CN110983169A - Large special pump body casting process - Google Patents

Large special pump body casting process Download PDF

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Publication number
CN110983169A
CN110983169A CN201911112888.7A CN201911112888A CN110983169A CN 110983169 A CN110983169 A CN 110983169A CN 201911112888 A CN201911112888 A CN 201911112888A CN 110983169 A CN110983169 A CN 110983169A
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China
Prior art keywords
parts
sand
casting
pump body
percent
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CN201911112888.7A
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Chinese (zh)
Inventor
何祥炎
孙国政
周万波
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Anhui Solid Foundry Co ltd
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Anhui Solid Foundry Co ltd
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Priority to CN201911112888.7A priority Critical patent/CN110983169A/en
Publication of CN110983169A publication Critical patent/CN110983169A/en
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C37/00—Cast-iron alloys
    • C22C37/10—Cast-iron alloys containing aluminium or silicon
    • 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
    • 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
    • B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
    • B22C1/20—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents
    • B22C1/22—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents of resins or rosins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/22—Moulds for peculiarly-shaped castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D47/00—Casting plants
    • B22D47/02—Casting plants for both moulding and casting
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/18—Hardening; Quenching with or without subsequent tempering
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/62—Quenching devices
    • C21D1/667—Quenching devices for spray quenching
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D5/00—Heat treatments of cast-iron
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/08—Making cast-iron alloys

Abstract

The invention discloses a large special pump body casting process which is characterized by comprising the following steps: step S1, batching; step S2, smelting; step S3, manufacturing a die; s4, manufacturing a bottom plate sand core and a sand core; step S5, pouring; and step S6, post-processing. The invention also discloses a large special pump body which is cast according to the large special pump body casting process. The large special pump body disclosed by the invention is simple in casting process, high in size precision of a casting, good in corrosion resistance and wear resistance, and high in raw material utilization rate, casting efficiency and finished product qualification rate.

Description

Large special pump body casting process
Technical Field
The invention relates to the technical field of pump body casting, in particular to a large special pump body casting process.
Background
In recent years, with the progress of science and technology and the development of society, large special pump bodies are widely used, are important components of various large instruments and equipment, and the quality performance of the pump bodies directly influences the overall performance of the large instruments and equipment. Casting is the primary method of producing these large specialty pump bodies. The quality of the pump body casting is greatly influenced by the selection of the casting process. Therefore, it is important to develop a casting process with good casting effect.
Casting is a relatively early metal hot working process mastered by human beings, and has a history of about 6000 years. Casting is a method in which liquid metal is cast into a casting cavity that conforms to the shape of a part, and after it is cooled and solidified, a part or a blank is obtained. The casting material is mostly metal (such as copper, iron, aluminum, tin, lead, etc.) which is originally solid but is heated to liquid state, and the material of the casting mold can be sand, metal or even ceramic. The pump body of the split pump in the traditional casting process has the advantages that under the condition of few levels, the flow channel is spacious, the pressure bearing is small, the wall is thin, the wall thickness difference is small, under the condition of controlling the pouring temperature, the pump body is molded by using common molding sand, the sand is easy to remove, the use requirement is met, when the level reaches more than 7 levels, the size of the flow channel is reduced after the volume of the pump body is reduced, the pressure bearing is increased, the difference between the wall thickness of the flow channel and the wall thickness of the outer portion is increased, the casting difficulty is increased, and the flow channel is bonded by the traditional pump body casting process, so that.
The pump body cast by the casting process in the prior art generally has the defect of large quality performance difference, the hardness and the wear resistance cannot meet the application environment requirement of the pump, and the pump body is easy to mix into casting mold materials during casting, so that the impurity content of the pump body is increased, and the manufacture of the pump body in the casting field is limited. In addition, the pump body casting process in the prior art is complicated, the engineering quantity is large, and the working efficiency is low; the defects of air holes, shrinkage porosity and infiltration are easily generated in the casting process, and the service life of the pump body is shortened.
The invention patent of China with application number 201510692785.8 discloses a pump body casting process, parting surfaces arranged along the middle opening upward are respectively prepared into an upper die and a lower die of an integral structure, and the upper die and the lower die are respectively arranged in an upper sand box and a lower sand box after being processed by a numerical control machine tool; duplicating into an upper casting mold and a lower casting mold by using resin sand; copying a bottom plate sand core and a sand core from mixed sand prepared from chromium ore sand and zircon sand; pre-preparing a sand core to a bottom plate sand core, placing the bottom plate sand core in a lower casting mold, feeding the poured molten metal into a cross gate and an inner gate in sequence through a sprue, and then introducing the molten metal into a cavity formed by an upper casting mold, the lower casting mold, the bottom plate sand core and the sand core for bottom casting; when the poured molten metal reaches the top of the riser from bottom to top, finishing pouring, namely adding a heating agent into the riser; opening the upper sand box and the lower sand box after the casting is completely cooled; and carrying out heat treatment after sand removal and dead head removal. The invention has the advantages of simple process, high dimensional precision of the casting and good corrosion resistance and wear resistance; but the process has large engineering quantity and low working efficiency; the defects of air holes, shrinkage porosity and infiltration are easily generated in the casting process, the hardness is low, and the service life of the pump body is shortened.
Therefore, the development of the casting process of the large special pump body, which has the advantages of simpler process, higher size precision of a casting, better corrosion resistance and wear resistance and better appearance, meets the market demand, has wide market value and application prospect, and has very important significance for promoting the development of the industry of the large special pump body.
Disclosure of Invention
The invention mainly aims to provide a casting process for a large special pump body, which is simple in process, high in casting size precision, good in corrosion resistance and wear resistance, high in raw material utilization rate, casting efficiency and finished product qualification rate; the pump body has no shrinkage porosity in the casting and solidification process, particularly, the part with obvious structural change has full internal feeding and no air holes, the pinhole degree in the product can be effectively controlled, the requirements of the internal and external quality of the product are met, the qualification rate of the product is improved, and the economic value, the social value and the ecological value are high.
In order to achieve the above purposes, the technical scheme adopted by the invention is as follows: the casting process of the large special pump body is characterized by comprising the following steps of:
step S1, batching: weighing the raw materials according to the formula of the cast iron material;
step S2, smelting: adding the mixed material prepared in the step S1 into an electric furnace to be smelted into molten liquid, then transferring the molten liquid into a refining furnace to be refined, adding a refining agent in the refining process, skimming, sampling to carry out stokehole component analysis, adjusting components in the molten iron to meet the requirements according to the detection result, deslagging after refining, discharging the molten iron out of the furnace at 1480-1560 ℃ to enter vermicular treatment, and adding a vermicular agent in the vermicular treatment stage;
step S3, manufacturing a mold: manufacturing a mould according to a pump body production design drawing, wherein the mould is an upper casting mould and a lower casting mould which consist of an upper movable mould and a lower fixed mould, and the upper casting mould and the lower casting mould are respectively arranged in an upper sand box and a lower sand box after extrusion forging forming; copying resin sand into an upper casting mold and a lower casting mold, and respectively manufacturing a sand core and a mold of the sand core by a numerical control machine according to the shape of a cavity;
step S4, manufacturing of the bottom plate sand core and the sand core: copying the mixed sand into a bottom plate sand core and a sand core; the mixed sand is prepared from the following raw materials in parts by weight: 10-20 parts of rare earth porcelain sand, 30-40 parts of molybdenum sand, 5-10 parts of attapulgite decolorized sand, 10-15 parts of gospel sand and 6-12 parts of mullite sand;
step S5, pouring: enabling the molten metal obtained through the treatment in the step S2 to flow into a cavity formed by the upper casting mold, the lower casting mold and the sand core through a pouring gate by using a casting machine for bottom casting; when the poured molten metal reaches the top of the riser from bottom to top, adding a heating agent into the riser;
step S6, post-processing: opening the upper sand box and the lower sand box after the casting is completely cooled; and carrying out heat treatment after sand removal and dead head removal.
Further, the cast iron material formula in step S1 includes, by mass: 1.5 to 3 percent of C, 1.5 to 2.5 percent of Si, 0.01 to 0.03 percent of Sn, 2 to 4 percent of Tc, 0.02 to 0.05 percent of Tl, 0.01 to 0.03 percent of Ba, 0.01 to 0.03 percent of Ir, 1 to 3 percent of Nb, 5 to 8 percent of Mo, 0.01 to 0.03 percent of Ru, 0.1 to 0.2 percent of Dy, less than or equal to 0.01 percent of Se, and the balance of Fe and inevitable impurities.
Further, the smelting temperature in the step S2 is 1500-1700 ℃, and the smelting time is 10-15 minutes.
Further, in step S2, the mass ratio of the refining agent to the melt is (0.1-0.3): 20.
Further, in the step S2, the refining agent is prepared from the following raw materials in parts by weight: 3-8 parts of aluminum carbide, 4-7 parts of potassium fluoride, 1-4 parts of calcium chloride, 0.5-2.5 parts of bismuth sulfate and 1-3 parts of cesium fluoroaluminate.
Further, in the step S2, the vermiculizer is at least one of rare earth magnesium silicon iron alloy and rare earth silicon iron alloy; the mass ratio of the molten liquid to the vermiculizer is 100 (0.3-0.7).
Further, the vermicular treatment time in step S2 is 15-25 minutes.
Further, the resin sand in the step S3 includes the following components in parts by weight: 40-60 parts of silica sand, 40-50 parts of quartz sand, 10-15 parts of gospel sand, 8-16 parts of mullite sand, 6-10 parts of furan resin, 2-4 parts of epoxy resin and 3-5 parts of ethylenediamine.
Further, the furan resin is at least one selected from urea-formaldehyde modified furan resin, phenol-formaldehyde modified furan resin, ketone-aldehyde modified furan resin and urea-formaldehyde phenol-formaldehyde modified furan resin.
Preferably, the epoxy resin is a bisphenol a type epoxy resin.
Further, the heat generating agent comprises the following components in parts by weight: 10-20 parts of ferrosilicon powder, 20-30 parts of charcoal powder and 5-10 parts of aluminum powder.
Further, in step S5, the mass ratio of the heat generating agent to the molten metal is (0.4-0.8): 100.
Further, the heat treatment in step S6 includes quenching and tempering treatments.
Further, the quenching specifically comprises: and (3) feeding the casting into a quenching furnace, controlling the temperature in the furnace at 610-680 ℃, preserving the temperature for 1-2h, and then spraying water on the casting for rapid cooling.
Further, the tempering is specifically as follows: and (3) feeding the quenched casting into a tempering furnace, controlling the furnace heat at 240-260 ℃, preserving the heat for 1-2h, and then discharging and naturally cooling to the normal temperature.
The invention also aims to provide the large special pump body which is cast according to the casting process of the large special pump body.
Due to the application of the technical scheme, compared with the prior art, the invention has the following advantages:
(1) the invention relates to a casting process of a large special pump body, wherein a formula of a cast iron material comprises the following components in percentage by mass: 1.5 to 3 percent of C, 1.5 to 2.5 percent of Si, 0.01 to 0.03 percent of Sn, 2 to 4 percent of Tc, 0.02 to 0.05 percent of Tl, 0.01 to 0.03 percent of Ba, 0.01 to 0.03 percent of Ir, 1 to 3 percent of Nb, 5 to 8 percent of Mo, 0.01 to 0.03 percent of Ru, 0.1 to 0.2 percent of Dy, less than or equal to 0.01 percent of Se, and the balance of Fe and inevitable impurities; the components have synergistic effect, so that the prepared pump body has high strength and hardness, good toughness and wear resistance, good heat resistance and corrosion resistance, excellent thermal fatigue resistance, high cost performance, excellent processability, high mechanical strength, long service life, and high economic value, social value and ecological value.
(2) The casting process of the large special pump body comprises the steps of S1 and batching; step S2, smelting; step S3, manufacturing a die; s4, manufacturing a bottom plate sand core and a sand core; step S5, pouring; and step S6, post-processing. The process has the advantages of short flow, low cost, high casting efficiency and finished product qualification rate, no shrinkage porosity in the casting solidification process, full internal feeding of parts with obvious structural change and no generation of air holes, can effectively control the pinhole degree in the product, and meets the requirements of the internal and external quality of the product.
(3) The invention relates to a large special pump body casting process, which is characterized in that a bottom plate sand core and a sand core are made of mixed sand, wherein the mixed sand is prepared from the following raw materials in parts by weight: 10-20 parts of rare earth porcelain sand, 30-40 parts of molybdenum sand, 5-10 parts of attapulgite decolorized sand, 10-15 parts of gospel sand and 6-12 parts of mullite sand. The raw materials have synergistic effect, so that the mixed sand has good comprehensive performance, high temperature resistance, wear resistance, fluidity, plasticity, air permeability and collapsibility, and is suitable for casting pump bodies and other various workpieces.
(4) The large special pump body casting process is characterized in that a refining agent is added, wherein the refining agent is prepared from the following raw materials in parts by weight: 3-8 parts of aluminum carbide, 4-7 parts of potassium fluoride, 1-4 parts of calcium chloride, 0.5-2.5 parts of bismuth sulfate and 1-3 parts of cesium fluoroaluminate. The raw materials of each component have synergistic effect, so that the refining effect is better, the molten iron precision is higher, the impurity content is smaller, and the comprehensive performance of the cast iron is further effectively improved.
(5) The casting process of the large special pump body adopts resin sand, and the resin sand comprises the following components in parts by weight: 40-60 parts of silica sand, 40-50 parts of quartz sand, 10-15 parts of gospel sand, 8-16 parts of mullite sand, 6-10 parts of furan resin, 2-4 parts of epoxy resin and 3-5 parts of ethylenediamine. The components have synergistic effect, so that the adhesive has high bonding strength, good corrosion resistance, difficult sand adhesion, shrinkage and settlement and wormcracking, and good reusability and collapsibility.
Detailed Description
The following description is presented to disclose the invention so as to enable any person skilled in the art to practice the invention. The preferred embodiments in the following description are given by way of example only, and other obvious variations will occur to those skilled in the art.
Example 1
The casting process of the large special pump body is characterized by comprising the following steps of:
step S1, batching: weighing the raw materials according to the formula of the cast iron material;
step S2, smelting: adding the mixed material prepared in the step S1 into an electric furnace to be smelted into molten liquid, then transferring the molten liquid into a refining furnace to be refined, adding a refining agent in the refining process, skimming, sampling to perform stokehole component analysis, adjusting components in the molten iron to meet requirements according to a detection result, removing slag after refining, discharging the molten iron out of the furnace at 1480 ℃ to enter vermicular treatment, and adding a vermicular agent in the vermicular treatment stage;
step S3, manufacturing a mold: manufacturing a mould according to a pump body production design drawing, wherein the mould is an upper casting mould and a lower casting mould which consist of an upper movable mould and a lower fixed mould, and the upper casting mould and the lower casting mould are respectively arranged in an upper sand box and a lower sand box after extrusion forging forming; copying resin sand into an upper casting mold and a lower casting mold, and respectively manufacturing a sand core and a mold of the sand core by a numerical control machine according to the shape of a cavity;
step S4, manufacturing of the bottom plate sand core and the sand core: copying the mixed sand into a bottom plate sand core and a sand core; the mixed sand is prepared from the following raw materials in parts by weight: 10 parts of rare earth porcelain sand, 30 parts of molybdenum sand, 5 parts of attapulgite decolorized sand, 10 parts of bright sand and 6 parts of mullite sand;
step S5, pouring: enabling the molten metal obtained through the treatment in the step S2 to flow into a cavity formed by the upper casting mold, the lower casting mold and the sand core through a pouring gate by using a casting machine for bottom casting; when the poured molten metal reaches the top of the riser from bottom to top, adding a heating agent into the riser;
step S6, post-processing: opening the upper sand box and the lower sand box after the casting is completely cooled; and carrying out heat treatment after sand removal and dead head removal.
The cast iron material formula in the step S1 comprises the following components in percentage by mass: 1.5% of C, 1.5% of Si, 0.01% of Sn0.01%, Tc 2%, 0.02% of Tl, 0.01% of Ba, 0.01% of Ir, 1% of Nb, 5% of Mo, 0.01% of Ru, 0.1% of Dy, less than or equal to 0.01% of Se, and the balance of Fe and inevitable impurities.
In the step S2, the smelting temperature is 1500 ℃, and the smelting time is 10 minutes.
In step S2, the mass ratio of the refining agent to the melt is 0.1: 20.
The refining agent in the step S2 is prepared from the following raw materials in parts by weight: 3 parts of aluminum carbide, 4 parts of potassium fluoride, 1 part of calcium chloride, 0.5 part of bismuth sulfate and 1 part of cesium fluoroaluminate.
In the step S2, the vermiculizer is rare earth magnesium silicon iron alloy; the mass ratio of the molten liquid to the vermiculizer is 100: 0.3.
The creep treatment time in step S2 was 15 minutes.
The resin sand in the step S3 comprises the following components in parts by weight: 40 parts of silica sand, 40 parts of quartz sand, 10 parts of goslarite sand, 8 parts of mullite sand, 6 parts of furan resin, 2 parts of epoxy resin and 3 parts of ethylenediamine.
The furan resin is urea-formaldehyde modified furan resin; the epoxy resin is bisphenol A type epoxy resin.
The heat generating agent comprises the following components in parts by weight: 10 parts of ferrosilicon powder, 20 parts of charcoal powder and 5 parts of aluminum powder.
In step S5, the mass ratio of the heat generating agent to the molten metal is 0.4: 100.
The heat treatment in step S6 includes quenching and tempering treatments.
The quenching specifically comprises the following steps: and (3) feeding the casting into a quenching furnace, controlling the temperature in the furnace at 610 ℃, preserving the heat for 1h, and then spraying water on the casting for rapid cooling.
The tempering specifically comprises the following steps: and (3) feeding the quenched casting into a tempering furnace, controlling the furnace heat at 240 ℃, preserving the heat for 1h, discharging the casting out of the furnace, and naturally cooling to the normal temperature.
The large special pump body is cast according to the large special pump body casting process.
Example 2
The casting process of the large special pump body is characterized by comprising the following steps of:
step S1, batching: weighing the raw materials according to the formula of the cast iron material;
step S2, smelting: adding the mixed material prepared in the step S1 into an electric furnace to be smelted into molten liquid, then transferring the molten liquid into a refining furnace to be refined, adding a refining agent in the refining process, skimming, sampling to perform stokehole component analysis, adjusting components in the molten iron to meet requirements according to a detection result, removing slag after refining, discharging the molten iron out of the furnace at 1500 ℃ to enter vermicular treatment, and adding a vermicular agent in the vermicular treatment stage;
step S3, manufacturing a mold: manufacturing a mould according to a pump body production design drawing, wherein the mould is an upper casting mould and a lower casting mould which consist of an upper movable mould and a lower fixed mould, and the upper casting mould and the lower casting mould are respectively arranged in an upper sand box and a lower sand box after extrusion forging forming; copying resin sand into an upper casting mold and a lower casting mold, and respectively manufacturing a sand core and a mold of the sand core by a numerical control machine according to the shape of a cavity;
step S4, manufacturing of the bottom plate sand core and the sand core: copying the mixed sand into a bottom plate sand core and a sand core; the mixed sand is prepared from the following raw materials in parts by weight: 12 parts of rare earth porcelain sand, 33 parts of molybdenum sand, 6 parts of attapulgite decolorized sand, 12 parts of bright sand and 8 parts of mullite sand;
step S5, pouring: enabling the molten metal obtained through the treatment in the step S2 to flow into a cavity formed by the upper casting mold, the lower casting mold and the sand core through a pouring gate by using a casting machine for bottom casting; when the poured molten metal reaches the top of the riser from bottom to top, adding a heating agent into the riser;
step S6, post-processing: opening the upper sand box and the lower sand box after the casting is completely cooled; and carrying out heat treatment after sand removal and dead head removal.
The cast iron material formula in the step S1 comprises the following components in percentage by mass: 1.9% of C, 1.9% of Si, 0.015% of Sn0.015%, 2.5% of Tc, 0.03% of Tl, 0.015% of Ba, 0.015% of Ir, 1.5% of Nb, 6% of Mo, 0.015% of Ru, 0.13% of Dy, less than or equal to 0.01% of Se, and the balance of iron and inevitable impurities.
In the step S2, the smelting temperature is 1550 ℃, and the smelting time is 11 minutes; in the step S2, the mass ratio of the refining agent to the molten liquid is 0.15: 20; the refining agent in the step S2 is prepared from the following raw materials in parts by weight: 4 parts of aluminum carbide, 5 parts of potassium fluoride, 2 parts of calcium chloride, 1 part of bismuth sulfate and 1.5 parts of cesium fluoroaluminate; in the step S2, the vermiculizer is rare earth ferrosilicon alloy; the mass ratio of the molten liquid to the vermiculizer is 100: 0.4; the creep treatment time in step S2 was 17 minutes.
The resin sand in the step S3 comprises the following components in parts by weight: 45 parts of silica sand, 43 parts of quartz sand, 12 parts of goslarite sand, 12 parts of mullite sand, 7 parts of furan resin, 2.5 parts of epoxy resin and 3.5 parts of ethylenediamine.
The furan resin is phenolic aldehyde modified furan resin; the epoxy resin is bisphenol A type epoxy resin.
The heat generating agent comprises the following components in parts by weight: 12 parts of ferrosilicon powder, 23 parts of charcoal powder and 6.5 parts of aluminum powder.
In step S5, the mass ratio of the heat generating agent to the molten metal is 0.5: 100.
The heat treatment in step S6 includes quenching and tempering treatments.
The quenching specifically comprises the following steps: feeding the casting into a quenching furnace, controlling the temperature in the furnace at 630 ℃, preserving heat for 1.2h, and then spraying water on the casting for rapid cooling; the tempering specifically comprises the following steps: and (3) feeding the quenched casting into a tempering furnace, controlling the furnace heat at 245 ℃, preserving the heat for 1.3h, discharging the casting out of the furnace, and naturally cooling to the normal temperature.
The large special pump body is cast according to the large special pump body casting process.
Example 3
The casting process of the large special pump body is characterized by comprising the following steps of:
step S1, batching: weighing the raw materials according to the formula of the cast iron material;
step S2, smelting: adding the mixed material prepared in the step S1 into an electric furnace to be smelted into molten liquid, then transferring the molten liquid into a refining furnace to be refined, adding a refining agent in the refining process, slagging off and sampling to carry out stokehole component analysis, adjusting components in the molten iron to meet requirements according to a detection result, deslagging after refining, discharging the molten iron out of the furnace at 1520 ℃ to enter vermicular treatment, and adding a vermicular agent in the vermicular treatment stage;
step S3, manufacturing a mold: manufacturing a mould according to a pump body production design drawing, wherein the mould is an upper casting mould and a lower casting mould which consist of an upper movable mould and a lower fixed mould, and the upper casting mould and the lower casting mould are respectively arranged in an upper sand box and a lower sand box after extrusion forging forming; copying resin sand into an upper casting mold and a lower casting mold, and respectively manufacturing a sand core and a mold of the sand core by a numerical control machine according to the shape of a cavity;
step S4, manufacturing of the bottom plate sand core and the sand core: copying the mixed sand into a bottom plate sand core and a sand core; the mixed sand is prepared from the following raw materials in parts by weight: 15 parts of rare earth porcelain sand, 35 parts of molybdenum sand, 8 parts of attapulgite decolorized sand, 13 parts of bright sand and 10 parts of mullite sand;
step S5, pouring: enabling the molten metal obtained through the treatment in the step S2 to flow into a cavity formed by the upper casting mold, the lower casting mold and the sand core through a pouring gate by using a casting machine for bottom casting; when the poured molten metal reaches the top of the riser from bottom to top, adding a heating agent into the riser;
step S6, post-processing: opening the upper sand box and the lower sand box after the casting is completely cooled; and carrying out heat treatment after sand removal and dead head removal.
The cast iron material formula in the step S1 comprises the following components in percentage by mass: 2.6% of C, 2% of Si, 0.02% of Sn0, 2-4% of Tc, 0.035% of Tl, 0.02% of Ba, 0.02% of Ir, 2% of Nb, 6.5% of Mo, 0.02% of Ru, 0.15% of Dy, less than or equal to 0.01% of Se, and the balance of iron and inevitable impurities.
In the step S2, the smelting temperature is 1600 ℃, and the smelting time is 13 minutes; the mass ratio of the refining agent to the molten liquid is 0.2: 20; the refining agent is prepared from the following raw materials in parts by weight: 6 parts of aluminum carbide, 5.5 parts of potassium fluoride, 2.5 parts of calcium chloride, 1.5 parts of bismuth sulfate and 2 parts of cesium fluoroaluminate; the vermiculizer is rare earth magnesium silicon iron alloy; the mass ratio of the molten liquid to the vermiculizer is 100: 0.5; the vermicular treatment time is 20 minutes.
The resin sand in the step S3 comprises the following components in parts by weight: 50 parts of silica sand, 45 parts of quartz sand, 13 parts of goslarite sand, 14 parts of mullite sand, 8 parts of furan resin, 3 parts of epoxy resin and 4 parts of ethylenediamine.
The furan resin is ketone-aldehyde modified furan resin; the epoxy resin is bisphenol A type epoxy resin.
The heat generating agent comprises the following components in parts by weight: 16 parts of ferrosilicon powder, 25 parts of charcoal powder and 7.5 parts of aluminum powder.
In step S5, the mass ratio of the heat generating agent to the molten metal is 0.6: 100.
The heat treatment in step S6 includes quenching and tempering treatments.
The quenching specifically comprises the following steps: feeding the casting into a quenching furnace, controlling the temperature in the furnace at 660 ℃, preserving heat for 1.5h, and then spraying water on the casting for rapid cooling; the tempering specifically comprises the following steps: and (3) feeding the quenched casting into a tempering furnace, controlling the furnace heat at 250 ℃, preserving the heat for 1.5h, discharging the casting out of the furnace, and naturally cooling to the normal temperature.
The large special pump body is cast according to the large special pump body casting process.
Example 4
The casting process of the large special pump body is characterized by comprising the following steps of:
step S1, batching: weighing the raw materials according to the formula of the cast iron material;
step S2, smelting: adding the mixed material prepared in the step S1 into an electric furnace to be smelted into molten liquid, then transferring the molten liquid into a refining furnace to be refined, adding a refining agent in the refining process, skimming, sampling to perform stokehole component analysis, adjusting components in the molten iron to meet requirements according to a detection result, removing slag after refining, discharging the molten iron out of the furnace at 1550 ℃ to enter vermicular treatment, and adding a vermicular agent in the vermicular treatment stage;
step S3, manufacturing a mold: manufacturing a mould according to a pump body production design drawing, wherein the mould is an upper casting mould and a lower casting mould which consist of an upper movable mould and a lower fixed mould, and the upper casting mould and the lower casting mould are respectively arranged in an upper sand box and a lower sand box after extrusion forging forming; copying resin sand into an upper casting mold and a lower casting mold, and respectively manufacturing a sand core and a mold of the sand core by a numerical control machine according to the shape of a cavity;
step S4, manufacturing of the bottom plate sand core and the sand core: copying the mixed sand into a bottom plate sand core and a sand core; the mixed sand is prepared from the following raw materials in parts by weight: 19 parts of rare earth porcelain sand, 38 parts of molybdenum sand, 9 parts of attapulgite decolorized sand, 14 parts of zirconium sand and 11 parts of mullite sand;
step S5, pouring: enabling the molten metal obtained through the treatment in the step S2 to flow into a cavity formed by the upper casting mold, the lower casting mold and the sand core through a pouring gate by using a casting machine for bottom casting; when the poured molten metal reaches the top of the riser from bottom to top, adding a heating agent into the riser;
step S6, post-processing: opening the upper sand box and the lower sand box after the casting is completely cooled; and carrying out heat treatment after sand removal and dead head removal.
The cast iron material formula in the step S1 comprises the following components in percentage by mass: 2.8% of C, 2.4% of Si, 0.028% of Sn0, 3.8% of Tc, 0.045% of Tl, 0.028% of Ba, 0.027% of Ir, 2.8% of Nb, 7.5% of Mo, 0.025% of Ru0, 0.18% of Dy, less than or equal to 0.01% of Se, and the balance of iron and inevitable impurities.
In the step S2, the smelting temperature is 1680 ℃, and the smelting time is 14 minutes; the mass ratio of the refining agent to the molten liquid is 0.28: 20; the refining agent is prepared from the following raw materials in parts by weight: 7 parts of aluminum carbide, 6.5 parts of potassium fluoride, 3.5 parts of calcium chloride, 2.3 parts of bismuth sulfate and 2.8 parts of cesium fluoroaluminate; the vermiculizer is formed by mixing rare earth magnesium silicon iron alloy and rare earth silicon iron alloy according to the mass ratio of 3: 5; the mass ratio of the molten liquid to the vermiculizer is 100: 0.65; the vermicular treatment time is 24 minutes.
The resin sand in the step S3 comprises the following components in parts by weight: 58 parts of silica sand, 49 parts of quartz sand, 14 parts of gospel sand, 15 parts of mullite sand, 9 parts of furan resin, 3.8 parts of epoxy resin and 4.8 parts of ethylenediamine; the furan resin is formed by mixing urea-formaldehyde modified furan resin, phenolic aldehyde modified furan resin, ketone aldehyde modified furan resin and urea-formaldehyde phenolic aldehyde modified furan resin according to the mass ratio of 1:2:3: 2; the epoxy resin is bisphenol A type epoxy resin.
The heat generating agent comprises the following components in parts by weight: 19 parts of ferrosilicon powder, 28 parts of charcoal powder and 9 parts of aluminum powder.
In step S5, the mass ratio of the heat generating agent to the molten metal is 0.75: 100.
The heat treatment in step S6 includes quenching and tempering treatment; the quenching specifically comprises the following steps: feeding the casting into a quenching furnace, controlling the temperature in the furnace at 670 ℃, preserving heat for 1.9h, and then spraying water on the casting for rapid cooling; the tempering specifically comprises the following steps: and (3) feeding the quenched casting into a tempering furnace, controlling the furnace heat at 255 ℃, preserving the heat for 1.9h, discharging the casting out of the furnace, and naturally cooling to the normal temperature.
The large special pump body is cast according to the large special pump body casting process.
Example 5
The casting process of the large special pump body is characterized by comprising the following steps of:
step S1, batching: weighing the raw materials according to the formula of the cast iron material;
step S2, smelting: adding the mixed material prepared in the step S1 into an electric furnace to be smelted into molten liquid, then transferring the molten liquid into a refining furnace to be refined, adding a refining agent in the refining process, skimming, sampling to perform stokehole component analysis, adjusting components in the molten iron to meet requirements according to a detection result, removing slag after refining, discharging the molten iron out of the furnace at 1560 ℃ to enter vermicular treatment, and adding a vermicular agent in the vermicular treatment stage;
step S3, manufacturing a mold: manufacturing a mould according to a pump body production design drawing, wherein the mould is an upper casting mould and a lower casting mould which consist of an upper movable mould and a lower fixed mould, and the upper casting mould and the lower casting mould are respectively arranged in an upper sand box and a lower sand box after extrusion forging forming; copying resin sand into an upper casting mold and a lower casting mold, and respectively manufacturing a sand core and a mold of the sand core by a numerical control machine according to the shape of a cavity;
step S4, manufacturing of the bottom plate sand core and the sand core: copying the mixed sand into a bottom plate sand core and a sand core; the mixed sand is prepared from the following raw materials in parts by weight: 20 parts of rare earth porcelain sand, 40 parts of molybdenum sand, 10 parts of attapulgite decolorized sand, 15 parts of zirconium sand and 12 parts of mullite sand;
step S5, pouring: enabling the molten metal obtained through the treatment in the step S2 to flow into a cavity formed by the upper casting mold, the lower casting mold and the sand core through a pouring gate by using a casting machine for bottom casting; when the poured molten metal reaches the top of the riser from bottom to top, adding a heating agent into the riser;
step S6, post-processing: opening the upper sand box and the lower sand box after the casting is completely cooled; and carrying out heat treatment after sand removal and dead head removal.
The cast iron material formula in the step S1 comprises the following components in percentage by mass: c3%, Si 2.5%, Sn0.03%, Tc 4%, Tl 0.05%, Ba 0.03%, Ir 0.03%, Nb 3%, Mo 8%, Ru 0.03%, Dy 0.2%, Se less than or equal to 0.01%, and the balance of Fe and inevitable impurities.
In the step S2, the smelting temperature is 1700 ℃, and the smelting time is 15 minutes; the mass ratio of the refining agent to the molten liquid is 0.3: 20; the refining agent in the step S2 is prepared from the following raw materials in parts by weight: 8 parts of aluminum carbide, 7 parts of potassium fluoride, 4 parts of calcium chloride, 2.5 parts of bismuth sulfate and 3 parts of cesium fluoroaluminate; the vermiculizer is rare earth magnesium silicon iron alloy; the mass ratio of the molten liquid to the vermiculizer is 100: 0.7; the vermicular treatment time was 25 minutes.
The resin sand in the step S3 comprises the following components in parts by weight: 60 parts of silica sand, 50 parts of quartz sand, 15 parts of gospel sand, 16 parts of mullite sand, 10 parts of furan resin, 4 parts of epoxy resin and 5 parts of ethylenediamine; the furan resin is urea-formaldehyde phenolic aldehyde modified furan resin; the epoxy resin is bisphenol A type epoxy resin.
The heat generating agent comprises the following components in parts by weight: 20 parts of ferrosilicon powder, 30 parts of charcoal powder and 10 parts of aluminum powder.
In step S5, the mass ratio of the heat generating agent to the molten metal is 0.8: 100.
The heat treatment in step S6 includes quenching and tempering treatment; the quenching specifically comprises the following steps: feeding the casting into a quenching furnace, controlling the temperature in the furnace at 680 ℃, preserving heat for 2 hours, and then spraying water on the casting for rapid cooling; the tempering specifically comprises the following steps: and (3) feeding the quenched casting into a tempering furnace, controlling the furnace heat at 260 ℃, preserving the heat for 2 hours, and then discharging from the furnace and naturally cooling to the normal temperature.
The large special pump body is cast according to the large special pump body casting process.
Comparative example 1
The present example provides a casting process for a large special pump body, which is basically the same as that in example 1, except that the mixed sand does not contain rare earth porcelain sand and mullite sand.
Comparative example 2
The present example provides a casting process for a large special pump body, which is basically the same as that in example 1, except that the cast iron material formulation does not contain Tl, Ba and Ir.
Comparative example 3
This example provides a casting process for a large specialty pump body, essentially the same as in example 1, except that the refining agent does not contain aluminum carbide and cesium fluoroaluminate.
Comparative example 4
This example provides a casting process for a large special pump body, which is essentially the same as that of example 1, except that the refining agent does not contain epoxy resin and gospel.
In order to further illustrate the beneficial technical effects of the casting process of the large special pump body in the embodiment of the present invention, the physical properties of the large special pump body cast by the casting process of the large special pump body described in the above embodiments 1 to 5 and comparative examples 1 to 7 were tested, and the test results are shown in table 1.
TABLE 1
Figure BDA0002273252190000111
Figure BDA0002273252190000121
As can be seen from Table 1, the large special pump body cast by the casting process of the large special pump body disclosed by the embodiment of the invention has the tensile strength of more than or equal to 601MPa, the elongation of more than or equal to 15.9%, the corrosion rate of less than 0.1mm/a and the abrasion loss of less than or equal to 0.11 mm/100H; the tensile strength of the comparative example is less than or equal to 567MPa, the elongation is less than or equal to 13.5%, the corrosion rate is more than or equal to 0.22mm/a, and the abrasion loss is more than or equal to 0.17 mm/100H; the addition of rare earth porcelain sand, mullite sand, Tl, Ba, Ir, aluminum carbide, cesium fluoroaluminate, epoxy resin and goslarite sand is beneficial to improving the performances of the large special pump body cast by the large special pump body casting process.
The foregoing is directed to embodiments of the present invention and, more particularly, to a method and apparatus for controlling a power converter in a power converter, including a power converter, a power.

Claims (10)

1. The casting process of the large special pump body is characterized by comprising the following steps of:
step S1, batching: weighing the raw materials according to the formula of the cast iron material;
step S2, smelting: adding the mixed material prepared in the step S1 into an electric furnace to be smelted into molten liquid, then transferring the molten liquid into a refining furnace to be refined, adding a refining agent in the refining process, skimming, sampling to carry out stokehole component analysis, adjusting components in the molten iron to meet the requirements according to the detection result, deslagging after refining, discharging the molten iron out of the furnace at 1480-1560 ℃ to enter vermicular treatment, and adding a vermicular agent in the vermicular treatment stage;
step S3, manufacturing a mold: manufacturing a mould according to a pump body production design drawing, wherein the mould is an upper casting mould and a lower casting mould which consist of an upper movable mould and a lower fixed mould, and the upper casting mould and the lower casting mould are respectively arranged in an upper sand box and a lower sand box after extrusion forging forming; copying resin sand into an upper casting mold and a lower casting mold, and respectively manufacturing a sand core and a mold of the sand core by a numerical control machine according to the shape of a cavity;
step S4, manufacturing of the bottom plate sand core and the sand core: copying the mixed sand into a bottom plate sand core and a sand core; the mixed sand is prepared from the following raw materials in parts by weight: 10-20 parts of rare earth porcelain sand, 30-40 parts of molybdenum sand, 5-10 parts of attapulgite decolorized sand, 10-15 parts of gospel sand and 6-12 parts of mullite sand;
step S5, pouring: enabling the molten metal obtained through the treatment in the step S2 to flow into a cavity formed by the upper casting mold, the lower casting mold and the sand core through a pouring gate by using a casting machine for bottom casting; when the poured molten metal reaches the top of the riser from bottom to top, adding a heating agent into the riser;
step S6, post-processing: opening the upper sand box and the lower sand box after the casting is completely cooled; and carrying out heat treatment after sand removal and dead head removal.
2. The casting process of the large special pump body according to claim 1, wherein the formula of the cast iron material in the step S1 comprises the following components in percentage by mass: 1.5 to 3 percent of C, 1.5 to 2.5 percent of Si, 0.01 to 0.03 percent of Sn, 2 to 4 percent of Tc, 0.02 to 0.05 percent of Tl, 0.01 to 0.03 percent of Ba, 0.01 to 0.03 percent of Ir, 1 to 3 percent of Nb, 5 to 8 percent of Mo, 0.01 to 0.03 percent of Ru, 0.1 to 0.2 percent of Dy, less than or equal to 0.01 percent of Se, and the balance of Fe and inevitable impurities.
3. The casting process of the large special pump body as claimed in claim 1, wherein the smelting temperature in step S2 is 1500-; the mass ratio of the refining agent to the molten liquid is (0.1-0.3) to 20; the refining agent in the step S2 is prepared from the following raw materials in parts by weight: 3-8 parts of aluminum carbide, 4-7 parts of potassium fluoride, 1-4 parts of calcium chloride, 0.5-2.5 parts of bismuth sulfate and 1-3 parts of cesium fluoroaluminate.
4. The casting process of the large special pump body according to claim 1, wherein the vermiculizer is at least one of rare earth magnesium silicon iron alloy and rare earth silicon iron alloy in step S2; the mass ratio of the molten liquid to the vermiculizer is 100 (0.3-0.7); the vermicular treatment time in step S2 is 15-25 minutes.
5. The casting process of the large special pump body according to claim 1, wherein the resin sand in the step S3 comprises the following components in parts by weight: 40-60 parts of silica sand, 40-50 parts of quartz sand, 10-15 parts of gospel sand, 8-16 parts of mullite sand, 6-10 parts of furan resin, 2-4 parts of epoxy resin and 3-5 parts of ethylenediamine.
6. The casting process of the large special pump body according to claim 1, wherein the furan resin is at least one selected from urea formaldehyde modified furan resin, phenolic aldehyde modified furan resin, ketone aldehyde modified furan resin and urea formaldehyde phenolic aldehyde modified furan resin; the epoxy resin is bisphenol A type epoxy resin.
7. The casting process of the large special pump body according to claim 1, wherein the exothermic agent comprises the following components in parts by weight: 10-20 parts of ferrosilicon powder, 20-30 parts of charcoal powder and 5-10 parts of aluminum powder; in step S5, the mass ratio of the heat generating agent to the molten metal is (0.4-0.8): 100.
8. The casting process of the large special pump body according to claim 1, wherein the heat treatment in the step S6 comprises quenching and tempering.
9. The casting process of the large special pump body according to claim 1, wherein the quenching is specifically as follows: the casting is sent into a quenching furnace, the temperature in the furnace is controlled at 610-680 ℃, the temperature is kept for 1-2h, and then the casting is sprayed by water for rapid cooling; the tempering specifically comprises the following steps: and (3) feeding the quenched casting into a tempering furnace, controlling the furnace heat at 240-260 ℃, preserving the heat for 1-2h, and then discharging and naturally cooling to the normal temperature.
10. A large special pump body cast according to any one of claims 1 to 9 by a casting process.
CN201911112888.7A 2019-11-14 2019-11-14 Large special pump body casting process Withdrawn CN110983169A (en)

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Application publication date: 20200410