, or graphite),102represents the filling of the mold with the molten metal/metal alloy,105represents an upper stopper (refractory material or metal tube with insulating coating, heated or preheated if necessary),106represents the withdrawal of the distaff upwards to allow the bath to drain,104represents the emptying of the metal bath still in fusion,107a solidified metal shell,108represents the interior surface of the solidified metal/alloy shell, which interior surface is in the form of a crystallographic surface whose surface condition depends on the type of metal alloy cast,109represents the exterior surface of the solidified metal/alloy shell, which exterior surface is complementary to the geometry of the mold cavity.
LaFigure 1C reprĂ©sente un moule permettant la prĂ©paration dâune coque solidifiĂ©e substantiellement fermĂ©e.101reprĂ©sente le moule (mĂ©tallique conseillĂ©),102reprĂ©sente le remplissage du moule avec le mĂ©tal/alliage mĂ©tallique en fusion,103reprĂ©sente un dispositif de trappe/bouchon (matĂ©riau isolant thermique ou mĂ©tallique, chauffĂ© ou prĂ©chauffĂ© selon besoin) ou autre dispositif placĂ© sous le moule ou sur le cĂŽtĂ© le moule dans certaines applications,104reprĂ©sente la vidange du bain de mĂ©tal en fusion,111reprĂ©sente une partie du moule isolĂ©e thermiquement ou chauffĂ©e (pas ou trĂšs peu dâalliage solidifiĂ©),110reprĂ©sente le plafond supĂ©rieur de lâempreinte,112reprĂ©sente une colonne de mĂ©tal liquide permettant de compenser le retrait volumique de lâalliage liquide lors de son refroidissement et dâassurer un minimum de pression mĂ©tallostatique en partie supĂ©rieure de lâempreinte pour la bonne venue de la gĂ©omĂ©trie de la piĂšce moulĂ©e,107reprĂ©sente une coque mĂ©tallique solidifiĂ©e,108reprĂ©sente la surface intĂ©rieure de la coque de mĂ©tal/alliage solidifiĂ©, laquelle surface intĂ©rieure est sous la forme dâune surface cristallographique dont lâĂ©tat de surface dĂ©pend du type dâalliage mĂ©tallique coulĂ©,109reprĂ©sente la surface extĂ©rieure de la coque de mĂ©tal/alliage solidifiĂ©, laquelle surface extĂ©rieure est complĂ©mentaire Ă la gĂ©omĂ©trie de lâempreinte du moule. ThereFigure 1C represents a mold allowing the preparation of a substantially closed solidified shell.101represents the mold (metallic recommended),102represents the filling of the mold with the molten metal/metal alloy,103represents a trapdoor/plug device (thermal insulating or metallic material, heated or preheated as needed) or other device placed under the mold or on the side of the mold in certain applications,104represents the emptying of the molten metal bath,111represents a thermally insulated or heated part of the mold (no or very little solidified alloy),110represents the upper ceiling of the footprint,112represents a column of liquid metal making it possible to compensate for the volume shrinkage of the liquid alloy during its cooling and to ensure a minimum of metallostatic pressure in the upper part of the cavity for the correct alignment of the geometry of the molded part,107represents a solidified metal shell,108represents the interior surface of the solidified metal/alloy shell, which interior surface is in the form of a crystallographic surface whose surface condition depends on the type of metal alloy cast,109represents the exterior surface of the solidified metal/alloy shell, which exterior surface is complementary to the geometry of the mold cavity.
A noter que les dimensions de la colonne (112) de mĂ©tal liquide sont fonction de la densitĂ© Ă lâĂ©tat liquide du mĂ©tal ou de lâalliage mĂ©tallique, du retrait volumique du mĂ©tal ou alliage liquide lors de son refroidissement et de la gĂ©omĂ©trie de la piĂšce (volume notamment, module thermique).Note that the dimensions of the column ( 112 ) of liquid metal are a function of the density in the liquid state of the metal or of the metal alloy, of the volume shrinkage of the metal or liquid alloy during its cooling and of the geometry of the room (particularly volume, thermal module).
LaFigure 2A représente le remplissage du moule. Figure 2A shows the filling of the mold.
LaFigure 2B représente le moule rempli. Figure 2B shows the filled mold.
LaFigure 2C représente la vidange du moule. Figure 2C shows emptying the mold.
LaFigure 2D représente le moule vidangé de métal/alliage en fusion, comprenant une coque de métal/alliage solidifié contre la paroi intérieure du moule. Figure 2D shows the mold drained of molten metal/alloy, including a shell of solidified metal/alloy against the interior wall of the mold.
LĂ©gende :201reprĂ©sente le moule/empreinte,202reprĂ©sente le four ou creuset Ă©tanche aux gaz et contenant le mĂ©tal ou lâalliage mĂ©tallique en fusion,203reprĂ©sente le mĂ©tal/alliage fondu,204reprĂ©sente lâarrivĂ©e dâair ou de gaz (azote, argon, ou autre) dont la pression peut augmenter pour permettre de remplir lâempreinte de maniĂšre contrĂŽlĂ©e,205reprĂ©sente le mĂ©tal/alliage mĂ©tallique solidifiĂ©,206reprĂ©sente la trappe ou le bouchon en matĂ©riau trĂšs isolant thermique, ou en matĂ©riau chauffĂ© ou prĂ©chauffĂ©, Ă©vitant la solidification (voire le perçage de la fine peau solidifiĂ©e Ă cet endroit) ; ou filtre(s) mĂ©tallique(s) ou rĂ©fractaire(s) Ă air chauffĂ©(s) pour rĂ©aliser lâappel dâair ou de gaz,207reprĂ©sente lâarrivĂ©e dâair ou de gaz (pression atmosphĂ©rique ou supĂ©rieure) pour favoriser/permettre la vidange de lâalliage encore liquide.Legend: 201 represents the mold/cavity, 202 represents the gas-tight furnace or crucible containing the molten metal or metal alloy, 203 represents the molten metal/alloy, 204 represents the inlet of air or gas ( nitrogen, argon, or other) whose pressure can increase to allow the cavity to be filled in a controlled manner, 205 represents the solidified metal/metal alloy, 206 represents the hatch or plug made of highly thermally insulating material, or of heated material or preheated, avoiding solidification (or even piercing the thin solidified skin at this location); or metallic or refractory heated air filter(s) to produce the air or gas intake, 207 represents the arrival of air or gas (atmospheric pressure or greater) for promote/allow the draining of the still liquid alloy.
LaFigure 3A représente le remplissage du moule. Figure 3A shows the filling of the mold.
LaFigure 3B représente le moule rempli. Figure 3B shows the filled mold.
LaFigure 3C représente la vidange du moule. Figure 3C shows emptying the mold.
LaFigure 3D représente le moule vidangé de métal/alliage en fusion, comprenant une coque de métal/alliage solidifié contre la paroi intérieure du moule. Figure 3D shows the mold drained of molten metal/alloy, including a shell of solidified metal/alloy against the interior wall of the mold.
LĂ©gende :301reprĂ©sente le moule / lâempreinte,302reprĂ©sente le four ou le creuset Ă©tanche aux gaz et contenant le mĂ©tal ou lâalliage mĂ©tallique en fusion,303reprĂ©sente le mĂ©tal/alliage fondu,304reprĂ©sente lâarrivĂ©e dâair ou de gaz (azote, argon, ou autre) dont la pression peut augmenter pour permettre de remplir lâempreinte de maniĂšre contrĂŽlĂ©e,305reprĂ©sente le mĂ©tal/alliage mĂ©tallique solidifiĂ© contre la paroi intĂ©rieure du moule,308reprĂ©sente la vanne de gaz situĂ©e sur la buse dâinjection,309reprĂ©sente lâarrivĂ©e de gaz ou dâair sous pression (atmosphĂ©rique ou supĂ©rieure) afin de favoriser / rendre possible la vidange.Legend: 301 represents the mold / impression, 302 represents the oven or gas-tight crucible containing the molten metal or metal alloy, 303 represents the molten metal / alloy, 304 represents the air inlet or of gas (nitrogen, argon, or other) whose pressure can increase to allow the cavity to be filled in a controlled manner, 305 represents the metal/metal alloy solidified against the interior wall of the mold, 308 represents the gas valve located on the injection nozzle, 309 represents the arrival of gas or air under pressure (atmospheric or higher) in order to promote / make emptying possible.
LaFigure 4A représente le remplissage du moule. Figure 4A shows the filling of the mold.
LaFigure 4B représente la vidange du moule. Figure 4B shows emptying the mold.
LaFigure 4C représente le démoulage de la coque solidifiée et le remplissage du godet de coulée. Figure 4C shows the unmolding of the solidified shell and the filling of the casting bucket.
LĂ©gende :400reprĂ©sente le four de maintien,401reprĂ©sente le bain du four de maintien de grande capacitĂ©,402reprĂ©sente le moule/empreinte,403reprĂ©sente le systĂšme dâobstruction (bouchon, trappe, quenouille, autre),404reprĂ©sente une liaison pivot,405reprĂ©sente un godet,406reprĂ©sente une goulotte de transvasement,407reprĂ©sente le transfert du mĂ©tal en fusion du godet vers lâempreinte,408reprĂ©sente lâinclinaison progressive pour permettre le bon remplissage de lâempreinte,409reprĂ©sente la vidange du surplus de liquide en fusion contenu dans lâempreinte, rĂ©cupĂ©rĂ©e dans le bain du four de maintien,410reprĂ©sente une liaison pivot du moule pour permettre le retournement de lâempreinte,411reprĂ©sente la rotation du moule lors du dĂ©moulage de la piĂšce,412reprĂ©sente le dĂ©moulage de la piĂšce sur un support,413reprĂ©sente un support du type grille mĂ©tallique,414reprĂ©sente la coque de mĂ©tal/alliage solidifiĂ© et dĂ©moulĂ©,415reprĂ©sente la rotation du systĂšme de louche/godet pour le puisage du mĂ©tal en fusion dans le four en parallĂšle de lâopĂ©ration de dĂ©moulage de la piĂšce.Legend: 400 represents the holding furnace, 401 represents the bath of the large capacity holding furnace, 402 represents the mold/cavity, 403 represents the obstruction system (cap, hatch, stopper, other), 404 represents a pivot connection , 405 represents a bucket, 406 represents a transfer chute, 407 represents the transfer of the molten metal from the bucket to the cavity, 408 represents the progressive inclination to allow good filling of the cavity, 409 represents the emptying of the surplus of molten liquid contained in the impression, recovered in the bath of the holding oven, 410 represents a pivot connection of the mold to allow the turning of the impression, 411 represents the rotation of the mold during unmolding of the part, 412 represents the unmolding of the part on a support, 413 represents a support of the metal grid type, 414 represents the solidified and demolded metal/alloy shell, 415 represents the rotation of the ladle/bucket system for drawing the molten metal from the oven in parallel with the part demolding operation.
LaFigure 5A reprĂ©sente une photographie dâun gabarit en bois. Figure 5A shows a photograph of a wooden template.
LaFigure 5B reprĂ©sente une photographie de la rĂ©alisation dâun moule en sable/extraction du gabarit en bois. Figure 5B represents a photograph of the creation of a sand mold/extraction of the wooden template.
LaFigure 5C reprĂ©sente une photographie du remplissage du moule en sable avec un alliage dâaluminium en fusion. Figure 5C shows a photograph of filling the sand mold with molten aluminum alloy.
LaFigure 5D représente une photographie du maintien du métal liquide dans le moule pour solidification. Figure 5D represents a photograph of the holding of the liquid metal in the mold for solidification.
LaFigure 5E représente une photographie de la vidange du métal liquide par le bas du moule. Figure 5E represents a photograph of the draining of the liquid metal from the bottom of the mold.
LaFigure 5F représente une photographie de la coque obtenue selon le procédé de moulage en sable. Figure 5F represents a photograph of the shell obtained using the sand casting process.
LaFigure 6A reprĂ©sente une photographie dâun banc dâessai de coulĂ©e vidangĂ©e.601reprĂ©sente un moule (coquille) en alliage dâaluminium.602reprĂ©sente un orifice permettant la vidange du bain de mĂ©tal en fusion, qui sera obstruĂ© par une quenouille, une trappe ou autre systĂšme,603reprĂ©sente un support de moule pivotant, permettant de dĂ©mouler la coque solidifiĂ©e,604reprĂ©sente le pivot pour la rotation du support de moule,605reprĂ©sente un bras de levier permettant de pivoter le moule lors du dĂ©moulage,606reprĂ©sente un chĂąssis fixe (structure mĂ©cano-soudĂ©e),607reprĂ©sente un lit de sable,608reprĂ©sente une poche de coulĂ©e, recueillant le mĂ©tal en fusion lors de la vidange du moule,609reprĂ©sente un brancard permettant de transporter la poche avec le mĂ©tal en fusion, pour retransvaser celui-ci dans le four. Figure 6A shows a photograph of a drained casting test bench. 601 represents an aluminum alloy mold (shell). 602 represents an orifice allowing the emptying of the bath of molten metal, which will be obstructed by a stopper, a trapdoor or other system, 603 represents a pivoting mold support, allowing the solidified shell to be unmolded, 604 represents the pivot for the rotation of the mold support, 605 represents a lever arm allowing the mold to be pivoted during demolding, 606 represents a fixed frame (mechanically welded structure), 607 represents a bed of sand, 608 represents a ladle, collecting the molten metal when emptying the mold, 609 represents a stretcher allowing the ladle to be transported with the molten metal, to transfer it back into the oven.
LaFigure 6B reprĂ©sente une photographie de la surface extĂ©rieure dâune coque en mĂ©tal solidifiĂ©. Figure 6B shows a photograph of the exterior surface of a solidified metal shell.
LaFigure 6C reprĂ©sente une photographie de la surface intĂ©rieure cristallographique dâune coque en mĂ©tal solidifiĂ©. Figure 6C shows a photograph of the crystallographic interior surface of a solidified metal shell.
LaFigure 8A reprĂ©sente lâinjection du mĂ©tal en fusion dans le moule et son maintien sous pression pendant la formation de la coque solidifiĂ©e. Figure 8A represents the injection of the molten metal into the mold and its maintenance under pressure during the formation of the solidified shell.
LaFigure 8B reprĂ©sente la vidange du moule, lâalimentation de la chemise en mĂ©tal fondu et la coque solidifiĂ©e obtenue. Figure 8B shows the emptying of the mold, the feeding of the molten metal jacket and the solidified shell obtained.
LĂ©gende :801reprĂ©sente la partie mobile du moule,802reprĂ©sente la partie fixe du moule,803reprĂ©sente la trappe ou le bouchon en matĂ©riau trĂšs isolant thermique, ou en matĂ©riau chauffĂ© ou prĂ©chauffĂ©, Ă©vitant localement la solidification (voire le perçage de la fine peau solidifiĂ©e Ă cet endroit) ; ou le(s) filtre(s) Ă air mĂ©tallique(s) ou rĂ©fractaire(s) chauffĂ©(s) pour rĂ©aliser lâappel dâair ou de gaz (azote, argon, ou autre) sous pression (atmosphĂ©rique ou supĂ©rieure) afin de favoriser / rendre possible la vidange,804reprĂ©sente le creuset du four de maintien,805reprĂ©sente le mĂ©tal/alliage fondu maintenu Ă la tempĂ©rature de coulĂ©e,806reprĂ©sente la chambre dâinjection appelĂ©e usuellement « le gooseneck »,807reprĂ©sente le piston dâinjection,808reprĂ©sente la tige du vĂ©rin hydraulique ou pneumatique qui pilote lâinjection,809reprĂ©sente la lumiĂšre obturable permettant le remplissage de la chemise dâinjection avec le mĂ©tal/alliage fondu,810reprĂ©sente le nez du col de cygne (extrĂ©mitĂ© du gooseneck) souvent appelĂ© « buse dâinjection »,811reprĂ©sente le manchon isolant ou chauffant Ă©vitant la solidification du mĂ©tal/alliage dans la buse dâinjection (en gĂ©nĂ©ral tempĂ©rature Ă©gale ou supĂ©rieure au liquidus),812reprĂ©sente lâalimentation de la chemise dâinjection en mĂ©tal/alliage fondu depuis le bain du four,813reprĂ©sente la surface extĂ©rieure de la coque de mĂ©tal/alliage solidifiĂ©, laquelle surface extĂ©rieure est complĂ©mentaire Ă la gĂ©omĂ©trie de lâempreinte du moule,814reprĂ©sente la surface intĂ©rieure de la coque de mĂ©tal/alliage solidifiĂ©, laquelle surface intĂ©rieure est sous la forme dâune surface cristallographique dont lâĂ©tat de surface dĂ©pend du type dâalliage mĂ©tallique coulĂ©,815reprĂ©sente la coque mĂ©tallique solidifiĂ©e contre la paroi intĂ©rieure du moule,816reprĂ©sente le dĂ©placement de la tige du vĂ©rin permettant de remplir lâempreinte de maniĂšre contrĂŽlĂ©e,817reprĂ©sente le retour de la tige du vĂ©rin permettant de vidanger le moule du mĂ©tal encore liquide et de recharger la chemise dâinjection en mĂ©tal fondu,818reprĂ©sente le plan de joint principal du moule (ici vertical).Legend: 801 represents the moving part of the mold, 802 represents the fixed part of the mold, 803 represents the hatch or the plug made of highly thermally insulating material, or of heated or preheated material, locally avoiding solidification (or even drilling of the thin skin solidified at this location); or the heated metallic or refractory air filter(s) to carry out the intake of air or gas (nitrogen, argon, or other) under pressure (atmospheric or higher) in order to promote/make emptying possible, 804 represents the crucible of the holding furnace, 805 represents the molten metal/alloy maintained at the casting temperature, 806 represents the injection chamber usually called "the gooseneck", 807 represents the piston injection, 808 represents the rod of the hydraulic or pneumatic cylinder which controls the injection, 809 represents the closable port allowing the filling of the injection liner with the molten metal/alloy, 810 represents the nose of the swan neck (end of the gooseneck) often called "injection nozzle", 811 represents the insulating or heating sleeve avoiding the solidification of the metal/alloy in the injection nozzle (generally temperature equal to or greater than the liquidus), 812 represents the power supply of the molten metal/alloy injection liner from the furnace bath, 813 represents the exterior surface of the solidified metal/alloy shell, which exterior surface is complementary to the geometry of the mold cavity, 814 represents the interior surface of the solidified metal/alloy shell, which inner surface is in the form of a crystallographic surface whose surface state depends on the type of metal alloy cast, 815 represents the metal shell solidified against the inner wall of the mold, 816 represents the movement of the cylinder rod making it possible to fill the cavity in a controlled manner, 817 represents the return of the cylinder rod making it possible to drain the mold of the still liquid metal and to reload the injection jacket with molten metal, 818 represents the main parting plane of the mold (here vertical).
LĂ©gende:906reprĂ©sente la chambre dâinjection appelĂ©e usuellement « le gooseneck »,919reprĂ©sente la poche dâair ou de gaz, dont la mise en pression permet le remplissage contrĂŽlĂ© de lâempreinte du moule,920reprĂ©sente la vanne pilotant lâarrivĂ©e dâair ou du gaz sous pression,921reprĂ©sente la lumiĂšre obturable permettant lâalimentation de la chemise dâinjection avec du mĂ©tal fondu et contenu dans le four de maintien. Legend : 906 represents the injection chamber usually called "the gooseneck", 919 represents the air or gas pocket, the pressurization of which allows the controlled filling of the mold cavity, 920 represents the valve controlling the inlet of air or gas under pressure, 921 represents the closable port allowing the supply of the injection liner with molten metal contained in the holding furnace.
A noter quâen moulage sous pression avec injection par air ou gaz, il existe des systĂšmes oĂč le gooseneck est montĂ© sur un pivot horizontal, permettant par sa rotation le remplissage de la chemise par le nez du col de cygne. Dans ce cas particulier, lâorifice mentionnĂ©921correspond alors Ă la buse dâinjection notĂ©e810dans la
LaFigure 10A reprĂ©sente lâalimentation de la chemise dâinjection en mĂ©tal fondu avec le moule prĂ©alablement refermĂ©. Figure 10A represents the feeding of the injection liner with molten metal with the mold previously closed.
LaFigure 10B reprĂ©sente lâinjection du mĂ©tal en fusion dans le moule et son maintien sous pression pendant la formation de la coque solidifiĂ©e. Figure 10B represents the injection of the molten metal into the mold and its maintenance under pressure during the formation of the solidified shell.
LaFigure 10C représente la vidange du moule et la coque solidifiée obtenue. Figure 10C represents the emptying of the mold and the solidified shell obtained.
LĂ©gende:1000reprĂ©sente le retour de la tige du vĂ©rin afin de recharger la chemise dâinjection en mĂ©tal fondu,1001reprĂ©sente la partie mobile du moule,1002reprĂ©sente la partie fixe du moule,1003reprĂ©sente la trappe ou le bouchon en matĂ©riau trĂšs isolant thermique, ou en matĂ©riau chauffĂ© ou prĂ©chauffĂ©, Ă©vitant localement la solidification (voire le perçage de la fine peau solidifiĂ©e Ă cet endroit) ; ou le(s) filtre(s) Ă air mĂ©tallique(s) ou rĂ©fractaire(s) chauffĂ©(s) pour rĂ©aliser lâappel dâair ou de gaz (azote, argon, ou autre) sous pression (atmosphĂ©rique ou supĂ©rieure) afin de favoriser / rendre possible la vidange,1004reprĂ©sente le remplissage de la chemise dâinjection avec du mĂ©tal fondu, grĂące Ă une louche manuelle, un godet automatique ou autre dispositif depuis le four de maintien,1005reprĂ©sente le mĂ©tal/alliage fondu dans la chemise avant lâinjection,1006reprĂ©sente la chambre dâinjection,1007reprĂ©sente le piston dâinjection,1008reprĂ©sente la tige du vĂ©rin hydraulique ou pneumatique qui pilote lâinjection,1009reprĂ©sente la lumiĂšre obturable permettant le remplissage de la chemise dâinjection avec le mĂ©tal/alliage fondu,1010reprĂ©sente le systĂšme dâobturation (bouchon, trappe, quenouille, autre) isolant thermique, qui peut ĂȘtre chauffant ou prĂ©chauffĂ©,1011reprĂ©sente lâattaque de coulĂ©e,1012reprĂ©sente le dĂ©placement de la tige du vĂ©rin permettant de remplir lâempreinte de maniĂšre contrĂŽlĂ©e,1013reprĂ©sente la surface extĂ©rieure de la coque de mĂ©tal/alliage solidifiĂ©, laquelle surface extĂ©rieure est complĂ©mentaire Ă la gĂ©omĂ©trie de lâempreinte du moule,1014reprĂ©sente la surface intĂ©rieure de la coque de mĂ©tal/alliage solidifiĂ©, laquelle surface intĂ©rieure est sous la forme dâune surface cristallographique dont lâĂ©tat de surface dĂ©pend du type dâalliage mĂ©tallique coulĂ©,1015reprĂ©sente la coque mĂ©tallique solidifiĂ©e contre la paroi intĂ©rieure du moule,1016reprĂ©sente lâarrivĂ©e dâair ou de gaz (pression atmosphĂ©rique ou supĂ©rieure) pour favoriser/permettre la vidange du mĂ©tal/alliage encore liquide,1017reprĂ©sente la vidange par gravitĂ© du mĂ©tal encore liquide dans le moule,1018reprĂ©sente le plan de joint principal du moule (ici vertical),1019reprĂ©sente le dĂ©placement de la partie mobile du moule afin dâextraire la coque solidifiĂ©e. Legend : 1000 represents the return of the cylinder rod in order to refill the injection jacket with molten metal, 1001 represents the moving part of the mold, 1002 represents the fixed part of the mold, 1003 represents the hatch or the plug made of highly insulating material thermal, or in heated or preheated material, locally avoiding solidification (or even piercing the thin solidified skin at this location); or the heated metallic or refractory air filter(s) to carry out the intake of air or gas (nitrogen, argon, or other) under pressure (atmospheric or higher) in order to promote/make emptying possible, 1004 represents the filling of the injection jacket with molten metal, using a manual ladle, an automatic bucket or other device from the holding furnace, 1005 represents the molten metal/alloy in the jacket before the injection, 1006 represents the injection chamber, 1007 represents the injection piston, 1008 represents the rod of the hydraulic or pneumatic cylinder which controls the injection, 1009 represents the closable port allowing the filling of the jacket injection with the molten metal/alloy, 1010 represents the sealing system (plug, hatch, stopper, other) thermal insulation, which can be heated or preheated, 1011 represents the casting attack, 1012 represents the movement of the rod of the cylinder allowing the cavity to be filled in a controlled manner, 1013 represents the exterior surface of the solidified metal/alloy shell, which exterior surface is complementary to the geometry of the mold cavity, 1014 represents the interior surface of the shell of solidified metal/alloy, which interior surface is in the form of a crystallographic surface whose surface state depends on the type of metal alloy cast, 1015 represents the metal shell solidified against the interior wall of the mold, 1016 represents the arrival of air or gas (atmospheric pressure or higher) to promote/allow the emptying of the still liquid metal/alloy, 1017 represents the emptying by gravity of the still liquid metal in the mold, 1018 represents the main parting plane of the mold (here vertical), 1019 represents the movement of the movable part of the mold in order to extract the solidified shell.
LaFigure 11A reprĂ©sente lâalimentation de la chemise chauffĂ©e/thermo-rĂ©gulĂ©e dâinjection en mĂ©tal fondu avec le moule prĂ©alablement refermĂ©. Figure 11A shows the supply of the heated/thermo-regulated molten metal injection jacket with the mold previously closed.
LaFigure 11B reprĂ©sente lâinjection du mĂ©tal en fusion dans le moule et son maintien sous pression pendant la formation de la coque solidifiĂ©e. Figure 11B represents the injection of the molten metal into the mold and its maintenance under pressure during the formation of the solidified shell.
LaFigure 11C représente la vidange du moule et la coque solidifiée obtenue. Figure 11C represents the emptying of the mold and the solidified shell obtained.
LĂ©gende:1100reprĂ©sente le retour de la tige du vĂ©rin afin de vidanger le moule et de recharger la chemise dâinjection en mĂ©tal fondu,1101reprĂ©sente la partie mobile du moule,1102reprĂ©sente la partie fixe du moule,1103reprĂ©sente la trappe ou le bouchon en matĂ©riau trĂšs isolant thermique, ou en matĂ©riau chauffĂ© ou prĂ©chauffĂ©, Ă©vitant localement la solidification (voire le perçage de la fine peau solidifiĂ©e Ă cet endroit) ; ou le(s) filtre(s) Ă air mĂ©tallique(s) ou rĂ©fractaire(s) chauffĂ©(s) pour rĂ©aliser lâappel dâair ou de gaz (azote, argon, ou autre) sous pression (atmosphĂ©rique ou supĂ©rieure) afin de favoriser / rendre possible la vidange,1104reprĂ©sente le remplissage de la chemise dâinjection avec du mĂ©tal fondu, grĂące Ă une louche manuelle, un godet automatique ou autre dispositif depuis le four de maintien,1105reprĂ©sente le mĂ©tal/alliage fondu dans la chemise avant lâinjection,1106reprĂ©sente la chambre chauffĂ©e/thermo-rĂ©gulĂ©e dâinjection,1107reprĂ©sente le piston dâinjection,1108reprĂ©sente la tige du vĂ©rin hydraulique ou pneumatique qui pilote lâinjection,1109reprĂ©sente la lumiĂšre obturable permettant le remplissage de la chemise dâinjection avec le mĂ©tal/alliage fondu,1111reprĂ©sente lâattaque de coulĂ©e,1112reprĂ©sente le dĂ©placement de la tige du vĂ©rin permettant de remplir lâempreinte de maniĂšre contrĂŽlĂ©e,1113reprĂ©sente la surface extĂ©rieure de la coque de mĂ©tal/alliage solidifiĂ©, laquelle surface extĂ©rieure est complĂ©mentaire Ă la gĂ©omĂ©trie de lâempreinte du moule,1114reprĂ©sente la surface intĂ©rieure de la coque de mĂ©tal/alliage solidifiĂ©, laquelle surface intĂ©rieure est sous la forme dâune surface cristallographique dont lâĂ©tat de surface dĂ©pend du type dâalliage mĂ©tallique coulĂ©,1115reprĂ©sente la coque mĂ©tallique solidifiĂ©e contre la paroi intĂ©rieure du moule,1116reprĂ©sente lâarrivĂ©e dâair ou de gaz (pression atmosphĂ©rique ou supĂ©rieure) pour favoriser/permettre la vidange du mĂ©tal/alliage encore liquide,1117reprĂ©sente le retour par gravitĂ© du mĂ©tal encore liquide dans la chemise chauffĂ©e/thermo-rĂ©gulĂ©e suite Ă la vidange,1118reprĂ©sente le plan de joint principal du moule (ici horizontal),1119reprĂ©sente lâouverture du moule permettant dâĂ©jecter la coque solidifiĂ©e. Legend : 1100 represents the return of the cylinder rod in order to empty the mold and reload the injection jacket with molten metal, 1101 represents the moving part of the mold, 1102 represents the fixed part of the mold, 1103 represents the hatch or the cap made of highly thermally insulating material, or of heated or preheated material, locally avoiding solidification (or even piercing the thin solidified skin at this location); or the heated metallic or refractory air filter(s) to carry out the intake of air or gas (nitrogen, argon, or other) under pressure (atmospheric or higher) in order to promote/make emptying possible, 1104 represents the filling of the injection jacket with molten metal, using a manual ladle, an automatic bucket or other device from the holding furnace, 1105 represents the molten metal/alloy in the jacket before the injection, 1106 represents the heated/thermo-regulated injection chamber, 1107 represents the injection piston, 1108 represents the rod of the hydraulic or pneumatic cylinder which controls the injection, 1109 represents the closable port allowing the filling the injection liner with the molten metal/alloy, 1111 represents the casting attack, 1112 represents the movement of the cylinder rod allowing the cavity to be filled in a controlled manner, 1113 represents the exterior surface of the shell of solidified metal/alloy, which exterior surface is complementary to the geometry of the mold cavity, 1114 represents the interior surface of the solidified metal/alloy shell, which interior surface is in the form of a crystallographic surface whose state of surface depends on the type of metal alloy cast, 1115 represents the metal shell solidified against the interior wall of the mold, 1116 represents the arrival of air or gas (atmospheric pressure or higher) to promote/allow the emptying of the metal/ alloy still liquid, 1117 represents the return by gravity of the metal still liquid in the heated/thermo-regulated jacket following emptying, 1118 represents the main joint plane of the mold (here horizontal), 1119 represents the opening of the mold allowing eject the solidified shell.
LaFigure 12A reprĂ©sente lâalimentation de la chemise dâinjection en mĂ©tal fondu, juste avant la fermeture du moule. Figure 12A shows the feeding of the injection liner with molten metal, just before closing the mold.
LaFigure 12B reprĂ©sente lâinjection du mĂ©tal en fusion dans le moule et son maintien sous pression pendant la formation de la coque solidifiĂ©e. Figure 12B represents the injection of the molten metal into the mold and its maintenance under pressure during the formation of the solidified shell.
LaFigure 12C reprĂ©sente la vidange du moule et la partie solidifiĂ©e obtenue (piĂšce + pastille rĂ©siduelle dâinjection). Figure 12C represents the emptying of the mold and the solidified part obtained (part + residual injection pellet).
LĂ©gende :1200reprĂ©sente le retour de la tige du vĂ©rin afin dâalimenter la chemise dâinjection en mĂ©tal fondu avant la fermeture du moule,1201reprĂ©sente la partie supĂ©rieure mobile du moule,1202reprĂ©sente la partie infĂ©rieure fixe du moule,1203reprĂ©sente la trappe ou le bouchon en matĂ©riau trĂšs isolant thermique, ou en matĂ©riau chauffĂ© ou prĂ©chauffĂ©, Ă©vitant localement la solidification (voire le perçage de la fine peau solidifiĂ©e Ă cet endroit) ; ou le(s) filtre(s) Ă air mĂ©tallique(s) ou rĂ©fractaire(s) chauffĂ©(s) pour rĂ©aliser lâappel dâair ou de gaz (azote, argon, ou autre) sous pression (atmosphĂ©rique ou supĂ©rieure) afin de favoriser / rendre possible la vidange,1204reprĂ©sente le remplissage de la chemise dâinjection avec du mĂ©tal fondu, grĂące Ă une louche manuelle, un godet automatique ou autre dispositif depuis le four de maintien,1205reprĂ©sente le mĂ©tal/alliage fondu dans la chemise avant lâinjection,1206reprĂ©sente la chambre dâinjection ici intĂ©grĂ©e au moule,1207reprĂ©sente le piston dâinjection,1208reprĂ©sente la tige du vĂ©rin hydraulique ou pneumatique qui pilote lâinjection,1209reprĂ©sente le systĂšme dâobturation (bouchon, trappe, quenouille, autre) isolant thermique, qui peut ĂȘtre chauffant ou prĂ©chauffĂ©,1210reprĂ©sente la pastille dâinjection, rĂ©siduelle solidifiĂ©e, adhĂ©rente Ă la piĂšce moulĂ©e lors de son Ă©jection,1211reprĂ©sente la carotte de vidange,1212reprĂ©sente le dĂ©placement de la tige du vĂ©rin permettant le remplissage contrĂŽlĂ© de lâempreinte,1213reprĂ©sente la surface extĂ©rieure de la coque de mĂ©tal/alliage solidifiĂ©, laquelle surface extĂ©rieure est complĂ©mentaire Ă la gĂ©omĂ©trie de lâempreinte du moule,1214reprĂ©sente la surface intĂ©rieure de la coque de mĂ©tal/alliage solidifiĂ©, laquelle surface intĂ©rieure est sous la forme dâune surface cristallographique dont lâĂ©tat de surface dĂ©pend du type dâalliage mĂ©tallique coulĂ©,1215reprĂ©sente la coque mĂ©tallique solidifiĂ©e contre la paroi intĂ©rieure du moule,1216reprĂ©sente lâarrivĂ©e dâair ou de gaz (pression atmosphĂ©rique ou supĂ©rieure) pour favoriser/permettre la vidange du mĂ©tal/alliage encore liquide,1217reprĂ©sente le plan de joint principal du moule (ici horizontal),1218reprĂ©sente lâouverture du moule permettant dâĂ©jecter la coque solidifiĂ©e suite Ă la vidange,1219reprĂ©sente la vidange par gravitĂ© du mĂ©tal encore liquide.Legend: 1200 represents the return of the cylinder rod in order to supply the injection jacket with molten metal before closing the mold, 1201 represents the movable upper part of the mold, 1202 represents the fixed lower part of the mold, 1203 represents the hatch or cap made of highly thermally insulating material, or of heated or preheated material, locally avoiding solidification (or even drilling of the thin solidified skin at this location); or the heated metallic or refractory air filter(s) to carry out the intake of air or gas (nitrogen, argon, or other) under pressure (atmospheric or higher) in order to promote/make emptying possible, 1204 represents the filling of the injection jacket with molten metal, using a manual ladle, an automatic bucket or other device from the holding furnace, 1205 represents the molten metal/alloy in the jacket before injection, 1206 represents the injection chamber here integrated into the mold, 1207 represents the injection piston, 1208 represents the rod of the hydraulic or pneumatic cylinder which controls the injection, 1209 represents the shutter system ( plug, hatch, stopper, other) thermal insulator, which can be heated or preheated, 1210 represents the injection pellet, residual solidified, adhering to the molded part during its ejection, 1211 represents the drain core, 1212 represents the displacement of the cylinder rod allowing the controlled filling of the cavity, 1213 represents the exterior surface of the solidified metal/alloy shell, which exterior surface is complementary to the geometry of the mold cavity, 1214 represents the interior surface of the solidified metal/alloy shell, which inner surface is in the form of a crystallographic surface whose surface state depends on the type of metal alloy cast, 1215 represents the metal shell solidified against the inner wall of the mold, 1216 represents the the arrival of air or gas (atmospheric pressure or greater) to promote/allow the emptying of the still liquid metal/alloy, 1217 represents the main joint plane of the mold (here horizontal), 1218 represents the opening of the mold allowing ejecting the solidified shell following emptying, 1219 represents the emptying by gravity of the still liquid metal.
LaFigure 13A reprĂ©sente lâalimentation de la chemise dâinjection en mĂ©tal fondu, juste avant la fermeture du moule. Figure 13A shows the feeding of the injection liner with molten metal, just before closing the mold.
LaFigure 13B reprĂ©sente lâinjection du mĂ©tal en fusion dans le moule et son maintien sous pression pendant la formation de la coque solidifiĂ©e. Figure 13B represents the injection of the molten metal into the mold and its maintenance under pressure during the formation of the solidified shell.
LaFigure 13C représente la vidange du moule et la coque solidifiée obtenue. Figure 13C represents the emptying of the mold and the solidified shell obtained.
LĂ©gende :1300reprĂ©sente le retour de la tige du vĂ©rin afin dâalimenter la chemise dâinjection en mĂ©tal fondu avant la fermeture du moule et de vidanger la coque solidifiĂ©e avant lâouverture du moule,1301reprĂ©sente la partie supĂ©rieure mobile du moule,1302reprĂ©sente la partie infĂ©rieure fixe du moule,1303reprĂ©sente la trappe ou le bouchon en matĂ©riau trĂšs isolant thermique, ou en matĂ©riau chauffĂ© ou prĂ©chauffĂ©, Ă©vitant localement la solidification (voire le perçage de la fine peau solidifiĂ©e Ă cet endroit) ; ou le(s) filtre(s) Ă air mĂ©tallique(s) ou rĂ©fractaire(s) chauffĂ©(s) pour rĂ©aliser lâappel dâair ou de gaz (azote, argon, ou autre) sous pression (atmosphĂ©rique ou supĂ©rieure) afin de favoriser / rendre possible la vidange,1304reprĂ©sente le remplissage de la chemise dâinjection avec du mĂ©tal fondu, grĂące Ă une louche manuelle, un godet automatique ou autre dispositif depuis le four de maintien,1305reprĂ©sente le mĂ©tal/alliage fondu dans la chemise avant lâinjection,1306reprĂ©sente la chambre chauffĂ©e/thermo-rĂ©gulĂ©e dâinjection ici intĂ©grĂ©e au moule,1307reprĂ©sente le piston dâinjection,1308reprĂ©sente la tige du vĂ©rin hydraulique ou pneumatique qui pilote lâinjection,1309reprĂ©sente lâattaque de coulĂ©e,1312reprĂ©sente le dĂ©placement de la tige du vĂ©rin permettant le remplissage contrĂŽlĂ© de lâempreinte,1313reprĂ©sente la surface extĂ©rieure de la coque de mĂ©tal/alliage solidifiĂ©, laquelle surface extĂ©rieure est complĂ©mentaire Ă la gĂ©omĂ©trie de lâempreinte du moule,1314reprĂ©sente la surface intĂ©rieure de la coque de mĂ©tal/alliage solidifiĂ©, laquelle surface intĂ©rieure est sous la forme dâune surface cristallographique dont lâĂ©tat de surface dĂ©pend du type dâalliage mĂ©tallique coulĂ©,1315reprĂ©sente la coque mĂ©tallique solidifiĂ©e contre la paroi intĂ©rieure du moule,1316reprĂ©sente lâarrivĂ©e dâair ou de gaz (pression atmosphĂ©rique ou supĂ©rieure) pour favoriser/permettre la vidange du mĂ©tal/alliage encore liquide,1317reprĂ©sente le plan de joint principal du moule (ici horizontal),1318reprĂ©sente lâouverture du moule permettant dâĂ©jecter la coque solidifiĂ©e suite Ă la vidange et dâalimenter en mĂ©tal fondu la chemise dâinjection.Legend: 1300 represents the return of the cylinder rod in order to supply the injection jacket with molten metal before closing the mold and to drain the solidified shell before opening the mold, 1301 represents the movable upper part of the mold, 1302 represents the fixed lower part of the mold, 1303 represents the hatch or the plug made of highly thermally insulating material, or of heated or preheated material, locally avoiding solidification (or even drilling of the thin solidified skin at this location); or the heated metallic or refractory air filter(s) to carry out the intake of air or gas (nitrogen, argon, or other) under pressure (atmospheric or higher) in order to promote/make emptying possible, 1304 represents the filling of the injection jacket with molten metal, using a manual ladle, an automatic bucket or other device from the holding furnace, 1305 represents the molten metal/alloy in the jacket before injection, 1306 represents the heated/thermo-regulated injection chamber here integrated into the mold, 1307 represents the injection piston, 1308 represents the rod of the hydraulic or pneumatic cylinder which controls the injection, 1309 represents the casting attack, 1312 represents the movement of the cylinder rod allowing the controlled filling of the cavity, 1313 represents the exterior surface of the solidified metal/alloy shell, which exterior surface is complementary to the geometry of the cavity of the mold, 1314 represents the interior surface of the solidified metal/alloy shell, which interior surface is in the form of a crystallographic surface whose surface condition depends on the type of metal alloy cast, 1315 represents the solidified metal shell against the interior wall of the mold, 1316 represents the arrival of air or gas (atmospheric pressure or greater) to promote/allow the emptying of the still liquid metal/alloy, 1317 represents the main joint plane of the mold (here horizontal), 1318 represents the opening of the mold allowing the solidified shell to be ejected following emptying and the injection liner to be supplied with molten metal.
LaFigure 14A reprĂ©sente lâalimentation de la chemise dâinjection en mĂ©tal fondu, juste avant la fermeture du moule. Figure 14A shows the feeding of the injection liner with molten metal, just before closing the mold.
LaFigure 14B reprĂ©sente lâinjection du mĂ©tal en fusion dans le moule et son maintien sous pression pendant la formation de la coque solidifiĂ©e. Figure 14B represents the injection of the molten metal into the mold and its maintenance under pressure during the formation of the solidified shell.
LaFigure 14C représente la vidange du moule et la coque solidifiée obtenue. Figure 14C represents the emptying of the mold and the solidified shell obtained.
LĂ©gende :1400reprĂ©sente le retour de la tige du vĂ©rin afin dâalimenter la chemise dâinjection en mĂ©tal fondu avant la fermeture du moule et de vidanger la coque solidifiĂ©e avant lâouverture du moule,1401reprĂ©sente la partie supĂ©rieure mobile du moule,1402reprĂ©sente la partie infĂ©rieure fixe du moule,1403reprĂ©sente la trappe ou le bouchon en matĂ©riau trĂšs isolant thermique, ou en matĂ©riau chauffĂ© ou prĂ©chauffĂ©, Ă©vitant localement la solidification (voire le perçage de la fine peau solidifiĂ©e Ă cet endroit) ; ou le(s) filtre(s) Ă air mĂ©tallique(s) ou rĂ©fractaire(s) chauffĂ©(s) pour rĂ©aliser lâappel dâair ou de gaz (azote, argon, ou autre) sous pression (atmosphĂ©rique ou supĂ©rieure) afin de favoriser / rendre possible la vidange,1404reprĂ©sente le remplissage de la chemise dâinjection avec du mĂ©tal fondu, grĂące Ă une louche manuelle, un godet automatique ou autre dispositif depuis le four de maintien,1405reprĂ©sente le mĂ©tal/alliage fondu dans la chemise avant lâinjection,1406reprĂ©sente la chambre chauffĂ©e/thermo-rĂ©gulĂ©e dâinjection ici intĂ©grĂ©e au moule,1407reprĂ©sente le piston dâinjection,1408reprĂ©sente la tige du vĂ©rin hydraulique ou pneumatique qui pilote lâinjection,1412reprĂ©sente le dĂ©placement de la tige du vĂ©rin permettant le remplissage contrĂŽlĂ© de lâempreinte,1413reprĂ©sente la surface extĂ©rieure de la coque de mĂ©tal/alliage solidifiĂ©, laquelle surface extĂ©rieure est complĂ©mentaire Ă la gĂ©omĂ©trie de lâempreinte du moule,1414reprĂ©sente la surface intĂ©rieure de la coque de mĂ©tal/alliage solidifiĂ©, laquelle surface intĂ©rieure est sous la forme dâune surface cristallographique dont lâĂ©tat de surface dĂ©pend du type dâalliage mĂ©tallique coulĂ©,1415reprĂ©sente la coque mĂ©tallique solidifiĂ©e contre la paroi intĂ©rieure du moule,1416reprĂ©sente lâarrivĂ©e dâair ou de gaz (pression atmosphĂ©rique ou supĂ©rieure) pour favoriser/permettre la vidange du mĂ©tal/alliage encore liquide,1417reprĂ©sente le plan de joint principal du moule (ici horizontal),1418reprĂ©sente lâouverture du moule permettant dâĂ©jecter la coque solidifiĂ©e suite Ă la vidange et dâalimenter en mĂ©tal fondu la chemise dâinjection.Legend: 1400 represents the return of the cylinder rod in order to supply the injection jacket with molten metal before closing the mold and to drain the solidified shell before opening the mold, 1401 represents the movable upper part of the mold, 1402 represents the fixed lower part of the mold, 1403 represents the hatch or the plug made of highly thermally insulating material, or of heated or preheated material, locally avoiding solidification (or even drilling of the thin solidified skin at this location); or the heated metallic or refractory air filter(s) to carry out the intake of air or gas (nitrogen, argon, or other) under pressure (atmospheric or higher) in order to promote/make emptying possible, 1404 represents the filling of the injection jacket with molten metal, using a manual ladle, an automatic bucket or other device from the holding furnace, 1405 represents the molten metal/alloy in the jacket before injection, 1406 represents the heated/thermo-regulated injection chamber here integrated into the mold, 1407 represents the injection piston, 1408 represents the rod of the hydraulic or pneumatic cylinder which controls the injection, 1412 represents the movement of the cylinder rod allowing controlled filling of the cavity, 1413 represents the exterior surface of the solidified metal/alloy shell, which exterior surface is complementary to the geometry of the mold cavity, 1414 represents the interior surface of the solidified metal/alloy shell, which inner surface is in the form of a crystallographic surface whose surface state depends on the type of metal alloy cast, 1415 represents the metal shell solidified against the inner wall of the mold, 1416 represents the arrival of air or gas (atmospheric pressure or greater) to promote/allow the emptying of the still liquid metal/alloy, 1417 represents the main joint plane of the mold (here horizontal), 1418 represents the opening of the mold allowing to eject the solidified shell following emptying and to supply molten metal to the injection jacket.
Exemple 1Example 1 .. Procédure générale de la fusion de la matiÚre métalliqueGeneral procedure for melting metallic material
La charge (lingots et/ou piĂšces recyclĂ©es) a Ă©tĂ© fondue dans un four de fusion Ă©lectrique ou Ă combustible. Le four utilisĂ© correspond Ă un four classique de fonderie. Le bain fondu a Ă©tĂ© portĂ© puis maintenu Ă une tempĂ©rature supĂ©rieure au liquidus de lâalliage dâune valeur dite de surchauffe plus une valeur estimĂ©e de perte de tempĂ©rature liĂ©e au transvasement dans la louche/poche de coulĂ©e. La surchauffe au-dessus du liquidus retenue a Ă©tĂ© comprise entre 0 et 200°C.The filler (ingots and/or recycled coins) was melted in an electric or fuel-fired melting furnace. The oven used corresponds to a classic foundry oven. The molten bath was brought and then maintained at a temperature higher than the liquidus of the alloy by a so-called overheating value plus an estimated value of temperature loss linked to transfer into the ladle/ladle. The superheat above the retained liquidus was between 0 and 200°C.
Pour de la production en sĂ©rie, la capacitĂ© du four de maintien et de puisage doit ĂȘtre assez grande vis-Ă -vis de lâempreinte du moule afin de ne pas trop refroidir le bain dans le four lors du transvasement des vidanges du moule.For mass production, the capacity of the holding and drawing oven must be large enough in relation to the footprint of the mold so as not to overcool the bath in the oven when transferring the drains from the mold.
En parallĂšle de la fusion de lâalliage selon lâexemple 1, le moule a Ă©tĂ© prĂ©parĂ©.In parallel with the melting of the alloy according to Example 1, the mold was prepared.
Le moule mĂ©tallique a Ă©tĂ© prĂ©chauffĂ© avant la premiĂšre coulĂ©e, Ă une tempĂ©rature approximative de 350°C pour la coulĂ©e des alliages dâaluminium. Pour mettre le moule Ă tempĂ©rature, des bruleurs Ă gaz ou des dispositifs Ă©lectriques de chauffe ont Ă©tĂ© utilisĂ©s.The metal mold was preheated before the first casting, to an approximate temperature of 350°C for casting aluminum alloys. To bring the mold to temperature, gas burners or electric heating devices were used.
Les empreintes des moules mĂ©talliques ont Ă©tĂ© revĂȘtues dâune fine couche de poteyage, dâune Ă©paisseur de 0,2 Ă 0,5 mm.The impressions of the metal molds were coated with a thin layer of clay, with a thickness of 0.2 to 0.5 mm.
Dans le cas dâun moule en sable, aucun prĂ©chauffage nâa Ă©tĂ© mis en Ćuvre.In the case of a sand mold, no preheating was carried out.
Le moule a Ă©tĂ© rempli de mĂ©tal en fusion lorsque la tempĂ©rature du mĂ©tal ou de lâalliage mĂ©tallique a Ă©tĂ© stabilisĂ©e dans le four de fusion-maintien (exemple 1), et lorsque la tempĂ©rature initiale du moule prĂ©chauffĂ© pour le dĂ©but de cycle a Ă©tĂ© atteinte (exemple 2).The mold was filled with molten metal when the temperature of the metal or metal alloy was stabilized in the melting-holding furnace (example 1), and when the initial temperature of the mold preheated for the start of the cycle was reached (example 2).
Le moule a Ă©tĂ© vidangĂ© du mĂ©tal en fusion rĂ©siduel lorsque la coque solidifiĂ©e a Ă©tĂ© formĂ©e contre la paroi intĂ©rieure du moule. La durĂ©e du sĂ©jour du mĂ©tal en fusion dans le moule dĂ©pend de lâĂ©paisseur de la coque souhaitĂ©e.The mold was drained of residual molten metal when the solidified shell was formed against the interior wall of the mold. The length of time the molten metal stays in the mold depends on the thickness of the desired shell.
Exemple 5. Fabrication dâune piĂšce creuse par un procĂ©dĂ© de moulage en sableExample 5. Manufacturing of a hollow part by a sand casting process
Un modĂšle en bois a Ă©tĂ© rĂ©alisĂ©, afin de confectionner un moule en sable (Figure 5A). AprĂšs la fabrication du moule en sable, lâalliage dâaluminium AlSi12 a Ă©tĂ© fondu et portĂ© Ă une tempĂ©rature dâenviron 700°C, soit 40°C environ au-dessus de la tempĂ©rature souhaitĂ©e de coulĂ©e. Le mĂ©tal en fusion a Ă©tĂ© transvasĂ© dans une poche de coulĂ©e Ă lâaide dâune grosse louche, afin de pouvoir apporter le mĂ©tal jusquâau moule grĂące Ă un brancard. La tempĂ©rature de lâaluminium Ă©tait dâenviron 660°C lors de la coulĂ©e dans le moule en sable (moule non chauffĂ©, Ă tempĂ©rature ambiante, environ 20°C). Le temps de remplissage Ă©tait de moins de 10 secondes, suivi par un temps de maintien du mĂ©tal en fusion dans le moule dâenviron 2 minutes.A wooden model was made to make a sand mold (Figure 5A). After the sand mold was made, the aluminum alloy AlSi12 was melted and heated to a temperature of approximately 700°C, approximately 40°C above the desired casting temperature. The molten metal was transferred into a ladle using a large ladle, in order to be able to bring the metal to the mold using a stretcher. The temperature of the aluminum was approximately 660°C during casting in the sand mold (unheated mold, at room temperature, approximately 20°C). The filling time was less than 10 seconds, followed by a holding time of the molten metal in the mold of approximately 2 minutes.
Pendant le temps de maintien du mĂ©tal en fusion dans le moule, la surface supĂ©rieure du bain mĂ©tallique en contact avec lâair a Ă©tĂ© Ă©crĂ©mĂ©e, ceci afin de retirer les peaux dâoxyde Ă©paisses (flottantes et issues du remplissage). Une poche de coulĂ©e Ă©tait installĂ©e sous le moule, afin de pouvoir recueillir le mĂ©tal encore en fusion lors de la vidange. Une fois le temps de 2 minutes environ Ă©coulĂ©, la trappe isolante situĂ©e sous le moule a Ă©tĂ© ouverte, permettant ainsi la vidange du bain de mĂ©tal encore liquide dans la poche. MalgrĂ© la matiĂšre isolante de la trappe, une peau de mĂ©tal solidifiĂ©e a pu se former contre, nĂ©cessitant Ă©ventuellement une intervention (e.g. avec une pointe mĂ©tallique) pour percer cette peau. AprĂšs un temps de vidange de moins de 10 secondes, lâalliage dâaluminium en fusion recueilli dans la poche sous le moule a Ă©tĂ© transportĂ© puis reversĂ© dans le creuset du four. AprĂšs refroidissement de la coque solidifiĂ©e, le moule en sable a Ă©tĂ© dĂ©cochĂ© afin de rĂ©cupĂ©rer la piĂšce. Celle-ci comporte une surface extĂ©rieure complĂ©mentaire Ă lâempreinte du moule (Figure 6B) et une surface intĂ©rieure cristallographique, rĂ©sultant du mode naturel de solidification du mĂ©tal/alliage utilisĂ© (Figure 6C).During the time the molten metal was held in the mold, the upper surface of the metal bath in contact with the air was skimmed, in order to remove the thick oxide skins (floating and resulting from the filling). A pouring ladle was installed under the mold, in order to be able to collect the metal still in fusion during emptying. Once the time of approximately 2 minutes had elapsed, the insulating hatch located under the mold was opened, thus allowing the bath of metal still liquid in the bag to be drained. Despite the insulating material of the hatch, a solidified metal skin could have formed against it, possibly requiring intervention ( eg . with a metal point) to pierce this skin. After an emptying time of less than 10 seconds, the molten aluminum alloy collected in the pocket under the mold was transported and then poured back into the crucible of the furnace. After cooling the solidified shell, the sand mold was removed in order to recover the part. This has an exterior surface complementary to the mold cavity (Figure 6B) and a crystallographic interior surface, resulting from the natural mode of solidification of the metal/alloy used (Figure 6C).
Exemple 6. Fabrication en série de multiples piÚcesExample 6. Mass production of multiple parts
Une fabrication en série de plusieurs piÚces a été réalisée comme schématisée dans la
Un moule mĂ©tallique en alliage dâaluminium AlSi7Mg a Ă©tĂ© rĂ©alisĂ© par moulage au sable et par usinage. Cette coquille a Ă©tĂ© installĂ©e sur un banc dâessai, chĂąssis mĂ©cano-soudĂ© en partie articulĂ© pour permettre la rotation du moule afin de dĂ©mouler la piĂšce produite. Ce banc dispose de brĂ»leurs, situĂ©s sous le moule, afin de chauffer (voire de maintenir) lâempreinte Ă la tempĂ©rature souhaitĂ©e avant la coulĂ©e du mĂ©tal. Le moule a Ă©tĂ© surĂ©levĂ© pour accueillir une poche de coulĂ©e, situĂ©e en dessous du moule, le tout reposant sur un lit de sable pour des questions de sĂ©curitĂ©.An AlSi7Mg aluminum alloy metal mold was made by sand casting and machining. This shell was installed on a test bench, a mechanically welded chassis partly articulated to allow the rotation of the mold in order to unmold the part produced. This bench has burners, located under the mold, in order to heat (or even maintain) the impression at the desired temperature before casting the metal. The mold was raised to accommodate a pouring ladle, located below the mold, all resting on a bed of sand for safety reasons.
Avant la premiĂšre coulĂ©e, lâalliage dâaluminium (AlSi12) a Ă©tĂ© fondu dans le creuset du four et portĂ© Ă une tempĂ©rature comprise de 750°C Ă 790°C, soit environ 50°C au-dessus de la tempĂ©rature souhaitĂ©e de coulĂ©e. Pendant ce temps, la coquille mĂ©tallique moulante a Ă©tĂ© sablĂ©e, installĂ©e sur le banc dâessai, chauffĂ©e par des brĂ»leurs Ă gaz, et poteyĂ©e. Pour la coulĂ©e, le moule a Ă©tĂ© portĂ© Ă une tempĂ©rature comprise de 164°C Ă 243°C. De la mĂȘme maniĂšre, la quenouille (tube dâacier revĂȘtu de poteyage isolant) a Ă©tĂ© chauffĂ©e Ă une tempĂ©rature nettement supĂ©rieure Ă la tempĂ©rature du liquidus de lâalliage, afin que le mĂ©tal en fusion ne puisse pas se solidifier Ă son contact. Une fois la tempĂ©rature souhaitĂ©e du mĂ©tal en fusion atteinte dans le four, la poche de coulĂ©e a Ă©tĂ© remplie, puis apportĂ©e proche du moule grĂące Ă un brancard. La tempĂ©rature du mĂ©tal en fusion dans la poche Ă©tait alors dâenviron 720°C juste avant la coulĂ©e. Cette poche fut rapidement dĂ©versĂ©e dans le moule, environ 17 secondes. Puis le temps de maintien du mĂ©tal/alliage en fusion dans le moule mĂ©tallique a Ă©tĂ© dâenviron 14 secondes(selon diffĂ©rents essais, ce temps peut varier de 14 secondes Ă 1 minute). Ensuite la quenouille qui obstruait lâorifice du moule a Ă©tĂ© retirĂ©e, permettant de vidanger le mĂ©tal encore en fusion dans le moule, afin de dĂ©verser celui-ci dans la poche de coulĂ©e situĂ©e en dessous (Figure 1B). Cette poche a alors Ă©tĂ© retirĂ©e et transportĂ©e avec un brancard jusquâau creuset du four. La tempĂ©rature de lâalliage dâaluminium juste avant son transvasement dans le four Ă©tait comprise de 577°C Ă 588°C. Enfin, pour dĂ©mouler la piĂšce, une grille mĂ©tallique a Ă©tĂ© installĂ©e au-dessus du moule ; puis le moule et son support ont Ă©tĂ© pivotĂ©s Ă 180°C afin de permettre le dĂ©moulage de la piĂšce chaude produite sans la dĂ©former (Figures 4C, 6B et 6C). La piĂšce dĂ©posĂ©e sur la grille a Ă©tĂ© dĂ©placĂ©e ailleurs dans lâatelier pour son refroidissement. La coque en mĂ©tal solidifiĂ©e, ainsi produite, prĂ©sente une surface extĂ©rieure complĂ©mentaire Ă lâempreinte du moule (Figure 6B) et une surface intĂ©rieure cristallographique, rĂ©sultant du mode naturel de solidification du mĂ©tal/alliage utilisĂ© (Figure 6C).Before the first casting, the aluminum alloy (AlSi12) was melted in the furnace crucible and heated to a temperature between 750°C and 790°C, approximately 50°C above the desired temperature of casting. During this time, the form-fitting metal shell was sandblasted, installed on the test bench, heated by gas burners, and potted. For casting, the mold was brought to a temperature between 164°C and 243°C. In the same way, the stopper (steel tube coated with insulating coating) was heated to a temperature significantly higher than the liquidus temperature of the alloy, so that the molten metal could not solidify on contact with it. Once the desired temperature of the molten metal was reached in the oven, the ladle was filled, then brought close to the mold using a stretcher. The temperature of the molten metal in the ladle was then around 720°C just before casting. This bag was quickly poured into the mold, approximately 17 seconds. Then the holding time of the molten metal/alloy in the metal mold was approximately 14 seconds ( according to different tests, this time can vary from 14 seconds to 1 minute). Then the stopper which obstructed the mold orifice was removed, allowing the metal still molten in the mold to be drained, in order to pour it into the pouring ladle located below (Figure 1B). This bag was then removed and transported with a stretcher to the crucible of the furnace. The temperature of the aluminum alloy just before its transfer into the oven was between 577°C and 588°C. Finally, to unmold the part, a metal grid was installed above the mold; then the mold and its support were rotated to 180°C to allow the hot part produced to be unmolded without deforming it (Figures 4C, 6B and 6C). The part placed on the grid was moved elsewhere in the workshop for cooling. The solidified metal shell, thus produced, has an exterior surface complementary to the mold cavity (Figure 6B) and a crystallographic interior surface, resulting from the natural mode of solidification of the metal/alloy used (Figure 6C).
Le procĂ©dĂ© peut ĂȘtre rĂ©pĂ©tĂ© pour produire des piĂšces successives. Les coulĂ©es successives aident ainsi Ă entretenir la tempĂ©rature du moule.The process can be repeated to produce successive parts. The successive pours thus help to maintain the temperature of the mold.
Claims (14)
- une surface extérieure lisse comprenant des grains métallurgiques,
- une surface intérieure cristallographique, et
- une Ă©paisseur moyenne homogĂšne, en particulier de 0,2 mm Ă 2 mm,
ladite piĂšce mĂ©tallique Ă©tant constituĂ©e dâun mĂ©tal ayant un point de fusion supĂ©rieur Ă 180°C, en particulier supĂ©rieur Ă 320°C,
dans laquelle la topologie de ladite surface intérieure cristallographique comprend des reliefs correspondant aux cristaux métallurgiques, en particulier des reliefs correspondant aux cristaux dendritiques ou aux cristaux polyédriques ou aux cellules eutectiques.Hollow metal part comprising:
- a smooth exterior surface comprising metallurgical grains,
- a crystallographic interior surface, and
- a uniform average thickness, in particular from 0.2 mm to 2 mm,
said metal part being made of a metal having a melting point greater than 180°C, in particular greater than 320°C,
in which the topology of said crystallographic interior surface comprises reliefs corresponding to metallurgical crystals, in particular reliefs corresponding to dendritic crystals or polyhedral crystals or eutectic cells.
- uneĂ©tape 1dâinjection dâune masse liquide de mĂ©tal fondu dans un moule, depuis un contenant comprenant ledit mĂ©tal fondu, pour obtenir un moule comprenant du mĂ©tal fondu ;
- uneĂ©tape 2de solidification partielle dudit mĂ©tal fondu au sein du moule pendant un temps suffisant pour former une coque mĂ©tallique solidifiĂ©e en contact avec les parois du moule prĂ©sentant une tempĂ©rature infĂ©rieure Ă la tempĂ©rature dusolidusdudit mĂ©tal fondu, et maintenir en phase liquide la partie restante de la masse liquide initiale dudit mĂ©tal fondu contenue Ă lâintĂ©rieur de la coque mĂ©tallique solidifiĂ©e, pour obtenir une partie solide constituĂ©e de la coque mĂ©tallique solidifiĂ©e, et une phase liquide constituĂ©e de la partie restante de la masse liquide initiale dudit mĂ©tal fondu ;
- uneétape 3de soustraction de la susdite phase liquide, ladite étape de soustraction étant effectuée sans basculement du moule ; et
- uneétape 4de récupération de la piÚce métallique creuse sous forme de coque métallique solidifiée,
ledit procĂ©dĂ© ayant une mise au mille de 1 :1 Ă 1,2 :1, de prĂ©fĂ©rence dâenviron 1:1, en particulier de 1:1.Method of manufacturing a hollow metal part according to any one of claims 1 to 3, said method comprising at least the following steps:
- a step 1 of injecting a liquid mass of molten metal into a mold, from a container comprising said molten metal, to obtain a mold comprising molten metal;
- a step 2 of partial solidification of said molten metal within the mold for a time sufficient to form a solidified metal shell in contact with the walls of the mold having a temperature lower than the solidus temperature of said molten metal, and maintain the part in the liquid phase remaining of the initial liquid mass of said molten metal contained inside the solidified metal shell, to obtain a solid part consisting of the solidified metal shell, and a liquid phase consisting of the remaining part of the initial liquid mass of said molten metal;
- a step 3 of subtracting the above liquid phase, said subtraction step being carried out without tilting the mold; And
- a step 4 of recovering the hollow metal part in the form of a solidified metal shell,
said method having a target setting of 1:1 to 1.2:1, preferably about 1:1, particularly 1:1.
dans lequel le moule prĂ©sente des moyens dâappel dâair ou de gaz dans le haut du moule, lesdits moyens dâappel dâair ou de gaz Ă©tant fermĂ©s lors de lâĂ©tape 1 dâinjection et lors de lâĂ©tape 2 de solidification,
dans lequel lâĂ©tape 3 de soustraction est favorisĂ©e ou rendue possible par lâouverture desdits moyens dâappel dâair ou de gaz entrainant un appel dâair ou de gaz, notamment dâazote ou dâargon, sous pression, en particulier Ă une pression Ă©gale ou supĂ©rieure Ă la pression atmosphĂ©rique.Manufacturing process according to any one of claims 5 to 11,
in which the mold has means for drawing air or gas into the top of the mold, said means for drawing air or gas being closed during injection step 1 and during step 2 solidification,
in which step 3 of subtraction is favored or made possible by the opening of said means for drawing air or gas resulting in a draw of air or gas, in particular nitrogen or argon, under pressure, in particular at a pressure equal to or greater than atmospheric pressure.
- la fabrication dâune premiĂšre piĂšce mĂ©tallique selon le procĂ©dĂ© de fabrication selon lâune quelconque des revendications 5 Ă 12, et
- la fabrication dâune deuxiĂšme piĂšce mĂ©tallique, selon le procĂ©dĂ© de fabrication selon lâune quelconque des revendications 5 Ă 12, dans lequel le mĂ©tal utilisĂ© versĂ© dans lâĂ©tape 1 de versement est le mĂ©tal soustrait lors de lâĂ©tape 3 de soustraction de la fabrication de la premiĂšre piĂšce.
- the manufacture of a first metal part according to the manufacturing process according to any one of claims 5 to 12, and
- the manufacture of a second metal part, according to the manufacturing method according to any one of claims 5 to 12, in which the metal used poured in step 1 of pouring is the metal subtracted during step 3 of subtraction of the manufacture of the first part.
Priority Applications (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| FR2213453A FR3143393A1 (en) | 2022-12-15 | 2022-12-15 | METHOD FOR MANUFACTURING HOLLOW METAL PARTS BY MOLDING, WITHOUT CORE |
| PCT/EP2023/086188 WO2024126841A1 (en) | 2022-12-15 | 2023-12-15 | Coreless molding manufacturing method for hollow metal parts |
| FR2314322A FR3143392A1 (en) | 2022-12-15 | 2023-12-15 | METHOD FOR MANUFACTURING HOLLOW METAL PARTS BY MOLDING, WITHOUT CORE |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| FR2213453A FR3143393A1 (en) | 2022-12-15 | 2022-12-15 | METHOD FOR MANUFACTURING HOLLOW METAL PARTS BY MOLDING, WITHOUT CORE |
| FR2213453 | 2022-12-15 |
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| Publication Number | Publication Date |
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| FR3143393A1 true FR3143393A1 (en) | 2024-06-21 |
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Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
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| FR2213453A Pending FR3143393A1 (en) | 2022-12-15 | 2022-12-15 | METHOD FOR MANUFACTURING HOLLOW METAL PARTS BY MOLDING, WITHOUT CORE |
| FR2314322A Pending FR3143392A1 (en) | 2022-12-15 | 2023-12-15 | METHOD FOR MANUFACTURING HOLLOW METAL PARTS BY MOLDING, WITHOUT CORE |
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| Application Number | Title | Priority Date | Filing Date |
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| FR2314322A Pending FR3143392A1 (en) | 2022-12-15 | 2023-12-15 | METHOD FOR MANUFACTURING HOLLOW METAL PARTS BY MOLDING, WITHOUT CORE |
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| FR (2) | FR3143393A1 (en) |
| WO (1) | WO2024126841A1 (en) |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2646824B1 (en) | 1989-03-25 | 1997-03-28 | Honda Motor Co Ltd | MOTORCYCLE CHASSIS, AND METHOD AND APPARATUS FOR ITS MANUFACTURE |
Family Cites Families (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| BE786990A (en) * | 1971-08-02 | 1973-01-31 | Pechiney Aluminium | APPARATUS FOR MOLDING THIN LAYERS |
| AU501813B2 (en) * | 1975-12-01 | 1979-06-28 | Lero Diecasters Pty. Limited Priors Pty. Limited | Slush casting hollow objects |
| GB2124526B (en) * | 1982-07-30 | 1986-09-03 | Worswick Alan | Casting hollow articles |
| JPH03143607A (en) * | 1989-10-31 | 1991-06-19 | Nissan Motor Co Ltd | Manufacturing device for hollow core |
| DE3941538A1 (en) * | 1989-12-19 | 1991-06-20 | So Periferna Technika | METHOD AND DEVICE FOR THE PRODUCTION OF CASTING PIECES HAVING CAVITIES |
| JPH0938761A (en) * | 1995-07-28 | 1997-02-10 | Sintokogio Ltd | Production of low melting metallic core |
| JP2000263212A (en) * | 1999-03-17 | 2000-09-26 | Aisin Takaoka Ltd | Production of casting having hollow part and apparatus usable to the same |
| RU2663788C1 (en) * | 2017-07-19 | 2018-08-09 | ЀДЎДŃĐ°Đ»ŃĐœĐŸĐ” ĐłĐŸŃŃĐŽĐ°ŃŃŃĐČĐ”ĐœĐœĐŸĐ” бŃЎжДŃĐœĐŸĐ” ĐŸĐ±ŃĐ°Đ·ĐŸĐČĐ°ŃДлŃĐœĐŸĐ” ŃŃŃĐ”Đ¶ĐŽĐ”ĐœĐžĐ” ĐČŃŃŃĐ”ĐłĐŸ ĐŸĐ±ŃĐ°Đ·ĐŸĐČĐ°ĐœĐžŃ "ĐĐŸŃĐșĐŸĐČŃĐșĐžĐč Đ°ĐČОаŃĐžĐŸĐœĐœŃĐč ĐžĐœŃŃĐžŃŃŃ (ĐœĐ°ŃĐžĐŸĐœĐ°Đ»ŃĐœŃĐč ĐžŃŃĐ»Đ”ĐŽĐŸĐČĐ°ŃДлŃŃĐșĐžĐč ŃĐœĐžĐČĐ”ŃŃĐžŃĐ”Ń)" | Method of manufacturing of hollow mold parts |
-
2022
- 2022-12-15 FR FR2213453A patent/FR3143393A1/en active Pending
-
2023
- 2023-12-15 WO PCT/EP2023/086188 patent/WO2024126841A1/en unknown
- 2023-12-15 FR FR2314322A patent/FR3143392A1/en active Pending
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2646824B1 (en) | 1989-03-25 | 1997-03-28 | Honda Motor Co Ltd | MOTORCYCLE CHASSIS, AND METHOD AND APPARATUS FOR ITS MANUFACTURE |
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