US3864815A - Method of making a lined die casting by employing a transplant coating - Google Patents
Method of making a lined die casting by employing a transplant coating Download PDFInfo
- Publication number
- US3864815A US3864815A US423065A US42306573A US3864815A US 3864815 A US3864815 A US 3864815A US 423065 A US423065 A US 423065A US 42306573 A US42306573 A US 42306573A US 3864815 A US3864815 A US 3864815A
- Authority
- US
- United States
- Prior art keywords
- core
- casting
- coating
- die
- cores
- 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.)
- Expired - Lifetime
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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
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/0009—Cylinders, pistons
-
- 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
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4998—Combined manufacture including applying or shaping of fluent material
- Y10T29/49982—Coating
- Y10T29/49984—Coating and casting
-
- 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
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4998—Combined manufacture including applying or shaping of fluent material
- Y10T29/49988—Metal casting
- Y10T29/49989—Followed by cutting or removing material
Definitions
- 57 BSTRACT A method for die casting a part having a hard wear resistant liner.
- the invention is directed to the preservation of the integrity of the liner by initially casting the part with extensions that are machined off during finishing.
- the body of the housing is cast from an aluminum alloy and the interior coating comprises a layer of metal such as stainless steel, another hard iron alloy, or ceramic material, alloys of refractory metals or hard materials such as tungsten or titanium carbides.
- the coating is most advantageously applied by the transplant coating process shown and described in Bauer US. Pat. No 3,083,424.
- the present invention is directed to an improvement of this process for a specialized application.
- the coating metals are brittle by nature and since the coating on the longitudinal bore which constitutes the operating face of the housing must be totally continuous and without cracks or chips great care must be exercised in handling the coated core before inserting it into the die casting machine and in handling the casting immediately after the casting operation. If the edges of the coated core become chipped or cracked, and these cracks carry over into the transplant coated surface of the casting then the casting itself must be rejected.
- the present invention assures that no chipping or cracking of the coating in the operating area of the casting will occur.
- the coating material is sprayed on to each core individually which requires a short cycle including loading of the coating machine, initiation of spraying, stopping and unloading of the spraying machine.
- the coated core must be then transported to the casting machine although in practice a number of coated cores are held on racks awaiting insertion into the casting die.
- the present invention provides a method by which a plurality of cores can be loaded and sprayed at the same time, then separated from each other and stored while awaiting introduction into the die casting machine. Further, the invention provides a method whereby the coated surface exposed to the die casting die is so disposed that no cracking or chipping of the active area of the resulting casting can occur.
- each core temporarily has applied to it masking plates which are bolted to opposite faces of the sides of the core prior to spraying. These masking plates stay with the core during both the spraying and casting operations and receive temporary coatings in the same manner as the cores.
- only a single masking 'plate is applied to a core.
- the invention comprises a method of forming by die casting, a coated or composite article, by applying to a core a mask made up of one or more masking plates which as an assembly will ultimately be placed in a die casting machine.
- the periphery of the assembled mask and core is then sprayed with a material which will form the coating for the interior of the cast article.
- the coated core and mask as an assembly is then placed in the die cavity of a die casting machine and metal is forced into the cavity under normal die casting pressures. The casting metal bonds securely to the coating material.
- the casting and core assembly are then removedfrom the die casting machine as a unit.
- the core and mask can be parted from the casting by differential expansion assuming that the casting is made ofa metal having a relatively higher coefficient of thermal expansion than the core which is usually the case.
- the core and mask having a lower coefficient of thermal expansion than the casting, will push easily away axially of the casting.
- the core assembly is then returned to the spray area for recoating. If two masking plates have been used, one may be removed first from the core assembly and the remaining plate and the core taken from the casting as above described. In either event the transplanted coat will extend well beyond the operating face of the casting since it has been applied to the periphery of the mask which lies outside the operating face of the casting.
- FIG. 1 is a diagrammatic elevational view of a group of four cores and associated masks mounted in a coating machine, and undergoing the coating step;
- FIG. 2 is a diagrammatic elevational view showing the coated cores separated along an arbor
- FIG. 3 is a diagrammatic view of a coated core mounted in a die after the casting shot has been made, but prior to extraction;
- FIG. 4 is an exploded view showing removal of a core and mask from a casting
- FIG. 5 is a diagrammatic view of an alternate form of the invention in which only a single mask is associated with each core during coating;
- FIG. 6 is an elevational view of a core and mask assembly
- FIG. 7 is a central vertical sectional view of a casting and core with anassociated mask coated in accordance with the procedure indicated in FIG. 5;
- FIG. 8 is an exploded view of a casting, core and mask after extraction and disassembly in which the core is coated in accordance with the procedure of FIG. 5;
- FIG. 9 is a fragmentary enlarged view of the area shown in the circle in FIG. 4.
- FIG. 10 is an enlarged sectional view of the area shown in the circle in FIG. 8.
- each of a plurality of core pieces 11 is mounted on the arbor or spindle 12 of a rotating machine that resembles a lathe having a headstock l3 and some means for driving the same (not shown).
- Each of the cores 11 is flanked by a masking plate 14 on each side.
- the masking plates follow the contour of the cores but are made slightly larger than the cores for reasons which will be subsequently described.
- Each of the masking plates 14 is chamfered at its periphery so that when two masking plates abut each other a V- groove is established at to facilitate cracking the coated assembly apart into discrete coated core-plate elements.
- the masking plates 14 may be bolted to or held in association with the cores 1! in any suitable.
- the coating gun is diagrammatically indicated at 16 in FIG. 1.
- the gun is moved laterally during the coating process as diagrammatically shown from a position in which the innermost core assembly is sprayed to a position in which the outermost core assembly is sprayed, the coating being equally deposited throughout the length and periphery of the cores and plates.
- the coated core and plate assembly is inserted in the die of a die casting machine and the shot is made in a normal manner.
- the metal of the casting enters intimately against the coated core and also against the periphery of each of the coated masking plates 14.
- the casting, core and plates are removed from the machine as a unit.
- one of the masking plates is released from engagement with the core and removed outwardly simply by driving it away while the core 11 and the other of the masking plates 14 are removed as a unit from the completed casting.
- This latter removal is preferably made by differential expansion. If the casting and core assembly are heated, the casting will expand to a greater extent than the core since the casting is made of aluminum alloy or other light metal and the core is usually an iron alloy having significantly lower coefficient of thermal expansion.
- This differential expansion permits the easy removal of the now coated casting from the core and the coating is said to be transplanted from the core to the interior longitudinal bore of the casting.
- the casting has a bead-like peripheral extension which has received the coating from the masking plate 14 on each side. It is necessary to machine the casting to form a precisely finished active side face by which the housings of a two-rotor engine are abutted with an interposed gasket and against which the end plates of the engine will lie in service. When the active face of the housing is machined away the beads 20 are also machined away and no coating appears on the sidewalls of the finished housing. The coating is confined to the inner surface of the housing.
- FIGS. 5, 6, 7, 8 and 10 A second modification of the method of the present invention is indicated diagrammatically in FIGS. 5, 6, 7, 8 and 10.
- a single masking plate is used between each of the core ele- 4 ments 10.
- the masking plates are designated 14a in FIG. 5.
- the masking plates are fixed to one side of each of the cores and the other side of each of the cores is slightly grooved as at 21.
- a spray gun 22 v directs the spray of coating material particles at an angle to the axis of the cores as shown in FIG. 5. As there indicated, a spray angle of approximately 45 degrees would be satisfactory, and the spray gun 22 is moved axially over the assembled group of cores.
- the masking plates, designated 14a are larger in diameter than the associated cores they exert a shielding effect on that portion of each of the cores in their shadow".
- the sprayed material is deposited with a heavy deposit ,on one side of the masking plate and a substantially lighter, practically non-existent, coating on the opposite-side of the masking plate in that region 21 where the core is grooved.
- the coated core and assembled masking plate are inserted into the die of a die casting machine and the casting is made.
- the core is then disassembled from the casting as shown in FIG. 8 and the masking plate 14a may be removed from the cores if desired or may be left in place.
- the casting has a circumferential bead to which the coating is transplanted on that side where the masking plate 14a occurred.
- the casting On the opposite side the casting has abead that extends radially inward relative to the coated surface where the grooved portion of the core occurred. This inwardly extending bead has almost no coating on it.
- both of the side beads are machined away leaving an active side face that may be precisely finished as in the previous modification of the invention.
- the coating on the interior longitudinal bore surface of the casting is thus protected in each instance from cracking or chipping in those areas where a wear resistant surface is necessary.
- a method of forming a die casting having an interior longitudinal bore surface which is coated with a hard wear resistant material and side faces which are initially formed with bead portions that are machined off in the finishing of the completed casting comprises assembling on an arbor a group of die cores and interposed masking plates between the cores, spraying the coating material over the exposed peripheral surfaces of the cores and masking plates, individually separating the core assemblies from each other so that each core remains attached to at least one masking plate and the coating thereon remain undisturbed, introducing the coated core and attached masking plate into a die, introducing molten metal into the die under normal die casting pressures to adhere to the coating material, removing the completed casting and core and masking plate from the die as a unit, separating the core and masking plate from the casting leaving a coated longitudinal bore and a coated extending bead portion in that area where the masking plate occurred, and machining away the extending bead and its 6 gle masking plate is affixed to the opposite side of the core, and in
Abstract
Description
Claims (4)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US423065A US3864815A (en) | 1973-12-10 | 1973-12-10 | Method of making a lined die casting by employing a transplant coating |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US423065A US3864815A (en) | 1973-12-10 | 1973-12-10 | Method of making a lined die casting by employing a transplant coating |
Publications (1)
Publication Number | Publication Date |
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US3864815A true US3864815A (en) | 1975-02-11 |
Family
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Application Number | Title | Priority Date | Filing Date |
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US423065A Expired - Lifetime US3864815A (en) | 1973-12-10 | 1973-12-10 | Method of making a lined die casting by employing a transplant coating |
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US (1) | US3864815A (en) |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3937266A (en) * | 1973-08-20 | 1976-02-10 | Ford Motor Company | Method for application of wear-resistant coating |
US4494297A (en) * | 1981-10-06 | 1985-01-22 | Asea Aktiebolag | Method of producing castings with means to facilitate burr removal |
US4519119A (en) * | 1980-11-19 | 1985-05-28 | Kabushiki Kaisha Toyoda Jidoshokki Seisakusho | Method of manufacturing a piston for a swash plate type compressor |
US4732206A (en) * | 1980-12-19 | 1988-03-22 | Semco, Inc. | Plunger tip having a safety indicator surface |
US5084964A (en) * | 1989-07-28 | 1992-02-04 | Wagner Spray Tech Corporation | Aluminum die casting |
US20020029675A1 (en) * | 2000-09-09 | 2002-03-14 | Aichele Werkzeuge Gmbh | Rotary cutting device |
US6702908B1 (en) | 2002-01-16 | 2004-03-09 | Hamilton Sundstrand Corporation | Method of making a cylinder block with unlined piston bores |
US9975173B2 (en) | 2013-06-03 | 2018-05-22 | United Technologies Corporation | Castings and manufacture methods |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3083424A (en) * | 1959-05-07 | 1963-04-02 | Nat Lead Co | Method for producing coated die castings |
US3098270A (en) * | 1961-04-18 | 1963-07-23 | Nat Lead Co | Die casting method and article |
US3216072A (en) * | 1961-12-13 | 1965-11-09 | Nat Lead Co | Die casting method and apparatus |
US3450189A (en) * | 1966-08-22 | 1969-06-17 | Int Nickel Co | Process of coating metal castings |
US3533329A (en) * | 1968-01-09 | 1970-10-13 | Ercole Galli | Method for manufacturing light alloy pistons with an insert of a different metal,and pistons manufactured thereby |
US3797101A (en) * | 1972-11-27 | 1974-03-19 | Nl Industries Inc | Method of making die castings having multi-layer coated surfaces |
-
1973
- 1973-12-10 US US423065A patent/US3864815A/en not_active Expired - Lifetime
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3083424A (en) * | 1959-05-07 | 1963-04-02 | Nat Lead Co | Method for producing coated die castings |
US3098270A (en) * | 1961-04-18 | 1963-07-23 | Nat Lead Co | Die casting method and article |
US3216072A (en) * | 1961-12-13 | 1965-11-09 | Nat Lead Co | Die casting method and apparatus |
US3450189A (en) * | 1966-08-22 | 1969-06-17 | Int Nickel Co | Process of coating metal castings |
US3533329A (en) * | 1968-01-09 | 1970-10-13 | Ercole Galli | Method for manufacturing light alloy pistons with an insert of a different metal,and pistons manufactured thereby |
US3797101A (en) * | 1972-11-27 | 1974-03-19 | Nl Industries Inc | Method of making die castings having multi-layer coated surfaces |
Cited By (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3937266A (en) * | 1973-08-20 | 1976-02-10 | Ford Motor Company | Method for application of wear-resistant coating |
US4519119A (en) * | 1980-11-19 | 1985-05-28 | Kabushiki Kaisha Toyoda Jidoshokki Seisakusho | Method of manufacturing a piston for a swash plate type compressor |
US4732206A (en) * | 1980-12-19 | 1988-03-22 | Semco, Inc. | Plunger tip having a safety indicator surface |
US4494297A (en) * | 1981-10-06 | 1985-01-22 | Asea Aktiebolag | Method of producing castings with means to facilitate burr removal |
US5084964A (en) * | 1989-07-28 | 1992-02-04 | Wagner Spray Tech Corporation | Aluminum die casting |
US20020029675A1 (en) * | 2000-09-09 | 2002-03-14 | Aichele Werkzeuge Gmbh | Rotary cutting device |
US8100040B2 (en) * | 2000-09-09 | 2012-01-24 | Aichele Werkzeuge Gmbh | Rotary cutting device |
US6702908B1 (en) | 2002-01-16 | 2004-03-09 | Hamilton Sundstrand Corporation | Method of making a cylinder block with unlined piston bores |
US7401588B1 (en) | 2002-01-16 | 2008-07-22 | Hamilton Sundstrand Corporation | Cylinder block with unlined piston bores |
US9975173B2 (en) | 2013-06-03 | 2018-05-22 | United Technologies Corporation | Castings and manufacture methods |
US11213885B2 (en) | 2013-06-03 | 2022-01-04 | Raytheon Technologies Corporation | Castings and manufacture methods |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: FARLEY METALS, INC., 233 SOUTH WACKER DRIVE, CHICA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNOR:NL INDUSTRIES, INC. A NJ CORP.;REEL/FRAME:004217/0800 Effective date: 19831212 |
|
AS | Assignment |
Owner name: NATWEST USA CREDIT CORP. Free format text: SECURITY INTEREST;ASSIGNOR:FARLEY METALS, INC.,;REEL/FRAME:004739/0041 Effective date: 19870729 |
|
AS | Assignment |
Owner name: FARLEY, INC. Free format text: CHANGE OF NAME;ASSIGNOR:FARLEY METALS, INC.;REEL/FRAME:004917/0556 Effective date: 19880809 |
|
AS | Assignment |
Owner name: BANK OF NEW YORK, THE Free format text: SECURITY INTEREST;ASSIGNOR:FARLEY INC.;REEL/FRAME:005221/0038 Effective date: 19890404 |
|
AS | Assignment |
Owner name: FARLEY, INC. Free format text: RELEASED BY SECURED PARTY;ASSIGNOR:NATWEST USA CREDIT CORP.;REEL/FRAME:005221/0044 Effective date: 19890331 |
|
AS | Assignment |
Owner name: CONTINENTAL BANK N.A. Free format text: SECURITY INTEREST;ASSIGNOR:DOEHLER-JARVIS LIMITED PARTNERSHIP, A DE. LIMITED PARTNERSHIP;REEL/FRAME:005388/0825 Effective date: 19900720 |
|
AS | Assignment |
Owner name: FARLEY INC., ILLINOIS Free format text: CHANGE OF NAME;ASSIGNOR:FARLEY METALS, INC., A CORP. OF DE.;REEL/FRAME:005456/0880 Effective date: 19871222 |
|
AS | Assignment |
Owner name: FARLEY INC. Free format text: RELEASED BY SECURED PARTY;ASSIGNOR:BANK OF NEW YORK, THE;REEL/FRAME:005489/0398 Effective date: 19900717 |
|
AS | Assignment |
Owner name: FARLEY INC. Free format text: CHANGE OF NAME;ASSIGNOR:FARLEY METALS, INC., A CORP. OF DE;REEL/FRAME:005847/0581 Effective date: 19871222 |