WO2015053373A1 - 半凝固鋳鍛造装置及び方法並びに鋳鍛造品 - Google Patents
半凝固鋳鍛造装置及び方法並びに鋳鍛造品 Download PDFInfo
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- WO2015053373A1 WO2015053373A1 PCT/JP2014/077106 JP2014077106W WO2015053373A1 WO 2015053373 A1 WO2015053373 A1 WO 2015053373A1 JP 2014077106 W JP2014077106 W JP 2014077106W WO 2015053373 A1 WO2015053373 A1 WO 2015053373A1
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- lower mold
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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
- B22D18/02—Pressure casting making use of mechanical pressure devices, e.g. cast-forging
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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
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/007—Semi-solid pressure die casting
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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
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
- B22D17/229—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies with exchangeable die part
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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
- B22D19/00—Casting in, on, or around objects which form part of the product
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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
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/04—Casting in, on, or around objects which form part of the product for joining parts
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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
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling 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
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/09—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure
- B22D27/11—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure making use of mechanical pressing devices
Definitions
- the present invention relates to a semi-solid cast forging apparatus and method and a cast forged product.
- the semi-solid casting technology is known as a technology for reducing weight (thinning) and improving mechanical properties.
- Semi-solid casting techniques include the rheocast method and the thixocast method.
- the rheocast method is a method in which an alloy is cooled while being stirred from a liquid state, and primary crystals are grown in a granular form and formed when a predetermined solid phase ratio is reached, and is also called a semi-solid die casting method.
- the thixocasting method is a method in which the alloy is melted and then solidified with stirring to produce a billet, and then the billet is heated again in the solid-liquid coexisting state during casting. Also called the casting method.
- the thixocasting method has a problem that a special billet whose organization is adjusted is expensive.
- NRC method Ube's New Rheocasting Process
- Patent Document 1 a method in which a slurry in a solid-liquid coexistence state is injected into an injection sleeve after a predetermined amount of solid phase is crystallized.
- NRC method requires a long time to produce a semi-solid slurry, and has a limit to miniaturization of spherical crystals because the equipment is large and expensive and the number of nuclei generated is not sufficient.
- Patent Document 2 As a technique for breaking such a limit, that is, as a technique for quickly and easily producing a slurry at a low cost with a small facility and increasing the number of nuclei generated, a nanocast method using electromagnetic stirring (Patent Document 2) or a cup using self stirring A law (Patent Document 3) is provided.
- melt forging techniques for forging a molten metal in a mold for example, techniques described in Patent Documents 5 and 6 are provided for techniques using a rheocast method and techniques using a thixocast method.
- the technique described in Patent Document 5 is to install a bulk mixture (billet) in a semi-solid state in the center of a lower mold heated to a temperature lower than that of the bulk mixture, and then bring the upper mold closer to the lower mold. A massive mixture in a semi-solidified state is compressed and deformed.
- Patent Document 5 has a problem that the raw material mass is large with respect to the product mass, and thus the cost is high.
- the “raw material mass” is the mass of the raw material supplied into the lower mold
- the “product mass” is the mass of the portion excluding burrs, surplus meat and other parts outside the product.
- both raw material mass and product mass are masses at room temperature.
- a product having a thin part for example, a thickness part of 1 mm or less
- Patent Document 6 Japanese Patent Application Laid-Open No.
- a molten metal material is poured into a press mold and stored for a certain period of time with a preload applied to the whole.
- a molten forging technique is disclosed in which an additional pressure is applied to at least a part of a metal material to cause deformation.
- Non-Patent Document 1 discloses a technique in which a semi-solid slurry is generated in a metal container close to a product shape, the semi-solid slurry is put into a mold, and compression molding is performed using the mold. According to this method, a spherical structure can be obtained, but it is necessary to prepare a semi-solid slurry once and transfer it to a mold. Moreover, the mass of the raw material relative to the mass of the product is large, and this technology also increases the cost from the raw material side.
- JP 2003-126950 A Japanese Patent No. 4134310 Japanese Patent No. 39198110 WO2013 / 039247A JP 2009-235498 A Japanese Patent Laid-Open No. 4-182054
- the present invention provides a semi-solid cast forging method capable of manufacturing a product having a thin part (thick part of 1 mm or less) with an extremely high material yield without using complicated processes and apparatuses. For the purpose.
- the invention according to claim 1 is a molten metal forging device for pouring a molten metal into a cavity of a lower mold, moving the upper mold or the lower mold, and performing molding in a semi-solid state.
- the semi-solid melt forging device is capable of adjusting the speed so that the time until the start of the subsequent molding is 0.1-10 seconds.
- the invention according to claim 2 is the semi-solid melt forging device according to claim 1, wherein the speed can be adjusted so that the time from the pouring to the start of molding is 0.1-5 seconds.
- the invention according to claim 3 is the semi-solid melt forging device according to claim 1 or 2, wherein the distance between the upper die and the lower die when pouring the molten metal into the cavity is 30-50 cm. .
- the invention according to claim 4 is the semi-solid molten forging device according to any one of claims 1 to 3, wherein the speed of the upper die or the lower die is variable at least between 0.03-5 m / s. is there.
- the invention according to claim 5 is a semi-solid molten metal forging method in which a molten metal is poured into a cavity of a lower mold, the upper mold or the lower mold is moved, and molding is performed in a semi-solid state.
- This is a semi-solid melt forging method in which a slurry is prepared so that the particle size in the slurry later becomes 50 ⁇ m or less, and mold forming is started within a time range of 0.1-10 seconds after the pouring.
- the invention according to claim 6 is the semi-solid melt forging method according to claim 5, wherein the speed can be adjusted so that the time from the pouring to the start of molding is 0.1-5 seconds.
- the molten metal is poured into the lower die of the press controlled so that the solid phase ratio becomes a desired constant value so that supercooling occurs, and the fluidity is increased by compression.
- the upper mold contacts the semi-solid slurry, and the subsequent mold moves from the upper mold to the lower mold at a speed of 0.1 to 1.5 m / s.
- This is a semi-solid cast forging method in which the semi-solid slurry is compressed to form a product.
- the molten metal is poured into the lower mold of the press controlled so that the solid phase ratio becomes a desired constant value so that supercooling occurs, and the particle size is 50 ⁇ m or less.
- the upper mold contacts the semi-solid slurry and the upper mold or the lower mold is moved at a speed of 0.1 to 1.5 m / s thereafter. This is a semi-solid cast forging method in which the semi-solid slurry is compressed to form a product.
- the invention according to claim 10 is the semi-solid cast forging method according to any one of claims 5 to 9, wherein the molten metal temperature at the time of pouring is 10 to 30 ° C higher than the liquidus temperature.
- the invention according to claim 11 is the semi-solid cast forging method according to any one of claims 5 to 10, wherein a cooling rate when passing through the liquidus is 2 ° C / s or more.
- the invention according to claim 12 is the semi-solid cast forging method according to any one of claims 5 to 11, wherein the temperature of the lower mold is 200 ° C ⁇ 100 ° C. *
- the invention according to claim 13 is the semi-solid cast forging method according to any one of claims 5 to 12, wherein the temperature of the upper die is different from the temperature of the lower die.
- the invention according to claim 14 is the semi-solid cast forging method according to claim 13, wherein the temperature of a part or all of the upper die is lower than the temperature of the lower die.
- the invention according to claim 15 is the semi-solid cast forging method according to any one of claims 5 to 14, wherein (product mass) / (raw material mass) is 0.9 or more.
- the invention according to claim 16 is the semi-solid cast forging method according to any one of claims 5 to 14, wherein another member is embedded in the semi-solid slurry to make a product made of a composite material.
- the invention according to claim 17 is the semi-solid cast forging method according to claim 15, wherein a pin rod is inserted into the upper mold and another member is detachably held at the tip of the pin rod.
- the invention according to claim 18 is the semi-solid cast forging method according to claim 17, wherein the other member is held on the pin rod by a magnetic force or a vacuum chuck force.
- the invention according to claim 19 is the semi-solid cast forging method according to any one of claims 5 to 18, wherein a powder release agent is used as the release agent.
- the invention according to claim 20 is a semi-solid cast forged product having a spherical structure of 50 ⁇ m or less and partially having a forged structure.
- the invention according to claim 21 is the semi-solid cast forged product according to claim 20, wherein another member is embedded in the main body, and the other member is embedded at the time of molten metal forging.
- the invention according to claim 22 is the semi-solid cast forged product according to claim 20, wherein the structure in the vicinity of the other member is a forged structure.
- the invention according to claim 23 is the semisolid cast forged product according to any one of claims 19 to 22, wherein the semisolid cast forged product is a connecting rod.
- the invention according to Claim 24 is a semi-solid cast forged product formed by the method according to any one of Claims 5 to 19.
- the present invention relates to a hot water forging device, which is a device for performing mold forming in a semi-solid state therein.
- the molten metal forging device after pouring the molten metal into the mold, clamps the mold, waits for it to reach the solid state, and after reaching the solid state, applies a load to part or the whole as required to shrink The space of minutes is not generated.
- This technique is different from forging.
- the molding is not performed with a large forging pressure.
- the mold only functions as a container for holding the molten metal until solidification.
- a pressure is applied to a part or all of the solid phase, the amount of processing is an amount corresponding to the amount of shrinkage and shrinkage, so the deformation resistance at the time of processing is small, and therefore work hardening hardly occurs. Therefore, the conventional molten forging apparatus does not need to increase the moving speed of the mold, and therefore the moving speed of the mold is designed to be slow.
- the present invention is a molten metal forging device for pouring a molten metal into a cavity of a lower mold, moving the upper mold or the lower mold, and performing molding in a semi-solid state.
- the molten metal is poured into the cavity of the lower mold.
- a semi-solid slurry is formed in the lower mold cavity.
- the present invention has one feature in forming a semi-solid slurry in the lower mold cavity. That is, a semi-solid slurry is not formed outside the mold, and the mold is formed when the slurry is placed on the lower mold.
- the present invention has one feature in forming a semi-solid slurry in the lower mold cavity. That is, it does not form a semi-solid slurry outside the mold and transfer the slurry onto the lower mold to perform mold forming.
- a further feature of the present invention is that the properties of the slurry are controlled when the slurry is formed in the lower mold. Conventionally, there is no technique for controlling the properties of the slurry when forming the slurry in the mold. *
- the properties of the slurry can be controlled by controlling the pouring temperature of the lower mold cavity (preferably the melting point plus 5-50 ° C. or less, more preferably the melting point plus 5-30 ° C. or less) from the molten metal after pouring.
- the amount of heat removal and the heat removal rate are controlled so that the degree of supercooling is a certain level or more and the particle size of the particles in the slurry is controlled to 50 ⁇ m or less. What is necessary is just to design considering the heat capacity of the mold, the thermal conductivity, the lower mold temperature, the latent heat of the molten metal, and the like. It is preferable to perform the pouring from a certain height above the bottom of the lower mold cavity so that self-stirring occurs after pouring.
- the pouring from a height that is twice or more the height direction of the space inside the mold formed when the upper mold and the lower mold are combined.
- pouring was performed from a height of 3.5 times or more the average diameter D of the lower mold from the bottom of the lower mold.
- the average diameter may be set to 1/2 the product area of the lower mold. “The height at which self-stirring occurs depending on the product shape may be obtained in advance by experimentation.”
- crystal grain size, strength, and mold filling degree in the product vary depending on the time from pouring to the start of mold forming.
- the conventional molten metal forging is a die forging in the sense of compensating for shrinkage shrinkage, it always has a holding time after pouring.
- a slurry having a particle size of 50 ⁇ m or less may be formed instantaneously after pouring.
- the slurry in that state contains many nuclei without disappearing.
- the present inventor conducted a search for specific conditions for semi-solid cast forging. Depending on the conditions of the semi-solid slurry in the mold (and hence the preparation conditions thereof), even if the raw material mass was significantly reduced, It has been found that a product having no part and a good metal structure may be obtained.
- the molten metal is poured into the lower die of the press controlled so that the solid phase ratio becomes a desired constant value so that supercooling occurs.
- the number of nuclei generated by controlling the degree of supercooling, and hence the grain size of crystals (for example, primary crystals) in the semi-solidified slurry.
- the molten metal temperature during pouring should be 10 to 30 ° C. higher than the liquid phase temperature. Is preferred. If it is less than 10 ° C., solidification may start before the generation of nuclei, and if it exceeds 30 ° C., the generated nuclei may disappear due to latent heat.
- the degree of supercooling can be controlled by adjusting the temperature of the lower mold, it is possible to form a semi-solid slurry having crystals of 30 ⁇ m or less and 10 ⁇ m or less that are finer than 50 ⁇ m or less.
- the lower mold temperature tends to cause overcooling. Therefore, in actual production, the crystal grain size can be adjusted by conducting an experiment in advance to change the temperature of the lower mold.
- the cooling rate when passing through the liquidus is preferably 2 ° C./s or higher, more preferably 20 ° C./s or higher.
- the cooling rate is 2 ° C./s or more, the temperature difference between the surface portion and the inside of the molten metal is eliminated in a short time. That is, the entire temperature becomes uniform in a short time. Therefore, the generated nuclei are not unevenly distributed and are considered to be more distributed throughout.
- the semi-solid slurry is prepared by controlling so that supercooling occurs.
- Semi-solid slurry has little variation in temperature distribution, so that nuclei are evenly distributed and solidification hardly occurs locally. Therefore, fine crystal grains (primary crystals) are uniformly and densely distributed.
- solidification occurs locally due to surface tension when flowing in a liquid state, and the solidified portion serves as a flow stopper, so that the thin portion is difficult to be filled.
- the semi-solid slurry of the present invention it is presumed that local solidification hardly occurs because the semi-solid slurry preferably moves as it rolls because it has fine crystal grains of 50 ⁇ m or less as a whole.
- the present inventor made such a semi-solid slurry and tried an experiment, but the thin portion was not always filled.
- the particle size is measured by taking the average of the major axis and the single diameter.
- the present inventor has found that the press speed has an effect, and when the press speed is changed, if the compression is performed in the range of 0.1 to 1.5 m / s, the thin wall becomes thin.
- the present invention has been found out that even if there is a part, it can be filled. What is important in the pressing speed is that the speed after the upper die comes into contact with the semi-solid slurry is in the range of 0.1 to 1.5 m / s. From the start of mold movement until the upper mold contacts the semi-solid slurry, it moves through the space without resistance. However, depending on the capacity of the press device, the semi-solid slurry may exist and it may become resistance and speed may decrease. . This is especially true when the solid phase ratio is high. Therefore, it is necessary to keep the pressing speed after the upper die contacts the semi-solid slurry at 0.1 m / s or more.
- the pressing speed during that time is also preferably 0.1 to 1.5 m / s. If the upper mold comes into contact with the semi-solidified slurry having fine crystal grains of 50 ⁇ m or less and the pressing speed after the compression by pressurization (that is, the pressurization speed) is increased, it becomes semi-solid. The apparent viscosity of the coagulated slurry decreases. Such a decrease in apparent viscosity occurs only when the particle diameter is as fine as 50 ⁇ m or less. This is because when the pressurization rate is increased, the shear rate also increases.
- the particle size is fine, the viscosity is small, and by increasing the press speed, the viscosity can be further lowered and the fluidity can be increased. Even a product having a part can be molded. In particular, it is assumed that the remarkable molding effect that molding is possible even when (product mass) / (raw material mass) is close to 90% is due to such a decrease in viscosity.
- the viscosity does not decrease even when the crystal grain size is as small as 50 ⁇ m or less (product mass) / (raw material mass) is not necessarily good z. . Therefore, it is set to 0.1 m / s or more.
- 0.5 m / s or more is more preferable.
- the above effect is saturated and an impact on the mold occurs, and there is a possibility of gas entrainment, so that it is 1.5 m / s or less.
- the flow limit solid phase ratio varies depending on the material. Conventionally, for example, there is no aluminum alloy made at 80%.
- the apparent viscosity can be lowered by reducing the particle size to 50 ⁇ m or less and increasing the pressing speed to 0.1 m / s or more. The rate becomes high, and it becomes possible to use a semi-solid slurry having a high solid phase rate.
- the portion where solidification has started upon contact with the mold surface becomes a forged structure similar to the processed structure by plastic deformation, and a product having a cast structure and a forged structure can be obtained.
- the solid phase ratio may be determined according to the desired product structure. For example, it may be appropriately determined within a range of 20 to 90%.
- the temperature of the lower mold is preferably 200 ° C. ⁇ 100 ° C.
- the temperature may be appropriately adjusted so that the heat balance (thermal equilibrium) described later can be obtained by the heat capacity (varies depending on the volume and material) of the lower mold.
- the metal structure of the product can be appropriately adjusted according to other conditions.
- the temperature of part or all of the upper mold can be set lower than the temperature of the lower mold.
- the temperature of the upper mold is set lower than that of the lower mold, heat is also removed from the upper mold, so the temperature difference between the upper and lower sides of the semi-solid slurry can be reduced. it can. That is, when there is a temperature difference between the upper and lower surfaces of the semi-solidified slurry, a difference occurs in the generation and disappearance of nuclei, and as a result, the structure of the product becomes non-uniform.
- the heat capacity of the mold is large or the heat transfer coefficient is large. Therefore, if the heat removal amount is too large, the heat removal amount can be adjusted by using a powder release agent.
- the powder release agent plays a role of heat resistance because it has a larger heat transfer coefficient than the water-soluble release agent.
- the water-soluble mold release agent lowers the mold temperature and makes it difficult to adjust the heat balance. Therefore, a powder mold release agent is preferable.
- an excellent product having excellent mechanical properties and having a fine structure can be produced not only for a thin product but also for a thick product without using a complicated process or apparatus.
- Forming device 12 Bed 14 Column 20 Slide 22 Hydraulic cylinder 24 Upper die 32 Bolster 34 Lower die 50d Product 51 Other member (ball) 53 pin rod
- FIG. 1 is an overall configuration diagram showing an example of a forming apparatus applied to an aluminum alloy forming method according to the present invention.
- This device is a simplified version of the device disclosed in Japanese Patent Application Laid-Open No. 2007-118030.
- a molding apparatus 10 shown in FIG. 1 is, for example, a hydraulic press, and a frame is constituted by a bed 12, a column 14, and a crown 16, and a slide 20 is movable in a vertical direction by a guide portion 18 provided on the column 14. Guided. A driving force is transmitted to the slide 20 by a first hydraulic cylinder 22 provided on the crown 16, and the slide 20 is moved in the vertical direction in FIG. An upper mold 24 is attached to the lower end of the slide 20.
- a lower die 34 is attached on a bolster 32 provided on the bed 12 of the molding apparatus 10.
- the molten metal, semi-solid slurry, and semi-solid preform billet arranged in the space in the lower mold 38 are compressed to form a product.
- the heat capacity of the lower mold 34 is designed.
- the heat capacity of the lower mold, the heat capacity of the molten metal to be poured, and the soaking heat are calculated in advance so that the specific solid fraction can be selected arbitrarily when the lower mold and the poured material reach a thermal equilibrium state.
- the lower mold dimensions, the molten metal temperature, the lower mold temperature, the molten metal amount, and the like were designed so that the heat balance was achieved at a predetermined solid phase ratio.
- Tc is the melt initial temperature
- those Tm is the lower mold initial temperature
- H ⁇ f obtained by dividing the latent heat of solidification in the specific heat
- fs is the solid fraction.
- ⁇ is obtained by dividing the amount of heat necessary for increasing the temperature of the lower mold by 1K by the amount of heat necessary for increasing the temperature of the molten metal by 1K, and is given by the following equation.
- ⁇ ( ⁇ m c m V m ) / ( ⁇ c c c V c ) ⁇ (2)
- ⁇ is the density
- c is the specific heat
- V is the volume
- the subscript c indicates the molten metal
- the subscript m indicates the lower mold.
- the molten metal When pouring the molten metal into the lower mold, the molten metal was poured from the bottom of the lower mold at a height of 3.5 times the average diameter D of the lower mold.
- the average diameter is 1/2 the product area of the lower mold.
- the product shape is not particularly limited, but the bottom surface of the lower mold is preferably flat. Even if the bottom surface has a shape with a height, the height difference is preferably 1 ⁇ 2 or less, more preferably 1 ⁇ 4 or less of the thickness of the product.
- the molten metal accumulates in a low part, and an imbalance occurs in the compression rate.
- the metal subject to the present invention is not particularly limited.
- low melting point alloys such as aluminum alloys are effective.
- Al-Si-based (ADC1), Al-Si-Mg-based (ADC3), Al-Si-Cu-based (ADC10, 10Z, ADC12, 12Z, ADC14), Al-Mg-based (ADC5, 6) etc. are also preferably used.
- magnesium alloys zinc alloys and other alloys in addition to aluminum alloys.
- the solid phase ratio is high, the fluidity is deteriorated, a high pressure is required for injection, and it is difficult to fill the thin portion in the mold.
- the solid phase ratio is preferably 30% or more.
- press pressure will become high when it exceeds 60%, 60% or less is preferable.
- the cooling rate when passing through the liquidus is preferably 2 ° C./s or more.
- the cooling rate is preferably 2 ° C./s or more, and particularly when it is 20 ° C./s or more, very fine particles (particle size 2 to 4 ⁇ m) are distributed.
- the presence of the fine particles is considered to enable the production of a die-cast product that is thinner and has little gas entrainment and almost no nest.
- Example 1 In this example, a connecting rod was created.
- the upper mold 24 and the lower mold 34 shown in FIG. 2 were used.
- the optimum conditions were obtained in advance so that the melt temperature in the mold was a semi-solid slurry having an appropriate solid phase ratio, and semi-solid cast forging was performed.
- the process of semi-solid cast forging is as follows. 1-Setting of molten metal temperature and mold temperature 2-Pouring of the lower mold 3-Movement to the mold clamping position 4-Clamping 5-Filling 6-Molding completed 7-Mold opening 8-Removing the molded product
- the molten metal was poured into the space of the lower mold 34.
- the upper mold 24 was lowered and the semi-solid slurry was compressed to form a product.
- the molding machine was a 20-ton hydraulic servo press manufactured by Koei Seisakusho, and the mold temperature was set to 250 ° C. for both the lower mold 34 (fixed side) and the upper mold 24 (movable side), and the molten metal temperature was set to 620 ° C. (AC4CH).
- the molten metal was poured into the lower mold 34 and the upper mold 24 was lowered at a speed of 0.1 m /.
- Example 2 a product made of a composite was formed. That is, a product in which balls 51 were embedded as other members at both ends of the connecting rod was formed.
- a pin rod 53 that holds the ball 51 is inserted into the upper mold 25.
- the holding of the ball 51 by the pin rod may be a holding by a magnetic force, a holding by a vacuum chucking force or other methods.
- Example 2 In the same manner as in Example 1, the molten metal was poured into the lower mold 34 (FIG. 6), and then the upper mold 24 was lowered. The ball 51 was lowered together with the upper die 34 and embedded in the semi-solid slurry (FIG. 7). The balls 51 remain on the product side as the semi-solid slurry is solidified. At that time, more than half of the ball is embedded in the body. Therefore, since the diameter of the ball is larger than the diameter of the entrance portion, the ball is not detached. In addition, when embedding a member having a shape other than a spherical shape, if a suitable case is bent, it will not be detached.
- FIG. 8 shows an appearance photograph of the semi-solid molded product and the observation result of the metal structure of the molded product (connecting rod).
- the primary crystal ⁇ is slightly irregular in size, but the average particle size is about 50 ⁇ m.
- a degree of spherical structure was observed throughout the molded article. As a result, shrinkage foci and segregation were hardly observed, and good ones were obtained. Since the final product has a spherical crystal structure of 50 ⁇ m, the crystal grain size in the semi-solidified slurry stage is smaller than this.
- a plastic flow is observed in the high load portion (ball portion) of the connecting rod, and a fine structure that can be expected to have high strength is formed. That is, this portion is considered to be a forged structure due to high load and solidification due to the low temperature resulting in plastic deformation.
- a forged structure can also be formed in the cast structure as described above.
- an excellent cast product having no shrinkage nest and non-metallic inclusions and having a fine structure can be produced not only for a thin product but also for a thick product. Therefore, the present invention can be used not only in the field of electronic and electrical parts but also in, for example, automobile parts.
- the present invention is not limited to the connecting rod and can be applied to any shape.
- the present invention can be applied to a cross-sectional H-shaped member, a cross-sectional I-shaped member, a thorn-shaped member, a cross-shaped member, an aluminum wheel, and other products, and the industrial application field is not limited.
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Abstract
Description
レオキャスト法は、合金を液体状態から撹拌しながら冷却して、初晶を粒状に成長させて所定の固相率に到達した時点で成形する方法で、半凝固ダイカスト法とも呼ばれる。
一方、チクソキャスト法は、合金を溶融した後に撹拌しながら一旦凝固させてビレットを製作し、鋳造の際に再度ビレットを加熱して固液共存状態にしてから成形する方法であり、半溶融ダイキャスト法とも呼ばれる。
チクソキャスト法は、組織調整された特殊なビレットが高価であるという問題点がある。また、ビレットを再溶融して半溶融スラリーとしたものを鋳造するため、省エネルギーに欠けるという問題点がある。さらに、一度鋳造したものは再溶解して使用できないため、リサイクルできないという問題もある。そのため、現在はレオキャストが主流である。
しかしながら、NRC法は、半凝固スラリーの生成に時間を要し、設備が大きく高価であることと核発生数が十分でないため球状結晶の微細化に限界があった。
特許文献5記載技術は、半凝固状態になった塊状混合物(ビレット)を、塊状混合物より低い温度に加熱されている下型の中央に設置し、ついで、上型を下型に接近させることで半凝固状態にある塊状混合物を圧縮変形させている。
また、薄肉部(例えば1mm以下の厚み部)を有する製品の場合、薄肉部には余肉を付しておく必要があるため、その部分は切削加工せざるを得ず、そのための工程もコスト高の要因となってしまう。
特許文献6(特開平4-182054号公報)では、プレス型内に金属材料の溶湯を注湯後、全体に予圧をかけた状態で一定時間保存し、凝固開始から凝固終了後300℃低下するまでの間金属材料の少なくとも一部に付加的圧力を加えて変形を与える溶湯鍛造技術が開示されている。
また、非特許文献1には、製品形状に近い金属容器の中に半凝固スラリーを生成し、半凝固スラリーを金型に投入し、金型により圧縮成形を行う技術が開示されている。
この方法によれば球状組織は得られるが、一旦半凝固スラリーを作成し、それを金型に移す工程が必要である。また、製品質量に対する原料質量が大きく、この技術も原料面からコスト高となる。
本発明は、湯鍛造装置に係り、その中の半凝固状態で型成形を行うための装置である。
すなわち、図9に示すように、注湯温度を720℃、660℃、640℃と変化させたところ、640℃の場合は、それ以上の温度の場合に比べて短時間で全体が均一温度になった。
なお、図に示す実験は、AC4CHで行った。
薄肉部を有する場合には、液体状態で流動すると表面張力のため局部的に凝固が生じ、凝固部が流動のストッパーとなるため薄肉部は充填されがたい。それに対して、本発明の半凝固スラリーの場合は、好ましくは粒径が50μm以下という微細な結晶粒を全体的に有しているため転がるように移動するため局部的凝固が生じにくいと推測される。その結果、薄肉部があったとしても充填される。そのため、余分な肉を設けなくともよく、材料の節約となり、また、余肉の切削という工程を省略することができる。
本発明者は、かかる半凝固スラリーを作成して実験を試みたが、必ずしも、薄肉部が充填されない場合があった。なお、粒径は、長径と単径との平均をとって測定する。
プレス速度で重要なことは、上型が半凝固スラリーと接触した以降の速度が0.1~1.5m/sの範囲内であることである。型の移動開始から、上型が半凝固スラリーに接触するまでは空間を抵抗なく移動するが、プレス装置の容量によっては、半凝固スラリーが存在するためそれが抵抗となり速度が低下することがある。特に、固相率が高い場合は、そのようになりやすい。従って、上型が半凝固スラリーに接触後のプレス速度が0.1m/s以上に維持されるようにしておく必要がある。
50μm以下の微細な結晶粒を有している半凝固スラリーに、上型が半凝固スラリーと接触し、加圧による圧縮が始まった後のプレス速度(すなわち、加圧速度)を高速にすると半凝固スラリーの見かけ粘度は低下する。かかる見かけ粘度の低下は50μm以下という微細な粒径の場合にのみ生ずることである。これは、加圧速度を高速にするとせん断速度も上昇するため、チクソトロピー状態の液体試料に与える歪みのせん断速度を上昇させたときに徐々に粘度が下がるという現象が本半凝固スラリーにおいても生じているためではないかと推測される。その結果、固相率が高い半凝固スラリーであっても流動性が確保される。
12 ベッド
14 コラム
20 スライド
22 油圧シリンダ
24 上型
32 ボルスタ
34 下型
50d 製品
51 他の部材(ボール)
53 ピンロッド
図1は本発明に係るアルミニウム合金の成形方法に適用される成形装置の一例を示す全体構成図である。この装置は、特開2007-118030号公報において開示されている装置をシンプルにしたものであらう。
図1に示す成形装置10は、例えば、油圧プレスであり、ベッド12、コラム14及びクラウン16でフレームが構成され、スライド20は、コラム14に設けられたガイド部18により鉛直方向に移動自在に案内されている。スライド20は、クラウン16上に設けられた第1油圧シリンダ22によって駆動力が伝達され、図1上で上下方向に移動させられる。このスライド20の下端には上型24が取り付けられている。
スライド20を下降させることにより下型38内の空間部に配置された溶湯、半凝固スラリー、半凝固プレフォームビレットを圧縮加工し、製品を形成する。
下型34の熱容量が設計される。
γ=(ρmcmVm)/(ρcccVc) -(2)
ここで、ρは密度、cは比熱、Vは体積であり、添字cは溶湯、添字mは下型のものであることを示す。
一般的には、固相率が高いと流動性が悪くなり、射出には高い圧力を要し、金型内の薄肉部を充填することは困難になると考えられている。
固相率としては30%以上が好ましい。ただ、60%を超えるとプレス圧力が高くなってしまうため、60%以下が好ましい。
冷却速度は2℃/s以上が好ましく、特に20℃/s以上の場合には、非常に微細な(粒径2~4μm)な粒子が分布する。この微粒子の存在が、より薄肉でかつガスの巻き込み、巣がほとんど無いダイカスト製品の製造を可能としていると考えられる。
本例では、コンロッドの作成を行なった。
型は、図2に示す上型24と下型34とを用いた。
あらかじめ金型内における溶湯温度が適正な固相率をもつ半凝固スラリーになるよう最適条件を求め、半凝固鋳鍛造成形を行った。
半凝固鋳鍛造成形の工程を次に示す。
1-溶湯温度・金型温度の設定
2-下金型への注湯
3-型締め位置への移動
4-型締め
5-充填
6-成形完了
7-型開
8-成形品の取り出し
次いで、図4に示すように、上型24を下降させ、半凝固スラリーを圧縮し、製品を形成した。
成形機は光栄製作所製20ton油圧サーボプレスを用い金型温度は下型34(固定側)、上型24(可動側)のいずれも250℃とし、溶湯温度は620℃(AC4CH)に設定した。
溶湯を下型34へ注湯し、上型24を0.1m/の速度で下降させた。上型24が半凝固スラリーに接触後もそのままの速度、すなわち、0.1m/sの速度を維持してプレス成形を行った。
凝固後型から製品50dを取り出した。
なお、成形条件を整理した結果を下記に示す。
溶湯材質
:AC4CH
液相線温度TL :610~612℃
固相線温度Ts :555℃
注湯温度
:620℃
上型の温度 :250℃
下型の温度 :250℃
型締め速度
:0.1m/s
(製品質量)/(原料質量):0.9/1
固相率
:60%
下型への注湯高さ:下型キャビティ底面から50cmの高さ
本例では、複合物からなる製品を形成した。すなわち、コンロッドの両端に他の部材としてボール51を埋め込んだ製品を形成した。
本例では、図5に示すように、上型25にボール51を保持するピンロッド53を挿入した。ピンロッドによるボール51の保持は、磁気力による保持でもよいし、真空チャック力その他の手法による保持でもよい。
このように、本発明では、複雑な形状を有する部材であっても母材側(半凝固スラリー)に埋め込むことが可能であるので、溶接などを行わなくとも強固な結合を有する複合部材を形成することができる。
他の点は実施例1と同様とした。
最終製品において50μmの球状結晶組織を有しているため、半凝固スラリー段階での結晶の粒径はこれより小さい。
なおコンロッドの高負荷部分(ボール部)には塑性流動が見られ、高強度を期待できる微細な組織が形成されている。すなわち、この部分は、高負荷であるとともに、低温であったために固化して塑性変形が生じて鍛造組織になったものと考えられる。
本発明では、このように、鋳造組織内に鍛造組織を形成することもできる。
本発明は、コンロッドに限らず、あらゆる形状に適用可能である。例えば、断面H状部材、断面I状部材、オカマ形状の部材、十字形状の部材、アルミホイールその他の製品に適用が可能であり、産業上の利用分野も限定されない。
Claims (24)
- 下型のキャビティー内に溶湯を注湯し、上型又は前記下型を移動させ、半凝固状態で成型を行うための溶湯鍛造装置であって、前記注湯後前記成型開始までの時間が0.1-10秒となるように前記速度が調整可能である半凝固溶湯鍛造装置。
- 前記注湯後前記成型開始までの時間が0.1-5秒となるように前記速度が調整可能である請求項1記載の半凝固溶湯鍛造装置。
- 前記キャビティー内に前記溶湯を注湯する際における上型と下型との距離は30-50cmである請求項1又は2項記載の半凝固溶湯鍛造装置。
- 前記上型又は前記下型の速度が少なくとも0.03-5m/sの間で可変である請求項1乃至3のいずれか1項記載の半凝固溶湯鍛造装置。
- 下型のキャビティー内に溶湯を注湯し、上型又は前記下型を移動させ、半凝固状態で成型を行う半凝固溶湯鍛造方法であって、前記注湯後におけるスラリー中の粒径が50μm以下となるようにしてスラリーを作成し、前記注湯後0.1-10秒の範囲の時間内に型成形を開始する半凝固溶湯鍛造方法。
- 前記注湯後前記成型開始までの時間が0.1-5秒となるように前記速度が調整可能である請求項5記載の半凝固溶湯鍛造方法。
- 固相率が所望する一定の値となるように制御されたプレスの下型内に、過冷却が生じるように溶湯を注湯して、半凝固スラリーを作成後、少なくとも上型が前記半凝固スラリーに接触して以降の速度が0.1~1.5m/sの速度で上型ないし前記下型を移動させることにより前記半凝固スラリーを圧縮して製品を形成する半凝固鋳鍛造法。
- 固相率が所望する一定の値となるように制御されたプレスの下型内に、過冷却が生じるように溶湯を注湯して、圧縮により流動性が上がる粒径の結晶粒を有する半凝固スラリーを作成後、少なくとも上型が前記半凝固スラリーに接触して以降の速度が0.1~1.5m/sの速度で上型ないし前記下型を移動させることにより前記半凝固スラリーを圧縮して製品を形成する半凝固鋳鍛造法。
- 固相率が所望する一定の値となるように制御されたプレスの下型内に、過冷却が生じるように溶湯を注湯して、粒径が50μm以下の結晶粒を有する半凝固スラリーを作成後、少なくとも上型が前記半凝固スラリーに接触して以降の速度が0.1~1.5m/sの速度で上型ないし前記下型を移動させることにより前記半凝固スラリーを圧縮して製品を形成する半凝固鋳鍛造法。
- 注湯時における溶湯温度は、液相温度より10~30℃高い温度である請求項5ないし9のいずれか1項記載の半凝固鋳鍛造法。
- 液相線を通過する際における冷却速度は2℃/s以上である請求項5ないし10のいずれか1項記載の半凝固鋳鍛造法。
- 前記下型の温度は、200℃±100℃である請求項5ないし11のいずれか1項記載の半凝固鋳鍛造法。
- 前記上型の温度と前記下型の温度とは異なっている請求項5ないし12のいずれか1項記載の半凝固鋳鍛造法。
- 前記上型の一部又は全部の温度は前記下型の温度より低い温度である請求項13記載の半凝固鋳鍛造法。
- (製品質量)/(原料質量)が0.9以上である請求項5ないし14のいずれか1項記載の半凝固鋳鍛造法。
- 半凝固スラリー中に他の部材を埋込んで、複合材からなる製品とする請求項5ないし15のいずれか1項記載の半凝固鋳鍛造法。
- 前記上型にピンロッドを挿入し、該ピンロッドの先端に他の部材を着脱可能に保持させておく請求項16記載の半凝固鋳鍛造法。
- 前記他の部材を、磁気力又は真空チャック力により前記ピンロッドに保持する請求項16記載の半凝固鋳鍛造法。
- 離型剤として、粉末離型剤を用いる請求項5ないし18のいずれ1項記載の半凝固鋳鍛造法。
- 50μm以下の球状組織を有するとともに、一部に鍛造組織を有する半凝固鋳鍛造品。
- 本体に他の部材が埋め込まれており、当該他の部材は、溶湯鍛造時に埋め込まれたものである請求項19記載の半凝固鋳鍛造品。
- 前記他の部材近辺における組織は鍛造組織である請求項21記載の半凝固鋳鍛造品。
- 前記半凝固鋳鍛造品はコンロッドである請求項19乃至22のいずれか1項記載の半凝固鋳鍛造品。
- 請求項5乃至19のいずれか1項記載の方法により形成した半凝固鋳鍛造品。
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JP6253730B1 (ja) * | 2016-08-04 | 2017-12-27 | 有限会社ティミス | 半凝固スラリの鍛造システム |
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CN107199321B (zh) * | 2017-06-02 | 2018-11-06 | 重庆大学 | 一种时变控制半固态成形工艺 |
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CN109175291A (zh) * | 2018-09-13 | 2019-01-11 | 河南科技大学 | 一种中小型锌基合金轴套的半熔态微压模铸制备方法 |
CN114799131A (zh) * | 2022-04-22 | 2022-07-29 | 南京航空航天大学 | 一种金属材料的负压引流式铸锻成形装置与方法 |
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JPWO2015053373A1 (ja) | 2017-03-09 |
US10118219B2 (en) | 2018-11-06 |
JP6284048B2 (ja) | 2018-02-28 |
TW201519973A (zh) | 2015-06-01 |
US20160228946A1 (en) | 2016-08-11 |
TWI665035B (zh) | 2019-07-11 |
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