Manufacturing of micro-structured functional magnesium components by transplantation of thermal sprayed coatings using lost cores during pressure die casting

通过在压力压铸过程中使用消失型芯移植热喷涂涂层来制造微结构功能镁部件

• 批准号: 281145974
• 负责人: Professor Dr.-Ing. Dirk Biermann
• 金额: --
• 依托单位: Institut für Spanende Fertigung
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2015
• 资助国家: 德国
• 起止时间: 2014-12-31 至 2017-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/281145974?language=en
• 关键词: Manufacturing; micro; structured; functional; magnesium

Aim of this research project will be to further develop the coating transplantation process and combine it with alternative materials and new innovative tool concepts. In the course of the coating transplantation the coating process is integrated into a die casting process by inserting a thermal spray coated mold insert into a die casting mold.During the casting process the melt infiltrates the pore network of the coating, creating a form locked joint. The feasibility of this process has already been proven for aluminum die casting. As an alternative casting material magnesium, with its excellent suitability for lightweight construction, is now in focus of this research project. Determining the difference to the transplantation process using aluminum based alloys and meeting the resulting challenges, not in the least, offers the opportunity to expand the basic understanding of the coating transplantation process. In this context it is also necessary to examine the specific corrosion problems resulting from the compound, consisting of coating and casting material, created during the transplantation process.The working hypothesis is, that suitable material choice and multi-layered coatings created by thermal spraying allow the coating structure to be adjust above and below the infiltration area as well as at the coating edges in such a way, that the increased corrosion resulting from the electrochemical potential of magnesium can be limited to a technically usable minimum.The usage of lost cores, especially salt cores, also shows great potential for the transplantation process. These would make it possible to produce components with a coated complex internal geometry. To this end, several challenges must be met. In addition to the difficulty of coating salt cores, several technical difficulties concerning production must be overcome and handling concepts be developed. The aim of the corresponding operating point will be to develop suitable processes for pretreating the surface of the salt cores for coating and to adapt the coating process accordingly, as well as to determine processing parameters which allow for the creation of complex geometries in salt. Based on the processing parameters the developed salt core geometries are provided by functional surface structures to enhance the characteristics of the manufactured workpiece.

本研究项目的目的是进一步发展涂层移植工艺，并将其与替代材料和新的创新工具概念联合收割机相结合。在涂层移植的过程中，通过将热喷涂的模具插入压铸模具中，将涂层工艺集成到压铸工艺中。在铸造过程中，熔体渗透涂层的孔隙网络，形成形状锁定接头。该工艺的可行性已经在铝压铸中得到了验证。镁合金作为一种替代铸造材料，具有良好的轻质结构适用性，目前是本研究项目的重点。确定与使用铝基合金的移植过程的差异并应对由此产生的挑战，至少提供了扩大对涂层移植过程的基本理解的机会。在这种情况下，还需要检查移植过程中产生的由涂层和铸造材料组成的复合物引起的特定腐蚀问题。工作假设是，适当的材料选择和通过热喷涂产生的多层涂层允许在渗透区域上方和下方以及在涂层边缘调整涂层结构，由于镁的电化学电势而引起的腐蚀增加可以限制在技术上可用的最小值。使用丢失的芯，特别是盐芯，也显示出移植过程的巨大潜力。这将使得生产具有涂覆的复杂内部几何形状的部件成为可能。为此，必须应对若干挑战。除了涂覆盐芯的困难之外，还必须克服与生产有关的几个技术困难，并开发处理概念。相应操作点的目的将是开发用于预处理盐芯表面以进行涂覆的合适工艺，并相应地调整涂覆工艺，以及确定允许在盐中产生复杂几何形状的工艺参数。根据加工参数，功能性表面结构提供了开发的盐芯几何形状，以增强所制造工件的特性。