Process for casting components

Abstract

Method for casting components, wherein the casting is carried out by means of pressure die casting, and wherein a component is cast from at least two different casting materials (1, 2), and wherein each casting material (1, 2) is a metal or a metal alloy.

Description

[0001] The present invention relates to a method for casting components and a casting device for casting components.

[0002] Processes and devices for casting components are known, for example, for automotive components, such as body parts. A wide variety of requirements can apply to such components, such as specific strengths, conductivities, corrosion resistance, and the like. These criteria often have to be met locally in very different ways. Furthermore, the most cost-effective production possible should be achieved. Conventional casting processes often only allow for components optimized for one or a few of these requirements.

[0003] It is therefore an object of the present invention to provide a method for casting components with which components with particularly flexible material properties can be produced efficiently and cost-effectively. Furthermore, it is an object of the invention to provide a casting device with which components with flexible material properties can be produced simply and efficiently.

[0004] The object is achieved by a method according to claim 1 and by a casting device according to claim 11.

[0005] The method according to the invention for casting components is characterized in that the casting is carried out by die casting, and in that a component is cast from at least two different casting materials. Each of the at least two casting materials is a metal or a metal alloy.

[0006] In particular, die casting is carried out using a permanent mold.

[0007] Different casting materials are considered to be materials with different compositions. Preferably, at least one of the alloy components has a concentration difference of at least 2% in the at least two casting materials.

[0008] In particular, the casting materials differ in such a way as to provide different material properties after solidification, i.e. in corresponding parts of the finished component.

[0009] In particular, the casting process involves pouring the at least two different materials separately into a die used in die casting. This means that the casting process is designed in such a way that the different materials do not mix with each other, or only mix to a limited extent.

[0010] In particular, the process involves producing a single, one-piece component from the at least two casting materials. This means that the different materials are poured into the casting mold directly adjacent to one another to produce a single, one-piece component.

[0011] The process offers the advantage of being able to produce components with properties that are particularly flexible and tailored to the specific application in a simple and cost-effective manner. Components can be manufactured with precisely optimized local properties. In particular, structural properties as well as surface properties of the component can be specifically influenced during the casting process. This eliminates, for example, subsequent surface treatment steps or additional design measures. This allows components with desired properties to be manufactured particularly efficiently. This also allows the weight and overall costs of the manufactured components to be kept particularly low.

[0012] The use of die casting also enables serial production in high quantities, for example, in large series. Furthermore, die casting can produce particularly flexible geometries, such as particularly thin walls or structured surfaces, which can, for example, enable a good bond between the different casting materials. Furthermore, high temperatures can be used to cast the casting materials in die casting, which can positively influence the formation of intermetallic phases between the different casting materials, ensuring a strong bond between the casting materials.

[0013] Preferably, the component is cast from the at least two different casting materials in exactly one common casting mold. This means that the different casting materials are filled into exactly one casting mold, which preferably has exactly one cavity into which the casting materials are each poured as a melt. This allows for a particularly efficient production of a one-piece component.

[0014] Particularly preferably, during casting, the at least two different casting materials are filled into the casting mold at least temporarily simultaneously. Preferably, the casting materials can be filled into the casting mold completely simultaneously, i.e., with overlapping times. This allows casting to be carried out particularly time-efficiently. Furthermore, it is advantageous that, by filling the casting mold at least temporarily simultaneously, the casting materials are simultaneously present in liquid form as a melt and come into contact with one another, allowing, for example, slight mixing to take place, thereby enabling a particularly good bond between the different casting materials to form the one-piece component.

[0015] Preferably, the at least two different casting materials are filled into the casting mold via at least two sprues. This means that a separate sprue is provided for each casting material, through which this casting material can be poured into the casting mold. This allows for the casting mold to be filled with the different casting materials in a particularly simple and targeted manner.

[0016] Further preferably, the mold is filled using turbulent mold filling. This means that, when the materials are poured into the mold, a turbulent flow of the melt is present, at least in part. This allows for local mixing in the contact area of the different materials within the mold, enabling a reliable bond between the different materials to form the component.

[0017] During casting, the at least two different casting materials are preferably filled into the casting mold one after the other. This means that a second casting material is only poured into the casting mold once the first casting material has been poured in. Preferably, the different casting materials can be poured in immediately one after the other or at a predetermined time interval. This allows for particularly simple casting of components made of several different alloys.

[0018] Preferably, the component to be cast is shaped during at least two filling processes by changing a slide position. This means that the casting of the component takes place at least partially using a slide. For example, the slide is arranged in a first slide position during filling of the first casting material and, in particular, defines a shape of a partial region of the component to be produced from the first casting material. The slide is then moved to a second slide position, preferably in such a way that a cavity is created between the partial region cast from the first casting material and the slide, into which cavity the second casting material is poured. This makes it particularly easy to produce a component which, for example, has an edge region at least locally made of the second casting material.

[0019] More preferably, the component is cast using at least two casting molds. In particular, the two casting molds are designed differently. The casting of the component is preferably carried out in such a way that a first partial region of the component is cast from the first casting material in a first casting mold. Subsequently, in particular, this first partial region is arranged in a second casting mold, wherein the second casting material is then poured into this second casting mold, in particular poured onto the first partial region, in order to produce the finished component. This makes it possible, for example, to easily achieve particularly flexible shapes for the component to be cast.

[0020] Particularly preferably, the at least two different casting materials are designed such that the manufactured component has locally different material properties. Different material properties are achieved, in particular, by the different casting materials, including corrosion resistance, hardness, weldability, thermal conductivity, and / or electrical conductivity. As a result, the method allows components with locally flexibly adapted properties to be produced particularly easily and efficiently.

[0021] Preferably, the at least two different casting materials are bonded to one another in a materially bonded and / or form-fitting and / or frictionally locking manner, in particular during the casting process. A materially bonded connection can preferably be facilitated by an adhesion promoter. A form-fitting connection can preferably be achieved by providing a shape in a contact region of the different casting materials that creates local undercuts, so that the subregions of the different casting materials are held together in a form-fitting manner. A force-fitting connection can preferably be achieved by at least one of the casting materials at least partially enclosing another, wherein the two casting materials have different thermal expansion coefficients.For example, the two sections of the different casting materials can be cast coaxially to each other. Due to the different thermal expansions, these two sections are connected to each other in a force-locking manner, for example, through solidification. This process allows for the simple production of particularly robust components.

[0022] Furthermore, the invention leads to a casting device designed to carry out the described method. The casting device preferably comprises at least one casting mold, a filling device, and a control device configured to actuate the filling device and carry out the method.

[0023] The invention is explained in more detail below using exemplary embodiments. These show: Fig. 1 a highly simplified schematic view of a method for casting components according to a first embodiment of the invention, Fig. 2 a highly simplified schematic view of a first step of a method for casting components according to a second embodiment of the invention, Fig. 3 a highly simplified schematic view of a second step of the method of the second embodiment, Fig. 4 a highly simplified schematic view of a first step of a method for casting components according to a third embodiment of the invention, Fig. 5 a highly simplified schematic view of a second step of the method of the third embodiment, Fig. 6 a highly simplified schematic view of a method for casting components according to a fourth embodiment of the invention, and Fig. 7 a highly simplified schematic view of a method for casting components according to a fifth embodiment of the invention.

[0024] In the following, preferred embodiments of methods for casting components, which are carried out by means of a casting device 50, are explained. Fig. 1 and Fig. 2. Identical or functionally identical components are always provided with the same reference symbols.

[0025] Using the method according to the invention, any component can be manufactured. Body components for vehicles, such as motor vehicles, can be manufactured particularly advantageously.

[0026] The process allows for the simple and cost-effective production of components with properties that can be flexibly adapted to the specific application. In particular, mechanical properties can be optimally adapted locally.

[0027] For this purpose, components are cast from at least two different casting materials 1, 2 using the method. In the exemplary embodiments described below and illustrated in the figures, exactly two different casting materials 1, 2 are provided. Alternatively, more than two different casting materials 1, 2 can also be used.

[0028] The different casting materials 1, 2 differ in their respective compositions, which leads to different material properties in the solidified state. Specifically, the casting materials 1, 2 are used in such a way that local areas with different corrosion resistance and / or hardness and / or weldability and / or thermal conductivity and / or electrical conductivity are created in the corresponding regions of the manufactured component.

[0029] In particular, two different aluminum alloys are used as casting materials 1 and 2. Thus, the process can also be referred to as multi-alloy casting.

[0030] In the first embodiment of the Fig. 1, the casting of the component is carried out by means of a casting device 50, which has exactly one casting mold 10. The casting device 50 has two separate sprues 11, 12, wherein one of the two casting materials 1, 2 is poured into the casting mold 10 via each of the two sprues 11, 12. In addition, a separate vent 31, 32 is provided on the casting mold 10 for each casting material 1, 2.

[0031] The feeding of the casting materials 1, 2 via the sprues 11, 12 into the casting mold 10 is carried out by means of a filling device 55 shown schematically in a highly simplified manner in the figures.

[0032] In detail, the casting is carried out by means of the casting device 50 in pressure casting, i.e. the two casting materials 1, 2, which are present as a melt during casting, are filled into the casting mold 10 under high pressure.

[0033] In the first embodiment of the Fig. 1, the two different casting materials 1, 2 are filled into the casting mold 10 at least temporarily simultaneously. Preferably, the casting mold 10 is filled completely simultaneously using the two casting materials 1, 2.

[0034] Filling under high pressure results in, in particular, turbulent filling of the casting mold 10. As a result, the two different casting materials 1, 2 at least partially mix in a transition region 3. This advantageously provides at least a partial transition between the materials, enabling a homogeneous, one-piece component and a particularly strong connection between the different casting materials 1, 2. In particular, this process allows the production of a one-piece component with optimal material quality and particularly good mechanical properties.

[0035] Fig. 2 shows a highly simplified schematic view of a first step of a method for casting components according to a second embodiment of the invention. Fig. Figure 3 shows a highly simplified schematic view of a second step of the method of the second embodiment. The second embodiment essentially corresponds to the first embodiment of the Fig. 1, with the difference that the two different casting materials 1, 2 are filled into the casting mold 10 one after the other.

[0036] In addition, the casting device 50 in the second embodiment additionally comprises a slide 51.

[0037] In the first step of the Fig. 2, the first casting material 1 is filled in, with the slide 51 being in a closed first slide position.

[0038] Subsequently, after the first casting material 1 has been completely filled, a predetermined period of time can preferably be waited so that the first casting material 1 is at least partially solidified or in a doughy state. Alternatively, preferably, the filling of the second casting material 2 can begin immediately.

[0039] To fill the second casting material 2 in the second step of the Fig. 3, the slide 51 is first moved into an open second slide position. This creates a cavity in the casting mold 10 between the slide 51 and the first casting material 1, into which the second casting material 2 can be poured.

[0040] Preferably, before the second casting material 2 is poured in, an adhesion promoter can be introduced in the region of the connection zone between the two casting materials 1, 2 in order to improve the connection by bonding the casting materials 1, 2 to one another.

[0041] Fig. 4 shows a highly simplified schematic view of a first step of a method for casting components according to a third embodiment of the invention. Fig. Figure 5 shows a highly simplified schematic view of a second step of the method of the third embodiment. The third embodiment essentially corresponds to the first embodiment of the Fig. 1, with the difference that the two different casting materials 1, 2 are cast one after the other and that two separate casting molds 21, 22 are used.

[0042] In the Fig. In the first step of the method of the third embodiment shown in Figure 4, the first casting material 1 is poured into a first casting mold 21. After solidification, a semi-finished product 17 made from the first casting material 1 is removed from the first casting mold 21 and then placed into a second casting mold 22. Subsequently, the second casting material 2 is poured into the second casting mold 22, in which the semi-finished product 17 is located (see Figure 4). Fig. 5).

[0043] Preferably, in the third embodiment, before the second casting material 2 is filled in, a bonding agent can be introduced in the region of the bonding zone between the two casting materials 1, 2, that is to say in particular onto the surface of the semi-finished product 7, in order to improve the bonding by bonding the casting materials 1, 2 to one another in a materially bonded manner.

[0044] Fig. Figure 6 shows a highly simplified schematic view of a method for casting components according to a fourth embodiment of the invention. The fourth embodiment essentially corresponds to the third embodiment of the Fig. 4 and Fig. 5, with the difference of an alternative connection mechanism between the two casting materials 1, 2. In the fourth embodiment of the Fig. 6 is preferably formed by shaping the first casting mold 21 (cf. Fig. 4) an edge region of the semi-finished product 17 made from the first casting material is produced in such a way as to produce a form-fitting region 4 (cf. Fig. 6). The form-fitting area 4 has, at least locally, a plurality of at least partially undercut areas into which, when the second casting material 2 is poured (cf. Fig. 5) this can flow in so that the two casting materials 1, 2 are joined particularly firmly together by positive interlocking.

[0045] Fig. Figure 7 shows a highly simplified schematic view of a method for casting components according to a fifth embodiment of the invention. The fifth embodiment essentially corresponds to the third embodiment of the Fig. 3 and Fig. 4, with the difference of another alternative connection mechanism between the two casting materials 1, 2. In the fifth embodiment of the Fig. 7, a force-locking connection between the two casting materials 1, 2 is created. This is achieved by the second casting material 2 completely enclosing the first casting material 1 in at least one partial area. Preferably, the two casting materials 1, 2 are arranged concentrically in at least this partial area, as shown in Fig.7. The two casting materials 1, 2 have such different thermal expansion coefficients that when the casting materials 1, 2 solidify, different contractions occur, which lead to a force connection between the two casting materials 1, 2 in order to achieve a firm connection with each other. List of reference symbols 1 first casting material 2 second casting material 3 Transition area 4 Form-fitting area 10 Casting mold 11 first sprue 12 second sprue 17 Semi-finished products 21 first casting mold 22 second mold 31 first venting 32 second vent 50 Pouring device 51 sliders 55 Filling device

Claims

[1] Process for casting components, - wherein the casting is carried out by means of pressure casting, and - wherein a component is cast from at least two different casting materials (1, 2), and - wherein each casting material (1, 2) is a metal or a metal alloy. [2] Method according to claim 1, wherein the component is cast by means of exactly one casting mold (10). [3] Method according to claim 2, wherein during casting the at least two different casting materials (1, 2) are filled into the casting mold (10) at least temporarily simultaneously. [4] Method according to one of claims 2 or 3, wherein the at least two different materials (1, 2) are filled into the casting mold (10) by means of at least two sprues (11, 12). [5] Method according to one of claims 3 or 4, wherein the filling of the casting mold (10) is carried out by means of turbulent mold filling. [6] Method according to claim 2, wherein during casting the at least two different casting materials (1, 2) are filled successively into the casting mold (10). [7] Method according to claim 6, wherein a shaping of the component takes place in at least two filling processes by changing a slide position. [8] Method according to claim 1, wherein the component is cast by means of at least two casting molds (21, 22). [9] Method according to one of the preceding claims, wherein the at least two different casting materials (1, 2) are designed such that the manufactured component has locally different material properties, in particular corrosion resistance and / or hardness and / or weldability and / or thermal conductivity and / or electrical conductivity. [10] Method according to one of the preceding claims, wherein the at least two different casting materials (1, 2) are bonded to one another in a material-locking and / or form-locking and / or force-locking manner. [11] Casting device which is designed to carry out the method according to one of the preceding claims.

Images