WO2005051567A1 - Moulding composition - Google Patents
Moulding composition Download PDFInfo
- Publication number
- WO2005051567A1 WO2005051567A1 PCT/GB2004/004776 GB2004004776W WO2005051567A1 WO 2005051567 A1 WO2005051567 A1 WO 2005051567A1 GB 2004004776 W GB2004004776 W GB 2004004776W WO 2005051567 A1 WO2005051567 A1 WO 2005051567A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- moulding composition
- composition according
- mould
- lubricant
- pattern
- Prior art date
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
- B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives
- B22C1/14—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives for separating the pattern from the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
- B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
- B22C1/18—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents
- B22C1/181—Cements, oxides or clays
Definitions
- This invention relates to moulding compositions, and more particularly to a moulding composition and a method of manufacture for the production of a mould for metal casting.
- gypsum or plaster moulds for the manufacture of intricate, high surface quality metal castings is well-known.
- aluminium alloy impeller blades for automotive turbochargers, pumps and fans which often have severe undercut portions, can be cast successfully in disposable plaster moulds which are broken after the metal has solidified to extract the casting.
- Investment casting wherein the mould is manufactured using the lost-wax process, can be employed for casting metal articles in small quantities, but is unsuitable for high volume production of aluminium alloy castings.
- the pattern for the mould is usually a re-usable, flexible shaped rubber member. A slurry of the plaster in water is poured around the rubber pattern and allowed to dry and harden.
- the rubber pattern is extracted from the hardened plaster mould to leave a mould cavity of the required shape.
- intricate designs, such as impeller blades it is often difficult to remove the rubber pattern without damaging either the pattern or the mould. Frequently the fine detail of the internal cavity is disturbed, leaving defects that are not discovered until the metal casting is revealed.
- a lubricant can facilitate the removal of the pattern from the metal casting mould.
- the present invention provides a moulding composition for the production of a mould for metal casting from a pattern, wherein the composition comprises an effective amount of a particulate, water- insoluble lubricant, the lubricant being selected such that it does not evolve deleterious quantities of gases or vapours at the casting temperature of the metal.
- the invention provides a method of manufacture of a mould for metal casting, wherein a slurry of a moulding composition is disposed around a flexible pattern and allowed to harden to produce a mould, which method comprises including in the moulding composition an effective amount of a solid, water-insoluble lubricant such that separation of the pattern from the mould is facilitated.
- the invention also provides a method of metal casting using a mould produced from a moulding composition and/or by a method of manufacture according to the invention and a cast metal article produced therefrom.
- the moulding composition is preferably an inorganic composition, although moulding compositions derived from hardenable organic polymeric compounds are not excluded.
- hardenable organic compounds can include, for example, polyacrylates and glass iono ers, comprising, for example, metal oxides and polyacrylic acid.
- the moulding composition comprises one or more finely- divided particulate inorganic water-hardenable materials, for example, gypsum, calcined gypsum, plaster of Paris, anhydrous calcium sulphate, wollastonite, cement, lime, other similar plaster-forming materials, and mixtures thereof.
- the moulding composition can also contain inorganic aggregates and inert fillers, for example, sand, perlite, magnesium oxide and vermiculite; inorganic fibres, for example glass, alumina or boron carbide fibres; and organic fillers, for example, wood particles and fibres.
- inorganic aggregates and inert fillers for example, sand, perlite, magnesium oxide and vermiculite
- inorganic fibres for example glass, alumina or boron carbide fibres
- organic fillers for example, wood particles and fibres.
- the moulding composition comprises from 70 to 99.9 % by weight calcined gypsum.
- the moulding composition comprises from 0 to 30 % by weight wollastonite, and 0 to 5 % by weight cement.
- the moulding composition is preferable one that hardens on contact with water, although other liquids, for example, organic liquids, are not excluded.
- the moulding composition ⁇ s preferably used in the form of a slurry, which can comprise, for example, a mixture of from 30 to 70 % by weight of particulates .
- the moulding composition can comprise foaming agents or other pore-forming materials for introducing porosity into the mould.
- foaming agents or other pore-forming materials for introducing porosity into the mould.
- Such materials are, however, not always advantageous, and, for example, an improved casting apparatus and method using a relatively impermeable plaster mould is described in our co-pending UK patent application No.039805.6.
- pore- forming additives are omitted and the resultant mould is relatively impermeable to gases .
- the water-insoluble lubricant is preferably an inorganic lubricant, since these are less likely to evolve deleterious gases at the pouring temperature of the molten metal.
- Suitable lubricants include, for example, bentonite, various clays, graphite, boron nitride, molybdenum disulphide and. mixtures thereof.
- Organic lubricants which could also be used include metal stearates, paraffin or microcrystalline waxes, and higher molecular weight polyethylene glycols . Very good results have been obtained using bentonite, which is the preferred lubricant for the present invention.
- a particularly preferred moulding composition in accordance with the invention comprises calcined gypsum, cement, inorganic inert fillers and bentonite.
- the moulding composition comprises from 0.1 to 5% of the lubricant, by weight of solids content, more preferably from 0.5 to 4% by weight, and most preferably from 1 to 3% by weight.
- the pattern is preferably a shaped, flexible member, more especially a flexible natural or synthetic rubber member.
- the flexibility of the pattern, together with the presence of the lubricant enables the pattern to be deformed and removed from the hardened mould, even when there are severe undercut regions in the mould cavity.
- a plaster moulding composition was prepared by mixing 87 % by weight calcined gypsum plaster with 12 % by weight wollastonite and 1 % by weight cement. All percentages are based on the total weight of the composition (without water addition) . Bentonite was then added to the composition as a lubricant, in amounts of 0.5%, 1 %, 2 % and 5 % by weight respectively, based on the total weight of the composition.
- a flexible rubber pattern in the shape of an impeller blade was placed in an open vessel and the vessel filled with the slurry. After allowing the slurry to dry and harden the rubber pattern was removed to expose the mould cavity.
- the mould was filled with aluminium alloy in a standard casting method and after quenching a high quality impeller blade was produced. It was found that the presence of the bentonite lubricant made separation of the rubber pattern from the mould much easier than when the lubricant was omitted. In addition, far less finishing work was required on the aluminium casting" .
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Lubricants (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Abstract
A particulate,inorganic water hardenable, material based moulding composition for the production of a mould for metal casting from a pattern, wherein the composition comprises an effective amount of a particulate, water-insoluble lubricant, the lubricant being selected such that it does not evolve deleterious quantities of gases or vapours at the casting temperature of the metal.
Description
MOULDING COMPOSITION
This invention relates to moulding compositions, and more particularly to a moulding composition and a method of manufacture for the production of a mould for metal casting.
The use of gypsum or plaster moulds for the manufacture of intricate, high surface quality metal castings is well-known. For example, aluminium alloy impeller blades for automotive turbochargers, pumps and fans, which often have severe undercut portions, can be cast successfully in disposable plaster moulds which are broken after the metal has solidified to extract the casting. Investment casting, wherein the mould is manufactured using the lost-wax process, can be employed for casting metal articles in small quantities, but is unsuitable for high volume production of aluminium alloy castings. In the latter case, the pattern for the mould is usually a re-usable, flexible shaped rubber member. A slurry of the plaster in water is poured around the rubber pattern and allowed to dry and harden. Subsequently the rubber pattern is extracted from the hardened plaster mould to leave a mould cavity of the required shape. With intricate designs, such as impeller blades, it is often difficult to remove the rubber pattern without damaging either the pattern or the mould. Frequently the fine detail of the internal cavity is disturbed, leaving defects that are not discovered until the metal casting is revealed.
According to the present invention, it has surprisingly been found that the provision of a lubricant can facilitate the removal of the pattern from the metal casting mould.
In a first aspect, the present invention provides a moulding composition for the production of a mould for metal casting from a pattern, wherein the composition comprises an effective amount of a particulate, water- insoluble lubricant, the lubricant being selected such that it does not evolve deleterious quantities of gases or vapours at the casting temperature of the metal.
In another aspect, the invention provides a method of manufacture of a mould for metal casting, wherein a slurry of a moulding composition is disposed around a flexible pattern and allowed to harden to produce a mould, which method comprises including in the moulding composition an effective amount of a solid, water-insoluble lubricant such that separation of the pattern from the mould is facilitated.
In still further aspects, the invention also provides a method of metal casting using a mould produced from a moulding composition and/or by a method of manufacture according to the invention and a cast metal article produced therefrom.
The moulding composition is preferably an inorganic composition, although moulding compositions derived from hardenable organic polymeric compounds are not excluded. Such hardenable organic compounds can include, for example,
polyacrylates and glass iono ers, comprising, for example, metal oxides and polyacrylic acid. Preferably, however, the moulding composition comprises one or more finely- divided particulate inorganic water-hardenable materials, for example, gypsum, calcined gypsum, plaster of Paris, anhydrous calcium sulphate, wollastonite, cement, lime, other similar plaster-forming materials, and mixtures thereof. The moulding composition can also contain inorganic aggregates and inert fillers, for example, sand, perlite, magnesium oxide and vermiculite; inorganic fibres, for example glass, alumina or boron carbide fibres; and organic fillers, for example, wood particles and fibres.
Preferably the moulding composition comprises from 70 to 99.9 % by weight calcined gypsum. Preferably the moulding composition comprises from 0 to 30 % by weight wollastonite, and 0 to 5 % by weight cement.
The moulding composition is preferable one that hardens on contact with water, although other liquids, for example, organic liquids, are not excluded.
The moulding composition ±s preferably used in the form of a slurry, which can comprise, for example, a mixture of from 30 to 70 % by weight of particulates .
If desired, the moulding composition can comprise foaming agents or other pore-forming materials for introducing porosity into the mould. Such materials are, however, not always advantageous, and, for example, an improved casting apparatus and method using a relatively impermeable plaster mould is described in our co-pending UK
patent application No.039805.6. In a preferred moulding composition according to the invention, therefore, pore- forming additives are omitted and the resultant mould is relatively impermeable to gases .
The water-insoluble lubricant is preferably an inorganic lubricant, since these are less likely to evolve deleterious gases at the pouring temperature of the molten metal. Suitable lubricants include, for example, bentonite, various clays, graphite, boron nitride, molybdenum disulphide and. mixtures thereof. Organic lubricants which could also be used include metal stearates, paraffin or microcrystalline waxes, and higher molecular weight polyethylene glycols . Very good results have been obtained using bentonite, which is the preferred lubricant for the present invention.
A particularly preferred moulding composition in accordance with the invention comprises calcined gypsum, cement, inorganic inert fillers and bentonite.
Preferably the moulding composition comprises from 0.1 to 5% of the lubricant, by weight of solids content, more preferably from 0.5 to 4% by weight, and most preferably from 1 to 3% by weight.
In the method of the invention, the pattern is preferably a shaped, flexible member, more especially a flexible natural or synthetic rubber member. The flexibility of the pattern, together with the presence of the lubricant enables the pattern to be deformed and
removed from the hardened mould, even when there are severe undercut regions in the mould cavity.
The invention is illustrated by the following non- limitative Example:
EXAMPLE
A plaster moulding composition was prepared by mixing 87 % by weight calcined gypsum plaster with 12 % by weight wollastonite and 1 % by weight cement. All percentages are based on the total weight of the composition (without water addition) . Bentonite was then added to the composition as a lubricant, in amounts of 0.5%, 1 %, 2 % and 5 % by weight respectively, based on the total weight of the composition.
After thorough mixing of the constituents, in each case, 56 % by volume of the moulding composition was mixed with 44 % by volume of water to form a slurry.
In manufacturing the metal casting mould, a flexible rubber pattern in the shape of an impeller blade was placed in an open vessel and the vessel filled with the slurry. After allowing the slurry to dry and harden the rubber pattern was removed to expose the mould cavity. The mould was filled with aluminium alloy in a standard casting method and after quenching a high quality impeller blade was produced. It was found that the presence of the bentonite lubricant made separation of the rubber pattern from the mould much easier than when the lubricant was omitted. In
addition, far less finishing work was required on the aluminium casting" .
The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.
All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.
Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
The invention is not restricted to the details of any foregoing embodiments . The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
Claims
A moulding composition for the production of a mould for metal casting from a pattern, wherein the composition comprises an ' effective amount of a particulate, water-insoluble lubricant, the lubricant being selected such that it does not evolve deleterious quantities of gases or vapours at the casting temperature of the metal.
A moulding composition according to claim 1, which comprises finely-divided particulate inorganic water- hardenable materials .
3. A moulding composition according to claim 1 or 2, which comprises gypsum, calcined gypsum, plaster of Paris, anhydrous calcium sulphate, wollastonite, cement, lime, other similar plaster-forming materials, or a mixture thereof.
4. A moulding composition according to any one of the preceding claims, which comprises from 70 to 99.9 % by weight calcined gypsum.
5. A moulding composition according to any one of the preceding claims, which comprises from 0 to 30 % by weight wollastonite.
6. A moulding composition according to any one of the preceding claims, wherein the composition is in the form of a slurry comprising a mixture of from 30 to 70 % by volume of the composition in water.
7. A moulding composition according to any one of the preceding claims, wherein the water-insoluble lubricant is an inorganic lubricant.
8. A moulding composition according to claim 7, wherein the lubricant is bentonite, a clay, graphite, boron nitride, molybdenum disulphide or a mixture thereof.
9. A moulding composition according to claim 8, wherein the lubricant is bentonite.
10. A moulding composition according to any one of the preceding claims, which comprises calcined gypsum, cement, wollastonite, inorganic inert filler and bentonite .
11. A moulding composition according to any one of the preceding claims, which comprises from 0.5 to 4 % by weight of the lubricant, based on the total weight of the composition.
12. A method of manufacturing a mould for metal casting, wherein a slurry of a moulding composition is disposed around a pattern and allowed to harden to produce a mould, which method comprises including in the moulding composition an effective amount of a solid, water-insoluble lubricant such that separation of the pattern from the mould is facilitated.
13. A method according to claim 12, wherein there is used a moulding composition according to any one of claims 1 to 11.
14. A method according to claim 12 or 13, wherein the pattern is a flexible rubber pattern.
15. A method of metal casting using a mould produced from a moulding composition according to any one of claims 1 to 11.
16. A method of metal casting using a mould produced by a method according to any one of claims 12 to 15.
17. A cast metal article produced by a method according to claim 15 or 16.
18. A disposable mould produced from a moulding composition according to any one of claims 1 to 11.
19. A disposable mould produced by a method according to any one of claims 12 to 15.
20. A disposable mould according to claim 18 or 19 that is relatively gas impermeable.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0326999.0 | 2003-11-20 | ||
| GB0326999A GB2408260A (en) | 2003-11-20 | 2003-11-20 | Moulding composition including water-insoluble lubricant |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2005051567A1 true WO2005051567A1 (en) | 2005-06-09 |
Family
ID=29764128
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/GB2004/004776 WO2005051567A1 (en) | 2003-11-20 | 2004-11-10 | Moulding composition |
Country Status (2)
| Country | Link |
|---|---|
| GB (1) | GB2408260A (en) |
| WO (1) | WO2005051567A1 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| BR112021019380A2 (en) * | 2019-03-29 | 2021-12-07 | Goodwin Plc | Coating powders, methods for making a coating foundry paste and for making a casting and use of a composition as a coating powder |
Citations (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2389539A (en) * | 1943-07-23 | 1945-11-20 | Peerpatco Inc | Foundry composition |
| US3007803A (en) * | 1958-01-29 | 1961-11-07 | Noble | Casting plaster |
| US3641229A (en) * | 1970-07-01 | 1972-02-08 | Research Corp | Method of making a permeable ceramic mold used as a substitute for plaster of paris molds |
| GB1274113A (en) * | 1969-09-24 | 1972-05-10 | Tsniitmash | A liquid self-hardening mixture for the production of foundry cores and moulds and method for the production thereof |
| US3743692A (en) * | 1972-06-19 | 1973-07-03 | Chemotronics International Inc | Method for the removal of refractory porous shapes from mating formed materials |
| US4081283A (en) * | 1976-02-23 | 1978-03-28 | Pmcma Research Group | Plaster molding composition |
| US4541471A (en) * | 1983-05-06 | 1985-09-17 | Giulini Chemie Gmbh | Process for the production of precision castings by the gypsum-mold process |
| JPS6268650A (en) * | 1985-09-20 | 1987-03-28 | Toyota Motor Corp | Molding material for precision casting |
| JPH04329948A (en) * | 1991-04-30 | 1992-11-18 | Noritake Co Ltd | Baking method of cast mold of embedding material for dental use |
| FR2845988A1 (en) * | 2002-10-17 | 2004-04-23 | Microcast | Ceramic mixture with a refractory plaster base and charged with minerals to improve the strength of the refractory blocks used in precision casting operations for a wide range of industries |
Family Cites Families (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| NO118158B (en) * | 1965-10-22 | 1969-11-17 | Mitsubishi Heavy Ind Ltd | |
| GB1178363A (en) * | 1968-01-24 | 1970-01-21 | Ceskoslovenska Akademie Ved | Improvements in or relating to the Manufacture of Moulds for Use in Glass Shaping. |
| GB1232500A (en) * | 1968-12-23 | 1971-05-19 | ||
| CS155928B1 (en) * | 1972-02-15 | 1974-06-24 | ||
| US3966479A (en) * | 1973-02-27 | 1976-06-29 | Dentsply Research & Development Corporation | Dental investment material |
| GB2062605A (en) * | 1979-11-08 | 1981-05-28 | Grinham A | Cement composition |
-
2003
- 2003-11-20 GB GB0326999A patent/GB2408260A/en not_active Withdrawn
-
2004
- 2004-11-10 WO PCT/GB2004/004776 patent/WO2005051567A1/en active Application Filing
Patent Citations (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2389539A (en) * | 1943-07-23 | 1945-11-20 | Peerpatco Inc | Foundry composition |
| US3007803A (en) * | 1958-01-29 | 1961-11-07 | Noble | Casting plaster |
| GB1274113A (en) * | 1969-09-24 | 1972-05-10 | Tsniitmash | A liquid self-hardening mixture for the production of foundry cores and moulds and method for the production thereof |
| US3641229A (en) * | 1970-07-01 | 1972-02-08 | Research Corp | Method of making a permeable ceramic mold used as a substitute for plaster of paris molds |
| US3743692A (en) * | 1972-06-19 | 1973-07-03 | Chemotronics International Inc | Method for the removal of refractory porous shapes from mating formed materials |
| US4081283A (en) * | 1976-02-23 | 1978-03-28 | Pmcma Research Group | Plaster molding composition |
| US4541471A (en) * | 1983-05-06 | 1985-09-17 | Giulini Chemie Gmbh | Process for the production of precision castings by the gypsum-mold process |
| JPS6268650A (en) * | 1985-09-20 | 1987-03-28 | Toyota Motor Corp | Molding material for precision casting |
| JPH04329948A (en) * | 1991-04-30 | 1992-11-18 | Noritake Co Ltd | Baking method of cast mold of embedding material for dental use |
| FR2845988A1 (en) * | 2002-10-17 | 2004-04-23 | Microcast | Ceramic mixture with a refractory plaster base and charged with minerals to improve the strength of the refractory blocks used in precision casting operations for a wide range of industries |
Non-Patent Citations (2)
| Title |
|---|
| PATENT ABSTRACTS OF JAPAN vol. 011, no. 266 (M - 620) 28 August 1987 (1987-08-28) * |
| PATENT ABSTRACTS OF JAPAN vol. 017, no. 171 (C - 1044) 2 April 1993 (1993-04-02) * |
Also Published As
| Publication number | Publication date |
|---|---|
| GB2408260A (en) | 2005-05-25 |
| GB0326999D0 (en) | 2003-12-24 |
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