CN113894244A - 一种粉末固化无机自硬砂及制芯方法 - Google Patents
一种粉末固化无机自硬砂及制芯方法 Download PDFInfo
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
- B22C1/10—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 for influencing the hardening tendency of the mould material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
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- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
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- B22C1/18—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 inorganic agents
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
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- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
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- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
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- Engineering & Computer Science (AREA)
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Abstract
本发明涉及一种砂及制芯方法,尤其是一种粉末固化无机硬砂及制芯方法,属于铸造技术领域。一种粉末固化无机自硬砂,包括以下重量百分比的组分:占天然硅砂重量0.8%~2.0%的粉末固化剂,占天然硅砂重量1.8%~3.0%的无机粘结剂和余量的天然硅砂。与现有技术相比,本发明具有如下显著优点,通过改性水玻璃和粉末硬化剂实现粉末自硬方式,从而使砂型达到树脂砂的强度、溃散、抗吸湿性又综合了传统水玻璃砂的低发气量、退让性。
Description
技术领域
本发明涉及一种砂及制芯方法,尤其是一种粉末固化无机硬砂及制芯方法,属于铸造技术领域。
背景技术
铸造工业属于高能耗、污染严重的行业,尤其是在生产过程中对环境的污染——固体废弃物和空气污染。近年来,随着国家环保要求的提高,铸造企业面临着越来越大的生产压力,国家制定了越来越多的新标准,并且提高了旧有的标准的要求。对污染物的排放提出了严格的要求,并且积极推进降低污染排放的科学研究。金属熔炼及浇注成型的过程中产生污染的最大源头便是造型材料上,生产车间从混砂、砂型制作、型芯制作、浇注、固化冷却、落砂、清理、打磨等后续处理均会从造型材料上产生污染。可以说正真决解铸造污染的方案是从源头杜绝有害气体的产生及固体废气无物——造型材料。
有机树脂砂造型材料。呋喃树脂、酚醛树脂、三乙胺等有机树脂应用于铸造,是近代以来综合性能最为优良的造型材料类别,在砂型强度、抗吸湿性、表面粗糙度、溃散性和再生性能等五个方面具有显著的优势。其缺点主要有三个方面,需要进一步改进:1.发气量和最大发气速率高。采用树脂砂生产铸件,侵入式气孔是最常见的缺陷之一。目前覆膜砂发气量已普遍降低至12ml/g左右,但相比新型无机粘结剂低于5ml/g的发气量仍需改进。此外树脂砂的最大发气速率也是需要进一步改进的难点,由于树脂砂透气性较差,相比发气量,最大发气速率也是导致铸件气孔不可忽略的重要因素之一,这一点可能要从提高树脂阻燃特性等方面入手。2.型砂退让性差。树脂砂通常用来生产铸铁件而不适用于铸钢件是普遍共识,但随着铸件表面要求的提高,近年来越来越多的铸钢件直接采用或者结合覆膜砂砂型/芯进行生产,但由于树脂砂高温持久时间长,退让性差,铸件易产生裂纹缺陷。尤其在汽车行业中,普遍采用覆膜砂生产不锈钢铸件,裂纹一直是危害最大而且最普遍的问题之一。3.有害气体排放。树脂不完全燃烧容易产生各类有害气体和有机小分子挥发物,这是目前树脂砂面临的最大问题,现在所采取的的措施有采用木香树脂、邦尼树脂等芳香类树脂、增加制芯和浇注过程中的吸气罩、采用喷淋中和等,但这些措施都是治标不治本,而且需要极大的设备投入、动能消耗和维护管理成本,增加铸造企业的负担,使得原本就微利的铸造行业雪上加霜。
无机粘结剂砂造型材料。传统的无机粘结剂砂主要有硅酸盐砂和磷酸盐砂两类。硅酸盐砂粘结剂为水玻璃,水玻璃有钠水玻璃、钾水玻璃、锂水玻璃等,均为碱金属硅酸盐的水溶液,商业名为泡花碱,铸造中主要应用的是钠水玻璃。水玻璃砂的硬化方式可分为热硬法、气硬法和自硬法三大类。热硬法是利用装备加热使砂型脱水硬化,其强度高,水玻璃加入量在3%~4%,但生产效率低、能耗大,砂型加热时其表面先受热固化,内部的水蒸气不易排除,故厚大件砂型强度不足。普通CO2气硬法是水玻璃粘结剂由于设备简单,操作方便,使用灵活,成本低廉,在国内外大多数的铸钢件生产中得到了广泛的应用。其硬化速度快,强度高;硬化后起模,铸件精度高。但是型砂强度低,水玻璃加入量高达7%~8%或者更多;含水量大,易潮湿,冬季硬透性差;溃散性差,旧砂再生困难,大量旧砂的废气导致环境碱性污染。粉末硬化剂自硬法是利用一些能够吸附水、颗粒小、表面积大的粉末使水玻璃脱水黏度增加,从而产生粘结力。这种粉末自硬砂操作简单、成本低,可以在很短时间内获得高强度砂型,但是粉末硬化剂加入量大,损耗粘结剂也较多,导致粘结剂的加入量无法降低,一般在6%~7%或者更多,且最后加重粉尘污染,因而限制了其应用。
有机酯自硬法是利用有机脂代替CO2气体作为水玻璃的硬化剂。其型砂具有较高的强度,水玻璃的加入量可降至3.5%以下;冬季硬透性好,硬化速度可调整;溃散性好,旧砂干法再生,回用率%≥70%,减少水玻璃碱性废砂对环境的污染;型砂热塑性好,发气量低,可以克服呋喃树脂砂生产铸钢件时易出现的裂纹、气孔等缺陷;可以克服CO2水玻璃砂存在的砂型表面稳定性差、容易过吹等工艺问题。但是型砂硬化速度较慢,流动性差。
综上所述,以水玻璃为主要粘结剂的无机砂具有诸多优点并在铸造行业被广泛采用,但存在3个突出的问题:1.强度低。不论是二氧化碳硬化水玻璃还是酯硬化水玻璃,水玻璃砂砂强度相对树脂砂要低很多,而且表面容易吸潮而失去强度,因此其铸件容易产生砂眼和表面粘砂。因此对于高端铸件,水玻璃砂难以满足表面质量要求。2.抗吸湿性差。磷酸盐无机粘结剂在某方面表现出有机树脂的特点,特别是溃散性好,并且耐高温、耐热冲击、耐腐蚀。硅酸盐粘结剂在吸湿性上比磷酸盐略好,但也有未解决的问题,铸型或砂芯存放过程中,因吸收空气中的水分而使强度降低,特别是在高湿度季节。3.溃散性差。水玻璃砂存在800℃附近存在二次烧结硬化现象,因此其浇注后的残留强度往往远高于原始砂强度,因此水玻璃砂溃散性差。控制杂质含量,提高水玻璃纯度,降低水玻璃加入量,是改善其溃散性的可能途径之一。
发明目的
本发明的目的在于:针对上述现有技术存在的缺点,提出一种粉末固化无机自硬砂及制芯方法,从而解决现有树脂砂发气量大、退让性差、有害气体排放和传统水玻璃砂强度低、抗吸湿性差、溃散性差的问题。
本发明首先提出一种粉末固化无机自硬砂,包括以下重量百分比的组分:占天然硅砂重量0.8%~2.0%的粉末固化剂,占天然硅砂重量1.8%~3.0%的无机粘结剂和余量的天然硅砂。
上述配比中的所述粉末固化剂包括以下重量百分比的组分:
10%~23%的铝粉,
70%~80%的无定形二氧化硅粉,
5%~10%的碳化铝粉,
0.3%~1.5%的石墨粉,
0.5%~1.5%的滑石粉。
其中,铝粉、无定形二氧化硅粉粉末、碳化铝粉等三种主要参与反应的粉末的粒度宜控制在15μm~75μm。其优点在于,当粉末粒度小于15μm时,粉末尺寸小,比表面积比大,反应剧烈,不利于固化反应过程的稳定控制。当粉末粒度大于75μm时,粉末反应速度较慢,会降低固化速度,从而影响到生产效率。
上述配比中的所述无机粘结剂为硅酸盐粘结剂。进一步的,所述硅酸盐粘结剂的重量百分比成分为:
硅酸钠30%~40%
氢氧化钾5%~10%
磷酸氢二钠1%~3%
氧化铝0.1%~1%
氧化铁0.1%~1%
氧化镁0.1%~1%
氧化锌0.1%~1%
氢氧化钠5%~10%
其余为水。
水玻璃砂是铸造生产中应用最为广泛的三大砂型之一。硬化方式有CO2硬化法、自硬法和加热硬化,三种其硬化方式原理都是将水玻璃粘结剂进行脱水随后形成凝胶从而固化。发明人在研究过程中发现,在一定范围内提高水玻璃模数方式便会使其强度提高,但其流动性会降低,综合少量的磷酸盐系,即使强度可达到2Mpa以上,达到树脂砂强度,即在水玻璃中加入磷酸氢二钠作为增强剂进行改性。树脂类粘结剂在高温下会燃烧挥发,所以溃散性好,而水玻璃在高温下会熔融,这是其溃散性差的主要原因,而研究发现,在水玻璃中加入可溶性介质,阻止水玻璃在高温下熔融,冷却后形成块状玻璃晶体,如氧化铝、氧化铁、氧化锌、氧化镁高熔点氧化物,破坏水玻璃高温熔融形成的玻璃晶体,即在水玻璃中加入氧化铝、氧化铁、氧化锌、氧化镁作为溃散剂进行改性。为了进一步增强其溃散性,加入氢氧化钾,水玻璃在高温烧结后会形成泡沫状钾长石,破坏高温熔融形成玻璃晶体,提高溃散性。
研究是以粉末自硬法方式综合CO2硬化法和加热硬化优点进行固化,传统是利用一些能够吸附水、颗粒小、表面积大的粉末使水玻璃脱水黏度增加,从而产生粘结力。如硅酸二钙、硅铁粉、赤泥、铬矿渣、氟硅酸钠等。本发明的粉末固化剂采用在水玻璃加入氢氧化钠作为发生剂,利用铝粉与其发生放热从而热固化,碳化铝和水玻璃进行脱水加速固化后续可作为溃散剂增加其溃散性能,加入无定形二氧化硅可溶于水玻璃提高模数提高强度以及在水玻璃凝胶外围形成致密的硬化膜从而增加其抗吸湿性能。通过加入石墨粉和滑石粉增加水玻璃砂的流动性。
通过上述配比实现了一种热固化粉末自硬法,本发明进一步提供粉末固化无机硬砂制芯方法,包括以下步骤:
第一步、制备固化剂——将以下重量百分比的粉料混合制成无机自硬砂自热粉末固化剂
10%~23%铝粉
70%~80%无定形二氧化硅粉
5%~10%碳化铝粉
0.3%~1.5%石墨粉
0.5%~1.5%滑石粉;
第二步、添加无机粘结剂——在天然硅砂中加入其总重量1.8%~3.0%的无机粘结剂均匀混合;
第三步、添加固化剂——在第二步混合完成后,按天然硅砂总重量0.8%~2.0%加入第一步制备的无机自硬砂自热粉末固化剂,均匀混合,制成混合砂;
第四步、填砂成型——将第三步制成的混合砂填入成型模具;
第五步、固化定型——经1min—5min反应放热脱水,使混合砂在模具中固化定型,得到所需粉末固化无机自硬砂制芯。
与现有技术相比,本发明具有如下显著优点,通过改性水玻璃和粉末硬化剂实现粉末自硬方式,从而使砂型达到树脂砂的强度、溃散、抗吸湿性又综合了传统水玻璃砂的低发气量、退让性。
具体实施方式
实施例1
一种粉末固化无机硬砂制芯方法,其在原砂(天然硅砂)中加入其总重量1.8%~3.0%的无机粘结剂混砂,随后按照混合砂总重量的0.8%~2.0%加入粉末固化剂混砂,采用连续式混砂机填入模具,通过粉末固化剂与无机粘结剂发生放热反应,使无机粘结剂固化,从而得到无机自硬砂。
天然硅砂的成分如下表:
表1
粉末固化剂的成分如下表:
表2
无机粘结剂的成分如下表:
表3
粉末固化无机自硬砂制备砂芯,包括以下步骤:
(1)在原砂中加入其总重量的2.4%加入无机粘结剂继续混砂30s~90s;
(2)混合完成后按照原砂总重量的1.5%加入粉末固化剂混砂;
(3)将步骤(2)混好的无机自硬机砂手工填入模具;
(4)经过5min反应放热脱水固化成型,即得无机自硬砂砂芯。
性能如下表:
表4
实施例2
一种粉末固化无机硬砂制芯方法,其在原砂(天然硅砂)中加入其总重量1.8%~3.0%的无机粘结剂混砂,随后按照混合砂总重量的0.8%~2.0%加入粉末固化剂混砂,采用连续式混砂机填入模具,通过粉末固化剂与无机粘结剂发生放热反应,使无机粘结剂固化,从而得到无机自硬砂。
原砂的成分如下表:
表5
粉末固化剂的成分如下表:
表6
无机粘结剂为硅酸盐粘结剂,成分如下表:
表7
粉末固化无机自硬砂制备砂型,包括以下步骤:
(1)在原砂中加入其总重量的2.4%加入无机粘结剂继续混砂30s~90s;
(2)混合完成后按照原砂总重量的1.5%加入粉末固化剂混砂;
(3)将步骤(2)混好的无机自硬机砂手工填入模具;
(4)经过2min反应放热脱水固化成型,即得无机自硬砂砂芯。
性能如下表:
表8
对比例1
本对比例采用与实施例中相同的原砂和粘结剂,其原砂的成分如下表。不同之处在于粉末固化剂中铝粉、无定形二氧化硅粉含量与本发明不相同。
表9
粉末固化剂的成分如下表:
表10
无机粘结剂为硅酸盐粘结剂,成分如下表:
表11
粉末固化无机自硬砂制备砂芯,包括以下步骤:
(1)在原砂中加入其总重量的2.4%加入无机粘结剂继续混砂30s~90s;
(2)混合完成后按照原砂总重量的1.5%加入粉末固化剂混砂;
(3)将步骤(2)混好的无自硬机砂手工填入模具;
(4)固化速度过快,砂型不成型。
性能测试如下表:
表12
对比例2
采用市售常规有机固化剂,乙二醇二醋酸酯制作砂芯,其粘结剂为水玻璃,性能指标如表13所示,所制备的砂芯在及时强度,24小时强度及1000℃发气量等性能指标均低于实施例的制备方法。
表13
除上述实施例外,本发明还可以有其他实施方式。凡采用等同替换或等效变换形成的技术方案,均落在本发明要求的保护范围。
Claims (8)
1.一种粉末固化无机自硬砂,包括以下重量百分比的组分:
占天然硅砂重量0.8%~2.0%的粉末固化剂,占天然硅砂重量1.8%~3.0%的无机粘结剂和余量的天然硅砂。
2.根据权利要求1所述粉末固化无机自硬砂,其特征在于:所述粉末固化剂包括以下重量百分比的组分:
10%~23%的铝粉,
70%~80%的无定形二氧化硅粉,
5%~10%的碳化铝粉,
0.3%~1.5%的石墨粉,
0.5%~1.5%的滑石粉。
3.根据权利要求2所述粉末固化无机自硬砂,其特征在于:所述铝粉、无定形二氧化硅粉和碳化铝粉的粉末粒度为15μm~74μm。
4.根据权利要求1所述粉末固化无机自硬砂,其特征在于:所述无机粘结剂为硅酸盐粘结剂。
5.根据权利要求4所述粉末固化无机自硬砂,其特征在于:所述硅酸盐粘结剂包括以下按重量百分比的组分,
30%~40%的硅酸钠,
5%~10%的氢氧化钾,
1%~3%的磷酸氢二钠,
0.1%~1%的氧化铝,
0.1%~1%的氧化铁,
0.1%~1%的氧化镁,
0.1%~1%的氧化锌,
5%~10%的氢氧化钠,
其余为水。
6.一种粉末固化无机自硬砂的制芯方法,包括以下步骤:
第一步、制备粉末固化剂--将以下重量百分比的组分10%~23%的铝粉,70%~80%的无定形二氧化硅粉,5%~10%的碳化铝粉,0.3%~1.5%的石墨粉,0.5%~1.5%的滑石粉混合,得到粉末固化剂;
第二步、添加无机粘结剂--在天然硅砂中加入其总重量1.8%~3.0%的无机粘结剂均匀混合;
第三步、添加固化剂--在第二步混合完成后,按天然硅砂总重量0.8%~2.0%加入第一步制备的粉末固化剂,均匀混合,制成混合砂;
第四步、填砂成型--将第三步制成的混合砂填入成型模具;
第五步、固化定型--经放热反应脱水,使混合砂在模具中固化定型,得到所需粉末固化无机自硬砂制芯。
7.根据权利要求6所述粉末固化无机自硬砂的制芯方法,其特征在于:所述第二步混合时间30s-90s。
8.根据权利要求6所述粉末固化无机自硬砂的制芯方法,其特征在于:所述第五步中放热反应时间为1min-5min。
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Country or region after: China Address after: 213011 258 Wuyi Road, Changzhou, Jiangsu Applicant after: CRRC Qishuyan Locomotive and Rolling Stock Technology Research Institute Co.,Ltd. Address before: 213011 258 Wuyi Road, Changzhou, Jiangsu Applicant before: CRRC QISHUYAN INSTITUTE Co.,Ltd. Country or region before: China |