CN108927504B - Casting process of large aluminum alloy engine case part - Google Patents
Casting process of large aluminum alloy engine case part Download PDFInfo
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- CN108927504B CN108927504B CN201710385509.6A CN201710385509A CN108927504B CN 108927504 B CN108927504 B CN 108927504B CN 201710385509 A CN201710385509 A CN 201710385509A CN 108927504 B CN108927504 B CN 108927504B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/06—Making non-ferrous alloys with the use of special agents for refining or deoxidising
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/02—Alloys based on aluminium with silicon as the next major constituent
- C22C21/04—Modified aluminium-silicon alloys
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
The invention discloses a casting process of a large aluminum alloy engine case part, wherein the basic outline dimension of the case part is 1400 mm x460 mm x195 mm, the wall thickness of a main body is 5-7 mm, the whole case is a semi-closed large cavity structure, the outline is slender, and an internal casting oil way is adopted.
Description
Technical Field
The invention belongs to the field of casting, in particular to a method for casting large-scale engine parts, and particularly relates to a method for casting a semi-closed large-scale cavity structure engine casing part with a slender outline and an internally cast oil way.
Background
The large-scale aluminum alloy engine casing (hereinafter referred to as casing) mainly bears the bearing reaction force of a gear shaft, the vibration of an engine and the maneuvering load, the maximum working temperature is 175 ℃, and cast aluminum alloy casting machines are adopted for machining and forming. The basic outline dimension of the engine case is 1400 mm, x460 mm, x195 mm, the main body wall thickness is 5-7 mm, the whole engine case is of a semi-closed large-scale cavity structure, the outline is slender, and an internal casting oil way is adopted, so that great technical difficulty is brought to casting of an engine case casting. The main technical difficulties are represented as follows: firstly, a complex oil circuit system is arranged in the casing, the oil circuit space trend is zigzag, the wall thickness is very thin, the oil circuit is required to have accurate shape and size, accurate and reliable fixing and positioning means, good surface quality, deformability and the like, so that the oil circuit can be ensured to be completely formed to meet the functional requirement, and the performance of the whole casing is not influenced; secondly, the casting forming of the semi-closed large-scale inner cavity is the key for obtaining the success of the casting, the inner cavity of the casting is provided with a complex oil path, and the core of the inner cavity of the casting generates great thermal shrinkage stress, so that the casting is the main reason for generating deformation and cracks.
The existing casing casting has the technical problems of uneven casting forming wall thickness, poor internal metallurgical quality, low dimensional precision, easy deformation, crack generation, rough surface and the like.
Disclosure of Invention
The object of the present invention is to provide a method for manufacturing a casting mould for casting components of an aircraft engine casing, which reduces or avoids the aforementioned technical problems.
In order to solve at least one technical problem, the invention provides a casting process of a large aluminum alloy engine case part, wherein the basic outline dimension of the case part is 1400 mm x460 mm x195 mm, the thickness of a main body wall is 5-7 mm, the entire case is a semi-closed large cavity structure, the outline is slender, and an inner casting oil way is formed, and the casting process route comprises the following steps:
s1, initially designing a casting blank structure by adopting an anti-gravity investment precision casting process, and adjusting structural parameters such as process ribs, wall thickness, boss positions and the like on the premise of not influencing the use of parts, so that the casting blank structure is more suitable for casting production;
s2, casting a casing casting, wherein a copper pipe and a P L M-polycarbon gypsum core are adopted to manufacture a composite core, namely, a zinc alloy outer support is adopted to manufacture a semicircular core bar, the shape and structure of the core bar are consistent with the shape and structure of a slender three-dimensional structure core, the copper pipe and the zinc alloy are firmly cast together by an investment precision casting process, and the P L M-polycarbon gypsum core is pressed to enable the zinc alloy outer support and the P L M-polycarbon gypsum core to be integrated, so that the casing casting is ensured not to be dislocated in the casting process;
designing and manufacturing a set of wax pattern, fixing the P L M-polycarbonate gypsum core composite core in the wax pattern, pressing the wax pattern to realize the manufacture of the wax pattern, and obtaining a casing shell through coating, dewaxing and roasting;
s3, casing casting is carried out by adopting a counter-pressure casting process, firstly, a casting construction diagram is simulated by using MAGMA casting simulation software, a flow field, a temperature field and a stress field of a casting are analyzed, the structure, a pouring system and casting process parameter design of the casting are optimized, a roasted casing shell is placed in a sand box, and sodium silicate sand is filled around the casing shell for counter-pressure casting of the casting;
s4, molten aluminum smelting and pouring control, wherein in the pouring process, a reasonable mold filling speed and a differential pressure tank pressure maintaining pressure are determined, a reasonable pouring temperature is determined, and a signal lamp is arranged at the highest point of each casting to ensure that the mold filling time of each casting is within +/-2S;
s5, performing heat treatment on the castings, namely simulating by using heat treatment software to determine the optimal heat treatment process scheme of the castings, such as the placement position, the water inlet direction, the water inlet time, the water temperature and the like of the castings, and designing a reasonable fixture for heat treatment of the castings to ensure that the heat treatment of the castings is not deformed; marking off the casting, machining an auxiliary clamping table according to a line, locking and fixing the auxiliary clamping table with a heat treatment clamp, and placing the auxiliary clamping table perpendicular to the quenching medium surface to reduce the deformation generated by heat treatment of the casting as much as possible; and hot isostatic pressing is adopted, so that the dimensional stability of the casting is improved, and the mechanical property of the casting is improved.
Further, the zinc alloy described in S2 is ZA-27 zinc-based alloy, and its mechanical properties are: sigma b is 350-400 MPa,5 is 2.0-3.0%, HB = 100-120, and the melting point is about 380 ℃; the shell is roasted to the temperature of about 900 ℃, and the zinc alloy can be completely melted and even boiled.
Furthermore, the content of Fe in the aluminum ingot or alloy ingot used as the raw material of the aluminum liquid in S4 is less than 0.1%, and the chemical components of the cast aluminum alloy comprise Si 6.8-7.2%, Mg0.5-0.6%, Ti0.15-0.20%, Be0.1-0.2% and Fe less than 0.1%.
Further, the aluminum liquid in the S4 adopts long-acting alterant metal strontium (0.04-0.06%) and rare earth (0.2-0.3%) to modify the aluminum liquid, and the modification process has the advantages that the secondary dendrite spacing of the sample is minimum, the air holes are few, and silicon particles are punctiform or vermicular, small eutectic clusters and dispersed; and determining the modification effect of the aluminum liquid by combining an observation fracture (phi 15) method and a processing test block high-power metallographic observation method.
Further, the mold filling speed in S4 is 0.0014-0.004 MPa/S, and the pressure maintaining difference of the differential pressure tank is not less than 0.5 MPa. The pouring temperature is 690-710 ℃.
The invention has the following beneficial effects:
1. the casing casting adopts a composite core of a copper pipe and a P L M-polycarbonate gypsum core to realize a whole core, so that the core assembly precision is greatly improved, the casting has good deformability, the stress and deformation of the casting are greatly reduced, and the casting metallurgical defects such as size deformation and cracks of the casting are greatly reduced;
2. because the casting is in a semi-circular arc shape, the casting structure is slender. By adopting uniform casting shrinkage rate, the semi-arc shape has larger deviation with the theoretical size, and the reverse deformation process design is needed, so the casting construction drawing is simulated by adopting MAGMA5 casting simulation software, the flow field, the temperature field and the stress field of the casting are analyzed, and the casting structure is optimized;
3. the casing casting adopts a counter-pressure casting process, wherein the counter-pressure casting is that a casting mold is solidified under a large pressure difference, namely, a compact structure can be obtained because a casting is solidified under a high pressure (the feeding capacity is 4-5 times that of low-pressure casting and 7-8 times that of gravity casting); and because the pressure of the differential pressure casting is higher, the solubility of hydrogen in the aluminum liquid is increased, and the metal solidification speed is increased under high pressure, so that the hydrogen cannot be separated out in time and exists in the casting in the original state when the alloy is solidified, thereby greatly reducing the separated-out air holes (pin holes); simultaneously, external pressure can also participate in feeding, when the casting is solidified under high pressure, shrinkage cavities and microcracks which appear can be filled in time, the hidden danger of some cracks is eliminated by welding to a certain extent, the mechanical property of the casting is correspondingly improved, and the casting has the following outstanding advantages: (1) the casting defects of casting air hole shrinkage, shrinkage porosity and the like are eliminated; (2) improving the surface roughness of the casting; (3) the hot cracking tendency of the large complex casting during solidification is obviously reduced; (4) the counter-pressure casting has strong feeding pressure; (5) the differential pressure casting can reduce the solidification time by 20-25%, correspondingly reduce the deterioration and decline phenomenon in the solidification period, and refine the crystal grains, thereby being the best method for obtaining high-quality aluminum alloy castings at present.
4. The P L M-poly carbon gypsum core is made of new generation fire resistant poly carbon gypsum, the core is high temperature resistant, soluble, can be made into various complex shapes, is easy to clean, has the highest fire resistance of 2800 ℃, has obvious superiority compared with the traditional core, becomes loose after casting, can be easily removed, can clean the ultra complex inner cavity by vibration and simple tools, can clean the ultra complex inner cavity by soaking at normal temperature and washing with water, has excellent deformability, does not need any treatment on the joint with the silica sol shell, does not deform and crack the joint, and has size precision and surface luminosity superior to the silica sol shell.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to the accompanying drawings, and the described embodiments are only some embodiments, not all embodiments, of the present invention.
The basic outline dimension of the casing component prepared in the embodiment is 1400 mm, x460 mm, x195 mm, and the main body wall thickness is 5-7 mm, the whole casing is a semi-closed large-scale cavity structure, the outline is elongated, and the casting process route comprises the following steps:
firstly, a casting blank structure is preliminarily designed by adopting an anti-gravity method investment precision casting process, and structural parameters such as process ribs, wall thickness, boss positions and the like are adjusted on the premise of not influencing the use of parts, so that the casting blank structure is more suitable for casting production; on the premise of not influencing the use of parts, structural parameters such as process ribs, wall thickness, boss positions and the like are adjusted, so that the casting blank structure is more suitable for casting production.
Secondly, casting a casing casting, namely, manufacturing a composite core by adopting a copper pipe and a P L M-polycarbon gypsum core, namely, manufacturing a semicircular core bone by adopting a zinc alloy outer support, wherein the shape and the structure of the core bone are consistent with the shape of a slender three-dimensional structure core, firmly casting the copper pipe and the zinc alloy together by an investment precision casting process, pressing the P L M-polycarbon gypsum core to enable the zinc alloy outer support and the P L M-polycarbon gypsum core to be integrated, so that the casing casting is not dislocated in the casting process, melting and separating the zinc alloy when roasting a shell, wherein the zinc alloy, such as ZA-27 zinc-based alloy, has the mechanical properties that sigma b is 350-400 MPa,5 is 2.0-3.0%, HB = 100-120 and the melting point is about 380 ℃, roasting the shell to the temperature of about 900 ℃, the zinc alloy can be completely melted and even boiled, corroding through chemical reaction, and thus obtaining a compact copper pipe casting with accurate size, smooth inner wall and aluminum structure;
designing and manufacturing a set of wax pattern, fixing the P L M-polycarbonate gypsum core composite core in the wax pattern, pressing the wax pattern to realize the manufacture of the wax pattern, and obtaining the casing shell through coating, dewaxing and roasting.
Thirdly, casing casting is carried out by adopting a counter-pressure casting process, firstly, a casting construction diagram is simulated by using MAGMA (Magma casting simulation software), a flow field, a temperature field and a stress field of a casting are analyzed, the structure, a pouring system and casting process parameter design of the casting are optimized, a roasted casing shell is placed in a sand box, and sodium silicate sand is filled around the casing shell for counter-pressure casting of the casting;
fourthly, molten aluminum smelting and pouring control are carried out, the content of Fe in an aluminum ingot or an alloy ingot which is used as a raw material of the molten aluminum is required to be less than 0.1%, the chemical components of cast aluminum alloy comprise Si 6.8-7.2%, Mg0.5-0.6%, Ti0.15-0.20%, Be0.1-0.2% and Fe <0.1%, in the pouring process, the filling speed is determined to be 0.0014-0.004 MPa/s, the pressure maintaining difference of a differential pressure tank is not less than 0.5MPa, the pouring temperature is 690-710 ℃, a signal lamp is arranged at the highest point of the casting, and the filling time of each casting is guaranteed to be within +/-2 s. The aluminum liquid is modified by long-acting modifier metal strontium (0.04-0.06%) and rare earth (0.2-0.3%), and the modification process has the advantages that the secondary dendrite spacing of a sample is minimum, the air holes are few, silicon particles are dotted or worm-shaped, eutectic clusters are small and dispersed; and determining the modification effect of the aluminum liquid by combining an observation fracture (phi 15) method and a processing test block high-power metallographic observation method.
Fifthly, performing heat treatment on the casting, namely simulating by using heat treatment software to determine the optimal heat treatment process scheme of the casting, such as the placement position, the water inlet direction, the water inlet time, the water temperature and the like of the casting, and designing a reasonable casting heat treatment clamp to ensure that the casting is not deformed during heat treatment; marking off the casting, machining an auxiliary clamping table according to a line, locking and fixing the auxiliary clamping table with a heat treatment clamp, and placing the auxiliary clamping table perpendicular to the quenching medium surface to reduce the deformation generated by heat treatment of the casting as much as possible; and hot isostatic pressing is adopted, so that the dimensional stability of the casting is improved, and the mechanical property of the casting is improved.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (5)
1. The casting process of the large-scale aluminum alloy engine case part comprises the following steps of according to the basic outline dimension of the case part of 1400 mm x460 mm x195 mm, according to the thickness of a main body of 5-7 mm, wherein the whole case is of a semi-closed large-scale cavity structure, and is provided with a slender outline and an internal casting oil way, and the casting process is characterized in that: the casting process route comprises the following steps:
s1, preliminarily designing a casting blank structure by adopting an anti-gravity investment precision casting process, and adjusting the structural parameters of process ribs, wall thickness and boss positions on the premise of not influencing the use of parts, so that the casting blank structure is more suitable for casting production;
s2, casting a casing casting, namely, manufacturing a composite core by adopting a copper pipe and a P L M-polycarbon gypsum core, namely, firstly, manufacturing a semicircular core bone by adopting a zinc alloy outer support, wherein the shape and the structure of the core bone are consistent with the shape of a slender three-dimensional structure core, firmly casting the copper pipe and the zinc alloy together by adopting an investment precision casting process, pressing the P L M-polycarbon gypsum core to enable the zinc alloy outer support and the P L M-polycarbon gypsum core to be integrated, so that the casing casting is not dislocated in the casting process, melting and separating the zinc alloy during casing roasting, corroding the copper pipe through a chemical reaction to obtain a complex oil circuit with accurate size, smooth inner wall and compact aluminum casting tissue;
s3, casing casting is carried out by adopting a counter-pressure casting process, firstly, a casting construction diagram is simulated by using MAGMA casting simulation software, a flow field, a temperature field and a stress field of a casting are analyzed, the structure, a pouring system and casting process parameter design of the casting are optimized, a roasted casing shell is placed in a sand box, and sodium silicate sand is filled around the casing shell for counter-pressure casting of the casting;
s4, molten aluminum smelting and pouring control, wherein in the pouring process, a reasonable mold filling speed and a differential pressure tank pressure maintaining pressure are determined, a reasonable pouring temperature is determined, and a signal lamp is arranged at the highest point of each casting to ensure that the mold filling time of each casting is within +/-2S;
s5, performing heat treatment on the castings, namely simulating by using heat treatment software to determine the optimal heat treatment process scheme of the castings, such as the placement position, the water inlet direction, the water inlet time and the water temperature, and designing a reasonable fixture for heat treatment of the castings to ensure that the heat treatment of the castings is not deformed; marking off the casting, machining an auxiliary clamping table according to a line, locking and fixing the auxiliary clamping table with a heat treatment clamp, and placing the auxiliary clamping table perpendicular to the quenching medium surface to reduce the deformation generated by heat treatment of the casting as much as possible; and hot isostatic pressing is adopted, so that the dimensional stability of the casting is improved, and the mechanical property of the casting is improved.
2. The casting process according to claim 1, wherein the zinc alloy in S2 is ZA-27 zinc-based alloy, and the mechanical properties are as follows: sigma b is 350-400 MPa,5 is 2.0-3.0%, HB = 100-120, and the melting point is about 380 ℃; the shell is roasted to the temperature of about 900 ℃, and the zinc alloy can be completely melted and even boiled.
3. The casting process according to claim 1, wherein the content of Fe in a raw material aluminum ingot or alloy ingot of the molten aluminum in S4 is less than 0.1%, and the chemical components of cast aluminum alloy comprise Si 6.8-7.2%, Mg0.5-0.6%, Ti0.15-0.20%, Be0.1-0.2% and Fe < 0.1%.
4. The casting process according to claim 1, wherein the aluminum liquid in S4 adopts long-acting alterant metal strontium (0.04-0.06%) and rare earth (0.2-0.3%) altered aluminum liquid, and the alteration process has the advantages that the secondary dendrite spacing of a sample is minimum, the air holes are few, silicon particles are dotted or worm-shaped, eutectic clusters are small and are dispersed; and determining the modification effect of the aluminum liquid by combining an observation fracture (phi 15) method and a processing test block high-power metallographic observation method.
5. The casting process according to claim 1, wherein the filling speed in S4 is 0.0014-0.004 MPa/S, the pressure difference of a differential pressure tank is not less than 0.5MPa, and the pouring temperature is 690-710 ℃.
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| CN111097894A (en) * | 2019-12-31 | 2020-05-05 | 西安西工大超晶科技发展有限责任公司 | Method for improving streamline defects of confluence area of ZL210A alloy casting |
| CN113941700B (en) * | 2020-07-17 | 2023-04-04 | 中国兵器工业第五九研究所 | Method for repairing defects of aluminum alloy casting |
| CN118321526B (en) * | 2024-06-13 | 2024-09-06 | 中国航发北京航空材料研究院 | Complex oil cavity pipeline inside casing casting and preparation method thereof |
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