Background technology
In recent years, very fast based on the castings production technical development of centrifugal casting, also promoted the development that the technology of cast tube is produced in domestic use centrifugal casting simultaneously.As everyone knows; Adopt the die spinning technology to produce the casting technique that cast tube is a kind of advanced person; In this technology; Coating is key technology; When producing foundry goods with the die spinning method that applied coating, not only productivity ratio greatly improves, and labour intensity significantly descends; And casting quality is high, greatly reduces percent defective.
Diatomite be die spinning with refractory powder the most frequently used in the coating, its chemical composition is with SiO
2Be main, contain a small amount of Al
2O
3, Fe
2O
3, CaO, MgO, K
2O and organic substance also have 3.5%~3.8% the crystallization water etc.Through research, China Changbai Mountain diatomite SiO
2Content is up to 91.98%, and thermal conductivity is 0.0263Wm
-1K
-1, bulk density 0.32g/cm
3, pore volume 0.45cm
3/ g, specific area 19.1m
2G
-1, impurity is few, the high temeperature chemistry stable performance, can effectively remove the crystallization water and organic matter after the processing, is the desirable refractory material of Mould Coating for Centrifugal Cast.Diatomaceous in addition porous makes it have the gas storage function, and varigrained diatomite mixes use, can improve the surface quality of coating and cast tube.
Sodium bentonite is a suspending agent the most frequently used in the water based paint, can make water based paint have thixotropy preferably.Sodium bentonite is to be the clay of essential mineral with the montmorillonite, and its particle particle very little (less than 0.1 μ m) not only is adsorbed on its particle surface by the moistening back of water moisture, also can get into and form the colloid particle between its crystal layer, becomes colloidal solution again.The bentonite particle forms the space network structure in colloidal solution, make bentonite slurry have yield value, and the particle particle of refractory powder is difficult for sinking.In addition, bentonite can also effectively improve the intensity (after surpassing 4%, intensity does not have significant change) of coating.At present, big multiple enterprises adds higher bentonite content in coating, to improve the suspension and the thixotropy of coating; But bentonite content surpasses at high about 5% o'clock; Often make the tiny dispersion of foam, it is very big to be difficult for gathering come-up and coating gas forming amount, often makes cast tube more pore occur.
Present most of chill coating adopts waterglass as binding agent.Waterglass has lower gas forming amount as inorganic binder, can satisfy general requirement of producing, but uses coating its intensity and the instability of waterglass as binding agent.Discover that when temperature rose to 400~450 ℃, the adhesive strength of waterglass coating and mould wall was reduced to 0.14~0.15Kg/cm
2, this is because the silicon gel produces cracking because of dehydration.Temperature raises again, and the gel sintering shows as intensity and raises.When temperature reaches 600 ℃, the gel fusing, it is low that adhesive strength is changeed, and the adhesive strength in the time of 900~1000 ℃ is lower than 0.15Kg/cm
2Centrifugal casting technique to the requirement of chill coating intensity is: elevated temperature strength wants high, with the impact of opposing molten metal; Retained strength is low, so that cleaning.The temperature variant strength character of this and waterglass is on the contrary, especially contains a large amount of sodium ions in the waterglass, at high temperature can form low-melting compound, can increase the weight of this harmful trend again.Consequently: coating intensity sharply descends under the high temperature of casting, is washed away by molten metal and is subjected to displacement, and produces local the gathering, causes the coating wall unevenness, causes the cast tube surface to be uneven, and surface smoothness is too poor; The while casting mold is heated inhomogeneous, produces extra thermal stress, influences mould life; After cast tube cooling, residual coating intensity rises, and low-melting compound especially occurs, and the higher very difficult cleaning of intensity all has bad influence to life-span of tube drawing operation and casting mold.Can know according to above-mentioned analysis, use waterglass to be difficult to be fit to the requirement of high-quality spun cast pipe as the coating of binding agent.
Summary of the invention
The object of the invention is exactly to the above-mentioned deficiency in the background technology; The centrifugal casting of research and development novel metal type replaces using the coating of waterglass with coating; Make its sintering phenomenon, higher high temperature strength, lower character such as retained strength with thixotropy preferably, heat insulating ability, lower gas forming amount, appropriateness; Make its tube drawing in die spinning technology smooth; Defectives such as foundry goods free of pinholes, pore, spoken parts in traditional operas, slag inclusion, burning into sand, penetration, chemical scab guarantee that cast tube has higher quality.
In order to realize the foregoing invention purpose, the present invention provides a kind of die spinning coating, and this coating contains following each component: diatomite, sodium bentonite, sodium phosphate trimer and water.
Above-mentioned die spinning with coating in, preferred: said coating also contains Ludox.
Above-mentioned die spinning with coating in; When only considering diatomite, sodium bentonite, sodium phosphate trimer, four components of Ludox; Proportion relation between diatomite, sodium bentonite, sodium phosphate trimer and the Ludox is counted according to percentage by weight: preferred diatomite is 93~98.2wt%; Sodium bentonite is 1~4wt%; Sodium phosphate trimer is 0.3~1.5wt%, and Ludox is 0~2.0wt%; Further preferred diatomite is 93.7~96.3wt%, and sodium bentonite is 2.5~3.5wt%, and sodium phosphate trimer is 0.6~1.3wt%, and Ludox is 0.6~1.5wt%; Further preferred again diatomite is 94.5~96.0wt%, and sodium bentonite is 2.5~3.5wt%, and sodium phosphate trimer is 0.8~1.25wt%, and Ludox is 0.65~1.25wt%; More preferably diatomaceous content ratio is 94.8~95.2wt%, and sodium bentonite is 2.9~3.1wt%, and sodium phosphate trimer is 0.95~1.05wt%, and Ludox is 0.95~1.05wt%; Most preferably sodium bentonite is 3%; Sodium phosphate trimer is 1%, Ludox is 1%, and diatomite is 95%.
Above-mentioned die spinning with coating in, the weight content of water is 1~1.5 times of diatomite weight content in the preferred said coating.
Above-mentioned die spinning with coating in, preferred said diatomite is that granularity is 325 purpose diatomite or varigrained diatomaceous mixtures.
The present invention also provides the preparation method of a kind of die spinning with coating, each described die spinning coating that this coating is claim 1~7, and this preparation method may further comprise the steps:
Bentonite and water are mixed the step that mixes of first stipulated time in the first regulation ratio;
The binding agent that adds sodium phosphate trimer and Ludox to mixture after being mixed adds step;
Mixture to adding sodium phosphate trimer and Ludox stirs the suspension obtaining step that obtains suspension;
Said suspension and said diatomite one are reinstated the step that rolls that puddle mixer rolls; With
Aging step with paste sealing back second stipulated time of ageing.
In the preparation method of above-mentioned die spinning with coating, preferred: rolling in the step said, is the water that adds the second regulation ratio while rolling when said suspension is rolled with said diatomite.
In the preparation method of above-mentioned die spinning with coating, preferred: the said first regulation ratio is 1: 15~1: 25, the said second regulation ratio be make diatomite and water ratio between 1: 1~1~1.5.
In the preparation method of above-mentioned die spinning with coating, preferred: said first stipulated time is equal to, or greater than 12 hours, and said second stipulated time is equal to, or greater than 12 hours.
In the preparation method of above-mentioned die spinning with coating, preferred: the said first regulation ratio is 1: 20, and said first stipulated time is equal to, or greater than 24 hours, and said second stipulated time is equal to, or greater than 24 hours.
The specific embodiment
In order to solve the existing defective of mentioning in the background technology, the present inventor seeks the alternative materials of waterglass through various tests and theory analysis.
Through the inventor research and analyse discovery, Ludox during as the paint adhesion agent coating elevated temperature strength high; The viscosity of Ludox is less, and the powder liquor ratio of coating can improve greatly, thereby coating surface intensity is improved, and hardness improves, to obtain the bright and clean cast(ing) surface of high-quality; The using silica-sol wash good stability, and can adopt the mode of air dry to obtain intensity; And be that nontoxic nothing is corroded non-inflammable explosive article, with its coatings formulated environmentally safe, to personal safety.
In addition, the present inventor has also attempted with the auxiliary material of washing powder as coating, promptly with washing powder as auxiliary agent, the result finds to use washing powder can improve suspension, caking property and the intensity of coating as auxiliary agent.Trace it to its cause, roughly following: the Na in the washing powder
+Ca in the replaceable bentonite
2+, bentonite is played activation, thereby improves suspension, the caking property of coating; Wherein, the sodium phosphate trimer in the washing powder not only can be used as the suspension of auxiliary agent raising coating but also sodium phosphate trimer can obviously strengthen coating as binding agent intensity.
The inventor has designed following a kind of die spinning coating based on above understanding, and this coating comprises diatomite, sodium bentonite, sodium phosphate trimer and water at least.In addition, this coating can also comprise Ludox.
In above-mentioned coating, diatomaceous chemical composition mainly is SiO
2, it can be the diatomite (such as 325 order diatomite) of single granularity, also can be varigrained diatomaceous mixture (can improve the surface quality of coating and cast tube), and to select diatomite for use mainly be as refractory powder.In addition; Diatomaceous content ratio (by weight percentage) is between 93%~98.2%; Preferably between 93.7%~96.3%; More preferably between 94.5%~96.0%; Further preferably between 94.8%~95.2%; (the aforementioned proportion relation is a content of not considering water most preferably to be 95%; Only consider diatomite; Sodium bentonite; Calculate when sodium phosphate trimer and Ludox; Sodium bentonite in this specification; The content of sodium phosphate trimer and Ludox also is to adopt Same Way to calculate---promptly just consider diatomite; Sodium bentonite; The proportioning that sodium phosphate trimer and Ludox draw that is to say that aforementioned proportion relation is diatomite; Sodium bentonite; These four kinds of components contents percentage sums of sodium phosphate trimer and Ludox are to obtain under 100% prerequisite).
In above-mentioned coating; The base bentonite of receiving mainly is to play a role as suspending agent; Suspension and thixotropy in order to improve coating in the at present big multiple enterprises; Often add higher bentonite content; But consider that bentonite content surpasses at high about 5% o'clock; Increased number of stomata can appear in the handcuffs pipe; And bentonite content surpasses the intensity that can not obviously improve coating after 4% again; So in the present invention bentonitic content (by weight percentage) between 1%~4% preferably between 2.5%~3.5%; Further preferably between 2.9%~3.1%, most preferably about 3%.
In addition, the chemical composition of sodium bentonite mainly is: (Na, Ca)
0.33(Al, Mg, Fe)
2[(Si, Al)
4O
10] (OH)
2NH
2O
The situation of Ludox and sodium phosphate trimer again, the two all is mainly in coating, to play binding agent, certainly the Na in the sodium phosphate trimer
+Because can replace the Ca in the bentonite
2+Improve the suspension and the caking property of coating with activated bentonite, so sodium phosphate trimer still is used to improve the suspension and the close-burning auxiliary agent of coating.
Tripolyphosphate sodium content (by weight percentage) changes between 0.3%~1.5%, preferably between 0.6%~1.3%, changes, more preferably between 0.8%~1.25%, further preferably between 0.95%~1.05%, most preferably about 1.0%.
Ludox content (by weight percentage) changes between 0~2% that (Ludox content was 0 corresponding above-mentioned " this coating comprises diatomite, sodium bentonite and sodium phosphate trimer at least " mentioned; Be that coating also can not comprise Ludox); Preferably between 0.6%~1.5%, change; More preferably between 0.65%~1.25%; Further preferably between 0.95%~1.05%, most preferably about 1.0%.
It is 1 following that the chemical formula of relevant chemical composition is tabulated
The chemical formula that table 1 is corresponding with raw material
Raw material |
Chemical formula |
Diatomite |
SiO
2 |
Bang profit soil |
(Na,Ca)
0.33(Al,Mg,Fe)
2[(Si,Al)
4O
10](OH)
2·nH
2O
|
Sodium phosphate trimer |
Na
5P
3O
10 |
Ludox |
SiO
2·nH
2O
|
The preparation of coating
The present invention through select diatomite as refractory powder, sodium bentonite as suspending agent, sodium phosphate trimer and Ludox as binding agent and water as carrier fluid, adopt the novel water-based die spinning coating of rolled-on method preparation.Concrete processing step is following
Step 1: bentonite and water are mixed a period of time according to a certain percentage.About the proportionate relationship between bentonite and the water, the ratio of bentonite and water can change preferably 1: 20 between 1: 15~1: 25 in general.About the time of stirring, generally be that long any time is better, stirring for a long time is for activated bentonite, makes coating have higher suspension.Generally speaking, preferred mixing time is more than 12 hours, more than the further preferred 24h.In general experimentation, choose the mixing time of 12h, test effect can reach requirement.In addition, if the bentonite mixing time is too short, it is poor that coating shows as suspension, and its each composition can't be evenly dispersed in the suspension, and the performance of coating different parts is also inequality after causing spraying, in addition the coating easy blocking shower nozzle of suspension difference.
Step 2: the bentonite and the water that will mix the stipulated time stir back adding binding agent;
Step 3: stir behind the adding binding agent and obtain suspension;
Step 4: after the bentonite suspension that stirs sent into puddle mixer and roll a period of time with diatomite, add water step by step, after coating to be rolled has good thixotropy, stop to add water.Good thixotropy is meant that coating receives when shearing, and denseness diminishes, and when stopping to shear, denseness increases again, promptly one touches the character that promptly becomes.In addition, have good thixotropic coating and have good glossiness.
Step 5: the coating sealing back ageing a period of time for preparing.About the length of digestion time, in order to improve the suspension of coating, generally be that the longer the better, preferably more than 12 hours, further preferred more than 24h hour, we have just adopted 24 hours digestion time in the confirmatory experiment below us.
Step 6: during use, (but (promptly when paint is coated in metal die) in use, the ratio of water in coating is taller with its suspension that is modulated into proper density and viscosity.Coating must also will add a certain amount of water when being modulated into proper density and concentration, the amount of entry that this process adds will be looked process condition (like the speed in when spraying, coating layer thickness etc.) and decided.
The result of use of coating
In order to prove the result of use of above-mentioned coating of the present invention, the present invention has done following experimental verification.
This experiment mainly is to the influence of die spinning with coating property according to diatomite, sodium bentonite, Ludox, sodium phosphate trimer; Utilize the various character of coating to characterize the performance of coating, come finally to confirm whether coating can reach requirement through cast-in-place experiment afterwards in factory.
At first be carried out to the branch design, the coating formula that table 2 designs for the data according to raw-material various performances and field trial, wherein diatomite has adopted 325 single order diatomite.
The centrifugal casting coating of the different raw material ratios of table 2
Tested number |
325 order diatomite |
Sodium bentonite |
Sodium phosphate trimer |
Ludox |
1 |
95.2% |
4% |
0.8% |
0% |
2 |
94.75% |
4% |
0.6% |
0.65% |
3 |
95% |
3% |
1% |
1% |
Experimental procedure:
1. preparation testing equipment: be ready to this experiment must various instrument and equipments, and check and adjust the running status of instrument and equipment.
2. design the composition proportion of coating, and use rolled-on method to be mixed with coating material, its technology is: bentonite and water are pressed 1 to 20 mixed 24h, treat that it stirs the back and adds binding agent; To utilize rolling apparatus such as compaction type puddle mixer to roll 2h (when rolling, the part by weight of diatomite and water is between 1 to 1 to 1 to 1.5) with diatomite after the suspension adding suitable quantity of water that stir; The coating sealing back ageing 24h for preparing during use, is modulated into into the suspension of proper density and viscosity with it.Whether stopping to add water when rolling is to have good thixotropy according to paste to carry out.Adding an amount of water is that Bian Jiashui is rolled on the limit, relevant with the process of rolling, and promptly occurs stopping to add water after the good thixotropy, and adding water is not disposable completion.
3. coating each item performance test:
1. the test of suspension: adopt the relative altitude sedimentation; Coating is poured in the tool plug graduated cylinder of Φ 25mm * 100mL; Make it reach 100mL absolute altitude place; (the water based paint time of repose is long usually after leaving standstill a period of time; The alcohol-base paint time of repose is short; But be testing standard mostly with 24h), measure its clear layer volume again, suspension can calculate by the formula following formula
Φ=(100-υ)/100%
υ in the formula---the volume (ml) of the coating top clarification stillness of night in the graduated cylinder
2. strength of coating:,, therefore mainly carry out the judgement of intensity at present according to the situation of washing away of coating and the surface quality factor of foundry goods etc. in the casting test because its certainty of measurement is limited though generally adopt SUM coating surface strength tester to carry out ionization meter.In the centrifugal casting casting cycle, the coating that intensity is low is washed away by molten metal easily, and after the molten metal cooling, the cast tube mouth of pipe has a large amount of coating residues, causes the defective of slag inclusion, burning into sand easily; Otherwise strength of coating is high more, and the casting cycle floating coat does not have the phenomenon of washing away, and the casting back mouth of pipe does not have the coating residue, and in this external casting cycle, the displacement of the high more coating of strength of coating is more little, so cast(ing) surface fineness is also good more.
3. gas-forming property test: adopt GET-3 intelligence gas-forming property analyzer.Concrete steps are: utilize spray gun to be sprayed on evenly, densely on 200 ℃ the iron plate through the mode of spraying the suspension for preparing, coating layer thickness is 0.2~0.3mm, and with the coating grind into powder.Gas release measuring instrument is warming up to 1000 ℃, and keeps constant temperature, take by weighing style 500g again, place porcelain boat (before the use, porcelain boat needs behind 1000 ℃ of calcination 30min, to place the drier cool to room temperature).The porcelain boat that fills sample is sent into the quartz ampoule red heat part of gas release measuring instrument, with stopper the mouth of pipe is sealed rapidly, register instrument is the opening entry data simultaneously.
4. field trial: utilize the die spinning technology that is coated with sample 1~3 respectively to check of the influence of various coating to the quality of cast tube.In centrifugal casting technique, have related parameter to be: cast temperature is 1200~1300 ℃, and the pipe die temperature is 170~200 ℃, and coating layer thickness is 0.25~0.3mm.Spoken parts in traditional operas phenomenon and machinery through observing the washing away phenomenon, pin hole whether occurs of the cast tube that obtains after the centrifugal casting, cast tube surface smoothness, cast tube of casting back, chemical scab phenomenon etc. compare analysis to the effect of coating.
The result of above-mentioned various test and analysis is as shown in table 3.
Table 3 coating data
From the suspendability aspect, 3 set products do not have difference, from coating wash away that phenomenon is seen, the spoken parts in traditional operas phenomenon of cast tube, mechanochemistry scab phenomenon see that 3 set products also are all less than occurring.Three set products are difference to some extent aspect gas-forming property, cast tube pin hole phenomenon and cast tube surface smoothness just.Wherein in No. 1 and No. 2 coating, bentonitic too high levels, the coating gas forming amount is excessive, causes coating to have a small amount of pin hole to produce, though still have a small amount of pore to occur in No. 2 coating, because of the adding of Ludox, it is good that the surface smoothness of cast tube becomes.In No. 3 coating, excessive and reduced bentonitic consumption for fear of gas-forming property, be further enhanced surface fineness, strengthened the consumption of sodium phosphate trimer and Ludox, in test subsequently, cast tube has been obtained good effect.
The present invention compares with background technology has tangible advance; Through select diatomite as refractory powder, sodium bentonite as suspending agent, sodium phosphate trimer and Ludox as binding agent and water as carrier fluid, adopt rolled-on method to prepare a kind of novel water-based die spinning coating.
Empirical tests; This coating has suspension value height, thixotropy is good; Intensity that gas forming amount is low, higher and heat-insulating property; Cast tube surface quality height, free of pinholes, the pore of producing with its, wash away, open defects such as slag inclusion, penetration, chemical scab, spoken parts in traditional operas; For enterprise provides cost savings, be very good water-base metal type centrifugal casting coating.