Hydraulic composition for additive manufacturing device, and process for producing casting mold

Patent metadata

Field	Value
Publication number	US-11655190-B2
Application number	US-201716465929-A
Country	US
Kind code	B2
Filing date	Jun 28, 2017
Priority date	Jun 28, 2016
Publication date	May 23, 2023
Grant date	May 23, 2023

Abstract

The present invention has solved the problems of conventional molding materials, and provides a hydraulic composition for additive manufacturing devices having high strength development, particularly high early strength development, and less generation of gas defect and graphite spheroidization defect. Specifically, the hydraulic composition for additive manufacturing devices of the present invention at least contains calcium aluminate. It is preferable that the hydraulic composition contain 0.5-10 parts by mass of gypsum with respect to 100 parts by mass of the calcium aluminate.

First claim

The invention claimed is:

1. A hydraulic composition for an additive manufacturing device, comprising:
a binder having 90 to 100% by mass of calcium aluminate and 0 to 10% by mass of a cement, and
0.5 to 10 parts by mass of anhydrous gypsum based on 100 parts by mass of the calcium aluminate,
wherein the hydraulic composition is capable of being molded by the additive manufacturing device into a plurality of shapes arranged in horizontal planes with reduced gas generation defect and with reduced graphite spheroidization defect.

2. The hydraulic composition for an additive manufacturing device according to claim 1 , wherein 100 to 400 parts by mass of sand is further contained with respect to 100 parts by mass of the calcium aluminate.

3. The hydraulic composition for an additive manufacturing device according to claim 1 ,
wherein 100 to 400 parts by mass of sand is contained with respect to 100 parts by mass of the binder,
the calcium acuminate has a molar ratio of CaO/Al 2 O 3 from 1.5 to 3.0; and
the cement has a content of calcium silicate of 25% by mass or more.

4. The hydraulic composition for an additive manufacturing device according to claim 2 , wherein the sand is one or more selected from silica sand, olivine sand, and artificial sand.

5. The hydraulic composition for an additive manufacturing device according to claim 1 , further comprising as a hardening accelerator, one or more selected from alkali metal carbonate salt, alkali metal lactate salt, alkaline earth metal lactate salt, and alkali metal silicate salt.

6. The hydraulic composition for an additive manufacturing device according to claim 1 , wherein the calcium aluminate is amorphous calcium aluminate.

7. The hydraulic composition for an additive manufacturing device according to claim 1 , wherein 0.1 to 1.0% by mass of hydrophobic fumed silica is contained.

8. A process for producing a casting mold, wherein the casting mold is produced by using an additive manufacturing device and the hydraulic composition for an additive manufacturing device according to claim 1 .

9. A hydraulic composition for an additive manufacturing device according to claim 1 , comprising:
100 to 400 parts by mass of sand with respect to 100 parts by mass of the binder containing 90 to 95% by mass of (A) the calcium aluminate and 5 to 10% by mass of (B) the cement as follows:
(A) the calcium aluminate having a molar ratio of CaO/Al 2 O 3 from 1.5 to 3.0; and
(B) the cement having a content of calcium silicate of 25% by mass or more,
wherein a total content of the calcium aluminate and the cement is 100% by mass, and
wherein the hydraulic composition is molded by the additive manufacturing device into the plurality of shapes arranged in horizontal planes with reduced gas generation defect and with reduced graphite spheroidization defect.

10. The hydraulic composition for an additive manufacturing device according to claim 9 , comprising gypsum in an amount of 0.5 to 10 parts by mass with respect to 100 parts by mass of the calcium aluminate.

11. The hydraulic composition for an additive manufacturing device according to claim 10 , wherein the gypsum is in a state of being contained in cement.

12. The hydraulic composition for an additive manufacturing device according to claim 9 , wherein a setting (initial set) of the cement measured according to JIS R5210 is within 3 hours 30 minutes.

13. The hydraulic composition for an additive manufacturing device according to claim 9 , wherein the sand is one or more selected from silica sand, olivine sand, and artificial sand.

14. The hydraulic composition for an additive manufacturing device according to claim 9 comprising, as a hardening accelerator, one or more members selected from the group consisting of alkali metal carbonate salt, alkali metal lactate salt, alkaline earth metal lactate salt, and alkali metal silicate salt.

15. The hydraulic composition for an additive manufacturing device according to claim 9 , wherein the calcium aluminate is amorphous calcium aluminate.

16. A process for producing a casting mold, wherein the casting mold is produced by using the hydraulic composition for an additive manufacturing device according to claim 9 .

17. A hydraulic composition for an additive manufacturing device according to claim 1 , comprising:
100 to 400 parts by mass of sand,
100 parts by mass of the binder containing 90 to 95% by mass of (A) the calcium aluminate and 5 to 10% by mass of (B) the cement as follows:
(A) the calcium aluminate having a molar ratio of CaO/Al 2 O 3 of 1.5 to 3.0; and
(B) the cement containing 25% by mass or more of calcium silicate, and 0.5 to 10 parts by mass of gypsum with respect to 100 parts by mass of the calcium aluminate,

wherein the hydraulic composition is molded by the additive manufacturing device into the plurality of shapes arranged in horizontal planes with reduced gas generation defect and with reduced graphite spheroidization defect.

18. The hydraulic composition for an additive manufacturing device according to claim 17 ,
wherein the sand is one or more selected from silica sand, olivine sand, and artificial sand, and
wherein a setting (initial set) of the cement measured according to JIS R5210 is within 3 hours 30 minutes.

Assignees

• Taiheiyo Cement Corp

Inventors

• OHGI Yoshifumi
• Ogawa Yoji
• Tanimura Makoto
• Toba Atsuya
• Suzuki Hayato

Classifications

• B22C1/10 Primary

  for influencing the hardening tendency of the mould material (influencing the hardening tendency of the binding agent only B22C1/16) · CPC title

• C04B14/06

  Quartz; Sand · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• C04B2111/00181

  Mixtures specially adapted for three-dimensional printing (3DP), stereo-lithography or prototyping · CPC title

• Y02W30/91

  Use of waste materials as fillers for mortars or concrete · CPC title