methods for preparing a mixture of molding material and casting molds or cores, and inorganic binder

专利摘要:
1/1 summary "hand" to prepare a mixture of molding material and casting molds or cores, and inorganic binder containing wool�io "the invention relates to mixtures of material molding containing woolio comprising a refractory main molding material, an inorganic binder, and amorphous silicon dioxide as an additive in the production of molds and cores for metal casting. the invention additionally relates to a method for producing molds and cores using molding material mixtures, and to molds and cores produced according to the method.
公开号:BR112015031261B1
申请号:R112015031261
申请日:2014-06-17
公开日:2020-05-05
发明作者:Lincke Hannes；Deters Heinz；Resch Ronja
申请人:Ask Chemicals Gmbh；
IPC主号:

专利说明:

METHODS FOR PREPARING A MOLDING MATERIAL MIXTURE AND CASTING MOLDS OR MACHINES, AND, INORGANIC LITHIUM CONTAINING BINDER [001] The invention relates to molding material mixtures based on inorganic binders to prepare molds and cores for metal casting, comprising at least one basic refractory impression material, one or more lithium compounds, at least soluble glass as an inorganic binder and amorphous silica as an additive. Furthermore, the invention relates to a component system for preparing molding material mixtures, an inorganic binder containing lithium, and a method for preparing molds and cores using molding material mixtures, and molds and cores prepared using the method.
Prior art [002] Foundry molds are essentially made of molds, or molds and cores together, which represent the negative shapes of the cast to be prepared. These cores and molds consist of a refractory material, for example, quartz sand, and a suitable binder, which provides adequate mechanical strength to the casting mold after it is removed from the molding tool. The basic refractory impression material is preferably present in a fluid form, so that it can be filled into a suitable hollow mold and compacted therein. The binder creates solid cohesion between the particles of the basic impression material, so that the casting mold achieves the necessary mechanical stability.
[003] Casting molds have to satisfy several requirements.
First, during the actual casting process, they must have sufficient mechanical strength and temperature resistance so that they can receive the liquid metal in the cavity formed by one or more (partial) casting molds. After the solidification process begins, the mechanical stability of the casting is ensured by a layer of metal
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2/44 solidified that forms along the wall of the casting mold.
[004] The material of the foundry mold now has to break under the influence of the heat released by the metal so that it loses its mechanical resistance, thus eliminating the cohesion between individual particles that the refractory material has. Ideally, the casting mold breaks again into fine sand, which can be effortlessly removed from the casting.
[005] Since casting molds are subjected to very high thermal and mechanical stresses during the casting process, defects can form on the contact surface between the liquid metal and the casting mold. Defects are formed, for example, by virtue of the casting mold cracking or by virtue of liquid metal penetrating the microstructure of the casting mold. Normally, therefore, the foundry mold surfaces that come into contact with the liquid metal are provided with a protective coating, also known as a liquid suspension of refractory material to improve the core surface.
[006] Thus, through these coatings, the surface of the foundry mold can be modified and adapted to the properties of the metal to be processed. For example, the liquid suspension of refractory material to improve the surface of the core can improve the appearance of the casting, preparing a smooth surface, since the liquid suspension of refractory material to improve the surface of the core smoothes irregularities caused by the particle size of the core. molding material. In iron and steel casting, some defects form on the surface of the cast, for example, a surface with holes, rough or mineralized, splinters, alveoli, or pinhead holes, or white and black coatings are formed.
[007] If the above-described defects occur, elaborate post-processing of the cast part surface is necessary to achieve the desired surface properties. This requires additional work steps and
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3/44 thus results in lower productivity or higher costs. If defects appear on the surfaces of the casting that are difficult to access or even completely inaccessible, this can also lead to the loss of the casting.
[008] Furthermore, the liquid suspension of refractory material to improve the surface of the core can metallurgically affect the casting, in which, for example, additives are selectively transferred to the casting on the surface of the casting by means of the liquid suspension of material refractory to improve the core surface, improving the surface properties of the casting.
[009] Furthermore, liquid suspensions of refractory material to improve the surface of the core form a layer that chemically isolates the molten mold from the liquid metal during casting. In this way, any adhesion between the casting and the casting mold is prevented, so that the casting can be removed from the casting mold without difficulty. However, the liquid suspension of refractory material to improve the core surface can also be used to systematically control the heat transfer between the liquid metal and the casting mold, for example, in order to achieve the development of a certain metallic microstructure by cooling speed.
[0010] A liquid suspension of refractory material to improve the surface of the male normally consists of an inorganic refractory material and a binder, dissolved or suspended in a suitable solvent, for example, water or alcohol. When possible, the use of liquid suspensions of refractory material to improve the surface of the alcohol-containing tap should be avoided and, instead, aqueous systems should be used, since organic solvents cause emissions during the drying process.
[0011] Both organic and inorganic binders can be
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4/44 used to prepare molds and, in each case, they can be cured using cold or hot methods. A cold method is the name applied to methods of this type that are essentially carried out without heating the molding tools used for tapping, usually at room temperature or at any temperature caused by a reaction that occurs. Curing is performed, for example, by passing a gas through the mixture of impression material to be cured and thus triggering a chemical reaction. In hot methods, the molding material mixture, after molding, is heated, for example, by a hot molding tool, to a temperature high enough to expel the solvent contained in the binder and / or to initiate a chemical reaction that cures the binder.
[0012] Because of their technical characteristics, organic binders currently have greater significance in the market. However, regardless of their composition, they have the drawback that they decompose during casting and, in the process, sometimes emit considerable amounts of harmful materials, such as benzene, toluene and xylene. In addition, smelting with organic binders generally leads to odor and smoke discomfort. In some systems, undesirable emissions still form during the preparation and / or storage of the foundry molds. Even though, over the years, it has been possible to reduce emissions, they cannot be avoided completely with organic binders.
[0013] For this reason, in recent years, research and development activity has again turned to inorganic binders in order to further improve these and other product properties of molds and cores prepared using them.
[0014] Inorganic binders have long been known, especially those based on soluble glasses. They found more widespread use in the fifties and sixties of the twentieth century, but with the
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5/44 emergence of modern organic binders, they quickly lost their significance. Three different methods are available to cure soluble glasses:
- Passage of a gas, for example, CO2, air, or a combination of the two, through the binder
- Addition of liquid or solid curing agents, for example, esters, and
- Thermal curing, for example, in the hot box method or by microwave treatment.
[0015] Thermal curing of soluble glass is discussed, for example, in US 5,474,606, in which a binder system consisting of alkaline soluble glass and aluminum silicate is described.
[0016] However, the use of inorganic binder systems is often associated with other drawbacks, as will be described in detail in the following comments.
[0017] A drawback of inorganic binders is that the foundry molds prepared from them have relatively low strengths. This is particularly apparent immediately after removing the casting mold from the tool. The resistances at this time, which are also known as hot resistors, are particularly important for the preparation of complicated molded and / or thin-walled articles and their safe handling. However, cold resistance, that is, resistance after complete curing of the casting mold, is also an important criterion in order that the desired casting is prepared with the required dimensional accuracy.
[0018] Furthermore, the relatively high viscosity of inorganic binders compared to organic binders has disadvantageous effects on their use in automated mass preparation of castings.
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6/44 [0019] Since higher viscosity is accompanied by reduced molding material blend, delicate hollow molds, such as those required, for example, to prepare complicated and / or thin-walled molded parts, cannot be properly compressed.
[0020] An important additional drawback of inorganic binders is their relatively low shelf life in the presence of high humidity. Atmospheric humidity is expressed as a percentage at a given temperature by relative humidity, or in g / m ³ by absolute atmospheric humidity. The shelf life of foundry molds prepared by hot curing and using inorganic binders decreases markedly, especially at an absolute atmospheric humidity of 10 g / m ³ , which is noted by a distinct decrease in the resistance of foundry molds, especially those prepared by hot curing, during storage. This effect, especially in the case of hot curing, is attributable to a polycondensation back reaction with air water, leading to the softening of the binder bonds.
[0021] The decrease in strength in such storage conditions is sometimes associated with the appearance of so-called storage cracks. The decrease in strength weakens the microstructure of the casting mold, which in some places, in areas of high mechanical stress, can lead to easy breaking of the casting mold.
[0022] In addition to the shelf life at high atmospheric humidity, hot-cured males using an inorganic binder have low strength compared to organic binders in the sense of water-based molding material coatings, such as liquid suspensions of refractory material to improve the male's surface. In other words, its strengths are greatly reduced by the coating, for example, with a liquid suspension of refractory material to improve the male surface, and this method can only be implemented in practice with
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7/44 great difficulty.
[0023] EP 1802409 Bl describes that greater strengths and longer shelf life can be achieved by using a basic refractory molding material, a soluble glass-based binder and a fraction of particulate amorphous silica. As curing methods here, especially hot curing is described in more detail. Another possibility to increase the shelf life is the use of organosilicon compounds, as explained, for example, in US 6,017,978.
[0024] As Owusu reports, the shelf life of inorganic binders especially presents a problem in the case of hot curing, while CO2-cured casting molds are distinctly more resistant to high atmospheric humidity (Owusu, AFS Transactions, Vol. 88, 1980, pp. 601-608). Owusu describes that the shelf life can be increased by adding inorganic additives such as LI2CO3 or ZnCO. Owusu considers that the low solubility of these additives and the high hydration numbers of the cations contained have a positive effect on the stability of the silicate gel and thus on the shelf life of the soluble glass binder. However, increasing the shelf life by changing the composition of the inorganic binder liquid is not investigated in this publication.
[0025] Improved moisture resistance of soluble glass binder is described in DE 2652421 Al and US 4,347,890. DE 2652421 Al especially addresses several methods for preparing lithium-containing binders based on aqueous solutions of alkaline silicate. The binders described in DE 2652421 Al are characterized by a weight ratio Na2Ü and / or K2O: L12O: S1O2 in the range of 0.80 to 0.99: 0.01 to 0.20: 2.5 to 4.5, which corresponds to an L12O / M2O value of the material quantity from 0.02 to 0.44 and an S1O2 / M2O molar ratio of 1.8 to 8.5. Here, [M2O] designates the sum of the quantities of alkaline oxide materials. The binders described here have greater water resistance, that is, they have less tendency to absorb
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8/44 water from the atmosphere, as demonstrated by gravimetric investigations. Although the manufacture of foundry molds is listed as a possible application, no statements are made regarding the strengths of the prepared molds, let alone their expiration date.
[0026] US 4347890 describes a method for preparing an inorganic binder consisting of an aqueous solution of sodium silicate and a solution of a lithium compound, with lithium hydroxide and lithium silicate being especially preferred. The lithium compound is added to increase the binder's moisture stability. The alkaline silicate binder according to US 4,347,890 contains a mixture of substance L12O / M2O (M2O = L12O + Na2Ü) from 0.05 to 0.44.
Prior art problems and problem statement [0027] Inorganic binder systems for use in foundries known to this day still leave room for improvement. First, it is desirable to develop an inorganic binder system that:
a) makes it possible to prepare foundry molds that are stable during storage, even at high atmospheric humidity. An adequate shelf life is especially desirable to allow storage of molds for longer periods of time after they are prepared and thus to increase the processing window of the manufacturing process.
b) it reaches an appropriate level of humidity required in the automatic manufacturing process, in particular adequate hot or cold resistance.
c) with a basic impression material, it provides a mixture of impression material with good fluidity, so that casting molds with complex geometry can also be obtained. Since the fluidity of the molding material mixture depends directly on the viscosity of the binder, said viscosity must at least be reduced to the maximum
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9/44 possible.
d) allows the preparation of casting molds with improved stability of the prepared cores compared to molding material coatings with a water content in the vehicle of at least 50% by weight The vehicle is the constituent of the mold material coating that can be evaporated at 160 ° C and normal pressure (101.3 kPa (1,013 mbar)). Since such coatings of water-based molding material are preferable for the aforementioned aspect and, for the sake of occupational safety, it is desirable to also use them for casting molds that have been prepared with inorganic binders.
e) it is associated with low costs for foundries, since the binder is only intended for a single use. In particular, the fraction of lithium in the binder has to be selected to be low, since the costs of lithium compounds have increased considerably recently due to increased demand.
[0028] Therefore, the invention was based on the goal of providing a mixture of molding material from a binder to prepare foundry molds for metal processing that meets the aforementioned requirements (a) to (e).
Summary of the invention [0029] This goal is achieved by mixtures of molding material, binders and method for preparing molds and casting cores with the resources of the respective dependent claims. Advantageous further developments form the subject matter of the patent subclaims or will be described below.
[0030] Surprisingly, it has been observed that, by using a mixture of molding material containing lithium based on an inorganic binder that has a defined quantitative composition ratio [LI2O _to active] / [M2O] (M = alkali metal) and a defined molar ratio [SÍO2HM2O] in
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10/44 each case according to the following definition, the tasks described above can be carried out distinctly more effectively.
[0031] In particular, the molding material mixture according to the invention is characterized by the fact that the foundry molds prepared therefrom have a longer shelf life together with a high level of resistance. At the same time, foundry molds prepared with the molding material mixture according to the invention are more stable, compared to water-based molding material coatings, that is, molding material coatings with a content of water in the vehicle of at least 50% by weight. These positive characteristics are accompanied by lower viscosity of the binder and thus better fluidity of the molding material mixture according to the invention. It is surprising that these advantages can only be achieved if the molar ratio [LI2O _to active] / [M2O] and the molar ratio [S1O2] / [M2O] fall within certain well-defined limits and, at the same time, amorphous particulate silica is added. in the mix of impression material.
[0032] Compared with the prior art, molding material mixtures according to the inventions enable foundries to prepare foundry molds with an appropriate shelf life and greater stability, compared to water-based molding material coatings, without having to provide inconveniences in terms of its strengths or the fluidity of the molding material mixture.
[0033] The molding material mixture according to the invention has:
• a basic refractory impression material; and • particulate amorphous S1O2; and • soluble glass as an inorganic binder;
• one or more lithium compounds, where the molar ratio [LI2O _to active] / [M2O] in the
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11/44 molding corresponds to 0.030 to 0.17, preferably 0.035 to 0.16 and in particular preferably 0.040 to 0.14, and the [S1O2] / [M2O] molar ratio ranges from 1.9 to 2.47, preferably 1.95 to 2.40 and in particular preferably 2 to 2.30.
[0034] According to the present invention, [S1O2], [M2O] and [LÍ2O _a tivo] always have the following meanings:
[M2O] the amount of substance in mol of alkali metal M, calculated as M2O, where finally only the following compounds enter the calculation: amorphous alkali silicates, alkali metal oxides and alkali metal hydroxides, including the hydrates thereof, where Li in the calculation as part of F without an activity factor, [Li2 O TiVo] the amount of substance in mol of Li, calculated as L12O where ultimately only the following compounds included in the calculation: amorphous lithium silicate, lithium oxides and lithium hydroxide, including their hydrates, according to the following diagram with regard to activity factors.
[S1O2] is the amount of substance in mol of Si, calculated as S1O2, where finally only the following compounds enter the calculation: amorphous alkaline silicates.
[0035] According to one embodiment, the molding material mixture according to the invention to prepare foundry molds for metal processing can preferably be prepared by grouping at least the following three components, initially separated from each other:
• Component (F) comprises a basic refractory impression material without soluble glass;
• Component (B) comprises a soluble glass as an inorganic binder and without added SiCFamorfo particulate;
• Component (A) comprises particulate amorphous S1O2 as the component additive and optionally one or more lithium compounds as
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12/44 solid and without soluble glass.
[0036] Component (A) is called the additive. According to this embodiment of the invention, component (B), including component (A), has a molar ratio [LI2O _to active] / [M2O] of 0.030 to 0.17, preferably 0.035 to 0.16 and in particular preferably 0.040 to 0.14 and a [S1O2] / [M2O] molar ratio of 1.9 to 2.47, preferably 1.95 to 2.40 and in particular preferably from 2 to 2.30 auf.
[0037] Surprisingly, it has been observed that the activity of the lithium compounds in the invention depends on the way in which the used lithium compounds are added, and thus the aforementioned compounds have different activities. This fact is taken into consideration in the definition of an asset content [TiVo Li2 O], which defines the lithium content and the definition of the active compounds, using the following set of activity factors (scheme):
[Li2 O _at ivo] = 1 * amorphous lithium silicate which are added through the inorganic binder component (B), calculated as mol L12O + * lithium oxide, which is added by the inorganic binder component (B) , calculated as mol of L12O, + * lithium hydroxide, which is added using the inorganic binder component (B), calculated as mol of L12O ΊΟ, 33 * amorphous lithium silicates, which are not added by means of the binder (B ), calculated as mol of L12O, ΊΟ, 33 * lithium oxide, which is not added by means of the inorganic binder (B), calculated as mol of L12O, ΊΟ, 33 * lithium hydroxide, which is not added by means of binder (B), calculated as mol of L12O (* = multiplied), including their hydrates. In each case, 0.33 or 1 is the
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13/44 activity factor (molar).
[0038] The definitions given for [M2 O], [S1O2] and [Li2 O TiVo] apply to all types and categories of the present invention, including, for example, the setting for [Κ2θ] / [Μ2θ].
[0039] Surprisingly, it was observed that, based on the calculated molar content of [L12O], a maximum of three times amorphous lithium silicates, lithium oxide or lithium hydroxide (molar) have to be used if these compounds are added by means of the additive component, compared to the molar amount of lithium silicate, lithium oxide or amorphous lithium hydroxide added by means of the inorganic binder component (B), in which they are usually / preferably dissolved.
[0040] In particular, preferably the lithium compound (s) is / are dissolved completely in the inorganic binder component (B). A component (B) like this contains soluble glass like the inorganic binder and has:
• a [S1O2] / [M2O] molar ratio of 1.9 to 2.47, preferably 1.95 to 2.40 and in particular preferably of 2 to 2.30 auf and • a [LI2O _to active] molar ratio / [M2O] from 0.030 to 0.17, preferably 0.035 to 0.16 and in particular preferably 0.040 to 0.14. [0041] The additive component consists of one or more solids, especially in the form of a fluid powder. Preferably, all the lithium compounds that contribute to the [LiO2 _to i _V o] content are present in component B.
Detailed description of the invention [0042] The usual materials for preparing foundry molds can be used as the basic refractory impression material (referred to as the basic impression material (s) for the sake of brevity below). For example, quartz, zirconia or chromium sand, olivine, vermiculite, bauxite and refractory clay are suitable. It is not necessary to exclusively use sand
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New 14/44. In order to conserve resources and avoid costs, it is advantageous to use the maximum possible amount of used regenerated sand.
[0043] For example, a suitable sand is described in WO 2008/101668 Al (= US 2010/173767 Al). Also suitable are regenerated materials obtained by washing and then drying. Regenerated materials obtained by purely mechanical treatment can also be used. As a rule, regenerated materials can replace at least 70% by weight of new sand, preferably at least about 80% by weight and in particular preferably at least about 90% by weight.
[0044] The average diameter of basic molding materials is generally between 100 pm and 600 pm, preferably between 120 pm and 550 pm and in particular preferably between 150 pm and 500 pm. The particle size can be determined, for example, by screening according to DIN 66165 (Part 2).
[0045] Furthermore, artificial impression materials can also be used as basic impression materials, especially as additives to the aforementioned basic impression materials, but also as the exclusive basic impression material, for example, glass globules, frits of glass, the basic spherical ceramic molding materials known by the name "Cerabeads" or "Carboaccucast" or aluminum silicate microspheres. These aluminum silicate microspheres are sold, for example, by Omega Minerals Germany GmbH, Norderstedt, under the name “Omega-Spheres”. Similar products are also available from PQ Corporation (USA) under the name "Extendospheres".
[0046] It has been observed in aluminum smelting experiments that when basic artificial molding materials are used, especially glass globules, glass frits or microspheres, less molding sand continues to stick to the metal surface after casting than when quartz sand is used. The use of basic artificial impression materials,
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15/44 therefore allows the preparation of smoother casting surfaces, with which complicated post-treatment by means of blasting is not necessary, or at least only considerably smaller. [0047] In this regard, it is not necessary to prepare all the basic impression materials from the basic artificial impression materials. The preferred fraction of the basic artificial molding materials is at least about 3% by weight, in particular preferably at least about 5% by weight, in particular preferably at least about 10% by weight, preferably at least about 15% by weight, in particular preferably at least about 20% by weight, in each case based on the total amount of the basic refractory molding material.
[0048] As an additional constituent, the molding material mixture according to the invention has an inorganic binder based on alkaline silicate solutions. Aqueous solutions of alkaline silicates, especially lithium, sodium and potassium silicates, which are also called soluble glass, are also used as binders in other areas, for example, under construction.
[0049] The preparation of soluble glass is done, for example, on a large industrial scale, melting quartz sand and alkaline carbonates at temperatures of 1,350 ° C to 1,500 ° C. Soluble glass is initially obtained in the form of fragments of solid glass, which is dissolved in water by the influence of temperature and pressure. An additional method for preparing soluble glasses is the direct dissolution of quartz sand with sodium hydroxide.
[0050] The alkaline silicate solution obtained can then be adjusted to the desired [SiChHMzO] molar ratio by adding alkaline hydroxides and / or alkaline oxides, as well as their hydrates. Furthermore, the composition of the alkaline silicate solution can be adjusted by dissolving alkaline silicates with a different composition. In addition to alkaline silicate solutions, solid hydrated alkaline silicates can also be
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16/44 used, for example, the product groups Kasolv, Britesil or Pyramid of PQ Corporation.
[0051] Binders can also be based on soluble glasses and which contain more than one of the alkali ions mentioned. Furthermore, soluble glasses can also contain polyvalent ions such as boron or aluminum (corresponding soluble glasses are described, for example, in EP 2305603 Al (= US 2012/196736 Al)).
[0052] The lithium-containing binder or the mixture of molding material containing lithium is prepared by adding a lithium compound, namely, amorphous lithium silicate, L12O and / or LiOH, to an inorganic binder. Amorphous lithium silicate, L12O and LiOH here also include hydrates thereof. The lithium compound can also be added as a powder or in an aqueous solution or suspension. In a preferred embodiment, the lithium-containing binder is a homogeneous solution of the lithium compounds described above in the binder according to the invention.
[0053] Furthermore, the addition of the lithium compound in the molding material mixture can also occur exclusively by means of component (A), the additive, but it is preferred to add the lithium compound at least partially, preferably exclusively, through component (B), the inorganic binder.
[0054] Surprisingly, it was observed that, with the use of the molding material mixture according to the invention, casting molds with distinctly improved shelf life, as well as greater stability, compared to molding material-based coatings water, as well as immediate high and cold resistances, necessary for automated mass preparation, can be prepared. In addition, component (B), the inorganic binder, according to the invention is characterized by low viscosity and thus high fluidity of the molding material mixture prepared with it, compared to the prior art.
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17/44 [0055] However, the effect according to the invention was only observed if both the [LI2O _to active] / [M2O] molar ratio and the [S1O2] / [M2O] molar ratio fell within certain limits and the above-mentioned lithium compounds were used. The positive effect of lithium, even at low concentrations, on the moisture stability of foundry molds prepared from the molding material mixture according to the invention has not been explained. Without being tied to this theory, the inventors believe that the small Li ⁺ ion beam with the same charge has a stabilizing effect on the silicate structure.
[0056] As usual for inorganic binders based on alkaline silicates, the composition of the inorganic binder component according to the invention is specified in terms of the fractions of S1O2, K2O, Na2Ü, L12O and H2O.
[0057] The quantitative ratio [Li2 O TiVo] / [M2 O] of the molding material mixture, inorganic binder and the additive component or the inorganic binder alone is greater than or equal to 0.030, preferably greater than or equal to 0.035 and particular preferably greater than or equal to 0.040. The upper limits are less than or equal to 0.17, preferably less than or equal to 0.16 and in particular preferably less than or equal to 0.14. The aforementioned upper and lower limit values can be combined as desired.
[0058] At the same time, the [SiÜ2] / [M2O] molar ratio of the molding material mixture, inorganic binder and additive component or inorganic binder alone is greater than or equal to 1.9, preferably greater than or equal to 1.95 and in particular preferably greater than or equal to 2.
[0059] The upper limit for the molar ratio [S1O2] / [M2O] is less than or equal to 2.47, preferably less than or equal to 2.40 and in particular preferably less than or equal to 2.30. Preferred upper and lower limit values can be combined as desired.
[0060] Inorganic binders preferably have a fraction
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18/44 solids greater than or equal to 20% by weight, preferably greater than or equal to 25% by weight, in particular preferably greater than or equal to 30% by weight and in particular preferably more than or equal to 33% by weight. The upper limits for the soluble content of the preferred soluble glasses are less than or equal to 55% by weight, preferably less than or equal to 50% by weight, in particular preferably less than or equal to 45% by weight and in particular preferably less than or equal to to 42% by weight. The fraction of solids is defined here as the fraction by weight of M ₂ O and SiO ₂ .
[0061] In a preferred embodiment, the inorganic binder according to the invention contains amorphous lithium silicate, as well as sodium and potassium silicates. Soluble glasses containing potassium have lower viscosities compared to pure sodium soluble glass or mixed lithium-sodium soluble glasses. The particularly preferred mixed lithium-sodium-potassium glasses according to the invention thus combine the advantage of greater moisture stability with a simultaneously high humidity level and an additional reduction in viscosity. Low viscosity values are especially indispensable for automated mass preparation in order to guarantee good fluidity of the molding material mixture and thus make even complex core geometries possible. The potassium content of the inorganic binder according to the invention, however, cannot be so high, since excessively high potassium content will negatively affect the shelf life of the prepared casting molds.
[0062] Preferably, the molar ratio [K ₂ O] / [M ₂ O] in the inorganic binder, especially in component B, is greater than 0.03, in particular preferably greater than 0.06 and in particular preferably greater than 0 ,1. For the upper limit of the quantitative ratio [K ₂ O] / [M ₂ O], a value less than or equal to 0.25, preferably less than or equal to 0.2 and in particular preferably less than or equal to 0.15 is obtained . The upper limit values
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19/44 and below mentioned can be combined in the desired way. Finally, the following compounds are introduced in the calculation of [K2O]: potassium silicates, potassium oxides and amorphous potassium hydroxides, including their hydrates.
[0063] Depending on the use and the desired resistance level, more than 0.5% by weight, preferably more than 0.75% by weight and in particular preferably more than 1% by weight of the binder according to the invention is used . The upper limits are less than 5% by weight, preferably less than 4% by weight and in particular preferably less than 3.5% by weight. These statements in each case refer to the basic impression material. The% by weight information refers to the inorganic binder with a fraction of solids as previously indicated, that is, the% by weight information includes the diluent.
[0064] Based on the amount of alkaline silicates, calculated as M2O and S1O2, added to the basic impression material with the inorganic binder according to the invention, without considering the diluent, the amount of the binder used is 0.2 to 2, 5% by weight, preferably 0.3 to 2% by weight relative to the basic impression material, where M2O has the previously stated meaning.
[0065] In an additional embodiment, the binder according to the invention can additionally contain alkaline borates. Alkaline borates as constituents of soluble glass binder are described, for example, in GB 1566417, where they are used for complexing carbohydrates. Typical added amounts of alkaline borates are from 0.5% by weight to 5% by weight, preferably between 1% by weight and 4% by weight and in particular preferably between 1% by weight and 3% by weight, based on weight of the binder.
[0066] A fraction of amorphous particulate S1O2 in the form of the additive component is added to the mixture of molding material of
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20/44 according to the invention to increase the resistance level of the foundry molds prepared with such molding material mixtures. An increase in the resistances of the foundry molds, especially the increase in their hot resistances, can be advantageous in the automated manufacturing process. The particulate amorphous silica has a particle size preferably less than 300 pm, preferably less than 200 pm, in particular preferably less than 100 pm. The particle size can be determined by sieve analysis. The sieve residue of the amorphous particulate SiCL for passing through a 125 pm (120 mesh) sieve preferably ranges from no more than 10% by weight, in particular preferably no more than 5% by weight and very in particular preferably not more than 2% by weight.
[0067] The sieve residue is determined using the machine sieving method described in DIN 66165 (Part 2), where, in addition, a chain ring is used as a sieving aid.
[0068] The amorphous S1O2 preferably used in accordance with the present invention has a water content of less than 15% by weight, especially less than 5% by weight and in particular preferably less than 1% by weight. In particular, amorphous S1O2 is used as a fluid powder.
[0069] Silicas prepared synthetically and naturally occurring can be used as amorphous S1O2. However, the latter, known, for example, by DE 102007045649, are not preferred, since they generally contain considerable fractions of crystalline material and, therefore, are classified as carcinogenic.
[0070] The synthetic term is defined as non-naturally occurring amorphous S1O2, but its preparation comprises a chemical reaction (initiated by human), for example, the preparation of silica sols by ion exchange processes from alkaline silicate solutions , precipitation from
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21/44 alkaline silicate solutions, silicon tetrachloride flame hydrolysis or the reduction of quartz sand with coke in an electric arc furnace in the preparation of ferrosilicon and silicon. Amorphous S1O2 prepared by the aforementioned method is also known as S1O2 pyrogen.
[0071] Occasionally, synthetic amorphous S1O2 is only interpreted to include precipitated silica (CAS-Nr. 112926-00-8) and S1O2 prepared by flame hydrolysis (Pyrogenic silica, Smoked silica, CAS-Nr. 112945-52- 5), whereas the product prepared during the manufacture of ferrosilicon or silicon is merely called amorphous S1O2 (Silica smoke, Microsilica, CAS-Nr. 69012-64-12). For the purposes of the present invention, the product prepared during the manufacture of ferrosilicon or silicon is designated as synthetic amorphous S1O2.
[0072] The preferred materials for use are precipitated silica and pyrogenic S1O2, that is, that prepared by hydrolysis by flame or in an electric arc furnace. In particular, preferably used are S1O2 prepared by thermal decomposition of ZrSiÜ4 (see DE 102012020509) and S1O2 prepared by oxidation of metallic Si using an oxygen-containing gas (see DE 102012020510).
[0073] Also preferred is quartz glass powder (mainly amorphous S1O2), which has been prepared from crystalline quartz by melting and rapid cooling, so that the particles are spherical and not fragmented (see DE 102012020511). The average primary particle size of the synthetic amorphous silica can vary between 0.05 pm and 10 pm, especially between 0.1 pm and 5 pm and in particular preferably between 0.1 pm and 2 pm.
[0074] The primary particle size can be determined, for example, by dynamic light scattering (for example, Horiba LA 950) or by scanning electron microscopy (SEM imaging, for example, with the company's New NanoSEM 230 FEI). To avoid crowding
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22/44 of particles, before measuring particle size, samples are dispersed in water in an ultrasonic bath. Furthermore, using SEM photographs, details of the primary particle shape up to the order of magnitude of 0.01 pm can be viewed. For SEM measurements, S1O2 was dispersed in distilled water and then applied to an aluminum support with a copper strip attached before the water was evaporated.
[0075] Preferably, the average primary particle size is between 0.05 pm and 10 pm, measured by dynamic light scattering (eg Horiba LA 950) and optionally verified by scanning electron microscopic photography.
[0076] Furthermore, the specific surface area of the synthetic amorphous silica was determined using gas absorption measurements (BET method) according to DIN 66131. The specific surface area of the synthetic amorphous S1O2 is preferably between 1 and 35 M2 / g, preferably between 1 and 17 M ₂ / g and in particular preferably between 1 and 15 M2 / g. Optionally, the products can also be mixed, for example, to obtain targeted mixtures with certain particle size distributions.
[0077] The purity of amorphous S1O2 can vary widely depending on the method of preparation and the manufacturer. Types with an S1O2 content of at least 85% by weight, preferably at least 90% by weight and in particular preferably at least 95% by weight have been shown to be suitable.
[0078] Depending on the application and the desired resistance level, between 0.1% by weight and 2% by weight of the particulate amorphous S1O2 are used, preferably between 0.1% by weight and 1.8% by weight, in particular preferably between 0.1% by weight and 1.5% by weight, in each case based on the basic impression material.
[0079] The ratio of soluble glass to particulate metal oxide and especially amorphous S1O2 can be varied within wide limits. This provides the advantage of greatly improving the initial resistances of
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23/44 males, that is, the resistance immediately after removal of the tool, without a substantial effect on the final resistance. This is mainly of great interest in light metal casting. On the one hand, high initial strengths are desired so that, after they are prepared, the taps can be transported without problems or combined in complete tappings and, on the other hand, the final strengths must not be too high in order to to avoid problems in the disintegration of the core after casting, that is, after casting it must be possible to remove the basic impression material from the cavities of the casting mold without problems.
[0080] Based on the weight of the binder (including diluent or solvent), particulate amorphous S1O2 is preferably present in the molding material mixture in a fraction of 2 to 60% by weight, in particular preferably from 3 to 55% by weight and in particular preferably between 4 and 50% by weight.
[0081] The addition of amorphous S1O2 can be done according to EP 1802409 BI both before and after adding binder, directly in the refractory material, but, alternatively, as described in EP 1884300 Al (= US 2008/029240 Al), first a premixture of S1O2 with at least part of the binder or sodium hydroxide solution can be prepared and then mixed in the solid refractory. The binder or fraction of binder that is still present and has not been used for the premix can be added to the refractory material either before or in addition to or with the premix.
[0082] In an additional embodiment, the barium sulfate of the additive component can be added to further improve the casting surface area, especially in light metal casting, such as aluminum casting. Barium sulfate can be synthetically prepared and / or natural barium sulfate, that is, added in the form of minerals containing barium sulfate such as heavy spar or barite.
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24/44 [0083] This and other features of the appropriate barium sulfate as well as the mixture of impression material prepared with it are described in further detail in DE 102012104934, the content of the description of which is incorporated by reference in the description of this intellectual property, to the extent applicable.
[0084] In an additional embodiment, the additive component of the molding material mixture according to the invention can also comprise at least mixed aluminum oxides and / or aluminum / silicon oxides in particulate form or aluminum and zirconium metal oxides in particulate form, as described in more detail in DE 102012113073 or DE 102012113074 - to the extent that the additives described are also considered to be part of the present intellectual property description. With the use of additives of this type, castings, especially made of iron or steel, with very high surface qualities can be obtained after the casting of the metal, so that after removal of the casting mold, little or no post-processing of the cast part surface is required.
[0085] In an additional embodiment, the additive component of the molding material mixture according to the invention may comprise a phosphorus-containing compound. Such an additive is preferred in the case of very thin wall sections of a casting mold and especially in the case of taps, since in this way the thermal stability of the taps or the thin wall section of the casting mold can be increased. This is especially significant if the liquid metal impacts an oblique surface during casting and causes a pronounced erosive effect there, due to the high metallostatic pressure, or can lead to deformations of especially final wall sections of the casting mold. Suitable phosphorus compounds have little or no effect on the processing time of molding material mixtures according to
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25/44 invention. Suitable representatives and their addition amounts are described in detail in WO 2008/046653 A1 and these, therefore, also become part of the description of the present intellectual property.
[0086] The preferred fraction of the phosphorus-containing compound, based on the basic molding material, is between 0.05 and 1.0% by weight and preferably between 0.1 and 0.5% by weight.
[0087] In an additional embodiment, the mixture of molding material according to the invention can be added with the additive component of organic compounds (according to EP 1802409B1 and W02008 / 046651). A small amount of organic compounds added can be advantageous for special applications - for example, to regulate the thermal expansion of the cured molding material mixture. However, an addition like this is not preferred, as it is again associated with CO2 emissions and other pyrolysis products.
[0088] Binders containing water generally have a lower fluidity, compared to binders based on organic solvents. This means that molding tools with narrow passages and multiple changes of direction are more difficult to fill. As a result, males may have sections with inadequate compaction, which can again result in casting defects during casting. According to an advantageous embodiment, the additive component of the molding material mixture according to the invention contains a fraction of clad lubricants, especially graphite or M0S2. Surprisingly, it has been observed that when such lubricants, especially graphite, are added, even complex molds with thin wall sections can be prepared, where the casting molds have uniformly high density and strength, so that essentially no casting defects were observed during casting. The amount of clad lubricants added, especially graphite, preferably reaches 0.05 to 1% by weight, in
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26/44 particularly preferably 0.05 to 0.5% by weight, based on the basic impression material.
[0089] In substitution, or in addition to clad lubricants, active surface substances, especially surfactants, can also be used in the inorganic binder component to further improve the fluidity of the molding material mixture according to the invention. Suitable representatives of these compounds are described, for example, in WO 2009/056320 Al (= US 2010/0326620 Al). Especially surfactants with sulfuric acid or sulfonic acid groups should be mentioned in this regard. Additional suitable representatives and the respective amounts to be added are described in detail in WO 2009/056320 A1 and, therefore, this also becomes part of the description of the present intellectual property.
[0090] In addition to the mentioned constituents, the molding material mixture according to the invention can comprise additional additives. For example, release agents can be added to facilitate the removal of the cores from the molding tool. Suitable release agents are, for example, calcium stearate, fatty acid esters, waxes, natural resins or special alkyd resins. To the extent that these release agents are soluble in the binder and do not separate from it even after prolonged storage, especially at low temperatures, they may already be present in the binder component, but they can also be part of the additive.
[0091] In addition, silanes can also be added to the molding material mixture according to the invention, for example, to further increase the storage stability of the taps or their resistance to water-based molding material coatings . According to an additional preferred embodiment, the molding material mixture according to the invention therefore contains a fraction of at least
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27/44 minus a silane. Silanes that can be used, for example, include aminosilanes, epoxies silanes, mercaptosilanes, hydroxysilanes and ureidossilanes. Examples of silanes of this type are γ-aminopropyltrimethoxysilane, γ-hydroxypropyl-trimethoxysilane, 3-uidopropyltrimethoxysilane, γ-mercaptopropyl-trimethoxysilane, γ-glycidoxypropyltrimethoxysilane, 3- (3,4-epoxycyclohexyl) -trimethoxysilane, aminoethyl) -yaminopropyl-trimethoxysilane and the triethoxy analog compounds thereof. The silanes mentioned, especially the aminosilanes, can also be pre-hydrolyzed. Based on the binder, about 0.1% by weight to 2% by weight of silane are typically used, preferably approximately 0.1% by weight to 1% by weight.
[0092] If the matrix molding material mixture contains silanes, it is usually added in the form in such a way that they are incorporated into the binder beforehand. However, they can also be added to the impression material.
[0093] In preparing the molding material mixture, the basic refractory molding material is placed in a mixer and then first the liquid component is added and mixed with the basic refractory molding material until a uniform layer of the binder has formed an uniform binder layer on the particles of the basic refractory impression material.
[0094] The duration of the mixture is selected in such a way that an intimate mixture of basic refractory impression material and liquid component occurs. The mixing duration depends on the amount of the molding material mixture to be prepared and the mixing unit used. The mixing time is preferably selected between 1 and 5 minutes. Preferably, with further stirring of the mixture, the solid component (s) in the form of amorphous silica and optionally additional pulverized solids is (are) then added and mixing is continued. Here also the mixing time
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28/44 depends on the amount of mixing material to be prepared and the mixing apparatus used. The mixing time is preferably selected between 1 and 5 minutes. A liquid component can be a mixture of several liquid components or all of the individual liquid components, where they can be added to the molding material mixture jointly or successively. In practice, it has been shown that it is effective to first add the (other) solid components to the basic refractory impression material, mix them, and only then introduce the liquid component (s) into the mixture, followed by mixing again. .
[0095] The molding material mixture is then brought into the desired shape. The usual methods are employed for molding. For example, the molding material mixture can be blasted onto the molding tool using a compressed air blasting machine. An additional possibility is to allow the molding material mixture to flow freely from the mixer to the molding tool and compact it there by stirring, stamping or pressing.
[0096] The molding material mixture according to the invention can basically be cured by all known curing methods for soluble glasses, such as a hot cure method or by CCE. A further development of the CO2 method, which involves a combination of gasification with CO2 and air, is described in DE 102012103705.1 and also represents a suitable method for curing the molding material mixture according to the invention.
[0097] To accelerate the cure, CO2 or air or both gases can also be heated in this method, for example, to temperatures up to 100 ° C. [0098] An additional method for curing the molding material mixture according to the invention is curing using liquid (for example, organic esters, triacetin, etc.) or solid catalysts (for example, suitable aluminum phosphates).
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29/44 [0099] An additional method for preparing casting molds is the so-called Rapid Phototyping. This technology is especially differentiated by the fact that the molding material mixture is not pressure-compressed in the desired mold, but, first, the solid components such as the basic molding material and any additives are applied in layers. In the next step, the liquid component of the molding material mixture is systematically printed on the sand / additive mixture. Then, the casting mold is prepared by curing the “printed” areas. For inorganic binders, curing in the area of Rapid Phototyping technology occurs, among other things, by microwave curing, curing with a liquid or solid catalyst or by drying in an oven or in the air. Additional details of the Rapid Phototyping technology can be found, among other places, in EP 0431924 Bl and US 6610429 B2.
[00100] Hot curing is preferred. Here, the molding material mixture is subjected to a temperature of 100 to 300 ° C, preferably 120 to 250 °. In hot curing, water is extracted from the molding material mixture. As a result, presumably, condensation reactions between silanol groups are also initiated, so that crosslinking of the soluble glass begins.
[00101] For example, heating can be carried out in a molding tool, which preferably has a temperature of 100 to 300 ° C, in particular preferably 120 ° C to 250 ° C. Preferably a gas (e.g., air) is passed through the molding material mixture, where this gas preferably has a temperature of 100 to 180 ° C, in particular preferably 120 to 150 ° C. Additional details regarding curing the casting mold are described in particular in EP 1802409 B1, and this is also considered to be a constituent of the description of the present intellectual property.
[00102] Removing water from the molding material mixture can
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30/44 also occur in which the heating of the molding material mixture is done by microwave irradiation.
[00103] For example, microwave irradiation can be done after the casting mold has been removed from the molding tool. In this case, however, the casting mold must already have sufficient strength. As previously explained, for example, this can be achieved in that at least one outer shell of the casting mold is already cured in the molding tool. According to the Rapid Phototyping technology described above, the removal of water from the molding material mixture can also be done in which the heating of the molding material mixture is prepared by microwave action. For example, it is possible to mix the basic impression material with the powdered solid component (s), apply this mixture in layers on a surface and print on the individual layers using a liquid binder component, especially a soluble glass, where, in each case, the layer-by-layer application of the mixture of solids occurs using the liquid binder. At the end of this process, that is, after the end of the last printing process, the entire mixture can be heated in a microwave oven.
[00104] The methods according to the invention are inherently suitable for preparing all foundry molds suitable for metal casting, thus, for example, cores and molds.
[00105] Despite the high strengths that can be achieved with the molding material mixture according to the invention, the males prepared from these molding material mixes present good disintegration after casting, so that the material mixture molding can be removed even from narrow, angled cast piece sections after the casting process is completed. The molds prepared from the mixture of molding material according to
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31/44 with the invention are generally suitable for the casting of metals, for example light metals, non-ferrous metals or ferrous metals.
[00106] An additional advantage is that the casting mold has very high stability under mechanical stress, so that even thin-walled sections of the casting mold can be made without being deformed by the metastatic pressure during the casting process. A further object of the invention is, therefore, a casting mold which was obtained using the method described above according to the invention.
[00107] The invention will be explained in more detail based on the following examples, without being limited to these.
Examples:
1. Preparation of the soluble glass binder from a lithium hydroxide solution [00108] Tables 1, 2, 3 and 4 provide an overview of the composition of the various soluble glass binders according to the invention and not according to the invention that were examined within the architecture of the present investigation. Soluble glass binders are prepared by mixing the chemical compounds listed in Tables 1 and 2 to prepare a homogeneous solution. They were not used until the day after they were prepared mixed to ensure that they were homogeneous. The concentration of alkali oxides and [SiO _2] soluble in glass binders used, as well as their molar ratios and quantitative ratios [tive Li ₂ O] / [M ₂ O], are summarized in Tables 4 and 5.
[00109] Table 3 provides a summary of the molding material mixtures to which the lithium compound was added by means of the additive component. In these cases, the solid lithium compound was added together with the amorphous SiO ₂ (cf. 2.1).
2. Validity term studies
2.1 Preparation of mixtures of impression material
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32/44 [00110] 100 parts by weight (PBW) of quartz sand (quartz sand H32 from Quarzwerke GmbH) were placed in the bowl of a Hobart mixer (Model HSM 10). Then, 2 PBW of the binder was added with agitation and, in each case, intensively mixed with the sand for 1 minute. After adding the binder, 0.5 PBW of amorphous S1O2 was added and this was also mixed for 1 minute. Amorphous S1O2 was a POS B-W 90 LD amorphous silicon oxide from Possehl Erzkontor GmbH.
2.2 Preparation of specimens [00111] To test mixtures of impression material, rectangular test bars with dimensions of 150 mm x 22.36 mm x 22.36 mm were prepared (so-called Georg Fischer bars). A portion of a molding material mixture prepared according to 3.1 was transferred to the storage hopper of a H 2.5 Hot Box blasting machine from Rõperwerk-GieBereimaschinen GmbH, Viersen, DE, with its heated molding tool at 180 ° C.
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co <D oo rí

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b) BASF SE 48/50 soluble sodium glass; molar ratio [SiO ₂ ] / [M ₂ O] approximately 2.82; content of
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a) substance concentration value, calculated for the inorganic binder component.
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37/44 [00112] The rest of the respective mixture of molding material for refilling the male blasting machine was stored in a carefully closed container to protect it from drying and prevent premature reaction with CO ₂ present in the air.
[00113] Molding material mixtures were introduced from the storage tank into the molding tool using compressed air (500 kPa (5 bar)). The residence time in the hot molding tool to cure the mixtures was 35 seconds. To speed up the curing process, hot air (200 kPa (2 bar), 100 ° C at the tool inlet) was passed through the molding tool during the last 20 seconds. The impression tool was opened and the specimen was removed.
2.3 Resistance tests on the prepared test bars [00114] To determine the flexural strengths, the test bars were placed in a Georg Fischer resistance tester equipped with a 3-point bending device and the force that resulted in the break the test bar was measured. Flexural strengths were determined both immediately, that is, a maximum of 10 seconds after removal (hot resistances) and approximately 24 hours after preparation (cold resistances). The expiry date was investigated by subsequently storing the males for an additional 24 hours in an acclimatized test cabinet (from Rubarth Apparate GmbH) at 30 ° C and a relative atmospheric humidity of 60%, which corresponds to an absolute atmospheric humidity of 18, 2 g / m ³ , and its flexural strength was measured again. The accuracy with which the specified values for temperature and atmospheric humidity were prepared by the acclimatized test cabinet was regularly checked with a testo 635 calibrated humidity / temperature / pressure dewpoint measuring device from the company testo.
[00115] The results of the resistance tests are presented in the
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Table 6. The values given here are mean values from multiple determinations in at least 4 males.
2.4 Results [00116] While the binders in Examples 1.1 to 1.6 differ only in terms of their [LI2O _to active] / [M2O] ratio of substances, the binders in Examples 1.7 to 1.12 have a different molar ratio in a value constant for the [LI2O _at i _V o] / [M2O] of the substance ratio. Comparison of Examples 1.1 to 1.6 thus clarifies the effect of the value [Li2 O _at ivo] / [M2 O] of the ratio of substances in resistance values while Examples 1.7 to 1.12 reflects the effect of the molar ratio [S1O2] / [M 2 O].
Table 6
Flexural strengths of prepared test bars
# Hot resistances [N / cm ² ] Cold resistances a ⁾ [N / cm ² ] After storage in an acclimatized test cabinet ^b) [N / cm ² ] After storage in an acclimatized test cabinet ^c) [%]1.1 100 398 123 30.9 not according to the invention 1.2 100 398 248 62.3 according to the invention 1.3 100 393 280 71.2 according to the invention 1.4 100 375 303 80.8 according to the invention 1.5 100 363 323 89.0 according to the invention 1.6 100 355 335 94.4 according to the invention 1.7 95 445 100 22.5 not according to the invention 1.8 95 440 155 35.2 not according to the invention 1.9 105 430 240 55.8 according to the invention 1.10 100 385 243 63.1 according to the invention 1.11 110 365 283 77.5 according to the invention 1.12 120 355 265 74.6 according to the invention 1.13 125 305 287 94.1 not according to the invention 2.1 150 425 147 34.6 not according to the invention 2.2 130 378 268 70.9 according to the invention 2.3 140 313 310 99.0 according to the invention 3.1 140 378 88 23.3 not according to the invention 3.2 65 340 15 4.4 not according to the invention 3.3 130 380 305 80.3 according to the invention
a) Resistance determination was made after 24 hours of storage at room temperature
b) The determination of resistances was made after 24 hours of storage in a test cabinet acclimatized to 30 ° C and 60% relative atmospheric humidity after storage at room temperature.
c) Other resistances after storage in the test cabinet acclimatized to cold resistance.
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Effect of the ratio [L2O _to active] / [M2O] of the amount of substances in the binder:
[00117] The flexural strengths summarized in Table 6 clearly confirm the positive effect that can be achieved by adding lithium in the binder's shelf life.
[00118] While the strengths of males prepared with the binder of Example 1.1 decrease to 71% after storage for a day at high atmospheric humidity, the losses of resistance of males prepared with the other lithium-rich binders are distinctly less pronounced. This effect occurs even in the case of binding with a ratio _[V i _at the Li2 O] / [M2O] 0.047 relatively low. Comparison of Examples 1.2 to 1.6 clearly shows that with increase in the value [Li2 O _at ivo] / [M2 O] of the ratio of substances, the shelf life of the binder increases, such that a residual strength of 94%, based on cold resistance, after storage in the acclimatized test cabinet can be achieved.
[00119] With respect to hot resistance, Examples 1.1 to 1.6 do not show any difference, whereas, in the case of cold resistance, with an increase in the value [L2O _at i _V o] / [M2O] of the substance ratio, a significant worsening of the values up to 40 N / cm ² is observed.
[00120] Examples 1.1 to 1.6 make it clear that sand cores prepared with these binders have long useful lives, with simultaneously high cold resistance. An additional increase in the ratio value of substances does not cause any significant improvement in the shelf life, while cold resistances decrease.
[00121] These observations can be made for both mixed Li-Na soluble glasses and mixed Li-Na-K soluble glasses, as demonstrated by Examples 2.1 to 2.3.
[00122] Example 3.3 clarifies the effect according to the invention for
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40/44 mixtures of impression material in which the lithium compound was added as an additive. Compared to Examples 3.1 and 3.2, not according to the invention, which do not contain any lithium, the shelf life of the males prepared with these binders is distinctly long, while the cold resistances remain at the same good level.
Effect of the molar ratio [S1O2] / [M2O] of the binder:
[00123] As can be seen from Examples 1.7 to 1.13, with an increase in the molar ratio, hot resistances increase, while cold resistances decrease.
[00124] Furthermore, it can also be observed that the increase in the molar ratio of the binder has a distinct positive effect on the shelf life of the prepared sand cores. While, for examples 1.11 to 1.13, the strengths of the males after storage in the acclimatized test cabinet increase with the increase of the molar ratio, due to the opposite tendency to decrease the cold strengths in the absolute improvement can be achieved. Thus, for the molar ratio [S1O2] / [M2O], there is an ideal point, which the binders of compositions 1.9 to 1.12 present. A lower molar ratio leads to a distinctly reduced shelf life, while an additional increase in the molar ratio has a negative effect on cold resistance.
3. Investigations of the binder viscosity
3.1 Viscosity measurements [00125] Viscosity measurements were made using a Brookfield viscometer equipped with a small sample adapter. In each case, about 15 g of the binder to be tested were transferred to the viscometer and its viscosity measured with spindle 21 at a temperature of 25 ° C and a rotational speed of 100 rpm. The measurement results are summarized in Table 7.
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Table 7
Viscosity of used binders
# Viscosity [mPa · s]1.1 63 not according to the invention 1.2 64 according to the invention 1.3 66 according to the invention 1.4 66 according to the invention 1.5 71 according to the invention 1.6 79 according to the invention 1.7 78 not according to the invention 1.8 70 not according to the invention 1.9 66 according to the invention 1.10 66 according to the invention 1.11 63 according to the invention 1.12 68 according to the invention 1.13 73 not according to the invention 2.1 24 not according to the invention 2.2 25 according to the invention 2.3 27 according to the invention
3.2 Results [00126] While the binders of Examples 1.1 to 1.6 and differ only in terms of its value [Li2 O TiVo] / [M2 O] of the ratio of substances, the binders of Examples 1.7 to 1.12 have a molar ratio [S1O2] / [ M 2 O] at a constant value different from the value for [TiVo Li2 O] / [M2 O] of the ratio of substances. The comparison of Examples 1.1 to 1.6 thus clarifies the effect of the [LI2O _to ti _V o] / [M2O] value of the substance ratio on viscosity, whereas Examples 1.7 to 1.12 reflect the effect of the molar ratio.
Effect of the [LI2O _a ti _V o] / [M2O] value of the binder substance ratio:
[00127] The viscosity values summarized in Table 7 makes it clear that the viscosity of the binder increases with increase in the value [TiVo Li2 O] / [M2 O] of the ratio of substances.
Effect of the molar ratio [S1O2] / [M2O] of the binder:
[00128] The viscosity of the binder passes through a minimum of the molar ratio in the area of the binders of Examples 1.9 to 1.11 according to the invention.
Effect of the K2O fraction of the binder:
[00129] In Examples 2.1 to 2.3, the viscosity is distinctly below
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42/44 of the viscosity of the other examples, due to the low solids content of these binders. Ο K2O dissolved in the binder on the other hand, however, has a positive effect on viscosity, although this is not apparent from a comparison of the viscosity of Examples 2.1 to 2.3 with that of Examples 1.1, 1.3 and 1.5, due to the smaller solids contents of Examples 2.1 to 2.3.
[00130] Briefly, it can be stated that the binders according to the invention of Examples 1.2 to 1.6, 1.9 to 1.12 and 2.2 to 2.3 represent an improvement, compared to the prior art, since the sand males prepared with it have good shelf life simultaneously with high cold resistance. In addition, the binders according to the invention are characterized by low viscosity values and, thanks to their relatively low lithium content, low preparation costs.
4. Investigations regarding the stability of the liquid suspension of refractory material to improve the surface of the core
4.L Preparation and investigations of test specimen resistance with liquid suspension of refractory material to improve the surface of the core [00131] To investigate the stability of the liquid suspension of refractory material to improve the surface of the core, soluble glass binders
2.1 and 1.3, the preparation of which was described in 1, were used. The preparation of the mixture of impression material or test bars used is described in
2.1 and 2.2. The quantities added are identical to the declarations made in
2.2, and POS B-W 90 LD particulate amorphous silica (Supplier: Possehl Erzkontor GmbH) was also used. As an additional additive, 0.1 PBW of shiny powdered graphite (Manufacturer: Luh) is added to the molding material mix along with the amorphous S1O2.
[00132] After preparation, the males were kept at room temperature for 24 hours for complete curing and then immersed in
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43/44 a liquid suspension of refractory material to improve the male surface for 1 to 4 seconds.
[00133] The liquid suspension of refractory material to improve the surface of the core was a liquid suspension of refractory material to improve the surface of the slightly aqueous alkaline core (pH = 6.5 to 8.5) with a water content of approximately 51 % and a viscosity of approximately 0.3 to 0.6 Pa · s at 25 ° C (product MIRATEC W 8 from ASK Chemicals GmbH). The exposed males, that is, coated with a thin film of the liquid suspension of refractory material to improve the male's surface, were immediately dried in a drying oven (Model FED 115, Binder Co.) at 100 ° C. An air change rate of 10 m ³ / h was achieved by means of an air supply pipe.
[00134] The flexural strengths of the test bars coated with liquid suspension of refractory material to improve the male surface were determined after 2, 6, 12 and 24 minutes, in each case after the start of the drying procedure. Table 8 summarizes the results of the stress tests. The values given here are average values of 10 males in each case. For comparison, the flexural strength of test bars without liquid suspension of refractory material to improve the core surface was determined.
Table 8
Flexural strengths [N / cm ² ] of the prepared test bars
Dwell time [min] in drying oven at 100 ° C / after removing the liquid suspension bath of refractory material to improve the core surface Soluble glass binder 2.1, not according to the invention Soluble glass binder 1.3, not according to the invention 0 / week Soluble glass binder 415 385 2 / with soluble glass binder 280 260 6 / with soluble glass binder 90 230 12 / with soluble glass binder 150 235 24 / with soluble glass binder 255 250
Petition 870190099305, of 10/03/2019, p. 51/60
44/44
4.2 Results [00135] The flexural strengths clearly demonstrate that the males prepared with the molding material mixture according to the invention are much more stable, compared to the liquid suspension of refractory material to improve the male surface. Both males prepared with the binder according to the invention and males not prepared with the binder according to the invention undergo minimum resistance approximately 6 minutes after being removed from the liquid suspension bath of refractory material to improve the surface of the male before his resistance increases distinctly again. At this moment, in which the minimum resistance occurs, the lesser stability of the males prepared with binder 1.3 according to the invention is clear. While males prepared with binder 2.1, not according to the invention, decline to a resistance of 90 N / cm ² , males prepared with binder 1.3 have a resistance of 235 N / cm ^2, [00136] Especially for mass production automated, such a decrease in strength as shown in the example with binder 2.1 is extremely disadvantageous, since the prepared casting molds are not sufficiently resistant to mechanical stress at such low strength values.

权利要求:
Claims (22)
[1]
1. Method for preparing a mixture of impression material, characterized by the fact that the mixture of impression material is prepared by joining at least three of the following components, each of which is provided separate from one another:
• component (F) comprising at least one basic refractory impression material and without soluble glass;
• component (B) comprising at least one soluble glass as an inorganic binder, where the soluble glass has a molar ratio [S1O2] / [M2O] of 1.90 to 2.47 and does not comprise particulate amorphous S1O2 and • component (A ) comprising at least amorphous particulate S1O2 as an additive component and without soluble glass, where components (A) and (B) together have a [LI2O _to active] / [M2O] molar ratio of 0.03 to 0.17, where [M2O] is the amount of substance in mol of alkali metal M, calculated as M2O, where finally only the following compounds enter the calculation: amorphous alkali silicates, alkali metal oxides and alkali metal hydroxides, including hydrates of thereof, wherein Li is included as part of F without an activity factor, [Li2 O TiVo] is the amount of substance in mol of Li, calculated as L12O wherein finally only the following compounds included in the calculation: lithium silicates amorphous, lithium oxides and lithium hydroxide, including their hydrates, [S1O2] is the amount of substance in mol of Si, calculated as S1O2, wherein finally only the following compounds included in the calculation: alkali silicates amorphous, in which an activity factor in the calculation of the molar amount of [Li2 O TiVo] as follows:
Petition 870190099305, of 10/03/2019, p. 53/60
[2]
2Π [TiVo Li2 O] = 1 * amorphous lithium silicate which are added as the inorganic binder component of the constituent (B), calculated as mol Li ₂ O +
1 * lithium oxide, which is added as a constituent of the inorganic binder component (B), calculated as mol Li ₂ O, +
1 * lithium hydroxide, which is added as a constituent of the inorganic binder component (B), calculated as mol Li ₂ O +
0.33 * amorphous lithium silicates, which are not added as a constituent of the inorganic binder component (B), calculated as mol of Li ₂ O, +
0.33 * lithium oxide, which is not added as a constituent of the inorganic binder component (B), calculated as mol of Li ₂ O, +
0.33 * lithium hydroxide, which is not added as a constituent of the inorganic binder component (B), calculated as mol of Li ₂ O, in each case including their hydrates, where component (B) comprises LiO ₂ , LiOH and / or amorphous lithium silicate.
2. Method according to claim 1, characterized in that the particulate amorphous SiO ₂ has a BET greater than or equal to 1 m ² / g and less than or equal to 35 m ² / g, preferably less than or equal to 17 m ² / g in particular preferably less than or equal to 15 m ² / g.
[3]
Method according to any one of the preceding claims, characterized in that the average particle diameter, determined by dynamic light scattering, of the particulate amorphous SiO ₂ in the molding material mixture is between 0.05 pm and 10 pm , especially between 0.1 pm and 5 pm and in particular preferably between 0.1 pm and 2 pm.
[4]
4. Method according to any of the claims
Petition 870190099305, of 10/03/2019, p. 54/60 > Π, characterized by the fact that the molding material mixture contains particulate amorphous SiO ₂ • in quantities of 0.1 to 2% by weight, preferably 0.1 to 1.5% by weight, in each case based on the basic impression material, and independently of it • 2 to 60% by weight, in particular preferably 4 to 50% by weight based on the weight of the binder, where the solids fraction of the binder corresponds to 20 to 55% by weight, preferably from 25 to 50% by weight.
[5]
Method according to any one of the preceding claims, characterized in that the amorphous SiO ₂ used has a water content of less than 15% by weight, especially less than 5% by weight and in particular preferably less than 1% in weight and, regardless of them, it is used especially as a fluid powder.
[6]
Method according to any one of the preceding claims, characterized in that the molding material mixture contains a maximum of 1% by weight, preferably a maximum of 0.2% by weight of organic compounds.
[7]
Method according to any one of the preceding claims, characterized in that the inorganic binder component (B) has a molar ratio [K ₂ O] / [M ₂ O] of 0.03 to 0.25, preferably 0.06 to 0.2, in particular preferably from 0.1 to 0.15 in the inorganic binder.
[8]
Method according to any one of the preceding claims, characterized in that the soluble glass is present in the molding material in an amount of 0.2 to 2.5% by weight, preferably 0.3 to 2% by weight of soluble alkaline silicates in relation to the basic molding material and calculated as the oxides thereof, and / or
Petition 870190099305, of 10/03/2019, p. 55/60
ΜΊ ο binder has a solids fraction greater than or equal to 20% by weight and less than or equal to 55% by weight, preferably greater than or equal to 25% by weight and less than or equal to 50% by weight, in particular preferably greater than or equal to 30% by weight and less than or equal to 45% by weight, and in particular preferably greater than or equal to 33% by weight and less than or equal to 42% by weight, based on the binder.
[9]
9. Method according to any one of the preceding claims, characterized by the fact that the lithium compound is added exclusively as a constituent of the inorganic binder and independently thereof, optionally also additionally [TiVo Li2 O] is defined as follows:
the amount of substance in mol of Li, calculated as L12O, exclusive of the following compounds: amorphous lithium silicates and / or lithium hydroxide, including their hydrates.
[10]
Method according to any one of the preceding claims, characterized in that the molding material mixture furthermore contains surfactants, preferably selected from the group of anionic surfactants, especially those with a sulfonic acid group or sulfonate group.
[11]
Method according to claim 10, characterized in that the surfactant is present in the molding material mixture in a fraction of 0.001 to 1% by weight, in particular preferably 0.01 to 0.2% by weight with based on the weight of the basic refractory impression material.
[12]
12. Method according to any of the preceding claims, characterized in that the molar ratio [S1O2] / [M2O] is from 1.95 to 2.40, preferably from 2 to 2.30.
[13]
13. Method according to any one of the preceding claims, characterized by the fact that the molar ratio [LI2O _to active] / [M2O] is
Petition 870190099305, of 10/03/2019, p. 56/60
5/7
0.035 to 0.16, preferably 0.04 to 0.14.
[14]
14. Method according to any one of the preceding claims, characterized by the fact that lithium silicate, L12O and LiOH, including their hydrates, are present in a homogeneous solution in the binder or in a homogeneous solution in component (B) and are homogeneous and completely dissolved, without a precipitate, in the aqueous solvent as a constituent of the binder or component (B).
[15]
15. Inorganic binder containing lithium (B), characterized by the fact that it comprises at least soluble glass as the inorganic binder and having • a molar ratio [S1O2] / [M2O] of 1.9 to 2.47 in the inorganic binder (B ) and • a [LI2O _to active] / [M2O] molar ratio of 0.04 to 0.14 in the inorganic binder (B), where [M2O] is the amount of substance in mol of alkali metal M, calculated as [ M2O], where finally only the following compounds enter the calculation: amorphous alkali silicates, alkali metal oxides and alkali metal hydroxides, including their hydrates, where Li is included as part of M without an activity factor, [LILY _at ivo] is the amount of substance in mol Li, calculated as [L12O], where finally only the following compounds enter the calculation: amorphous lithium silicates, lithium oxides and lithium hydroxide, including their hydrates, [S1O2] is the amount of substance in mol Si, calculated as [S1O2], where finally only the compounds The following items are included in the calculation: amorphous alkaline silicates, and an activity factor is included in [LÍ2O _at i _V o] as follows:
Petition 870190099305, of 10/03/2019, p. 57/60
6/7 [TiVo Li2 O] = 1 * amorphous lithium silicate which are added as an inorganic binder component of the constituent (B), calculated as mol [L12O] +
1 * lithium oxide, which is added as a constituent of the inorganic binder component (B), calculated as mol [L12O] +
1 * lithium hydroxide, which is added as a constituent of the inorganic binder component (B), calculated as mol [L12O], in each case including their hydrates, and L12O, LiOH and / or amorphous lithium silicate, including their hydrates are present in a homogeneous solution in the binder containing lithium and are completely without precipitate homogeneously dissolved in the aqueous solvent as a constituent of the binder containing lithium.
[16]
16. Inorganic binder containing lithium according to claim 15, characterized in that the inorganic binder containing lithium has a molar ratio [S1O2] / [M2O] from 1.95 to 2.40, preferably from 2 to 2.30 .
[17]
17. A lithium-containing binder according to claim 15 or 16, characterized in that the binder additionally comprises surfactants, preferably selected from the group of anionic surfactants, especially those with a sulfonate or sulfonic acid group.
[18]
18. Binder containing lithium according to claim 15 or 16, characterized by the fact that the binder has a molar ratio [Κ2θ] / [Μ2θ] from 0.03 to 0.25, preferably 0.06 to 0.2 and in particular preferably from 0.1 to 0.15.
[19]
19. Method for preparing foundry molds or cores, characterized by the fact that it comprises:
• the method for preparing the molding material mix
Petition 870190099305, of 10/03/2019, p. 58/60
7/7 as defined in at least one of claims 1 to 14, • introducing the impression material mixture into a mold, and • curing the impression material mixture.
[20]
20. Method according to claim 19, characterized by the fact that the mixture of molding material is introduced into the mold using a male blasting machine operated by compressed air and the mold is a molding tool and the molding tool has one or more gases passing through it, especially CO2 or gases containing CO2, preferably CO2 heated above 60 ° C and / or heated air above 60 ° C.
[21]
21. Method according to claim 19 or 20, characterized in that the molding material mixture is exposed to a temperature of at least 100 ° C for less than 5 min for curing.
[22]
22. Method according to claim 19, characterized in that a gas, preferably air, is passed through the mixture of molding material to cure it and said gas has a temperature of 100 to 180 ° C, particularly preferred by 120 to 150 ° C.

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法律状态:
2018-11-06| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|

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2019-07-16| B06A| Notification to applicant to reply to the report for non-patentability or inadequacy of the application according art. 36 industrial patent law|

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2020-03-24| B09A| Decision: intention to grant|

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2020-05-05| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 17/06/2014, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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DE102013106276.8A|DE102013106276A1|2013-06-17|2013-06-17|Lithium-containing molding material mixtures based on an inorganic binder for the production of molds and cores for metal casting|

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PCT/DE2014/000306|WO2014202042A1|2013-06-17|2014-06-17|Lithium-containing molding material mixture based on an inorganic binder for producing molds and cores for metal casting|

---