• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    A method of casting a low alloy steel using a mold is disclosed. The method includes receiving a mold (124) with a foam model (104) that is arranged in a sand mold. The received foam model (104) is covered with a permeable refractory coating and is placed between the compacted sand and the sand mold. The method further includes pouring a molten metal, having a low-alloy steel with a carbon content in a range from 0.1 to about 0.4 percent, into the mold (124) to evaporate the foam model (104) and removing it gasification products through the permeable refractory coating (112) to form a low alloy steel casting (152). The method further includes removing the low alloy steel casting (152) from the mold.
    公开号:CH708869B1
    申请号:CH01740/14
    申请日:2014-11-10
    公开日:2020-03-31
    发明作者:Zhao Qi；Tribeni Persaud Daniel；Park Junyoung；Douglas Arnett Michael；Victor Moore Brian；Robert Hayashi Steven
    申请人:Gen Electric；
    IPC主号:
    专利说明:

    State of the art
    The present description relates generally to casting, and more particularly to a lost foam casting of low-alloy steel with a carbon content in a range from 0.1 to about 0.4 percent.
    Generally, sand casting requires multiple cores for casting complex structures such as turbine housings, turbochargers, crankcases, blowers and the like. The use of multiple cores increases material and labor costs and can also lead to long lead times when casting.
    Lost foam casting can be used to overcome the cost and lead time problems. However, the casting obtained by the lost foam casting may have an excessively high carbon content. Furthermore, in the case of lost foam casting, bound green sand is used as a reinforcing medium in a sand mold, whereby a gaseous product or bubbles can be produced when a molten metal is poured into the casting mold, whereby the gaseous product is enclosed in the casting. Carbon absorption and gas entrapment during lost foam casting are caused by the incomplete removal of the foam before the molten metal solidifies within the casting mold. The remaining foam creates soot, and the gases enclosed in the casting produce a carbon content that is locally above the required upper limit.
    Furthermore, the molten metal, which is poured into the mold, can also react with the bound green sand, which leads to the melting of the sand with the casting, which creates sand burns that can affect the surface of the casting. The process of removing the sand burns from the casting can further increase processing costs.
    [0005] There is therefore a need for an improved casting process for producing a low-alloy steel with a very low carbon content.
    Brief description of the invention
    The invention is defined on the basis of a method according to claim 1.
    [0007] The method may include: forming the foam model with a cavity; Making a permeable refractory coating material with a predefined rheology; Applying the permeable refractory coating material to the foam model to form the permeable refractory coating on the foam model; and placing the foam model in the sand mold and filling unbound sand between the foam model and the sand mold and compacting the unbound sand to form the compacted sand to support the foam model.
    Each of the above methods can provide that the foam model comprises a foam material with a bulk density in a range from 13 to about 23 kg / m 3.
    Each of the above methods can provide that the foam model has a foam material with a surface density in a range from 13 to about 50 kg / m 3.
    [0010] Each of the above methods may include the foam model including a foam material comprising at least one of a polystyrene, a polymethyl methacrylate and / or a polystyrene and polymethyl methacrylate copolymer material.
    Any of the above methods can provide that the permeable refractory coating comprises an inorganic binder and a backbond material that includes alumina and / or zircon.
    Each of the above methods can provide that the permeable refractory coating has a permeability in a range from about 10 to about 100 microns.
    Each of the above methods can provide that the permeable refractory coating has a permeance in a range from about 2000 to about 24,000 microns.
    Any of the above methods can provide that the application comprises forming the permeable refractory coating on the foam model by dipping or a flood coating process.
    [0015] Each of the above methods can provide that the disposition further includes forming multiple vent channels in the foam model and through the unbound sand disposed in the sand mold.
    [0016] Each of the above-mentioned methods can provide that the compacted sand has a permeability in a range from about 100 to about 2000 μm 2.
    Each of the above methods can provide that the casting comprises feeding the molten metal into a cavity of the foam model at a rate in the range of about 0.1 to about 0.8 kg / s / cm 2, which is Foam model comprises a polystyrene and polymethyl methacrylate copolymer material with a bulk density in a range from about 16 to about 28 kg / m 3.
    Each of the above methods can provide that the casting comprises feeding the molten metal into a cavity of the foam model at a rate in the range of about 0.1 to about 0.3 kg / s / cm 2, which Foam model comprises a polystyrene material with a bulk density in a range from about 14 to about 20 kg / m 3.
    Each of the above methods can provide that the casting comprises feeding the molten metal into a cavity of the foam model at a rate in the range of about 0.04 to about 0.2 kg / s / cm 2, wherein the Foam model comprises a polymethyl methacrylate material with a bulk density in a range from about 13 to about 18 kg / m 3.
    Each of the above methods can provide that the casting includes feeding the molten metal at a temperature in a range from about 1593 degrees Celsius to about 1705 degrees Celsius (about 2900 to about 3100 degrees Fahrenheit) into a cavity of the foam model.
    [0021] A casting mold is also disclosed. The mold contains a sand mold with compacted sand. The mold also includes a foam model with a cavity which is arranged in the sand mold, so that the compacted sand is arranged between the foam model and the sand mold. The foam model includes a permeable refractory coating with a permeability in a range from about 10 to about 100 microns and a permeance in a range from about 2000 to about 24,000 microns. The compacted sand has a permeability in a range from about 100 to about 1000 μm 2. The foam model has a bulk density in a range from about 13 to about 28 kg / m 3 and a surface density in a range from about 13 to about 35 kg / m 3.
    The foam model of each of the above systems can include a foam material that includes at least one polystyrene, a polymethyl methacrylate, and / or a polystyrene and polymethyl methacrylate copolymer material.
    The permeable refractory coating of each of the above systems can include an inorganic binder and a backbond material that includes alumina and / or zircon.
    Each of the above systems may further include multiple vent channels formed in the foam model and by the unbound sand that is arranged in the sand mold.
    [0025] A low alloy steel casting can be created comprising: a carbon content in a range from about 0.1 to about 0.4 percent; carbon uptake in a range from about 0.12 to about 0.16 percent; a surface defect of less than 1 percent; and less than zero percent gas entrapment.
    Brief description of the drawings
    [0026] These and other features and aspects of embodiments of the present disclosure will be better understood when the following detailed description is read with reference to the accompanying drawings, in which like characters designate parts that are the same in all drawings, and wherein:<tb> Fig. 1 <SEP> is a schematic flow diagram illustrating a method of manufacturing a mold according to an embodiment;<tb> Fig. 2 <SEP> is a schematic flow diagram illustrating a method of manufacturing a low alloy steel casting using the mold according to the embodiment of FIG. 1;<tb> Fig. 3A <SEP> is a perspective view of an alloy steel casting made using a conventional casting process; and<tb> Fig. 3B <SEP> is a perspective view of a low alloy steel casting made in accordance with embodiments of FIGS. 1 and 2.
    Detailed description of the invention
    [0027] A method for casting a low-alloy steel is disclosed. More precisely, the provision of a casting mold with a foam model, which is arranged between compacted sand and a sand mold, is disclosed. The method further includes pouring a molten metal of low-alloy steel into the mold to allow the foam model to evaporate to form a low-alloy steel casting. The method also includes removing the low alloy steel casting from the mold.
    The production of a casting mold is described. The method involves forming a foam model with a cavity and applying a permeable refractory coating to the foam model. The method further includes placing the foam model in a sand mold and filling unbound sand between the foam model and the sand mold to form the mold. The method further includes compacting the unbound sand to produce compacted sand in the mold.
    FIG. 1 is a schematic flow diagram illustrating a method 100 for producing a mold 124 according to an embodiment. The method 100 includes a step 102 in which a foam model 104 is formed, for example, by mechanically processing a solid block of foam material. In some other embodiments, foam model 104 may be formed by injection molding or the like. The foam material has a bulk density in a range from about 13 to about 28 kg / m 3 and a surface density in a range from about 13 to about 50 kg / m 3. A bulk density of the foam model 104 can be defined as the mass of several particles per total volume that is occupied by the foam model 104. A surface density of the foam model 104 can be defined as the mass per unit area of the foam model 104. The foam model 104, which has the bulk density in the above range, enables dimensional stability, a controllable filling rate of a molten metal and the removal of a gasification product from the foam model 104. The foam model 104, which has the surface density in the above range, enables control a sequence of filling the molten metal into the cavity of the mold 124.
    The foam material includes at least one polystyrene, a polymethacrylate and / or a polystyrene and polymethacrylate copolymer material. In one embodiment, the process of forming the foam model 104 may include the step of injecting pre-expanded beads of the foam material into a preheated mold (not shown in FIG. 1) at low pressure. Furthermore, the preheated mold has a shape of the foam model and can consist of aluminum material or the like. The process may further include applying steam to the pre-expanded beads in the preheated mold to form the foam model 104 with the desired shape.
    In the illustrated embodiment, the foam model 104 has three legs 104a, 104b, 104c and a body 104d which connects the legs 104a-104c to one another. The foam model 104 shown in the embodiment is for illustration purposes only and should not be construed as limiting the invention.
    The method 100 further includes a step 106, in which a plurality of ventilation channels 103a are formed in the foam model 104. Each vent channel 108a removes a gasification product from the foam model 104 during a molding process. The method 100 further includes a step 110 in which a permeable refractory coating 112 is formed on the foam model 104. Step 110 further includes a step of making a permeable refractory coating material 114 with a predefined rheology. The permeable refractory coating material 114 includes an inorganic binder and a backbond material including alumina and / or zircon.
    [0033] In one embodiment, the permeable refractory coating 112 is applied to the foam model 104 by a dipping process or a flood coating process. The dipping process may include dipping the foam model 104 into a container (not shown in FIG. 1) containing a slurry of the permeable refractory coating material 114 and then drying to form the permeable refractory coating 112 on the foam model 104. The flood coating process may include using a flood coating device 116 to spray the permeable refractory coating material 114 onto the foam model 104 to form the permeable refractory coating 112. The flood coater 116 sprays the permeable refractory coating material 114 at a low shear rate to prevent damage to the foam model 104. The permeable refractory coating material 1114, which has the predefined rheology, facilitates dip coating and flood coating of the foam model 104.
    The permeable refractory coating 112 has a permeability in a range from about 10 to about 100 microns and a permeance in a range from about 2000 to about 24,000 microns. Permeability can be defined as the ability of coating 112 to flow the gasification product through permeable refractory coating 112. Permeance can be defined as a product of the permeability and thickness of the permeable refractory coating 112. The permeable refractory coating 111, which has permeability in the range defined above, makes it possible to prevent mineralization in order to achieve a desired surface quality of a cast alloy from low alloy To obtain steel (as shown in Fig. 3B). Likewise, the permeable refractory coating 112, which has a permeance in the above range, enables a controllable fill rate of a molten metal and removal of a gasification product from the foam model 104.
    The method 100 further includes a step 118 in which the foam model 104 is placed in a sand mold 120 and unbound sand 122 is filled between the foam model 104 and the sand mold 120 to form a mold 124. In some embodiments, sand mold 120 may include two halves that are clamped together to form mold 124. The foam model 104 can be held in the sand mold 120 by a plurality of supports 126 in order to structurally reinforce the foam model 104 and to make it more stable. A pouring well 128, a channel 130 and a riser pipe 132 are also connected to the foam model 104. A molten metal is successively delivered to the foam model 104 via the pool 128, the riser pipe 132 and the channel 130. The mold 124 also has a plurality of ventilation channels 108b which extend outward from the foam model 104 through the unbound sand 122. The plurality of vent channels 108b are used to remove the gasification product from the foam model 104 during the molding process. In one embodiment, the plurality of ventilation channels 108b are made of ceramic material. In the illustrated embodiment, the plurality of ventilation channels 108b are arranged downstream of the foam model 104 in order to intensify the ventilation of the gasification product.
    The method 100 further includes a step 134 in which the unbound sand 122, which is arranged between the foam model 104 and the sand mold 120, is compacted to form a compacted sand 136. The compaction of the unbound sand 122 is performed using a compaction device 138. In one embodiment, compaction device 138 applies a variable frequency and amplitude vibration to unbound sand 122 to form compacted sand 136. In one embodiment, compactor 138 applies a vacuum force to unbound sand 122 to form compacted sand 136. The compacted sand 136 has a permeability in a range from approximately 100 to approximately 2000 μm 2. The permeability of the compressed sand 136 in the above range enables control of the dimensional accuracy of the low alloy steel casting and the rate at which the gasification product is removed from the foam model 104. The densified sand 136 gives the foam model 104 structural stability during the molding process. Furthermore, the compacted sand 136 of the embodiment is naturally dry and contains no binders or additives for binding and reinforcing the foam model 104.
    Fig. 2 is a schematic flow diagram illustrating a method 140 for making a cast 152 from low alloy steel using mold 124 in accordance with the embodiment of Fig. 1.
    The method 140 includes a step 142 in which a molten metal 144 is poured over the pool 128, the channel 130 and the riser pipe 132 into the mold 124. The molten metal 144 can be kept at a high temperature and then poured from a spoon 143 into the mold 124. The molten metal 144 includes a low-alloy steel with a carbon content in a range from about 0.1 to about 0.4 percent. In one embodiment, the molten metal 144 has a temperature in a range from about 1593 degrees Celsius to about 1705 degrees Celsius (about 2900 to about 3100 degrees Fahrenheit). Furthermore, the molten metal 144 is fed at a rate of about 0.04 to about 0.8 kg / s / cm 2. The feed rate of the molten metal 144 in the above-mentioned range enables the foam model 104 to be completely removed from the mold 124 and also allows the gasification products 148 to be carefully removed from the foam model 104. The temperature of the molten metal 144 in the above-mentioned range enables the foam model 104 to be completely evaporated.
    In one embodiment, the molten metal 144 is in a temperature range from about 1649 degrees Celsius to about 1705 degrees Celsius (about 3000 to about 3100 degrees Fahrenheit) at a rate in a range from about 0.1 to about 0.8 kg / s / cm <2> fed into a cavity 146 of the foam model 104. In such an embodiment, the foam model 104 includes a polystyrene and polymethyl methacrylate copolymer material with a bulk density in a range from about 16 to about 28 kg / m 3. In another embodiment, the molten metal 144 is in a temperature range from about 1593 degrees Celsius to about 1705 degrees Celsius (about 2950 to about 3000 degrees Fahrenheit) at a rate in a range from about 0.1 to about 0.3 kg / s / cm <2> fed into the cavity 146 of the foam model 104. In such an embodiment, the foam model 104 includes a polystyrene material with a bulk density in a range from about 14 to about 20 kg / m 3. In yet another embodiment, the molten metal 144 is in a temperature range from about 1593 degrees Celsius to about 1621 degrees Celsius (about 2900 to about 2950 degrees Fahrenheit) at a rate in a range from about 0.04 to about 0.2 kg / s / cm <2> fed into the cavity 146 of the foam model 104. In such an embodiment, the foam model 104 includes a polymethyl methacrylate material with a bulk density in a range from about 13 to about 18 kg / m 3.
    The molten metal 144 allows the foam model 104 to evaporate and forms a gasification product 148. The gasification product 148 is removed through the permeable refractory coating 112 and the plurality of ventilation channels 108a, 108b. The permeable refractory coating 112 also prevents the molten metal 144 from reacting with the compressed sand 136, thereby avoiding the formation of sand burns. The method 140 further includes a step 150 in which the low alloy steel 152 casting is removed from the mold 124. In a step 154, the low alloy steel cast 152, which has a carbon content in the range of about 0.1 to about 0.4 percent and which has the shape of the foam model 104, is obtained. The low alloy steel casting also has a carbon pickup in a range of about 0.12 to about 0.16 percent, a surface defect (e.g. sand burns) of less than 1 percent, and gas entrapment of less than zero percent.
    Figure 3A is a perspective view of an alloy steel casting 162 made using a conventional casting process. The low alloy steel casting 162 has a plurality of sand burn points 164 formed on a surface 166 of the low alloy steel casting 162. The sand burns 164 are formed due to a reaction of the molten metal with the green sand and the generation of gas bubbles during the casting process.
    Fig. 3B is a perspective view of a cast alloy 152 made of low alloy steel made in accordance with the embodiments of Figs. 1 and 2. Low alloy steel casting 152 has comparatively fewer sand burn points 174 formed on surface 176 of low alloy steel casting 152. Furthermore, the casting 152 made of low-alloy steel is free of gas bubbles, core cracks and sulfur pickups.
    The example of a lost foam casting process discussed herein provides for the required dimensional accuracy due to the elimination of a model lift angle and mold seams and because it allows dimensional tolerances. The use of unbound dry sand reduces the generation of gases and a reaction with the molten metal, which has a carbon content in the range of about 0.1 to 0.4 percent, resulting in the formation of a casting with relatively fewer sand burns and gas pockets in the casting. The type of foam material, the flow rate and the temperature at which the molten metal is poured into the mold lead to a complete removal of the foam model from the mold, which leads to the casting being formed with a reduced content or a reduced absorption of carbon becomes.
    A method for casting a low alloy steel using a mold is disclosed. The process involves receiving a mold with a foam model placed in a sand mold. The received foam model is covered with a permeable refractory coating and is placed between the compacted sand and the sand mold. The method further includes pouring a molten metal, having a low alloy steel with a carbon content in a range of 0.1 to about 0.4 percent, into the mold to allow the foam model to evaporate and removing gasification products through the permeable one Fireproof coating to form a low alloy steel casting. The method also includes removing the low alloy steel casting from the mold.
    权利要求:
    Claims (9)
    [1]
    1. A method comprising:Providing a mold (124) comprising a foam model (104) provided with a permeable refractory coating disposed in a sand mold (120) and compressible unbound sand (122) sandwiched between the foam model (104) and the sand mold (120) is arranged;Compacting the unbound sand (122) to form the compacted sand (136) to support the foam model (104);Pouring a molten metal (144), which has a low-alloy steel (152) with a carbon content in a range from 0.1 to 0.4 percent, into the mold (124) to allow the foam model (104) to evaporate, and removing it a gasification product (148) through the permeable refractory coating (112) to form a low alloy steel (152) casting (162); andRemoving the low alloy steel casting (162) from the mold (124).
    [2]
    2. The method of claim 1 comprising:Forming the foam model (104) with a cavity (146) andManufacture the permeable refractory coating material (114) with a predefined rheology.
    [3]
    3. The method of claim 2, wherein the foam model (104) comprises a foam material having a bulk density in a range from 13 to 28 kg / m 3;and / or wherein the foam model (104) comprises a foam material with a surface density in a range from 13 to 50 kg / m 3.
    [4]
    4. The method of claim 2, wherein the foam model (104) includes a foam material comprising at least one polystyrene, a polymethyl methacrylate and / or a polystyrene and polymethyl methacrylate copolymer material.
    [5]
    5. The method of claim 2, wherein the permeable refractory coating (112) comprises an inorganic binder and a backbond material that includes alumina and / or zircon; and / or wherein the permeable refractory coating (112) has a permeability in a range from 10 to 100 µm <2>; or wherein the permeable refractory coating (112) has a permeance in a range from 2000 to 24,000 µm <3>.
    [6]
    6. The method of claim 2, wherein the applying comprises forming the permeable refractory coating (112) on the foam model (104) by dipping or a flood coating process; and / or wherein the arranging further includes forming a plurality of vent channels (108a, 108b) in the foam model (104) and through the unbound sand (122) disposed in the sand mold (120); and / or wherein the compacted sand (136) has a permeability in a range from 100 to 2000 μm 2.
    [7]
    7. The method of claim 1, wherein the casting feeds the molten metal (144) into a cavity (146) of the foam model (104) at a rate in a range of 0.1 to 0.8 kg / s / cm 2 wherein the foam model (104) comprises a polystyrene and polymethyl methacrylate copolymer material having a bulk density in a range from 16 to 280 kg / m 3; and / or wherein the casting comprises feeding the molten metal (144) into a cavity (146) of the foam model (104) at a rate in a range from 0.1 to 0.3 kg / s / cm 2, wherein the Foam model (104) comprises a polystyrene material with a bulk density in a range from 14 to 20 kg / m 3; or wherein the casting comprises feeding the molten metal (144) into a cavity (146) in the foam model (104) at a rate in a range from 0.04 to 0.2 kg / s / cm 2, the foam model (104) comprises a polymethyl methacrylate material having a bulk density in a range from 13 to 18 kg / m 3; and / or wherein the casting comprises feeding the molten metal (144) at a temperature in a range from 1593 to 1705 degrees Celsius into a cavity (146) of the foam model (104).
    [8]
    8. casting mold (124) for producing a casting (146) from low-alloy steel (152), which comprises a foam model (104), which is provided with a permeable refractory coating, which is arranged in a sand mold (120), and compacted unbound Sand (122) disposed between the foam model (104) and the sand mold (120) for use in a method according to any one of the preceding claims.
    [9]
    9. casting (146) made of low-alloy steel (152), produced by a method according to claim 1.
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    同族专利:
    公开号 | 公开日
    US10046382B2|2018-08-14|
    CH708869A2|2015-05-15|
    DE102014116222A1|2015-05-21|
    CH708869A8|2015-07-31|
    GB201419306D0|2014-12-17|
    GB2521740B|2016-10-19|
    US20150139850A1|2015-05-21|
    CN104646628A|2015-05-27|
    GB2521740A|2015-07-01|
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    法律状态:
    2015-06-15| PK| Correction|Free format text: BERICHTIGUNG ERFINDER |
    2015-07-31| PK| Correction|Free format text: ERFINDER BERICHTIGT. |
    2017-03-15| NV| New agent|Representative=s name: GENERAL ELECTRIC TECHNOLOGY GMBH GLOBAL PATENT, CH |
    2019-05-31| NV| New agent|Representative=s name: FREIGUTPARTNERS IP LAW FIRM DR. ROLF DITTMANN, CH |
    优先权:
    申请号 | 申请日 | 专利标题
    US14/081,116|US10046382B2|2013-11-15|2013-11-15|System and method for forming a low alloy steel casting|
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