Filter element for flow calming and / or cleaning of a melt obtained during casting and a method for producing a filter element

Abstract

Filter element for flow calming and / or cleaning of a melt used in casting, which is passed through the filter element, wherein the filter element is designed as three-dimensional web structures with openings as flow channels through which liquid melt is passed, and Webs of the web structure with particles of predominantly SiO2, predominantly Al2O3, predominantly aluminosilicate, with cerium-stabilised ZrO2 or chromite as a material that can be used as a mould material in foundry technology, characterized in that the particles are bonded together using a furan resin binder, a phenol-based binder or an inorganic water-based alkali silicate binder as a binder, whereby a proportion of binder with which the particles are bonded is maintained in the range of 1 vol.% to 5 vol.% in relation to the amount of bonded particles and the webs are provided on their surface with a closed coating with a minimum layer thickness of 50 µm of a polymer resin.

Description

[0001] The invention relates to a filter element for flow calming and / or cleaning of a melt used in casting and to a method for producing a filter element.

[0002] In the field of metal melt filtration, there are various approaches to increasing the filtration efficiency of the filters used. In most cases, the filter material is modified or substituted with other materials. For example, DE 10 2011 109 681 A1 describes an increase in the filtration efficiency of "common metal melt filter geometries" through an active surface coating. "Common metal melt filter geometries" include open-cell foam ceramic geometries, honeycomb geometries, spaghetti filter geometries, perforated filter geometries, and fiber fabric filters, none of which correspond to a defined filter and flow structure for optimal laminarization of the melt. DE 10 2011 109 682 A1 and DE 10 2020 000 969 A1 describe the use of carbon-bonded materials for iron and aluminum melt filtration. The filters are defined as “foamed structures”.DE 10 2011 109 684 A1 on the removal of gases from melts by means of filters, DE 2016 106 708 A1 on the use of filters for continuous metal melt filtration and DE 10 2018 201577 A1 on the removal of inclusions of different chemical compositions by means of ceramic metal melt hybrid filters also describe filters with a foamed or not clearly defined filter structure.

[0003] WO 2017 / 008092 A1 describes a process for producing metal filters made of molybdenum or tungsten. Molybdenum or tungsten powder with varying grain sizes is sintered, with the sinter bridges providing the filter's strength and the non-sintered areas forming the pores for metal melt filtration. This variant of filter production also lacks clearly defined filter or flow structures. The technical solution described in EP 3 325 428 B1 describes a filter element constructed from three-dimensional geometric cages designed to purify the melt. The filter element is produced either by printing thermoplastic and subsequently coating the printed framework with ceramic slip and firing it, or by printing a ceramic slip.While these filter elements may have defined filter structures, they only fulfill the function of melt cleaning and not laminarization. Furthermore, the filter elements are made of a sintered ceramic that does not decompose thermally after use and therefore cannot be recycled, or only to a very limited extent.

[0004] For example, WO 2020 / 187982 A1 discloses a filter element and a method for the additive production of a filter element.

[0005] DE 10 2018 201 577 A1 concerns a ceramic metal melt filter.

[0006] WO 95 / 19943 A1 describes a matrix composite element.

[0007] The present invention is based on the object of realizing defined filter and flow structures that enable a conversion from turbulent to largely laminar flow of liquid melt by flow calming and / or effective retention of impurities that may be contained in the molten metal, as well as a simple and environmentally friendly disposal of used filter elements.

[0008] According to the invention, this object is achieved with a filter element having the features of claim 1. Claim 4 relates to a manufacturing method. Advantageous embodiments and further developments of the invention can be realized with features defined in the dependent claims.

[0009] A filter element according to the invention for flow stabilization and / or purification of a melt used during casting, which is passed through the filter element, is formed with a three-dimensional web structure with perforations as flow channels through which the liquid melt is passed. Liquid melt can flow through the perforations formed by the web structure between the webs, and the webs can be manufactured in such a way that the flow is laminarized by flow stabilization and contaminants, e.g., oxides, can be retained by the filter element.

[0010] The web structure is formed with particles made of a material suitable for molding in foundry technology and a binder. The particles are bonded together by the binder, and the webs are coated on their surfaces with a polymer resin.

[0011] Particles used are composed predominantly of SiO2, predominantly Al2O3, predominantly aluminosilicate, cerium-stabilized ZrO2, or chromite. "Predominantly" should be understood to mean a proportion of at least 80 vol.%, particularly preferably at least 90 vol.%, and most preferably at least 95 vol.%.

[0012] For example, you can use quartz sand or chromite, which consists mainly of chromium and iron oxide, or minerals that are also known as mullite.

[0013] The particles are bonded together using a furan resin binder, a phenolic resin-based binder, or an inorganic binder. A furan resin binder can be a furfuryl alcohol-based binder. Phenolic resin-based binders can be hot-curing (e.g., an acid-curing phenolic resole binder) or cold-curing. A water-based alkali silicate binder is used as an inorganic binder.

[0014] Depending on the binder used, curing can be achieved by thermal treatment in which a sufficiently high temperature is reached, irradiation with suitable electromagnetic radiation or by adding a binder-specific hardener component to the binder.

[0015] The coating used to cover the surfaces of the webs is made of a polymer resin, such as epoxy resin. The coating is continuous and has a layer thickness of at least 50 µm.

[0016] The proportion of binder, with which the particles are bonded, is maintained in the range of 1 vol.% to 5 vol.% relative to the quantity of bonded particles. The preferred proportion is approximately 2 vol.%.

[0017] The webs of the web structure should be filled with particles with an average particle size of d 50in the range 63 µm to 1000 µm.

[0018] Open pockets should be formed at the perforations forming flow channels to accommodate impurities contained in the melt. This can be achieved using additive manufacturing techniques, which will be discussed in more detail below, by implementing appropriately controlled production.

[0019] In principle, the manufacturing process involves forming webs layer by layer using particles made from a material that can be used as a mold material in foundry technology, by locally bonding the particles to a binder. At the start of curing or after the binder has cured, the surface of the webs is coated with a polymer resin. Curing can begin with the formation of a web structure in one layer and then continue until complete curing is achieved. A subsequent layer can be structured if complete curing has not yet been achieved. In these cases, a hardener component can preferably be applied together with the binder, or irradiation with suitable electromagnetic radiation can be used to achieve curing.Alternatively, thermal treatment can be performed at a temperature sufficient to cure the binder. Thermal treatment can be performed on a green body that already has the three-dimensional basic web structure of a filter element.

[0020] One approach to this is to apply the loose particles, or particles that already contain a portion of the binder or are coated with binder, as a layer on a build platform using powder-bed-based additive manufacturing. The particles of the topmost layer are locally exposed to the binder, thereby bonding the particles together in a locally defined manner within the plane of the respective layer. The application of the binder should be metered and controlled two-dimensionally along the surface of each layer formed with loose particles.

[0021] After forming a predefined geometric web structure for the level of a respective layer by cohesive bonding of particles with binder, the build platform is then lowered by one layer thickness and a new layer of loose particles is applied, in which particles are again cohesively bonded with binder to form a predefined geometric web structure in this level.

[0022] The process steps of layer application, locally defined material bonding of particles with the binder and lowering of the construction platform are repeated until the specified three-dimensional web structure of the filter element has been formed.

[0023] Subsequently, loose, non-bonded particles are first removed, and then the coating is applied to the surfaces of the webs using a polymer resin. The coating can be applied by dipping, flow coating, or spraying.

[0024] As an alternative to powder-bed-based production, an uncoated filter element can be produced purely by printing. A paste / suspension containing particles, a binder, and optionally a hardener component is applied layer by layer through at least one nozzle until the three-dimensional web structure with the webs and perforations serving as flow channels is formed. The coating is then applied to the surfaces of the webs using a polymer resin. Depending on the binder, curing occurs either after the formation of a layer or ply of the paste / suspension or only after the formation of a complete web structure. The paste / suspension can be applied in metered quantities, either as individual drops or as filaments.At least one nozzle is positioned accordingly by two-dimensional movement of its outlet opening and the applied mass flow of suspension is controlled locally according to the geometry and dimensions of the web structure.

[0025] For example, one can proceed by scanning a commercially available 20 ppi foam ceramic filter (50 mm x 50 mm x 20 mm) using micro-computer tomography to obtain a true-to-original CAD model of a foam ceramic filter. This CAD model is then additively manufactured three-dimensionally using sand and a binder. This involves using quartz sand (SiO2: >99.1 vol.%; average particle size d) mixed with an activator (p-toluenesulfonic acid). 500.14 mm) is applied layer by layer to a build platform and then printed with a binder, which cures to form furan resin (binder content: 2 vol%). To increase mechanical and thermal strength, the printed filter geometry in the form of a three-dimensional ridge structure is subsequently impregnated with a polymer resin on the ridge surfaces.

[0026] The resulting filter element was then tested for its thermal shock behavior and the dynamic and thermal stresses encountered during aluminum casting using a test method for determining thermal shock resistance in aluminum melts. The filter element withstood these stresses and did not break. Furthermore, thermal decomposition was already evident in light-colored areas on the filter element. This decomposition leads to the filter element breaking down into its basic components after use, making it possible to reclaim residual melt material.

[0027] In the preliminary test described here, a foam ceramic filter structure was chosen as the template for controlling the additive manufacturing, as this serves as the worst case for the occurring mechanical and thermal forces due to the small web thickness of 0.5 mm.

[0028] Casting tests with an aluminum melt have shown that, despite the low web thicknesses, an additively manufactured filter element, which essentially consists of the bonded particles of a molding material, can withstand the expected loads and that melt cleaning can also be achieved. Furthermore, further tests have demonstrated that a filter element according to the invention thermally decomposes after use and can thus be completely separated from the solidified aluminum and contaminants that have settled on the filter element during use. The invention can be used to provide filter elements with defined retention and / or flow structures. Application examples have shown that even very delicate three-dimensional web structures are feasible and that these structures, after impregnation of the web surfaces with polymer resin, can withstand the loads encountered, at least in aluminum casting.

[0029] The invention enables flow-optimized filter geometries to be provided using additive manufacturing with an advantageous filter element material. This makes it possible to design and manufacture a filter element according to improved flow-related aspects. The design freedom and reproducible manufacturing process avoid the disadvantages of a foam ceramic filter. During processing of the filter element material, loose, pourable particles are wetted or mixed with a binder in layers. In this way, sufficient strength can be achieved through the cohesive bond. After use and after flow of liquid melt, the filter element can at least partially disintegrate, which occurs through thermal decomposition of the binder.The bond between particles is at least largely broken, and the used particles, once again in loose form, can be introduced into a foundry's material cycle. No materials are generated that require landfilling.

[0030] The invention offers possibilities for an optimized design and layout of the entire filter element geometry, particularly the dimensioning of webs and perforations, with the alignment of flow channels formed by perforations, allowing the liquid melt to flow through such that laminar flow after passing through a filter element and the greatest possible retention capacity for contaminants can be achieved. This makes it possible to develop and provide a filter element with defined flow channels and separation pockets. The reproducible and design-free processing of the filter material is a new process that is not yet established on the market.

[0031] Research has shown that there is no known evidence of such filter element structures currently being used or developed. The development of additively manufactured filter elements is characterized by a high degree of innovation.

[0032] The invention also offers ecological and economic advantages as a result of the use of the new filter structures. Compared to foam ceramic filters, the additive manufacturing of the flow-optimized filter structures requires significantly less energy, as the sintering process of the ceramic slip is eliminated. This makes production significantly more environmentally friendly, and foundries can reduce their CO2 footprint by using the filter elements according to the invention. Since an additively manufactured filter element disintegrates due to the thermal action of the melt after casting and the particulate material can be returned to the recycling cycle, landfill and transport costs can be saved. Furthermore, the additively manufactured filter elements are significantly less expensive to manufacture than foam ceramic filters, both in large-scale and small-scale production.Another significant advantage of the development is that the filter structures can be specifically designed according to their respective area of ​​application.

[0033] The raw materials used are inexpensive and a relatively small amount of energy is required to produce the filter elements.

Claims

[1] Filter element for flow calming and / or cleaning of a melt used in casting, which is passed through the filter element, wherein the filter element is designed as three-dimensional web structures with openings as flow channels through which liquid melt is passed, and Webs of the web structure with particles of predominantly SiO2, predominantly Al2O3, predominantly aluminosilicate, with cerium-stabilised ZrO2 or chromite as a material that can be used as a mould material in foundry technology, characterized by , that the particles are bonded together using a furan resin binder, a phenol-based binder or an inorganic water-based alkali silicate binder as a binder, whereby a proportion of binder with which the particles are bonded is maintained in the range of 1 vol.% to 5 vol.% in relation to the amount of bonded particles and the webs are provided on their surface with a closed coating with a minimum layer thickness of 50 µm of a polymer resin. [2] Filter element according to claim 1, characterized by that the webs are filled with particles with an average particle size d 50 in the range 63 µm to 1000 µm. [3] Filter element according to one of the preceding claims, characterized by that open pockets are formed at the openings forming the flow channels to receive impurities contained in a melt in a predefined position and dimension. [4] Method for producing a filter element according to one of the preceding claims, characterized bythat webs made of particles of a material which can be used as a moulding material in foundry technology are formed layer by layer by locally defined material-locking connection of the particles with a binder and with the start of curing or after the curing of the binder the surface of the webs is covered with a coating of a polymer resin. [5] Method according to the preceding claim, characterized by that the loose particles or particles that already contain binder or are coated with binder are applied as a layer to a building platform and particles of the respective uppermost layer are locally exposed to the binder and thereby particles are locally bonded to one another in the plane of the respective layer, and After forming a predetermined geometric web structure for the level of a respective layer by bonding particles with binder, the construction platform is lowered by one layer thickness and a new layer of loose particles is applied, in which particles are again bonded with binder to form a predetermined geometric web structure in this level, whereby the process steps of layer application, locally defined material-locking connection of particles with the binder and lowering of the construction platform are repeated until the specified three-dimensional web structure of the filter element has been formed and subsequently first loosely non-materially bonded particles are removed and then the coating is applied to the surfaces of the webs with a polymer resin, which cures under normal conditions and / or by thermal treatment and / or irradiation with electromagnetic radiation and / or by adding a catalyst. [6] Method according to claim 5, characterized by that a paste formed with the particles and the binder is applied layer by layer through at least one nozzle until the three-dimensional web structure with the webs and openings are formed as flow channels and then the coating with a polymer resin is applied to the surfaces of the webs.