Classifications

• • 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
• • 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
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
  • B22D25/00—Special casting characterised by the nature of the product
  • B22D25/005—Casting metal foams
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C1/00—Making non-ferrous alloys
  • C22C1/08—Alloys with open or closed pores
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C1/00—Making non-ferrous alloys
  • C22C1/08—Alloys with open or closed pores
  • C22C1/083—Foaming process in molten metal other than by powder metallurgy
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C1/00—Making non-ferrous alloys
  • C22C1/08—Alloys with open or closed pores
  • C22C1/083—Foaming process in molten metal other than by powder metallurgy
  • C22C1/087—Foaming process in molten metal other than by powder metallurgy after casting in solidified or solidifying metal to make porous metals
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C2204/00—End product comprising different layers, coatings or parts of cermet

Definitions

• the invention relates to a method for producing metal / metal foam composite components, in particular of metal moldings made of light metal materials compared to Conventionally produced moldings weight reduced are.
• the invention further relates to this method manufactured moldings and their use in light metal structures.
• foamable Aluminum semi-finished products are atomised aluminum powder, to which a blowing agent is added.
• a blowing agent for example, to DE 197 44 300 A1 a pressed from a powder mixture Body in a heated, closed vessel at temperatures above the decomposition temperature of the blowing agent and / or the melting temperature of the metal.
• the powder is compressed in this process and the resulting Molding is in the profession2020 area of a Component inserted and by heating up to 650 ° C. foamed.
• the shell may be subject to improper deformation or the foaming process is uneven.
• Possible is also a production of foams by sintering metallic hollow spheres or an infiltration of molten metals in cores or packing which, after solidification of the Melt be removed.
• JP 03017236 metallic Article with cavities generated by the fact that gases in one Molten metal are dissolved and the foaming process by sudden pressure reduction is initiated. By cooling the melt is stabilized foam.
• JP 09241780 AA becomes more metallic Foam obtained under controlled release of propellant gases, in which a metal is initially at temperatures below the decomposition temperature of the blowing agent used melted becomes. By subsequent dispersion of the blowing agent in molten metal and heating the matrix over the temperature then needed to release propellant gases A metal foam is established.
• WO 92/21457 A1 describes the production of aluminum foam such that gas under injected the surface of a molten metal where abrasive substances serve as stabilizers.
• W.Thiele Filler-containing aluminum sponge - a more compressible Casting material for the absorption of impact energy. in: metal 28, 1974, Issue 1, pp 39 to 42 describes the preparation of foam aluminum.
• the desired cavities are in size, shape and location in the form of a loose bed easily compressible inorganic lightweight materials, such as Example blown clay minerals, expanded clay, glass foam balls or hollow corundum balls, etc. specified.
• the lightweight packing is placed in a mold. The remaining spaces of the bed are filled up with metal.
• the so Aluminum sponge obtained is relatively poor mechanical resilient and contains the material of the bed.
• DE 11 64 103 B relates to a process for the production of metal foam bodies.
• This method becomes a solid Substance that decomposes on heating to form gas, with a molten metal mixed in such a way that the solid substance is wetted by the metal.
• a molten metal for example powdered titanium hydride of a molten alloy made of aluminum and magnesium at a temperature of 600 ° C added.
• the thus formed closed foam is then poured into a mold to cool and to solidify. Again, obviously not in a closed System but worked in an open system.
• GB 892934 relates to the production of complex structures with foamed metal core and closed non-porous Surface.
• JP Patent Abstracts of Japan 07145435 A describes the preparation of foamed metal wires.
• Molten aluminum is placed in a furnace with the aid of a propellant foams and fed to a continuous casting device.
• the molten aluminum in the foamed state is interposed Cooled a pair of upper and lower conveyor belts to get a continuous strand. This is in a predetermined Cut way to the foamed aluminum wires.
• the foamed aluminum wire or strand be formed by melting the foamed Aluminum between a wire with a groove and a conveyor belt draws. The molten aluminum wire thus becomes obtained by rolling or drawing.
• EP 0 666 784 B1 describes a method for molding a Particle stabilized metal foam, in particular an aluminum alloy in which a composite of a metal matrix and finely divided solid stabilizing particles is heated above the solidus temperature of the metal matrix and Gas bubbles in the molten metal compound below Surface to thereby stabilize, liquid foam on the surface of the molten metal composite train.
• Characteristic is a molding of metal foam by pressing the stabilized liquid Foam in a mold and with a pressure that is only sufficient that the liquid foam assumes the shape of the mold, without that the cells of the foam are significantly compressed.
• the molded article is then cooled by subsequent cooling and solidifying the foam.
• the foam is here pressed into the mold by means of a movable plate.
• a first moving plate pushes the liquid foam into the Form, and the molded foam article is a smooth Surface formed.
• a second moving plate will be in pressed the foam inside the mold to contact the foam article form smooth inner surfaces.
• the shaping can also done by rollers.
• Another method for the production of moldings made of metal foam EP 0 804 982 A2 teaches.
• the foaming takes place in a heated chamber outside a mold, the volume of the introduced into the chamber powder metallurgical Starting material for the metal foam in its foamed with the entire foam capacity phase the volume of a filling of the mold substantially corresponds. All metal foam in the chamber becomes pressed into the mold, in which a foaming with the remaining foaming capacity is continued until complete Filling in the mold.
• the casting mold is a sand or ceramic mold, the metal foam is used as a semi-finished in the Chamber introduced and only after foaming, e.g. by means of of a piston, pressed into the mold. When pressed of the foam in the mold, this is sheared. The shape becomes not filled with a foam of intentionally inhomogeneous structure.
• DE 195 01 508 C1 discloses a method for producing a Cavity profile with reduced weight and increased Stiffness, e.g. a component for the chassis of a motor vehicle. This is made of die-cast aluminum and in its Cavities is a core of aluminum foam. The integrated foam core is based on powder metallurgy Made and then on the inner wall of a Casting tool fixed and by die casting with metal cast around.
• a wheel for a motor vehicle which comprises at least one metallic foam core, the is arranged exposed to the inside of the wheel and has a cast wall towards the outside of the wheel.
• Foam core made of aluminum foam is used for casting the wheel in a mold is inserted and positioned so that between the Mold and the foam core when pouring the outer cast skin arises.
• DE 195 02 307 A1 describes a deformation element in whose Housing a filling of an aluminum foam as an energy absorber is provided.
• the housing can be made of metal or Plastic exist.
• the filler is a mere insert without material connection to the housing.
• WO 9 964 287 discloses a method for the production of automotive components, by metal foam introduced into the cavity or core of the metal component is foamed, or is foamed in the cavity of the component. It will no metal part introduced into the cavity of a mold.
• the release or blowing of propellant gases in metal melts is not suitable for the production of near net shape components, as a system consisting of melt with occluded gas bubbles is not sufficiently stable in time to shaping Tools to be processed.
• the solution to the above problem consists in a method for the production of metal / metal foam composite components, in which one is a plane or forms a shaped metal part in the cavity of a casting mold, wherein the cavity is at least partially through the metal part is limited, and then a mixture of a Molten metal and a solid at room temperature Propellant introduces into the cavity and foams there.
• this form can expand on one or more pages limit the resulting metal foam, at least but part of the surface of this process inside the StanfordDumenden cavity resulting foam is formed by the previously inserted metal part.
• the inventive method allows the production of a wide range of composite components.
• metal parts It can be a variety of cavities provided Moldings that are applicable in metal structures are, for example, hollow beams or rims.
• Moldings that are applicable in metal structures are, for example, hollow beams or rims.
• too various casting methods find application, for example Low pressure or die casting process.
• the foamed mold cavity only partially is limited by the inserted metal parts
• the inserted metal part a sheet metal foamed onto the metal foam according to the invention can be.
• Sheet metal in the mold cavity can be so on easy way to produce sandwich components.
• the metal is injected directly from the melting chamber with up to about 10 7 Pa in the mold in the present invention preferred cold chamber method, eg for materials of Al and Mg alloys, the melt in a cold intermediate chamber and from there with more as 10 8 Pa pressed into the mold.
• the casting capacity of the hot chamber process is higher, but also the wear of the system.
• the benefits of die casting are good material strength, clean nascent surfaces of the resulting body on the inside of the mold cavity, high dimensional accuracy, the possibility of complex casting design, and high working speed. These advantages can be further improved by vacuum (vacuum in the mold).
• the metals selected from non-ferrous metals and non-precious metals in particular selected from magnesium, calcium, aluminum, Silicon, titanium or zinc and their alloys.
• non-ferrous metals and non-precious metals in particular selected from magnesium, calcium, aluminum, Silicon, titanium or zinc and their alloys.
• ferrous metals and precious metals Assistance of the present invention to the resulting composite foamable with a preformed metal part are also used.
• alloy is used is, this is to be understood that this contains at least 30 wt .-% of said metal.
• preferred procedure includes the filling the required volume of molten metal in the Filling or casting chamber and their introduction into a mold cavity, in which the whoCumende metal part is inserted, adding the blowing agent to the molten metal.
• molten metal and propellants are in a preferred embodiment brought together in the mold cavity, wherein the Form or the cavity remaining in the form völumendefiniert filled with the melt-blowing agent mixture respectively is underfilled.
• the blowing agent not directly into the mold cavity, but in one Filling or casting chamber brought into contact with the molten metal and then the mixture in the mold cavity with introduced the inserted metal body.
• metal piece can be before, during and / or after introducing the molten metal into the respective chamber respectively.
• the propellant is directly in the filling or casting chamber or in the mold cavity to the molten metal added, each in a single operation from the previously formed non-foamed metal body the corresponding metal foam structure is produced.
• the propellant should be in terms of its decomposition temperature on the melting temperature of the casting material (molten metal) be coordinated.
• the decomposition may only above start from 100 ° C and should not be higher than about 150 ° C be above the melting temperature.
• the resulting workpiece forms the foam structure, below the melting temperature of the previously in the mold inlaid metal lies.
• the melting temperature of the molten metal above the Melting temperature of the inserted metal part is, a particularly good bond between preformed metal part and resulting foam structure formed.
• the amount of blowing agent to be used depends on the necessary conditions. Particularly preferred in According to the present invention, the blowing agent in a Amount of 0.1 to 10 wt .-%, in particular 0.2 to 1 wt .-%, based on the mass of the formation of the metal foam used amount of metal used.
• Gas-releasing propellants which are solid at room temperature in particular light metal hydrides, such as magnesium hydride.
• light metal hydrides such as magnesium hydride.
• autocatalytic produced magnesium hydride for example sold under the name TEGO Magnan®.
• titanium hydride, carbonates, hydrates and / or readily vaporizable substances, which are also used in the Prior art already for the foaming of metals have been used.
• the insertion into the molding chamber was such that the Anschuss (opening for introducing the liquid metal) the location of the metal cavity into the mold cavity.
• the closed casting chamber of the die-casting machine was as blowing agent magnesium hydride in powder form the liquid Metal added. Almost simultaneously, a fast started Insertion of the mixture of propellant and molten metal in the mold cavity and thus also in the inlaid Metal workpiece remaining cavity.
• the cavity was volume defined underfilled. Due to the resulting turbulence good mixing took place in the remaining one Mold cavity that supports foaming. It formed a foam structure in the interior of the cavity of the inserted metal part off, on the walls of the die-casting mold a dense and homogeneous surface showed.

Landscapes

• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Materials Engineering (AREA)
• Metallurgy (AREA)
• Organic Chemistry (AREA)
• Manufacture Of Alloys Or Alloy Compounds (AREA)
• Powder Metallurgy (AREA)
• Laminated Bodies (AREA)

Priority Applications (1)

Applications Claiming Priority (3)

Publications (2)

Family

ID=7687551

Family Applications (1)

Country Status (8)

Cited By (3)

Families Citing this family (43)

Family Cites Families (33)

• 2001
  • 2001-06-07 DE DE10127716A patent/DE10127716A1/de not_active Withdrawn
• 2002
  • 2002-05-25 EP EP02743107A patent/EP1392875B1/de not_active Expired - Lifetime
  • 2002-05-25 ES ES02743107T patent/ES2239234T3/es not_active Expired - Lifetime
  • 2002-05-25 JP JP2003507322A patent/JP4322665B2/ja not_active Expired - Fee Related
  • 2002-05-25 AT AT02743107T patent/ATE291644T1/de active
  • 2002-05-25 CA CA002444248A patent/CA2444248C/en not_active Expired - Fee Related
  • 2002-05-25 DE DE50202549T patent/DE50202549D1/de not_active Expired - Lifetime
  • 2002-05-25 WO PCT/EP2002/005774 patent/WO2003000942A1/de not_active Ceased
  • 2002-06-05 US US10/162,978 patent/US6874562B2/en not_active Expired - Fee Related

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