CN107931764B - 一种陶瓷焊锡喷嘴的生产工艺 - Google Patents
一种陶瓷焊锡喷嘴的生产工艺 Download PDFInfo
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Abstract
一种陶瓷焊锡喷嘴及其生产工艺,其中陶瓷焊锡喷嘴,包括管状的喷嘴本体,所述喷嘴本体中沿长度方向设有圆形的用于注入锡球的内孔,所述内孔的上半截侧壁的采用直伸位构造,所述喷嘴本体的前端设有喷嘴出口,所述内孔的下半截侧壁为从内孔的上半截侧壁的衔接处至喷嘴出口的开口处逐渐缩小的锥形,本发明的焊锡喷嘴采用前端锥度的形式设计,有效的控制卡球的情况发生,在锡球输送到焊锡喷嘴的一瞬间锡球就可沿内孔20度的锥度快速定位,不会出现高度上或是位置上的差别,可快速准确定位后发射激光熔化锡球时以保证锡液的准确温度,能有效保证高精密的焊接。
Description
技术领域
本发明涉及陶瓷焊锡技术领域,具体涉及一种陶瓷焊锡喷嘴及其生产工艺。
背景技术
焊锡行业包括高速精密微锡焊、激光滴锡焊接、激光锡球焊接、球焊、锡珠焊等,图1 为传统锡焊焊接过程的示意图,如图1所示,焊接过程中采用的是激光通过光纤传输,其输出口安装于锡球出口上方,在环形腔体上设置有供高压气进入的入口,通过激光融化锡球,然后高压惰性气体可保证有足够的压力将熔化的锡球滴落,又可以保证熔化的焊锡不会被氧化,焊接精度高,焊接效果好。
该行业中焊锡喷嘴是该套系统内最为关键也最为核心的一个零件,焊锡喷嘴尺寸精度要求高,光洁度同心度及不粘锡抗氧化方面都要求相当高。但是,目前现有的设计技术与加工制约的关系,在原有的焊锡喷嘴设计上只能用钨钢材料做到全锥的形式,而全锥形式焊锡喷嘴的缺点较多:1、锥度长坡度长角度小,因锡球本身的公差及圆度影响在锡球落入时易卡在中间和高度不稳定产生的焊接不良,限制了细小精密焊接要求;2、因内孔角度小锡球熔化后与焊锡喷嘴接触面积大,距离长在焊球熔化时焊锡喷嘴带走的热量影响到焊接结果,造成焊接不稳定等因素。
发明内容
本发明为了解决现有技术存在的上述问题,提供了一种陶瓷焊锡喷嘴及其生产工艺,以解决传统焊锡喷嘴上只能用钨钢材料做到全锥形,而影响焊接质量的问题。
为实现上述目的,本发明提供了一种陶瓷焊锡喷嘴,包括管状的喷嘴本体,所述喷嘴本体中沿长度方向设有圆形的用于注入锡球的内孔,所述内孔的上半截侧壁采用直伸位构造,所述喷嘴本体的前端设有喷嘴出口,所述内孔的下半截侧壁为从内孔的上半截侧壁的衔接处至喷嘴出口的开口处逐渐缩小的锥形。
作为本发明的进一步优选技术方案,所述喷嘴本体的长度为10mm。
作为本发明的进一步优选技术方案,所述内孔为直伸位构造的管径为Φ1.74mm,所述喷嘴出口处的口径为Φ0.49mm,所述内孔的下半截侧壁的锥形夹角角度为20度。
本发明还提供了一种上述任一项所述的陶瓷焊锡喷嘴的生产工艺,具体包括以下步骤:
步骤S1,将配料在密练机中进行充分密练,密练时间为20至30分钟,以使每份材料充分拌匀形成浆;
步骤S2,将密练均匀的浆加入陶瓷注射成型机的料斗内,并采用冷室劲压成型机进行成型,以得到喷嘴毛坯;
步骤S3,将喷嘴毛坯置入耐火治具中,并放入高温炉中进行脱蜡排脂处理;
步骤S4,将脱蜡后的喷嘴毛坯置入烧结治具中,并放入高温烧结炉中进行烧结,其中,烧结温度为1750℃~1860℃,在达到烧结温度后需保持10-12个小时,然后关炉自然冷却至常温;
步骤S5,将烧结好的喷嘴毛坯放入真空高温设备内进行加碳真空发黑处理,其处理时间为48小时,温度为1100℃~1300℃,以使得喷嘴毛坯变成黑色;
步骤S6,将变成黑色的喷嘴毛坯进行研磨和抛光处理,以使其外径和内孔达到设计要求;
步骤S7,将研磨和抛光处理达要求的喷嘴毛坯用10%的稀盐酸进行清洗,再用清水洗净、干燥以得到成品喷嘴。
作为本发明的进一步优选技术方案,所述步骤S1中的配料包括:Al2O3粉末、棕榈酸甘油、酯六甲基磷酰三胺、聚乙烯醇、石墨粉、长石、丙烯酸、烯丙基聚乙二醇和低温石蜡。
作为本发明的进一步优选技术方案,所述配料的质量比为:
Al2O3粉末80-90
棕榈酸甘油0.8-1
酯六甲基磷酰三胺0.5-0.8
聚乙烯醇0.5-1
石墨粉0.1-0.6
长石0.1-0.6
丙烯酸0.3-0.8
烯丙基聚乙二醇0.3-0.8
低温石蜡7.2-10
其中,Al2O3粉末纯度为99.9%以上,其材料粒度为1到3μm。
作为本发明的进一步优选技术方案,所述步骤S3中将喷嘴毛坯置入耐火治具中,并放入高温炉中进行脱蜡排脂处理具体包括以下步骤:
S31,放入承载有喷嘴毛坯的耐火治具,打开高温炉缓慢加热到370-400摄氏度,其中,喷嘴毛坯放入高温炉时炉镗温度不能高于50摄氏度,且升温时段需控制在3-4个小时,以使得喷嘴毛坯内的水分、石蜡在受热时从Al2O3中熔化并气化流出;
S32,炉镗温度达到370摄氏度后保持2-3小时;
S33,将炉镗温度升温到750-800摄氏度并保持2-3小时,以使喷嘴毛坯中各可分解的配料充分分解燃烧、气化,最后关闭高温炉并自然降至常温。
作为本发明的进一步优选技术方案,所述喷嘴毛坯放入耐火治具中时,各喷嘴毛坯之间预留有3mm的间距,以使得其有足够的空间进行蒸发。
作为本发明的进一步优选技术方案,所述步骤S4中将脱蜡后的喷嘴毛坯置入烧结治具中时,各喷嘴毛坯在未施加外力下,依次靠拢并排列整齐。
本发明可以达到如下有益效果:
本发明的陶瓷焊锡喷嘴,通过包括管状的喷嘴本体,所述喷嘴本体中沿长度方向设有圆形的用于注入锡球的内孔,所述内孔的上半截侧壁的采用直伸位构造,所述喷嘴本体的前端设有喷嘴出口,所述内孔的下半截侧壁为从内孔的上半截侧壁的衔接处至喷嘴出口的开口处逐渐缩小的锥形,使得本发明的焊锡喷嘴采用前端锥度的形式设计,有效的控制卡球的情况发生,在锡球输送到焊锡喷嘴的一瞬间锡球就可沿内孔20度的锥度快速定位,不会出现高度上或是位置上的差别,可快速准确定位后发射激光熔化锡球时以保证锡液的准确温度,能有效保证高精密的焊接。
本发明的陶瓷焊锡喷嘴的生产工艺,通过包括以下步骤:将配料在密练机中进行充分密练,密练时间为20至30分钟,以使每份材料充分拌匀形成浆;将密练均匀的浆加入陶瓷注射成型机的料斗内,并采用冷室劲压成型机进行成型,以得到喷嘴毛坯;将喷嘴毛坯置入耐火治具中,并放入高温炉中进行脱蜡排脂处理;将脱蜡后的喷嘴毛坯置入烧结治具中,并放入高温烧结炉中进行烧结,其中,烧结温度为1750℃~1860℃,在达到烧结温度后需保持10-12个小时,然后关炉自然冷却至常温;将烧结好的喷嘴毛坯放入真空高温设备内进行加碳真空发黑处理,其处理时间为48小时,温度为1100℃~1300℃,以使得喷嘴毛坯变成黑色;将变成黑色的喷嘴毛坯进行研磨和抛光处理,以使其外径和内孔达到设计要求;将研磨和抛光处理达要求的喷嘴毛坯用10%的稀盐酸进行清洗,再用清水洗净、干燥以得到成品喷嘴,使得本发明的焊锡喷嘴采用前端锥度的形式设计,有效的控制卡球的情况发生,在锡球输送到焊锡喷嘴的一瞬间锡球就可沿内孔20度的锥度快速定位,不会出现高度上或是位置上的差别,可快速准确定位后发射激光熔化锡球时以保证锡液的准确温度,能有效保证高精密的焊接。
附图说明
下面结合附图和具体实施方式对本发明作进一步详细的说明。
图1为传统锡焊焊接过程的示意图;
图2为本发明陶瓷焊锡喷嘴提供的一实例的结构示意图;
图3为本发明陶瓷焊锡喷嘴的生产工艺提供的一实例的生产工艺流程图。
图中:1、内孔,2、上半截侧壁,3、下半截侧壁,4、喷嘴出口,100、喷嘴本体。
本发明目的实现、功能特点及优点将结合实施例,参照附图做进一步说明。
具体实施方式
下面将结合附图以及具体实施方式,对本发明做进一步描述。较佳实施例中所引用的如“上”、“下”、“左”、“右”、“中间”及“一”等用语,仅为便于叙述的明了,而非用以限定本发明可实施的范围,其相对关系的改变或调整,在无实质变更技术内容下,当亦视为本发明可实施的范畴。
图2为本发明陶瓷焊锡喷嘴提供的一实例的结构示意图,如图2所示,陶瓷焊锡喷嘴包括管状的喷嘴本体100,所述喷嘴本体100中沿长度方向设有圆形的用于注入锡球的内孔 1,所述内孔1的上半截侧壁2采用直伸位构造,所述喷嘴本体100的前端设有喷嘴出口4,所述内孔1的下半截侧壁3为从内孔1的上半截侧壁2的衔接处至喷嘴出口4的开口处逐渐缩小的锥形,本发明的焊锡喷嘴采用前端锥度的形式设计,有效的控制卡球的情况发生,在锡球输送到焊锡喷嘴的一瞬间锡球就可沿内孔120度的锥度快速定位,不会出现高度上或是位置上的差别,可快速准确定位后发射激光熔化锡球时以保证锡液的准确温度,能有效保证高精密的焊接。
具体实施中,所述喷嘴本体100的长度为10mm,所述内孔1为直伸位构造的管径为Φ1.74mm,所述喷嘴出口4处的口径为Φ0.49mm,所述内孔1的下半截侧壁3的锥形夹角角度为20度。
图3为本发明陶瓷焊锡喷嘴的生产工艺提供的一实例的生产工艺流程图,如图3所示,本发明的陶瓷焊锡喷嘴的生产工艺,具体包括以下步骤:
S1,将配料在密练机中进行充分密练,密练时间为20至30分钟,以使每份材料充分拌匀形成浆;
S2,将密练均匀的浆加入陶瓷注射成型机的料斗内,并采用冷室劲压成型机进行成型,以得到喷嘴毛坯;
S3,将喷嘴毛坯置入耐火治具中,并放入高温炉中进行脱蜡排脂处理;
S4,将脱蜡后的喷嘴毛坯置入烧结治具中,并放入高温烧结炉中进行烧结,其中,烧结温度为1750℃~1860℃,在达到烧结温度后需保持10-12个小时,然后关炉自然冷却至常温;
S5,将烧结好的喷嘴毛坯放入真空高温设备内进行加碳真空发黑处理,其处理时间为 48小时,温度为1100℃~1300℃,以使得喷嘴毛坯变成黑色;
S6,将变成黑色的喷嘴毛坯进行研磨和抛光处理,以使其外径和内孔1达到设计要求;
S7,将研磨和抛光处理达要求的喷嘴毛坯用10%的稀盐酸进行清洗,再用清水洗净、干燥以得到成品喷嘴。
其中,在研磨和抛光处理的过程中,先用无芯研磨加工其外径,使其外径达图纸指定尺寸后夹持外径用内外圆磨床加工内孔1,内孔1用带锥度的600#金钢石磨头研磨,内孔1研磨尺寸预留0.01mm,内孔1加工好后用平面磨床研磨两个端面,到图纸指定尺寸;当各尺寸加工好后放入流体抛光设备,用1μm以下的钻石研磨膏加机油对内孔1进行流体抛光,抛光压力控制在3-3.5MPa,时间10分钟左右,确保内孔1尺寸满足图纸要求。
具体实施中,所述步骤S1中的配料包括:Al2O3粉末、棕榈酸甘油、酯六甲基磷酰三胺、聚乙烯醇、石墨粉、长石、丙烯酸、烯丙基聚乙二醇和低温石蜡。
具体实施中,所述配料的质量比为:
Al2O3粉末80-90
棕榈酸甘油0.8-1
酯六甲基磷酰三胺0.5-0.8
聚乙烯醇0.5-1
石墨粉0.1-0.6
长石0.1-0.6
丙烯酸0.3-0.8
烯丙基聚乙二醇0.3-0.8
低温石蜡7.2-10
其中,Al2O3粉末纯度为99.9%以上,其材料粒度为1到3μm。
具体实施中,所述步骤S3中将喷嘴毛坯置入耐火治具中,并放入高温炉中进行脱蜡排脂处理具体包括以下步骤:
S31,放入承载有喷嘴毛坯的耐火治具,打开高温炉缓慢加热到370-400摄氏度,其中,喷嘴毛坯放入高温炉时炉镗温度不能高于50摄氏度,且升温时段需控制在3-4个小时,以使得喷嘴毛坯内的水分、石蜡在受热时从Al2O3中熔化并气化流出;
S32,炉镗温度达370摄氏度后保持2-3小时;
S33,将炉镗温度升温到750-800摄氏度并保持2-3小时,以使喷嘴毛坯中各可分解的配料充分分解燃烧、气化,最后关闭高温炉并自然降至常温;
具体实施中,所述喷嘴毛坯放入耐火治具中时,各喷嘴毛坯之间预留有3mm的间距,以使得其有足够的空间进行蒸发,以使的各毛坯之间有足够的空间进行加热蒸发。
具体实施中,所述步骤S4中将脱蜡后的喷嘴毛坯置入烧结治具中时,各喷嘴毛坯在未施加外力下,依次靠拢并排列整齐,如施加外力则易容导致毛坯损坏,如果每件之间间隙过大则高温烧结时又易容使毛坯变形,因此多件毛坯需相互依靠排列,使毛坯间相互支撑,又不能用外力压堆在一起。
虽然以上描述了本发明的具体实施方式,但是本领域熟练技术人员应当理解,这些仅是举例说明,可以对本实施方式做出多种变更或修改,而不背离本发明的原理和实质,本发明的保护范围仅由所附权利要求书限定。
Claims (4)
1.一种陶瓷焊锡喷嘴的生产工艺,其特征在于,
所述陶瓷焊锡喷嘴包括管状的喷嘴本体,所述喷嘴本体中沿长度方向设有圆形的用于注入锡球、激光和氮气的内孔,所述内孔的上半截侧壁采用直伸位构造,所述喷嘴本体的前端设有喷嘴出口,所述内孔的下半截侧壁为从内孔的上半截侧壁的衔接处至喷嘴出口的开口处逐渐缩小的锥形;其中,所述喷嘴本体的长度为10mm,所述内孔为直伸位构造的管径为Φ1.74mm,所述喷嘴出口处的口径为Φ0.49mm,所述内孔的下半截侧壁的锥形夹角角度为20度;
陶瓷焊锡喷嘴的生产工艺包括以下步骤:
S1,将配料在密练机中进行充分密练,密练时间为20至30分钟,以使每份材料充分拌匀形成浆,所述配料为以下质量比的组分:
Al2O3粉末80-90
棕榈酸甘油0.8-1
酯六甲基磷酰三胺0.5-0.8
聚乙烯醇0.5-1
石墨粉0.1-0.6
长石0.1-0.6
丙烯酸0.3-0.8
烯丙基聚乙二醇0.3-0.8
低温石蜡7.2-10
其中,Al2O3粉末纯度为99.9%以上,其材料粒度为1到3μm;
S2,将密练均匀的浆加入陶瓷注射成型机的料斗内,并采用冷室劲压成型机进行成型,以得到喷嘴毛坯;
S3,将喷嘴毛坯置入耐火治具中,并放入高温炉中进行脱蜡排脂处理;
S4,将脱蜡后的喷嘴毛坯置入烧结治具中,并放入高温烧结炉中进行烧结,其中,烧结温度为1750℃~ 1860℃,在达到烧结温度后需保持10-12个小时,然后关炉自然冷却至常温;
S5,将烧结好的喷嘴毛坯放入真空高温设备内进行加碳真空发黑处理,其处理时间为48小时,温度为1100℃~ 1300℃,以使得喷嘴毛坯变成黑色;
S6,将变成黑色的喷嘴毛坯进行研磨和抛光处理,以使其外径和内孔达到设计要求;
S7,将研磨和抛光处理达要求的喷嘴毛坯用10%的稀盐酸进行清洗,再用清水洗净、干燥以得到成品喷嘴。
2.根据权利要求1所述的陶瓷焊锡喷嘴的生产工艺,其特征在于,所述步骤S3中将喷嘴毛坯置入耐火治具中,并放入高温炉中进行脱蜡排脂处理具体包括以下步骤:
S31,放入承载有喷嘴毛坯的耐火治具,打开高温炉缓慢加热到370摄氏度,其中,喷嘴毛坯放入高温炉时炉膛温度不能高于50摄氏度,且升温时段需控制在3-4个小时,以使得喷嘴毛坯内的水分、石蜡在受热时从Al2O3中熔化并气化流出;
S32,炉膛温度达到370摄氏度后保持2-3小时;
S33,将炉膛温度升温到750-800摄氏度并保持2-3小时,以使喷嘴毛坯中各可分解的配料充分分解燃烧、气化,最后关闭高温炉并自然降至常温。
3.根据权利要求2所述的陶瓷焊锡喷嘴的生产工艺,其特征在于,所述喷嘴毛坯放入耐火治具中时,各喷嘴毛坯之间预留有3mm的间距,以使得其有足够的空间进行蒸发。
4.根据权利要求3所述的陶瓷焊锡喷嘴的生产工艺,其特征在于,所述步骤S4中将脱蜡后的喷嘴毛坯置入烧结治具中时,各喷嘴毛坯在未施加外力下,依次靠拢并排列整齐。
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