Casting installation for casting metal casting material and method for casting metal casting material

Abstract

The invention relates to a casting installation (1) for casting metal casting material, wherein the casting installation (1) has a melt-pool container (2) for providing casting material in a liquid state, a casting device (4), designed for forcing casting material into a casting die of the casting device (4), and a dosing container (5), which can be moved from the melt-pool container (2) to the casting device (4) and is in particular designed as a dosing pipette, so that the dosing container (5) can take up a dosable amount of casting material from the melt-pool container (2) into a receiving space (8) of the dosing container (5) and deliver it to the casting device (4), wherein the dosing container (5) is coupled to an evacuation device (11) of the casting installation (1) in order to use the evacuation device (11) to evacuate the receiving space (8) to form a negative pressure in the receiving space (8) for the purpose of receiving the amount of casting material into the receiving space (8). To achieve a high level of operational capability, it is provided that the casting installation (1) has a conditioning station (3) with an induction unit (7), wherein, before the dosing container (5) delivers casting material to the casting device (4), it is possible, in particular as a matter of choice, for the dosing container (5) to be moved in relation to the conditioning station (3), in order for the casting material to be agitated electromagnetically by means of the induction unit (7) for transforming the casting material into a thixotropic state. The invention also relates to a method for casting metal casting material.

Description

[0001] Casting plant for casting metallic casting material and method for casting metallic casting material

[0002] The invention relates to a casting plant for casting metallic casting material, wherein the casting plant has a molten bath container for providing casting material in a liquid state, a casting device designed to press casting material into a casting mold of the casting device, and a dosing container movable from the molten bath container to the casting device, in particular designed as a dosing pipette, in order to receive a dosable amount of casting material from the molten bath container into a receiving space of the dosing container and to deliver it to the casting device, wherein the dosing container is coupled to an evacuation device of the casting plant in order to evacuate the receiving space with the evacuation device for receiving the amount of casting material into the receiving space to create a negative pressure in the receiving space.

[0003] The invention further relates to a method for casting metallic casting material, wherein a metered amount of casting material is taken up from a molten bath container with liquid casting material into a receiving space of the metering container using a metering container, in particular a metering pipette, or casting material is introduced into the receiving space in a solid state, after which the metering container is moved from the molten bath container to a casting device, and casting material is delivered from the receiving space to the casting device in order to press the casting material delivered to the casting device into a casting mold of the casting device using the casting device, wherein when liquid casting material is taken up with the metering container for receiving the amount of casting material into the receiving space, the receiving space is evacuated using an evacuation device so that a negative pressure is formed in the receiving space.

[0004] Casting systems for casting liquid, metallic casting material are known. A dosing pipette, typically movable by a robot arm, is used to withdraw a specific amount of casting material from a melting pot while evacuating the dosing pipette. The dosing pipette is then moved by the robot arm to a die-casting device, and the casting material is fed from the dosing pipette to a casting chamber of the die-casting device. The die-casting device is configured to inject the casting material fed to the casting chamber into a casting mold of the die-casting device in order to produce a component by cooling the casting material in the mold. The purpose of the melting pot is generally to provide a molten bath of liquid casting material.The purpose of the dosing pipette is typically to transfer a defined amount of liquid casting material from the crucible to the die casting machine and deliver it to the casting chamber with reduced oxidation effects and reduced casting material losses. In this way, a measured amount of liquid casting material can be practically fed to the die casting machine, and components can be manufactured by injecting liquid casting material into the mold.

[0005] Another type of casting system is the casting system for thixocasting, also known as semi-solid casting. This typically involves ladling liquid casting material from a melting crucible into a conditioning crucible. The casting material is then conditioned in the conditioning crucible to convert the liquid state into a thixotropic state. Conditioning typically involves cooling and stirring the casting material in the conditioning crucible, frequently using a stirring tool, to create a thixotropic or solid-liquid phase of the casting material, usually with shearing of the casting material. The casting material typically forms a slurry-like body of casting material in the conditioning crucible.The thixotropic casting material is then typically tipped from the crucible into a casting chamber of a die-casting machine, which is typically designed to press the thixotropic casting material into a mold without turbulence. Casting machines designed for thixocasting can generally produce near-net-shape components with high precision. Compared to liquid die-casting machines, thixotropic die-casting machines usually require a complicated process and a space-intensive setup.

[0006] This is where the invention comes in. The object of the invention is to provide a casting system of the type mentioned above, which has improved usability. Furthermore, it is an aim of the invention to provide a method for casting metallic casting material of the type mentioned above, which has improved usability.

[0007] The object is achieved according to the invention by a casting plant of the type mentioned at the outset, if the casting plant has a conditioning station with an induction unit, wherein the dosing container can be moved, in particular selectively, to the conditioning station before the casting material is delivered to the casting device with the dosing container in order to stir the casting material electromagnetically with the induction unit in order to convert the casting material into a thixotropic state.

[0008] The invention is based on the idea of ​​using a design of a casting system for liquid casting, based on a dosing container movable from a molten bath container to a casting device, wherein the dosing container is designed to receive a dosed amount of casting material from the molten bath container into an evacuable receiving space of the dosing container, in order to implement thixotropic casting, in particular thixotropic die casting. In this way, a casting system for liquid casting can be used for thixotropic casting with reduced effort, in particular selectively. This is achievable if the dosing container is used for conditioning the casting material. Conditioning typically refers to a treatment of the casting material to convert the casting material, in particular starting from a liquid phase of the casting material, into a thixotropic phase of the casting material.It has been shown that a thixotropic phase of the casting material can be achieved by electromagnetically stirring the, particularly liquid, casting material in the receiving chamber. The dosing container is preferably a dosing pipette. If the casting system has a conditioning station with an induction unit for electromagnetically stirring the casting material in the receiving chamber using the induction unit, a thixotropic state of the casting material in the receiving chamber can be achieved. The dosing container is usually movable into a conditioning position relative to the induction unit, in which conditioning position the casting material in the receiving chamber can be electromagnetically stirred using the induction unit.In this way, it is possible to collect the casting material into the dosing container, in particular the receiving chamber, with reduced interaction with the ambient atmosphere, in particular with reduced oxidation effects, then convert it into a thixotropic state, and then deliver it to the casting device via the dosing container. This enables a high level of operational capability of the casting system.

[0009] The molten bath container, which may be a melting crucible, for example, is typically designed to hold liquid casting material, typically as a molten bath, or to make it available for removal using the dosing container. Typically, after holding a, in particular metered, amount of casting material with the dosing container from the molten bath container and in particular after electromagnetic stirring of the casting material in the receiving space, the dosing container can be moved to the casting device using the induction unit in order to release casting material from the receiving space to the casting device. The molten bath container and the casting device are typically separate objects and / or arranged at a distance from one another. The induction unit is typically controlled, in particular regulated, in such a way that a temperature and / or a solid phase proportion of the casting material in the receiving space can be adjusted using the induction unit.It has been shown that it is advantageous if the solid phase content is less than 20%, in particular between 0.1% and 20%, preferably between 1% and 15%, particularly preferably between 3% and 10%. With such a solid phase content, particularly trouble-free handling of the thixotropic material is possible, especially with regard to handling the dosing container when the thixotropic material is located in the receiving space.

[0010] It is advantageous if the casting system has an electronic control device for controlling, in particular regulating, the casting system. The electronic control device typically has a microcontroller for this purpose. The electronic control device can be designed to control, in particular regulate, the casting system, preferably in an automated manner, in particular depending on the casting material composition.

[0011] The casting system typically has a movement device with which the dosing container can be moved, in particular in a controlled, preferably regulated, manner. In particular, the dosing container can be moved with the movement device from the molten bath container to the conditioning station and / or to the casting device. The movement device can be designed to move the dosing container along one or more, in particular orthogonally aligned, movement axes. The movement device can be, for example, a pivoting arm or gantry robot. The dosing container is typically mechanically connected to the movement device, in particular detachably connected to the movement device. The movement device can be controlled, in particular regulated, by the electronic control device and in particular coupled accordingly to the electronic control device.

[0012] The dosing container usually has an evacuable receiving space in order to create a negative pressure in the receiving space when the receiving space is evacuated using the evacuation device. It is usually provided that in order to receive casting material, the casting material is sucked into the receiving space when the receiving space is evacuated. The dosing container, in particular the receiving space, is usually designed such that in order to receive casting material into the receiving space, casting material can be fed to the receiving space from an underside of the dosing container, in particular the receiving space, and / or in order to discharge casting material from the receiving space, casting material can be removed from the receiving space via an underside of the dosing container, in particular the receiving space. Casting material can usually be fed to the receiving space at a lower region, in particular a deepest region, of the receiving space and / or removed from the receiving space.The dosing container is generally designed such that, when the receiving space is partially filled with casting material, an atmospheric volume is present above the casting material, sealed off from the surroundings of the dosing container. Typically, the evacuation device is connected to the atmospheric volume in a gas-conducting manner in order to discharge gas from the atmospheric volume via the evacuation device. It is advantageous if the evacuation device is connected to the receiving space in a gas-conducting manner at an upper side of the receiving space, in particular at a highest region of the receiving space. The receiving space typically forms a cavity that can be closed with a closure means of the dosing container. The receiving space is generally formed with receiving space walls, which preferably substantially completely enclose the receiving space.Typically, the receiving space walls of the dosing container are formed at least partially, preferably substantially entirely, from a ceramic material. The dosing container can be designed to receive a, in particular metered, amount of the liquid casting material into the receiving space by at least partially immersing the dosing container in a liquid casting material or melt bath received by the melt bath container. The melt bath is typically formed with liquid casting material. It is expedient if the dosing container has outer walls which are designed to be inert at least in sections, so that inert sections of the outer walls can be immersed in the melt bath, in particular substantially without chemical reaction between the sections and the melt bath, in order to receive casting material from the melt bath with the dosing container.Typically, the outer walls of the dosing container are formed at least partially, preferably essentially entirely, from a ceramic material. The dosing container is typically designed to receive liquid casting material into the receiving space, in particular from the melt bath container. The dosing container is typically designed to discharge flowable, thixotropic casting material from the receiving space, in particular to the casting device, typically a casting chamber of the casting device.

[0013] The dosing container typically has a casting material opening for receiving casting material into the dosing container, in particular the receiving space, and / or for dispensing casting material from the dosing container, in particular the receiving space, via the casting material opening. The dosing container can expediently be designed to supply casting material to the receiving space via the casting material opening and / or to dispense it from the receiving space via the casting material opening. The casting material opening is generally connected to the receiving space in a casting material-conducting manner. The dosing container can have a controllable, in particular adjustable, closing means for closing and / or opening the casting material opening. The closing means can be controlled, in particular regulated, by the control device and, in particular, coupled accordingly to the electronic control device.When the casting material opening is open, casting material can be supplied to the receiving space via the casting material opening or discharged from the receiving space via the casting material opening. In particular, when the casting material opening is closed, the passage of casting material through the casting material opening can be substantially prevented by the closure means. The closure means is preferably a closure plug. Accordingly, it is advantageous if the dosing container has a casting material opening that can be closed with a controllable closure means, in particular a controllably movable closure plug, in order to supply casting material to the receiving space via the casting material opening when the casting material opening is open. The dosing container can expediently have several casting material openings.In particular, the dosing container can have a first casting material opening for receiving liquid casting material via the first casting material opening into the receiving space and a second casting material opening for dispensing flowable casting material via the second casting material opening. The first casting material opening and / or the second casting material opening can be designed as described for the casting material opening. The first casting material opening and the second casting material opening can be opened or closed separately from one another, in particular in a controllable, preferably regulatable, manner, usually with one or more closing means, which closing means can be designed as described in this document. In particular, the first casting material opening and the second casting material opening can each be assigned a separate closing means in order to open or close the respective casting material opening with the closing means.The dosing container can be designed for a dosed intake of casting material into the dosing container, in particular the receiving space, and / or for a dosed discharge of casting material from the dosing container, in particular the receiving space.

[0014] In order to receive liquid casting material from the molten bath container using the dosing container, the casting material opening is preferably immersed in a liquid casting material or molten bath provided by the molten bath container, so that casting material, in particular below a molten bath surface of the molten bath, can be received into the receiving space via the casting material opening. The dosing container is usually designed accordingly. In this way, oxidation effects can be efficiently reduced, in particular avoided. It is advantageous if the casting material opening of the dosing container is arranged in a bottom region of the dosing container, preferably oriented downwards. This makes it practical to receive casting material by immersing the bottom region, in particular the casting material opening, in liquid casting material or a molten bath in the receiving space.It is advantageous if the dosing container is designed such that, when the casting material opening is open, flowable casting material can flow out of the receiving space automatically. The dosing container can be controlled, in particular regulated, by the electronic control device and, in particular, can be coupled accordingly to the electronic control device.

[0015] The evacuation device typically comprises a vacuum pump to evacuate the receiving space, in particular to create a negative pressure in the receiving space. As a rule, when the casting material opening is immersed in the molten bath, casting material can be fed to the receiving space, in particular sucked into the receiving space, via the casting material opening, while evacuating the receiving space, in particular creating a negative pressure in the receiving space. As a rule, the evacuation device, in particular a vacuum pump, is connected to the receiving space in a gas-conducting manner, in particular via an evacuation line. Gas can be discharged from the receiving space via the evacuation line, in particular sucked out using the evacuation device. The evacuation line preferably connects to the receiving space on an upper side of the receiving space. The evacuation device can be part of the dosing container.The evacuation device can be designed to variably control, in particular regulate, a negative pressure in the receiving space, in particular when casting material is received in the receiving space. A suction force acting on the casting material in the receiving space, especially for receiving and / or discharging casting material into or out of the receiving space, can be controlled, in particular regulated, by this device. The evacuation device can be controlled, in particular regulated, by the electronic control device and, in particular, can be coupled accordingly to the electronic control device.

[0016] It is advantageous if the casting system has a gas supply device for supplying gas, in particular inert gas, for example argon, to the receiving space via the gas supply device. The gas supply can be controlled, in particular regulated. The gas supply device can be connected to the dosing container, in particular to the receiving space, via a gas supply line. The gas supply device can be controlled, in particular regulated, by the electronic control device and, in particular, can be coupled accordingly to the electronic control device, in particular for transmitting control signals. It is expedient if the dosing container has a fill level measuring device for determining a fill level, in particular fill volume, of the receiving space with casting material. The fill level measuring device can be designed to measure a weight and / or a fill level of a casting material in the receiving space.The fill level measuring device can be implemented with one or more measuring sensors. Immersion of the dosing container into a melt pool located in the melt pool container to receive casting material from the melt pool into the dosing container, in particular into the receiving space, can occur depending on a determination of the fill level of the receiving space by the fill level measuring device. The receiving and / or discharge of casting material from the dosing container, in particular the receiving space, can occur depending on a determination of the fill level of the receiving space by the fill level measuring device.

[0017] It is practical if the receiving space has a first receiving space segment with a cross-sectional area that tapers in a casting material discharge direction of the receiving space. The casting material opening is usually arranged downstream of the first receiving space segment in the casting material discharge direction of the receiving space. The first receiving space segment can expediently open into the casting material opening or a casting material channel forming the casting material opening. The casting material discharge direction of the receiving space usually refers to a flow direction of the casting material in the receiving space when casting material is discharged from the receiving space via the casting material opening for discharge of the casting material. The first receiving space segment can be arranged downstream of a second receiving space segment in the casting material discharge direction of the receiving space, wherein the second receiving space segment has an essentially constant cross-sectional area.For example, the second receiving space segment can be formed with cylindrical shell-shaped wall sections and / or the first receiving space segment can be formed with conical shell-shaped, in particular truncated cone-shaped, wall sections. The wall sections are usually part of the receiving space walls of the receiving space. Typically, the dosing container, in particular the receiving space walls and / or an outer surface, preferably the shell surface, of the dosing container, is predominantly, in particular substantially, formed with or from ceramic material. It is practicable if the casting material opening is formed by a casting material channel, which casting material channel is connected to the receiving space in a casting material-conducting manner. Casting material can be supplied to and / or discharged from the receiving space via the casting material channel.The casting material channel typically has an average cross-sectional area through which casting material can flow, which is smaller than an average cross-sectional area of ​​the receiving space, in particular of the receiving space segment. The cross-sectional area of ​​the receiving space, in particular of the receiving space segment, is typically oriented orthogonally to the casting material discharge direction of the receiving space. The casting material channel typically connects to the receiving space on an underside of the receiving space in a casting material-conducting manner. The casting material channel and / or the casting material opening can be formed by a tubular nozzle of the dosing container, which nozzle protrudes from a base body of the dosing container, in particular downwards. The receiving space is typically located predominantly, preferably substantially, in the base body of the dosing container. It is advantageous if the nozzle has a tapered outer diameter in a protrusion direction of the nozzle.The removal direction typically refers to a direction in which the nozzle protrudes outward from the base body. Typically, a longitudinal extension of the nozzle is oriented parallel to the removal direction. The removal direction is preferably oriented downward. "Down" typically refers to a direction in which the dosing container, for holding casting material, is at least partially immersed in a liquid casting material or melt bath.

[0018] It is expedient if the dosing container is designed for dispensing flowable, thixotropic casting material, in particular to the casting device. It is advantageous if the dosing container is designed to dispense flowable metallic casting material, in particular thixotropic casting material, with a solid phase content of more than 0.1%, in particular between 0.1% and 20%, preferably between 1% and 15%, particularly preferably between 3% and 10%, from the receiving space to the casting device, usually via the casting material opening. Casting material in a thixotropic state with such a solid phase content can thus be dispensed from the dosing container to the casting device with minimal disruption. In particular, a corresponding design of the casting material opening, in particular of the casting material channel, is required for dispensing casting material with such a solid phase content from the receiving space.This is particularly relevant because otherwise blockages with thixotropic casting material may occur in the dosing container, especially in the area of ​​the casting material opening.

[0019] It is advantageous if the casting material opening can be controlled, in particular regulated, in such a way that flowable metallic casting material with a solid phase content of more than 3%, preferably between 3% and 20%, particularly preferably between 3% and 15%, can be released from the receiving space to the casting device via the casting material opening. The casting material opening can be controlled, in particular regulated, by the electronic control device.

[0020] It is advantageous if the ratio of an average diameter of the receiving space to a diameter of the casting material opening is from 2 to 15, in particular from 3 to 12, preferably from 5 to 10, particularly preferably from 5 to 8. This enables the dosing container to handle thixotropic material in the dosing container with minimal disruption, while simultaneously reducing oxidation effects. The diameter of the receiving space is usually measured orthogonally to a casting material discharge direction of the receiving space. The diameter of the casting material opening is usually measured orthogonally to a casting material discharge direction of the casting material opening, in which direction the casting material flows through the casting material opening when casting material is discharged from the receiving space for discharging the casting material via the casting material opening.

[0021] Casting material discharge direction of the receiving space usually refers to a flow direction of the casting material in the receiving space when casting material is discharged from the receiving space for discharging the casting material via the casting material opening.

[0022] Typically, the induction unit defines a treatment receptacle into which the dosing container for electromagnetic stirring of the casting material in the receiving space can be at least partially inserted, so that the dosing container is at least partially surrounded by the induction unit. It is expedient if the treatment receptacle and the dosing container are designed to correspond in shape to one another. The treatment receptacle typically defines the conditioning position of the dosing container. The dosing container is usually the conditioning station, in particular the induction unit, and can be inserted into the receiving space without contact. The dosing container is typically inserted into the treatment receptacle with the movement device.

[0023] It is preferred if the induction unit is formed with one or more inductors, in particular induction coils. The inductors usually define the treatment receptacle. The respective inductor can be an induction coil having a plurality of coil windings. The electromagnetic induction field is usually generated by means of electrical current flow through the coil windings. A region encompassed by the coil windings usually defines the treatment receptacle. The coil windings are generally arranged on a casing of a rotating body, for example a cylinder or a cone. For example, the induction unit can be formed by a cylindrical induction coil having a plurality of coil windings, wherein a region encompassed, in particular enclosed, by the coil windings is the treatment receptacle.The inductors are typically designed to generate an electromagnetic induction field to electromagnetically stir the casting material in the receiving chamber when the dosing container is in the conditioning position. Stirring the casting material typically causes shearing of the casting material to create a thixotropic state of the casting material, particularly with a defined solid phase content. It is advantageous if the induction unit is designed such that, in the conditioning position, the dosing container is enclosed by the induction unit in all directions orthogonal to a direction of insertion of the dosing container into the treatment receptacle.

[0024] It is advantageous if the dosing container can be inserted into the treatment receptacle in such a way that at least 20%, in particular at least 50%, preferably at least 65%, of a volume of the receptacle is located within the treatment receptacle. This allows a specific solid phase proportion of the casting material to be efficiently set in the receptacle. It is particularly advantageous if at least 75%, in particular at least 85%, preferably at least 90%, of a volume of the receptacle is located within the treatment receptacle. In particular, substantially the entire receptacle can be located within the treatment receptacle. In this way, a conversion of the casting material into the thixotropic state can be controlled, in particular regulated, with high precision.

[0025] It is preferred if the dosing container can be inserted into the treatment receptacle, in particular in a controlled, preferably regulated manner, such that at least 20%, in particular at least 50%, preferably at least 65%, of a filling volume of the receiving space is located within the treatment receptacle. This makes it possible to efficiently set a specific solid phase proportion of the casting material in the receiving space. It is particularly advantageous if at least 75%, in particular at least 85%, preferably at least 90%, of a filling volume of the receiving space is located within the treatment receptacle. In particular, essentially the entire filling volume of the receiving space with casting material can be located within the treatment receptacle. The filling volume of the receiving space refers to the volume of the receiving space occupied by casting material in the receiving space. The filling volume can expediently be determined using the fill level measuring device.In this way, the transformation of the casting material into the thixotropic state can be controlled, particularly regulated, with particularly high precision. Insertion into the treatment receptacle can be controlled, particularly regulated, usually depending on the fill volume of the receptacle. This can be done with the electronic control device.

[0026] As a rule, a temperature and / or a solid phase content in the casting material of the receiving chamber can be adjusted using a control, in particular a regulation, of the conditioning station, in particular the induction unit, in the conditioning position of the dosing container. Typically, in the conditioning position of the dosing container, the casting material in the receiving chamber is allowed to cool and / or actively cooled to achieve a thixotropic state of the casting material, in particular in parallel with the electromagnetic stirring of the casting material. The conditioning station, in particular the induction unit, can be controlled, in particular regulated, by the electronic control device and, in particular, can be coupled accordingly to the electronic control device, usually via an electrical control line.It is advantageous if the conditioning station has a cooling device with which the casting material in the receiving space can be cooled when the dosing container is guided to the conditioning station or in the conditioning position of the dosing container, in particular in parallel with the electromagnetic stirring of the casting material with the induction unit. This allows the thixotropic state of the casting material to be implemented particularly efficiently. Cooling with the cooling device can be controlled, in particular regulated, usually with the electronic control device. The cooling device can be formed with one or more cooling elements through which a cooling liquid can flow, which are preferably arranged and designed such that they surround the dosing container at least in sections when the dosing container is guided to the conditioning station or in the conditioning position of the dosing container.The cooling elements can be cooling channels, which can in particular be designed as part of a cooling circuit.

[0027] The induction unit can advantageously be designed to be movable, so that the induction unit can partially move along with the dosing container. This allows conditioning, in particular electromagnetic stirring, of the casting material in the receiving space to take place while the dosing container is moved. This movement can occur when the dosing container is at least partially inserted into the treatment receptacle. This allows high efficiency to be achieved. The induction unit can be moved, in particular in a controlled, preferably regulated, manner using a movement device of the casting system. The movement device can be implemented with the movement device. Alternatively, it can be expedient for the induction unit to be passively moved along with the dosing container, for example by implementing a mechanical connection between the dosing container and the conditioning station, in particular the induction unit.The mechanical connection can be controlled, in particular regulated, and can be activated or deactivated.

[0028] The casting device typically has a casting chamber, into which casting material is delivered via the dosing container. The casting mold of the casting device is typically arranged downstream of the casting chamber, so that the casting material can be pressed from the casting chamber into the casting mold using a pressing element, in particular a pressing piston, of the casting device. The casting device is typically a die-casting device and / or a forming device, in particular a drop-forging device. The casting device can be controlled, in particular regulated, by the electronic control device and, in particular, can be coupled accordingly to the electronic control device.

[0029] The dosing container, the movement device, the conditioning station, and / or the casting device can each be controlled, in particular regulated, by a separate electronic control device, which is in particular part of the casting system. The dosing container, the movement device, the conditioning station, and / or the casting device can be coupled to the electronic control device for the transmission of control signals, usually via electrical control lines.

[0030] The object of the invention is achieved by a method for casting metallic casting material of the type mentioned above, wherein the dosing container is moved, in particular selectively, to a conditioning station with an induction unit before the casting material is delivered to the casting device, after which the casting material in the receiving space is electromagnetically stirred by the induction unit in order to convert the casting material into a thixotropic state. The method can be implemented with the casting system described in this document. By using the dosing container for conditioning, whereby the casting material in the receiving space of the dosing container is converted into a thixotropic state, the casting of thixotropic casting material can be implemented efficiently, in particular selectively. In this way, a high level of usability can be achieved.Typically, after the casting material has been converted into the thixotropic state in the receiving chamber, the casting material is dispensed from the dosing container to the casting device, after which the casting material in the thixotropic state is pressed into the casting mold of the casting device. The pressing process is usually carried out without turbulence. The dosing container is typically a dosing pipette, which is designed to draw liquid casting material into the dosing pipette or its receiving chamber, creating a vacuum.

[0031] Preferably, the dosing container is used to take liquid casting material, in particular in a dosed amount, from a molten bath container into a receiving space of the dosing container. Alternatively, usually with smaller and / or cost-intensive quantities of casting material, it can be advantageous if casting material in a solid state, usually as a piece product, is added to the receiving space of the dosing container, usually with a dosed amount of casting material. As a rule, when or in the case of liquid casting material being taken up by the dosing container and / or when or in the case of casting material in a solid state being taken up by the dosing container for the reception of the, in particular dosed, amount of casting material into the receiving space, the receiving space is evacuated using the evacuation device, so that a negative pressure is created in the receiving space.

[0032] It is advantageous if, in particular optionally, in a first process sequence, the casting material in the receiving space is converted into a thixotropic state by means of the conditioning station and thixotropic casting material is delivered to the casting device using the dosing container, or alternatively, in a second process sequence, the casting material in the receiving space is not converted into a thixotropic state by means of the conditioning station, but rather the casting material is delivered to the casting device in a liquid state from the dosing container. The casting material delivered to the casting device is usually injected into a casting mold using the casting device. In the first process sequence, the casting material is usually pressed into the casting mold by the casting device in a thixotropic state. In the second process sequence, the casting material is usually pressed into the casting mold by the casting device in a liquid state.The first process sequence or the second process sequence can each be implemented as described in this document. The casting system can be designed accordingly to carry out the first process sequence and / or the second process sequence. The first process sequence and the second process sequence can take place one after the other. In the first process sequence, in particular in contrast to the second process sequence, the dosing container is usually not moved to the conditioning station or into the conditioning position for electromagnetic stirring of the casting material in the receiving space. The first process sequence and the second process sequence can be carried out using different casting molds of the casting device. The first process sequence and the second process sequence can have the same or different composition of the casting material.The casting system can expediently have several melt pool containers, with the dosing container being movable to different melt pool containers to receive casting material from the respective melt pool container. It is expedient if casting material with different casting material compositions, in particular different melt pool compositions, is received or provided in different melt pool containers, usually in a liquid state or as a melt pool.

[0033] The method for casting metallic casting material can be designed according to the features and effects described in this document in the context of a casting system, particularly above. The same applies to the casting system with regard to the method.

[0034] It is advantageous if the conditioning station sets a solid phase content of the casting material in the receiving chamber between 0.1% and 20%, in particular between 1% and 20%, preferably between 3% and 15%. With such a solid phase content, particularly trouble-free handling of the thixotropic material is possible, especially with regard to handling the dosing container with thixotropic material in the receiving chamber.

[0035] It is advantageous if the casting material in the receiving chamber is actively cooled in parallel with the electromagnetic stirring to convert the casting material into a thixotropic state. This allows the thixotropic state of the casting material in the receiving chamber to be achieved particularly efficiently. This can be achieved with a cooling device in the conditioning station.

[0036] It is advantageous if the casting system is controlled, in particular regulated, in an automated manner. This can be implemented using the electronic control device, which can be designed for this purpose. The control, in particular regulated, can take place depending on a casting material quantity and / or casting material composition of the casting material. It is particularly advantageous if the conditioning station, in particular the induction unit, is controlled, in particular regulated, in an automated manner depending on a material composition, in particular alloy composition, of the casting material in order to set a thixotropic state of the casting material, in particular with a predefined solid phase proportion. The electronic control device can be designed for this purpose. This can be implemented efficiently because a high degree of reproducibility can be achieved by using the dosing container for conditioning.In particular, oxidation effects can usually be neglected and / or the receiving space, which is usually largely isolated from the environment, allows for precise control of the transformation of the casting material in the receiving space into the thixotropic state.

[0037] The casting material is typically a metal alloy, especially a light metal alloy. Preferably, the casting material is a magnesium-based alloy, aluminum-based alloy, or copper-based alloy.

[0038] Liquid casting material typically refers to casting material at a temperature above the casting material's liquidus temperature. Thixotropic casting material typically refers to casting material in a semi-solid state, or at a temperature between the casting material's liquidus temperature and solidus temperature. Typically, the melt pool container, conditioning station, pouring device, and dosing container are separate items and / or arranged at a distance from each other.

[0039] Further features, advantages, and effects of the invention will become apparent from the following description of an exemplary embodiment. The drawings, to which reference is made, show:

[0040] Fig. 1 is a schematic representation of the casting plant;

[0041] Fig. 2 and Fig. 3 show microscopic images of a material structure of components manufactured with the casting system with and without the use of a conditioning station of the casting system.

[0042] Fig. 1 schematically shows a casting system 1 and a process sequence for casting metallic casting material. The casting system 1 has a molten bath container 2, a conditioning station 3, a casting device 4, and a dosing container 5 movable by a movement device 6. Fig. 1 shows states of interaction of the dosing container 5 with the molten bath container, the conditioning station 3, and the casting device 4. The molten bath container 2 is designed to hold or provide liquid casting material. The dosing container 5 can be moved by the movement device 6 from the molten bath container 2, in particular selectively, to the conditioning station 3 and to the casting device 4. The movement device 6 can, for example, be a pivoting arm.It is provided that the dosing container 5 can receive a quantity of liquid casting material from the molten bath container 2 into a receiving space 8 of the dosing container 5, after which the dosing container 5 is moved, in particular selectively, to the conditioning station 3 using the movement device 6 in order to electromagnetically stir the casting material in the receiving space 8 using an induction unit 7 of the conditioning station 3 in order to convert the casting material from a liquid state to a thixotropic state. The electromagnetic stirring generally takes place while the casting material is cooling in the receiving space 8. The dosing container 5 can then be moved to the casting device 4 using the movement device 6 in order to deliver the thixotropic casting material from the receiving space 8 to the casting device 4, usually a casting chamber 9 of the casting device 4.The casting material delivered to the casting chamber 9 can then be pressed into a casting mold of the casting device 4 using a pressing element 10, in particular a pressing piston, of the casting device 4, in order to produce a component as the casting material cools in the casting mold. The dosing container 5 is coupled to an evacuation device 11, with which evacuation device 11 the receiving space 8 can be evacuated, so that a negative pressure can be created in the receiving space 8 for receiving, in particular sucking, casting material into the receiving space 8. The evacuation device 11 is generally connected to the receiving space 8 in a gas-conducting manner via an evacuation line 12 in order to evacuate the receiving space 8 via the evacuation line 12.The dosing container 5 typically has a casting material opening 13 connected to the receiving space 8 in a casting material-conducting manner for receiving casting material via the casting material opening 13 into the receiving space 8 and / or for discharging casting material via the casting material opening 13 from the receiving space 8. Typically, the casting material opening 13 is immersed in a liquid casting material located in the molten bath container 2 in order to receive casting material via the casting material opening 13 into the receiving space 8. In this way, a metered amount of casting material can be received with the dosing container 5 under reduced oxidation effects and then the dosing container 5 can be used, in particular selectively, for pouring liquid casting material with the pouring device 4 or for pouring thixotropic casting material with the pouring device 4.

[0043] The induction unit 7 is typically formed with an induction coil having multiple coil windings. The induction coil forms a treatment receptacle into which the dosing container 5 can be at least partially inserted to electromagnetically stir the casting material in the receiving space 8. It is practical if the dosing container 5 is inserted into the treatment receptacle such that at least 20% of the volume of the receiving space 8, preferably at least 20% of the volume of the receiving space 8 filled with casting material, is located within the treatment space. In this way, a specific, in particular predetermined, solid phase fraction in the casting material can be set in the thixotropic state.

[0044] To deliver the thixotropic casting material in the receiving space 8 to the casting device 4, the thixotropic casting material is delivered to the casting device 4, in particular its casting chamber 9, via the casting material opening 13. For this purpose, it is advantageous if the ratio of an average diameter of the receiving space 8 to a diameter of the casting material opening 13 is from 2 to 15. Alternatively, preferably cumulatively, it is advantageous if the thixotropic casting material with a solid phase content of more than 3%, in particular between 3% and 20%, is delivered from the receiving space 8 to the casting device 4 via the casting material opening 13. In this way, trouble-free operation can be achieved when handling, in particular dispensing, the thixotropic casting material with the dosing container 5.

[0045] Fig. 2 and Fig. 3 show microscopic images of a material structure of components produced with the casting system 1 of Fig. 1 with and without use of the conditioning station 3 of the casting system 1. The microscopic images show, by way of example, a material structure of components which are produced with an Al-Si7 alloy as the casting material using the casting system 1. Fig. 2 shows a material structure of a component which is produced without use of the conditioning station 3, i.e. by injecting liquid casting material into the casting mold using the casting device 4. Fig. 3 shows a material structure of a component which is produced with the use of the conditioning station 3, i.e. by transferring the casting material in the receiving space 8 with the conditioning station 3 into a thixotropic state, wherein a solid phase portion of

[0046] 5% was converted, and the thixotropic casting material was subsequently pressed into the casting mold using the casting device 4. The microscopic image in Fig. 2 shows a dendritic grain structure. In contrast, the image in Fig. 3 shows a globular grain structure.

[0047] If liquid casting material can be received by a dosing container 5 into an evacuable receiving space 8 of the dosing container 5, after which the casting material in the receiving space 8 can be electromagnetically stirred by an induction unit 7 of a conditioning station 3 in the receiving space 8 in order to convert the casting material from a liquid state to a thixotropic state and subsequently deliver the thixotropic casting material to a casting device 4 for introduction into a casting mold, thixotropic casting or a component produced by thixotropic casting can be implemented with little effort and with reduced oxidation effects. In particular, the casting system 1 can be used, in particular selectively, for casting with liquid casting material and / or casting with thixotropic casting material. This enables the implementation of a casting system 1 with high usability.

Claims

Patent claims 1. A casting system (1) for casting metallic casting material, wherein the casting system (1) comprises a melt bath container (2) for providing casting material in a liquid state, a casting device (4) designed to inject casting material into a casting mold of the casting device (4), and a metering container (5) movable from the melt bath container (2) to the casting device (4), in particular designed as a metering pipette, in order to receive a metered amount of casting material from the melt bath container (2) into a receiving space (8) of the metering container (5) and to deliver it to the casting device (4), wherein the metering container (5) is coupled to an evacuation device (11) of the casting system (1) in order to evacuate the receiving space (8) with the evacuation device (11) for receiving the amount of casting material into the receiving space (8) to create a negative pressure in the receiving space (8), characterized in thatthat the casting plant (1) has a conditioning station (3) with an induction unit (7), wherein the dosing container (5) is movable, in particular selectively, to the conditioning station (3) before the casting material is delivered with the dosing container (5) to the casting device (4), in order to electromagnetically stir the casting material with the induction unit (7) to convert the casting material into a thixotropic state.

2. Casting system (1) according to claim 1, characterized in that the dosing container (5) has a casting material opening (13) which can be closed by a controllable closing means, in particular a closing plug, in order to supply casting material to the receiving space (8) via the casting material opening (13) when the casting material opening (13) is open.

3. Casting system (1) according to claim 2, characterized in that the casting material opening (13) of the dosing container (5) is arranged in a bottom region of the dosing container (5).

4. Casting system (1) according to claim 2 or 3, characterized in that the casting material opening (13) is formed by a tubular nozzle of the dosing container (5), which nozzle protrudes from a base body of the dosing container (5).

5. Casting system (1) according to one of claims 1 to 4, characterized in that the dosing container (5) is designed to deliver flowable metallic casting material with a solid phase content of more than 0.1%, in particular between 0.1% and 20%, preferably between 1% and 15%, in particular preferably between 3% and 10%, from the receiving space (8) to the casting device (4).

6. Casting plant (1) according to one of claims 1 to 5, characterized in that the induction unit (7) defines a treatment receptacle into which the dosing container (5) for electromagnetic stirring of the casting material in the receiving space (8) can be at least partially inserted, so that the dosing container (5) is at least partially surrounded by the induction unit (7).

7. Casting plant (1) according to claim 6, characterized in that the induction unit (7) is formed with one or more inductors, in particular induction coils, wherein the inductors define the treatment receptacle.

8. Casting system (1) according to claim 6 or 7, characterized in that the dosing container (5) can be inserted into the treatment receptacle in such a way that at least 20%, in particular at least 50% of a volume of the receiving space (8) is located within the treatment receptacle.

9. Casting plant (1) according to one of claims 1 to 8, characterized in that the conditioning station has a cooling device with which the casting material in the receiving space (8) can be cooled when the dosing container (5) is guided to the conditioning station, in particular in parallel with the electromagnetic stirring of the casting material with the induction unit (7).

10. Casting plant (1) according to one of claims 1 to 9, characterized in that the cooling device is formed with one or more cooling elements through which a cooling liquid can flow, which are preferably arranged and designed such that they surround the dosing container (5) at least in sections in a position of the dosing container (5) guided to the conditioning station.

11. Casting system (1) according to one of claims 1 to 10, characterized in that the induction unit (7) is designed to be movable, so that the induction unit (7) can be partially moved together with the dosing container (5).

12. A method for casting metallic casting material, wherein a metered amount of casting material is taken from a molten bath container (2) containing liquid casting material into a receiving space (8) of the dosing container (5) using a dosing container (5), in particular a dosing pipette, or casting material is introduced into the receiving space (8) in a solid state, after which the dosing container (5) is moved from the molten bath container (2) to a casting device (4), and casting material is delivered from the receiving space (8) to the casting device (4) in order to press the casting material delivered to the casting device (4) into a casting mold of the casting device (4) with the casting device (4), wherein when liquid casting material is taken up with the dosing container (5) for receiving the amount of casting material into the receiving space (8), the receiving space (8) is evacuated with an evacuation device (11) so that a negative pressure is created in the receiving space (8), characterized in thatthat the dosing container (5) is moved to a conditioning station (3) with an induction unit (7) before the casting material is delivered to the casting device (4), after which the casting material in the receiving space (8) is electromagnetically stirred by the induction unit (7) in order to convert the casting material into a thixotropic state.

13. Method according to claim 12, characterized in that the conditioning station (3) sets a solid phase proportion of the casting material in the receiving space (8) between 0.1% and 20%.

14. Method according to claim 12 or 13, characterized in that the casting material in the receiving space (8) is actively cooled in parallel with the electromagnetic stirring in order to convert the casting material into the thixotropic state.

15. Method according to one of claims 12 to 14, characterized in that the conditioning station (3), in particular the induction unit (7), is controlled automatically depending on a material composition of the casting material, in particular is regulated in order to set a thixotropic state of the casting material, in particular with a predefined solid phase content.

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