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Expandable core for use in casting

a technology of expanding salt core and casting core, which is applied in the direction of manufacturing tools, foundry moulding apparatus, foundry patterns, etc., can solve the problems of increasing cost, no commercial record, and inability to easily remove sand, so as to increase the degree of casting freedom and the effect of bending strength

Inactive Publication Date: 2006-08-24
YAMAHA MOTOR CO LTD
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention relates to an expendable salt-core for use in high pressure die-casting processes. The salt-core is made from a salt material and is designed to withstand high casting pressures and can be easily removed after the casting process. Compared to traditional sand cores, the salt-core is more efficient and cost-effective. The technical effect of the invention is to provide a reliable and efficient expendable core for high pressure die-casting processes.

Problems solved by technology

With a sand core, chiefly because a so-called metal penetration phenomenon occurs, that is, the melt enters gaps among sand grains in the boundary with the core and accordingly the sand cannot be easily removed.
Hence, the sand removing operation is cumbersome, leading to an increase in cost.
Although the specification of patent reference 5 describes that an engine block is produced by die-casting using the salt core, it has no commercial record.

Method used

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  • Expandable core for use in casting
  • Expandable core for use in casting
  • Expandable core for use in casting

Examples

Experimental program
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Effect test

first embodiment

[0094] A core for use in casting according to one embodiment of the present invention will be described in detail with reference to FIGS. 1 to 5.

[0095]FIG. 1 is a partially cutaway perspective view of a cylinder block which is cast using a core for use in casting according to the present invention. FIGS. 2 and 3 are graphs each showing the relationship between the addition of synthetic mullite and the banding strength, FIG. 4 includes views showing a bending sample, and FIG. 5 is a graph showing the relationship between the weight of the bending sample and the bending force.

[0096] Referring to FIG. 1, reference numeral 1 denotes an engine cylinder block which is cast using a salt core 2 serving as a core for use in casting according to the present invention. The cylinder block 1 serves to form a motorcycle water-cooling 4-cycle 4-cylinder engine, and is formed into a predetermined shape by die-casting. The cylinder block 1 according to this embodiment integrally has a cylinder bod...

second embodiment

[0126] A salt core according to the present invention can use granular aluminum borate (9Al2O3.2B2O3) as a ceramic material. When aluminum borate was mixed in potassium chloride, a bending strength as shown in FIG. 6 was obtained.

[0127]FIG. 6 is a graph showing the relationship between the addition of aluminum borate and the bending strength. The bending strength shown in FIG. 6 is obtained by conducting the experiment shown in the first embodiment by using aluminum borate as a ceramic material. The lines in FIG. 6 are approximate curves drawn using the method of least squares.

[0128] As aluminum borate to be used for the experiment, three types shown in Table 5 below were selected from commercially available granular products.

TABLE 5ParticleMaximumName ofChemicalName ofDensitysizeAddition in SampleAdditionName of CeramicProductformulaeShapeManufacturer(g / cm3)(μm)(wt %)(wt %)Aluminum borateAlbolite9Al2O3.2B2O3ParticulateShikoku2.932.310, 15, x20, x3015PF03ChemicalsCorp.Aluminum b...

third embodiment

[0135] A salt core according to the present invention can use granular silicon nitride (Si3N4) as a ceramic material. When silicon nitride was mixed in potassium chloride, a bending strength as shown in FIG. 7 was obtained.

[0136]FIG. 7 is a graph showing the relationship between the addition of silicon nitride and the bending strength. The bending strength shown in FIG. 7 is obtained by conducting the experiment shown in the first embodiment by using silicon nitride as a ceramic material. The lines in FIG. 7 are approximate curves drawn using the method of least squares.

[0137] As silicon nitride to be used for the experiment, four types shown in Table 7 below were, selected from commercially available granular products.

TABLE 7ParticleMaximumName ofName ofChemicalName ofDensitysizeAddition in SampleAdditionCeramicProductformulaeShapeManufacturer(g / cm3)(μm)(wt %)(wt %)SiliconNP-600Si3N4ParticulateDENKI KAGAKU3.180.720, 24, 33, 25, x30, x35, x4025nitrideKOGYO K.K.SiliconMM-5MFSi3N4...

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Abstract

A salt core (2) is formed by casting a mixed material of a salt material and a ceramic material. Any one of a chloride, bromide, carbonate, and sulfate of potassium or sodium is used as the salt material. As the ceramic material, granular one having a density falling within a range of 2.2 g / cm3 (exclusive) to 4 g / cm3 (inclusive) is used.

Description

TECHNICAL FIELD [0001] The present invention relates to expendable salt-core for use in casting, which is loaded in a mold used for forming non-ferrous alloy castings, particularly a high pressure die-casting mold as well, can withstand a high casting pressure environment, and is formed from a salt material. BACKGROUND ART [0002] Conventionally, high pressure die-casting can afford to manufacture with high volume production for complicated-shape components with high dimensional accuracy at a low cost. Although, depending on the shape restriction of the components, an expendable core for use in casting may have to be used. Conventionally, as an expendable core, in addition to expendable sand cores formed using sand, a so-called salt core is available. The salt core is a very attractive choice in the light of the productivity. [0003] More specifically, after casting process is finished, the salt core can be removed by dissolving it with hot water or steam. When the salt core is used, ...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B22C5/18B22D33/04B22C1/00B22C1/18B22C9/10
CPCB22C9/105
Inventor YAOKAWA, JUNANZAI, KOICHIYAMADA, YOUJI
Owner YAMAHA MOTOR CO LTD