A METHOD FOR MANUFACTURE OF HYBRID METAL ALLOY CASTINGS

Abstract

A method of producing hybrid castings, combined, movably joined from metal alloys in sand or permanent casting molds, where the method for manufacture of hybrid castings, especially with movable connections, in sand moulds or permanent moulds, comprises preparing metal components if the form of cast-in pieces, insert (5) for setting in the cope or drag (1,2), pre-heating to a given temperature depending on the material to increase the adhesion of the cast-in piece, insert (5) surface in the process of casting a hybrid casting (4), resulting in a final product comprising connected, movable hybrid components as an assembly for direct use.

Claims

1. A method for manufacture of hybrid castings, especially with movable connections, in sand moulds or permanent moulds, comprising preparing metal components in a form of cast-in pieces, insert (5) for setting in the cope or drag (1, 2), pre-heating to a given temperature depending on the material to increase the adhesion of the cast-in piece, insert (5) surface in the process of casting a hybrid casting (4), characterized in that on a piece in the form of a cast-in piece, insert (5) and/or on the core (3) surface and/or the mould (1, 2) surface if there is not a core (3) applying a separating agent (6) in the area of achieving the movable connection of the hybrid casting (4), with cast-in piece, insert (5) on the entire surface of the movable connection, to a thickness from 1 mm to 5 mm, setting the cast-in piece, insert (5) on the tooling pattern (4) or in a core made of core sand, filling the complete mould (1, 2) cope and drag by moulding sand and/or relatively firmly in the specially designed cope or drag (1, 2) cavity, setting and positioning the cast-in piece, insert (5) and/or the core with the cast-in piece, insert (5) wherefore mould (1, 2) cavity is surface based (8) and joins, filling the complete mould with a casting alloy by pouring through the sprue (7), after the metal solidify in the mould, knocking out the complete hybrid casting (4), together with the cast-in piece, insert (5), removing any instances of flash, removing the separating agent (6) from between the cast-in piece (5) and the casting (4), resulting in a final product comprising connected, movable hybrid components as an assembly for direct use or further processing.

2. The method according to claim 1, characterized in that the metal piece for the movable connection, i.e., the cast-in piece, insert (5) is made of the same material as the casting (4) or a different steel material, cast iron or cast steel.

3. The method according to claim 1, characterized in that the separating agent (6) in the movable connection of the hybrid casting (4) with the cast-in piece, insert (5) is preferably a ceramic material in liquid, solid or foam form.

4. The method according to claim 1, characterized in that the separating agent (6) in the form of a ceramic material in the movable connection of the hybrid casting (4) with a cast-in piece, insert (5) is removed mechanically.

5. The method according to claim 1, characterized in that the separating agent (6) in the form of a ceramic material in the movable connection of the hybrid casting (4) with a cast-in piece, insert (5) is removed by immersion in a medium in an ultrasonic cleaner or by high-frequency vibrations.

6. The method according to claim 1, characterized in that the separating agent (6) the ceramic material is with the addition of lubricating elements or is in the form of a bearing alloy.

7. The method according to claim 1, characterized in that the separating agent (6) in the form of a ceramic material separating the two materials in the pouring process has a thermal resistance of minimum 400 C.

8. The method according to claim 1, characterized in that the thermal resistance of the separating agent (6) in the form of a ceramic material depends on the material of the cast-in piece, insert (5) and the casting alloy used for the casting (4).

9. The method according to claim 1, characterized in that the separating agent (6) in the form of a ceramic material is applied in the area of achieving the movable connection of the hybrid casting by with a brush and/or by spraying.

Description

DETAILED DESCRIPTION

[0018] The invention is shown realized as an example in a drawing where

[0019] FIG. 1 with detail D shows an engineering drawing of a cross-section of the mould layout and the pouring technique for manufacture of the hybrid casting,

[0020] FIG. 2 shows an engineering drawing of a cross-section plan view of the mould layout and the pouring technique for manufacture of the hybrid casting,

[0021] FIG. 3 shows an example casting made by following the description of the invention.

EXAMPLE 1

[0022] A method for manufacture of hybrid castings especially with movable connections in sand or permanent moulds where a metal cast-in piece 5 for setting in the cope or drag 1,2 is heated up to a temperature of 60 C. to increase the adhesion of the cast-in piece 5 surface in casting the hybrid casting 4 comprises applying a separating agent which is a ceramic material 6 of a thermal resistance of minimum 700 C. with a brush in the area of achieving the movable connection of the hybrid casting, on the entire surface of the movable connection on the alloy steel cast-in piece 5 prepared beforehand, to a thickness of 1.0 mm, then preparing the cope and drag 1, 2 and setting the cast-in piece in the tooling on the cope pattern for the cope 1, filling the cope and drag 1,2 with moulding sand, then aligning the surfaces 8 using locating points and closing in a known way and filling with liquid aluminum alloy through the sprue 7, and, after solidification of the casting 4 in the mould 1,2, knocking out the complete casting 4 with the cast-in piece 5 in a known way, removing any instances of flash, removing the separating agent in the form of ceramic material 6 from between the cast-in piece 5 and the casting 4 by mounting in a fixture prepared beforehand and by using vibrations until the ceramic material 6 crumbles and rotational movement of the cast-in piece on the casting 4 is achieved. The final, hybrid product of combined movable components, as an assembly of the cast-in piece 5 and the casting 4 is ready for direct use or further processing.

EXAMPLE 2

[0023] A method for manufacture of hybrid castings especially with movable connections in sand or permanent moulds where a metal cast-in piece 5 for setting in the cope or drag 1,2 is heated up to a temperature of 60 C. to increase the adhesion of the cast-in piece 5 surface in casting the hybrid casting 4 comprises applying a separating agent which is a ceramic material 6 of a thermal resistance of minimum 700 C. by spraying in the area of achieving the movable connection of the hybrid casting, on the entire surface of the movable connection on the alloy steel cast-in piece 5 prepared beforehand, to a thickness of 3 mm, then preparing the cope and drag 1,2 and setting and aligning the cast-in piece on the cope pattern in the cope half of the mould, then aligning the surfaces 8 of the mould 1,2 halves using locating points, then closing the mould, then filling with liquid aluminum alloy through the sprue 7, and, after solidification of the casting 4 in the mould 1,2, knocking out the complete casting 4 with the cast-in piece 5 in a known way, removing any instances of flash, removing the separating agent in the form of ceramic material 6 from between the cast-in piece 5 and the casting 4 by mounting in a fixture prepared beforehand in an ultrasonic cleaner where, as a result of ultrasounds, the ceramic material 6 crumbles and separates from the casting 4 and the final, hybrid product of combined movable components is obtained, as an assembly of the cast-in piece 5 and the casting 4, ready for direct use or further processing.