EP0535421B1 - Method and device for manufacturing of component parts - Google Patents

Abstract

The invention relates to a method and devices for manufacturing component parts, in which molten metal is introduced into a mould cavity (1) formed by at least two mould halves (3, 4) and solidified under pressure. To create monitorable and controllable production conditions for optimisation of the product properties, it is envisaged, according to the invention, that the material to be liquefied, for example in the form of solid billets (11), be introduced into filling chambers (6) connected directly to the mould cavity (1) via large cross-sections (5) of flow with the aid of press plungers (7), melted, pushed further into the mould cavity (1), in a compact flow, with the aid of the press plungers (7) and, after complete closure of the mould cavity (1), made to solidify under pressure in the cavity. <IMAGE>

Description

The invention relates to a method and a device for producing components, in which liquid or partially liquid material is introduced into a mold cavity formed at least from two mold halves.

In the shaping of components from the liquid or partially liquid material state, a variety of different methods and devices are known, which more or less successfully meet the requirements placed on a high-quality workpiece with regard to freedom of design, surface quality and in particular optimal material properties with the most rational production possible .

The causes of defects are mainly the large number of manufacturing parameters, which usually come into effect at the same time in the shortest possible time, often with mutual influence, and thus largely elude both detection and regulation.

The manufacturing process essentially consists of only two steps. The first step is the preparation of the shaping tool and the melting of the material batch. In the second step, the melt is then transported from the separate furnace via distribution systems into the mold cavity, where it should solidify to the desired component under controlled thermal conditions and under sufficiently high supply pressure.

While the manufacturing parameters can still be checked relatively well in the first step and can also be optimized shortly before the actual shaping begins, the decisive second step leads to largely unsteady conditions, which lead to a wide range of parameters with serious effects on the product properties.

These fluctuations in the production conditions in the known casting processes are initially caused by the use of a free-falling pouring jet when transporting the melt from the melting furnace to the casting device and predominantly also when filling the mold. Here, intensive reactions with the gases in the atmosphere and the mold cavity occur, which lead to a marked reduction in the material quality. In addition, there are uncontrollable temperature losses on the pouring jet, which affects the mold filling and solidification conditions and also increases the risk of rejects during production. Further strong fluctuations in the mold filling conditions result from the uneven flow processes when using the free-falling pouring stream, which also influence the solidification process. A number of other parameters, which are also common in conventional manufacturing practice, are decisive for the solidification process of the workpiece in the mold are subject to large fluctuations. Particularly noteworthy here are the heat transfer conditions from the melt to the mold wall and the shrinkage and shrinkage processes coupled with the cooling and solidification of the melt and the solid body just formed. The latter are the cause of the defects that often occur in castings, such as cavities and shrinkage porosity, while the shrinkage of just solidified workpiece areas due to the formation of air gaps subjects the heat transfer into the mold wall to large fluctuations and impairs dimensional accuracy. In order to eliminate or minimize these errors, in particular by positioning feeders on the casting in connection with a solidification steering, a considerable manufacturing effort has to be made.

Finally, the component quality is determined by the additional occurrence of structural porosity, which is caused by the separation of gases dissolved in the melt, e.g. Hydrogen, or the inclusion of gases in the mold cavity during solidification is reduced.

In the known die casting process, the batch of alloy to be processed is melted in a separate premelting furnace and then transferred to the holding furnace on the die casting machine by means of transport pans. From there, the melt quantity required for a cast reaches the mostly horizontal shot chamber with a ladle or other metering device via a freely falling pouring jet, where the melt first forms a pool with a large surface area and cools down rapidly. For the casting process which is initiated immediately, the shot piston pushes the melt together in the shot chamber in accelerated movement, preferably avoiding splashes and air pockets, until it reaches the gate leading upwards into the mold cavity. From that point onwards the melt is sprayed at high speed into the mold cavity, which it fills in a fraction of a second. In this case, the inclusion of gas residues from the mold cavity in the structure of the very rapidly solidifying casting is practically unavoidable, which leads to the known disadvantages of the die-cast product, such as a lack of elongation, lack of weldability and curability.

In vacuum die casting, process variants are known in which the melt is sucked out of the holding furnace into the shot chamber in connection with the evacuation of the mold cavity before the shot. In addition to the disadvantages already encountered with standard die casting, especially with the horizontal shot chamber, additional melt formation occurs in the intake pipe due to the melt column falling back when the mold is opened, which leads to corresponding inclusions in the cast product. In addition, a vacuum application with certain melts (e.g. magnesium alloys) or alloy additives due to a higher vapor pressure can cause problems.

In the known low-pressure die-casting process, the melt is pressed from below into the casting mold from the holding furnace by means of gas pressure via a riser pipe and is held in the mold under a slight excess pressure of maximum 1 bar until the solidification is complete. This process enables a small amount of circulation in the cast production, but requires special measures against oxide formation in the riser pipe and, due to its convection-related long cycle times, proves to be disadvantageous compared to other casting processes.

In liquid pressing, press casting or displacement casting, the melt is poured from above with a freely falling pouring jet into an initially open die, the lower one Part of it completely or partially filled out. After removing the pouring trowel, a stamp moves into the die from above and displaces the melt to completely fill all the shape contours. The solidification takes place under the further pressure of the punch, so that a workpiece with a dense structure can be obtained if sufficient ventilation of the mold cavity has been achieved. This process could not prevail in production technology because it is cumbersome and time-consuming and only supplies simple, thick-walled workpieces.

The various pressure and pressure casting processes described above are known in particular from the Gießerei-Lexikon, 1991 edition, specialist publisher Schiele and Schön, Berlin.

In a device according to DE-PS 30 23 917, the melt is conveyed from a swiveling casting unit from below into a die. Disadvantages also appear here: the necessary filling of the casting chamber swung out together with the piston and drive via the free-falling pouring jet by means of scoop dosing from a separate holding oven, the additional steps of pivoting back and coupling the casting unit to the mold, and the complex and expensive overall construction.

From US-A-4 436 140 a device is known which is suitable for carrying out the classic vertical cold chamber die casting method. This device consists of two mold halves, with a gate system being used for the mold filling, which is fed via a filling chamber located laterally below the mold, which has a stamp for expressing the melt. The filling chamber is filled via a funnel-shaped sprue cup with a free falling pouring stream. In this case, disadvantageous temperature losses and oxide formation, air pockets and their swirling occur, which lead to the known problems with regard to the component properties. Following the filling of the chamber, a second piston is inserted into it, which closes the pouring opening of the pouring cup and serves to maintain a pressure after the mold has been filled. When the repressing pressure is applied, air is compressed at the same time, which in turn gets into the melt and thus into the casting mold and leads to disadvantageous air pockets. Both the mold filling and the recompression are effected via a gate system, which causes a deflection of the material flow during the filling process and thus also leads to disadvantageous turbulence and a flow restriction. This inevitably increases the injection pressure required. Another disadvantage is that the sealing feed must also take place via this gate, which is only possible for a limited time. This bleed also means that shrinkage can only be avoided to a limited extent by means of post-compaction, and particularly critical product areas such as, for example, material accumulations, cannot be influenced.

Finally, all the known methods have in common a lack of sufficient control options for the parameters that come into effect during the course of the method, so that the necessary narrowing of their spreading widths is hindered and the accuracy or reproducibility in product quality that is indispensable for rational production cannot be achieved.

The object of the present invention is to create a novel method and a novel device which enable the production of heavy-duty components, in particular also with large dimensions, complex shapes and multiple functions, in a compact system with tightest coupling and control of the production steps with simultaneous cycle shortening in a particularly efficient manner. In particular, the conditions for the processes during melting, mold filling and solidification are to be optimized, so that components with a particularly fine-grained and dense structure with a high degree of uniformity are obtained.

This object is achieved with the features of claim 1 or 21.

The method according to the invention is distinguished by a number of considerable advantages.

The charging bodies can be optimally matched to the component weight, so that the material expenditure which is considerable in the conventional working method is avoided. So there is the possibility that the plunger end face can be used as a molded wall part.

Since, according to the invention, the filling chamber is formed directly adjacent to the mold cavity, there are minimal transport or conveying paths for the melt, so that the disadvantages known from the prior art are avoided. First of all, there are no disadvantageous temperature fluctuations, uncontrollable oxide formation and loss of burn-up. Due to the possibility of suitable Setting mold filling temperatures in the filling chamber with the appropriate heating can also process supercooled or partially solidified material. Due to the large filling cross-sections and short flow paths, a strongly calmed mold filling with a compact melt volume is achieved without spraying and swirling. Since there is no atomization of the melt during mold filling due to the low filling pressure and the possible large cross-sections compared to the die-casting process, lost cores can also be used in a similar way to gravity die casting.

The present invention is furthermore suitable for introducing prefabricated solid bodies into the mold cavity which are to be connected to the melt material or to be integrated into the component. The solid bodies can consist, for example, of semi-finished profiles, which are then connected during the filling process by the melt, which then solidifies to form nodes. The possible melting of the profile ends to be connected ensures an optimal bond. In this way, the production of larger frame structures is made possible, for example, for chassis or body construction. Following the example of reinforced concrete structures, prefabricated reinforcements made of high-strength materials can be fixed in a suitable manner in the mold cavity and integrated into a heavy-duty component by the melt after solidification. In a similar way, it is possible to include packing elements remaining in the component for the production of box-shaped structures with high structural strength.

The application of metallic coatings or layers, fire-resistant reinforcements of combustion chamber walls are further examples of the various problem-solving options provided by composite materials using the new process and in particular the simultaneous filling of a mold cavity with melts from different materials. The latter also offers particular advantages in the manufacture of components with particular local stress. The distribution of several filling chambers over larger areas allows the production of particularly large shapes for correspondingly larger components or for the production of several parts at the same time.

In both cases, the flow paths are significantly shortened during mold filling, so that local overheating and areas that are too cool as well as a material-intensive, branched gate and feed system are avoided.

Further advantages lie in the possibility of dividing the filling chamber into a lower melting and an upper pressing area and then exchanging the melting chamber with the aid of an appropriate manipulator. If several melting chambers are assigned to the pressing chamber that is firmly connected to the mold, the melting time is shortened significantly on the one hand, and on the other hand rapid replacement is possible if wear occurs. The floor required for a mobile melting chamber can be realized in various ways, such as. B. Use of a movable disc, which may remain on the component with additional function; solid bottom on the melted charging body as a "plunger"; cup-shaped, non-melting casing of the charging body; additional plunger.

In addition, the subdivision of the filling chamber into the melting and pressing chamber enables the use of different materials for these different functional areas, for example ceramics or cermets for the melting chamber and hot-work steel for the pressing chamber. Finally brings also the possible use of highly refractory, electrically non-conductive materials for the melting chamber wall when using induction heating advantages.

For mold filling, it is particularly advantageous if, on the one hand, there are several large inflow openings for the melt directly in the mold cavity and, on the other hand, this is reduced to the specified component dimensions only while it is being filled, taking advantage of the respective component geometry, so that sufficiently large flow cross sections also in the mold cavity consist. This reduction in the volume of the mold cavity can take place, for example, by lowering a molded ball part and fully inserting core slides or suitable molded parts. These measures support the displacement effect of the plunger, shorten the flow paths and increase the filling speed. Impairment of the form filling capacity of the melt by cooling and partial solidification are avoided, so that the dreaded cold running problem is eliminated. The proposed complete closing of the mold immediately before the build-up of a higher pressure, as proposed at the end of the mold filling, also enables a free extraction for the gases which are present in the mold cavity or in contact of the melt with the mold wall size during the mold filling. These can escape before the melt flowing in compactly, so that the extremely disadvantageous gas inclusions occurring in known, similar processes in the component structure are prevented.

The solidification of the component, which increases after the mold filling, is known to cause a considerable volume deficit due to the solidification shrinkage, which considerably affects the component properties in the form of loosening of the structure, internal and external cavities and dimensional deviations can affect. In order to limit errors, material additions are required which are used in the prior art as feeders that solidify with the component. Experience has shown that their effectiveness is limited and the cost of materials is considerable. According to the invention, a more uniform material addition distributed over the component is more advantageous, which essentially starts at the end of the mold filling by increasing the mold space at the locations particularly suitable for this purpose, and the volume of which is reset to the desired component dimensions during the solidification. The required enlargement of the mold space can be achieved, for example, by an elastic bulge that can be regulated via the mold wall thickness, caused by pressure increase in the filler material, and limited by pressure elements, which then also provide the provision. With appropriate training, the pressure elements can also take on a cooling function and implement a solidification control by suitable timing of the activation. For the structural sealing feed during the solidification process, it is also advantageous if the melt located in the narrowing feed channels is moved. This can also be achieved with the help of the pressure elements in cooperation with the plunger by using pulsating pressure at a suitable frequency. The coordination of the above-mentioned measures results in an optimization of the solidification process and, last but not least, a clear reduction in cycle times due to the elimination of the disadvantageous early shrinkage from the mold wall with local interruption of the heat flow.

To start the process flow z. B according to FIG. 1, the charging bodies with the aid of a feed device and the plunger - in the case of multiple melting chambers also directly - transported into the melting chambers, which had previously been flushed with protective gas together with the press chambers and the mold cavity. After melting, the plungers push the melt through the press chambers to fill the mold into the mold cavity. This is initially opened to the outside in the sense of an optimized mold filling without spraying and gas interlacing with sufficiently large ventilation channels or, depending on the particular component geometry, is not yet completely closed at the beginning and during the mold filling. Thus, during the mold filling, the gases located in the mold cavity or additionally generated by the melt coming into contact with the mold release agent can completely escape upwards before the melt, which essentially flows in compactly from below, or can be suctioned off by applying negative pressure. If there is the possibility, with a suitable component geometry, that the mold can only be fully closed during mold filling, for example by lowering a bale part or completely retracting core slides, these measures also improve mold ventilation and further increase the filling speed due to the additional displacement effect with short flow paths . Both increase the mold filling capacity of the melt in a special way, so that the feared cold running risk is eliminated.

At the end of the mold filling, the mold is then completely closed, which in the case of use of ventilation channels by covering them takes place, for example, with the aid of slides, which can also stop any melt emerging. At this time, with the help of the plunger and other pressure elements installed in a suitable place in the mold walls, such as, for example, movable mold inserts, ejector pins or mold components a local elastic mold wall deformation to exert pressure, the cooling and solidifying component to compensate for the volume deficit caused by the solidification shrinkage under a corresponding pressing pressure. The melt volume required for the compensation is kept ready at the respective points of contact of the melt with the pressure elements by the enlargement of the mold space set there at the end of the mold filling.

The pressure can be from all pressure elements simultaneously, for. B. jerky, exercised and maintained until the component completely solidifies. However, a pressing pressure pulsating with a suitable frequency can also prove to be particularly advantageous for the sealing supply of the structure in complex-shaped components with larger wall thickness differences and material accumulations. Here, for example, two pressure transmitters can correspond to one another over a suitable distance in such a way that the melt is reversibly displaced during the solidification within a feed channel connecting them, which significantly improves the feed conditions. Finally, pressure transmitters can be used in conjunction with mold cooling, for example the swell sequence cooling according to DE-PS 26 46 060, which has been used successfully in the mold casting process, a significant reduction in cycle times being achievable.

Fig. 1

eine Seitenansicht, teilweise im Schnitt, eines ersten Ausführungsbeispieles der erfindungsgemäßen Vorrichtung,

Fig. 2

eine Seitenansicht, teils im Schnitt, eines zweiten Ausführungsbeispieles der erfindungsgemäßen Vorrichtung,

Fig. 3

ein weiteres Ausführungsbeispiel gemäß der Erfindung, bei dem die Füllkammer 2 in eine Preßkammer und eine Schmelzkammer unterteilt ist,

Fig. 4

ein weiteres Ausführungsbeispiel gemäß der Erfindung, bei dem das zu verarbeitende Material in einen Behälter eingesetzt, der Füllkammer zugeführt wird,

Fig. 5

ein Detail der Wandausbildung der Gießform mit einem die Wand verformenden Preßkolben und

Fig. 6

ein Detail der Wandausbildung der Gießform, bei dem die Wandverformung über ein Kühl-/Heizmittel erfolgt.

The invention is described below using exemplary embodiments in conjunction with the drawing, in which:

Fig. 1

a side view, partially in section, of a first embodiment of the device according to the invention,

Fig. 2

a side view, partly in section, of a second embodiment of the device according to the invention,

Fig. 3

another embodiment according to the invention, in which the filling chamber 2 is divided into a press chamber and a melting chamber,

Fig. 4

a further embodiment according to the invention, in which the material to be processed is inserted into a container which is fed to the filling chamber,

Fig. 5

a detail of the wall formation of the mold with a plunger deforming the wall and

Fig. 6

a detail of the wall formation of the casting mold, in which the wall deformation takes place via a coolant / heating medium.

In the exemplary embodiment according to FIG. 1, the mold cavity is formed by an upper mold part 3 and a lower mold part 4. The upper mold part 3 is fastened to a clamping plate 15 and is arranged such that it can be displaced in height by means of a locking device 10 in the form of a toggle lever. The toggle lever is actuated via a hydraulic drive 16 which is attached to the machine frame 9b.

The lower mold part 4 is carried by the machine frame 9a and has 3 openings 5 on its underside, via which the liquefied material is pressed into the mold cavity 1. Filling chambers 2 are connected to the openings 5 and penetrate the machine frame 9 and form two regions, namely an upper pressing chamber 23 and a lower melting chamber 24.

Below the filling chambers 2 there is a feed table 12 for feeding blanks 11 into the filling chambers 2.

The blanks 11 are introduced into the melting chamber 24 with the aid of plungers 7, each plunger 2 being assigned a plunger 7. The plungers 7 are arranged on a plunger plate 18 which is displaced via a hydraulic drive 17 which is fastened to the machine frame 9c. The blanks 11 are, as shown in Fig. 1, pushed over the downward moving plunger and inserted into the melting chamber 24 via this. After the blanks have melted, the melt is moved upwards into the press chamber 23 by means of the plunger 7, whereupon the latter can exit into the mold cavity 1. Because of the large cross sections of the openings 5, this insertion can take place without great turbulence and with a relatively low pressure. In this embodiment, the upper part of the mold is lifted slightly from the lower part of the mold, so that the air in the mold cavity can escape through the gap between the upper part 3 and the lower part 4. After the mold has been completely filled, the upper part 3 is sealingly lowered onto the lower part 4, whereupon the melt solidifies with the application of the high pressure, for example by the plunger 7.

The melting chamber 24 is advantageously heated via an induction heater 8, with the hollow cylinder consisting of high-strength steel having to pass through both areas in the case of a one-piece design of the filling chamber 2 as a pressing chamber and melting chamber.

In the exemplary embodiment according to FIG. 2, the blank 11 or the charging bolt is melted in a low-pressure melting furnace 13, with the blanks 11 being a Feed pipe 21 are introduced into the furnace 13. The feed pipe 21 is sealed by means of a seal 26 which is arranged between the blank 11 and the inner wall of the feed pipe 21. Via a riser pipe 14, which is provided with a level sensor 22, the melt is pressed into the filling chamber 6 via an opening 20. After the filling chamber 6 has been filled, the plunger 7 is moved upward, the opening 20 being closed, so that no further material can flow into the filling chamber 6. The melt material 19 is then pressed through the openings 5 according to FIG. 1 into the mold cavity.

The melting and dosing device according to FIG. 2 is also particularly suitable for the production of particularly large components with increased material requirements. Here, the melt can be pressed from the melting furnace 13 through the metering gap 20 and the filling chamber 6 into the mold cavity, in which case the plunger 7 merely ends the mold filling and takes over the make-up - if necessary in conjunction with further pressure elements in the mold wall. When using a plurality of filling chambers 6, these can be supplied with melt via branches or multiple arrangement of the filling tube 14.

3, the same parts are provided with the same reference numerals. This embodiment differs from that of FIG. 1 essentially in that the filling chamber 2 is formed in two parts and is divided into a separate press chamber 23 and melting chamber 24. The melting chamber 24 can be displaced relative to the pressing chamber 23, so that the melting process of the blank 11 can take place elsewhere, wherein the individual melting chambers can, for example, also be arranged in a carousel. This is advantageous because this can significantly increase the performance of the casting device, because the melting time no longer extends the mold filling and solidification time for the manufacture of the component. In addition, the inner sleeve of the melting chamber 24 can also be produced from an insulating material which then does not necessarily have to withstand high compressive forces. This sleeve made of insulating material 27 is then surrounded by the induction heater 8.

Since the plunger 7 is inserted into the movable melting chamber from below, either a displaceable base 28 must be inserted into the melting chamber, which prevents the melting material from escaping, or the heating device is arranged so that the lower area of the blank does not melt, so that the blank itself forms the bottom closure.

An insulating ring 29 is arranged to hinder the flow of heat from the melting chamber 24 into the plate 9a.

Bores 31, which are arranged in the wall of the lower mold part 4 or the upper mold part 3, are used to vent the mold cavity 1 when the melt material is inserted. These openings 31 are then closed by a slide 32 which is actuated by the displacement of the platen 15 into the closed position.

Furthermore, the upper mold part 3 is supported by a spring 33 with respect to the platen 15. This spring has the effect that, on the one hand, the upper mold part rests with sufficient pressure on the lower mold part 4 during mold filling, but on the other hand the openings 31 are not yet closed by the slide 32. After the openings 31 have been closed and during solidification under high pressure, the clamping plate 15 lies with the slide plate 41 frictionally on the upper mold part 3, so that the upper mold part and lower mold part are then pressed against one another with the desired pressure.

The pressure maintained during the solidification process can be applied either by the plunger 7 or by a further plunger 30, whereby a reversible flow of the melt in the mold cavity 1 can also be obtained by the interaction of both pistons during the solidification process.

4, the same parts are provided with the same reference numerals. This embodiment differs from that according to FIG. 3 in that the charging material is introduced into the melting chamber 24 in a cup 35 made of refractory material and is melted therein. Following this, the cup including all or part of the melted material is pushed into the press chamber 23 by means of the plunger 7. The actual introduction of the melt material into the mold cavity 1 then takes place by means of a plunger 34 which dips into the cup from above, the melt being displaced from this and reaching the mold cavity 1 between the piston wall and the cup inner wall.

The exemplary embodiment according to FIG. 5 shows a wall section 36, for example of the upper or lower mold part, this wall section 36 being formed from a relatively thin material, so that it deforms during the filling process of the mold cavity 1. Arranged behind this flexible wall section 36 is a plunger 37 which can be provided, for example, with bores 38 for a coolant or heating medium. During the solidification process the plunger 37 is pressed against the flexible wall section 36, so that the pressure in the material can be maintained even during the solidification process.

The embodiment according to FIG. 6 likewise shows a flexible wall section 36, behind which a pressure chamber 39 is arranged. This wall section can also be deformed away from the mold space - to enlarge it - during the mold filling, this deformation then being reversed again during the solidification process due to a pressure medium introduced through a pipe 40, wherein a deformation of the wall section 36 towards the molding space is likewise obtained can. These enlargements of the mold space at the suitable component areas at the end of the mold filling and the corresponding reductions during solidification by the device examples according to FIGS. 3, 5 and 6 compensate for the volume deficit in the component caused by the solidification shrinkage. The pressure medium can also be used for cooling or heating the corresponding wall section 36.

All of the measures described can be optimized and coordinated using computer-aided measurement and control technology and thus brought about a special synergy effect.

Claims (37)

1. A method for manufacturing component parts, in which fluid or partially fluid substance is poured into a mould cavity formed from at least two mould halves, wherein the material in at least one filling chamber directly below the mould cavity is brought to a level of consistency suitable for mould filling, is subsequently conveyed uphill into the mould cavity which is - for the purpose of ventilation - not yet fully closed, and is held therein, after the mould cavity is closed during hardening, at a pressure which is adjustable in a locally varying manner.
2. A method according to Claim 1, characterised in that the substance to be reduced to a fluid state is feed into the filling chamber in a solid form.
3. A method according to Claim 1, characterised in that the material is feed into the filling chamber in fluid form.
4. A method according to any one of Claims 1 to 3, characterised in that parts of the mould are at least partially open at the start of filling, and are completely closed towards the end of mould filling.
5. A method according to any one of Claims 1 to 4, characterised in that at least one mould half has ventilation ducts which are closed at the end of mould filling.
6. A method according to any one of Claims 1 to 5, characterised in that the latest time that the mould space volume is increased in comparison with the volume of the solidified component part is towards the end of mould filling, and during solidification the increase in volume is cancelled.
7. A method according to any one of Claims 1 to 6, characterised in that for sealed feeding of the component structure during solidification, the pressure is altered intermittently.
8. A method according to Claim 7, characterised in that when a plurality of pressure members are used which have pressure surges co-ordinated with each other to such an extent that the melt in the feed ducts during solidification is moved in a reversible manner.
9. A method according to any one of Claims 1 to 8, characterised in that the mould halves are cooled.
10. A method according to any one of Claims 1 to 9, characterised in that a plurality of cooling zones are activated in the mould halves according to the expansion sequence cooling principle.
11. A method according to Claim 10, characterised in that the cooling zones in the mould are activated in co-ordination with the pressure members fitted into the wall of the mould halves.
12. A method according to either Claim 10 or 11, characterised in that that cooling members and pressure members are combined to form a functional unit.
13. A method according to any one of Claims 1 to 12, characterised in that when a plurality of filling chambers are used, they are charged with different materials.
14. A method according to any one of Claims 1 to 13, characterised in that the substance to be melted or the melt is charged into the filling chamber in a cup-shaped shell made of fire-resistant material, and is displaced therefrom, for mould filling, by a plunger moving downwardly from or with the mould upper section.
15. A method according to Claim 14, characterised in that a filled cup is inserted into the filling chamber by a plunger forming an abutment during pressing.
16. A method according to any one of Claims 1 to 15, characterised in that the filling chamber is subdivided into a melting and pressing area.
17. A method according to any one of Claims 14 to 16, characterised in that conveying of the cup is performed by the plunger.
18. A method according to any one of Claims 1 to 17, characterised in that solid structures are inserted into the mould cavity, fixed and - by pouring in the melt - are connected to each other or are integrated in the component.
19. A method according to any one of Claims 1 to 18, characterised in that the charging structures remain in a solid state in the region of their lower end surface during melting in the filling chamber.
20. A method according to any one of Claims 1 to 18, characterised in that the melt in the filling chamber is metered with the aid of regulation of the gas pressure above the melt level in the oven and also [with] the volume of the charging structure insert in conjunction with a level sensor.
21. A device for manufacturing component parts, in particular according to the method according to any one of Claims 1 to 20, with a mould cavity (1) which is formed of at least one mould upper part (3) and a mould lower part (4), wherein the bottom of the mould lower part (4) is provided with at least one opening (5) which is directly connected to a filling chamber (6) which is fillable with charging material, has contents displaceable by a plunger (7) and is provided with a heating mechanism (8), and wherein the material contained in the mould cavity (1) can be pressurised by way of a plurality of pressure members (17, 7; 30; 36, 37; 34), and the device is provided with a closable ventilation opening (3, 4, 31).
22. A device according to Claim 21, characterised in that a plunger (7) can be inserted into the filling chamber (6) vertically from below.
23. A device according to either of Claims 21 or 22, characterised in that a plurality of openings (5) each connected to a filling chamber (6) are formed on the mould lower part (4).
24. A device according to any one of Claims 21 to 23, characterised in that the mould lower part (4) is connected to the rigid clamping plate (9) of the device, while the mould upper part (3) is arranged on the clamping plate (15) so as to be vertically movable, and is provided with closing means (10).
25. A device according to any one of Claims 21 to 24, characterised in that the filling chamber (6) is provided with an induction heating mechahism (8).
26. A device according to any one of Claims 21 to 25, characterised in that the filling chamber (6) consists of several parts (melting and pressing part) and may be formed from different materials.
27. A device according to any one of Claims 21 to 26, characterised in that a solid charging structure (11) can be brought to the filling chamber (6) using feed means.
28. A device according to Claim 27, characterised in that the feed means is connected to a magazine and comprises a feed table (12).
29. A device according to any one of Claims 21 to 28, characterised in that a plurality of movable melting chambers (24) each provided with a heating mechanism (8) are associated, as parts of the filling chambers (6), with one of the plungers (7).
30. A device according to any one of Claims 21 to 29, characterised in that the plunger (7) is displaceable together with a melting chamber (24) between a rigid clamping plate (9a) and a plunger plate (18).
31. A device according to Claim 29 or 30, characterised in that the filling chamber (6, 24) is provided with a displaceable bottom (28).
32. A device according to any one of Claims 21 to 26, characterised in that the melt (19) can be poured into the filling chamber (6) by means of a filling pipe (14) from a melt furnace (13) which is supplied with solid charging material by way of a feed pipe (21) with sealing (26).
33. A device according to any one of Claims 21 to 32, characterised in that the end surface of the plunger (7) is, in its final position, a shaping surface of the mould cavity (1).
34. A device according to any one of Claims 21 to 33, characterised in that the mould cavity (1) is provided with ventilation openings (31) which are closable, with slide-shaped closing members (32), at the end of mould filling.
35. A device according to any one of Claims 21 to 34, characterised in that at least one part of the mould wall (36) is flexibly constructed, and can be pressurised on the side facing away from the mould cavity (1) by means of pressure members (30, 37, 39, 40).
36. A device according to Claim 35, characterised in that the pressure members (30, 37, 39, 40) are provided with a cooling mechanism and/or heating mechanism (38, 39, 40).
37. A device according to any one of Claims 21 to 36, characterised in that for improving mould filling, vibrators are attached to the mould wall.

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