CN104308072B - Carbon fiber-based precoated sand material for selective laser sintering and preparation method thereof - Google Patents
Carbon fiber-based precoated sand material for selective laser sintering and preparation method thereof Download PDFInfo
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- CN104308072B CN104308072B CN201410467968.5A CN201410467968A CN104308072B CN 104308072 B CN104308072 B CN 104308072B CN 201410467968 A CN201410467968 A CN 201410467968A CN 104308072 B CN104308072 B CN 104308072B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
- B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
- B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
- B22C1/20—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents
- B22C1/22—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents of resins or rosins
- B22C1/2233—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents of resins or rosins obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
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Abstract
The invention discloses the carbon fiber-based precoated sand material and preparation method thereof for selective laser sintering；Carbon fiber-based precoated sand material component is chopped carbon fiber, roughing sand, organic binder bond, curing agent, lubricant, coupling agent and dispersant；Its preparation method is: chopped carbon fiber is carried out surface modification treatment, prepare by below scheme again: roughing sand adds resin and adds part of stearic acid calcium and the coupling agent aqueous solution for preparing adds the urotropine firming agent containing chopped strand and adds residue calcium stearate cooling screening and shake out, and obtains product.The invention have the advantage that (1) carbon fiber plays conduction of heat, limit the contraction that sintered part is overall to a certain extent, reduce the warping phenomenon in forming process, (2) precoated sand has been remarkably improved the heat endurance of coated sand after laser sintered melting, the phenolic resin curing reaction of local and interlayer junction in acceleration of sintering layer, hence it is evident that improve the first base intensity of laser sintering forming element.
Description
Technical field
The invention belongs to field of novel, be specifically related to a kind of carbon fiber-based precoated sand material for selective laser sintering and preparation method thereof.
Background technology
Selective Laser Sintering (SLS), it is a kind of using laser as controlled thermal source, by solid freeform technology (the Solid Freeform Fabrication of dusty material selective sintering, SFF), it uses discrete, accumulation forming principle, by computer aided design and manufacture, by the three-dimensional CAD model of part is carried out hierarchy slicing process, obtain the cross section profile information of each layer, again solid powder material is sintered, make the most bonding, progressively superposition, thus quickly obtain 3D solid.Do not restricted by part shape structure complexity, it is not necessary to any moulds of industrial equipment, and manufacturing cycle short production cost is low.Precoated sand is one of the common used material for selective laser sintering RP technique, its surface is coated with by various interpolation materials such as phenolic resin, when laser sintering rapid forming technology, cool and solidify after making its melted by heat by LASER HEATING phenolic resin, so that precoated sand bonding forms core.
Along with the requirements such as, complex-shapedization thin-wall light-weighted to foundry goods, dimensional accuracy and surface quality improve constantly, the complicated sand mold (core) utilizing SLS technology to prepare also has certain gap at aspects such as institutional framework, mechanical property, dimensional accuracy and surface quality.Poor thermal conductivity due to precoated sand, laser beam irradiation time is short, precoated sand sintered part generally also exists that sintering initial strength is on the low side and the defect such as surface quality difference, and the content of binding agent is higher, the gas forming amount causing sand mold (core) is big, gas permeability and collapsibility are poor, it is difficult to meet the production requirement of high-quality dominance energy intricate casting.
Carbon fiber has the characteristics such as low-density, high intensity, high-modulus, high temperature resistant, resist chemical, low resistance, high heat conduction, low-thermal-expansion, chemically-resistant radiation and good biocompatibility.Additionally, also have the distinctive flexibility of fiber and programmable, its specific strength and specific modulus are superior to other inorfils.Using carbon fiber-reinforced precoated sand material, during laser sintered, carbon fiber is not involved in the interaction between laser and dusty material in principle, and the phase being intended only as in composition plays the effect of heat transfer, improves thermal conductivity and the electric conductivity of precoated sand material.Additionally, due to the existence of carbon fiber, necessarily the densified of precoated sand is served certain impact, limit the contraction that sintered part is overall to a certain extent, it is ensured that the dimensional accuracy of sintered part.
Summary of the invention
Object of the present invention is to provide a kind of carbon fiber-based precoated sand material for selective laser sintering and preparation method thereof；The method is using carbon fiber as the important reinforcement of precoated sand material, carbon fiber is a kind of polycrystalline fibre axially arranged along fiber by incomplete graphite crystallization, the advantage with the compactness strengthening the laser sintered part of precoated sand, the SLS precoated sand sintered part simultaneously obtained has higher mechanical property and dimensional accuracy.
Major experimental material used by the present invention:
For the carbon fiber-based precoated sand material of selective laser sintering, its constituent is: roughing sand 90 ~ 95%, chopped carbon fiber are 2.5 ~ 5.0%, organic binder bond 2.5 ~ 3%, curing agent 0.375 ~ 0.51%, lubricant are 0.0015 ~ 0.0018%, coupling agent is 0.0025 ~ 0.003% and dispersant is 0.1125 ~ 0.153%.
Chopped carbon fiber: phosphorus content >=95%, average diameter is 7 ~ 10 μm, a length of 1 ~ 2.5mm, and tensile strength is 3.6 ~ 3.8 GPa, and growth rate is 1.5%, and modulus is 220-240 GPa, and bulk density is 1.76 g/cm3。
Roughing sand: spherical or the most spheroidal nice foundry sand, dihedral coefficient≤1.1, composition is Al2O3>=75%, Fe2O3≤ 5%, TiO2≤ 5%, refractoriness is 1800～2000 DEG C, and coefficient of thermal expansion is 0.13%(1000 DEG C and heats 10 minutes), average grain diameter is less than 0.212mm, granularmetric composition 40～80 mesh.
Organic binder bond: solid thermoplastics phenolic resin, softening point is 80～90 DEG C, free phenol content≤1.8%, polymerization speed is (150 DEG C) 58～70s, in yellow, transparent cake, size-reduced, be milled into powder, crossing packed for standby use after 100 mesh sieves, model is PF-1904.
Curing agent: methenamine (hexa), white crystalline powder, fusing point is 119～122 DEG C,
About 263 DEG C of distillations.
Lubricant: calcium stearate, the trickleest white powder, fusing point is more than 140 DEG C, and fineness is 200 mesh sieve percent of pass >=99.0%.
Coupling agent: silane coupling agent KH-550, colourless transparent liquid, boiling point is 217 DEG C.
Dispersant: hydroxypropyl methyl cellulose (HPMC) dispersant.
First the present invention carries out surface modification treatment to chopped carbon fiber, carbon fiber-based precoated sand material is prepared again: roughing sand adds resin and adds part of stearic acid calcium and the coupling agent aqueous solution for preparing adds the urotropine firming agent containing chopped strand and adds residue calcium stearate cooling screening and shake out, and obtains selective laser sintering carbon fiber-based precoated sand material by following coating technique flow process.
The preparation method of the carbon fiber-based precoated sand material for selective laser sintering of the present invention, it is characterised in that step is as follows:
Step one: use gamma-ray irradiation facture or electrochemical polymerization method that chopped carbon fiber is carried out surface modification treatment.
Step 2: use hot method coating technique, carry out roughing sand sieving the sand grains obtaining required particle diameter, it is heated to 180 DEG C ~ 200 DEG C again, it is discharged in puddle mixer after roughing sand is cooled to 140 DEG C ~ 160 DEG C, when roughing sand temperature is down to 110 DEG C ~ 130 DEG C, resin is added thereto so that roughing sand and resin are sufficiently mixed and uniform overlay film.
Step 3: the chopped carbon fiber after step one being processed joins in urotropine firming agent according to a certain percentage, is added HPMC dispersant, is stirred by ultrasonic vibration so that chopped carbon fiber is uniformly dispersed in curing agent solution.
Step 4: add part calcium stearate and the coupling agent aqueous solution prepared in step 2 gained precoated sand, stirring a period of time, when precoated sand temperature is down to about 100 DEG C, the urotropine firming agent that step 3 with the addition of chopped carbon fiber again adds in precoated sand, resin is made to carry out curing reaction under heat effect, formed and a kind of do not melt insoluble material, sand grains is securely bonded together, during chopped carbon fiber is also evenly distributed in overlay film sand grains simultaneously, prepare carbon fiber-based sand in coating phenolic resin.
Step 5: added in configured precoated sand by residue calcium stearate, be sufficiently mixed uniformly, put sand, water-cooled is to room temperature, broken, and screening i.e. can get the carbon fiber-based precoated sand of selective laser sintering.
The invention provides a kind of carbon fiber-based precoated sand material for selective laser sintering, have the advantage that compared with the precoated sand material of traditional approach preparation
(1) during laser sintered, carbon fiber is not involved in the interaction between laser and dusty material in principle, and the phase being intended only as in composition plays the effect of heat transfer.Additionally, due to the existence of carbon fiber, necessarily the densified of coated sand is served certain impact, limit the contraction that sintered part is overall to a certain extent；
(2) due to the addition of chopped carbon fiber, improve the rate of heat transfer within coated sand material granule to a certain extent, this is for accelerating the homogenization of precoated sand temperature around carbon fiber, and then reduces the thermograde in sintering region, and the warping phenomenon reduced in forming process is highly beneficial；
(3) precoated sand is after laser sintered melting, and its viscosity significantly reduces, in viscous state.And temperature is the highest, its viscosity is the lowest, is more conducive to the densified of powder particle.But the too high meeting of temperature makes precoated sand produce thermal decomposition, thus reduces the mechanical property of sintered part.The addition of chopped carbon fiber significantly improves the heat endurance of coated sand, promotes local and the phenolic resin curing reaction of interlayer junction in sinter layer.Secondly, the addition of chopped carbon fiber serves the effect of bearing stress, thus has reached to strengthen the effect of precoated sand sintering forming element just base intensity.
In a word, the present invention uses chopped carbon fiber to strengthen selective laser sintering precoated sand material, owing to coated sand creates being bonded of chemistry with chopped carbon fiber surface, the heat endurance making precoated sand is improved, chopped strand is fairly obvious to the enhancing effect of precoated sand, it is high that selective laser sintering carbon fiber-based precoated sand sintered part has first intensity, collapsibility is good, the advantage that gas forming amount is little, can be used for selective laser sintering structure complicated, the foundry goods that performance requirement is high, the overlay film sand mold (core) complicated especially for precinct laser sintering technology monolithic molding also combines model casting and has superiority in terms of high-performance large-scale complex thin wall castings fast precise shaping, for promoting Aero-Space, the rapid response manufacturing ability of auto industry and other scientific domain has huge using value and bright prospects.
Accompanying drawing explanation
Fig. 1 is the preparation flow figure of selective laser sintering carbon fiber-based precoated sand material of the present invention.
Detailed description of the invention
Embodiment 1
A kind of carbon fiber-based precoated sand material for selective laser sintering sequentially includes the following steps:
Step one: use gamma-ray irradiation facture that chopped carbon fiber is carried out surface modification treatment, first a diameter of 7 μm, the chopped carbon fiber of a length of 2.5mm are put in acetone soln, it is dried after cleaning 48h, it is dipped in equipped with in the irradiation bottle of tetraethylene-glycol acetone soln that active functional group group concentration is 2 mol/L again, by one end maintaining nitrogen purge 2 min of 2 passages of irradiation bottle, seal after oxygen wait getting rid of in bottle, it is placed in Co gamma-ray irradiation source, carries out co-irradiation grafting by the irradiation dose of 200kGy modified.After chopped carbon fiber radiation treatment more standby with being placed in vacuum drying oven after acetone cleaning in 50 DEG C of dry 12 h.
Step 2: use hot method coating technique, carries out the spherical or the most spheroidal nice foundry sand of dihedral coefficient≤1.1 sieving to obtain 70/270 purpose five sieve series sand 1000g, Solid thermoplastic's phenolic resin is ground into the uniform Phenolic resin powder that particle diameter is 60 μm.Again nice foundry sand is heated to 180 DEG C, cross after nice foundry sand is cooled to 150 DEG C by 50s and be discharged in sand muller, when nice foundry sand temperature is down to 120 DEG C, 25g phenolic resin (accounting for the 2.5% of nice foundry sand weight) is added thereto, 80s is stirred so that nice foundry sand and phenolic resin are sufficiently mixed and uniform overlay film in puddle mixer.
Step 3: chopped carbon fiber step one processed weighs 35g(and accounts for the 3.5% of nice foundry sand weight) add in the aqueous solution that 3.75g hexa (mass fraction accounting for Phenolic resin powder is 15%) is prepared, add 0.12gHPMC dispersant (mass fraction accounting for hexa is 3.0%), stirred by ultrasonic vibration so that chopped carbon fiber is uniformly dispersed in hexa solution.
Step 4: (mass fraction accounting for Phenolic resin powder is 1% for addition 1.5g part calcium stearate (mass fraction accounting for phenolic resin is 6.0%) and 0.25g coupling agent aqueous solution in step 2 gained precoated sand, it is made into the aqueous solution that mass fraction is 10%), puddle mixer stirring 35s.When precoated sand temperature is down to 110 DEG C, then the hexa solution that step 3 with the addition of chopped carbon fiber adds in precoated sand, and puddle mixer stirring 80s prepares carbon fiber-based sand in coating phenolic resin.
Step 5: 1.5g is remained calcium stearate (mass fraction accounting for phenolic resin is 6.0%) again and adds in the precoated sand prepared, puddle mixer stirring 60s is sufficiently mixed uniformly, puts sand, and water-cooled is to room temperature, broken, screening, i.e. can get the carbon fiber-based precoated sand of selective laser sintering.
Embodiment 2
A kind of carbon fiber-based precoated sand material for selective laser sintering sequentially includes the following steps:
Step one: use electrochemical polymerization facture that chopped carbon fiber is carried out surface modification treatment, first by a diameter of 7 μm, the chopped carbon fiber of a length of 1.5mm is put into after cleaning 48h in acetone soln, again with sulfuric acid as electrolyte, deionized water is solvent, add the monomer that mass fraction is 1% and be made into electrolyte, then with carbon fiber as anode, graphite is negative electrode, at ambient temperature, after carrying out electrolysis polymerization 60s by 90 mA polymerization electric currents, by deionized water, chopped carbon fiber surface is carried out again, thus remove electrolyte ion and the unconverted monomer of remained on surface, finally put it in vacuum drying oven standby in 50 DEG C of dry 12 h.
Step 2: use hot method coating technique, carries out the spherical or the most spheroidal nice foundry sand of dihedral coefficient≤1.1 screening and obtains 70/200 purpose four sieve series sand 1000g, Solid thermoplastic's phenolic resin is ground into the uniform Phenolic resin powder that particle diameter is 60 μm.Nice foundry sand is heated to 200 DEG C, cross after nice foundry sand is cooled to 160 DEG C by 50s and be discharged in sand muller, when nice foundry sand temperature is down to 130 DEG C, 30g phenolic resin (accounting for the 3.0% of nice foundry sand weight) is added thereto, 100s is stirred so that nice foundry sand and phenolic resin are sufficiently mixed and uniform overlay film in puddle mixer.
Step 3: chopped carbon fiber step one processed weighs 50g(and accounts for the 5.0% of nice foundry sand weight) add in the aqueous solution that 5.1g hexa (mass fraction accounting for Phenolic resin powder is 17%) is prepared, add 0.12gHPMC dispersant (mass fraction accounting for hexa is 3.0%), stirred by ultrasonic vibration so that chopped carbon fiber is uniformly dispersed in hexa solution.
Step 4: (mass fraction accounting for Phenolic resin powder is 1% for addition 1.5g part calcium stearate (mass fraction accounting for phenolic resin is 6.0%) and 0.3g coupling agent aqueous solution in step 2 gained precoated sand, it is made into the aqueous solution that mass fraction is 10%), puddle mixer stirring 35s.When precoated sand temperature is down to 110 DEG C, then the hexa solution that step 3 with the addition of chopped carbon fiber adds in precoated sand, and puddle mixer stirring 100s prepares carbon fiber-based sand in coating phenolic resin.
Step 5: 1.5g is remained calcium stearate (mass fraction accounting for phenolic resin is 6.0%) again and adds in the precoated sand prepared, puddle mixer stirring 60s is sufficiently mixed uniformly, puts sand, and water-cooled is to room temperature, broken, screening, i.e. can get the carbon fiber-based precoated sand of selective laser sintering.
Claims (7)
1., for the carbon fiber-based precoated sand material of selective laser sintering, its constituent is: roughing sand 90 ~ 95%, chopped carbon fiber are 2.5 ~ 5.0%, organic binder bond 2.5 ~ 3%, curing agent 0.375 ~ 0.51%, lubricant are 0.0015 ~ 0.0018%, coupling agent is 0.0025 ~ 0.003% and dispersant is 0.1125 ~ 0.153%；Described chopped carbon fiber phosphorus content >=95%, average diameter is 7 ~ 10 μm, a length of 1 ~ 2.5mm, and tensile strength is 3.6 ~ 3.8 GPa, and percentage elongation is 1.5%, and modulus is 220-240 GPa, and bulk density is 1.76 g/cm3；Described chopped carbon fiber uses gamma-ray irradiation process or electrochemical polymerization method to reapply in carbon fiber-based precoated sand material after carrying out surface modification treatment；Described dispersant is hydroxypropyl methyl cellulose HPMC dispersant.
Carbon fiber-based precoated sand material for selective laser sintering the most according to claim 1, it is characterised in that: described roughing sand is spherical or the most spheroidal nice foundry sand, dihedral coefficient≤1.1, and composition is Al2O3>=75%, Fe2O3≤ 5%, TiO2≤ 5%, refractoriness is 1800～2000 DEG C, and the coefficient of thermal expansion under the conditions of heating 10 minutes at 1000 DEG C is 13%, and average grain diameter is less than 0.212mm, granularmetric composition 40～80 mesh.
Carbon fiber-based precoated sand material for selective laser sintering the most according to claim 1, it is characterized in that: described organic binder bond is solid thermoplastics phenolic resin, softening point is 80～90 DEG C, free phenol content≤1.8%, polymerization speed under the conditions of 150 DEG C is 58 ~ 70s, in yellow, transparent cake.
Carbon fiber-based precoated sand material for selective laser sintering the most according to claim 1, it is characterised in that: described curing agent is methenamine, white crystalline powder.
Carbon fiber-based precoated sand material for selective laser sintering the most according to claim 1, it is characterised in that: described lubricant is calcium stearate, the trickleest white powder.
Carbon fiber-based precoated sand material for selective laser sintering the most according to claim 1, it is characterised in that: described coupling agent is silane coupling agent KH-550, colourless transparent liquid.
7. the preparation method of the carbon fiber-based precoated sand material for selective laser sintering according to claim 3, it is characterised in that step is as follows:
Step one: use gamma-ray irradiation facture or electrochemical polymerization method that chopped carbon fiber is carried out surface modification treatment；
Step 2: use hot method coating technique, carry out roughing sand sieving the sand grains obtaining required particle diameter, it is heated to 180 DEG C ~ 200 DEG C again, it is discharged in puddle mixer after roughing sand is cooled to 140 DEG C ~ 160 DEG C, when roughing sand temperature is down to 110 DEG C ~ 130 DEG C, described solid thermoplastics phenolic resin is added thereto so that roughing sand and described solid thermoplastics phenolic resin are sufficiently mixed and uniform overlay film；
Step 3: the chopped carbon fiber after step one being processed joins in curing agent according to a certain percentage, stirs with ultrasonic vibration so that chopped carbon fiber is uniformly dispersed in curing agent solution；
Step 4: add partial lubrication agent and the coupling agent aqueous solution prepared in step 2 gained precoated sand, stirring a period of time, when precoated sand temperature is down to about 100 DEG C, the curing agent that step 3 with the addition of chopped carbon fiber again adds in precoated sand, solid thermoplastics phenolic resin is made to carry out curing reaction under heat effect, formed and a kind of do not melt insoluble material, sand grains is securely bonded together, prepare carbon fiber-based sand in coating phenolic resin；
Step 5: rest lubricant added in the precoated sand prepared, is sufficiently mixed uniformly, puts sand, and water-cooled, to room temperature, crushes, sieves, i.e. can get the carbon fiber-based precoated sand of selective laser sintering.
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| CN106563773A (en) * | 2016-10-19 | 2017-04-19 | 江苏大学 | Method for preventing mixed crystal defect of single crystal blade based on laser heating technology |
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