CN104014747A - Gravity casting process for turbocharger compressor casing - Google Patents
Gravity casting process for turbocharger compressor casing Download PDFInfo
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- CN104014747A CN104014747A CN201410242122.1A CN201410242122A CN104014747A CN 104014747 A CN104014747 A CN 104014747A CN 201410242122 A CN201410242122 A CN 201410242122A CN 104014747 A CN104014747 A CN 104014747A
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- electrolytic aluminum
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Abstract
A gravity casting process for a turbocharger compressor casing is disclosed. The process comprises steps of: 1) preparing a core; 2) preparing a sand mold; 3) assembling, drying and preheating; 4) smelting a ZL101A aluminum alloy; 5) pouring at a temperature of about 690 DEG C; and 6) cleaning, performing thermal processing and machining. Casting moulding sand is mainly modified so as to reduce the rejection rate of castings. The rate of defects comprising sand burning, air holes, cracks, cold shut, shrinkage cavity, looseness, and the like of the turbocharger compressor casing prepared by the process is lower than 3%. Mechanical properties of the castings are as follows through testing: the tensile strength is not less than 320 MPa, the yield strength is not less than 285 MPa, the percentage elongation is not less than 4.8%, the hardness is not less than 90 HB, and the metallographic phase is higher than the 3 level. The mechanical properties can fully meet using requirements.
Description
Technical field
The present invention relates to aluminium alloy casting technology field.
Background technology
The compressor casing of turbocharger is the important pressurized part in turbocharger, improves admission pressure increase aeration quantity thereby the waste gas that exhaust gas turbocharge principle utilizes engine to discharge carrys out drives impeller through the shell compressed air of calming the anger.In the time that engine speed speeds, the waste gas velocity of discharge is also synchronizeed and is speeded with turbocompressor rotating speed, now impeller just compresses more air and enters in compressor casing, so just can make more air be pressed onto in the cylinder of engine, engine fuel is fully burnt, increase engine efficiency, produced larger power, reduced toxic emission.And the admission pressure of increase engine is mainly that the exhaust-driven turbo-charger exhaust-gas turbo charger being mounted on engine is realized.
Compressor casing in turbocharger is turbine vitals, along with the extensive use of vehicle turbine supercharging technology, its structure, mechanical performance is required and has had higher requirement service life.
Because turbocharger air compressor shell wall is thin, complex-shaped, in the time adopting routine casting molding sand to carry out gravitational casting, percent defective is high, reaches more than 20%; And cast properties is only: tensile strength 200MPa, percentage elongation 3.5%, hardness 75HB.CN201110112326.X discloses a kind of low-pressure casting process of turbocharger air compressor shell, the turbocharger air compressor shell of casting has good mechanical performance, with good machinability, its good mechanical performance, tensile strength >=280MPa, yield strength >=280MPa, percentage elongation >=4%, hardness >=90HB, metallographic is more than 3 grades.Although the disclosed method of the document has improved the intensity of foundry goods, whether it does not disclose its percent defective index and makes moderate progress, moreover the equipment that low pressure casting need to be complete, and equipment investment and maintenance cost are high, have increased the cost of foundry goods.
Summary of the invention
For the deficiencies in the prior art, one of object of the present invention is to provide a kind of technique of gravitational casting turbocharger air compressor shell, than traditional gravity foundry technology, the present invention is mainly by the improvement to casting sand, thereby significantly improve the yield rate of foundry goods and the mechanical property of foundry goods, both reduce casting cost, improved again the mechanical property of foundry goods.
For achieving the above object, the technical scheme that the application adopts is as follows:
A technique for gravitational casting turbocharger air compressor shell, described technique comprises the steps:
1) coremaking: according to the shape of turbocharger air compressor shell inner flow passage, size, cover sand sintering by high strength and prepare core;
2) prepare sand mold: utilize casting sand to prepare sand mold according to turbocharger air compressor shell external shape profile, this casting sand forms in respect of following raw materials according with weight portion: quartzy roughing sand fresh sand 60-64 part, quartz roughing sand old sand 24-28 part, electrolytic aluminum residue powder 3-5 part, zircon sand 4-6 part, cenosphere 1-6 part, binding agent slip 16-18 part, water 22-26 part; Wherein, the granularity of quartz roughing sand fresh sand is 100-200 order, and the granularity of quartzy roughing sand old sand is 150-250 order, and the granularity of electrolytic aluminum residue powder and zircon sand is-300 orders, the granularity of cenosphere is about 10-60 μ m, binding agent is made up of following component by weight percentage: starch 36-40%, furane resins 6-8%, calcium-base bentonite 14-16%,-100 order Bagasse-cellulose powder 3-5%, zinc stearate 1-2%, sodium phosphate trimer 2-3%, surplus is water;
3) assembling, oven dry, preheating: by core and sand mold assembling, after oven dry, be preheated to 200-220 DEG C;
4) melting ZL101A aluminium alloy;
5) cast: pouring temperature is approximately 690 DEG C;
6) cleaning, heat treatment and machined.
Wherein electrolytic aluminum residue powder can obtain by the following method: the electrolytic aluminum residue reclaiming from electrolytic aluminium factory by removal of impurities abatement processes and clean up, is carried out to ball milling after oven dry, cross 300 mesh standard sieves after ball milling, obtain-300 object electrolytic aluminum residue powders.
The present invention is mainly by improving yield rate and the cast properties of foundry goods to the adjustment of casting sand performance.Its Sand aggregate adopts quartzy roughing sand fresh sand, the collocation of quartzy roughing sand old sand, conservation cost; Add appropriate zircon sand and can improve the refractoriness of molding sand, the resistance to performance of watering of casting mold is improved.The creationary electrolytic aluminum residue powder that adds in molding sand, solve the problem of electrolytic aluminum residue waste recovery, save cost, find owing to containing remaining aluminium and aluminium oxide in electrolytic aluminum residue powder simultaneously, with by cast aluminium alloy homogeneity composition, can improve the surface quality of aluminium alloy, play unexpected technique effect.Add appropriate cenosphere and improved the permeability of casting mold; By the blending powder of several powders, both make mould permeability energy good simultaneously, reduced casting flaw, made again any surface finish of foundry goods.Adopt taking starch as main brand-new binding agent collapsibility excellence after intensity, casting while making the casting-up by this sand conditioning.
Through a large amount of experiment statistics, adopts turbocharger air compressor shell prepared by technique of the present invention scab, pore, crackle, cold shut, shrinkage cavity, the ratio of defects such as loosen below 3%; Unexpected discovery simultaneously, except yield rate improves, the mechanical property of foundry goods is compared traditional gravitational casting and is also significantly promoted, through test: tensile strength >=320MPa, yield strength >=285MPa, percentage elongation >=4.8%, hardness >=90HB, metallographic is more than 3 grades.Meet instructions for use completely.
Detailed description of the invention
Embodiment mono-
A technique for gravitational casting turbocharger air compressor shell, described technique comprises the steps:
1) coremaking: according to the shape of turbocharger air compressor shell inner flow passage, size, cover sand sintering by high strength and prepare core;
2) prepare sand mold: utilize casting sand to prepare sand mold according to turbocharger air compressor shell external shape profile, this casting sand forms in respect of following raw materials according with weight portion: 60 parts of quartzy roughing sand fresh sands, 28 parts of quartz roughing sand old sands, 3 parts of electrolytic aluminum residue powders, 6 parts of zircon sands, 1 part of cenosphere, 18 parts of binding agent slips, 22 parts, water; Wherein, the granularity of quartz roughing sand fresh sand is 100-200 order, and the granularity of quartzy roughing sand old sand is 150-250 order, and the granularity of electrolytic aluminum residue powder and zircon sand is-300 orders, the granularity of cenosphere is about 10-60 μ m, binding agent is made up of following component by weight percentage: starch 36%, furane resins 8%, calcium-base bentonite 14%,-100 order Bagasse-cellulose powder 5%, zinc stearate 1%, sodium phosphate trimer 3%, surplus is water;
3) assembling, oven dry, preheating: by core and sand mold assembling, after oven dry, be preheated to 200-220 DEG C;
4) melting ZL101A aluminium alloy;
5) cast: pouring temperature is approximately 690 DEG C;
6) cleaning, heat treatment and machined.
Embodiment bis-
A technique for gravitational casting turbocharger air compressor shell, described technique comprises the steps:
1) coremaking: according to the shape of turbocharger air compressor shell inner flow passage, size, cover sand sintering by high strength and prepare core;
2) prepare sand mold: utilize casting sand to prepare sand mold according to turbocharger air compressor shell external shape profile, this casting sand forms in respect of following raw materials according with weight portion: 64 parts of quartzy roughing sand fresh sands, 24 parts of quartz roughing sand old sands, 5 parts of electrolytic aluminum residue powders, 4 parts of zircon sands, 6 parts of cenospheres, 16 parts of binding agent slips, 26 parts, water; Wherein, the granularity of quartz roughing sand fresh sand is 100-200 order, and the granularity of quartzy roughing sand old sand is 150-250 order, and the granularity of electrolytic aluminum residue powder and zircon sand is-300 orders, the granularity of cenosphere is about 10-60 μ m, binding agent is made up of following component by weight percentage: starch 40%, furane resins 6%, calcium-base bentonite 16%,-100 order Bagasse-cellulose powder 3%, zinc stearate 2%, sodium phosphate trimer 2%, surplus is water;
3) assembling, oven dry, preheating: by core and sand mold assembling, after oven dry, be preheated to 200-220 DEG C;
4) melting ZL101A aluminium alloy;
5) cast: pouring temperature is approximately 690 DEG C;
6) cleaning, heat treatment and machined.
Embodiment tri-
A technique for gravitational casting turbocharger air compressor shell, described technique comprises the steps:
1) coremaking: according to the shape of turbocharger air compressor shell inner flow passage, size, cover sand sintering by high strength and prepare core;
2) prepare sand mold: utilize casting sand to prepare sand mold according to turbocharger air compressor shell external shape profile, this casting sand forms in respect of following raw materials according with weight portion: 62 parts of quartzy roughing sand fresh sands, 26 parts of quartz roughing sand old sands, 4 parts of electrolytic aluminum residue powders, 5 parts of zircon sands, 3 parts of cenospheres, 17 parts of binding agent slips, 24 parts, water; Wherein, the granularity of quartz roughing sand fresh sand is 100-200 order, and the granularity of quartzy roughing sand old sand is 150-250 order, and the granularity of electrolytic aluminum residue powder and zircon sand is-300 orders, the granularity of cenosphere is about 10-60 μ m, binding agent is made up of following component by weight percentage: starch 38%, furane resins 4%, calcium-base bentonite 15%,-100 order Bagasse-cellulose powder 4%, zinc stearate 1.5%, sodium phosphate trimer 2.3%, surplus is water;
3) assembling, oven dry, preheating: by core and sand mold assembling, after oven dry, be preheated to 200-220 DEG C;
4) melting ZL101A aluminium alloy;
5) cast: pouring temperature is approximately 690 DEG C;
6) cleaning, heat treatment and machined.
Applicant's statement, the present invention illustrates detailed process equipment and process flow process of the present invention by above-described embodiment, but the present invention is not limited to above-mentioned detailed process equipment and process flow process, do not mean that the present invention must rely on above-mentioned detailed process equipment and process flow process and could implement.Person of ordinary skill in the field should understand, any improvement in the present invention, and the selections of the equivalence replacement to the each raw material of product of the present invention and the interpolation of auxiliary element, concrete mode etc., within all dropping on protection scope of the present invention and open scope.
Claims (2)
1. a technique for gravitational casting turbocharger air compressor shell, is characterized in that, described technique comprises the steps:
1) coremaking: according to the shape of turbocharger air compressor shell inner flow passage, size, cover sand sintering by high strength and prepare core;
2) prepare sand mold: utilize casting sand to prepare sand mold according to turbocharger air compressor shell external shape profile, this casting sand forms in respect of following raw materials according with weight portion: quartzy roughing sand fresh sand 60-64 part, quartz roughing sand old sand 24-28 part, electrolytic aluminum residue powder 3-5 part, zircon sand 4-6 part, cenosphere 1-6 part, binding agent slip 16-18 part, water 22-26 part; Wherein, the granularity of quartz roughing sand fresh sand is 100-200 order, and the granularity of quartzy roughing sand old sand is 150-250 order, and the granularity of electrolytic aluminum residue powder and zircon sand is-300 orders, the granularity of cenosphere is about 10-60 μ m, binding agent is made up of following component by weight percentage: starch 36-40%, furane resins 6-8%, calcium-base bentonite 14-16%,-100 order Bagasse-cellulose powder 3-5%, zinc stearate 1-2%, sodium phosphate trimer 2-3%, surplus is water;
3) assembling, oven dry, preheating: by core and sand mold assembling, after oven dry, be preheated to 200-220 DEG C;
4) melting ZL101A aluminium alloy;
5) cast: pouring temperature is approximately 690 DEG C;
6) cleaning, heat treatment and machined.
2. the technique of a kind of gravitational casting turbocharger air compressor shell as claimed in claim 1, it is characterized in that, wherein electrolytic aluminum residue powder can obtain by the following method: by the electrolytic aluminum residue reclaiming from electrolytic aluminium factory by removal of impurities abatement processes and clean up, after oven dry, carry out ball milling, after ball milling, cross 300 mesh standard sieves, obtain-300 object electrolytic aluminum residue powders.
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108465772A (en) * | 2018-06-22 | 2018-08-31 | 佛山市高明利钢精密铸造有限公司 | A kind of preparation method of the special molding sand of large-size stainless steel product monoblock cast |
| CN108705026A (en) * | 2018-06-22 | 2018-10-26 | 佛山市高明利钢精密铸造有限公司 | A kind of complex-shaped stainless steelwork casts the preparation method of special molding sand |
| WO2024065982A1 (en) * | 2022-09-27 | 2024-04-04 | 长兴鼎峰铸材科技股份有限公司 | Highly exothermic riser for turbocharger shell and preparation process therefor |
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| CN103056277A (en) * | 2012-12-06 | 2013-04-24 | 青岛美璞精工机械有限公司 | Thermal-insulation attaching material for steel castingsand process method |
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| US20020108733A1 (en) * | 1996-12-27 | 2002-08-15 | Jaime Prat Urreiztieta | Molding sand appropiate for the fabrication of cores and molds |
| WO2008110378A1 (en) * | 2007-03-15 | 2008-09-18 | AS Lüngen GmbH | Composition for the production of feeders |
| WO2012025084A1 (en) * | 2010-07-30 | 2012-03-01 | Ask Chemicals Gmbh | Binder system based on polyurethane for producing cores and casting molds using cyclic formaldehydes, molding material mixture, and method |
| WO2012041294A1 (en) * | 2010-09-30 | 2012-04-05 | Ask Chemicals Gmbh | Binder containing substituted benzenes and naphthalenes for producing cores and molds for metal casting, mold material mixture, and method |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108465772A (en) * | 2018-06-22 | 2018-08-31 | 佛山市高明利钢精密铸造有限公司 | A kind of preparation method of the special molding sand of large-size stainless steel product monoblock cast |
| CN108705026A (en) * | 2018-06-22 | 2018-10-26 | 佛山市高明利钢精密铸造有限公司 | A kind of complex-shaped stainless steelwork casts the preparation method of special molding sand |
| WO2024065982A1 (en) * | 2022-09-27 | 2024-04-04 | 长兴鼎峰铸材科技股份有限公司 | Highly exothermic riser for turbocharger shell and preparation process therefor |
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| CN104014747B (en) | 2016-04-20 |
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Effective date of registration: 20161010 Address after: 525259 Jinshan Development Zone, Maoming, Guangdong, Gaozhou Patentee after: GAOZHOU CITY GOLDEN MOUNTAIN ZHIFA FOUNDRY FACTORY Address before: Yinzhou District Heng Jie Heng Jie Zhen Road 315181 No. 50 Zhejiang city of Ningbo Province Patentee before: Zhu Xiaoying |
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Effective date of registration: 20220722 Address after: 525200 Jinshan Avenue, Jinshan Development Zone, Gaozhou City, Maoming City, Guangdong Province Patentee after: GAOZHOU JINSONG CASTING Co.,Ltd. Address before: 525259 Jinshan Development Zone, Gaozhou City, Maoming City, Guangdong Province Patentee before: GAOZHOU CITY GOLDEN MOUNTAIN ZHIFA FOUNDRY FACTORY |
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