CN102284694A - Sand-casting molding method of airplane cabin door - Google Patents
Sand-casting molding method of airplane cabin door Download PDFInfo
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Abstract
The invention relates to a sand-casting molding method of an airplane cabin door. The specific requirements are as follows in sequence: utilizing an SR-1 refined deteriorated thinning agent to treat aluminum solution and argon gas; adding fluxing agent, rotating and blowing to carry out a combined refining; utilizing a whole core producing technology matched forming method of 'parting an outline and matching an inner core' to guarantee a size precision of the wall thickness of a thin casting and a size precision of a whole structure of the casting; utilizing a counter-pressure casting to guarantee that the casting mould filling is complete and a better inner quality is obtained; utilizing an innovative heat treatment method to prevent the problem that the thin-wall casting is extremely easy to be deformed. Through the gathered optimization and innovation of smelting, molding and casting processes and a heat treatment method, a low-cost and short-cycle casting and molding method of a light aluminum casting with a complicated whole thin-wall framework structure is developed; the casting obtained by the method has a thinner wall thickness and better mechanical property and inner quality; and the method provided by the invention has the advantages of simple process, fewer needed devices and tremendous technological and economic advantages.
Description
Technical field
The present invention relates to the aluminium alloy casting forming method, a kind of sand casting forming method of aircraft door specifically is provided.
Background technology
In the prior art, aluminium alloy thin-walled foundry goods (for example aircraft cabin class foundry goods) foundry engieering is the technological difficulties of restriction technical development.In present generation aircraft is made, adopt the high-strength aluminum alloy foundry goods to replace deformation processing after welding or riveted joint sub-assembly can significantly alleviate construction weight, reduce manufacturing cost, shorten the manufacturing cycle.On commercial and military various aircraft, extensively adopt aluminium alloy casting spare to become the main trend of our times aircraft manufacturing.
Aircraft is big with aluminium alloy casting hatch door size, complex structure, wall are thin, and the routine casting method is difficult to realize the complete type that fills; Because load and reliability need, hatch door is very high to mechanical property and inherent quality requirement, and the routine casting method can't reach.Therefore, present existing hatch door class cast casting technology all is the patent or the proprietary technology of a few international major company exploitation.For example, the external cooling melted module precise casting technology fast that adopts makes the hot shell cast of foundry goods, can cool off fast after being full of casting mold, thereby obtain tiny crystalline structure, guarantees mechanical castings.The typical melted module precise casting technology of cooling fast has the HERO Premium of TITAL company exploitation
The SOPHIA technology of the scientific and technological development project exploitation in technology and Europe.China does not also have the manufacturing technology of the ripe aluminium alloy thin-walled foundry goods of aircraft door class at present.
Counter-pressure casting can make the casting stable filling type, solidifies under pressure, is the important process method of producing high-compactness, high-performance foundry goods.But common counter-pressure casting is not suitable for producing the very thin foundry goods of wall thickness.Because the simultaneous pressure that adopts when type is filled in counter-pressure casting is bigger, between 500～700Kpa, can in type, form bigger back-pressure usually, influence the type that fills of liquid metal; In addition, the air thermal conductivity factor is big under the high pressure, causes casting mold that the cooling effect of filling the type molten metal is strengthened, and also influences the thin-walled place of liquid metal filling casting mold.Therefore, conventional counter-pressure casting technology is unfavorable for the complete type that fills of thin-section casting.It is reported that it is that 5.5mm torpedo shell and vane thickness are the generating equipment impeller of 6mm that the aluminium alloy castings that present China goes out with the counter-pressure casting explained hereafter has main wall thickness.Have only 2mm hatch door foundry goods as wall thickness, conventional counter-pressure casting technology can't be produced.
In order to cast thinner aluminium alloy castings, China has developed adjustable pressure casting technology and vacuum differential pressure foundry engieering.These two kinds of casting techniques all are at the vacuum condition lower charging type, help the complete type that fills of thin-section casting, and for improving the feeding a casting ability, casting mold is full of back supercharging fast.But because thin-section casting solidifies after filling type very soon, foundry goods crystallization actual pressure is not high, and foundry goods compactness is bad, is easy to occur defectives such as pin hole.Aircraft door is very high to the internal quality of casting and mechanical property requirements, adopts pressure regulation or vacuum differential pressure casting technique to be difficult to reach requirement.
Usually the main wall thickness of aircraft cabin class foundry goods has only about 2mm, complex structure, and inspection specifications requires high, its the casting difficulty mainly be because of wall thickness too thin, be difficult to the complete type that fills, foundry goods body mechanical property and internal flaw are required height, be difficult to reach the acceptance condition requirement.
People expect to obtain the sand casting forming method of the better aircraft door of a kind of technique effect.
Summary of the invention
The sand casting forming method that the purpose of this invention is to provide the better aircraft door of a kind of technique effect.
The sand casting forming method of a kind of aircraft door of the present invention, being used to cast wall thickness is 1.5～3mm aluminium alloy hatch door class thin-section casting, it is characterized in that: the sand casting forming method specific requirement of described aircraft door is:
Use the SR-1 refinement and denaturation fining agent processing aluminium liquid and the argon gas of the preparation of patent ZL200510047615.0 method to add flux rotary blowing composite refining, make that aluminium liquid modification effect is more excellent, the gentle content of slag is lower, reach the crystal grain of refinement final casting more to improve the purpose that obtains better internal soundness foundry goods after mechanical property and purifying and the purification;
Use the whole core-making technique of " profile somatotype, inner core join beat " to cooperate the group type method of accurate design, not only guaranteed light casting wall thickness dimension precision like this and the more important thing is the overall structure dimensional accuracy that has guaranteed foundry goods;
Adopt the mode of counter-pressure casting, foundry goods solidifies under pressure, so that it is thinner that foundry goods is organized, guarantees simultaneously that casting solidification process is in to be not easy to form the pressure state of separating out pore, guarantees the high compactness of foundry goods;
Adopt special special heat treatment method afterwards, guarantee that mechanical castings meets the demands and avoided the heat treatment deformation that foundry goods that heat treatment process causes is extremely difficult or can't proofread and correct.
The sand casting forming method of aircraft door of the present invention, it is characterized in that: in the sand casting forming method of described aircraft door, to aluminum alloy melt in the stove carry out refining, requirement rotten, thinning processing is: use SR-1 refinement and denaturation fining agent by the preparation of patent ZL200510047615.0 method, aluminum alloy melt in the stove is carried out refining, rotten, refinement integrated treatment, and specific practice is:
The consumption of precentagewise weighing SR-1 refinement and denaturation fining agent is put in the baking oven with the iron ware splendid attire for handling 0.5～5% of aluminium liquid, toasts 2～4 down at 280～330 ℃ (more preferably 300 ℃) (more preferably 3) hour;
Then it is poured on equably aluminium liquid surface, adopt the graphite pressure head (Fig. 5) of band micropore that the refinement and denaturation fining agent is pressed into aluminium liquid, be pressed into the different positions and the degree of depth (referring to Fig. 6) at every turn, continue 30 seconds～1 minute, the entire process process continues 25～30 minutes, spread all over the interior aluminium liquid of crucible everywhere, skim after finishing dealing with;
Add the SR-1 processing and finish static 5～10 minutes of back, cast decompression sample is measured alloy liquid air content once more, pours into a mould the template sample simultaneously, disconnects sample, and with the naked eye procuratorial work fracture thickness degree is rule of thumb judged the alloy grain degree; Whether the visual examination fracture exists is mingled with, if having in alloy air content, fracture thickness degree and the inclusion content one defective, just need add SR-1, handle once more so that guarantee qualified entirely up to air content, grain size and field trash.
The sand casting forming method of aircraft door of the present invention, also claimed following preferred content:
In the sand casting forming method of described aircraft door, adopt the quick melted alloy of melting resistance furnace, specific requirement is: after furnace charge in the smelting furnace melts clear and adjusts composition, with portable swiveling jetting device blowing argon gas 8～15min (referring to Fig. 3) in stove, carry out the refining first time, and adopt decompression method (referring to Fig. 4) to measure alloy liquid air content.
In the sand casting forming method of described aircraft door, prepare hatch door foundry goods core moulding as shown in Figure 1 and group type technological requirement is:
Process as shown in Figure 7, in an one-piece core box, make the required inner core of foundry goods simultaneously, promptly earlier with after the combination of core box housing, insert alignment pin in the relevant position, then dividing plate is inserted (dividing plate promptly forms casting section thickness), afterwards locating piece is stuck in dividing plate and housing on, in remaining each cavity, insert self-hardening resin sand, promptly formed the whole inner cores of foundry goods of a mould multicore after waiting sand hard;
Play core afterwards, and carry out necessary corner and repair and sectional repair; Casting mold and core surface are sprayed one deck zirconium firefly powder coating equably, cover complete, thickness homogeneous, no current mark, spot (eyes observation), can begin the group type after drying;
The group type is crossed the range request (see figure 8): the mo(u)ld bottom half level of approximation is positioned on the ground, in reserving good locating hole, insert and the alignment pin of same size and number when making inner core, inner core is fixed on the mo(u)ld bottom half, then with the sand mold and the core of foundry goods, comprise the chill of inlaying in sand mold and the core, the surface all is heated to 50～70 ℃, with mo(u)ld top half buckle get final product etc. to be cast.
In the sand casting forming method of described aircraft door, preparing as shown in Figure 1, 2, the counter-pressure casting technological requirement of hatch door foundry goods is:
When composition, gas and impurity content and the fracture roughness of aluminum alloy melt are qualified entirely, after casting mold is ready to, on smelting furnace, add a cover central dividing plate, place stalk and casting mold, counter-pressure casting machine upper tank body is installed;
Temperature of aluminum liquid in the smelting furnace is adjusted to 700～720 ℃, prepare cast;
Select the counter-pressure casting simultaneous pressure between 350～450KPa, rise liquid and filling velocity 71～90mm/s, crust boost pressure 5～15KPa, a jar decompression method realization differential pressure is filled type in the employing;
After casting pouring and pressurize are finished, open jar on the counter-pressure casting machine, take out casting mold, carry out cleaning, heat treatment and the check of foundry goods, finish the casting of hatch door foundry goods shown in Fig. 1,2.
In the sand casting forming method of described aircraft door, preparing as shown in Figure 1, 2, the Technology for Heating Processing requirement of hatch door foundry goods is: adopt and fill with little steel ball (diameter of the steel ball 5-10mm) as Figure 10,11 frame structures, foundry goods is coated wherein fully, then 541 ± 5 ℃ of insulations 12 hours, in water temperature 50-80 ℃ the water in 30 second time, quenched fast 8～12 minutes;
Foundry goods is taken out from the steel ball frame of sealing, carry out timeliness, technology is 160 ± 5 ℃ of insulations 8 hours, has promptly finished the heat treatment of foundry goods.Under the effect of steel ball, the quenching process medium casting can't be out of shape or have only minimum distortion, has just prevented the foundry goods quenching distortion, and enough slits are arranged between the steel ball in addition, can enter cooling water, allow foundry goods reach enough cooling velocity to obtain excellent mechanical property.
Aircraft cabin class thin-wall aluminum alloy foundry goods counter-pressure casting moulding process of the present invention, its the most outstanding being characterised in that by the tolerance in the restriction alloy liquid (is observed the number of bubbles in the decompression sample process of setting, no more than 5) and oxidation impurities content (according to the fracture range estimation), improve the degree of purity of aluminum alloy melt, the acquisition internal soundness is better, the foundry goods that mechanical property is higher (guarantees material quality, the refinement of SR-1 refinement and denaturation), utilize counter-pressure casting to fill type technology, select distinctive casting filling technological parameter, strict control mold temperature and pouring temperature, realized the complete type that fills of hatch door foundry goods, and guaranteed that the body mechanical property and the internal flaw of foundry goods reach acceptance requirement.Mechanical property requirements is specific as follows:
Appointed area (Fig. 1,2 center favored area): tensile strength 〉=345MPa, yield strength 〉=280MPa, percentage elongation 〉=5%;
Non-appointed area: tensile strength 〉=310MPa, yield strength 〉=250MPa, percentage elongation 〉=3%; The internal flaw quality requirement is as shown in table 1.
Table 1
With existing counter-pressure casting technology ratio, the present invention has adopted lower simultaneous pressure and higher filling velocity (simultaneous pressure 350-450KPa, filling velocity 71-90mm/s, be higher than general foundry goods), realized that main wall thickness has only the complete type that fills of the thin-walled hatch door foundry goods of 2mm, guaranteeing simultaneously that casting solidification process is in is not easy to form the pressure state of separating out pore, has guaranteed the high compactness of foundry goods.Refractory ceramics casting-up with external exploitation, and then the fast cold precision casting process ratio of managing quick cooling, the hatch door casting solidification of the technology of the present invention is faster, therefore crystallization crystal grain is thinner, and easier assurance mechanical property (can stablize and reach more than the 345MPa, is higher than Chinese high-quality ZL114A alloy-steel casting by mechanical property, this alloy reaches about 320MPa usually), technology succinct (comparing with the Castingother method) needs the equipment of usefulness few simultaneously, and the huge production cost advantage is arranged.
Technology for Heating Processing of the present invention adopts the coating steel ball of innovating, and foundry goods is tightly wrapped, and prevents that foundry goods from producing the distortion that is difficult to or can't proofreaies and correct in quenching process; And leave sufficient gap between the steel ball, can allow foundry goods reach sufficiently high cooling velocity, to obtain excellent mechanical property.
The casting and molding method of the aluminium alloy thin-walled foundry goods of hatch door class of the present invention, being used to cast wall thickness is 1.5～3mm aluminium alloy hatch door class thin-section casting, the casting and molding method of described aluminium alloy thin-walled foundry goods is can simplified summary as follows: use SR-1 refinement and denaturation inorganic agent to handle aluminium liquid and argon gas adds flux rotary blowing composite refining, make that aluminium liquid modification effect is more excellent, the gentle content of slag is lower, the crystal grain that reaches refinement final casting more is to improve the foundry goods that obtains better internal soundness after mechanical property and purifying and the purification.
In essence, the present invention uses the whole core-making technique of " profile somatotype, integral body join beat " to cooperate the group type method of accurate design, has not only guaranteed light casting wall thickness dimension precision, the more important thing is the overall structure dimensional accuracy that has guaranteed foundry goods.The present invention adopts the mode of counter-pressure casting, and foundry goods solidifies under pressure, and it is thinner that foundry goods is organized, and guarantees simultaneously that casting solidification process is in to be not easy to form the pressure state of separating out pore, has guaranteed the high compactness of foundry goods.The present invention adopts special heat treatment method, guarantees that mechanical castings meets the demands and avoided the heat treatment deformation that foundry goods that heat treatment process causes is extremely difficult or can't proofread and correct.
The present invention optimizes innovation by set, with the pure aluminium liquid of high-quality more, more accurate moulding, group type technology, more advanced casting technique and the heat treatment technics of innovation, developed casting and molding method low-cost, the whole thin walled framed structure light aluminum alloy of short-period complexity foundry goods, the casting section thickness that this method obtains is thinner, mechanical property and internal soundness are more excellent, more under lightweight, the trend of more saving, this method has huge technology and economic advantages in current pursuit.
Description of drawings
The present invention is further detailed explanation below in conjunction with drawings and the embodiments:
Fig. 1 is the hatch door foundry goods basic structure and the foundry goods appointed area sketch of required casting, and number designation 1 is depicted as two ear portions of foundry goods among Fig. 1;
Fig. 2 is the cast model figure vertical view corresponding with Fig. 1, and figure center favored area is the foundry goods appointed area, and internal soundness and mechanical property reach the appointed area requirement, and other zones reach the requirement of non-appointed area; Appointed area, the non-appointed area corresponding internal flaw quality requirement of difference are specifically referring to table 1;
Fig. 3 is rotation graphite shower nozzle refining principle schematic, the graphite shower nozzle that will have micropore gos deep in the aluminium liquid, effect lower link drive graphite shower nozzle at exterior power is pressed arrow direction rotation among the figure, and come-up was carried out refining to remove slag, the gas in the aluminium liquid after argon gas and refining flux threw away from shower nozzle under the effect of rotational shear power; Number designation 8 is graphite head handle (promptly rotate graphite shower nozzle connecting rod, be specially reinforcement rod) among Fig. 7, and label 9 (promptly rotates the graphite shower nozzle for the graphite head that has micropore, the micropore naked eyes be cannot see), 12 expressions be crucible, 13 expression aluminium liquid, 14 expression direction of rotation arrows; Number designation 8,9 expressions is not homogeneous object among Fig. 3 and Fig. 5, and pole is a reinforcing bar among Fig. 5, is to be screwed on the graphite head of front with the spiral shell button, just presses down SR-1 flux in aluminium liquid in order to hold with hand; Fig. 3 is whole, and complete in making, top pole satisfies following requirement: 1) connect the outer buttons rotating motor and rotate by graphite head; 2) certain length allows graphite head can descend aluminium liquid certain depth; 3) connecting rod is a hollow, and solvent can arrive graphite head along hollow hole, enters aluminium liquid under the effect of revolving force, plays the refining effect; Be that both shapes of 9 are different fully as label among Fig. 3,5 in addition;
Fig. 4 constitutes schematic diagram for the decompression test sample devices of measuring the alloy air content; Corresponding diagram 8 is explained as follows: the monkey after the preheating 15 is placed on the base plate 16, in crucible 15, pour an amount of aluminium liquid into, immediately with on vacuum (-tight) housing 17 covers, make the vacuum (-tight) housing 17 inherent utmost points reach the near vacuum state in the short time by vavuum pump, make decompression sample 18 under nearly vacuum state, solidify, gas in the aluminium liquid can be under vacuum state as much as possible separating out, some can be overflowed and (can observe bubble and record count in the process of setting in the glass window above the vacuum (-tight) housing 17 19, as a criterion judging aluminium liquid air content), some can not be overflowed but form pore in sample inside in addition, the many more sample densities of pore are more little, and reduced density is to judge another standard of alloy air content;
Fig. 5 is the graphite head structural representation sketch that has handle, and among Fig. 5, number designation 8 is graphite head handle (being specially reinforcement rod), and label 9 is for having the graphite head (the micropore naked eyes be cannot see) of micropore;
Fig. 6 is for carrying out SR-1 refinement and denaturation handling principle simplified schematic diagram (graphite head is pressed into position and degree of depth schematic diagram); Wherein number designation 10,11 expression is at different time graphite head to be pressed into diverse location to carry out the graphite head that the SR-1 refinement and denaturation is handled with the degree of depth, and what number designation 12 was represented is crucible;
Fig. 7 is the whole preparation principle schematic diagram of inner core;
Fig. 8 is a hatch door foundry goods group type Principle of Process schematic diagram; Among the figure, two little cores of number designation 2 expressions formation journal stirrup, 3 expression top boxs, the whole hatch door foundry goods of 4 expressions, 5 expression alignment pins, 6 expression nowels, 7 expression inner cores; Hatch door foundry goods group type is crossed range request and is: earlier nowel 6 is put in ground as Fig. 3 level, will forms the inner core 7 of foundry goods main part and the little core 2 usefulness alignment pins 5 of formation journal stirrup then and be fixed in the nowel 6, top box 3 is buckled promptly finished the group type again; Because be that whole coremaking and group type adopt same alignment pin 5 fixing, the size and the position that form final casting wall thickness slit are very accurate, have so just guaranteed casting section thickness and physical dimension tolerance;
Fig. 9 is the required inner core detailed structure of a hatch door foundry goods schematic diagram;
Figure 10 is the Principles of Heating Processing schematic diagram, at first prepare the airtight housing (mainly do load usefulness, be not drawn as airtight for the signal principle among Figure 10) of a grid type, lining last layer gauze on framework, be used to wrap up steel ball, foundry goods is put in the frame and is wrapped in the steel ball fully.Like this under the effect of steel ball, the quenching process medium casting can't be out of shape or have only minimum distortion, has just prevented the foundry goods quenching distortion, and enough slits are arranged between the steel ball in addition, can enter cooling water, allow foundry goods reach enough cooling velocity to obtain excellent mechanical property;
Figure 11 Principles of Heating Processing are simulated three-dimensional audio-visual picture; During practical operation steel ball foundry goods is wrapped up fully and also housing airtight, for ease of saying something, do not illustrate that whole steel balls do not seal housing yet among Figure 11.
The specific embodiment
Aircraft cabin class thin-wall aluminum alloy casting sand mold cast shaping process, detailed process is as follows successively:
1) adopts refined aluminium ingot, monocrystalline silicon, magnesium ingot, aluminium titanium intermediate alloy, aluminium beryllium intermediate alloy and hatch door foundry goods foundry returns alloyage, batching chemical composition (according to percentage by weight that is wt%) is: Si:6.9, Mg:0.57, Ti:0.12, Be:0.048, impurity element satisfy Fe＜0.01, Mn＜0.01, every kind of other impurity element are less than 0.05, and summation is less than 0.15, and surplus is Al.
2) prepare hatch door foundry goods self-hardening resin sand casting external form as shown in Figure 1, 2 according to common resin-bonded sand cast form technology.
3) adopting the crucible capacity is the resistance furnace molten alloy of 300kg, and furnace charge is molten clear, and adjusts composition, waits for that the aluminum alloy melt temperature raises.
4) when the temperature of aluminium liquid reaches 720 ℃, with portable swiveling jetting device blowing argon gas 8min in stove, carry out the refining first time, and cast decompression sample, measure alloy liquid air content.
5) behind the ar blowing refining, when the temperature of aluminium liquid reaches 710 ℃, use the SR-1 refinement and denaturation fining agent by the preparation of patent ZL200510047615.0 method, aluminum alloy melt in the stove is carried out refining, rotten, refinement integrated treatment, the consumption of SR-1 is for handling 1.5% of aluminium liquid.
6) add the SR-1 processing and finish static 5～10 minutes of back, cast decompression sample is poured into a mould the template sample simultaneously once more, disconnect sample, with the naked eye procuratorial work fracture grain size is judged the alloy structure degree of refinement, whether the visual examination fracture exists is mingled with, and has reached requirement through after-treatment.
7) baking sand mold and core before mould assembly comprises the chill of inlaying in sand mold and the core, and the surface all will be heated to 50～70 ℃, then mould assembly immediately.
8) composition, gas and impurity content and the grain size when aluminum alloy melt is qualified entirely, after casting mold is ready to, adds a cover central dividing plate on smelting furnace, places stalk and casting mold, and counter-pressure casting machine upper tank body is installed.
9) temperature of aluminum liquid in the smelting furnace is adjusted to 700～720 ℃, prepare cast.
10) select the counter-pressure casting simultaneous pressure at 400Kpa, rise liquid speed 71mm/s, filling velocity 80mm/s, crust boost pressure 10Kpa, a jar decompression method realization differential pressure is filled type in the employing.
After casting pouring and pressurize are finished, open jar on the counter-pressure casting machine, take out casting mold, carry out the cleaning of foundry goods according to a conventional method.
11) by shown in Figure 10,11 foundry goods is coated steel ball heat treatment, 541 ± 5 ℃ of insulations 12 hours, in water temperature 50-80 ℃ the water in 30 second time, quenched fast about 10 minutes.Foundry goods is taken out from the steel ball frame of sealing, carry out the operation of 8 hours timeliness of 160 ± 5 ℃ of insulations.
Obtain the attached casting sample of foundry goods mechanical property:
Tensile strength Rm=365 (Mpa), yield strength Rp0.2=305 (Mpa), percentage elongation A=7.5%.
11 the sample mechanical properties in foundry goods body appointed area reach:
Tensile strength Rm mean value 372 (Mpa), minimum of a value 355 (Mpa), maximum 380 (Mpa);
Yield strength Rp0.2 mean value 311 (Mpa), minimum of a value 295 (Mpa), maximum 335 (Mpa);
Percentage elongation A mean value 8.4%, minimum of a value 5.5%, maximum 10%.
The dimensional accuracy of foundry goods, surface quality and Non-Destructive Testing result reach the acceptance criteria requirement that the user provides.
Class thin-wall aluminum alloy foundry goods counter-pressure casting moulding process such as hatch door, detailed process are as follows successively:
1) furnace charge is selected, and adopts high-purity aluminium ingot that market can purchase, pure silicon and other need add intermediate alloy to, and the chemical composition of foundry returns should satisfy the acceptance requirement of hatch door foundry goods chemical composition.
2) make hatch door by method shown in Figure 7 and cast required inner core method, make the required external form of foundry goods, carry out necessary corner behind the type and repair and sectional repair by normal sand casting method.With casting mold and the even scrubbing brush one deck of core surface zirconium firefly powder coating, cover complete, thickness homogeneous, no current mark, spot, can begin the group type after drying, group type process following (Fig. 8,9): mo(u)ld bottom half is placed horizontally on the ground, adopt alignment pin again, inner core is fixed on the mo(u)ld bottom half, with mo(u)ld top half buckle get final product etc. to be cast.
3) smelting furnace adopts resistance furnace, and melted alloy is accurately controlled the aluminum alloy melt temperature in the fusion process fast.
4) furnace charge is molten clear in smelting furnace, and after adjusting composition, with portable swiveling jetting device blowing argon gas 8～15min in stove, carries out the refining first time, and cast decompression sample, measures alloy liquid air content.
5) use the SR-1 refinement and denaturation fining agent for preparing by patent ZL200510047615.0 method, aluminum alloy melt in the stove is carried out refining, rotten, refinement integrated treatment.The SR-1 refinement and denaturation fining agent of precentagewise weighing approrpiate wts is put in the baking oven with the iron ware splendid attire, and 300 ℃ were toasted about 3 hours down; Then it is poured on equably aluminium liquid surface, adopt graphite pressure head (Fig. 5) with holes that the refinement and denaturation fining agent is pressed into aluminium liquid, be pressed into the different positions and the degree of depth at every turn, continue about 30 seconds to 1 minute, the entire process process continues 25 to 30 minutes, spread all over the interior aluminium liquid of crucible everywhere, skim after finishing dealing with.
6) add the SR-1 processing and finish static 5～10 minutes of back, pour into a mould the decompression sample once more, measure alloy liquid air content, pour into a mould the template sample simultaneously, disconnect sample, with the naked eye procuratorial work fracture thickness degree, rule of thumb judge the alloy structure degree of refinement, whether the visual examination fracture exists is mingled with, and alloy air content, fracture thickness degree and inclusion content are qualified after the single treatment;
7) sand mold of foundry goods and core comprise the chill of inlaying in sand mold and the core, and the surface all will be heated to 50～70 ℃, then mould assembly immediately.
8) composition, gas and impurity content and the grain size when aluminum alloy melt is qualified entirely, after casting mold is ready to, adds a cover central dividing plate on smelting furnace, places stalk and casting mold, and counter-pressure casting machine upper tank body is installed.
9) temperature of aluminum liquid in the smelting furnace is adjusted to 700～720 ℃, prepare cast.
10) select the counter-pressure casting simultaneous pressure between 350～450Kpa, rise liquid and filling velocity 71～90mm/s, crust boost pressure 5～15Kpa, a jar decompression method realization differential pressure is filled type in the employing.
After casting pouring and pressurize are finished, open jar on the counter-pressure casting machine, take out casting mold, carry out the cleaning of foundry goods according to a conventional method.
11) by shown in Figure 10,11 foundry goods is coated steel ball heat treatment, 541 ± 5 ℃ of insulations 12 hours, in water temperature 50-80 ℃ the water in 30 second time, quenched fast about 10 minutes.Foundry goods is taken out from the steel ball frame of sealing, carry out the operation of 8 hours timeliness of 160 ± 5 ℃ of insulations.
With existing counter-pressure casting technology ratio, present embodiment has adopted lower simultaneous pressure and higher filling velocity, realized that main wall thickness has only the complete type that fills of the thin-walled hatch door foundry goods of 2mm, guaranteeing simultaneously that casting solidification process is in is not easy to form the pressure state of separating out pore, has guaranteed the high compactness of foundry goods.Refractory ceramics casting-up with external exploitation, and then the fast cold precision casting process ratio of managing quick cooling, the hatch door casting solidification of the described technology of present embodiment is faster, crystallization crystal grain is thinner, so easier assurance mechanical property, technology is succinct simultaneously, needs the equipment of usefulness few, and the huge production cost advantage is arranged.
The production technology of foundry goods except counter-pressure casting fill type technological parameter and embodiment 1 different, all the other are identical with embodiment 1.Present embodiment selects counter-pressure casting to fill the type technological parameter: simultaneous pressure rises liquid speed 71mm/s at 350Kpa, filling velocity 90mm/s, and crust boost pressure 15Kpa, a jar decompression method realization differential pressure is filled type in the employing.
Obtain the attached casting sample of foundry goods mechanical property:
Tensile strength Rm=375 (Mpa), yield strength Rp0.2=315 (Mpa), percentage elongation A=8.5%.
11 the sample mechanical properties in foundry goods body appointed area reach:
Tensile strength Rm mean value 378 (Mpa), minimum of a value 365 (Mpa), maximum 385 (Mpa);
Yield strength Rp0.2 mean value 323 (Mpa), minimum of a value 310 (Mpa), maximum 340 (Mpa);
Percentage elongation A mean value 7%, minimum of a value 5.5%, maximum 8.5%.
The dimensional accuracy of foundry goods, surface quality and Non-Destructive Testing result reach the acceptance criteria requirement that the user provides.
The production technology of foundry goods except counter-pressure casting fill type technological parameter and embodiment 1 different, all the other are identical with embodiment 1.Present embodiment selects counter-pressure casting to fill the type technological parameter: simultaneous pressure rises liquid speed 71mm/s at 450Kpa, filling velocity 71mm/s, and crust boost pressure 5Kpa, a jar decompression method realization differential pressure is filled type in the employing.
Obtain the attached casting sample of foundry goods mechanical property:
Tensile strength Rm=360 (Mpa), yield strength Rp0.2=300 (Mpa), percentage elongation A=10%.
11 the sample mechanical properties in foundry goods body appointed area reach:
Tensile strength Rm mean value 361 (Mpa), minimum of a value 350 (Mpa), maximum 375 (Mpa);
Yield strength Rp0.2 mean value 302 (Mpa), minimum of a value 285 (Mpa), maximum 320 (Mpa);
Percentage elongation A mean value 8.8%, minimum of a value 7.5%, maximum 10.5%.
The dimensional accuracy of foundry goods, surface quality and Non-Destructive Testing result reach the acceptance criteria requirement that the user provides.
Claims (6)
1. the sand casting forming method of an aircraft door, being used to cast wall thickness is 1.5～3mm aluminium alloy hatch door class thin-section casting, it is characterized in that: the sand casting forming method specific requirement of described aircraft door is:
Use SR-1 refinement and denaturation fining agent processing aluminium liquid and argon gas to add flux rotary blowing composite refining;
Use the whole core-making technique cooperation group type method of " profile somatotype, inner core join beat ", guarantee the overall structure dimensional accuracy of light casting wall thickness dimension precision and foundry goods;
Adopt the mode of counter-pressure casting, foundry goods solidifies under pressure so that guarantee the high compactness of foundry goods;
Heat-treat afterwards, guarantee the heat treating castings distortion that mechanical castings meets the demands and avoided heat treatment process to cause.
2. according to the sand casting forming method of the described aircraft door of claim 1, it is characterized in that: in the sand casting forming method of described aircraft door, to aluminum alloy melt in the stove carry out refining, requirement rotten, thinning processing is: use SR-1 refinement and denaturation fining agent, aluminum alloy melt in the stove is carried out refining, rotten, refinement integrated treatment, and specific practice is:
The consumption of precentagewise weighing SR-1 refinement and denaturation fining agent is put in the baking oven with the iron ware splendid attire for handling 0.5～5% of aluminium liquid, toasts 2～4 hours down at 280～330 ℃;
Then it is poured on equably aluminium liquid surface, adopts the graphite pressure head of band micropore that the refinement and denaturation fining agent is pressed into aluminium liquid, be pressed into the different positions and the degree of depth at every turn, continue 30 seconds～1 minute, the entire process process continues 25～30 minutes, spread all over the interior aluminium liquid of crucible everywhere, skims after finishing dealing with;
Add the SR-1 processing and finish static 5～10 minutes of back, cast decompression sample is measured alloy liquid air content once more, pours into a mould the template sample simultaneously, disconnects sample, and procuratorial work fracture thickness degree is judged the alloy grain degree; Whether the inspection fracture exists is mingled with, so that guarantee that air content, grain size and field trash are qualified entirely.
3. according to the sand casting forming method of the described aircraft door of claim 2, it is characterized in that: in the sand casting forming method of described aircraft door, adopt the quick melted alloy of melting resistance furnace, specific requirement is:
After furnace charge in the smelting furnace melts clear and adjusts composition, with swiveling jetting device blowing argon gas 8～15min in stove, carry out the refining first time, and adopt the decompression method to measure alloy liquid air content.
4. according to the sand casting forming method of the described aircraft door of claim 1, it is characterized in that: in the sand casting forming method of described aircraft door, preparation hatch door foundry goods core moulding and group type technological requirement are:
In an one-piece core box, make the required inner core of foundry goods simultaneously, promptly earlier with after the combination of core box housing, insert alignment pin in the relevant position, then dividing plate is inserted (dividing plate promptly forms casting section thickness), afterwards locating piece is stuck in dividing plate and housing on, in remaining each cavity, insert self-hardening resin sand, promptly formed the whole inner cores of foundry goods of a mould multicore after waiting sand hard;
Play core afterwards, and carry out necessary corner and repair and sectional repair; Casting mold and core surface are sprayed one deck zirconium firefly powder coating equably, cover complete, thickness homogeneous, no current mark, spot, can begin the group type after drying;
The group type is crossed range request: the mo(u)ld bottom half level of approximation is positioned on the ground, in reserving good locating hole, insert and the alignment pin of same size and number when making inner core, inner core is fixed on the mo(u)ld bottom half, then with the sand mold and the core of foundry goods, comprise the chill of inlaying in sand mold and the core, the surface all is heated to 50～70 ℃, with mo(u)ld top half buckle get final product etc. to be cast.
5. according to the sand casting forming method of the described aircraft door of claim 1, it is characterized in that: in the sand casting forming method of described aircraft door, the counter-pressure casting technological requirement of hatch door foundry goods is:
When composition, gas and impurity content and the fracture roughness of aluminum alloy melt are qualified entirely, after casting mold is ready to, on smelting furnace, add a cover central dividing plate, place stalk and casting mold, counter-pressure casting machine upper tank body is installed;
Temperature of aluminum liquid in the smelting furnace is adjusted to 700～720 ℃, prepare cast;
Select the counter-pressure casting simultaneous pressure between 350～450KPa, rise liquid and filling velocity 71～90mm/s, crust boost pressure 5～15KPa, a jar decompression method realization differential pressure is filled type in the employing;
After casting pouring and pressurize are finished, open jar on the counter-pressure casting machine, take out casting mold, carry out cleaning, heat treatment and the check of foundry goods, finish the casting of hatch door foundry goods.
6. according to the sand casting forming method of one of them described aircraft door of claim 1～5, it is characterized in that: in the sand casting forming method of described aircraft door, the Technology for Heating Processing of preparation hatch door foundry goods requires: adopt frame structure to fill with the little steel ball of diameter 5-10mm, foundry goods is coated wherein fully, then 541 ± 5 ℃ of insulations 12 hours, in water temperature 50-80 ℃ the water in 30 second time, quenched fast 8～12 minutes;
Foundry goods is taken out from the steel ball frame of sealing, carry out timeliness, technology is 160 ± 5 ℃ of insulations 8 hours, has promptly finished the heat treatment of foundry goods.
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| CN2010102020586A CN102284694A (en) | 2010-06-18 | 2010-06-18 | Sand-casting molding method of airplane cabin door |
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Application publication date: 20111221 |