CN112658199A - Environment-friendly paint for casting aluminum-silicon alloy by lost foam and preparation method thereof - Google Patents
Environment-friendly paint for casting aluminum-silicon alloy by lost foam and preparation method thereof Download PDFInfo
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Abstract
The invention discloses an aluminum-silicon alloy environment-friendly paint for lost foam casting and a preparation method thereof. The air permeability of the coating can be maintained at a proper position after the expandable graphite is heated and expanded, hydrogen and other decomposition gases can escape conveniently, slag inclusion holes are prevented from being formed, and meanwhile, when the hydrogen passes through the coating layer, copper oxide can react with the hydrogen precipitated from the aluminum alloy at high temperature to generate water and elemental copper, so that the formation of hydrogen pinholes is effectively eliminated. Due to proper air permeability, the defects of needle pricks, sand sticking, node knots and the like easily generated on the surface of the aluminum alloy casting caused by overhigh air permeability can be effectively prevented.
Description
Technical Field
The invention relates to the field of aluminum alloy casting coating, in particular to an aluminum-silicon alloy environment-friendly coating for lost foam casting and a preparation method thereof.
Background
The basic principle of the lost foam casting is as follows: after a fireproof coating layer is coated on a foaming plastic mould with a similar casting shape, the mould is placed in a sand box, dry sand is filled around the mould, the mould is compacted and modeled through vibration, then molten metal is poured, and the foamed plastic is pyrolyzed and disappears under the heat action of the high-temperature molten metal, so that the molten metal is filled in a space where the foamed plastic film disappears, and the model filling is completed.
Because the pouring temperature of the aluminum alloy is much lower than that of cast iron, generally about 750 ℃, the selection of the components of the coating and the performance of the coating are different. At the casting temperature of 750-780 ℃, the hydrogen absorption of the aluminum alloy is serious, and hydrogen is easily separated out from the aluminum alloy liquid in the cooling process of the aluminum alloy liquid, so that the casting is easily subjected to the formation of dispersive hydrogen pinholes. The existing casting coating solves the problem that the air permeability is improved mainly by improving the air permeability of the coating, and the problem that the slag inclusion holes caused by the fact that the gas decomposed by the foam pattern is too late to discharge the aluminum alloy liquid in the process of forming the gas generated by the foam pattern and solidifying the aluminum alloy liquid can be effectively relieved by improving the air permeability of the coating, but the air permeability of the coating is too large, the defects of acupuncture, sand sticking, node knots and the like are easily generated on the surface of a casting, and the air permeability is not enough, so that the insufficient pouring or the increase of pin holes and the like.
The refractory aggregate of the aluminum alloy coating is generally selected from diatomite powder, talcum powder, pearl powder, earthy graphite and the like with low refractoriness. Because the alloy casting temperature is low, the gasification of the pattern is difficult, and more liquid patterns remain, so that the coating is required to have stronger adsorbability. Coating compositions such as diatomaceous earth powder and attapulgite have certain influence on improving the adsorbability of the coating. Can solve the pinhole defect caused by incomplete gasification of the pattern due to the reduction of the pouring temperature.
The melting temperature of liquid aluminum alloy is much lower than that of steel materials, and the thermal decomposition vaporization of a model can absorb a large amount of heat when molten metal is poured, so that the temperature of the flowing front edge of the alloy is reduced, and casting defects such as cold shut, subcutaneous air holes and the like are easily formed when the molten metal is solidified and cooled. The coating chosen therefore needs to be able to absorb the heat generated by the casting, aid in heat dissipation, or have good heat dissipation properties, and secondly aid in the cooling and solidification of the casting, thus preventing cold shut, subcutaneous porosity defects. Because the temperature of the lost foam casting is above 750 ℃, a high-temperature adhesive is selected: clay, bentonite, water glass, silica sol, phosphate, sulfate and polyaluminium chloride, and can prevent the adhesive from being damaged at high temperature.
The coating for the aluminum-silicon alloy casting in China is always consistent with the iron casting. The development of special paint for aluminum-silicon alloy lost foam casting is few, and a series of problems of poor paint performance, low surface quality precision of castings, incompact interior and the like exist in use.
Disclosure of Invention
The technical problems to be solved by the invention are as follows: the problem that hydrogen pinholes and slag inclusion holes are easy to occur in the casting process of the aluminum-silicon alloy lost foam is solved.
In order to solve the technical problems, the invention provides the following technical scheme:
an environment-friendly paint for casting aluminum-silicon alloy by using a lost foam is prepared from the following components in parts by weight: 100 parts of refractory base material, 2-6 parts of sodium bentonite, 0.4-0.6 part of CMC, 2-3 parts of silica sol, 0.03 part of JFC, 3-5 parts of polyvinyl acetate, 4-7 parts of polyvinyl alcohol, 0.01-0.02 part of tributyl phosphate, 0.02-0.04 part of sodium pentachlorophenate, a proper amount of water and 5-20 parts of a hydrogen removing agent.
Preferably, the hydrogen removing agent is formed by mixing CuO and expandable graphite powder.
Preferably, the mass ratio of the CuO to the expandable graphite is 1: 1-6.
Preferably, the fireproof base material consists of 30-35 wt% of diatomite and 65-70 wt% of mica powder.
A preparation method of the lost foam casting aluminum-silicon alloy environment-friendly coating comprises the following specific preparation steps:
(A) weighing raw material components according to the mixture ratio, grinding and mixing the refractory base material, the sodium bentonite and the dehydrogenation agent, and sieving the mixture with a 200-mesh sieve;
(B) adding CMC, silica sol, JFC, polyvinyl acetate and polyvinyl alcohol into 50-100 parts by weight of water, heating to 90 ℃, fully stirring for dissolving, adding tributyl phosphate and sodium pentachlorophenate, stirring uniformly, and naturally cooling at room temperature to obtain a base solution;
(C) adding the refractory base material, the sodium bentonite and the dehydrogenation agent into the base solution, and fully and uniformly stirring to obtain the complete coating.
The invention has the following beneficial effects:
the air permeability of the coating can be maintained at a proper position after the expandable graphite is heated and expanded, hydrogen and other decomposition gases can escape conveniently, slag inclusion holes are prevented from being formed, and meanwhile, when the hydrogen passes through the coating layer, copper oxide can react with the hydrogen precipitated from the aluminum alloy at high temperature to generate water and elemental copper, so that the formation of hydrogen pinholes is effectively eliminated. Due to proper air permeability, the defects of needle pricks, sand sticking, node knots and the like easily generated on the surface of the aluminum alloy casting caused by overhigh air permeability can be effectively prevented.
Detailed Description
The following examples are included to provide further detailed description of the present invention and to provide those skilled in the art with a more complete, concise, and exact understanding of the principles and spirit of the invention.
Example 1: the environment-friendly paint for the lost foam casting aluminum-silicon alloy is prepared by the following steps:
(A) weighing the following raw materials in parts by weight: 100 parts of refractory base material, 2 parts of sodium bentonite, 0.4 part of CMC, 2 parts of silica sol, 0.03 part of JFC, 3 parts of polyvinyl acetate, 4 parts of polyvinyl alcohol, 0.01 part of tributyl phosphate, 0.02 part of sodium pentachlorophenate and 5 parts of dehydrogenating agent;
(B) grinding and mixing a refractory base material, sodium bentonite and a dehydrogenation agent, and sieving by a 200-mesh sieve; the hydrogen removing agent in the embodiment is obtained by mixing CuO and expandable graphite powder according to the mass ratio of 1: 1. The fireproof base material consists of 30 parts of diatomite and 70 parts of mica powder.
(C) Adding CMC, silica sol, JFC, polyvinyl acetate and polyvinyl alcohol into 50 parts by weight of water, heating to 90 ℃, fully stirring for dissolving, adding tributyl phosphate and sodium pentachlorophenate, stirring uniformly, and naturally cooling at room temperature to obtain a base solution;
(D) adding the refractory base material, the sodium bentonite and the dehydrogenation agent into the base solution, and fully and uniformly stirring to obtain the complete coating.
Selection of refractory base materials
When the aluminum-silicon alloy is cast, oxides are generated on the surface during casting, and the products are alkaline and are easy to react with acid refractory base materials such as quartz powder, mullite and the like to corrode the coating and the casting surface, so neutral or alkaline silicate materials are selected as the base materials. The cast aluminum temperature is 750-780 ℃, under the condition of ensuring enough fire resistance, the cost can be saved as a principle, expensive zirconium refractory materials such as corundum powder and zirconite powder are avoided as much as possible, and therefore, diatomite and mica are finally selected as the refractory base materials.
The silicon dioxide or the alumina does not react with the diatomite, the pearl powder and the mica, and the diatomite accounts for 30 to 35 percent: the coating has certain normal temperature and high temperature strength, so that the coating can be prevented from falling off when a foam pattern collides, and simultaneously can resist the scouring of molten metal, and the diatomite is neutral, non-toxic, good in suspension performance, good in adsorption capacity, high in porosity, strong in absorptivity, stable in thermochemical property and the like, so that excellent surface performance can be provided for the coating, and the adhesive force can be improved. The strength of the coating can be effectively improved, and meanwhile, due to the fact that the pore volume is large, the coating has an adsorption effect on impurities generated by foam, the defects that the impurities enter the liquid alloy to form air holes and the like can be avoided, the surface quality of a casting is improved, meanwhile, the coating also has good heat insulation performance, and the flowing performance of molten metal is improved.
65% -70% of mica powder: the mica powder has heat resistance, flame retardance and abrasion resistance, stable chemical properties and good suspension performance in water, is beneficial to discharging gas cracked by the foam mold out of a coating at high temperature, and can be used as a suspending agent to strongly prevent water and corrosive substances from permeating, so that the defects of air holes and slag inclusion generated after the aluminum-silicon alloy is molded are reduced. Generally, talc powder may be used in place of mica powder, but in this case, the talc powder may decompose MgO due to its high temperature in cooperation with cordierite, and has a strong fluxing action to fill up the pores of the coating layer, which may prevent gas from being discharged, thereby causing defects such as pores, and thus mica powder is generally preferred.
Selection of suspending agents
The suspending agent serves to provide a uniform suspension of the individual powder particles in the carrier liquid to ensure a uniform coating of the ingredients on the pattern surface, while at the same time the suspending agent imparts the desired rheological characteristics to the coating. The suspending agent we used this time is bentonite, CMC (carboxymethylcellulose). Bentonite and carboxymethylcellulose (CMC) are commonly used as binders, but in lost foam casting water-based coatings, because they do not overcome the hydrophobic nature of the smooth surface of the polystyrene foam pattern, with which they do not coat the surface of the foam pattern. However, the fine particles of bentonite swell in water to form a hydrated film, adhere and float on the macromolecular chains of CMC, and are lapped into a three-dimensional network structure to prevent the refractory aggregate particles from stacking and sinking, thereby improving the suspension performance of the floating material. When the bentonite suspending agent is selected, the coating is easy to crack when the addition amount is larger on the premise of ensuring the suspension property. When the addition amount of the CMC is within the range of 0.4-0.6%, the leveling property of the coating is relatively stable, the coating hanging property of the coating is relatively good at the moment, and the coating can be uniformly and flatly coated on the surface of a sample to obtain a coating with a certain thickness; the suspensibility and the pressure resistance showed good rising tendency, and when the addition amount was 0. When the content of the CMC is 6 percent, the optimal state is achieved, and the drying crack resistance is also optimal, so that the optimal addition amount of the CMC is determined to be about 0.6 percent; the addition amount of the sodium bentonite is increased from 1% to 7%, and the suspension performance of the coating is increased from 80% to 99%; when the addition amount of the sodium bentonite is in a range of 1-5%, the suspension property of the coating is obviously improved from 80% to 96%, so that the addition amount of the sodium bentonite is improved when various coatings are prepared, and the suspension property of the coating can be greatly improved.
Selection of the Binder
When the content of the silica sol is 2-3 percent (accounting for the refractory base material), the viscosity of the coating is gradually reduced, but the change is slow; and 3-5% of polyvinyl acetate emulsion is added: the polyvinyl acetate solution is a water-soluble organic solvent, can be dried by air at normal temperature, does not react with other binders, does not thicken with bentonite-CMC, and has certain benefit on brushing property.
4% -7% of polyvinyl alcohol: the polyvinyl alcohol is a water-soluble polymer, has higher strength and low gas evolution, is used together with sodium bentonite, and can obtain good quick-drying property and brushing property. The polyvinyl alcohol designation PVA17-88 for the foundry binder is shown in the following table
TABLE 1 Performance index of PVA178-88 Binders
Selection of liquid carriers and aids
Taking proper amount of water as carrier liquid, 0.01-0.02% of tributyl phosphate carbonate: for defoaming agents.
Sodium pentachlorophenate 0.02% -0.04%: an antiseptic bactericide.
Example 2: the environment-friendly paint for the lost foam casting aluminum-silicon alloy is prepared by the following steps:
(A) weighing the following raw materials in parts by weight: 100 parts of refractory base material, 6 parts of sodium bentonite, 0.6 part of CMC, 3 parts of silica sol, 0.03 part of JFC, 5 parts of polyvinyl acetate, 7 parts of polyvinyl alcohol, 0.02 part of tributyl phosphate, 0.04 part of sodium pentachlorophenate and 20 parts of dehydrogenating agent;
(B) grinding and mixing a refractory base material, sodium bentonite and a dehydrogenation agent, and sieving by a 200-mesh sieve; the hydrogen removing agent in the embodiment is obtained by mixing CuO and expandable graphite powder according to the mass ratio of 1: 6. The fireproof base material consists of 35 parts of diatomite and 65 parts of mica powder.
(C) Adding CMC, silica sol, JFC, polyvinyl acetate and polyvinyl alcohol into 100 parts by weight of water, heating to 90 ℃, fully stirring for dissolving, adding tributyl phosphate and sodium pentachlorophenate, stirring uniformly, and naturally cooling at room temperature to obtain a base solution;
(D) adding the refractory base material, the sodium bentonite and the dehydrogenation agent into the base solution, and fully and uniformly stirring to obtain the complete coating.
Example 3: the environment-friendly paint for the lost foam casting aluminum-silicon alloy is prepared by the following steps:
(A) weighing the following raw materials in parts by weight: 100 parts of refractory base material, 4 parts of sodium bentonite, 0.5 part of CMC, 2.5 parts of silica sol, 0.03 part of JFC, 4 parts of polyvinyl acetate, 5.5 parts of polyvinyl alcohol, 0.015 part of tributyl phosphate, 0.03 part of sodium pentachlorophenate and 10 parts of dehydrogenating agent;
(B) grinding and mixing a refractory base material, sodium bentonite and a dehydrogenation agent, and sieving by a 200-mesh sieve; the hydrogen removing agent in the embodiment is obtained by mixing CuO and expandable graphite powder according to the mass ratio of 1: 4. The fireproof base material consists of 33 parts of diatomite and 67 parts of mica powder.
(C) Adding CMC, silica sol, JFC, polyvinyl acetate and polyvinyl alcohol into 75 parts by weight of water, heating to 90 ℃, fully stirring for dissolving, adding tributyl phosphate and sodium pentachlorophenate, stirring uniformly, and naturally cooling at room temperature to obtain a base solution;
(D) adding the refractory base material, the sodium bentonite and the dehydrogenation agent into the base solution, and fully and uniformly stirring to obtain the complete coating.
Comparative example 1: the rest is the same as example 3, except that no copper oxide powder is added and the dehydrogenation agent consists entirely of expandable graphite powder.
The coating proportioning system in example 3 is adopted to research the elimination effect of the hydrogen scavenger on hydrogen pinholes by taking the mass ratio of CuO and expandable graphite powder as variables, the detection standard of the pinhole defects is carried out by ISO10049-1992, and the pinhole grades of cast aluminum alloys are described as follows:
TABLE 1 pinhole grade criteria
The measurement results are shown in table 2:
TABLE 2 influence of dehydrogenation agent ratio on pinhole and permeability of casting
The results in Table 2 show that as the proportion of the expandable graphite in the hydrogen scavenger is increased, the air permeability of the coating is increased, the pinholes in the casting do not gradually decrease or disappear with the increase of the air permeability, and when the expandable graphite in the coating is less, the apparent porosity is small, the air permeability of the coating is poor, hydrogen and other decomposed gases separated out from the aluminum alloy melt can not effectively penetrate through the coating layer, therefore, CuO in the sintered coating layer can not fully contact with hydrogen and react to eliminate the hydrogen, so that the hydrogen is remained in the aluminum alloy to form pinholes or slag inclusion holes, and when the proportion of the expanded graphite is increased, although the air permeability is improved, the CuO content in the coating is reduced, and the hydrogen in the aluminum alloy melt cannot be effectively removed, so the pinhole grade is poor, and the air permeability of the expandable graphite is improved even if the proportion of the expandable graphite is too high, but the defects such as needle-punching defects, slag inclusion and the like are easily generated. When the ratio of CuO to expandable graphite is 1: 1-1: 6, the gas escape efficiency can be improved, hydrogen can be eliminated dynamically in the casting process, so that the hydrogen in the aluminum alloy melt is separated out rapidly, the CuO and the hydrogen react to consume the hydrogen continuously, most of the hydrogen is separated out before the aluminum alloy is completely solidified, and finally the occurrence of casting pinholes is reduced.
The coating proportioning system in example 3 is used to study the air permeability and pinhole defects of the coating and observe the quality of the external surface of the casting with the weight parts of the dehydrogenation agent as variables, and the results are as follows:
TABLE 3 Effect of dosage of Hydrogen scavenger on casting quality and coating breathability
The results in table 3 show that when the dosage of the dehydrogenation agent is too low, the expandable graphite causes less loose structures in the sintered coating layer, the air permeability of the coating is poor, so that gas cannot be discharged outside, and pores or pinholes are more, and when the dosage of the dehydrogenation agent is too high, although the pinhole defect can be effectively eliminated, the expandable graphite is heated and expands to form too many porous structures, so that the outer surface of a casting is pricked due to too high air permeability, the slag inclusion phenomenon is caused, and the outer surface quality is poor. In addition, too much expanded graphite causes a great reduction in the post-sintering strength of the coating.
Table 4 physicochemical indices of the coatings prepared in example 3
In conclusion, the air permeability of the coating can be maintained at a proper position after the expandable graphite is heated and expanded, hydrogen and other decomposition gases can escape conveniently, slag inclusion holes are prevented from being formed, and meanwhile, when the hydrogen passes through the coating, copper oxide can react with the hydrogen precipitated from the aluminum alloy at high temperature to generate water and elemental copper, so that the formation of hydrogen pinholes is effectively eliminated. Due to proper air permeability, the defects of needle pricks, sand sticking, node knots and the like easily generated on the surface of the aluminum alloy casting caused by overhigh air permeability can be effectively prevented.
The above embodiments are only for illustrating the technical idea of the present invention, and the protection scope of the present invention cannot be limited thereby, and any modification made on the basis of the technical scheme according to the technical idea proposed by the present invention falls within the protection scope of the present invention; the technology not related to the invention can be realized by the prior art.
Claims (5)
1. The environment-friendly paint for the lost foam casting aluminum-silicon alloy is characterized by being prepared from the following components in parts by weight: 100 parts of refractory base material, 2-6 parts of sodium bentonite, 0.4-0.6 part of CMC, 2-3 parts of silica sol, 0.03 part of JFC, 3-5 parts of polyvinyl acetate, 4-7 parts of polyvinyl alcohol, 0.01-0.02 part of tributyl phosphate, 0.02-0.04 part of sodium pentachlorophenate, a proper amount of water and 5-20 parts of a hydrogen removing agent.
2. The environment-friendly paint for the lost foam casting aluminum-silicon alloy according to claim 1, which is characterized in that: the hydrogen removing agent is formed by mixing CuO and expandable graphite powder.
3. The environment-friendly paint for the lost foam casting aluminum-silicon alloy as claimed in claim 2, which is characterized in that: the mass ratio of the CuO to the expandable graphite is 1: 1-6.
4. The environment-friendly paint for the lost foam casting aluminum-silicon alloy according to claim 1, which is characterized in that: the fireproof base material consists of 30-35 wt% of diatomite and 65-70 wt% of mica powder.
5. The preparation method of the environment-friendly paint for the lost foam casting of aluminum-silicon alloy according to any one of claims 1 to 4, is characterized by comprising the following specific preparation steps:
(A) weighing raw material components according to the mixture ratio, grinding and mixing the refractory base material, the sodium bentonite and the dehydrogenation agent, and sieving the mixture with a 200-mesh sieve;
(B) adding CMC, silica sol, JFC, polyvinyl acetate and polyvinyl alcohol into 50-100 parts by weight of water, heating to 90 ℃, fully stirring for dissolving, adding tributyl phosphate and sodium pentachlorophenate, stirring uniformly, and naturally cooling at room temperature to obtain a base solution;
(C) adding the refractory base material, the sodium bentonite and the dehydrogenation agent into the base solution, and fully and uniformly stirring to obtain the complete coating.
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| CN115815520A (en) * | 2023-02-14 | 2023-03-21 | 中北大学 | Core coating for aluminum alloy freeze casting and preparation process thereof |
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Application publication date: 20210416 Assignee: Anhui Yuanhao Environmental Protection Technology Co.,Ltd. Assignor: ANHUI INSTITUTE OF INFORMATION TECHNOLOGY Contract record no.: X2022980021122 Denomination of invention: An Environmentally Friendly Coating for Aluminum Silicon Alloy in EPC and Its Preparation Method Granted publication date: 20220408 License type: Common License Record date: 20221112 |