• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    Free function method, free casting apparatus and cast part. The present invention relates to a free casting method which includes an out-of-conduction step leading out of molten metal from an out-of-conduction area (p) provided at a source to temporarily retain the molten metal by means of foil films. surface (f) generated on an external surface, and a forming step to obtain a body formed by solidifying retained molten metal (ms) driven outward through a hardening passage (l1) depending on a desired cast part shape, wherein the retained cast metal is solidified after being cast into the desired cast part shape by applying an external force to it at positions between an unrestricted source part of the retained cast metal near the surface of the molten metal and an interface of solidification defined as a boundary between the retained molten metal and the body formed in the forming stage.
    公开号:BR112013006358B1
    申请号:R112013006358
    申请日:2011-09-12
    公开日:2018-08-28
    发明作者:Iwahori Hiroaki；Yaokawa Jun；Amano Norihiro；Ueno Noriyuki；Kobayashi Takehito；Iwata Yasushi；Sugiyama Yoshio
    申请人:Toyota Motor Co Ltd；
    IPC主号:
    专利说明:

    (54) Title: FREE CASTING METHOD, FREE CASTING APPLIANCE AND CASTING PIECE (51) Int.CI .: B22D 11/12; B22D 23/00 (30) Unionist Priority: 17/09/2010 JP 2010209761 (73) Holder (s): TOYOTA JIDOSHA KABUSHIKI KAISHA (72) Inventor (s): JUN YAOKAWA; YOSHIO SUGIYAMA; YASUSHI IWATA; HIROAKI IWAHORI; NORIHIRO AMANO; NORIYUKI UENO; TAKEHITO KOBAYASHI (85) National Phase Start Date: 03/15/2013
    1/20
    Invention Patent Descriptive Report for FREE CASTING METHOD, FREE CASTING APPLIANCE AND CASTING PIECE.
    Technical Field [001] The present invention relates to an inrush casting method (hereinafter referred to as free casting method) which is capable of obtaining a cast part without using a casting mold that conventionally was believed to be indispensable for casting, to a free-casting apparatus used appropriately for the method and to a casting obtained by the method and by the apparatus.
    Prior Art [002] Metal products created in complicated shapes are often produced by casting. Casting is a production process in which metal having fluidity (molten metal) is solidified into a desired shape to obtain a target melt. It was long believed in the common knowledge of the art that a casting mold having a cavity suitable for a desired shape of a target casting was an indispensable device for casting. Therefore, the casting methods employed in a conventional manner often led to a variety of problems caused by using the casting molds. The problems are, for example, casting defects (solidification crack, shrink porosity, gas bubbles, etc.), non-uniformity of solidified structure, deterioration of material produced, environmental load or similar. Several technical approaches have been proposed to solve each of the conventional problems from a microscopic point of view.
    [003] Except these technical approaches, some technical solutions were revealed, which approach the problems differently from the conventional casting methods in which molds
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    2/20 casting is used. Patent literatures that report examples of a casting technique like this are listed below.
    List of References
    Patent Literature [004] PTL 1: Japanese Unexamined Patent Application Publication No. 63-199050;
    PTL 2: Unexamined Japanese Patent Application Publication No. 2-205232;
    PTL 3: Japanese Unexamined Patent Application Publication No. 2-251341;
    PTL 4: Japanese Unexamined Patent Application Publication No. 9-248657.
    Summary of the Invention
    Technical Problem [005] The method revealed in Patent Literature 1, however, can only obtain metallic materials having columnar and simple bar shapes, failing to perform casting that demands a high degree of freedom in the shapes.
    [006] The methods disclosed in Patent Literature 2 to 4 also have a technical disadvantage in that a molten metal outlet is structurally constrained by a mold and a dividing element provided on a molten metal surface level on the side of its source supply. Therefore, these methods in a similar way are unable to perform such a casting that demands a high degree of freedom in the shapes, practically failing to obtain a casting having a smoothly curved surface or shape. It would be a logical thing that, in these methods, oxides or the like would stick to the mold and the dividing element provided at the surface level of the molten metal, failing to safely obtain a casting having a desired shape and quality.
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    3/20 [007] The present invention has been made in consideration of the circumstances mentioned above. The aim of the present invention is to provide an inrush casting method that is capable of easily obtaining castings having complicated shapes by essentially solving the various technical problems involved in conventional casting techniques. The present invention additionally provides an apparatus used suitably for the casting method, and a casting obtained by means of the casting method. Solution to the Problem [008] The inventors of the present invention worked hard to solve the problems, and finally discovered, as a result of research and trial method experiments, a casting method in which molten metal can be solidified into a desired shape for obtain a target casting without using a casting mold. The inventors continued to develop the discovery to further expand their technical scope, and finally completed the present invention described below.
    Free Casting Method:
    (1) A free smelting method according to the present invention is a smelting method that can obtain melted parts without using smelting molds, including: an outward driving step to smelted molten metal out of its level. surface to be retained by itself temporarily by means of surface film generated on an external surface or by surface tension, in which the molten metal is supplied to the molten metal retained through the surface level; and a forming step to obtain a body formed by solidifying the retained molten metal driven out along a hardening passage depending on a desired form of casting, wherein the retained molten metal is solidified after being changed to the desired shape at apply a force
    Petition 870180058021, of 07/04/2018, p. 6/30
    4/20 external to it in positions between an unrestricted source part of the molten metal retained in the vicinity of the surface level of the molten metal and a solidification interface defined as a boundary between the retained molten metal and the body formed in the formation step .
    (2) The free casting method according to the present invention can solve the conventional technical problems inevitably generated by the conventional casting methods in which casting molds are used. The present invention can dispense with any casting molds, which enables a casting to be produced as molten metal is always supplied when solidifying, thus preventing casting defects that conventionally occur in molds (for example, solidification crack, shrink porosity, inclusion (gas bubbles)). Because of this technical advantage, the method can be used to cast alloys that are likely to have solidification cracks or the like when conventional methods are employed (for example, worked aluminum alloys of the JIS 6000 series or similar), and can easily be obtained complicated shaped castings made of alloys. Thus, the free casting method according to the present invention is available for a wider selection of alloys to obtain castings.
    [009] Additionally, the method according to the present invention can dispense with any casting molds to obtain castings, thus notably improving a degree of freedom in the shapes of castings. Therefore, such castings that are conventionally difficult to obtain can be produced cheaply using the method. For example, molded castings with undercuts and long molded castings that are difficult to obtain can easily be produced using the free casting method according to the present invention. The free casting method
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    5/20 according to the present invention makes it unnecessary to prepare any particular production equipment or production steps for use depending on types of castings or casting molds. This results favorably in reducing manufacturing costs, improving manufacturing flexibility such as enabling small batch production with a variety of products, reducing the size of production equipment, improving a plant environment or the like.
    [0010] Because the surface of the mold cavity does not affect the solidification of the molten metal in the free smelting method according to the present invention, it is easy to control a cooling rate and a solidification direction, and thus obtain a smelting melt. high quality with well controlled solidification structure.
    [0011] Additionally, the free casting method according to the present invention can significantly reduce an amount of molten metal used for a part other than a product itself, thus achieving a remarkable improvement in material yield and a great reduction of return scrap. The free casting method according to the present invention makes it unnecessary to melt and retain a large amount of molten metal before casting a large product when melting raw materials little by little depending on demands. The method can thus reduce the use of metallic material and can also save energy required for casting. Thus, the free smelting method according to the present invention can bring a large amount of contribution to saving resources, saving energy and lower environmental burden (for example, reducing CO2 emissions).
    (3) As described so far, the present invention provides an excellent casting method that essentially solves a number of technical problems generated by conventional casting methods.
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    Although details of an exact mechanism of the casting method according to the present invention have not been identified precisely, we are presently considering the mechanism as described below.
    [0012] The molten metal is in a liquid or coexistent state of solid and liquid and therefore has fluidity. Therefore, the molten metal does not have any specific shape except its shape which is defined by a casting mold or the like (the surface of the mold cavity), which means that the molten metal is not usually kept (retained) in any particular way.
    [0013] However, when a solid (induction body) is brought into contact with a molten metal surface and raised slowly, the molten metal in a particular shape is raised together by about several tens of millimeters without using a casting mold. or similar. The molten metal is thus considered to be retained by at least one surface film (eg, oxide film) or by surface tension generated on an elevated molten metal surface.
    [0014] The molten metal retained like this (molten metal retained) is not solidified; therefore, its form is temporary or transitional. Therefore, the retained molten metal can have its shape changed varying depending on a direction or a passage in which the molten metal is guided or an external or similar force applied to it from the outside. When the retained molten metal is thus properly shaped for a desired melt and then cooled to solidify, a melt having the desired shape can be obtained even without using a casting mold. Because the original part of the molten metal retained in the vicinity of the surface level of the molten metal is not restricted, the shape of the retained molten metal has a very high degree of freedom. Therefore, a casting can
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    7/20 be easily obtained in a complicated form. The free casting method according to the present invention can efficiently obtain castings of complicated shapes without causing casting defects. [0015] There are different methods for cooling the retained molten metal to be solidified, examples of which are: a method of cooling the retained molten metal by directly blowing a refrigerant gas over it, and a method of cooling the retained molten metal indirectly when using a induction metal body or a solidified part of the molten metal. One of the cooling methods can be used, or some of the methods can be combined.
    [0016] When the retained molten metal is cooled indirectly when using the already solidified part, the cooling methods can be applied directionally from the already solidified part to an un-solidified part. This helps to obtain a perfect casting where a casting defect such as shrink porosity is avoided. In addition, the free casting method according to the present invention can easily obtain a high quality cast piece having a directional solidified structure which is difficult to obtain by means of conventional casting methods in which casting molds are used.
    [0017] According to the free casting method in which the molten metal is not cooled in a casting mold, solidification crack, which is possibly generated in conventional casting methods because of the restriction of thermal construction by the casting molds , is prevented from occurring. Because of this technical advantage, it is possible in the method to obtain castings made of alloys, such as 6000 series worked aluminum alloys (JIS), which are likely to have solidification crack in conventional casting methods.
    Free Casting Apparatus:
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    8/20 [0018] The present invention is applicable not only to the free-casting method described so far, but also to a free-casting apparatus used appropriately for the method. A free-smelting apparatus according to the present invention comprises a crucible in which molten metal is contained, and a shaped supply element configured to apply an external force to the retained molten metal driven out of a surface level of the contained molten metal. in the crucible and temporarily retained by a surface film or by surface tension generated on an external surface to mold the molten metal retained into a shape. The casting apparatus thus structurally characterized can be used for the free casting method.
    [0019] The free-melting apparatus preferably further comprises a drive source configured to guide an induction body having a solid to induce a basic shape designed to obtain a desired cast shape along a hardening passage depending on the shape of desired casting from the surface of the molten metal in the crucible. The free melting apparatus preferably further comprises a nozzle used to blow fluid onto an external surface of the retained molten metal or an external surface of a formed body obtained by solidifying the retained molten metal.
    Cast Part:
    [0020] The present invention is also applicable to a cast piece obtained by means of the free casting method and the free casting apparatus described so far. A casting according to the present invention preferably has a directional solidified structure in which the solidified structure is directionally disposed.
    Others:
    (1) The material, shape and dimension of the cast according to
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    9/20 with the present invention are not particularly limited.
    (2) Unless otherwise reported, x - y reported in the specification for the present invention includes a lower limit value x and an upper limit value y. The upper limit value and the lower limit value reported in the specification of the present invention can be combined variably and expressed in a range of numbers such as this from a - b. Any arbitrary numerical values included in the technical scope reported in the specification can be used as an upper limit value and a lower limit value to define a range of numbers.
    Brief Description of the Drawings [0021] Figure 1 is a conceptual view of a free-casting apparatus.
    [0022] Figure 2 is an enlarged partial view of the free-casting apparatus shown in Figure 1.
    [0023] Figure 3 is an image of a cast obtained through free casting.
    [0024] Figures 4A-4C are microscopic images of the microstructure of the cast. Figure 4A is a microscopic image of the microstructure in a vertical plane of the R axis. Figure 4B is a microscopic image of the microstructure in a vertical plane of the theta axis. Figure 4C is a microscopic image of the microstructure in a vertical Z-axis plane.
    [0025] Figure 5 is an image of another cast piece obtained through free casting.
    [0026] Figure 6 is an image of yet another cast piece obtained through free casting.
    REFERENCE LISTING free crucible casting machine
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    10/20 supply elements of cooling nozzle (nozzle) initiator (induction body) drive source
    M cast metal
    MS retained cast metal
    MS part of origin
    C1, C2 casting
    L1 pass (hardening pass)
    G refrigerant
    Description of Modalities [0027] The present invention will be described more specifically by means of modalities. The description of this specification including the following description of modalities can be applied in an appropriate manner not only to a free-casting method and to a free-casting apparatus, but also to a casting obtained by means of the method and apparatus in accordance with with the present invention. One or more of the following component resources can be added arbitrarily to the aforementioned constitution of the present invention. A primary feature regarding a casting method can be considered that of a casting when it is understood as a product by process. It should be noted that the most appropriate modality depends on a target application, required characteristics or the like.
    Free Casting Method:
    [0028] Main steps included in the free casting method according to the present invention are an outward driving step and a forming step.
    Driving Out Step:
    (1) The driving out step is a step in which an
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    11/20 part of the molten metal contained in a container such as a crucible is taken out of a supply source, for example, a surface level of the molten metal, to be retained by itself depending on a desired shape of a piece fused. When castings are produced continuously, the lead-out step and the forming step work as a sequence of steps.
    [0029] An outward driving area from which retained molten metal is conducted outwards is located in the vicinity of a boundary between the surface level of the molten metal contained in the crucible and the retained molten metal, and a source part of the molten metal retained is formed near the outward driving area.
    (2) The retained molten metal is preferably driven outward, for example, by using an induction body provided to induce a basic shape designed to obtain the desired molten part shape and bring the induction body into contact with the molten metal in the driving area out and raising the induction body. In this way, the retained molten metal can be stably retained, and the molten part can be formed in a stable form. Another advantage of driving out the molten metal retained in this mode is that the molten metal retained can be transferred by using the induction body in the forming step.
    [0030] The induction body has a shape like this in that it is suitable for the basic shape (for example, circular shape, annular shape). The induction body can be made of any material as long as the molten metal sticks to it. For directional solidification of the molten metal in one direction from the induction body to the outward driving area or the like, the induction body is preferably a metal body (solid material) superior in heat transmission (heat conductivity, heat transfer ). The body material of
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    12/20 induction is therefore not necessarily the same metal as that of the molten metal.
    (3) An atmosphere where the retained molten metal is led out is not particularly limited. When the retained molten metal is carried out under oxidation atmosphere or atmosphere, an oxide film is generated as a surface film on an external surface of the retained molten metal. When the retained molten metal is carried out under a nitrogen atmosphere, a nitride film is generated as a surface film on it. Even when the retained molten metal is driven out under an atmosphere like this in which no surface film is generated, the retained molten metal can be retained by surface tension generated on the surface of the molten metal.
    Formation Stage:
    (1) The forming step is a step in which the retained molten metal is solidified while being guided depending on a desired shape of the melt so that a formed body (melt) having a desired shape is obtained. As previously described, the retained molten metal, while having a temporarily retained shape, is not solidified. Therefore, the retained molten metal can be changed to a desired shape by regulating and adjusting a passage where it moves after the outward driving step and an external force applied to it.
    [0031] The molten metal retained having the original part unrestricted can be easily changed into various complicated shapes. The retained molten metal is guided to a desired shape by using a form supply element (a tool such as a palette, guide or roller) placed in contact with the retained molten metal or by blowing a flow-controlled fluid (gas) or pressure controlled to apply fluid pressure to it. Then the
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    13/20 retained molten metal can be changed into various complicated shapes, and a casting having an arbitrary shape can be obtained accordingly. The retained molten metal can be guided to a desired shape not only from the side of an external surface, but also from the side of an internal surface of the retained molten metal. When the retained molten metal is guided to a desired shape on the sides of its outer surface and inner surface, the thickness of the retained molten metal as well as its shape can be easily adjusted or adjusted.
    [0032] Once the retained molten metal is thus modeled and formed, castings having shapes hitherto difficult to obtain by means of conventional casting methods in which casting molds are used (for example, recessed casting) can be used. easily obtained. This facilitates the production of castings having shapes that can be difficult to obtain by simply controlling the movement of the retained molten metal along a hardening passage described below.
    [0033] The passage where the retained molten metal is guided is preferably an ascending passage having at least one ascending component, because the retained molten metal can be guided and controlled more easily when pulled upwards (lifting step). The hardening passage can be a straight, curved or spiral passage extending vertically upwards. The hardening passage can be a regularly configured passage or an irregularly configured passage.
    (2) Examples of methods for cooling the retained molten metal are: directional solidification when using the induction body or already solidified part, and cooling by cooling by blowing any of several refrigerants to the retained molten metal or the body formed near a solidification interface on the sides of the surfaces
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    Internal and external 14/20. Refrigerants can be blown into the retained molten metal in order to not only cool, but also to form the retained molten metal. Examples of the refrigerant are gases such as air, nitrogen gas or inactive gas, or liquid such as water. When the liquid is used as the refrigerant, the trapped molten metal can be cooled quickly and efficiently by the heat of vaporization. In particular, when the liquid is sprayed depending on an amount of heat of solidification of the retained molten metal, the liquid used as the refrigerant is prevented from falling on the molten metal, and the refrigerant can be easily recovered. [0034] When nozzles are provided on external or internal sides of the retained molten metal, the refrigerant can be easily sprayed. How many nozzles are provided and where they are placed can be properly decided depending on any desired shape and solidified structure of the cast. When, for example, a plurality of nozzles or an annular nozzle is provided on the outside of the retained molten metal, the total retained molten metal can be cooled uniformly. As a result, a casting having neatly solidified structure can be obtained.
    Cast Metal:
    [0035] The type of the molten metal is not particularly limited. The metal can be iron, aluminum, magnesium or titanium, or an alloy obtained from any of these metals. The molten metal reported in the specification for the present invention is not necessarily limited to a metal whose total content is in the liquid phase. The molten metal can be a metal in the solid and liquid coexistence phase in which the solid phase is mixed with the liquid phase, in which case the solid phase and the liquid phase are not necessarily made of the same material. The molten metal can be composite materials.
    Others:
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    15/20 [0036] The intended end use for the casting according to the present invention is not particularly limited. The melt may be a near-final product or a material to be further processed further before being finished (intermediate material). The present invention can easily and inexpensively obtain castings having complicated shapes or solidified structure hitherto difficult to obtain by means of conventional casting methods in which casting molds are used. Therefore, the cast part according to the present invention can be used in a wide range of products in technical fields where cast parts were not used conventionally.
    Example 1 [0037] The present invention will be described in further detail with reference to examples.
    Free Casting Apparatus:
    (1) Figure 1 is a conceptual view of a free melting apparatus 1. Figure 2 is an enlarged view of a part of the free melting apparatus shown in Figure 1. The free melting apparatus 1 has a crucible 10, wherein the molten metal M is contained, and an inner supply element 111 and an outer supply element 112 provided immediately above a surface level of the molten metal M in the crucible 10 (which are collectively called elements form 11), a plurality of the cooling nozzles 13 provided in an upward direction of the form 11 supply elements, from which a coolant G is blown out approximately by annular shape, an initiator 14 (induction body) made of metal and having an annular sectional shape, and a driving source 15 that raises the initiator 14.
    [0038] The drive source 15 can control a speed
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    16/20 elevation (ascent rate) of the initiator 14 and an elevation direction (direction of movement) of the initiator 14. The initiator 14 is movable along an upward passage (hardening passage) configured arbitrarily. The amount of the refrigerant G (air is used in Example 1) blown by the cooling nozzles 13 and its jet pressure can be controlled arbitrarily by means of a controller provided separately (not shown in the drawings).
    (2) When the molten metal M is guided by the primer 14 and pulled upwards from an area leading outwards P of the crucible 10 (lifting step), a thin annular surface film F (oxide film) is generated on the external surfaces of the molten metal M on its internal and external surfaces. These surface films F (or molten metal surface tension M) form the retained molten metal MS carried out and retained in an annular (conical) shape.
    [0039] Since the retained molten metal MS is retained by the surface films F, the retained molten metal MS extends upwards by about a height h from the surface level of the molten metal M in the crucible 10. The height h or a nearby height is a solidification interface B where the liquid phase changes to the solid phase. In an upward direction of the solidification interface B, the retained molten metal MS is solidified so that a molten part C1 (formed body) having a desired shape (for example, annular shape) is obtained. The direction of solidification of the molten part C1 cooled by means of heat removal by the initiator 14 and by the refrigerant G blown into it by the cooling nozzles 13 is a direction of the initiator 14 towards the outward driving area P. Therefore, the part casting C1 has directional solidified structure formed in a direction where the casting C1 extends.
    [0040] An MSa annular origin part of the retained molten metal MS
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    17/20 formed in the vicinity of the outward driving area P of the molten metal is not restricted. When the form supply elements 11 in contact with the retained molten metal MS are respectively moved to the right and left, the original part MSa can freely change its shape according to the behavior of the form supply elements 11. As a result, the retained molten metal MS is free of any restrictions and can be easily changed into any complicated shapes by the shape supply elements 11.
    Free Casting:
    (1) A cast part actually produced by the free melting apparatus 1 is described below.
    [0041] Crafted aluminum alloy (Al) (JIS A6063), which is conventionally known as a difficult to melt metal because solidification crack or the like is likely to occur, has been used as the metallic material of molten metal M. O prepared metallic material was melted and placed in crucible 10, and then maintained at 680 ° C.
    [0042] The internal supply element 111 suspended on the surface of the molten metal M was a thermal insulating element having a disk shape and formed in the diameter (D) size of 40 mm x thickness of 3 mm. The outer supply element 112 was a thermal insulating element having a ring shape and constructed in the inner diameter size D of 60 mm x outer diameter D of 100 mm x thickness of 3 mm. The outward driving area P was formed by the form 11 supply elements and was annular in shape with a clearance of 10 mm (inner diameter D 40 mm x outer diameter D 60 mm).
    [0043] The primer 14 was a cylindrical element made of steel and formed in the internal diameter D size of 44 mm x external diameter D of 56 mm x height of 100 mm. The eight cooling nozzles 13 were
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    18/20 equally spaced in an annular form in an upward direction of the supply elements of form 11. The respective cooling nozzles 13 blew air at about 30 ° C at the rate of 200 L / min.
    (2) The primer 14 was placed in contact with the molten metal surface M in the area leading outward P. Once the solidification of the molten metal M started on the lower end side of the primer 14, the primer 14 was raised along of a linear passage L1 (hardening passage) with a rising speed of 40 mm / min with the air continuously blown by the eight cooling nozzles 13. Then, the molten metal retained MS retained by the surface films F (oxide films) (outward driving step, lifting step) was driven outward, and the casting C1 having a cylindrical shape and directionally solidified in an upward direction of solidification interface B (forming step) was formed. The C1 cast was formed in the external diameter size D of 55 mm x thickness of 5 mm.
    [0044] In an intermediate stage of the formation stage, the form 11 supply elements were put into action. That is, the inner supply element 111 and the outer supply element 112 have been displaced in such a way that the original part MSa of the retained molten metal MS has expanded its diameter. As a result, a C2 casting having a cylindrical shape and an elliptical shape in section and formed in the outside diameter size greater than 80 mm x outside diameter less than 55 mm x thickness 4 mm was obtained. Figure 3 is an image of casting C1 and casting C2 (collectively called casting C). The obtained castings C did not show any casting defect such as shrink porosity or solidification crack and had a uniform and thin cast surface.
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    19/20 (3) Figures 4A-4C are microscopic images of the microstructure of the C1 cast. Figures 4A to 4C are the microscopic images of the microstructures respectively in a vertical plane radially (vertical plane of the R axis), a vertical plane circumferentially (vertical plane of the theta axis), and a vertical plane in the extension direction (vertical plane of the axis) Z). It is known from these images that the C1 cast has a favorable directional solidified structure. In the images, a bleached part is columnar structure which is a primary alpha phase crystal grown in the direction of elevation (Al in the FCC structure), and a darkened part is a phase of Mg2Si finally crystallized after the columnar structure is grown. Example 2
    Free Casting Method:
    [0045] Figures 5 and 6 are images of another melt obtained by means of the free melting apparatus 1. To obtain a C3 melt shown in Figure 5, the horizontal displacement speed (to the right and to the left) of primer 14 and the rate of ascent of primer 14 were set to 1: 1, and the retained molten metal MS was guided along a zigzag passage (hardening passage) tilted from the vertical direction by about 45 degrees and then formed. The C3 casting also had a directional solidified structure. The C3 casting did not show any casting defect such as shrink porosity or solidification crack, and had a smooth, uniform casting surface.
    [0046] To obtain a C4 casting shown in Figure 6, the displacement passage of the primer 14 (guiding passage of the retained molten metal MS) having the zigzag shape is changed to a passage having a spiral shape (hardening passage ), and the retained molten metal MS is then formed. More
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    20/20 specifically, the primer 14 was placed in contact with the molten metal M in the outward driving area P, and the primer 14 was then raised slightly with the ascent rate of 84 mm / min (outward driving step, lifting step). With the rate of ascent sustained constantly, the primer 14 was then displaced with the circumferential speed of 28 mm / min along the outer periphery of a radius of 10 mm (D of 20 mm). The C4 castings thus obtained also had a directional solidified structure. The C4 casting did not show any casting defect such as shrink porosity or solidification crack, and had a smooth, uniform casting surface. [0047] When form supply elements are used to form the castings shown in Figures 5 and 6, castings having very complicated shapes can be obtained efficiently with a high product quality ensured at the same time.
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    权利要求:
    Claims (8)
    [1]
    1. Free casting method that is able to obtain castings (C1) without using casting molds, including:
    an outward driving step to drive out molten metal (M) from its surface level to be temporarily retained by itself by a surface film (F) generated on an external surface or by surface tension, where molten metal (M) is supplied to retained molten metal (MS) through the surface level; and a forming step to obtain a body formed by solidifying the retained molten metal (MS) carried out along a hardening passage (L1) depending on a desired molten part shape, characterized by the fact that the retained molten metal (MS) is solidified after being changed to the desired shape by applying an external force to it in positions between an unrestricted source part (MSa) of the retained molten metal (MS) in the vicinity of the surface level of the molten metal (M) and a solidification interface (B) defined as a boundary between the retained molten metal (MS) and the body formed in the forming step.
    [2]
    2. Free casting method according to claim 1, characterized in that the step of conducting outward includes a step of carrying an induction body (14) having a solid provided to induce a basic shape of the casting (C1 ) to be in contact with the molten metal surface (M).
    [3]
    Free casting method according to claim 1, characterized in that the forming step includes a lifting step to lift the retained molten metal (MS) along an upward passage which is the hardening passage (L1) having at least one parent component.
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    2/2
    [4]
    4. Free smelting apparatus, comprising:
    a crucible (10) in which molten metal (M) is contained, and characterized by a shape supply element (111, 112) configured to apply an external force to the retained molten metal driven out of a surface level of the molten metal (M) contained in the crucible (10) and temporarily retained by a surface film (F) generated on an external surface or by surface tension to mold the retained molten metal (MS) into a shape, in which the free-melting apparatus can be used for the free smelting method as defined in claim 1.
    [5]
    Free-melting apparatus according to claim 4, characterized in that it further comprises a drive source (15) configured to guide an induction body (14) having a solid to induce a basic shape designed to obtain a shape of desired casting over a hardening passage (L1) depending on the desired shape of casting (C1) from the surface of the molten metal (M) in the crucible (10).
    [6]
    6. Free-casting apparatus according to claim 4, characterized in that it further comprises a nozzle (13) used to blow fluid onto an external surface of the retained molten metal or an external surface of a formed body (C1) obtained when solidifying the retained molten metal (MS).
    [7]
    7. Casting part (C1) characterized by being obtained by the free casting method as defined in claim 1.
    [8]
    8. Casting part (C1) according to claim 7, characterized by the fact that it has directional solidified structure in which the solidified structure is arranged directionally.
    Petition 870180058021, of 07/04/2018, p. 25/30
    1/4
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    公开号 | 公开日
    KR20150080637A|2015-07-09|
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    EP2616200B1|2018-10-24|
    WO2012035752A1|2012-03-22|
    AU2011303303B2|2014-12-18|
    US9457396B2|2016-10-04|
    KR20150033744A|2015-04-01|
    KR20130061174A|2013-06-10|
    KR101612687B1|2016-04-14|
    CN104985145B|2017-05-10|
    BR112013006358A8|2018-02-27|
    RU2550465C2|2015-05-10|
    BR112013006358A2|2017-07-18|
    CN103124604B|2015-08-12|
    KR101612686B1|2016-04-14|
    US9120146B2|2015-09-01|
    CA2810485A1|2012-03-22|
    JP5373728B2|2013-12-18|
    EP2616200A1|2013-07-24|
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    法律状态:
    2018-04-10| B06A| Notification to applicant to reply to the report for non-patentability or inadequacy of the application according art. 36 industrial patent law|
    2018-07-17| B09A| Decision: intention to grant|
    2018-08-28| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 12/09/2011, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    JP2010209761A|JP5373728B2|2010-09-17|2010-09-17|Free casting method, free casting apparatus and casting|
    PCT/JP2011/005124|WO2012035752A1|2010-09-17|2011-09-12|Free casting method, free casting apparatus, and casting|
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