DE102011108126A1 - Manufacturing cast component, preferably a cast knot, comprises inserting at least one metallic inlay profile, preferably inlay-sheet profile into a casting mold, and at least positively recasting with a cast metal in partial areas - Google Patents

Abstract

Manufacturing cast component, preferably a cast knot, comprises (i) inserting at least one metallic inlay profile (1a, 1b, 1c), preferably inlay-sheet profile into a casting mold, and (ii) at least positively recasting with a cast metal (2) in partial areas, where at least one inlay profile, preferably at least one inlay-sheet profile is inserted with an open end in the casting mold and an integral connection is produced between the inlay profile and the cast metal during casting. Independent claims are also included for: (1) the cast component, preferably cast knot, comprising at least one metallic inlay profile, preferably inlay-sheet profile, which is at least positively subjected to re-casting with the cast metal in partial areas, where at least one inlay profile has a surface coating, preferably an alloy coating, through which the integral connection between the inlay profile and the cast metal is created; (2) a motor vehicle body component comprising multiple profiles, which are connected with each other, where at least two profiles are connected with each other by the above mentioned cast component, which includes at least two inlay profiles, where the each inlay profile is cast by a cast metal connecting in partial areas, and the inlay profiles, in each case are connected with at least one of the profiles; and (3) manufacturing the identically shaped motor vehicle body components, comprising (I) producing identically shaped car body components from multiple profiles or at least two profiles, preferably deep-drawing sheet-profiles, which are connected with each other, (II) choosing a set of at least two cast components, depending on the design-type, preferably the metal-type of the car body components to be produced, from at least two sets available for disposal, and (III) inter-connecting at least one portion of the total existing profiles with the cast component of the chosen set.

Description

The invention relates to a method for producing a cast component, in particular a cast node, in which at least one metallic insert profile, in particular insert sheet metal profile is inserted into a casting mold and partially cast with casting metal at least in a form-fitting manner. The invention furthermore also relates to a cast component, in particular a cast node, comprising at least one metallic insert profile, in particular insert sheet metal profile, which is partially encapsulated with a cast metal at least in a form-fitting manner.

The invention further relates to a cast component, a motor vehicle body component, and a method for producing a motor vehicle body component.

A method for producing a cast component or a cast component itself is known, for example, from the publication WO 2006/122423 A1 by Applicant Magna International Inc.

In the method described there Einlegerprofile be cast with a cast metal to form a hybrid component, which may consist of two different metals, namely, on the one hand, the metal, which is used for encapsulation and the metal from which the Einlegerprofil.

In this known method, the insert profile is encapsulated with a very high pressure, for example in the range of 2-4 tons per square inch, which in addition to a positive connection, which is automatically formed by the Umgießen, also a high adhesion between the encapsulated metal and the inserted insert profile arises, which is particularly supported by the fact that, for example, aluminum as a cast metal during cooling shrinks greatly compared to an existing example of sheet steel insert profile, so that increased by the cooling of traction.

Due to the extreme forces acting in this case, however, this known method is limited to use as Einlegerprofil such profiles, whose encapsulated end is closed on the one hand to prevent penetration of the casting metal into the molded end, which would otherwise prevent the adhesion and on the other hand, that the closed hollow profiles have a round cross-section, since all other cross-sectional shapes would otherwise lead to a squeezing of the cast hollow profile due to the high forces acting on all sides. This method known in the prior art is thus limited to these limiting parameters or profile shapes.

It is further known in the art that z. B. in the field of application of the bodywork and the chassis modern motor vehicles and components made of different materials, especially different metals to be produced. In particular, due to increasing demands on the so-called lightweight construction on the one hand and the always desired cost reduction on the other hand, a tendency for mixed construction of different materials is enhanced.

Here, the most suitable material should be used at relevant points, for example to achieve the best compromise between weight and cost. Such places are z. B. the connection node where z. B. in motor vehicles in the A-, B- or C-pillars several profiles have a common connection location.

There is therefore a great need to efficiently connect different materials, in particular different metals. Especially in the automotive industry, the usual types of connection are spot welding and MIG-MAG welding. Although there are other types of connection, for example, to connect different materials together, such as gluing, stamping, riveting, clinching, etc., the establishment of these connection techniques would require a conversion already in the process of manufacturing bodies and chassis of established facilities together with this resulting costs.

In addition, there is a further need to see how to modularize vehicle bodies and chassis and thus realize, for example by a modular design, different vehicles on the same manufacturing platform.

It is therefore an essential object of the invention to provide a method and a cast component that allows a mixed construction, so for example the connection of different metals within the cast component and which further using the classical and, often established welding equipment, such as point and / or MIG MAG welding can be processed further.

In addition, a cast component and a method for producing a body component or a whole body is to be provided that does not have the aforementioned limitations of the aforementioned prior art, but preferably the mixed construction basically arbitrary profile shapes and any metals allowed.

According to the invention this object is achieved by a method for producing a cast component, in particular a cast node of the type mentioned, in which at least one insert profile, in particular at least one insert profile with an open end inserted into the mold and a cohesive connection between Einlegerprofil during casting and the cast metal is produced. In addition to such an integral connection according to the invention, a positive and / or non-positive connection can exist between the at least one insert profile and the cast metal.

A casting node, which can be formed by the casting component preferably, is its such component that forms a connection node between two profiles. Such a preferred casting node therefore has at least two insert profiles, preferably three or more, which are interconnected by metal casting and which can be connected to other profiles, for. B. those of the same metal or the same alloy.

In the same way, therefore, the object is achieved by a cast component of the type mentioned, in which at least one insert profile is encapsulated with an open end in the cast metal.

It is thus an essential core idea of the invention, in addition to the technologically caused form fit when casting around at least one insert profile not to rely primarily on an emerging adhesion, as used in the publication mentioned above to produce stable and durable castable components, but that Rather, to achieve a high stability between the at least one insert profile, in particular a depositor sheet metal profile, and the cast metal according to the invention, in addition, a material bond is produced.

It is therefore possible with the method of the invention to produce cast components which withstand the strongest possible stresses and can be produced inexpensively and with high variability. It is particularly advantageous in the invention that profiles can be encapsulated with open ends.

In this case, an open end of a profile is understood to mean that all surfaces of this end region can be encircled by the cast metal or flowed during casting at the cast-over end region of the profile. An open profile is thus within the meaning of the invention not only a hollow profile with non-closed end, but also any profile that has no cavities at the end, or even cavities into which the casting material during casting can at least partially penetrate, especially if this is not done by the front end. A deep-drawn sheet metal component of any metal is z. For example, such a profit.

It is essential for the method according to the invention or the casting component produced thereby that the at least one encapsulated insert profile is encapsulated only partially, so that a cast component is produced in the inventive method, in which from the casting area the at least one insert profile with a non-cast Projecting portion of the casting so that this area of a Einlegerprofils can be used to connect to this area by conventional and often established bonding techniques other components, such as profiles, in particular profiles of the same metal as the Einlegerprofil where the connection is made should. The procedures that can be used here for connecting, z. B. standard welding methods, such as spot, MAG, laser welding, etc.

For a cast component according to the invention, it is essential that at least one insert profile is encapsulated with the method according to the invention.

In a preferred embodiment, it can also be provided that more than one insert profile is encapsulated, thus thus an inventive casting component has a cast-around area, protrude from the non-encapsulated portions of Einlegerprofilen in at least two different directions.

According to the invention, therefore, it is also possible, in a cast profile of the type according to the invention in addition to the selected cast metal, such as a light metal, for. As aluminum or magnesium, as well as steel, Einlegerprofile of different metals and different shapes at the same time to use. It can be made on the cast metal and a mix of Einführprofilen that would otherwise be difficult or impossible to connect.

Of course, it is possible to design all Einlegerprofile of the same metal.

It can be provided in all variants that a Einlegerprofil consists of a metal that has a higher or equal melting temperature as the cast metal.

Basically, it can be provided here, for example, that the casting metal is selected from aluminum, magnesium or steel, wherein the Insert profiles, for example, be selected from aluminum sheet, magnesium sheet or steel sheet. It may be in these sheets of Einlegerprofile to such sheets, which are formed open at the over-molded ends, for example.

Unlike the cited prior art, the method according to the invention does not require the use of high pressure, so that casting can take place in a low-pressure region or even in the unpressurized region under ambient pressure conditions and thus the inflow of the casting metal into open profile ends is prevented or, if so an inflow into open profile ends takes place, is at least irrelevant, since the principle of frictional connection in contrast to the prior art in the present process has no or only a minor importance and the permanent stability of the cast component according to the invention by the aforementioned substance, in particular in addition to the molding and / or adhesion occurs.

The method according to the invention and a cast component produced according to these methods can be used with particular preference to produce cast components or cast nodes for motor vehicle bodies, in particular body pillars, or body parts with them.

For example, such a cast component or casting node can be used to form an A, B or C pillar of a motor vehicle, wherein the cast node, for example, may have three or more form-different Einlegerprofile, which are interconnected by the cast metal. Likewise, other body components or whole bodies of the cast components can be made in connection with profiles to be joined.

There is thus a particularly significant advantage according to the invention in that for the production of cast components for vehicle bodies in a manufacturing process, the cast components with at least one insert profile, in the aforementioned columns, for example, with two, three or more Einlegerprofilen, are always made of the same shape, wherein However, depending on the body type, so for example, classic steel construction or lightweight construction, z. B. by aluminum or magnesium, the metal type of Einlegerprofile and / or the casting metal is selected.

Thus, in the same way body components or whole bodies of always the same shape but different materials can be created without the need for a change in the manufacturing process, depending on the requirements of the profiles to be joined and / or the cast components, the desired or required metal can be selected ,

This has the particular advantage that the basically same work platform can be used in a production line, regardless of whether the vehicle just produced is one of classic construction, lightweight construction or mixed construction, as to define the type only on different cast components with different deposit profiles and / or cast metal, but always the same form is used.

It can thus be prepared according to the invention automotive bodies or their components, the several interconnected profiles, eg. B. from deep-drawn sheets, wherein the connection between two or more profiles is carried out by a casting node, in which at least two Einlegerprofile partially casted by a cast metal and are connected to each other, in particular where there is a material bond between cast metal and Einlegerprofil. The connection between two body profiles thus takes place via the insert profiles and the cast metal. For example, the sequence of elements between two profiles is: Profile1 Inlay Profile Cast Metal Insert Profile2. A Einlegerprofil and a profile are connected by conventional joining techniques, z. B. by welding.

The insert profiles, which according to the invention may, for example, also have open profile ends and, in particular, not rotationally symmetrical profile ends in cross-section, may for example have any non-round cross-section. Due to the fact that the Umgießen can take place without pressure or with respect to the aforementioned prior art significantly reduced pressures, there is no risk that a cross-sectional shape of a Einlegerprofils is destroyed by traction.

In order to improve the stability of a manufactured cast component according to the invention in addition to the achieved material bond according to the invention, it may also be provided to additionally introduce indentations or recesses in front of the process of encapsulation in a depositor profile at least at one end to be encapsulated.

As a result, the positive connection that occurs in any case during the casting process is further promoted and, moreover, the surface of a depositor profile in the encapsulated region is increased, so that, according to the invention, the regions of the material bond also increase in terms of area.

In one embodiment, it can be provided that the at least one insert profile consists of a metal or an alloy which melts at least in the surface area at the temperature of the casting metal prevailing in the casting process. Thus, in this embodiment, the cast metal with the metal melted at least in the surface area of the Einlegerprofils enter into a material and positive connection.

It may also be provided in one embodiment that the at least one insert profile is provided with a surface coating, in particular an alloy coating, at least in its end region to be encapsulated, wherein the surface coating effects a material connection between the insert profile and the cast metal.

In one embodiment of the invention, it may be provided that a silicon alloy layer or an aluminum-silicon layer is used as a coating which effects the material bond between the cast metal and the metal of the insert profile. When using such a layer, which can be applied to the insert profile before casting, for example, already in the manufacturing process of the sheet of Einlegerprofils in the rolling mill or the later-shaped Einlegerprofils, can be effected according to the invention that the metal, which is used for casting, in this Surface coating diffused and thereby the material bond is formed.

Thus, an intermetallic phase may arise in the transition region between the cast metal and the metal of the insert profile, which in a particularly preferred embodiment has ductile properties. Optionally, the ductility of such a resulting phase may be favored by specially selected coating alloys.

In one possible embodiment, it can be provided, for example, to provide a depositor profile made of sheet steel with such a silicon alloy layer or AlSi layer and partially encapsulated by aluminum as cast metal. For example, cast components for the production of body columns can be produced for the classic steel body construction, for example, have three Einlegerprofile different design of sheet steel, which are cast together in a casting process by aluminum metal and bonded cohesively.

In an alternative embodiment, it may also be provided as a coating of a Einlegerprofils, for example, a Einlegerblechprofils, z. As steel, a Zn or ZnNi layer used when casting the cast metal, z. B. Al, a solder connection to the insert profile can be created or favors. Here, this type of layer acts in particular wetting promoting against the cast metal, which causes the material bond.

In another embodiment, it can also be provided that the insert profile has a coating with the same metal, of which the cast metal or which at least comprises the cast metal, wherein during the casting, in particular by melting, a connection between two identical metals.

The following layer materials or alloys can be used, for example: Zn, ZnFe, ZnAl, ZnNi.

The layer thicknesses of all possible layers can z. B. in the range of 2 to 20 microns, for example, in an electrolytic coating. By the process of hot-dip galvanizing larger Zn-based layer thicknesses can be achieved, for. B. to 120 micrometers.

In one embodiment, it may therefore be envisaged to use as cast metal a light metal, for example aluminum and as Einlegerprofil a steel sheet, said steel sheet, however, with a layer of light metal, for. B. aluminum layer is provided, for example by electrolytic coating, fire coating, dip coating or vapor deposition. In the casting process with the molten cast metal, z. B. aluminum metal is therefore an at least partially melting the light metal surface coating, z. B. the aluminum surface coating of the steel insert profile, so that this causes a material bond.

Of course, it is also possible to use the same metals for the cast metal and the metal of the insert profile, ie to encase an aluminum insert profile with aluminum cast metal, for example. In such a case, it requires no special coating, but it can be provided here for realizing the method according to the invention that not only a Einlegerprofil of the same metal as the cast metal is arranged on a cast component of the inventive design, but at least one other Einlegerprofil from another Metal, which is integrally bonded according to the invention in the cast metal.

In particular, in this way there is also the possibility within a motor vehicle body partially in the further bodywork light metals, such as magnesium or To use aluminum and in other areas to produce classical construction, for example by steel profiles. It can also take place within a body, a material change, z. B. in that two profiles of different metals are connected by means of a casting node, or are connected, are cast in the deposit profiles of these two different metals. A casting node of the type according to the invention thus acts as a material adapter.

Accordingly, a cast component or the method according to the invention described above significantly facilitates the so-called mixed construction in motor vehicle production by the possibility of selectively combining the most varied insert profiles with one another in a cast component of the type according to the invention or optionally in a cast component depending on the type of metal to be used Depositor profiles or even the cast metal to select.

Embodiments of the invention will be described below.

The 1 shows a cast component of the type according to the invention as a so-called Gußknoten, in which in this example the casting node for a motor vehicle A-pillar is shown.

The cast component has a total of three deposit profiles 1a . 1b and 1c , which may be made of sheet steel or alternatively made of aluminum or even of different metals, for example.

Here, therefore, there is the possibility of all Einlegerprofile 1a , b and c at the same time only out of steel or at the same time only made of aluminum or even the possibility to partially manufacture the Einlegerprofile steel and aluminum, etc., so that a cast component, in particular cast nodes of the inventive type accordingly Einlegerprofile of different metals simultaneously can. The insert profiles 1a . 1b and 1c In particular, if they are different to the metal of the casting metal, have a surface coating, which favor or cause a material bond between cast metal and the metal of the insert profile.

Here the execution is such that the Einlegerprofile 1a , b and c with their ends facing each other through cast aluminum 2 are encapsulated, according to the invention, the material connection in particular in addition to positive engagement and / or adhesion and thus creates a stable, permanently usable component for bodywork.

The 2 shows a cast component according to the invention according to the 1 in which, as the production progresses, e.g. B. a motor vehicle body to which from the casting area 2 outstanding ends of the insert profiles 1a , b and c other components 3a , b and c are respectively fixed, for example by classical welding techniques, such as spot welding, MIG or MAG welding.

The method or casting component according to the invention here particularly favors transitions within a motor vehicle or a body of such between different types of metal. For example, it is possible to produce a roof structure in light metal construction, characterized in that the Einlegerprofil 1a z. B. made of aluminum, so that another spar 3a Made of aluminum sheet can be connected to this easily welding technology.

On the other hand, here, for example, the other components 3c and 3b be made of sheet steel and inserts 1b and 1c made of steel also be connected by welding technology.

Against the background of the problems with a welded joint between steel and aluminum, it is thus evident that such metal transitions can be produced without difficulty by means of a cast connection, in particular of the material-locking type according to the invention, since these transitions between the same metals are required for the respective weld transitions which are required in the body construction can be made, however, the metal change within the cast component according to the invention in the preferably cohesive pouring different types of metal Einlegerprofile arises.

It is also apparent that in the manufacturing process of a motor vehicle with z. B. cast components according to the 1a , these components can always be made the same shape, but with different metals of Einlegerprofile and / or the casting metal.

Accordingly, different types of cast components can basically be provided in the same production process in order to be able to produce bodies on the one hand in classic steel construction and on the other hand in modern lightweight construction or in mixed construction, which requires neither a platform change nor a change of welding equipment.

The 3 shows an example of a section of a car body, so thus a body component here two profiles 3a . 3b the body component, the z. B. manufactured as a sheet metal deep-drawn are not directly connected but indirectly via a cast node, or a cast component. The profile 3a can z. B. be made of a first metal, which is the metal of the Einlegerprofils 1a corresponds, for. B. Al or steel on which the profile 3a is attached. The profile 3b may consist of a second other metal, as well as the Einlegerprofil 1b , z. As steel or Al, to which this is attached. It can thus between the profiles 3a . 3b a metal change takes place from steel to aluminum or vice versa or between other different metals. Here is the connection of the depositor profiles 1a and 1b again over the cast metal 2 ,

Of course, the profits 3a and 3b made of the same metal, eg. As steel or aluminum. Thus, a body component in the case described above z. B. different metals include, for. B. lightweight construction in the roof area and steel construction in the floor area or a body or a body component may be made entirely of light metal (eg Al or Mg) or completely made of steel, each using the same shape Gottenknoten, but optionally with light metal insert profiles or steel insert profiles.

Depending on the requirements, the profiles to be joined can be connected to the cast components of one of several available sets of cast components. This has the advantage that the production always remains identical and thus the production paths within a production can remain the same. Depending on the requirements (type of material / type of metal), different profiles and cast components are selected, which are, however, identical in shape for each body component to be produced.

QUOTES INCLUDE IN THE DESCRIPTION

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Cited patent literature

• WO 2006/122423 A1 [0003]

Claims (16)

Method for producing a cast component, in particular a cast node, in which at least one metallic insert profile ( 1a . 1b . 1c ), in particular insert sheet metal profile inserted into a mold and partly with cast metal ( 2 ) is at least positively sealed, characterized in that in the mold at least one insert profile ( 1a . 1b . 1c ), in particular at least one insert profile ( 1a . 1b . 1c ) with an open end and during casting a cohesive connection between Einlegerprofil ( 1a . 1b . 1c ) and the cast metal ( 2 ) is produced. Method according to claim 1, characterized in that the at least one insert profile ( 1a . 1b . 1c ) is / is provided with a surface coating, in particular an alloy coating, at least in its end region to be encapsulated, wherein the surface coating forms the integral connection between the insert profile ( 1a . 1b . 1c ) and the cast metal ( 2 ) causes. A method according to claim 2, characterized in that a Si alloy layer or AlSi layer is used as the coating and the casting metal at least partially diffused during casting in the layer, in particular whereby an intermetallic, preferably ductile phase between cast metal ( 2 ) and insert profile ( 1a . 1b . 1c ) arises. A method according to claim 2, characterized in that a Zn or ZnFe or ZnAl or ZnNi layer is used as the coating and during casting the cast metal ( 2 ) a solder joint to the insert profile ( 1a . 1b . 1c ) received. Method according to claim 2, characterized in that the insert profile ( 1a . 1b . 1c ) has a coating with the same metal from which the cast metal ( 2 ) or which the cast metal ( 2 ), wherein during the casting, in particular by melting, a connection between two identical metals takes place. Method according to one of the preceding claims, characterized in that at least one insert profile ( 1a . 1b . 1c ) with an open profile end, in particular with a non-round cross section without pressure or with a low pressure casting, z. B. low pressure sand casting process is poured. Method according to one of the preceding claims, characterized in that in an insert profile ( 1a . 1b . 1c ) are introduced at least at an end to be embossed indentations before Umgießen. Method according to one of the preceding claims, characterized in that for the production of cast components for vehicle bodies, the cast components with at least one Einlegerprofil ( 1a . 1b . 1c ), in particular several Einlegerprofilen be made of always the same shape, depending on the body type, the metal type of Einlegerprofile ( 1a . 1b . 1c ) is selected. Method according to one of the preceding claims, characterized in that the cast metal ( 2 ) is selected from: aluminum, magnesium or steel and the insert profiles ( 1a . 1b . 1c ) are made of: aluminum sheet, magnesium sheet or steel sheet. Cast component, in particular cast node, comprising at least one metallic insert profile ( 1a . 1b . 1c ), in particular insert sheet metal profile that partially with a cast metal ( 2 ) is encapsulated at least in a form-fitting manner, characterized in that at least one insert profile ( 1a . 1b . 1c ) has a surface coating, in particular an alloy coating, by means of a cohesive connection between Einlegerprofil ( 1a . 1b . 1c ) and the cast metal ( 2 ) consists. Cast component according to claim 10, characterized in that it is a cast node of a motor vehicle body pillar, in particular an A, B or C pillar, wherein the cast node has at least two, in particular shape-different Einlegerprofile ( 1a . 1b . 1c ) through the cast metal ( 2 ) are connected. Motor vehicle body component comprising a plurality of profiles, which are connected to each other, characterized in that at least two profiles are connected to each other by means of a Gußbauteils, in particular according to one of the preceding claims 10 or 11, which has at least two Einlegerprofile, each partially encapsulated by a Gusmetall connecting and each connected to at least one of the profiles. Motor vehicle body component according to claim 12, characterized in that it comprises profiles of different metals, wherein at least two profiles of different metals are connected by means of a Gußbauteils, in particular according to one of the preceding claims 10 or 11, which has at least two Einlegerprofile of the same different metals, wherein metal-level insert profiles and profiles are interconnected. Motor vehicle body component according to claim 12, characterized in that it comprises at least one set of cast components for connecting profiles a metal type, in particular according to one of the preceding claims 10 or 11, wherein the cast components are optionally selected from a plurality of predetermined types of metal, wherein the cast components are differentiated according to the metal type of Einlegerprofile and / or the cast metal. A method for producing a similar shape motor vehicle body parts, in which each of the same shape body parts of several, especially at least two profiles, in particular thermoforming sheet profiles is produced, which are interconnected, characterized in that depending on the type, in particular the metal type of the body part to be manufactured a set of at least two cast components, in particular according to one of the preceding claims 10 or 11, is selected from at least two available sets and with the cast components of the selected set at least a part of the total existing profiles are joined together. Method according to claim 15, characterized in that a set of cast components a. Insert profiles of the same metal comprises or b. Insert profiles made of different metals.

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