CN111185574B - Lost foam casting process of nodular iron casting - Google Patents
Lost foam casting process of nodular iron casting Download PDFInfo
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- CN111185574B CN111185574B CN202010174109.2A CN202010174109A CN111185574B CN 111185574 B CN111185574 B CN 111185574B CN 202010174109 A CN202010174109 A CN 202010174109A CN 111185574 B CN111185574 B CN 111185574B
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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
- B22C9/046—Use of patterns which are eliminated by the liquid metal in the mould
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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
- B22C1/16—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
- B22C1/2233—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 obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- B22C1/224—Furan polymers
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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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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C37/00—Cast-iron alloys
- C22C37/04—Cast-iron alloys containing spheroidal graphite
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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
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Abstract
The invention relates to the field of metal material preparation, in particular to a lost foam casting process of a nodular iron casting; the concrete components comprise: c: 3.4% -3.7%, Si: 2.4% -2.8%, Mn: 0.3% -0.5%, Cu: 0.35% -0.4%, Mg: 0.045% -0.05%, phosphorus: < 0.1%, rare earth oxide: 0.04-0.05% of iron, and the balance of iron; the invention discloses a lost foam casting process of nodular iron castings, and discloses a method for preparing the nodular iron castings by using the lost foam process, wherein a sulfur-free furan resin curing agent is applied to a resin sand mold curing technology, so that sulfur elements in a sulfur-containing compound are prevented from permeating into the surface of molten iron, MgS is generated with Mg, and a spheroidizing element Mg is consumed, so that other non-spherical graphite is prevented from being generated, and the surface recession defect that the surface layer of the nodular iron castings is not spheroidized is avoided; the ductile iron casting has good structure uniformity, and can effectively increase the fatigue strength and prolong the service life of the casting.
Description
Technical Field
The invention relates to the field of metal materials, in particular to a lost foam casting process of a nodular iron casting.
Background
The ductile iron is a high-strength cast iron material developed in the 20 th century and the fifties, the comprehensive performance of the ductile iron is close to that of steel, and the ductile iron is successfully used for casting parts which are complex in stress and high in requirements on strength, toughness and wear resistance based on the excellent performance of the ductile iron.
The lost foam casting coating is one of key technologies of lost foam casting, and occupies a very important position in the whole casting process. The lost foam casting coating is required to have high temperature air permeability. On lost foam casting equipment, the high-temperature air permeability of the coating directly influences the quality of a casting to a great extent, the high temperature means that the fire resistance of the coating is certain and the thermal expansion coefficient is low, and the air permeability of the coating ensures that gas generated by model gasification can pass through the coating and be pumped away by a pump through gaps between the molding materials. The lost foam casting coating has good coating property. The coating of the paint is thicker, so that the requirement of the paint is to have plastic deformation capacity and strictly control the flowing property of the paint, and a small amount of thixotropic agent can be added into the paint taking thermosetting resin as a binder to improve the coating property of the paint.
201810226050.X discloses wear-resistant nodular cast iron which comprises the following components in percentage by weight: 3-3.8% of carbon, 1.2-1.5% of silicon, 3-6% of manganese, 0.5-0.8% of tungsten, 0.1-0.5% of vanadium, 0.01-0.02% of sulfur, 0.04-0.08% of magnesium, 0.02-0.08% of niobium, 0.05-0.1% of tantalum and the balance of iron. The wear-resisting property of the nodular iron casting can be obviously improved by optimizing the components and the proportion of the nodular iron, the nodular iron has good casting property and machining property, and the preparation method has reasonable design of process conditions, is easy to control and is beneficial to casting production.
201910470111.1 provides a method for strengthening a ball milling cast iron roller and a strengthened ball milling cast iron roller, belonging to the technical field of metal surface treatment. The invention adopts laser cladding and laser alloying to respectively prepare the priming cladding layer and the alloying layer, combines the material for the priming cladding layer and the material for the alloying layer to obtain the non-cracked priming cladding layer and the strengthened alloying layer, simultaneously has lower heat input for both the laser cladding and the laser alloying, generates smaller heat affected zone and thermal deformation, further improves the quality of the priming cladding layer and the alloying layer, and overcomes the defect that the surface of the nodular cast iron roller is easy to crack and cannot be strengthened by the nodular cast iron roller due to the conventional surface technology such as surfacing welding, plasma arc cladding, spray welding and the like. The data of the examples show that: through actual comparison tests, the steel passing amount of the strengthened nodular cast iron roller is improved by more than 2 times compared with that of the non-strengthened nodular cast iron roller.
201810575481.7 provides a wear-resistant and high-temperature-resistant nodular cast iron, which relates to the field of nodular cast iron and comprises the following components in percentage by weight: c: 3-4%, Ge: 2-3%, Ga: 2-3%, Mo: 1-1.5%, Ti: 2-3%, La: 1-1.5%, Pr: 1-1.5%, Ce: 1-1.5%, P: 0.1-0.3%, S: 0.1 to 0.2 percent, the balance being Fe and other inevitable impurities in the production process, and the invention effectively improves the wear-resisting and high-temperature-resisting performance of the ball-milling cast iron by selecting raw materials, optimizing the formula and improving the preparation method.
The coating can not only isolate the direct contact of the molten metal and the molding sand and prevent the physical and chemical sand adhesion of the casting, but also form and protect the cavity of the casting, and although the lost foam casting process is rapidly developed at present, the used refractory coating for the lost foam cannot meet the ideal requirement. And the coating performance directly influences the quality of the casting.
The graphite form of the surface layer of the nodular iron casting prepared by the current patent and the prior art is composed of flake or vermicular graphite, so that the defect that the surface layer of the nodular iron casting is not spheroidized is generated.
Disclosure of Invention
In order to solve the problems, the invention provides a lost foam casting process of a nodular iron casting.
A lost foam casting process of nodular iron castings comprises the following process flows:
step one, foam molding: cutting foam by adopting a computer automatic cutting technology, then making a mould from the cut foam, spraying a fireproof coating for a lost foam after the assembly is finished, drying the mould in a drying room at 50-60 ℃ after the spraying is finished, and repeatedly drying for 3-5 times to ensure that the foam mould does not contain moisture;
step two, casting process: adding furan resin accounting for 0.5-1.5% of the weight of the sand and a curing agent accounting for 0.15-0.5% of the weight of the sand into the sand, uniformly stirring, paving a sand cushion bottom with the height of 10-20cm at the bottom of a sand box, then placing a mold into the sand box, covering the mold by adopting rain-type shakeout, keeping the mold level with a sand box cover, enabling the sand to be in seamless contact through slight shock and mechanical shock of the sand box, then standing for 30-120min at room temperature, and curing the sand mold; then pouring molten iron at the temperature of 1350-;
step three, sand removal: separating the sand from the casting by an automatic box turnover machine, and then enabling the casting to enter a shot blasting machine through a lifting hook to remove the refractory coating;
step four: stress relief: and finally obtaining a finished product through an industrial resistance furnace.
The curing agent is a sulfur-free furan resin curing agent and is prepared by the following method:
adding 40-60 parts of toluene into a reaction kettle according to the mass parts, heating to 40-60 ℃, dropwise adding 5-10 parts of phosphoric acid into the reaction kettle, heating to 90-110 ℃ after dropwise adding, reacting for 6-12h, cooling to 20-30 ℃ after reaction, adding 5-15 parts of trichloroacetic acid, 8-22 parts of mellitic acid, 1-5 parts of citric acid, 30-40 parts of water and 2-7 parts of animal glue, mixing and stirring for 40-60min, and discharging.
The preparation method of the ductile iron casting molten iron comprises the following steps:
putting the raw materials into a smelting furnace according to the mass portion, controlling the temperature at 1440 ℃ and 1490 ℃ for smelting to obtain molten iron, adding 0.8-1.2% of inoculant into a ladle, then flushing the molten iron to uniformly melt the molten iron, then pouring, adopting stream inoculation during pouring, and adding 0.05-0.15% of stream inoculant; the concrete components comprise: c: 3.4% -3.7%, Si: 2.4% -2.8%, Mn: 0.3% -0.5%, Cu: 0.35% -0.4%, Mg: 0.045% -0.05%, phosphorus: < 0.1%, rare earth oxide: 0.04-0.05% and the balance of iron.
The fireproof coating for the lost foam is prepared by the following method:
adding 5-12 parts of polyvinyl acetate, 1-5 parts of sodium carboxymethylcellulose, 1.5-3.2 parts of intermediate product 1, 1-5 parts of wood fiber, 0.02-0.07 part of polyoxyethylene octylphenol ether-10 and 300 parts of 200-containing n-butanol into a dispersion machine, controlling the rotating speed at 1100-containing steps/min, dispersing for 30-60min, adding 35-50 parts of bauxite, 23-33 parts of light calcium carbonate and 2-6 parts of bentonite, controlling the rotating speed of the dispersion machine at 400-containing steps/min, uniformly stirring for 20-40min, and stirring uniformly to obtain the refractory coating for lost foam.
The method is characterized in that: the preparation method of the intermediate product 1 comprises the following steps:
adding 0.5-2.2 parts of N-allylmaleimide, 2.5-4.9 parts of methyl silicon (glycol) diacetate, 1-3.2 parts of magnesium acrylate, 1.2-3.2 parts of triallyl borate, 0.02-0.06 part of chloroplatinic acid and 100-200 parts of N-butyl alcohol into a reaction kettle according to the parts by mass, and mixing for 0.5-2 hours at 80-100 ℃; intermediate 1 is obtained.
The inoculant is a silicon-calcium-barium inoculant.
The sand is round, and can be contacted irregularly and seamlessly during vibration.
The refractory coating for the lost foam adopts N-allyl maleimide, methyl silicon (glycol) diacetate, triallyl borate and magnesium acrylate to respectively carry out hydrosilylation reaction to generate an intermediate product 1 containing maleimide, boron and magnesium, and the reaction is shown as follows:
the intermediate product 1 is uniformly dispersed in the refractory coating for the lost foam, so that the heat resistance of the refractory coating for the lost foam is effectively improved, the heat insulation and preservation effects can be achieved in the high-temperature sintering process of the refractory coating, the carbon ablation is reduced, the carbon structure of the refractory coating is effectively preserved, and meanwhile, the crosslinking density of the coating can be improved, and sulfur elements can be blocked and absorbed. Has the function of preventing sulfur seepage and avoids causing the surface spheroidization recession of the ductile iron. On the premise of not influencing the comprehensive performance of the coating, the problems of blocking and absorbing sulfur-containing substances by the coating layer are further solved, and the content of sulfur on the surface of a casting is reduced; ensure the stable normal temperature service performance of the paint.
The invention discloses a lost foam casting process of nodular iron castings, and discloses a method for preparing the nodular iron castings by using the lost foam process, wherein a sulfur-free furan resin curing agent is applied to a resin sand mold curing technology, so that sulfur elements in a sulfur-containing compound are prevented from permeating into the surface of molten iron, MgS is generated with Mg, and a spheroidizing element Mg is consumed, so that other non-spherical graphite is generated, and meanwhile, a refractory coating for a lost foam is added to play a role in preventing sulfur seepage, so that the surface of the nodular iron castings is free from spherical recession under the combined action; the ductile iron casting has good structure uniformity, and can effectively increase the fatigue strength and prolong the service life of the casting.
Drawings
Fig. 1 is a metallographic image, magnified 100 times, of the ductile iron casting prepared in example 2.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The sample is a self-designed sample, the metallographic sample is cut into 10mm multiplied by 20mm, the microscopic structure of the surface of the sample is analyzed through a Scanning Electron Microscope (SEM), the recession layer thickness is a flaky graphite region and a vermicular graphite region, and the thicker the recession layer thickness is, the more serious the surface recession defect is.
The tensile strength was tested in accordance with the GB _ T32498 and 2016 requirements.
The invention is further illustrated by the following specific examples:
example 1
A lost foam casting process of nodular iron castings comprises the following process flows:
step one, foam molding: cutting foam by adopting a computer automatic cutting technology, then making a mould from the cut foam, spraying a fireproof coating for a lost foam after the assembly is finished, drying the mould in a drying room at 50 ℃ after the spraying is finished, and repeatedly drying for 3 times to ensure that the foam mould does not contain moisture;
step two, casting process: adding furan resin accounting for 0.5 percent of the weight of the sand and a curing agent accounting for 0.15 percent of the weight of the sand into the sand, uniformly stirring, paving a sand cushion bottom with the height of 10cm at the bottom of a sand box, then putting a mold into the sand box, covering the mold by adopting rain-showering type shakeout, leveling the mold with a sand box cover, enabling the sand box to be in seamless contact through slight shock and machine shock, then standing for 30min at room temperature, and curing a sand mold; then pouring the molten iron at 1350 ℃, wherein the dust removal work is always operated during pouring;
step three, sand removal: separating the sand from the casting by an automatic box turnover machine, and then enabling the casting to enter a shot blasting machine through a lifting hook to remove the refractory coating;
step four: stress relief: and finally obtaining a finished product through an industrial resistance furnace.
The curing agent is a sulfur-free furan resin curing agent and is prepared by the following method:
adding 40kg of toluene into a reaction kettle, heating to 40 ℃, dropwise adding 5kg of phosphoric acid into the reaction kettle, heating to 90 ℃ after dropwise adding, reacting for 6 hours, cooling to 20 ℃ after the reaction is finished, adding 5kg of trichloroacetic acid, 8kg of benzene hexacarboxylic acid, 1kg of citric acid, 30kg of water and 2kg of animal glue, mixing and stirring for 40min, and discharging.
The preparation method of the ductile iron casting molten iron comprises the following steps:
putting the raw materials into a smelting furnace, controlling the temperature to be 1440 ℃ for smelting to obtain molten iron, adding 0.8% of inoculant into a ladle, then flushing the molten iron to uniformly melt the molten iron, then pouring, adopting stream inoculation during pouring, and adding 0.05% of stream inoculant; the concrete components comprise: c: 3.4%, Si: 2.4%, Mn: 0.3%, Cu: 0.35%, Mg: 0.045%, phosphorus: < 0.1%, rare earth oxide: 0.04% and the balance of iron.
The fireproof coating for the lost foam is prepared by the following method:
adding 5kg of polyvinyl acetate, 1kg of sodium carboxymethylcellulose, 1.5kg of intermediate product 1, 1kg of wood fiber, 0.02kg of polyoxyethylene octylphenol ether-10 and 200kg of n-butyl alcohol into a dispersion machine, controlling the rotating speed at 1100 r/min, dispersing for 30min, adding 35kg of bauxite, 23kg of light calcium carbonate and 2kg of bentonite, controlling the rotating speed of the dispersion machine at 400 r/min, uniformly stirring for 20min, and stirring uniformly to obtain the refractory coating for the lost foam.
The method is characterized in that: the preparation method of the intermediate product 1 comprises the following steps:
adding 0.5kg of N-allylmaleimide, 2.5kg of methyl silicon (glycol) diacetate, 1kg of magnesium acrylate, 1.2kg of triallyl borate, 0.02kg of chloroplatinic acid and 100kg of N-butanol into a reaction kettle, and mixing at 80 ℃ for 0.5 hour; intermediate 1 is obtained.
The rare earth oxide is cerium dioxide.
The inoculant is a silicon-calcium-barium inoculant.
The sand is round, and can be contacted irregularly and seamlessly during vibration.
The thickness of the regression layer of the prepared nodular iron casting is 34 mu m, and the tensile strength of the sample is 864 MPa.
Example 2
A lost foam casting process of nodular iron castings comprises the following process flows:
step one, foam molding: cutting foam by adopting a computer automatic cutting technology, then making a mould from the cut foam, spraying a fireproof coating for a lost foam after the assembly is finished, drying the mould in a drying room at 55 ℃ after the spraying is finished, and repeatedly drying for 4 times to ensure that the foam mould does not contain moisture;
step two, casting process: adding furan resin accounting for 1 percent of the weight of the sand and a curing agent accounting for 0.25 percent of the weight of the sand into the sand, uniformly stirring, paving a sand cushion bottom with the height of 15cm at the bottom of a sand box, then putting a mold into the sand box, covering the mold by adopting rain-type shakeout, leveling the mold with a sand box cover, enabling the sand box to be in seamless contact through slight shock and mechanical shock, then standing for 60min at room temperature, and curing a sand mold; then pouring the molten iron at 1380 ℃, wherein the dust removal work is always operated during pouring;
step three, sand removal: separating the sand from the casting by an automatic box turnover machine, and then enabling the casting to enter a shot blasting machine through a lifting hook to remove the refractory coating;
step four: stress relief: and finally obtaining a finished product through an industrial resistance furnace.
The curing agent is a sulfur-free furan resin curing agent and is prepared by the following method:
50kg of toluene is put into a reaction kettle, the temperature is raised to 50 ℃, 8kg of phosphoric acid is dripped into the reaction kettle, the temperature is raised to 100 ℃ after the dripping is finished, the reaction is carried out for 9 hours, the temperature is lowered to 25 ℃ after the reaction is finished, 10kg of trichloroacetic acid, 14kg of benzene hexacarboxylic acid, 3kg of citric acid, 35kg of water and 5kg of animal glue are added, and the materials are mixed and stirred for 50 minutes, so that the material can be discharged.
The preparation method of the ductile iron casting molten iron comprises the following steps:
putting the raw materials into a smelting furnace, controlling the temperature to 1480 ℃ for smelting to obtain molten iron, adding 1% of inoculant into a ladle, then flushing the molten iron to uniformly melt the molten iron, then pouring, adopting stream inoculation during pouring, and adding 0.1% of stream inoculant; the concrete components comprise: c: 3.5%, Si: 2.6%, Mn: 0.4%, Cu: 0.38%, Mg: 0.048%, phosphorus: < 0.1%, rare earth oxide: 0.04% and the balance of iron.
The fireproof coating for the lost foam is prepared by the following method:
adding 7kg of polyvinyl acetate, 2kg of sodium carboxymethylcellulose, 1.9kg of intermediate product 1, 3kg of wood fiber, 0.03kg of polyoxyethylene octylphenol ether-10 and 220kg of n-butyl alcohol into a dispersion machine, controlling the rotating speed at 1120 revolutions per minute, dispersing for 40min, adding 41kg of bauxite, 28kg of light calcium carbonate and 3kg of bentonite, controlling the rotating speed of the dispersion machine at 420 revolutions per minute, uniformly stirring for 25min, and stirring uniformly to obtain the refractory coating for the lost foam.
The method is characterized in that: the preparation method of the intermediate product 1 comprises the following steps:
1kg of N-allylmaleimide, 2.8kg of methyl silicone (glycol) diacetate, 2.3kg of magnesium acrylate, 1.8kg of triallyl borate, 0.03kg of chloroplatinic acid, 150kg of N-butanol and mixing at 87 ℃ for 1 hour; intermediate 1 is obtained.
The rare earth oxide is rubidium oxide.
The inoculant is a silicon-calcium-barium inoculant.
The sand is round, and can be contacted irregularly and seamlessly during vibration.
The thickness of the regression layer of the prepared nodular iron casting is 27 mu m, and the tensile strength of the sample is 879 MPa.
The detection report of the prepared ductile iron casting sample of the embodiment is as follows:
example 3
A lost foam casting process of nodular iron castings comprises the following process flows:
step one, foam molding: cutting foam by adopting a computer automatic cutting technology, then making a mould from the cut foam, spraying a fireproof coating for a lost foam after the assembly is finished, drying the mould in a drying room at 60 ℃ after the spraying is finished, and repeatedly drying for 5 times to ensure that the foam mould does not contain moisture;
step two, casting process: adding furan resin accounting for 1.5 percent of the weight of the sand and a curing agent accounting for 0.5 percent of the weight of the sand into the sand, uniformly stirring, paving a sand cushion bottom with the height of 20cm at the bottom of a sand box, then putting a mold into the sand box, covering the mold by adopting rain-showering type shakeout, keeping the mold flat with a sand box cover, enabling the sand box to be in seamless contact through slight shock and machine shock, then standing for 120min at room temperature, and curing a sand mold; then pouring the molten iron at 1400 ℃, wherein the dust removal work is always operated during pouring;
step three, sand removal: separating the sand from the casting by an automatic box turnover machine, and then enabling the casting to enter a shot blasting machine through a lifting hook to remove the refractory coating;
step four: stress relief: and finally obtaining a finished product through an industrial resistance furnace.
The curing agent is a sulfur-free furan resin curing agent and is prepared by the following method:
adding 60kg of toluene into a reaction kettle, heating to 60 ℃, dropwise adding 10kg of phosphoric acid into the reaction kettle, heating to 110 ℃ after dropwise adding, reacting for 12 hours, cooling to 30 ℃ after reaction, adding 15kg of trichloroacetic acid, 22kg of mellitic acid, 5kg of citric acid, 40kg of water and 7kg of animal glue, mixing and stirring for 60 minutes, and discharging.
The preparation method of the ductile iron casting molten iron comprises the following steps:
putting the raw materials into a smelting furnace, controlling the temperature to 1490 ℃ for smelting to obtain molten iron, adding 1.2% of inoculant into a ladle, then flushing the molten iron to uniformly melt the molten iron, then pouring, adopting stream inoculation during pouring, and adding 0.05% -0.15% of stream inoculant; the concrete components comprise: c: 3.7%, Si: 2.8%, Mn: 0.5%, Cu: 0.4%, Mg: 0.05%, phosphorus: < 0.1%, rare earth oxide: 0.05% and the balance of iron.
The fireproof coating for the lost foam is prepared by the following method:
adding 12kg of polyvinyl acetate, 5kg of sodium carboxymethylcellulose, 3.2kg of intermediate product 1, 5kg of wood fiber, 0.07kg of polyoxyethylene octylphenol ether-10 and 300kg of n-butyl alcohol into a dispersion machine, controlling the rotating speed at 1200 r/min, dispersing for 60min, adding 50kg of bauxite, 33kg of light calcium carbonate and 2-6kg of bentonite, controlling the rotating speed of the dispersion machine at 500 r/min, uniformly stirring for 40min, and uniformly stirring to obtain the refractory coating for the lost foam.
The method is characterized in that: the preparation method of the intermediate product 1 comprises the following steps:
2.2kg of N-allylmaleimide, 4.9kg of methyl silicone (glycol) diacetate, 3.2kg of magnesium acrylate, 3.2kg of triallyl borate, 0.06kg of chloroplatinic acid and 200kg of N-butanol were added to a reaction kettle and mixed at 100 ℃ for 2 hours; intermediate 1 is obtained.
The rare earth oxide is lanthanum oxide.
The inoculant is a silicon-calcium-barium inoculant.
The sand is round, and can be contacted irregularly and seamlessly during vibration.
The thickness of the regression layer of the prepared nodular iron casting is 24 microns, no spheroidization regression exists on the surface of the nodular iron casting, and the tensile strength of the sample is 881 MPa.
Comparative example 1
A lost foam casting process of nodular iron castings comprises the following process flows:
step one, foam molding: cutting foam by adopting a computer automatic cutting technology, then making a mould from the cut foam, spraying a fireproof coating for a lost foam after the assembly is finished, drying the mould in a drying room at 55 ℃ after the spraying is finished, and repeatedly drying for 4 times to ensure that the foam mould does not contain moisture;
step two, casting process: adding furan resin accounting for 1 percent of the weight of the sand and a curing agent accounting for 0.25 percent of the weight of the sand into the sand, uniformly stirring, paving a sand cushion bottom with the height of 15cm at the bottom of a sand box, then putting a mold into the sand box, covering the mold by adopting rain-type shakeout, leveling the mold with a sand box cover, enabling the sand box to be in seamless contact through slight shock and mechanical shock, then standing for 60min at room temperature, and curing a sand mold; then pouring the molten iron at 1380 ℃, wherein the dust removal work is always operated during pouring;
step three, sand removal: separating the sand from the casting by an automatic box turnover machine, and then enabling the casting to enter a shot blasting machine through a lifting hook to remove the refractory coating;
step four: stress relief: and finally obtaining a finished product through an industrial resistance furnace.
The curing agent is a sulfur-free furan resin curing agent and is prepared by the following method:
50kg of toluene is put into a reaction kettle, the temperature is raised to 50 ℃, 8kg of phosphoric acid is dripped into the reaction kettle, the temperature is raised to 100 ℃ after the dripping is finished, the reaction is carried out for 9 hours, the temperature is lowered to 25 ℃ after the reaction is finished, 10kg of trichloroacetic acid, 14kg of benzene hexacarboxylic acid, 3kg of citric acid, 35kg of water and 5kg of animal glue are added, and the materials are mixed and stirred for 50 minutes, so that the material can be discharged.
The preparation method of the ductile iron casting molten iron comprises the following steps:
putting the raw materials into a smelting furnace, controlling the temperature to 1480 ℃ for smelting to obtain molten iron, adding 1% of inoculant into a ladle, then flushing the molten iron to uniformly melt the molten iron, then pouring, adopting stream inoculation during pouring, and adding 0.1% of stream inoculant; the concrete components comprise: c: 3.5%, Si: 2.6%, Mn: 0.4%, Cu: 0.38%, Mg: 0.048%, phosphorus: < 0.1%, rare earth oxide: 0.04% and the balance of iron.
The fireproof coating for the lost foam is prepared by the following method:
adding 7kg of polyvinyl acetate, 2kg of sodium carboxymethylcellulose, 1.9kg of intermediate product 1, 3kg of wood fiber, 0.03kg of polyoxyethylene octylphenol ether-10 and 220kg of n-butyl alcohol into a dispersion machine, controlling the rotating speed at 1120 revolutions per minute, dispersing for 40min, adding 41kg of bauxite, 28kg of light calcium carbonate and 3kg of bentonite, controlling the rotating speed of the dispersion machine at 420 revolutions per minute, uniformly stirring for 25min, and stirring uniformly to obtain the refractory coating for the lost foam.
The rare earth oxide is rubidium oxide.
The inoculant is a silicon-calcium-barium inoculant.
The sand is round, and can be contacted irregularly and seamlessly during vibration.
The thickness of the regression layer of the prepared nodular iron casting is 270 mu m, and the tensile strength of the sample is 682 MPa.
Comparative example 2
A lost foam casting process of nodular iron castings comprises the following process flows:
step one, foam molding: cutting foam by adopting a computer automatic cutting technology, then making a mould from the cut foam, spraying a fireproof coating for a lost foam after the assembly is finished, drying the mould in a drying room at 55 ℃ after the spraying is finished, and repeatedly drying for 4 times to ensure that the foam mould does not contain moisture;
step two, casting process: adding furan resin accounting for 1 percent of the weight of the sand and a curing agent accounting for 0.25 percent of the weight of the sand into the sand, uniformly stirring, paving a sand cushion bottom with the height of 15cm at the bottom of a sand box, then putting a mold into the sand box, covering the mold by adopting rain-type shakeout, leveling the mold with a sand box cover, enabling the sand box to be in seamless contact through slight shock and mechanical shock, then standing for 60min at room temperature, and curing a sand mold; then pouring the molten iron at 1380 ℃, wherein the dust removal work is always operated during pouring;
step three, sand removal: separating the sand from the casting by an automatic box turnover machine, and then enabling the casting to enter a shot blasting machine through a lifting hook to remove the refractory coating;
step four: stress relief: and finally obtaining a finished product through an industrial resistance furnace.
The curing agent is a sulfur-free furan resin curing agent and is prepared by the following method:
50kg of toluene is put into a reaction kettle, the temperature is raised to 50 ℃, 8kg of phosphoric acid is dripped into the reaction kettle, the temperature is raised to 100 ℃ after the dripping is finished, the reaction is carried out for 9 hours, the temperature is lowered to 25 ℃ after the reaction is finished, 10kg of trichloroacetic acid, 14kg of benzene hexacarboxylic acid, 3kg of citric acid, 35kg of water and 5kg of animal glue are added, and the materials are mixed and stirred for 50 minutes, so that the material can be discharged.
The preparation method of the ductile iron casting molten iron comprises the following steps:
putting the raw materials into a smelting furnace, controlling the temperature to 1480 ℃ for smelting to obtain molten iron, adding 1% of inoculant into a ladle, then flushing the molten iron to uniformly melt the molten iron, then pouring, adopting stream inoculation during pouring, and adding 0.1% of stream inoculant; the concrete components comprise: c: 3.5%, Si: 2.6%, Mn: 0.4%, Cu: 0.38%, Mg: 0.048%, phosphorus: < 0.1%, rare earth oxide: 0.04% and the balance of iron.
The fireproof coating for the lost foam is prepared by the following method:
adding 7kg of polyvinyl acetate, 2kg of sodium carboxymethylcellulose, 1.9kg of intermediate product 1, 3kg of wood fiber, 0.03kg of polyoxyethylene octylphenol ether-10 and 220kg of n-butyl alcohol into a dispersion machine, controlling the rotating speed at 1120 revolutions per minute, dispersing for 40min, adding 41kg of bauxite, 28kg of light calcium carbonate and 3kg of bentonite, controlling the rotating speed of the dispersion machine at 420 revolutions per minute, uniformly stirring for 25min, and stirring uniformly to obtain the refractory coating for the lost foam.
The method is characterized in that: the preparation method of the intermediate product 1 comprises the following steps:
1kg of N-allylmaleimide, 2.8kg of methyl silicon (glycol) diacetate, 0.6kg of magnesium acrylate, 1.8kg of triallyl borate, 0.03kg of chloroplatinic acid, 150kg of N-butanol and mixing at 87 ℃ for 1 hour; intermediate 1 is obtained.
The rare earth oxide is rubidium oxide.
The inoculant is a silicon-calcium-barium inoculant.
The sand is round, and can be contacted irregularly and seamlessly during vibration.
The thickness of the regression layer of the prepared nodular iron casting is 127 mu m, and the tensile strength of the sample is 796 MPa.
Comparative example 3
A lost foam casting process of nodular iron castings comprises the following process flows:
step one, foam molding: cutting foam by adopting a computer automatic cutting technology, then making a mould from the cut foam, spraying a fireproof coating for a lost foam after the assembly is finished, drying the mould in a drying room at 55 ℃ after the spraying is finished, and repeatedly drying for 4 times to ensure that the foam mould does not contain moisture;
step two, casting process: adding furan resin accounting for 1 percent of the weight of the sand and a curing agent accounting for 0.25 percent of the weight of the sand into the sand, uniformly stirring, paving a sand cushion bottom with the height of 15cm at the bottom of a sand box, then putting a mold into the sand box, covering the mold by adopting rain-type shakeout, leveling the mold with a sand box cover, enabling the sand box to be in seamless contact through slight shock and mechanical shock, then standing for 60min at room temperature, and curing a sand mold; then pouring the molten iron at 1380 ℃, wherein the dust removal work is always operated during pouring;
step three, sand removal: separating the sand from the casting by an automatic box turnover machine, and then enabling the casting to enter a shot blasting machine through a lifting hook to remove the refractory coating;
step four: stress relief: and finally obtaining a finished product through an industrial resistance furnace.
The curing agent is a sulfur-free furan resin curing agent and is prepared by the following method:
50kg of toluene is put into a reaction kettle, the temperature is raised to 50 ℃, 8kg of phosphoric acid is dripped into the reaction kettle, the temperature is raised to 100 ℃ after the dripping is finished, the reaction is carried out for 9 hours, the temperature is lowered to 25 ℃ after the reaction is finished, 10kg of trichloroacetic acid, 14kg of benzene hexacarboxylic acid, 3kg of citric acid, 35kg of water and 5kg of animal glue are added, and the materials are mixed and stirred for 50 minutes, so that the material can be discharged.
The preparation method of the ductile iron casting molten iron comprises the following steps:
putting the raw materials into a smelting furnace, controlling the temperature to 1480 ℃ for smelting to obtain molten iron, adding 1% of inoculant into a ladle, then flushing the molten iron to uniformly melt the molten iron, then pouring, adopting stream inoculation during pouring, and adding 0.1% of stream inoculant; the concrete components comprise: c: 3.5%, Si: 2.6%, Mn: 0.4%, Cu: 0.38%, Mg: 0.048%, phosphorus: < 0.1%, rare earth oxide: 0.04% and the balance of iron.
The fireproof coating for the lost foam is prepared by the following method:
adding 7kg of polyvinyl acetate, 2kg of sodium carboxymethylcellulose, 1.9kg of intermediate product 1, 3kg of wood fiber, 0.03kg of polyoxyethylene octylphenol ether-10 and 220kg of n-butyl alcohol into a dispersion machine, controlling the rotating speed at 1120 revolutions per minute, dispersing for 40min, adding 41kg of bauxite, 28kg of light calcium carbonate and 3kg of bentonite, controlling the rotating speed of the dispersion machine at 420 revolutions per minute, uniformly stirring for 25min, and stirring uniformly to obtain the refractory coating for the lost foam.
The method is characterized in that: the preparation method of the intermediate product 1 comprises the following steps:
1kg of N-allylmaleimide, 2.8kg of methyl silicone (glycol) diacetate, 1.8kg of triallyl borate, 0.03kg of chloroplatinic acid, 150kg of N-butanol and 87 ℃ were added to a reaction kettle and mixed for 1 hour; intermediate 1 is obtained.
The rare earth oxide is rubidium oxide.
The inoculant is a silicon-calcium-barium inoculant.
The sand is round, and can be contacted irregularly and seamlessly during vibration.
The thickness of the regression layer of the prepared nodular iron casting is 143 mu m, and the tensile strength of the sample is 817 MPa.
Comparative example 4
A lost foam casting process of nodular iron castings comprises the following process flows:
step one, foam molding: cutting foam by adopting a computer automatic cutting technology, then making a mould from the cut foam, spraying a fireproof coating for a lost foam after the assembly is finished, drying the mould in a drying room at 55 ℃ after the spraying is finished, and repeatedly drying for 4 times to ensure that the foam mould does not contain moisture;
step two, casting process: adding furan resin accounting for 1 percent of the weight of the sand and a curing agent accounting for 0.25 percent of the weight of the sand into the sand, uniformly stirring, paving a sand cushion bottom with the height of 15cm at the bottom of a sand box, then putting a mold into the sand box, covering the mold by adopting rain-type shakeout, leveling the mold with a sand box cover, enabling the sand box to be in seamless contact through slight shock and mechanical shock, then standing for 60min at room temperature, and curing a sand mold; then pouring the molten iron at 1380 ℃, wherein the dust removal work is always operated during pouring;
step three, sand removal: separating the sand from the casting by an automatic box turnover machine, and then enabling the casting to enter a shot blasting machine through a lifting hook to remove the refractory coating;
step four: stress relief: and finally obtaining a finished product through an industrial resistance furnace.
The curing agent is a sulfur-free furan resin curing agent and is prepared by the following method:
50kg of toluene is put into a reaction kettle, the temperature is raised to 50 ℃, 8kg of phosphoric acid is dripped into the reaction kettle, the temperature is raised to 100 ℃ after the dripping is finished, the reaction is carried out for 9 hours, the temperature is lowered to 25 ℃ after the reaction is finished, 10kg of trichloroacetic acid, 14kg of benzene hexacarboxylic acid, 3kg of citric acid, 35kg of water and 5kg of animal glue are added, and the materials are mixed and stirred for 50 minutes, so that the material can be discharged.
The preparation method of the ductile iron casting molten iron comprises the following steps:
putting the raw materials into a smelting furnace, controlling the temperature to 1480 ℃ for smelting to obtain molten iron, adding 1% of inoculant into a ladle, then flushing the molten iron to uniformly melt the molten iron, then pouring, adopting stream inoculation during pouring, and adding 0.1% of stream inoculant; the concrete components comprise: c: 3.5%, Si: 2.6%, Mn: 0.4%, Cu: 0.38%, Mg: 0.048%, phosphorus: < 0.1%, rare earth oxide: 0.04% and the balance of iron.
The fireproof coating for the lost foam is prepared by the following method:
adding 7kg of polyvinyl acetate, 2kg of sodium carboxymethylcellulose, 1.9kg of intermediate product 1, 3kg of wood fiber, 0.03kg of polyoxyethylene octylphenol ether-10 and 220kg of n-butyl alcohol into a dispersion machine, controlling the rotating speed at 1120 revolutions per minute, dispersing for 40min, adding 41kg of bauxite, 28kg of light calcium carbonate and 3kg of bentonite, controlling the rotating speed of the dispersion machine at 420 revolutions per minute, uniformly stirring for 25min, and stirring uniformly to obtain the refractory coating for the lost foam.
The method is characterized in that: the preparation method of the intermediate product 1 comprises the following steps:
1kg of N-allylmaleimide, 2.8kg of methyl silicone (glycol) diacetate, 0.6kg of magnesium acrylate, 0.03kg of chloroplatinic acid and 150kg of N-butanol were added to a reaction kettle and mixed at 87 ℃ for 1 hour; intermediate 1 is obtained.
The rare earth oxide is rubidium oxide.
The inoculant is a silicon-calcium-barium inoculant.
The sand is round, and can be contacted irregularly and seamlessly during vibration.
The thickness of the regression layer of the prepared nodular iron casting is 122 mu m, and the tensile strength of the sample is 835 MPa.
Claims (6)
1. A lost foam casting process of nodular iron castings comprises the following process flows:
step one, foam molding: cutting foam by adopting a computer automatic cutting technology, then making a mould from the cut foam, spraying a fireproof coating for a lost foam after the assembly is finished, drying the mould in a drying room at 50-60 ℃ after the spraying is finished, and repeatedly drying for 3-5 times to ensure that the foam mould does not contain moisture;
step two, casting process: adding furan resin accounting for 0.5-1.5% of the weight of the sand and a curing agent accounting for 0.15-0.5% of the weight of the sand into the sand, uniformly stirring, paving a sand cushion bottom with the height of 10-20cm at the bottom of a sand box, then placing a mold into the sand box, covering the mold by adopting rain-type shakeout, keeping the mold level with a sand box cover, enabling the sand to be in seamless contact through slight shock and mechanical shock of the sand box, then standing for 30-120min at room temperature, and curing the sand mold; then pouring molten iron at the temperature of 1350-;
step three, sand removal: separating the sand from the casting by an automatic box turnover machine, and then enabling the casting to enter a shot blasting machine through a lifting hook to remove the refractory coating;
step four: stress relief: finally, a finished product is obtained through an industrial resistance furnace;
the curing agent is a sulfur-free furan resin curing agent and is prepared by the following method:
adding 40-60 parts of toluene into a reaction kettle according to the mass parts, heating to 40-60 ℃, dropwise adding 5-10 parts of phosphoric acid into the reaction kettle, heating to 90-110 ℃ after dropwise adding, reacting for 6-12h, cooling to 20-30 ℃ after reaction, adding 5-15 parts of trichloroacetic acid, 8-22 parts of mellitic acid, 1-5 parts of citric acid, 30-40 parts of water and 2-7 parts of animal glue, mixing and stirring for 40-60min, and discharging.
2. A lost foam casting process for ductile iron castings according to claim 1, characterized by: the preparation method of the ductile iron casting molten iron comprises the following steps:
putting the raw materials into a smelting furnace according to the mass portion, controlling the temperature at 1440 ℃ and 1490 ℃ for smelting to obtain molten iron, adding 0.8-1.2% of inoculant into a ladle, then flushing the molten iron to uniformly melt the molten iron, then pouring, adopting stream inoculation during pouring, and adding 0.05-0.15% of stream inoculant; the concrete components comprise: c: 3.4% -3.7%, Si: 2.4% -2.8%, Mn: 0.3% -0.5%, Cu: 0.35% -0.4%, Mg: 0.045% -0.05%, phosphorus: < 0.1%, rare earth oxide: 0.04-0.05% and the balance of iron.
3. A lost foam casting process for ductile iron castings according to claim 2, characterized by: the rare earth oxide is cerium dioxide or rubidium oxide or lanthanum oxide.
4. A lost foam casting process for ductile iron castings according to claim 2, characterized by: the inoculant is a silicon-calcium-barium inoculant.
5. A lost foam casting process for ductile iron castings according to claim 1, characterized by: the sand is round, and can be contacted irregularly and seamlessly during vibration.
6. A lost foam casting process for ductile iron castings according to claim 1, characterized by: the fireproof coating for the lost foam is prepared by the following method:
adding 0.5-2.2 parts of N-allylmaleimide, 2.5-4.9 parts of methyl silicon (glycol) diacetate, 0.1-3.2 parts of magnesium acrylate, 1.2-3.2 parts of triallyl borate, 0.02-0.06 part of chloroplatinic acid and 200 parts of N-butyl alcohol according to the parts by mass in a reaction kettle, and mixing for 0.5-2 hours at 80-100 ℃; so as to obtain a product 1 which is,
adding 5-12 parts of polyvinyl acetate, 1-5 parts of sodium carboxymethylcellulose, 1.5-3.2 parts of product 1, 1-5 parts of wood fiber, 0.02-0.07 part of polyoxyethylene octylphenol ether-10 and 300 parts of 200-one-phase n-butanol into a dispersion machine, controlling the rotating speed at 1100-1200 turns/min, dispersing for 30-60min, adding 35-50 parts of bauxite, 23-33 parts of light calcium carbonate and 2-6 parts of bentonite, controlling the rotating speed of the dispersion machine at 400-one-phase 500 turns/min, and uniformly stirring for 20-40min until the mixture is uniformly stirred to obtain the refractory coating for lost foam.
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| CN114260419B (en) * | 2021-12-03 | 2024-03-19 | 山东大众机械制造股份有限公司 | Casting method of cast steel excavator driving wheel |
| CN117753928B (en) * | 2024-02-22 | 2024-04-26 | 潍坊卓安重工科技有限公司 | Lost foam casting method for manufacturing ball mill end cover by utilizing spheroidal graphite cast iron |
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Denomination of invention: A lost foam casting process for ductile iron castings Effective date of registration: 20221128 Granted publication date: 20210219 Pledgee: Pujiang County Sub branch of Postal Savings Bank of China Co.,Ltd. Pledgor: Zhejiang Pujiang Jingyu Casting Co.,Ltd. Registration number: Y2022330003276 |
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