CN102424945A - High-melting metal mold shell non-internal stress rapid manufacturing process and device - Google Patents
High-melting metal mold shell non-internal stress rapid manufacturing process and device Download PDFInfo
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- CN102424945A CN102424945A CN2011103766964A CN201110376696A CN102424945A CN 102424945 A CN102424945 A CN 102424945A CN 2011103766964 A CN2011103766964 A CN 2011103766964A CN 201110376696 A CN201110376696 A CN 201110376696A CN 102424945 A CN102424945 A CN 102424945A
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Abstract
The invention discloses a high-melting metal mold shell non-internal stress rapid manufacturing process and a device; the manufacturing speed is high; the period is short; the cost is low; and the mold service life is long. The process particularly comprises the following steps of: step 1, texturing treatment of a master mold; step 2, alloying treatment of the master mold surface; step 3, high-melting metal arc spraying, that is, spraying a high-melting metal spraying material on the master mold surface after alloying treatment, wherein the high-melting metal wire material is used as a self-fluxing electrode and an arc with an extremely high temperature generated by gas discharge is used as a heat source, atomizing the high-melting metal material in a molten state by high-speed gas flow of compressed gas, spraying and depositing the molten spraying particles on the alloyed master mold surface, lowering a workbench by a certain height after a layer of cross section is formed so as to perform spraying of a next layer, circulating the above steps so as to finally form a dense metal coating with a thickness of 5-30 mm which is the mold shell.
Description
Technical field
The present invention relates to the method for manufacture and the equipment of fast mould, particularly a kind of refractory metal mould shell internal stress free quick manufacturing process and equipment.
Background technology
The metal arc spraying rapid die-manufacturing technology is a kind of mold making technology based on " duplicating "; It with a mock-up (or being called prototype) as master mold; With electric arc is thermal source,, and makes its injection, is deposited on the master mold surface the atomizing of the metallic substance of molten state through high velocity air; Form certain thickness compact metal shell, i.e. the mould shell.The mould shell has accurately copied the shape of prototype, has obtained required mold cavity, after accomplishing aftertreatment technologys such as reinforcement, the demoulding, polishing, can accomplish the quick manufacturing of mould.The manufacturing of electric arc spraying mould generally no longer needs additional machining after accomplishing, and just can directly be used for being shaped making.Also can carry out the numerical control precision work of few cutting output according to practical situation and needs, therefore, the electric arc spraying mold making technology comes down to a kind of " near-net-shape mold making technology ".
The metal spraying mould is standard with the master mold, and mold cavity size, geometric accuracy depend on master mold fully, and mold cavity surface and meticulous decorative pattern thereof once form simultaneously; So molding speed is fast, the manufacturing cycle is short, and cost is low; Have long die life simultaneously; Manufacturing cycle is about the half the of traditional digital control processing, and manufacturing expense can be saved more than 25% at least, becomes the important channel of new product development and small serial production.Mold surface finish is good; Technology is simple; Equipment requirements is low; Relatively be suitable for the quick manufacturing of injection mold, transfer mold, sheet-metal press working mould, complicated and have in blowing, plastic uptake, PVC injection, PU foaming and all kinds of injecting molding die of the various polyurethane products of meticulous decorative pattern in surface shape, the characteristic details that decorative pattern duplicates even can reach 5 μ m.
This fast mould manufacturing technology has been widely used in industries such as aircraft, automobile, household electrical appliances, furniture, shoemaking, artistic handicraft using at present.In the U.S. and coastal area of southeastern China, manufacturers has all adopted the electric arc spraying mould to produce on its automatic moulding production unit at the bottom of nearly all polyurethane shoe.In automobile making, can be used for producing wheel, automobile instrument panel, cushion, head cushion, spoiler, automotive trim ceiling etc.In recent years; The electric arc spraying mold making technology has begun to be used to make stamping die of automotive covering part; Spray material is different, and intensity, hardness, precision and the life-span of spraying mould also are not quite similar, thereby range of application also there are differences; The trial-production that is suitable for the automobile sample car that has, have in addition can on production line, substitute traditional steel die and produce.
At home; The material of spraying molding mainly is middle low melting point metal; Xi'an Communications University and Yantai Machinery Technology Inst. are domestic research and development unit the earliest; Advanced manufacturing technology institute of Xi'an Communications University; Since the nineties, technology for quickly manufacturing models such as surface forming mold making technology, low melting point alloy cast molding mold making technology and resin mould mold making technology have been carried out long term studies and practice, and (the ZL200810232335.0 that on metal spraying by electric arc moulding Rapid tooling, has patent of invention; ZL03134500.X).Drag in ChangAn Automobile, Luoyang one, on enterprise application such as marine suitable, the little vapour in Liuzhou.Through trial-production check, the 3D data of qualified fast mould are used for making producing in enormous quantities use steel die, can avoid in the design of steel die and makes repeatedly, guarantees that the steel die time processing is successful.
Because spray material be in the pseudo-alloy of low-melting Zn and Al; Intensity and hardness are relatively low; Die life is shorter, and prepared mould can only be used for trial production of new products and small serial production, and can not make large mould; The full-sized car cladding member mold that particularly drawing coefficient is bigger has seriously restricted application and the development of Rapid Manufacturing Technology in mould is made.
The arc spraying technology of HMP, high hardness material is realized than being easier on metal mother, but at the surperficial mfg. moulding die shell of nonmetal master mold, is had big difficulty on the technology.For example; Refractory metal such as carbon steel, steel alloy when spraying shell shrinking percentage, thermal stresses, porosity all bigger; Shell is easy to crack, warpage, peel off, and the mould shell is made difficulty, and processing parameter control is difficult to grasp; Distortion of mould shell and internal stress are all bigger, can't satisfy the industrial production needs.
Summary of the invention
The deficiency that low melting point metal electric arc spraying Rapid tooling exists in the present invention is directed to provides a kind of refractory metal mould shell internal stress free quick manufacturing process and equipment, and its manufacturing speed is fast, and the cycle is short, and cost is low, has long die life simultaneously.
For realizing above-mentioned purpose, the present invention adopts following technical scheme:
A kind of refractory metal mould shell internal stress free quick manufacturing process, concrete preparation process is:
The texturing treating processes of said step 1 is: utilize the pressurized gas of pressure 0.2～1.3Mpa carry fine abrasive that particle diameter is 10～50 μ m, through nozzle with the high speed of 150～180m/s to the friction texturing process of master mold surface, make master mold surface roughness Ra value reach 3.2-12.5 μ m.
Said refractory metal spray material is a carbon steel, and the massfraction of carbon is 1.0-1.4%, and hardness is 180-210HB.
When said refractory metal mould shell prepared, the temperature that spraying particle arrives master mold or established shell surface was 2400-2700 ℃, and spraying particle bump master mold or the speed that has formed shell are 60-75m/s; The solid phase massfraction that spraying particle arrives master mold or established shell surface is 40-60%; The speed of cooling that spraying particle arrives master mold or established shell surface is (0.8-1.6) * 10
5K/s.
Described spray gun translational speed is 0.2-0.6m/s.
The employed pressurized gas of described electric arc spraying is a rare gas element.
The spray angle of described spray gun is 85-89 °, and the spray angle of spray gun is the medullary ray of spray gun outlet and the angle between the tangent line of master mold surface.
A kind of refractory metal mould shell internal stress free quick manufacturing process is with equipment, and it comprises spray gun, and spray gun is connected with strainer, water-and-oil separator, gas compressor through pipeline, and gas compressor is connected with gas-holder, on pipeline, is provided with air regulating device; Said spray gun symmetry is installed in the pair of conductive mouth in the collets, is provided with the pressurized gas nozzle between two ignition tips, and the angle theta of two ignition tips is between 30 °～60 °; Be provided with the metallize silk in each ignition tip, the metallize silk is connected with wire drive feeder, and the diameter D of ignition tip is 1.2-1.5 a times of metallize filament diameter; Be respectively equipped with the economize on electricity piece on two ignition tips, the economize on electricity piece is connected with cable.
The pipeline that said spray gun is connected with strainer is provided with tensimeter, reducing valve and SV and gate valve; Pipeline between water-and-oil separator and the gas compressor is provided with vacuum breaker; Pressurized gas jet exit side at collets is provided with the arc light cover; Wire drive feeder has two, and their structures are identical, is made up of the wire pushing roller of wire leading pipe and cooperation with it, and cooperates with corresponding ignition tip respectively.
Described pressurized gas nozzle is made up of stable section, contraction section, throat, expansion segment, the diameter D of stable section
0With throat diameter D
1Ratio is 1.6-2; The length L of stable section
0With the contraction section length L
1Ratio 2-2.8; The diameter D of expansion segment
2With throat diameter D
1Ratio is 1.3-1.5; The length L of contraction section
1With the expansion segment length L
2Ratio 1.2-1.5.
Principle of the present invention is: in thermal spray process, the process that molten metal particle hits master mold forms shell is that a temperature has the process than big change, because the heat physical properties of type shell material and master mold material there are differences, makes shell may produce unrelieved stress.And bigger unrelieved stress is not only restricting the thickness of shell, and is to influence shell bonding strength and accuracy factors.The stress that produces in the thermospray mainly is divided into three major types:
1) spraying thermal stresses.In the thermal spray process, when the high temperature molten drop strikes the master mold surface, in a short period of time with 10
5～10
6℃/speed of s is cooled to the master mold temperature, because the thermal contraction of shell receives the restriction of master mold, thereby forms tensile stress.Available following formula calculates:
σ
q＝TEC
0(T
m-T
s)E
c (1)
In the formula:
σ
q-spraying thermal stresses;
TEC
0The coefficient of linear expansion of-type shell material;
T
mThe fusing point of-type shell material;
T
s-master mold has deposited the temperature of shell;
E
cThe Young's modulus of-type shell material.
2) cooling stress.Cooling stress is after spraying process finishes, the stress that shell and master mold produce owing to shell is different with the coefficient of linear expansion of master mold material in the process of cool to room temperature.This stress can be used computes:
In the formula: σ
Cooling-cooling stress;
T
f, T
R-be respectively shell temperature and room temperature;
α
c, α
s-be respectively the thermal expansivity of shell and master mold;
t
c, t
s-be respectively the thickness of shell and master mold;
E
c, E
s-be respectively the Young's modulus of shell and master mold.
Because there is tensile stress in the coefficient of linear expansion of type shell material greater than the coefficient of linear expansion of master mold material in the shell.
3) percussive pressure stress.In spraying process, spraying particle high-speed impact master mold or established shell make master mold or shell because of bearing the stress that particle impacting deforms and produces.
The shock strength of particle is directly proportional with its kinetic energy: the kinetic energy of particle can be expressed as:
In the formula: E
kThe kinetic energy of-particle; The quantity of n-particle; The quality of m-particle; V
nThe speed of-particle hits master mold.
And residual compressive stress and shock strength that bump produces are linear:
σ
peening＝KE
k (4)
In the formula, σ
PeeningThe residual compressive stress that-bump produces; Dynamic factor when K is impact.
Can find out that by formula (3) and (4) velocity of particle is big more, the kinetic energy of particle is also just big more, and the residual compressive stress that produces because of bump like this is also big more.
If obtain the shell of internal stress free, need satisfy following formula:
σ
q+σ
cooling＝σ
peening (5)
The technical scheme that the present invention takes for this reason is:
(1) texturing of master mold is handled: for sticking power and the contact area that improves master mold and coated material; Needing that texturing is carried out on the master mold surface handles; Utilize the pressurized gas of pressure 0.2～1.3Mpa carry fine abrasive that particle diameter is 10～50 μ m, through nozzle with the high speed of 150～180m/s to the friction texturing process of master mold surface, make master mold surface roughness Ra value reach 3.2-12.5 μ m.
(2) the master mold surface alloying is handled: in order to improve the bonding strength of coated material and master mold, spraying 2-5mm has the high low-melting alumel of bonding properties on the master mold surface of handling through texturing, or the molybdenum duraluminum, or aluminium zinc.
(3) high-melting metal arc spraying: refractory metal is sprayed to the master mold surface through Alloying Treatment through arc spraying apparatus; Spray gun moves spray gun according to the master mold outline shape under the control of computingmachine, be thermal source with refractory metal silk material as the electric arc of self-fluxing nature electrode gas discharge generation extreme temperatures; High velocity air through pressurized gas is with the high melting point metal materials atomizing of molten state; The fused spraying particle is sprayed, is deposited on through on the master mold surface of alloying, after a layer cross section is shaped and accomplishes, worktable decline certain altitude; Descend the spraying of one deck again; So circulate, finally form the compact metal coating of 5-30mm thickness, i.e. the mould shell.
Said refractory metal spray material is a carbon steel, and the massfraction of carbon is 1.0-1.4%, and hardness is 180-210HB.
When said refractory metal mould shell prepared, the temperature that spraying particle arrives master mold or established shell surface was 2400-2700 ℃, and spraying particle bump master mold or the speed that has formed shell are 60-75m/s.
The solid phase massfraction that said spraying particle arrives master mold or established shell surface is 40-60%.
Said spray gun translational speed is 0.2-0.6m/s.
The employed pressurized gas of said electric arc spraying is a rare gas element.
The spray angle of said spray gun is 85-89 °, and the spray angle of spray gun is the medullary ray of spray gun outlet and the angle between the tangent line of master mold surface.
The speed of cooling that said spraying particle arrives master mold or established shell surface is (0.8-1.6) * 10
5K/s.
Said arc spraying apparatus is by gas-holder, gas compressor, vacuum breaker, water-and-oil separator, strainer; SV, gate valve, reducing valve, tensimeter, spray gun constitutes; The gas compressor left end links to each other with gas-holder, and right-hand member links to each other with vacuum breaker, the right-hand member of vacuum breaker successively and water-and-oil separator, strainer, gate valve; Reducing valve, spray gun is connected, and between gate valve and reducing valve, connects SV, connects tensimeter between reducing valve and the spray gun.
Said spray gun is by the metallize silk, wire leading pipe, wire pushing roller, economize on electricity piece, cable; Collets, ignition tip, the pressurized gas nozzle, the arc light cover, molten drop constitutes; The metallize silk, wire leading pipe, economize on electricity piece, cable; Ignition tip respectively has 2, and with pressurized gas nozzle symmetric arrangement, wire pushing roller has 4, per 2 constitute a wire drive feeder; And with symmetric arrangement about the silk of metallize, the angle theta of two ignition tips is between 30 °～60 °, and the pressurized gas upstream side of the injector links to each other with reducing valve left end pipeline, and the diameter D of ignition tip is 1.2-1.5 a times of metallize filament diameter; Collets inside is equipped with pressurized gas nozzle and ignition tip, in the outside, collets left side, economize on electricity piece and cable is installed, and the arc light cover is installed in the collets right-hand member outside.
Said pressurized gas nozzle is made up of stable section, contraction section, throat, expansion segment, the diameter D of stable section
0With throat diameter D
1Ratio is 1.6-2; The length L of stable section
0With the contraction section length L
1Ratio 2-2.8; The diameter D of expansion segment
2With throat diameter D
1Ratio is 1.3-1.5; The length L of contraction section
1With the expansion segment length L
2Ratio 1.2-1.5.
Refractory metal mould shell Rapid Manufacturing Technology is the mold making technology of a kind of " duplicating "; It with a mock-up (or being called prototype) as master mold; With electric arc is thermal source, through the metallic substance atomizing of high velocity air with molten state, spraying particle is sprayed, is deposited on the master mold surface; Form certain thickness compact metal coating, i.e. the mould shell.Shell has accurately copied the shape of prototype, has obtained required mold cavity.Master mold can be that rapid prototyping, product are in kind or obtain through High-speed NC Machining.
The manufacturing of electric arc spraying mould shell generally no longer needs additional machining after accomplishing, and just can directly be used for being shaped making.Also can carry out the numerical control precision work of few cutting output according to practical situation and needs, therefore, the electric arc spraying mold making technology comes down to a kind of " near-net-shape mold making technology ".
The invention has the beneficial effects as follows: metal spraying mould shell is standard with the master mold, and mold cavity size, geometric accuracy depend on master mold fully, and mold cavity surface and meticulous decorative pattern thereof once form simultaneously; So manufacturing speed is fast, the cycle is short, and cost is low; Have long die life simultaneously; Manufacturing cycle is about the half the of traditional digital control processing, and manufacturing expense can be saved more than 25% at least, becomes the important channel of new product development and small serial production.Mold surface finish is good; Technology is simple; Equipment requirements is low; Relatively be suitable for the quick manufacturing of injection mold, transfer mold, sheet-metal press working mould, complicated and have in blowing, plastic uptake, PVC injection, PU foaming and all kinds of injecting molding die of the various polyurethane products of meticulous decorative pattern in surface shape, the characteristic details that decorative pattern duplicates even can reach 5 μ m.
Refractory metal mould shell Rapid Manufacturing Technology is owing to adopt dystectic spray material; It has intensity height, characteristics that wear resistance is good; The hardness that not only can improve low melting point alloys such as zinc-aluminium is lower, the work-ing life of mould and defective that range of application receives certain limitation, and can replace steel die to realize the quick manufacturing of full-sized car cladding member mold.
The temperature, the spraying particle that arrive master mold or established shell surface through the spraying particle of control high-melting metal arc spraying arrive the solid phase massfraction on master mold or established shell surface and the speed of cooling that spraying particle arrives master mold or established shell surface; Make the HMP coating by high temperature in cryogenic process of cooling; The volumetric shrinkage distortion that is caused because of expanding with heat and contract with cold; Change the cryotron centered cubic lattice into the high temperature austenite face-centered cubic lattice and offset, realize zero deformation manufacturing because of the caused volumetric expansion distortion of structural transformation.
Clash into master mold or formed the speed of shell, the translational speed of spray gun and the spray angle of spray gun through the control spraying particle; Percussive pressure stress that sprays generation and the tensile stress that spraying thermal stresses and cooling stress produce are cancelled out each other, realize the internal stress free manufacturing.
The employed pressurized gas of electric arc spraying is a rare gas element; Not only can carry spraying particle and arrive the realization spraying of master mold surface; And rare gas element to the heat transfer in molten drop atomizing and the deposition process, organize formation, oxide content, sedimentation effect and substrate temperature that direct influence is all arranged; Reduce Yin Gaowen and overheated and the iron that causes and the oxidation of carbon, help improving the quality of coating.
The surface hardness of high-melting metal arc spraying quickly manufacturing mould shell that adopts the present invention program is greater than HRC46, free form surface shape error＜3% (1m), and the surface roughness Ra value is less than 3.2 μ m.Sheet-metal press working reaches more than 20,000 die life, and cost is saved more than 25% than conventional steel mould at least, and the cycle is reduced to 1/3～1/5.
1-3 can find out that obviously compare with low-melting aluminium zinc, intensity, hardness and work-ing life and the die manufacturing cost of high-melting metal arc spraying quickly manufacturing mould shell all have remarkable advantages from table.
Table 1 ZnAl15 and the contrast of T11 strength of coating
Table 2 ZnAl15 and the contrast of T11 hot spray coating hardness
Table 3 high-melting metal arc spraying fast mould technology compares with similar technology
Description of drawings
Fig. 1 is the placement synoptic diagram of the master mold of a kind of embodiment at worktable;
Fig. 2 is that the master mold surface texturing of this embodiment is handled synoptic diagram;
Fig. 3 is that the master mold surface alloying of this embodiment is handled synoptic diagram;
Fig. 4 is the spraying refractory metal synoptic diagram of this embodiment;
Fig. 5 is the refractory metal mould shell synoptic diagram of this embodiment;
Fig. 6 is the arc spraying system schematic diagram of this embodiment;
Fig. 7 is the spray gun structure sketch of this embodiment;
Fig. 8 is the pressurized gas nozzle geometry synoptic diagram of this embodiment.
Wherein, 1 worktable, 2 master molds, 3 abrasive materials, 4 abrasive jetss, 5 low melting point alloy layers, 6 lower melting point spraying particles, 7 spray guns; 8 high-meltiing alloy layers, 9 HMP spraying particles, 10 gas-holder, 11 gas compressors, 12 vacuum breakers, 13 water-and-oil separators, 14 strainers; 15 SV, 16 gate valves, 17 reducing valve, 18 tensimeters, 19 metallize silks, 20 wire leading pipes, 21 wire pushing rollers; 22 economize on electricity pieces, 23 cables, 24 collets, 25 ignition tips, 26 pressurized gas nozzles, 27 arc light covers, 28 molten drops.
Embodiment
Below in conjunction with accompanying drawing and embodiment the present invention is further specified.
Embodiment 1: preparation process is:
(1) preparation of master mold: (Rapid Prototyping-RP) directly produces master mold itself through rapid prototyping technology, carries out some necessary aftertreatments and machining then to obtain the desired mechanical property of master mold, dimensional precision and surfaceness.In conjunction with shown in Figure 1, the master mold for preparing 2 is preheating to 360 ℃ earlier after, be placed into again on the worktable 1.
(2) texturing of master mold is handled: combine Fig. 2 visible; Utilize pressure to carry the fine corundum abrasive 3 that particle diameter is 25 μ m for the high pressure gas of 0.7Mpa; The massfraction of corundum abrasive 3 is 7%; Thorough mixing after abrasive jets 4 with the high speed of 175m/s to master mold 2 surface friction texturing processes, make master mold 2 surface roughness Ra values reach 6.3 μ m.
(3) the master mold surface alloying is handled: combine shown in Figure 3; Use low melting point alloy with the lower melting point alumel as spraying; Being sprayed on master mold 2 surfaces of handling through texturing with the alumel lower melting point spraying particle 6 of spray gun 7 with molten state, is the thick low melting point alloy layer 5 of 2mm up to forming thickness.
(4) high-melting metal arc spraying: combine Fig. 4 visible; Through arc spraying apparatus refractory metal T11 is sprayed to through on the master mold surface of Alloying Treatment; Spray gun 7 is under the control of computingmachine; Move spray gun according to the master mold outline shape, the translational speed of spray gun is 0.36m/s, and the angle between the medullary ray of spray gun outlet and the master mold surface tangent line is 89 °.Is thermal source with refractory metal T11 silk material as the electric arc of self-fluxing nature electrode gas discharge generation extreme temperatures; High velocity air through the pressurized gas argon gas forms HMP spraying particle 9 with the molten drop atomizing of molten state; The temperature that HMP spraying particle 9 arrives master molds 2 or established shell surface is 2600 ℃, and HMP spraying particle 9 bump master molds 2 or the speed that has formed shell are 70m/s.The solid phase massfraction that HMP spraying particle 9 arrives master mold or established shell surface is 55%, and the speed of cooling that HMP spraying particle 9 arrives master mold or established shell surface is 1.2 * 10
5K/s.The fused spraying particle is sprayed, is deposited on through on the master mold surface of alloying, and after a layer cross section was shaped and accomplishes, worktable 1 decline certain altitude descend the spraying of one deck again, so circulates, and finally forms the compact metal coating of 25mm thickness.
T11 refractory metal coating is by martensite, carbide, and residual austenite is formed, and the massfraction of T11 refractory metal coated component is: C: (1.05～1.14) %, Si≤0.35%, Mn≤0.40%, surplus is an iron, and hardness is 207HB, and fusing point is 1454 ℃.
(5) demoulding forms shell: combine Fig. 5 visible, master mold 2 is thrown off, can form needed mould shell, the mould shell is formed by stacking on low melting point alloy layer 5 and high-meltiing alloy layer 8.
In conjunction with Fig. 7; During spray equipment work; Two rhizoid shape metallize silks 19 are sent to respectively in the ignition tip 25 in the spray gun 7 through wire leading pipe 20 and wire pushing roller 21 even successive; Ignition tip 25 connects the positive and negative electrode of power supply respectively through economize on electricity piece 22 and cable 23, ignition tip 25 is fixed in the collets 24, and guarantees the reliable insulation of two metallize silks 19 before not contacting.When two metallize silk 19 ends owing to sending to when being in contact with one another, be short-circuited and produce electric arc, make silk 19 end instant meltings in metallize form molten drops 28, in conjunction with Fig. 6 and Fig. 7; Gas in the gas-holder 10 is through gas compressor 11, vacuum breaker 12, water-and-oil separator 13, strainer 14; Gate valve 16, reducing valve 17 gets into the pressurized gas nozzle 26 in the spray gun 7; Visible in conjunction with Fig. 8, high pressure gas make air-flow even through stable section, reduce turbulence level; Contraction section quickens air-flow, will guarantee that simultaneously the exit flow of contraction section is even, straight and stable; Diameter is D
1Part be throat, air-flow makes air-flow change supersonic speed into from subsonic speed through throat; It is D through diameter that expansion segment further accelerates to the supersonic airstream of throat the Mach number that is designed
2Outlet ejection, the pressurized gas of ejection forms spraying particle with the molten drop atomizing of metallize, is ejected into the master mold surface with very high speed, forms the electric arc spraying layer.
Embodiment 2: preparation process is:
(1) preparation of master mold: adopt indirect die-manufacturing method, as model, make master mold indirectly through technologies such as the type of turning over, aftertreatments with the RP prototype.In conjunction with shown in Figure 1, the master mold for preparing 2 is preheating to 420 ℃ earlier after, be placed into again on the worktable 1.
(2) texturing of master mold is handled: combine Fig. 2 visible; Utilize pressure to carry the fine silicon carbide abrasive 3 that particle diameter is 34 μ m for the high pressure gas of 0.85Mpa; The massfraction of silicon carbide abrasive 3 is 4%; Thorough mixing after abrasive jets 4 with the high speed of 195m/s to master mold 2 surface friction texturing processes, make master mold 2 surface roughness Ra values reach 3.2 μ m.
(3) the master mold surface alloying is handled: combine shown in Figure 3; Use low melting point alloy with the lower melting point aluminium zinc as spraying; Being sprayed on master mold 2 surfaces of handling through texturing with the aluminium zinc lower melting point spraying particle 6 of spray gun 7 with molten state, is the thick low melting point alloy layer 5 of 1.5mm up to forming thickness.
(4) high-melting metal arc spraying: combine Fig. 4 visible; Through arc spraying apparatus refractory metal T13 is sprayed to through on the master mold surface of Alloying Treatment; Spray gun 7 is under the control of computingmachine; Move spray gun according to the master mold outline shape, the translational speed of spray gun is 0.5m/s, and the angle between the medullary ray of spray gun outlet and the master mold surface tangent line is 85 °.Is thermal source with refractory metal T13 silk material as the electric arc of self-fluxing nature electrode gas discharge generation extreme temperatures; High velocity air through the pressurized gas helium forms HMP spraying particle 9 with the molten drop atomizing of molten state; The temperature that HMP spraying particle 9 arrives master molds or established shell surface is 2650 ℃, and HMP spraying particle 9 bump master molds or the speed that has formed shell are 66m/s.The solid phase massfraction that HMP spraying particle 9 arrives master mold or established shell surface is 53%, and the speed of cooling that HMP spraying particle 9 arrives master mold or established shell surface is 1.35 * 105k/s.The fused spraying particle is sprayed, is deposited on through on the master mold surface of alloying, and after a layer cross section was shaped and accomplishes, worktable 1 decline certain altitude descend the spraying of one deck again, so circulates, and finally forms the compact metal coating of 35mm thickness.
T13 refractory metal coating is by martensite, carbide, and residual austenite is formed.The massfraction of T13 refractory metal coated component is: C: (1.25～1.35) %, and Si≤0.35%, Mn≤0.40%, surplus is an iron, and hardness is 217HB, and fusing point is 1453 ℃.
(5) demoulding forms shell: combine Fig. 5 visible, master mold is thrown off, can form needed mould shell, the mould shell is formed by stacking on low melting point alloy layer 5 and high-meltiing alloy layer 8.
Claims (10)
1. a refractory metal mould shell internal stress free quick manufacturing process is characterized in that, concrete preparation process is:
Step 1, the texturing of master mold is handled;
Step 2, the master mold surface alloying is handled: spraying 2-5mm has the high low-melting alumel of bonding properties on the master mold surface of handling through texturing, or the molybdenum duraluminum, or aluminium zinc;
Step 3, high-melting metal arc spraying: the refractory metal spray material is sprayed to through the master mold of Alloying Treatment surface, during spraying under the control of computingmachine; Move spray gun according to the master mold outline shape; Is thermal source with refractory metal silk material as the electric arc of self-fluxing nature electrode gas discharge generation extreme temperatures, and the high velocity air through pressurized gas sprays the high melting point metal materials atomizing of molten state, be deposited on the fused spraying particle through on the master mold surface of alloying; After one layer cross section is shaped and accomplishes; Worktable decline certain altitude descends the spraying of one deck again, so circulation; The final compact metal coating that forms 5-30mm thickness, i.e. mould shell.
2. refractory metal mould shell internal stress free quick manufacturing process as claimed in claim 1; It is characterized in that; The texturing treating processes of said step 1 is: utilize the pressurized gas of pressure 0.2～1.3Mpa carry fine abrasive that particle diameter is 10～50 μ m, through nozzle with the high speed of 150～180m/s to the friction texturing process of master mold surface, make master mold surface roughness Ra value reach 3.2-12.5 μ m.
3. refractory metal mould shell internal stress free quick manufacturing process as claimed in claim 1 is characterized in that said refractory metal spray material is a carbon steel, and the massfraction of carbon is 1.0-1.4%, and hardness is 180-210HB.
4. refractory metal mould shell internal stress free quick manufacturing process as claimed in claim 1; It is characterized in that; When said refractory metal mould shell prepares; The temperature that spraying particle arrives master mold or established shell surface is 2400-2700 ℃, and spraying particle bump master mold or the speed that has formed shell are 60-75m/s; The solid phase massfraction that spraying particle arrives master mold or established shell surface is 40-60%; The speed of cooling that spraying particle arrives master mold or established shell surface is (0.8-1.6) * 10
5K/s.
5. refractory metal mould shell internal stress free quick manufacturing process as claimed in claim 1 is characterized in that described spray gun translational speed is 0.2-0.6m/s.
6. refractory metal mould shell internal stress free quick manufacturing process as claimed in claim 1 is characterized in that the employed pressurized gas of described electric arc spraying is a rare gas element.
7. refractory metal mould shell internal stress free quick manufacturing process as claimed in claim 1 is characterized in that the spray angle of described spray gun is 85-89 °, and the spray angle of spray gun is the medullary ray of spray gun outlet and the angle between the tangent line of master mold surface.
8. the said refractory metal mould of claim 1 a shell internal stress free quick manufacturing process is with equipment; It comprises spray gun; Spray gun is connected with strainer, water-and-oil separator, gas compressor through pipeline, and gas compressor is connected with gas-holder, on pipeline, is provided with air regulating device; It is characterized in that said spray gun symmetry is installed in the pair of conductive mouth in the collets, is provided with the pressurized gas nozzle between two ignition tips, the angle theta of two ignition tips is between 30 °～60 °; Be provided with the metallize silk in each ignition tip, the metallize silk is connected with wire drive feeder, and the diameter D of ignition tip is 1.2-1.5 a times of metallize filament diameter; Be respectively equipped with the economize on electricity piece on two ignition tips, the economize on electricity piece is connected with cable.
9. refractory metal mould shell internal stress free quick manufacturing process as claimed in claim 8 is characterized in that with equipment the pipeline that said spray gun is connected with strainer is provided with tensimeter, reducing valve and SV and gate valve; Pipeline between water-and-oil separator and the gas compressor is provided with vacuum breaker; Pressurized gas jet exit side at collets is provided with the arc light cover; Wire drive feeder has two, and their structures are identical, is made up of the wire pushing roller of wire leading pipe and cooperation with it, and cooperates with corresponding ignition tip respectively.
10. use equipment like claim 8 or 9 described refractory metal mould shell internal stress free quick manufacturing process, it is characterized in that said pressurized gas nozzle is made up of stable section, contraction section, throat, expansion segment, the diameter D of stable section
0With throat diameter D
1Ratio is 1.6-2; The length L of stable section
0With the contraction section length L
1Ratio 2-2.8; The diameter D of expansion segment
2With throat diameter D
1Ratio is 1.3-1.5; The length L of contraction section
1With the expansion segment length L
2Ratio 1.2-1.5.
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| CN102424945B CN102424945B (en) | 2013-06-12 |
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| CN110064732A (en) * | 2019-05-14 | 2019-07-30 | 广东鸿特精密技术（台山）有限公司 | A kind of casting mould and its manufacturing method that Quick uniform is cooling |
| CN113755783A (en) * | 2020-07-28 | 2021-12-07 | 英迪那米(徐州)半导体科技有限公司 | Electric arc spraying treatment method for steel surface |
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| CN102212773A (en) * | 2010-04-02 | 2011-10-12 | 沈阳工业大学 | Method for rapidly manufacturing steel-base mould by thermal spraying |
| CN202278158U (en) * | 2011-11-23 | 2012-06-20 | 青岛理工大学 | Equipment for quickly manufacturing high-melting metal die shell under no internal stress |
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| CN102424945B (en) | 2013-06-12 |
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Effective date of registration: 20201130 Address after: Group 18, Hainan village, Hai'an town, Hai'an County, Nantong City, Jiangsu Province, 226601 Patentee after: NANTONG TONGTU MECHANICAL & ELECTRICAL MANUFACTURE Co.,Ltd. Address before: 266033 No. 11, Fushun Road, Sifang District, Shandong, Qingdao Patentee before: QINGDAO TECHNOLOGICAL University |