EP2468903B1 - Procédé de fabrication de moulages à graphite sphéroïdal - Google Patents

Procédé de fabrication de moulages à graphite sphéroïdal Download PDF

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Publication number
EP2468903B1
EP2468903B1 EP11195727.0A EP11195727A EP2468903B1 EP 2468903 B1 EP2468903 B1 EP 2468903B1 EP 11195727 A EP11195727 A EP 11195727A EP 2468903 B1 EP2468903 B1 EP 2468903B1
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Prior art keywords
weight
metal
less
loads
molds
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Not-in-force
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EP11195727.0A
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German (de)
English (en)
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EP2468903A1 (fr
Inventor
Ignacio Alvarez
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Frenos Iruna Sal
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Frenos Iruna Sal
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    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C1/00—Refining of pig-iron; Cast iron
    • C21C1/10—Making spheroidal graphite cast-iron
    • C21C1/105—Nodularising additive agents
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C1/00—Refining of pig-iron; Cast iron
    • C21C1/10—Making spheroidal graphite cast-iron
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D5/00—Heat treatments of cast-iron
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/08—Making cast-iron alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C37/00—Cast-iron alloys
    • C22C37/04—Cast-iron alloys containing spheroidal graphite
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C37/00—Cast-iron alloys
    • C22C37/06—Cast-iron alloys containing chromium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C37/00—Cast-iron alloys
    • C22C37/10—Cast-iron alloys containing aluminium or silicon

Definitions

  • the present invention relates to a process for the manufacturing of spheroidal castings by using metal or permanent molds.
  • the resulting mechanical properties of the new parts are considered of great interest due to, among other things, the large number of graphite spheroids obtained in the parts.
  • spheroidal casting constitutes one of the materials that have been most widely used since its discovery in the 1950s. Compared to laminar or grey casting, the formation and subsequent growth of graphites in spheroidal form leads to significant increases in the break loads, the elastic limits, and, especially, in the elongations of the material. An adequate combination of these three mechanical properties entails the obtaining of materials with a wide range of technological applications.
  • This refractory material is characterized by a comparatively low thermal conductivity, which greatly limits the cooling rate of the cast alloy inside this type of molds.
  • the present invention relates to a new process for the manufacturing of spheroidal cast iron parts, which solves all the disadvantages mentioned above, when molds made up of mixtures containing silica sand (SiO 2 ) as the primary constituent are used. This is done by using metal or "permanent" molds.
  • This new type of mold has the following advantages:
  • This new technique can be used for the manufacturing of castings for the automotive industry, hydraulic components, metal molds for the glass industry, centrifuged tubes, etc.
  • the use of metal molds greatly accelerates the solidification rate and subsequent cooling of the material, causing major changes in the structures obtained in the as-cast state.
  • a first aspect of the present invention is a process for manufacturing spheroidal castings, which comprises the following steps:
  • the metal loads are selected from the group formed by high carbon ingots, foundry chip briquettes, pig iron, scrap metal, steel from the automotive sector, returns or any combination thereof.
  • the metal loads are selected from high-carbon ingots, returns, foundry chip briquettes, steel from the automotive industry or any combination thereof.
  • composition of the metal loads is:
  • the composition of the metal loads is:
  • composition of the loads is:
  • the process of fusion of the metal loads is performed in rotary kilns.
  • the melting and stay times of said metal load is 60 to 80 minutes (hours), preferably 70 minutes.
  • the step of adjusting the carbon and silicon contents are added depending on the content in the molten metal (metal loads) obtained in step a) in order to optimize the next step c) of spheroidization, such that the molten metal loads are transferred to at least 1 induction furnace (1000 Hz), preferably 3 induction furnaces.
  • the temperature of the base metal is maintained within a range between 1400 and 1500°C, preferably between 1400 and 1450°C.
  • the spheroidization treatment comprises the following steps:
  • the FeSiMg alloy comprises the following composition:
  • the FeSiMg alloy comprises the following composition:
  • the inoculant comprises the following composition:
  • the inoculant comprises the following composition:
  • stamped steel clippings are added until they cover the FeSiMg.
  • a casting step is performed in metal or "permanent" molds. Said step comprises the following sub-steps:
  • spheroidization is understood to mean a method for relieving the residual stresses in a high-carbon steel, consisting of heating for a long time at the lowest transformation temperature thereof, followed by slow cooling until it reaches room temperature.
  • the fusion process of the materials was carried out in rotary kilns with a capacity of 5500 kg.
  • the discharge of metal from the electric furnace is performed such that the metal falls on the
  • the slag was conveniently removed from the metal and the latter was quickly transferred to a ladle with a capacity of about 80 kg and equipped with an outlet siphon.
  • the purpose of this device is to prevent the introduction of the slag formed inside the molds during the casting.
  • the metal contained in the casting ladle was occasionally slagged off with this same aim.
  • the casting of the molds was performed manually through the siphon, ensuring that the casting cup was kept full throughout the entire process of filling the molds.
  • Table 2 Chemical compositions of the metal treated with Mg Element (%) C Si Mn P S Cu Cr 3.95-4.05 2.40-2.50 0.60-0.70 0.035-0.07 0.010-0.017 0.01-0.02 0.01-0.03
  • the silica sand molds were manufactured using a high-pressure vertical molding line (12 kp/cm 2 ) and mixtures composed of: 80.8% of re-used silica sand, 9.3% of activated sodium bentonite, 4.5% of carbonaceous material, 3.6% of water and 1.8% of new silica sand.
  • the mixtures were sent to the molding machine with a compactibility of 38-41 %.
  • the permanent molds were manufactured by machining a crude foundry product, cast into a mold previously prepared for this purpose.
  • the material used to prepare this crude product is flake graphite cast iron of the EN-GJL-200 grade.
  • the molds were coated internally with a layer of refractory paint and mounted on a carousel with a capacity for 12 molds, all equipped with an internal water refrigeration system.
  • a system of acetylene-fed burners was used to provide a layer of coal dust on the refractory paint that covers the internal face of the metal molds.
  • the addition of this carbonaceous layer may be regulated in each case.
  • the temperature of the molds was controlled manually.
  • the parts used to conduct this study are: a component of the brakes used in wind furnaces and a clamping jaw for railway tracks.
  • the weight of the brake caliper is 7.2 kg, showing sections between 5 and 43 mm. In the case of the jaw, the weight is 0.35 kg and sections vary between 5 and 12 mm. Thus, it is possible to evaluate the effect of different cooling rates in the same component.
  • Figure 1 shows the configuration of the half-molds designed to manufacture jaws for use in the railway sector.
  • the parts manufactured in both the permanent molds and in those manufactured with the silica sand mixtures correspond to the brake caliper.
  • the jaw was manufactured using only metal molds. After the manufacturing thereof, the parts were unmolded and, subsequently, shot blasted.
  • the materials of these parts were subjected to metallographic study in order to determine the spheroidization index (SI), the nodular density (N) and the composition of the metal matrix in different sections.
  • SI spheroidization index
  • N nodular density
  • the values of these parameters were obtained by analyzing 5 different observation fields in each sample and comparing them to standard patterns [15, 16].
  • the mechanical properties were determined on test-tubes machined directly on the parts. The dimensions of these test-tubes were dependent on the area of the part wherefrom they were obtained.
  • iron carbides Another structural phase detected, which reveals the behavior described above, is iron carbides. This type of compounds are formed only in the clamping jaws, i.e. in the narrower sections with more critical cooling kinetics. It is logical to verify that the highest concentration of carbides was observed in the peripheral areas pertaining to the narrower sections in this part. The more rapid cooling that occurred in these areas in contact with the metal mold favors the appearance of carbide phases. In these cases, effective control of the temperature of the molds and ensuring effective inoculation in the metal casting becomes even more relevant.
  • the surface defects that may be observed in certain parts and most often are: slag and wrinkles or folds.
  • surface wrinkles in spheroidal cast iron pieces it was observed that they are favored when using longer casting times and/or, primarily, the temperatures of the metal molds are higher.
  • Table 4 shows the values of the maximum load at breakage (B), the elastic limit (EL) and the elongation (E) obtained from the traction assays performed to determine the mechanical properties of the selected parts.
  • the mechanical assays were conducted only on the three parts subjected to the ferritization heat treatment described in Figure 2 .
  • the traction test-tubes were machined from two areas in each part. In the brake calipers, these areas correspond to the space designed for the hydraulic system (pot) and the central body (center).
  • the test-tubes were obtained from the support wedge and the support area of the part. Table 4.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)

Claims (13)

  1. Procédé pour fabriquer des pièces sphéroïdales en fonte, qui comprend les étapes suivantes :
    a) fusion des charges de métal à des températures comprises entre 1400°C et 1600°C ; dans lequel les charges de métal sont sélectionnées dans le groupe formé par des lingots à haute teneur en carbone, des retours, des briquettes de copeaux de fonderie, de l'acier provenant de l'industrie automobile ou n'importe laquelle de leurs combinaisons ;
    b) ajustement des teneurs en carbone et silicium des charges de métal fondues durant l'étape (a) à la composition suivante :
    - C : de 3.95 à 4.05% en poids ;
    - Si : de 1.00 à 2.60% en poids ;
    - Mn : de 0.4 à 0.8% en poids.
    c) traitement de sphéroïdisation des charges de métal obtenues durant l'étape (b) à des températures inférieures à 1148°C, comprenant les sous-étapes suivantes :
    a. ajout de FeSiMg dans une proportion de 0.7 à 1.0% en poids par rapport au poids total des charges de métal à une poche de traitement ; dans lequel l'alliage FeSiMg comprend la composition suivante jusqu'à 100% :
    - Si : de 30 à 60% en poids ;
    - Mg : de 1 à 30% en poids ;
    - Ca : de 0.1 à 4% en poids ;
    - Al : de 0.1 à 3% en poids, et
    - Fe : de 30 à 60% en poids.
    b. ajout d'un inoculant sur FeSiMg dans une proportion de 0.15 à 0.20% en poids par rapport au poids total des charges de métal ; dans lequel l'inoculant comprend la composition suivante jusqu'à 100% :
    - Si : de 50 à 90% en poids ;
    - Ca : de 0.1 à 5.5% en poids ;
    - Al : de 0.1 à 5% en poids, et
    - Fe : de 15 à 35% en poids.
    c. ajout de rognures d'acier au mélange obtenu durant la sous-étape b. ;
    d. remplissage de 20 à 30% en volume de la poche avec les charges de métal obtenues durant l'étape b. ;
    e. ajout des charges de métal en fusion de l'étape b. jusqu'à ce que la poche soit remplie, et
    f. décrassage du métal traité obtenu durant la sous-étape e, et
    d. procédé de coulée des charges de métal obtenues durant l'étape (c) dans des moules en métal.
  2. Le procédé selon la revendication 1, dans lequel la charge de métal a la composition suivante jusqu'à 100% :
    - entre 25 et 90% de lingots à haute teneur en carbone, de préférence entre 30 et 80%, et
    - entre 1 et 50% de retours, de préférence entre 1 et 35%.
  3. Le procédé selon la revendication 2, dans lequel la charge de métal comprend en outre :
    - un pourcentage égal ou inférieur à 30% d'acier provenant du secteur automobile, de préférence un pourcentage égal ou inférieur à 25% ;
    - un pourcentage égal ou inférieur à 50% de briquettes de copeaux de fonderie, de préférence un pourcentage égal ou inférieur à 35% ;
  4. Le procédé selon la revendication 1, dans lequel la charge de métal a la composition suivante :
    - 75% de lingots à haute teneur en carbone ;
    - 20% d'acier provenant de l'industrie automobile, et
    - 5% de retours.
  5. Le procédé selon la revendication 1, dans lequel la charge de métal a la composition suivante :
    - 33.33% de lingots à haute teneur en carbone ;
    - 33.33% de briquettes de copeaux de fonderie, et
    - 33.33% de retours.
  6. Le procédé selon n'importe laquelle des revendications 1 à 5, dans lequel le processus de fusion des charges de métal s'effectue dans des fours rotatifs, à une température de fusion de la charge entre 1430 et 1450°C.
  7. Le procédé selon n'importe laquelle des revendications 1 à 6, dans lequel les temps de fusion et d'attente de ladite charge de métal est de 60 à 80 minutes, de préférence de 70 minutes.
  8. Le procédé selon n'importe laquelle des revendications 1 à 7, où, durant l'étape d'ajustement de la teneur en carbone et silicium, les charges de métal en fusion de l'étape a) sont transférées dans au moins 1 four à induction, de préférence 3 fours à induction consécutifs, et sont maintenues à une température comprise entre 1400 et 1500°C, de préférence à une température entre 1400 et 1450°C.
  9. Le procédé selon n'importe laquelle des revendications 1 à 8, dans lequel l'alliage FeSiMg comprend la composition suivante jusqu'à 100% :
    - Si : de 40 à 48% en poids ;
    - Mg : de 4 à 10% en poids ;
    - Ca : de 0.5 à 1.5% en poids ;
    - Al : de 0.3 à 1.2% en poids, et
    - Fe : de 35 à 50% en poids.
  10. Le procédé selon la revendication 9, dans lequel l'alliage FeSiMg comprend en outre un pourcentage égal ou inférieur à 3% en poids de terres rares, de préférence un pourcentage égal ou inférieur à 1.3% en poids de terres rares.
  11. Le procédé selon n'importe laquelle des revendications 1 à 10, dans lequel l'inoculant comprend la composition suivante jusqu'à 100% :
    - Si : de 68 à 78% en poids ;
    - Ca : de 0.3 à 1.9% en poids ;
    - Al : de 0.3 à 1.5% en poids, et
    - Fe : de 20 à 30% en poids.
  12. Le procédé selon la revendication 11, dans lequel l'inoculant comprend en outre un pourcentage égal ou inférieur à 15% en poids de Ba, un pourcentage égal ou inférieur à 5% en poids de Bi et un pourcentage égal ou inférieur à 4.5% en poids de terres rares, de préférence l'inoculant comprend un pourcentage égal ou inférieur à 9.5% en poids de Ba, un pourcentage égal ou inférieur à 1.2% en poids de Bi et un pourcentage égal ou inférieur à 1 % en poids de terres rares.
  13. Le procédé selon n'importe laquelle des revendications 1 à 12, dans lequel l'étape d), de coulée dans des moules en métal, comprend les sous-étapes suivantes :
    a. transfert du métal de l'étape sphéroïdisation dans une poche de coulée équipée d'un siphon d'évacuation ;
    b. décrassage du métal traité de l'étape précédente ;
    c. remplissage des moules de métal ou permanents via un siphon ;
    d. ajout d'une veine d'un inoculant à la coulée de métal, dans un pourcentage de poids de 0.15% par rapport au métal traité dans la poche, dont la composition est :
    - C : 3.70 à 3.85% en poids ;
    - Si : 2.55 à 2.67% en poids ;
    - Mn : 0.6 à 0.7% en poids :
    - P : 0.035 à 0.07% en poids ;
    - S : 0.010 à 0.014% en poids ;
    - Mg : 0.023 à 0.036% en poids, et
    - Cu : 0.01 à 0.02% en poids.
    e. démoulage des pièces de métal obtenues, et
    f. grenaillage des pièces obtenues durant l'étape précédente.
EP11195727.0A 2010-12-27 2011-12-26 Procédé de fabrication de moulages à graphite sphéroïdal Not-in-force EP2468903B1 (fr)

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ES201031959A ES2362241B1 (es) 2010-12-27 2010-12-27 Procedimiento de fabricación de piezas de fundición esferoidal.

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EP2468903B1 true EP2468903B1 (fr) 2014-10-15

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JP5839461B2 (ja) * 2011-10-07 2016-01-06 曙ブレーキ工業株式会社 球状黒鉛鋳鉄の製造方法、および、球状黒鉛鋳鉄を用いた車両用部品の製造方法
JP5839465B2 (ja) 2011-12-22 2016-01-06 曙ブレーキ工業株式会社 球状黒鉛鋳鉄の製造方法および球状黒鉛鋳鉄部材の製造方法
CN103668333B (zh) * 2012-08-31 2016-04-13 沈阳铝镁设计研究院有限公司 铝用阳极组装用低磷低硫灰铸铁配方及生产方法
CN105018668A (zh) * 2015-08-06 2015-11-04 潘桂枝 一种球墨铸铁球化剂
US10787726B2 (en) * 2016-04-29 2020-09-29 General Electric Company Ductile iron composition and process of forming a ductile iron component
CN108950370A (zh) * 2018-07-26 2018-12-07 含山县兴达球墨铸铁厂 一种耐磨耐低温的球墨铸铁
CN110983171B (zh) * 2019-12-20 2022-04-22 十堰市泰祥实业股份有限公司 铁型覆砂生产铸态高强度全铁素体球墨铸铁差速器壳的方法
CN113930660B (zh) * 2021-08-30 2022-08-09 格力(武安)精密装备制造有限公司 食品级炊具的铸件及其制备方法

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US2837422A (en) * 1955-08-27 1958-06-03 Metallgesellschaft Ag Addition agents for the treatment of molten cast iron
NL6401801A (fr) * 1964-02-25 1965-08-26
AT344765B (de) * 1975-08-07 1978-08-10 Waagner Biro Ag Verfahren zur gezielten herstellung von gusseisen mit kugelgrafit, insbesondere fuer dickwandige gussstuecke
US4971623A (en) * 1989-06-08 1990-11-20 The Electricity Council Process for making as-cast ferritic spheroidal graphitic ductile iron
JP4561778B2 (ja) * 2007-06-04 2010-10-13 株式会社日立製作所 エレベーター用非常止め装置
US7846381B2 (en) * 2008-01-29 2010-12-07 Aarrowcast, Inc. Ferritic ductile cast iron alloys having high carbon content, high silicon content, low nickel content and formed without annealing
CN101643814A (zh) * 2008-08-07 2010-02-10 遵义金业机械铸造有限公司 利用废旧金属经特种球化处理生产球墨铸铁的方法

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ES2362241A1 (es) 2011-06-30
EP2468903A1 (fr) 2012-06-27

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