CN103240791A - Ceramic slurry liquidity control method for gel injection molding - Google Patents
Ceramic slurry liquidity control method for gel injection molding Download PDFInfo
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Abstract
The invention discloses a ceramic slurry liquidity control method for gel injection molding. The ceramic slurry liquidity control method includes: controlling ceramic power particle morphology through improving surface roughness of a negative resin mold, selecting an optimal grading scheme, utilizing vacuum injection molding and additional ultrasound/ a mechanical vibration field, and realizing fully compact molding by high-solid-content ceramic slurry to a small complex cooling structure in a hollow negative turbine blade mold. With the ceramic slurry liquidity control method for gel injection molding, good liquidity of the high-solid-content ceramic slurry is realized, and size filling for the small cooling structures such as 0.5mm exhausting edges and phi 0.4mm impact holes inside the hollow negative turbine blade mold is realized.
Description
Technical field
The invention belongs to the photocuring rapid prototyping technical field, relate to the mobile control method that a kind of gel injection-moulding is used ceramic size.
Background technology
Efficient cooling aero-engine, gas turbine hollow turbine vane inside have complicated small cooling structure, traditional investment casting method is coated with extension after with the assembling of ceramic core and wax pattern, sintering is made the hollow turbine vane ceramic-mould after changing wax, this method can be applied to the single-wall structure hollow blade preferably, but is difficult to be applied in the double wall blade that contains small impact opening.
Prepare the integrated ceramic casting mold based on photocuring rapid prototyping and gel casting process, can solve the problem of the moulding in earlier stage of double wall impact opening or post-production well.Wherein propose to make ceramic size once to flow and filled the whole hollow turbine vane light-cured resin of type minus mould.And the typical cooling structure in the hollow turbine vane comprise tiny exhaust limit (＜1mm), small air film hole, impact opening (＜Φ 0.5mm) etc., this fine structure of fine and close fully filling has proposed very high requirement to the flowability of ceramic size, will guarantee that simultaneously the ceramic-mould for preparing has the good high-temperature mechanical property.
Summary of the invention
The problem that the present invention solves is to provide the mobile control method of a kind of gel injection-moulding with ceramic size, adopt high solid loading gel injection-moulding ceramic size, and control its flowability, can reach the small cooling structure of filling hollow turbine vane minus mould inside fully.
The present invention is achieved through the following technical solutions:
A kind of gel injection-moulding mobile control method of ceramic size comprises following operation:
1) be that 15～20% caustic solutions are (30～40) according to mass ratio with methyl alcohol or ethanol with mass concentration: the ratio of (60～70) is mixed, and obtains corrosive liquid;
With utilizing the light-cured resin mould of photocuring rapid prototyping method preparation to be immersed in the corrosive liquid, apply ultrasonic vibration field simultaneously, carry out surface corrosion and handle, light-cured resin die surface roughness is reached below the Ra6;
After corrosion finishes the light-cured resin mould being taken out water cleans up also air-dry;
2) preparation viscosity is below 0.4Pa.s, and solid volume fraction is not less than 65% gel injection-moulding ceramic size;
3) the light-cured resin mould after surface corrosion is handled be placed on the ultrasonic vibration frequency be 30～40KHz ultrasonic vibration after the match, and apply the mechanical oscillation that vibration frequency is 45～60Hz;
Ceramic size is placed in the type vacuum injecting and forming machine, the vacuum environment that applies the relative vacuum degree and be 0.08～0.09MPa is carried out degasification, use charging mechanism that catalyst, initator are successively added in the ceramic size, begin the notes type after stirring, ceramic size is packed in the light-cured resin mould fully.
When described surface corrosion is handled, the light-cured resin mould is soaked into 3～5min in the corrosive liquid, applies the ultrasonic vibration field of 30～40kHz simultaneously.
Being prepared as of described ceramic size:
Press the organogel monomer: the mass ratio of deionized water=10～20:100, dispersant: the mass ratio configuration premixed liquid of deionized water=2～4:100, adding concentrated ammonia liquor adjusting pH is 9～10;
Volume ratio by ceramic powder: deionized water=70:30～60:40 joins premixed liquid with ceramic particle, fully carries out ball milling, obtains ceramic size; Ceramic powder is spherical alpha-aluminium oxide, comprises that the average grain diameter size is the coarse granule of 30～40um and the fine grained of 2～5um, and coarse granule and fine grained volume ratio are 60～66:34～40;
Ceramic powder is added in the premixed liquid by amount, after the use mixer stirs, puts into planetary ball mill and fully take out behind the ball milling.
Described organogel monomer is by acrylamide: N, the mixing of the mass ratio of N '-methylene-bisacrylamide=20～25:1; Dispersant is that mass concentration is 18% Sodium Polyacrylate.
The ceramic size for preparing is placed vacuum degassing in the type vacuum injecting and forming machine in advance, by catalyst: the mass ratio of premixed liquid=0.2～0.5:100, initator: the mass ratio of premixed liquid=1～2:100 successively adds catalyst, initator, begins the notes type after forming machine stirs.
Described when ceramic size injects, the photocuring mould is placed in the ultrasonic vibrator, and the ultrasonic vibration frequency is 30～40KHz, and ultrasonic vibrator places on the mechanical vibration generator system, and vibration frequency is 45～60Hz, and the slurry poring rate is controlled at 3～6ml/s.
Compared with prior art, the present invention has following beneficial technical effects:
The gel injection-moulding provided by the invention mobile control method of ceramic size, by improving resin minus die surface roughness, control ceramic powder granule-morphology, selected optimization grating scheme, use the vacuum injection molding and add ultrasonic/mechanical oscillation field, realized that the high solid loading ceramic size fills type to the complete densification of the complicated small cooling structure of hollow turbine vane minus mould inside.
The gel injection-moulding provided by the invention mobile control method of ceramic size, in advance hollow turbine vane light-cured resin mould being carried out surface corrosion handles, resin die table roughness after the processing is down to below the Ra6 by Ra20, eliminate photocureable rapid shaping step effect, improve the die surface roughness, reduced the flow resistance that die surface produces ceramic size.
The gel injection-moulding provided by the invention mobile control method of ceramic size, by the thickness grain composition of optimizing, make its solid concentration reach the highest when guaranteeing gel injection-moulding with the ceramic size flowability, be regular spherical by controlling alumina powder jointed granule-morphology, intergranular frictional impact when having weakened slurry and flowing has greatly improved the flowability of slurry.
The gel injection-moulding provided by the invention mobile control method of ceramic size, when cast hollow turbine vane light-cured resin mould, apply vacuum environment, and the mobile filling velocity of control, prevent the phenomenon of feeling suffocated when slurry fills type, apply ultrasonic/oscillator field simultaneously, with the mobile of further raising ceramic size and remove micro-bubble in the slurry, further improve flowability and filling compactness when slurry is filled fine structure, thereby guaranteed the filling of minus mould micro-structure (air film hole, impact opening).
Gel injection-moulding provided by the invention can be realized the flowability that the high solid loading ceramic size is good with the mobile control method of ceramic size, satisfies the slurry of small cooling structures such as the inner 0.5mm exhaust of hollow turbine vane limit, Φ 0.4mm impact opening and fills.
The specific embodiment
The present invention is described in further detail below in conjunction with specific embodiment, and the explanation of the invention is not limited.
The invention provides a kind of gel injection-moulding mobile control method of ceramic size, by improving resin minus die surface roughness, control ceramic powder granule-morphology, selected optimization grating scheme, use the vacuum injection molding and add ultrasonic/mechanical oscillation field, realized that the high solid loading ceramic size fills type to the complete densification of the complicated small cooling structure of hollow turbine vane minus mould inside.
Concrete to describe with the flow control of mold-filling capacity of ceramic size towards hollow turbine vane high solid loading gel injection-moulding, adopt alcohol/strong base solution, at first hollow turbine vane light-cured resin mould being carried out surface corrosion handles, eliminate photocureable rapid shaping step effect, the die surface roughness is reduced to below the Ra6 by Ra20, thus the flow resistance that die surface produces when reducing ceramic size and filling type.
Adopt water base, AM-MBAM system to prepare the gel injection-moulding slurry, ceramic powder adopts spherical, the spherical alpha alumina powder of class, according to suitable size ratio, volume ratio grating design principle, and accurately control the ball milling time, obtain prefabricated up to 65% solid concentration, have better flowability, apparent viscosity to be lower than the ceramic size of 0.4Pa.s.
When ceramic size is filled hollow turbine vane light-cured resin mould, apply vacuum environment and add oscillator field, with the mobile of further raising ceramic size and remove micro-bubble in the slurry, thereby guarantee the filling of minus mould micro-structure (air film hole, impact opening).This method can realize the flowability that the high solid loading ceramic size is good, satisfies the slurry of small cooling structures such as the inner 0.5mm exhaust of hollow turbine vane limit, Φ 0.4mm impact opening and fills.
Embodiment 1:
At solid wall cooling hollow turbine vane, contain the wide exhaust limit of 0.5mm that is.
Configuration 500g ethanol/NaOH corrosive liquid, be 15% sodium hydroxide solution comprising 150g absolute ethyl alcohol and 350g concentration, the light-cured resin mould is soaked into corrosive liquid 5min, apply the ultrasonic vibration field of 30kHz simultaneously, after corrosion finishes mould is taken out water and clean up and air-dry, use surface roughometer Measurement die surface roughness as below the Ra6.
Filling this hollow turbine vane sl prototype resin die fully needs 160ml ceramic size at least, and gel injection-moulding can reach 65% with the solid concentration of ceramic size.Configuration 96g concentration is 15% gel premixed liquid, and comprising the 72g deionized water, 12g acrylamide monomer, 0.5g methylene-bisacrylamide crosslinking agent, 8.3g mass fraction are 18% Sodium Polyacrylate dispersant solution, and the 3.2g concentrated ammonia liquor.Use the regular spherical alpha alumina powder of process grating as the solid phase of ceramic size, 531g is the powder 340g of 30um and the powder 191g that average grain diameter is 3um comprising average grain diameter altogether.Ceramic powder is added to advance in the uniform gel premixed liquid of stirring and dissolving by amount, use mixer to stir simultaneously, become thick-pasty until slurry, the slurry packing is gone in the planetary ball mill, be that 8:1 adds corundum ball milling ball and begins ball milling according to the pellet mass ratio, take out behind the 1h, obtain to have the ceramic size of splendid flowability, use coaxial cylinder viscometer to record its apparent viscosity below 0.4Pa.s.
Hollow turbine vane light-cured resin mould is fixed in the water-bath ultrasonic vibrator, and ultrasonic vibrator is installed on the mechanical vibration generator system.Ceramic size is put into ZK-800 type type vacuum injecting and forming machine, open vavuum pump and be evacuated to 0.08MPa and pressurize, after stirring slurry 3～5min, use charging mechanism that pre-configured 0.17g catalyst and 0.85g initator are successively added in the ceramic size, stir fast simultaneously.Open the ultrasonic vibrator that predetermined frequency is 30KHz, open mechanical vibration generator system simultaneously, the adjusting vibration frequency is 60Hz.Close and begin to pour into ceramic size behind the agitator and make it fill mould fully, treat that gel solidifies fully and drying after, use Y.cheetah micron X ray 3-D imaging system to observe internal structure, find that exhaust limit structure fills complete and fine and close.
Embodiment 2:
At double wall cooling hollow turbine vane, contain wide impact opening for the exhaust limit of 0.6mm and Φ 0.4mm.Configuration 500g ethanol/NaOH corrosive liquid, be 20% sodium hydroxide solution comprising 150g absolute ethyl alcohol and 350g concentration, the light-cured resin mould is soaked into corrosive liquid 4min, apply the ultrasonic vibration field of 30kHz simultaneously, after corrosion finishes mould is taken out water and clean up and air-dry, use surface roughometer Measurement die surface roughness as below the Ra6.
Filling this hollow turbine vane sl prototype resin die fully needs 200ml ceramic size at least, and gel injection-moulding can reach 65% with the solid concentration of ceramic size.Configuration 120g concentration is 15% gel premixed liquid, and comprising the 90g deionized water, 15g acrylamide monomer, 0.7g methylene-bisacrylamide crosslinking agent, 10.3g mass fraction are 18% Sodium Polyacrylate dispersant solution, and the 4g concentrated ammonia liquor.Use the regular spherical alpha alumina powder of process grating as the solid phase of ceramic size, 664g is the powder 425g of 40um and the powder 239g that average grain diameter is 5um comprising average grain diameter altogether.Advance dissolve in the gel premixed liquid that stir by the amount interpolation ceramic powder, use mixer to stir simultaneously, become thick-pasty until slurry, the slurry packing is gone in the planetary ball mill, be that 8:1 adds corundum ball milling ball and begins ball milling according to the pellet mass ratio, take out behind the 1h, obtain to have the ceramic size of splendid flowability, use coaxial cylinder viscometer to record its apparent viscosity below 0.4Pa.s.
Hollow turbine vane light-cured resin mould is fixed in the water-bath ultrasonic vibrator, and ultrasonic vibrator is installed on the mechanical vibration generator system.Ceramic size is put into ZK-800 type type vacuum injecting and forming machine, open vavuum pump and be evacuated to 0.08MPa and pressurize, after stirring slurry 3～5min, use charging mechanism that pre-configured 0.21g catalyst and 1.06g initator are successively added in the ceramic size, stir fast simultaneously.Open the ultrasonic vibrator that predetermined frequency is 30KHz, open mechanical vibration generator system simultaneously, the adjusting vibration frequency is 60Hz.Close and begin to pour into ceramic size behind the agitator and make it fill mould fully, treat that gel solidifies fully and drying after, use Y.cheetah micron X ray 3-D imaging system to observe internal structure, find that exhaust limit and impact opening structure fill complete and fine and close.
Embodiment 3:
At solid wall cooling hollow turbine vane, contain the air film hole of Φ 0.35mm.Configuration 400g ethanol/NaOH corrosive liquid, be 15% sodium hydroxide solution comprising 120g absolute ethyl alcohol and 280g concentration, the light-cured resin mould is soaked into corrosive liquid 4min, apply the ultrasonic vibration field of 40kHz simultaneously, after corrosion finishes mould is taken out water and clean up and air-dry, use surface roughometer Measurement die surface roughness as below the Ra6.
Filling this hollow turbine vane sl prototype resin die fully needs 180ml ceramic size at least, and gel injection-moulding can reach 65% with the solid concentration of ceramic size.Configuration 116g concentration is 20% gel premixed liquid, and comprising the 80g deionized water, 19.1g acrylamide monomer, 0.9g methylene-bisacrylamide crosslinking agent, 13g mass fraction are 18% Sodium Polyacrylate dispersant solution, and the 3g concentrated ammonia liquor.Use the regular spherical alpha alumina powder of process grating as the solid phase of ceramic size, 600g is the powder 366g of 40um and the powder 224g that average grain diameter is 3um comprising average grain diameter altogether.Advance dissolve in the gel premixed liquid that stir by the amount interpolation ceramic powder, use mixer to stir simultaneously, become thick-pasty until slurry, the slurry packing is gone in the planetary ball mill, be that 8:1 adds corundum ball milling ball and begins ball milling according to the pellet mass ratio, take out behind the 1h, obtain to have the ceramic size of splendid flowability, use coaxial cylinder viscometer to record its apparent viscosity below 0.4Pa.s.
Hollow turbine vane light-cured resin mould is fixed in the water-bath ultrasonic vibrator, and ultrasonic vibrator is installed on the mechanical vibration generator system.Ceramic size is put into ZK-800 type type vacuum injecting and forming machine, open vavuum pump and be evacuated to 0.08MPa and pressurize, after stirring slurry 3～5min, use charging mechanism that pre-configured 0.2g catalyst and 1.0g initator are successively added in the ceramic size, stir fast simultaneously.Open the ultrasonic vibrator that predetermined frequency is 40KHz, open mechanical vibration generator system simultaneously, the adjusting vibration frequency is 60Hz.Close and begin to pour into ceramic size behind the agitator and make it fill mould fully, treat that gel solidifies fully and drying after, use Y.cheetah micron X ray 3-D imaging system to observe internal structure, find that the air film hole structure fills complete and fine and close.
Claims (6)
1. the mobile control method of a gel injection-moulding usefulness ceramic size is characterized in that, comprises following operation:
1) be that 15～20% caustic solutions are (30～40) according to mass ratio with methyl alcohol or ethanol with mass concentration: the ratio of (60～70) is mixed, and obtains corrosive liquid;
With utilizing the light-cured resin mould of photocuring rapid prototyping method preparation to be immersed in the corrosive liquid, apply ultrasonic vibration field simultaneously, carry out surface corrosion and handle, light-cured resin die surface roughness is reached below the Ra6;
After corrosion finishes the light-cured resin mould being taken out water cleans up also air-dry;
2) preparation viscosity is below 0.4Pa.s, and solid volume fraction is not less than 65% gel injection-moulding ceramic size;
3) the light-cured resin mould after surface corrosion is handled be placed on the ultrasonic vibration frequency be 30～40KHz ultrasonic vibration after the match, and apply the mechanical oscillation that vibration frequency is 45～60Hz;
Ceramic size is placed in the type vacuum injecting and forming machine, the vacuum environment that applies the relative vacuum degree and be 0.08～0.09MPa is carried out degasification, use charging mechanism that catalyst, initator are successively added in the ceramic size, begin the notes type after stirring, ceramic size is packed in the light-cured resin mould fully.
2. gel injection-moulding as claimed in claim 1 is characterized in that with the mobile control method of ceramic size, when described surface corrosion is handled, the light-cured resin mould is soaked into 3～5min in the corrosive liquid, applies the ultrasonic vibration field of 30～40kHz simultaneously.
3. gel injection-moulding as claimed in claim 1 is characterized in that with the mobile control method of ceramic size, being prepared as of described ceramic size:
Press the organogel monomer: the mass ratio of deionized water=10～20:100, dispersant: the mass ratio configuration premixed liquid of deionized water=2～4:100, adding concentrated ammonia liquor adjusting pH is 9～10;
Volume ratio by ceramic powder: deionized water=70:30～60:40 joins premixed liquid with ceramic particle, fully carries out ball milling, obtains ceramic size; Ceramic powder is spherical alpha-aluminium oxide, comprises that the average grain diameter size is the coarse granule of 30～40um and the fine grained of 2～5um, and coarse granule and fine grained volume ratio are 60～66:34～40;
Ceramic powder is added in the premixed liquid by amount, after the use mixer stirs, puts into planetary ball mill and fully take out behind the ball milling.
4. gel injection-moulding as claimed in claim 3 is characterized in that described organogel monomer is by acrylamide: N, the mixing of the mass ratio of N '-methylene-bisacrylamide=20～25:1 with the mobile control method of ceramic size; Dispersant is that mass concentration is 18% Sodium Polyacrylate.
5. gel injection-moulding as claimed in claim 3 is with the mobile control method of ceramic size, it is characterized in that, the ceramic size for preparing places vacuum degassing in the type vacuum injecting and forming machine in advance, by catalyst: the mass ratio of premixed liquid=0.2～0.5:100, initator: the mass ratio of premixed liquid=1～2:100 successively adds catalyst, initator, begins the notes type after forming machine stirs.
6. gel injection-moulding as claimed in claim 1 is with the mobile control method of ceramic size, it is characterized in that, when ceramic size injects, the photocuring mould is placed in the ultrasonic vibrator, the ultrasonic vibration frequency is 30～40KHz, ultrasonic vibrator places on the mechanical vibration generator system, and vibration frequency is 45～60Hz, and the slurry poring rate is controlled at 3～6ml/s.
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Cited By (3)
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| CN106431367A (en) * | 2016-09-07 | 2017-02-22 | 山东工业陶瓷研究设计院有限公司 | Photocurable fused silica slurry and preparing method and application thereof |
| CN107791512A (en) * | 2016-09-07 | 2018-03-13 | 佳能株式会社 | Three-dimensional manufacture device, three-dimensional manufacture object preparation method and the container for three-dimensional manufacture device |
| CN109434017A (en) * | 2018-12-19 | 2019-03-08 | 福建省宝山机械有限公司 | A kind of wax material essence die manufacturing process |
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| CN101301677A (en) * | 2008-06-03 | 2008-11-12 | 西安交通大学 | Method for quickly and precisely casting complex parts |
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Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN106431367A (en) * | 2016-09-07 | 2017-02-22 | 山东工业陶瓷研究设计院有限公司 | Photocurable fused silica slurry and preparing method and application thereof |
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| CN107791512B (en) * | 2016-09-07 | 2022-05-17 | 佳能株式会社 | Three-dimensional manufacturing apparatus, three-dimensional manufactured object manufacturing method, and container for three-dimensional manufacturing apparatus |
| CN109434017A (en) * | 2018-12-19 | 2019-03-08 | 福建省宝山机械有限公司 | A kind of wax material essence die manufacturing process |
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