CN110560668A - Gravity casting method and equipment for ceramic hollow sphere/metal matrix composite foam material - Google Patents
Gravity casting method and equipment for ceramic hollow sphere/metal matrix composite foam material Download PDFInfo
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- CN110560668A CN110560668A CN201910854429.XA CN201910854429A CN110560668A CN 110560668 A CN110560668 A CN 110560668A CN 201910854429 A CN201910854429 A CN 201910854429A CN 110560668 A CN110560668 A CN 110560668A
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- 238000005266 casting Methods 0.000 title claims abstract description 199
- 239000000919 ceramic Substances 0.000 title claims abstract description 119
- 238000000034 method Methods 0.000 title claims abstract description 72
- 230000005484 gravity Effects 0.000 title claims abstract description 54
- 239000006261 foam material Substances 0.000 title claims abstract description 38
- 239000011156 metal matrix composite Substances 0.000 title claims abstract description 38
- 229910052751 metal Inorganic materials 0.000 claims abstract description 112
- 239000002184 metal Substances 0.000 claims abstract description 112
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- 229910002804 graphite Inorganic materials 0.000 claims description 5
- 239000010439 graphite Substances 0.000 claims description 5
- 238000005495 investment casting Methods 0.000 claims description 5
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 5
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- NRTOMJZYCJJWKI-UHFFFAOYSA-N Titanium nitride Chemical compound [Ti]#N NRTOMJZYCJJWKI-UHFFFAOYSA-N 0.000 claims description 4
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 claims description 4
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- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 claims description 4
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 4
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 4
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 claims description 4
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 claims description 4
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Classifications
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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
- B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
- B22D23/04—Casting by dipping
-
- 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
Abstract
The invention provides a gravity casting method and equipment of a ceramic hollow sphere/metal matrix composite foam material on the basis of the existing metal gravity casting equipment and process, wherein the ceramic hollow sphere and a filter screen are filled in a casting mould in the molding process, the casting mould is preheated and then adopts the traditional gravity casting method with low cost and simple process flow, and the metal liquid is fully infiltrated and filled in gaps among the hollow spheres in the casting process to obtain the low-density ceramic hollow sphere/metal matrix composite foam material; aiming at a complex thin-wall casting with a large size, a heat source is adopted outside a casting mold to heat molten metal in the seepage and mold filling processes in the pouring process, so that the molten metal is ensured to fully seep in a long flowing distance. The ceramic hollow sphere/metal matrix composite foam material prepared by the method has the functions of low density, energy absorption, sound insulation, shock absorption and electromagnetic shielding, the ceramic hollow spheres in the composite foam material are uniformly distributed, and the quality of the foam metal material is high.
Description
Technical Field
The invention belongs to the field of foam metal manufacturing, and particularly relates to a ceramic hollow sphere/metal matrix composite foam material, a gravity casting method and gravity casting equipment thereof.
Background
The foam metal material has the excellent characteristics of low density, energy absorption, shock absorption, sound insulation, sound absorption and the like, and is always a hot point direction for the development and application of novel materials at home and abroad. The ceramic hollow ball is implanted into a metal matrix to manufacture a ceramic ball/metal matrix composite material, belonging to the new direction of foam metal preparation. Compared with the traditional foam metal, the ceramic ball/metal matrix composite material has higher relative density and improved mechanical property, and can be applied to manufacturing equipment such as aircraft carrier flight decks, light fast-assembly bridges, military vehicle anti-mine bottom plates, bulletproof composite armors, heavy equipment airborne buffer platforms, light missile launching well covers, train anti-collision structures, railway and highway sound insulation barriers, highway vibration isolation pads, safety school buses and the like.
The first way to prepare ceramic hollow sphere/metal matrix foam metal materials by casting process at present is to promote the seepage process of metal liquid to the preform by negative pressure during casting process, for example:
(1) The invention patent with publication number CN109513906A provides a method for producing a hollow sphere metal composite foam material, which comprises the following steps: preparing a mould, wherein the mould is provided with a cavity, and the shape of the cavity is set according to the shape of a structural part to be prepared; preheating hollow ceramic balls, and filling the hollow ceramic balls into the cavity, wherein the hollow ceramic balls are closely arranged; heating and melting the metal raw material, and heating the metal melt to a casting temperature for later use; pouring the metal melt into the cavity, connecting the cavity with a negative pressure tank, pumping negative pressure, and infiltrating and filling the metal melt into gaps of the hollow ceramic balls under a negative pressure environment; and naturally cooling the metal melt, and demolding to obtain the hollow sphere metal composite foam material structural member. The method needs to add a negative pressure device and a matched mould with good tightness, has high manufacturing cost and complex flow and is not suitable for metal poured under vacuum condition.
(2) The invention patent with the publication number of CN104588617B provides a method for preparing a metal-based light composite material in one step, and the patent adopts a method that hollow balls are poured into a casting mold for preheating, the ceramic balls account for 2/3 of the volume of the casting mold, molten metal is poured from the upper part of the casting mold, and air is pumped from the lower part of the casting mold. The method is similar to the production method of the hollow sphere metal composite foam material provided by the invention patent with the publication number of CN109513906A in the problems, the vacuumizing time is long, the infiltration speed is slow, the production efficiency is low, the volume fraction of the prepared composite hollow sphere is low, the material density is high, and the method is not suitable for engineering popularization and application.
(3) The invention patent with the publication number of CN106435242A provides a metal-based ceramic composite material and a preparation method thereof, wherein the metal-based ceramic composite material is prepared by a vacuum infiltration flow method, hollow ceramic balls of the metal-based hollow ceramic ball composite material prepared by the method are distributed loosely, the occupied volume of the hollow ceramic balls is only 45% -55% of that of the composite material, the overall lightweight level of the composite material is poor, the infiltration of molten metal is ensured by the vacuum in a hollow ball accumulation casting mold, the accumulation mode of the hollow balls needs to be kept unchanged in the infiltration flow process, and the operation difficulty is high.
(4) The invention patent with the publication number of CN103614586B provides Al2O3The preparation method of the hollow sphere/aluminum porous composite material adopts a 20-40 Mpa pressure seepage method to prepare the aluminum-based aluminum oxide hollow sphere composite foam, the problems of the method are similar to those of the production method of the hollow sphere metal composite foam material provided by the invention patent with the publication number of CN109513906A, besides, the hollow sphere needs to be made into a precast block, the process is complex, and the hollow ceramic sphere is easy to break under high pressure.
the second way of preparing the hollow ceramic sphere/metal-based foam metal material by the casting process at present is to promote the seepage process of the metal liquid to the preform by stirring during the casting process, such as:
(1) the invention patent with the publication number of 108486400A provides a metal-based hollow sphere composite foam material and a preparation method thereof. The composite foam material comprises a metal matrix and ceramic hollow spheres, wherein the ceramic hollow spheres are uniformly distributed in the metal matrix. The preparation method is simple to operate and low in cost, and the metal-based hollow sphere composite foam material is prepared by adding the ceramic hollow sphere into the metal liquid and stirring the ceramic hollow sphere and the metal liquid after solidification. The method is suitable for the condition that the density of the ceramic ball is not similar to that of the molten metal, the prepared composite material cannot achieve the light weight target, if the density of the ceramic ball is low, the ceramic ball floats in the molten metal, and a corresponding solution is not provided in the patent.
(2) The invention patent with the publication number of CN104498759B provides a preparation method of a mixed hollow sphere metal-based light composite material, which is characterized in that a plurality of hollow sphere materials are mixed and added into a tackified alloy liquid, and the metal-based light composite material is prepared by electromagnetic stirring. The metal-based hollow sphere composite material prepared by the method has poor uniformity and high density due to various factors such as buoyancy, stirring and the like, and is difficult to prepare the light and uniform metal-based composite material. And the tackifying measure not only increases the manufacturing cost, but also limits the types of applicable metals.
The third way of preparing the hollow ceramic sphere/metal-based foam metal material by the casting process at present is to promote the seepage process of the metal liquid to the preform by an extrusion method during the casting process, such as:
(1) the invention patent with the publication number of CN103667849B provides a metal-based ceramic composite material and a manufacturing method and application thereof, wherein a solid ceramic ball composite material is prepared by a direct extrusion casting molding method, and the density of the composite material prepared by the method is high.
In summary, the existing preparation technology of the ceramic hollow sphere/metal matrix composite has the defects of large relative density, poor uniformity, limited casting shape and size and metal types, complex process flow, fragile ceramic hollow sphere, high manufacturing cost, poor applicability to different metals and the like of the composite foam material.
Disclosure of Invention
In order to solve the technical problems, the invention aims to provide a gravity casting method capable of preparing a ceramic hollow sphere/metal matrix composite foam material with low density and uniformly distributed internal ceramic hollow spheres, and the gravity casting method can be used for manufacturing castings with various metal shapes by simple improvement on the basis of metal gravity casting equipment and metal gravity casting process.
The purpose of the invention is realized by adopting the following technical scheme. The gravity casting method of the ceramic hollow sphere/metal matrix composite foam material provided by the invention comprises the following steps of:
[ step one ]: preparing and manufacturing a casting mold for gravity casting, wherein the casting mold is provided with a cavity, and the size of the cavity is set according to a casting product and a pouring system; at least one of the inside of a cavity corresponding to the casting product in the casting mold and the inside of a cavity corresponding to the gating system is provided with a filter screen placing groove;
[ step two ]: preparing ceramic hollow balls and a filter screen with the mesh number capable of preventing the ceramic hollow balls with the theoretically minimum grain size from passing through;
[ step three ]: placing the ceramic hollow spheres into a cavity corresponding to a casting product in a casting mold, enabling the ceramic hollow spheres to be closely arranged, placing the filter screen into a filter screen placing groove, and fixing the ceramic hollow spheres in the cavity corresponding to the casting product in the casting mold before pouring metal liquid to obtain a set of casting mold filled with the ceramic hollow spheres and the filter screen;
[ step four ]: preheating a casting mold provided with the ceramic hollow spheres and the filter screen, placing the preheated casting mold in a casting area, and then quickly casting molten metal obtained by heating and melting metal raw materials into the casting mold; or
Firstly, placing a casting mold provided with ceramic hollow spheres and a filter screen to a casting area, arranging heat source equipment on the outer side of the casting mold, then quickly casting molten metal obtained after heating and melting metal raw materials into the casting mold, simultaneously starting the heat source equipment to heat the molten metal in the seepage and filling process, and closing the heat source equipment after the molten metal is completely filled;
[ step five ]: and after the molten metal is solidified and formed, closing the gravity casting equipment, removing the casting mold and the casting head structure, and cleaning to obtain the ceramic hollow sphere/metal matrix composite foam material casting.
Further, in the step one, the casting mold is one of a sand mold, a graphite mold and a precision casting mold shell, and the manufacturing method thereof is at least one of numerical control machining, 3D printing and mold manufacturing.
Further, in the second step, at least one of titanium carbide, boron carbide, silicon carbide, titanium nitride, silicon nitride, aluminum oxide and zirconium oxide is used as the material of the ceramic hollow sphere, and the particle size of the ceramic hollow sphere is in the range of 0.5-8 mm.
further, in the [ step two ], at least one of a ceramic fiber net and a glass fiber net is used for the filter net.
Further, the time for completely filling the molten metal in the step four is 1-60 seconds after the pouring process is finished. The gravity casting method of the ceramic hollow sphere/metal matrix composite foam material has the following beneficial effects:
1. The method has the advantages that the method can realize the full seepage of the metal liquid in the gaps between the ceramic hollow spheres by adopting the existing metal gravity casting equipment and process or adding simple heat source equipment on the basis of the existing metal gravity casting equipment and process, and has the advantages of good seepage effect, simple process flow, high production efficiency, low manufacturing cost and the like;
2. the method has the advantages that the molten metal in the seepage and filling process is heated by the heat source, the preheating step in the prior art can be replaced, the promotion effect on the seepage process of the molten metal is more obvious, the molten metal can be fully permeated and filled, the method can be used for manufacturing simple or complex large-size thin-wall casting products, and the adaptability to products with different shapes and manufacturing difficulties is high;
3. the process is simple, the molten metal filling effect is good, stable production can be realized, and batch production and personalized customization of products are easy to realize;
4. the sand mould, the graphite mould and the precision casting mould shell used for gravity casting are easy to realize mould separation, and the distribution area of the ceramic hollow sphere/metal matrix composite foam material in the casting structure can be controlled by the mould separation design and the placement position control of the filter screen.
The ceramic hollow sphere/metal matrix composite foam material prepared by the gravity casting method has the following advantages:
1. The prepared ceramic hollow sphere/metal matrix composite foam material has the functions of low density, energy absorption, sound insulation, shock absorption and electromagnetic shielding;
2. The ceramic hollow spheres in the manufactured ceramic hollow sphere/metal matrix composite foam material are uniformly distributed, and the quality of the foam metal material is high.
The purpose of the invention is realized by adopting the following technical scheme. The gravity casting equipment for the ceramic hollow sphere/metal matrix composite foam material is provided with a pouring area for placing a casting mold, and the pouring area is provided with a heat source device which is positioned outside the casting mold when the casting mold is placed in the pouring area and is used for heating molten metal in a seepage mold filling process when the molten metal is poured into a cavity in the casting mold.
According to the gravity casting equipment for the ceramic hollow spheres/the metal matrix composite foam material, disclosed by the invention, the simple heat source equipment is added on the basis of the structure of the existing metal gravity casting equipment, so that the metal liquid can be fully infiltrated in gaps among the ceramic hollow spheres, and the qualified ceramic hollow spheres/metal matrix composite foam material is manufactured.
The foregoing description is only an overview of the technical solutions of the present invention, and in order to make the technical means of the present invention more clearly understood, the present invention may be implemented in accordance with the content of the description, and in order to make the above and other objects, features, and advantages of the present invention more clearly understood, the following preferred embodiments are described in detail with reference to the accompanying drawings.
drawings
FIG. 1 is a gravity casting process design of a ceramic hollow sphere/metal matrix composite foam sheet;
FIG. 2 is a gravity casting process design of a ceramic hollow sphere/metal matrix composite foam casting with a heat source device;
[ reference numerals ]
1. A pouring system; 2. a filter screen; 3. casting; 4. filling a ceramic hollow ball structure in the casting; 5. an electromagnetic induction coil.
Detailed Description
The following describes the specific structure, operation principle and operation process of the present invention in detail with reference to the accompanying drawings and embodiments.
example one
this example designs a gravity casting method for a ceramic hollow sphere/metal matrix composite foam sheet casting, preferably, the casting has a thickness within 20 mm. With reference to fig. 1, the gravity casting method comprises the following steps:
[ step one ]: preparing and manufacturing a casting mold for gravity casting, wherein a cavity is arranged in the casting mold, the size of the cavity is set according to a casting product and a pouring system, and the parting of the casting mold needs to ensure that the ceramic hollow spheres and the filter screen can be conveniently added in addition to considering the manufacturing and assembling processes. Meanwhile, a filter screen placing groove is preset at the upper position of the inner pouring gate of the casting mold, so that the filter screen can be conveniently removed along with a pouring system in the casting cleaning process at the later stage.
specifically, the casting mold is one of a sand mold, a graphite mold and a precision casting mold shell, and the manufacturing method of the casting mold is one or more of numerical control machining, 3D printing and mold manufacturing.
[ step two ]: preparing the ceramic hollow ball and the filter screen. The filter screen is used for fixing the ceramic hollow ball in a cavity corresponding to a casting product in the casting mould before metal liquid is poured, and the mesh number of the filter screen is required to be capable of preventing the ceramic ball with the theoretically minimum particle size from passing through.
specifically, the ceramic hollow sphere is made of at least one of titanium carbide, boron carbide, silicon carbide, titanium nitride, silicon nitride, aluminum oxide and zirconium oxide, and the particle size of the ceramic hollow sphere is in the range of 0.5-8 mm.
Specifically, the filter screen uses one or two of a ceramic fiber net and a glass fiber net.
[ step three ]: and sequentially placing the ceramic hollow ball and the filter screen into a cavity of the casting mould. The ceramic hollow balls are closely arranged in the cavities corresponding to the casting products, and the filter screen is placed in a filter screen placing groove preset at the upper position of the inner sprue and used for fixing the ceramic hollow balls in the cavities corresponding to the casting products to prevent the ceramic hollow balls from entering a pouring system. The mold is then assembled and preheated.
[ step four ]: and placing the casting mold into a pouring area of gravity casting equipment, heating and melting the metal raw material, and quickly pouring molten metal into the casting mold by adopting a gravity casting method.
[ step five ]: and after the molten metal is solidified and formed, closing the gravity casting equipment, removing the casting mold and the casting head structure, and cleaning to obtain the ceramic hollow sphere/metal matrix composite foam sheet casting.
On the basis of metal gravity casting equipment and process for existing production, the ceramic hollow ball and the filter screen are selected, the porous structure occupying process of the foam material and the fixation of the ceramic ball are achieved, and the thin ceramic hollow ball/metal matrix composite foam sheet can be manufactured. The foam metal sheet can be applied to the fields of light weight, noise reduction, energy absorption, electromagnetic shielding and the like, and the sandwich structure plate manufactured by compounding the sheet with other plates can be used for manufacturing light structure members of high-end equipment and civil products such as aerospace ships and weapons, and functional members such as noise reduction, energy absorption, electromagnetic shielding and the like.
In this embodiment, the filter screen placing groove is preset at a position near the inner gate in the casting mold, but in other embodiments of the present invention, the filter screen placing groove may be preset at other positions in the cavity corresponding to the gating system as needed.
Example two
compared with the existing gravity casting equipment, the gravity casting equipment for the ceramic hollow sphere/metal matrix composite foam material provided by the invention has the following differences: the invention adds a set of heat source equipment which is positioned outside a casting mold when the casting mold is placed in a pouring area and is used for heating molten metal in a seepage and mold filling process when the molten metal is poured into a cavity in the casting mold on the existing gravity casting equipment.
Referring to fig. 2, in the present embodiment, a set of electromagnetic induction heater is additionally arranged in a pouring area for placing a casting mold on a gravity casting device, and a plurality of electromagnetic induction coils 5 included in the electromagnetic induction heater are arranged in the pouring area along a vertical direction.
before pouring molten metal, the casting mold filled with the ceramic hollow spheres is placed in a pouring area of gravity casting equipment, and at the moment, a plurality of electromagnetic induction coils surround the outer side of the casting mold layer by layer along the vertical direction. Then melting metal into molten metal through melting equipment, pouring the molten metal into a cavity of a casting mold through a pouring cup for seepage and mold filling, simultaneously starting an electromagnetic induction heater, and heating the molten metal in the seepage and mold filling process by a plurality of electromagnetic induction coils positioned on the outer side of the casting mold, thereby improving the process of flowing and cooling the molten metal in the existing gravity casting equipment into the process of flowing and heating and offsetting the cooling, and ensuring that the molten metal is always kept in a liquid state before the mold filling is complete. And after the mold is completely filled, closing the electromagnetic induction heater, naturally cooling the molten metal in the casting mold, and finally solidifying and forming to obtain the qualified ceramic hollow sphere/metal matrix composite foam material.
EXAMPLE III
Referring to fig. 2, for a large-sized complex thin-walled casting, on the basis of the gravity casting apparatus of the second embodiment, the gravity casting method for a ceramic hollow sphere/metal matrix composite foam casting is designed, and includes the following steps:
[ step one ]: preparing and manufacturing a casting mold for gravity casting, wherein a cavity is arranged in the casting mold, the size of the cavity is set according to a casting product and a pouring system, and the parting of the casting mold needs to consider the processes of filling ceramic hollow spheres and placing filter screens besides the manufacturing and assembling processes. Simultaneously, a placing groove for the filter screen is preset in a cavity corresponding to the casting system in the casting mold, so that the filter screen can be conveniently removed along with the casting system in the casting cleaning process in the later period.
specifically, the casting mold is one of a sand mold, a graphite mold and a precision casting mold shell, and the manufacturing method of the casting mold is one or more of numerical control machining, 3D printing and mold manufacturing.
[ step two ]: preparing the ceramic hollow ball and the filter screen. The filter screen is used for fixing the ceramic hollow ball in a cavity corresponding to a casting product in the casting mould before metal liquid is poured, and the mesh number of the filter screen is required to be capable of preventing the ceramic ball with the theoretically minimum particle size from passing through.
Specifically, the ceramic hollow sphere is made of at least one of titanium carbide, boron carbide, silicon carbide, titanium nitride, silicon nitride, aluminum oxide and zirconium oxide, and the particle size of the ceramic hollow sphere is in the range of 0.5-8 mm.
Specifically, the filter screen uses one or two of a ceramic fiber net and a glass fiber net.
[ step three ]: and sequentially placing the ceramic hollow ball and the filter screen into a cavity of the casting mould. The ceramic hollow balls are closely arranged in the cavities corresponding to the casting products, and the filter screen is placed in a filter screen placing groove preset in the cavity corresponding to the pouring system to fix the ceramic hollow balls in the cavities corresponding to the casting products, so that the ceramic hollow balls are prevented from entering the pouring system. And then assembling the casting mold, and fastening and clamping the casting mold by using a tool clamp.
[ step four ]: and placing the casting mold in a pouring area of gravity casting equipment, wherein a plurality of electromagnetic induction coils are arranged on the outer side of the casting mold in a surrounding mode. And then heating and melting the metal raw material, quickly pouring molten metal into the casting mold by adopting a gravity casting method, simultaneously starting an electromagnetic induction heater to heat the molten metal in the seepage and mold filling process, and closing the electromagnetic induction heater after the molten metal is completely filled.
for large-size complex thin-wall castings, the existing gravity casting equipment and process are difficult to ensure the complete seepage and mold filling of molten metal. In the embodiment, the electromagnetic induction heater arranged outside the casting mold is adopted to heat the molten metal in the seepage and mold filling process in the pouring process, the step can replace the preheating step in the prior art, the promotion effect on the molten metal seepage process is more remarkable, and the molten metal can be ensured to be fully permeated and filled.
the time for the molten metal to be completely filled is determined according to the type of the molten metal, the heating efficiency of the electromagnetic induction heater and the flowing length of the molten metal in the ceramic hollow ball area. In the embodiment, the time for completely filling the molten metal is 1-60 seconds after the pouring process is finished.
[ step five ]: and after the molten metal is solidified and formed, closing the gravity casting equipment, removing the casting mold and the casting head structure, and cleaning to obtain the ceramic hollow sphere/metal matrix composite foam material casting.
On the basis of the existing metal gravity casting equipment and process for production, an electromagnetic induction heater is additionally arranged on the outer side of a casting mold and is used for heating molten metal in the seepage and mold filling process after the molten metal is poured into the casting mold, so that the molten metal is ensured to fully flow and seep and fill under a longer flowing distance, and the preparation of a complex composite foam metal casting is realized; meanwhile, the ceramic hollow ball and the filter screen are adopted to respectively realize the porous structure occupying process of the foam material and the fixation of the ceramic ball. The complex casting of the composite foam metal prepared by the embodiment can be applied to the fields of light weight, noise reduction, energy absorption, electromagnetic shielding and the like, and is used for manufacturing functional parts of light weight, noise reduction, energy absorption, electromagnetic shielding and the like in various fields.
In this embodiment, the electromagnetic induction heating device is used as a heat source device for heating the molten metal in the percolation filling process, but other types of heat source devices may be adopted in other embodiments of the present invention.
In this embodiment, the filter screen placing groove is preset in the cavity corresponding to the casting system in the casting mold, and certainly, in other embodiments of the present invention, the filter screen placing groove may be preset in the cavity corresponding to the casting product, so as to control the distribution area of the ceramic hollow sphere/metal matrix composite foam material in the casting structure.
Finally, the above embodiments are only used for illustrating the technical solutions of the present invention and not for limiting, and other modifications or equivalent substitutions made by the technical solutions of the present invention by those of ordinary skill in the art should be covered within the scope of the claims of the present invention as long as they do not depart from the design and scope of the technical solutions of the present invention.
Claims (7)
1. The gravity casting method of the ceramic hollow sphere/metal matrix composite foam material is characterized by comprising the following steps of:
[ step one ]: preparing and manufacturing a casting mold for gravity casting, wherein the casting mold is provided with a cavity, and the size of the cavity is set according to a casting product and a pouring system; at least one of the inside of a cavity corresponding to the casting product in the casting mold and the inside of a cavity corresponding to the gating system is provided with a filter screen placing groove;
[ step two ]: preparing ceramic hollow balls and a filter screen with the mesh number capable of preventing the ceramic hollow balls with the theoretically minimum grain size from passing through;
[ step three ]: placing the ceramic hollow spheres into a cavity corresponding to a casting product in a casting mold, enabling the ceramic hollow spheres to be closely arranged, placing the filter screen into a filter screen placing groove, and fixing the ceramic hollow spheres in the cavity corresponding to the casting product in the casting mold before pouring metal liquid to obtain a set of casting mold filled with the ceramic hollow spheres and the filter screen;
[ step four ]: preheating a casting mold provided with the ceramic hollow spheres and the filter screen, placing the preheated casting mold in a casting area, and then quickly casting molten metal obtained by heating and melting metal raw materials into the casting mold; or
Firstly, placing a casting mold provided with ceramic hollow spheres and a filter screen to a casting area, arranging heat source equipment on the outer side of the casting mold, then quickly casting molten metal obtained after heating and melting metal raw materials into the casting mold, simultaneously starting the heat source equipment to heat the molten metal in the seepage and filling process, and closing the heat source equipment after the molten metal is completely filled;
[ step five ]: and after the molten metal is solidified and formed, closing the gravity casting equipment, removing the casting mold and the casting head structure, and cleaning to obtain the ceramic hollow sphere/metal matrix composite foam material casting.
2. The gravity casting method of the ceramic hollow sphere/metal matrix composite foam material according to claim 1, wherein the casting mold in the step one is one of a sand mold, a graphite mold and a precision casting film shell, and the manufacturing method thereof is at least one of numerical control machining, 3D printing and mold manufacturing.
3. The gravity casting method of hollow ceramic sphere/metal matrix composite foam according to claim 1, wherein at least one of titanium carbide, boron carbide, silicon carbide, titanium nitride, silicon nitride, aluminum oxide and zirconium oxide is used as the material of the hollow ceramic sphere in the step two, and the particle size of the material is in the range of 0.5-8 mm.
4. The gravity casting method for ceramic hollow sphere/metal matrix composite foam material according to claim 1, wherein at least one of ceramic fiber mesh and glass fiber mesh is used for the filter screen in the step (II).
5. The gravity casting method of the ceramic hollow sphere/metal matrix composite foam material according to claim 1, wherein the time for completely filling the molten metal in the step four is 1-60 seconds after the pouring process is finished.
6. A hollow ceramic sphere/metal matrix composite foam produced by the gravity casting method of any one of claims 1 to 5.
7. The gravity casting equipment for the ceramic hollow sphere/metal matrix composite foam material is provided with a pouring area for placing a casting mold, and is characterized in that the pouring area is provided with heat source equipment which is positioned outside the casting mold when the casting mold is placed in the pouring area and is used for heating molten metal in a seepage and filling process when the molten metal is poured into a cavity in the casting mold.
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