CASTING APPARATUS, CASTING PROCESS AND CAST COMPONENT

Abstract

A casting device and a casting processes for producing a cast component in a mold in which a mold cavity is formed, and a cast component produced by means of the casting process. The casting device includes a first melt feeder, configured to receive a first molten material, a second melt feeder, configured to receive a second molten material, and a feed device configured for simultaneous or temporally independent charging of the mold cavity with the first molten material from the first melt feeder and the second molten material from the second melt feeder by means of gravity. It is provided that the feed device has at least one first outlet that can be introduced into the mold cavity and can be moved relative to the mold cavity in order to charge the mold cavity with the first molten material and/or the second molten material.

Claims

1. A casting device for producing a cast component in a mold in which a mold cavity is formed, the casting device comprising: a first melt feeder configured to receive a first molten material, a second melt feeder configured to receive a second molten material, and a feed device configured for one of at least in part simultaneous and at least in part temporally overlapping charging of the mold cavity with the first molten material from the first melt feeder and the second molten material from the second melt feeder by means of gravity, wherein the feed device has at least one first outlet that can be introduced into the mold cavity and can be moved relative to the mold cavity in order to charge the mold cavity with at least one of the first molten material and the second molten material.

2. The casting device of claim 1, wherein the at least one first outlet is one of connectable and connected to the first melt feeder for charging the mold cavity with the first molten material through a first feed line, wherein the feed device comprises at least one second outlet which is configured to be introduced into the mold cavity and is configured to be moved relative to the mold cavity, and which is one of connectable and connected to the second melt feeder for charging the mold cavity with the second molten material through a second feed line, and wherein the first feed line and the second feed line are separated from one another such that the first molten material and the second molten material are not mixed together within the feed device.

3. The casting device of claim 2, wherein the at least one first outlet and the at least one second outlet are movable relative to one other and relative to the mold cavity.

4. The casting device of claim 1, wherein the feed device is configured for creating a material mixture comprising respective proportions of the first molten material and the second molten material, and for charging the mold cavity with the material mixture through the at least one first outlet.

5. The casting device of claim 4, wherein the feed device comprises a Y-shaped feed section for creating the material mixture.

6. The casting device of claim 2, further comprising at least one of: a positioning device by means of which at least one of the at least one first outlet and the at least one second outlet are movable relative to the mold cavity (4) in all three spatial directions, and a control device by means of which a flow of the first molten material to the mold cavity and a flow of the second molten material to the mold cavity are controllable independently from one another.

7. A casting method for producing a cast component in a mold, the casting method comprising the steps of: providing a casting device according to claim 1, providing a mold in which a mold cavity is formed, providing a first molten material in the first melt feeder and a second molten material in the second melt feeder, introducing the at least one first outlet, charging the mold cavity with the first molten material and with the second molten material by means of gravity through the at least one first outlet, moving the at least one first outlet within the mold cavity during the charging so that the at least one first outlet is guided during the charging in a defined positional relationship to a surface of the first molten material or the second molten material introduced into the mold cavity.

8. The casting method of claim 7, wherein at least one of: at least one of the first molten material and the second molten material is a metal melt; the first molten material and the second molten material have different material compositions; and the first molten material and the second molten material have different temperatures.

9. A cast component produced by the casting method of claim 7, wherein the cast component has a first area with a first material property formed by a solidification of the first molten material and a second area with a second material property formed by a solidification of the second molten material, wherein a transition area with a continuous transition between the first material property and the second material property is formed between the first area and the second area.

10. The cast component of claim 9, wherein the cast component is a vehicle part.

11. The casting method of claim 7, wherein introducing the at least one first outlet into the mold cavity comprises introducing both the at least one first outlet and the at least one second outlet into the mold cavity.

12. The casting method of claim 7, wherein charging the mold cavity with the first molten material and with the second molten material by means of gravity through the at least one first outlet comprises charging the mold cavity with the first molten material and with the second molten material by means of gravity through both the at least one first outlet comprises and the at least one second outlet.

13. The casting method of claim 7, wherein moving the at least one first outlet within the mold cavity during the charging comprises moving both the at least one first outlet and the at least one second outlet within the mold cavity during the charging.

14. The cast component of claim 10, wherein the vehicle part is an engine part.

15. The cast component of claim 14, wherein the engine part is a cylinder crank case.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0050] Exemplary embodiments of the subject matter of the application are subsequently explained by way of the drawings. As shown in each case schematically,

[0051] FIG. 1 a casting device according to a first example,

[0052] FIG. 2 a casting device according to a second example.

[0053] Repeating and similar features of different embodiments are provided with identical alphanumeric reference symbols in the images.

DETAILED DESCRIPTION OF THE DRAWINGS

[0054] Casting device 1 shown in FIG. 1 is configured for producing a cast component 2 (in the image in the process of being cast) in a mold 3 in which a mold cavity 4 is formed.

[0055] Casting device 1 comprises a first melt feeder 5 which comprises a first reservoir 6 and a first supply line 7 which is fluidically connected to first reservoir 6. First melt feeder 5 is equipped to receive a first molten material 8 (represented by square symbols).

[0056] Casting device 1 additionally comprises a second melt feeder 9 which comprises a second reservoir 10 and a second supply line 11 which is fluidically connected to second reservoir 10. Second melt feeder 9 is designed to receive a second molten material 12 (represented by circular symbols).

[0057] In the example shown, reservoirs 6, 10 are part of casting device 1 and are firmly connected to the respective supply line 7, 11. Alternatively, however, it may be provided that molten materials are to be fed into casting device 1 from external reservoirs or lines that are to be provided separately.

[0058] Casting device 1 further comprises a feed device 13, equipped for simultaneous and/or time-independent charging of mold cavity 4 with first molten material 6 from first melt feeder 5 and second molten material 8 from second melt feeder 7 by means of gravity.

[0059] The feed device 13 comprises a first outlet 14, which may be introduced into mold cavity 4 and is movable relative to mold cavity 4, for charging mold cavity 4 with first molten material 8 and/or second molten material 12. Feed device 13 and melt feeders 5, 9 preferably comprise a fireproof material and are equipped to receive metal melts. The fireproof material is typically only poorly wettable by metal melts.

[0060] The mold 3 is a permanent mold in this example, but may alternatively be a lost mold. The direction, in which gravity acts and against which the mold is filled during the casting using the proposed casting device, is hereinafter referred to as vertical direction 15, any direction perpendicular thereto as horizontal direction 16.

[0061] The first outlet 14 is fluidically connected by a first feed line 17 to first melt feeder 5 for charging mold cavity 4 with the first molten material 8 and/or with the second molten material 12.

[0062] The feed device 13 is equipped to create a material mixture 18, comprising respective proportions of first and second molten material 8, 12, and to charge mold cavity 4 with material mixture 18 through first outlet 14. The feed device 13 thus forms a common injector for both molten materials 8, 12.

[0063] The feed device 13 comprises a Y-shaped feed section for creating material mixture 18. In order to ensure thorough mixing of molten materials 8, 12, the first feed line 17 as a common supply line section is provided with a sufficient length for both molten materials 8, 12. Additionally or alternatively, mixing elements may be arranged within a common supply line section.

[0064] The casting device 1 comprises a positioning device (not shown), for example a robotic device with three translational degrees of freedom, by means of which entire feed device 13 including melt feeders 5, 9and thus in particular the first outlet 14is movable relative to the mold cavity 4 in all three spatial directions.

[0065] The casting device comprises a first control device 20, by means of which a first flow of first molten material 8 to the mold cavity 4 may be controlled, and a second control device 21, by means of which a second flow of second molten material 12 to the mold cavity 4 may be controlled. The control devices 20, 21 are formed as plug devices, but may alternatively be formed as or include vacuum devices or other types of control devices.

[0066] The first and second flows are independently controllable from one another in order to achieve a controllable mixing of first and second molten materials 8, 12 to form material mixture 18 within feed device 13, as well as an overall controllable flow of material mixture 18 through the first outlet 14.

[0067] The casting device 1 is suitable for a casting process for producing cast component 2 in the mold 3 and is shown in FIG. 1 during use in the casting process.

[0068] The casting process comprises the following steps: [0069] providing the casting device 1, [0070] providing the mold 3 with the mold cavity 4 formed therein, [0071] providing the first molten material 8 in the first melt feeder 5 and the second molten material 12 in the second melt feeder 9, [0072] introducing the first outlet 14 into the mold cavity 4, [0073] charging the mold cavity 4 with the first molten material 8 and with the second molten material 12 in the form of the material mixture 18, formed within the feed device 13, by means of gravity through the first outlet 14, [0074] moving the first outlet 14 within the mold cavity 4 during charging, so that the first outlet 14 is guided in a defined positional relationship to a melt surface 22 of the material mixture 18 introduced into the mold cavity 4 during the charging.

[0075] FIG. 1 shows the casting device 1, after the first outlet 14 has been introduced into the mold cavity 4 by a feeder 23 of the mold 3, during the charging of mold cavity 4 with molten material 8. The first outlet 14 is thereby positioned just below the melt surface 22 by means of the positioning device.

[0076] The first molten material 8 and the second molten material 12 are metal melts of different material composition, wherein other molten materials are also usable in the method (with a corresponding design of casting device 1). The molten materials may additionally have different temperatures and/or differ in other properties.

[0077] The casting process also includes controlling the first flow of the first molten material 8 towards the mold cavity and the second flow of the second molten material 12 towards the mold cavity to create a spatially variable mixing ratio of the first molten material 8 and the second molten material 12 within the mold cavity 4.

[0078] The cast component 2 produced by means of the casting process (shown in FIG. 1 in a partially produced and not yet fully solidified form) thus has a first area 24 with a first material property formed by solidification of the first molten material 8 (here: high proportion of first molten material 8) and a second area 25 with a second material property formed by solidification of the second molten material 12 (here: high proportion of second molten material 12). A transition area 26 with a continuous transition (transition gradient) between the first material property and the second material property is formed between the first area 24 and the second area 25. Several such transition gradients may also be provided.

[0079] The common injector for both molten materials 8, 12, formed by feed device 13 of casting device 1, enables the production of cast component 2 in particular the creation of a transition gradient along vertical direction 15 (as shown in FIG. 1), wherein good homogeneity in horizontal direction 16 may be ensured.

[0080] As an additional or alternative step of the casting process, it may be provided that the temperature of the material mixture 18 introduced into the mold cavity 4 is increased in a final temporal phase of the casting process, with respect to previous phases, in particular by providing the first and second molten materials 8, 12 at different temperatures and correspondingly varying the respective flows. In this way, a thermal hotspot may be directed in a targeted manner into an upper area of the cast component 2 being produced and the feeding capability may be improved.

[0081] The casting device 1 shown in FIG. 2 differs from the casting device 1 shown in FIG. 1 in particular in that feed device 13 comprises two fluidically separated injectors. Therefore, only the aspects that differ from the casting device 1 are described below.

[0082] In addition to the first outlet 14, which is connected to the first melt feeder 5 for charging the mold cavity 4 with the first molten material 8 through the first feed line 17, casting device 1 comprises a second outlet 27, which is connected to the second melt feeder 9 for charging the mold cavity 4 with the second molten material 12 through a second feed line 28.

[0083] Like the first outlet 14, the second outlet 27 may also be introduced into mold cavity 4 and may be movable relative to mold cavity 4. The first outlet and 14 and the second outlet 27 are furthermore movable relative to one other (by means of two independent positioning devices (not shown here)).

[0084] The first feed line 17 and the second feed line 28 are separated from one another in such a way that the first molten material 8 and the second molten material 12 are not mixed together within the feed device 13.

[0085] The casting device 1 is thus suitable for another example of a casting process which is essentially the same as that described above.

[0086] Deviating from the previous example, the casting process here comprises: [0087] introducing the first outlet 14 and the second outlet 27 into the mold cavity, [0088] charging the mold cavity 4 with the first molten material 8 through the one first outlet 14 and with the second molten material 12 through the second outlet 27 by means of gravity, [0089] moving the first outlet 14 and the second outlet 27 within the mold cavity 4 during the charging, so that the respective outlet 14, 27 is guided during the charging in a defined positional relationship to the melt surface 22 of the first and second molten materials 8, 12 introduced into the mold cavity 4.

[0090] In this example, a mixing of the first and second molten materials 8, 12 is not carried out until after they have been introduced into the mold cavity 4.

[0091] In this example as well, by controlling the first flow of the first molten material 8 to the mold cavity 4 and the second flow of the second molten material 12 to the mold cavity 4 by means of the control devices 20, 21, a spatially variable mixing ratio of the first molten material 8 and the second molten material 12 may be created within the mold cavity 4.

[0092] The cast component 2 produced in this way (shown in FIG. 2 in a partially produced and not yet fully solidified form) thus also has a first area 24 with a first material property formed by solidification of the first molten material 8 (here: high proportion of the first molten material 8) and a second area 25 with a second material property formed by solidification of the second molten material 12 (here: high proportion of the second molten material 12). A transition area 26 with a continuous transition (transition gradient) between the first material property and the second material property is formed between the first area 24 and the second area 25.

[0093] In this example, the transition gradient is arranged in horizontal direction 16 (determined by a horizontal spacing of the outlets 14, 27). In addition, a transition gradient may be created in vertical direction 15, determined by the relative flow rates or flow speeds of the molten materials 8, 12 through the respective outlets 14, 27. Several horizontal and/or vertical transition gradients may also be provided.

[0094] In addition to the listed components, the casting device 1 or the casting device 1 may comprise one or more further melt feeders, each equipped to receive a further molten material (exemplary embodiments not shown). Fluidically separated injectors, common injectors or combinations of both variants may be used herein. For example, two or more fluidically separated injector units may be provided, wherein one or more of the injector units may be designed as a common injector for two or more miscible molten materials.

LIST OF REFERENCE NUMERALS

[0095] 1, 1 casting device [0096] 2, 2 cast component [0097] 3 mold [0098] 4 mold cavity [0099] 5 first melt feeder [0100] 6 first reservoir [0101] 7 first supply line [0102] 8 first molten material [0103] 9 second melt feeder [0104] second reservoir [0105] 11 second supply line [0106] 12 second molten material [0107] 13 feed device [0108] 14 first outlet [0109] vertical direction [0110] 16 horizontal direction [0111] 17 first feed line [0112] 18 material mixture [0113] 19 Y-shaped feed section [0114] first control device [0115] 21 second control device [0116] 22 melt surface [0117] 23 feeder [0118] 24 first area [0119] second area [0120] 26 transition area [0121] 27 second outlet [0122] 28 second feed line