US20180369906A1 - Sand shell-moulding method for the production of a part for use in the automotive and aeronautics fields - Google Patents
Sand shell-moulding method for the production of a part for use in the automotive and aeronautics fields Download PDFInfo
- Publication number
- US20180369906A1 US20180369906A1 US15/563,023 US201615563023A US2018369906A1 US 20180369906 A1 US20180369906 A1 US 20180369906A1 US 201615563023 A US201615563023 A US 201615563023A US 2018369906 A1 US2018369906 A1 US 2018369906A1
- Authority
- US
- United States
- Prior art keywords
- shell
- moulding method
- automotive
- production
- sand shell
- 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.)
- Abandoned
Links
- 238000000034 method Methods 0.000 title claims abstract description 26
- 239000004576 sand Substances 0.000 title claims abstract description 15
- 238000010112 shell-mould casting Methods 0.000 title claims abstract description 13
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 7
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 10
- 239000000956 alloy Substances 0.000 claims abstract description 10
- 229910052751 metal Inorganic materials 0.000 claims abstract description 8
- 239000002184 metal Substances 0.000 claims abstract description 8
- 238000005242 forging Methods 0.000 claims description 2
- 238000003825 pressing Methods 0.000 claims description 2
- 230000008901 benefit Effects 0.000 description 4
- 238000010791 quenching Methods 0.000 description 4
- 230000000171 quenching effect Effects 0.000 description 4
- 238000007711 solidification Methods 0.000 description 4
- 230000008023 solidification Effects 0.000 description 4
- 238000001816 cooling Methods 0.000 description 3
- 239000007788 liquid Substances 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 238000010146 3D printing Methods 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 230000002500 effect on skin Effects 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/002—Hybrid process, e.g. forging following casting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
Definitions
- the present disclosure relates to the foundry technical sector, notably to alloys of aluminum, magnesium, copper or other similar materials. More particularly, the present disclosure relates to a sand shell-moulding method, for the production of a part for use in the automotive and aeronautics fields.
- the sand shell-moulding method is well-known to a person skilled in the art.
- thermosetting resin which, in contact with a pattern plate, heated to a temperature of around 200° C., hardens over a layer of a few millimeters, constituting the shell.
- Each shell corresponds to a half-mould, which is then polymerized, then glued.
- This moulding method has several advantages, among which mention may be made of the possibility of producing very complex geometries, as well as the possibility of integrating various functions onto the part in question, for example an exhaust manifold on a cylinder head for motor vehicles. Other advantages are to be noted, for example, the reduction in weight of the parts obtained. Such a method requires, furthermore, low investment, and enables the number of machining operations to be reduced.
- the preform is subjected to a combined pressing and forging operation, as based on the method known under the brand COBAPRESS.
- This COBAPRESS method is based on, for example, the teachings from patent EP 0 119 365.
- This sand shell-moulding method enables mechanical characteristics to be obtained which are considerably better than those obtained in the case of a sand shell-moulding method, according to the prior art, as the test results below show, carried out with the same type of metal or alloy.
- SDAS corresponds to the interdendritic space, Rp to the elastic limit, Rm, to the mechanical resistance and A % to the elongation.
- the method combines the advantages of pouring into a sand shell making it possible to obtain parts having complex geometries, with a decrease in weight, reduction in machining operations, while requiring little investment, and while having good characteristics, as is shown by the comparative tests above. It is noted also that the application of the COBAPRESS method enables a large reduction in porosities, and of the skin effect.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Mold Materials And Core Materials (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Powder Metallurgy (AREA)
- Body Structure For Vehicles (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Forging (AREA)
Abstract
A sand shell-moulding method for the production of a part for use in the automotive and aeronautics fields, in which: a metal or alloy is poured into the shell mould in order to produce a part; the shell is forcibly and rapidly cooled; and an operation of decoring of the part is realized.
Description
- The present disclosure relates to the foundry technical sector, notably to alloys of aluminum, magnesium, copper or other similar materials. More particularly, the present disclosure relates to a sand shell-moulding method, for the production of a part for use in the automotive and aeronautics fields.
- The sand shell-moulding method is well-known to a person skilled in the art.
- It consists of using sand, pre-coated with a thermosetting resin which, in contact with a pattern plate, heated to a temperature of around 200° C., hardens over a layer of a few millimeters, constituting the shell. Each shell corresponds to a half-mould, which is then polymerized, then glued.
- Among the various sand shell-moulding methods, mentioned may be made of Croning, hot box, cold box, warm box, inorganic, etc).
- This moulding method has several advantages, among which mention may be made of the possibility of producing very complex geometries, as well as the possibility of integrating various functions onto the part in question, for example an exhaust manifold on a cylinder head for motor vehicles. Other advantages are to be noted, for example, the reduction in weight of the parts obtained. Such a method requires, furthermore, low investment, and enables the number of machining operations to be reduced.
- In contrast, the parts obtained by this shell-moulding method have mechanical characteristics, which are not always satisfactory in certain fields of application, considering the very low solidification rates.
- It would appear, therefore, that a shell-moulding method is particularly well-suited to the manufacture of complex geometrical parts, when these parts do not require good mechanical characteristics.
- Yet, it has emerged that not only is the geometry of parts becoming increasingly complex but the mechanical characteristics of such parts must reach high levels, in order to meet specifications.
- From this prior art and this situation, it therefore seems important to be able to improve the sand shell-moulding method, in order to be able to obtain parts with very complex geometries, having good mechanical characteristics.
- To overcome such a problem, a sand shell-moulding method has been designed according to which, in a first embodiment:
-
- a metal or alloy is poured into the shell in order to produce a part,
- the shell is forcibly and rapidly cooled,
- an operation of decoring of the part is realized.
- Such a method has particularly advantageous application in the automotive and aeronautical fields, for the production of very complex parts, requiring very good mechanical characteristics. The sand shell is manufactured, in a known way, according to a method adapted to the nature of the part to be obtained (hot box, cold box, warm box, 3D printing, etc.). The shell thicknesses are also adapted, according to the characteristics of the part to be obtained, in order to reach the best possible compromise between the metallostatic pressure and thermal resistance of the interface.
- As indicated, after having poured the metal or alloy, the sand shell, containing said metal or said alloy, still in a liquid state, or in the solidification phase, is then cooled, for example, via quenching. In a known manner, this quenching can be by means of water, oil, air, or any other means enabling such cooling. Rapid and forced cooling means that the shell is quenched while the alloy is still liquid. By way of a non-limiting example, the quenching temperature is lower than 100° C.
- These two operations of pouring and cooling have a two-fold benefit, which is, firstly, to enable the orientation of the solidification front by establishing, during quenching, a thermal gradient, and secondly, to increase the solidification rates, and consequently, the mechanical characteristics of the resulting part.
- The part then simply needs to be subjected to a conventional decoring operation, said decoring may be chemical, thermal or mechanical.
- In another embodiment of the method, a metal or alloy is poured into the shell in order to no longer produce a final part, but rather a preform. The profile of the shell is, obviously, consequently adapted. Then, as previously indicated, the shell is cooled, in a forced and rapid manner, and an operation of decoring of the preform is realized.
- In this embodiment of the moulding method, the preform is subjected to a combined pressing and forging operation, as based on the method known under the brand COBAPRESS. This COBAPRESS method is based on, for example, the teachings from patent EP 0 119 365.
- This sand shell-moulding method, according to this disclosure, enables mechanical characteristics to be obtained which are considerably better than those obtained in the case of a sand shell-moulding method, according to the prior art, as the test results below show, carried out with the same type of metal or alloy.
- Shell Moulding Method According to the Prior Art:
-
- SDAS: 60-70 μm
- Rp0.2=200-220 MPa
- Rm=240-260 MPa
- A %=1-2%
- Shell Moulding Method According to the Present Disclosure:
-
- SDAS: 30-35 μm
- Rp0.2=220-260 MPa
- Rm=290-310 MPa
- A %=6-8%
- formulae wherein SDAS corresponds to the interdendritic space, Rp to the elastic limit, Rm, to the mechanical resistance and A % to the elongation.
- It appears from the characteristics of the method that the method combines the advantages of pouring into a sand shell making it possible to obtain parts having complex geometries, with a decrease in weight, reduction in machining operations, while requiring little investment, and while having good characteristics, as is shown by the comparative tests above. It is noted also that the application of the COBAPRESS method enables a large reduction in porosities, and of the skin effect.
Claims (2)
1/ A sand shell-moulding method, for the production of a part for use in the automotive and aeronautics fields, in which:
a metal or alloy is poured into the shell in order to produce a part,
the shell is forcibly and rapidly cooled,
an operation of decoring of the part is realized.
2/ A sand shell-moulding method, for the production of a part for use in the automotive and aeronautics fields, in which:
a metal or alloy is poured into the shell in order to produce a preform,
the shell is forcibly and rapidly cooled,
an operation of decoring of the preform is realized,
the preform is subjected to a combined pressing and forging operation.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| FR1552788 | 2015-04-01 | ||
| FR1552788A FR3034332A1 (en) | 2015-04-01 | 2015-04-01 | PROCESS FOR SANDING CARAPLE MOLDING FOR THE PRODUCTION OF A PART IN THE AUTOMOTIVE AND AERONAUTICS FIELD |
| PCT/FR2016/050579 WO2016156692A1 (en) | 2015-04-01 | 2016-03-16 | Sand shell-moulding method for the production of a part for use in the automotive and aeronautics fields |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| US20180369906A1 true US20180369906A1 (en) | 2018-12-27 |
Family
ID=53274664
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US15/563,023 Abandoned US20180369906A1 (en) | 2015-04-01 | 2016-03-16 | Sand shell-moulding method for the production of a part for use in the automotive and aeronautics fields |
Country Status (10)
| Country | Link |
|---|---|
| US (1) | US20180369906A1 (en) |
| EP (1) | EP3277451A1 (en) |
| JP (1) | JP2018516761A (en) |
| KR (1) | KR20170132771A (en) |
| CN (1) | CN107427906A (en) |
| CA (1) | CA2981374A1 (en) |
| FR (1) | FR3034332A1 (en) |
| MA (1) | MA41836A (en) |
| MX (1) | MX2017012495A (en) |
| WO (1) | WO2016156692A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11958105B2 (en) | 2022-03-09 | 2024-04-16 | Honda Motor Co., Ltd. | Rapid solidification of molded products |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4222429A (en) * | 1979-06-05 | 1980-09-16 | Foundry Management, Inc. | Foundry process including heat treating of produced castings in formation sand |
| EP0058180A1 (en) * | 1980-08-29 | 1982-08-25 | Fischer Ag Georg | Method for quenching sand hollow forms and cast metallic pieces, application of that method and apparatus for carrying out that method. |
| EP0119365A1 (en) * | 1983-03-14 | 1984-09-26 | Thomas Di Serio | Method of producing pieces of aluminium or aluminium alloy |
| US5450665A (en) * | 1992-12-18 | 1995-09-19 | Riken-Chuzo Corporation | Method for manufacturing a hollow camshaft having oil-feeding holes on its chilled face |
| US20030106665A1 (en) * | 2001-12-06 | 2003-06-12 | Song Shihong Gary | Rapid solidification investment casting |
Family Cites Families (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3763926A (en) * | 1971-09-15 | 1973-10-09 | United Aircraft Corp | Apparatus for casting of directionally solidified articles |
| JPS57202943A (en) * | 1981-06-05 | 1982-12-13 | Kubota Ltd | Manufacture of casting mold |
| JPH02280956A (en) * | 1989-04-21 | 1990-11-16 | Kobe Steel Ltd | Lost wax casting method |
| UA39902C2 (en) * | 1994-08-08 | 2001-07-16 | Сіменс Акцієнгезельшафт | METHOD AND DEVICE FOR DIRECTED HARDENING OF MELT |
| US6311760B1 (en) * | 1999-08-13 | 2001-11-06 | Asea Brown Boveri Ag | Method and apparatus for casting directionally solidified article |
| US8186418B2 (en) * | 2010-09-30 | 2012-05-29 | General Electric Company | Unidirectional solidification process and apparatus therefor |
| US20130160967A1 (en) * | 2011-12-23 | 2013-06-27 | General Electric Company | Casting methods for making articles having a fine equiaxed grain structure |
| FR2995235B1 (en) * | 2012-09-11 | 2016-12-09 | Snecma | FOUNDRY MODEL |
| US10082032B2 (en) * | 2012-11-06 | 2018-09-25 | Howmet Corporation | Casting method, apparatus, and product |
| FR3000910B1 (en) * | 2013-01-17 | 2015-05-01 | Snecma | PROCESS FOR MANUFACTURING A PIECE BY LOST WAX FOUNDRY AND DIRECTED COOLING |
| CN103286279B (en) * | 2013-07-03 | 2015-02-11 | 韶关市富迪精密铸造有限公司 | Novel casting technique of semitrailer brake drum |
-
2015
- 2015-04-01 FR FR1552788A patent/FR3034332A1/en not_active Ceased
-
2016
- 2016-03-15 MA MA041836A patent/MA41836A/en unknown
- 2016-03-16 JP JP2018502335A patent/JP2018516761A/en active Pending
- 2016-03-16 WO PCT/FR2016/050579 patent/WO2016156692A1/en not_active Ceased
- 2016-03-16 CA CA2981374A patent/CA2981374A1/en not_active Abandoned
- 2016-03-16 EP EP16712064.1A patent/EP3277451A1/en not_active Withdrawn
- 2016-03-16 US US15/563,023 patent/US20180369906A1/en not_active Abandoned
- 2016-03-16 KR KR1020177027455A patent/KR20170132771A/en not_active Withdrawn
- 2016-03-16 CN CN201680019693.6A patent/CN107427906A/en active Pending
- 2016-03-16 MX MX2017012495A patent/MX2017012495A/en unknown
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4222429A (en) * | 1979-06-05 | 1980-09-16 | Foundry Management, Inc. | Foundry process including heat treating of produced castings in formation sand |
| EP0058180A1 (en) * | 1980-08-29 | 1982-08-25 | Fischer Ag Georg | Method for quenching sand hollow forms and cast metallic pieces, application of that method and apparatus for carrying out that method. |
| EP0119365A1 (en) * | 1983-03-14 | 1984-09-26 | Thomas Di Serio | Method of producing pieces of aluminium or aluminium alloy |
| US5450665A (en) * | 1992-12-18 | 1995-09-19 | Riken-Chuzo Corporation | Method for manufacturing a hollow camshaft having oil-feeding holes on its chilled face |
| US20030106665A1 (en) * | 2001-12-06 | 2003-06-12 | Song Shihong Gary | Rapid solidification investment casting |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11958105B2 (en) | 2022-03-09 | 2024-04-16 | Honda Motor Co., Ltd. | Rapid solidification of molded products |
Also Published As
| Publication number | Publication date |
|---|---|
| JP2018516761A (en) | 2018-06-28 |
| EP3277451A1 (en) | 2018-02-07 |
| FR3034332A1 (en) | 2016-10-07 |
| WO2016156692A1 (en) | 2016-10-06 |
| MA41836A (en) | 2018-02-06 |
| MX2017012495A (en) | 2018-07-06 |
| CN107427906A (en) | 2017-12-01 |
| KR20170132771A (en) | 2017-12-04 |
| CA2981374A1 (en) | 2016-10-06 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| AS | Assignment |
Owner name: SAINT JEAN INDUSTRIES, FRANCE Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:DI SERIO, EMILE THOMAS;MALHERBE, GUILLAUME;DUPERRAY, LIONEL;REEL/FRAME:043739/0489 Effective date: 20170916 |
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| STPP | Information on status: patent application and granting procedure in general |
Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION |
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| STPP | Information on status: patent application and granting procedure in general |
Free format text: NON FINAL ACTION MAILED |
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| STPP | Information on status: patent application and granting procedure in general |
Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER |
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| STPP | Information on status: patent application and granting procedure in general |
Free format text: FINAL REJECTION MAILED |
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| STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |