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EP2014391B1 - Procédé de fabrication d'un noyau et/ou sable de moule pour des besoins de fonderie - Google Patents

Procédé de fabrication d'un noyau et/ou sable de moule pour des besoins de fonderie Download PDF

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Publication number
EP2014391B1
EP2014391B1 EP08009314.9A EP08009314A EP2014391B1 EP 2014391 B1 EP2014391 B1 EP 2014391B1 EP 08009314 A EP08009314 A EP 08009314A EP 2014391 B1 EP2014391 B1 EP 2014391B1
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EP
European Patent Office
Prior art keywords
additive
binding agent
inorganic
swelling
sand
Prior art date
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Application number
EP08009314.9A
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German (de)
English (en)
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EP2014391A2 (fr
EP2014391A3 (fr
Inventor
Cornelius Grefhorst
Spyridon Tzintos
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S & B Industrial Minerals GmbH
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S & B Industrial Minerals GmbH
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Publication of EP2014391A2 publication Critical patent/EP2014391A2/fr
Publication of EP2014391A3 publication Critical patent/EP2014391A3/fr
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives

Definitions

  • the invention relates to a method for producing a core and / or molding sand for foundry purposes, after which a granular mineral molding base material is mixed with an inorganic additive and an inorganic binder.
  • Core sands for foundry purposes are generally used to define cores in castings.
  • molding sand generally refers to a sand or a sand-like mold base material, which dictates the outer shape of the desired casting.
  • Core sand and foundry sand fall largely under the generic term foundry sand or foundry mold base material. That is, in the present case, it is not necessarily sands, but generally granular foundry molds.
  • a lustrous carbon generator or, in general, coal dust / hydrocarbon resin is usually added in addition to a binder such as bentonite, as described, for example, in US Pat DE 30 17 119 A1 is described.
  • a binder such as bentonite
  • the main reasons for the use of coal dust in the foundry sand foundry are that an improved casting surface is achieved and sand buildup is largely avoided.
  • the mold can be advantageously separated from the sand and casting errors are reduced.
  • the dosage can be easily made and the costs are relatively low.
  • Example II discloses a composition for foundry cores and molds consisting of sand, binders and additives that are mixed. Suitable additives are those based on organic substances, for example cellulose-containing, are used. As a result, in particular emissions are still to be feared and ultimately casting errors as described can not be ruled out.
  • the invention is based on the technical problem of further developing such a method so that in particular harmful emissions are avoided and the quality of the casting is improved.
  • the invention proposes a method according to claim 1.
  • This is a total as an additive inorganic Blveshadditiv used with a Blähbaum of at least 9, so an inorganic blowing additive, which in any case has a higher Blähbaum than coal.
  • an inorganic additive is expressly used, specifically a special additive, namely a bulking additive.
  • a bulking additive are characterized by having a free swelling index of at least 9, as defined in more detail in DIN 51741.
  • the swelling index preferably even assumes values of more than 10, in particular more than 20.
  • the swell ratio is even around 100.
  • the Blähiereiere expresses that the inorganic swelling additive in question at a certain (high) temperature (expansion temperature) multiplied its volume, for example, tenfold. From the increase in volume can then be deduced on the Blähiere, wherein the multiplication of the volume as a factor in about the Blähiere corresponds.
  • This fact can essentially be attributed to the fact that the inorganic swelling additive, such as, for example, perlite, vermiculite or (expanded) graphite, has a relatively high moisture content in the form of intracrystalline water.
  • a chemical in the interior is conceivable, which provides an expansion of the Blähadditives when exposed to heat.
  • blowing rates are generally determined so that the inorganic swelling additive in question is optionally ground and then heated in a crucible. From a comparison of the volume before and after heating can then be deduced on the Blähiere. In most cases, (blowing) temperatures of more than 300 ° C are used at this point.
  • the inorganic blowing additive before addition to the molding sand and especially before the eientlichen casting has not reached the above-mentioned Blähtemperaturen of about 300 ° C or even more.
  • the respective bulking additives arrange advantageously in the range of binder bridges, which are built up by the inorganic binder between the individual granular grains of the molding material in order to represent the mold in the desired shape.
  • the inorganic swelling additive present in the area of these binder bridges now ensures that the blowing additives in question expand at the casting temperatures that are achieved, which are usually above the specified expansion temperatures of about 300 ° C. and more.
  • the binder bridges are broken, so that the granular mineral molding material decomposes immediately after completion of the mold, because the binder does not fulfill its original binding function for the preparation of the binder bridges. That is, the bond between the individual grains of the molding base material or of the molding sand is physically or mechanically dissolved, by the inorganic blowing additive, which expands targeted and initiated by the casting process.
  • the abovementioned decomposition process can be controlled or regulated via the temperature and / or selection or modification of the respective blowing additives.
  • the various inorganic blowing additives mentioned show a different temperature expansion behavior and consequently also different blow molding temperatures at which the expansion process starts or reaches its maximum.
  • mixtures for example to mix vermiculite with perlite in a certain ratio.
  • the swelling behavior of the inorganic swelling additive can be precisely adjusted and controlled both with regard to the temperature behavior of the expansion as such and with regard to the achieved expansions.
  • organic additives are dispensed with throughout, be it for the preparation of the binder or as additive or bulking additive.
  • the unavoidable in the prior art emissions of, for example, carbon monoxide or benzene, as well as contaminants based thereon reliably and already prevented from the beginning.
  • the expanding nature of the expanding additive closes any pores remaining in the mold during casting, which greatly reduces the casting surface and its roughness. Because the liquid metal finds in the mold no pores, in which it can penetrate.
  • expanding graphite as an inorganic blowing additive has complementary positive properties to the effect that any separating oils, condensates and any resulting benzene are bound. This can be attributed to the high porosity of graphite and its non-polar character.
  • graphite can be loaded or combined with additional materials, which are stored in the compulsory spaces.
  • sulfur can be used at this point.
  • so-called Graphite bisulfate which is prepared by the treatment of highly crystalline natural graphite with a mixture of sulfuric acid and with the addition of various oxidants.
  • the inorganic bulking additive can not only take over or take over the function of blasting the binder bridges between the individual grains of the granular mineral molding base material, but also being able to bind individual potentially harmful emissions, such as oil, benzene or other mostly carbonated condensation products.
  • the inorganic blowing additive can be specifically modified by additives or stored materials such as sulfur. The stored materials are automatically released during the onset of the blow molding process and can develop the desired effect.
  • the finished mixture of the molding base material, the blowing additive and the binder is compacted, taking into account a density increase of at least 20 g / dm 3 .
  • the core and / or molding sand or the foundry sand or foundry molding base material can generally be prepared in such a way that casting defects are practically reduced to a minimum. Because of the increased compression of the mold, penetrations of the liquid casting material or metal into the casting mold can be reduced to a minimum. In any case, it is an inorganic additive, so that so far observed in the prior art harmful emissions virtually no longer occur.
  • the binder can be mixed with the inorganic additive or blowing additive before its addition to the granular mineral molding base itself. Consequently, the inorganic binder and the inorganic blowing additive or additive form an inorganic premix, which may also be present as a mixture particles or premix particles themselves (pellet).
  • the binder and the swelling additive or additive are processed by coextrusion to the mixing particles or the pellets.
  • other methods of preparation are conceivable in order to process the binder and the swelling additive or additive to the mentioned mixture particles or pellets.
  • the invention recommends such a thickness of about 5 .mu.m to 500 .mu.m, in particular from 10 .mu.m to 200 .mu.m.
  • the average grain diameter may be about 65 microns, wherein the mixture particles are subjected to a total grinding process to adjust the specified particle size spectrum.
  • the invention recommends to provide a separate screening / grinding process at this point and to work with a grain size in the range of 10 nm to 3000 nm.
  • the average particle diameter should be about 1000 nm or 1 ⁇ m.
  • the binder is usually in a grain size of originally about 10 microns to about 200 microns ago.
  • the shell or binding envelope responsible for the use of, for example, bentonite for the bonding process between the individual grains of the molding base material has a layer thickness of about 3.5 ⁇ m.
  • the maximum of 3 microns (3000 nm) particles or grains of Blähadditivs easily bring into the binding envelope in question (with greater thickness than the largest grain diameter) of the bentonite or the binder or store.
  • the bulking additive is arranged exactly in the region of the bonding bridges already mentioned above and can unfold its effect of breaking the binding bridge in each case.
  • the invention usually resorts to a granular mineral sand, in particular quartz sand, which is usually present in a mean grain size smaller than 0.5 mm, wherein the grain usually moves in the range between 0.10 mm to 0.30 mm ,
  • the inorganic additive is incorporated directly into the shell or binding shell of the binder or the bentonite or can be incorporated, it is advisable to process both of the aforementioned ingredients (binder and blowing additive) together.
  • This can be done by the already mentioned extrusion process, which directly ensures that the swelling additive penetrates into the binding envelope in question. Because this is ensured by the pressure prevailing in the compulsory molding press for the extrusion process.
  • the abovementioned mixture particles or premix particles of the binder with embedded swelling additive and / or a loose premix of the binder and the swelling additive is then mixed with the molding material for final mixing.
  • the proportion of the molding base material is usually about 80 wt .-% or more, whereas the remaining 20 wt .-% filled in the maximum of the binder, the organic additive or the blowing additive and possibly one or more other additives become.
  • These additives may be porous mineral materials or particles such as clinoptilolite, a catalyst such as manganese oxide, (silver treated) zeolite, or the like, which will crack any harmful hydrocarbon emissions.
  • an oxidizing agent is added in order to burn or split any absorbed organic components.
  • the aforementioned oxidizing agent can be added as an additive of calcium carbonate, for example, the binder in a weight proportion of about 10 wt .-%.
  • the oxidizing agent can be realized according to the invention in such a way that the binder or the bentonite is activated with sodium oxalate or comparable additives.
  • bentonite is usually one used, which contains at least 85 wt .-% montmorillonite as the main component.
  • the finished mixture of the granular mineral molding material, the binder and the blowing additive and optionally the additives is then finally compacted.
  • a stamping device which may be, for example, a molding press or a pile driver with a plurality of rams.
  • compression methods or corresponding devices are used today, which provide for a corresponding compaction by shooting, by generating air pulses, by means of pressing.
  • a core and / or molding sand or a finished mixture is observed whose density has a density increase in the range of more than 20 g / dm 3 , in particular more than 30 g / dm 3 .
  • the molding sand can be processed with high compression, and consequently the casting mold produced therefrom is also present in the increased density.
  • the high compression of the mold penetration of the liquid casting material (metal) into the casting mold is reduced to a minimum.
  • the catalyst and / or an oxidizing agent any harmful emissions are bound or split during casting.
  • bentonite with an addition of more than 9% by weight of carbonate, based on the bentonite or the binder, can be used as the oxidizing agent.
  • the inventive addition of the inorganic additive respectively Blähadditivs with a Blähbaum of at least 9 and the inorganic binder or their use for the production of a core and / or molding sand for foundry purposes ensures that the fluidity of the foundry molding sand is increased and its disintegration after making the Gusswerk GmbHs is accelerated and otherwise takes place almost residue-free.
  • additives such as zeolite as a catalyst or of oxidants optimizes the absorption of possibly still resulting organic emissions, their application anyway by the absence of organic binders and organic additives and also by resorting to only inorganic additives per se on a Minimum is reduced.
  • additives such as zeolite as a catalyst or of oxidants
  • Sodium-activated calcium bentonite as a binder is mixed with an inorganic bulking additive, which is expanded graphite or vermiculite.
  • an inorganic bulking additive which is expanded graphite or vermiculite.
  • the individual compositions are given in the table below.
  • a distinction is made between a loose premix of the additive with the inorganic binder and, on the other hand, between pellets which have been produced by prior combined extrusion of the additive with the blowing additive.
  • the abovementioned pellets or the premix was dried and ground, so that on the output side a water content of about 10% by weight is observed and an average particle diameter of about 0.063 mm.
  • the pellets or premix particles are then sieved and ground to a mean grain size of about 65 ⁇ m. If a loose premix of the additive and the inorganic blowing additive has been investigated, an average grain size of about 65 ⁇ m has also been set. Subsequently, the foundry molding sand or the core and / or foundry sand for foundry purposes was prepared by filling the granular mineral molding base material, in the exemplary embodiment quartz sand, into a pug mill.
  • the quartz sand was mixed with 2.5 wt% (deionized) water for a period of one minute. Subsequently, the bentonite was added to about 7 wt .-%, based on the molding material, and the inorganic blowing additive to about 5 wt .-%, based on the binder or the bentonite. Alternatively, the pellets were filled from the binder including embedded swelling additive in the edge of the pan.
  • the finished mixtures were sieved, taking into account a 3 mm sieve, so that on the output side a foundry molding sand or a lump-free ready mix of the original grain distribution was available. Thereafter, the molding foundry sand in question was compacted, in the example in a cylinder of length 100 mm with a diameter of 50 mm at a pressure of 100 N / cm 2 .
  • Table 1 shows in column 1 a granular molding material with an addition of only 7 wt .-% bentonite as a binder, based on the molding material.
  • Column 2 shows the mold base in question with an addition of 7 wt .-% bentonite as a binder and 2 wt .-% carbon as an organic additive, each based on the molding material, according to the prior art.
  • column 3 a granular molding base material with an addition of 7 wt .-% bentonite and 5 wt .-% expandable graphite is reproduced.
  • Column 4 shows as well as column 3 the granular molding material with 7 wt .-% bentonite as a binder and 5 wt .-% vermiculite added as an inorganic blowing additive, each as loose mixture components and compacted according to the example described.
  • column 5 the molding material plus 7 wt .-% bentonite and 5 wt .-% expandable graphite according to the example in column 3 is shown, however, in such a way that the bentonite was extruded together with the expandable graphite to the pellets or premix particles .
  • Column 6 finally shows the granular molding material with an addition of 7 wt .-% bentonite and 5 wt .-% vermiculite as in the example of column 4, but again in the form of mixture components or pellets, which have been prepared by co-extrusion. All ready mixes have been compacted as described.
  • a narrow area at the head of a specimen has been heated very strongly to temperatures of about 1000 ° C. After a certain time of 15, 30 or 60 seconds, the binding force of the foundry sand was measured.
  • the hot compressive strength was measured with a Simpson & Gerosa high temperature compressive strength tester. For this purpose, the sample was introduced into the tester and heated to temperatures up to 980 ° C for a period of 12 min. Thereafter, the maximum compressive strength was measured.
  • a foundry molding sand was prepared by adding a mixture of bentonite, a macrocrystalline graphite, expandable graphite, and a porous additive component or a porous additive to the masterbatch as a premix, as described in Example 1.
  • the compounding ingredients added to the mold base include about 85% by weight of bentonite, 8.5% by weight of the macrocrystalline graphite, 3% by weight of the expanded graphite and 3.5% by weight of natural zeolite (clinoptilolite).
  • the abovementioned premix constituents as a whole are added to the molding material at about 8% by weight, based on the finished mixture, so that the Form base material in the finished mixture occupies a share of about 92 wt .-%.
  • This foundry molding sand mixture according to the invention is compared with a conventional mixture of a molding base with 7 wt .-% bentonite and 2 wt .-% coal dust, which is characterized in the following Table 2 as "prior art".
  • Table 2 State of the art invention Compaction or degree of compaction % 40 40 density g / dm 3 1505 1545 Dry compressive strength at 150 ° C / 3 hrs. N / cm2 27 35 Dry compressive strength at 350 ° C / 1.5 hrs. N / cm2 19 0 Dry pressure strength at 550 ° C / 45 min. N / cm2 16 0
  • the binding effect has drastically decreased, which supports the previously given interpretation that the foundry molding sand according to the invention disintegrates reliably immediately after production of the casting material.
  • the mold base material as a whole is not destroyed and can easily be reprocessed, with recycling rates or regeneration rates for the basic molding material of up to 98% being observed. That is, in a casting usually go only a maximum of 2 wt .-% of mold base lost.
  • Fig. 1 a foundry molding sand according to the embodiment 2.
  • Fig. 1 is the beginning of the breaking up of the respective binding bridge to recognize, while the Fig. 2 represents the broken bond bridge.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Mold Materials And Core Materials (AREA)

Claims (9)

  1. Procédé de fabrication d'un sable à noyaux et/ou d'un sable de coulée pour la fonderie, selon lequel
    - on mélange le composant de moulage de base minéral granulé avec un additif de gonflage faisant preuve d'un indice de gonflement au creuset d'au moins 9, ainsi qu'avec un agent de liaison anorganique et selon lequel
    - on compacte le mélange final du composant de moulage de base, de l'additif de gonflage et de l'agent de liaison, à savoir jusqu'à une augmentation de la densité d'au moins 20g/dm3.
  2. Procédé selon la revendication 1, caractérisé en ce que qu'on mélange d'abord l'agent de liaison avec l'additif de gonflage et on ajoute ensuite ce mélange de fonderie au composant de moulage de base.
  3. Procédé selon la revendication 1 ou la revendication 2, caractérisé en ce qu'on prépare l'agent de liaison et l'additif de gonflage par extrusion commune en particules de mélange (pellets) pour les ajouter au composant de moulage de base.
  4. Procédé selon la revendication 3, caractérisé en ce qu'on tamise les particules du mélange jusqu'à obtenir une granulation de 5 µm à 500 µm, notamment de 10 µm à 200 µm.
  5. Procédé selon l'une quelconque des revendications 1 à 4, caractérisé en ce qu'on fait sécher le prémélange de l'agent de liaison et de l'additif de gonflage jusqu'à obtenir une teneur en eau inférieure à 20 % en poids, notamment inférieure à 10 % en poids.
  6. Procédé selon l'une quelconque des revendications 1 à 5, caractérisé en ce que le prémélange de l'agent de liaison et de l'additif de gonflage contient environ 80 % en poids ou plus d'agent de liaison et environ 20 % en poids ou moins d'additif de gonflage, ainsi que le cas échéant d'autres adjuvants.
  7. Procédé selon la revendication 6, caractérisé en ce qu'en tant qu'adjuvants à l'additif de gonflage et à l'agent de liaison, on met en oeuvre par exemple un catalyseur et/ou un agent d'oxydation, comme par exemple de la bentonite avec plus de 10 % en poids de carbonate.
  8. Procédé selon l'une quelconque des revendications 1 à 7, caractérisé en ce qu'on compacte le mélange fini du composant de moulage de base, de l'additif de gonflage, de l'agent de liaison anorganique et le cas échéant de l'adjuvant au moyen d'un procédé de compression, comme le sautage, par impulsion d'air, par pressage, etc.
  9. Procédé selon l'une quelconque des revendications 1 à 8, caractérisé en ce qu'on met en oeuvre l'additif de gonflage avec une granulation de l'ordre de 10 nm à 3000 nm.
EP08009314.9A 2007-06-12 2008-05-21 Procédé de fabrication d'un noyau et/ou sable de moule pour des besoins de fonderie Active EP2014391B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE102007027621A DE102007027621A1 (de) 2007-06-12 2007-06-12 Verfahren zur Herstellung eines Kern-und/oder Formsandes für Gießereizwecke

Publications (3)

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EP2014391A2 EP2014391A2 (fr) 2009-01-14
EP2014391A3 EP2014391A3 (fr) 2011-08-31
EP2014391B1 true EP2014391B1 (fr) 2014-03-12

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US (1) US8029711B2 (fr)
EP (1) EP2014391B1 (fr)
DE (1) DE102007027621A1 (fr)

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CN104174810A (zh) * 2014-08-29 2014-12-03 无锡柯马机械有限公司 一种铸造工艺

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DE102009041677A1 (de) 2009-09-16 2011-03-24 Süd-Chemie AG Gießereiadditiv auf Grafitbasis
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FR2991314B1 (fr) * 2012-05-30 2014-06-06 Saint Gobain Placo Composition de platre pour moules refractaires
BR112015015966A2 (pt) * 2013-01-04 2017-07-11 S & B Ind Minerals Gmbh método para a produção de uma areia para núcleos e/ou areia de moldar para fins de fundição
CN104384437A (zh) * 2014-11-17 2015-03-04 无锡市百顺机械厂 一种铸造工艺
KR101840275B1 (ko) 2016-06-28 2018-03-20 현대자동차주식회사 차량용 질석 코어 및 그 제조 방법
EP3524372A1 (fr) * 2018-02-08 2019-08-14 Akademia Gorniczo-Hutnicza im. Stanislawa Staszica w Krakowie Mélange sableux de moulage ou de noyau
WO2020069272A1 (fr) * 2018-09-28 2020-04-02 Imerys Usa, Inc. Production d'une composition de prémélange de fonderie
CN114309452B (zh) * 2021-11-15 2023-07-25 北京仁创砂业铸造材料有限公司 覆膜砂添加剂、覆膜砂及其制备方法

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CN104174810A (zh) * 2014-08-29 2014-12-03 无锡柯马机械有限公司 一种铸造工艺

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US8029711B2 (en) 2011-10-04
EP2014391A2 (fr) 2009-01-14
EP2014391A3 (fr) 2011-08-31
US20090025606A1 (en) 2009-01-29
DE102007027621A1 (de) 2008-12-18

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