Background technology
The density of Birmasil is little, specific strength is high, adopts articles made of aluminium alloy bearing under same load-up condition, can alleviate the weight of structure, thereby the application of articles made of aluminium alloy is very extensive.Aluminium alloy is divided into two large class, i.e. Birmasil and pressure processing aluminium alloys according to the difference of processing method.In Birmasil again with the difference of the alloying element that mainly adds and be divided into four series, i.e. cast Al-Si alloy, casting Al-Cu alloy, cast aluminum-molykote composite material magnesium alloy, cast aluminum-molykote composite material kirsite.The dendrite of alusil alloy is undeveloped, and crystallization temperature interval is minimum in a few class Birmasils, thereby its casting character is also best.
The casting technique of alusil alloy is a lot, has high-pressure casting, low pressure casting, sand casting, permanent mold casting, model casting, shell moulded casting etc.At present, for the larger foundry goods of weight (as the aluminium-silicon alloy casting of weight used for high-voltage switch more than 20kg), in production, the most frequently used technique is sand casting and permanent mold casting.In actual production, user has proposed new requirement to the exploitation of alusil alloy product successively, not only requires to shorten the trial-produce period of new product, the price of reduction product, but also the performance of foundry goods is had higher requirement.As tensile strength >=310MPa, percentage elongation >=5% of the requirement ZL101A of Henan Pinggao Toshiba High Voltage Switchgear Co., Ltd. sand-cast, and in GB/T 1173-1995, set quota is only: >=275MPa, >=2%.Wide in variety for above aluminium-silicon alloy casting used for high-voltage switch, batch is little, quality requirement is high and aluminium-silicon alloy casting used for high-voltage switch is larger, the weight of part foundry goods reaches feature more than 30Kg, what often use aborning is gravity die casting process.But permanent mold casting is long with the fabrication cycle of mould, generally need the time of 3~5 months, and the manufacturing expense of mould is high, the price of every mold between 6~120,000 yuan not etc.The mechanical performance of aluminium-silicon alloy casting used for high-voltage switch is had relatively high expectations, and is difficult to meet the requirement of foundry goods by conventional sand mold mould pouring technology.
Summary of the invention
The above-mentioned defect existing for solving prior art, the object of the present invention is to provide a kind of aluminium-silicon alloy casting tilt pouring method used for high-voltage switch, the method process costs is low, mould positioning precision is high, casting yield is high, can realize aluminium alloy and flow the laminar flow filling in mold cavity, the microstructure of refinement alusil alloy, can obtain dense structure, foundry goods that mechanical performance is higher.
Another object of the present invention is to provide a kind of special sand mold mould using in said method, positioning precision is high, realize the tilt pouring technique of sand mold mould, the raising of effective guarantee sand-cast quality, substitute conventional metal casting mould, shorten the fabrication cycle of casting molds, also saved a large amount of Mold Making expenses.
For achieving the above object, the technical solution used in the present invention is: this aluminium-silicon alloy casting tilt pouring method used for high-voltage switch, is characterized in that preparing in the steps below:
(1) preparation molding sand: the self-curing mo(u)ld casting mould that adopts CP5000 series casting resin to make as binding agent, in the time of preparation molding sand, the use amount of CP5000 series casting resin accounts for
molding sand quality0.7~1.2%;
(2) model and core box preparation: model and core box are prepared by Al-alloy metal material, or are prepared by the timber of silica gel, hard, in the time of analogue formation and core box, adopts digital control processing, directly imitative type or the processing of LOM fast shaping technology, to shorten its manufacturing cycle; Self-hardening resin sand mold casting mold is made up of two halves, be provided with at least two positioners at die joint place, described positioner comprises that a side half module die joint is provided with guide pillar, and on opposite side half module die joint, correspondence is provided with guide pin bushing, by the cooperation of guide pillars and bushes, mould is carried out to matched moulds location; The ratio of the rising head weight of alusil alloy and the rising head weight of foundry goods is in 120% left and right; Local thermal center place at foundry goods arranges chill, and the setting position of chill is determined according to the concrete structure of foundry goods; At sprue gate, screen pack is set, can effectively reduces the content of field trash in aluminum-silicon alloy liquid;
(3) dry processing: adopt brushing technique or pre-heating technique to be dried processing for the resin bonded sand mould mould of aluminium-silicon alloy casting used for high-voltage switch; Wherein brushing technique is: at its mold cavity surface with CTD-8 type alcohol-base paint brushing three times and light dry processing; Its method for warming up is: evenly toast the mold cavity surface of sand mold mould with liquefied gas spray gun, baking time is determined according to the die cavity size of sand mold mould, minimumly should continue 15 minutes;
(4) alusil alloy melting refining processing: at alusil alloy ZL101A(GB/T 1173-1995) in add by mass percentage 0.35~0.80% rare earth alloy, adopt production scene melting once technology, use graphite crucible to carry out melting, stop crucible and increase iron factor, adopt the melting, the refining techniques that do not stir, add by mass percentage " handing over bigger " multi-functional flux of 1.2~2.8%, before adding, first flux is carried out the preheating insulation of 1~2 hour at 120 DEG C~150 DEG C; Before furnace charge adds, at the bottom of graphite crucible, be evenly sprinkled into 30% of flux total amount; In the time that furnace charge enters semi-molten state, be more evenly sprinkled into remaining 70%; In the time that aluminium alloy is heated to predetermined pouring temperature, leave standstill 20~30 minutes, after skimming, can use, whole fusion process does not need to stir, and has reduced to greatest extent the content of oxide inclusion in aluminium alloy;
(5) the secondary metamorphic processing of aluminum-silicon alloy liquid: exceed 2.5 hours when the duration of pouring of aluminum-silicon alloy liquid, must carry out secondary metamorphic processing.Aluminum-silicon alloy liquid secondary metamorphic uses 0.5~1.0% Na salt;
(6) tilt pouring: when aluminium-silicon alloy casting used for high-voltage switch adopts the tilt pouring of self-curing mo(u)ld mould: 730~740 DEG C of secondary metamorphic temperature; 150~200 DEG C of the mold cavity surface preheat temperatures of self-curing mo(u)ld mould; Pouring temperature: 710~720 DEG C; The filling time of tilt pouring 15~40 seconds;
(7) heat treatment: the quenching of ZL101A aluminium-silicon alloy casting used for high-voltage switch is carried out in shaft furnace, Ageing Treatment is to carry out in batch-type furnace, 535 DEG C of insulations 8 hours, after coming out of the stove, in 25 seconds, enter the quenching-in water 3 minutes of 25~80 DEG C, then 175 DEG C of insulations 8 hours, the air cooling of coming out of the stove was to room temperature.
The special sand mold mould of this aluminium-silicon alloy casting tilt pouring used for high-voltage switch, there is the sand mold mould body of being made by self-hardening sand, it is characterized in that: described sand mold mould body is made up of two half modules, be respectively arranged with the guide pillars and bushes that plays matched moulds positioning action cooperatively interacting in the die joint side of two half modules, described guide pillars and bushes is at least two covers; The outside of described sand mold mould body is provided with base plate, baffle plate and fixed head, the fixed head of the sprue gate side of corresponding sand mold mould body is provided with aluminium alloy by mouth, be fixedly installed storage bin(hopper) by mouth side, base plate is provided with the first leg and the hinge for propping sand mould body level, described baffle plate is provided with after the upset of propping sand mould body and coordinates the second leg supporting with described hinge, is provided with screen pack in the position, sprue gate of sand mold mould body.
Adopt the beneficial effect of technique scheme: in pouring procedure of the present invention, the serial casting resin of CP5000 of selecting Ashland chemical company of U.S. technology to produce is as moulding sand binder.CP5000 series casting resin is the special at room temperature curing resin of the non-ferrous metal such as aluminium, magnesium sand casting, formed by two kinds of components, chemical reactivity unique between two components makes sand mold mould in the situation that pouring temperature is lower, also have good collapsibility, and this is also that other casting resin is incomparable.Use the sand mold mould of this fabrication techniques, at room temperature 10~30 minutes, can harden completely, within after the demoulding 1 hour, can be used for cast and produce, whole solidification process does not need heating.Add CP5000 series casting resin itself and almost have no irritating odor, thereby make work situation also obtain improving well.
In conventional alusil alloy Foundry Production, the alusil alloy melting of carrying out at Foundry Production Worksite is the secondary fusion of the aluminium-silicon ingots that composition is qualified, although this technique comparative maturity, simple, cost is higher.The present invention is the melting once technique adopting at Foundry Production Worksite, directly use fine aluminium ingot to add the composition element of needs to carry out melting at Foundry Production Worksite, the smelting technology of directly pouring into a mould after refining, rotten processing, its essence is exactly to cancel the melting preparation process of alloy pig manufacturer, in reducing scaling loss, saving the energy, reduce the overall cost of alloy melting.
In ZL101A, contain 0.25~0.45% magnesium, magnesium content capping value, adopts after quenching and complete Ageing Treatment, can obtain higher tensile strength and yield limit, keeps certain plasticity simultaneously.According to aluminium-silicon alloy casting high strength used for high-voltage switch (
>=310MPa), high elongation rate (
>=5%) specific requirement, in actual alloy melting process, the content of magnesium adopts the higher value in allowed band.Adopt tilt pouring technology, during due to tilt pouring, aluminium alloy levelling is steady, little to the scouring force of mold cavity, avoid aluminium alloy flow the turbulent flow in running channel or in die cavity or splash, can realize aluminium alloy and flow the laminar flow filling in mold cavity, the exhaust of realization order, thereby can obtain dense structure, foundry goods that mechanical performance is higher.When cast, screen pack is set in running gate system, can effectively reduces the content of field trash in aluminum-silicon alloy liquid.Can be as the field trash of nucleus when the crystallization owing to having removed a part, can make alusil alloy liquid phase ability forming core at lower temperature, thereby the phase of alusil alloy and the crystallization degree of supercooling of eutectic phase are increased, the number of spontaneous nucleation increases, thereby refinement the microstructure of alusil alloy, accelerate the process of setting of alusil alloy, improved the mechanical performance of aluminium-silicon alloy casting.The heat treatment of foundry goods, fully improves the mechanical performance of foundry goods, improves the machinability of foundry goods; Stablize tissue and the size of foundry goods; Eliminate the internal stress causing due to casting section thickness is inhomogeneous, quick cooling etc.; Eliminate segregation and acicular constituent.According to conventional thinking, when Foundry Production, the matched moulds of sand mold mould location is to realize by the positioner on sandbox, but this is obviously inappropriate for wide in variety, batch aluminium-silicon alloy casting used for high-voltage switch little, that casting body product moment is not large.Because the intensity of self-hardening resin sand is higher, guide pillar, guide pin bushing positioner in self-hardening resin sand mold casting mold, are used, so not only solve the accurate orientation problem of self-hardening resin sand mold casting mold two-half die, and owing to not needing to use sandbox location, the sandbox using can remove molding immediately after sand mold mould is certainly hard time, greatly save and made the required sandbox quantity of resin bonded sand mould mould, not only shorten the fabrication cycle of casting molds, but also saved a large amount of Mold Making expenses.
Utilize the selective absorption characteristic of Na atom, make the atom of the enrichment of N a of twin trench place of silicon crystal growth front end, thereby the speed that attenuating silicon atom or silicon atom tetrahedron length get on is suppressed twin trench growth mechanism.In the time that this mechanism is suppressed effectively, the direction of growth of silicon crystal changes into [100] or [110] crystal orientation, and only having a little part is along [211] crystal orientation, so just makes silicon crystal become the fibrous of garden section from sheet; Meanwhile, twin trench growth mechanism suppressed, has also promoted the branch of silicon crystal.Like this, after processing with Na salt secondary metamorphic, the Eutectic Silicon in Al-Si Cast Alloys in aluminium alloy just becomes height branch, bending by sheet and has the fibrous of garden section, thereby has improved the mechanical performance of foundry goods.
In the research process of this project, each processing step has carried out a large amount of verification experimental verifications in production scene.And carried out the batch trial production of month, produce 50 tons of aluminium-silicon alloy castings used for high-voltage switch by the tilt pouring new technology of self-hardening resin sand mold mould.The Performance Detection that machine adds rear product shows, the dense structure of foundry goods, and yield rate is more than 90%, and property indices has has all met or exceeded the requirement specifying in research of technique design specifications.
The mechanical performance of the foundry goods (material ZL101A) of producing by New Casting Technique is as shown in the table.
Detailed description of the invention
The special sand mold mould of aluminium-silicon alloy casting tilt pouring used for high-voltage switch as shown in Fig. 1,2,3,4,5, there is the sand mold mould body 1 of being made by self-hardening sand, described sand mold mould body is made up of two half modules 1.1,1.2, core 14 is positioned at sand mold mould body 1, be respectively arranged with the guide pillar 3 and the guide pin bushing 2 that play matched moulds positioning action that cooperatively interact in the die joint side of two half modules, described guide pillars and bushes is at least two covers; The outside of described sand mold mould body is provided with base plate 4, baffle plate 5 and fixed head 6, the fixed head 6 of the sprue gate side of corresponding sand mold mould body is provided with aluminium alloy by mouth 7, be fixedly installed the storage bin(hopper) 8 of splendid attire aluminium alloy 9 by mouth 7 sides, base plate is provided with the first leg 10 and the hinge 11 for propping sand mould body level, described baffle plate is provided with after the upset of propping sand mould body and coordinates the second leg 12 supporting with described hinge, is provided with screen pack 13 in the position, sprue gate of sand mold mould body.
Use above-mentioned mould can realize the tilt pouring of aluminium-silicon alloy casting used for high-voltage switch, specifically operation in the steps below:
(1) preparation molding sand: the self-curing mo(u)ld casting mould that adopts CP5000 series casting resin to make as binding agent, in the time of preparation molding sand, the use amount of CP5000 series casting resin accounts for 0.7~1.2% of molding sand quality;
(2) model and core box preparation: model and core box can be Al-alloy metal materials, also can be the timber of silica gel, hard, in the time of analogue formation and core box, can adopt digital control processing, directly imitative type or the processing of LOM fast shaping technology, to shorten its manufacturing cycle; In the two-half die of self-hardening resin sand mold casting mold, a side is provided with guide pillar, and opposite side correspondence is provided with guide pin bushing, by the cooperation of guide pillars and bushes, mould is carried out to matched moulds location; The ratio of the rising head weight of alusil alloy and the rising head weight of foundry goods is in 120% left and right; Local thermal center place at foundry goods arranges chill, and the concrete setting position of chill is determined according to the concrete structure of foundry goods; At sprue gate, screen pack is set, can effectively reduces the content of field trash in aluminum-silicon alloy liquid;
(3) dry processing: adopt brushing technique or pre-heating technique to be dried processing for the resin bonded sand mould mould of aluminium-silicon alloy casting used for high-voltage switch; Wherein brushing technique is: at its mold cavity surface with CTD-8 type alcohol-base paint brushing three times and light dry processing; Its method for warming up is: evenly toast the mold cavity surface of sand mold mould with liquefied gas spray gun, baking time is determined according to the die cavity size of sand mold mould, minimumly should continue 15 minutes;
(4) alusil alloy melting: aluminium Si-Mg alloy ZL101A(GB/T 1173-1995) add rare earth alloy (additional proportion and composition) in alusil alloy, adopt production scene melting once technology, controlling the mass percentage content of magnesium in ZL101A is 0.45%, use graphite crucible to carry out melting, stop crucible and increase iron factor, adopt the melting, the refining techniques that do not stir, adopt " handing over bigger " multi-functional flux, before use, first flux is carried out the insulation of 1~2 hour at 120~150 DEG C; Before furnace charge adds, at the bottom of graphite crucible, be evenly sprinkled into 30% of flux total amount; In the time that furnace charge enters semi-molten state, be more evenly sprinkled into remaining 70%; In the time that aluminium alloy is heated to predetermined pouring temperature, leave standstill 20~30 minutes, after skimming, can use, whole fusion process does not need to stir, and has reduced to greatest extent the content of oxide inclusion in aluminium alloy; Use Na salt pair aluminium alloy to carry out secondary metamorphic processing;
(5) tilt pouring: when aluminium-silicon alloy casting used for high-voltage switch adopts the tilt pouring of self-curing mo(u)ld mould: 730~740 DEG C of secondary metamorphic temperature; 150~200 DEG C of the mold cavity surface preheat temperatures of self-curing mo(u)ld mould; Pouring temperature: 710~720 DEG C; The filling time of tilt pouring 15~40 seconds;
(6) heat treatment: the quenching of ZL101A aluminium-silicon alloy casting used for high-voltage switch is carried out in shaft furnace, Ageing Treatment is to carry out in batch-type furnace, 535 DEG C of insulations 8 hours, after coming out of the stove, in 25 seconds, enter the quenching-in water 3 minutes of 25~80 DEG C, then 175 DEG C of insulations 8 hours, come out of the stove air cooling to room temperature, see accompanying drawing 6.