CN101073821A - Method for casting mould core and shell integrated ceramic - Google Patents
Method for casting mould core and shell integrated ceramic Download PDFInfo
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- CN101073821A CN101073821A CN 200710018082 CN200710018082A CN101073821A CN 101073821 A CN101073821 A CN 101073821A CN 200710018082 CN200710018082 CN 200710018082 CN 200710018082 A CN200710018082 A CN 200710018082A CN 101073821 A CN101073821 A CN 101073821A
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Abstract
The invention is concerned with a kind of ceramic mould method with integrated mould core and mould shell. At first, produce the resin mould with loss-on-ignition character with laser quick shaped technology and the resin mould has complex inner cavity and figure structure to form integrated cooling channel. Mix ceramic grain, organic substance and deionwater into ceramic slurry and keep the ceramic slurry filling the whole resin mould by controlling the pressure of ceramic slurry. Pour the slurry with vibration to get close-grained ceramic mould core and mould shell, after solidify, the mould core and mould shell will connect with through ceramic slurry and it gets the integrated ceramic mould by drying, heating to degrease and sintering. The ceramic mould core and mould shell connects as a whole and formed in once without assembly and this keep the precision of position between ceramic mould core and mould shell. This ceramic mould is fit to produce the mould with thin wall and complex cavity structure, such as gas turbine engine vane and enhances the percent of pass to mould greatly.
Description
Technical field
The present invention relates to the model casting technical field, be specifically related to thin-walled, have foundry goods model casting, particularly a kind of core and the shell integrated ceramic casting mold manufacture method of complicated inner-cavity structure (can constitute a cooling duct at least).
Background technology
In the gas-turbine engine course of work, the gas-turbine engine blade wants to bear high temperature for a long time, high pressure draught impacts, along with gas-turbine engine power constantly increases and the lasting raising of turbine inlet temperature, its service temperature often surpasses gas-turbine engine blade mother metal fusing point, so efficiently cool off blade (particularly moving vane) by cooling medium such as air, steam the complicated cooling duct of portion design within it in gas-turbine engine blade design process.Because gas-turbine engine blade profile and inner chamber relative positional accuracy require high, belong to thin-wall construction spare again, minimum wall thickness (MINI W.) can reach 0.3mm～0.6mm, so the model casting technology is widely used in the manufacturing of gas-turbine engine blade.
The basic process of traditional blade model casting is: at first prepare ceramic core by molding press; Secondly ceramic core is assembled in the Wax mold, then injects paraffin, form the wax-pattern (profile of wax-pattern is identical with blade profile) that includes ceramic core; Be coated with the extension ceramic size once more on the wax-pattern surface and prepare shell, melted paraffin in the high steam stove, acquisition has the shell of core, pours into a mould high-temperature metal liquid at last, after treating its cooling, adopt mechanical system or chemical mode or two kinds of modes that combine to remove ceramic core, shell acquisition foundry goods.
Because ceramic core is assembled to and has position error and rigging error in the Wax mold process, the while less stable, in follow-up casting, dewaxing process and under the effect of high-temperature metal liquid, can depart from original position, thereby directly influence the mutual alignment precision of ceramic core and shell, cause the core shift phenomenon, influence final casting dimension accuracy, very easily bore a hole for the blade of thin-wall construction.
Summary of the invention
The objective of the invention is to, a kind of core and shell integrated ceramic casting mold manufacture method are provided, this method is applied to integrated ceramic core, shell manufacturing technology in the model casting production, guarantees the castings production quality of the inner-cavity structure of thin-walled, complexity.
In order to realize above-mentioned task, the present invention takes following technical solution:
A kind of core and shell integrated ceramic casting mold manufacture method, it is characterized in that, but this method is at first used laser fast forming technology manufacturing burning-loss resin die, but should include the complicated inner cavity structure by the burning-loss resin die, can constitute the one cooling duct at least; Then ceramic particle, organic matter and deionized water evenly are mixedly configured into ceramic size, but are full of whole burning-loss resin die by the control grouting pressure to guarantee ceramic size, the limit vibration of marginal not slurry is to obtain closely knit ceramic core, shell; After treating its curing, core, shell link together by ceramic size; Make the integrated ceramic casting mold through super-dry processing, heating degreasing and sintering at last.
Integrated ceramic core of the present invention, shell manufacturing technology do not need to prepare in advance the compression moulding die and the Wax mold of ceramic core, its system shell, coremaking time weak point, thus reduce production costs greatly, saved the production time; Ceramic core, shell one-shot forming, naturally connect by ceramic size, be connected firmly, reliably, there are not position error and rigging error, precision height in mutual alignment between ceramic core, the shell, defectives such as core shift, perforation can be avoided, the foundry goods of thin-walled, inner-cavity structure complexity can be produced, as the gas-turbine engine blade.
The present invention is by integrated ceramic core, shell manufacture method, and the core shell joins together in manufacture process, and having guaranteed has very high mutual alignment precision between them, greatly improve the qualification rate of the foundry goods of thin-walled, complicated inner cavity.
The objective of the invention is to adopt commaterial to make ceramic core, shell, the two has the same expansion coefficient, helps guaranteeing the dimensional accuracy of foundry goods.
The objective of the invention is to shorten the shell preparation time greatly because ceramic size has good flowability and mold-filling capacity.Replica is good, has overcome the shortcoming that can't duplicate minutias such as zanjon, groove in traditional model casting system shell process.
Description of drawings
Figure 1 shows that a certain gas-turbine engine leaf cross-section figure; Label among the figure is represented respectively: 1, cooling duct, 2, inwall, 3, outer wall, 4, blade;
Fig. 2 is integrated ceramic core, shell manufacture process schematic diagram.Label among the figure is represented respectively: 10, core, 20, shell, 30, resin die, 40, the junction;
Below contrast Fig. 1 and Fig. 2 read the specific embodiment, can understand characteristics of the present invention complete, exactly.
The specific embodiment
Core of the present invention and shell integrated ceramic casting mold manufacture method, the foundry goods of being produced belongs to thin-wall construction spare, has complicated inner-cavity structure, can constitute a cooling duct at least.
Preparation one cover resin die, design is useful on and guarantees the uniform part of ceramic shell wall thickness on the resin die, and design has the cast gate and the rising head of casting high-temperature metal on the ceramic-mould.With ceramic size in certain pressure is made a bet the resin mould, grouting pressure, its value at 0.01MPa in the 0.1MPa scope.Through solidified forming, drying, degreasing, roasting, obtain ceramic core, the shell join together, for having the complicated inner cavity structure and casting thin-wall production provides casting mold.Naturally join the formation ceramic-mould when core and shell moulding together, the method by roasting makes ceramic core, shell have certain intensity oxide potteryization to a certain extent.Need not to assemble once more, core and shell are linked together by slurry, without any need for additional attachment.Ceramic core, shell are evenly dry, do not produce cracking, metaboly.
Utilize the quick curing photosensitive resin of laser to make resin die, but resin die belong to a kind of resin die of burning-loss, can remove by pyrolysismethod or chemical method.The present invention burns resin die by the method for slowly heating and loses.It is few that resin die burns the residue that loses, and residue can not produce harmful effect to casting quality.
Ceramic size is evenly to be mixed by deionized water, organic matter and ceramic particle, and wherein, the volume ratio that alumina ceramic grain accounts for slurry is 50%～55%, and surplus is a deionized water; Organic matter is (by acrylamide monomer and N, N '-methylene diacrylamine forms (the constituent mass ratio is 24: 1) or by methyl diacrylamine monomer and N, N '-methylene diacrylamine is formed (the constituent mass ratio is 6: 1)) concentration is 10%～20% in deionized water.
Ceramic size has good flowability and mold-filling capacity.
With reference to Fig. 1, a certain gas-turbine engine blade 4 includes inwall 2 and outer wall 3, and all designing on wall and in the middle of the blade has cooling duct 1, and wall unevenness is even, inner chamber, outer shape complexity.In the present invention, resin die with have the external and internal compositions identical with the gas-turbine engine blade.
1. the preparation of resin die
Adopt the photocuring rapid prototyping technology to prepare resin die in the present invention, its basic process is that the gas-turbine engine blade that at first utilizes the commercial CAD system alignment to prepare to make carries out the three-dimensional solid modeling design, by special computer section software three-dimensional CAD model is cut into plurality of thin layer plane graph data again.When photocuring rapid prototyping begins, lifting platform drops to apart from liquid level usually less than 0.1mm (a few tenths of approximately millimeter, the thickness that is equivalent to the section of cad model basecoat) locate, the x-y laser scanner scans liquid level according to the graphics plane data of ground floor (being basecoat) section subsequently, and that part of liquid resin that this one deck of liquid level is shone by laser is owing to light polymerization is solidificated on the lifting platform.Then lowering or hoisting gear drives lifting platform again and makes its decline be equivalent to the height of second layer slice thickness, the x-y laser scanner scans liquid level according to the graphics plane data of second layer section again, on the resin that one deck had solidified before new one deck liquid resin curing also tightly was bonded at, so repeat to complete until whole resin die.
Because photopolymerization reaction is based on the effect of light rather than based on the effect of heat, so only need the lower lasing light emitter of power when working.In addition,, add that chain reaction can control well, can guarantee that polymerisation does not occur in outside the laser point because there is not thermal diffusion, thereby resin die machining accuracy height, surface quality is good, can make complex-shaped, meticulous part, the production efficiency height.
2. ceramic size
The main composition of ceramic size is alumina ceramic grain, organic matter and deionized water.Alumina ceramic grain particle diameter (D
50) be 15 microns, 100 milliliters deionized water configuration 395 gram aluminium oxide, organic matter concentration in deionized water is 12.5%.The ceramic size that configures has high solid phase (volume fraction is greater than 50%) and low viscosity (its viscosity is less than 1Pa.s), and good flowability and mold-filling capacity are filled complicated inner chamber for ceramic size assurance is provided.
Ceramic size is injected in the resin die.Be full of the whole blade inner chamber by accurate control grouting pressure to guarantee ceramic size in the present invention, the limit vibration of marginal not slurry is to obtain closely knit ceramic core, shell; In the present invention as shown in Figure 2, ceramic size injects resin die 30, treat that it solidifies after, form core 10 and shell 20 simultaneously, shell and core join together by junction 40, thereby guarantee mutual alignment precision between them.
3. dry
After making ceramic slurry curing by the mode that adds catalyst or heating, ensuing technology is to remove moisture in the ceramic size.Whether even, directly have influence in follow-up degreasing or the sintering process if dewatering, whether ceramic core, shell ftracture, breakage.The mode drying of taking PEG400 (polyethylene glycol) solution and microwave vacuum to combine among the present invention avoids dehydration inhomogeneous, produces local stress.Treat behind the ceramic slurry curing base substrate to be put into PEG400 (polyethylene glycol) solution, dry 2～3 hours, change in the micro-wave vacuum case dry 5～6 hours subsequently over to, and control base substrate dehydration temperaturre is below 40 ℃.
4. degreasing
Degreasing is meant by the method for pyrolysis and removes organic matter and resin die in the ceramic size among the present invention.Because content of organics is less in the ceramic size, only accounts for 2% to 5% of ceramic size weight, removes than being easier to; In addition, but resin die is a kind of burning-loss resin, and residual ash content is low after its pyrolysis, there is not the element that influences casting quality in the residue, ftracture in skimming processes for fear of shell simultaneously, guarantee that core, shell shape are complete, the method that the present invention takes to heat is carried out degreasing.Complete for degreasing, make the core shell that certain intensity be arranged before roasting, take the fast mode of heating in slow earlier back.Its concrete technology is as follows, and firing equipment is box resistance-heated furnace, room temperature go into stove with per hour 6 ℃ be warming up to 300 ℃, be incubated 1 hour; Then with per hour 50 ℃ be warming up to 600 ℃, be incubated 1 hour; Again with per hour 100 ℃ be warming up to 900 ℃, be incubated 1 hour; Cool to room temperature with the furnace.
5. core and shell integrated ceramic mold roasting
Because high-temperature metal produces thermal shock to core, shell during follow-up casting, therefore will appropriate intensified ceramic core, shell, make it have higher bending strength.Make alumina particle potteryization to a certain extent by high-temperature roasting among the present invention, its bending strength can reach 20Mpa; Roasting technique: be warming up to 1350 ℃～1400 ℃ with 50 ℃～100 ℃/h programming rate, be incubated 4～6 hours, stove is chilled to below 240 ℃ and comes out of the stove then.
Claims (5)
1. core and shell integrated ceramic casting mold manufacture method, it is characterized in that, but this method is at first used laser fast forming technology manufacturing burning-loss resin die, but should include complicated inner cavity and contour structures by the burning-loss resin die, can constitute the one cooling duct at least; Then ceramic particle, organic matter and deionized water evenly are mixedly configured into ceramic size, but are full of whole burning-loss resin die by the control grouting pressure to guarantee ceramic size, the limit vibration of marginal not slurry is to obtain closely knit ceramic core, shell; After treating its curing, core, shell link together by ceramic size; Make the integrated ceramic casting mold through super-dry processing, heating degreasing and sintering at last.
2. the method for claim 1 is characterized in that, prescription is in the described ceramic size: the volume ratio that alumina ceramic grain accounts for slurry is 50%～55%, and surplus is a deionized water; Organic matter concentration in deionized water is 10%～20%.
3. the method for claim 1 is characterized in that, but adopts the quick curing photosensitive resin of laser to make the burning-loss resin die fast.
4. the method for claim 1 is characterized in that, the fast mode of heating in slow earlier back is taked in described heating degreasing, and firing equipment is box resistance-heated furnace, and room temperature is gone into stove and is warming up to 300 ℃ with per hour 5 ℃～10 ℃, is incubated 0.5～1 hour; Then be warming up to 600 ℃, be incubated 0.5～1 hour with per hour 30 ℃～50 ℃; Again with per hour 100 ℃ be warming up to 900 ℃～1000 ℃, be incubated 1～2 hour; Cool to room temperature with the furnace.
5. method as claimed in claim 1 or 2 is characterized in that, described organic matter is: acrylamide monomer and N, and N '-methylene diacrylamine is formed, and its constituent mass ratio is 24: 1; Perhaps by methyl diacrylamine monomer and N, N '-methylene diacrylamine is formed, and its constituent mass ratio is 6: 1.
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| CNB2007100180822A CN100560248C (en) | 2007-06-19 | 2007-06-19 | A kind of core and shell integrated ceramic casting mold manufacture method |
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| CN101987347A (en) * | 2010-09-29 | 2011-03-23 | 西安交通大学 | Manufacturing method of core for casting engine exhaust manifold |
| CN101695741B (en) * | 2009-10-30 | 2011-03-30 | 沈阳黎明航空发动机(集团)有限责任公司 | Method for positioning mold core and mold shell of hollow blade |
| CN101992268A (en) * | 2010-11-20 | 2011-03-30 | 沈阳工业大学 | Preparation process of high-temperature alloy multigang hollow turbine blade |
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