Large bore aluminum piston ceramic filtration gating system

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By optimizing the gating system structure and using a 30ppi foam ceramic filter, the problems of aluminum liquid flow rate control and purity were solved, enabling efficient aluminum piston production and meeting the quality requirements of high-performance engines.

CN224525936UActive Publication Date: 2026-07-21BINZHOU BOHAI PISTON CO LTD

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Patent Information

Authority / Receiving Office: CN · China
Patent Type: Utility models(China)
Current Assignee / Owner: BINZHOU BOHAI PISTON CO LTD
Filing Date: 2025-07-14
Publication Date: 2026-07-21

AI Technical Summary

Technical Problem

The existing casting system cannot effectively control the flow rate of molten aluminum, resulting in severe turbulence and serious secondary pollution of the molten aluminum. Furthermore, the existing filters cannot effectively remove non-metallic inclusions and gases, leading to an increase in defects in aluminum pistons and making it difficult to meet the quality requirements of high-performance engines.

Method used

A ceramic filter casting system for large-diameter aluminum pistons is designed. Through the design of a specific internal sprue and transverse sprue, combined with a 30ppi foam ceramic filter, the flow rate of molten aluminum is controlled and oxide inclusions are removed. A split-type pouring cup and mold structure is adopted to improve flow rate control and purity.

Benefits of technology

It effectively reduces turbulence, improves the purity of molten aluminum, lowers the defect rate, enhances the high-temperature fatigue performance of aluminum pistons, meets the quality requirements of high-performance engines, improves production efficiency, and reduces mold processing costs.

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Abstract

The utility model relates to a big cylinder diameter aluminum piston ceramic filtering pouring system, including the outer mould of inside being provided with the cavity, the riser is established in the cavity top surface center of cavity, the inside of outer mould is provided with the inner gate of communicating with the cavity at its cavity entrance, the inside of outer mould is established with the cross gate of communicating with the inner gate below the bottom of one end of inner gate far away from the cavity entrance, the straight gate of communicating with the cross gate and going through the top surface of outer mould upwards is formed above the end of cross gate in the inside of outer mould, the top surface of outer mould is connected the pouring basin above the straight gate through bolt, and the outlet channel axis of pouring basin bottom coincides with the straight gate axis. The utility model is applicable to big cylinder diameter aluminum alloy piston of metal type gravity casting, improves the control ability to the aluminum liquid flow rate, reduces the turbulence generation to the high temperature fatigue performance of big cylinder diameter aluminum piston is enhanced, prolongs its life, satisfies the strict demand of high -performance engine to piston quality.

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Description

Technical Field

[0001] This utility model relates to the field of piston casting technology, specifically to a ceramic filter casting system for a large-diameter aluminum piston. Background Technology

[0002] The large-diameter aluminum piston adopts a top riser-facing structure, which increases the length of the sprue in the gating system. During the pouring process, the flow velocity of the molten aluminum increases before entering the runner through the sprue. The gating system used for gravity casting of aluminum pistons in metal molds lacks a molten aluminum deceleration structure, making it impossible to effectively control the flow velocity of the molten aluminum before entering the mold cavity. Turbulence is obvious in the early stage of pouring, causing secondary contamination of the molten aluminum.

[0003] The gating system used for gravity casting of aluminum pistons in metal molds can only use fiber filter plates. These filter plates have large pores and poor high-temperature resistance, and can only play a certain role in flow obstruction. They are difficult to effectively remove non-metallic inclusions and gases from molten aluminum, which leads to an increase in defects such as inclusions on the outer circle, gaps at the edge of the insert ring, and pores. It is also difficult to ensure the density and uniformity of the microstructure.

[0004] The casting system for ceramic filters is only suitable for sand casting of iron parts, not for gravity casting of aluminum pistons using metal molds. Furthermore, ceramic filters can only be placed at an angle, limiting their application conditions. Utility Model Content

[0005] To address the shortcomings of existing technologies, this utility model provides a ceramic filter casting system for large-diameter aluminum pistons, which improves the control of aluminum liquid flow rate, reduces turbulence and defects, improves the purity of castings, enhances the high-temperature fatigue performance of large-diameter aluminum pistons, extends their service life, and meets the stringent quality requirements of high-performance engines for pistons.

[0006] This utility model is achieved through the following technical solution:

[0007] A ceramic filter casting system for large-diameter aluminum pistons is provided, comprising an outer mold with an internal cavity, a riser at the center of the top surface of the outer mold, an ingate communicating with the cavity at the cavity entrance of the outer mold, a sprue communicating with the sprue at the bottom of the end of the sprue away from the cavity entrance of the outer mold, a sprue communicating with the sprue, and a sprue communicating with the sprue and extending upward through the top surface of the outer mold above the end of the sprue. A sprue cup is bolted to the top surface of the outer mold above the sprue, and the axis of the outlet flow channel at the bottom of the sprue cup coincides with the axis of the sprue.

[0008] This design uses a pouring cup to receive molten aluminum and guide it into the sprue. As the molten aluminum passes through the runner, the flow rate is balanced, preventing oxidation and splashing. The runner is located below the bottom of the ingate, allowing the molten aluminum to sink first and then rise, which quickly reduces the flow rate of the molten aluminum. This allows it to flow smoothly into the outer mold cavity through the ingate at a lower flow rate, minimizing turbulence, reducing secondary contamination of the molten aluminum, and improving the performance of the pouring piston.

[0009] Furthermore, the outer mold is formed by splicing the left half mold and the right half mold. The sprue is formed on the right half mold, the runner is formed on the left half mold, and the ingate has ingate grooves formed on the left half mold and the right half mold. The two ingate grooves are spliced together to form the ingate.

[0010] By setting the outer mold to a split left and right structure, the internal flow channels can be easily processed. The outer mold can be assembled into a whole by splicing, which is convenient to operate and low in cost.

[0011] Furthermore, the cross-sectional area of the sprue is one-third of the cross-sectional area of the pouring cup.

[0012] The cross-sectional area of the sprue is one-third of the cross-sectional area of the pouring cup, which allows the molten aluminum to quickly fill the sprue and expel the gas inside the sprue quickly, preventing gas from entering the molten aluminum and preventing air bubbles inside the molten aluminum from causing quality problems in the cast product.

[0013] Furthermore, the height of the gating system is higher than the height of the riser.

[0014] The height of the sprue is higher than that of the riser, which can provide sufficient pressure head force. After pouring, the molten aluminum can fill the riser, preventing defects caused by insufficient feeding capacity of the riser.

[0015] Furthermore, the cross-sectional area of the horizontal runner is twice that of the vertical runner.

[0016] The cross-sectional area of the horizontal runner is designed to be twice that of the sprue, so that the aluminum liquid accelerated by the sprue can quickly reduce its flow rate when entering the horizontal runner, balance the flow rate of the aluminum liquid, and prevent oxidation and splashing. The horizontal runner can guide the aluminum liquid through the ingate into the cavity of the outer mold.

[0017] Preferably, at least one of the following locations is provided with a ceramic filter via a pre-set receiving groove: inside the horizontal runner, inside the vertical runner, at the connection between the horizontal runner and the vertical runner, or at the connection between the horizontal runner and the ingate.

[0018] Ceramic filters can remove oxide inclusions and secondary slag from molten aluminum, significantly improve the purity of molten aluminum, and help reduce the flow rate of molten aluminum.

[0019] Preferably, the ceramic filter is a 30ppi foam ceramic filter with an internal three-dimensional network skeleton structure.

[0020] The 30ppi foam ceramic filter has a high porosity of 70%-90% and a three-dimensional network skeleton structure. It has strong high temperature resistance and can effectively remove oxide inclusions and secondary slags in aluminum liquid, significantly improving the purity of aluminum liquid.

[0021] Furthermore, the axis of the sprue forms an angle of 2 to 10° with the axis of the outer mold.

[0022] The beneficial effects of this utility model are:

[0023] This invention designs the horizontal runner below the bottom of the ingate, so that when the molten aluminum enters the horizontal runner from the sprue, it first sinks and then rises. The cross-sectional area of the horizontal runner is twice that of the sprue, which can effectively reduce the flow rate of the molten aluminum before it enters the mold cavity, thereby minimizing the generation of turbulence and reducing secondary contamination of the molten aluminum.

[0024] The 30ppi foam ceramic filter has high porosity (70%-90%) and a three-dimensional network skeleton structure, which can effectively remove oxide inclusions and secondary inclusions in aluminum liquid, significantly improve the purity of aluminum liquid, and also help reduce the flow rate of aluminum liquid and reduce defects in castings.

[0025] This invention, through the design of the horizontal gating system, controls the fluctuation of the aluminum liquid flow rate at the inlet gating system to within ±5%. Combined with the filtration treatment of a 30ppi foam ceramic filter, it can reduce at least 80% of the oxide inclusions and secondary inclusions in the aluminum liquid, thereby improving the high-temperature fatigue performance and reliability of large-diameter aluminum pistons.

[0026] The separate structure of the pouring cup and the outer mold in this invention saves time when replacing or modifying the pouring cup, thus improving casting production efficiency. It also makes mold maintenance easier and more convenient, enables modular mold processing, saves materials, simplifies mold processing, shortens the mold manufacturing cycle, and reduces mold processing costs. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the structure of Embodiment 1 of this utility model.

[0028] Figure 2 This is a schematic diagram of the structure of Embodiment 2 of this utility model.

[0029] Figure 3 This is a schematic diagram of the structure of Embodiment 3 of this utility model.

[0030] Figure 4 This is a schematic diagram of the outer mold structure in Embodiment 4 of this utility model.

[0031] Figure 5 This is a schematic diagram of the structure of the left half of the mold in Embodiment 4 of this utility model.

[0032] Figure 6 This is a schematic diagram of the right half of the mold in Embodiment 4 of this utility model.

[0033] As shown in the figure:

[0034] 1. Sprue cup, 2. Sprue, 3. Runner, 4. Ingate, 5. Ceramic filter, 6. Outer mold, 7. Left half mold, 8. Right half mold. Detailed Implementation

[0035] To clearly illustrate the technical features of this solution, the following detailed implementation method will be used to explain the solution.

[0036] Example 1:

[0037] A ceramic filter casting system for a large-diameter aluminum piston includes an outer mold 6 with an internal cavity. A riser is formed at the center of the top surface of the outer mold 6. An ingate 4 communicating with the cavity is provided inside the outer mold 6 at its cavity inlet. A sprue 3 communicating with the ingate 4 is formed below the bottom of the end of the sprue 4 away from the cavity inlet. A sprue 2 communicating with the sprue 3 and extending upwards through the top surface of the outer mold 6 is formed above the end of the sprue 3. A sprue cup 1 is bolted to the top surface of the outer mold 6 above the sprue 2. The axis of the outlet runner at the bottom of the sprue cup 1 coincides with the axis of the sprue 2. The axis of the sprue 2 forms a 9° angle with the axis of the outer mold 6.

[0038] The outer mold 6 is formed by splicing the left half mold and the right half mold. The sprue 2 is formed on the right half mold, the sprue 3 is formed on the left half mold, and the ingate 4 has ingate grooves formed on the left half mold and the right half mold. The two ingate grooves are spliced together to form the ingate.

[0039] Based on the material and pouring volume of the φ180 piston, a flow rate coefficient of 0.4 is selected, and the cross-sectional area of the pouring cup 1 is designed to be 9cm². 2 and volume 200cm 3 The sprue cup 1 serves to receive molten aluminum, prevent splashing and overflow, guide the molten aluminum into the sprue 2, and control the flow rate of the molten aluminum. The sprue cup 1 and the outer mold 6 are separate structures, connected and fixed by bolts. The cross-sectional area of the sprue 2 is designed to be 3cm². 2 With a length of 220cm, it serves to provide pressure, reduce gas entrapment, and guide molten aluminum into the horizontal runner 3; the cross-sectional area of the horizontal runner 3 is designed to be 6cm². 2 It serves to balance the flow rate of molten aluminum, prevent oxidation and splashing, and guide the molten aluminum through the inner sprue 4 into the cavity of the outer mold 6;

[0040] A ceramic filter 5 is installed inside the sprue 2. The diameter of the ceramic filter 5 is larger than that of the sprue 2. The ceramic filter 5 is a 30ppi foam ceramic filter with a three-dimensional network skeleton structure inside. It plays a role in removing oxide inclusions and secondary slag from the aluminum liquid, significantly improving the purity of the aluminum liquid, and helping to reduce the flow rate of the aluminum liquid.

[0041] Example 2:

[0042] Based on the material and pouring volume of the φ160 piston, a flow rate coefficient of 0.3 is selected, and the cross-sectional area of the pouring cup 1 is designed to be 6 cm². 2 and volume 150cm 3 The pouring cup 1 and the outer mold 6 also adopt a split structure and are fixed by bolts.

[0043] The cross-sectional area of the straight gating channel 2 is 2cm². 2 With a length of 180cm, it serves to provide pressure, reduce gas entrapment, and guide molten aluminum into the horizontal runner 3; the cross-sectional area of the horizontal runner 3 is 4cm². 2 A 30ppi foam ceramic filter 5 is selected and designed to be placed vertically in the horizontal runner 3. The horizontal runner 3 has a pre-set receiving groove for holding the ceramic filter 5. The diameter of the ceramic filter 5 is larger than the diameter of the horizontal runner 3, which plays a role in removing oxide inclusions and secondary slag in the aluminum liquid, significantly improving the purity of the aluminum liquid, and helping to reduce the flow rate of the aluminum liquid.

[0044] Example 3:

[0045] Based on the material and pouring volume of the φ175 piston, a flow rate coefficient of 0.4 is selected, and the cross-sectional area of the pouring cup 1 is designed to be 9 cm². 2 and volume 200cm 3 It serves to receive molten aluminum, prevent splashing and overflow, guide molten aluminum into the sprue 2, and control the flow rate of molten aluminum. The sprue cup 1 and the outer mold 6 adopt a separate structure.

[0046] Design the cross-sectional area of the straight sprue 2 to be 3cm². 2 With a length of 220cm, it serves to provide a pressure head, reduce gas entrapment, and guide molten aluminum into the horizontal runner 3; the cross-sectional area of the horizontal runner 3 is 6cm². 2 It plays a role in balancing the flow rate of molten aluminum, preventing oxidation and splashing, and guiding the molten aluminum through the inner gate 4 into the cavity of the outer mold 6; a 30ppi foam ceramic filter 5 is selected and designed to be placed flat at the junction of the straight runner 2 and the horizontal runner 3, which plays a role in removing oxide inclusions and secondary inclusions in the molten aluminum, significantly improving the purity of the molten aluminum, and helping to reduce the flow rate of the molten aluminum.

[0047] Example 4:

[0048] A ceramic filter casting system for a large-diameter aluminum piston includes an outer mold 6 with an internal cavity. A riser is formed at the center of the top surface of the outer mold 6. An ingate 4 communicating with the cavity is provided inside the outer mold 6 at its cavity inlet. A sprue 3 communicating with the ingate 4 is formed below the bottom of the end of the sprue 4 away from the cavity inlet. A sprue 2 communicating with the sprue 3 and extending upwards through the top surface of the outer mold 6 is formed above the end of the sprue 3. A sprue cup 1 is bolted to the top surface of the outer mold 6 above the sprue 2. The axis of the outlet runner at the bottom of the sprue cup 1 coincides with the axis of the sprue 2. The axis of the sprue 2 forms a 3° angle with the axis of the outer mold 6.

[0049] like Figure 4-6 As shown, the outer mold 6 is formed by splicing the left half mold 7 and the right half mold 8. The sprue 2 is formed on the right half mold 8, the sprue 3 is formed on the left half mold 7, and the ingate 4 is formed on the left half mold 7 and the right half mold 8. The two ingate grooves are spliced together to form the ingate 4.

[0050] A ceramic filter 5 is placed vertically in the horizontal runner 3, and the diameter of the ceramic filter 5 is larger than the diameter of the horizontal runner 3.

[0051] Of course, the above description is not limited to the examples above. Technical features of this utility model not described can be implemented by or using existing technology, and will not be repeated here. The above embodiments and drawings are only used to illustrate the technical solution of this utility model and are not intended to limit this utility model. This utility model has been described in detail with reference to preferred embodiments. Those skilled in the art should understand that any changes, modifications, additions or substitutions made by those skilled in the art within the scope of this utility model do not depart from the spirit of this utility model and should also fall within the protection scope of the claims of this utility model.

Claims

1. A ceramic filter casting system for large-diameter aluminum pistons, comprising an outer mold with an internal cavity, characterized in that: A riser is opened at the center of the top surface of the outer mold cavity. An ingate connected to the cavity is set at the cavity entrance of the outer mold cavity. A sprue connected to the sprue is opened below the bottom of the end of the sprue away from the cavity entrance of the outer mold cavity. A sprue connected to the sprue and extending upward through the top surface of the outer mold cavity is formed above the end of the sprue. A sprue cup is bolted to the top surface of the outer mold cavity above the sprue cup. The axis of the outlet runner at the bottom of the sprue cup coincides with the axis of the sprue.

2. The large-diameter aluminum piston ceramic filter casting system according to claim 1, characterized in that: The outer mold is formed by splicing the left half mold and the right half mold. The sprue is formed on the right half mold, the runner is formed on the left half mold, and the ingate has ingate grooves formed on the left half mold and the right half mold. The two ingate grooves are spliced together to form the ingate.

3. The large-diameter aluminum piston ceramic filter casting system according to claim 1 or 2, characterized in that: The cross-sectional area of the sprue is one-third of the cross-sectional area of the pouring cup.

4. The large-diameter aluminum piston ceramic filter casting system according to claim 3, characterized in that: The height of the gating system is higher than the height of the riser.

5. The large-diameter aluminum piston ceramic filter casting system according to claim 1 or 2, characterized in that: The cross-sectional area of the horizontal runner is twice that of the vertical runner.

6. The large-diameter aluminum piston ceramic filter casting system according to claim 1 or 2, characterized in that: A ceramic filter is provided at least at one of the following locations: inside the horizontal runner, inside the vertical runner, at the connection between the horizontal runner and the vertical runner, or at the connection between the horizontal runner and the ingate.

7. The large-diameter aluminum piston ceramic filter casting system according to claim 6, characterized in that: The diameter of the ceramic filter is larger than the diameter of the runner or the connection between runners.

8. The large-diameter aluminum piston ceramic filter casting system according to claim 6, characterized in that: The ceramic filter is a 30ppi foam ceramic filter with an internal three-dimensional network skeleton structure.

9. The large-diameter aluminum piston ceramic filter casting system according to claim 1, characterized in that: The axis of the sprue forms an angle of 2 to 10° with the axis of the outer mold.