CASTING MOLD FOR CASTING COMPONENTS AND METHOD FOR THE PRODUCTION THEREOF

Abstract

The present invention relates to a casting mold for casting components. The casting mold comprises at least one casting mold frame made of metal and/or of an alloy, and also one or more ceramic casting mold inserts introduced into the at least one casting mold frame. The casting mold insert or the casting mold inserts has/have the negative contour or part of the negative contour of a component to be produced or of the combination of a component to be produced with one or more casting cores. The present invention also relates to a method for producing the casting mold according to the invention and to the use of the casting mold according to the invention.

Claims

1. A casting mold for casting components, comprising: at least one casting mold frame made of a metal or of an alloy; and at least one ceramic casting mold insert which is configured to be introduced into the at least one casting mold frame and which comprises a negative contour or a part of the negative contour of a component to be produced, or of a combination of a component to be produced with at least one casting core.

2. The casting mold according to claim 1, wherein the at least one ceramic casting mold insert includes a material that is at least one of: AlN, SiAlON, SiN, SiSiC, SiC, zirconium oxide, aluminum oxide, ATI, or a mixture thereof.

3. The casting mold according to claim 1, wherein the ceramic casting mold insert includes a material that has a heat conductivity of from 1.5 to 50 W/mK, inclusive.

4. The casting mold according to claim 1, wherein the ceramic casting mold insert includes a material that has a heat conductivity between 100 and 220 W/mK, inclusive.

5. The casting mold according to claim 1, further comprising: multiple ceramic casting mold inserts introduced into the at least one casting mold frame, wherein the multiple casting mold inserts comprise the negative contour or the part of the negative contour of the component to be produced or of the combination of a component to be produced with at least one casting core, wherein the ceramic casting mold inserts each include a material, and wherein the materials of at least two of the ceramic casting mold inserts have at least one of: a different heat conductivity or a different coefficient of thermal expansion.

6. The casting mold according to claim 5, wherein, at least one of the ceramic casting mold inserts introduced into the casting mold frame includes a material that has at least one of: a heat conductivity between 1.5 and 50 W/mK, inclusive or a coefficient of thermal expansion between 0.5 and 3.5.Math.e.sup.−6/K, inclusive, and wherein the material is at least one of: SiN, SiAlON, ATI or a mixture thereof.

7. The casting mold according to claim 1, wherein the ceramic casting mold insert includes silicon-infiltrated silicon carbide (SiSiC).

8. The casting mold according to claim 7, wherein the ceramic casting mold insert includes at least one passivation layer, the passivation layer including a material, and wherein the material is at least one of: carbon, silicon nitride, or a mixture thereof.

9. The casting mold according to claim 1, wherein the metal or the alloy is at least one of: an iron-nickel alloy, an iron-nickel-cobalt alloy, tool steel, cast iron, and mixtures or alloys thereof.

10. A method for producing a casting mold, the method comprising: introducing a ceramic casting mold insert into at least one casting mold frame made of metal or of an alloy, wherein the casting mold insert comprises a negative contour or a part of the negative contour of a component to be produced or of a combination of a component to be produced with at least one casting core.

11. The method according to claim 10, wherein the ceramic casting mold insert includes silicon-infiltrated silicon carbide (SiSiC).

12. The method according to claim 11, wherein the ceramic casting mold insert is provided with at least one passivation layer, wherein the passivation layer is comprised of a material, and wherein the material is at least one of: carbon, silicon nitride, or mixtures thereof.

13. The method according to claim 12, further comprising: applying at least one layer with the material of the passivation layer to the ceramic casting mold insert; and subjecting the at least one applied layer is to a temperature treatment in an inert gas atmosphere, wherein the temperature treatment is performed at least one of: a temperature in a range between 1000° C. and 1400° C., inclusive, or for a duration of between 12 h to 120 h, inclusive.

14. The method according to claim 10, wherein the casting is performed using a low-pressure die casting method.

15. The casting mold according to claim 3, wherein the material has a coefficient of thermal expansion of from 0.5 to 3.5.Math.e.sup.−6/K, inclusive.

16. The casting mold according to claim 3, wherein the material is at least one of: SiN, SiAlON, ATI, or a mixture thereof.

17. The casting mold according to claim 4, wherein the material has a coefficient of thermal expansion between 4.0 to 5.6.Math.e.sup.−6/K, inclusive, and wherein the material is at least one of: AlN, SiSiC, or a mixture thereof.

18. The casting mold according to claim 5, wherein at least one of the casting mold inserts introduced into the casting mold frame includes a material that has at least one of: a heat conductivity between 100 and 220 W/mK, inclusive or a coefficient of thermal expansion between 4.0 and 5.6.Math.e.sup.−6/K, inclusive, and wherein the material is at least one of: AlN, SiSiC, or a mixture thereof.

19. The casting mold according to claim 9, wherein the iron-nickel alloy is Invar, and wherein the iron-nickel-cobalt alloy is Kovar.

20. The method of claim 13, wherein the inert gas atmosphere is a nitrogen gas atmosphere.

21. A casting mold for casting components, the casting mold comprising: a casting mold frame made of at least one of: a metal or an alloy; a ceramic casting mold insert configured to be introduced into the casting mold frame, the casting mold insert comprising: a negative contour, or a part of the negative contour, of a component or a combination of a component to be produced with a casting core; and wherein the ceramic casting mold insert includes a material that has a heat conductivity of between 1.5 and 50 W/mK, inclusive, wherein the material is at least one of: SiN, SiAlON, ATI, or a mixture thereof.

22. The casting mold of claim 21 further comprising: a second casting mold insert configured to be introduced into the casting mold frame, wherein the second casting mold insert includes a second material, and wherein the second material has at least one of, a different heat conductivity or a different coefficient of thermal expansion than the material of the casting mold insert.

Description

EXEMPLARY EMBODIMENT

[0044] A casting mold for low-pressure die casting, consisting of two mold parts, is constructed as follows: Each mold half consists of a casting mold frame, in which there is inserted a casting mold insert made of aluminum nitride. The appropriate negative component contour is formed in the upper side of the casting mold insert, wherein the further design of the mold inserts is suitable for ceramics, in particular in respect of a minimization of stresses occurring as a result of cyclical thermal stress. The minimum wall thickness of the mold insert is 10 mm. The underside and the side faces of the casting mold insert are surrounded by a casting mold frame which is fabricated from an iron-nickel-cobalt alloy (Fe54Ni29Co17). The mold frame is shaped such that planar contact with the underside and the side faces of the ceramic mold insert is possible. The casting mold frame has a minimum wall thickness of 25 mm and is provided with channels for controlling the temperature of the casting mold frame and the mold insert. The casting mold frame is mounted on a carrier plate made of tool steel, to which further components are attached (for example coupling plate for closing cylinders, ejectors, etc.). The mold halves are guided on a base plate made of tool steel for opening and closing. A sleeve made of aluminum titanate that is conical on the inner side is inserted into the base plate for the transition from the riser into the closed mold. The casting mold is temperature-controlled via the casting mold frame by an oil temperature-control system, wherein the maximum temperature at the casting mold frame does not exceed 350° C. The described casting mold is used for lightweight metal casting up to 800° C.