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WO2005058529A2 - Systeme et procede de moulage sous pression, produit coule sous pression - Google Patents

Systeme et procede de moulage sous pression, produit coule sous pression Download PDF

Info

Publication number
WO2005058529A2
WO2005058529A2 PCT/US2004/042289 US2004042289W WO2005058529A2 WO 2005058529 A2 WO2005058529 A2 WO 2005058529A2 US 2004042289 W US2004042289 W US 2004042289W WO 2005058529 A2 WO2005058529 A2 WO 2005058529A2
Authority
WO
WIPO (PCT)
Prior art keywords
tube
unit
metal
mold
edge
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.)
Ceased
Application number
PCT/US2004/042289
Other languages
English (en)
Other versions
WO2005058529A3 (fr
Inventor
Sean Seaver
Robert Hollacher
Chuck Barnes
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.)
SPX Technologies Inc
Original Assignee
SPX Corp
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 SPX Corp filed Critical SPX Corp
Priority to EP04814468A priority Critical patent/EP1694454A4/fr
Publication of WO2005058529A2 publication Critical patent/WO2005058529A2/fr
Publication of WO2005058529A3 publication Critical patent/WO2005058529A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/0072—Casting in, on, or around objects which form part of the product for making objects with integrated channels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/007—Semi-solid pressure die casting

Definitions

  • the present invention relates generally to die casting. More particularly, the present invention relates to the casting of components having internal passages.
  • a method for production of a casting incorporating a passage comprising disposing at least one tube in a mold and casting a metal around the tube.
  • the metal may be molten or semi-solid metal and comprise aluminum and aluminum alloys.
  • the tubes of the invention may also comprise any metal, including, but not limited to, steel, and be crimped or clamped in some embodiments.
  • the outer surface of the tubes can be treated prior to casting. Such treatments include spraying the surface with an aluminum composition, shot blasting, and/or metal plating.
  • fluids may be passed through the cast-in tubes before, during, and after casting.
  • Molds of the present invention may comprise passages that match the direction of the tube through the casting.
  • a system for production of a casting incorporating a passage comprising a disposing means that places at least one tube in a mold and a casting means that casts a metal around the tube.
  • the metal may be molten or semi-solid metal and comprise aluminum and aluminum alloys.
  • the tubes of the invention may also comprise any metal, including, but not limited to, steel, and be crimped or clamped in some embodiments.
  • the outer surface of the tubes can be treated prior to casting.
  • Such treatments include spraying the surface with an aluminum composition, shot blasting, and/or metal plating.
  • fluids may be passed through the cast-in tubes before, during, and after casting. Molds of the present invention may comprise passages that match the direction of the tube through the casting.
  • Another embodiment of the invention provides a cast product having at least one tube and metal cast around the tube.
  • FIG. 1 is a diagrammatic representation of a tube and mold, designed with passages to hold the tube.
  • FIG. 2. is a cross-sectional view taken along the 2—2 in FIG. 1.
  • FIG.3 is a diagrammatic representation of an alternate tube design and mold, also designed with a passage to accommodate the tube.
  • FIG. 4 is a cross-sectional view taken from the 4-4 in FIG. 3.
  • FIG. 5 is a diagrammatic representation of a tube design that crosses over itself.
  • FIG.6 is a diagrammatic representation of two tubes that comprise an intersection.
  • An embodiment in accordance with the present invention provides a method for the production of castings with incorporated passages, where the castings are from cast metal and where tubes are cast-in with a superheated molten metal to form the passages.
  • the cast metal may be any metal including, but not limited to steel, zinc, magnesium, or combinations thereof.
  • aluminum and aluminum alloys are cast.
  • Aluminum alloys include 357 alloy, 380 alloy, ADC12 alloy, 356.2 alloy, and other aluminum-silicon alloys.
  • a variety of presses and die cast methods may be used with the present invention.
  • THT presses may be classified as "indexing- type" or "shuttle-type.” Though the indexing press will be detailed in an embodiment below, both types of presses may be used in the instant invention.
  • the THT presses such as a 200 Ton Indexing Shot Machine, a 1000 Ton Shuttle Machine, or a 100 Ton Shuttle Machine, in particular, are capable of operating at a higher speed and with a shorter cycle time than previously known die casting presses and which, as a result, produce higher quality parts with reduced porosity.
  • the die casting presses are also simpler and less expensive in construction, requiring less maintenance and therefore more convenient to service.
  • the casting methods of the present invention need not be limited to die casting methods of molten metal. In fact, in some embodiments, semi-solid metal (SSM) casting may be preferred. SSM casting is defined broadly herein to encompass any casting technique whereby the metal introduced into a die cavity is greater than 20% granular (i.e., solids).
  • SSM casting techniques that are known in the art include, but are not limited to, rheocasting and thixocasting.
  • SSM casting may be preferred in some embodiments of the present invention because it is performed at lower temperatures where often 20% -70% of the metal is granular and thus in a slurry, rather than liquid state. The cooler temperatures can extend the useful life of the dies. Moreover, the slurry state of the metal reduces turbulence within the metal flow as it is introduced into the die, so as to reduce the incorporation of air and gas into the metal as it is being cast. Thus, porosity and quality control complications are reduced. [0025] In one embodiment, vertical die cast presses are used with SSM casting techniques.
  • the indexing time i.e., the delay between indexing between the pour station 80 and transfer station 85
  • the indexing time can be used to control the time the molten metal is cooled in the shot sleeve to reach the SSM range. That is, the amount of time the metal spends in the shot sleeve before it is injected into the molds can be regulated or optimized for a desirable microstructure.
  • molten metal at a predetermined temperature may be poured into the shot sleeve of shuttle presses, i.e. presses that lack the indexing feature.
  • the shear forces present in SSM casting may be more suitable to the present invention in some embodiments over traditional molten metal casting methods. In such an event, larger tubes ranging from about 0.25 inches to about 0.37 inches in outer diameter may be incorporated into the cast-in tube castings than otherwise possible.
  • Many metals and alloys known in the art can be used for SSM casting and can be employed with the instant invention.
  • aluminum-silicon alloys can be used. By definition, aluminum alloys with up to but less than about 11.7 weight percent Si are defined "hypoeutectic", whereas those with greater than about 11.7 weight percent Si are defined "hypereutectic".
  • Tubes that may be cast-in in the present invention may comprise any metal, preferably steel or hydraulic tubing in some embodiments.
  • the steel tubes can have a composition with less than about 0.17 weight percent carbon, less than about 0.35 weight percent silicon, less than about 0.04 weight percent sulfur, less than about 0.04 weight percent phosphorus and between about 0.40- 0.80 weight percent manganese.
  • the tubes are free from surface defects, blow holes and cracks.
  • Tubes of the present invention can be of varying wall thickness. Where deformation of the tube is not desirable, the wall thickness and composition is preferably strong enough to withstand pressures of 6,000 psi to 20,000 psi and more preferably, pressures of 8,000 psi to 12,000 psi. For steel tubes, the corresponding wall thickness may range from about 0.02 inches to about 0.04 inches, but a wider range may also be acceptable. [0030] Referring now to FIGS. 1 and 2 there is shown a die 1 into which a guide 2 has been cut. The guide 2 can be cut to fit the path of a tube 3 which is to be embedded into the metal cast. The tube 3 may of any design or path.
  • the tube 3 may have one opening on one face of the mold or cast and then another opening on another face of the mold or cast as shown in FIG. 1.
  • tube 3 may have and opening on one face and then be tapered, crimped, or clamped at the other end such that fluids become trapped inside the cast as shown in FIGS. 3 and 4.
  • tubes may have paths that cross over (FIG. 5) or intersect (FIG. 6). All such configurations and others are within the scope of the present invention.
  • more than one tube may be incorporated into a cast-in tube mold or product. All such tubes should be accounted for in the design of the mold such that guide 2 may be cut into each half of the mold to accommodate the tube or tubes.
  • the tubes 3 may optionally be machined at one or more openings 4. For example, threading for screws or bolts may be inserted.
  • the outer surface of the tubes may be coated with a thin surface layer to reduce the likelihood of tube movement (such as slipping or rolling) within the cast product. Coatings may include, such as, for example, alumina and aluminum oxide, and may be sprayed on or plated. The thickness of such coating applications will be apparent to one of ordinary skill in the art. Other treatments to the outer surface of the tubes can include shot blasting or grating.
  • the tubes are then secondarily located and secured using a reverse passages in the upper half of the mold such that the tube is secured and crimped or clamped in place.
  • the metal is be cast is heated in a range from about 10°C to about 15°C above the liquidus temperature (i.e., the semi-solid temperature).
  • the semi-solid temperature i.e., the semi-solid temperature
  • the melt temperature is then allowed to cool to form a semi-solid slurry before it is finally cast.
  • the mold 1 and tube 3 design is such that, optionally, a cooling medium can be passed through the tubing before, during, and/or after the casting process is taking place.
  • couplers may be added to the open end of the tube allow for entry of fluids for cooling.
  • the couplers could then be removed, machined, or sheared from the final cast product.
  • This procedure may enhance internal casting cooling rates and thus, cycle times.
  • internal cooling has the potential to improve the metallurgical properties and/or casting integrity of the final cast product.
  • improved tube bonding with the cast is possible.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Continuous Casting (AREA)

Abstract

Une forme de réalisation de la présente invention se rapporte à un procédé de production de pièces coulées à tubes incorporés, lesdites pièces coulées étant en métal coulé et lesdits tubes étant coulés avec un métal en fusion surchauffé. Plusieurs tubes ou plusieurs formes peuvent être incorporés dans l'invention. Cette invention concerne également un procédé de refroidissement de l'intérieur d'un produit coulé avant, pendant et après le coulage du produit.
PCT/US2004/042289 2003-12-17 2004-12-16 Systeme et procede de moulage sous pression, produit coule sous pression Ceased WO2005058529A2 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP04814468A EP1694454A4 (fr) 2003-12-17 2004-12-16 Systeme et procede de moulage sous pression, produit coule sous pression

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US10/736,557 US20050133187A1 (en) 2003-12-17 2003-12-17 Die casting method system and die cast product
US10/736,557 2003-12-17

Publications (2)

Publication Number Publication Date
WO2005058529A2 true WO2005058529A2 (fr) 2005-06-30
WO2005058529A3 WO2005058529A3 (fr) 2005-09-29

Family

ID=34677212

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2004/042289 Ceased WO2005058529A2 (fr) 2003-12-17 2004-12-16 Systeme et procede de moulage sous pression, produit coule sous pression

Country Status (3)

Country Link
US (1) US20050133187A1 (fr)
EP (1) EP1694454A4 (fr)
WO (1) WO2005058529A2 (fr)

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7673389B2 (en) * 2005-07-19 2010-03-09 International Business Machines Corporation Cold plate apparatus and method of fabrication thereof with a controlled heat transfer characteristic between a metallurgically bonded tube and heat sink for facilitating cooling of an electronics component
DE102006030699B4 (de) * 2006-06-30 2014-10-02 Daimler Ag Gegossener Stahlkolben für Verbrennungsmotoren
EP2151875B1 (fr) * 2008-08-07 2014-10-22 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Procédé et dispositif de fabrication d'un composant doté d'une pièce d'insertion intégrée
TWI472388B (zh) * 2009-12-01 2015-02-11 Metal Ind Res & Dev Ct Casting with metal insert and its manufacturing method
ITMI20121739A1 (it) * 2012-10-16 2014-04-17 Unical Ag Spa Procedimento per la realizzazione di uno scambiatore di calore ad elementi pressofusi.
JP6036275B2 (ja) * 2012-12-25 2016-11-30 アイシン精機株式会社 鋳ぐるみ用のパイプの保持装置
JP6688794B2 (ja) * 2014-11-11 2020-04-28 エイチ．シー． スターク インコーポレイテッド マイクロリアクターシステムおよびマイクロリアクター方法
CN110625089A (zh) * 2019-10-28 2019-12-31 宁波优耐特模具有限公司 新能源汽车驱动电机ecu壳体模具及壳体制造工艺

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Also Published As

Publication number Publication date
US20050133187A1 (en) 2005-06-23
WO2005058529A3 (fr) 2005-09-29
EP1694454A2 (fr) 2006-08-30
EP1694454A4 (fr) 2007-04-04

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