Lost Pattern Casting with Self-Forming Coolers
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Solution Overview
Problem
Cast metal parts obtained from lost models using existing processes often have insufficient fine structure, high porosity, and poor mechanical characteristics due to inadequate cooling, leading to inhomogeneous properties and complex geometry challenges at a high cost.
Innovation Solution
A method involving the use of thermosetting elements and coolers to control and accelerate solidification, where thermosetting elements are introduced in contact with free faces of the lost model and coolers are placed against support surfaces, facilitating the casting of metal parts with improved mechanical characteristics and complex geometries by guiding molten metal solidification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cooling elements are placed in the container to contact bearing surfaces of the lost model, then the elongation coefficient of the metal part is improved, but the structure becomes inhomogeneous and porosity increases due to inadequate cooling of free faces
Solution Approach 1:
The patent applies local quality by differentiating the treatment of bearing surfaces versus free faces. Cooling elements are strategically positioned to contact bearing surfaces, while thermosetting material is applied specifically to free faces to provide localized cooling. This ensures each surface type receives appropriate cooling treatment, achieving homogeneous structure throughout the casting without compromising the elongation coefficient improvements gained from bearing surface cooling.
Solution Approach 2:
The cooling system is segmented into two distinct components: traditional cooling elements for bearing surfaces and thermosetting material applications for free faces. This segmentation allows independent optimization of cooling strategies for different surface types, resolving the contradiction by ensuring both bearing surfaces and free faces receive targeted cooling treatment, thereby achieving structural homogeneity while maintaining improved mechanical properties.
2Ease of manufacture
If traditional lost pattern process is used, then the production cost is low, but the metal part has high porosity and insufficient fine structure
Solution Approach 1:
The patent applies preliminary action by pre-coating the lost model with thermosetting material before casting. This preparatory step ensures that free faces are equipped with cooling capability in advance, which actively promotes fine structure formation during casting. This preliminary intervention maintains the simplicity and low cost of the lost pattern process while significantly improving the fine structure quality of the resulting metal part.
3Device complexity
If cooling elements are positioned only against support surfaces, then the process is simple, but the mechanical characteristics are poor due to inadequate cooling of free faces
Solution Approach 1:
The patent applies self-service by utilizing the thermosetting material's inherent properties to provide cooling functionality. The thermosetting material is applied to free faces and automatically provides cooling during the casting process without requiring additional active cooling systems. This self-service approach improves mechanical characteristics by enabling free face cooling while maintaining simplicity in the overall cooling system design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in metal parts with enhanced mechanical properties, low porosity, and fine structure, enabling the production of complex geometries at a lower cost compared to traditional methods, while minimizing environmental impact and optimizing production flexibility.
Implementation Method 1
a step of admitting a phase change element into contact with the thermosetting element
Implementation Method 2
the thermosetting element is introduced into contact with at least one free face that comprises the lost model
Implementation Method 3
a step of placing at least one cooler against a support surface that includes the lost model
Implementation Method 4
The lost model is sublimated when the liquid metal comes to replace it
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5f
AI summary
The invention relates to a method for obtaining a metal part from a lost pattern. The invention relates to a method for obtaining a metal part from a lost pattern (2) arranged inside a container (1). The method includes a step (A) of filling the container (1) with a filling material (3). The method includes a step (B) of placing a thermosetting element (7) in contact with at least one free surface (8) constituting the lost pattern (2).