Manufacturing Process for Thin Walled Casting of Intricate Shapes

本提案的目的是探讨可行性和技术 利用该方法制造复杂薄壁铸件的优点 预热到铸件金属熔化温度的永久模具 金属. 模具可以是冲头和冲模的形式。 熔融 金属将被引入预热的模具中， 冲头将被降低到模具中。 模具预热到 熔融金属的温度将确保完全填充 凸模和凹模之间的复杂薄壁腔体。 凝固 铸造金属通过引入预定量的 水或冷空气进入冲头的冷却通道， 下一次生产不需要对冲头和模具进行大量的再加热， 铸造 冲头和模具材料将是如在本发明中使用的合金钢。 压铸行业 将在腔上采用合适的涂层 表面，以便于从模具中取出铸件。 铝 合金将在该提议中用作铸造金属;然而， 该技术也可以应用于锡合金， 铅锌镁和铜。 这项工作将探索最低限度的 铸件厚度、显微组织、强度和塑性性能， 和循环时间。 通过拟议的过程， 为了获得比压铸工艺更小的壁厚，即， 0.040 "或更小，而不需要在模具中使用的压力 铸造工艺 铸造金属的性能也可以增强。

The goal of this proposal is to explore the feasibility and technical merits of a process for making intricate thin wall castings by using permanent molds preheated to the metal melting temperature of the cast metal. The molds would be in the form of a punch and a die. The molten metal would be introduce into the preheated die and then the preheated punch would be lowered into the die. The preheat of the molds to the temperature of the molten metal would ensure complete filling of the intricate thin walled cavity between the punch and die. Solidification of the cast metal is achieved by introduction of a predetermined quantity of water or cold air into the cooling channel of the punch in such quantity that no extensive reheating of the punch and die is needed for the next casting. The punch and die material would be alloy steel as used in the die casting industry. A suitable coating would be employed on the cavity surfaces to facilitate extraction of the casting from the die. Aluminum alloy will be employed as the cast metal in this proposal; however, application of this techniques should also be possible to alloys of tin, lead, zinc, magnesium and copper. This work will explore the minimum casting thickness, the microstructure, strength and ductility properties, and the cycle time. With the proposed process it may be possible to attain wall thicknesses smaller than with the die casting process, i.e. 0.040" or less, without the need for pressure as is employed in the die casting process. Properties of the cast metal may also be enhanced.