CN114042858A - Method for self-collapsing of high-strength carbon-free casting mold in evaporative pattern cavity along with cooling of casting - Google Patents
Method for self-collapsing of high-strength carbon-free casting mold in evaporative pattern cavity along with cooling of casting Download PDFInfo
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- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 5
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- INJRKJPEYSAMPD-UHFFFAOYSA-N aluminum;silicic acid;hydrate Chemical compound O.[Al].[Al].O[Si](O)(O)O INJRKJPEYSAMPD-UHFFFAOYSA-N 0.000 claims description 4
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- 239000000378 calcium silicate Substances 0.000 description 1
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 1
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- BCAARMUWIRURQS-UHFFFAOYSA-N dicalcium;oxocalcium;silicate Chemical compound [Ca+2].[Ca+2].[Ca]=O.[O-][Si]([O-])([O-])[O-] BCAARMUWIRURQS-UHFFFAOYSA-N 0.000 description 1
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C3/00—Selection of compositions for coating the surfaces of moulds, cores, or patterns
-
- 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
Abstract
The invention discloses a method for self-collapsing of a high-strength carbon-free casting mold of a lost foam cavity along with cooling of a casting, which comprises the following steps: preparing and coating a fluid or wet aggregate: the aggregate is divided into a surface layer material and a back layer material, and is prepared by different components respectively; performing composite molding on the EPS pattern and the aggregate; initially setting the casting mold; drying the casting mold and gasifying the EPS mold to form a carbon-free cavity to obtain a cavity casting mold; and pouring molten metal to obtain a casting. The method can simplify the process, improve the work efficiency and the operation reliability, is environment-friendly, less and pollution-free, and breaks through the limitation that the gasification shell method for coating multilayer coatings on paraffin wax investment casting and lost foam EPS patterns can only be suitable for producing small castings.
Description
Technical Field
The invention relates to the technical field of lost foam casting, in particular to a method for enabling a high-strength carbon-free casting mold in a lost foam cavity to automatically collapse along with cooling of a casting.
Background
Lost foam casting is an advanced process technology with light weight and high efficiency in 21 st century, more than 4000 lost foam casting enterprises exist in China, more than 1500 lost foam casting enterprises exist, the lost foam casting enterprises adopt a process of oxygen enrichment, first burning empty and then pouring molten metal under dry sand negative pressure, for example, a method for quickly cooling and eliminating carbon defects by high-performance coating negative pressure combustion empty shell pouring airflow is adopted in lost foam casting disclosed in China patent with publication number CN101690976A, the method has great breakthrough and advancement compared with the traditional full mold casting, the carbon increasing defects of steel lost foam castings are better eliminated and controlled, but due to the limitation of different burning empty time, casting structures and sizes, Polystyrene foam (Expanded Polystyrene, EPS for short) in general cases is difficult to be completely burnt in empty molds, the burning empty degree is mostly in the range of 80-95%, namely more than 5% of residual carbon exists, namely, the threat of micro carbon increasing still exists, for castings with high requirements, such as special castings of weapons, war industry, national defense equipment, high-speed rails, aviation, aerospace and other equipment, the requirements cannot be met, and the EPS pattern can be completely empty without carbon residue only after sufficient gasification time at the temperature of more than 500 ℃. If the investment casting imitating hollow shell method is implemented, the investment casting water glass or silica sol coating is adopted, the process is complicated, the production period is long, the pollution in the coating curing and roasting process is serious, the energy consumption is remarkable, the air permeability of the shell can be ensured only by roasting for a long time at the temperature of more than 1000 ℃, and the coating is not easy to desalt and clean, thereby actually belonging to the laggard process with less slow speed and expense. In 4000 lost foam foundries around the country, almost all the foundries usually need to produce castings, especially castings of low carbon steel, low carbon alloy steel and the like, which have high quality requirements and need to be strictly controlled, and are single or small in batches or large in batches. Therefore, the EPS gasification empty shell carbon-free casting technology is a practical problem which is urgently needed to be solved by China and international lost foam casting.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a method for self-collapsing of a high-strength carbon-free casting mold with a lost foam cavity along with cooling of a casting. The method can simplify the process, improve the work efficiency and the operation reliability, is environment-friendly, less and pollution-free, and breaks through the limitation that the gasification shell method for coating multilayer coatings on paraffin wax investment casting and lost foam EPS patterns can only be suitable for producing small castings.
The technical scheme for realizing the purpose of the invention is as follows:
a method for self-collapsing of a high-strength carbon-free casting mold with a lost foam cavity along with cooling of a casting comprises the following steps:
s1, preparing and coating the fluid or wet aggregate:
the aggregate is divided into a surface layer material and a back layer material, and is prepared from different components:
s1-1, preparing a surface layer fluid aggregate, wherein the components in percentage by weight are as follows:
15-25% of ordinary cement, 71-81% of kyanite, 1% of polyacrylamide, 1% of plant powder and 2% of alpha starch, sieving the raw materials with a sieve of 150-200 meshes, mixing, adding water accounting for 50-80% of the total weight of the 5 materials, and stirring for 15-25 min to form a fluid or toothpaste-like aggregate;
s1-2, preparing a back layer wet aggregate, wherein the components in percentage by weight are as follows:
20-30% of ordinary cement, 69-79% of 20-100 mesh filling sand material and 1% of plant powder, wherein the particle size of the plant powder is 0.5-3 mm, after mixing, adding water accounting for 15-25% of the total weight of the 3 materials, and stirring for 8-12 min to form a wet aggregate;
s2, carrying out composite molding on the EPS pattern and the aggregate:
brushing or scraping the surface layer aggregate on the surface of the EPS mould (similar to putty scraping), and turning to the next procedure when the thickness of the EPS mould in a wet state without creep reaches 3-4 mm:
placing the EPS mould attached with the surface layer aggregate in a sand box and filling the back layer aggregate for molding;
s3, initial setting of casting mold:
after the composite modeling procedure is finished, the mixture is placed for more than 6 hours to naturally solidify to form a solid model with better strength, and is placed for more than 24 hours at normal temperature;
s4, forming a carbon-free cavity by drying the casting mold and gasifying the EPS pattern:
placing the dry solid casting mold in a gasification furnace with controllable temperature of 600-650 ℃, quickly gasifying and pyrolyzing the EPS mold, and obtaining a cavity casting mold after full gasification;
s5, pouring molten metal:
and pouring molten metal after the cavity casting mold is discharged to obtain a casting.
Further, in S1-2, the filling sand material is one or more of waste slag, waste refractory bricks, waste water glass casting sand, and reused lost foam casting filling dry sand.
Further, in S2, during molding, the sand box is placed on a flat plate, a layer of 4-5 cm thick back layer aggregate is padded on the bottom surface of the sand box, and the EPS pattern is placed on the back layer aggregate cushion layer, so that the wet and fluid back layer aggregate sand box can be filled for composite molding.
Further, in S4, the in-furnace vaporization time is 30min or more.
The invention takes ordinary portland cement as casting mould cement, prepares two different coagulants of fluid state and wet state, one coagulant is coated on the surface of an EPS pattern, and then the other coagulant is used for filling and forming, and is baked at 600-650 ℃ after being solidified for a certain time, so that the EPS pattern is fully gasified, and a high-strength casting mould with a carbon-free cavity is formed.
The invention has the characteristics, effects and advantages that:
1. the ordinary portland cement contains silicate as main component including dicalcium silicate, tricalcium silicate and tetracalcium aluminoferrite, and the tetracalcium aluminoferrite contains Al2O3And Fe2O3The calcium silicate has the function of resisting sand adhesion, the melting point of dicalcium silicate is high (2130 ℃), and the process from high temperature to 675 ℃ to complete cooling is always accompanied by beta-2 CaO. SiO2To gamma-2 CaO. SiO2The crystal form transformation and the reaction are violent, the expansion rate of the body reaches 10 percent, the self-collapsing and the yielding of the casting mold are increased, the defect of shrinkage cracks of the casting is eliminated, the casting is easy to desand by cleaning, and free SO is little2Silicon dust, which is a casting material having superior properties and being less used before the field of casting production;
2. polyacrylamide (PAM) in the surface layer aggregate has good flocculation property, thickening property, adhesion and resistance to drop, is neutral and nontoxic, and the PAM and alpha starch are matched to be beneficial to improving the adhesion and the coverage uniformity of the surface layer slurry aggregate on the surface of the EPS model; the addition of the plant powder is beneficial to improving the air permeability and the crack resistance; the material is a refractory material which is neutral, strong in steel liquid immersion resistance, small in expansion coefficient and good in stability;
3. the back layer aggregate plays a role of a protective surface layer, is suitable for filling sand materials with small thermal expansion and cold contraction deformation in principle, and is best for casting moulds with large structures by fully utilizing waste furnace slag, waste refractory bricks, waste water glass casting sand and durable reused lost foam casting filling dry sand, so that not only is waste resources fully utilized, but also the cracking resistance and the deformation resistance of the lost foam casting filling dry sand are far superior to those of the cheapest quartz raw sand;
4. good compounding of the surface layer and the back layer of the casting mold: the surface layer of the casting material is added with 15-25% of common cement, the back layer is added with 20-30% of common cement, the difference of the cement content of the surface layer and the back layer is reduced, the self-setting property of the surface layer and the back layer is approximate, the surface layer and the back layer are integrated into a whole, and the surface layer and the back layer are prevented from being separated from each other;
5. compared with the methods of paraffin wax investment casting, evaporative pattern imitating investment casting, brushing coating gasification shell and the like, the method not only simplifies the working procedure, improves the working efficiency and the operation reliability, is environment-friendly, less and pollution-free, but also breaks through the limitation that the method of paraffin wax investment casting and evaporative pattern EPS pattern coating gasification shell can only be suitable for producing small castings.
Drawings
FIG. 1 is a schematic diagram of an EPS pattern of a lost foam casting in an embodiment, which is placed in a sand box for molding.
In the figure, 1, an EPS model 2, a surface layer aggregate 3, a back layer aggregate 4, a sand box 5, a pouring gate 6, a riser 7 and a lifting hook are arranged.
Detailed Description
The technical solutions of the present invention will be fully described below with reference to the accompanying drawings and embodiments, and it is to be understood that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example (b):
as shown in FIG. 1, a method for self-collapsing of a high-strength carbon-free casting mold with a lost foam cavity as a casting cools comprises the following steps:
s1, preparing and coating the fluid or wet aggregate:
in order to obtain a casting mold with high strength, high air permeability and smooth inner cavity wall surface, the aggregate is divided into a surface layer material and a back layer material, and the aggregate is prepared from different components:
s1-1, preparing a surface layer fluid aggregate, wherein the components in percentage by weight are as follows:
20% of ordinary cement, 76% of kyanite, 1% of polyacrylamide, 1% of plant powder and 2% of alpha starch, sieving the raw materials with a 200-mesh sieve, mixing, adding water accounting for 65% of the total weight of the 5 materials, and stirring for 20min to form a fluid state or toothpaste-like aggregate;
s1-2, preparing a back layer wet aggregate, wherein the components in percentage by weight are as follows:
25% of ordinary cement, 74% of 20-100 mesh filling sand material and 1% of plant powder, wherein the particle size of the plant powder is 0.5-3 mm, after mixing, adding water accounting for 20% of the total weight of the 3 materials, and stirring for 10min to form a wet aggregate;
the filling sand material is one or more of waste slag particles, waste refractory brick particles, waste sodium silicate casting sand and reused lost foam casting filling dry sand;
s2, carrying out composite molding on the EPS pattern and the aggregate:
brushing or scraping the surface layer aggregate 2 on the surface of the EPS mould sample 1, wherein the thickness of the surface layer aggregate reaches about 4mm, and the surface layer aggregate can be transferred to the next procedure when the surface layer aggregate is in a wet state and does not creep:
placing the EPS mould sample 1 attached with the surface layer aggregate 2 in a sand box 4 to be filled with a back layer aggregate 3 for molding, wherein the sand box 4 can be movably detachable or fixed iron structure, placing the sand box 4 on a flat plate, padding a layer of back layer aggregate with the thickness of 4-5 cm on the bottom surface of the sand box, and then placing the EPS mould sample 1 on a back layer concrete cushion layer to be filled with the wet and fluid back layer aggregate sand box for composite molding; one end of the EPS model 1 is communicated with the pouring gate 5, and the other end is communicated with the riser 7;
s3, initial setting of casting mold:
after the composite modeling procedure is finished, the material is placed at normal pressure for more than 6 hours to naturally solidify to form a solid model with better strength, and the material is placed at normal temperature for more than 24 hours;
s4, forming a carbon-free cavity by drying the casting mold and gasifying the EPS pattern:
putting the dry solid mold into a gasification furnace with controllable temperature of 600-650 ℃, quickly gasifying and pyrolyzing the EPS mold, obtaining a cavity mold after full gasification, and taking out the cavity mold for pouring molten metal, wherein the time required by gasification in the furnace is changed according to factors such as density, structure, temperature condition in the furnace, capacity of the mold and the like, and is generally more than 30 min;
s5, pouring molten metal:
after the cavity casting mold is taken out of the furnace, the cavity casting mold is hung to a casting pit paved with dry sand through a hanging hook 7, and metal liquid is cast according to the production convention to obtain a high-grade precise high-quality casting without carbon defects.
The preferred embodiments of the present invention have been disclosed for illustrative purposes only and are not intended to limit the invention to the specific embodiments described. Obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and the practical application, to thereby enable others skilled in the art to best utilize the invention.
Claims (6)
1. A method for self-collapsing of a high-strength carbon-free casting mold with a lost foam cavity along with cooling of a casting is characterized by comprising the following steps:
s1, preparing and coating the fluid or wet aggregate:
the aggregate is divided into a surface layer material and a back layer material, and is prepared from different components:
s1-1, preparing a surface layer fluid aggregate, wherein the components in percentage by weight are as follows:
15-25% of ordinary cement, 71-81% of kyanite, 1% of polyacrylamide, 1% of plant powder and 2% of alpha starch, sieving the raw materials with a sieve of 150-200 meshes, mixing, adding water accounting for 50-80% of the total weight of the 5 materials, and stirring for 15-25 min to form a fluid or toothpaste-like aggregate;
s1-2, preparing a back layer wet aggregate, wherein the components in percentage by weight are as follows:
20-30% of ordinary cement, 69-79% of 20-100 mesh filling sand material and 1% of plant powder, wherein the particle size of the plant powder is 0.5-3 mm, after mixing, adding water accounting for 15-25% of the total weight of the 3 materials, and stirring for 8-12 min to form a wet aggregate;
s2, carrying out composite molding on the EPS pattern and the aggregate:
brushing or scraping the surface layer aggregate on the surface of the EPS pattern, and transferring the wet thickness without creep to 3-4 mm to the next procedure:
placing the EPS mould attached with the surface layer aggregate in a sand box and filling the back layer aggregate for molding;
s3, initial setting of casting mold:
after the composite modeling procedure is finished, the material is placed at normal temperature for more than 6 hours to naturally solidify to form a solid model with better strength, and is placed at normal temperature for more than 24 hours;
s4, forming a carbon-free cavity by drying the casting mold and gasifying the EPS pattern:
placing the dry solid casting mold in a gasification furnace with controllable temperature of 600-650 ℃, quickly gasifying and pyrolyzing the EPS mold, and obtaining a cavity casting mold after full gasification;
s5, pouring molten metal:
and pouring molten metal after the cavity casting mold is discharged to obtain a casting.
2. The method for self-collapsing of the high-strength carbon-free casting mold with the cavity of the lost foam as claimed in claim 1, wherein in S1-2, the sand-filling material is one or more of waste slag, waste refractory bricks, waste water glass casting sand, and reused lost foam casting dry sand.
3. The method according to claim 1, wherein in S2, the sand box is placed on a flat plate during molding, a 4-5 cm thick layer of the back layer aggregate is laid on the bottom surface of the sand box, and the EPS pattern is placed on the back layer aggregate cushion layer to fill the wet and fluidized back layer aggregate sand box for composite molding.
4. The method for self-collapsing of a high-strength carbon-free lost foam hollow mold according to claim 1, wherein in S4, the time for gasification in the furnace is 30min or more.
5. The method for self-collapsing of the high-strength carbon-free casting mold with the evaporative pattern, as claimed in claim 1, wherein in S1-1, the surface layer fluid aggregate is prepared, and the components are as follows by weight percent:
20% of ordinary cement, 76% of kyanite, 1% of polyacrylamide, 1% of plant powder and 2% of alpha starch.
6. The method of claim 1, wherein in S1-2, the backing layer is prepared from a wet aggregate, the components in weight percent being:
25% of ordinary cement, 74% of 20-100 mesh filling sand material and 1% of plant powder.
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