CN110871259A - Preparation method and application of aluminum activated ceramic surface layer slurry - Google Patents
Preparation method and application of aluminum activated ceramic surface layer slurry Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
- B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C3/00—Selection of compositions for coating the surfaces of moulds, cores, or patterns
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
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Abstract
The invention relates to the field of precision casting and material preparation, in particular to a preparation method and application of aluminum activated ceramic surface layer slurry. The base material is white corundum powder, the added component material is cobalt aluminate powder, the binder is ethyl silicate, and the mixture is mixed and stirred and then the viscosity is adjusted by deionized water to prepare the surface layer slurry. And then uniformly coating the surface layer slurry on a wax mould, naturally drying, dewaxing and preparing the shell. Before casting, the active element aluminum powder is sprayed in a cavity in a vacuum furnace, the aluminum and the cobalt oxide in the cobalt aluminate powder are subjected to a displacement reaction during casting, and the cobalt particles with face-centered cubic lattices are released and can be used as heterogeneous nucleation points to induce the nucleation of a large number of grains. The ceramic surface layer manufactured by the method has better chemical adaptability with high-temperature metal melt, and is applied to the precision casting industry.
Description
The technical field is as follows:
the invention relates to the field of precision casting and material preparation, in particular to a preparation method and application of aluminum activated ceramic surface layer slurry.
Background art:
in order to meet the requirements of high-end aerospace castings and future development, all links of the precision casting process must be strictly controlled, shell manufacturing is a key process in the precision casting process, and the surface quality of the shell is more and more concerned.
During the casting process, various physical and chemical actions can occur when the surface of the shell contacts with the high-temperature molten metal due to the high-temperature action. For example, chromium in the alloy reacts with cobaltous oxide to form chromium spinel, which causes surface sand-sticking and surface grain structure abnormality. The surface layer of the casting needs to be polished and repaired in the subsequent process, so that the process cost is increased, and the mechanical property and the application level of the casting are reduced.
Disclosure of Invention
The invention aims to provide a preparation method and application of aluminum activated ceramic surface layer slurry, which are suitable for the casting process of all metal materials and solve the problems of sand sticking of castings, abnormal and thick surface layer structure and the like.
The technical scheme of the invention is as follows:
a preparation method of aluminum activated ceramic surface layer slurry comprises the steps of mixing a base material of white corundum powder, an added component material of cobalt aluminate powder and an adhesive of ethyl silicate according to a proportion, uniformly stirring, and adjusting the viscosity of the slurry by deionized water to prepare the surface layer slurry; the weight ratio of the white corundum powder to the cobalt aluminate powder is 10: (4-8), wherein the ratio of the weight of the ethyl silicate to the total weight of the white corundum powder and the cobalt aluminate powder is 10: (6-10).
According to the preparation method of the aluminum activated ceramic surface layer slurry, the granularity of the white corundum powder is 10-30 mu m, and the granularity of the cobalt aluminate powder is 1-10 mu m.
The preparation method of the aluminum activated ceramic surface layer slurry comprises the steps of mixing the raw materials of white corundum powder, cobalt aluminate powder and ethyl silicate of the surface layer slurry, and stirring the mixture by using a stirrer for more than or equal to 4 hours.
The application of the aluminum activated ceramic surface layer slurry prepared by the method is applicable to the casting process of all metal materials; firstly, uniformly coating surface layer slurry on a wax mould, naturally drying, coating back layer ceramic slurry, naturally drying, dewaxing, and preparing a shell; then, after the shell is placed in a heat-preserving barrel for heat preservation, spraying aluminum powder to the inner cavity of the shell, and pouring a casting immediately after spraying the aluminum powder; and finally, detecting the surface quality and the grain size.
The application of the aluminum activated ceramic surface layer slurry has the advantage that the surface layer slurry is uniformly coated on the wax mold, and the thickness of the surface layer slurry is 0.2-0.8 mm.
In the application of the aluminum activated ceramic surface layer slurry, after the surface layer slurry is coated on a wax mold, the surface layer slurry is naturally dried for 4-8 hours in an environment with the temperature of 18-24 ℃ and the humidity of 30-80%.
The application of the aluminum activated ceramic surface layer slurry comprises the steps of coating the back layer ceramic slurry with the thickness of 1-8 mm after the surface layer slurry is dried, and naturally drying for 4-8 hours; dewaxed and formed into a shell.
The application of the aluminum activated ceramic surface layer slurry is that before casting, the shell is insulated in a heat-insulating barrel at the temperature of 600-700 ℃ for more than 4 hours.
The application of the aluminum activated ceramic surface layer slurry comprises the steps of spraying aluminum powder to an inner cavity of a shell in a heat-insulating barrel in a vacuum furnace before pouring, wherein the spraying amount accounts for 0.1-1.0% of the total weight of cobalt aluminate powder.
The application of the aluminum activated ceramic surface layer slurry has the advantages that the granularity of sprayed aluminum powder is 1-10 mu m, and the aluminum powder is immediately poured after being sprayed.
The design idea of the invention is as follows:
according to the invention, the defect statistics of the cast produced actually shows that the proportion of the sticky sand and the coarse surface crystal grains in all the defects is relatively large. Analysis shows that the two defects are related to the surface layer property, Cr, Fe and the like in the alloy. Al has a higher reducing power for cobalt oxide than Cr, and aluminum has a low melting point and tends to adhere to the heated shell surface layer. The product Co after casting is directly used as a nucleation substrate. Therefore, Al element is adhered to the surface of the surface layer, and the effects of protecting elements such as Cr, Fe and the like in the alloy and strengthening grain refinement are achieved.
The invention has the advantages and beneficial effects that:
1. the preparation method and the application of the aluminum activated ceramic surface layer slurry can practically and effectively solve the problems of sand sticking of castings, abnormal thick surface structure and the like, and improve the quality and the performance of the castings.
2. The preparation method and the application of the aluminum activated ceramic surface layer slurry are convenient to operate, easy to control, beneficial to improving the qualified rate of castings, cost-saving, and high in economic benefit and long-term application prospect.
3. According to the invention, the surface layer is coated with an active element aluminum before casting, so that the aluminum and the cobalt oxide are subjected to a replacement reaction, the formation of chromium ore slag is prevented, cobalt atoms are replaced from the cobalt oxide, and the surface grain refinement of the casting is facilitated.
4. The ceramic surface layer manufactured by the method has better chemical adaptability with high-temperature metal melt, and is applied to the precision casting industry.
Description of the drawings:
FIG. 1 shows the morphology of the grains prepared under the conditions of example 1.
FIG. 2 shows the morphology of grains prepared using a shell without added aluminum powder.
FIG. 3 shows the morphology of the grains prepared under the conditions of example 2.
FIG. 4 shows the morphology of the grains prepared under the conditions of example 3.
The specific implementation mode is as follows:
in the specific implementation process, the adopted matrix material is white corundum powder, the added component material is cobalt aluminate powder, the binder is ethyl silicate, and the mixture is mixed and stirred and then the viscosity is adjusted by deionized water to prepare the surface layer slurry. And then coating the surface layer slurry on a wax mould uniformly, dewaxing after natural drying to prepare a shell, and finally casting to obtain a casting. Before casting, the active element aluminum powder is sprayed in a cavity in a vacuum furnace, the aluminum and the cobalt oxide in the cobalt aluminate powder are subjected to a displacement reaction during casting, and the cobalt particles with face-centered cubic lattices are released and can be used as heterogeneous nucleation points to induce the nucleation of a large number of grains.
The method comprises the first step of mixing white corundum powder, cobalt aluminate powder and ethyl silicate in proportion, uniformly stirring, adjusting the viscosity by using deionized water, measuring the viscosity of the slurry by using a No. 5 flow cup, and adjusting the viscosity value to be within the range of 10-40 s to obtain the surface layer slurry. The mixture ratio is as follows: the weight ratio of the white alundum powder to the cobalt aluminate powder is 10: (4-8), wherein the ratio of the weight of the ethyl silicate to the total weight of the white corundum powder and the cobalt aluminate powder is 10: (6-10). The particle size distribution is as follows: the granularity of the white corundum powder is 10-30 mu m, and the granularity of the cobalt aluminate powder is 1-10 mu m. Stirring with L-shaped stirrer for 4 hr or more. And step two, uniformly coating the surface layer slurry on a wax mold, wherein the thickness of the surface layer slurry is 0.2-0.8 mm, and naturally drying the surface layer slurry for 4-8 hours in an environment with the temperature of 18-24 ℃ and the humidity of 30-80%. And thirdly, coating conventional back layer ceramic slurry with the thickness of 1-8 mm, and naturally drying for 4-8 hours. And fourthly, dewaxing to prepare the shell. And fifthly, casting under the same equipment and process parameters, before casting, keeping the temperature of the shell in a heat-preservation barrel at 600-700 ℃ for more than 4 hours, spraying aluminum powder into the inner cavity of the shell, wherein the spraying amount accounts for 0.1-1.0% of the total weight of the cobalt aluminate powder, the granularity is 1-10 mu m, and immediately casting after spraying the aluminum powder. And finally, detecting the surface quality and the grain size.
The present invention will be explained in further detail below by way of examples and figures.
Example 1
In this embodiment, in the first step, white corundum powder, cobalt aluminate powder, and ethyl silicate are mixed in proportion and stirred uniformly to obtain a surface layer slurry. The mixture ratio is as follows: the weight ratio of the white alundum powder to the cobalt aluminate powder is 5: 4, the weight ratio of the ethyl silicate to the total weight of the white corundum powder and the cobalt aluminate powder is 1: 1. the particle size distribution is as follows: the granularity of the white corundum powder is 25.2 mu m, the granularity of the cobalt aluminate powder is 7.5 mu m, the white corundum powder and the cobalt aluminate powder are stirred for 20 hours, the mixture is mixed and stirred, the viscosity of the mixture is adjusted by deionized water, and the viscosity value of the slurry is measured by a No. 5 flow cup for 30s, so that the surface layer slurry is prepared. And secondly, uniformly coating the surface layer slurry on a wax mold, wherein the thickness of the surface layer slurry is 0.5mm, and naturally drying the surface layer slurry for 7 hours in an environment with the temperature of 20 ℃ and the humidity of 60%. And thirdly, coating back layer ceramic slurry with the thickness of 4.35mm, naturally drying for 8 hours, and dewaxing to prepare the shell. And fourthly, before casting, placing the shell in a 650 ℃ heat-preserving barrel, preserving heat for 8 hours, and spraying aluminum powder into the inner cavity of the shell, wherein the spraying amount accounts for 0.1 percent of the total weight of the cobalt aluminate powder, and the granularity is 10 mu m. And fifthly, casting a casting immediately after spraying aluminum powder, wherein the casting alloy is of the brand number: K418B, and carrying out surface quality and grain size detection.
As shown in FIGS. 1 and 2, the crystal grain morphology prepared by the embodiment and the existing shell without aluminum powder is compared, and after the aluminum powder is added, the surface of the casting is smooth and round, no sand is adhered, and the crystal grains on the surface are fine and uniform.
Example 2
In this embodiment, in the first step, white corundum powder, cobalt aluminate powder, and ethyl silicate are mixed in proportion and stirred uniformly to obtain a surface layer slurry. The mixture ratio is as follows: the weight ratio of the white alundum powder to the cobalt aluminate powder is 10: 7, the weight ratio of the ethyl silicate to the total weight of the white corundum powder and the cobalt aluminate powder is 5: 3. the particle size distribution is as follows: the granularity of the white corundum powder is 12 mu m, the granularity of the cobalt aluminate powder is 8.8 mu m, the mixture is stirred for 16 hours, the viscosity of the mixture is adjusted by deionized water after the mixture is mixed and stirred, and the viscosity value of the slurry is measured by a No. 5 flow cup for 20s, so that the surface layer slurry is prepared. And secondly, uniformly coating the surface layer slurry on a wax mold, wherein the thickness of the surface layer slurry is 0.4mm, and naturally drying the surface layer slurry for 6.5 hours in an environment with the temperature of 18 ℃ and the humidity of 40%. And thirdly, coating back layer ceramic slurry with the thickness of 4.23mm, naturally drying for 6 hours, and dewaxing to prepare the shell. And fourthly, before casting, placing the shell in a 700 ℃ heat-preserving barrel, preserving heat for 6 hours, and spraying aluminum powder into the inner cavity of the shell, wherein the spraying amount accounts for 1.0 percent of the weight of the cobalt aluminate powder, and the particle size is 5 mu m. And fifthly, casting a casting immediately after spraying aluminum powder, wherein the casting alloy is of the brand number: K418B, and carrying out surface quality and grain size detection.
As shown in fig. 2 and fig. 3, the grain morphology prepared by using the present embodiment and the existing shell without aluminum powder is compared, and after the aluminum powder is added, the surface of the casting is smooth and round, no sand is adhered, and the surface grains are fine and uniform.
Example 3
In this embodiment, first, white corundum powder, cobalt aluminate powder, and ethyl silicate are mixed in proportion, and stirred uniformly to obtain a surface layer slurry. The mixture ratio is as follows: the weight ratio of the white alundum powder to the cobalt aluminate powder is 5: 3, the proportion of the weight of the ethyl silicate to the total weight of the white corundum powder and the cobalt aluminate powder is 10: 9. the particle size distribution is as follows: the granularity of the white corundum powder is 18.2 mu m, the granularity of the cobalt aluminate powder is 6.7 mu m, the mixture is stirred for 12 hours, the mixture is mixed and stirred, the viscosity of the mixture is adjusted by deionized water, and the viscosity value of the slurry is measured by a No. 5 flow cup for 40s, so that the surface layer slurry is prepared. And secondly, uniformly coating the surface layer slurry on a wax mold, wherein the thickness of the surface layer slurry is 0.78mm, and naturally drying the surface layer slurry for 6 hours in an environment with the temperature of 24 ℃ and the humidity of 80%. And thirdly, coating back layer ceramic slurry with the thickness of 6.59mm, naturally drying for 7 hours, and dewaxing to prepare the shell. And fourthly, before casting, placing the shell in a 600 ℃ heat-preserving barrel, preserving heat for 10 hours, and spraying aluminum powder into the inner cavity of the shell, wherein the spraying amount accounts for 0.6 percent of the total weight of the cobalt aluminate powder, and the granularity is 3 mu m. And fifthly, casting a casting immediately after spraying aluminum powder, wherein the casting alloy is of the brand number: K418B, and carrying out surface quality and grain size detection.
As shown in fig. 2 and 4, the crystal grain morphology prepared by the embodiment and the existing shell without aluminum powder is compared, and after the aluminum powder is added, the surface of the casting is smooth and round, no sand is adhered, and the crystal grains on the surface are fine and uniform.
The results of the examples show that the ceramic surface layer manufactured by the invention has higher high-temperature strength and good chemical adaptability, and is applied to the precision casting industry, and the grain size of the casting cast by the ceramic surface layer is not only small, but also is uniformly distributed. The invention is convenient and feasible, does not waste cost, can be directly applied to actual production, has great practicability and controllability, and is beneficial to improving the quality and the performance of parts.
Claims (10)
1. A preparation method of aluminum activated ceramic surface layer slurry is characterized in that a base material is white corundum powder, an added component material is cobalt aluminate powder, a binder is ethyl silicate, the white corundum powder, the cobalt aluminate powder and the binder are mixed in proportion and uniformly stirred, and the viscosity of the slurry is adjusted by deionized water to prepare surface layer slurry; the weight ratio of the white corundum powder to the cobalt aluminate powder is 10: (4-8), wherein the ratio of the weight of the ethyl silicate to the total weight of the white corundum powder and the cobalt aluminate powder is 10: (6-10).
2. The method for preparing the aluminum activated ceramic facing slurry according to claim 1, wherein the white corundum powder has a particle size of 10 to 30 μm, and the cobalt aluminate powder has a particle size of 1 to 10 μm.
3. The method for preparing the aluminum activated ceramic surface layer slurry as claimed in claim 1, wherein the raw materials of the surface layer slurry, namely white corundum powder, cobalt aluminate powder and ethyl silicate, are mixed and stirred by a stirrer for more than or equal to 4 hours.
4. The application of the aluminum activated ceramic surface layer slurry prepared by the method according to any one of claims 1 to 3, wherein the aluminum activated ceramic surface layer slurry prepared by the method is suitable for casting processes of all metal materials; firstly, uniformly coating surface layer slurry on a wax mould, naturally drying, coating back layer ceramic slurry, naturally drying, dewaxing, and preparing a shell; then, after the shell is placed in a heat-preserving barrel for heat preservation, spraying aluminum powder to the inner cavity of the shell, and pouring a casting immediately after spraying the aluminum powder; and finally, detecting the surface quality and the grain size.
5. The application of the aluminum activated ceramic surface layer slurry as claimed in claim 4, wherein the surface layer slurry is uniformly coated on the wax pattern, and the thickness of the surface layer slurry is 0.2-0.8 mm.
6. The application of the aluminum activated ceramic surface layer slurry as claimed in claim 4, wherein the surface layer slurry is coated on a wax mold and then naturally dried for 4-8 hours in an environment with a temperature of 18-24 ℃ and a humidity of 30-80%.
7. The application of the aluminum activated ceramic surface layer slurry as claimed in claim 6, wherein after the surface layer slurry is dried, the back layer ceramic slurry is coated, the thickness is 1-8 mm, and then the surface layer slurry is naturally dried for 4-8 hours; dewaxed and formed into a shell.
8. The application of the aluminum activated ceramic facing slurry as claimed in claim 7, wherein the shell is insulated in a 600-700 ℃ insulating barrel for more than 4 hours before casting.
9. The application of the aluminum activated ceramic facing slurry according to claim 8, wherein before casting, aluminum powder is sprayed into the inner cavity of the shell in the heat-insulating barrel in a vacuum furnace, and the spraying amount accounts for 0.1-1.0% of the total weight of the cobalt aluminate powder.
10. The application of the aluminum activated ceramic facing slurry according to claim 9, wherein the particle size of the sprayed aluminum powder is 1-10 μm, and the aluminum powder is poured immediately after the spraying.
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