CN104209497B - A kind of large-scale complex thin-wall Mg alloy part plaster casting method - Google Patents

A kind of large-scale complex thin-wall Mg alloy part plaster casting method Download PDF

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CN104209497B
CN104209497B CN201410455615.3A CN201410455615A CN104209497B CN 104209497 B CN104209497 B CN 104209497B CN 201410455615 A CN201410455615 A CN 201410455615A CN 104209497 B CN104209497 B CN 104209497B
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casting
pouring
coating
chill
apperance
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CN104209497A (en
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李华伦
孙伟明
焦婧
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Shanxi Yinguang Huasheng Magnesium Co Ltd
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Shanxi Yinguang Huasheng Magnesium Co Ltd
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Abstract

The present invention relates to a kind of large-scale complex thin-wall Mg alloy part plaster casting method, at the apperance top finishing original position coating of assembling, at heat energy-saving position, unsetting chill is set, make the compound component of unsetting chill by percentage to the quality for phenolic resin 1.25%, toluenesulfonic acid 0.4%, boric acid 1-1.5%, bentonite 2%, surplus are 70-140 object chromite sand, pouring cast part in adjustable pressure casting device, apperance is poured into the pouring position that the gypsum mould made is placed in pressure adjusting casting machine, fills containing 0.1%-1.0%SF in tank 6dry air or CO 2atmosphere, implements vacuum pouring and supercharging is solidified, and pouring temperature is 710 DEG C-750 DEG C, the vacuum of initial is-0.6 ~-0.8Mpa, freezing pressure 0.020-0.025Mpa.Adopt the inventive method can anti-oxidation, improve mold-filling capacity, reduce cast-internal and occur shrinkage cavity shrinkage porosity, obtain the higher Mg alloy castings of density.

Description

A kind of large-scale complex thin-wall Mg alloy part plaster casting method
Technical field
The present invention relates to casting method, specifically, is a kind of large-scale complex thin-wall Mg alloy part plaster casting method.
Background technology
Magnesium alloy large-sized foundry goods many employings sand casting, but casting accuracy is low, and large size, thin walled intricate casting production difficulty is very large.Therefore, in recent years, many R&D workers have carried out a series of research to gypsum mould in the application of magnesium alloy cast.When plaster casting height aluminium alloy containing magnesium, magnesium alloy, oxide inclusion is many, liquid level tension force is large, fill type weak effect, produces pore, is mingled with, the tendency of the defect such as shrinkage porosite is large.Main cause is that magnesium chemism is large, fierce exothermic reaction can be there is with gypsum under its liquid temperature, therefore, serious oxidation can be there is in plaster casting Mg alloy castings, anti-oxidation is the Focal point and difficult point of plaster casting magnesium alloy, and the oxidation reaction of liquid magnesium alloy and gypsum and burning, product are involved in foundry goods to be become and be mingled with.Magnesium alloy solidification latent heat is few, and thin-walled goes out possibility misrun, and the large planar section that especially wall is thin fills type difficulty; Gypsum mould gas permeability is very poor, and the difficulty of feeling suffocated of casting process is trapped in casting mold; Plaster casting magnesium alloy solidification is slow, easily occurs coarse grains, causes mechanical property to reduce.
Summary of the invention
The technical problem to be solved in the present invention is to provide a kind of large-scale complex thin-wall Mg alloy part plaster casting method, and shrinkage cavity shrinkage porosity appears in especially anti-oxidation, the mold-filling capacity that improves, reduction cast-internal, obtains the technology of the higher Mg alloy castings of density.
A kind of large-scale complex thin-wall Mg alloy part plaster casting method of the present invention, comprises step:
(1) at the apperance top finishing original position coating of assembling, by percentage to the quality, coating consists of the following composition, 140-250 object chromite powder 10-20%, talcum powder 25%, boric acid 5%, FeS 2powder 2%, frerrous chloride 2-3%, TiB 2powder 1.5%, OP emulsifying agent 0.15%, attapulgite clay 0.32%, Ludox 1.5%, all the other are water.
Casting form both can adopt expanded polystyrene (EPS) apperance, may also be the complex of wax-pattern or polystyrene and wax-pattern, at apperance external coating coating.Coating has several functions, comprising: coating is containing hydrophobic constituent element, and during grouting, in calcium plaster, gas is excluded by the micropore in dope layer; Dope layer isolation casting process magnesium alloy contacts with the direct of gypsum mould, to overcome gypsum mould and liquid magnesium alloy, avoids reacting between the two, prevents the oxidized or burning of magnesium, thus elimination oxide-film or combustion product field trash; Micropore in coating contributes to the exhaust of vacuum pouring, prevents from feeling suffocated, and avoids bubble residence to become defect in foundry goods; Improve cast(ing) surface flatness, avoid cast(ing) surface flow liner; Increase the wetability of metal liquid stream, improve mold-filling capacity; Increase the forming core core that molten metal solidifies, refinement casting crystalline grain etc.Coating is sprayed directly into apperance surface and belongs to not occupy-place coating, can not affect the dimensional accuracy of gypsum mould.
(2) unsetting chill is set at heat energy-saving position, makes the compound component of unsetting chill by percentage to the quality for phenolic resin 1.25%, toluenesulfonic acid 0.4%, boric acid 1-1.5%, bentonite 2%, surplus are 70-140 object chromite sand.
, easily there is shrinkage porosite in thick general goal, defect that thickness junction produces hot tearing and other type is formed because of latent heat and Heat transmission in the Wall-Thickness Difference that the many existence of heavy castings are larger.Casting Numerical Simulation software carries out iron chill shock chilling simulation and optimal design, obtains chill optimum position and shape.The unsetting chill adopted in step (2) is by the ferrochrome powder of high heat conduction, high hot melt and adding material mixing, is kneaded into pureed, a certain amount of walk is pinched into the apperance of foundry goods conformal, be attached to the bottom of apperance or side and to compress conformal closely sealed, pour into calcium plaster after solidification, become a part for casting mold.During casting pouring, high heat conduction in chill constituent element, large than the molten metal Quench of hot material to this position, promoting to solidify, avoid casting flaw to occur, is a kind of effective ways eliminating defect.
(3) pouring cast part in adjustable pressure casting device, pours into apperance the pouring position that the gypsum mould made is placed in pressure adjusting casting machine, fills containing 0.1%-1.0%SF in tank 6dry air or CO 2atmosphere, implements vacuum pouring and supercharging is solidified, and pouring temperature is 710 DEG C-750 DEG C, the vacuum of initial is-0.6 ~-0.8Mpa, freezing pressure 0.020-0.025Mpa.
Adjustable pressure casting technological process comprises inflation, rises liquid, fills type, the link such as pressurize and release.Cavity filling process as an important step of casting process, much casting flaw, as all closely related with it in misrun, volume gas, oxidation, slag inclusion, cold shut etc.The running gate system of adjustable pressure casting is directly connected with the stalk be positioned at below casting mold, and when filling type, liquid metal is introduced from ingate, filling casting mold from bottom to top.Such as certain casting mold is according to the pressure lower charging type of setting, and filling velocity is 0.3m/s (cast gate place), and filling time is about 37s.Molten metal is risen to by stalk and is full of whole die cavity, cavity filling process smooth sequential, does not roll up the phenomenons such as gas, splashing, cold shut and misrun.Process of setting is top-down consecutive solidification.During mold filling and solidification, the distribution of foundry goods longitudinal temperature is that middle and lower part temperature is high, and head temperature is low, and the temperature difference progressively increases, and transverse temperature distribution is along ingate to both sides from high to low.Cast top transverse temperature difference is little, and the foundry goods bottom transverse temperature difference is large, and filling time distribution is large, and this Temperature Distribution is just in time conducive to filling and the feeding of molten metal.Substantially top-down order is achieved.
As preferred scheme, whole powder puddle mixers in coating are dry mixed 10 minutes by the preparation method of the coating in step (1), add OP emulsifying agent, water and Ludox more mixed 20 minutes, after this add remaining water and the mixed system of other leftover materials continuation at whipping process.
As preferred scheme, the construction method of the unsetting chill in step (2) is dry mixed evenly chromite sand, phenolic resin and boric acid, finally adds toluenesulfonic acid again, and the mulling time is 5-10 minute.
As preferred scheme, in step (1), thickness of coating layer controls between 0.11-0.14mm.
In process of setting, the thick large part of foundry goods creates thermal center, causes surrounding metal first to solidify and forms independent liquid phase region, make it obtain feeding, probably produce shrinkage porosity defect of contraction cavity after solidifying.Solve this problem, need accelerate thick large part cooling rate, chill or heat conducting coating can be dealt with problems.Employing heat-conductive coating is convenient and swift, less to the change of foundry goods and mould, and brush coating can cast out several foundry goods, is therefore good selection.The thermal center process relative difficult of corner: cooling rate is difficult to stop thermal center to produce too slowly, and cooling rate is too fast, causes corner first to be solidified.Adopt the method for amorphous iron chill of the present invention to pour into a mould, cast-internal occurs that the probability of shrinkage cavity shrinkage porosity greatly reduces, and improves yield rate, obtains the foundry goods that density is higher, reaches technical requirement.
By the comparison of cast magnesium alloy sheet sample, the mold-filling capacity that adjustable pressure casting, low pressure casting, counter-pressure casting and gravity are cast contrasts, and finds the mold-filling capacity that adjustable pressure casting can provide the most excellent.Freezing pressure is higher, and the operating time is shorter, and the cast structure obtained is finer and close, and Mg alloy castings tensile property is higher.Test shows, improves pouring temperature, both can solve magnesium alloy problem of oxidation, and liquid magnesium alloy can be made again to obtain in gypsum mould and well fill type under the condition of high vacuum degree under protection gas condition.Freezing pressure is higher, and the operating time is shorter, and the cast structure obtained is finer and close, and Mg alloy castings tensile property is higher.Pour into a mould, fill the optimised process of the large-scale complex thin-wall large-scale complex thin-wall Mg alloy casting of type and Under Pressure Solidification under adopting adjustable pressure casting to realize the vacuum in protection compression ring border.Conventional gravity casting sample compares, and the tensile strength of adjustable pressure casting sample improves 8-10%, and percentage elongation improves about 100-150%, and its performance obtains showing and promotes; Pressure regulation shaping precision casting technology can keep excellent mold-filling capacity while molten metal steadily enters casting mold die cavity, and foundry goods thinnest part can reach 0.25mm, and clear-cut; Complete solidify at regulatable differential pressure action lower charging type, thermograde and setting rate all will obtain synchronous lifting, contribute to being formed the fine grained texture of more uniform compact; Invention introduces application of vacuum means, the bleb thus obtained can obviously be suppressed, and the foundry goods of acquisition strengthens its intensity and performance further by heat treatment; Its distinctive casting technique makes the hot investment casting of large-scale complex thin-wall foundry goods become a reality.The high metallurgical quality that the present invention is applicable to the production of thin-section casting and the larger intricate casting of wall thickness transition is produced.In higher vacuum, higher pouring temperature under gas shielded state, both can solve magnesium alloy problem of oxidation, and liquid magnesium alloy can be made again to obtain in gypsum mould and well fill type.Enter after solidifying, boost pressure is higher and the rate of rise is faster, and foundry goods is finer and close, performance is higher.For implementing above-mentioned cast and solidifying process, adjustable pressure casting has many-sided advantage, particularly produces the application in large-scale complex thin-wall magnesium platform gold castings production.
Accompanying drawing explanation
Fig. 1 is the adjustable pressure casting equipment schematic diagram of pouring gypsum type Mg alloy castings.
In figure, 1-vacuum/pressurized table, 2-upper room, 3-vavuum pump and protection gas interface I; 4-gypsum mould, 5-room dividing plate up and down, 6-stalk, 7-vavuum pump and protection gas interface II; 8-crucible, 9-holding furnace, 10-lower room, 11-power line and pickup wire interface window.
Detailed description of the invention
Before using adjustable pressure casting equipment, by carrying out three-dimensional modeling, solid modelling, numbered analog simulation to cast member, Optimizing Process Parameters also finds out optimum implementation.Arranging amorphous iron chill, the technique of adjustable pressure casting and parameter etc. with apperance coating, thermal center in preferred plan is theoretical foundation of the present invention, then becomes actual process through actual tests with after improving.The foaming of polystyrene steam manufactures apperance chunk, after being assembled into apperance, being coated with coating, drying, pasting amorphous iron chill at thermal center place, after solidification, apperance is placed in framed in, perfusion calcium plaster.Sclerosis, oven dry, roasting become gypsum mould.
The first step
The modeling and simulation stage.Carry out numerical simulation and process optimization to the present invention and relevant prerequisite plaster casting technology, the technique that enforcement is formulated is based upon on reliable basis.Specific works comprises and carries out three-dimensional modeling by electronic drawing to cast member and increase the solid modellings such as pouring and riser systems, chill, casting mold, the numerical simulation of the heat transfer of area of computer aided cast form process, biography speed, mass transfer, temperature field, velocity field, concentration field, stress field, screen cast analog simulation, to simulation result analysis, assessment, corrective measure is proposed, Optimization Technology, finds out preferred plan from theoretical and emulation.Apperance paint thickness in preferred plan, thermal center arrange amorphous iron chill, the technique of adjustable pressure casting and parameter and especially want refinement, to obtain the preferred plan etc. of foundry engieering.
Second step
At the apperance top finishing original position coating of assembling.By percentage to the quality, coating consists of the following composition, 140-250 object chromite powder 10%(or 15% or 20%), talcum powder 25%, boric acid 5%, FeS 2powder 2%, frerrous chloride 2-3%, TiB 2powder 1.5%, OP emulsifying agent 0.15%, attapulgite clay 0.32%, Ludox 1.5%, all the other are water.
Whole powders in coating are dry mixed 10 minutes at puddle mixer, then add OP emulsifying agent, suitable quantity of water and Ludox wet mixing 20 minutes.Start mixer (rotating speed is greater than 1380r/min), add residue water at whipping process and carry out mixed system with other leftover materials, total mixing time >=1 hour.
Mixed coating magma processed is thicker, is easy to longer-term storage, but for the ease of coating construction, can add in addition as required after suitable quantity of water stirs and be coated with, the methods such as brushing, spraying all can adopt.Dope layer general control is between 0.11 ~ 0.14mm, and some privileged sites also can not be coated with or few painting as required.After brushing terminates, indoor placement, ambient humidity will keep being less than 30%, natural air drying, during as needs rapid draing, can hot blast drying, hot blast temperature controls be no more than 65 DEG C of scopes.Coating has isolation gypsum mould and liquid magnesium alloy, is beneficial to the exhaust of cast, improves cast(ing) surface flatness, improves the effect such as mold-filling capacity, refinement cast(ing) surface crystal grain.
3rd step
At heat energy-saving position, unsetting chill is set.The compound component making unsetting chill is phenolic resin 1.25%, toluenesulfonic acid 0.4%, boric acid 1%(or 1.2% or 1.5% by percentage to the quality), bentonite 2%, surplus be 70-140 object chromite sand.
Chill construction technology is: the construction method of unsetting chill is dry mixed evenly chromite sand, phenolic resin and boric acid, finally adds toluenesulfonic acid again, and the mulling time is 5-10 minute.
Chromite sand can not mix with other sand.The life-span of often criticizing sand is 5 minutes, therefore molding operation must be rapidly.By apperance conformal mould compacting amorphous iron chill, be covered in the apperance surface of position of regulation after the demoulding and fixed.To be shaped and the amorphous iron chill long-term storage consistency after solidifying, the residual strength after cast are low.
4th step
The preparation of gypsum mould.Large-scale complex thin-wall Mg alloy castings need of production pours into a large amount of calcium plasters at the appointed time, therefore, adopts vacuum to mix slurry, priming by vacuum.Teeter chamber is led to by the grout valve couplet on the door.Polystyrene apperance is placed in steel framed in fixing, and position will be poured into aim at valve export.Close perfusion valve and perfusion compartment door, wait for perfusion gypsum mixed slurry.First suitable quantity of water is put in teeter chamber when mixing slurry, in filling a prescription after all solids powder mixing and stirring, be sprinkled into while stirring in the water of tank diameter, after all adding, close teeter chamber's top cover immediately, start to vacuumize and stir, in 30 seconds, vacuum 0.05-0.06MPa, mixing time are 2-3 minute, speed of agitator 250-350 rev/min.Before terminating stirring soon, vacuumize grouting room, the vacuum equal with teeter chamber or slightly low (such as teeter chamber is 0.05MPa, and grouting room is 0.06MPa) of grouting room is in case injection when being in the milk, splashing and vacuum are poured in down a chimney.Stir and terminate, open valve grouting immediately, perfusion is generally no more than 1-1.5 minute.Perfusion should be avoided directly impacting module, slurry should be made to introduce along case limit, from bottom box-frame, rise gradually, prevent gas to be detained.Grouting terminates, breaking vacuum immediately, takes out box-frame, rinses teeter chamber rapidly, thoroughly remove defective material.The framed standing 1-1.5 hour of perfusion, period is strictly on guard against vibrations, otherwise unfavorable to the precision of gypsum mould, intensity, complete line.Continue placement more than 24 hours, most of moisture is lost.Then adopt infrared heating, also at the air blast drying room of 80-90 DEG C of moving air, more than 10 hours low temperature dryings can be carried out, to remove the most of moisture in gypsum mould.Then stage intensification roasting is adopted in natural gas heating circulating atmosphere furnace.
5th step
Adopt adjustable pressure casting device pouring cast part.As shown in Figure 1, casting device comprises room 2 and lower room 10, is separated by upper and lower room dividing plate 5, and gypsum mould 4 is placed in room 2, and the housing of upper room 2 is provided with vacuum/pressurized table 1.In lower room 10, holding furnace 9 is set; crucible 8 is arranged in holding furnace 9; stalk 6 is fixed in dividing plate 5 bottom, upper and lower room; the housing of upper room 2 and lower room 10 is offered respectively vavuum pump and protection gas interface I3 and vavuum pump and protection gas interface II7, upper room 2 and lower room 10 are also respectively equipped with the interface window 11 of power line and pickup wire.
Setting technological parameter before cast, completed by control system follow procedure, portion link is by manually completing.The key link of pouring cast part is: prepare, fill protection gas, step-down, rise liquid, fill type, compression solidification, pressurize, venting, can opening, unload casting mold, de-casting mold.
After gypsum mould 4 takes out from roaster, temperature is set as 200-300 DEG C, the placement suitable for reading of the stalk 6 of the cast gate aligning equipment of casting mold, and fixing casting mold, connects sensor, the lower room 10 of cover.Curve or the technological parameter of cast and process of setting set in advance in computer for controlling.After the molten metal in holding furnace 9 reaches pouring temperature, casting starts, and injects SF in upper room 2, lower room 10 6, make the atmosphere of upper and lower room be air (or CO 2) SF 6, the combination of several atmosphere that what following table was listed is.
Numbering SF 6/% Air or CO 2/%
1 1 99
2 0.1 99.9
3 0.5 99.5
4 0.8 99.2
Then start-up simulation machine controller starts cast.Now pressure adjusting casting machine has computer for controlling automatically to complete various operation by established procedure.Usually do not need people to intervene, if program display is abnormal, if necessary, allow people to intervene by force.After foundry goods solidifies completely, by manually completing all the other operations.Open the vent valve of upper and lower room, slowly venting is to atmospheric pressure, opens lower room locking device, removes lower room, casting mold is hung out casting machine.De-gypsum adopts high pressure water flushing gypsum mould, is removed by foundry goods clean.Air-dry, excision dead head burr etc. subsequently, by technical conditions inspection, post processing, machining, surface treatment etc.
Parameter when vacuum pouring and supercharging are solidified is; Pouring temperature is 710 DEG C-750 DEG C, the vacuum of initial is-0.6 ~-0.8Mpa, freezing pressure 0.020-0.025Mpa.
aircraft mass activity canopy skeleton Mg alloy castings is cast
Aircraft movable cabin skeleton comprises frontal arc frame, middle arc frame, backarc frame.With the Mega-boule of ZM-5 magnesium alloy cast, the penetrating skeleton in space be made up of the bar of different cross section, block, plate, then the integrated member of formation is added through machine.Skeleton overall structure is high to mechanical property, dimensional accuracy, rigidity requirement, has strict restriction to casting flaw.Because its size large (maximum package is 125Ox820x500 millimeter), complex contour, reconciliation precision require high, casting difficulty.Former technique adopts sand casting to produce, and moulding, reconciliation precision are restive, need many places additional process correction amount, not only have impact to castability, also increase machining amount, cause qualified casting very low.
The technological process adopting plaster casting to produce is as follows: cast member carries out three-dimensional modeling, solid modelling, numbered analog simulation, and Optimization Technology also finds out preferred plan.In preferred plan, the initial foundation that amorphous iron chill, the technique of adjustable pressure casting and parameter etc. are this patents is set with apperance coating, thermal center, then becomes technique through actual tests after improving.The foaming of polystyrene steam manufactures apperance chunk, after being assembled into apperance, being coated with coating, drying, pasting amorphous iron chill at thermal center place, after solidification, apperance is placed in framed in.Gypsum mould is become through perfusion calcium plaster, sclerosis, oven dry, roasting.Gypsum mould takes out from roaster, fixing casting mold at the accurate location of casting machine, by the cover cap cover of upper room, locking.Curve or the technological parameter of cast and process of setting set in advance in computer for controlling.After the liquid magnesium alloy in holding furnace 9 reaches pouring temperature, casting starts, to upper and lower indoor injection %SF 6, make the atmosphere of upper and lower room become 99% air+1%SF 6.Now pressure adjusting casting machine has computer for controlling automatically to complete various operation by the parameter of established procedure and setting.After foundry goods solidifies completely, open the vent valve of upper and lower room, slowly venting is to atmospheric pressure, opens lower room locking device, removes lower room, casting mold is hung out casting machine.De-gypsum: water under high pressure breaks up gypsum, removes clean, air-dry, excision dead head burr etc. by foundry goods.Finally by technical conditions inspection, post processing, machining etc.
Adopt plaster casting, utilize foamed polystyrene apperance, adopt apperance coating, amorphous iron chill, protection gas under vacuum pouring-pressure forming (adjustable pressure casting), with higher pouring temperature under vacuum, magnesium alloy can be avoided to be oxidized, viscosity resistance, capillary resistance, gas counter-pressure can be reduced again, outstanding especially in the effect of thin-walled die cavity, ensure filling; Amorphous iron chill improves temperature field and increases pressure when solidifying, and the setting rate of foundry goods obtains reasonable adjusting.The technology of the present invention essentially eliminates defect, cast-internal occurs that the probability of shrinkage cavity shrinkage porosity greatly reduces, improve yield rate, obtain the foundry goods that density is higher, the performance number that foundry goods exemplary position cuts sample is tensile strength 240MPa, yield strength 170MPa, percentage elongation 7%, meets the technical standard requirement of part.

Claims (3)

1. a large-scale complex thin-wall Mg alloy part plaster casting method, comprises step:
(1) at the apperance top finishing original position coating of assembling, by percentage to the quality, coating consists of the following composition, 140-250 object chromite powder 10-20%, talcum powder 25%, boric acid 5%, FeS 2powder 2%, frerrous chloride 2-3%, TiB 2powder 1.5%, OP emulsifying agent 0.15%, attapulgite clay 0.32%, Ludox 1.5%, all the other are water; Thickness of coating layer controls between 0.11-0.14mm;
(2) unsetting chill is set at heat energy-saving position, makes the compound component of unsetting chill by percentage to the quality for phenolic resin 1.25%, toluenesulfonic acid 0.4%, boric acid 1-1.5%, bentonite 2%, surplus are 70-140 object chromite sand;
(3) pouring cast part in adjustable pressure casting device, pours into apperance the pouring position that the gypsum mould made is placed in pressure adjusting casting machine, fills containing 0.1%-1.0%SF in tank 6dry air or CO 2atmosphere, implements vacuum pouring and supercharging is solidified, and pouring temperature is 710 DEG C-750 DEG C, the vacuum of initial is-0.6 ~-0.8Mpa, freezing pressure 0.020-0.025Mpa.
2. method according to claim 1, it is characterized in that: the whole powder puddle mixers in coating are dry mixed 10 minutes by the preparation method of the coating in step (1), add OP emulsifying agent, water and Ludox more mixed 20 minutes, after this add remaining water and the mixed system of other leftover materials continuation at whipping process.
3. method according to claim 1, is characterized in that: the construction method of the unsetting chill in step (2) is dry mixed evenly chromite sand, phenolic resin and boric acid, finally adds toluenesulfonic acid again, and the mulling time is 5-10 minute.
CN201410455615.3A 2014-09-10 2014-09-10 A kind of large-scale complex thin-wall Mg alloy part plaster casting method Active CN104209497B (en)

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