US20110003164A1 - Method for casting a material, utilization of the method, casting mould for implementing the method and objects manufactured in accordance with the method and in the casting mould, as well as core for being inserted into such a casting mould - Google Patents

Method for casting a material, utilization of the method, casting mould for implementing the method and objects manufactured in accordance with the method and in the casting mould, as well as core for being inserted into such a casting mould Download PDF

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Publication number
US20110003164A1
US20110003164A1 US12/802,893 US80289310A US2011003164A1 US 20110003164 A1 US20110003164 A1 US 20110003164A1 US 80289310 A US80289310 A US 80289310A US 2011003164 A1 US2011003164 A1 US 2011003164A1
Authority
US
United States
Prior art keywords
casting
core
accordance
mold
casting mould
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US12/802,893
Inventor
Marc Menge
Holger Oppelt
Uwe Lange
Manikandan Loganathan
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
KSM Castings Group GmbH
Original Assignee
KSM Castings GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by KSM Castings GmbH filed Critical KSM Castings GmbH
Assigned to KSM CASTINGS GMBH reassignment KSM CASTINGS GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LANGE, UWE, OPPELT, HOLGER, MENGE, MARC, LOGANATHAN, MANIKANDAN
Publication of US20110003164A1 publication Critical patent/US20110003164A1/en
Assigned to KSM CASTINGS GROUP GMBH reassignment KSM CASTINGS GROUP GMBH MERGER (SEE DOCUMENT FOR DETAILS). Assignors: KSM CASTINGS GMBH
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D35/00—Equipment for conveying molten metal into beds or moulds
    • B22D35/04—Equipment for conveying molten metal into beds or moulds into moulds, e.g. base plates, runners
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
    • B22C1/18—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents
    • B22C1/185—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents containing phosphates, phosphoric acids or its derivatives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
    • B22C1/18—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents
    • B22C1/186—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents contaming ammonium or metal silicates, silica sols
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • 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 B22D1/00 - B22D21/00
    • B22D23/006—Casting by filling the mould through rotation of the mould together with a molten metal holding recipient, about a common axis
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals

Definitions

  • the invention pertains to a method for casting a material that is initially transferred from its solid state into a free-flowing state and subsequently poured into a mould, in which the material solidifies.
  • the invention furthermore pertains to moulds for implementing the method and objects that are or were manufactured in accordance with the method and/or in such moulds.
  • the invention ultimately also pertains to a core that this inserted into such moulds.
  • mould cores or cores or core assemblies are required in the manufacture of castings with hollow spaces or with particularly complex geometries.
  • the invention aims to avoid the disadvantages of the cited casting methods and to develop methods for casting materials that make it possible to reduce or even entirely dispense with the costly subsequent or finish processing of castings, particularly in the casting of complex castings.
  • the invention furthermore aims to make available such a method that ensures a high and constant quality of the castings being manufactured.
  • the cycle, material, energy and transport efficiency should also be improved.
  • Another objective of the invention consists of making available a generic method that is particularly harmless to the environment.
  • the method for casting a material by transferring said material into a free-flowing state by means of heating and introducing the material into a casting mould is characterized in that the introduction of the material into the casting mould is at least partly realized with the aid of tilt casting or the tilt casting principle and a core moulded of core moulding material and an inorganic binder is inserted into the casting mould in advance.
  • the inventive method makes it possible to manufacture highly integrated and complex castings that are characterized by an improved surface. Consequently, the surface advantageously contains no or only isolated defects caused by the inserted core such as pores, shrink holes or veins.
  • the inventive casting process in the form of a combination of tilt casting and an inorganic core that is inserted in advance proved particularly advantageous.
  • the method makes it possible to manufacture complex castings of high quality, wherein a reduction of the costly subsequent or finish processing or treatment is simultaneously achieved. The latter usually form the main bottlenecks in production of castings. It is therefore possible to reduce the cleaning and control costs.
  • Another advantageous aspect is the environmental compatibility of the inventive method. Emissions and odors during the manufacture of castings are avoided or reduced because only small amounts of organic compounds or decomposition products, if any, are released during the casting process due to the utilization of an inorganic core.
  • Sand or silica sand is preferably used as core moulding material. This material in the form of a process residue of sorts is particularly well suited for recycling after the casting process.
  • the inorganic binder used preferably consists of a binder on the basis of silicate, borate and/or phosphate. This results in an additionally improved reduction of possible casting defects. According to the invention, pores and shrink holes occur much less frequently.
  • the invention also pertains to the utilization of the inventive method for manufacturing complex castings, preferably pump housings, particularly high-pressure pump housings, or turbocharger housings.
  • the invention also pertains to a tiltable mould or a tiltable permanent mould, particularly for implementing the inventive method, wherein a core moulded of core moulding material, preferably of sand, and an inorganic binder is inserted into the mould.
  • core moulding material preferably of sand
  • inorganic binder is inserted into the mould.
  • the invention furthermore pertains to castings that are or were manufactured in accordance with the inventive method and/or by means of the inventive casting moulds, wherein these casting products consist of light metal alloys such as, in particular, aluminum alloys that are advantageously manufactured in accordance with the gravity method.
  • the invention ultimately also pertains to a core for being inserted into a casting mould that can be at least partly tilted in accordance with the tilt casting principle, wherein the core is moulded of a core moulding material, preferably of sand, with an inorganic binder, preferably on the basis of silicate, borate and/or phosphate.
  • a core moulding material preferably of sand
  • an inorganic binder preferably on the basis of silicate, borate and/or phosphate.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Mold Materials And Core Materials (AREA)

Abstract

The invention pertains to methods for manufacturing objects in moulds, the moulds used for the manufacture and objects manufactured in accordance with the method and/or in the moulds.

Description

  • The invention pertains to a method for casting a material that is initially transferred from its solid state into a free-flowing state and subsequently poured into a mould, in which the material solidifies. The invention furthermore pertains to moulds for implementing the method and objects that are or were manufactured in accordance with the method and/or in such moulds. The invention ultimately also pertains to a core that this inserted into such moulds.
  • Among gravity casting methods, four casting methods essentially have prevailed, namely bottom casting, lateral casting, top casting and tilt casting. A detailed description of these casting methods can be found in DE 10 2006 058 145 A1.
  • It is known that so-called mould cores or cores or core assemblies are required in the manufacture of castings with hollow spaces or with particularly complex geometries.
  • It is also known that such mould cores frequently cause defects in the casting and, in particular, impair the cast surface of the casting. Time-consuming operations are required in order to repair such defects in the cast surface. This type of subsequent or finish processing is complicated and therefore costly, in particular, on complex castings that need to fulfill very strict quality requirements.
  • Based on this state of the art, the invention aims to avoid the disadvantages of the cited casting methods and to develop methods for casting materials that make it possible to reduce or even entirely dispense with the costly subsequent or finish processing of castings, particularly in the casting of complex castings. The invention furthermore aims to make available such a method that ensures a high and constant quality of the castings being manufactured. The cycle, material, energy and transport efficiency should also be improved. Another objective of the invention consists of making available a generic method that is particularly harmless to the environment.
  • According to the invention, the method for casting a material by transferring said material into a free-flowing state by means of heating and introducing the material into a casting mould is characterized in that the introduction of the material into the casting mould is at least partly realized with the aid of tilt casting or the tilt casting principle and a core moulded of core moulding material and an inorganic binder is inserted into the casting mould in advance.
  • Although a person skilled in the art had to fear that an inorganic core is destroyed or fractures during tilt casting, it was surprisingly determined that the inventive method makes it possible to manufacture highly integrated and complex castings that are characterized by an improved surface. Consequently, the surface advantageously contains no or only isolated defects caused by the inserted core such as pores, shrink holes or veins. In this context, the inventive casting process in the form of a combination of tilt casting and an inorganic core that is inserted in advance proved particularly advantageous. The method makes it possible to manufacture complex castings of high quality, wherein a reduction of the costly subsequent or finish processing or treatment is simultaneously achieved. The latter usually form the main bottlenecks in production of castings. It is therefore possible to reduce the cleaning and control costs.
  • Another advantageous aspect is the environmental compatibility of the inventive method. Emissions and odors during the manufacture of castings are avoided or reduced because only small amounts of organic compounds or decomposition products, if any, are released during the casting process due to the utilization of an inorganic core.
  • Sand or silica sand is preferably used as core moulding material. This material in the form of a process residue of sorts is particularly well suited for recycling after the casting process.
  • It also proved particularly advantageous that no core dressing needs to be applied onto the core in order to produce a largely flawless and smooth surface of the casting. This eliminates another costly production step. It was determined that the combination of tilt casting and an inorganic core without dressing results in a particularly flawless surface, i.e., a surface without or with only a few shrink holes, pores or veining defects. It is therefore possible to cast complex castings of high quality, the subsequent or finish processing of which would be very difficult in accordance with the state of the art, wherein this subsequent or finish processing is now largely expendable in accordance with the invention. The disadvantageous adhesion of dressing on the castings being manufactured is advantageously eliminated. Despite the lack of dressing, it was impossible to detect any core mould material or sand adhering to the casting in the inventive combination of tilt casting and an inorganic core without dressing. The cleaning and control costs can be reduced in this fashion.
  • The inorganic binder used preferably consists of a binder on the basis of silicate, borate and/or phosphate. This results in an additionally improved reduction of possible casting defects. According to the invention, pores and shrink holes occur much less frequently.
  • The invention also pertains to the utilization of the inventive method for manufacturing complex castings, preferably pump housings, particularly high-pressure pump housings, or turbocharger housings.
  • The invention also pertains to a tiltable mould or a tiltable permanent mould, particularly for implementing the inventive method, wherein a core moulded of core moulding material, preferably of sand, and an inorganic binder is inserted into the mould. This significantly reduces the effort for cleaning the mould, particularly at the core locating points. The tools are preserved and have a longer service life.
  • The invention furthermore pertains to castings that are or were manufactured in accordance with the inventive method and/or by means of the inventive casting moulds, wherein these casting products consist of light metal alloys such as, in particular, aluminum alloys that are advantageously manufactured in accordance with the gravity method.
  • The invention ultimately also pertains to a core for being inserted into a casting mould that can be at least partly tilted in accordance with the tilt casting principle, wherein the core is moulded of a core moulding material, preferably of sand, with an inorganic binder, preferably on the basis of silicate, borate and/or phosphate.

Claims (9)

1. A method for casting a material by transferring said material into a free-flowing state by means of heating and introducing the material into a casting mold, wherein the introduction of the material into the casting mold is at least partly realized with the aid of the tilt casting principle, wherein a core molded of core molding material and an inorganic binder is inserted into the casting mold in advance.
2. A method, particularly according to claim 1, wherein sand is used as core molding material.
3. A method, particularly according to claim 1, wherein no core dressing is applied onto the core.
4. A method, particularly according to claim 1, wherein an inorganic binder on the basis of silicate, borate and/or phosphate is used.
5. The utilization of the method according to claim 1 for manufacturing a pump housing, particularly a high-pressure pump housing, or a turbocharger housing.
6. A tiltable casting mold or tiltable permanent mold, particularly for implementing the method according to claim 1, wherein a core molded of core molding material, preferably sand, and an inorganic binder is inserted into the mold.
7. A casting product, wherein it is manufactured in accordance with claim 1 or in a tiltable casting mold wherein a core molded of core molding material, preferably sand, and an inorganic binder is inserted into the mold.
8. A casting product, wherein it consists of a light metal alloy such as, in particular, aluminum alloys that is advantageously manufactured by means of the gravity method in accordance with claim 1.
9. A core for being inserted into a casting mold that can be at least partly tilted in accordance with the tilt casting principle, wherein the core is molded of a core molding material, preferably sand, with an inorganic binder, preferably on the basis of silicate, borate and/or phosphate.
US12/802,893 2009-07-01 2010-06-16 Method for casting a material, utilization of the method, casting mould for implementing the method and objects manufactured in accordance with the method and in the casting mould, as well as core for being inserted into such a casting mould Abandoned US20110003164A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102009031425.3 2009-07-01
DE102009031425 2009-07-01

Publications (1)

Publication Number Publication Date
US20110003164A1 true US20110003164A1 (en) 2011-01-06

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US12/802,893 Abandoned US20110003164A1 (en) 2009-07-01 2010-06-16 Method for casting a material, utilization of the method, casting mould for implementing the method and objects manufactured in accordance with the method and in the casting mould, as well as core for being inserted into such a casting mould

Country Status (4)

Country Link
US (1) US20110003164A1 (en)
CN (1) CN102059336A (en)
DE (1) DE102010023644A1 (en)
FR (1) FR2947468A1 (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10253833B2 (en) 2017-06-30 2019-04-09 Honda Motor Co., Ltd. High performance disc brake rotor
US11187290B2 (en) 2018-12-28 2021-11-30 Honda Motor Co., Ltd. Aluminum ceramic composite brake assembly

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2916976B1 (en) * 2013-10-19 2017-03-08 Peak Deutschland GmbH Method for producing lost cores or molded parts for the production of cast parts

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3480070A (en) * 1967-02-16 1969-11-25 Abex Corp Permanent mold for casting a wheel
US3545524A (en) * 1967-02-16 1970-12-08 Abex Corp Method of casting a wheel
US4298049A (en) * 1979-08-17 1981-11-03 Westran Corporation Method for assembling molds
JPH09136155A (en) * 1995-11-10 1997-05-27 Asahi Tec Corp Tiltable casting device and core used with this device
US5735335A (en) * 1995-07-11 1998-04-07 Extrude Hone Corporation Investment casting molds and cores
US6540007B2 (en) * 1998-03-10 2003-04-01 Montupet S.A. Molding process for the mass production of aluminum alloy castings and associated items of equipment
US20040060685A1 (en) * 2001-06-11 2004-04-01 Ranjan Ray Centrifugal casting of titanium alloys with improved surface quality, structural integrity and mechanical properties in isotropic graphite molds under vacuum
US6929053B1 (en) * 2004-05-26 2005-08-16 General Motors Corporation Mold fill method and system
US20080314549A1 (en) * 2007-06-12 2008-12-25 Ralf-Joachim Gerlach Molding material mixture, molded part for foundry purposes and process of producing a molded part

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3302919A (en) * 1965-11-12 1967-02-07 Abex Corp Apparatus for casting metal wheels
CN1021026C (en) * 1990-08-30 1993-06-02 包钢综合企业公司第三铸造厂 Casting method of central casting pipe
US6139619A (en) * 1996-02-29 2000-10-31 Borden Chemical, Inc. Binders for cores and molds
CN1298775A (en) * 1999-12-08 2001-06-13 芦华居 Composite adhesive for sand core of mechanical casting
CN100404168C (en) * 2005-12-30 2008-07-23 广西玉柴机器股份有限公司 Diesel engine four-valve cylinder head gravity casting die and casting method thereof
DE102006058145A1 (en) * 2006-12-09 2008-06-12 Ksm Castings Gmbh Method for processing, in particular casting, a material, casting mold for carrying out the method and articles produced by the method or in the casting mold

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3480070A (en) * 1967-02-16 1969-11-25 Abex Corp Permanent mold for casting a wheel
US3545524A (en) * 1967-02-16 1970-12-08 Abex Corp Method of casting a wheel
US4298049A (en) * 1979-08-17 1981-11-03 Westran Corporation Method for assembling molds
US5735335A (en) * 1995-07-11 1998-04-07 Extrude Hone Corporation Investment casting molds and cores
JPH09136155A (en) * 1995-11-10 1997-05-27 Asahi Tec Corp Tiltable casting device and core used with this device
US6540007B2 (en) * 1998-03-10 2003-04-01 Montupet S.A. Molding process for the mass production of aluminum alloy castings and associated items of equipment
US20040060685A1 (en) * 2001-06-11 2004-04-01 Ranjan Ray Centrifugal casting of titanium alloys with improved surface quality, structural integrity and mechanical properties in isotropic graphite molds under vacuum
US6929053B1 (en) * 2004-05-26 2005-08-16 General Motors Corporation Mold fill method and system
US20080314549A1 (en) * 2007-06-12 2008-12-25 Ralf-Joachim Gerlach Molding material mixture, molded part for foundry purposes and process of producing a molded part

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10253833B2 (en) 2017-06-30 2019-04-09 Honda Motor Co., Ltd. High performance disc brake rotor
US10550902B2 (en) 2017-06-30 2020-02-04 Honda Motor Co., Ltd. High performance disc brake rotor
US11187290B2 (en) 2018-12-28 2021-11-30 Honda Motor Co., Ltd. Aluminum ceramic composite brake assembly

Also Published As

Publication number Publication date
CN102059336A (en) 2011-05-18
FR2947468A1 (en) 2011-01-07
DE102010023644A1 (en) 2011-01-05

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AS Assignment

Owner name: KSM CASTINGS GMBH, GERMANY

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:MENGE, MARC;OPPELT, HOLGER;LANGE, UWE;AND OTHERS;SIGNING DATES FROM 20100506 TO 20100520;REEL/FRAME:024609/0111

AS Assignment

Owner name: KSM CASTINGS GROUP GMBH, GERMANY

Free format text: MERGER;ASSIGNOR:KSM CASTINGS GMBH;REEL/FRAME:029155/0787

Effective date: 20120815

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION