CN111906246A - Casting system and manufacturing method and pouring method thereof - Google Patents
Casting system and manufacturing method and pouring method thereof Download PDFInfo
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- CN111906246A CN111906246A CN202010624868.4A CN202010624868A CN111906246A CN 111906246 A CN111906246 A CN 111906246A CN 202010624868 A CN202010624868 A CN 202010624868A CN 111906246 A CN111906246 A CN 111906246A
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- casting
- shell
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- coating
- molten metal
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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
- B22C9/043—Removing the consumable pattern
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/082—Sprues, pouring cups
Abstract
The invention relates to a pouring method of an investment casting heat-preservation cover, in particular to a casting system and a manufacturing method and a pouring method thereof. Compared with the prior art of a common investment precision casting pouring system process, the invention has the greatest characteristic that a 'heat preservation cover' is arranged outside a casting, molten metal is poured into a casting shell which is qualified by roasting from a pouring cup during pouring, the liquid level gradually rises along with the continuous pouring of the molten metal into a casting cavity, the molten metal enters the casting cavity and also enters an outer 'heat preservation cover' cavity to form a high-temperature barrier layer which plays a heat preservation role on the casting cavity, the heat dissipation speed of the molten metal in the casting cavity is greatly reduced, the fluidity of the high-temperature molten metal is kept till the casting cavity is full, and the casting is obtained after solidification. The heat-insulating device has the function of insulating the casting cavity, greatly reduces the heat dissipation speed of the molten metal in the casting cavity, and keeps the fluidity of the high-temperature molten metal until the cavity is full of the molten metal.
Description
Technical Field
The invention relates to a pouring process method for an investment casting heat-preservation cover, in particular to a pouring process method for producing a thin-wall casting with larger size. In particular to a casting system, a manufacturing method and a pouring method thereof.
Background
At present, for producing a thin-wall alloy steel casting with large length and width sizes, the difficulty is how to fill a cavity with molten metal to obtain a casting with complete overall size.
When the existing process method is adopted to produce the thin-wall alloy steel casting with the wall thickness less than 1.2 mm and the appearance more than 150 multiplied by 100 multiplied by 15, the previous method comprises the following steps: firstly, a thick and large pouring channel is adopted to produce a thin-wall casting; secondly, a thick-wall casting is produced firstly and then is processed into a thin-wall part by a machining method. However, both methods have disadvantages: first, when thin-walled castings are produced by using a thick and large runner, the defects of bending deformation are easily generated in the castings, and some castings are difficult to obtain qualified castings through correction. Secondly, the method of casting into a thick-walled casting and then machining into a thin-walled part has the following disadvantages: material waste: the redundant material on the thick casting is processed and changed into waste material; secondly, the investment is large: the workpiece needs to be put into a machining clamp; manpower is wasted: the operation can be completed only by human consumption of manpower and electric power.
In summary, there are two drawbacks to the prior art for producing thin-walled castings with large length and width dimensions: firstly, the quality cannot be guaranteed; secondly, there is a lot of waste.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: overcomes the defects of the prior casting method, provides a pouring process method, and produces high-quality thin-wall alloy steel castings with the wall thickness of less than 1.2 mm and the appearance of more than 150 multiplied by 100 multiplied by 15. The structure of the casting system with the heat-insulating cover is shown in figure 1. Mainly comprises a pouring cup 1, a sprue 2, a casting 3 and a heat-preservation cover 4. The invention is different from the process method of the common investment precision casting gating system in that a heat-preservation cover 4 surrounding a casting cavity is arranged on the outer side of a casting 3 of the casting system (as shown in figure 2). The working process of the heat preservation cover 4 is as follows: after the molten metal is poured into the cavity of the casting 3, the liquid level gradually rises, the molten metal enters the cavity of the casting 3 and also enters the cavity of the outer heat-insulating cover 4 to form a high-temperature barrier layer which plays a role in heat insulation of the cavity of the casting 3, the heat dissipation speed of the molten metal in the cavity of the casting 3 is greatly reduced, and the fluidity of the high-temperature molten metal is kept till the cavity is full of the molten metal.
Technical scheme
A method of manufacturing a casting system, comprising the steps of:
manufacturing a metal mold of a casting system according to the existing casting process;
1) a heat preservation cover 4 surrounding a cavity of the casting 3 is arranged on the outer side of the casting 3 of the casting system;
2) manufacturing a casting system wax pattern by using a metal mold of the casting system;
3) manufacturing a casting 3 wax mold, and welding the casting 3 wax mold to a casting system wax mold to form a wax mold group;
4) cleaning the wax module;
5) the manufacturing of the shell comprises the steps of preparing a coating, manufacturing a surface layer shell, manufacturing a transition layer shell and manufacturing a back layer shell.
Wherein:
5) preparing a middle coating according to the ingredient proportion shown in the table 1 to prepare a shell-making coating;
TABLE 1
5) The preparation of the middle-surface layer shell specifically comprises the following steps:
immersing the wax die set into the surface layer coating, not stopping rotating, uniformly coating the wax die set with the coating, taking out, spraying zircon sand, and drying for 5-6 h;
5) the middle transition layer type shell specifically comprises: and dip-coating the transition layer coating by the same method as the surface layer shell, scattering mullite sand, and drying for 8-10 h. Then, coating, sanding and drying are carried out, and the steps are repeated twice, so that a transition layer shell is prepared;
5) the manufacturing method of the middle-back layer shell specifically comprises the following steps: and dip-coating the back layer coating by the same method as the surface layer shell, scattering mullite sand, and drying for 12-15 h. Then, coating, sanding and drying are carried out for three times, and the back shell is prepared;
further comprises sealing slurry: sealing the slurry by using a back coating and drying for 16-24 h.
The method also comprises the steps of putting the mould set with the finished shell into a dewaxing kettle for dewaxing, and obtaining the mould shell after dewaxing is finished;
the method also comprises the step of putting the shell into a mould shell roasting furnace to roast at the temperature of 1000-1100 ℃; and pouring the molten metal into the roasted shell and solidifying to obtain a casting 3.
During pouring, molten metal is poured into a casting 3 shell qualified in roasting through a sprue 2 from a pouring cup 1, the liquid level gradually rises after the molten metal is continuously poured into a casting 3 cavity, and the molten metal enters the casting 3 cavity and also enters an outer side heat-insulating cover 4 cavity to form a high-temperature blocking layer.
The material of foundry goods 3 with it is unanimous to keep warm to cover 4, and the heat preservation of 3 outsides of foundry goods covers 4 and 3 integrated into one piece of foundry goods, the cover 4 thickness that keeps warm is adjusted according to actual demand.
Technical effects
Compared with the prior art of a common investment precision casting pouring system process, the invention has the greatest characteristic that a 'heat preservation cover' is arranged outside a casting, molten metal is poured into a casting shell which is qualified by roasting from a pouring cup during pouring, the liquid level gradually rises along with the continuous pouring of the molten metal into a casting cavity, the molten metal enters the casting cavity and also enters an outer 'heat preservation cover' cavity to form a high-temperature barrier layer which plays a heat preservation role on the casting cavity, the heat dissipation speed of the molten metal in the casting cavity is greatly reduced, the fluidity of the high-temperature molten metal is kept till the casting cavity is full, and the casting is obtained after solidification.
Drawings
FIG. 1 is an elevation view of a casting system with an insulated shroud;
FIG. 2 is a side view of a casting system with a heat shield;
FIG. 3 is a perspective view of a heat-insulating cover structure;
FIG. 4 is a front view of the structure of the heat-retaining cover;
wherein: a pouring cup-1, a sprue-2, a casting-3 and a heat-insulating cover-4.
Detailed Description
A method of manufacturing a casting system, comprising the steps of:
manufacturing a metal mold of a casting system according to the existing casting process;
1) a heat preservation cover 4 surrounding a casting cavity is arranged on the outer side of a casting of the casting system;
2) manufacturing a casting system wax pattern by using a metal mold of the casting system;
3) manufacturing a casting 3 wax mold, and welding the casting 3 wax mold to a casting system wax mold to form a wax mold group;
4) cleaning the wax module;
5) the manufacturing of the shell comprises the steps of preparing a coating, manufacturing a surface layer shell, manufacturing a transition layer shell and manufacturing a back layer shell.
Wherein:
5) preparing a middle coating according to the ingredient proportion shown in the table 1 to prepare a shell-making coating;
TABLE 1
According to the formula of the coating in the table, the viscosity of the surface layer flow cup is 30-35 seconds, the viscosity of the transition layer flow cup is 20-26 seconds, and the viscosity of the back layer flow cup is 11-16 seconds. The viscosity of the flow cup is the speed of the completion of the flow in unit time, and the viscosity is higher when the flow cup is longer, and the viscosity is lower when the flow cup is shorter.
5) The preparation of the middle-surface layer shell specifically comprises the following steps:
immersing the wax die set into the surface layer coating, not stopping rotating, uniformly coating the wax die set with the coating, taking out, spraying zircon sand, and drying for 5-6 h;
5) the middle transition layer type shell specifically comprises: and dip-coating the transition layer coating by the same method as the surface layer shell, scattering mullite sand, and drying for 8-10 h. Then, coating, sanding and drying are carried out, and the steps are repeated twice, so that a transition layer shell is prepared;
5) the manufacturing method of the middle-back layer shell specifically comprises the following steps: and dip-coating the back layer coating by the same method as the surface layer shell, scattering mullite sand, and drying for 12-15 h. Then, coating, sanding and drying are carried out for three times, and the back shell is prepared;
and sealing the slurry by using a back layer coating, and drying for 16-24 h.
The method also comprises the steps of putting the mould set with the finished shell into a dewaxing kettle for dewaxing, and obtaining the mould shell after dewaxing is finished;
the method also comprises the step of putting the shell into a mould shell roasting furnace to roast at the temperature of 1000-1100 ℃; and pouring the molten metal into the roasted shell and solidifying to obtain a casting 3.
A casting system is manufactured by the casting system manufacturing method.
A method for pouring by using the casting system comprises the following steps:
during pouring, molten metal is poured into a casting 3 shell qualified in roasting through a sprue 2 from a pouring cup 1, the liquid level gradually rises after the molten metal is continuously poured into a casting 3 cavity, and the molten metal enters the casting 3 cavity and also enters an outer side heat-insulating cover 4 cavity to form a high-temperature blocking layer.
The material of foundry goods 3 with it is unanimous to keep warm to cover 4, and the heat preservation of 3 outsides of foundry goods covers 4 and 3 integrated into one piece of foundry goods, the cover 4 thickness that keeps warm is adjusted according to actual demand.
Example (b): and (3) carrying out investment precision casting on the cover body casting.
Manufacturing a metal mold of a casting system according to the casting system structure shown in fig. 1;
manufacturing a casting system wax pattern by using a metal mold of the casting system;
thirdly, manufacturing a wax mould of the bracket casting, and welding the wax mould of the casting on the casting system to form a wax mould group, as shown in fig. 2;
fourthly, cleaning a wax die set;
the manufacturing of the shell comprises the steps of preparing the coating, manufacturing the surface layer shell, manufacturing the transition layer shell and manufacturing the back layer shell:
preparation of the coating: preparing a shell-making coating according to the ingredient proportion shown in the table 1;
preparing a surface layer shell: immersing the wax mould set into the surface layer coating, not stopping rotating, uniformly coating the wax mould set with the coating, taking out, spraying zircon sand, and drying for 5 hours;
preparing a transition layer shell: dip-coating the transition layer coating by the same method as the surface layer shell, scattering mullite sand, and drying for 8 h. Then, coating, sanding and drying are carried out, and the steps are repeated twice, so that a transition layer shell is prepared;
preparing a back layer shell: dip-coating the back layer coating by the same method as the surface layer shell, scattering mullite sand, and drying for 12 h. Then, coating, sanding and drying are carried out for three times, and the transition layer shell is prepared;
sealing the slurry: sealing the slurry by using a back layer coating, and drying for 20 hours;
sixthly, putting the module with the finished shell manufacturing into a dewaxing kettle for dewaxing, and obtaining a shell mold after dewaxing is finished;
putting the shell into a mould shell roasting furnace for roasting at 1050 ℃;
casting: pouring molten metal into a casting shell qualified for roasting from a pouring cup, wherein the liquid level gradually rises after the molten metal is continuously poured into a casting cavity, the molten metal enters the casting cavity and also enters an outer side 'heat preservation cover' cavity to form a high-temperature barrier layer which plays a heat preservation role on the casting cavity, the heat dissipation speed of the molten metal in the casting cavity is greatly reduced, the fluidity of the high-temperature molten metal is kept till the casting cavity is full of the molten metal, and the casting is obtained after solidification.
The self-sustaining effect: the wall thickness of the casting produced by using a casting system with a heat-preservation cover through dimension inspection, appearance inspection, magnetic force flaw detection and X-ray inspection is less than 1.2 mm, (the wall thickness 1.2 is obtained by actual operation experience value, the wall thickness of the casting is more than 3 mm under normal conditions), in the invention, if the wall thickness is more than 1.5 mm, the flowing property of the molten steel is poor, the temperature is slowly reduced, the casting is difficult to succeed, and the molten steel casting is not easy to fill the cavity), the initial inspection qualification rate of the thin-wall investment alloy steel casting with the appearance of more than 150 multiplied by 100 multiplied by 15mm is 55%, and the initial inspection qualification rate level of the common casting is reached.
Claims (10)
1. A method for manufacturing a casting system, which manufactures a metal mold of the casting system according to the existing casting process,
the method is characterized by comprising the following steps:
1) a heat preservation cover (4) surrounding a cavity of the casting (3) is arranged on the outer side of the casting (3) of the casting system;
2) manufacturing a casting system wax pattern by using a metal mold of the casting system;
3) manufacturing a wax mould of the casting (3), and welding the wax mould of the casting (3) on the wax mould of the casting system to form a wax mould group;
4) cleaning the wax module;
5) the manufacturing of the shell comprises the steps of preparing a coating, manufacturing a surface layer shell, manufacturing a transition layer shell and manufacturing a back layer shell.
2. A casting system manufacturing method according to claim 1, wherein: preparing a shell-making coating according to the ingredient proportion shown in the table 1 by the coating preparation in the step 5);
TABLE 1
According to the formula of the coating in the table, the viscosity of the surface layer flow cup is 30-35 seconds, the viscosity of the transition layer flow cup is 20-26 seconds, and the viscosity of the back layer flow cup is 11-16 seconds.
3. A casting system manufacturing method according to claim 1, wherein: the preparation of the surface layer shell in the step 5) is specifically as follows: and (3) immersing the wax die set into the surface layer coating, not stopping rotating, uniformly coating the wax die set with the coating, taking out, spraying zircon sand, and drying for 5-6 h.
4. A casting system manufacturing method according to claim 1, wherein: the transition layer type shell in the step 5) is specifically as follows: dip-coating a transition layer coating by the same method as the surface layer shell, scattering mullite sand, and drying for 8-10 hours; then, coating, sanding and drying are carried out, and the steps are repeated twice, thus obtaining the transition layer shell.
5. A casting system manufacturing method according to claim 1, wherein: 5) the manufacturing method of the middle-back layer shell specifically comprises the following steps: dip-coating the back layer coating by the same method as the surface layer shell, scattering mullite sand, and drying for 12-15 h; then, the coating, the sanding and the drying are carried out for three times, and the back shell is prepared.
6. A casting system manufacturing method according to claim 5, wherein: further comprises sealing slurry: sealing the slurry by using a back coating and drying for 16-24 h.
7. A casting system manufacturing method according to claim 6, wherein: and the mould set after the shell manufacturing is finished is put into a dewaxing kettle for dewaxing, and the mould shell is obtained after dewaxing is finished.
8. A casting system made by the casting system manufacturing method of claims 1-7.
9. A method of pouring using the casting system of claim 8, wherein: placing the shell into a mould shell roasting furnace to roast at the temperature of 1000-1100 ℃; and pouring the molten metal into the roasted shell and solidifying to obtain the casting (3).
10. The method of casting according to claim 9, wherein: when pouring, the molten metal is poured into a casting (3) shell qualified in roasting through the sprue (2) from the pouring cup (1), the liquid level gradually rises after the molten metal is continuously poured into the casting cavity, and the molten metal enters the outer side heat-insulating cover cavity while entering the casting (3) cavity to form a high-temperature blocking layer.
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| CN202010624868.4A CN111906246A (en) | 2020-07-02 | 2020-07-02 | Casting system and manufacturing method and pouring method thereof |
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| CN202010624868.4A CN111906246A (en) | 2020-07-02 | 2020-07-02 | Casting system and manufacturing method and pouring method thereof |
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2020
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Application publication date: 20201110 |