CN110370423B - Casting method of ceramic and metal integrated part based on layered extrusion forming - Google Patents
Casting method of ceramic and metal integrated part based on layered extrusion forming Download PDFInfo
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- CN110370423B CN110370423B CN201910691963.3A CN201910691963A CN110370423B CN 110370423 B CN110370423 B CN 110370423B CN 201910691963 A CN201910691963 A CN 201910691963A CN 110370423 B CN110370423 B CN 110370423B
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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
- B22D19/00—Casting in, on, or around objects which form part of the product
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
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Abstract
The invention belongs to the field of rapid casting, and discloses a casting method of a ceramic/metal integrated part based on layered extrusion forming. S1, designing three-dimensional structures of the ceramic shell and the ceramic core according to the shape of the part; s2, adopting a multi-head layered deposition forming method of multiple ceramic materials to realize the precise integral forming of the shell with multiple ceramic materials and a layer gradient structure; s3, drying, degreasing, sintering and post-processing the ceramic shell and the ceramic core blank; s4, preheating the processed ceramic shell and the ceramic core, and finishing metal liquid filling through vacuum precision casting; and S5, after the molten metal is completely cooled, removing the ceramic core to form an internal pore channel of the metal and ceramic part, and obtaining the ceramic/metal integrated part. According to the method, the double-layer or three-layer ceramic shells with different thicknesses and densities are prepared by a layered extrusion forming method, and the filling of the molten metal is completed by combining a vacuum precision casting technology, so that the precision casting forming of the ceramic/metal integrated part is realized.
Description
Technical Field
The invention belongs to the field of rapid casting, and particularly relates to a casting method of a ceramic/metal integrated part based on layered extrusion forming.
Background
With the rapid development of industries such as aerospace, automobiles and the like, the use temperature of parts at certain parts is higher and more, and the use environment is more and more complex, so that more severe requirements are provided for the use performance of the parts at the parts. For example, aviation turbine engine blades are developing towards high thrust-weight ratio, high efficiency, low oil consumption and long service life, but high temperature not only causes creep rupture of the blades, but also erosion and oxidation of the blades by high-temperature combustion gas can cause corrosion of metal blades, and then rupture occurs. At present, the properties of high temperature resistance, corrosion resistance, oxidation resistance and the like of parts are mainly improved by adopting a metal ceramic composite material and a ceramic coating method.
Patent document CN 107127340A discloses a rapid forming method for metal ceramic parts, in which the cost of the metal, ceramic powder and photosensitive resin used is high, and the material composition and the post sintering process are complicated. Patent document CN 103917502B discloses that a high temperature thermal barrier coating is applied in the gas turbine technology, and is deposited on the surface of a component by thermal spraying treatment, and the preparation process of the thermal barrier coating is complex and the cost is high. In addition, patent document CN 105814280B discloses a thermal barrier coating for turbine moving and stationary blades, which uses zirconia (YSZ) as a raw material and adopts a selective laser melting technology to realize coating of ceramic on the blades, and the preparation process of the thermal barrier coating is complicated and has high cost.
Although the method can be used for preparing parts meeting different requirements, the preparation efficiency is low, the ceramic layer is thin (less than or equal to 0.5mm), the cost is high, the service life is short, and the process is complex. Therefore, it is required to find a method for manufacturing a ceramic/metal integrated part having high production efficiency, low manufacturing cost and excellent member performance.
Disclosure of Invention
Aiming at the defects or improvement requirements of the prior art, the invention provides a casting method of a ceramic/metal integrated part based on layered extrusion forming, wherein double-layer or three-layer ceramic shells with different thicknesses and densities are prepared by layered extrusion forming, and the filling and injection of metal are completed by combining a vacuum precision casting technology, so that the precise casting forming of the ceramic and metal integrated part is realized. The ceramic shells are divided in layers, a multi-head layered deposition forming method is adopted, different ceramic materials are adopted for each sub-ceramic shell to be deposited and formed respectively, meanwhile, a ceramic core is adopted to construct an internal pore channel of a metal/ceramic integrated part, a vacuum precision casting technology is combined, the ceramic/metal integrated part is integrally and precisely cast and formed, the precision of the internal pore channel structure of the formed part is high, the whole production efficiency is high, the preparation cost is low, the thickness of the ceramic layer of the ceramic/metal integrated part prepared by the invention can be precisely controlled according to materials and requirements, and good interface combination is formed among the sub-ceramic shells, the ceramic shells and the metal layers, so that the requirement on the service performance of the metal material is reduced, the high temperature resistance, the corrosion resistance and the corrosion resistance of a complex component are improved, Fracture toughness and other comprehensive properties.
In order to achieve the above object, the present invention provides a method for casting a ceramic/metal integrated part based on layered extrusion molding, comprising the steps of:
s1, according to the type of the ceramic material forming the ceramic shell, the ceramic shell of the ceramic/metal integrated part is divided in layers to obtain a plurality of layers of sub-ceramic shells which are connected in sequence, and a three-dimensional structure of the internal pore channels of the plurality of layers of sub-ceramic shells and the ceramic/metal integrated part is constructed;
s2, according to the three-dimensional structures of the multilayer sub-ceramic shells and the internal pore channels, carrying out layered deposition on the multilayer sub-ceramic shells and the internal pore channels by adopting a multi-head layered deposition forming method of multiple ceramic materials so as to obtain ceramic shell blanks formed by the multilayer sub-ceramic shells and ceramic core blanks filled in the internal pore channels;
s3, drying, degreasing, sintering and post-processing the ceramic shell and the ceramic core blank to obtain a ceramic shell and a ceramic core;
s4, preheating the ceramic shell and the ceramic core, and then carrying out vacuum precision casting to fill molten metal between the ceramic shell and the ceramic core;
and S5, after the molten metal is completely cooled, removing the ceramic core to obtain the ceramic/metal integrated part with the internal pore canal inside.
Preferably, the sub-ceramic shells are made of an outer shell and an inner shell made of different materials.
Preferably, the sub-ceramic shells further include a transition layer disposed between the outer shell and the inner shell.
More preferably, the porosity of the inner shell is larger than the porosity of the outer shell.
More preferably, the thickness of the outer shell is 0.5mm to 2mm, and the porosity is 5% to 20%.
More preferably, the inner shell has a thickness of 0.5 to 1.5mm and a porosity of 30 to 60%.
Further preferably, in step S2, the barrel used in the deposition forming process has a needle diameter of 0.05mm to 0.3 mm.
More preferably, in step S2, the deposition forming speed is 10mm/S to 40 mm/S.
Preferably, in step S2, the outer surface of the ceramic shell blank is further subjected to a finishing process to improve the surface accuracy of the ceramic shell blank.
In general, compared with the prior art, the above technical solution contemplated by the present invention can achieve the following beneficial effects:
1. according to the invention, the multilayer sub-ceramic shells with different thicknesses and densities are prepared by layered extrusion forming, and the filling and injection of metal are completed by combining a vacuum precision casting technology, so that the integrated precision casting forming of the ceramic/metal integrated part is realized. The whole process does not need a die, is simple, improves the preparation efficiency of integrated construction, saves cost, integrates the advantages of ceramics and metal, provides a new method for solving the problem of forming complex components made of dissimilar materials of metal and ceramics, reduces the requirement on the service performance of metal materials, and improves the comprehensive properties of high temperature resistance, corrosion resistance, fracture toughness and the like of the complex components.
2. The ceramic shell is composed of the outer shell and the inner shell which are made of different materials, so that the materials of the outer shell and the inner shell can be designed according to the actual requirements of parts, the thickness of the ceramic layer of the ceramic/metal integrated part prepared by the method can be accurately controlled according to the materials and the requirements, and each layer of the ceramic shell, the ceramic shell and the metal layer have good interface combination, so that the requirements on the service performance of the metal material are reduced, and the comprehensive performances of high temperature resistance, corrosion resistance, fracture toughness and the like of a complex component are improved.
3. The ceramic shell also comprises a transition layer arranged between the outer shell and the inner shell, so that the transition effect between different materials can be further realized, the materials of each layer can fully play the effect of the materials, and the interface combination between the layers is improved.
4. The porosity of the inner shell is less than that of the outer shell, further, the porosity of the outer shell is 5% -20%, and the porosity of the inner shell is 30% -60%, so that materials of all layers are designed according to the performance aspect of the part, and the preparation cost is further reduced on the basis of the mechanical performance of the part.
5. The casting method disclosed by the invention combines the 3D printing technology with vacuum precision casting, breaks through the design limit of the existing ceramic/metal integrated part, realizes the precise forming of the ceramic/metal integrated part, reduces the requirements on metal materials under extreme conditions, exerts the advantage of rapid manufacturing of 3D printing, and has the advantages of simple process and strong operability.
Drawings
FIG. 1 is a flow chart of a method for casting a ceramic/metal integrated part based on layered extrusion forming according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of a three-head ceramic slurry layered extrusion molding according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a four-headed ceramic slurry layered extrusion molding according to an embodiment of the present invention;
fig. 4 is a schematic structural diagram of a ceramic/metal integrated part prepared according to an embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
As shown in fig. 1 to 4, an embodiment of the present invention provides a casting method of a ceramic/metal integrated part based on layered extrusion forming, including the following steps:
(1) the method comprises the following steps of (1) carrying out layered division on ceramic shells of the ceramic/metal integrated part according to the types of ceramic materials forming the ceramic shells to obtain sequentially connected multilayer sub-ceramic shells, and constructing a three-dimensional structure of the multilayer sub-ceramic shells and internal pore channels of the ceramic/metal integrated part;
(2) according to the three-dimensional structures of the multilayer sub-ceramic shells and the internal pore channels, simultaneously carrying out layered deposition on the multilayer sub-ceramic shells and the internal pore channels by adopting a multi-head layered deposition forming method of multiple ceramic materials so as to obtain a ceramic shell blank body formed by the multilayer sub-ceramic shells and a ceramic core blank body filled in the internal pore channels; furthermore, the outer surface of the ceramic shell blank needs to be finished to improve the surface precision of the ceramic shell blank.
(3) Drying, degreasing, sintering and post-treating the ceramic shell and the ceramic core blank to obtain a ceramic shell and a ceramic core;
(4) preheating the ceramic shell and the ceramic core, and then carrying out vacuum precision casting to fill molten metal between the ceramic shell and the ceramic core; specifically, after preheating a ceramic shell and a ceramic core, filling and injecting liquid metal through vacuum precision casting, and realizing integrated precision casting and forming of ceramic/metal integrated parts; wherein, the ceramic shell and the ceramic core are preheated firstly to prevent the ceramic shell and the ceramic core from cracking in the vacuum casting process, and the high-temperature alloy and the inner layer of the ceramic shell form good interface combination through infiltration and reaction.
(5) And after the molten metal is completely cooled, removing the ceramic core to obtain the ceramic/metal integrated part with the internal pore canal inside.
As shown in fig. 2, the ceramic shell is preferably made of two different ceramic materials, and is divided into two connected sub-ceramic shells, i.e., an outer shell 4 and an inner shell 5, according to the two different ceramic materials. Correspondingly, in the deposition forming process, two kinds of ceramic slurry are respectively filled into the material cylinders 1 and 2 of the layered extrusion forming equipment, the ceramic slurry for manufacturing the ceramic core is filled into the material cylinder 3 of the layered extrusion forming equipment, according to the slicing path, the basic principle of layered extrusion forming layer by layer is adopted, the ceramic slurry in the material cylinder 1 forms the outer shell 4, the slurry in the material cylinder 2 forms the inner shell 5, and the slurry in the material cylinder 3 forms the ceramic core 6. Drying, degreasing, sintering and post-treating the formed ceramic shell and ceramic core blank; after preheating the ceramic shell and the ceramic core, performing vacuum precision casting to complete filling and injection of liquid metal; and after the molten metal is completely cooled, removing the mold core in water to realize the internal pore channels of the metal and the ceramic part, and obtaining the ceramic/metal integrated part.
As shown in fig. 3, as another preferred design of the present invention, the ceramic shell is made of three different ceramic materials, and is divided into three connected sub-ceramic shells, i.e., an outer shell 11, a transition layer 12, and an inner shell 13, according to the three different ceramic materials. Accordingly, in the deposition forming process, three kinds of ceramic slurry are respectively charged into the barrels 7, 8 and 9 of the layered extrusion forming apparatus, and according to the slicing path, the ceramic slurry in the barrel 7 forms the outer shell 11, the slurry in the barrel 8 forms the inner shell 12, the slurry in the barrel 9 forms the inner shell 13, and at the same time, the slurry in the barrel 10 forms the ceramic core 14, by using the basic principle that layered extrusion forming layers are stacked one on another. Drying, degreasing, sintering and post-treating the ceramic shell and the ceramic core blank which are printed and formed; after preheating the ceramic shell and the ceramic core, performing vacuum precision casting to complete filling and injection of liquid metal; and after the molten metal is completely cooled, removing the mold core in water to realize the internal pore channels of the metal and the ceramic part, and obtaining the ceramic/metal integrated part.
More preferably, the porosity of the inner shell is larger than the porosity of the outer shell.
More preferably, the thickness of the outer shell is 0.5mm to 2mm, and the porosity is 5% to 20%.
More preferably, the inner shell has a thickness of 0.5 to 1.5mm and a porosity of 30 to 60%.
Further preferably, the barrel used in the deposition molding process has a needle diameter of 0.05mm to 0.3 mm.
More preferably, the deposition forming speed is 10mm/s to 40 mm/s.
In the invention, the ceramic material for preparing the shell is a ceramic material with the functions of heat insulation, high-temperature corrosion resistance, oxidation resistance and the like. The ceramic material for preparing the inner shell can be tightly combined with the metal and the outer shell; the ceramic core can be removed in water after the vacuum precision casting is completed.
It is further preferred that the ceramic shell material from which the transition layer is made is formed integrally by reaction with the ceramic shell material from which the inner and outer shells are made during deposition, so as to form a good interfacial bond.
Example 1
(1) Designing a three-dimensional model of the double-layer ceramic shell and the inner pore canal according to the shape of the original blade, and carrying out Z-direction layered slicing on the three-dimensional model by adopting slicing software to obtain a layered processing instruction, wherein the diameter of a needle head is 0.05mm, and the height of a printing layer is 0.04 mm;
(2) preparing 3 kinds of uniformly dispersed ceramic slurry, adding the ceramic slurry into a printing charging barrel, wherein the printing speed is 10mm/s, and integrally preparing a ceramic outer shell, an inner shell and a ceramic core filled in an inner pore channel by using a layered extrusion forming device;
(3) drying, degreasing, sintering and post-treating the ceramic shell and the ceramic core blank which are printed and formed;
(4) after preheating the ceramic shell and the ceramic core, filling and injecting liquid metal in a vacuum environment;
(5) and after the molten metal is cooled, removing the ceramic core in water, and drying to obtain the metal/ceramic integrated blade.
The prepared ceramic and metal integrated blade has the outer shell thickness of 0.5mm, the porosity of 5%, the inner shell thickness of 0.5mm and the porosity of 30%.
Example 2
(1) Designing a three-dimensional model of the double-layer ceramic shell and the internal pore canal according to the shape of the original blade, and carrying out Z-direction layered slicing on the three-dimensional model by adopting slicing software to obtain a layered processing instruction, wherein the diameter of a needle head is 0.3mm, and the height of a printing layer is 0.24 mm;
(2) preparing the uniformly dispersed ceramic slurry in the step 3, adding the ceramic slurry into a printing charging barrel, wherein the printing speed is 40mm/s, and preparing a ceramic outer shell, an inner shell and a ceramic core blank by using a layered extrusion forming machine;
(3) drying, degreasing, sintering and post-treating the ceramic shell and the ceramic core blank which are printed and formed;
(4) after preheating the ceramic shell and the ceramic core, filling and injecting liquid metal in a vacuum environment;
(5) and after the molten metal is cooled, removing the ceramic core in water, and drying to obtain the ceramic/metal integrated blade.
The prepared ceramic/metal integrated blade has the outer shell thickness of 2mm, the porosity of 20 percent, the inner shell thickness of 1.5mm and the porosity of 60 percent
Example 3
(1) Designing a three-dimensional model of the double-layer ceramic shell and the internal pore canal according to the shape of the original blade, and carrying out Z-direction layered slicing on the three-dimensional model by adopting slicing software to obtain a layered processing instruction, wherein the diameter of a needle head is 0.2mm, and the height of a printing layer is 0.16 mm;
(2) preparing the uniformly dispersed ceramic slurry in the step 3, adding the ceramic slurry into a printing charging barrel, wherein the printing speed is 25mm/s, and preparing a ceramic outer shell, an inner shell and a ceramic core blank by using a layered extrusion forming machine;
(3) drying, degreasing, sintering and post-treating the ceramic shell and the ceramic core blank which are printed and formed;
(4) after preheating the ceramic shell and the ceramic core, filling and injecting liquid metal in a vacuum environment;
(5) and after the molten metal is cooled, removing the ceramic core in water, and drying to obtain the ceramic/metal integrated blade.
The prepared ceramic/metal integrated blade has the outer shell thickness of 1mm, the porosity of 15%, the inner shell thickness of 1mm and the porosity of 50%.
Example 4
(1) Designing a three-dimensional model of a three-layer ceramic shell and an internal pore channel according to the shape of an original blade, and carrying out Z-direction layered slicing on the three-dimensional model by adopting slicing software to obtain a layered processing instruction, wherein the diameter of a needle head is 0.15mm, and the height of a printing layer is 0.12 mm;
(2) preparing 4 kinds of uniformly dispersed ceramic slurry, adding the ceramic slurry into a printing charging barrel, wherein the printing speed is 20mm/s, and integrally preparing a ceramic outer shell, a transition layer, an inner shell and a ceramic core blank by using a layered extrusion forming device;
(3) drying, degreasing, sintering and post-treating the ceramic shell and the ceramic core blank which are printed and formed;
(4) after preheating the ceramic shell and the ceramic core, filling and injecting liquid metal in a vacuum environment;
(5) and after the molten metal is cooled, removing the ceramic core in water, and drying to obtain the ceramic/metal integrated blade.
The prepared ceramic/metal integrated blade has the outer shell with the thickness of 0.5mm, the porosity of 5%, the transition layer ceramic shell with the thickness of 0.5mm, the porosity of 10%, the inner shell with the thickness of 0.5mm and the porosity of 40%.
The invention provides a ceramic/metal integrated part integrated precision casting method based on layered extrusion forming. The invention provides a new rapid forming method for solving the forming of complex components made of dissimilar materials of metal and ceramic, breaks through the design limit of the existing metal and ceramic components, reduces the requirement on the service performance of metal materials under extreme conditions, improves the comprehensive performances of high temperature resistance, corrosion resistance, fracture toughness and the like of complex ceramic/metal integrated parts, and has simple whole preparation process and wide raw material sources.
It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.
Claims (9)
1. A casting method of a ceramic and metal integrated part based on layered extrusion molding is characterized by comprising the following steps:
s1, according to the type of the ceramic material forming the ceramic shell, the ceramic shell of the ceramic and metal integrated part is divided in layers to obtain a plurality of layers of sub-ceramic shells which are connected in sequence, and a three-dimensional structure of the internal pore channels of the plurality of layers of sub-ceramic shells and the ceramic and metal integrated part is constructed;
s2, according to the three-dimensional structures of the multilayer sub-ceramic shells and the internal pore channels, carrying out layered deposition on the multilayer sub-ceramic shells and the internal pore channels by adopting a multi-head layered deposition forming method of multiple ceramic materials so as to obtain ceramic shell blanks formed by the multilayer sub-ceramic shells and ceramic core blanks filled in the internal pore channels;
s3, drying, degreasing, sintering and post-processing the ceramic shell and the ceramic core blank to obtain a ceramic shell and a ceramic core;
s4, preheating the ceramic shell and the ceramic core, and then carrying out vacuum precision casting to fill molten metal between the ceramic shell and the ceramic core;
and S5, after the molten metal is completely cooled, removing the ceramic core to obtain the ceramic and metal integrated part with the internal pore canal inside.
2. The casting method as claimed in claim 1, wherein the plurality of sub-ceramic shells are composed of an outer shell and an inner shell which are made of different materials.
3. The casting method as recited in claim 2, wherein the plurality of sub-ceramic shells further comprises a transition layer disposed between the outer shell and the inner shell.
4. The casting method as recited in claim 2, wherein a porosity of the inner shell is greater than a porosity of the outer shell.
5. The casting method according to claim 2, wherein the shell has a thickness of 0.5 to 2mm and a porosity of 5 to 20%.
6. The casting method according to claim 2, wherein the thickness of the inner shell is 0.5mm to 1.5mm, and the porosity is 30% to 60%.
7. The casting method according to any one of claims 1 to 6, wherein in step S2, the barrel used in the deposition forming process has a needle diameter of 0.05mm to 0.3 mm.
8. The casting method according to any one of claims 1 to 6, wherein the deposition forming speed in step S2 is 10mm/S to 40 mm/S.
9. The casting method according to any one of claims 1 to 6, wherein in step S2, the outer surface of the ceramic shell blank is further subjected to a finishing treatment to improve the surface accuracy of the ceramic shell blank.
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