Innovative Binder and Refractory Coating Solutions For Highly …€¦ · 12/09/2014 · Barely...
Transcript of Innovative Binder and Refractory Coating Solutions For Highly …€¦ · 12/09/2014 · Barely...
«Innovative Binder and Refractory Coating Solutions For Highly Complex Castings»
«Kompleks Döküm Parçaları İçin Yeni Bağlayıcılar ve Refrakter Kaplamaları» Amine Serghini
(Metko HA)
4.Oturum: Kalıp ve Maça Teknolojileri 4th Session: Mould & Core Technologies
Oturum Başkanı/Session Chairman: Dr. Türsen Demir (Çukurova Kimya End. A.Ş.)
Oturumlarda yer alan sunumlar 15 Eylül 2014 Pazartesi tarihinde kongre web sayfasına (kongre.tudoksad.org.tr) yüklenecektir.
CHEMISCHE WERKE GMBH
7th International Ankiros Foundry Congress
September– 12th
, 2014
Innovative binder and refractory coating solutions for high complex castings
Amine Serghini* & Dr. Klaus Seeger
3
ENVIRONMENTAL REGULATIONS
IN EUROPE
1865 1906 1950 1960 1970 1980 1985 1990 1995 2006
0
200
400
600
800
Total:
800 Laws
2.800 Regulations
4.700 Administrative ruling
1865 - 1970: 20 Laws
1986 - today: >> 800
Laws / Guidelines
1971 - 1985: 94 Laws
With a growing environmental consciousness the number of environmental
laws and guidelines increased dramatically in recent years.
CO2-Emission standards for PC Worldwide
USA
CaliforniaCanada
Australia
China
EUJapan
100
120
140
160
180
200
220
240
260
280
2002 2004 2006 2008 2010 2012 2014 2016 2018
Year
CO
2-e
mis
sio
n [
g/k
m]
Light Construction using Downsizing
06A 1,6L – 2,0L
75 – 165 KW
06F 2,0L
125 – 200 KW
06H 1,8L – 2,0L
88 – 155 KW 06K 1,8L – 2,0L
125 – 221 KW
NA / Turbo
TFSI - ZKG 0
TFSI - EVOII
TFSI – Gen.3
Development of weight and Performance of engine blocks
From 1,6 – 2,0L GJL250
source: W.Görtz – Die Herstellung von hochkomplexen ZKG
Eisenwerk Brühl FST Duisburg 2014
5
Integration of different parts in the casting
• higher core complexity
Light construction
• core package production
• higher binder consumption
• thinner wall thickness
• restricted tolerance
Higher component load
• constant metallurgical proprieties
• Need for feeders
Lower costs
• Automation
Challenges by downsizing
Enhanced complexity
• 40 cores/ Flask for 4 engine blocks
• 173,6 kg core sand / Flask for 4 engine blocks
• 56 cores/ Flask for 4 engine blocks
• 333,4 kg core sand / Flask for 4 engine blocks
source: W.Görtz – Die Herstellung von hochkomplexen ZKG
Eisenwerk Brühl FST Duisburg 2014 7
3 mm
Wall thicknesses and tolerances for new
engine casting
8
6 - 8 mm
Former Casting
Wall thicknesses and tolerances for new
engine casting
9
Composition of the various Cold-Boxcomponents
0
10
20
30
40
50
60
70
80
90
100
Gasharz (Part 1) Aktivator (Part 2) Catalyst
Rate
[%
]
chemical agent main solvent co-solvent additivs
Solvent behaviour in PU-Cold-Box resin
14.09.2014 11 Präsentationsvorlage
Primarily:
• To reduce the viscosity of the base resin
Secondary
• To enhance several properties of the binder
Solvent influence:
• The gas behaviour of the binder system
• The Hazardous and fume emission of the binder
• The odour emission after pouring
Reducing the solvent content:
• Reducing the viscosity of the base resin
Viscosity of the base resin
• Modify the structure of the binder
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Structure of various Cold-Box-Resins
OH OH
O
OH
OHOH
m
n
OH OH
O
OH
OHOH
n
m
OH OH
O
OH
O
m
n
Si
OH OH
O
OH
O
n
m
O O
OSi
OSi
O
OO
O
O
O
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SIPURID-Structure - properties
1. Reduction of the OH-Groups Polarity reduced
Application of simple solvent packages possible
Viscosity of the base resin is reduced
Application of less solvent possible
Amount of Isocyanate can be reduced
2. Increase of the molecular mass
thermal stability improved
OH OH
O
OH
O
m
n
Si
OH OH
O
OH
O
n
m
O O
OSi
OSi
O
OO
O
O
O
Composition of the various Cold-Box
components
0
10
20
30
40
50
60
70
80
90
100
SIPURID 1 SIPURID 2 Catalyst
Co
nte
nt
[%]
chemical agent main solvent additives
Emissionen – Hazardous- BTX values
15
0
50
100
150
Benzol Toluol Xylol
SIPURID: reduce of gas pressure into the core
17
SIPURID– Practical experiences
Standard binder New binder
Section through a core package in casting position by cutout over a range of core and a
section of the corresponding cylinder block
Wall thicknesses and tolerances for new
engine casting
Due to the high complexity of these castings the number is increasing
especially in filigree thin and very complex cores. The risk of gas-related
casting defects will increase.
Wall thicknesses and tolerances for new
engine casting
For the production of complex castings in the core package technology
the use of more specific and tailored coatings to their production is
necessary.
uniform application thickness
very effective against sand expansion defects
controlled gas permeability
controlled refractoriness coated side part of a core package with integrated channel cores
Wall thicknesses and tolerances for new
engine casting
Wall thicknesses and tolerances for new
engine casting
350 to
400 µm
250 µm
Task
Formulation of suitable coating which can be applied thin and still eliminates casting
defects such as veining or penetration and offer an excellent peel-off from the casting
Testing carried out to improve cleanliness
Method:
A test casting was carefully designed to demonstrate adherence in thin
wall sections
Dipping procedure was improved to ensure constant coating thickness
Various coating formulation types were trailed
Test bars were produced, coated dried and inserted into the test
moulds ready for casting
Simulation of casting geometry
2.7 mm
22.4
mm
5.7 mm
Casting test: view of the mould
Grey Iron
Casting temp.: 1450 °C
Casting weight: 21 kg
The thin test bars simulate the customer conditions and the different
applied coatings show the performance of this
Measurement of layer thicknesses on test bars
Dip
pin
g d
irection
Test bars were measured in positions
1 – 3
Coating applied with an automatic
dip machine
Dipping time: 3 sec.
Hold time: 5 sec .
Removal : 3 sec.
Sand mixture:
100 pbw Silica sand
1.6 pbw Cold-Box binder
Layer thickness of different coatings
Coating A Coating B Coating C Coating D Coating E
Layer [µm]
Position 1 400 390 450 350 220
Layer [µm]
Position 2 490 440 510 360 220
Layer [µm]
Position 3 500 450 520 370 230
Δ Layer 1 to
Position 3 [µm] 100 60 70 20 10
3/5/3s
Observations:
Lower part of the core always has a tendency to pick up more due to the
higher pressure forces, building thickness onto the sand core
Choice of coating is important in obtaining consistent thickness on cores
Peel-off of different coatings
The above shows the sectioned casting with reduced adherences in section 9 and 10
Peel-off of different coatings
Coating A Coating E
Cleanliness
Cleanliness after casting / peel-off of the refractory coating
example: casting surface around the water jacket
Extensive sticking of the refractory
coating on the casting surface
Barely any refractory coating residues
to be found on the casting surface
(Source: Neue Halberg Guss GmbH, Brebach)
Summary
• Thin-walled engine blocks with integrated functionalities to reduce
the CO2 emission of future generations of motor vehicles
• The number of cores increases significantly and the complexity as
well
• Engine blocks are therefore produced by core package method with
vertical pouring
• New requirements for core binders and particularly for the coating
materials and their compositions:
• to cope with the task of gas evolution or gas problems
• to avoid expansion defect by low coating thickness
• to enhance the release of the coating after casting
• To guarantee a constant working condition an automatic viscosity
control has been developed
CHEMISCHE WERKE GMBH
Thank you for
your attention!