CN110871259B - 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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- 239000002002 slurry Substances 0.000 title claims abstract description 76
- 239000002344 surface layer Substances 0.000 title claims abstract description 71
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 56
- 239000000919 ceramic Substances 0.000 title claims abstract description 36
- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 29
- 238000002360 preparation method Methods 0.000 title abstract description 12
- 239000000843 powder Substances 0.000 claims abstract description 68
- 238000005266 casting Methods 0.000 claims abstract description 43
- CRHLEZORXKQUEI-UHFFFAOYSA-N dialuminum;cobalt(2+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[O-2].[O-2].[Al+3].[Al+3].[Co+2].[Co+2] CRHLEZORXKQUEI-UHFFFAOYSA-N 0.000 claims abstract description 38
- 229910052593 corundum Inorganic materials 0.000 claims abstract description 26
- 239000010431 corundum Substances 0.000 claims abstract description 26
- BOTDANWDWHJENH-UHFFFAOYSA-N Tetraethyl orthosilicate Chemical group CCO[Si](OCC)(OCC)OCC BOTDANWDWHJENH-UHFFFAOYSA-N 0.000 claims abstract description 16
- 239000011248 coating agent Substances 0.000 claims abstract description 15
- 238000000576 coating method Methods 0.000 claims abstract description 15
- 238000001035 drying Methods 0.000 claims abstract description 15
- 238000000034 method Methods 0.000 claims abstract description 12
- 239000000463 material Substances 0.000 claims abstract description 10
- 239000002245 particle Substances 0.000 claims abstract description 9
- 239000008367 deionised water Substances 0.000 claims abstract description 8
- 229910021641 deionized water Inorganic materials 0.000 claims abstract description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 8
- 239000011230 binding agent Substances 0.000 claims abstract description 3
- 238000005507 spraying Methods 0.000 claims description 20
- 239000010410 layer Substances 0.000 claims description 8
- 239000007769 metal material Substances 0.000 claims description 3
- 238000004321 preservation Methods 0.000 claims description 3
- 239000002994 raw material Substances 0.000 claims description 2
- 239000000203 mixture Substances 0.000 abstract description 15
- 238000005495 investment casting Methods 0.000 abstract description 7
- IVMYJDGYRUAWML-UHFFFAOYSA-N cobalt(ii) oxide Chemical compound [Co]=O IVMYJDGYRUAWML-UHFFFAOYSA-N 0.000 abstract description 6
- 229910000428 cobalt oxide Inorganic materials 0.000 abstract description 5
- 230000006911 nucleation Effects 0.000 abstract description 5
- 238000010899 nucleation Methods 0.000 abstract description 5
- 239000000126 substance Substances 0.000 abstract description 4
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 abstract description 3
- 229910052751 metal Inorganic materials 0.000 abstract description 3
- 239000002184 metal Substances 0.000 abstract description 3
- 229910017052 cobalt Inorganic materials 0.000 abstract description 2
- 239000010941 cobalt Substances 0.000 abstract description 2
- 238000006073 displacement reaction Methods 0.000 abstract description 2
- 239000000956 alloy Substances 0.000 description 6
- 229910045601 alloy Inorganic materials 0.000 description 6
- 239000011651 chromium Substances 0.000 description 6
- 239000004576 sand Substances 0.000 description 6
- 229910052804 chromium Inorganic materials 0.000 description 5
- 239000013078 crystal Substances 0.000 description 5
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 4
- 230000008901 benefit Effects 0.000 description 4
- 238000009826 distribution Methods 0.000 description 4
- 238000003756 stirring Methods 0.000 description 4
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 3
- 230000007547 defect Effects 0.000 description 3
- 238000001514 detection method Methods 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- 230000002159 abnormal effect Effects 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 230000005856 abnormality Effects 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- IUYLTEAJCNAMJK-UHFFFAOYSA-N cobalt(2+);oxygen(2-) Chemical compound [O-2].[Co+2] IUYLTEAJCNAMJK-UHFFFAOYSA-N 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 229910052596 spinel Inorganic materials 0.000 description 1
- 239000011029 spinel Substances 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Images
Classifications
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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
-
- 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
-
- 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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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Mold Materials And Core Materials (AREA)
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 (6)
1. The application of the 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 added component material and the cobalt aluminate powder are mixed according to a proportion and uniformly stirred, and the viscosity of the slurry is adjusted 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);
the particle size of the white corundum powder is 10-30 mu m, and the particle size of the cobalt aluminate powder is 1-10 mu m;
the aluminum activated ceramic surface layer slurry prepared by the method is suitable for 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; finally, detecting the surface quality and the grain size;
before pouring, spraying aluminum powder to the inner cavity of the shell in the heat-insulating barrel in a vacuum furnace, wherein the spraying amount accounts for 0.1-1.0% of the total weight of the cobalt aluminate powder; the granularity of the sprayed aluminum powder is 1-10 mu m, and the aluminum powder is immediately poured after being sprayed.
2. The application of 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.
3. The application of the aluminum activated ceramic surface layer slurry as claimed in claim 1, 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.
4. The application of the aluminum activated ceramic surface layer slurry as claimed in claim 1, 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%.
5. The application of the aluminum activated ceramic surface layer slurry as claimed in claim 4, wherein the surface layer slurry is dried, coated with the back layer ceramic slurry with the thickness of 1-8 mm, and then naturally dried for 4-8 hours; dewaxed and formed into a shell.
6. The application of the aluminum activated ceramic facing slurry as claimed in claim 5, wherein the shell is insulated in a 600-700 ℃ insulating barrel for more than 4 hours before casting.
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