CA2159391A1 - Gravity precision sand casting of aluminum and equivalent metals - Google Patents

Gravity precision sand casting of aluminum and equivalent metals

Info

Publication number
CA2159391A1
CA2159391A1 CA002159391A CA2159391A CA2159391A1 CA 2159391 A1 CA2159391 A1 CA 2159391A1 CA 002159391 A CA002159391 A CA 002159391A CA 2159391 A CA2159391 A CA 2159391A CA 2159391 A1 CA2159391 A1 CA 2159391A1
Authority
CA
Canada
Prior art keywords
mold
flow
sprue
aluminum
casting
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.)
Abandoned
Application number
CA002159391A
Other languages
French (fr)
Inventor
Robert Walker Grenkowitz
Michael John Braskich
Allen David Ackerman
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.)
Ford Motor Company of Canada Ltd
Original Assignee
Ford Motor Company of Canada Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ford Motor Company of Canada Ltd filed Critical Ford Motor Company of Canada Ltd
Publication of CA2159391A1 publication Critical patent/CA2159391A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D37/00Controlling or regulating the pouring of molten metal from a casting melt-holding vessel
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/08Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates

Abstract

A technique and accompanying apparatus to promote increased yield, improved surface finish and microstructure, and faster cycling time for precision-sand casting process. Aluminum products are cast by: (a) forming a precision sand mold, devoid of risers and/or vents, and a gating system consisting of a gravity feeding sprue and one or more runners effective to carry molten metal from the sprue only to the bottom of the mold cavity;
(b) planting a flow modifier in the gating system between the sprue and mold effective to convert the flow into laminar quiescent flow; and (c) filling the gating system with molten aluminum metal at a rate faster than 4 pounds/second as permitted by the laminar flow that more rapidly fills the mold and acts as a heat sink to prevent a drop in temperature of the in-coming molten metal and thereby increase yield as well as minimizing cycle time.

Description

2159~1 .

GRAVITY PRECISION SAND CASTING OF
ALUMINUM AND ~QulvALENT METALS

Background of the Invention Technical Field This invention relates to using core sand for precision molding of metal castings, particularly aluminum, and more particularly to enhancement of metal yield, metal properties and quality features such as surface finish using such casting technique.

Discussion of the Prior Art Precision-type sand casting (using core type sand such as zircon or silica) is known and has been used for at least 50 years in the commercial production of automotive castings, such as cylinder heads and blocks. This technique has many advantages, but it leaves certain features to be desired, such as increasing yield and improving the microstructure or surface finish of the casting, and increasing the speed of producing castings by such technique.
Risers, and to a lesser extent venting, have regularly been required in the molding system when sand casting aluminum. This is mAn~Ated to avoid shrinkage and pin holes in the solidifying regions. The risers serve as a molten reserve of aluminum that stays hotter to feed such - regions. Unfortunately such risers adversely affect yield of the process.
Such sand casting proceSses usually rely on gravity to feed molten metal to a runner system with the pressure head from the metal filling the sprue serving to provide a low level of pressurization for the metal in the runners. Due to the need to fill the risers during the pour, the cycle is slowed, allowing the molten temperature to drop and reach adverse temperature levels, particularly near the end of the mold filling. Thus, it is traditional - 21S93~1 to pour at higher metal temperatures to compensate for this aspect. This results in (i) a poorer surface finish, (ii) a poorer microstructure in the last metal to solidify, and (iii) poor production cycling.
The gravity runner system typically has abrupt changes in direction of sections of the runner system;
again, the metal must be poured at higher temperatures to maintain good fluidity over the slower cycle of the casting pour; this results in a flow that is somewhat turbulent.
Heat is readily transferred to the sand walls of the mold, often causing the sand particles to fracture, leading to poor surface finish for the metal casting. The higher pouring temperature tends to produce poorer metal microstructure in the regions last to solidify, producing a microstructure with wider dendritic arm spacing than desired.

Summary of the Invention This invention provides a technique and accompanying apparatus to solve the above problems while achieving increased yield, improved surface finish and microstructure, and faster cycling time for the casting process. The invention in a first aspect is a method of casting aluminum products comprising: (a) forming a precision sand mold, devoid of risers and/or vents, and a gating system consisting of a gravity feeding sprue and one - or more runners effective to carry molten metal from the _ _ sprue only to the bottom of the mold cavity; (b) planting a flow modifier in the gating system between the sprue and mold runner system to convert the flow into l~m; n~r quiescent flow; and (c) filling the gating system with molten aluminum metal at a rate in the range of 4-15 pounds per second as permitted by the l~m; n~r flow that more rapidly fills the mold and acts as an insulator to prevent a drop in temperature of the in-coming molten metal and thereby increase yield as well as m;n;m; zing cycle time.

A second aspect of this invention is an improved molding apparatus, comprising: (a) a precision sand mold devoid of risers and/or vents and having a mold cavity; (b) a runner system feeding the bottom of the mold at the largest metal regions of the mold cavity; (c) a sprue for gravity feeding of molten metal to the runner; (d) a flow modifier between the sprue and runners to effect laminar quiescent flow of the molten metal and to effect filtering of dross from the molten metal; and/or (e) a chill plate in the mold to at least control the solidification structure of the critical areas of the casting.

Brief Description of the Drawings Figure lA is a vertical sectional view of a mold and gating system to produce an automotive engine head casting, the mold and system e-mbodying the principles of this invention;
Figure lB is a perspective schematic illustration of the gating system of Figure lA showing the mold cavity broken away from the runner system;
Figure 2 is a reversed perspective illustration of the gating and mold system of Figure 1;
Figure 3 is an enlarged perspective illustration of the flow modifier utilized in Figures 1 and 2;
25Figure 4 is a graphical illustration of the relationship between aluminum flow rate and exposed surface --area of the flow modifier for providing l~m;n~r flow in _ _ _ distinction to filtratio~ and _ _ Figure 5 is a flow diagram illustrating the method steps of casting aluminum products according to the invention herein.

Detailed Description and Best Mode The gating system 10 (and Figure lB) must feed the largest to-be-cast metal masses 11 at the bottom of the mold cavity 12. This is necessary because of the conditions of directional solidification. For an automotive engine head casting, as shown in Figures 1 and 2, the casting cavity 12 desirably is oriented with the head deck 13 down; upright camtowers 14 are spaced at intervals 15 along the length of the head and bolt bosses 16 are aligned with the camtowers 14 to create enlarged metal mass zones which, for this casting, are the largest masses 11 adjacent the head deck. Concave com~bustion chamber roofs 17 are located between the camtowers 14, extending away from the head deck 13. The combustion cham~ber wall cavity and spark ignition sockets 19 as well as other cavities for valve train seats present complex internal shapes and demand optimum metal microstructure in the final casting.
The casting cavity is defined by the use of core-type sand (such as zircon or silica) walls 21; such sand walls are fabricated by conventional core making techniques.
The gating system 10 depends upon the gravity pressure head pushing the metal down a vertical sprue 23 to a horizontally extending runner system 27-28 that feeds the bottom 25 of the mold at the large mass zones 11. The sprue 23 should accept sufficient molten metal so that the filling of the mold can take place within m;nlml]m time and provide a pressure head sufficient to feed the casting while maintaining an excellent surface finish. For the --head casting cavity which here has an aluminum metal weight _ ~ _ of about 35-45 pounds, the sprue internal diameter is about 1-1/2 inches. To retain metal heat the sprue 23 can be insulated by a liner 26. The runner system may be split into two (or more) runner arms 27,28 to directly carry molten metal to the precise desired bottom locations of the mold cavity in a streamlined flow 29. Shallow ingates 30 (vertical channels) extend from the runners to connect the 35 top of the runner arms 27,28 to the large mass zones 11 at the bottom of the mold cavity. The runners have a cross-- 2159~91 sectional area of about six square inches which will taper to about three square inches for feeding the last of the ingates of the cylinder head example.
The sprue 23 has an enlarged base chamber 31 to facilitate transition of the molten metal to a horizontal flow; at the sides of the base cha-mber which connects to the entrance 32 to the runner system 27,28, is located a flow modifier 33 that extends across the flow area normal to the axis 29 of the flow. The flow modifier 33 is constructed to have a multitude of parallel equi-sized minute passages that promote l~m' n~r flow to the molten metal passing therethrough (see Figure 3). Such modifier may be fabricated of a high temperature extruded cellular ceramic, in various cell densities (about 300 cells per square inch). The modifier preferably has an open or porous area 36 that is about 50-80 percent of its total frontal exposed area 37. Such frontal exposed area 37 is preferably about 2-6 times the total choke area 38 of the gating system. Such porous area is also effective to filter, from the molten metal, slag dross and other non-metallic inclusions. Heretofore it has been believed that flow modifiers will lose their ability to filter molten metal at flow rates exceeding 4.0 pounds per second.
However, forming the modifier openings in squares or rectangles, and with the ratio of porosity to total area .5-.8, the modifier can convey molten aluminum at higher - rates with effective filtering of dross and slag (see _ _Figure 6). _ _ _ _ Such pouring rate permits an aluminum shot of about 75 pounds to be poured in 9 seconds (2 seconds to generate the head height and 7 seconds to deliver the molten metal through the sprue); see Figure 6.
To ensure enhanced metal microstructure at critical head surfaces, such as co-mbustion chambers, a cooled chill plate can be planted in the mold to define such surfaces.

Claims (11)

1. A method of casting aluminum products, comprising:
(a) forming a precision sand mold devoid of at least one of risers and vents, and a gating system consisting of a gravity feeding sprue and one or more runners effective to carry molten metal from said sprue only to the bottom of the mold cavity;
(b) planting a flow modifier in said gating system between the sprue and mold cavity to convert said flow into laminar flow; and (c) filling said gating system with molten aluminum metal at an enhanced pour rate permitted by said laminar flow that more readily fills the mold and acts as a heat insulator to keep the incoming molten metal at a higher temperature level thereby to minimize cycle time and improve the yield of the casting process.
2. The method as in claim 1, in which said mold has a chill plate effective to define the surfaces of critical casting areas.
3. The method as in claim 1, in which said runners directly feed the largest mass zones of said mold cavity.
4. The method as in claim 1, in which said modifier is constructed of a ceramic material having a cell density of about 300 cells/in2 and an exposed porous area appropriate for the pouring rate.
5. The method as in claim 1, in which said flow modifier is effective to filter dross, slag and non-metallic inclusions from said molten aluminum.
6. The method as in claim 1, in which said gating system is filled and poured within a time cycle of about 7 seconds or less for a typical 75 pound automotive head casting.
7. The method as in claim 1, in which said molten metal is filled in step (c) at a temperature of no greater than 1400°F.
8. The method as in claim 1, in which the aluminum metal is selected from the group of 356, 319 or other aluminum casting alloys.
9. An aluminum automotive head product produced by the process of claim 1.
10. An improved molding apparatus for casting aluminum products, comprising:
(a) a precision sand mold devoid of risers and/or vents;
(b) a runner system feeding the bottom of said mold at the largest metal mass zones of the mold cavity;
(c) a sprue for gravity feeding of molten metal to the runners;
(d) a flow modifier between said sprue and runners to effect laminar quiescent flow of the molten aluminium metal and to filter said molten metal of dross, slag and non-metallic inclusions; and (e) a chill plate in said mold to at least control the solidification structure of critical regions of the casting.
11. The apparatus as in claim 10, in which said modifier has an open porous area of 50-80 percent of the frontal area of said modifier.
CA002159391A 1994-10-07 1995-09-28 Gravity precision sand casting of aluminum and equivalent metals Abandoned CA2159391A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US08/319,901 US5620044A (en) 1994-10-07 1994-10-07 Gravity precision sand casting of aluminum and equivalent metals
US08/319,901 1994-10-07

Publications (1)

Publication Number Publication Date
CA2159391A1 true CA2159391A1 (en) 1996-04-08

Family

ID=23244082

Family Applications (1)

Application Number Title Priority Date Filing Date
CA002159391A Abandoned CA2159391A1 (en) 1994-10-07 1995-09-28 Gravity precision sand casting of aluminum and equivalent metals

Country Status (2)

Country Link
US (1) US5620044A (en)
CA (1) CA2159391A1 (en)

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JP3955168B2 (en) 1999-10-29 2007-08-08 日信工業株式会社 Method for manufacturing caliper body of disc brake for vehicle and caliper body
US6857462B2 (en) * 2002-11-25 2005-02-22 Honda Giken Kogyo Kabushiki Kaisha High pressure die cast process
US6929053B1 (en) 2004-05-26 2005-08-16 General Motors Corporation Mold fill method and system
US8702694B2 (en) * 2005-11-23 2014-04-22 Covidien Lp Auto-aligning ablating device and method of use
ES2702767T3 (en) * 2006-04-19 2019-03-05 Howmet Corp Sequential mold replenishment
CN102688990A (en) * 2012-06-15 2012-09-26 上海嘉朗实业有限公司 Aluminium alloy hydraulic motor shell gravity casting mould and manufacturing method thereof
CN104289675A (en) * 2013-07-16 2015-01-21 天津航天机电设备研究所 Bridge type multipoint synchronous pouring and casting mechanism for large castings
CN104550890A (en) * 2014-12-26 2015-04-29 宁夏共享装备有限公司 Pouring system for reducing mold filling speed in pouring gate
CN104985128B (en) * 2015-07-22 2018-01-05 湖北亚钢金属制造有限公司 One kind casting multi-laminate pours running gate system and technique
US20180029113A1 (en) * 2016-07-29 2018-02-01 GM Global Technology Operations LLC Direct squeeze casting
CN113319254A (en) * 2021-05-06 2021-08-31 北京鼎匠科技发展有限公司 Pouring system for regulating and controlling flow velocity of liquid metal in each pouring section and pouring process thereof

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Legal Events

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EEER Examination request
FZDE Discontinued