Method of forming casting with flow passage, and casting formed by the same

Patent metadata

Field	Value
Publication number	US-11602785-B2
Application number	US-201916691319-A
Country	US
Kind code	B2
Filing date	Nov 21, 2019
Priority date	Jan 31, 2019
Publication date	Mar 14, 2023
Grant date	Mar 14, 2023

Abstract

A method of forming a casting with a flow passage may include filling a tubular pipe with a filler to form a smart core; inserting the smart core into a mold having a cavity corresponding to a shape of the casting to be formed; injecting a molten metal into the cavity through a casting process; and removing the filler from the smart core, wherein a hardness of the tubular pipe is 70 Hv or more.

First claim

What is claimed is:

1. A method of forming a casting with a flow passage, comprising:
filling a tubular pipe with a filler to form a smart core;
filling both ends of the tubular pipe with resin;
inserting the smart core into a mold having a cavity corresponding to a shape of the casting to be formed;
injecting a molten metal into the cavity through a casting process;
cutting out portions of the tubular pipe that are filled with the resin; and
removing the filler from the smart core,
wherein a hardness of the tubular pipe is 70 Hv or more,
the method further comprises after filling both ends of the tubular pipe with resin and before inserting the smart core into the mold:
drawing and extruding the tubular pipe filled with the filler such that the filler is compacted to at least 95%; and
bending the tubular pipe filled with the filler in a shape corresponding to a shape of the flow passage to be formed in the casting,
wherein the molten metal and the tubular pipe are formed of an identical material, and
the tubular pipe is formed of aluminum.

2. The method of claim 1 , wherein the casting process is performed through a high-pressure casting process.

3. The method of claim 1 , wherein an elongation of the tubular pipe is 15% or more when tensing the tubular pipe which is not filled with the filler.

4. The method of claim 1 , wherein a particle size of the filler is 100 μm or less.

5. The method of claim 4 , wherein a thermal conductivity of the filler ranges from 0.1 W/m·° C. to 1 W/m·° C.

6. The method of claim 1 , wherein a thickness of the tubular pipe is 1.25 mm or more and less than 4 mm.

7. A method of forming a casting with a flow passage, comprising:
filling a tubular pipe with a filler to form a smart core;
filling both ends of the tubular pipe with resin;
inserting the smart core into a mold having a cavity corresponding to a shape of the casting to be formed;
injecting a molten metal into the cavity through a casting process;
cutting out portions of the tubular pipe that are filled with the resin; and
removing the filler from the smart core,
wherein a particle size of the filler is 100 μm or less,
the method further comprises after filling both ends of the tubular pipe with resin and before inserting the smart core into the mold:
drawing and extruding the tubular pipe filled with the filler such that the filler is compacted to at least 95%; and
bending the tubular pipe filled with the filler in a shape corresponding to a shape of the flow passage to be formed in the casting,
wherein the molten metal and the tubular pipe are formed of an identical material, and
the tubular pipe is formed of aluminum.

8. The method of claim 7 , wherein the filler is formed of silica-based material.

9. The method of claim 7 , wherein a thermal conductivity of the filler ranges from 0.1 W/m·° C. to 1 W/m·° C.

Assignees

• Hyundai Motor Co Ltd
• Kia Motors Corp

Inventors

• Jo Young-Rae
• Joo Hyo-Moon
• Kim Min-Soo
• Lee Ji-Yong

Classifications

• B22D19/0072 Primary

  for making objects with integrated channels · CPC title

• B22C9/106

  Vented or reinforced cores · CPC title

• B22D17/00

  Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure · CPC title

• B22C9/101

  Permanent cores · CPC title

• B22C21/14

  for reinforcing or securing moulding materials or cores, e.g. gaggers, chaplets, pins, bars · CPC title