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EP2941327B1 - Procede de fabrication d'un sable pour noyaux et ou moules de fonderie - Google Patents

Procede de fabrication d'un sable pour noyaux et ou moules de fonderie Download PDF

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Publication number
EP2941327B1
EP2941327B1 EP14700045.9A EP14700045A EP2941327B1 EP 2941327 B1 EP2941327 B1 EP 2941327B1 EP 14700045 A EP14700045 A EP 14700045A EP 2941327 B1 EP2941327 B1 EP 2941327B1
Authority
EP
European Patent Office
Prior art keywords
expandable graphite
sand
casting
core
weight
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.)
Not-in-force
Application number
EP14700045.9A
Other languages
German (de)
English (en)
Other versions
EP2941327A1 (fr
Inventor
Andreas Wolff
Bettina VENNEMANN
Dieter Genske
Peter OBERSCHELP
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Imertech SAS
Original Assignee
Imerys Metalcasting Germany GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Imerys Metalcasting Germany GmbH filed Critical Imerys Metalcasting Germany GmbH
Publication of EP2941327A1 publication Critical patent/EP2941327A1/fr
Application granted granted Critical
Publication of EP2941327B1 publication Critical patent/EP2941327B1/fr
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • 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
    • B22C1/14—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 for separating the pattern from the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
    • B22C1/18—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
    • B22C1/18—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents
    • B22C1/186—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents contaming ammonium or metal silicates, silica sols
    • B22C1/188—Alkali metal silicates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores

Definitions

  • the invention relates to a method for producing a core and / or foundry sand for foundry purposes, after which a granular mineral and refractory molding base material is mixed with at least one inorganic binder and additionally an inorganic blowing additive.
  • Bentonite is typically used as a binder.
  • the additional added blowing additive may be perlite, vermiculite or expandable graphite.
  • the bulking additive has a Blähinger of at least 9, that is, the Blveshadditiv in question multiplies its volume at a certain temperature accordingly. This temperature is typically at 300 ° C. As a result, harmful emissions in particular are avoided and the casting quality is improved.
  • Inorganic binders such as bentonite according to EP 2 014 391 A2 are equipped with the fundamental advantage over organic binders that significantly less pollutants are released during casting.
  • bentonite as an inorganic binder for molds and cores it is also possible in principle to use molding material mixtures for the production of casting molds for metal processing, which use a glass-water-based binder, as described in US Pat DE 10 2004 042 535 A1 is described.
  • JP 58968446 A a core or foundry sand for foundry purposes has become known, which in addition to a molding material such as sand in addition on vermiculite, mica or other thermally expanding particles.
  • a molding material such as sand in addition on vermiculite, mica or other thermally expanding particles.
  • water glass and phenolic resins and other binders are addressed. This should be improved in the end, the disintegration of the mold.
  • the US 3,848,655 A deals with the production of a steel bar. This is produced in a casting mold, for the realization of which a sand mixture is used. From the sand mixture, the mold is made using a binder. As possible binders various resins such as phenolic resins or water glass, cement and clay and mixtures are listed as examples. In addition, exothermic substances are used as an additive, which may be carbonaceous materials. Possible carbonaceous materials include coal dust or expanded graphite.
  • the individual grains of the granular mineral and refractory molding base material are bonded or glued together.
  • the molding base material is typically sand or quartz sand.
  • the physical curing of the binder, for example, from the water glass is done regularly by heating by moisture is removed by drying. Drying can be done in a hot core box, by hot air blowing in the core box concerned, or by microwave heating or in a conventional oven.
  • the grains of the molding base material are connected to each other via binder bridges produced with the aid of the binder.
  • the under the EP 2 014 391 A2 or according to the US 4 505 750 A Added added Blähadditive now ensure that the coring easier becomes. Because the swelling additive ensures that, for example, the core can be separated from the casting.
  • the DD 158 090 A1 with a method for controlling the strength of inorganic molding materials based on alkali metal silicate solutions.
  • the special characteristic of water glass is described as a binder and also the unsatisfactory decay properties are presented in this context.
  • the invention is based on the technical problem of developing a method of the type described above so that a perfect and rapid disintegration of the mold is associated with a perfect surface of the casting.
  • a generic method in the context of the invention is characterized in that are used as a binder water glass and as blowing additive expandable graphite.
  • water glass is first used as the binder.
  • Water glass is known to be solidified from a melt glassy water-soluble sodium and potassium silicates or their aqueous solutions. Depending on whether predominantly sodium or potassium silicates are contained, one speaks of soda water glass or potassium water glass.
  • Such waterglasses are characterized by a high rate of setting and low emissions.
  • the use of water glass in the foundry technology for hardening molds and cores is known in principle, as the DE 10 2004 042 535 A1 exemplified, but not in combination with an additional blowing additive in the form of expandable graphite.
  • expanded graphites are special graphites which typically expand by about 50 to 600 volume percent upon heating to temperatures above 150 ° C.
  • the aforesaid expansion can be determined, for example, so that the expandable graphite 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 volume increase.
  • a certain amount of expandable graphite (in g) is used in this process, so that not only the increase in volume can be specified, but also an expansion rate, ie the volume increase (in cm 3 ) per gram of expanded graphite used.
  • thermochemical analysis dimensional changes of expanded graphite or individual graphite particles are measured as a function of temperature and time.
  • the respective sample of expandable graphite is applied to a sample carrier and the dimensional changes of the sample are measured and recorded with the aid of a measuring probe as a function of the heating temperature and the heating time.
  • the powdery sample of expanded graphite can be introduced into a corundum crucible, which is covered with a steel crucible.
  • the steel crucible ensures the smooth transfer of the dimensional changes of the sample to the probe, which is in mechanical contact with the top of the steel crucible, as the sample expands.
  • the probe is subjected to an adjustable load.
  • thermochemical analysis TMA
  • EP 1 489 136 A1 the expanded graphite can be characterized by its rate of expansion, that is to say the volume increase (in cm 3 ) relative to the mass (in g), inter alia.
  • the expandability of expanded graphite can be attributed to the fact that between the lattice planes of the graphite impurities are embedded, which cause the expansion of the lattice plane spaces when energized.
  • These foreign constituents may be metallic groups, halogens, OH groups, acid residues or SOx and / or NOx.
  • weakly expanding expandable graphites are used which, on the one hand, considerably improve coring, and on the other hand have practically no negative influence on the surface of the casting which forms after casting.
  • an expanded graphite having an expansion rate of more than 10 cm 3 / g and in particular such having an expansion rate of 10 to 100 cm 3 / g, a maximum of 120 cm 3 / g, has proven to be particularly favorable.
  • the lower limit of 10 cm 3 / g is explained by the fact that only at such an expansion rate of expandable graphite a coring is made possible, that is, the shape without adherence to the casting properly disintegrates.
  • expansion rates of up to 350 cm 3 / g and especially those of up to 100 cm 3 / g are particularly preferred.
  • the expansion rate indicates the increase in volume of expandable graphite (in cm 3 ) relative to its mass (in g).
  • the expandable graphite In the production of the expandable graphite according to the invention generally sulfur or nitrogen compounds are incorporated into the individual layers of graphite. It is therefore SOx or NOx expandable graphite. These typically have a starting temperature for expansion that is greater than 180 ° C. In particular, a starting temperature of about 220 ° C is observed. That is, only above the specified temperatures (> 180 ° C), the previously stated volume increase is observed.
  • expandable graphite is typically used one whose particle size is more than 20 microns.
  • particles or grains are used in a diameter range from 20 .mu.m to 150 .mu.m and preferably those with a grain size between 150 .mu.m and 300 .mu.m.
  • the described grain size of the expanded graphite up to a maximum of 300 ⁇ m takes into account, among other things, the fact that usually granular mineral sand, in particular quartz sand, is used as the molding base material. This is usually in a mean grain size ⁇ 0.5 mm before, that is with a grain diameter of typically less than 500 microns. In general, its grain size ranges between 100 ⁇ m to 300 ⁇ m. As a result, the grains of on the one hand the expanded graphite and on the other hand the mold base material are approximately the same size, which favors the mixing of the molding material with the expandable graphite and its uniform distribution within the produced core and / or molding sand.
  • Expanded graphite generally has a carbon content of 85% to 99.5% by weight.
  • the maximum moisture of the expanded graphite is in the range of at most 1 wt .-%.
  • the PH value may be between 3 and 8.
  • the starting temperature is in the range between 180 ° C and 220 ° C.
  • the expandable graphite is added to the mixture in a proportion of up to about 1% by weight and preferably up to about 0.5% by weight.
  • the mixture is the mixture of the granular mineral molding base material and the at least one inorganic binder.
  • the inorganic blowing additive in the form of expandable graphite is added to this mixture.
  • Particularly preferred is a proportion of expandable graphite in the mixture in question of about 0.1 wt .-%.
  • the percentages by weight in each case relate to the molding material used.
  • the expanded graphite ensures that the surface of the casting that is formed is not or is not negatively affected. This can essentially be attributed to the fact that, on the one hand, the weak expansion of the expandable graphite does not exert excessive pressure on the grains of the basic molding material with pressure built up from the inside, but rather causes the moderate expansion rate mainly to break up the binder bridges. On the other hand, the expanding expanded graphite is in a particularly fine distribution, so that inclusions on the surface of the casting in principle can not or practically do not occur.
  • the bentonite-bonded test specimen corresponds to the state of the art, as used in the EP 2 014 391 A2 is described and used as an inorganic binder bentonite.
  • the water-glass-bonded test specimen belongs to the process according to the invention, in which water glass (in conjunction with expandable graphite as intumescent additive) is used as binder.
  • bentonite-bonded molding material 5% by weight bentonite (based on the quartz sand) + water + quartz sand was used as the bentonite-bonded molding material.
  • the bentonite-bonded molding material has 0.3 wt .-% expandable graphite (based on the quartz sand) with an expansion rate ⁇ 100 cm 3 / g. The entire production of the test specimens was carried out in the laborkorkergergang and according to the educachanurgiher ein VDG leaflet P 69.
  • the water-glass-bonded molding material according to the method of the invention from 1.6 wt .-% water glass (based on the quartz sand or the granular mineral mold base material) and the same proportion of expandable graphite as before and the rest quartz sand.
  • the test specimen was produced here in a wing mixer and the hardening of the water-glass bonded cores in a drying oven.
  • water glass bonded moldings or molding materials without stabilizing mold frame can be produced so that they can be handled freely and inexpensively and so can be used as bentonite bonded moldings also in terms of their casting technology application for a wider range of applications.
  • cores to form inner contours for example, water jacket cores in the production of molds for water-cooled engines to name, which can not be imagined with bentonite-bonded cores and handled.
  • the core and / or foundry sand produced by the process according to the invention can be used advantageously for the production of casting molds for iron-carbon alloys, aluminum alloys, copper alloys such as brass, bronze, etc. but also for magnesium alloys and castings produced therefrom.
  • the casting molds in question are typically used in the automotive industry. In fact, this makes it possible to realize casting molds which have particularly delicate structures with thin contours and in particular core contours in the range of only a few millimeters. Such narrow contours and in particular channels for cooling water in the production of cylinder heads can be realized particularly advantageously with the aid of casting molds which have been produced on the basis of the inventively producing core and / or molding sand.
  • the main advantages of the doctrine of invention are also the main advantages of the doctrine of invention.
  • Photograph shown is a casting shown in the left photo, which without expandable graphite recourse to a core and / or molding sand and water glass has been prepared as a binder.
  • the right photograph in the Fig. 1 shows the workpiece in question with added expanded graphite in an amount of 0.1 wt .-% based on the produced core or molding sand (also with water glass as a binder, in both cases the same grammages for water glass and the core or foundry sand and also the same core or molding sand was used.
  • the Fig. 2 and 3A to 3C show the basic process in the production of a mold using the core and / or molding sand according to the invention.
  • Fig. 2 one recognizes how predominantly hatched grains of sand 1, together with black inorganic binder or water glass 2, fill a water jacket core of a corresponding core shape.
  • Fig. 3A By way of example, two grains or grains of sand 1 of the basic molding material are coupled together by a bridge made of the inorganic binder or water glass 2 shown in black.
  • the Fig. 3B shows how when crossing the starting temperature, a crack in the formed by inorganic binder or the water glass 2 bridge between the sand grains 1 is formed. For this purpose, essentially the expanding graphite expanding above the starting temperature is responsible.
  • the Fig. 3C finally shows the breakage of the binder bridge 3 produced by the binder or water glass 2 in this way.

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

Claims (10)

  1. Procédé pour la fabrication d'un sable à noyaux et / ou d'un sable à moulage utilisé en fonderie, à la suite de quoi une matière de base de moulage granulaire minérale est mélangée avec au moins un liant inorganique et en plus un agent gonflant inorganique, caractérisée en ce que le liant utilisé est du silicate de sodium [verre soluble] et l'agent gonflant du graphite expansé, où le graphite expansé possède un taux d'expansion maximal de 350 cm3/g.
  2. Procédé selon la revendication 1, caractérisé en ce que le graphite expansé a un taux d'expansion de 10 à 100 cm3/g.
  3. Procédé selon la revendication 1 ou 2, caractérisé en ce que la température de départ pour l'expansion du graphite expansé se situe à plus de 180 °C, en particulier dans une plage comprise entre environ 180 °C et 220 °C.
  4. Procédé selon l'une des revendications 1 à 3, caractérisé en ce que le graphite expansé est ajouté avec une granulométrie de plus de 20 µm, en particulier dans une plage de 20 à 150 µm et de préférence entre environ 150 µm et 300 µm.
  5. Procédé selon l'une des revendications 1 à 4, caractérisé par l'utilisation de graphite expansé SOx ou NOx.
  6. Procédé selon l'une des revendications 1 à 5, caractérisé en ce le graphite expansé a une teneur en carbone de 85 % à 99,5 % en poids.
  7. Procédé selon l'une des revendications 1 à 6, caractérisé en ce que le graphite expansé est ajouté au mélange de base ainsi qu'au silicate de sodium à un taux d'environ 1 % en poids, préférablement avec un taux jusqu'à environ 0,5 % en poids et encore plus préférablement avec un taux jusqu'à environ 0,1 % en poids, à chaque fois par rapport à la base de moulage.
  8. Procédé selon l'une des revendications 1 à 7, caractérisé en ce que le graphite expansé est ajouté au silicate de sodium et ensuite mélangé avec la base de moulage ou ajouté à la base de moulage comme additif séparé, y compris le silicate de sodium.
  9. Utilisation d'un sable à noyaux et / ou d'un sable à moulage fabriqué selon les revendications 1 à 8 pour la fabrication de moules de coulage pour des alliages d'aluminium coulé, des alliages fer-carbone, des alliages de cuivre et / ou des alliages de magnésium.
  10. Utilisation selon la revendication 9, caractérisée en ce que le moule de coulage est utilisé dans l'industrie automobile.
EP14700045.9A 2013-01-04 2014-01-03 Procede de fabrication d'un sable pour noyaux et ou moules de fonderie Not-in-force EP2941327B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102013100060 2013-01-04
PCT/EP2014/050055 WO2014106646A1 (fr) 2013-01-04 2014-01-03 Procédé de fabrication d'un sable pour noyaux et/ou moules de fonderie

Publications (2)

Publication Number Publication Date
EP2941327A1 EP2941327A1 (fr) 2015-11-11
EP2941327B1 true EP2941327B1 (fr) 2018-07-25

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP14700045.9A Not-in-force EP2941327B1 (fr) 2013-01-04 2014-01-03 Procede de fabrication d'un sable pour noyaux et ou moules de fonderie

Country Status (6)

Country Link
US (2) US20150367406A1 (fr)
EP (1) EP2941327B1 (fr)
CN (1) CN105073298A (fr)
BR (1) BR112015015966A2 (fr)
MX (1) MX2015008691A (fr)
WO (1) WO2014106646A1 (fr)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
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
DE102018006415A1 (de) * 2018-08-15 2020-02-20 Goldschmidt Thermit Gmbh Verfahren zum Abdichten einer Gießform für aluminothermische Schienenschweißungen

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GB461104A (en) * 1935-05-25 1937-02-10 Victor Krosta Process for the manufacture of precision castings from metals and alloys of high melting point
DD158090A1 (de) 1981-04-10 1982-12-29 Eckart Flemming Verfahren zur festigkeitsregulierung anorganischer formstoffe auf der basis von alkalisilikatloesungen
NZ200714A (en) 1981-06-24 1984-12-14 May & Baker Ltd Bolus comprising active material on bobbin for delivery to rumen
JPS5868446A (ja) * 1981-10-20 1983-04-23 Toyota Central Res & Dev Lab Inc 易崩壊性鋳型組成物
JPS6045976B2 (ja) * 1983-05-25 1985-10-14 岩谷産業株式会社 チタン又はチタン合金鋳造用の自硬性鋳型材料
US4505750A (en) * 1983-11-25 1985-03-19 Venture Chemicals, Inc. Foundry mold and core sands
JPH04319039A (ja) * 1991-04-15 1992-11-10 Ohara:Kk 純チタンまたはチタン合金鋳造用鋳型材
US5769933A (en) * 1996-06-21 1998-06-23 Amcol International Corporation Activated carbon foundry sand additives and method of casting metal for reduced VOC emissions
CN1137793C (zh) * 2000-08-17 2004-02-11 上海交通大学 膨胀型石膏铸粉及其水调制浆方法
CA2469534A1 (fr) 2003-06-18 2004-12-18 Hilti Aktiengesellschaft L'utilisation de composes d'insertion a base de graphite thermoextensibles pour la production de joints de protection contre les incendies et methode pour leur production
DE102004042535B4 (de) * 2004-09-02 2019-05-29 Ask Chemicals Gmbh Formstoffmischung zur Herstellung von Gießformen für die Metallverarbeitung, Verfahren und Verwendung
DE102007027621A1 (de) * 2007-06-12 2008-12-18 S&B Industrial Minerals Gmbh Verfahren zur Herstellung eines Kern-und/oder Formsandes für Gießereizwecke
CN102773403B (zh) * 2012-07-07 2014-02-12 山西宇清环保有限公司 一种采用树脂砂生产翻板阀盖的方法
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

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Also Published As

Publication number Publication date
CN105073298A (zh) 2015-11-18
US9764377B2 (en) 2017-09-19
US20150367406A1 (en) 2015-12-24
WO2014106646A1 (fr) 2014-07-10
EP2941327A1 (fr) 2015-11-11
BR112015015966A2 (pt) 2017-07-11
US20160346830A1 (en) 2016-12-01
MX2015008691A (es) 2016-03-04

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