CN101602088A - A kind of preparation method of iron casting coating by flyash - Google Patents
A kind of preparation method of iron casting coating by flyash Download PDFInfo
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- CN101602088A CN101602088A CNA2009100233049A CN200910023304A CN101602088A CN 101602088 A CN101602088 A CN 101602088A CN A2009100233049 A CNA2009100233049 A CN A2009100233049A CN 200910023304 A CN200910023304 A CN 200910023304A CN 101602088 A CN101602088 A CN 101602088A
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Abstract
The invention discloses a kind of preparation method of iron casting coating by flyash, the iron casting coating that this method makes is by refractory powder, additive and carrier fluid are formed, wherein, refractory powder is made up of flyash and alumine, additive is by organobentonite, phenolic resins, PVB, CMC and defoamer are formed, carrier fluid is an alcohol, preparation process is with organobentonite, CMC, PVB and phenolic resins preliminary treatment, mix in mixer with other raw materials then, stir and dispersion, density and viscosity through grinding homogenizing and regulating coating, be encased in the coating special barrel, sealing makes finished product.This iron casting coating by flyash behind coating sand mold (core) surface, is lighted fast form and is become coating, strengthens mo(U)ld face intensity and anti-stick grittiness.Coating is easy to peel off behind the casting pouring, and sand removal is easy.Use this coating can obtain the good effect of surface quality of continuous castings.
Description
Technical field
The present invention relates to the preparation of cast paint, particularly a kind of preparation method of iron casting coating by flyash.
Background technology
Cast paint is to cover casting mold die cavity and whose surfaces, to improve the casting auxiliary material of performances such as its surperficial fire resistance, chemical stability, anti-molten metal erosion and anti-stick Sha Xing.Fireproof coating has crucial effect in foundry industry.Before the casting pouring,, can prevent defectives such as foundry goods scab, burning into sand, sand holes effectively, improve surface quality of continuous castings, reduce casting cost at mo(U)ld face coating one deck fireproof coating.
The mo(U)ld face applying coatings can reduce the cleaning work amount of foundry goods, lightens one's labor, and improves work situation.Estimation according to summary, the casting cleaning cost accounts for 30% of castings production totle drilling cost, and the disposal costs of foundry goods are reduced to about 15%, deducts about 5% coating and coating cost thereof, so, can make the disposal costs of foundry goods reduce by 10% behind the applying coatings.The more important thing is, because applying coatings has improved surface quality of continuous castings, reduced casting defect, improved casting quality, the foundry goods price is improved, and its economic benefit is more obvious.
Cast paint has experienced a quite long historical process.Before 4500, the casting craftsman of China just prepared and successful use cast paint.Up to 20th century, cast paint has just had and has developed rapidly.Along with the develop rapidly of science and technology in order to improve the market competitiveness of cast product, people begin to pay attention to the research of cast paint.Aspect the theoretical research and practical application of coating, important breakthrough has all been arranged, and various " patent coating " occur constantly.China pays attention to using and studying of coating since the eighties, and introduces some external coating material production technology, and some specialized cast paint manufacturers have also appearred in various places, beginning supplied goods coating.But China's coating no matter on the kind, qualitatively with the research of basic theory on compare abroad that also there is a big difference.The coating of most of factories still is that autogamy is personal, and the working condition in quality, work efficiency and the configuration place of the coating that many factories use is all relatively poor.
At present, iron casting coating mainly disposes coating with refractory materials such as graphite, silica flour, zirconium English powder, alumines as aggregate.Select for use refractory powder should consider its fundamental property and characteristics, as the granularity and the shape of refractory powder; Density; Refractoriness; Thermal coefficient of expansion; Chemical reactivity with the cast metal; Under pouring temperature with the chemical reactivity of molding sand; Pyroconductivity; Gas content; Raw-material degree and the price of being easy to get; Health is had or not harm, environmental pollution degree etc.On this basis, people are also constantly seeking various novel refractories, as flyash, electrofused mullite powder, schmigel etc.
Flyash is the solid waste that discharges behind the coal dust firing of thermal power plant, and iron casting coating by flyash is the emphasis that the present invention studies.Meet the requirement of cast paint in the chemical composition of flyash, physicochemical property and the mineral composition, can be used as the cast paint powder aggregate.
Summary of the invention
The objective of the invention is to, a kind of preparation method who adapts to the iron casting coating by flyash of sand mold iron casting production is provided.
In order to realize above-mentioned task, the present invention takes following technical solution:
A kind of preparation method of iron casting coating by flyash is characterized in that, comprises the following steps:
1) composition of formula material and mass percent thereof:
A, refractory powder: refractory powder is made up of flyash and alumine, and its mass percent is: flyash: 80%, and alumine: 20%;
B, additive: additive is made up of organobentonite, phenolic resins, PVB, CMC and defoamer, the mass percent that they account for refractory powder respectively is: organobentonite: 2%, and phenolic resins: 3.8%, PVB:0.5%, CMC:0.3%, defoamer: 0.1%;
C, carrier fluid: alcohol accounts for 35%~45% of refractory powder;
2) pre-treatment of raw material
Organobentonite: with the translucent paste of dimethylbenzene furnishing, the consumption of dimethylbenzene is 5~10 times of bentonites;
CMC: melt with cold water soak, make colloid shape and concentration and be 1%~2% the aqueous solution, soak time is more than 24h;
PVB: it is dissolved in alcohol, be made into concentration and be 2%~5% solution, soak time is more than 24h;
Phenolic resins: it is dissolved in alcohol, and the alcohol consumption is 3~5 times of phenolic resins;
3) mix stirring, dispersion
Join the good alcohol of weighing, flyash, alumine powder, defoamer, pretreated organobentonite, CMC, PVB, phenolic resins in the mixer successively, mix, stir and disperse, the speed of control mixer is at 600~1000r/min, mixing time is 1~2h, and coating is mixed.
4) grind homogenizing
The coating that stirs in the mixer sent into grind 30min in the colloid mill, and add carrier fluid, regulate the density and the viscosity of coating, reach the coating material production standard-required by the coating material production standard;
5) packing:
The coating of adjusting density and viscosity is encased in the coating special barrel, and sealing makes finished product.
The iron casting coating by flyash of the present invention's preparation behind coating sand mold (core) surface, is lighted fast form and is become coating, strengthens mo(U)ld face intensity and anti-stick grittiness.Coating is easy to peel off behind the casting pouring, and sand removal is easy.Use this coating can obtain the good effect of surface quality of continuous castings.
Description of drawings
Fig. 1 is fine coal iron casting coating preparation flow figure;
The present invention is described in further detail below in conjunction with drawings and Examples.
The specific embodiment
1, iron casting coating by flyash feasibility analysis
(1) chemical composition of flyash
Chemical composition is one of key property of flyash, is the main foundation of carrying out the iron casting coating by flyash experimental study.Great deal of research results shows: the main chemical compositions of flyash is SiO
2, Al
2O
3, CaO and Fe
2O
3Deng.The general excursion such as the table 1 of China's fly ash in electric power plant chemical composition.
Table 1: the chemical composition of flyash
(2) physicochemical property of flyash
Flyash is the powdery residue of being taken out of from boiler by flue gas behind the pulverized coal friring, be the ash content (being mainly the inorganic mineral of elements such as silicon, aluminium, calcium, iron) in the coal, experienced the solid particle that forms after the processes such as decomposition, sintering, fusion and cooling at boiler.Particle diameter is between 0.001mm~0.1mm.Flyash is linen powder, and the flyash that water content is big is black.The composition of flyash and character are to be determined by factors such as the condition of the composition of raw coal, burning and processing methods.Prove the mean specific gravity 2.14g/cm of China's flyash after deliberation
3
(3) mineral composition of flyash
Flyash has the chemical composition based on sial, and mineral facies comprise a large amount of glassy phases and mineral crystalline phase and various structure type.This mainly is because the kind of coal and the existence of multi mineral impurity.Essential mineral in the coal comprises silicate, oxide, carbonate, sulphite, sulfate, phosphate etc.Because the existence of these mineral, behind coal combustion and become ash content.In ash content (flyash), crystalline phase mainly contains quartz, mullite, mica, feldspar, bloodstone and compositions such as a small amount of calcite, anorthite.Ash content is exactly the mixture of these inorganic compounds, does not have fixing fusing point, usually with the fusing point of its softening temperature as it.According to the softening temperature of ash content, ash content can be divided into following three classes:
1. meltable ash content<1200 ℃;
2. 1200 ℃~1350 ℃ of fusible ash contents;
3. infusibility ash content>1350 ℃.
By analysis, in conjunction with as can be seen to the requirement of cast paint powder to physicochemical property, chemical composition and the mineral composition of flyash:
A, aspect composition, the used aggregate of cast paint generally has refractory materials such as silica flour, talcum powder, mica powder, corundum, zirconium English powder, magnesia powder, olive stone flour.And the main component of these refractory powders is SiO
2, Al
2O
3, CaO, MgO, ZrO
2, Fe
2O
3Deng.From top constituent analysis to flyash as can be seen, its main component comprises SiO
2, Al
2O
3, CaO, Fe
2O
3Deng, the fine coal ash composition conforms to substantially with the composition of cast paint aggregate.Thereby on chemical composition, meet the requirements substantially.
B, aspect physico-chemical property because the now used powder silica flour of cast paint, schmigel, bauxite, graphite powder, magnesia etc., proportion is all at 2.0g/cm
3More than.And the mean specific gravity of China's flyash is 2.14g/cm
3, thereby satisfy the requirement of powder to density.
C, generally being used for the refractory aggregate of cast paint, having than higher refractoriness, is that can weigh as the important indicator of powder, such as the refractory powder of zircon flour, corundum class.Owing in the mineral composition of flyash, be by the mullite phase composition greatly, and the fusing point of mullite is more than 1900 ℃, thereby makes flyash have certain refractoriness.From the softening temperature of flyash,, resistance to elevated temperatures is further improved if with addition of some other refractory powders.
In sum, to be used for the cast paint powder be feasible to flyash.
2, the basic recipe of iron casting coating is as shown in table 2 below:
Table 2: the basic recipe of iron casting coating
3, produce the economic benefit of iron casting coating with flyash
(1) the fly-ash Preparation cast paint has important practical significance
Flyash is the main solid waste of China, utilizing flyash to produce cast paint, is one of measure that realizes comprehensive utilization of resources, also is the strategy of the sustainable economic development advocated of China, not only fly ash has obtained utilization, and has prevented environmental pollution.Though ironcasting often adopts blacking, blacking can prevent foundry goods scab now, often stays one deck grey black on cast(ing) surface, causes environmental pollution serious when cast cleaning.And iron casting coating by flyash can be improved working conditions and environmental sanitation.
(2) investment is little, instant effect
The low price of flyash (40 yuan/ton) is invested 500,000 yuan and is founded the factory, and annual production can reach 1000 tons, if coating per ton is pressed 3000 yuan of calculating, 3,000,000 yuan of incomes from sales are promptly got a profit then.
(3) equipment is simple, easy to operate.
4, iron casting coating by flyash preparation
Referring to Fig. 1, preparation section comprises:
(1) pre-treatment of raw material
Organobentonite: with the translucent paste of dimethylbenzene furnishing, the consumption of dimethylbenzene is 5~10 times of bentonites;
CMC (sodium carboxymethylcellulose): melt with cold water soak, make the aqueous solution that colloid shape and concentration are 1-2%, soak time is more than 24h;
PVB (commercially available polyvinyl butyral resin or polyvinyl butyral film): it is dissolved in alcohol, be made into PVB concentration and be 2%~5% alcoholic solution, soak time is more than 24h;
Phenolic resins: it is dissolved in alcohol, be made into alcoholic solution, the alcohol consumption is 3~5 times in a phenolic resins.
(2) mix stirring, dispersion
The good alcohol of weighing, flyash, alumine powder, defoamer, pretreated organobentonite, CMC, PVB, phenolic resins are joined in the mixer successively, mix, stir and disperse.The speed of control mixer is at 600~1000r/min, and mixing time is 1~2h, and coating is mixed.
(3) grind homogenizing
The coating that stirs in the mixer sent into grind 30min in the colloid mill, make coating become stable system, have good suspending power, and add carrier fluid, regulate the density, viscosity of coating etc., to reach the coating standard requirement by the coating material production standard code.
(4) barrelling (jar)
The coating of adjusting viscosity is encased in the coating special barrel, and sealing makes finished product.
5, coating prepares equipment
(1) mixer: volume 0.3cm
3, the adjustable n=100~1000r/min of rotating speed
(2) colloid mill: JTM85DG type vertical colloid mill is a kind of ultra-fine grinding machinery, and it has functions such as pulverizing, emulsification, dispersion, homogeneous, stirring concurrently.
6, the every performance and the characteristics of coating
1) scope of application: iron casting coating by flyash adapts to the sand mold iron casting production.Behind applying coating sand mold (core) surface, light fast form and become coating, strengthen mo(U)ld face intensity and anti-stick grittiness.Coating is easy to peel off behind the casting pouring, and sand removal is easy.Use this coating can obtain the good effect of surface quality of continuous castings.
2) coating property is as shown in table 3
Table 3: the performance indications of coating
The key technical indexes | Test condition | Test result |
Coating appearance | Range estimation | Evenly |
Density/(g/cm 3) | The graduated cylinder method | 1.46 |
Suspension/(%) | Placed 2 hours | 98 |
Condition viscosity (φ 4 flow cups)/s | Flow cup 4mm | 14.61 |
Brushability | Brush or dip-coating | Smooth |
Trickling property | Apply on the sand mold | Defectives such as drop impression do not appear in coating |
Length of penetration | Coating is cut | 3 times of sand grains diameters |
Levelability | Whether observe has brush mark | Better |
Coating abrasion performance | Hand is scratched method | Good |
The high temperature crack resistance | 1200 ℃ of quick-fried heat tests | The I level |
3) performance characteristics of coating
(1) coating appearance is even, and coating does not have corrosive substance and radioactivity;
(2) coating has good suspension, and does not lump, easily stirs not corrupt going mouldy;
(3) viscosity is suitable, has good trickling and levelability, is easier at coating time ratio, and coating is even, defectives such as trickling and lamination do not occur;
(4) coating has higher penetrating power, and penetrating power is strong, and coating is not easy to crack, and anti-stick sand ability is strong;
(5) it is good that coating is lighted drying, and dry back abrasion property is good, and any crackle does not appear in the intensity height;
(6) at high temperature, the smooth surface flawless does not have between coating and the matrix and peels off phenomenon, and the high temperature crack resistance of coating reaches one-level;
(7) coating price is cheap.
7, iron casting coating by flyash uses embodiment:
The cast gray iron casting, casting quality is 650kg, wall thickness is 20mm.Adopt resin bonded sand mould.Iron casting coating by flyash is applied on the casting mold, 1~2 coating of mold cavity surface brushing, coating layer thickness is 0.5mm~1mm, light drying after, the coating flawless does not peel off, intensity is better.Carry out pouring experiment, the cast castings of gray cast iron, pouring temperature is 1350 ℃.The cast cleaning rear profile is clear, any scab phenomenon and other defective do not occur, and surface quality of continuous castings is good.
Claims (2)
1, a kind of preparation method of iron casting coating by flyash is characterized in that, comprises the following steps:
1) formula material and mass percent thereof are formed:
A, refractory powder: refractory powder is made up of flyash and alumine, and its mass percent is: flyash: 80%, and alumine: 20%;
B, additive: additive is made up of organobentonite, phenolic resins, PVB, CMC and defoamer, the mass percent that they account for refractory powder respectively is: organobentonite: 2%, and phenolic resins: 3.8%, PVB:0.5%, CMC:0.3%, defoamer: 0.1%;
C, carrier fluid: alcohol accounts for 35%~45% of refractory powder;
2) pre-treatment of raw material
Organobentonite: with the translucent paste of dimethylbenzene furnishing, the consumption of dimethylbenzene is 5~10 times of bentonites;
CMC: melt with cold water soak, make colloid shape and concentration and be 1%~2% the aqueous solution, soak time is more than 24h;
PVB: it is dissolved in alcohol, be made into concentration and be 2%~5% solution, soak time is more than 24h;
Phenolic resins: it is dissolved in alcohol, and the alcohol consumption is 3~5 times of phenolic resins;
3) mix stirring, dispersion
Join the good alcohol of weighing, flyash, alumine powder, defoamer, pretreated organobentonite, CMC, PVB, phenolic resins in the mixer successively, mix, stir and disperse, the speed of control mixer is at 600~1000r/min, mixing time is 1~2h, and coating is mixed.
4) grind homogenizing
The coating that stirs in the mixer sent into grind 30min in the colloid mill, and add carrier fluid, regulate the density and the viscosity of coating, reach the coating material production standard-required by the coating material production standard;
5) packing:
The coating of adjusting density and viscosity is encased in the coating special barrel, and sealing makes finished product.
2, the method for claim 1 is characterized in that, the granularity of described flyash is 300 orders and 200 orders, respectively accounts for half of flyash gross mass.
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