CN110467466A - 一种定制化增强陶瓷铸型型芯抗蠕变性能的方法 - Google Patents

一种定制化增强陶瓷铸型型芯抗蠕变性能的方法 Download PDF

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CN110467466A
CN110467466A CN201910820807.2A CN201910820807A CN110467466A CN 110467466 A CN110467466 A CN 110467466A CN 201910820807 A CN201910820807 A CN 201910820807A CN 110467466 A CN110467466 A CN 110467466A
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ceramic
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鲁中良
李涤尘
王程冬
苗恺
陈义
张凌锋
卢秉恒
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Xian Jiaotong University
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Abstract

本发明公开了一种定制化增强陶瓷铸型型芯抗蠕变性能的方法，属于光固化成型技术快速铸造领域。包括步骤：包括：1)利用UG软件设计树脂模具原型，并用光固化快速成型技术制造出光固化树脂模具2)在树脂模具中穿入特定的陶瓷棒或陶瓷纤维3)设计了凝胶注模陶瓷浆料配方，利用凝胶注模成型工艺实现陶瓷型壳坯体的成型。4)陶瓷铸型坯体真空冷冻干燥后，焙烧将树脂原型烧失掉后，便获得完整的一体化陶瓷铸型。本方法的冷冻干燥和焙烧过程能够提高型芯的抗变形能力，陶瓷棒和陶瓷纤维可以提高型芯的韧性和强度，通过定制化制造增强了陶瓷铸型型芯的抗蠕变性能，适用于实际生产。

Description

一种定制化增强陶瓷铸型型芯抗蠕变性能的方法
技术领域
本发明属于基于光固化成型技术的快速铸造领域，具体涉及一种定制化增强陶瓷铸型型芯抗蠕变性能的方法。
背景技术
快速成型技术是80年代末发展起来的新一代制造技术，光固化成型技术是快速成型技术中最成熟、成型精度最高的方法，它是采用光固化树脂材料，利用三维平板印刷方法制造原型，可以成型任意复杂形状的零件原型。光固化成型技术与传统的熔模铸造工艺相结合可以大大缩短熔模制备所需时间，并且省去了为制备蜡模而制造模具所耗费的时间和成本。通过光固化成型复杂的模具，再通过凝胶注模技术浇注陶瓷浆料，经过冷冻、干燥和烧结得到整体式空心涡轮叶片陶瓷模型。
传统的方法通过在陶瓷浆料中加入碳纤维，来提高芯型的强度，但这只是提高局部的强度，而且会影响铸型内腔的表面粗糙度。同样，传统的方法没有针对特定的陶瓷材料和铸型形状采用特定的方案。所以，探究一种定制化制造增强陶瓷铸型型芯抗蠕变性能的方法尤为重要。
发明内容
为了克服上述现有技术的缺点，本发明的目的在于提供一种定制化增强陶瓷铸型型芯抗蠕变性能的方法，该方法设计合理，通过定制化制造增强了陶瓷铸型型芯的抗蠕变性能，适用于实际生产。
为了达到上述目的，本发明通过以下技术方案来实现：
本发明公开了一种定制化增强陶瓷铸型型芯抗蠕变性能的方法，包括以下步骤：
1)利用UG软件设计树脂模具原型：
对于上下直通的型芯，在型芯的底部设计固定孔；对于非上下直通的弯曲型芯，在型芯底部和顶部对应设计固定孔；然后结合光固化快速成型法成型出带有固定孔的树脂模具原型；
2)选用并插入陶瓷棒/陶瓷纤维
对于上下直通的型芯，在型芯底部的固定孔中插入陶瓷棒；对于非上下直通的弯曲型芯，将陶瓷纤维弯曲后固定在型芯底部和顶部的固定孔中；
3)制备陶瓷浆料并浇注
制备凝胶注模用陶瓷浆料，利用凝胶注模成型工艺将陶瓷浆料灌注到经步骤2)处理后的树脂模具原型中，实现陶瓷铸型坯体的成型；
4)成型后处理
将成型陶瓷铸型坯体真空冷冻干燥后，焙烧除去树脂原型，再经高温烧结强化陶瓷铸型，获得完整的一体化陶瓷铸型。
优选地，所述固定孔的大小由型芯的直径确定，固定孔直径为型芯直径的1/10～1/5,此直径的陶瓷棒或陶瓷纤维可以最大限度发挥其作用。
优选地，所述的陶瓷棒为碳化硅陶瓷棒、氧化钇陶瓷棒、氧化锆陶瓷棒、氧化铝陶瓷棒和氧化硅陶瓷棒的一种或几种。
优选地，所述的陶瓷纤维为氧化铝纤维和/或碳化硅纤维。
优选地，所述的陶瓷浆料的基体材料为碳化硅陶瓷、氧化钇陶瓷、氧化锆陶瓷、氧化铝陶瓷或氧化硅陶瓷。
优选地，陶瓷铸型采用与基体材料匹配的陶瓷棒或陶瓷纤维增强抗蠕变性能，且陶瓷棒或陶瓷纤维与基体材料具有相同的热膨胀系数。
进一步优选地，碳化硅陶瓷铸型插入碳化硅陶瓷棒或碳化硅纤维；氧化钇陶瓷铸型插入氧化钇陶瓷棒、氧化铝陶瓷棒或氧化铝纤维；氧化锆陶瓷铸型插入氧化锆陶瓷棒、氧化铝陶瓷棒或氧化铝纤维；氧化铝陶瓷铸型插入氧化铝陶瓷棒、碳化硅陶瓷棒、氧化钇陶瓷棒、氧化锆陶瓷棒和氧化硅陶瓷棒，或者插入氧化铝纤维和碳化硅纤维；氧化硅陶瓷铸型插入碳化硅陶瓷棒、氧化硅陶瓷棒或碳化硅纤维。
优选地，陶瓷棒和陶瓷纤维采用AB胶固定在型芯的固定孔中。
优选地，陶瓷纤维或陶瓷棒与固定孔过盈配合。
优选地，步骤4)中，高温烧结的温度低于所用陶瓷棒或陶瓷纤维的熔点与现有技术相比，本发明具有以下有益的技术效果：
本发明公开的定制化增强陶瓷铸型型芯抗蠕变性能的方法，首先利用UG软件设计树脂模具原型，并用光固化快速成型技术制造出光固化树脂模具，在上下直通的树脂模具型芯的固定孔中穿入陶瓷棒，在非上下直通的弯曲树脂模具中穿入陶瓷纤维，针对上下直通型和非上下直通型的型芯分别采用陶瓷棒和陶瓷纤维，陶瓷棒和陶瓷纤维具有耐高温的性能，陶瓷棒刚度好，陶瓷纤维韧性好，形状保持能力强，而且不与陶瓷基体发生反应，能够降低型芯在制备过程中发生变形的可能，而且在金属浇铸的过程中也可以增强型芯的强度；最后，通过凝胶注模成型工艺获得陶瓷铸型坯体，坯体经过真空冷冻干燥和焙烧获得一体化陶瓷模型。冷冻干燥和焙烧过程能够提高型芯的抗变形能力，在后续的使用过程中，陶瓷棒和陶瓷纤维可以提高型芯的韧性和强度，避免型芯因强度和韧性不足而断裂。
进一步地，本发明针对五种不同陶瓷基体，采用的陶瓷棒或陶瓷纤维与陶瓷基体材料具有相同的膨胀系数，不会影响铸型基体材料性能，不引入杂质，防止烧结过程造成坯体开裂。对于不同的陶瓷基体也采用了特定的解决方案，实现了陶瓷铸型的定制化生产，有效地提高了铸型制造完整性和使用的可靠性。
附图说明
图1为上下直通型陶瓷棒铸型型芯的固定孔结构示意图；
图2为上下直通型陶瓷棒铸型型芯的固定孔的结构俯视图；
图3为上下直通型陶瓷铸型的结构示意图；
图4为非上下直通型陶瓷纤维铸型型芯的固定孔结构示意图；
图5为非上下直通型陶瓷纤维铸型型芯的固定孔的结构俯视图；
图6为非上下直通型陶瓷纤维铸型型芯的陶瓷纤维截面示意图；
其中，1为叶身，2为固定孔，3为型芯，4型壳，5为陶瓷棒，6为陶瓷铸型，7为陶瓷纤维。
具体实施方式
下面结合具体的实施例对本发明做进一步的详细说明，所述是对本发明的解释而不是限定。
本发明提供的一种定制化增强陶瓷铸型型芯抗蠕变性能的方法，步骤如下：
1)利用UG软件设计出树脂模具原型，在要穿入陶瓷棒或者陶瓷纤维的铸型的底部或者两端都设计固定孔，再并用光固化速成型技术成型出光固化树脂模具；
固定孔包括：上下直通的型芯，在型芯的底部设计固定孔；非上下直通的弯曲型芯，在型芯底部和顶部对应设计固定孔；
2)对于上下直通的型芯，在型芯底部的固定孔插入陶瓷棒；对于非上下直通的弯曲型芯，将陶瓷纤维弯曲后固定在型芯底部和顶部的固定孔中，并用AB胶固定；
3)设计凝胶注模陶瓷浆料配方，利用凝胶注模成型工艺实现陶瓷铸型坯体的成型；
4)将步骤3)成型处理得到的陶瓷铸型坯体经过冷冻、干燥和烧结得到整体式空心涡轮叶片陶瓷铸型。
本发明所使用的陶瓷纤维和陶瓷棒具有以下特点：
1、陶瓷纤维和陶瓷棒是根据基体的材料选取的，与基体具有相同的热膨胀系数，防止烧结过程造成坯体开裂。
例如：碳化硅陶瓷铸型插入碳化硅陶瓷棒或碳化硅纤维；氧化钇陶瓷铸型可插入氧化钇、氧化铝陶瓷棒或氧化铝纤维；氧化锆陶瓷铸型可插入氧化锆、氧化铝陶瓷棒或氧化铝纤维；氧化铝陶瓷铸型可插入氧化铝、碳化硅、氧化钇、氧化锆和氧化硅陶瓷棒，也可插入氧化铝和碳化硅纤维；氧化硅陶瓷铸型可插入碳化硅、氧化硅陶瓷棒或碳化硅纤维。
2、陶瓷纤维和陶瓷棒应具有耐高温的性能，陶瓷棒刚度好，陶瓷纤维韧性好，形状保持能力强，而且不与陶瓷基体发生反应。
3、陶瓷纤维和陶瓷棒能够降低型芯在制备过程中发生变形的可能，而且在金属浇铸的过程中也可以增强型芯的强度，该方法大大提高了陶瓷铸型型芯的抗蠕变性能。
本发明设计的固定孔根据型芯的直径确定，固定孔直径为型芯直径的1/10至1/5。
下面通过具体的实例对本发明进行详细的说明：
实施例1
对于上下直通的型芯，定制化增强整体式陶瓷铸型型芯抗蠕变性能的方法，包括以下步骤：
1)SL模型设计与制备
利用UG设计树脂模具的三维模型，设计固定孔，参照图1、图2和图3，其中，1为叶身；2为固定孔；3为上下直通的型芯；4为型壳；5为陶瓷棒；6为陶瓷铸型；将三维模型转换成STL文件，用切片软件切成厚度为0.15mm的二维切片文件，导入到光固化成型设备中制造出树脂模具，用工业酒精清除多余的树脂和支撑并晾干。
2)选用并插入陶瓷棒
对于上下贯通的型芯，参照图2，在固定孔内插入陶瓷棒过盈配合，底端用热熔胶固定在树脂模具底部。凝胶注模成型后，陶瓷棒埋在型芯内部，对型芯起到了增强作用，有效地提高了铸型制备过程中和后续铸造时型芯的抗蠕变性能。
3)制备陶瓷浆料并浇注
具体操作步骤为：
a.称量丙烯酰胺(AM，单体)、N,N-亚甲基双丙烯酰胺(MBAM，交联剂)、聚丙烯酸钠(分散剂)、聚乙二醇(PEG-6000)等有机物，混入去离子水中，搅拌至完全溶解，配制成一定有机物浓度的预混液；
b.称量固体粉料，并在容器中搅拌、混合均匀；
c.将混合后的固体粉料缓慢加入到预混液中，并不断搅拌，加入适量氨水调节pH值至9～11，制备出混合陶瓷浆料；
d.将混合陶瓷浆料在行星式球磨机上球磨1.5h，进行分散，获得流动性好的陶瓷浆料；
e.在真空环境中向步骤d制得的陶瓷浆料中加催化剂(四甲基乙二胺)、引发剂(硫酸铵水溶液)，然后灌注到树脂模具中，获得模具湿坯；
具体地，可以选取五种不同的陶瓷材料，碳化硅陶瓷、氧化钇陶瓷、氧化锆陶瓷、氧化铝陶瓷和氧化硅陶瓷。
陶瓷浆料中陶瓷粉末和矿化物占混合物体积的70％，余量为去离子水；矿化剂粉末占陶瓷粉末质量的10％，丙烯酰胺单体加入量为陶瓷粉末质量的2.8％；N,N-亚甲基双丙烯酰胺加入量为丙烯酰胺单体的的5％；分散剂加入量为陶瓷粉末质量的2.8％；有机物在去离子水中的质量浓度为30％；引发剂为丙烯酰胺单体的0.8％，催化剂为丙烯酰胺单体质量的0.05％；
4)坯体冷冻干燥
待步骤3)中的模具湿坯完全固化并耗散固化热后放入-10℃的冻柜中预冻，预冻工艺为慢冻，即先在-10℃环境中冷冻2～3h，待坯体中水完全冻结后将冻柜温度逐渐降至-80～-60℃，保温1～2h后将陶瓷冻坯取出并浸泡液氮进而去除表面树脂模壳，最后放入真空室内开始抽真空，隔板温度由-20℃缓慢升至-5℃，真空度控制在1～10Pa之间并保压，根据坯体大小选择真空干燥时间，一般为24-96小时，得到陶瓷铸型干坯；
5)烧失树脂模具与烧结
真空冷冻干燥完毕后取出陶瓷铸型干坯，放入马弗炉内进行预烧脱脂，预烧脱脂升温工艺为30℃/h升温至600℃，保温半小时后以240℃/h升温至1250℃并保温5h。脱脂完毕后待炉内温度降至100℃左右时可将陶瓷铸型取出，冷却至室温后使用喷气枪清理铸型内部的树脂残灰。然后在真空环境下将陶瓷铸型在MgCl2溶液中浸渍30分钟，干燥完成后进行终烧结。烧结工艺为：300℃/h升至1450℃并保温5h，烧结完毕后获得空心涡轮叶片整体式陶瓷铸型；
6)金属叶片铸造
为防止陶瓷铸型浇注金属液时型壳因热冲击而可能开裂的现象，浇铸前在表面涂挂2～3层熔模铸造用型壳料，风干后放入电炉内缓慢预热至1100℃，在真空浇铸炉内熔炼高温合金至液态准备浇铸，控制液态合金温度在1470℃进行真空浇铸，真空度控制在10Pa以下。浇铸凝固完成后将铸件取出空冷，去除表面型壳，使用化学方法进行脱芯处理，最终得到金属空心涡轮叶片。
实施例2
与实施例1不同在于，参照图2，对于上下直通的型芯，在型壳的底部设计固定孔，将陶瓷棒贯通插入，再用热熔胶固定即可。而对于非上下直通的型芯，如图4和图5，型芯的扭曲度高，刚度较好的陶瓷棒无法插入时，则在模具的上下两端分别设置固定孔，选用韧性好的陶瓷纤维7经过扭曲穿插于型腔中，陶瓷纤维7为氧化铝陶瓷纤维或碳化硅陶瓷纤维，根据陶瓷基体的材料进行选取，如图6所示，并用AB胶粘在两端的固定孔中。其余的工艺方法步骤与实施例1相同。
以上内容仅为说明本发明的技术思想，不能以此限定本发明的保护范围，凡是按照本发明提出的技术思想，在技术方案基础上所做的任何改动，均落入本发明权利要求书的保护范围之内。

Claims (10)

1.一种定制化增强陶瓷铸型型芯抗蠕变性能的方法，其特征在于，包括以下步骤：
1)利用UG软件设计树脂模具原型：
对于上下直通的型芯，在型芯的底部设计固定孔；对于非上下直通的弯曲型芯，在型芯底部和顶部对应设计固定孔；然后结合光固化快速成型法成型出带有固定孔的树脂模具原型；
2)选用并插入陶瓷棒/陶瓷纤维
对于上下直通的型芯，在型芯底部的固定孔中插入陶瓷棒；对于非上下直通的弯曲型芯，将陶瓷纤维弯曲后固定在型芯底部和顶部的固定孔中；
3)制备陶瓷浆料并浇注
制备凝胶注模用陶瓷浆料，利用凝胶注模成型工艺将陶瓷浆料灌注到经步骤2)处理后的树脂模具原型中，实现陶瓷铸型坯体的成型；
4)成型后处理
将成型陶瓷铸型坯体真空冷冻干燥后，焙烧除去树脂原型，再经高温烧结强化陶瓷铸型，获得完整的一体化陶瓷铸型。
2.根据权利要求1所述的定制化增强陶瓷铸型型芯抗蠕变性能的方法，其特征在于，所述固定孔的大小由型芯的直径确定，固定孔直径为型芯直径的1/10～1/5。
3.根据权利要求1所述的定制化增强陶瓷铸型型芯抗蠕变性能的方法，其特征在于，所述的陶瓷棒为碳化硅陶瓷棒、氧化钇陶瓷棒、氧化锆陶瓷棒、氧化铝陶瓷棒和氧化硅陶瓷棒的一种或几种。
4.根据权利要求1所述的定制化增强陶瓷铸型型芯抗蠕变性能的方法，其特征在于，所述的陶瓷纤维为氧化铝纤维和/或碳化硅纤维。
5.根据权利要求1所述的定制化增强陶瓷铸型型芯抗蠕变性能的方法，其特征在于，所述的陶瓷浆料的基体材料为碳化硅陶瓷、氧化钇陶瓷、氧化锆陶瓷、氧化铝陶瓷或氧化硅陶瓷。
6.根据权利要求1所述的定制化增强陶瓷铸型型芯抗蠕变性能的方法，其特征在于，陶瓷铸型采用与基体材料匹配的陶瓷棒或陶瓷纤维增强抗蠕变性能，且陶瓷棒或陶瓷纤维与基体材料具有相同的热膨胀系数。
7.根据权利要求6所述的定制化增强陶瓷铸型型芯抗蠕变性能的方法，其特征在于，碳化硅陶瓷铸型插入碳化硅陶瓷棒或碳化硅纤维；氧化钇陶瓷铸型插入氧化钇陶瓷棒、氧化铝陶瓷棒或氧化铝纤维；氧化锆陶瓷铸型插入氧化锆陶瓷棒、氧化铝陶瓷棒或氧化铝纤维；氧化铝陶瓷铸型插入氧化铝陶瓷棒、碳化硅陶瓷棒、氧化钇陶瓷棒、氧化锆陶瓷棒和氧化硅陶瓷棒，或者插入氧化铝纤维和碳化硅纤维；氧化硅陶瓷铸型插入碳化硅陶瓷棒、氧化硅陶瓷棒或碳化硅纤维。
8.根据权利要求1所述的定制化增强陶瓷铸型型芯抗蠕变性能的方法，其特征在于，陶瓷棒和陶瓷纤维采用AB胶固定在型芯的固定孔中。
9.根据权利要求1或8所述的定制化增强陶瓷铸型型芯抗蠕变性能的方法，其特征在于，陶瓷纤维或陶瓷棒与固定孔过盈配合。
10.根据权利要求1所述的定制化增强陶瓷铸型型芯抗蠕变性能的方法，其特征在于，步骤4)中，高温烧结的温度低于所用陶瓷棒或陶瓷纤维的熔点。
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