CN101862811A - Rapid investment casting method of complex thin-wall component - Google Patents
Rapid investment casting method of complex thin-wall component Download PDFInfo
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- CN101862811A CN101862811A CN201010111620A CN201010111620A CN101862811A CN 101862811 A CN101862811 A CN 101862811A CN 201010111620 A CN201010111620 A CN 201010111620A CN 201010111620 A CN201010111620 A CN 201010111620A CN 101862811 A CN101862811 A CN 101862811A
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Abstract
The invention discloses a rapid investment casting method of a complex thin-wall component, which belongs to the technical field of the precise casting, and is characterized in that polystyrene rapid formation technology is utilized to produce a thin-wall polystyrene foamed plastic investment casting pattern and a pouring system with complex shapes, the surface quality of the casting pattern is improved through a surface low-temperature wax infiltration process, the foamed plastic mould after the surface treatment is pulped for a plurality of times to produce an investment pattern molded shell, the investment pattern molded shell is roasted at high temperature, so the foamed plastic is completely gasified, and finally metal is poured to obtained the precise cast. Compared with the traditional investment casting method, the investment casting method has the advantages that the metal mould is free from being made, the formation efficiency of the cast is high, the precision is good, and the production period is short, and is particularly applicable to the middle and small rapid mass production of the complex shaped precise cast and the trial production of the new product.
Description
Technical field
The invention belongs to the precision casting technology field.It specifically is a kind of thin-wall complicated part rapid investment casting method.It is a kind of thin-wall complicated part investment casting method based on the polystyrene foam plastics RP technique.
Background technology
Precision-investment casting claims the lost-wax process casting again, is the technology of an excellence in the casting industry, and its application is very extensive.It is not only applicable to the casting of all kinds, various alloys, and the casting dimension accuracy of producing, surface quality are than other casting method height, even other casting method complexity of being difficult to be shaped, high temperature resistant, the foundry goods that is not easy to process, all can adopt precision-investment casting.
Generally speaking; the fusible pattern technological process is to use fusible material; for example wax material is made meltability model (being called for short fusible pattern or model); apply the special fireproof coating of several layers thereon, behind super-dry and whole shell of sclerosis formation, from shell, melt model with steam or hot water again; then shell is placed sandbox; fill dry moulding around it, at last casting mold is put into roaster, obtain foundry goods in casting molten metal wherein through after the high-temperature roasting.
Present domestic foundry enterprise generally adopts the metal die die mould to obtain the wax-pattern of part, has the problems such as wax-pattern easy deformation that the moulding cycle is long, cost is expensive, the low temperature wax material is made.Defectives such as simultaneously, the formwork die cavity is fallen into molding sand easily in the dewaxing operation of model casting, causes cast product knockout defective to occur after cast, and finished casting rate is low.The existence of these problems has seriously restricted the development of model casting technology.
Rapid shaping technique (RP) is a kind of new forming technique that develops rapidly over past ten years, can convert cad model to three-dimensional entity model fast.Systems such as SLA sl prototype technology, the manufacturing of FDM melt deposition, SLS selective laser sintering technology, the manufacturing of LOM laminated solid body, ERP polystyrene RP technique are arranged at present.The RP technology successfully is applied in the model casting production, and various RP technology can produce " fusible pattern " of model casting fast, manufacture and design thereby save metal die, have shortened the production cycle.As: the wax-pattern that FDM and SLS directly make, the papery fusible pattern of LOM, the resin fusible pattern of SLA and the foam mould of ERP all can replace traditional wax-pattern, are used for hot investment casting.Advantages such as wherein, the polystyrene foam plastics apperance that ERP makes has the dimensional accuracy height, and cost of manufacture is low, and the roasting gasification is abundant, residue is few, the most suitable alternative traditional wax-pattern is as the model casting apperance.
Summary of the invention
Long for the complexity, the production cycle that solve traditional casing tech by lost wax casting, material is numerous and diverse, cost is high and environmental pollution problems, the invention provides a kind of thin-wall complicated part rapid investment casting method.This method need not to make the metal die die mould, apperance forming efficiency height, precision is good, and is with short production cycle, be particularly suitable for the complicated shape precision casting in, small lot is made fast and the trial-production of new product.
The technical solution used in the present invention is: a kind of rapid investment casting method of complex thin-wall component, and concrete steps are:
1) polystyrene foam plastics apperance preparation:
Zhi Bei part carries out shape-designing and goes out three-dimensional entity model as required; Select rigidity and intensity density＞26Kg/m3 polystyrol plastic foam plate preferably then for use, adopt the polystyrene quickly shaping device to produce the foam plastics mould of part;
Utilize the polystyrene quickly shaping device to make running gate system.Foamed polystyrene pattern and running gate system are bonded together composition model casting apperance;
2) adopt low temperature to ooze wax technology p-poly-phenyl vinylic foam apperance and carry out surface treatment;
Because commodity polystyrol plastic foam plate material all is to be formed by the bonding of polystyrene bead second time of foaming one by one, the foam mould surface certainly exists latticed expanded bead interface.The interface of these dimplings makes the foam plastics mould rough surface reduce.If, then can make cast(ing) surface fineness not reach the hot investment casting quality requirement not to such model casting apperance surface treatment.Therefore,, be convenient to following process, need that the foam plastics mould that has prepared is oozed wax and handle in order to increase piece surface fineness.
It is that part is immersed in the molten wax liquid that tradition is oozed the wax method, and the insulation certain hour is finished.But the foam plastics mould intensity of preparation is lower owing to be shaped fast, and the easy contraction distortion of foam plastics mould when wax liquid temperature is too high influences follow-up model casting machining accuracy.Therefore, must reduce the integrality that the temperature of oozing wax guarantees fusible pattern, the fusing point of considering wax very low (about 60 ℃), shrinkage temperature (about 120 ℃) far below the boiling point and the polystyrene foam plastics of water, and wax is water insoluble, so the present invention adopts a kind of new surface to ooze ceroplastic, concrete processing step is: 1. earlier industrial wax and a certain proportion of water are put into heating container simultaneously; 2. water is heated to 80～90 ℃, wax is dissolved fully and bubbles through the water column; 3. with foamed plastics fusible pattern apperance surface waxdip, place it in air dry under 10～40 ℃ the ventilated environment then.By above-mentioned surface treatment, promptly increased the surface smoothness of foam plastics mould, increased mold strength again, for follow-up system shell operation offers convenience.
3) system shell: on the polystyrene foam plastics apperance, be coated with and hang the high solid phase of multilayer, low viscosity plastic refractory, to obtain firm fire-resistant investment shell.Plastic refractory of the present invention forms by refractory material, sodium silicate binder are mixed, from the internal layer slurry to outer slurry, in the refractory material sand grains from 70 orders to 20 orders, powder successively changes to 200 orders from 270 orders.Generally speaking, the surface layer granularity wants thin, back-up coat then to adopt thicker granularity to improve the gas permeability and the deformability of shell.Every layer of solid volume fraction is not less than 60% of slurry volume, always is coated with to hang six layers, and shell thickness reaches about 8mm.
Every layer is coated with slurry and needs to be coated with after the fully dry sclerosis again and hang one deck down on the module.Surface layer adopts air dry, and drying time is greater than 1h; Follow-up each layer adopts the chemicosolidifying method, immerses in the aqueous ammonium chloride solution being coated with the module of hanging plastic refractory, makes the Na in ammonium chloride and the sodium silicate binder
2Chemical reaction takes place in O, has impelled the gelling of waterglass, and its reaction is:
Na
2O.mSiO
2+2NH
4Cl+nH
2O＝mSiO
2.(n-1)H
2O+2NaCl+2NH
4OH。
4) roasting: after treating the dry sclerosis of investment shell, put it in the roaster, rise to 150 ℃ from room temperature, rise to 850 ℃ with the programming rate of 200 ℃/h from 150 ℃ again, 850 ℃ of insulations 2 hours with the programming rate of 50 ℃/h.After roasting, not only the polystyrene foam plastics module is gasified totally, and the moisture in the shell, residual wax material, NH
4Cl and salt grade and also are removed, and have further improved the intensity and the gas permeability of shell.
5) hot investment casting is shaped: the pouring liquid metal after cooling, obtains final precision casting.
At the terminal open type rising head of reserving of cast pattern, after shell roasting cooling, introduce compressed air by this rising head residue in the fusible pattern die cavity is removed in the polystyrene foam plastics module of the present invention; Pellet in the plastic refractory be in electro-corundum, silica, quartz sand, zirconia or the mullite one or more by the mixture of making a gesture of measuring arbitrarily, the powder main component is a silica flour.
The present invention utilizes the polystyrene RP technique to produce the thin-walled polystyrene foam plastics model casting apperance and the running gate system of complicated shape, ooze the surface quality that ceroplastic is improved cast pattern by surface low-temperature, again through the investment shell of hanging system repeatedly of the foamed plastics module after the surface treatment, roasting at high temperature is gasified totally foamed plastics, and last casting metal obtains precision casting.
Beneficial effect is: the present invention and traditional investment casting method are relatively, need not the metal die mould and just can realize the preparation of complicated shape fusible pattern, omitted the dewaxing operation simultaneously, shortened the production cycle of precision casting, reduce production cost, alleviated working strength of workers.
Description of drawings
Fig. 1 is technological process of the present invention;
Fig. 2 is the front view of complex thin-wall component
Fig. 3 is the side view of Fig. 2;
Fig. 4 is the foam mould picture group of complex thin-wall component.
The specific embodiment
Below in conjunction with drawings and Examples the present invention is described in further detail.
As shown in Figure 1, technical process of the present invention is: utilize the polystyrene RP technique to produce the thin-walled polystyrene foam plastics model casting apperance and the running gate system of complicated shape, ooze the surface quality that ceroplastic is improved cast pattern by surface low-temperature, again through the investment shell of hanging system repeatedly of the foamed plastics module after the surface treatment, roasting at high temperature is gasified totally foamed plastics, and last casting metal obtains precision casting.
Embodiment is the complex-curved thin-walled interlayer part of high-speed train head.
With reference to the complex-curved thin-walled sandwich of Fig. 2 and high-speed train head shown in Figure 3 because this part has complex-curved structure, and its heavy wall thick be 3mm, its metal die mould is difficult to design, therefore makes relatively more difficult.Utilize the process that proposes among the present invention then finely to address this problem.Concrete implementation step is as follows:
1) preparation foamed plastics module: applying three-dimensional modeling software Pro/E utilizes the polystyrene quickly shaping device to produce the foamed polystyrene pattern of part to Fig. 2 and parts modeling shown in Figure 3 then;
Utilize the polystyrene quickly shaping device to produce the foamed polystyrene pattern of running gate system;
The foamed polystyrene pattern bonding of part and running gate system is formed model casting module shown in Figure 4.
2) surface treatment: adopt the surface to ooze ceroplastic and carry out surface treatment.With the dip-coating 3 times in 80～90 ℃ low temperature wax liquid of acquired model casting module, each 5 minutes at interval, make wax liquid can evenly be coated in foamed plastics module surface.
Concrete processing step is: 1. earlier industrial wax and a certain proportion of water are put into heating container simultaneously; 2. water is heated to 80～90 ℃, wax is dissolved fully and bubbles through the water column; 3. with foamed plastics fusible pattern apperance surface waxdip 3 times, each 5 minutes at interval, place it in air dry under 10～40 ℃ the ventilated environment then.By above-mentioned surface treatment, promptly increased the surface smoothness of foam plastics mould, increased mold strength again, for follow-up system shell operation offers convenience.
3) system shell: be coated with extension 6 floor height solid phases, low viscosity plastic refractory on foamed plastics module surface successively, surface layer mainly is made up of refractory powder and binding agent, other each layer increases fire-resistant pellet successively, reduces refractory powder, but the solid volume fraction of overall refractory material remains on more than 60%.
The low viscosity plastic refractory forms by refractory material, sodium silicate binder are mixed, from the internal layer slurry to outer slurry, in the refractory material sand grains from 70 orders to 20 orders, powder successively changes to 200 orders from 270 orders.Surface layer fine size, back-up coat then adopt thicker granularity to improve the gas permeability and the deformability of shell.Every layer of solid volume fraction is not less than 60% of slurry volume, and shell thickness reaches 8mm.Every layer is coated with slurry and needs to be coated with after the fully dry sclerosis again and hang one deck down on the module.Surface layer adopts air dry, and drying time is greater than 1h; Follow-up each layer adopts the chemicosolidifying method, immerses in the aqueous ammonium chloride solution being coated with the module of hanging plastic refractory, makes the Na in ammonium chloride and the sodium silicate binder
2Chemical reaction takes place in O, has impelled the gelling of waterglass,
4) roasting: after treating the dry sclerosis of investment shell, put it in the roaster, programming rate with 50 ℃/h rises to 150 ℃ from room temperature, programming rate with 200 ℃/h rises to 850 ℃ from 150 ℃ again, 850 ℃ of insulations 2 hours, the foamed plastics module is gasified totally, and removes the moisture in the shell, residual wax material, NH
4Cl and salt grade.After shell cools off with stove, introduce compressed air, remove residue in the fusible pattern die cavity from opening wide rising head.
5) hot investment casting is shaped:
Acquired investment shell is preheating to 300 ℃, and cast A356.0 aluminium alloy after cooling, obtains the complex thin-wall aluminium alloy castings.
Claims (6)
1. rapid investment casting method of complex thin-wall component, it is characterized in that: concrete steps are:
1) polystyrene foam plastics cast pattern preparation;
Zhi Bei part carries out shape-designing and goes out three-dimensional entity model as required; Select rigidity and intensity density＞26Kg/m preferably then for use
3Polystyrol plastic foam plate adopts the polystyrene quickly shaping device to produce the foam plastics mould of part;
2) adopt low temperature to ooze wax technology p-poly-phenyl vinylic foam apperance and carry out surface treatment;
3) system shell: on the polystyrene foam plastics apperance, be coated with and hang the high solid phase low viscosity of multilayer plastic refractory, obtain firm fire-resistant investment shell;
4) roasting: after treating the dry sclerosis of investment shell, put it in the roaster, rise to 150 ℃ from room temperature, rise to 850 ℃ with the programming rate of 200 ℃/h from 150 ℃ again, 850 ℃ of insulations 2 hours with the programming rate of 50 ℃/h; After roasting, the polystyrene foam plastics module is gasified totally;
5) hot investment casting is shaped.
2. rapid investment casting method of complex thin-wall component according to claim 1, it is characterized in that: at the terminal open type rising head of reserving of described cast pattern, after shell roasting cooling, introduce compressed air by this rising head residue in the fusible pattern die cavity is removed.
3. a kind of rapid investment casting method of complex thin-wall component according to claim 1 is characterized in that: described shell thickness reaches about 8mm.
4. a kind of rapid investment casting method of complex thin-wall component according to claim 1 is characterized in that: described low temperature oozes ceroplastic and is: 1. earlier industrial wax and a certain proportion of water are put into heating container simultaneously; 2. water is heated to 80～90 ℃, wax is dissolved fully and bubbles through the water column; 3. with foamed plastics fusible pattern apperance surface waxdip, place it in air dry under 10～40 ℃ the ventilated environment then.
5. a kind of rapid investment casting method of complex thin-wall component according to claim 1 is characterized in that: the high solid-phase low-temperature plastic refractory of described system shell is mixed and is formed by refractory material, sodium silicate binder; From the internal layer slurry to outer slurry, in the refractory material sand grains from 70 orders to 20 orders, powder successively changes to 200 orders from 270 orders, surface layer fine size, back-up coat then adopt thicker granularity to improve the gas permeability and the deformability of shell, every layer of solid volume fraction is not less than 60% of slurry volume, always be coated with and hang six layers, about shell thickness 8mm.
6. a kind of according to claim 1 or 5 rapid investment casting method of complex thin-wall component, it is characterized in that: the described method of hanging the multiple layer refractory slurry that is coated with is: every layer is coated with slurry and needs to be coated with extension one deck down again after the dry sclerosis, surface layer adopts air dry, and drying time is greater than 1h; Follow-up each layer adopts the chemicosolidifying method, immerses in the aqueous ammonium chloride solution being coated with the module of hanging plastic refractory, makes the Na in ammonium chloride and the sodium silicate binder
2Chemical reaction takes place in O, impels the waterglass gelling.
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Application publication date: 20101020 |