CN108285332B - 一种3d打印陶瓷型铸造的材料及使用方法 - Google Patents

一种3d打印陶瓷型铸造的材料及使用方法 Download PDF

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CN108285332B
CN108285332B CN201810039108.XA CN201810039108A CN108285332B CN 108285332 B CN108285332 B CN 108285332B CN 201810039108 A CN201810039108 A CN 201810039108A CN 108285332 B CN108285332 B CN 108285332B
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张景豫
郭永斌
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Kocel Intelligent Machinery Ltd
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Abstract

本发明涉及一种3D打印陶瓷型，特别涉及一种3D打印陶瓷型铸造的材料及利用该材料使用3D打印机打印铸造陶瓷型的方法。一种3D打印陶瓷型铸造的材料包括打印成型用粉末材料、喷射用粘结剂，打印成型用粉末材料组分按质量分数包括煅烧铝矾土87‑98%，硅微粉1%‑5%，其它助剂1%‑5%；喷射用粘结剂为硅溶胶，所述硅溶胶粘度为8‑14cp、PH值为7.5‑8.5、SiO2浓度为10‑35%。3D打印陶瓷型铸造的材料利用3D打印机打印铸造陶瓷型，通过混料、打印、烘干、清理、烧结获得陶瓷型。通过本发明获得的陶瓷型抗压强度≥20MPa，陶瓷型表面光滑、质量优异。

Description

一种3D打印陶瓷型铸造的材料及使用方法
技术领域
本发明涉及3D打印领域、陶瓷型铸造领域，具体涉及一种3D打印陶瓷型铸造的材料和陶瓷型。
背景技术
陶瓷型铸造是精密铸造的一种重要方法，已广泛应用于工业生产。目前，陶瓷型的制作主要有两种方式：一种是利用硅酸乙酯的水解液作为粘结剂，与耐火材料配成浆料后，利用模具通过灌浆、结胶、起模、焙烧等工艺烧制而成；另一种是使用模具制作出蜡模后，利用硅溶胶和耐火粉料配制浆料，通过粘浆、撒砂、干燥、焙烧等工艺获得陶瓷壳型。这两种方法中都包含了模具的设计和制作，一种模具只能生产一种零件，不适用于小批量零件的生产，并且模具的制作需要大量的人工成本和材料成本，而且产品的形状也受到模具制作能力的限制；再者，当零件出现改动后，现有的模具基本不再具有利用的价值，也造成了大量的浪费。
发明内容
本发明的技术方案如下：
一种3D打印陶瓷型铸造的材料，其特征在于：包括打印成型用粉末材料、喷射用粘结剂；
所述打印成型用粉末材料按质量分数包括如下组分：煅烧铝矾土87-98%，硅微粉1%-5%，其它助剂1%-5%；
所述粉末材料的颗粒尺寸范围为140目-400目；
所述粉末材料的粒度分布为140目-200目范围占比为5%-15%，200目-270目范围占比为45%-60%，270目-325目范围占比25%-35%，325目-400目范围占比5%-10%；
所述煅烧铝矾土中Al2O3的含量为40-80%，Fe2O3的含量≤8%，灼烧减量≤0.5%；
所述煅烧铝矾土的煅烧温度≤1000℃；
所述硅微粉的SiO2含量≥99%，粒径325目-400目；
所述其它助剂为白云石、锰粉、磷铁矿的一种或多种组合，粒径140目-400目；
所述喷射用粘结剂为硅溶胶，其特征为SiO2浓度10-35%，粘度为8-14cp，PH值为7.5-8.5。
利用以上材料，使用3D打印机打印铸造陶瓷型的方法包括如下步骤：
第一步，打印成型用粉末材料混合均匀；
第二步，接上一步，将粉末放入供粉缸中，用铺粉辊均匀的铺敷一层粉料在3D打印机的升降台上；
第三步，接上一步，打印过程中，利用打印头将硅溶胶均匀的喷涂在粉床上；
第四步，接上一步，重复第二步和第三步至完成所有图形的按序打印；
第五步，接上一步，将打印机工作箱移至微波烘干炉中进行烘干；
第六步，接上一步，清除工作箱中除零件外的其他粉末材料，获得陶瓷型坯体；
第七步，接上一步，将陶瓷型坯体放入高温炉中进行烧结硬化，获得陶瓷型。
优选其中，混料使用三维混料机，也可使用其他类型混合方式；
优选其中，打印头可为压电式喷墨打印头；
优选其中，粉末铺敷的层厚范围为0.05-0.2mm；
优选其中，微波烘干工艺选用两种频率，频率分别为2450MHz和915MHz，用2450MHz加热2min后，停顿1min，再用915MHz加热5min，停顿3min后重复10-20次，加热过程中需保持通风排出挥发的气体；
优选其中，陶瓷型坯体抗压强度应大于3Mpa，避免清理过程中损伤坯体；
优选其中，陶瓷型坯体烧结温度为1100-1300℃，烧结时间为2-5h。
本发明利用微波烘干使硅溶胶300-600℃的范围内失水将粉末材料粘结，并在1100-1200℃的范围内，硅溶胶中和粉末材料中的SiO2与Al2O3发生固溶产生膨胀率低、强度高的莫来石相，过程中不引入杂质。本发明获得的陶瓷型抗压强度≥20MPa，利用硅微粉的烧结获得光滑的陶瓷型表面，陶瓷型质量优异，尤其适用于结构复杂的陶瓷型的制作。
具体实施方式
通过实例对本发明的技术方案作进一步具体说明，但本发明并不限于实施例。
选用经1000℃煅烧的优质铝矾土，其Al2O3含量71.2%，Fe2O3含量为4.45%，灼减量0.1%；硅微粉选用SiO2含量为99.93%的细粉，选325目过筛、 400目未过筛的部分；其它助剂使用300目电解锰粉；按照质量分数煅烧铝矾土96%，硅微粉3%，助剂1%的组分用三维混料仪混合均匀，混合后粒度分布为140目-200目范围12.4%，200目-270目范围53.3%，270目-325目范围占比28.4%，325目-400目范围占比5.9%；选用硅溶胶的参数为SiO2含量为27.3%，粘度为11.3cp，PH值为8.2；用3D打印机进行打印，铺粉层厚为0.12mm，打印头喷墨墨滴大小为20pL，喷墨分辨率为0.04mm；打印结束后，将工作缸取出放入微波炉中进行烘干，用2450MHz加热2min后，停顿1min，再用915MHz加热5min，停顿3min后重复20次，加热过程中需保持通风排出挥发的气体，烘干后用负压吸送的方式清除坯体表面粉末后，其中坯体的抗压强度为4.2Mpa，将坯体放入焙烧炉中在1250℃下焙烧3h后，获得铸造陶瓷型，抗压强度34.6MPa。

Claims (7)

1.一种3D打印陶瓷型铸造的材料，其特征在于：包括打印成型用粉末材料、喷射用粘结剂；
所述打印成型用粉末材料组分按质量分数包括煅烧铝矾土87-98％，硅微粉1％-5％，其它助剂1％-5％；
所述其它助剂为白云石、锰粉、磷铁矿的一种或多种组合；
所述喷射用粘结剂为硅溶胶；
所述硅溶胶的粘度为8-14cp、pH值为7.5-8.5、Si02浓度为10-35％；
所述打印成型用粉末材料的颗粒尺寸范围为140目-400目，粒度分布为140目-200目范围占比为5％-15％，200目-270目范围占比为45％-60％，270目-325目范围占比25％-35％，325目-400目范围占比5％-10％。
2.根据权利要求1所述的3D打印陶瓷型铸造的材料，其特征在于，所述煅烧铝矾土中Al2O3的含量为40-80％，Fe2O3的含量≤8％，灼烧减量≤0.5％，煅烧温度≤1000℃。
3.根据权利要求1所述的3D打印陶瓷型铸造的材料，其特征在于，所述硅微粉的SiO2含量≥99％，粒径325目-400目。
4.根据权利要求1所述的3D打印陶瓷型铸造的材料，其特征在于，所述其它助剂的粒径140目-400目。
5.一种3D打印铸造陶瓷型的制备方法，包括如下步骤：
第一步，将权利要求1-4任一所述的打印成型用粉末材料混合均匀；
第二步，将第一步混合均匀的粉末材料放入供粉缸中，用铺粉辊均匀的铺敷一层粉料在3D打印机的升降台上，粉末铺敷的层厚范围为0.05-0.2mm；
第三步，打印过程中，利用打印头将硅溶胶均匀的喷涂在粉床上；
第四步，重复第二步和第三步至完成所有图形的按序打印；
第五步，将打印机工作箱移至微波烘干炉中进行烘干，微波烘干工艺选用两种频率，频率分别为2450MHz和915MHz，用2450MHz加热2min后，停顿1min，再用915MHz加热5min，停顿3min后重复10-20次，加热过程中需保持通风排出挥发的气体；
第六步，清除工作箱中除零件外的其他粉末材料，获得陶瓷型坯体；
第七步，将陶瓷型坯体放入高温炉中进行烧结硬化，获得陶瓷型。
6.根据权利要求5所述的一种3D打印铸造陶瓷型的制备方法，其特征在于，陶瓷型坯体抗压强度应大于3Mpa，避免清理过程中损伤坯体。
7.根据权利要求6所述的一种3D打印铸造陶瓷型的制备方法，其特征在于，陶瓷型坯体烧结温度为1100-1300℃，烧结时间为2-5h。
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