CA2582687A1 - Near liquidus injection molding process - Google Patents

Near liquidus injection molding process Download PDF

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Publication number
CA2582687A1
CA2582687A1 CA002582687A CA2582687A CA2582687A1 CA 2582687 A1 CA2582687 A1 CA 2582687A1 CA 002582687 A CA002582687 A CA 002582687A CA 2582687 A CA2582687 A CA 2582687A CA 2582687 A1 CA2582687 A1 CA 2582687A1
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CA
Canada
Prior art keywords
alloy
metal
molding process
injection molding
matrix composite
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002582687A
Other languages
French (fr)
Other versions
CA2582687C (en
Inventor
Frank Czerwinski
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Husky Injection Molding Systems Ltd
Original Assignee
Husky Injection Molding Systems Ltd.
Frank Czerwinski
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Husky Injection Molding Systems Ltd., Frank Czerwinski filed Critical Husky Injection Molding Systems Ltd.
Publication of CA2582687A1 publication Critical patent/CA2582687A1/en
Application granted granted Critical
Publication of CA2582687C publication Critical patent/CA2582687C/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/007—Semi-solid pressure die casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D25/00—Special casting characterised by the nature of the product
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/003—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using inert gases
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S164/00—Metal founding
    • Y10S164/90—Rheo-casting

Abstract

An injection-molding process for molding a metal alloy into a near net shape article that is characterized in that the processing temperature of the alloy at injection is approaching the liquidus, preferably having a maximum solids content of 5 %, whereby a net-shape molded article can be produced that has a homogeneous, fine equi-axed structure without directional dendrites, and a minimum of entrapped porosity. Advantageously, the resulting solid article has optimal mechanical properties without the expected porosity and solidification shrinkage attributed to castings made from super-heated melts. Also disclosed is a metal-matrix composite including a metallic component, and also including a reinforcement component embedded in the metallic component, the metallic component and the reinforcement component molded, at a near-liquidus temperature of the metallic component, by a molding machine.

Claims (36)

1. An injection-molding process for molding a metal alloy into a near net shape article including the following steps:
feeding the alloy into to an injection-molding apparatus having a heated barrel assembly;
transporting the alloy through a melt passageway in the barrel assembly with a screw feeder disposed therein and heating the alloy to a near-liquidus temperature of the alloy;
accumulating a volume of alloy in an accumulation portion of the barrel assembly;
controlling the near-liquidus alloy temperature in the accumulation portion to maintain the alloy in a state having a maximum solids content of less than 3%; and injecting the alloy to fill a mold of pre-defined shape for solidication into the near net shape article having a fine equi-axed structure substantially without coarse directional dendrites..
2. An injection molding process according to Claim 1 further including a step of applying a pressure to the slurry intermediate the steps of mold filling and final solidification.
3. An injection molding process according to Claim 1 in which the alloy is selected from the following group: magnesium based alloys, aluminum based alloys, lead based alloys, zinc based alloys, and bismuth based alloys.
4. An injection molding process according to Claim 1 in which the alloy is fed in the form of mechanically comminuted chips.
5. An injection molding process according to Claim 1 in which the alloy is fed in the form of metal rapidly solidified into granules.
6. An injection molding process according to Claim 1 in which the alloy is a magnesium based alloy having a nominal composition known as AZ91D and the alloy is heated in the barrel to a temperature of nominally 595°C.
7. An injection molding process according to Claim 1 in which the alloy is a magnesium based alloy having a nominal composition known as AM60B and the alloy is heated in the barrel to a temperature of nominally 615°C.
8. An injection molding process according to Claim 1 in which the alloy is a magnesium based alloy having a nominal composition known as AJ52 and the alloy is heated in the barrel to a temperature of nominally 616°C.
9. An injection molding process according to Claim 1 in which the temperature of the alloy in the accumulation portion is controlled within 2°C of the liquidus temperature.
10. An injection molding process according to Claim 1 in which the temperature of the alloy in the accumulation portion is controlled with 1°C of the liquidus temperature.
11. An injection molding process according to Claim 1 in which any molten alloy is protected from oxidation by an inert gas.
12. An injection molding process according to Claim 11 in which the inert gas is argon.
13. An injection molding process according to Claim 1 in which the mold is adapted to form a near net shape having thin walls not exceeding 2mm.
14. The injection molding process according to Claim 1, wherein the step of controlling the alloy temperature maintains the alloy with a maximum solids content of about 1%.
15. The injection molding process according to Claim 1, wherein the step of controlling the alloy temperature maintains the alloy substantially without solids content.
16. An injection molding process according to Claim 1 wherein the metal alloy includes a metal-matrix composite.
17. The injection molding process according to Claim 1, wherein the step of controlling the near-liquidus alloy temperature in the accumulation portion maintains the alloy in a state having a maximum solids content of less than 2%.
18. A near net-shape article formed by an injection molding process according to any one of Claims 1 to 17 in which the near net shape solid has a homogeneous, fine equi-axed structure with no coarse directional dendrites.
19. The near net-shape article according to Claim 18 made from a magnesium based alloy having a nominal composition known as AZ91D and having a microstructure consisting of .alpha.-Mg grains with a typical size of 20µm.
20. The near net-shape article according to Claim 19 in which the .alpha.-Mg grains are surrounded by mostly discontinuous precipitates of a Mg17 A112 intermetalic phase.
21. A metal-matrix composite, comprising:
a metallic component;
a reinforcement component embedded in the metallic component, the metallic component and the reinforcement component are heated to a near-liquidus temperature of the metallic component and injection-molded by a molding machine; and the metallic component and the reinforcement component are formed into a slurry in the molding machine, the slurry having a maximum solid content of less than 3%; and the metallic component having a fine equi-axed structure substantially without coarse directional dendrites.
22. The metal-matrix composite of claim 21, wherein the metallic component includes an alloy of magnesium, the metallic component and the reinforcement component are formed into a slurry in the molding machine, the temperature of the slurry was held within a temperature range that extended from about 695 degrees Celsius to about 693 degrees Celsius.
23. The metal-matrix composite of claim 21, wherein the metallic component includes a magnesium-based alloy, an aluminum-based alloy, a zinc-based alloy and any combination and permutation thereof.
24. The metal-matrix composite of claim 21, wherein the metallic component includes a magnesium alloy AZ91D.
25. The metal-matrix composite of claim 21, wherein the metallic component and the reinforcement component combine to form a substantially homogeneous macro-structure.
26. The metal-matrix composite of claim 21, wherein the metallic component and the reinforcement component form a substantially homogeneous micro-structure.
27. The metal-matrix composite of claim 21, wherein the metallic component includes a metallic alloy slurry having a solids content.
28. The Metal-matrix composite of claim 21, wherein the reinforcement component is chemically reactive, at least in part, with the metallic component.
29. The metal-matrix composite of claim 21, wherein the reinforcement component is chemically non-reactive with the metallic component.
30. The metal-matrix composite of claim 21, wherein the reinforcement component includes a metallic alloy.
31. The metal-matrix composite of claim 21, wherein the reinforcement component includes a non-metallic component.
32. The metal-matrix composite of claim 21, wherein the reinforcement component includes a powder.
33. The metal-matrix composite of claim 21, wherein the reinforcement component includes silicon carbide (SiC).
34. The metal-matrix composite of claim 21, wherein the reinforcement component includes boron nitride (BN).
35. The metal-matrix composite of claim 21, wherein the molding machine includes an injection molding machine.
36. The metal-matrix composite of claim 21, wherein the metallic component and the reinforcement component are formed into the slurry in the molding machine, the slurry having a maximum solid content of less than 2%.
CA2582687A 2004-11-10 2005-11-09 Near liquidus injection molding process Expired - Fee Related CA2582687C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US10/985,879 US7255151B2 (en) 2004-11-10 2004-11-10 Near liquidus injection molding process
US10/985,879 2004-11-10
PCT/CA2005/001707 WO2006050599A1 (en) 2004-11-10 2005-11-09 Near liquidus injection molding process

Publications (2)

Publication Number Publication Date
CA2582687A1 true CA2582687A1 (en) 2006-05-18
CA2582687C CA2582687C (en) 2010-05-04

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
CA2582687A Expired - Fee Related CA2582687C (en) 2004-11-10 2005-11-09 Near liquidus injection molding process

Country Status (13)

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US (2) US7255151B2 (en)
EP (1) EP1819464A4 (en)
JP (1) JP2008519690A (en)
KR (1) KR20070085906A (en)
CN (1) CN101056728A (en)
AU (1) AU2005304221B2 (en)
BR (1) BRPI0517746A (en)
CA (1) CA2582687C (en)
IL (1) IL182379A0 (en)
MX (1) MX2007005401A (en)
RU (1) RU2352435C1 (en)
TW (1) TWI307368B (en)
WO (2) WO2006050597A1 (en)

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Also Published As

Publication number Publication date
KR20070085906A (en) 2007-08-27
EP1819464A1 (en) 2007-08-22
WO2006050599A1 (en) 2006-05-18
TWI307368B (en) 2009-03-11
JP2008519690A (en) 2008-06-12
MX2007005401A (en) 2007-07-04
CA2582687C (en) 2010-05-04
AU2005304221A1 (en) 2006-05-18
RU2352435C1 (en) 2009-04-20
WO2006050597A1 (en) 2006-05-18
RU2007121668A (en) 2008-12-20
BRPI0517746A (en) 2008-10-21
US7255151B2 (en) 2007-08-14
US20060096734A1 (en) 2006-05-11
CN101056728A (en) 2007-10-17
EP1819464A4 (en) 2008-11-12
TW200636081A (en) 2006-10-16
US20060096733A1 (en) 2006-05-11
IL182379A0 (en) 2007-07-24
US7237594B2 (en) 2007-07-03
AU2005304221B2 (en) 2008-06-05

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