CN101077836A - Method for preparing aluminum oxide base ceramic core - Google Patents
Method for preparing aluminum oxide base ceramic core Download PDFInfo
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- CN101077836A CN101077836A CN 200710018080 CN200710018080A CN101077836A CN 101077836 A CN101077836 A CN 101077836A CN 200710018080 CN200710018080 CN 200710018080 CN 200710018080 A CN200710018080 A CN 200710018080A CN 101077836 A CN101077836 A CN 101077836A
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Abstract
The process of making alumina-base ceramic mold core includes the first fast forming resin mold with complicated hollow structure for ceramic mold core, the subsequent compounding alumina-base ceramic slurry, depositing the ceramic slurry into the mold cavity of the resin mold in vacuum and vibration condition, curing the ceramic slurry, and eliminating organic matter and resin mold to obtain alumina-base ceramic mold core with high position accuracy. The present invention can make ceramic mold core with complete shape, curved and fine sizes and high position accuracy, and the ceramic mold core is applied mainly in precise casting of complicated high temperature alloy parts, such as vane of gas turbine.
Description
Technical field
The invention belongs to the casting and molding technology field, relate to the manufacture method of the preparation of ceramic core slurry, mould preparation and this type of ceramic core, specifically a kind of manufacture method of alumina based ceramic core.
Background technology
Gas turbine blades is the vitals of engine, for improving the over-all properties of engine, need improve constantly the preceding fuel gas temperature of turbine, but be subjected to the restriction of melting point metal, if on alloy material, want to improve the warm ability of holding of blade, therefore constantly improve blade cooling structure raising cooling performance and just become the target that turbine blade designs and the producer is pursued near the limit.
As shown in Figure 1, bigger different of the cooling structure of efficient air cooling blade and having in the past, the blade blade becomes the blade double wall from solid wall, and blade has been covered with the aperture about the about 0.5mm of the diameter that communicates with inner chamber, cold effect is brought up to more than 600 ℃ from 300 ℃, and blade holds warm ability and significantly improves.
The manufacturing of efficient air cooling blade, its gordian technique is the manufacturing of ceramic core, and its manufacturing process is more complicated, and size is littler, and performance requriements is higher.For this efficient air cooling blade, its ceramic core manufacture method is, hollow parts regarded as by a plurality of cores (form the core of centre hole and forms the core of thin-walled and pore) make up and form, utilize traditional ceramic injection forming technology that they are created respectively, before the compacting wax-pattern, bond together and form a combination type core then.The combination process of core is not only very consuming time, and accurately positioning difficulty is very big.If can not form correct position relation between the combination type core, will directly influence final casting dimension accuracy, particularly efficient air cooling blade, it is that wall thickness dimension is thin and uneven.
(publication number: CN 1134327A) provided a kind of molding complete core from base core and bonded core method, this method can improve the bearing accuracy between two cores to Chinese patent.But the precision of its mould is difficult to grasp.
Traditional ceramic core manufacture method is to adopt injection molding technology.Its mould needs in manufacturing and designing process repeatedly repeatedly and revises, and the production cycle is long, the cost height, and for complex-shaped complications, the tiny ceramic core of size, the design of its mould die joint, the manufacturing of mold cavity are very difficult.In addition, the flowability that ceramic injection forming process powder is good is to add a large amount of organic binder bonds, could realize complicated shape like this, but also brought the degreasing problem, degreasing is the most difficult most important link in the whole technology, incorrect degreasing process and degreasing parameter will cause defectives such as blank deformation, cracking, bubbling in the skimming processes, and the crackle that produces can not remedy by sintering with distortion; Skimming processes length consuming time in addition generally will spend time of tens hours even several days.
Summary of the invention
The objective of the invention is to, a kind of novel alumina based ceramic core manufacture method is provided, this method is to regard hollow parts as a cavity that is interconnected (if be not communicated with, can when mould, set up the part of connection), ceramic core is curing molding in disposable pressure injection process, naturally join together by ceramic size, do not need combination process, directly guarantee mutual alignment precision between core by mould itself.
In order to realize above-mentioned task, the present invention takes following technical solution:
A kind of alumina based ceramic core manufacture method is characterized in that this method comprises the following steps:
At first utilize the rapid shaping manufacturing technology to prepare the ceramic core resin die with complicated hollow structure fast, this ceramic core resin die has hollow structure, comprises two independently passages at least;
Prepare the alumina-based ceramic slurry then, the massfraction of this ceramic size consists of: alumina powder: 70%～85%, and organism: 2%～5%, pore-forming material: 1%～5%, mineralizer and toughner are 1%～5% respectively, deionized water supplies 100%;
Add the dispersion agent sodium polyacrylate at alumina base porcelain slurry, sodium polyacrylate accounts for 0.5% of alumina powder quality, grinds 1 hour in ball mills, and each component is mixed;
With ceramic size under vacuum, vibration condition pressure injection in the die cavity of ceramic core resin die, before pressure injection, ceramic size is vacuumized, vacuum degree control is between 0.01Mpa～0.1MPa, the degassing time is 5 minutes, to reduce or eliminate the bubble that produces in moulding process; Grouting pressure is at 1kg/cm
2～10kg/cm
2In the scope, vibrational frequency is 10Hz～300Hz during slip casting, and Oscillation Amplitude is in 1mm～3mm.
After treating the alumina-based ceramic slurry curing drying in the ceramic core mould, remove organism and resin die, can obtain the complete alumina ceramic core of shape with higher mutual alignment precision.
The present invention compares with traditional alumina based ceramic core manufacture method, has following technical characterstic:
(1) makes that the alumina based ceramic core moulding process is simple, be easy to control, can obtain the ceramic core that shape is complete, size is tiny.
(2) adopt the rapid prototyping mould to replace metal die, solved the complicated die die cavity and made difficult problem,, reduced production setup time simultaneously widely, saved production cost for complicated, tortuous alumina based ceramic core preparation provides assurance.
(3) a plurality of alumina based ceramic cores moulding simultaneously in disposable pressure injection process does not need the core combination operation, no loss of significance, and the manufacturing accuracy height of mould itself makes to have higher positional precision between the ceramic core.
Description of drawings
Fig. 1 is efficient air cooling blade construction synoptic diagram;
Fig. 2 is alumina-based ceramic slurry configuration technical process;
Fig. 3 is the alumina based ceramic core structural representation.
Below contrast the embodiment that Fig. 1, Fig. 2 and Fig. 3 and contriver provide and be described in further detail, can understand characteristics of the present invention complete, exactly.
Embodiment
Alumina based ceramic core manufacture method of the present invention, particular content embody following three aspects:
1) by control to organism, alumina powder volume fraction and level mixing ratio and various additives, the ceramic size of preparation good fluidity;
2) the rapid shaping manufacturing technology is applied to during the ceramic core mould makes the manufacturing of the ceramic core mould that realize fast, the complicated complications of inner chamber, size is tiny;
3) provided the alumina based ceramic core moulding process.Under vacuum and little condition of shaking with the ceramic size pressure injection in mold cavity, treat the ceramic slurry curing drying after, take suitable manner to remove organism and mould; The acquisition shape is complete, the core that size is tiny, have higher mutual alignment precision.
The present invention utilizes the rapid shaping technique mfg. moulding die, fast the sharpest edges of original shape technology are that it can fast, directly produce complex-shaped mould prototype, the mould prototype is an integral body, do not need to design a plurality of impressions and divide modular surface, and mould can take heating or chemical mode to remove in subsequent handling, making in the alumina based ceramic core process does not need stripping operation, has greatly simplified technical process.
The ceramic size good flowing properties of utilizing the present invention to dispose can be filled complicated die cavity, and shape is complete, the precision height, and also organic content is low, is easy to degreasing, the sintering character excellence.
It below is the specific embodiment that the contriver provides.
(1) alumina based ceramic core slurry
The component and the content of ceramic size comprise: the alumina powder massfraction accounts for 75% of ceramic size, and (that is: consist of 2 microns, 8 microns and 15 microns, proportioning is respectively 40%, 30% and 40% to the alumina powder grating; Organism accounts for 4% of ceramic size quality; Select powdered graphite or lime carbonate or starch as pore-forming material, it accounts for 2.5% of alumina powder quality; Mineralizer (MgO-TiO
2) and toughner (ZrO
2) account for alumina powder quality 3%; Add deionized water and supply 100%, guarantee that the ceramic size of configuration has good flowability and cavity filling ability, so that adopt the method for castable to make the core of the accurate complete complexity of shape.
Organism 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.
In the alumina-based ceramic slurry, add dispersion agent sodium polyacrylate (accounting for aluminum oxide quality 0.5%) and obtain uniform and stable ceramic size suspension; For each component is mixed, ceramic size was ground 1 hour in ball mills; Before pressure injection, need vacuumize ceramic size, to reduce or eliminate the bubble that produces in forming the slurry process, vacuum degree control is between 0.01MPa～0.1MPa, and the degassing time is 5 minutes.The configuration technical process of alumina-ceramic slurry such as Fig. 2.
(2) mould prepares fast
The efficient air cooling blade of internal combustion turbine (2) as shown in Figure 1, its wall thickness (3) is thin and uneven, and a plurality of hollow spaces (1) are arranged.Traditional metal die is made up of two modules up and down usually, but mould for the efficient air cooling blade of internal combustion turbine, iff relying on two modules are the die cavities that impossible form a plurality of hollows like this, need a plurality of die joints of design, make a plurality of die modules, cause the die manufacturing cost height like this, the manufacturing cycle is long, difficulty is big, or even impossible.
The present invention utilizes the efficient air cooling blade ceramic core of laser curing rapid prototyping machine manufacturing resin die, it can be removed in subsequent technique, and the shape of resin die and structure are exactly itself, does not need to design die joint and makes a plurality of die modules.
Concrete manufacturing processed is: at first set up efficient air cooling blade cad model by business software, export the standard input format stl file that the laser fast shaping machine can be accepted then, stl file is carried out layering to be handled, obtain the multilayer planar graph data, then liquid towards photosensitive resin DSM Somos14120 scans under the laser head mechanical arm drives, its scanning pattern is controlled by every layer plane graph data, by laser radiation to that layer liquid resin (about 0.1mm) owing to light polymerization solidifies, constantly go on, adding up to make until all layers finishes, and obtains and the on all four resin die of the shape and structure of part own at last.
(3) technique for making ceramic moulding core
Method with above-mentioned ceramic size oxygenerating Al-base ceramic core may further comprise the steps successively:
1, the ceramic size pressure injection is in the resin die die cavity.Resin die is fixed on the small vibrating platform, under vacuum environment, pressure injection under little vibration condition, little shaking helps slurry filling in resin die to be shaped.Grouting pressure is at 2kg/cm
2, vibrational frequency is 100Hz during slip casting, Oscillation Amplitude is 1mm.
2, ceramic slurry curing drying and moulding.By adjusting the content of initiator (concentration is 30% ammonium persulphate), control organism set time, be generally 20～40 minutes.Adopt low temperature (temperature is 35 ℃) microwave vacuum drying method that ceramic body is carried out drying, be generally time of drying 3～5 hours.
3, remove organism and resin die.Behind the ceramic blank drying, adopt pyrolysis method to remove organism and resin die, concrete heating process is as follows: heating installation is box resistance heading furnace, room temperature go into stove with per hour 10 ℃ be warming up to 300 ℃, be incubated 2 hours; With per hour 50 ℃ be warming up to 900 ℃, be incubated 1 hour; Cool to room temperature with the furnace.
4, obtain alumina based ceramic core.As shown in Figure 3, ceramic core (30) shape is complete, size tiny, (3A, 3B, 3C, 3D, 3E, 3F ... ..) keep higher mutual alignment precision each other.In order further to improve the normal temperature and the hot strength of alumina based ceramic core, can be with ceramic core 1350 ℃ of insulation roastings 1～3 hour.With the prefabricated accurate core of alumina based ceramic core, be used for intricate casting production, as the efficient air cooling blade of internal combustion turbine as investment cast.
Certainly in the step 1 of above-mentioned technique for making ceramic moulding core, grouting pressure can be at 1kg/cm
2～10kg/cm
2In the scope, vibrational frequency can be adjusted between 10Hz～300Hz during slip casting, and Oscillation Amplitude is all can implement in 1mm～3mm.
Claims (8)
1. an alumina based ceramic core manufacture method is characterized in that, this method comprises the following steps:
At first utilize the rapid shaping manufacturing technology to prepare the ceramic core resin die with complicated hollow structure fast, this ceramic core resin die has hollow structure, comprises two independently passages at least;
Prepare the alumina-based ceramic slurry then, the massfraction of this ceramic size consists of: alumina powder: 70%～85%, and organism: 2%～5%, pore-forming material: 1%～5%, mineralizer and toughner are 1%～5% respectively, deionized water supplies 100%;
Add the dispersion agent sodium polyacrylate at ceramic size, sodium polyacrylate accounts for 0.5% of alumina powder quality, ball mill ball milling 1 hour, each component is mixed;
With the alumina-based ceramic slurry under vacuum, vibration condition pressure injection in the die cavity of ceramic core resin die, before pressure injection, ceramic size is vacuumized, vacuum degree control is between 0.01MPa～0.1MPa, the degassing time is 5 minutes, to reduce or eliminate the bubble that produces in moulding process; Grouting pressure is at 1kg/cm
2～10kg/cm
2In the scope, vibrational frequency is 10Hz～300Hz during slip casting, and Oscillation Amplitude is in 1mm～3mm.
After treating the alumina-based ceramic slurry curing drying in the ceramic core mould, remove organism and resin die, can obtain the complete alumina based ceramic core of shape with higher mutual alignment precision.
2. method according to claim 1 is characterized in that, the material of described mould selects Resins, epoxy, silicone resin, polystyrene, polycarbonate or metal wherein a kind of.
3. method according to claim 1 is characterized in that described alumina powder by 2 microns 30～50%, 8 microns 30～50%, carries out grating greater than 10 micron 20～40%.
4. method according to claim 1 is characterized in that described organism 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.
5. method according to claim 1 is characterized in that, removes organism and resin die and takes the mode that heats.
6. method according to claim 1 is characterized in that, removes resin die and takes chemical solvents dissolved mode.
7. as method as described in the claim 5, it is characterized in that it is as follows to adopt pyrolysis method to remove the technology of organism and resin die: heating installation is box resistance heading furnace, room temperature go into stove with per hour 10 ℃ be warming up to 300 ℃, be incubated 2 hours; With per hour 50 ℃ be warming up to 900 ℃, be incubated 1 hour; Cool to room temperature with the furnace.
8. method according to claim 1 is characterized in that described pore-forming material is graphite or lime carbonate or starch.
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