U.S. patent application number 14/865453 was filed with the patent office on 2017-03-30 for die configuration for high temperature diecasting.
The applicant listed for this patent is UNITED TECHNOLOGIES CORPORATION. Invention is credited to Steven J. Bullied, Awadh B. Pandey, Brian S. Tryon.
Application Number | 20170087627 14/865453 |
Document ID | / |
Family ID | 58406170 |
Filed Date | 2017-03-30 |
United States Patent
Application |
20170087627 |
Kind Code |
A1 |
Bullied; Steven J. ; et
al. |
March 30, 2017 |
DIE CONFIGURATION FOR HIGH TEMPERATURE DIECASTING
Abstract
A die casting die includes a shoe comprised of a first material
and includes a pocket. An insert is arranged in the pocket. The
insert is comprised of a second material that is different from the
first material and the insert provides a contoured surface. A
coating is on the contoured surface. The coating provides a cast
part contour.
Inventors: |
Bullied; Steven J.; (Pomfret
Center, CT) ; Pandey; Awadh B.; (Jupiter, FL)
; Tryon; Brian S.; (Los Gatos, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
UNITED TECHNOLOGIES CORPORATION |
Hartford |
CT |
US |
|
|
Family ID: |
58406170 |
Appl. No.: |
14/865453 |
Filed: |
September 25, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B22D 17/2209 20130101;
B22C 3/00 20130101; B22D 17/04 20130101; B22D 17/2218 20130101 |
International
Class: |
B22D 17/22 20060101
B22D017/22; B22D 17/04 20060101 B22D017/04 |
Claims
1. A die casting die comprising: a shoe comprised of a first
material and including a pocket; an insert arranged in the pocket,
the insert comprised of a second material that is different from
the first material, and the insert providing a contoured surface;
and a coating on the contoured surface, the coating providing a
cast part contour.
2. The die casting die in claim 1, wherein the first material has a
thermal conductivity between 12 Wm.sup.-1K.sup.-1 and 62
Wm.sup.-1K.sup.-1.
3. The die casting die in claim 2, wherein the first material
comprises steel.
4. The die casting die in claim 1, wherein the second material has
a thermal conductivity above 350 Wm.sup.-1K.sup.-1.
5. The die casting die in claim 4, wherein the second material
comprises copper.
6. The die casting die in claim 1, wherein the coating has a
hardness between 36 HRC and 62 HRC.
7. The die casting die in claim 6, wherein the coating comprise at
least one of a cobalt chromium alloy, a cobalt alloy, and
ceramic.
8. The die casting die in claim 1, wherein the shoe includes at
least one passage for circulation of fluid.
9. A die casting system comprising: a first die including a first
shoe comprised of a first material, the first shoe including a
first pocket, a first insert arranged in the first pocket, the
first insert comprised of a second material that is different from
the first material, the first insert providing a first contoured
surface, and a first coating on the first contoured surface, the
first coating providing a first cast part contour; a second die
including a second shoe comprised of the first material, the shoe
including a second pocket, a second insert arranged in the second
pocket, the second insert comprised of the second material, the
second insert providing a second contoured surface, and a second
coating on the second contoured surface, the second coating
providing a second cast part contour, wherein the first die and the
second die are arranged to form a die cavity; a chamber in fluid
communication with the die cavity; and a plunger for injecting a
molten metal through the chamber into the die cavity.
10. The die casting system in claim 9, wherein the first material
has a thermal conductivity between 12 Wm.sup.-1K.sup.-1 and 62
Wm.sup.-1K.sup.-1.
11. The die casting system in claim 10, wherein the first material
comprises steel.
12. The die casting system in claim 9, wherein the second material
has a thermal conductivity above 350 Wm.sup.-1K.sup.-1.
13. The die casting system in claim 12, wherein the second material
comprises copper.
14. The die casting system in claim 9, wherein the first and second
coatings have a hardness between 36 HRC and 62 HRC.
15. The die casting system in claim 14, wherein the first and
second coatings comprise at least one of a cobalt chromium alloy, a
cobalt alloy, and ceramic.
16. The die casting system in claim 9, wherein at least one shoe
contains at least one passage for the circulation of fluid.
17. The die casting system in claim 17, having a multiple of fluid
lines attachable to the at least one fluid passage, the multiple of
fluid lines connectable to a cooling fluid source for fluid
communication between the at least one shoe and the cooling fluid
source.
18. A method for die casting comprising: arranging a first die and
a second die to form a cavity, the first die including a first shoe
comprised of a first material, the first shoe including a first
pocket, a first insert arranged in the first pocket, the first
insert comprised of a second material that is different from the
first material, the first insert providing a first contoured
surface, and a first coating on the first contoured surface, the
first coating providing a first cast part contour, the second die
including a second shoe comprised of the first material, the shoe
including a second pocket, a second insert arranged in the second
pocket, the second insert comprised of the second material, the
second insert providing a second contoured surface, and a second
coating on the second contoured surface, the second coating
providing a second cast part contour; forcing molten metal into the
cavity; retaining the molten metal in the cavity until the molten
metal becomes a solidified metal; and removing the solidified metal
from the cavity.
19. The method of claim 18, wherein at least one shoe includes
passages for circulation of fluid during the retaining step.
20. The method of claim 18, wherein the second material comprises
copper.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to International
Application No. PCT/US2014/014,900, filed Feb. 5, 2014, which
claims priority to U.S. Provisional Application No. 61/766,334,
filed on Feb. 19, 2013.
BACKGROUND
[0002] This disclosure relates to a die casting die and system used
in high temperature die casting.
[0003] Generally, die casting is a process that includes forcibly
moving molten metal into a die cavity to form a desired shape. More
particularly, the process includes the steps of forcing molten
metal into the die, retaining the metal in the die until it
solidifies, and removing the solidified part from the die.
[0004] One of the largest challenges in die casting is developing
die materials and a die configuration in order to maximize die life
while minimizing die cost. Because die casting is performed at high
temperatures, thermal mechanical fatigue can occur in the dies.
SUMMARY
[0005] In one exemplary embodiment, a die casting die includes a
shoe comprised of a first material and includes a pocket. An insert
is arranged in the pocket. The insert is comprised of a second
material that is different from the first material and the insert
provides a contoured surface. A coating is on the contoured
surface. The coating provides a cast part contour.
[0006] In a further embodiment of any of the above, the first
material has a thermal conductivity between 12 Wm.sup.-1K.sup.-1
and 62 Wm.sup.-1K.sup.-1.
[0007] In a further embodiment of any of the above, the first
material comprises steel.
[0008] In a further embodiment of any of the above, the second
material has a thermal conductivity above 350
Wm.sup.-1K.sup.-1.
[0009] In a further embodiment of any of the above, the second
material comprises copper.
[0010] In a further embodiment of any of the above, the coating has
a hardness between 36 HRC and 62 HRC.
[0011] In a further embodiment of any of the above, the coating
includes at least one of a cobalt chromium alloy, a cobalt alloy,
and ceramic.
[0012] In a further embodiment of any of the above, the shoe
includes at least one passage for circulation of fluid.
[0013] In another exemplary embodiment, a die casting system
includes a first die including a first shoe comprised of a first
material. The first shoe includes a first pocket. A first insert is
arranged in the first pocket. The first insert is comprised of a
second material that is different from the first material. The
first insert provides a first contoured surface, and a first
coating on the first contoured surface. The first coating provides
a first cast part contour. A second die includes a second shoe
comprised of the first material. The shoe includes a second pocket.
A second insert is arranged in the second pocket. The second insert
is comprised of the second material. The second insert provides a
second contoured surface and a second coating on the second
contoured surface. The second coating provides a second cast part
contour. The first die and the second die are arranged to form a
die cavity. A chamber is in fluid communication with the die
cavity, and a plunger for injecting a molten metal through the
chamber into the die cavity.
[0014] In a further embodiment of any of the above, the first
material has a thermal conductivity between 12 Wm.sup.-1K.sup.-1
and 62 Wm.sup.-1K.sup.-1.
[0015] In a further embodiment of any of the above, the first
material comprises steel.
[0016] In a further embodiment of any of the above, the second
material has a thermal conductivity above 350
Wm.sup.-1K.sup.-1.
[0017] In a further embodiment of any of the above, the second
material comprises copper.
[0018] In a further embodiment of any of the above, the first and
second coatings have a hardness between 36 HRC and 62 HRC.
[0019] In a further embodiment of any of the above, the first and
second coatings comprise at least one of a cobalt chromium alloy, a
cobalt alloy, and ceramic.
[0020] In a further embodiment of any of the above, at least one
shoe contains at least one passage for the circulation of
fluid.
[0021] In a further embodiment of any of the above, the die casting
system includes a multiple of fluid lines attachable to the at
least one fluid passage. The multiple of fluid lines are
connectable to a cooling fluid source for fluid communication
between the at least one shoe and the cooling fluid source.
[0022] In another exemplary embodiment, a method for die casting
includes arranging a first die and a second die to form a cavity.
The first die includes a first shoe comprised of a first material.
The first shoe includes a first pocket. A first insert is arranged
in the first pocket. The first insert is comprised of a second
material that is different from the first material. The first
insert provides a first contoured surface and a first coating on
the first contoured surface. The first coating provides a first
cast part contour. The second die includes a second shoe comprised
of the first material. The shoe includes a second pocket. A second
insert is arranged in the second pocket. The second insert is
comprised of the second material. The second insert provides a
second contoured surface and a second coating on the second
contoured surface. The second coating provides a second cast part
contour. The method includes forcing molten metal into the cavity.
The method includes retaining the molten metal in the cavity until
the molten metal becomes a solidified metal, and removing the
solidified metal from the cavity.
[0023] In a further embodiment of any of the above, at least one
shoe includes passages for circulation of fluid during the
retaining step.
[0024] In a further embodiment of any of the above, the second
material comprises copper.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The disclosure can be further understood by reference to the
following detailed description when considered in connection with
the accompanying drawings wherein:
[0026] FIG. 1 schematically illustrates a die casting system.
[0027] FIG. 2 schematically illustrates a die.
DETAILED DESCRIPTION
[0028] FIG. 1 schematically illustrates an example die casting
system that includes a die assembly 10 having a first die 12 and a
second die 14 that form a die cavity 16. The system further
includes a chamber 18 in fluid communication with the cavity 16. A
plunger 20 is used to force molten metal through the chamber 18
into the cavity 16. The molten metal is then retained in the cavity
16 until it becomes a solidified cast metal part. The cast part is
then removed from the cavity 16.
[0029] The first die 12 includes a first shoe 22 having a first
pocket 24. A first insert 26 arranged in the first pocket 24. In
the example, the first insert 26 is a separate structure from, but
removably affixed to the first shoe 22. The first insert 26
provides a contoured surface 28. The contoured surface 28 is coated
with a coating 30, which provides a contour of the part to be
cast.
[0030] FIG. 2 schematically illustrates the second die 14. The
second die 14 includes a second shoe 32, the second shoe having a
second pocket 34. A second insert 36 arranged in the second pocket
34. In the example, the second insert 36 is a separate structure
from, but removably affixed to the second shoe 32. The second
insert provides a contoured surface 38. The contoured surface 38 is
coated with a coating 40, which provides a contour of the part to
be cast. The first shoe 22 and second shoe 32 are comprised of a
first material, and the first insert 26 and the second insert 36
are comprised of a second material. The first material is different
from the second material.
[0031] One of ordinary skill in the art would recognize that the
system disclosed is not limited to having two dies with one insert
in each die. For example, more than two dies could be implemented,
as could more than one insert in each die.
[0032] In an example embodiment, the first shoe 22 and the second
shoe 32 are comprised of a material having a thermal conductivity
between 12 Wm.sup.-1K.sup.-1 and 62 Wm.sup.-1K.sup.-1. Example
materials in this range that could be used for the shoes 22, 32
include, but are not limited to, steel and steel alloys. A steel or
steel alloy die shoe will provide high strength to the die while
also acting as a heat sink.
[0033] The first insert 26 and the second insert 36 are comprised
of a highly thermal conductive substrate having a thermal
conductivity above 350 Wm.sup.-1K.sup.-1. Example materials in this
range that could be used for the inserts 26, 36 include, but are
not limited to, copper and copper alloys.
[0034] The insert coatings 30, 40 are approximately 0.1 inches
(2.54 mm) thick and are provided by a material having a hardness
between 36 HRC and 62 HRC. Materials in this range that could be
used as the coatings 30, 40 may be at least one of a cobalt
chromium alloy, a cobalt alloy, and ceramic. Coating the insert
will provide a deposited hard faced layer that will resist the
thermal shock on the insert during injection. The disclosed
configuration will transfer heat extremely quickly to the die shoe,
reducing the amount of stress on the inserts.
[0035] In the example, at least one of the shoes 22, 32 may include
at least one passage 42 for the circulation of fluid to regulate
the temperature of the die casting system. As illustrated in FIG.
1, the at least one passage 42 may be connected to a fluid source
by means of fluid lines 46, 48 to create fluid communication
between the fluid source 44 and the shoe 32. Fluid circulation
through the fluid passage 42 or passages is to occur at least
during the process of retaining the molten metal inside the cavity
16. An example of fluid that could be used to regulate the
temperature of the die casting system is oil at 600.degree. F. It
should be noted that the system is not limited to the disclosed
type of fluid or fluid temperature. Multiple fluid passages are
typically used.
[0036] By staggering the thermal conductivity of the die casting
system as done in the example embodiment, the heat from the molten
metal injected into the die cavity 16 will be quickly transferred
to the shoe 22, 32 and removed by the hot oil, which will increase
the life of the die insert 26, 36. Furthermore, the preferred
embodiment is constructed from relatively inexpensive materials.
The wear surface of the die assembly is a deposit coating 30, 40
that can be easily refurbished as necessary.
[0037] The system may be used in hot chamber and cold chamber die
casting. Generally, the die casting process involves forcing molten
metal into the cavity 16 formed by dies 12, 14, retaining the metal
until the molten metal solidifies into the desired cast part, and
then ejecting the solidified metal cast part from the die cavity
16. In the preferred embodiment, this process will include the
circulation of fluid through at least one passage 42 in at least
one of the shoes 22, 32 in order to regulate the temperature of the
die system. This circulation of fluid will occur during the molten
metal retention process, and may be implemented during other steps
as well.
[0038] Although an example embodiment has been disclosed, a worker
of ordinary skill in this art would recognize that certain
modifications would come within the scope of the claims. For that
reason, the following claims should be studied to determine their
true scope and content.
* * * * *