Patent Application
20240058860
The present disclosure relates to chills for casting of a sand cast aluminum part and, more particularly, hybrid chills with enhanced heat transfer for casting of a sand cast aluminum engine block of a vehicle.
Chills are used in casting for cooling during solidification of a sand cast aluminum part such as a sand cast aluminum engine block. Chills are placed on the sand cast to assist in heat transfer. With conventional chills, a sand cast aluminum part may still have undesirable porosity and cast aluminum dendrite arm spacing.
Thus, while current chills achieve their intended purpose, there is a need for a new and improved hybrid chill with enhanced heat transfer for casting of a sand cast aluminum part.
In accordance with one aspect of the present disclosure, a hybrid chill with enhanced heat transfer for casting of a sand cast aluminum part of a vehicle is provided. The hybrid chill comprises a base comprising an outer wall having a first side and a second side opposite the first side. Each of the first and second sides extends from a first longitudinal end to an opposite second longitudinal end and along a first lateral end and a second lateral end opposite the first lateral end. In this aspect, the outer wall is closed to define a hollow portion.
Moreover, the base further comprises a heat transfer fluid in a liquid phase disposed in the hollow portion. In this aspect, the heat transfer fluid has a boiling point of between 320° Celsius (° C.) and 400° C. at 1 bar for enhanced heat transfer during casting.
The chill further comprises a plurality of crankcase members. Each member is disposed on the first side and extends from the first lateral end to the second lateral end of the outer wall. Additionally, each member is parallel to and spaced apart from a respective adjacent member defining an open recess formed between adjacent members from the first lateral end to the second lateral end.
In one embodiment, the outer wall is gray iron (Fe) comprising 2.8 to 3.3 weight percent (wt %) carbon (C), 1.2 to 1.7 wt % silicon (Si), 0.8 to 1.2 wt % manganese (Mn), less than 0.15 wt % phosphorus (P), and less than 0.12 wt % sulfur (S). In another embodiment, the outer wall has a thickness of between 5 millimeters (mm) and 50 mm. In this embodiment, the outer wall is gray iron comprising 2.9 to 3.2 weight percent (wt %) carbon (C), 1.3 to 1.6 wt % silicon (Si), 0.9 to 1.1 wt % manganese (Mn), less than 0.15 wt % phosphorus (P), and less than 0.12 wt % sulfur (S).
In another embodiment, at least one crankcase member comprises an inner cavity formed therein and in fluid communication with the hollow portion of the body. The inner cavity comprises heat transfer fluid for increased heat transfer. In yet another embodiment, the inner cavity of the at least one crankcase member is formed by the outer wall having an inner surface. The inner surface has a surface roughness to increase surface area for enhanced heat transfer.
In another embodiment, the second side of the base comprises a plurality of fins formed thereacross from the first lateral end to the second lateral end. In this embodiment, each fin is spaced apart from a respective adjacent fin to define an open portion extending between adjacent fins from the first lateral end to the second lateral end for enhanced heat transfer.
In another embodiment, the heat transfer fluid is a silicon-based heat transfer fluid in the liquid phase. In yet another embodiment, the heat transfer fluid is a silicon-based heat transfer fluid comprising polydimethylsiloxane.
In accordance with another aspect of the present disclosure, a hybrid chill with enhanced heat transfer for casting of a sand cast aluminum engine block of a vehicle is provided. The hybrid chill comprises a base comprising an outer wall having a first side and a second side opposite the first side. Each of the first and second sides extends from a first longitudinal end to an opposite second longitudinal end and along a first lateral end and a second lateral end opposite the first lateral end. The outer wall is closed to define a hollow portion.
The base further comprises a silicon-based heat transfer fluid in a liquid phase disposed in the hollow portion. The heat transfer fluid has a boiling point of between 320° Celsius (° C.) and 400° C. at 1 bar for enhanced heat transfer during casting. The outer wall is gray iron comprising 2.8 to 3.3 wt % C, 1.2 to 1.7 wt % Si, 0.8 to 1.2 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S.
In this aspect, the chill further comprises a plurality of crankcase members. Each member is disposed on the first side and extends from the first lateral end to the second lateral end of the outer wall. Each member is parallel to and spaced apart from a respective adjacent member defining an open recess extending between adjacent members from the first lateral end to the second lateral end.
In one embodiment, the outer wall has a thickness of between 5 millimeters (mm) and 50 mm. In this embodiment, the outer wall is gray iron comprising 2.9 to 3.2 weight percent (wt %) carbon (C), 1.3 to 1.6 wt % silicon (Si), 0.9 to 1.1 wt % manganese (Mn), less than 0.15 wt % phosphorus (P), and less than 0.12 wt % sulfur (S).
In another embodiment, at least one crankcase member comprises an inner cavity formed therein and is in fluid communication with the hollow portion of the body. The inner cavity comprises heat transfer fluid for increased heat transfer. In one embodiment thereof, the inner cavity of the at least one crankcase member is formed by the outer wall having an inner surface. The inner surface has a surface roughness to increase surface area for enhanced heat transfer.
In yet another embodiment, the second side of the base comprises a plurality of fins formed thereacross from the first lateral end to the second lateral end. Each fin is spaced apart from a respective adjacent fin to define an open portion extending between adjacent fins from the first lateral end to the second lateral end for enhanced heat transfer. In another embodiment, the heat transfer fluid is a silicon-based heat transfer fluid comprising polydimethylsiloxane.
In accordance with yet another aspect of the present disclosure, a hybrid chill with enhanced heat transfer for casting of a sand cast aluminum engine block of a vehicle is provided. In this aspect, the hybrid chill comprises a base comprising an outer wall having a first side and a second side opposite the first side. Each of the first and second sides extends from a first longitudinal end to an opposite second longitudinal end and along a first lateral end and a second lateral end opposite the first lateral end.
In this aspect, the outer wall is closed to define a hollow portion. The base further comprises a heat transfer fluid in a liquid phase disposed in the hollow portion. The heat transfer fluid has a boiling point of between 320° C. and 400° C. at 1 bar for enhanced heat transfer during casting. The heat transfer fluid is a silicon-based heat transfer fluid comprising polydimethylsiloxane.
The chill further comprises a plurality of crankcase members, each member disposed on the first side and extending from the first lateral end to the second lateral end of the outer wall, each member being parallel to and spaced apart from a respective adjacent member defining an open recess extending between adjacent members from the first lateral end to the second lateral end.
In one embodiment, the outer wall is gray iron (Fe) comprising 2.8 to 3.3 wt % C, 1.2 to 1.7 wt % Si, 0.8 to 1.2 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S. In another embodiment, the outer wall has a thickness of between 30 mm and 50 mm and the outer wall is gray iron comprising 2.9 to 3.2 wt % C, 1.3 to 1.6 wt % Si, 0.9 to 1.1 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S.
In yet another embodiment, at least one crankcase member comprises an inner cavity formed therein and in fluid communication with the hollow portion of the body. Moreover, the inner cavity comprises heat transfer fluid for increased heat transfer.
In still another embodiment, the inner cavity of the at least one crankcase member is formed by outer wall having an inner surface. The inner surface has a surface roughness to increase surface area for enhanced heat transfer. In another embodiment, the second side of the base comprises a plurality of fins formed thereacross from the first lateral end to the second lateral end. Moreover, each fin is spaced apart from a respective adjacent fin to define an open portion extending between adjacent fins from the first lateral end to the second lateral end for enhanced heat transfer.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
Aspects of the present disclosure provide a hybrid chill with enhanced heat transfer capability for casting of a sand aluminum part of a vehicle. The hybrid chill comprises a heat transfer fluid (preferably silicon-based) disposed in a hollow portion thereof. The heat transfer fluid is in a liquid phase to provide enhanced heat transfer during solidification of the part.
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In one embodiment, the outer wall 14 is comprised of gray iron (Fe) comprising 2.8 to 3.3 weight percent (wt %) carbon (C), 1.2 to 1.7 wt % silicon (Si), 0.8 to 1.2 wt % manganese (Mn), less than 0.15 wt % phosphorus (P), and less than 0.12 wt % sulfur (S).
Preferably, the outer wall 14 may have a thickness of between 30 millimeters (mm) and 50 mm. In this embodiment, the outer wall is gray iron comprising 2.9 to 3.2 weight percent (wt %) C, 1.3 to 1.6 wt % Si, 0.9 to 1.1 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S.
Moreover, the outer wall 14 may have a thickness of greater than 50 mm. In this embodiment, the outer wall is gray iron comprising 2.8 to 3.1 weight percent wt % C, 1.2 to 1.5 wt % Si, 1.0 to 1.2 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S.
Additionally, the outer wall 14 may have a thickness of less than 30 mm. In this embodiment, the outer wall is gray iron comprising 3.0 to 3.3 weight percent wt % C, 1.4 to 1.7 wt % Si, 0.8 to 1.0 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S.
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In this embodiment, portions of the outer wall 114 may have a thickness greater than 50 mm in thickness and may be comprised of gray iron (Fe) comprising 2.8 to 3.1 weight percent wt % C, 1.2 to 1.5 wt % Si, 1.0 to 1.2 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S. Moreover, other portions of the outer wall 114 may have a thickness of between 30 mm and 50 mm. As such, the outer wall 114 is gray iron comprising 2.9 to 3.2 wt % C, 1.3 to 1.6 wt % Si, 0.9 to 1.1 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S.
Referring to
In this embodiment, a portion of the outer wall 214 may be less than 30 mm in thickness and comprised of gray iron (Fe) comprising 3.0 to 3.3 weight percent wt % C, 1.4 to 1.7 wt % Si, 0.8 to 1.0 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S. Moreover, other portions of the outer wall 214 may have a thickness of between 30 mm and 50 mm. As such, the outer wall 214 is gray iron comprising 2.9 to 3.2 wt % C, 1.3 to 1.6 wt % Si, 0.9 to 1.1 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S.
Referring to
In this embodiment, a portion of the outer wall 314 may be less than 30 mm in thickness and comprised of gray iron (Fe) comprising 3.0 to 3.3 weight percent wt % C, 1.4 to 1.7 wt % Si, 0.8 to 1.0 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S. Moreover, other portion of the outer wall 314 may have a thickness of between 30 mm and 50 mm. As such, the outer wall is gray iron comprising 2.9 to 3.2 wt % C, 1.3 to 1.6 wt % Si, 0.9 to 1.1 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S.
Referring to
In this embodiment, a portion of the outer wall 414 is less than 30 mm in thickness and comprised of gray iron (Fe) comprising 3.0 to 3.3 weight percent wt % C, 1.4 to 1.7 wt % Si, 0.8 to 1.0 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S. Moreover, other portion of the outer wall 414 may have a thickness of between 30 mm and 50 mm. As such, the outer wall is gray iron comprising 2.9 to 3.2 wt % C, 1.3 to 1.6 wt % Si, 0.9 to 1.1 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S. Moreover, other portions of the outer wall 414 may have a thickness greater than 50 mm in thickness and may be comprised of gray iron (Fe) comprising 2.8 to 3.1 weight percent wt % C, 1.2 to 1.5 wt % Si, 1.0 to 1.2 wt % Mn, less than 0.15 wt % P, and less than 0.12 wt % S.
It is to be understood that the hybrid chill may be used for various castings of any sand cast aluminum part of a vehicle such as a transmission block, a differential block or any other suitable vehicular part without departing from the spirit or scope of the present disclosure.
The description of the present disclosure is merely exemplary in nature and variations that do not depart from the gist of the present disclosure are intended to be within the scope of the present disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure.
