背景 シェル鋳型とはRCS(Rein Coated Sand)を原料とした砂型だ。保存性が良く、鋳肌がきれいなので中子(なかご)に利用される。しかし、ここで焼付きが生じる問題がある。焼付きとは鋳造欠陥の１つ鋳物砂と溶解金属が接着したことを指す。これには物理的要因と化学的要因がある。物理的要因には溶融金属に黒鉛の共晶凝固時の体積膨張などの圧力が生じる。この圧力により砂の隙間に侵入する。化学的要因には秒間で化学結合を起こしファイアライトを結成することで濡れ性が大きくなり砂の隙間に侵入する。焼付きは物理的要因と化学的要因が複合的に発生する。焼付き形態を定量化することで発生要因を明確にする。
目標 焼付き性定量評価法を開発し焼付き発生要因を明確にする。
報告 ①焼付き試料の表面と内部砂のSEM-EDX( Energy Dispersive X-ray Spectroscopy)の報告
②鋳造で焼付きを再現し注湯量による焼付き度合の調査報告
手順 ①焼付いたエンジン試料を一部カットし内部の砂の比較を行うためにSEM₋EDXによる元素マッピング調査を行った。
②ムライトウール鋳造とシェル中子の制製
結果 ①Fe,Si,Oが同一箇所に存在せずファイアライトが形成していないことから化学的要因での可能性が低い。砂粒(画像より)の様子は爆熱による可能性は低い。
②焼付き度合 小≧大>中
考察 ①このことからヘッド圧、黒鉛晶出による膨張が原因の可能性があると考えられる。
②溶湯量は焼付き度合には影響が少ない可能性
総括 ①SEM-EDMの調査により焼付きの要因は黒鉛の共晶凝固時の膨張による可能性
②鋳造実験の調査により焼付き度合には注湯量には影響が少ない可能性
今後の予定 ミクロ的な視点での調査
焼付き度合と注湯量との関係性を確認
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