Method for the production of a lattice part made of metal

Abstract

We describe a lattice part made of metal and a method for producing a lattice part made of metal or a metal alloy. The lattice has a thickness of less than 1 mm at a size of the gaps of less than 50 mm 2 . The lattice ( 5 ) comprises a connection made of knots, and perpendicular to the lattice surface has lattice bars and lattice knots of the same thickness. A method for the production of a lattice part made of metal, particularly made of light alloy, is characterized by a primary shaping process according to DIN 8580, wherein a mold is formed in the first step, a primary material is introduced in the mold cavity in the second step, the part is removed from the mold in the third step, and the finishing of the metallic lattice part is carried out in the fourth step.

1 . A method for producing a lattice part made of metal or of a metal alloy and forming a metallic node bond of lattice members, with the lattice having a thickness of less than 1 mm and openings with a surface area of less than 50 mm 2 , the method which comprises:
 producing the lattice by casting according to DIN 8680 and   in a first step, forming at least a part of the mold and jointing the mold;   in a second step, introducing a starting material of metal or a metal alloy at least in part into a cavity of the mold or applying the starting material to a profiled mold part, and establishing a master pattern;   subsequently, in a third step, at least partially removing the molded part from the mold; and   subsequently, in a fourth step, finishing of the molded part into a metallic lattice part.   
     
     
         2 . The method according to  claim 1 , wherein the first step comprises forming at least part of the mold by powder injection molding (PIM). 
     
     
         3 . The method according to  claim 1 , wherein in the first step, that mold part, which has been produced in the first step by powder injection molding (PIM), is produced making a mold material by mixing powder and a binder, granulating the mold material and injection molding the granules into a mold, thus forming a green body which can be further made into a brown body, which by sintering can be made to a mold part. 
     
     
         4 . The method according to  claim 3 , which comprises sintering the brown body into a sintered body having a porosity of 75 to 95% by volume. 
     
     
         5 . The method according to  claim 3 , which comprises mixing ceramic powder with the binder. 
     
     
         6 . The method according to  claim 1 , which comprises using a base alloy of magnesium containing, in percent by weight: 
       
         
           
                 
                 
                 
               
                     
                     
                 
                     
                   zinc (Zn) 
                   0.6 to 8.0; 
                 
                     
                   zirconium (Zr) 
                   up to 2.0; 
                 
                     
                   manganese (Mn) 
                   0.02 to 0.8; 
                 
                     
                   calcium (Ca) 
                   up to 1.2; 
                 
                     
                   antimony (Sb) 
                   up to 0.8; 
                 
                     
                   aluminum (Al) 
                   up to 0.8; 
                 
                     
                   silver (Ag) 
                   0.8 to 2.5; 
                 
                 
                 
               
                     
                   impurities, and remainder magnesium. 
                 
                     
                     
                 
             
                
               
               
                
                
                
                
                
                
                
               
            
             
                
                
               
            
           
         
       
     
     
         7 . The method according to  claim 6 , wherein the base alloy contains, in percent by weight: 
       
         
           
                 
                 
                 
               
                     
                     
                 
                     
                   zinc (Zn) 
                   0.8 to 6.2; 
                 
                     
                   zirconium (Zr) 
                   up to 1.0; 
                 
                     
                   manganese (Mn) 
                   0.04 to 0.6; 
                 
                     
                   calcium (Ca) 
                   up to 1.0; 
                 
                     
                   antimony (Sb) 
                   up to 0.5; 
                 
                     
                   aluminum (Al) 
                   up to 0.5; 
                 
                     
                   silver (Ag) 
                   0.1 to 2.0. 
                 
                     
                     
                 
             
                
               
               
                
                
                
                
                
                
                
                
               
            
           
         
       
     
     
         8 . The method according to  claim 1 , wherein the second step comprises introducing at least partially liquid metal into the mold cavity. 
     
     
         9 . The method according to  claim 8 , wherein the second step comprises die casting the metal into the mold cavity. 
     
     
         10 . The method according to  claim 1 , wherein the second step comprises introducing a starting material of metal powder and a binder into the mold cavity, and the fourth step comprises finishing by dense-sintering. 
     
     
         11 . The method according to  claim 10 , which comprises introducing the starting material into the mold cavity by injection molding or by metal injection molding (MIM). 
     
     
         12 . The method according to  claim 1 , wherein the third step comprises partially releasing the part out of or from the mold such that the part remains on a portion of the mold and is supported thereby, and wherein the subsequent fourth step comprises finishing the metallic lattice part by machining for producing desired exact dimensions, and subsequently removing the supporting mold portion. 
     
     
         13 . The method according to  claim 12 , wherein the step of removing the supporting mold portion comprises washing the mold portion out or chemically dissolving the mold portion.