Method for producing a cast aluminum component, and cylinder head for a motor vehicle, and production line for carrying out a method

Abstract

A method for producing a cast aluminum component having at least one reinforcing element arranged therein includes producing a core by placing at least one reinforcing element in a first mold and at least partially overmolding the at least one reinforcing element with a foam material. In the alternative, or in addition to, a core is produced by surrounding an inner element composed of a foam material by at least one reinforcing element. The method includes placing the core in a second mold and pouring liquid aluminum into the second mold and overcasting the core such that the liquid aluminum at least partially surrounds the core and the foam material is at least partially removed during the overcasting.

Claims

1. A method for producing a cast aluminum component having at least one reinforcing element arranged therein, the method comprising: a) producing a core comprising at least one of placing at least one reinforcing element in a first mold and at least partially overmolding the at least one reinforcing element with a foam material, and surrounding an inner element composed of a foam material by at least one reinforcing element; b) placing the core in a second mold; and c) pouring liquid aluminum into the second mold and overcasting the core such that the liquid aluminum at least partially surrounds the core and the foam material is at least partially removed during the overcasting.

2. The method according to claim 1, wherein the reinforcing element is a tape.

3. The method according to claim 1, wherein the reinforcing element comprises at least one of a metal matrix material and glass fibers.

4. The method according to claim 1, wherein the foam material comprises at least one of polystyrene and polyurethane.

5. The method according to claim 1, wherein the at least one reinforcing element is overmolded with the foam material via injection molding.

6. The method according to claim 1, wherein the core is produced by placing the at least one reinforcing element in the first mold and at least partially overmolding the at least one reinforcing element with the foam material via injection molding.

7. The method according to claim 1, wherein the core is produced by surrounding the inner element composed of the foam material by the at least one reinforcing element, and the inner element composed of the foam material is formed via injection molding.

8. The method according to claim 1, wherein the at least one reinforcing element is wound around the inner element composed of the foam material.

9. The method according to claim 1, wherein the at least one reinforcing element is laid on the inner element composed of the foam material.

10. The method according to claim 9 further comprising exerting pressure on the at least one reinforcing element laid on the inner element.

11. The method according to claim 10, wherein the pressure is exerted with a contact pressure roller.

12. The method according to claim 1, wherein the at least one reinforcing element is wound around the inner element composed of the foam material and laid on the inner element composed of the foam material.

13. The method according to claim 12 further comprising exerting pressure on the at least one reinforcing element laid on the inner element with a contact pressure roller.

14. The method according to claim 1, wherein the overcasting the core with the liquid aluminum is under high pressure.

15. The method according to claim 1, wherein the liquid aluminum solidifies such that the cast aluminum component is formed.

16. A cylinder head for a motor vehicle formed according to the method of claim 1.

17. A method for producing a cast aluminum component having at least one reinforcing element arranged therein, the method comprising: a) producing a core comprising by placing at least one reinforcing element in a first mold and at least partially overmolding the at least one reinforcing element with a foam material; b) placing the core in a second mold; and c) pouring liquid aluminum into the second mold and overcasting the core such that the liquid aluminum at least partially surrounds the core and the foam material is at least partially removed during the overcasting.

18. The method according to claim 17, wherein the foam material comprises at least one of polystyrene and polyurethane and the at least one reinforcing element is overmolded with the foam material via injection molding.

19. A method for producing a cast aluminum component having at least one reinforcing element arranged therein, the method comprising: a) producing a core by surrounding an inner element composed of a foam material by at least one reinforcing element; b) placing the core in a second mold; and c) pouring liquid aluminum into the second mold and overcasting the core such that the liquid aluminum at least partially surrounds the core and the foam material is at least partially removed during the overcasting.

20. The method according to claim 19, wherein the inner element composed of the foam material is surrounded by the at least one reinforcing element by at least one of winding the at least one reinforcing element around the inner element, and laying the at least one reinforcing element on the inner element and applying pressure on the at least one reinforcing element that is laid on the inner element.

Description

DRAWINGS

(1) In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:

(2) FIG. 1A shows a step of a method according to the present disclosure in accordance with a first form for producing a cast aluminum component;

(3) FIG. 1B shows another step of the method according to the present disclosure in accordance with the first form for producing the cast aluminum component;

(4) FIG. 1C shows still another step of the method according to the present disclosure in accordance with the first form for producing the cast aluminum component;

(5) FIG. 1D shows yet another step of the method according to the present disclosure in accordance with the first form for producing the cast aluminum component;

(6) FIG. 2A shows a step of a method according to the present disclosure in accordance with a second form for producing a cast aluminum component;

(7) FIG. 2B shows another step of the method according to the present disclosure in accordance with the first form for producing the cast aluminum component;

(8) FIG. 2C shows still another step of the method according to the present disclosure in accordance with the first form for producing the cast aluminum component; and

(9) FIG. 2D shows yet another step of the method according to the present disclosure in accordance with the first form for producing the cast aluminum component.

(10) The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION

(11) The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

(12) FIG. 1A shows a first method step, wherein a reinforcing element 10, here in the form of a tape 12 composed of a metal matrix material, is placed in a first mold 14. Formed in the first mold 14 is a cavity 16, which, in a second method step, shown in FIG. 1B, is filled with polyurethane foam (illustrated by dotted areas in the drawings). During this process, the tape 12 is overmolded with the polyurethane foam.

(13) After the hardening of the polyurethane foam, the core 18 which is then formed is removed together with the reinforcing element 10 arranged therein from the first mold 14 and, in accordance with method step 3 in FIG. 1C, is placed in a second mold 20.

(14) In a fourth method step, shown in FIG. 1D, a cast aluminum component 22 is produced by pouring aluminum (i.e., liquid aluminum) into the second mold 20. During pouring, the polyurethane foam volatilizes, and the volume is filled by the aluminum poured in (here illustrated by a hatched area). After the aluminum has hardened (i.e., solidified), the cast aluminum component 22 that has now formed is removed from the second mold 20. In some variations, the cast aluminum component 22 is a cylinder head 22 of a motor vehicle. In addition, in at least one variation FIGS. 1A to 1D show a production line for carrying out the method described above.

(15) FIGS. 2A to 2D likewise show a method for producing a cast aluminum component 22 with the reinforcing element 10 arranged therein, wherein, in this method, it is the production of the core which differs from the method described in conjunction with FIGS. 1A to 1D.

(16) In describing the second form below, the same reference signs as those used to describe the first form are used for identical or at least functionally identical elements.

(17) In a first method step, which is shown schematically in FIG. 2A, an inner element 24 composed of polyurethane foam is first of all produced. For this purpose, a cavity formed in a first mold 14 is filled with polyurethane foam (here illustrated by a dotted area).

(18) In a second method step (FIG. 2B), and as shown on the left hand side of the figure, a reinforcing element 10 in the form of a tape 12′ composed of a metal matrix material is wound around the inner element 24 composed of polyurethane foam, and as shown on the right hand side of FIG. 2B, a tape 12″ composed of a metal matrix material is laid on the inner element 24. In some variations a contact force F is exerted on the tape 12″ by a contact pressure roller 26 such that enhanced bonding of the tape 12″ to the inner element 24 is provided. It should be understood that in some variations one or more tapes 12′ are wound around the inner element 24 and in at least one variation a plurality of tapes 12″ are laid on the inner element 24. And in some variations one or more tapes 12′ are wound around the inner element 24 and a plurality of tapes 12″ are laid on the inner element 24.

(19) The inner element 24 composed of polyurethane foam, which is surrounded by the tape 12′ and/or 12″, now forms the core 18 and, in a third method step, which is shown in FIG. 2C, is placed in a second mold 20.

(20) In the fourth method step (FIG. 2D), liquid aluminum (here illustrated in hatched lines) is poured into the second mold 20, the polyurethane foam of the core 18 volatilizes, and the reinforcing elements 10 (not shown in FIG. 2D) remain in the cast aluminum component 22. After cooling, the finished cast aluminum component 22 is removed from the second mold 20. In some variations, the cast aluminum component 22 is a cylinder head 22 of a motor vehicle. In addition, in at least one variation FIGS. 2A to 2D show a production line for carrying out the method described above.

(21) Attention is furthermore drawn to the fact that the production of the cores 18 in accordance with the forms described above can also be combined, such that a core element with a reinforcing element is first of all formed, around which a tape is then wound, and/or a tape is laid on the core element.

(22) Unless otherwise expressly indicated herein, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word “about” or “approximately” in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, material, manufacturing, and assembly tolerances, and testing capability.

(23) As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”

(24) The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.