CN108311644B - Casting mold and casting method of solid solution reinforced ferrite nodular cast iron wind power casting - Google Patents
Casting mold and casting method of solid solution reinforced ferrite nodular cast iron wind power casting Download PDFInfo
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- CN108311644B CN108311644B CN201810230327.6A CN201810230327A CN108311644B CN 108311644 B CN108311644 B CN 108311644B CN 201810230327 A CN201810230327 A CN 201810230327A CN 108311644 B CN108311644 B CN 108311644B
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- 238000005266 casting Methods 0.000 title claims abstract description 156
- 238000000034 method Methods 0.000 title claims abstract description 35
- 229910001141 Ductile iron Inorganic materials 0.000 title claims abstract description 29
- 229910000859 α-Fe Inorganic materials 0.000 title claims abstract description 26
- 239000006104 solid solution Substances 0.000 title claims abstract description 20
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 164
- 229910052742 iron Inorganic materials 0.000 claims abstract description 82
- 239000004576 sand Substances 0.000 claims abstract description 14
- 239000002893 slag Substances 0.000 claims abstract description 11
- 244000035744 Hura crepitans Species 0.000 claims abstract description 9
- 238000010438 heat treatment Methods 0.000 claims abstract description 9
- 238000005728 strengthening Methods 0.000 claims abstract description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 6
- PMVSDNDAUGGCCE-TYYBGVCCSA-L Ferrous fumarate Chemical compound [Fe+2].[O-]C(=O)\C=C\C([O-])=O PMVSDNDAUGGCCE-TYYBGVCCSA-L 0.000 claims abstract description 4
- 238000011081 inoculation Methods 0.000 claims description 16
- 239000002054 inoculum Substances 0.000 claims description 9
- 238000003723 Smelting Methods 0.000 claims description 7
- 238000011144 upstream manufacturing Methods 0.000 claims description 7
- 229910000519 Ferrosilicon Inorganic materials 0.000 claims description 5
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 5
- 229910000861 Mg alloy Inorganic materials 0.000 claims description 4
- NCJRLCWABWKAGX-UHFFFAOYSA-N [Si].[Ca].[Ba] Chemical compound [Si].[Ca].[Ba] NCJRLCWABWKAGX-UHFFFAOYSA-N 0.000 claims description 4
- 238000011010 flushing procedure Methods 0.000 claims description 4
- 238000010183 spectrum analysis Methods 0.000 claims description 4
- 238000001816 cooling Methods 0.000 claims description 3
- 238000004088 simulation Methods 0.000 claims description 3
- 229910052717 sulfur Inorganic materials 0.000 claims description 3
- 239000011449 brick Substances 0.000 claims description 2
- 239000000919 ceramic Substances 0.000 claims description 2
- 239000004927 clay Substances 0.000 claims description 2
- 239000006260 foam Substances 0.000 claims description 2
- 229910052751 metal Inorganic materials 0.000 claims description 2
- 239000002184 metal Substances 0.000 claims description 2
- 230000007547 defect Effects 0.000 abstract description 5
- 238000009413 insulation Methods 0.000 abstract description 4
- 238000009826 distribution Methods 0.000 abstract description 2
- 239000000463 material Substances 0.000 description 20
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 13
- 238000004519 manufacturing process Methods 0.000 description 12
- 229910000805 Pig iron Inorganic materials 0.000 description 10
- 229910000831 Steel Inorganic materials 0.000 description 10
- 239000010959 steel Substances 0.000 description 10
- 230000008569 process Effects 0.000 description 9
- 229910002804 graphite Inorganic materials 0.000 description 7
- 239000010439 graphite Substances 0.000 description 7
- 229910052799 carbon Inorganic materials 0.000 description 6
- 239000002699 waste material Substances 0.000 description 6
- 239000002131 composite material Substances 0.000 description 5
- 239000011159 matrix material Substances 0.000 description 5
- 229910001018 Cast iron Inorganic materials 0.000 description 4
- 239000003795 chemical substances by application Substances 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 4
- 239000011572 manganese Substances 0.000 description 4
- 238000010079 rubber tapping Methods 0.000 description 4
- 238000010792 warming Methods 0.000 description 4
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 3
- 239000000956 alloy Substances 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 3
- 239000011574 phosphorus Substances 0.000 description 3
- 229910052698 phosphorus Inorganic materials 0.000 description 3
- 238000011160 research Methods 0.000 description 3
- 229910052710 silicon Inorganic materials 0.000 description 3
- 238000009423 ventilation Methods 0.000 description 3
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 2
- 229910052788 barium Inorganic materials 0.000 description 2
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 2
- 229910052791 calcium Inorganic materials 0.000 description 2
- 239000011575 calcium Substances 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- TXKMVPPZCYKFAC-UHFFFAOYSA-N disulfur monoxide Inorganic materials O=S=S TXKMVPPZCYKFAC-UHFFFAOYSA-N 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000005496 eutectics Effects 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 229910052748 manganese Inorganic materials 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000010703 silicon Substances 0.000 description 2
- 238000006467 substitution reaction Methods 0.000 description 2
- XTQHKBHJIVJGKJ-UHFFFAOYSA-N sulfur monoxide Chemical compound S=O XTQHKBHJIVJGKJ-UHFFFAOYSA-N 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- FQNGWRSKYZLJDK-UHFFFAOYSA-N [Ca].[Ba] Chemical compound [Ca].[Ba] FQNGWRSKYZLJDK-UHFFFAOYSA-N 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 229910001567 cementite Inorganic materials 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- KSOKAHYVTMZFBJ-UHFFFAOYSA-N iron;methane Chemical compound C.[Fe].[Fe].[Fe] KSOKAHYVTMZFBJ-UHFFFAOYSA-N 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000005457 optimization Methods 0.000 description 1
- 229910001562 pearlite Inorganic materials 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 150000002910 rare earth metals Chemical class 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 150000004763 sulfides Chemical class 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/082—Sprues, pouring cups
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/20—Measures not previously mentioned for influencing the grain structure or texture; Selection of compositions therefor
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C1/00—Refining of pig-iron; Cast iron
- C21C1/10—Making spheroidal graphite cast-iron
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/08—Making cast-iron alloys
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
Abstract
The invention discloses a casting mould and a casting method of a solid solution strengthening ferrite nodular cast iron wind power casting, wherein the casting mould comprises a sand box, a sand mould and a core, and a cavity structure formed by combining the sand mould and the core comprises the following components: the casting mould is provided with: the shape of the casting cavity is fit with the shape of the wind power casting, and a plurality of risers are arranged on the casting cavity; the pouring system comprises at least one iron inlet, at least one molten iron main runner, a central split-flow cavity, a plurality of molten iron runners and a plurality of filters; and the heating system comprises a plurality of hot air channels which are communicated and arranged above the casting cavity. In the casting mould, the pouring system is reasonable in distribution, the pouring time can be greatly shortened by a plurality of iron water runners, the iron feeding stability is ensured, and the defects of cold insulation and slag inclusion of castings can be effectively avoided by combining the use of the filter. The riser is arranged to ensure riser feeding of the cavity.
Description
Technical Field
The invention belongs to the technical field of casting, and particularly relates to a casting mold and a casting method of a solid solution reinforced ferrite nodular cast iron wind power casting.
Background
At present, with the increase of wind power market competition, wind power manufacturers develop high-power generator sets on one hand and control manufacturing cost on the other hand, and the light weight of the wind generator sets has become a trend, which requires that wind power castings must use wind power materials with higher strength.
Si is the most commonly used element in cast iron, and can strengthen ferrite and improve strength of ferrite. However, si has been previously thought to embrittle spheroidal graphite cast iron. In 1949, the first U.S. ductile iron patent to Mills believed that increasing the w (Si) content (> 2.5%) significantly reduced mechanical properties, particularly toughness, tensile strength, and ductility. In practical production and subsequent studies, the above expression was found to have great limitations, and in 1998 sweden has specified the production of QT450 with a w (Si) amount of 3.2%, the production of QT500 with a w (Si) amount of 3.7% and the production of QT500 with a w (Si) amount of 3.7%. The swedish indictor company considers that for the grade of 500MPa of tensile strength, si solid solution is utilized to strengthen ferrite, the elongation after breaking of the ferrite nodular cast iron is 2 times that of the conventional ferrite-pearlite nodular cast iron, meanwhile, the yield strength is increased, the yield ratio is increased from 0.6 to 0.8, the impact performance is slightly excellent, the production difficulty is overcome, and the Si reinforced nodular cast iron and ADI are called as second generation nodular cast iron. To date, 3 ductile iron patents reinforced with Si have been granted in the united states, etc., and countries such as finland have begun to use in production. At present, a plurality of foreign wind power complete machine enterprises have listed the novel material as a project for important development and research, and the novel material is intended for wind power castings.
At present, a plurality of foreign wind power manufacturers are researching and applying the material to wind power castings and do a great deal of research work, and some powerful wind power manufacturers in China start to develop towards the direction. On one hand, the silicon solid solution reinforced ferrite nodular cast iron is used as a novel wind power material, and on the other hand, the wall thickness of the casting can be reduced due to high yield ratio and good elongation, so that the weight of the casting is reduced. On the other hand, the weight reduction of the casting is beneficial to the reduction of the manufacturing cost, and the weight and the cost of the whole machine are also greatly reduced. Therefore, research and application of the novel wind power material have become an imperative trend.
However, compared with the common material, the cast silicon solid solution reinforced ferrite nodular cast iron material has poor molten iron flow property, has certain uniqueness and complexity in smelting process, modeling process and other aspects, and particularly has the problems of large slag inclusion tendency, larger shrinkage porosity tendency and the like when the material is used for casting wind power castings with large size and complex structure, so that the wind power castings of the material cannot be produced in mass, and the improvement of the process for casting the wind power castings of the material is urgently needed.
Disclosure of Invention
The invention aims to provide a casting mould of a solid solution reinforced ferrite nodular cast iron wind power casting, and the casting mould is used for casting the solid solution reinforced ferrite nodular cast iron wind power casting, so that the phenomena of slag inclusion and shrinkage porosity can be effectively solved, the performance of the wind power casting is improved, and meanwhile, mass production can be realized.
The casting mould of the solid solution strengthening ferrite nodular cast iron wind power casting comprises a sand box, a sand mould and a core, and is characterized in that the cavity structure of the casting mould comprises:
the wind power casting comprises a casting cavity, wherein the casting cavity is formed by combining a sand mold and a core, the shape of the casting cavity is matched with the shape of a wind power casting, and a plurality of risers are arranged on the casting cavity;
the pouring system comprises at least one iron inlet, at least one molten iron main runner, a central split cavity and a plurality of molten iron split runners, wherein the molten iron main runner and the molten iron split runners are arranged at the bottom of the casting mold, and the central split cavity is arranged at the central position of the bottom of the casting mold; the upstream of the molten iron main runner is communicated with the iron inlet, and the downstream of the molten iron main runner is communicated with the central split-flow cavity; the iron water flow passages are uniformly distributed in a divergent mode, the upstream is communicated with the central split cavity, the downstream tail end is communicated with the casting cavity, and the iron water flow passages are respectively provided with a filter; and
the heating system comprises a plurality of hot air channels, and the hot air channels are communicated and arranged above the casting cavity.
When the casting mold is manufactured, the manufacturing process is the same as that of a common casting mold, the sand mold is formed by falling sand into a sand box, a pouring system, a heating system and a central cavity are reserved in the sand mold, then a core is placed into the central cavity, the casting mold is formed after the mold is closed, the sand mold and the core are combined, and a casting cavity is formed in the middle.
In a preferred embodiment of the invention, the wind power casting is a wind power base, the wind power base comprises a bottom flange, a special-shaped curved surface and a hub mounting ring, the bottom flange is arranged at the bottom of the special-shaped curved surface, and the hub mounting ring is arranged at one side of the upper part of the special-shaped curved surface; and the shape of the casting cavity is fit with the shape of the wind power base.
Preferably, the inner wall of the pouring system adopts clay refractory bricks; the filter is a foam ceramic filter sheet.
Preferably, the sand box is a plastic box or a metal box.
The invention also aims to disclose a casting method of the solid solution reinforced ferrite nodular cast iron wind power casting, which comprises the following steps:
(a) Smelting furnace burden into molten iron; and (3) adjusting the furnace charge components through spectrum analysis, and controlling the carbon equivalent C in the molten iron: 3.4 to 3.5 percent, si:3.7 to 4.0 percent, mn:0.1 to 0.35 percent, P: < 0.04%, S: less than or equal to 0.012 percent, mg:0.04 to 0.07 percent, cr: < 0.05%, ti: less than 0.03%;
(b) Spheroidizing and inoculating molten iron;
(c) Pouring into the casting mould, filling and solidifying to obtain the casting.
By the method, the cast casting can meet the following requirements:
(1) Metallographic structure: ferrite and graphite nodules, wherein the ferrite is more than or equal to 95 percent, (cementite and phosphoeutectic) is less than 0.5 percent, the spheroidization rate is more than or equal to 90 percent, and the graphite nodules reach more than 5 grades of ISO 945 standard;
(2) Mechanical properties: the tensile strength Rm is more than or equal to 530MPa, the yield strength Rp0.2 is more than or equal to 400MPa, and the elongation A is more than or equal to 12.5%.
(3) -20 ℃ low temperature unnotched impact energy: the single value of the three samples is more than or equal to 5J, and the average value is more than or equal to 7J;
(4) Core nondestructive test, wherein UT of an important area meets 2 stages of EN12680-3, and the rest meets 3 stages; surface nondestructive inspection, MT of important areas meets grade 2 of EN1369, and the rest meets grade 3.
The composition of the material elements is comprehensively considered and controlled in the step a of the method of the invention.
Wherein, the C content has a great influence on the fluidity of the spheroidal graphite cast iron, and the improvement of the C content can improve the fluidity of the spheroidal graphite cast iron, and when the C content is 3.4-3.5%, the fluidity is the best, thereby being beneficial to casting forming and feeding.
The Si content influences the strength and the elongation of the spheroidal graphite cast iron, and the strength of the spheroidal graphite cast iron can be improved by improving the Si content, but the elongation can be reduced, and the mechanical property can meet the requirement when the Si content is 3.7-4.0%.
Mn has adverse effects on impact toughness and brittle transition temperature of spheroidal graphite cast iron, so low-manganese pig iron and scrap steel are selected as raw materials, and Mn content is controlled to be 0.1% -0.35%.
P is a harmful element, its solubility in cast iron is extremely low, and when its content is less than 0.05%, it is solid-dissolved in matrix, and has little effect on mechanical properties. When the content is more than 0.05%, phosphorus is extremely easy to segregate at the boundary of eutectic cells to form binary, ternary or composite phosphorus eutectic, the toughness of cast iron is reduced, and the toughness and brittleness transition temperature of cast iron are improved by phosphorus, so that the P content is controlled to be less than 0.04%.
S can consume a large amount of spheroidizing elements in the molten iron to form sulfides of magnesium and rare earth, and casting defects such as slag inclusion, air holes and the like are caused, so that the S content is controlled to be less than or equal to 0.012 percent
In order to realize the control of elements, the components of the furnace burden are preferably as follows: 40-50% of new pig iron, 30-40% of returned furnace material and 10-20% of scrap steel.
Further, the new pig iron is high-purity pig iron, wherein C: 4.0% or more, mn: less than or equal to 0.10 percent, P: less than or equal to 0.025 percent, S: less than or equal to 0.015 percent, and the sum of the anti-spheroidizing harmful alloy elements is less than or equal to 0.08 percent; the waste steel is sheet carbon waste steel, wherein C: less than or equal to 0.15 percent, mn: less than or equal to 0.40 percent, P: less than or equal to 0.03 percent, S: less than or equal to 0.03 percent.
Proper components of the nodulizer and the inoculant are selected, and the nodulizing process, the inoculation process and the like are optimized, so that the performance requirements of large-scale wind power castings can be met, and the stability of casting production and the consistency of product performance can be ensured. The components and the treatment process of the nodulizer and the inoculant which are suitable for new materials of wind power castings are prepared, and the castings with good metallographic structure, no broken graphite, nail graphite and other special-shaped graphite appear, round graphite balls, a large number of graphite balls and good comprehensive mechanical properties are obtained.
Preferably, in the step b, a low-rare earth ferrosilicon magnesium alloy nodulizer is selected, preferably 50% of Aiken 5813+50% of subpeak YFQ-55A is adopted, and a flushing method is adopted for spheroidizing, wherein the adding amount of the nodulizer is 1.0% -1.2%; the method comprises the following steps: the spheroidizing agent is pre-buried in a ladle and moderately compacted, spheroidizing treatment is carried out, the spheroidizing reaction is started when the iron yield is two thirds, and the iron tapping temperature is controlled to be 1400-1470 ℃ before the spheroidizing is carried out.
Preferably, in the step b, a silicon-calcium-barium inoculant is selected for inoculation, the addition amount of the inoculant is 0.6-0.65% of the weight of molten iron, and the inoculation is divided into secondary inoculation, specifically: the covering inoculation is added on the surface of molten iron before and after spheroidizing slag skimming, and the stream inoculation is added into the molten iron in the casting process. Preferably, the covering inoculation adopts the Rankine high calcium barium with the thickness of 3-8mm and the addition amount is 0.5%; stream inoculation adopts 0.2-0.7mm of Rankine thioxy, and the addition amount is 0.10-0.15%.
Preferably, the casting temperature in the step c is 1360-1370 ℃.
Preferably, before pouring in the step c, the casting cavity is ventilated and warmed by hot air at about 150 ℃ through the hot air channel.
Preferably, MAGMA or Any casting software is adopted for cooling simulation, and a chill is additionally arranged at a position where shrinkage porosity is easy to generate.
The invention has the beneficial effects that:
in the casting mould, the pouring system is reasonable in distribution, the pouring time can be greatly shortened by a plurality of iron water runners, the iron feeding stability is ensured, and the defects of cold insulation and slag inclusion of castings can be effectively avoided by combining the use of the filter. The riser is arranged in a targeted mode, and riser feeding of the die cavity can be guaranteed.
In the casting method, the reasonable design of the casting mould, the control of chemical components, the selection of nodulizing agent and inoculant, the optimization of the process of nodulizing and inoculation, the design of a pouring system, the arrangement of a cold iron riser, the setting of the hot air temperature of a cavity and the like are adopted. The casting problems of shrinkage porosity, slag inclusion, cold insulation, deformation and the like which are easy to generate in the casting process can be effectively solved, the mechanical property of the wind power casting can be effectively improved, and the production can be realized.
The hardness of the EN-GJS-600-10 casting of the full ferrite matrix produced by the method adopting the solid solution strengthening principle is distributed uniformly, so that the full ferrite matrix has better cutting processability, prolongs the service life of a cutter and reduces the machining cost.
Drawings
FIG. 1 is a schematic view of a composite chassis;
FIG. 2 is a schematic perspective view of a casting cavity, a gating system and a warming system within a mold of the present invention;
FIG. 3 is a schematic bottom view of a casting cavity, gating system and warming system within a mold of the present invention;
FIG. 4 is a schematic perspective view of a mold cavity and casting system within a conventional mold;
fig. 5 is a schematic bottom view of a mold cavity and a casting system within a conventional mold.
Reference numerals
The bottom flange 11, the special-shaped curved surface 12 and the hub mounting ring 13;
the casting mould comprises: a casting cavity 21; the casting system 22, a tapping hole 221, a molten iron main runner 222, a central split cavity 223, a molten iron split runner 224 and a filter 225; a warming system 23; riser 24;
ordinary casting: casting cavity 31; a casting system 32.
Detailed Description
The invention will be further illustrated with reference to specific examples. It should be understood that the following examples are illustrative of the present invention and are not intended to limit the scope of the present invention.
Example 1 casting mold for wind power base
Fig. 1 shows a GE3.2MW-130 integrated base, which comprises a bottom flange 11, a special-shaped curved surface 12 and a hub mounting ring 13, wherein the bottom flange 11 is arranged at the bottom of the special-shaped curved surface 12, and the hub mounting ring 13 is arranged at one side of the upper part of the special-shaped curved surface 12. The wind power base has the weight of 18.17T, the maximum size of 4042mm x 3600mm x 3010mm, the main wall thickness of 70-200mm and the material of QT600-10.
Taking the GE3.2MW-130 integrated base (QT 600-10) as an example, the casting mould of the solid solution reinforced ferrite nodular cast iron wind power casting correspondingly designed by the invention comprises a sand box, a sand mould and a core. The sand mould is formed by falling sand into a sand box, then a core is put into the sand box, and the mould is formed after mould assembling. The casting mold is provided with: a casting cavity 21, a pouring system 22 and a warming system 23. The casting cavity 21, the pouring system 22 and the heating system 23 are used as internal structures and are composed of a sand mold and a core, the combined shape of the casting cavity 21 is shown in fig. 2 and 3, the shape of the casting cavity 21 is fit with the shape of the wind power base, and a plurality of risers 24 are arranged on the casting cavity. The pouring system 22 comprises at least one iron inlet 221, two molten iron main runners 222, a central split cavity 223 and 9 molten iron runners 224, wherein the molten iron main runners 222 and the molten iron split runners 224 are arranged at the bottom of the casting mold, and the central split cavity 223 is arranged at the central position of the bottom of the casting mold; the upstream of the molten iron main runner 22 is communicated with the iron inlet 221, and the downstream is communicated with the central split cavity 223; the iron water channels 222 are uniformly distributed in a divergent mode, the upstream is communicated with the central diversion cavity 223, the downstream tail end is communicated with the casting cavity 21, and filters 225 are respectively arranged on the 9 iron water channels 224. The heating system 23 comprises a plurality of hot air channels which are communicated and arranged above the casting cavity 21.
Example 2 casting of a composite base (QT 600-10) of GE3.2MW-130 using the mold of example 1
Casting:
(a) Molten iron smelting
Charging material: 40-50% of new pig iron, 30-40% of returned furnace material and 10-20% of scrap steel.
Further, the new pig iron is high-purity pig iron, wherein C: 4.0% or more, mn: less than or equal to 0.10 percent, P: less than or equal to 0.025 percent, S: less than or equal to 0.015 percent, and the sum of the anti-spheroidizing harmful alloy elements is less than or equal to 0.08 percent; the waste steel is sheet carbon waste steel, wherein C: less than or equal to 0.15 percent, mn: less than or equal to 0.40 percent, P: less than or equal to 0.03 percent, S: less than or equal to 0.03 percent.
Smelting furnace burden into molten iron; and (3) adjusting the furnace charge components through spectrum analysis, and controlling the carbon equivalent C in the molten iron: 3.4 to 3.5 percent, si:3.7 to 4.0 percent, mn:0.1 to 0.35 percent, P: < 0.04%, S: less than or equal to 0.012 percent, mg:0.04 to 0.07 percent, cr: < 0.05%, ti: less than 0.03%;
(b) Spheroidizing and inoculating
Selecting a low-rare earth ferrosilicon magnesium alloy nodulizer (50% of Aiken 5813+50% of subpeaks YFQ-55A), and performing spheroidization by adopting a flushing method, wherein the adding amount of the nodulizer is 1.0% -1.2%; the method comprises the following steps: the spheroidizing agent is pre-buried in a ladle and moderately compacted, spheroidizing treatment is carried out, the spheroidizing reaction is started when the iron yield is two thirds, and the iron tapping temperature is controlled to be 1400-1470 ℃ before the spheroidizing is carried out.
Inoculating silicon-calcium-barium inoculant with the addition of 0.6-0.65% of the weight of molten iron, and inoculating twice, wherein the inoculating method specifically comprises the following steps: the covering inoculation (0.5% of the Aiken high-calcium barium 3-8 mm) is added on the surface of molten iron before and after spheroidizing slag skimming, and the stream inoculation (0.10-0.15% of the Aiken sulfur oxide 0.2-0.7 mm) is added into the molten iron in the pouring process.
(c) Filling type
And (3) ventilating and heating the casting cavity through the hot air channel by using hot air at the temperature of about 150 ℃. And (3) after Wen Man h of ventilation, pouring the spheroidized and inoculated molten iron into the casting mould of the embodiment 1, and filling and solidifying to obtain the casting.
And (3) cooling simulation is carried out by MAGMA or Any casting software, and a chiller is additionally arranged at a position where shrinkage porosity is easy to generate in the mould throwing process.
The method has the advantages that:
1. the molten iron flows through the pouring system, is split by 9 molten iron flow passages and filtered by 9 filters and then enters the casting cavity, so that the purity of molten iron and the charging of the molten iron can be ensured to be uniform and stable, the pouring time is shortened, and the slag inclusion defect of the casting can be avoided as much as possible.
2. The casting cavity is subjected to heating treatment through pre-ventilation, so that the cold insulation phenomenon is effectively avoided; meanwhile, the chill is placed at the position where shrinkage porosity is easy to occur, so that shrinkage porosity can be effectively avoided.
3. The hardness of the full ferrite matrix EN-GJS-600-10 cast piece produced by adopting the solid solution strengthening principle is uniformly distributed, so that the full ferrite matrix EN-GJS-600-10 cast piece has better cutting processability, the service life of a cutter is prolonged, and the machining cost is reduced.
Comparative example 1 casting GE2.5MW-120 Combined base (QT 400-18) using a conventional casting mold
GE2.5MW-120 the integrated base has the same structure as the GE3.2MW-130 integrated base of embodiment 1, and comprises a bottom flange, a special-shaped curved surface and a hub mounting ring. The wind power base has the weight of 18.66T, the maximum size of 4022mm is 3920mm, the main wall thickness of 60-128mm and the material of QT400-18.
Taking GE2.5MW-120 integrated base (QT 400-18) as an example, a common casting mold is adopted in comparative example 1, and the casting mold is provided with: the shape of the casting cavity 31 fits the shape of the wind power base and is raised laterally, and a plurality of air vents are arranged on the casting cavity as shown in fig. 4 and 5. The pouring system comprises two iron inlets, a filtering system and two molten iron main runners; the upstream of the molten iron main runner is communicated with the iron inlet, and the downstream is introduced into the casting cavity.
Casting:
(a) Molten iron smelting
Charging material: 55-75% of new pig iron, 20-35% of returned furnace material and 5-20% of scrap steel.
Further, the new pig iron is high-purity pig iron, wherein C: 4.0% or more, mn: less than or equal to 0.10 percent, P: less than or equal to 0.025 percent, S: less than or equal to 0.015 percent, and the sum of the anti-spheroidizing harmful alloy elements is less than or equal to 0.08 percent; the waste steel is sheet carbon waste steel, wherein C: less than or equal to 0.15 percent, mn: less than or equal to 0.40 percent, P: less than or equal to 0.03 percent, S: less than or equal to 0.03 percent.
Smelting furnace burden into molten iron; and (3) adjusting the furnace charge components through spectrum analysis, and controlling the carbon equivalent C in the molten iron: 3.75 to 3.85 percent of Si:1.8 to 2.4 percent of Mn:0.1 to 0.35 percent, P: less than or equal to 0.04 percent, S: less than or equal to 0.012 percent, mg:0.04 to 0.07 percent, cr: < 0.05%, ti: less than 0.03%;
(b) Spheroidizing and inoculating
Selecting a low-rare earth ferrosilicon magnesium alloy nodulizer (Aiken 5813), and performing spheroidization by adopting a flushing method, wherein the adding amount of the nodulizer is 1.0% -1.1%; the method comprises the following steps: the spheroidizing agent is pre-buried in a ladle and moderately compacted, spheroidizing treatment is carried out, the spheroidizing reaction is started when the iron yield is two thirds, and the iron tapping temperature is controlled to be 1400-1470 ℃ before the spheroidizing is carried out.
Inoculating silicon-calcium-barium inoculant with the addition of 0.7-1.25% of the weight of molten iron, and inoculating for three times, wherein the inoculating method specifically comprises the following steps: the covering inoculation (0.2-0.3% of 75 ferrosilicon inoculant 3-8 mm) is added on the surface of molten iron before spheroidizing slagging-off, the primary inoculation (0.4-0.8% of Aiken high-calcium barium 3-8 mm) is added on the surface of molten iron after spheroidizing slagging-off, and stream inoculation (0.10-0.15% of Aiken sulfur oxide 0.2-0.7 mm) is added into molten iron in the casting process.
(c) Filling type
And (3) ventilating and heating the casting cavity through the hot air channel by using hot air at the temperature of about 150 ℃. And (5) after Wen Man hours of ventilation, pouring the spheroidized and inoculated molten iron into a casting mould for filling and solidifying to obtain the casting.
Performance analysis was performed on the wind power bases cast in example 2 and comparative example 1, respectively
Example 2: GE3.2MW-130 composite base, which is made of QT600-10, has tensile strength of greater than or equal to 530MPa,0.2% yield strength of greater than or equal to 400MPa, elongation of greater than or equal to 12.5%, and impact resistance (no defects) at-20+/-2 ℃: the impact average value of the three samples is more than or equal to 7J, and the single impact average value is not less than 5J.
Comparative example 1: GE2.5MW-120 composite base, which is made of QT400-18, and has tensile strength of more than or equal to 370MPa,0.2% yield strength of more than or equal to 220MPa, elongation of more than or equal to 12%, and impact resistance (no notch) at-20+/-2℃: the impact average value of the three samples is more than or equal to 10J, and the single impact average value is not less than 7J.
To sum up: 1. the solid solution strengthening ferrite nodular cast iron wind power casting has better mechanical property combination (tensile strength, yield strength and elongation), and can lead the designer to reduce the wall thickness of the casting, thereby reducing the weight of the casting. 2. The solid solution strengthening ferrite nodular cast iron wind power casting has larger slag inclusion and shrinkage porosity tendency, and has higher requirements on various parameters such as the purity of molten iron, the molten iron components, the casting temperature and the like.
While the preferred embodiments of the present invention have been illustrated and described, the present invention is not limited to the embodiments, and various equivalent modifications and substitutions can be made by one skilled in the art without departing from the spirit of the present invention, and these equivalent modifications and substitutions are intended to be included in the scope of the present invention as defined in the appended claims.
Claims (4)
1. The casting method of the solid solution strengthening ferrite nodular cast iron wind power casting adopts a casting mould comprising a sand box, a sand mould and a core, and is characterized in that the cavity structure of the casting mould comprises:
the wind power casting comprises a casting cavity, wherein the casting cavity is formed by combining a sand mold and a core, the shape of the casting cavity is matched with the shape of a wind power casting, and a plurality of risers are arranged on the casting cavity; the wind power casting is a wind power base, the wind power base comprises a bottom flange, a special-shaped curved surface and a hub mounting ring, the bottom flange is arranged at the bottom of the special-shaped curved surface, and the hub mounting ring is arranged at one side of the upper part of the special-shaped curved surface; the shape of the casting cavity is fit with the shape of the wind power base;
the pouring system comprises at least one iron inlet, at least one molten iron main runner, a central split cavity and a plurality of molten iron split runners, wherein the molten iron main runner and the molten iron split runners are arranged at the bottom of the casting mold, and the central split cavity is arranged at the central position of the bottom of the casting mold; the upstream of the molten iron main runner is communicated with the iron inlet, and the downstream of the molten iron main runner is communicated with the central split-flow cavity; the iron water flow passages are uniformly distributed in a divergent mode, the upstream is communicated with the central split cavity, the downstream tail end is communicated with the casting cavity, and the iron water flow passages are respectively provided with a filter; and
the heating system comprises a plurality of hot air channels which are communicated and arranged above the casting cavity; the casting method comprises the following steps:
(a) Smelting furnace burden into molten iron; and (3) adjusting the furnace charge components through spectrum analysis, and controlling C in molten iron: 3.4 to 3.5 percent, si:3.7 to 4.0 percent, mn:0.1 to 0.35 percent, P: < 0.04%, S: less than or equal to 0.012 percent, mg:0.04 to 0.07 percent, cr: < 0.05%, ti: less than 0.03%;
(b) Spheroidizing and inoculating molten iron; selecting a low-rare earth ferrosilicon magnesium alloy nodulizer, and performing spheroidization by adopting a flushing method, wherein the adding amount of the nodulizer is 1.0% -1.2%; the method comprises the following steps: embedding a nodulizer into a ladle, moderately compacting, performing spheroidization, starting spheroidization when the iron yield is two thirds, and controlling the iron yield temperature to be 1400-1470 ℃ before spheroidization; inoculating silicon-calcium-barium inoculant with the addition of 0.6-0.65% of the weight of molten iron, and inoculating twice, wherein the inoculating method specifically comprises the following steps: the cover inoculation is added on the surface of molten iron before and after spheroidizing slag skimming, and the stream inoculation is added into the molten iron in the casting process;
(c) Pouring into the casting mould for filling and solidifying to obtain a casting; before casting, the casting cavity is ventilated and heated by hot air with the temperature of about 150 ℃ through the hot air channel, and the casting temperature is 1360-1370 ℃.
2. The casting method of the solid solution strengthening ferrite ductile iron wind power casting according to claim 1, wherein the inner wall of the pouring system adopts clay refractory bricks; the filter is a foam ceramic filter sheet.
3. The casting method of solid solution strengthened ferritic spheroidal graphite cast iron wind power casting according to claim 1, wherein the sand box is a plastic box or a metal box.
4. The casting method of the solid solution strengthening ferrite nodular cast iron wind power casting according to claim 1, wherein MAGMA or Any casting software is adopted for cooling simulation, and a chill is additionally arranged at a position where shrinkage porosity is easy to generate.
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