CN113953453A - Precision casting process for eliminating scab iron - Google Patents
Precision casting process for eliminating scab iron Download PDFInfo
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- CN113953453A CN113953453A CN202111231174.5A CN202111231174A CN113953453A CN 113953453 A CN113953453 A CN 113953453A CN 202111231174 A CN202111231174 A CN 202111231174A CN 113953453 A CN113953453 A CN 113953453A
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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
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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
- B22C13/085—Moulding machines for making moulds or cores of particular shapes for shell moulds or shell cores by investing a lost pattern
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
- B22C7/02—Lost patterns
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/12—Treating moulds or cores, e.g. drying, hardening
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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
- Y02P10/20—Recycling
Abstract
The invention provides a precision casting process for eliminating scab iron, which comprises the steps of manufacturing a wax mould, manufacturing a shell on a surface layer, manufacturing a shell on a second layer, manufacturing a shell on a third layer, manufacturing a shell on a fourth layer, manufacturing a shell on a fifth layer, sealing slurry to form a shell, dewaxing, roasting, casting and checking, wherein the environmental temperature, the humidity and the airing time are strictly controlled in the process of manufacturing the shell, so that the wax mould cannot deform and the shell cannot crack.
Description
Technical Field
The invention relates to the technical field of investment casting, in particular to a precision casting process for eliminating scab iron.
Background
The investment casting is also called lost wax casting, and comprises the procedures of wax pressing, wax trimming, tree forming, slurry dipping, wax melting, molten metal casting, post-treatment and the like. Lost wax casting is a process in which a wax pattern for a part to be cast is made of wax, and then the wax pattern is coated with a slurry to obtain a shell. And after the shell is dried, putting the shell into hot water to melt the internal wax mold, taking out the shell with the melted wax mold, pouring molten metal into the shell from a pouring gate, and cooling the shell to obtain the parts required by shell vibration.
However, when investment casting is carried out, the time, humidity and temperature for airing in the shell making process are difficult to control, so that wax molds expand, mold shells bulge and even crack inside the mold shells, and scab iron defective products are formed after casting is finished, so that the finished product rate is low, and the casting cost is increased.
Disclosure of Invention
The invention aims to solve the defects in the prior art and provides a precision casting process for eliminating scab iron.
In order to achieve the purpose, the invention adopts the following technical scheme:
a precision casting process for eliminating scab iron comprises the following steps:
s1: manufacturing a wax mould: selecting quantitative low-temperature white wax for heating and melting as a film material, simultaneously heating and melting polyethylene and melting into a mold material, fully stirring, placing in a heat preservation box at 53-65 ℃ for heat preservation for 12h, taking out, cooling, carving wax by using a wax carving machine according to a drawing under a clean environment, cleaning a wax mold by using a neutral cleaning solution, and airing to form the wax mold;
s2: preparing a shell by a surface layer: uniformly coating plateau mortar which is prepared by 330 meshes of plateau sand and has the viscosity of 45-50mPa.s on the outer surface of a wax mould with a clean and dustless surface layer, uniformly spraying 90-130 meshes of plateau sand to form a surface layer shell, keeping the surface layer shell in a clean environment, keeping the humidity at 40-60% rh, keeping the temperature at 24 +/-2 ℃, and airing for 8-12 h;
s3: preparing a shell by two layers: uniformly coating plateau mortar which is prepared from 330 meshes of plateau sand and has the viscosity of 23-26mPa.s on the surface of the surface layer shell, uniformly spraying 90-130 meshes of plateau sand to form a two-layer shell, keeping the two-layer shell in a clean environment, keeping the humidity at 40-60% rh, keeping the temperature at 24 +/-2 ℃, and airing for 8-12 h;
s4: preparing a shell by three layers: uniformly coating mullite slurry which is prepared from 250-mesh mullite powder and has the viscosity of 15-17mPa.s on the surface of the two-layer shell, uniformly spraying 40-mesh mullite sand to form a three-layer shell, and keeping the three-layer shell in a clean environment, wherein the humidity is 50-60% rh, the temperature is 24 +/-2 ℃, and the air drying time is 7-9 h;
s5: four-layer shell making: uniformly coating mullite slurry which is prepared by 200 meshes of mullite powder and has the viscosity of 15-17mPa.s on the surface of the three-layer shell, uniformly spraying 20 meshes of mullite sand to form a four-layer shell, keeping the four-layer shell in a clean environment, keeping the humidity at 50-60% rh, keeping the temperature at 24 +/-2 ℃, and airing for 6-8 h;
s6: preparing a shell by five layers: uniformly coating mullite slurry which is prepared from mullite powder of 200 meshes and has the viscosity of 15-17mPa.s on the surface of the four-layer shell, uniformly spraying mullite sand of 20 meshes to form five-layer shell, keeping the five-layer shell in a clean environment, keeping the humidity at 50-60% rh, keeping the temperature at 24 +/-2 ℃, and airing for 6-8 h;
s7: sealing slurry and forming a shell: uniformly coating mullite slurry which is prepared from 200-mesh mullite powder and has the viscosity of 15-17mPa.s on the surface of the five-layer shell to finish slurry sealing, keeping the environment clean and the humidity of 50-60% rh at the temperature of 24 +/-2 ℃, and airing for 6h for later use to finish shell manufacturing;
s8: dewaxing: putting the shell subjected to slurry sealing into a dewaxing kettle for heating, and quickly melting a wax mold to form a cavity;
s9: roasting: placing the prepared shell into an electric heating furnace for roasting, evaporating water in the shell to harden the shell, wherein the heating temperature is 1150 +/-20 ℃, and the heating time is 0.5 h;
s10: casting: preparing molten metal, heating to 1640 +/-10 ℃, casting the molten metal in a cavity of a shell, cooling, then vibrating and crushing the shell by using a shell vibrating machine, and stripping the shell to obtain a blank;
s11: and (3) inspection and processing: and (5) inspecting the blank, removing defective products and processing the blank.
The temperature and the humidity in the shell manufacturing process are strictly controlled, reinforced air drying is reduced or avoided, each layer of the shell is naturally dried within the time strictly controlled in a clean room, so that the wax pattern is prevented from shrinking or expanding, roasting and hardening are further performed, moisture in the shell is further dried, casting is performed again, and breakage or bubbling cannot occur inside the shell, so that the formation of the iron crust on the blank is eliminated, the bulge is reduced, and the casting yield and the casting capacity are improved.
Fine and smooth high-temperature-resistant plateau sand is used as the material of the surface shell and the two layers of shells, the internal structure of the shell is further refined, the surface layer and the two layers of shells at the innermost layer of the shell have higher strength, and the risk of bulging or cracking is reduced.
Further, in the step S2, plateau mortar is uniformly applied in the following manner: coating is started, after the plateau mortar is prepared, a first brush is used for coating the plateau mortar at one time in a mode that slurry is dipped by a brush piece from bottom to top along the outer surface of a wax mould, then a second brush is finished by the brush piece from bottom to top along the edge of a first brush mark, the whole outer surface is coated in sequence, whether hard blocks and pits exist in the coating process is checked, the repairing process is carried out, and one-time coating is finished;
finishing at least 4 times of coating according to a one-time coating mode until a hard shell with the thickness of 4-5mm is formed;
in the process from the two-layer shell to the slurry sealing and forming shell, the smearing mode of mullite slurry is the same as that of high-grade mortar in S2.
Plateau mortar and mor slurry are smeared in a mode of uniformly smearing layer by layer in the shell manufacturing process, the mode is that the smearing strength and thickness are ensured in the preparation process of each layer of the shell, the smearing mode from bottom to top is adopted, the characteristic that a brush receives the slurry is utilized, the slurry is prevented from dripping in the smearing process to influence the smearing thickness, each layer of the shell has the optimal strength, the integral strength of the shell is enhanced, the thickness of each layer is kept uniform, the shell is high in strength and not prone to bulge cracking, and accordingly the generation of scab iron after casting is reduced.
Further, in the S1, the content of the polyethylene accounts for 4% -5.5% of the molding material.
Further, in S11, the blank member with slight bulge is subjected to grinding repair.
Compared with the prior art, the invention has the beneficial effects that: (1) strictly controlling the temperature and humidity in the shell manufacturing process, reducing or avoiding reinforced air drying, naturally drying each layer of the shell in a clean room within strictly controlled time, so that the wax pattern is reduced and cannot shrink or expand, the shell cannot crack, then roasting and hardening are carried out, and further drying moisture is carried out, thus casting is carried out again, the interior of the shell cannot crack or bubble, thus eliminating the formation of iron crusts on blank pieces, reducing bulges, and improving the casting yield and capacity; (2) fine and high-temperature-resistant plateau sand is used as the material of the surface shell and the second shell, the structure inside the shell is further refined, the surface layer and the second shell of the innermost layer of the shell have higher strength, and the risk of bulging or cracking is reduced; (3) plateau mortar and mor slurry are smeared in a mode of uniformly smearing layer by layer in the shell manufacturing process, the mode is that the smearing strength and thickness are ensured in the preparation process of each layer of the shell, the smearing mode from bottom to top is adopted, the characteristic that a brush receives the slurry is utilized, the slurry is prevented from dripping in the smearing process to influence the smearing thickness, each layer of the shell has the optimal strength, the integral strength of the shell is enhanced, the thickness of each layer is kept uniform, the shell is not prone to bulge cracking, and the generation of cast iron is reduced.
Drawings
Fig. 1 is a schematic flow chart of embodiment 1 of the present invention.
Detailed Description
In order to further understand the objects, structures, features and functions of the present invention, the following embodiments are described in detail.
Example 1, fig. 1, a fine casting process for removing scab iron, comprising the steps of:
step 1: manufacturing a wax mould: selecting quantitative low-temperature white wax for heating and melting as a film material, simultaneously heating and melting polyethylene and melting into a mold material, fully stirring, placing in a heat preservation box at 53-65 ℃ for heat preservation for 12h, taking out, cooling, carving wax by using a wax carving machine according to a drawing under a clean environment, cleaning a wax mold by using a neutral cleaning solution, and airing to form the wax mold;
the shrinkage and deformation of the wax pattern can be reduced by eliminating moisture and gas in the wax material and controlling the environment of the wax pattern in the subsequent shell manufacturing process.
Step 2: preparing a shell by a surface layer: uniformly coating plateau mortar which is prepared by 330 meshes of plateau sand and has the viscosity of 45-50mPa.s on the outer surface of a wax mould with a clean and dustless surface layer, uniformly spraying 90-130 meshes of plateau sand to form a surface layer shell, keeping the surface layer shell in a clean environment, keeping the humidity at 40-60% rh, keeping the temperature at 24 +/-2 ℃, and airing for 8-12 h;
the high crude sand used in the examples is high crude sand imported from Australia;
and step 3: preparing a shell by two layers: uniformly coating plateau mortar which is prepared from 330 meshes of plateau sand and has the viscosity of 23-26mPa.s on the surface of the surface layer shell, uniformly spraying 90-130 meshes of plateau sand to form a two-layer shell, keeping the two-layer shell in a clean environment, keeping the humidity at 40-60% rh, keeping the temperature at 24 +/-2 ℃, and airing for 8-12 h;
and 4, step 4: preparing a shell by three layers: uniformly coating mullite slurry which is prepared from 250-mesh mullite powder and has the viscosity of 15-17mPa.s on the surface of the two-layer shell, uniformly spraying 40-mesh mullite sand to form a three-layer shell, and keeping the three-layer shell in a clean environment, wherein the humidity is 50-60% rh, the temperature is 24 +/-2 ℃, and the air drying time is 7-9 h;
and 5: four-layer shell making: uniformly coating mullite slurry which is prepared by 200 meshes of mullite powder and has the viscosity of 15-17mPa.s on the surface of the three-layer shell, uniformly spraying 20 meshes of mullite sand to form a four-layer shell, keeping the four-layer shell in a clean environment, keeping the humidity at 50-60% rh, keeping the temperature at 24 +/-2 ℃, and airing for 6-8 h;
step 6: preparing a shell by five layers: uniformly coating mullite slurry which is prepared from mullite powder of 200 meshes and has the viscosity of 15-17mPa.s on the surface of the four-layer shell, uniformly spraying mullite sand of 20 meshes to form five-layer shell, keeping the five-layer shell in a clean environment, keeping the humidity at 50-60% rh, keeping the temperature at 24 +/-2 ℃, and airing for 6-8 h;
and 7: sealing slurry and forming a shell: uniformly coating mullite slurry which is prepared from 200-mesh mullite powder and has the viscosity of 15-17mPa.s on the surface of the five-layer shell to finish slurry sealing, keeping the environment clean and the humidity of 50-60% rh at the temperature of 24 +/-2 ℃, and airing for 6h for later use to finish shell manufacturing;
setting the temperature, humidity and drying time in the steps 2 to 7 according to the coated slurry component, and ensuring that the wax mold is also in a stable environment and does not deform in the drying process of each layer of the shell;
and 8: dewaxing: putting the shell subjected to slurry sealing into a dewaxing kettle for heating, and quickly melting a wax mold to form a cavity;
and step 9: roasting: placing the prepared shell into an electric heating furnace for roasting, evaporating water in the shell to harden the shell, wherein the heating temperature is 1150 +/-20 ℃, and the heating time is 0.5 h;
step 10: casting: preparing molten metal, heating to 1640 +/-10 ℃, casting the molten metal in a cavity of a shell, cooling, then vibrating and crushing the shell by using a shell vibrating machine, and stripping the shell to obtain a blank;
step 11: and (3) inspection and processing: and (5) inspecting the blank, removing defective products and processing the blank.
In the step 2, plateau mortar is uniformly coated in the following manner: coating is started, after the plateau mortar is prepared, a first brush is used for coating the plateau mortar at one time in a mode that slurry is dipped by a brush piece from bottom to top along the outer surface of a wax mould, then a second brush is finished by the brush piece from bottom to top along the edge of a first brush mark, the whole outer surface is coated in sequence, whether hard blocks and pits exist in the coating process is checked, the repairing process is carried out, and one-time coating is finished;
finishing at least 4 times of coating according to a one-time coating mode until a hard shell with the thickness of 4-5mm is formed;
and (3) in the process from the two-layer shell to the sealing slurry forming shell, the smearing mode of the Molai slurry is the same as that of the plateau mortar in the step (2).
In the step 1, the content of the polyethylene accounts for 4-5.5% of the molding material.
In step 11, the blank with slight bulge is subjected to polishing repair.
Example 2, the plateau sand in step 2 and step 3 was replaced with brown corundum sand, namely:
step 2: preparing a shell by a surface layer: uniformly coating brown corundum mortar which is prepared from 300-mesh brown corundum sand and has the viscosity of 47mPa.s on the outer surface of a wax mould with a clean and dustless surface layer, uniformly spraying 90-130-mesh brown corundum sand to form a surface layer shell, and keeping the surface layer shell in a clean environment, wherein the humidity is 40-60% rh, the temperature is 24 +/-2 ℃, and the air drying time is 8-12 h;
and step 3: preparing a shell by two layers: uniformly coating brown corundum mortar which is prepared from 300-mesh brown corundum sand and has viscosity of 24mPa.s on the surface of the surface layer shell, uniformly spraying 90-130-mesh brown corundum sand to form a double-layer shell, and keeping the double-layer shell in a clean environment, wherein the humidity is 40-60% rh, the temperature is 24 +/-2 ℃, and the air drying time is 8-12 h;
the surface layer and the two layers of shells of the shell are made of brown corundum sand, so that the inner surface of the shell can obtain a fine surface effect, and the shell also has the characteristic of high temperature resistance and meets the casting condition.
The present invention has been described in relation to the above embodiments, which are only exemplary of the implementation of the present invention. It should be noted that the disclosed embodiments do not limit the scope of the invention. Rather, it is intended that all such modifications and variations be included within the spirit and scope of this invention.
Claims (4)
1. The precision casting process for eliminating the scab iron is characterized by comprising the following steps of: the method comprises the following steps:
s1: manufacturing a wax mould: selecting quantitative low-temperature white wax for heating and melting as a film material, simultaneously heating and melting polyethylene and melting into a mold material, fully stirring, placing in a heat preservation box at 53-65 ℃ for heat preservation for 12h, taking out, cooling, carving wax by using a wax carving machine according to a drawing under a clean environment, cleaning a wax mold by using a neutral cleaning solution, and airing to form the wax mold;
s2: preparing a shell by a surface layer: uniformly coating plateau mortar which is prepared by 330 meshes of plateau sand and has the viscosity of 45-50mPa.s on the outer surface of a wax mould with a clean and dustless surface layer, uniformly spraying 90-130 meshes of plateau sand to form a surface layer shell, keeping the surface layer shell in a clean environment, keeping the humidity at 40-60% rh, keeping the temperature at 24 +/-2 ℃, and airing for 8-12 h;
s3: preparing a shell by two layers: uniformly coating plateau mortar which is prepared from 330 meshes of plateau sand and has the viscosity of 23-26mPa.s on the surface of the surface layer shell, uniformly spraying 90-130 meshes of plateau sand to form a two-layer shell, keeping the two-layer shell in a clean environment, keeping the humidity at 40-60% rh, keeping the temperature at 24 +/-2 ℃, and airing for 8-12 h;
s4: preparing a shell by three layers: uniformly coating mullite slurry which is prepared from 250-mesh mullite powder and has the viscosity of 15-17mPa.s on the surface of the two-layer shell, uniformly spraying 40-mesh mullite sand to form a three-layer shell, and keeping the three-layer shell in a clean environment, wherein the humidity is 50-60% rh, the temperature is 24 +/-2 ℃, and the air drying time is 7-9 h;
s5: four-layer shell making: uniformly coating mullite slurry which is prepared by 200 meshes of mullite powder and has the viscosity of 15-17mPa.s on the surface of the three-layer shell, uniformly spraying 20 meshes of mullite sand to form a four-layer shell, keeping the four-layer shell in a clean environment, keeping the humidity at 50-60% rh, keeping the temperature at 24 +/-2 ℃, and airing for 6-8 h;
s6: preparing a shell by five layers: uniformly coating mullite slurry which is prepared from mullite powder of 200 meshes and has the viscosity of 15-17mPa.s on the surface of the four-layer shell, uniformly spraying mullite sand of 20 meshes to form five-layer shell, keeping the five-layer shell in a clean environment, keeping the humidity at 50-60% rh, keeping the temperature at 24 +/-2 ℃, and airing for 6-8 h;
s7: sealing slurry and forming a shell: uniformly coating mullite slurry which is prepared from 200-mesh mullite powder and has the viscosity of 15-17mPa.s on the surface of the five-layer shell to finish slurry sealing, keeping the environment clean and the humidity of 50-60% rh at the temperature of 24 +/-2 ℃, and airing for 6h for later use to finish shell manufacturing;
s8: dewaxing: putting the shell subjected to slurry sealing into a dewaxing kettle for heating, and quickly melting a wax mold to form a cavity;
s9: roasting: placing the prepared shell into an electric heating furnace for roasting, evaporating water in the shell to harden the shell, wherein the heating temperature is 1150 +/-20 ℃, and the heating time is 0.5 h;
s10: casting: preparing molten metal, heating to 1640 +/-10 ℃, casting the molten metal in a cavity of a shell, cooling, then vibrating and crushing the shell by using a shell vibrating machine, and stripping the shell to obtain a blank;
s11: and (3) inspection and processing: and (5) inspecting the blank, removing defective products and processing the blank.
2. The precision casting process for eliminating scab iron as claimed in claim 1, wherein: in the step S2, plateau mortar is uniformly coated in the following way: coating is started, after the plateau mortar is prepared, a first brush is used for coating the plateau mortar at one time in a mode that slurry is dipped by a brush piece from bottom to top along the outer surface of a wax mould, then a second brush is finished by the brush piece from bottom to top along the edge of a first brush mark, the whole outer surface is coated in sequence, whether hard blocks and pits exist in the coating process is checked, the repairing process is carried out, and one-time coating is finished;
finishing at least 4 times of coating according to a one-time coating mode until a hard shell with the thickness of 4-5mm is formed;
in the process from the two-layer shell to the slurry sealing and forming shell, the smearing mode of mullite slurry is the same as that of high-grade mortar in S2.
3. The precision casting process for eliminating scab iron as claimed in claim 1, wherein: in the S1, the content of the polyethylene accounts for 4-5.5% of the mold material.
4. The precision casting process for eliminating scab iron as claimed in claim 1, wherein: in S11, the blank with slight bulge is subjected to grinding repair.
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