EP2204246B1 - Noyaux de fonderie dotés de propriétés de dénoyautage I améliorées - Google Patents

Noyaux de fonderie dotés de propriétés de dénoyautage I améliorées Download PDF

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Publication number
EP2204246B1
EP2204246B1 EP09175206.3A EP09175206A EP2204246B1 EP 2204246 B1 EP2204246 B1 EP 2204246B1 EP 09175206 A EP09175206 A EP 09175206A EP 2204246 B1 EP2204246 B1 EP 2204246B1
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EP
European Patent Office
Prior art keywords
sand
binder
core
casting
core according
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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EP09175206.3A
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German (de)
English (en)
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EP2204246A3 (fr
EP2204246A2 (fr
Inventor
Lorenz Ratke
Barbara Milow
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Deutsches Zentrum fuer Luft und Raumfahrt eV
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Deutsches Zentrum fuer Luft und Raumfahrt eV
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
    • B22C1/18—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents
    • B22C1/183—Sols, colloids or hydroxide gels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
    • B22C1/20—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents
    • B22C1/22—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents of resins or rosins
    • B22C1/2233—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents of resins or rosins obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • B22C1/2246—Condensation polymers of aldehydes and ketones

Definitions

  • the present invention relates to foundry cores with improved gutting properties, a process for their preparation and their use.
  • Shapes and cores are usually sand cast from quartz sand, for special applications but also from other sands (alumina, zirconia, olivine, chrome ore) produced in which the grains of sand are bonded together by polymeric binder and a dimensionally stable for the duration of mold filling with liquid metal Forming a composite.
  • sands alumina, zirconia, olivine, chrome ore
  • mechanical aids shaking, shaking, tapping
  • thermal aids or pressurized water can be used for coring or dissolution of the mold.
  • binders Today, phenolic resins, polyurethanes, ureas and furan resins, which are complexly chemically modified (chemical additives), are used as binders to meet the requirements of the foundries. Likewise aerogels are known. The binders are optimized to the applications in their chemical composition to meet the conflicting requirements, such as
  • binders of the prior art can not yet be regarded as optimal at the present time. So affect Adhesion of molten metal to the mold and core material as well as the mineralization of the casting surface, the casting quality, the demoulding and the coring as well as the subsequent use of the casting. Almost all binders are difficult to remove on filigree or complex shaped castings, leaving buildup and mineralization, and a coarse, rough casting surface.
  • the problem underlying the present invention is solved by a foundry core comprising sand, binder and resorcinol-formaldehyde airgel granules (RF airgel granules), wherein the proportion of airgel granules ranges from 0.18 to 0.93 wt .-% and add the proportions of sand, binder, airgel granules and optionally the proportions of other ingredients to 100 wt .-%.
  • RF airgel granules resorcinol-formaldehyde airgel granules
  • Binders for the sands may be inorganic or organic in nature, the inorganic binders being divided into natural and synthetic inorganic binders.
  • Natural inorganic binders include clays such as montmorillonite, glauconite, kaolinite, illite or attapulgite.
  • Synthetic inorganic binders include, among others, water glass, cement and gypsum.
  • Organic binders include synthetic resins such as phenolic, urea and furan resins as well as ethyl silicate.
  • Oils, carbohydrate binders, water-soluble liquid binders based on sulfite blue, molasses, dextrose, alkanolamines and pitch binders are still used ( KE Höner "Founding”, Ullmann's Encyclopedia of Industrial Chemistry, pp. 271-287, Vol. 12, 4th edition, Verlag Chemie Weinheim, 1976 ).
  • RF aerogels according to the invention comprise colloidal substances which are gelled and subcritically dried. They have a low density and high, open porosity. They consist only of about 10 to 30 vol .-% of a solid, while the rest of their volume through the surrounding gas or vacuum is filled, that is, they have a high surface area (up to 50 - 300 m 2 / g).
  • Inorganic aerogels but also, for example, the RF airgel of the present invention as an organic airgel are usually inherently hydrophilic. Aerogels are considered one of the lightest materials and the best heat insulators.
  • Airgel granules are obtained in particular by the milling of airgel monoliths.
  • Hydrophilic means water-loving, that is, the used RF-Aerogelgranulat shows a pronounced interaction with polar solvents like water.
  • the hydrophilic RF aerogels used have a wetting angle with water of ⁇ 10 °.
  • a possible reason for the improvements observed by the foundry core according to the invention could be related to the fact that the RF aerogels used have macroscopic dimensions but are nanostructured (like all aerogels).
  • the use of a sufficient proportion of this airgel granules could now cause the melt, the mold can no longer sufficiently reactive wet the mold, since the nanostructure of the airgel granules allows only punctiform contacts. In this way, attachments and mineralization would be suppressed. It is surprising, however, that such an effect can be achieved with an organic airgel, since it inevitably at least partially decomposes under the thermal stresses during the casting, that is charred to a carbon airgel granules.
  • the castings obtained via the use of the foundry cores according to the invention prove to be very smooth (exact casting quality), adhesions and mineralization are significantly suppressed compared to castings of the prior art.
  • the sand preferably comprises quartz sand, an Al 2 O 3 -based and / or a mullite-based sand.
  • corundum sands of similar size (0.1 to 0.9 mm) can also be used.
  • the quartz sands shown above are new sands, in fact these are only added to the "old sands" in foundries to a limited extent.
  • Used sand is the sand that accumulates when the castings are emptied out of the molds, which, after appropriate cooling and reconditioning, is returned to the molding shop.
  • the reprocessing has two tasks to accomplish: cleaning the quartz grain from adhering binders and removing dusty constituents. In this process, any remaining agglomerates are mechanically comminuted and thus the binder coats partially removed from the quartz grains. In this process, the originally rather rounded surface of the grain of sand undergoes a change. From around she is too fragmented. This grain shape is important for the process of forming material, thus ensuring that only a comparatively small amount of binder is needed.
  • the mixture of which the foundry core is produced a sand content of 83 to 95 wt .-% wherein here 1 to 20 wt .-% virgin sand and 80 to 99 wt .-% regenerate (circuit molding material, that is purified reused sand) are preferred.
  • the addition of regenerated sand can be dispensed with, especially in red, brass and bronze castings.
  • the proportion of binder is preferably 1 to 10 wt .-%.
  • Sand, binder and Airogelgranulatanteil add up to 100 wt .-% or vol .-%.
  • the airgel granules preferably have a particle size distribution in the order of magnitude of the sand.
  • the airgel granules and / or the sand have / have a particle size distribution in a range from 0.1 to 0.9 mm.
  • the airgel granules preferably have a particle size / particle size distribution in a range of ⁇ 0.5 mm.
  • the proportion of airgel granules is in a range from 0.18 to 0.93, preferably from 0.5 to 0.75 wt .-%.
  • the proportion of airgel granules in the core in a range of 5 to 15, in particular from 8 to 12 vol .-%.
  • the binder is preferably an organic binder, in particular a binder or a binder mixture, which comprises at least one member selected from phenolic resins, urea resins, furan resins, polyurethane resins and resorcinol-formaldehyde resins, and RF airgel binders.
  • Organic binders have been found to be preferred, as charring of the binder occurs during casting and this contributes to further ease of gutting and reduces mineralization.
  • the compaction is done for example by core shooting, shaking, tapping and / or pounding.
  • temperatures of 20 to 300 ° C have been found to be particularly suitable, in particular 80 to 250 ° C.
  • the duration of the curing is preferably a few seconds to minutes.
  • Drying of foundry cores is either completed after curing or by storage of the cores at room temperature or at temperatures above room temperature to 300 ° C from 1 to 24 hours or in the microwave.
  • the object underlying the invention is achieved by the use of the foundry core according to the invention in metal casting, in particular in non-ferrous metal, light metal or cast iron.
  • the core is removed after the solidification of the melt by a thermal treatment at elevated temperature, in particular a temperature of ⁇ 350 ° C, or mechanically (shaking, ultrasound, knocking).
  • the removal with a thermal treatment is advantageous because here the core decomposes without leaving any residue.
  • RF airgel granules were used.
  • monoliths were prepared via the sol-gel process to produce RF airgel granules.
  • the following molar ratios were used: resorcinol (MERCK, very pure) to water (deionized): 0.044, formaldehyde (VWR, 37%, aqueous solution) to resorcinol: 1.38 and resorcinol to catalyst (sodium carbonate anhydrous for analysis, Merck): 1,512.63.
  • resorcinol MERCK, very pure
  • VWR formaldehyde
  • VWR formaldehyde
  • resorcinol to catalyst sodium carbonate anhydrous for analysis, Merck
  • RF Aerogel binder proved to be particularly advantageous: For the production of bending bars, 500 g of sand mixture (MinSand 230 / natural sand, mixing ratio 1: 0.208), 10% by volume of RF airgel granules (3.4 g, grain size ⁇ 0.5 mm) and 62 g of RF binder (own production , Sol aqueous solution, composition according to the molar ratios: resorcinol (MERCK, purest) to water (deionized): 0.044, formaldehyde (VWR, 37%, aqueous solution) to resorcinol: 1.38 and resorcinol to catalyst (sodium carbonate anhydrous to Analysis, Merck): 1512.63).
  • the bending bars were hand-molded and then dried at 40 ° C in a warming cabinet. The Entkernbarkeit was significantly improved, the cores decomposed thermally. The castings had a smooth surface.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Dispersion Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mold Materials And Core Materials (AREA)

Claims (10)

  1. Noyau de moulage contenant du sable, un liant et des granulés d'aérogel résorcinol-formaldéhyde, dans lequel la proportion des granulés d'aérogel est comprise entre 0,18 et 0,93 % en poids, et les proportions de sable, de liant, de granulés d'aérogel et éventuellement les proportions d'autres ingrédients font un total de 100 % en poids.
  2. Noyau selon la revendication 1, caractérisé en ce que ledit sable comprend du sable siliceux, un sable à base de Al2O3, et/ou un sable à base de mullite.
  3. Noyau selon la revendication 1 ou 2, caractérisé en ce que lesdits granulés d'aérogel et/ou ledit sable présentent une distribution granulométrique comprise entre 0,1 et 0,9 mm.
  4. Noyau selon l'une quelconque des revendications 1 à 3, caractérisé en ce que lesdits granulés d'aérogel présentent une granulométrie comprise dans une gamme de ≤ 0,5 mm.
  5. Noyau selon l'une quelconque des revendications 1 à 4, caractérisé en ce que la proportion des granulés d'aérogel est comprise entre 5 et 15 %, notamment entre 8 et 12 %, en volume.
  6. Noyau selon l'une quelconque des revendications 1 à 5, caractérisé en ce que la proportion des granulés d'aérogel dans le noyau est comprise entre 0,5 et 0,75 % en poids.
  7. Noyau selon l'une quelconque des revendications 1 à 6, caractérisé en ce que ledit liant est un liant organique, notamment un liant ou mélange de liants comprenant au moins un élément choisi parmi les résines phénoliques, les résines d'urée, les résines furanniques, les résines de polyuréthane, les résines résorcinol-formaldéhyde et les liants d'aérogel RF.
  8. Procédé pour la fabrication d'un noyau de moulage selon l'une quelconque des revendications 1 à 7, caractérisé en ce que l'on effectue les étapes consistant à :
    a. mélanger les granulés d'aérogel avec du sable et un liant,
    b. introduire le mélange dans un moule négatif du noyau, éventuellement suivi d'une compression du mélange,
    c. faire durcir le liant, et
    d. éliminer le noyau du moule négatif.
  9. Utilisation d'un noyau de moulage selon l'une quelconque des revendications 1 à 7 en coulée de métal, notamment en coulée de métal lourd non-ferreux, de métal léger ou de fer.
  10. Utilisation selon la revendication 9, caractérisée en ce que le noyau est éliminé par traitement thermique à température élevée, notamment à une température de ≥ 300 °C.
EP09175206.3A 2008-11-12 2009-11-06 Noyaux de fonderie dotés de propriétés de dénoyautage I améliorées Active EP2204246B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE102008056856A DE102008056856A1 (de) 2008-11-12 2008-11-12 Gießereikerne mit verbesserten Entkernungseigenschaften I

Publications (3)

Publication Number Publication Date
EP2204246A2 EP2204246A2 (fr) 2010-07-07
EP2204246A3 EP2204246A3 (fr) 2012-01-04
EP2204246B1 true EP2204246B1 (fr) 2018-10-03

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EP09175206.3A Active EP2204246B1 (fr) 2008-11-12 2009-11-06 Noyaux de fonderie dotés de propriétés de dénoyautage I améliorées

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EP (1) EP2204246B1 (fr)
DE (1) DE102008056856A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2024120666A1 (fr) 2022-12-09 2024-06-13 Deutsches Zentrum für Luft- und Raumfahrt e.V. Granulat d'aérogel destiné à être utilisé dans la technologie de fonderie

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017102317A1 (fr) * 2015-12-15 2017-06-22 Robert Bosch Gmbh Procédé de fabrication d'un moule en sable pour fonderie, notamment d'un noyau en sable pour fonderie, avec inclusion d'un procédé de compression tridimensionnel et mélange de sables destiné au procédé

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19911847A1 (de) * 1999-03-17 2000-09-28 Deutsch Zentr Luft & Raumfahrt Fein- und Formguß in Kunststoff/Kohlenstoff-Aerogelen
DE19939062A1 (de) * 1999-08-18 2001-02-22 Deutsch Zentr Luft & Raumfahrt Verwendung von Kunststoff/Kohlenstoff-Aerogelen als Kernwerkstoff
EP1236525A3 (fr) * 2001-02-15 2003-07-02 Alcan Technology & Management AG Moule de coulée
DE10357539A1 (de) * 2003-12-10 2005-07-21 Deutsches Zentrum für Luft- und Raumfahrt e.V. Herstellung von füllstoffhaltigen Aerogelen
DE102006003198A1 (de) 2006-01-24 2007-07-26 Deutsches Zentrum für Luft- und Raumfahrt e.V. Kerne für den Leichtmetall- und/oder den Feinguss
DE102006021151A1 (de) * 2006-05-06 2007-11-08 Deutsches Zentrum für Luft- und Raumfahrt e.V. Kernwerkstoff aus tonhaltigem Sand enthaltendem Aerogelsand
DE102006056093B4 (de) * 2006-11-17 2012-09-27 Deutsches Zentrum für Luft- und Raumfahrt e.V. Kernwerkstoff aus Aerogelsand enthaltend Additivsand und dessen Verwendung

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
None *

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2024120666A1 (fr) 2022-12-09 2024-06-13 Deutsches Zentrum für Luft- und Raumfahrt e.V. Granulat d'aérogel destiné à être utilisé dans la technologie de fonderie
DE102022132848A1 (de) 2022-12-09 2024-06-20 Deutsches Zentrum für Luft- und Raumfahrt e.V. Aerogelgranulat für die Verwendung in der Gießerei

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Publication number Publication date
EP2204246A3 (fr) 2012-01-04
DE102008056856A1 (de) 2010-05-20
EP2204246A2 (fr) 2010-07-07

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