CN113461412A - Core-shell integrated casting mold with controllable gap and preparation method and application thereof - Google Patents
Core-shell integrated casting mold with controllable gap and preparation method and application thereof Download PDFInfo
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- CN113461412A CN113461412A CN202110714966.1A CN202110714966A CN113461412A CN 113461412 A CN113461412 A CN 113461412A CN 202110714966 A CN202110714966 A CN 202110714966A CN 113461412 A CN113461412 A CN 113461412A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
- B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C13/00—Moulding machines for making moulds or cores of particular shapes
- B22C13/08—Moulding machines for making moulds or cores of particular shapes for shell moulds or shell cores
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/10—Cores; Manufacture or installation of cores
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
- B22D27/045—Directionally solidified castings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y70/00—Materials specially adapted for additive manufacturing
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/14—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silica
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/62605—Treating the starting powders individually or as mixtures
- C04B35/62645—Thermal treatment of powders or mixtures thereof other than sintering
- C04B35/62655—Drying, e.g. freeze-drying, spray-drying, microwave or supercritical drying
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3224—Rare earth oxide or oxide forming salts thereof, e.g. scandium oxide
- C04B2235/3225—Yttrium oxide or oxide-forming salts thereof
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/42—Non metallic elements added as constituents or additives, e.g. sulfur, phosphor, selenium or tellurium
- C04B2235/428—Silicon
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
- C04B2235/54—Particle size related information
- C04B2235/5418—Particle size related information expressed by the size of the particles or aggregates thereof
- C04B2235/5436—Particle size related information expressed by the size of the particles or aggregates thereof micrometer sized, i.e. from 1 to 100 micron
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
- C04B2235/602—Making the green bodies or pre-forms by moulding
- C04B2235/6026—Computer aided shaping, e.g. rapid prototyping
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
- C04B2235/656—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes characterised by specific heating conditions during heat treatment
- C04B2235/6567—Treatment time
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Abstract
The invention discloses a core-shell integrated casting mold with controllable clearance, a preparation method and application thereof, wherein the preparation method comprises the following steps: step 1, constructing a core-shell integrated three-dimensional model; step 2, performing 3D printing on the basis of the core-shell integrated three-dimensional model to obtain a model of the core-shell integrated casting mold; step 3, casting core ceramic slurry into the model of the core-shell integrated casting mold through the core gate, and casting shell ceramic slurry into the model of the core-shell integrated casting mold through the shell gate to obtain a blank of the core-shell integrated casting mold; and 4, carrying out freeze drying, degreasing and high-temperature sintering on the blank of the core-shell integrated casting mold to obtain the core-shell integrated casting mold with a preset gap. The preparation method of the core-shell integrated casting mold provided by the invention has the advantages that the process is simple, the gas film hole head is easy to process, the core-shell is tightly contacted, and the gas film hole cannot be broken.
Description
Technical Field
The invention belongs to the technical field of additive manufacturing, and particularly relates to a core-shell integrated casting mold with controllable gaps, and a preparation method and application thereof.
Background
Turbine blades are key components of gas turbine power plants, and the continuous improvement of their structure and materials is key to increasing the efficiency of energy utilization and to obtaining high performance equipment (power plants) and products (e.g., aircraft). The operating temperature of the turbine blades is directly proportional to the engine efficiency, and increasing the operating temperature also means that the emission of harmful greenhouse gases can be reduced; the air film hole is a structure on the turbine blade, and air can be sprayed out from the air film hole to form an air film layer to cover the surface of the blade so as to isolate heat, thereby achieving the purpose of improving the working temperature of the blade.
In the traditional forming mode, a punching mode is usually used for obtaining the gas film hole, a complex gas film hole model cannot be manufactured, and the defects of recasting layers and the like are also caused. In view of the above situation, there is a strong need for a new forming process, wherein the use of direct casting to form the film hole is a new approach to solve the manufacturing difficulty. In the method, the ceramic core is directly molded, but the two ends of the ceramic core are fixed on the main core and the outer shell, so that the structure is slender, and the solid support structure is easy to break during sintering; and because the core type shells are in close contact, the ceramic can have thermal expansion after sintering, which easily causes the problems of core type shell fracture, loose contact of the core type shells, air film hole fracture and the like.
Disclosure of Invention
The invention aims to provide a core-shell integrated casting mold with controllable gap, a preparation method and application thereof, so as to solve one or more technical problems. The preparation method of the core-shell integrated casting mold provided by the invention has the advantages that the process is simple, the gas film hole head is easy to process, the core-shell is tightly contacted, and the gas film hole cannot be broken.
In order to achieve the purpose, the invention adopts the following technical scheme:
the invention relates to a preparation method of a core-shell integrated casting mold with controllable clearance, which comprises the following steps:
and 4, carrying out freeze drying, degreasing and high-temperature sintering on the blank of the core-shell integrated casting mold to obtain the core-shell integrated casting mold with a preset gap.
The invention is further improved in that in the step 1, the structure of the free end of the convex part is a following structure, a round head structure or an oval head structure.
A further development of the invention is that a gap is provided between the end face of the free end and the bottom face of the recess, which gap is formed by a predetermined cladding at the free end of the projection.
In a further improvement of the present invention, the coating layer is a metal sheet or a resin sheet, and the metal sheet has a melting point lower than that of the ceramic.
In a further development of the invention, the metal sheet is an aluminum foil sheet.
The invention is further improved in that the thickness of the coating layer is 400-600 microns.
In a further improvement of the invention, in step 3, the sintering expanding agent is magnesium oxide, aluminum, silicon oxide, yttrium oxide or silicon powder.
The core-shell integrated mold prepared by any preparation method of the invention.
The invention relates to application of a core-shell integrated casting mold in preparation of turbine blades.
Further, the step for preparing the turbine blade specifically includes:
and casting a high-temperature alloy in the core-shell integrated casting mould through a directional solidification process, cooling, and then removing redundant parts on the surface of the metal blade through post-treatments such as machining, grinding, polishing and the like to obtain the turbine blade with a smooth surface.
Compared with the prior art, the invention has the following beneficial effects:
the invention provides a core-shell integrated casting mold with controllable gaps and a preparation method and application thereof based on a photocuring rapid molding technology. The invention provides a new solution for solving the problem of the gas film hole fracture of the core-shell integrated casting mold, and can promote the development of turbine blades and gas turbines.
In the invention, the free ends (the free ends of the convex parts) of the gas film hole forming structures with different structures can be used for enabling the mold core shell to be tightly contacted, and the structure of the gas film hole head is easy to process and remove, the process is simple, and the cost is lower; use different gas film pore head structures, can make core type shell contact inseparable, avoided gas film pore department to appear the problem of fracture or vibration, and the structure of gas film pore head is easily processed and is got rid of.
Compared with the traditional forming process, the method has the advantages that a certain gap can be formed between the core type shells by utilizing the resin sheets and the aluminum foil sheets, and the gap is filled by the sintering expansion rate of the slurry, so that the problem of the fracture of the air film hole of the core type shell can be solved, and the core type shell integrated casting mold with higher quality can be printed.
The invention is based on the photocuring rapid prototyping technology, uses slurry prepared by different types of ceramic particles, and can control the temperature and further control the clearance of the core shell in the sintering process due to different thermal expansion coefficients, so that the core shell forms different expansion amounts in a common sintering furnace, and further forms a structure with a specific clearance, the core shell structure can be well improved, and the problem of fracture caused by over-thin core is avoided. After high temperature sintering, the free ends of the projections expand to fill the gap between the core shells by different sintering expansion rates of the core shell slurry. The method has reasonable design and simple process, forms a specific gap between the core shells, and effectively solves the problem of core shell fracture.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art are briefly introduced below; it is obvious that the drawings in the following description are some embodiments of the invention, and that for a person skilled in the art, other drawings can be derived from them without inventive effort.
FIG. 1 is a schematic flow chart of a method of making a controlled gap core-shell unified mold according to an embodiment of the present invention;
FIG. 2 is a schematic illustration of a core shell configuration in accordance with an embodiment of the present invention;
FIG. 3 is a schematic illustration of a core shell film hole configuration in accordance with an embodiment of the present invention;
FIG. 4 is a schematic diagram of a conformal gas film hole structure in an embodiment of the present invention;
FIG. 5 is a schematic diagram of a round-nose shaped pore structure in an embodiment of the invention;
in the figure, 1, a shell; 2. a core; 3. a gap; 4. a boss portion; 5. a conformal structure; 6. a coating layer; 7. a round head configuration.
Detailed Description
In order to make the purpose, technical effect and technical solution of the embodiments of the present invention clearer, the following clearly and completely describes the technical solution of the embodiments of the present invention with reference to the drawings in the embodiments of the present invention; it is to be understood that the described embodiments are only some of the embodiments of the present invention. Other embodiments, which can be derived by one of ordinary skill in the art from the disclosed embodiments without inventive faculty, are intended to be within the scope of the invention.
Referring to fig. 1 and 2, a method for manufacturing a mold core and a mold shell integrated mold with controllable gap according to an embodiment of the present invention includes the following steps:
1) designing a core-shell integrated three-dimensional model with a specific gap and a special-shaped air film hole forming structure by utilizing modeling software; exemplarily, the core 2 in the step 1) is provided with a plurality of protruding portions 4, one end of each protruding portion 4 is a fixed support, the other end of each protruding portion 4 is a free end, the free end is a protruding structure relative to the core 2, and the protruding portion is in a shape of a conformal structure 5, a round-head structure 7 or an oval head structure; the mould shell 1 is provided with a plurality of grooves corresponding to the protrusions 4.
The three-dimensional model of the mold core 2 is provided with a connecting free end and connecting fixed ends, and the number of the connecting fixed ends is one; the three-dimensional model of the mold core is fixedly connected with the three-dimensional model of the mold shell 1 through the connecting fixed end, and a gap 3 is arranged between the free end and the mold shell 1.
2) In the 3D printing process, a coating layer 6 is directly formed on the outer surface of the resin part core 2, so that a preset gap is formed (the coating layer 6 is burnt out in the post-treatment); illustratively, the covering layer 6 is a resin sheet or a metal sheet; the metal sheet is an aluminum foil sheet which is a material easy to burn, and the thickness ranges of the aluminum foil sheet and the resin sheet are 400-600 microns.
3) Respectively preparing core shell ceramic slurry added with different sintering expanding agents, and simultaneously pouring corresponding ceramic slurry at a customized pouring gate to obtain a core shell integrated casting blank; the sintering expanding agent comprises magnesium oxide, aluminum, silicon oxide, yttrium oxide, silicon powder and the like; the customized gate refers to a separate gate for the core and the shell, which are separately poured with the core slurry and the shell slurry.
In the embodiment of the invention, after high-temperature sintering, the free ends of the air film holes are expanded through different sintering expansion rates of the core-type shell slurry, so that gaps among the core-type shells are filled.
4) And (3) freeze-drying the blank, degreasing, sintering at high temperature, and removing the resin sheet or the metal sheet covered on the surface of the casting blank to obtain the core-shell integrated casting mould with a specific gap.
The preferred embodiment of the present invention further includes:
5) and pouring high-temperature alloy in the core-shell integrated casting mould through a directional solidification process, cooling, and removing the redundant part on the surface of the metal blade through a specific post-treatment process to obtain the metal blade with a smooth surface. Exemplary post-processing processes include machining, grinding, polishing, and the like.
Compared with the prior art, the invention is based on the photocuring rapid prototyping technology, uses the slurry prepared by different types of ceramic particles, and can control the temperature and further control the clearance of the core shell in the sintering process due to different thermal expansion coefficients, so that the core shell forms different expansion amounts in a common sintering furnace, and further forms a specific clearance structure, the core shell structure can be well improved, and the problem of fracture caused by over-thin core is avoided. The problem of ceramic mold fracture of the core shell can be well solved by using the resin sheet/metal sheet to coat the outer surface of the core. Use different gas film pore head structures, can make core type shell contact inseparable, avoided gas film pore department to appear the problem of fracture or vibration, and the structure of gas film pore head is easily processed and is got rid of. The method has reasonable design and simple process, forms a specific gap between the core shells, and effectively solves the problem of core shell fracture.
Example 1
The embodiment of the invention provides a core and shell integrated casting mold with controllable gaps, a preparation method and an application thereof, wherein the preparation method comprises the following steps:
1) a three-dimensional model with a specific gap core shell and a special-shaped air film hole core is established by utilizing modeling software, and then a resin piece prototype for pouring ceramic slurry is manufactured by adopting a photocuring molding device, wherein the molding resin is 8981 resin, and the molding precision is 0.02 mm. When a core resin prototype was printed using a stereolithography apparatus, a resin sheet having a thickness of 400 microns was printed on the outer surface of the core, wherein the film hole structure is a conformal film hole structure as shown in fig. 3.
2) Preparing slurry of different ceramic particles based on a gel casting process, thereby obtaining different types of core ceramic slurry and shell ceramic slurry:
preparing core ceramic slurry: and dissolving the core ceramic slurry into deionized water according to a certain proportion, adding the premixed solution, and stirring. Wherein the core ceramic slurry comprises 55 wt% of 40 micron silicon oxide, 30 wt% of 5 micron silicon oxide, 9 wt% of 2 micron silicon oxide and 6 wt% of 40 micron silicon powder. The silicon powder is a sintering expanding agent;
preparing shell ceramic slurry: dissolving the shell ceramic slurry into deionized water according to a certain proportion, adding the premixed solution, and stirring. Wherein the core ceramic slurry respectively comprises 65 wt% of 40 micron alumina, 32 wt% of 2 micron alumina and 3 wt% of 3 micron yttrium oxide. Yttrium oxide is used as a sintering expanding agent;
ball milling: and respectively putting the core ceramic slurry and the shell ceramic slurry into a ball milling tank, adding a certain amount of corundum milling balls, and carrying out ball milling to obtain the core shell ceramic slurry with uniform dispersion and good fluidity.
3) Proper amount of catalyst and initiator are added into the prepared core-type shell ceramic slurry, and the mixture is quickly and uniformly stirred. And (3) setting the vacuum degree to be-0.08 MPa under a casting machine, casting the core ceramic slurry from a core gate, casting the shell ceramic slurry from a shell gate, and standing the prepared core-shell integrated casting mold for 25min at the temperature of 20 ℃ to solidify the core-shell integrated casting mold to obtain the core-shell ceramic casting mold.
4) And (4) placing the obtained casting mold in a freezing box, freezing and degreasing.
5) And (4) putting the degreased casting mould into a common sintering furnace, and sintering at high temperature. The core-shell integrated casting mold with a specific gap is obtained by utilizing the difference of the thermal expansion coefficients of the core ceramic slurry and the shell ceramic slurry, and meanwhile, the gap in the figure 3 is eliminated through the thermal expansion amount. Wherein the sintering temperature is 1300 ℃, and the sintering time is 6 h.
6) And after obtaining the core and shell integrated casting mold meeting the directional solidification requirement, connecting the core and shell integrated casting mold with a water-cooled copper disc, and then placing the core and shell integrated casting mold in a three-chamber vacuum directional solidification furnace for directional solidification casting of the turbine blade. The turbine blade is made of nickel-based high-temperature alloy, the casting temperature is 1500 ℃, and the drawing speed of the water-cooling copper plate is regulated to be 5.5 mm/min. And after the metal blade is cooled, removing the redundant part on the surface of the metal blade through the processes of depoling treatment, machining, grinding, polishing and the like to obtain the metal blade with a smooth surface.
Example 2
The embodiment of the invention provides a core and shell integrated casting mold with controllable gaps, a preparation method and an application thereof, wherein the preparation method comprises the following steps:
1) a three-dimensional model with a specific gap core shell and a special-shaped air film hole core is established by utilizing modeling software, and then a resin piece prototype for pouring ceramic slurry is manufactured by adopting a photocuring molding device, wherein the molding resin is 8981 resin, and the molding precision is 0.05 mm. When the core resin piece prototype is printed by using the photocuring molding equipment, the outer surface of the core is coated with a layer of aluminum foil sheet with the thickness of 500 microns, wherein the air film hole structure is a round head-shaped air film hole structure as shown in figure 4.
2) Preparing slurry of different ceramic particles based on a gel casting process, thereby obtaining different types of core ceramic slurry and shell ceramic slurry:
preparing core ceramic slurry: and dissolving the core ceramic slurry into deionized water according to a certain proportion, adding the premixed solution, and stirring. Wherein the core ceramic slurry respectively comprises 22 wt% of 100 micron silicon oxide, 40 wt% of 40 micron aluminum oxide, 21 wt% of 5 micron aluminum oxide, 14 wt% of 2 micron silicon oxide and 3 wt% of 40 micron silicon powder. The silicon powder is a sintering expanding agent;
preparing shell ceramic slurry: dissolving the shell ceramic slurry into deionized water according to a certain proportion, adding the premixed solution, and stirring. Wherein the core ceramic slurry respectively comprises 62.5 wt% of 40 micron alumina, 32 wt% of 5 micron alumina, 4 wt% of 40 micron magnesia and 1.5 wt% of 40 micron magnesia. Magnesium oxide is a sintering expanding agent;
ball milling: and respectively putting the core ceramic slurry and the shell ceramic slurry into a ball milling tank, adding a certain amount of corundum milling balls, and carrying out ball milling to obtain the core shell ceramic slurry with uniform dispersion and good fluidity.
3) Proper amount of catalyst and initiator are added into the prepared core-type shell ceramic slurry, and the mixture is quickly and uniformly stirred. And (3) setting the vacuum degree to be-0.07 MPa under a casting machine, casting the core ceramic slurry from a core gate, casting the shell ceramic slurry from a shell gate, and standing the prepared core-shell integrated casting mold for 20min at the temperature of 25 ℃ to solidify the core-shell integrated casting mold to obtain the core-shell ceramic casting mold.
4) And (4) placing the obtained casting mold in a freezing box, freezing and degreasing.
5) And (4) putting the degreased casting mould into a common sintering furnace, and sintering at high temperature. The core-shell integrated casting mold with a specific gap is obtained by utilizing the difference of the thermal expansion coefficients of the core ceramic slurry and the shell ceramic slurry, and meanwhile, the gap in the figure 4 is eliminated through the thermal expansion amount. Wherein the sintering temperature is 1350 ℃ and the sintering time is 6 h.
6) And after obtaining the core and shell integrated casting mold meeting the directional solidification requirement, connecting the core and shell integrated casting mold with a water-cooled copper disc, and then placing the core and shell integrated casting mold in a three-chamber vacuum directional solidification furnace for directional solidification casting of the turbine blade. The turbine blade material is selected from cobalt-based high-temperature alloy, the casting temperature is 1250 ℃, and the drawing speed of the water-cooling copper plate is regulated and controlled to be 5 mm/min. And after the metal blade is cooled, removing the redundant part on the surface of the metal blade through the processes of depoling treatment, machining, grinding, polishing and the like to obtain the metal blade with a smooth surface.
In the embodiment of the invention, the success rate of the formed core-shell integrated casting mold is improved by about 20 percent, the problems of air film hole breakage and the like caused by thermal expansion of the core-shell casting mold can be effectively solved, and the method is greatly helpful for the actual production process.
In summary, the embodiment of the invention discloses a gap-controllable core-shell integrated casting mold and a preparation method and application thereof, and belongs to the field of rapid molding of photocuring rapid molding technology. The method comprises the following steps: 1) designing a three-dimensional model of the core-type shell with a specific gap and a special-shaped air film hole by utilizing modeling software; 2) in the 3D printing process, a layer of resin sheet is directly formed on the outer surface of a resin part core or a layer of metal sheet is coated on the outer surface of the core after printing is finished; 3) respectively preparing core shell ceramic slurry added with different sintering expanding agents, and simultaneously pouring corresponding ceramic slurry at a customized pouring gate to obtain a core shell integrated casting blank; 4) freeze-drying, degreasing and sintering the blank at high temperature, and removing resin sheets or metal sheets covered on the surface of the casting blank to obtain a core-shell integrated casting mold with a specific gap; 5) and pouring high-temperature alloy in the core-shell integrated casting mould through a directional solidification process, and removing the redundant part on the surface of the metal blade through a specific process after cooling to obtain the metal blade with a smooth surface. According to the invention, the controllable gap is designed, the fixed support of the gas film hole is changed into a single support, the manufacturing capacity of the micro core can be improved, the breakage of the gas film hole is avoided, and the casting success rate of the gas film hole is improved.
Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art can make modifications and equivalents to the embodiments of the present invention without departing from the spirit and scope of the present invention, which is set forth in the claims of the present application.
Claims (10)
1. The preparation method of the core-shell integrated casting mold with the controllable gap is characterized by comprising the following steps of:
step 1, constructing a core-shell integrated three-dimensional model; the core-shell integrated three-dimensional model comprises a core three-dimensional model and a shell three-dimensional model; the mold core three-dimensional model is provided with a connecting free end and connecting fixed ends, and the number of the connecting fixed ends is one; the core three-dimensional model is fixedly connected with the shell three-dimensional model through the connecting and fixing end; the mold core three-dimensional model is provided with a plurality of bulges for forming the air film holes, the mold shell three-dimensional model is provided with a plurality of grooves, the free end of each bulge extends into the corresponding groove, and a gap is arranged between the end surface of each free end and the bottom surface of each groove; the mold core three-dimensional model is provided with a mold core pouring gate, and the mold shell three-dimensional model is provided with a mold shell pouring gate;
step 2, performing 3D printing on the basis of the core-shell integrated three-dimensional model to obtain a model of the core-shell integrated casting mold;
step 3, casting core ceramic slurry into the model of the core-shell integrated casting mold through the core gate, and casting shell ceramic slurry into the model of the core-shell integrated casting mold through the shell gate to obtain a blank of the core-shell integrated casting mold; wherein, different sintering expanding agents are added into the core ceramic slurry and the shell ceramic slurry;
and 4, carrying out freeze drying, degreasing and high-temperature sintering on the blank of the core-shell integrated casting mold to obtain the core-shell integrated casting mold with a preset gap.
2. A method of making a controlled gap core-shell unified mold as claimed in claim 1, wherein in step 1, the configuration of the free end of said boss is a follower configuration, a round head configuration or an oval head configuration.
3. A method of making a gap controllable core-shell mould as claimed in claim 1, wherein a gap is provided between the end surface of the free end and the floor of the recess, the gap being formed by a pre-clad layer at the free end of the boss.
4. A method of making a controlled gap core-shell unified casting mold as claimed in claim 3, wherein said coating layer is a metal sheet or a resin sheet, said metal sheet having a melting point lower than that of ceramic.
5. The method of claim 4, wherein the metal sheet is aluminum foil.
6. The method of claim 3, wherein the thickness of the coating layer is 400 to 600 μm.
7. The method of claim 1, wherein in step 3, the sintering expanding agent is magnesium oxide, aluminum, silicon oxide, yttrium oxide, or silicon powder.
8. A core-shell integral mold produced by the production method described in any one of claims 1 to 7.
9. Use of a core-shell unitary mold as claimed in claim 8 for the manufacture of turbine blades.
10. Use of a controlled gap core shell unified mold as claimed in claim 9, wherein said step for preparing turbine blades comprises in particular:
and casting a high-temperature alloy in the core-shell integrated casting mould through a directional solidification process, cooling, and then removing the redundant part on the surface of the metal blade through machining, grinding and polishing post-treatment to obtain the turbine blade with a smooth surface.
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