Lost Core - neue Perspektiven im Druckguss

Dario Pierri, Bhler AG

1 | Bhler | FHNW Giessereitag 2013

Introduction to Lost Core Technology.

Basic Idea of Lost Core Technology.
Using lost cores in the HPDC process to create undercuts or fluid ducts. Integrating additional functions in HPDC parts. Reducing machining, sealing and assembling.

INNOVATIVE TECHNICAL SOLUTIONS WITH LOST CORE TECHNOLOGY.

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Introduction to Lost Core Technology.

Overview of Different Lost Core Technologies.

Lost Core Technologies

Other Technologies
Melt Out Gas Injection Tubes

Sand Cores

Salt Core Technologies

Inorganic

Organic

Croning

Solid Phase

Liquid Phase

Coatings Pressed

Shot Blast

Semisolid

100% Liquid

Sintered or not Sintered

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Introduction to Lost Core Technology.

Properties of Salt Core Technology.

PROPERTIES
Smooth surface quality. High resistance to heat. Water soluble. Thermal insulator.

ADVANTAGES
No use of chemical binders. No use of coating. No use of toxic salts.

CHALLENGES
Ceramic behavior (brittle). Needs to be demolded for HPDC process. Limited in volume dimensions.

EXAMPLES

3D-Freiformflchen Projekt 3D-Free-form Surfaces Project

Volkswagen AG Volkswagen AG

BOCAR Bhler AG

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Salt Core Simulation.

Material properties of salt mixture.

Material property Solidustemperature Liquidustemperature Density Specific heat Thermal conductivity Latent heat of fusion Thermal expansion Viscosity Youngs Modulus Poisson ratio Avg. bending strength

Solid 2.3 2.5 kg/dm3 1.0 1.4 kJ/kg*K 2 - 4 W/m*K 4e-05 6e-05 K-1 > 10000 N/mm2 0.18 0.24 > 18 MPa

Liquid ca. 640C ca. 690C 1.7 1.9 kg/dm3 1.6 1.9 kJ/kg*K 1 - 2 W/m*K ~ 400 kJ/kg 1 - 2 mPas salt core specimen

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Possibilities of simulation.
Simulation with materials salt and aluminum.

Salt Core Production

Design of gating and venting system (salt die) Pre-check of shot profile Check of solidification

Aluminum Casting
Design of gating and venting system Check of flow circulation around salt core

FSI Simulation
Fluid-Structure-Interaction: Calculation of forces affecting the salt core during filling process

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Aluminum Simulation.
Results of FSI Simulation.
Prediction of stresses on core surface by using Fluid Structure Interaction Simulation. Comparison of impact due to different ingate velocities.
Velocity 2 ~ 80 m/s

Velocity 1 ~ 40 m/s

Velocity 3 ~ 120 m/s

Finite Elements Method - Mesh (FEM)

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Part and Die Design for Lost Core Technology.

Salt core
Research of Shrinkage behavior. Part design of salt core.

Die design for salt core production

Gating system design for salt core. Thermo balance of the salt core die. Salt core positioning before aluminum casting
HPDC die; Symposium sample

New design ideas for HPDC parts

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Process steps.
Overview of production chain.

Mixing

Dosing

Stock / Quality

Insert Salt Core Aluminium Casting Salt Core removal / recycling

Salt stock

Melting

Salt Casting

Quality check

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Process steps
Salt Mixing, melting and dosing.
Mixing:
Salt mixture is mixed in the furnace by

dosing contemporarly the different salts.

Mixing

Dosing

Mixture ratio is dosed with Bhler micro-

dosingscale.

Salt stock

Melting

Melting & Dosing:

holding furnace / ladler. dosing furnace.

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Process steps.
Salt core casting out of liquid phase

Mixing

Dosing

Stock / Quality

Insert Salt Core Aluminium Casting Salt Core removal / recycling

Salt stock

Melting

Salt Casting

Quality check

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Process steps.
Salt core casting out of liquid phase - Movie

Movie

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Process steps.
Aluminum casting with salt core inlay.

Mixing

Dosing

Stock / Quality

Salt Core inlay Aluminum Casting Salt Core removal / recycling

Salt stock

Melting Salt Casting

Quality check

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Process steps.
Aluminum casting with salt core inlay.

The correct support of the salt core in the die is relevant know-how. FSISimulation optimises the second phase (filling phase). Shot is real-time controlled. This is very important in order to avoid

the breaking of the inserted salt core and to guarantee a high reproducibiltiy of the shot.

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Process steps.
Removing of salt core

Mixing

Dosing

Stock / Quality

Salt Core inlay Aluminium Casting Salt Core removal / recycling

Salt stock

Melting Salt Casting

Quality check

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Process steps.
Removing of salt core
Requirements for a core-removing unit: 100% removing of salt.

No damage of the aluminum part.

Low cycle time.

Energy and resource saving.

Cut through the aluminium part after removing the salt core

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Process steps.
Removing of salt core
Different geometries of salt cores are removable with water-jet: blind hole. curved channels.
Examples for removed cores.

Values for 3-cylinder engine block: Process values: Removal time Water consumption Water pressure Water temperature 90 sec 30 - 40 l max. 600 bar 20C

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Salt recycling.
Reduce impact on environment and process costs.
Salt water Only a little percentage of salt is dissolved during the removing process. Salt content in water after removing <1%. Saltwater can be reused for the removing of salt cores. Residual water has to be neutralised (pH<8.0) before it flows into the drain. Salt Runner system is remelted Part of the removed salt is also remelted.

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Summary.
Process chain and necessary machines for Lost Core production.
Mixing Melting&Dosing Salt Core Casting Aluminium Casting Core Removing

Ladler or dosing furnace

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Thank you.

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Backup

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Why is Bhler developping Lost Core technology?

Existing processes (e.g. Mercury Marine, Yamaha)

were developed only for their own needs.

At the moment there isnt an equipment

manufacturer that is able to provide a complete solution for industrial process with high efficiency.

Bhlers focus is to provide the necessary

equipment for the Lost Core technology that is suitable for industrial process with high efficiency.

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Patents
With our patents we protect the process and the mixture in order to guarantee the freedom to operate of our customers. Patent on process for salt core production Patent on salt mixture Patent on removal process

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Aluminum Simulation.
Results of FSI Simulation.
Ingate velocity has an influence on core viability. Intensification pressure may not be applied before the cavity is filled completely.
5.00E+07 4.50E+07
Mean Iso Stress @ 0.7 m/s Mean Iso Stress @ 1.4 m/s Mean Iso Stress @ 2.1 m/s Ingate Velocity @ 0.7 m/s Ingate Velocity @ 1.4 m/s Ingate Velocity @ 2.1 m/s

140 120 100 80 60 40 20 0 2.220

Mean Iso Stress [Pa]

3.50E+07 3.00E+07 2.50E+07 2.00E+07 1.50E+07 1.00E+07 5.00E+06 0.00E+00 2.170

2.180

2.190

2.200

2.210

Filling Time t [s]

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Ingate Velocity [m/s]

4.00E+07

Calculation for cost effectiveness.

Example for cost calculation
1. Casting of salt cores
Formkosten pro Salzkern Giesskosten pro Salzkern Material- und Schmelzkosten pro Salzkern 0.41 EUR 1.20 EUR 0.49 EUR

Kosten pro Salzkern

2.10 EUR

2. Overcasting with aluminium Cost calculation done by the customer. Comparable to standard DC with inserts. 3. Core removing
Werkzeugkosten pro Salzkern Entkernungskosten pro Salzkern Wasserverbrauchkosten pro Kern Sondermll Entsorgungskosten pro Kern (0.7kg) 0.18 0.71 0.11 0.22 EUR EUR EUR EUR

Kosten pro Entkernung

1.22 EUR

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Calculation for cost effectiveness.

To ensure market penetration the salt core technology has to have
lower process costs than alternative process (e.g. gravity casting with sand cores).

We calculated the process costs of different parts. The cost

effectiveness is promising.

Water outlet in gravity casting with sand core

Water outlet in HPDC with salt core

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Technology substitutions or fully new parts.

Lost Core

Process substitution

Application on existing technologies

New parts

permanent mold. sand casting.

low pressure die casting. permanent mold. injection molding.

Vision.

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