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EP0759825B1 - Process for manufacturing diecast parts - Google Patents

Process for manufacturing diecast parts Download PDF

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Publication number
EP0759825B1
EP0759825B1 EP96908074A EP96908074A EP0759825B1 EP 0759825 B1 EP0759825 B1 EP 0759825B1 EP 96908074 A EP96908074 A EP 96908074A EP 96908074 A EP96908074 A EP 96908074A EP 0759825 B1 EP0759825 B1 EP 0759825B1
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EP
European Patent Office
Prior art keywords
parting compound
parting
plunger
additives
additive
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.)
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EP96908074A
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German (de)
French (fr)
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EP0759825A1 (en
Inventor
Jean-Pierre Gabathuler
Ivan GYÖNGYÖS
Hans-Günther THURNER
Jürgen Wüst
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Magna BDW Technologies GmbH
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Magna BDW Technologies GmbH
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Priority to EP96908074A priority Critical patent/EP0759825B1/en
Publication of EP0759825A1 publication Critical patent/EP0759825A1/en
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Publication of EP0759825B1 publication Critical patent/EP0759825B1/en
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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
    • 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
    • B22D17/2015—Means for forcing the molten metal into the die
    • B22D17/2038—Heating, cooling or lubricating the injection unit
    • 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
    • B22D17/14—Machines with evacuated die cavity
    • 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
    • B22D17/2007—Methods or apparatus for cleaning or lubricating moulds

Definitions

  • the invention relates to a method for producing die-cast parts made of a light metal alloy.
  • Die casting process for the production of light metal parts for all types of industrial reuse, for example in the automotive industry or in device manufacturing have been special in recent years therefore have been further developed to large quantities to be able to manufacture inexpensively.
  • These include the so-called “Squeezecasting", in which a densification in the Form takes place, or the so-called developed by the applicant "MFT” method according to DE-OS 23 23 426 and DE-PS 30 02 886, which significantly evacuates the mold hollow body rapidly has improved. This made a faster firing order and a large throughput possible.
  • US Pat. No. 5,076,344 describes a method in which a Standard aluminum alloy in the molten state over one Riser pipe is filled into a casting chamber. From there the molten aluminum alloy with the help of a plunger an evacuated mold cavity and introduced into the casting chamber. In the mold cavity the concentration of the release agent is an alkali halide, 0.5 to 3 wt .-%, while in the Casting chamber the release agent, which is also used here as lubricant is used in a concentration of 2 to 7% by weight is present.
  • This method is preferred as a release agent an aqueous potassium iodide solution is used.
  • the release agent, that applied to the mold or to the plunger is prevented that the aluminum alloy on the walls of the Mold cavity or the plunger and the casting chamber stick remains. The release agent thus causes a continuous and trouble-free process flow.
  • alkali halides in particular Potassium iodide
  • this salt is the steel-containing device parts in which the method is carried out is corroded. Even the filling process, which is about a riser pipe is cumbersome.
  • Another Problem this method known from the prior art is that the quality of die casting by gas inclusions and others Contamination is reduced. The corrosion of the steel can lead to contamination in the metal alloy, since Detach corroded particles and particles from the steel surface can.
  • the processors of these light metal parts are now expecting them additionally improved material properties, such as higher Strength, lower weights, thin walls, complicated Geometry, further processability, such as weldability, heat treatability, or the possibility to use modern Connection technologies when installing and removing these parts.
  • the adverse effect of the alkali halides on the steel-containing parts of the process device can be reduced or avoided if the Release agent by adding corrosion-inhibiting additives bring a pH of at least 8. This has to Consequence that the process is continuous over a long period of time and can be carried out more effectively.
  • Additives are, for example, hexamethylenetetramine, to dicyclohexylamine nitrite or potassium hydroxide.
  • Hexamethylenetetramine and dicyclohexylamine nitrite are the release agents, such as indicated above, in a concentration of approximately 0.02 to 0.5 Vol .-% added, preferably in a concentration of 0.05 Vol .-% to 0.25 vol.%.
  • the Release agent in a further advantageous embodiment of the Invention additives added for stabilization.
  • a stabilizer is preferably sodium thiosulfate in a concentration from 0.01 to 0.5 vol.% added. This makes it clear Decreasing the quality of the release agent prevents what happens in turn affects the quality of the die-cast parts.
  • the release agent is preferred Sodium thiosulfate, which decomposes the release agent counteracts by UV radiation and / or organic additives, such as. Fungicides or bactericides that are responsible for formation counteract fungi or the like, added. So that is ensures long-term durability of the release agent according to the invention.
  • release agents can be used instead of alkali halides contain graphite dust.
  • Release agent Graphite bases were used 20 to 30 years ago. you However, use was made under the requirement of increased productivity, due to the heavy contamination of the casting device and the associated time-consuming cleaning and maintenance work more and more reduced. Object of the present invention However, as already mentioned, the procedure is not increased productivity, but increased quality of die casting. Taking this into account find the past improved graphite additives application. The improvement results in a smaller grain size of 1 - 1.5 ⁇ m, and the use of graphite additives in higher dilutions.
  • Another advantage of the method according to the invention is that the quality of the die casting by avoidance or reduction of the inclusions, for example, from cleavage products Release agents and lubricants arise, is improved. Thereby the ductility of the product is also significantly improved. This is significant improvement in die casting quality attributed to that used in the inventive method Vacuum is much higher than the vacuum that comes from known methods is used.
  • the vacuum according to the invention relates to a range below 50 mbar. This improved vacuum of the method according to the invention reached by the plunger an extension in the direction the piston movement axis. This extension causes at the exit of the piston on the side of the mold cavity one Sealing the casting chamber.
  • Casting chamber before filling the molten metal alloy heated so that pre-solidification is not possible in the first place is made of a material that has a low coefficient of thermal conductivity having. This is particularly useful here of ceramic materials.
  • the metal feed of the method according to the invention is also versus the feed known from the prior art is advantageous. While often in the prior art Vacural suction technology is used i.e. the metal supply over a riser pipe is carried out in the process according to the invention Metal using an ordinary ladle or dosing furnace introduced into the casting chamber. The use of a Ladle or a dosing oven is opposed to the use of a riser pipe is technically easier to handle.
  • the parts manufactured using the new process can do a lot be designed thin-walled and large area.
  • the good shaping properties leave the designer a great deal of freedom.
  • the lightweight material by saving weight.
  • the other requirements such as consistent quality series production, high ductility, weldability and thus also guaranteeing repairability. It will be too meets the conditions of crash safety.
  • Many types of joining techniques enable the combination with sheet metal or extruded profiles.
  • Lubricants are from the prior art known. However, hexamethylenetetramine and Dicyclohexylamine nitrite, each in a concentration of 0.02 up to 0.5 vol.% used.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Mold Materials And Core Materials (AREA)
  • Lubricants (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Casting Support Devices, Ladles, And Melt Control Thereby (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

PCT No. PCT/EP96/01182 Sec. 371 Date Nov. 18, 1996 Sec. 102(e) Date Nov. 18, 1996 PCT Filed Mar. 19, 1996 PCT Pub. No. WO96/29165 PCT Pub. Date Sep. 26, 1996Parts are diecast from a light metal alloy which in the molten state is fed under gravity into a casting chamber of a diecasting machine and whence forced by a plunger into a mould chamber which undergoes controlled evacuation in accordance with the position of a plunger. A parting compound is applied to at least one mold half and the application of a lubricant to the plunger. The light metal alloy consists of a primary alloy of invariable composition, with a limit placed on the proportions of Cu, Fe and Zn; the alloy undergoes smelting treatment, de-gassing and/or filtration before being introduced. The vacuum in the mould chamber is below 50 mbar when the molten alloy is introduced and the parting compound contains alkali halides and anti-corrosion additives.

Description

Die Erfindung betrifft ein Verfahren zur Herstellung von Druckgußteilen aus einer Leichtmetallegierung. Druckgießverfahren zur Herstellung von Leichtmetallteilen für alle Arten der industriellen Weiterverwendung, zum Beispiel im Automobilbau oder in der Geräteherstellung sind in den letzten Jahren insbesondere deshalb weiterentwickelt worden, um hohe Stückzahlen kostengünstig herstellen zu können. Hierzu gehören das sogenannte "Squeezecasting", bei dem eine Nachverdichtung in der Form erfolgt, oder das von der Anmelderin entwickelte sogenannte "MFT"-Verfahren gemäß DE-OS 23 23 426 und DE-PS 30 02 886, welches das schnelle Evakuieren des Formhohlkörpers erheblich verbessert hat. Dadurch wurde eine schnellere Schußfolge und ein großer Durchsatz möglich.The invention relates to a method for producing die-cast parts made of a light metal alloy. Die casting process for the production of light metal parts for all types of industrial reuse, for example in the automotive industry or in device manufacturing have been special in recent years therefore have been further developed to large quantities to be able to manufacture inexpensively. These include the so-called "Squeezecasting", in which a densification in the Form takes place, or the so-called developed by the applicant "MFT" method according to DE-OS 23 23 426 and DE-PS 30 02 886, which significantly evacuates the mold hollow body rapidly has improved. This made a faster firing order and a large throughput possible.

Daneben wurde der Produktionsprozeß hinsichtlich Trenn- und Schmiermittel für die Forminnenseiten und auch für den Preßkolben verbessert, was ebenfalls zur Erhöhung der Produktivität führte.In addition, the production process with regard to separation and Lubricant for the inside of the mold and also for the plunger improved, which also increases productivity led.

So beschreibt die US-PS 5 076 344 ein Verfahren, in dem eine Standardaluminiumlegierung in geschmolzenem Zustand über ein Steigrohr in eine Gießkammer eingefüllt wird. Von dort wird die geschmolzene Aluminiumlegierung mit Hilfe eines Preßkolbens in einen evakuierten Formhohlraum und in die Gießkammer eingebracht. Im Formhohlraum beträgt die Konzentration des Trennmittels, ein Alkalihalogenid, 0,5 bis 3 Gew.-%, während in der Gießkammer das Trennmittel, das hier gleichzeitig als Schmiermittel verwendet wird, in einer Konzentration von 2 bis 7 Gew.-% vorliegt. Bei diesem Verfahren wird als Trennmittel vorzugsweise eine wäßrige Kaliumjodidlösung verwendet. Das Trennmittel, das auf die Form bzw. auf den Preßkolben aufgebracht wird, verhindert, daß die Aluminiumlegierung an den Wänden des Formhohlraums bzw. des Preßkolbens und der Gießkammer haften bleibt. Das Trennmittel bewirkt somit einen kontinuierlichen und störungsfreien Verfahrensablauf.For example, US Pat. No. 5,076,344 describes a method in which a Standard aluminum alloy in the molten state over one Riser pipe is filled into a casting chamber. From there the molten aluminum alloy with the help of a plunger an evacuated mold cavity and introduced into the casting chamber. In the mold cavity the concentration of the release agent is an alkali halide, 0.5 to 3 wt .-%, while in the Casting chamber the release agent, which is also used here as lubricant is used in a concentration of 2 to 7% by weight is present. This method is preferred as a release agent an aqueous potassium iodide solution is used. The release agent, that applied to the mold or to the plunger is prevented that the aluminum alloy on the walls of the Mold cavity or the plunger and the casting chamber stick remains. The release agent thus causes a continuous and trouble-free process flow.

Der Nachteil an der Verwendung von Alkalihalogeniden, insbesondere Kaliumjodid, besteht darin, daß dieses Salz die stahlhaltigen Vorrichtungsteile, in denen das Verfahren durchgeführt wird, korrodiert. Auch das Einfüllverfahren, das über ein Steigrohr erfolgt, ist umständlich. Ein weiteres Problem dieses aus dem Stand der Technik bekannten Verfahrens ist, daß die Qualität des Druckgusses durch Gaseinschlüsse sowie andere Verunreinigungen vermindert wird. Die Korrosion des Stahls kann zu Verunreinigungen in der Metallegierung führen, da sich korrodierte Teilchen und Partikel von der Stahloberfläche ablösen können.The disadvantage of using alkali halides, in particular Potassium iodide, is that this salt is the steel-containing device parts in which the method is carried out is corroded. Even the filling process, which is about a riser pipe is cumbersome. Another Problem this method known from the prior art is that the quality of die casting by gas inclusions and others Contamination is reduced. The corrosion of the steel can lead to contamination in the metal alloy, since Detach corroded particles and particles from the steel surface can.

Zudem sind die bekannten Verfahren oftmals kompliziert aufgebaut und erfordern einen hohen konstruktiven Aufwand, welcher wiederum einen hohen Wartungsaufwand nach sich zieht. Dadurch werden diese Verfahren unwirtschaftlich.In addition, the known methods are often of complex construction and require a high level of design effort, which in turn entails a high level of maintenance. Thereby these processes become uneconomical.

Inzwischen erwarten die Weiterverarbeiter dieser Leichtmetallteile zusätzlich verbesserte Materialeigenschaften, wie höhere Festigkeit, geringere Gewichte, Dünnwandigkeit, komplizierte Geometrie, Weiterverarbeitbarkeit, wie Schweißbarkeit, Wärmebehandelbarkeit, oder die Möglichkeit zum Einsatz moderner Verbindungstechnologien beim Ein- und Ausbau dieser Teile. The processors of these light metal parts are now expecting them additionally improved material properties, such as higher Strength, lower weights, thin walls, complicated Geometry, further processability, such as weldability, heat treatability, or the possibility to use modern Connection technologies when installing and removing these parts.

Es besteht daher die Aufgabe, ein Verfahren verfügbar zu machen, welches den oben genannten Anforderungen genügt. Diese Aufgabe wird erfindungsgemäß ausgehend von einem bekannten Verfahren nach dem oberbegriff des Anspruchs 1; durch eine Kombination der folgenden Merkmale gelöst:

  • Es werden Primärlegierungen eingesetzt. Diese haben eine konstante Zusammensetzung, wobei die Anteile der Elemente Kupfer, Eisen und Zink begrenzt werden. Ausgangsmaterialien für diese Primärlegierungen sind beispielsweise AlSi7Mg0,3 mit einem Eutektikumanteil von ca. 35% mit hoher Duktilität und hoher Dauerfestigkeit sowie eutektische oder naheutektische Al-Si-Legierungen, verschiedene Al-Mg-Legierungen und hochreine Mg-Legierungen.
  • Diese Legierungen werden vor dem Einbringen einer Schmelzbehandlung, wie Entgasung und/oder Filtration unterworfen.
  • Das im Formhohlraum zum Zeitpunkt der Einbringung der geschmolzenen Legierung erzeugte Vakuum liegt unter 50 mbar.
  • Das vor dem Einbringen der Schmelze auf die Formflächen aufgebrachte Trennmittel umfaßt entweder Alkalihalogenide, denen ein Additiv zur Korrosionshemmung mit bis zu einem pH-Wert von mindestens 8 zugesetzt wird oder das Trennmittel besteht aus Graphitstaub mit einer Partikelgröße von 1 - 1,5 µm.
There is therefore the task of making a method available which meets the above requirements. This object is achieved based on a known method according to the preamble of claim 1; solved by a combination of the following features:
  • Primary alloys are used. These have a constant composition, with the proportions of the elements copper, iron and zinc being limited. Starting materials for these primary alloys are, for example, AlSi7Mg0.3 with a eutectic content of approx. 35% with high ductility and high fatigue strength, as well as eutectic or near-eutectic Al-Si alloys, various Al-Mg alloys and high-purity Mg alloys.
  • These alloys are subjected to a melt treatment, such as degassing and / or filtration, before introduction.
  • The vacuum created in the mold cavity at the time the molten alloy is introduced is below 50 mbar.
  • The release agent applied to the mold surfaces prior to the introduction of the melt either comprises alkali halides to which an additive for corrosion inhibition with a pH of up to at least 8 is added, or the release agent consists of graphite dust with a particle size of 1-1.5 μm.

Mit dieser Kombination lassen sich die Anforderungen erfüllen, wobei fast alle herkömmlichen Druckgießmaschinen an den neuen Verfahrensablauf leicht angepaßt werden können. Bevorzugt werden Maschinen, deren Gießkammer unter Ausnutzung der Schwerkraft gefüllt wird. With this combination, the requirements can be met, with almost all conventional die casting machines on the new Procedure can be easily adjusted. To be favoured Machines whose casting chamber takes advantage of gravity is filled.

Erfindungsgemäß wurde festgestellt, daß die nachteilige Wirkung der Alkalihalogenide auf die stahlhaltigen Teile der Verfahrensvorrichtung reduziert bzw. vermieden werden kann, wenn die Trennmittel durch Zusatz von korrosionshemmenden Additiven auf einen pH-Wert von mindestens 8 gebracht werden. Dies hat zur Folge, daß das Verfahren über eine längere Zeit kontinuierlich und effektiver durchgeführt werden kann. Bei den zugesetzten Additiven handelt es sich zum Beispiel um Hexamethylentetramin, um Dicyclohexylaminnitrit oder Kaliumhydroxid. Hexamethylentetramin und Dicyclohexylaminnitrit werden den Trennmitteln, wie oben angegeben, in einer Konzentration von ca. 0,02 bis 0,5 Vol.-% zugesetzt, bevorzugt in einer Konzentration von 0,05 Vol.-% bis 0,25 Vol.%.According to the invention it was found that the adverse effect of the alkali halides on the steel-containing parts of the process device can be reduced or avoided if the Release agent by adding corrosion-inhibiting additives bring a pH of at least 8. This has to Consequence that the process is continuous over a long period of time and can be carried out more effectively. With the added Additives are, for example, hexamethylenetetramine, to dicyclohexylamine nitrite or potassium hydroxide. Hexamethylenetetramine and dicyclohexylamine nitrite are the release agents, such as indicated above, in a concentration of approximately 0.02 to 0.5 Vol .-% added, preferably in a concentration of 0.05 Vol .-% to 0.25 vol.%.

Um eine Fällung oder ein Ausflocken des Trennmittels, insbesondere bei Verwendung von Kaliumjodid, zu verhindern, werden dem Trennmittel in einer weiteren vorteilhaften Ausgestaltung der Erfindung Additive zur Stabilisierung zugegeben. Als Stabilisator wird bevorzugterweise Natriumthiosulfat in einer Konzentration von 0,01 bis 0,5 Vol.% zugegeben. Damit wird eine deutliche Qualitätsminderung des Trennmittels verhindert, was sich wiederum auf die Qualität der Druckgußteile auswirkt.Precipitation or flocculation of the release agent, in particular when using potassium iodide, the Release agent in a further advantageous embodiment of the Invention additives added for stabilization. As a stabilizer is preferably sodium thiosulfate in a concentration from 0.01 to 0.5 vol.% added. This makes it clear Decreasing the quality of the release agent prevents what happens in turn affects the quality of the die-cast parts.

In einer weiteren vorteilhaften Ausgestaltung der Erfindung werden dem Trennmittel Additive zur Konservierung bzw. Haltbarmachung beigegeben. Bevorzugterweise werden dem Trennmittel Natriumthiosulfat, welches einer Zersetzung des Trennmittels durch UV-Strahlung entgegenwirkt und/oder organische Zuschlagstoffe, wie z.B. Fungizide oder Bakterizide, die der Bildung von Pilzen oder ähnlichem entgegenwirken, beigegeben. Damit ist eine Langzeithaltbarkeit des erfindungsgemäßen Trennmittels gewährleistet.In a further advantageous embodiment of the invention are additives for preservation or preservation of the release agent added. The release agent is preferred Sodium thiosulfate, which decomposes the release agent counteracts by UV radiation and / or organic additives, such as. Fungicides or bactericides that are responsible for formation counteract fungi or the like, added. So that is ensures long-term durability of the release agent according to the invention.

Alternativ können Trennmittel Anwendung finden, die anstelle von Alkalihalogeniden Graphitstaub enthalten. Trennmittel auf Graphitbasis wurden bereits vor 20 - 30 Jahren verwendet. Ihr Einsatz wurde aber unter der Vorgabe einer erhöhten Produktivität, aufgrund der starken Verschmutzung der Gießvorrichtung und der damit verbundenen zeitintensiven Reinigungs- und Wartungsarbeiten mehr und mehr reduziert. Aufgabe des vorliegenden erfindungsgemäßen Verfahrens ist jedoch, wie bereits erwähnt, nicht eine erhöhte Produktivität, sondern eine erhöhte Qualität des Druckgusses. Unter diesem Aspekt finden gegenüber der Vergangenheit verbesserte Graphitzusätze Anwendung. Die Verbesserung resultiert in einer geringeren Korngröße von 1 - 1,5 µm, sowie die Verwendung von Graphitzusätzen in höheren Verdünnungen.Alternatively, release agents can be used instead of alkali halides contain graphite dust. Release agent Graphite bases were used 20 to 30 years ago. you However, use was made under the requirement of increased productivity, due to the heavy contamination of the casting device and the associated time-consuming cleaning and maintenance work more and more reduced. Object of the present invention However, as already mentioned, the procedure is not increased productivity, but increased quality of die casting. Taking this into account find the past improved graphite additives application. The improvement results in a smaller grain size of 1 - 1.5 µm, and the use of graphite additives in higher dilutions.

Unter dem Gesichtspunkt erhöhter Qualität kann, wiederum alternativ, anstatt der oben erwähnten Alkalihalogenide ein von der amerikanischen Firma Acheson unter der Marke AQUADAG vertriebenes Mittel in wässriger Verdünnung von 1:70 bis 1:200 Anwendung finden.From the point of view of increased quality, again alternatively, instead of the alkali halides mentioned above, one of sold by the American company Acheson under the AQUADAG brand Medium in aqueous dilution from 1:70 to 1: 200 Find application.

Ein weiterer Vorteil des erfindungsgemäßen Verfahrens ist, daß die Qualität des Druckgusses durch Vermeidung bzw. Reduzierung der Einschlüsse, die beispielsweise durch Abspaltprodukte aus Trenn- und Schmiermitteln entstehen, verbessert wird. Dadurch wird auch die Duktilität des Produkts erheblich verbessert. Diese erhebliche Verbesserung der Druckgußqualität ist darauf zurückzuführen, daß das im erfindungsgemäßen Verfahren verwendete Vakuum wesentlich höher ist als das Vakuum, das in den aus dem Stand der Technik bekannten Verfahren verwendet wird. Das erfindungsgemäße Vakuum betrifft einen Bereich unter 50mbar. Dieses verbesserte Vakuum des erfindungsgemäßen Verfahrens wird erreicht, indem der Preßkolben eine Verlängerung in Richtung der Kolbenbewegungsachse aufweist. Diese Verlängerung bewirkt beim Austritt des Kolbens auf der Seite des Formhohlraums eine Abdichtung der Gießkammer. Dadurch wird ein Eintritt von Trennmittel, von Luft, und von anderen gasförmigen Abspaltprodukten über die Einfüllöffnung der Gießkammer verhindert. Eine weitere Verbesserung des Vakuums erfolgt dadurch, daß die Gießkammeröffnung eine zur Kolbenbewegung radial beweglich angeordnete Verschließvorrichtung aufweist. Die Verschließvorrichtung hat die Wirkung, daß ebenfalls ein Ansaugen von Luft verhindert wird und gleichzeitig die zur Evakuierung des Formhohlraums zur Verfügung stehende Zeit verlängert wird.Another advantage of the method according to the invention is that the quality of the die casting by avoidance or reduction of the inclusions, for example, from cleavage products Release agents and lubricants arise, is improved. Thereby the ductility of the product is also significantly improved. This is significant improvement in die casting quality attributed to that used in the inventive method Vacuum is much higher than the vacuum that comes from known methods is used. The The vacuum according to the invention relates to a range below 50 mbar. This improved vacuum of the method according to the invention reached by the plunger an extension in the direction the piston movement axis. This extension causes at the exit of the piston on the side of the mold cavity one Sealing the casting chamber. This prevents the release agent from entering, of air, and of other gaseous separation products prevented via the filling opening of the casting chamber. Another Improvement of the vacuum takes place in that the casting chamber opening one radially movable for piston movement Has closing device. The closing device has the effect that also prevents air intake is and at the same time for evacuating the mold cavity Available time is extended.

Ein weiteres Problem, das aus dem Stand der Technik hinreichend bekannt ist, besteht darin, daß die geschmolzene Metallegierung beim Einfüllen in die Gießkammer auf eine kühlere Umgebung trifft und somit ein Teil der geschmolzenen Metallegierung in der Vorrichtung erstarrt. Diese Vorerstarrungen können sich nicht nur nachteilig auf den kontinuierlichen Verlauf des Verfahrens auswirken, sondern auch zu einer Qualitätsverminderung des Druckgußmaterials führen.Another problem that is sufficient from the prior art is known is that the molten metal alloy when pouring into the casting chamber to a cooler environment hits and thus part of the molten metal alloy in the device freezes. These pre-solidifications can not only disadvantageous to the continuous course of the process impact, but also to a reduction in quality of the die casting material.

Um infolgedessen derartige Vorerstarrungen zu vermeiden, wird nach einem weiteren Aspekt des erfindungsgemäßen Verfahren die Gießkammer vor dem Einfüllen der geschmolzenen Metallegierung beheizt, so daß eine Vorerstarrung gar nicht erst möglich wird. Eine weitere Alternative besteht darin, daß die Gießkammer aus einem Material besteht, das einen geringen Wärmeleitungskoeffizienten aufweist. Hier bietet sich insbesondere die Verwendung von keramischen Materialien an.In order to avoid such pre-solidification as a result according to a further aspect of the method according to the invention Casting chamber before filling the molten metal alloy heated so that pre-solidification is not possible in the first place. Another alternative is that the casting chamber is made of a material that has a low coefficient of thermal conductivity having. This is particularly useful here of ceramic materials.

Um darüber hinaus weitere Lufteinschlüsse in der geschmolzenen Metallegierung zu reduzieren, wird der Querschnitt der Gießkammer bananenförmig ausgebildet. Diese Ausgestaltung hat zur Folge, daß der geschmolzene Legierungsstrom, der sich wellenförmig durch die Gießkammer bewegt, nicht am Ende in die Gießkammer zurückläuft und infolge der dadurch entstehenden Turbulenzen und Vermischungen weitere Luft- bzw. Gaseinschlüsse zur Folge hat.In addition, more air pockets in the melted To reduce metal alloy, the cross section of the casting chamber Banana-shaped. This configuration has Consequence that the molten alloy stream, which is wavy moved through the casting chamber, not in the end into the casting chamber runs back and as a result of the resulting turbulence and mixtures further air or gas inclusions for Consequence.

Auch die Metallzufuhr des erfindungsgemäßen Verfahrens ist gegenüber der Zufuhr, die aus dem Stand der Technik bekannt ist, vorteilhaft. Während im Stand der Technik häufig die Vacuralansaugtechnik verwendet wird d.h. die Metallzufuhr über ein Steigrohr erfolgt, wird im erfindungsgemäßen Verfahren das Metall mittels eines gewöhnlichen Schöpflöffels oder eines Dosierofens in die Gießkammer eingebracht. Die Verwendung eines Schöpflöffels oder eines Dosierofens ist gegenüber der Verwendung eines Steigrohrs technisch einfacher handhabbar.The metal feed of the method according to the invention is also versus the feed known from the prior art is advantageous. While often in the prior art Vacural suction technology is used i.e. the metal supply over a riser pipe is carried out in the process according to the invention Metal using an ordinary ladle or dosing furnace introduced into the casting chamber. The use of a Ladle or a dosing oven is opposed to the use of a riser pipe is technically easier to handle.

Die gemäß der vorliegenden Erfindung hergestellten Teile erreichen nicht nur eine höhere Festigkeit, ein besseres Korrosionsverhalten, sondern sind auch besser weiterverarbeitbar, wie die folgende Tabelle zeigt. Standard-Druckguß MFT (DE-PS 3002886) gemäß vorl. Erfindung Schweißbark. nein nur mittels Elektronenstrahl ja Wärmebehandelbarkeit max 400°C 480 - 500°C 530°C Bruchdehnung (bei Rp 0,2 = 140MPa) ≥ 3% ≥ 6% ≥ 15% Streckgrenze ≥ 160 MPa (bei A5= 1%) ≥ 160 MPa (bei A5= 3%) ≥ 200 MPa (bei A5= 6%) Biegewechselfestigkeit (107 Zyklen) 80 - 100 MPa > 100 MPa > 120 MPa Korrosionsbeständigkeit gegen Salzw. bedingt bedingt gut The parts produced according to the present invention not only achieve higher strength, better corrosion behavior, but are also easier to process, as the following table shows. Standard die casting MFT (DE-PS 3002886) according to the present invention Weldability No only by means of an electron beam Yes Heat treatability max 400 ° C 480-500 ° C 530 ° C Elongation at break (at Rp 0.2 = 140MPa) ≥ 3% ≥ 6% ≥ 15% Stretch limit ≥ 160 MPa (with A5 = 1%) ≥ 160 MPa (with A5 = 3%) ≥ 200 MPa (with A5 = 6%) Flexural fatigue strength (10 7 cycles) 80-100 MPa > 100 MPa > 120 MPa Corrosion resistance to salt water conditionally conditionally Good

Die nach dem neuen Verfahren hergestellten Teile können sehr dünnwandig und großflächig ausgelegt werden. Die guten Formgebungseigenschaften lassen dem Konstrukteur einen großen Gestaltungsspielraum. Durch geeignete Formung von Versteifungen lassen sich beispielsweise Karosserieknoten oder -aufhängeteile für den Automobilbau herstellen. Hierbei kommen die Vorteile des leichten Werkstoffes durch Gewichtseinsparung zugute. Dennoch sind die übrigen Anforderungen, wie gleichbleibende Qualität einer Serienfertigung, hohe Duktilität, Schweißbarkeit und damit auch die Reparaturfähigkeit gewährleistet. Es werden auch die Bedingungen der Crashsicherheit erfüllt. Vielerlei Arten von Verbindungstechniken ermöglichen die Kombination mit Blechen oder Strangpreßprofilen.The parts manufactured using the new process can do a lot be designed thin-walled and large area. The good shaping properties leave the designer a great deal of freedom. By appropriately shaping stiffeners body knots or suspension parts, for example for automotive manufacturing. Here are the advantages the lightweight material by saving weight. Yet are the other requirements, such as consistent quality series production, high ductility, weldability and thus also guaranteeing repairability. It will be too meets the conditions of crash safety. Many types of joining techniques enable the combination with sheet metal or extruded profiles.

Bei den in dem erfindungsgemäßen Verfahren eingesetzten Schmiermitteln handelt es um sich aus dem Stand der Technik bekannte. Bevorzugt werden jedoch Hexamethylentetramin und Dicyclohexylaminnitrit jeweils in einer Konzentration von 0,02 bis 0,5 Vol.% verwendet.In those used in the method according to the invention Lubricants are from the prior art known. However, hexamethylenetetramine and Dicyclohexylamine nitrite, each in a concentration of 0.02 up to 0.5 vol.% used.

Claims (31)

  1. A process for manufacturing diecast parts from a light metal alloy, with a limit placed on the proportion of iron, which in the molten state is fed under gravity into the casting chamber of a diecasting machine and whence forced by a plunger into a mould chamber, the evacuation of which is controlled in accordance with the position of the plunger, comprising the steps of:
    applying a halide-containing parting compound or graphite as a parting compound onto a least one mould half, applying a lubricant onto the plunger,
    characterized in
    that said light metal alloy is a primary alloy of invariable composition, with a limit placed on the proportions of Cu, Fe and Zn, which undergoes a smelting treatment such as de-gassing and/or filtration before being introduced,
    the vacuum in the mould chamber is below 50 mbar when the molten alloy is introduced, and
    the parting compound either comprises alkali halides to which anti-corrosion additives have been added up to a pH value of at least 8, or graphite powder of a particle size of between 1 - 1.5 µm.
  2. The process as claimed in claim 1
    characterized in
    that the casting chamber is heated or made of a material of a low coefficient of thermal conduction, e.g. ceramic.
  3. The process as claimed in claim 1
    characterized in
    that the plunger has an extension in the direction of the plunger movement axis, which - when the plunger exits on the side of the mould chamber - will seal off the filling chamber, thus preventing air from being introduced via the feed aperture of the casting chamber.
  4. The process as claimed in claim 1
    characterized in
    that the casting chamber aperture exhibits closing means mounted movably radially to the movement of the plunger.
  5. The process as claimed in claim 1
    characterized in
    that the casting chamber is "banana-shaped" in cross-section.
  6. The process as claimed in claim 1
    characterized in
    that potassium iodide (0.5 - 5 %) is used as the parting compound.
  7. The process as claimed in claim 1
    characterized in
    that the parting compound comprises the additive hexamethylene-tetramine at a concentration of approx. 0.02 to 0.5 per cent by volume.
  8. The process as claimed in claim 1
    characterized in
    that the parting compound comprises the additive dicyclohexylamine nitrite at a concentration of approx. 0.02 to 0.5 per cent by volume.
  9. The process as claimed in claim 1
    characterized in
    that the parting compound comprises the additive potassium hydroxide.
  10. The process as claimed in one of the preceding claims
    characterized in
    that additives are added to the parting compound for stabilisation purposes.
  11. The process as claimed in claim 10
    characterized in
    that the additive used for stabilizing the parting compound is sodium thiosulfate.
  12. The process as claimed in claim 11
    characterized in
    that sodium thiosulfate is added at a concentration of between 0.01 and 0.5 per cent by volume.
  13. The process as claimed in one of the preceding claims
    characterized in
    that additives are added to the parting compound for preservation purposes.
  14. The process as claimed in claim 13
    characterized in
    that the additive used for preserving the parting compound is sodium thiosulfate.
  15. The process as claimed in claim 13
    characterized in
    that the additive used for preserving the parting compound is an organic addition agent.
  16. The process as claimed in claim 15
    characterized in
    that fungicides and/or bactericides are added as additives.
  17. The process as claimed in claim 1
    characterized in
    that the lubricant contains hexamethylene-tetramine at a concentration of between 0.02 to 0.5 per cent by volume.
  18. The process as claimed in claim 1
    characterized in
    that the lubricant contains dicyclohexylamine nitrite at a concentration of between 0.02 to 0.5 per cent by volume.
  19. A parting compound for use in a diecasting process as claimed in claim 1 containing alkali halides in aqueous solution
    characterized in
    that said parting compound contains anti-corrosion additives.
  20. The parting compound as claimed in claim 19
    characterized in
    that said parting compound is potassium iodide (0.5 - 5 %).
  21. The parting compound as claimed in claims 19 or 20
    characterized in
    that said parting compound contains additives for adjusting the pH value.
  22. The parting compound as claimed in claim 21
    characterized in
    that said parting compound has a pH value of pH 8 to pH 9.
  23. The parting compound as claimed in claim 19
    characterized in
    that the additives comprise hexamethylene-tetramine or dicyclohexylamine nitrite at a concentration of 0.02 to 0.5 per cent by volume.
  24. The parting compound as claimed in claim 19
    characterized in
    that the additive is potassium hydroxide.
  25. The parting compound as claimed in one of the preceding claims
    characterized in
    that it contains additives for stabilizing said parting compound.
  26. The parting compound as claimed in claim 23
    characterized in
    that the additive for stabilizing said parting compound is sodium thiosulfate.
  27. The parting compound as claimed in claim 26
    characterized in
    that said parting compound contains sodium thiosulfate at a concentration of between 0.01 to 0.5 per cent by volume.
  28. The parting compound as claimed in one of the preceding claims
    characterized in
    that it contains additives for preservation purposes.
  29. The parting compound as claimed in claim 28
    characterized in
    that the additive for preserving the parting compound is sodium thiosulfate.
  30. The parting compound as claimed in claim 28
    characterized in
    that the additive for preserving the parting compound is an organic addition agent.
  31. The parting compound as claimed in claim 30
    characterized in
    that the additives are fungicides and/or bactericides.
EP96908074A 1995-03-20 1996-03-19 Process for manufacturing diecast parts Expired - Lifetime EP0759825B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP96908074A EP0759825B1 (en) 1995-03-20 1996-03-19 Process for manufacturing diecast parts

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
EP95104092 1995-03-20
EP95104092 1995-03-20
PCT/EP1996/001182 WO1996029165A1 (en) 1995-03-20 1996-03-19 Process for manufacturing diecast parts
EP96908074A EP0759825B1 (en) 1995-03-20 1996-03-19 Process for manufacturing diecast parts

Publications (2)

Publication Number Publication Date
EP0759825A1 EP0759825A1 (en) 1997-03-05
EP0759825B1 true EP0759825B1 (en) 1999-08-18

Family

ID=8219087

Family Applications (1)

Application Number Title Priority Date Filing Date
EP96908074A Expired - Lifetime EP0759825B1 (en) 1995-03-20 1996-03-19 Process for manufacturing diecast parts

Country Status (8)

Country Link
US (1) US6024158A (en)
EP (1) EP0759825B1 (en)
JP (1) JP4068139B2 (en)
AT (1) ATE183422T1 (en)
BR (1) BR9605884A (en)
DE (1) DE59602781D1 (en)
ES (1) ES2136980T3 (en)
WO (1) WO1996029165A1 (en)

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Publication number Priority date Publication date Assignee Title
JP3508627B2 (en) * 1998-07-14 2004-03-22 日本軽金属株式会社 Die casting method and die casting products
EP1034863A1 (en) * 1999-03-05 2000-09-13 Alusuisse Technology & Management AG Method for die casting of light metals
DE19945461A1 (en) * 1999-09-22 2001-04-19 Linde Gas Ag Process for improving the magnesium die casting process
IT1317350B1 (en) 2000-06-20 2003-06-16 Idra Presse S P A STRUCTURE OF INJECTOR PARTICULARLY FOR VACUUM DIE-CASTING SYSTEM.
JP4481481B2 (en) * 2000-12-13 2010-06-16 三和油化工業株式会社 Aqueous mold release agent for die casting and die casting method using the same
US10316616B2 (en) 2004-05-28 2019-06-11 Schlumberger Technology Corporation Dissolvable bridge plug
JP2006187797A (en) * 2005-01-07 2006-07-20 Asahi Organic Chem Ind Co Ltd Coating agent composition for mold and mold coated thereof
US8770261B2 (en) * 2006-02-09 2014-07-08 Schlumberger Technology Corporation Methods of manufacturing degradable alloys and products made from degradable alloys
EP2336756A1 (en) * 2009-12-15 2011-06-22 Nxp B.V. Liquid immersion sensor

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JPS5037138B2 (en) * 1972-07-10 1975-12-01
DE2323426A1 (en) * 1973-05-09 1974-11-28 Thurner Bayer Druckguss Air extn. or evacuation of cavity in pressure die casting - with automatic operation of stopper on air suction channel leading to vacuum chamber
SU772678A1 (en) * 1979-04-13 1980-10-23 Предприятие П/Я А-1872 Injection mould coating
DE3002886A1 (en) * 1980-01-28 1981-07-30 Bayrisches Druckguß-Werk Thurner KG, 8015 Markt Schwaben DIE CASTING MACHINE AND METHOD FOR OPERATING THE SAME
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JPS60203335A (en) * 1984-03-26 1985-10-14 Honda Motor Co Ltd How to apply mold release agent
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JP2964369B2 (en) * 1992-07-01 1999-10-18 日立粉末冶金株式会社 Release agent for mold casting

Also Published As

Publication number Publication date
US6024158A (en) 2000-02-15
WO1996029165A1 (en) 1996-09-26
DE59602781D1 (en) 1999-09-23
JPH10501745A (en) 1998-02-17
JP4068139B2 (en) 2008-03-26
EP0759825A1 (en) 1997-03-05
ATE183422T1 (en) 1999-09-15
BR9605884A (en) 1997-09-16
ES2136980T3 (en) 1999-12-01

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