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US2903375A - Method of coating a mould for use in a foundry - Google Patents

Method of coating a mould for use in a foundry Download PDF

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Publication number
US2903375A
US2903375A US670643A US67064357A US2903375A US 2903375 A US2903375 A US 2903375A US 670643 A US670643 A US 670643A US 67064357 A US67064357 A US 67064357A US 2903375 A US2903375 A US 2903375A
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Prior art keywords
coating
mould
last
moulds
chromium
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US670643A
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Peras Lucien
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Renault SA
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Renault SA
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C23/00—Tools; Devices not mentioned before for moulding
    • B22C23/02—Devices for coating moulds or cores
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00—Stock material or miscellaneous articles
    • Y10S428/922—Static electricity metal bleed-off metallic stock
    • Y10S428/9335—Product by special process
    • Y10S428/939—Molten or fused coating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/1266—O, S, or organic compound in metal component
    • Y10T428/12667—Oxide of transition metal or Al
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12771—Transition metal-base component
    • Y10T428/12861—Group VIII or IB metal-base component
    • Y10T428/12951—Fe-base component
    • Y10T428/12972—Containing 0.01-1.7% carbon [i.e., steel]

Definitions

  • the invention relates to a method ofpreparation of foundry moulds.
  • a further difliculty arises from the very intense ther mal shock to which the mould is subjected, and from the high temperature reached over the whole surface of contact between the chill-mould and the liquid metal; for that reason, it is the general rule, as in the case of ingot moulds in steel works, to apply a coating to the surface.
  • the pourings follow each other regularly at very short intervals into the same mould, and the usual techniques of coating do not give satisfactory results.
  • the application of a refractory coating has a powerful cooling effect on the surface of the mould at each application by brush or by spraying gun as a result of the evaporation of the dispersive liquid.
  • Projection by a spraying gun of a molten refractory product such as alumina on the mould, before it is put into service, does not give a satisfactory adhesion and resistance to thermal shock of the coating on the mould, especially in those parts of the moulds which form projections.
  • the method forming the object of the invention does not have any of the drawbacks referred to and enables a large number of successive mouldings to be effected without deterioration of the coating and, in consequence, ensures a long life in service of the metal mould for the pouring of ferrous alloys such as cast-iron, but this process is equally applicable to the moulding of any metal or alloy with a high melting point, such as aluminium bronze, stainless steel, refractory alloys with a base of nickel, etc.
  • This process consists in applying successively, before the moulds are put into service, at least two difierent coatings, the first of which has intermediate properties between the metal mould and the last refractory coating.
  • the first coating is formed, starting from rods prepared either by rolling or by drawing, or by melting and moulding, or by moulding a powder which is then sintered.
  • This coating is constituted by a relatively refractory metallic alloy, or of a cermet or a mixture of refractory oxide and metallic alloy rich in metal; in both cases, the alloy is rich in chromium (18% to 80% for example) and is used in wire or in rods and projected by means of a projection blow-pipe at a sufficiently high temperature to melt the alloy and to project it in very small drops on the surface of the metal mould on which the spray condenses to give a highly ad- Patented Sept. 8, 1959 "ice herent fine film
  • this first coating there may be employed:
  • These rods may be-made by moulding from powder and sintering at about 1700" in hydrogen or an inert gas.
  • the second coating also projected by means of a blowpipe gunis formedby a cermet rich in alumina, the metallic portion of which is rich in chromium and can be constituted by one of 'the following alloys:
  • the proportion of the metallic part to the alumina may be comprised between 10% and 50% by weight of metal to to 50% of alumina respectively.
  • the alloy can be previously prepared and then reduced to powder, mixed intimately with the alumina and with an organic agglomerating product in an aqueous or alcoholic medium, so as to obtain a paste which is moulded or drawn into rods which are then dried, baked and sintered at high temperature in an inert atmosphere such as hydrogen.
  • the alloy can be obtained by effecting the mixture directly of the pure metals in powder form with alumina, compressing the powdered mixture into the form of rods, and then sinteiing at high temperature in an inert atmosphere.
  • the coating of the mould is limited to the two coatings described; in the case of a greater number of coatings, the intermediate layers may be of the same nature as either of the two others or again they may be of an intermediate nature or composition.
  • the layers thus formed on the mould may be covered with a purely refractory coating of the usual type.
  • This coating may be projected in the molten state by means of a blow-pipe, it may be a liquid or an emulsion applied with a spray gun or with a brush, or finally it may be a solid projected in the state of a cloud of dust, for example by means of a small blower or a sooty flame.
  • This solid may be alumina, silica, a silico-aluminate, or any other refractory product, graphite, lamp-black, or acetylene black; it may contain an organic material such as tar or lac.
  • a method of protecting the surfaces of metallic moulds for casting metals and alloys which comprises the application in succession to said surfaces before said moulds are put in service, of a plurality of coatings including a first coating and a last coating, with said last coating comprising a cermet containing 50 to 90% 0f coatings being applied by projection in molten form,
  • a method of protecting the surfaces of metallic moulds for casting metals and alloys which comprises the application in succession to said surfaces before said moulds are put in service, of a plurality of coatings including a first coating and a last coating, with said last coating comprising a cermet containing 50 to 90% of alumina and to 50% of a metal component containing 70 to 100% chromium, and said first coating being an alloy containing to chromium, said first and said last coatings being applied by projection in molten form.
  • a method of protecting the surfaces of metallic moulds for casting metals and alloys which comprises the application in succession to said surfaces before said moulds are put in service, of a plurality of coatings including a first coating and a last coating, with said last coating comprising a cermet containing to 90% of alumina and 10 to 50% of a metal component containing to 100% chromium, and said first coating being an alloy containing 10 to 30% of a metal selected from the group consisting of molybdenum, tungsten, nickel, cobalt and iron, the balance being chromium, said first and said last coatings being applied by projection in molten form.
  • a method of protecting the surfaces of metallic moulds for casting metals and alloys which comprises the application in succession to said surfaces before said moulds are put in service, of a plurality of coatings in cluding a first coating and a last coating, with said last coating comprising a cermet containing 50 to 90% of alumina and 10 to 50% of a metal component containing 70 to 100% chromium, and said first coating being a cermet containing 10 to 30% of a metal selected from the group consisting of molybdenum, tungsten, nickel, cobalt and iron, and up to 20% of alumina, the balance being chromium, said first and said last coatings being applied by projection in molten form.
  • a method of protecting the surfaces of metallic moulds for casting metals and alloys which comprises the application in succession to said surfaces before said moulds are put in service, of a plurality of coatings including a first coating and a last coating, with said last coating comprising a cermet containing 50 to 90% of alumina and 10 to 50% of a metal component containing 70 to 100% chromium, and said first coating being a cermet containing up to 20% of alumina and at least of an alloy containing 70 to of chromium, said first and said last coatings being applied by projection in molten form.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)

Description

Sept. 8, 1959 L. PERAS 2,903,375
METHOD OF COATING A MOULD FOR USE IN A FOUNDRY Filed July 9, 1957 MOULD SECTION Cr ALLOY Cr CERMET INV TOR.
LUCIEN P RAS ATTORNEY United States Patent NIETHOD OF- COATING'A MOULD F OR USE IN-A FOUNDRY Lucien Pras, Billaucourt, France, assignor to Regie Nationale des Usines Renault, Billancourt, France, a French works The invention relates to a method ofpreparation of foundry moulds.
The casting of ferrous alloys, steels or cast-iron, in metal chill-moulds or permanent metal moulds, whether the casting is carried out by gravity, by centrifuging or by injection under pressure, encounters serious difliculties arising from the tendency of-weldin'g ofthe cast alloy to themetallic chill-mould, especially in the regions of highest'temp'eratures, that is to say at the point where the jet'of metal comes in contact with the mould or at the parts of the mouldwhich form a ridge or projection in the interior of the moulding.
A further difliculty arises from the very intense ther mal shock to which the mould is subjected, and from the high temperature reached over the whole surface of contact between the chill-mould and the liquid metal; for that reason, it is the general rule, as in the case of ingot moulds in steel works, to apply a coating to the surface. When however it is necessary to work at a high rate of production, the pourings follow each other regularly at very short intervals into the same mould, and the usual techniques of coating do not give satisfactory results. The application of a refractory coating has a powerful cooling effect on the surface of the mould at each application by brush or by spraying gun as a result of the evaporation of the dispersive liquid. Projection by a spraying gun of a molten refractory product such as alumina on the mould, before it is put into service, does not give a satisfactory adhesion and resistance to thermal shock of the coating on the mould, especially in those parts of the moulds which form projections.
The method forming the object of the invention does not have any of the drawbacks referred to and enables a large number of successive mouldings to be effected without deterioration of the coating and, in consequence, ensures a long life in service of the metal mould for the pouring of ferrous alloys such as cast-iron, but this process is equally applicable to the moulding of any metal or alloy with a high melting point, such as aluminium bronze, stainless steel, refractory alloys with a base of nickel, etc. This process consists in applying successively, before the moulds are put into service, at least two difierent coatings, the first of which has intermediate properties between the metal mould and the last refractory coating.
The first coating is formed, starting from rods prepared either by rolling or by drawing, or by melting and moulding, or by moulding a powder which is then sintered. This coating is constituted by a relatively refractory metallic alloy, or of a cermet or a mixture of refractory oxide and metallic alloy rich in metal; in both cases, the alloy is rich in chromium (18% to 80% for example) and is used in wire or in rods and projected by means of a projection blow-pipe at a sufficiently high temperature to melt the alloy and to project it in very small drops on the surface of the metal mould on which the spray condenses to give a highly ad- Patented Sept. 8, 1959 "ice herent fine film For this first coating there may be employed:
Either a ferritic steel having 15 to 30% of chromium,
Or a-nickel chrome austenitic steel having 15 to 30% of chromium;
Or an alloy of the type Ni, 20% Cr (1 to 2% Mn approximately); all these steels and alloys may be used in rollor drawn rods;
Or an alloy of the type Cr 15 to 30%, Fe 5 to-20%, W or M00 to 5%, Si and -Al 0 to 2%, Co the remainder, used in the form of cast rods;
Or an alloy or a cermet of the type: 10 to 30% of one of the metals such as: molybdenum, tungsten, nickel, cobalt, iron,- 0 to 20% of=alumina, the remainderbeing chromium. These rods may be-made by moulding from powder and sintering at about 1700" in hydrogen or an inert gas.
The second coating, also projected by means of a blowpipe gunis formedby a cermet rich in alumina, the metallic portion of which is rich in chromium and can be constituted by one of 'the following alloys:
Cr 80%M0 20% Cr 80%'Ni 20% Cr 80%Co 20% or any other alloy containing more than 70% of chromium.
In this cermet, the proportion of the metallic part to the alumina may be comprised between 10% and 50% by weight of metal to to 50% of alumina respectively.
The alloy can be previously prepared and then reduced to powder, mixed intimately with the alumina and with an organic agglomerating product in an aqueous or alcoholic medium, so as to obtain a paste which is moulded or drawn into rods which are then dried, baked and sintered at high temperature in an inert atmosphere such as hydrogen. The alloy can be obtained by effecting the mixture directly of the pure metals in powder form with alumina, compressing the powdered mixture into the form of rods, and then sinteiing at high temperature in an inert atmosphere.
In the majority of cases, the coating of the mould is limited to the two coatings described; in the case of a greater number of coatings, the intermediate layers may be of the same nature as either of the two others or again they may be of an intermediate nature or composition.
When so desired, the layers thus formed on the mould may be covered with a purely refractory coating of the usual type. This can be applied either once and for all before the mould is put into service, or periodically from time to time, or before each pouring. This coating may be projected in the molten state by means of a blow-pipe, it may be a liquid or an emulsion applied with a spray gun or with a brush, or finally it may be a solid projected in the state of a cloud of dust, for example by means of a small blower or a sooty flame. This solid may be alumina, silica, a silico-aluminate, or any other refractory product, graphite, lamp-black, or acetylene black; it may contain an organic material such as tar or lac.
In the accompanying drawing there is shown diagrammatically in cross section a mould section having its cavity coated in accordance with the above-described method.
I claim:
1. A method of protecting the surfaces of metallic moulds for casting metals and alloys, which comprises the application in succession to said surfaces before said moulds are put in service, of a plurality of coatings including a first coating and a last coating, with said last coating comprising a cermet containing 50 to 90% 0f coatings being applied by projection in molten form,
2. A method of protecting the surfaces of metallic moulds for casting metals and alloys, which comprises the application in succession to said surfaces before said moulds are put in service, of a plurality of coatings including a first coating and a last coating, with said last coating comprising a cermet containing 50 to 90% of alumina and to 50% of a metal component containing 70 to 100% chromium, and said first coating being an alloy containing to chromium, said first and said last coatings being applied by projection in molten form.
3. A method of protecting the surfaces of metallic moulds for casting metals and alloys, which comprises the application in succession to said surfaces before said moulds are put in service, of a plurality of coatings including a first coating and a last coating, with said last coating comprising a cermet containing to 90% of alumina and 10 to 50% of a metal component containing to 100% chromium, and said first coating being an alloy containing 10 to 30% of a metal selected from the group consisting of molybdenum, tungsten, nickel, cobalt and iron, the balance being chromium, said first and said last coatings being applied by projection in molten form.
4. A method of protecting the surfaces of metallic moulds for casting metals and alloys, which comprises the application in succession to said surfaces before said moulds are put in service, of a plurality of coatings in cluding a first coating and a last coating, with said last coating comprising a cermet containing 50 to 90% of alumina and 10 to 50% of a metal component containing 70 to 100% chromium, and said first coating being a cermet containing 10 to 30% of a metal selected from the group consisting of molybdenum, tungsten, nickel, cobalt and iron, and up to 20% of alumina, the balance being chromium, said first and said last coatings being applied by projection in molten form.
5. A method of protecting the surfaces of metallic moulds for casting metals and alloys, which comprises the application in succession to said surfaces before said moulds are put in service, of a plurality of coatings including a first coating and a last coating, with said last coating comprising a cermet containing 50 to 90% of alumina and 10 to 50% of a metal component containing 70 to 100% chromium, and said first coating being a cermet containing up to 20% of alumina and at least of an alloy containing 70 to of chromium, said first and said last coatings being applied by projection in molten form.
References Cited in the file of this patent UNITED STATES PATENTS 2,090,408 Vance Aug. 17, 1937 Y 2,697,670 Gaudenzi et al. July 20, 1953 2,730,458 Schulze Jan. 10, 1956 2,775,531 Montgomery et al. Dec. 25, 1956 2,811,466 Samuel Oct. 29, 1957

Claims (1)

1. A METHOD OF PROTECTING THE SURFACES OF METALLIC MOULDS FOR CASTING METALS AND ALLOYS, WHICH COMPRISES THE APPLICATION IN SUCCESSION TO SAID SURFACES BEFORE SAID MOULDS ARE PUT IN SERVICE, OF A PLURALITY OF COATINGS INCLUDING A FIRST COATING AND A LAST OATING, WITH SAID LAST COATING COMPRISING A CERMET CONTAINING 50 TO 90% OF ALUMINA AND 10 TO 50% OF METAL COMPNENT CONTAINING 70 TO 100% CHROMIUM AND SAID FRIST COATING BEING DIFFERENT FROM SAID LAST COATING AND COMPRISING AN ALLOY CONTAINING AT LEAST 15% CHROMIUM, SAID FIRST AND SAID LAST COATINGS BEING APPLIED BY PROJECTION IN MOLTEN FORM.
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Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3031331A (en) * 1959-10-23 1962-04-24 Jr William L Aves Metal-ceramic laminated skin surface
US3053689A (en) * 1958-07-09 1962-09-11 Gen Motors Corp Process of coating austenitic steel with chromium alloy coatings
US3054694A (en) * 1959-10-23 1962-09-18 Jr William L Aves Metal-ceramic laminated coating and process for making the same
US3084064A (en) * 1959-08-06 1963-04-02 Union Carbide Corp Abradable metal coatings and process therefor
US3089196A (en) * 1959-08-10 1963-05-14 Rand Corp Process for making laminated material
US3091548A (en) * 1959-12-15 1963-05-28 Union Carbide Corp High temperature coatings
US3159932A (en) * 1961-01-19 1964-12-08 Zenith Radio Corp Channel indicator
US3188705A (en) * 1958-12-29 1965-06-15 Gen Motors Corp Mold core
US3191252A (en) * 1958-12-29 1965-06-29 Gen Motors Corp Coating protection of metal surfaces during casting
US3216072A (en) * 1961-12-13 1965-11-09 Nat Lead Co Die casting method and apparatus
US3266107A (en) * 1964-07-02 1966-08-16 American Radiator & Standard Coated mold and method of coating same
US3302251A (en) * 1962-10-18 1967-02-07 Mannesmann Ag Molybdenum lined mold for continuous casting
US3401736A (en) * 1963-08-27 1968-09-17 Bridgestone Cycle Ind Co Process for formation of non-abrasive refractory rubbing surface having high thermal conductivity by casting
US3427178A (en) * 1964-07-15 1969-02-11 Latex & Polymer Research Corp Method for coating a mold with a polyurethane release agent
US3844729A (en) * 1971-03-25 1974-10-29 Schwarzkopf Dev Co Metals having wear-resistant surfaces and their fabrication
US4113002A (en) * 1975-12-11 1978-09-12 Kubota, Ltd. Chill preventing arrangement for use in centrifugal casting and method for preventing chill thereby
US4120930A (en) * 1974-08-08 1978-10-17 Lemelson Jerome H Method of coating a composite mold
US5336560A (en) * 1991-12-20 1994-08-09 United Technologies Corporation Gas turbine elements bearing alumina-silica coating to inhibit coking
US5415219A (en) * 1992-07-21 1995-05-16 Hagen Batterie Ag Grid casting mold for the casting of lead grids for accumulators and methods for its manufacture

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2090408A (en) * 1931-10-30 1937-08-17 Eaton Erb Foundry Company Mold coating
US2697670A (en) * 1952-07-28 1954-12-21 Bbc Brown Boveri & Cie Ceramic coated chromium steel
US2730458A (en) * 1950-10-03 1956-01-10 Ver Dentsche Metallwerke Ag Method of increasing the scaling resistance of metallic objects
US2775531A (en) * 1949-05-10 1956-12-25 Univ Ohio State Res Found Method of coating a metal surface
US2811466A (en) * 1953-03-18 1957-10-29 Metal Diffusions Inc Process of chromizing

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2090408A (en) * 1931-10-30 1937-08-17 Eaton Erb Foundry Company Mold coating
US2775531A (en) * 1949-05-10 1956-12-25 Univ Ohio State Res Found Method of coating a metal surface
US2730458A (en) * 1950-10-03 1956-01-10 Ver Dentsche Metallwerke Ag Method of increasing the scaling resistance of metallic objects
US2697670A (en) * 1952-07-28 1954-12-21 Bbc Brown Boveri & Cie Ceramic coated chromium steel
US2811466A (en) * 1953-03-18 1957-10-29 Metal Diffusions Inc Process of chromizing

Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3053689A (en) * 1958-07-09 1962-09-11 Gen Motors Corp Process of coating austenitic steel with chromium alloy coatings
US3188705A (en) * 1958-12-29 1965-06-15 Gen Motors Corp Mold core
US3191252A (en) * 1958-12-29 1965-06-29 Gen Motors Corp Coating protection of metal surfaces during casting
US3084064A (en) * 1959-08-06 1963-04-02 Union Carbide Corp Abradable metal coatings and process therefor
US3089196A (en) * 1959-08-10 1963-05-14 Rand Corp Process for making laminated material
US3031331A (en) * 1959-10-23 1962-04-24 Jr William L Aves Metal-ceramic laminated skin surface
US3054694A (en) * 1959-10-23 1962-09-18 Jr William L Aves Metal-ceramic laminated coating and process for making the same
US3091548A (en) * 1959-12-15 1963-05-28 Union Carbide Corp High temperature coatings
US3159932A (en) * 1961-01-19 1964-12-08 Zenith Radio Corp Channel indicator
US3216072A (en) * 1961-12-13 1965-11-09 Nat Lead Co Die casting method and apparatus
US3302251A (en) * 1962-10-18 1967-02-07 Mannesmann Ag Molybdenum lined mold for continuous casting
US3401736A (en) * 1963-08-27 1968-09-17 Bridgestone Cycle Ind Co Process for formation of non-abrasive refractory rubbing surface having high thermal conductivity by casting
US3266107A (en) * 1964-07-02 1966-08-16 American Radiator & Standard Coated mold and method of coating same
US3427178A (en) * 1964-07-15 1969-02-11 Latex & Polymer Research Corp Method for coating a mold with a polyurethane release agent
US3844729A (en) * 1971-03-25 1974-10-29 Schwarzkopf Dev Co Metals having wear-resistant surfaces and their fabrication
US4120930A (en) * 1974-08-08 1978-10-17 Lemelson Jerome H Method of coating a composite mold
US4113002A (en) * 1975-12-11 1978-09-12 Kubota, Ltd. Chill preventing arrangement for use in centrifugal casting and method for preventing chill thereby
US5336560A (en) * 1991-12-20 1994-08-09 United Technologies Corporation Gas turbine elements bearing alumina-silica coating to inhibit coking
US5415219A (en) * 1992-07-21 1995-05-16 Hagen Batterie Ag Grid casting mold for the casting of lead grids for accumulators and methods for its manufacture

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