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Lost Core Neue Perspektiven Im Druckguss Dario Pierri Buhler Ag
Lost Core Neue Perspektiven Im Druckguss Dario Pierri Buhler Ag
Sand Cores
Inorganic
Organic
Croning
Solid Phase
Liquid Phase
Coatings Pressed
Shot Blast
Semisolid
100% Liquid
PROPERTIES
Smooth surface quality. High resistance to heat. Water soluble. Thermal insulator.
ADVANTAGES
No use of chemical binders. No use of coating. No use of toxic salts.
CHALLENGES
Ceramic behavior (brittle). Needs to be demolded for HPDC process. Limited in volume dimensions.
EXAMPLES
Volkswagen AG Volkswagen AG
BOCAR Bhler AG
Material property Solidustemperature Liquidustemperature Density Specific heat Thermal conductivity Latent heat of fusion Thermal expansion Viscosity Youngs Modulus Poisson ratio Avg. bending strength
Solid 2.3 2.5 kg/dm3 1.0 1.4 kJ/kg*K 2 - 4 W/m*K 4e-05 6e-05 K-1 > 10000 N/mm2 0.18 0.24 > 18 MPa
Liquid ca. 640C ca. 690C 1.7 1.9 kg/dm3 1.6 1.9 kJ/kg*K 1 - 2 W/m*K ~ 400 kJ/kg 1 - 2 mPas salt core specimen
Possibilities of simulation.
Simulation with materials salt and aluminum.
Aluminum Casting
Design of gating and venting system Check of flow circulation around salt core
FSI Simulation
Fluid-Structure-Interaction: Calculation of forces affecting the salt core during filling process
Aluminum Simulation.
Results of FSI Simulation.
Prediction of stresses on core surface by using Fluid Structure Interaction Simulation. Comparison of impact due to different ingate velocities.
Velocity 2 ~ 80 m/s
Velocity 1 ~ 40 m/s
Process steps.
Overview of production chain.
Mixing
Dosing
Stock / Quality
Salt stock
Melting
Salt Casting
Quality check
Process steps
Salt Mixing, melting and dosing.
Mixing:
Salt mixture is mixed in the furnace by
Mixing
Dosing
dosingscale.
Salt stock
Melting
Process steps.
Salt core casting out of liquid phase
Mixing
Dosing
Stock / Quality
Salt stock
Melting
Salt Casting
Quality check
Process steps.
Salt core casting out of liquid phase - Movie
Movie
Process steps.
Aluminum casting with salt core inlay.
Mixing
Dosing
Stock / Quality
Salt stock
Quality check
Process steps.
Aluminum casting with salt core inlay.
The correct support of the salt core in the die is relevant know-how. FSISimulation optimises the second phase (filling phase). Shot is real-time controlled. This is very important in order to avoid
the breaking of the inserted salt core and to guarantee a high reproducibiltiy of the shot.
Process steps.
Removing of salt core
Mixing
Dosing
Stock / Quality
Salt stock
Quality check
Process steps.
Removing of salt core
Requirements for a core-removing unit: 100% removing of salt.
Process steps.
Removing of salt core
Different geometries of salt cores are removable with water-jet: blind hole. curved channels.
Examples for removed cores.
Values for 3-cylinder engine block: Process values: Removal time Water consumption Water pressure Water temperature 90 sec 30 - 40 l max. 600 bar 20C
Salt recycling.
Reduce impact on environment and process costs.
Salt water Only a little percentage of salt is dissolved during the removing process. Salt content in water after removing <1%. Saltwater can be reused for the removing of salt cores. Residual water has to be neutralised (pH<8.0) before it flows into the drain. Salt Runner system is remelted Part of the removed salt is also remelted.
Summary.
Process chain and necessary machines for Lost Core production.
Mixing Melting&Dosing Salt Core Casting Aluminium Casting Core Removing
Thank you.
Backup
manufacturer that is able to provide a complete solution for industrial process with high efficiency.
equipment for the Lost Core technology that is suitable for industrial process with high efficiency.
Patents
With our patents we protect the process and the mixture in order to guarantee the freedom to operate of our customers. Patent on process for salt core production Patent on salt mixture Patent on removal process
Aluminum Simulation.
Results of FSI Simulation.
Ingate velocity has an influence on core viability. Intensification pressure may not be applied before the cavity is filled completely.
5.00E+07 4.50E+07
Mean Iso Stress @ 0.7 m/s Mean Iso Stress @ 1.4 m/s Mean Iso Stress @ 2.1 m/s Ingate Velocity @ 0.7 m/s Ingate Velocity @ 1.4 m/s Ingate Velocity @ 2.1 m/s
2.180
2.190
2.200
2.210
4.00E+07
2.10 EUR
2. Overcasting with aluminium Cost calculation done by the customer. Comparable to standard DC with inserts. 3. Core removing
Werkzeugkosten pro Salzkern Entkernungskosten pro Salzkern Wasserverbrauchkosten pro Kern Sondermll Entsorgungskosten pro Kern (0.7kg) 0.18 0.71 0.11 0.22 EUR EUR EUR EUR
1.22 EUR
Lost Core
Process substitution
New parts
Vision.