CN101941228B - Preparation method of electric heating ceramic die for precision spray forming - Google Patents
Preparation method of electric heating ceramic die for precision spray forming Download PDFInfo
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Abstract
The invention belongs to the field of spray forming of materials and relates to a preparation method of an electric heating ceramic die for precision spray forming, which is characterized by designing and manufacturing a prototype with concave and convex surface, duplicating a silicon rubber template on the prototype, duplicating a wax template on the silicon rubber template, duplicating a ceramic template with concave and convex surface on the wax template, and assembling the ceramic template and an electric heating wire furnace into the electric heating ceramic die. The ceramic template is pre-heated from the bottom part in an aerosolization can which is formed by spray forming, thereby improving the density and the surface quality of a deposit preform formed by precision spray forming. The preparation method has the advantages of solving the related design and the manufacturing problems of the pre-heated ceramic die in the aerosolization can, control the temperature of the ceramic die more accurately and further improve the density of the deposit preform formed by the precision spray forming.
Description
Technical field
The invention belongs to the injection of material forming field; Relate to the preparation method of a kind of accurate injection molding with the electric-heating ceramic mould; It is characterized in that and in the aerosolization jar of injection molding, to carry out preheating, with density and the surface quality that improves accurate injection molding deposit preform from the bottom to ceramic template.
Background technology
At present, general injection molding is not high to the pattern and the dimension precision requirement of deposit preform bottom surface.Deposition substrate is cylinder iron coiled and during not preheating, and too low and cooling velocity is too fast because of the embryo deposit layer temperature of deposit preform bottom surface, the deposit preform edge can warpage.And accurate injection molding requires the deposit preform bottom surface that the higher pattern of dimensional accuracy is arranged, and the deposit preform edge can not warpage, and require the gas porosity of deposit preform bottom surface low, density is high.This just requires deposition substrate to adopt the low ceramic die of thermal conductivity, and ceramic die also will be preheating to suitable temperature, requires usually to reach more than 500 ℃.Though after also can preheating ceramic die, put it into again in the atomization tank, begin injection molding after vacuumizing in the outside of aerosolization jar.But this method is difficult to control more exactly the required preheat temperature of ceramic die, makes the difficult quality of deposit preform bottom surface reach the requirement of accurate injection molding.
Summary of the invention
Use the metal bed die in order to overcome existing injection molding, or ceramic bed die preheats outside the aerosolization jar and put into jar again, the shortcoming that the bed die temperature should not be controlled the invention solves the relevant design and the manufacturing issue of preheated ceramic mould in the aerosolization jar.
The technical solution adopted for the present invention to solve the technical problems is:
Design and make a prototype that convex-concave surface arranged → turn on the prototype system silicon rubber template → on the silicon rubber template, turn over system wax template → on wax template, turn over control surface have ceramic template → ceramic template and the heating wire stove of concavo-convex pattern to be assembled into can electrically heated ceramic die.
1. an accurate injection molding is with the preparation method of electric-heating ceramic mould, and said method step is following:
1.1 design and make the prototype template that a diameter 200mm-400mm has convex-concave surface;
1.2 on the prototype template of convex-concave surface, turn over system silicon rubber template;
1.3 on silicon rubber mould, turn over the system wax template;
1.4 on wax template, turn over the ceramic template that control surface has the thickness 8mm-35mm of concavo-convex pattern;
1.5 ceramic template and heating wire stove etc. are assembled into can electrically heated ceramic die.
2. in the said step 1.4, said ceramic template is the zircon ceramics template, or the aluminium oxide ceramics template.
3. the making of said zircon ceramics template comprises the preparation of ceramic template surface layer and ceramic die backboard layer;
Make ceramic template surface layer earlier, method is following:
3.1 ceramic slurry preparation
(1) adds required Ludox;
(2) start mechanical agitator and stir, rotating speed is more than 60 rev/mins;
(3) press the amount that every liter of Ludox adds the surfactant of 3.5-4.0 gram, surfactant is a neopelex;
(4) press the powder liquor ratio and slowly add required zircon powder at 4: 1, avoid zircon powder powder caking;
(5) add the antifoaming agent that 1.2-1.3 restrains by every liter of Ludox, antifoaming agent is a n-octyl alcohol;
(6) mix after, measure dope viscosity with the flow cup flow cup, add zircon powder or Ludox adjustment slip according to viscosity;
(7) stirring can be used in 8-24 hour.
3.2 compressed air spraying:
At first wax-pattern is cleaned up with absolute ethyl alcohol, under compressed air pressure, surperficial to wax-pattern with spray gun winding-up slip; The about 1mm of every layer thickness, every layer sprayed slip after, carry out stucco, it is 200 order zircon powder that refractory material is used in stucco; 2～3 layers of the surface shell numbers of plies.
3.3 zircon template surface layer is dry:
Zircon template surface layer drying process: 22～25 ℃ of environment temperatures, ambient humidity 50%～70% is preferably in more than 60%, and drying time is more than 6 hours.
On zircon template surface layer, make backing layer again, method is following:
3.4 slip preparation:
(1) adds required Ludox;
(2) start mechanical agitator and stir, rotating speed is more than 60 rev/mins;
(3) press the powder liquor ratio and slowly add required zircon powder at 4: 1, prevent the powder caking;
(4) elementary mixing evenly after, measure dope viscosity with the flow cup flow cup, add powder or Ludox is adjusted slip according to viscosity;
(5) stirring can be used more than 6 hours.
3.5 slip is coated with extension
Adopt directly coating and two kinds of methods of spray gun winding-up to carry out every layer thickness 1～2mm; Every layer sprayed slip after, evenly stucco; The number of plies of backing layer shell is at 4～10 layers;
3.6 dry:
Zircon backing layer shell drying process parameter is: 20～25 ℃ of environment temperatures, and ambient humidity 40%～70%, fully drying after carry out next layer operation more than 6 hours drying time again.
4. said aluminium oxide shell ceramic die plate is made the preparation that comprises surface layer and backing layer, makes surface layer earlier, and method is following:
4.1 slip preparation
(1) adds required Ludox;
(2) start mechanical agitator and stir, 50 rev/mins of rotating speeds;
(3) add the surfactant that 3.5-4.0 restrains by every liter of Ludox, surfactant is a neopelex;
(4) press the powder liquor ratio and slowly add required α-Al at 4: 1
2O
3Powder is avoided α-Al
2O
3Powder powder caking;
(5) should add the amount 1.2-1.3 gram of antifoaming agent by every liter of Ludox, add n-octyl alcohol;
(6) elementary mixing evenly after, measure dope viscosity with the flow cup flow cup, according to viscosity adding α-Al
2O
3Powder powder or Ludox adjustment slip;
(7) backing layer coating mixing time is less than the mixing time of investment precoat, all new timings of coating, and mixing time should be greater than 10 hours; The new timing of part coatings, mixing time can foreshorten to about 5 hours and can use.
The powder liquor ratio of the comparable surface layer zircon of the powder liquor ratio slip of backing layer slip is lower slightly, and along with the increase of the number of plies, the powder liquor ratio can reduce gradually, but is not less than 3.8g/ml.
4.2 it is the same with the step 3.2 in the claim 3.
4.3 ceramic template is dry:
Alumina formwork surface layer drying process parameter is: 22～25 ℃ of temperature, and humidity 50%～80% is preferably in more than 60%, and fully drying after just can carry out next layer operation more than 6 hours drying time;
4.4 on ceramic template surface layer, make backing layer again
It is identical with surface layer that the backing layer slip is coated with extension technology, can adopt two kinds of methods of direct coating and spray gun winding-up to carry out every layer thickness 1～2mm.Every layer sprayed slip after, evenly stucco.The number of plies of backing layer is confirmed according to the size of ceramic die board size, generally about 4～10 layers.
Zircon template backing layer drying process parameter is: environment temperature is preferably in 20～25 ℃, and ambient humidity is generally 40%～70%, and drying time is more than 6 hours.Fully just can carry out next layer operation after the drying.
The present invention is in atomization tank, and the heating ceramic mould from the bottom can be controlled the temperature of ceramic die more accurately, and then improves the density of accurate injection molding deposit preform.
If with the ceramic template of several cm thicks of ceramic size disposal pouring, be prone to crackle when dry.The present invention adopts hot investment casting to make the technology of ceramic shell surface layer and backing layer.Generally speaking, the used refractory powder of surface layer and backing layer slurry is different.Because surface layer can contact with molten metal, can not react with molten metal, should use the high refractory powder of purity.Make ceramic template and adopt the method for repeatedly spraying or brushing ceramic size, every layer thickness is coated with down one deck again less than 1mm after the drying, do the cracking that can avoid ceramic template like this.
Advantage of the present invention is relevant design and the manufacturing issue that has solved preheated ceramic mould in the aerosolization jar, can control the temperature of ceramic die more accurately, and then improves the density of accurate injection molding deposit preform.
The specific embodiment
Embodiment 1
Compressed air spraying method prepares the zircon ceramics template
Key step is following:
1. design and make the prototype template that a diameter 200mm-400mm has convex-concave surface;
2. on the prototype template of convex-concave surface, turn over system silicon rubber template;
3. on silicon rubber mould, turn over the system wax template;
4. on wax template, turn over control surface the ceramic template of the thickness 8mm-35mm of concavo-convex pattern is arranged;
5. be assembled into can electrically heated ceramic die for zircon ceramics template and heating wire stove etc.
The key of making accurate injection molding electric-heating ceramic mould be diameter 400mm of preparation, thickness 1cm, there is the ceramic template of meticulous concaveconvex structure on the surface.Preparation technology's flow process of pottery template is: there is the prototype template → silicon rubber template → cured template → ceramic template surface layer+ceramic die backboard layer → dewaxing → sintering → relief type pottery template of meticulous concaveconvex structure on the surface.
Preparation zircon ceramics template surface layer
Zircon surface layer refractory material is 100～200 order zircon powder, and Ludox is made binding agent, adds surfactant and antifoaming agent.It is 200 purpose zircon powder that refractory material is used in stucco.
(1) slip preparation
The charging sequence of zircon surface layer slip preparation is: Ludox → surfactant → zircon powder → antifoaming agent.Its coating preparation process is following.
1) adds required Ludox;
2) start mechanical agitator and stir, 60 rev/mins of rotating speeds;
3) should add amount 3.7 gram of surfactant by every liter of Ludox, add neopelex;
4) press the powder liquor ratio and slowly add required zircon powder at 4: 1, avoid the powder caking;
5) should add amount 1.25 gram of antifoaming agent by every liter of Ludox, add n-octyl alcohol;
6) elementary mixing evenly after, measure dope viscosity with the flow cup flow cup, add powder or Ludox is adjusted slip according to viscosity;
7) stirring re-used more than 12 hours.
Because zircon proportion is bigger, is easy in whipping process, precipitate.In order to avoid the zircon deposition as far as possible, can improve the method for mixing speed and improve.When investment precoat all was virgin material, mixing time should be used greater than 24 hours ability, the material of part for newly joining, and mixing time can shorten to 12 hours.In the coating whipping process, should suitably replenish a certain amount of deionized water according to the evaporation situation and enter, to guarantee that dope viscosity is constant basically.
(2) compressed air spraying method
Hang evenly because directly painting method should not be coated with, be coated with the bridging slurry so also adopt compressed air to jet in the experiment.At first wax-pattern is cleaned up with absolute ethyl alcohol, under compressed air pressure, surperficial to wax template with spray gun winding-up slip.Spraying process can make slip be coated with better than direct coating process and be suspended to the wax template surface, and coating is even, and does not have bubble.The about 1mm of every layer thickness, every layer sprayed slip after, carry out stucco, it is 200 order zircon powder that refractory material is used in stucco.
(3) zircon surface layer drying process parameter
Zircon surface layer drying process parameter is: environment temperature is preferably in 22～25 ℃, and ambient humidity is generally 50%～70%, is preferably in more than 60%, and drying time is more than 6 hours.Fully just can carry out next layer operation after the drying.
Adopting the bulk density of the obtained zircon surface layer of blowing process is 3.24g/cm
3, density is 75.9%, bending strength is 30.74MPa.Make diameter and reach more than the 400mm, there is the zircon ceramics template of fine structure on the surface.
On zircon template surface layer, prepare backing layer
The backing layer preparation is roughly the same with the technology of zircon template surface layer, just no longer adds surfactant and antifoaming agent.As backing layer refractory material and sanding material, Ludox is made binding agent with 200 order zircon powder.
(1) backing layer slip preparation
Backing layer slip preparation basic procedure is:
1) adds required Ludox;
2) start mechanical agitator and stir, 60 rev/mins of rotating speeds or higher;
3) press the powder liquor ratio and slowly add required zircon powder at 4: 1, prevent the powder caking;
4) elementary mixing evenly after, measure dope viscosity with the flow cup flow cup, add the zircon powder or Ludox is adjusted slip according to viscosity;
5) stirring can be used greater than 10 hours.
Backing layer coating mixing time is less than the mixing time of investment precoat, all new timings of coating, and mixing time should be greater than 10 hours; The new timing of part coatings, mixing time can foreshorten to about 5 hours and can use.The powder liquor ratio of backing layer slip is 4: 1～3.8: 1, and along with the increase of the number of plies, the powder liquor ratio reduces gradually.
(2) slip is coated with and hangs and drying
It is identical with zircon template surface layer that the backing layer slip is coated with extension technology, can adopt two kinds of methods of direct coating and spray gun winding-up to carry out every layer thickness 1～2mm.Every layer sprayed slip after, evenly stucco.The number of plies of backing layer is confirmed according to the size of template size, generally about 4～10 layers.
Zircon backing layer drying process parameter is: environment temperature is preferably in 20～25 ℃, and ambient humidity is generally 40%～70%, and drying time is more than 6 hours.Fully just can carry out next layer operation after the drying.
The powder liquor ratio plays a part crucial to the performance of slip and ceramic template.The best powder liquor ratio of zircon slip is 4.0g/ml.
The pottery template under calm condition when dry major influence factors be environment temperature and ambient humidity.Drying of ceramic template under the calm condition, only drying condition are 22 ± 2 ℃ of environment temperatures, ambient humidity 50%～70%.
Along with the raising of sintering temperature, the shrinkage factor of ceramic template improves, and density increases, and bending strength and compression strength all increase.The zircon ceramics template is behind 1350 ℃ of sintering, and shrinkage factor is 1.7%, and density reaches 75.9%, bending strength 30.74MPa, compression strength 73MPa.
The accurate injection molding bed die of assembling electrical heating zircon ceramics template
Be placed on the thick zircon ceramics template of 10mm on the 3kW electric furnace, between the space fill with fire resisting material particle, heat that ceramic template surface temperature can reach more than 600 ℃ after 30 minutes.
Embodiment 2
Directly painting method prepares electrical heating zircon ceramics template
Basic step such as instance 1.The zircon surface layer adopts the mode that at first directly applies to carry out.Earlier wax template is cleaned up with absolute ethyl alcohol, dry the back and just can coating be executed the wax template upper surface that is suspended to horizontal positioned, slip is sprawled under the flowability of self and is covered the wax template surface, does not have the place that covers with the hairbrush repairing.About every layer thickness 1～2mm, ground floor can be slightly thin.Every layer be coated with hung slip after, need carry out stucco, it is 200 order zircon powder stuccos that the zircon surface layer can directly use, stucco is wanted evenly.2～3 layers of the surface layer numbers of plies.
Adopting directly painting method is 3.22g/cm through the 1350 ℃ of prepared ceramic die plate bulk of sintering density
3, density is 75.6%, bending strength is 26.28MPa; Make diameter and reach more than the 400mm, there is the zircon ceramics template of fine structure on the surface.
Embodiment 3
Preparation aluminium oxide ceramics template
The used refractory powder of aluminium oxide ceramics template surface layer is α-Al
2O
3Electro-corundum is made binding agent with Ludox, adds surfactant and antifoaming agent.Stucco is 200 purpose α-Al with refractory powder
2O
3Powder.
The charging sequence of aluminium oxide surface layer slip preparation is: Ludox → surfactant → α-Al
2O
3Powder → antifoaming agent.Preparation process is following in detail.
1) adds required Ludox;
2) start mechanical agitator and stir, 50 rev/mins of rotating speeds;
3) should add the amount of surfactant by every kilogram of Ludox, add neopelex;
4) press the powder liquor ratio and slowly add required α-Al
2O
3Powder is avoided the powder caking;
The amount of the antifoaming agent that 5) should add by every kilogram of Ludox adds n-octyl alcohol;
6) elementary mixing evenly after, measure dope viscosity with the flow cup flow cup, adjust slip according to viscosity;
7) being stirred to the process stipulation time can use.
Aluminium oxide ceramics template surface layer drying process parameter is: 22～25 ℃ of temperature, and humidity is generally 50%～80%, is preferably in more than 60%, and fully drying after just can carry out next layer operation more than 6 hours drying time.
Other step such as instance 1.
Embodiment 4
Prepare thick zircon ceramics template
Basic step such as instance 1.With the heating of 3kW electric furnace, surface temperature can reach more than 500 ℃ after 50 minutes in the bottom of the zircon ceramics template of 35 millimeters thick.
Claims (2)
1. an accurate injection molding is characterized in that with the preparation method of electric-heating ceramic mould preparation process is following:
1.1 design and make the prototype template that a diameter 200mm-400mm has convex-concave surface;
1.2 on the prototype template of convex-concave surface, turn over system silicon rubber template;
1.3 on the silicon rubber template, turn over the system wax template;
1.4 on wax template, turn over the ceramic template that control surface has the thickness 8mm-35mm of concavo-convex pattern; Said ceramic template is the zircon ceramics template, and the making of said zircon ceramics template comprises the preparation of ceramic template surface layer and ceramic die backboard layer;
Make ceramic template surface layer earlier, method is following:
1.4.1 ceramic slurry preparation
(1) adds required Ludox;
(2) start mechanical agitator and stir, rotating speed is more than 60 rev/mins;
(3) add surfactant by every kilogram of Ludox 3.5-4.0 gram, surfactant is a neopelex;
(4) press the powder liquor ratio and slowly add required zircon powder at 4: 1, avoid zircon powder powder caking;
(5) add antifoaming agent 1.2-1.3 gram by every kilogram of Ludox, antifoaming agent is a n-octyl alcohol;
(6) mix after, measure dope viscosity with the flow cup flow cup, add zircon powder or Ludox adjustment slip according to viscosity;
(7) stirring can be used in 8-24 hour;
1.4.2 compressed air spraying:
At first wax-pattern is cleaned up with absolute ethyl alcohol, under compressed air pressure, surperficial to wax-pattern with spray gun winding-up slip; Every layer thickness is 1mm, every layer sprayed slip after, carry out stucco, it is 200 order zircon powder that refractory material is used in stucco;
1.4.3 zircon template surface layer is dry:
Zircon template surface layer drying process: 22～25 ℃ of environment temperatures, ambient humidity 50%～70%, drying time is more than 6 hours;
On zircon template surface layer, make backing layer again, method is following:
1.4.4 slip preparation:
(1) adds required Ludox;
(2) start mechanical agitator and stir, rotating speed is more than 60 rev/mins;
(3) press the powder liquor ratio and slowly add required zircon powder at 4: 1, prevent the powder caking;
(4) elementary mixing evenly after, measure dope viscosity with the flow cup flow cup, add powder or Ludox is adjusted slip according to viscosity;
(5) stirring can be used more than 8 hours;
1.4.5 slip is coated with extension:
Adopt directly coating or two kinds of methods of spray gun winding-up to carry out every layer thickness 1～2mm; Every layer sprayed slip after, evenly stucco; The number of plies of backing layer shell is at 4～10 layers;
1.4.6 dry:
Zircon backing layer shell drying process parameter is: 20～25 ℃ of environment temperatures, and ambient humidity 40%～70%, fully drying after carry out next layer operation more than 6 hours drying time again;
1.5 ceramic template and heating wire stove are assembled into can electrically heated ceramic die.
2. an accurate injection molding is characterized in that with the preparation method of electric-heating ceramic mould preparation process is following:
1.1 design and make the prototype template that a diameter 200mm-400mm has convex-concave surface;
1.2 on the prototype template of convex-concave surface, turn over system silicon rubber template;
1.3 on the silicon rubber template, turn over the system wax template;
1.4 on wax template, turn over the ceramic template that control surface has the thickness 8mm-35mm of concavo-convex pattern; Said ceramic template is the aluminium oxide ceramics template; Said aluminium oxide ceramics template construct comprises the preparation of surface layer and backing layer, makes surface layer earlier, and method is following:
1.4.1 slip preparation
(1) adds required Ludox;
(2) start mechanical agitator and stir, 50 rev/mins of rotating speeds;
(3) add the surfactant that 3.5-4.0 restrains by every kilogram of Ludox, surfactant is a neopelex;
(4) press the powder liquor ratio and slowly add required α-Al at 4: 1
2O
3Powder is avoided α-Al
2O
3Powder powder caking;
(5) add the antifoaming agent that 1.2-1.3 restrains by every kilogram of Ludox, antifoaming agent is a n-octyl alcohol;
(6) elementary mixing evenly after, measure dope viscosity with the flow cup flow cup, according to viscosity adding α-Al
2O
3Powder powder or Ludox adjustment slip;
(7) backing layer coating mixing time is less than the mixing time of investment precoat, all new timings of coating, and mixing time should be greater than 10 hours; The new timing of part coatings, mixing time foreshortens to about 5 hours and can use;
The powder liquor ratio of backing layer slip is 4: 1～3: 1, and along with the increase of the number of plies, the powder liquor ratio reduces gradually;
1.4.2 at first wax-pattern is cleaned up with absolute ethyl alcohol, under compressed air pressure, surperficial to wax-pattern with spray gun winding-up slip; Every layer thickness is 1mm, every layer sprayed slip after, carry out stucco, it is 200 order alumina powders that refractory material is used in stucco;
1.4.3 ceramic template is dry:
Alumina formwork surface layer drying process parameter is: 22～25 ℃ of temperature, and humidity 60%～80%, fully drying after just can carry out next layer operation more than 6 hours drying time;
1.4.4 on ceramic template surface layer, make backing layer again
It is identical with surface layer that the backing layer slip is coated with extension technology, adopts directly coating or two kinds of methods of spray gun winding-up to carry out every layer thickness 1～2mm; Every layer sprayed slip after, evenly stucco; The number of plies of backing layer confirms that according to the size of ceramic die board size number of plies scope is 4～10 layers;
Alumina formwork backing layer drying process parameter is: environment temperature is at 20～25 ℃, and ambient humidity is 40%～70%, and drying time is more than 6 hours; Fully just can carry out next layer operation after the drying;
1.5 ceramic template and heating wire stove are assembled into can electrically heated ceramic die.
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