System and method for moulding metal parts

Abstract

A system and method for moulding metal parts having a first metal structure (4) which is integrally attached to a rotating machine, where said structure (4) is associated with a cover (3) and a plurality of fastening elements (1, 2), and where, in turn, the structure (4) is integrally attached to a cylindrical metal die (5) containing a ceramic mould (7) and hardened sand (6) for filling the die (5).

Claims

1. A method for moulding metal parts, the method comprising the steps of: a) making a polystyrene model of a metal part; b) impregnating the polystyrene model with a liquid zirconium sand and binder mixture; c) coating the polystyrene model with zirconium sand; d) introducing the polystyrene model in a drying oven for about thirty minutes at 30 C.; e) applying a liquid layer of a silica and silicon dioxide binder mixture to the polystyrene model; f) coating the polystyrene model with kaolin; g) introducing the polystyrene model in a drying oven for about 45 minutes at 50 C.; h) repeating steps f) and g) until the polystyrene model obtains a ceramic thickness of between 10 and 15 millimeters; i) introducing the polystyrene model in a high-temperature oven for about an hour at a temperature of 1050 C. until the polystyrene becomes volatile and a ceramic mould (7) is obtained; j) attaching the mould (7) to a die (5) inside the latter and adding hardened sand (6); and k) attaching the die (5) to a structure or base (4), and attaching the structure or base to a centrifuging machine and casting a molten material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) A series of drawings that help to better understand the invention and which expressly relate to an embodiment of said invention provided as a non-limiting example thereof is very briefly described below.

(2) FIG. 1 shows a view of a practical embodiment of the system for moulding metal parts, object of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

(3) The attached drawings show a preferred embodiment of the invention. More specifically, it comprises a first metal structure or base (4) which is integrally attached to a rotating machine, said machine rotating the assembly at a high speed, and where said structure (4) is associated with a cover (3) and with a plurality of fastening nuts (1) and bolts (2), and where, in turn, the structure is integrally attached to a cylindrical metal die (5) containing a ceramic mould (7) and hardened sand (6) for filling the die (5).

(4) The method of moulding ceramic parts includes:

(5) i) In a first step, producing a polystyrene model of the part to be produced; said model can be produced by injecting polystyrene onto an aluminium mould in the event of mass production of parts, or by means of machining a polystyrene block from a polystyrene block for producing unitary parts.
ii) In a second step, introducing the polystyrene model in a liquid ceramic Milled Zircon (zirconium sand) and Primcote (a binder) mixture until the model is fully impregnated.
iii) In a third step, coating the impregnated model with a layer of zirconium sand.
iv) Subsequently introducing the obtained part in a drying oven for about thirty minutes at 30 C.
v) Then, once the part is taken out of the oven, applying a liquid layer of a ceramic mixture made up of Fascote Binder (silica binder) and Fascote Refractary (silicon dioxide).
vi) Coating the part with a Molochite type (kaolin) ceramic material.
vii) Introducing the part in a drying oven for about 45 minutes at a temperature of 50 C.
viii) Repeating steps vi) and vii) until the part obtains a ceramic thickness of between 10 and 15 millimeters.
ix) Introducing the part in a high-temperature oven for about an hour at a temperature of 1050 C. so that the polystyrene becomes volatile, obtaining the ceramic mould (7).
x) Attaching the mould (7) to the die (5) inside the latter and adding hardened sand (6).
xi) Fixing the structure or base (4) to the centrifuging machine and casting the molten metal at a variable rate depending on the particular needs of each part, obtaining the final metal part.