CN102259167A - Method for casting turbocharger encloser casting - Google Patents
Method for casting turbocharger encloser casting Download PDFInfo
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- CN102259167A CN102259167A CN2010101842672A CN201010184267A CN102259167A CN 102259167 A CN102259167 A CN 102259167A CN 2010101842672 A CN2010101842672 A CN 2010101842672A CN 201010184267 A CN201010184267 A CN 201010184267A CN 102259167 A CN102259167 A CN 102259167A
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Abstract
The invention discloses a method for casting a turbocharger encloser, comprising the following steps: mulling, molding, manufacturing cores, integrating, smelting furnace burden, tapping, nodulizing, inoculating, pouring, cooling, unpacking, cleaning castings and checking product quality; designing a template into one type comprising 2-8 piece; adopting a completely symmetrical template layout; correspondingly arranging two to eight casting cavities; and casting by the slice-type ingate distributed pouring technology: and after melted iron enters a direct pouring gate, the melted iron passes through a filter provided with a ceramic filter screen below the direct pouring gate, and flows into a horizontal pouring gate, and then the melted iron enters the casting cavity via the ingate to fill in the cavity, wherein the pouring temperature is 1380-1460DEG C, and the top end surface of a far-end side opposite to the ingate inlet of the casting in each casting cavity is provided with two heat-insulation dead heads for feeding. The tensile strength of the casting body is more than or equal to 400MPa, the yield strength is more than or equal to 250MPa, the percentage elongation is more than or equal to 15%, the body hardness is 130-180HBS, the metallographic structure ferrite is more than or equal to 90%, the percent of spheroidization is more than or equal to 90%, the size of graphite is 4-7 grades, and no carbide is permitted to exist.
Description
Technical field
The present invention relates to a kind of casting method, particularly a kind of casting method of turbocharger case foundry goods.
Background technology
The turbine case is the key components and parts of ship turbine booster, because the turbocharger operation environment is abominable, must guarantee that inner high temperature compressed gas is stored in the volute under high pressure, therefore require the casing component material to have favorable tissue compactness and high toughness.
At above-mentioned requirements, the parts regulation ball China ink cast iron QT400-15 trade mark.The mechanical performance of foundry goods will satisfy tensile strength 〉=400MPa, yield strength 〉=250MPa, percentage elongation 〉=15%, body hardness 130～180HBS; Metallographic structure requires ferrite 〉=90%, nodularization rate 〉=90%, and 4～7 grades of graphite sizes do not allow carbide and exist.Product inside does not allow to exist any casting flaw.The technical indicator characteristics of this product are: require ferrite 〉=90%, need in the production process raw material are strictly controlled.
The working environment of turbocharger case foundry goods is more abominable, therefore very high to the material requirement of foundry goods, product detects and need satisfy tensile strength 〉=400MPa, yield strength 〉=250MPa in each appointed part sampling of body, percentage elongation 〉=15%, hardness 130～180HBS.
These parts have very high requirement to surface quality of continuous castings, especially do not allow the existence of presentation quality defectives such as scab, burr.
Therefore how to satisfy above-mentioned specification requirement, become the key of successfully casting this foundry goods.
Summary of the invention
The turbocharger case foundry goods of producing the purpose of this invention is to provide a kind of casting method of turbocharger case, so that can satisfy above-mentioned specification requirement.
For achieving the above object, the technical solution used in the present invention is:
The casting method of turbocharger case, its step comprise mulling, moulding, coremaking, mould assembly, furnace charge melting, tap a blast furnace nodularization and inoculation, cast, cooling, unpack, casting cleaning and product quality inspection; It is characterized in that: template is designed to two～eight on a type, takes the template layout of symmetry fully, and correspondence is established two～eight foundry goods die cavities; In casting technique, adopt several sheet type ingate distributing pouring technologies: the filter that is provided with foam ceramic filter after iron liquid enters from sprue through the sprue below, flow into some the cross gates of symmetry fully simultaneously, enter the foundry goods die cavity via the sheet type ingate respectively afterwards, be full of die cavity; Pouring temperature is controlled at 1380～1460 ℃; The top end face of each foundry goods die cavity in the distal side of relative foundry goods ingate import is provided with two insulated feeders and carries out feeding.
The spheroidization and inoculation treatment process of tapping a blast furnace of the present invention comprises that tap a blast furnace spheroidising and ferrosilicon inovulant breed two links for twice.The nodularization dosage that is added is 1.0～2.5% of the melting amount of tapping a blast furnace, and the chemical component weight percentage of nodulizer is: Mg 5.0～7.5%, RE 1.0～4.0%, Si 35～48%, Ca 1.0～3.0% and Fe surplus, the granularity of nodulizer are 3～25mm.Described inovulant breeds the ferrosilicon inovulant that adds iron liquid gross weight 0.2～0.5% after the nodularization of promptly once tapping a blast furnace for twice, stirring is subsequently skimmed and is added iron liquid, and carry out breeding the second time, the ferrosilicon inovulant with 0.2～0.5% is added to envelope and carries out the rabbling hoe slag.The granularity of used ferrosilicon inovulant is 3～25mm, and the chemical component weight percentage of ferrosilicon inovulant is Si 72～75%, Al 0.4～1.5%, Ca 0.4～1.0% and Fe surplus.
In the described cast step, iron liquid will guarantee that the iron liquid casting temperature is at 1380～1460 ℃ after the nodulizer inoculation.Adopt sulphur oxygen inovulant to carry out current-following inoculation in the casting process, used sulphur oxygen inovulant granularity is 0.1～1.0mm, chemical component weight percentage is Si 70～76%, Al0.75～1.25%, Ca 0.75～1.25%, Ce 1.5～2.0%, S 0.5～0.8%, O 0.3～0.5% and Fe surplus, and the percentage that addition accounts for iron liquid total amount is 0.05～0.2%.The chemical component weight percentage of last cast product is: C 3.2～3.8%, Si 2.0～3.0%, Mn≤0.45%, P≤0.07%, S≤0.03%, RE 0.01～0.04%, Mg 0.02～0.08% and Fe surplus.
Product after above melting spheroidization and inoculation processing makes cast has the metallographic structure of nodularization rate 〉=90%, ferrite 〉=90%, carbides-free, to guarantee the mechanical performance of products requirement.
In order to obtain not have the cast product of defective, taked following measure on the technology:
(1) because this casting dimension is less, be designed to four on a type, take the template layout of symmetry fully, guaranteed that four foundry goods are in identical state in cavity filling process, and then obtain the identical foundry goods of quality state, for quality testing afterwards provides assurance and foundation.
(2) adopt a plurality of sheet type ingate distributing pouring technologies: have the filter of foam ceramic filter to flow into four cross gates of symmetry fully simultaneously through the below after iron liquid enters from sprue, enter the foundry goods die cavity via four thin slice ingates respectively afterwards; Guarantee that pouring temperature is controlled at 1380～1460 ℃, this technological measure can guarantee that cast product does not produce cold shut and gas hole defect.
(3) place floamed ceramics filtrating piece in the sprue bottom and filter iron liquid, remove the impurity in the iron liquid, thereby prevent that product from producing dreg defect.
(4) in the thicker position of cast top of ingate offside 4 pairs of foundry goods of two insulated feeders are set respectively and carry out feeding, guarantee to obtain the complete foundry goods of dense structure.
(5) being coated with in the material process at step of overall modelling, do not adopt traditional brushing mode in order to obtain clear cast(ing) surface attractive in appearance, but respectively core and external form are adopted comparatively advanced dipping process and flowcoating process, be about to the core working face and immerse the formal coating that flows through mold cavity surface in the coating with employing coating, the brushing vestige and the coating that produce when these two kinds of technologies can be avoided brushing are effectively piled up at the die cavity wedge angle.
Key technology of the present invention is:
In iron casting was produced, the mechanical performance index that make the mechanical performance of foundry goods body reach trade mark regulation was the very difficult thing of part.In addition this mechanical performance of products specified point has five positions, and these five positions almost are evenly distributed on each position of foundry goods.This just makes that technical difficulty increases greatly.Reach this specification requirement of cast product, the cast product of production is reached:
(1) each position of foundry goods does not allow to have any casting flaw: comprise that foundry goods inside can not exist micro-shrinkage porosite and dreg defect;
(2) metallographic structure at each position of foundry goods will reach basically identical: comprise that the nodularization rate all should be good (all reach 〉=90%), and matrix will be consistent (ferrite all should more than 90%).
In order to reach this two production control technical indicators, the test of the selection (being the position and the quantity of rising head) of injection mode of iron liquid on casting technique (being the position and the quantity of ingate) and rising head determines it is very important.Because in the time of will making casting solidification by the adjustment of these two factors on casting technique, the heat distribution of foundry goods each several part is in the state of comparison equilibrium.Through test of many times, through constantly changing after the position and quantity of pouring and riser systems, just reach technology ideal effect of the present invention at last.
The invention has the beneficial effects as follows:
The present invention adopts the layout designs of many on a type in technological design, adopt end face distributing pouring technology, and at the top of foundry goods insulated feeder is placed in comparatively thick big position, the utilization rate of the molding sand of Ti Gaoing effectively, also saved production cost when enhancing productivity for company, fully the layout of symmetry has also guaranteed the uniformity on a plurality of casting qualities of same case, for after at random sampling Detection work rational foundation is provided; Open running gate system helps realizing filling the type effect fast, has effectively overcome cold shut and gas hole defect that thin-section casting very easily produces; The sheet type ingate that disperses has been avoided the undue concentration of heat, thereby has eliminated the shrinkage porosite that the thicker position of upper surface may occur.
After adopting casting method of the present invention, the turbocharger case foundry goods tensile strength 〉=400MPa, the yield strength 〉=250MPa that produce, percentage elongation 〉=15%, body hardness 130～180HBS; Metallographic structure requires ferrite 〉=90%, nodularization rate 〉=90%, and 4～7 grades of graphite sizes, carbides-free exists.Each position of foundry goods exists without any casting flaw, meets client's specification requirement fully.
Description of drawings
Fig. 1 is the schematic diagram of one embodiment of the invention.
Fig. 2 is the cutaway view of one embodiment of the invention medium casting die cavity.
The specific embodiment
The present invention will be further described below in conjunction with drawings and Examples.
Referring to Fig. 1, Fig. 2, the casting method of ship turbine booster case foundry goods of the present invention comprises the steps:
1) mulling, moulding and coremaking
Ship turbine booster case foundry goods carries out moulding after adopting automatic pug mixer to mix the system furan resin self curing sand, and template is designed to four on a type, takes the template layout of symmetry fully, and correspondence is established four foundry goods die cavities 3; Sprue 4 belows are provided with the filter 5 of foam ceramic filter, and connect four cross gates 6 of symmetry fully, are communicated with foundry goods die cavity 3 via four sheet type ingates 7 respectively again; The top end face of each foundry goods die cavity 3 in the distal side of relative foundry goods ingate import is provided with two insulated feeders 8 and carries out feeding.
On cope match plate circle shape pad, place insulated feeder 8 before the moulding, carry out back-up sand, consolidation, molding then, repair type, and carry out flow coat operation and surperficial burn out process; Then make two cores of 1#, 2# 1,2, and placement is standby after carrying out dip-coating and skin drying.
2) mould assembly
Down be lowered to 2 1#, 2 # core 1,2 in order among the sand mold b, place foam ceramic filter a slice in filter 5: after blowing off the floating sand in sand mold a, the b up and down, hanging changes upward that sand mold carries out mould assembly and with to be cast behind the tight case of bolt etc.
3) furnace charge melting
Dispose furnace charge earlier, the composition percentage by weight of furnace charge is: the pig iron 30%, foundry returns 30%, steel scrap 40%, then the furnace charge that configures is carried out the melting of iron liquid in the preface input medium-frequency induction furnace successively, smelting temperature is 1560 ℃, leave standstill insulation 5～10 minutes, allow impurity in the iron liquid is fully floating to come up, after covering with deslagging agent slag is taken off outside the stove, prevent that impurity is deposited in the iron liquid.
4) spheroidization and inoculation that taps a blast furnace is handled
Comprising taps a blast furnace carries out spheroidising and two parts of twice inoculation of ferrosilicon inovulant.Wherein spheroidising is adopted and is poured the method spheriodization process thereof, the nodulizer granularity is 3～25mm, the nodulizer addition is 1.5%, iron liquid tapping temperature is 1560 ℃, the amount of tapping a blast furnace is 2/3 of a total amount for the first time, the reagentia time of nodulizer and iron liquid is 40～90 seconds, question response finishes the ferrosilicon inovulant that the back adds the total amount 0.3% of tapping a blast furnace, and add remaining 1/3 iron liquid, stir the scum silica frost that scratches clean iron liquid surface afterwards, add 0.3% ferrosilicon inovulant of iron liquid gross weight again, and stir and skim, cover thermal-insulating covering agent at last and go to pour into a mould.Wherein the chemical component weight percentage of nodulizer is: Mg 6.75%, RE 2.35%, Si 44%, Ca 2.0% and Fe surplus; The chemical component weight percentage of ferrosilicon inovulant is: Si 74%, Ca 0.6%, Al 0.55% and Fe surplus, the granularity of ferrosilicon inovulant are 3～25mm.
5) cast
The pouring temperature of iron liquid is 1435 ℃.After iron liquid was poured into by cup, the filter through the foamed filter net had blocked the impurity in the iron liquid, had reduced the possibility of foundry goods generation dreg defect.Iron liquid has slowed down the flow velocity of iron liquid through behind the filter in addition, has alleviated the impulsive force of iron liquid to casting mold, thereby has reduced the possibility of sand washing; It is steady that iron liquid fills type, helps reducing the secondary oxidation of iron liquid in casting mold, thereby reduce the appearance of dreg defect.Iron liquid flows into four cross gates 6 subsequently simultaneously, flows into each foundry goods die cavity 3 by four sheet type ingates 7 respectively again, reaches the steadily purpose of cast of quick dispersion; Adopt sulphur oxygen inovulant to carry out current-following inoculation in the casting process, the granularity of used sulphur oxygen inovulant is 0.1～1.0mm, the chemical component weight percentage of sulphur oxygen inovulant is Si 73.2%, Al 0.87%, Ca 0.96%, Ce1.76%, S 0.64%, O 0.52% and Fe surplus, and the percentage that addition accounts for iron liquid total amount is 0.10%: the chemical composition total amount percentage of final casting product is: C 3.67% Si2.75%, Mn 0.36%, P 0.045%, S 0.011%, RE 0.015%, Mg 0.054% and Fe surplus.
6) cooling is unpacked
7) casting cleaning
8) quality inspection
The product of disqualified upon inspection is done to eliminate and is scrapped processing, and keep in the qualified foundry goods certified products warehouse that enters.
After adopting casting method of the present invention, foundry goods gross weight 11.5kg, the heavy 6.5kg of dead head, product yield is 63.8%, to this type of than light casting, these data are comparatively desirable, can create certain economic benefit for company.
The material trademark of product is spheroidal graphite cast-iron QT400-15, the mechanical performance test result of product body: tensile strength 405～485MPa, yield strength 260～345MPa, percentage elongation 15.2～23.5%, hardness 143～176HBS; Cast product metallographic structure testing result is: nodularization rate 90%, ferrite 92%, carbides-free exist; The chemical composition testing result of product: C 3.67%, Si 2.75%, Mn 0.36%, P 0.045%, S 0.011%, RE 0.015%, Mg 0.054% and Fe surplus; Cast product through ultrasonic wave defects detection result without any casting flaw.Cast product satisfies client's technical conditions requirement fully.
The main technologic parameters of table 1 embodiment of the invention
The main testing result of table 2 embodiment of the invention
The technical process of embodiment 2,3,4,5 is no longer set forth with embodiment 1.
Claims (7)
1. the casting method of turbocharger case, its step comprise mulling, moulding, coremaking, mould assembly, furnace charge melting, tap a blast furnace nodularization and inoculation, cast, cooling, unpack, casting cleaning and product quality inspection; It is characterized in that: template is designed to two～eight on a type, takes the template layout of symmetry fully, and correspondence is established two～eight foundry goods die cavities; In casting technique, adopt several sheet type ingate distributing pouring technologies: the filter that is provided with foam ceramic filter after iron liquid enters from sprue through the sprue below, flow into some the cross gates of symmetry fully simultaneously, enter the foundry goods die cavity via the sheet type ingate respectively afterwards, be full of die cavity; Pouring temperature is controlled at 1380～1460 ℃; The top end face of each foundry goods die cavity in the distal side of relative foundry goods ingate import is provided with two insulated feeders and carries out feeding.
2. the casting method of turbocharger case as claimed in claim 1 is characterized in that: described furnace charge melting step comprises furnace charge configuration and melting, and the percentage by weight of furnace charge configuration is: the pig iron 20～50%, foundry returns 20～40%, steel scrap 10～60%; Adopt the medium-frequency induction furnace melting, 1460～1580 ℃ of smelting temperatures.
3. the casting method of turbocharger case as claimed in claim 1 is characterized in that: the described spheroidization and inoculation treatment process of tapping a blast furnace comprises that tap a blast furnace spheroidising and ferrosilicon inovulant breed two links for twice.
4. the casting method of turbocharger case as claimed in claim 3, it is characterized in that: the nodularization dosage that is added is 1.0～2.5% of the melting amount of tapping a blast furnace, the chemical component weight percentage of nodulizer is: Mg 5.0～7.5%, RE 1.0～4.0%, Si 35～48%, Ca 1.0～3.0% and Fe surplus, the granularity of nodulizer are 3～25mm.
5. the casting method of turbocharger case as claimed in claim 3, it is characterized in that: described inovulant breeds the ferrosilicon inovulant that adds iron liquid gross weight 0.2～0.5% after the nodularization of promptly once tapping a blast furnace for twice, stirring is subsequently skimmed and is added iron liquid, and carry out breeding the second time, the ferrosilicon inovulant with 0.2～0.5% is added to envelope and carries out the rabbling hoe slag; The granularity of used ferrosilicon inovulant is 3～25mm, and the chemical component weight percentage of ferrosilicon inovulant is Si 72～75%, Al0.4～1.5%, Ca 0.4～1.0% and Fe surplus.
6. the casting method of turbocharger case as claimed in claim 1 is characterized in that: in the described cast step, iron liquid will guarantee that the iron liquid casting temperature is at 1380～1460 ℃ after the nodulizer inoculation; Adopt sulphur oxygen inovulant to carry out current-following inoculation in the casting process, used sulphur oxygen inovulant granularity is 0.1～1.0mm, chemical component weight percentage is Si 70～76%, Al0.75～1.25%, Ca 0.75～1.25%, Ce 1.5～2.0%, S 0.5～0.8%, O 0.3～0.5% and Fe surplus, and the percentage by weight that addition accounts for iron liquid total amount is 0.05～0.2%; The chemical component weight percentage of last cast product is: C 3.2～3.8%, Si 2.0～3.0%, Mn≤0.45%, P≤0.07%, S≤0.03%, RE 0.01～0.04%, Mg 0.02～0.08% and Fe surplus.
7. the casting method of turbocharger case as claimed in claim 1, it is characterized in that: in the described cast step, product after above melting spheroidization and inoculation processing makes cast has the metallographic structure of nodularization rate 〉=90%, ferrite 〉=90%, carbides-free, to guarantee the mechanical performance of products requirement.
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| CN102717032A (en) * | 2012-07-09 | 2012-10-10 | 江苏多为泵业股份有限公司 | Precision casting method for automobile turbocharger casing part |
| CN102876998A (en) * | 2012-09-29 | 2013-01-16 | 西峡县众德汽车部件有限公司 | Heat-resistant steel, turbocharger conjoined casing and preparation method of turbocharger conjoined casing |
| CN102912211A (en) * | 2012-11-08 | 2013-02-06 | 南车戚墅堰机车有限公司 | Smelting method for cylinder cover of marine diesel engine |
| CN103341594A (en) * | 2013-07-03 | 2013-10-09 | 河南星鹏铸件有限责任公司 | Casting method of brake shell |
| CN104190876A (en) * | 2014-08-29 | 2014-12-10 | 无锡柯马机械有限公司 | Casting process for turbocharger compressor shell |
| CN104493095A (en) * | 2015-01-09 | 2015-04-08 | 宁波日星铸业有限公司 | Pouring system and pouring method of thin-wall casting |
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| CN106583663B (en) * | 2016-12-22 | 2018-12-07 | 常州中车汽车零部件有限公司 | A kind of turbine case casting method |
| CN108160934A (en) * | 2018-02-10 | 2018-06-15 | 东风本田汽车零部件有限公司 | A kind of engine cam more than one piece casting technique and casting mould |
| CN108160934B (en) * | 2018-02-10 | 2023-10-24 | 东风本田汽车零部件有限公司 | Multi-piece casting process and casting mold for engine cam shaft |
| CN108311644A (en) * | 2018-03-20 | 2018-07-24 | 江苏吉鑫风能科技股份有限公司 | A kind of casting mold and casting method of solution strengthening ferrite ductile cast iron wind power casting |
| CN108311644B (en) * | 2018-03-20 | 2024-01-12 | 江苏吉鑫风能科技股份有限公司 | Casting mold and casting method of solid solution reinforced ferrite nodular cast iron wind power casting |
| CN108555244A (en) * | 2018-04-24 | 2018-09-21 | 上柴动力海安有限公司 | A kind of cast iron sand core manufacturing method |
| CN110238346A (en) * | 2019-07-18 | 2019-09-17 | 成都艾特安科技有限公司 | The method of green casting vehicle turbocharger shell |
| CN113118385A (en) * | 2019-12-31 | 2021-07-16 | 辽宁锦鸿数控机械制造有限公司 | Steel casting pouring device |
| CN113732246A (en) * | 2021-09-07 | 2021-12-03 | 襄阳云威机械有限公司 | Method for reducing deformation and sand adhesion of shell mold casting |
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