CN114210926A - Turbine blade investment casting shell and casting process thereof - Google Patents
Turbine blade investment casting shell and casting process thereof Download PDFInfo
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- CN114210926A CN114210926A CN202111538279.5A CN202111538279A CN114210926A CN 114210926 A CN114210926 A CN 114210926A CN 202111538279 A CN202111538279 A CN 202111538279A CN 114210926 A CN114210926 A CN 114210926A
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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
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- B22C9/22—Moulds for peculiarly-shaped castings
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Abstract
The invention discloses an investment casting shell of a turbine blade and a casting process thereof, wherein the process comprises the following steps: designing the size and the number of the wax removal air vents according to the structure of a casting and a module, and arranging a processing space of the wax removal air vents at a position 0-15 mm away from an exhaust edge in an inner cavity of a wax mould die of the casting; then, obtaining a casting module through wax injection, pressure maintaining, cleaning and combination, and manufacturing a shell by the casting module; grinding a wax discharge air port; and dewaxing, roasting and repairing the obtained casting module, and shaking, washing and sealing the shell to obtain the shell. The method is simple and easy to implement, is convenient for batch production, can reduce the manufacturing time of the wax mould, ensures the quality of the shell, reduces the production cost, improves the production efficiency, and has good consistency and high qualification rate of the obtained shell.
Description
Technical Field
The invention belongs to the technical field of precision casting, and relates to a turbine blade investment casting shell and a casting process thereof.
Background
The turbine blade is one of important parts of the gas turbine, is generally formed by adopting a high-temperature alloy investment casting method through integral precision casting, and has great casting difficulty. The size of the blade is complex, the length of the blade is about 200-300 mm, the chord width is 75-85 mm, and the maximum thickness of the blade profile is about 13 mm. The exhaust edge R1-1.5 mm, the difference of the thickness of the blade profile in air intake and exhaust is large, when the shell is dewaxed, wax is melted and gasified when meeting high temperature, the melting and gasification speed of the thinnest part of the module shell is fastest, and if liquid or gas cannot be discharged in time, the shell is burst to form micro cracks and even visually visible cracks. At present, during process design, a manufactured wax mould structure of the wax discharge vent is welded at a position, corresponding to an auxiliary dewaxing and ventilating position, of a mould group for investment casting, and then the mould group with the wax discharge vent structure is dipped in slurry, sprayed with sand and made into a shell to obtain the shell with the wax mould structure of the wax discharge vent, so that cracks are prevented from being generated during dewaxing and roasting of the shell. However, this method has the following problems: when the wax mould structure of the de-waxing air vent is welded at the thin-wall structure of the wax mould of the part, the operation is difficult, the wax mould of the part is easy to deform, the trimming time of the wax mould is increased, the production efficiency is low, and the production consistency is poor. In the prior art, a forming pouring gate with a wax discharge port and a preparation and blocking method thereof (CN105458180B) provide a forming pouring gate with a wax discharge port for reducing wax residue and shell cracks in a dewaxing process of a shell, and a precision casting process of a gate plate casting (CN110695317B) convenient for wax discharge and exhaust provides that 4 wax discharge nails are arranged at the wax discharge low point of each gate plate wax mould so as to effectively discharge wax liquid and gas in the shell. A technology for discharging the dewaxing wax liquid from the shell of precision casting (CN101406933A) features that a wax discharging channel is additionally arranged at the lowest point where the wax mould is not easy to flow out, and is connected to the internal or main pouring channel for flowing out the wax liquid from the shell. The prior art makes the module structure complicated and does not have significant exhaust of gas from the mould shell. And for the blade with larger size change, the shell crack at the exhaust edge R of the blade still has no good solution.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides the investment casting shell of the turbine blade and the casting process thereof, which effectively ensure the reliability and consistency of the shell, are convenient for batch production, can reduce the manufacturing time of a wax mould, reduce the production cost and improve the production efficiency.
The invention is realized by the following technical scheme:
a turbine blade investment casting shell preparation process comprises the following steps:
s1: designing the size and the number of the wax removal air vents according to the structure of a casting and a module, and arranging a processing space of the wax removal air vents at a position 0-15 mm away from an exhaust edge in an inner cavity of a wax mould die of the casting;
s2: injecting wax materials into the wax mould die which is finished with the step S1 and maintaining pressure to obtain a casting wax mould;
s3: manufacturing a pouring channel wax mold according to the casting process requirement;
s4: cleaning the casting wax mold and the pouring channel wax mold, combining the casting wax mold and the pouring channel wax mold to obtain a casting module, and manufacturing a shell of the casting module;
s5: after step S4 is completed, the wax removal vent is milled;
s6: and (4) dewaxing, roasting and repairing the casting module which is subjected to the step S5, and shaking, washing and sealing the shell to obtain the shell.
Preferably, in step S1, when the casting has a machining allowance, the wax discharge vent is provided at a portion having the machining allowance; when the inner sprue of the die set is consistent with the thickness dimension of the casting, the wax-removing air vent is arranged on the inner sprue.
Preferably, in the step S1, the diameter of the designed de-waxing air vent is 3-10 mm, the height of the designed de-waxing air vent is 5-15 mm, a first radius is arranged at the joint of the de-waxing air vent and the casting, and the radius of the first radius is 1-2 mm.
Preferably, the temperature of the wax material injected in the step S2 is 50-62 ℃, the injection pressure is 15-20 bar, the injection time is 30-45S, and the pressure maintaining time is 20-160S.
Preferably, in the step S3, a second radius is arranged at an outer leakage sharp corner of the pouring gate wax mold, and the radius of the second radius is 2-5 mm.
Preferably, in the step S4, the casting module shell manufacturing includes circularly coating 7-10 layer slurry and reinforcing layer sand, the casting module shell manufacturing includes miancen, and when the next layer coating is performed, the rotation direction of the casting module is opposite to the rotation direction of the casting module when the previous layer coating is performed.
Preferably, in step S4, the grain size of the sand material of the reinforcement layer gradually increases from the inner layer to the outer layer.
Preferably, in step S5, when there is no groove structure between the wax pattern of the casting and the wax pattern of the pouring channel, the wax vent on one casting is ground; when a groove structure is arranged between the casting wax mold and the pouring channel wax mold, the wax discharge air ports on the casting are all ground.
Preferably, in the step S6, the casting mold is dewaxed, and then is naturally stored for at least 12 hours and then is baked.
An investment casting shell obtainable by any of the above processes.
Compared with the prior art, the invention has the following beneficial technical effects:
a turbine blade investment casting shell preparation technology sets a de-waxing air vent at a position 0-15 mm away from an exhaust edge, after a mold is assembled, the de-waxing air vent on a casting wax mold is ground, so that liquid or gas generated during dewaxing is timely discharged, the casting wax mold with the de-waxing air vent is extruded through a casting wax mold, the casting wax mold is prevented from deforming at the welding de-waxing air vent, and cracking of the shell is effectively avoided. The method is simple and easy to implement, is convenient for batch production, can reduce the manufacturing time of the wax mould, ensures the quality of the shell, reduces the production cost and improves the production efficiency.
Further, when the casting has machining allowance, the wax removal air vent is arranged at the part with the machining allowance; when the inner sprue of the die set is consistent with the thickness of the casting or is in smooth transition, the wax-removing air vent is arranged on the inner sprue. And the wax material at the wax removal vent can be cut off together when the inner pouring gate is cut after a casting is poured, so that the process of polishing and removing the wax material at the wax removal vent is avoided.
Furthermore, the joint of the wax-removing air vent and the casting is designed to be provided with the first rounding, so that the defects of slag inclusion and the like caused by cracking of the shell at the joint can be effectively prevented.
Furthermore, the temperature of the wax material for injection is 50-62 ℃, the injection pressure is 15-20 bar, the injection time is 30-45 s, and the pressure maintaining time is 20-160 s, so that the size and appearance integrity of the wax-removing vent hole can be effectively ensured.
Furthermore, the radius of the second rounding is 2-5 mm, so that the large thickness difference of the shell caused by the small sharp angle or fillet is reduced, and the thickness uniformity of the shell is effectively improved.
Furthermore, when adjacent layers are coated and hung, the rotation directions of the casting modules are opposite, and the thickness uniformity of the shell can be effectively improved.
Furthermore, the gradual change of the sand granularity is adopted between different layers in the shell manufacturing process, so that the strength of the shell can be effectively improved.
Furthermore, if no groove structure exists between the casting wax mold and the pouring channel wax mold, 1 casting wax-removing air vent is ground before dewaxing, so that the production efficiency is improved to a great extent.
Furthermore, after the casting module is dewaxed, the casting module is naturally stored for at least 12 hours and then is roasted, so that the quality of the shell can be effectively ensured.
An investment casting shell is manufactured by a casting wax mold with a wax removal air vent, and the shell is good in consistency and high in qualification rate.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the embodiments will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present invention and therefore should not be considered as limiting the scope, and for those skilled in the art, other related drawings can be obtained according to the drawings without inventive efforts.
FIG. 1 is a schematic view of the arrangement of a wax discharge vent in example 2 of the present invention;
FIG. 2 is a schematic view of the arrangement of the wax discharge vent in example 3 of the present invention;
fig. 3 is a partial enlarged view in the direction M in fig. 2.
In the figure: 1. and 2, a wax discharge air port, 2, a casting wax mold, 3, an exhaust edge, 41, an inner pouring gate, 51, a cross pouring gate, 42, a pouring gate system, 52, a support rod, 6 and a ceramic pouring gate cup.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. The components of embodiments of the present invention generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations.
Thus, the following detailed description of the embodiments of the present invention, presented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention. 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.
It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, it need not be further defined and explained in subsequent figures.
In the description of the embodiments of the present invention, it should be noted that if the terms "upper", "lower", "horizontal", "inner", etc. are used for indicating the orientation or positional relationship based on the orientation or positional relationship shown in the drawings or the orientation or positional relationship which is usually arranged when the product of the present invention is used, the description is merely for convenience and simplicity, and the indication or suggestion that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and thus, cannot be understood as limiting the present invention. Furthermore, the terms "first," "second," and the like are used merely to distinguish one description from another, and are not to be construed as indicating or implying relative importance.
Furthermore, the term "horizontal", if present, does not mean that the component is required to be absolutely horizontal, but may be slightly inclined. For example, "horizontal" merely means that the direction is more horizontal than "vertical" and does not mean that the structure must be perfectly horizontal, but may be slightly inclined.
In the description of the embodiments of the present invention, it should be further noted that unless otherwise explicitly stated or limited, the terms "disposed," "mounted," "connected," and "connected" should be interpreted broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
The invention is described in further detail below with reference to the accompanying drawings:
example 1
A preparation process of an investment casting shell of a turbine blade comprises the following steps:
s1: according to the casting and the module structure, the size and the number of the wax discharge air vents are designed. When the shell is dewaxed, the wax is melted and gasified when meeting high temperature, the melting and gasifying speed of the thinnest part of the module shell is fastest, and if liquid or gas cannot be discharged in time, the shell is burst to form micro cracks and even visually visible cracks. Therefore, the wax removal air vent is arranged in a range of 0-15 mm away from the exhaust edge, and the exhaust edge is the thinnest part of the casting and is most prone to cracking. More preferably, when the foundry goods has the machining allowance, the de-waxing air vent sets up in the position that has the machining allowance, and when the ingate of module was unanimous with the foundry goods size, the de-waxing air vent set up on the ingate, can effectively improve de-waxing air vent and wax matrix's be connected compactness and steadiness.
Processing a space required by a wax discharge air vent at a correspondingly designed wax discharge air vent structure in an inner cavity of a wax mould of a casting; the diameter of design wax removal blow vent is 3 ~ 10mm, highly is 5 ~ 15mm, and sets up first radius with the foundry goods junction, the radius of first radius is 1 ~ 2 mm.
S2: and (5) injecting the special wax material for the precision investment casting into the wax mould die which is finished with the step S1, and maintaining the pressure to obtain the casting wax mould. The temperature of the wax material is 50-62 ℃, the injection pressure is 15-20 bar, the injection time is 30-45 s, and the pressure maintaining time is 20-160 s, so that the completeness of the size and the appearance of the wax-removing vent hole is effectively ensured.
S3: and manufacturing the pouring channel wax mold according to the casting process requirement. And a second rounding is arranged at the outer leakage sharp corner of the pouring gate wax mold, and the radius of the second rounding is 2-5 mm so as to reduce the large thickness difference of the shell caused by the undersize of the sharp corner or the fillet.
S4: cleaning the casting wax mold and the pouring channel wax mold, and cleaning parting lines, wax chips and the like on the wax mold. And then combining the casting wax mold and the pouring channel wax mold to obtain a casting module, deoiling the casting module, and then manufacturing a shell of the casting module. The casting module shell manufacturing comprises 7-10 layers of circulating coating surface layer slurry and reinforcing layer sand, and when the next layer is coated, the rotating direction of the casting module is opposite to the rotating direction of the previous layer when the previous layer is coated. Meanwhile, the granularity of the sand material of the reinforcing layer gradually increases from the inner layer to the outer layer.
Can adopt silica sol and zircon powder preparation surface course ground paste, the module rotates in the feed cylinder repeatedly, generally is 2 circles, then rotates 1 ~ 2 circles in the feed cylinder top for the ground paste evenly covers on whole module surface, and each position bubble-free, then evenly scribbles on the sand spreader and hangs one deck corundum sand and do. The surface layer adopts 46# or 70# or 100# white corundum sand, and is naturally dried for not less than 12 hours.
The reinforcing layer and the sealing layer are made of slurry made of quick-drying silica sol and zircon powder, the second layer is made of 36# mullite Kate sand, and the third layer is made of 24# mullite Kate sand. After each layer of shell is dried, the surface is cleaned, particularly the back of floating sand at the groove, and the next layer of coating can be carried out. And 7-10 layers of coating in a circulating way, and then adding a sealing layer. When the shell is manufactured by the automatic line of the mechanical arm, the rotation directions of the odd number layers and the even number layers are opposite when slurry is dipped and sand is spread, so that the uniformity of the thickness of the shell is improved. The self-drying of the reinforcing layer is more than 3 hours.
S5: and (5) after the step (S4) is completed, grinding the wax discharge air port until the wax mould of the wax discharge air port is exposed. When the casting wax mold and the pouring channel wax mold are not provided with a groove structure, namely the casting and the pouring channel are communicated up and down, left and right, and a wax discharge air vent on the casting is ground; when a groove structure is arranged between the casting wax mold and the pouring channel wax mold, namely the structure of the casting or the pouring channel is complex, the wax discharge air vent on each casting needs to be ground.
S6: and (4) dewaxing the casting module which is subjected to the step S5 by adopting a steam dewaxing method, wherein the pressure is 0.5-0.7 MPa, the dewaxing time is 15-30 minutes, and the wax in the shell is completely removed. Then the mixture is stored for at least 12 hours under natural conditions and then is roasted. During roasting, the charging temperature of the shell is not more than 300 ℃, the roasting temperature is 850 ℃, and the temperature is kept for 1 hour. And then repairing the wax-removing air vent by using shell-repairing cement, and finally shaking, washing and sealing the shell to obtain the shell.
The invention provides a setting principle of a de-waxing air vent: namely, when the shell is dewaxed, the wax is melted and gasified when meeting high temperature, the melting and gasification speed of the thinnest part of the module shell is fastest, if liquid or gas can not be discharged in time, the shell is burst, and microcracks are formed and even cracks can be seen visually. Therefore, the de-waxing air vent should be set in the range of 0-15 mm at the thinnest part of the module. According to the part and the module structure, the wax mould structure, the number and the sticking position of the wax discharge air vent are designed, and according to the designed wax discharge air vent structure, the space with the size requirement of the wax discharge air vent is processed at the corresponding wax discharge air vent structure of the inner cavity of the casting wax mould. Through part wax matrix mould, the part of extrusion area wax removal vent hole wax matrix has stopped part wax matrix to take place to warp in welding wax removal vent hole department, and makes the shell simple manufacture of taking the wax removal vent hole structure, the uniformity is good, and the batch production of being convenient for can reduce the wax matrix preparation time. The de-waxing vent is arranged in a range of 0-15 mm away from the thinnest part of the part size, is generally arranged at a part with machining allowance, and is smoothly connected with the part or an inner gate to prevent the defects of slag inclusion and the like caused by the cracking of a shell at a switching part. If the size of the die set inner gate is consistent with that of the blade, the de-waxing air vent is arranged on the inner gate, and after a casting is poured, the de-waxing air vent bar is cut off together when the inner gate is cut, so that the working procedure of polishing and removing the de-waxing air vent bar is avoided; if the parts and the pouring channel are communicated up and down, left and right, the dewaxing air vents on 1 part are ground before dewaxing, and the production efficiency is improved to a great extent. In addition, the runner system adopts a larger fillet, which is beneficial to improving the thickness uniformity of the shell; during shell making, the sand granularity which is gradually changed is adopted between different layers, so that the strength of the shell is improved. By the method, the rejection rate of the shell is reduced to 0 from 90%, the production cost is reduced to a great extent, and the production efficiency is improved.
Example 2
As shown in FIG. 1, in the present embodiment, a certain aircraft guide blade is taken as an example, the blade has a length of about 200mm, a chord width of 80mm and an exhaust edge R1-1.5 mm, and the shell is manufactured by the following method:
(1) designing a wax mould structure of a wax discharge air vent and a sticking position in the mould set.
When the shell is dewaxed, the wax is melted and gasified when meeting high temperature, the melting and gasifying speed of the thinnest part of the module shell is fastest, and if liquid or gas cannot be discharged in time, the shell is burst to form micro cracks and even visually visible cracks. The size of the inner sprue of the die set is consistent with that of the blade, and the wax-removing air vent can be arranged on the inner sprue. The wax-removing vent is smoothly connected with the inner gate in a switching way of R1-2 mm.
(2) According to the designed structure of the wax removal air vent, the diameter phi is 10mm, the height is 15mm, and the wax removal air vent is positioned on the exhaust side of a sprue in a part. And processing a space with the size requirement of the wax discharge air port at the position of the structure of the wax discharge air port of the inner sprue corresponding to the inner cavity of the casting wax mold.
(3) Pressing a wax mould with an inner sprue and a wax discharge vent, injecting wax materials into the mould and maintaining pressure. The temperature of the wax material for injection is 50-58 ℃, the injection pressure is 15-20 bar, the injection time is 30-45 s, and the pressure maintaining time is 20-35 s.
(4) And (3) pressing a pouring system, and rounding R2-R5 (brought out by a mold) at the outer leakage sharp corner, so that the large difference of the shell thickness caused by too small sharp corner or fillet is reduced.
(5) And (5) finishing the wax mold. And cleaning parting lines, wax chips and the like on the wax mould.
(6) And combining the wax mold module and removing oil from the wax mold module.
(7) And carrying out module shell manufacturing. Adopt silica sol and zircon powder preparation surface course ground paste, the module rotates in the feed cylinder repeatedly, is generally 2 circles, then rotates 1 ~ 2 circles in the feed cylinder top for the ground paste evenly covers on whole module surface, and each position bubble-free, then evenly scribbles one deck corundum sand on the sand scattering machine. The surface layer adopts 46# white corundum sand, and is naturally dried for not less than 12 hours.
The reinforcing layer and the sealing layer are made of slurry made of quick-drying silica sol and zircon powder, the second layer is made of 36# mullite Kate sand, and the third layer is made of 24# mullite Kate sand. After each layer of shell is dried, the surface is cleaned, particularly the back of floating sand at the groove, and the next layer of coating can be carried out. The coating is carried out circularly for 10 layers, and then a sealing layer is added. When the shell is manufactured by the automatic line of the mechanical arm, the rotation directions of the odd number layers and the even number layers are opposite when slurry is dipped and sand is spread, so that the uniformity of the thickness of the shell is improved. The self-drying of the reinforcing layer is more than 3 hours.
(8) The part structure and the pouring channel are communicated up and down, left and right, and the shell is ground to open 1 of the paraffin removal air ports. And after the shell is manufactured, grinding the wax removal vent until the wax mold of the wax removal vent is exposed.
(9) Dewaxing by a steam dewaxing method, wherein the pressure is as follows: 0.5MPa to 0.7MPa, and the dewaxing time is 15 to 30 minutes, so that the wax in the shell is completely removed.
(10) The dewaxed shell can be roasted after being stored for not less than 12 hours, the charging temperature of the shell is not more than 300 ℃, the roasting temperature is as follows: the temperature is kept at 850 ℃ for 1 hour.
(11) And repairing the wax-removing air vent by using shell-repairing cement. And shaking, washing and sealing.
(12) Obtaining the qualified shell.
Example 3
As shown in FIG. 2, in the present embodiment, taking a 3 rd stage turbine blade of a certain combustion engine as an example, the blade has a length of about 260mm, a chord width of 75-85 mm, a maximum thickness of about 13mm, a flange plate width of about 50mm, a tenon thickest part of about 40mm, and an exhaust edge R1-1.5 mm, and the manufacturing method of the shell is carried out according to the following steps:
(1) designing a wax mould structure of a wax discharge air vent and a sticking position in the mould set.
When the shell is dewaxed, the wax is melted and gasified when meeting high temperature, the melting and gasifying speed of the thinnest part of the module shell is fastest, and if liquid or gas cannot be discharged in time, the shell is burst to form micro cracks and even visually visible cracks. Therefore, the de-waxing air vent should be arranged in the range of 0-15 mm at the thinnest part of the part size, and is generally arranged at the part with machining allowance. The size of the wax removal air vent can be determined according to the size of a part, the diameter phi is 3mm, the height is 5mm, the distance from the air vent to the air exhaust edge is 10.2mm, and the distance from the air vent to the air exhaust edge is mainly used for ensuring the bonding strength of a wax mould of the wax removal air vent and a wax mould of the part. The wax-removing air vent and the part should be smoothly connected.
(2) According to the designed structure of the wax removal air vent, the space with the size requirement of the wax removal air vent is processed at the corresponding structure of the wax removal air vent in the inner cavity of the casting wax mold.
(3) And (3) placing the manufactured cold wax core into a casting wax mold, injecting wax material into the mold, and maintaining the pressure. The temperature of the wax material for injection is 58-62 ℃, the injection pressure is 15-20 bar, the injection time is 30-45 s, and the pressure maintaining time is 150-160 s.
(4) And (3) pressing a pouring system, and rounding R2-R5 (brought out by a mold) at the outer leakage sharp corner, so that the large difference of the shell thickness caused by too small sharp corner or fillet is reduced.
(5) And (5) finishing the wax mold. And cleaning parting lines, wax chips and the like on the wax mould.
(6) And combining the wax mold module and removing oil from the wax mold module.
(7) And carrying out module shell manufacturing. Adopt silica sol and zircon powder preparation surface course ground paste, the module rotates in the feed cylinder repeatedly, is generally 2 circles, then rotates 1 ~ 2 circles in the feed cylinder top for the ground paste evenly covers on whole module surface, and each position bubble-free, then evenly scribbles one deck corundum sand on the sand scattering machine. The surface layer adopts 70# white corundum sand, and is naturally dried for not less than 12 hours.
The reinforcing layer and the sealing layer are made of slurry made of quick-drying silica sol and zircon powder, the second layer is made of 36# mullite Kate sand, and the third layer is made of 24# mullite Kate sand. After each layer of shell is dried, the surface is cleaned, particularly the back of floating sand at the groove, and the next layer of coating can be carried out. 7 layers are coated in a circulating way, and then a sealing layer is added. When the shell is manufactured by the automatic line of the mechanical arm, the rotation directions of the odd number layers and the even number layers are opposite when slurry is dipped and sand is spread, so that the uniformity of the thickness of the shell is improved. The self-drying of the reinforcing layer is more than 3 hours.
(8) The structure of the part and the pouring gate is complex, after the shell is manufactured, the wax removal air vent on each blade needs to be ground until the wax mould is exposed, and the structural schematic diagram of the wax removal air vent is shown in figure 3.
(9) Dewaxing by a steam dewaxing method, wherein the pressure is as follows: 0.5MPa to 0.7MPa, and the dewaxing time is 15 to 30 minutes, so that the wax in the shell is completely removed.
(10) The dewaxed shell can be roasted after being stored for not less than 12 hours, the charging temperature of the shell is not more than 300 ℃, the roasting temperature is as follows: the temperature is kept at 850 ℃ for 1 hour.
(11) And repairing the wax-removing air vent by using shell-repairing cement. And shaking and sealing.
(12) Obtaining the qualified shell.
Example 4
In the embodiment, taking a 4 th-stage turbine blade of a certain combustion engine as an example, the blade is about 300mm long, the chord width is 75-85 mm, the maximum thickness is about 13mm, the width of a flange plate is about 50mm, the thickest part of a tenon is about 40mm, and the exhaust edge R1-1.5 mm, and the manufacturing method of the shell with the wax removal air vent structure is carried out according to the following steps:
(1) designing a wax mould structure of a wax discharge air vent and a sticking position in the mould set.
When the shell is dewaxed, the wax is melted and gasified when meeting high temperature, the melting and gasifying speed of the thinnest part of the module shell is fastest, and if liquid or gas cannot be discharged in time, the shell is burst to form micro cracks and even visually visible cracks. Therefore, the wax removal air vent should be arranged in the range of 0 mm-15 mm at the thinnest part of the part size, and is generally arranged at the part with machining allowance. The size of the wax removal air vent can be determined according to the size of a part, the diameter phi is 3mm, the height is 8mm, the distance from the air vent to the air exhaust edge is 10.2mm, and the distance from the air vent to the air exhaust edge is mainly used for ensuring the bonding strength of a wax mould of the wax removal air vent and a wax mould of the part. The wax-removing air vent and the part should be smoothly connected.
(2) According to the designed structure of the wax removal air vent, the space with the size requirement of the wax removal air vent is processed at the corresponding structure of the wax removal air vent in the inner cavity of the casting wax mold.
(3) And (3) placing the manufactured cold wax core into a casting wax mold, injecting wax material into the mold, and maintaining the pressure. The temperature of the wax material for injection is 58-62 ℃, the injection pressure is 15-20 bar, the injection time is 30-45 s, and the pressure maintaining time is 150-160 s.
(4) And (3) pressing a pouring system, and rounding R2-R5 (brought out by a mold) at the outer leakage sharp corner, so that the large difference of the shell thickness caused by too small sharp corner or fillet is reduced.
(5) And (5) finishing the wax mold. And cleaning parting lines, wax chips and the like on the wax mould.
(6) And combining the wax mold module and removing oil from the wax mold module.
(7) And carrying out module shell manufacturing. Adopt silica sol and zircon powder preparation surface course ground paste, the module rotates in the feed cylinder repeatedly, is generally 2 circles, then rotates 1 ~ 2 circles in the feed cylinder top for the ground paste evenly covers on whole module surface, and each position bubble-free, then evenly scribbles one deck corundum sand on the sand scattering machine. The surface layer adopts 70# white corundum sand, and is naturally dried for not less than 12 hours.
The reinforcing layer and the sealing layer are made of slurry made of quick-drying silica sol and zircon powder, the second layer is made of 36# mullite Kate sand, and the third layer is made of 24# mullite Kate sand. After each layer of shell is dried, the surface is cleaned, particularly the back of floating sand at the groove, and the next layer of coating can be carried out. 7 layers are coated in a circulating way, and then a sealing layer is added. When the shell is manufactured by the automatic line of the mechanical arm, the rotation directions of the odd number layers and the even number layers are opposite when slurry is dipped and sand is spread, so that the uniformity of the thickness of the shell is improved. The self-drying of the reinforcing layer is more than 3 hours.
(8) The structure of the part and the pouring gate is complex, and after the shell is manufactured, the wax discharge air vent on each blade needs to be ground to expose the wax mould at the position.
(9) Dewaxing by a steam dewaxing method, wherein the pressure is as follows: 0.5MPa to 0.7MPa, and the dewaxing time is 15 to 30 minutes, so that the wax in the shell is completely removed.
(10) The dewaxed shell can be roasted after being stored for not less than 12 hours, the charging temperature of the shell is not more than 300 ℃, the roasting temperature is as follows: the temperature is kept at 850 ℃ for 1 hour.
(11) And repairing the wax-removing air vent by using shell-repairing cement. And shaking and sealing.
(12) Obtaining the qualified shell.
Example 5
A turbine blade investment casting shell preparation process comprises the following steps:
s1: at the limit design wax discharge air vent of exhausting, the diameter of design wax discharge air vent is 3mm, highly is 5mm, and sets up first radius with the foundry goods junction, the radius of first radius is 1 mm. Processing a space required by a wax discharge air vent at a correspondingly designed wax discharge air vent structure in an inner cavity of a wax mould of a casting;
s2: and (5) injecting the special wax material for the precision investment casting into the wax mould die which is finished with the step S1, and maintaining the pressure to obtain the casting wax mould. Wherein the temperature of the wax material for injection is 50 ℃, the injection pressure is 15bar, the injection time is 30s, and the dwell time is 20 s.
S3: and manufacturing the pouring channel wax mold according to the casting process requirement. And a second rounding is arranged at the outer leakage sharp corner of the pouring channel wax mould, and the radius of the second rounding is 2 mm.
S4: cleaning the casting wax mold and the pouring channel wax mold, and cleaning parting lines, wax chips and the like on the wax mold. And then combining the casting wax mold and the pouring channel wax mold to obtain a casting module, deoiling the casting module, and then manufacturing a shell of the casting module. The casting module shell manufacturing comprises circulating coating surface layer slurry and reinforcing layer sand for 7 times, and when the coating is carried out for adjacent times, the rotation directions of the casting modules are opposite. Adopt silica sol and zircon powder preparation surface course ground paste, the module rotates 2 rings in the feed cylinder repeatedly, then rotates 1 ring above the feed cylinder for the ground paste evenly covers on whole module surface, and each position bubble-free, then evenly coats and hangs a layer 46# white corundum sand on the sand spreader, natural drying 15 hours. The second layer used 36# Mullica sand and the third layer used 24# Mullica sand. The reinforcing layer and the sealing layer are made of slurry made of quick-drying silica sol and zircon powder, and after each shell is dried, the surface of each shell, particularly the floating sand at the groove, can be cleaned, and then the next layer can be coated. 7 layers are coated in a circulating way, and then a sealing layer is added.
S5: and (5) after the step (S4) is completed, grinding the wax discharge air port until the wax mould of the wax discharge air port is exposed. And a groove structure is not formed between the casting wax mold and the pouring gate wax mold, and a wax discharge air port on the casting is ground.
S6: and (4) dewaxing the casting module which is subjected to the step S5 by adopting a steam dewaxing method, wherein the pressure is 0.5MPa, and the dewaxing time is 15 minutes. Then the mixture is stored for 20 hours under natural conditions and then is roasted. During roasting, the shell charging temperature is 100 ℃, the roasting temperature is 850 ℃, and the temperature is kept for 1 hour. And then repairing the wax-removing air vent by using shell-repairing cement, and finally shaking, washing and sealing the shell to obtain the shell.
Example 6
A turbine blade investment casting shell preparation process comprises the following steps:
s1: at the design wax discharge air vent of 5mm departments apart from the air discharge limit, the diameter of design wax discharge air vent is 7mm, highly is 10mm, and sets up first radius with the foundry goods junction, the radius of first radius is 1.5 mm. Processing a space required by a wax discharge air vent at a correspondingly designed wax discharge air vent structure in an inner cavity of a wax mould of a casting;
s2: and (5) injecting the special wax material for the precision investment casting into the wax mould die which is finished with the step S1, and maintaining the pressure to obtain the casting wax mould. Wherein the temperature of the wax material for injection is 60 ℃, the injection pressure is 17bar, the injection time is 40s, and the dwell time is 100 s.
S3: and manufacturing the pouring channel wax mold according to the casting process requirement. And a second rounding is arranged at the outer leakage sharp corner of the pouring channel wax mould, and the radius of the second rounding is 3 mm.
S4: cleaning the casting wax mold and the pouring channel wax mold, and cleaning parting lines, wax chips and the like on the wax mold. And then combining the casting wax mold and the pouring channel wax mold to obtain a casting module, deoiling the casting module, and then manufacturing a shell of the casting module. The casting module shell manufacturing comprises cyclic coating of surface layer slurry and reinforcing layer sand for 8 times, and when the coating is performed for adjacent times, the rotation directions of the casting modules are opposite. Adopt silica sol and zircon powder preparation surface course ground paste, the module rotates 2 rings in the feed cylinder repeatedly, then rotates 2 rings in the feed cylinder top for the ground paste evenly covers on whole module surface, and each position bubble-free, then evenly coats and hangs a layer 70# white corundum sand on the sand spreader, and natural drying is no less than 12 hours. The second layer used 36# Mullica sand and the third layer used 24# Mullica sand. The reinforcing layer and the sealing layer are made of slurry made of quick-drying silica sol and zircon powder, and after each shell is dried, the surface of each shell, particularly the floating sand at the groove, can be cleaned, and then the next layer can be coated. Coating 8 layers in a circulating way, and then adding a sealing layer.
S5: and (5) after the step (S4) is completed, grinding the wax discharge air port until the wax mould of the wax discharge air port is exposed. And a groove structure is not formed between the casting wax mold and the pouring gate wax mold, and a wax discharge air port on the casting is ground.
S6: and (4) dewaxing the casting module which is subjected to the step S5 by adopting a steam dewaxing method, wherein the pressure is 0.6MPa, and the dewaxing time is 17 minutes. Then the mixture is stored for 15 hours under natural conditions and then is roasted. During roasting, the shell charging temperature is 200 ℃, the roasting temperature is 850 ℃, and the temperature is kept for 1 hour. And then repairing the wax-removing air vent by using shell-repairing cement, and finally shaking, washing and sealing the shell to obtain the shell.
Example 7
A turbine blade investment casting shell preparation process comprises the following steps:
s1: at the design wax discharge air vent apart from exhaust limit 15mm department, the diameter of design wax discharge air vent is 10mm, highly is 15mm, and sets up first radius with the foundry goods junction, the radius of first radius is 2 mm. Processing a space required by a wax discharge air vent at a correspondingly designed wax discharge air vent structure in an inner cavity of a wax mould of a casting;
s2: and (5) injecting the special wax material for the precision investment casting into the wax mould die which is finished with the step S1, and maintaining the pressure to obtain the casting wax mould. Wherein the temperature of the wax material for injection is 62 ℃, the injection pressure is 20bar, the injection time is 45s, and the dwell time is 160 s.
S3: and manufacturing the pouring channel wax mold according to the casting process requirement. And a second rounding is arranged at the outer leakage sharp corner of the pouring channel wax mould, and the radius of the second rounding is 5 mm.
S4: cleaning the casting wax mold and the pouring channel wax mold, and cleaning parting lines, wax chips and the like on the wax mold. And then combining the casting wax mold and the pouring channel wax mold to obtain a casting module, deoiling the casting module, and then manufacturing a shell of the casting module. The casting module shell manufacturing comprises circulating coating surface layer slurry and reinforcing layer sand material for 10 times, and when the coating is carried out for adjacent times, the rotation directions of the casting modules are opposite. Adopt silica sol and zircon powder preparation surface course ground paste, the module rotates 2 rings in the feed cylinder repeatedly, then rotates 2 rings in the feed cylinder top for the ground paste evenly covers on whole module surface, and each position bubble-free, then evenly coats and hangs a layer 100# white corundum sand on the sand spreader, and natural drying is no less than 12 hours. The second layer used 36# Mullica sand and the third layer used 24# Mullica sand. The reinforcing layer and the sealing layer are made of slurry made of quick-drying silica sol and zircon powder, and after each shell is dried, the surface of each shell, particularly the floating sand at the groove, can be cleaned, and then the next layer can be coated. The coating is carried out circularly for 10 layers, and then a sealing layer is added.
S5: and (5) after the step (S4) is completed, grinding the wax discharge air port until the wax mould of the wax discharge air port is exposed. The castings or runners are complex in structure and the wax removal vents on each casting need to be ground away.
S6: and (4) dewaxing the casting module which is subjected to the step S5 by adopting a steam dewaxing method, wherein the pressure is 0.7MPa, and the dewaxing time is 30 minutes. Then the mixture is stored for 16 hours under natural conditions and then is roasted. During roasting, the shell charging temperature is 150 ℃, the roasting temperature is 850 ℃, and the temperature is kept for 1 hour. And then repairing the wax-removing air vent by using shell-repairing cement, and finally shaking, washing and sealing the shell to obtain the shell.
The above is only a preferred embodiment of the present invention, and is not intended to limit the present invention, and various modifications and changes will occur to those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. A turbine blade investment casting shell preparation process is characterized by comprising the following steps:
s1: designing the size and the number of the wax removal air vents according to the structure of a casting and a module, and arranging a processing space of the wax removal air vents at a position 0-15 mm away from an exhaust edge in an inner cavity of a wax mould die of the casting;
s2: injecting wax materials into the wax mould die which is finished with the step S1 and maintaining pressure to obtain a casting wax mould;
s3: manufacturing a pouring channel wax mold according to the casting process requirement;
s4: cleaning the casting wax mold and the pouring channel wax mold, combining the casting wax mold and the pouring channel wax mold to obtain a casting module, and manufacturing a shell of the casting module;
s5: after step S4 is completed, the wax removal vent is milled;
s6: and (4) dewaxing, roasting and repairing the casting module which is subjected to the step S5, and shaking, washing and sealing the shell to obtain the shell.
2. The process of manufacturing a turbine blade investment casting shell according to claim 1, wherein in step S1, when the casting has machining allowance, the wax discharge vent is disposed at the position where the machining allowance is provided; when the inner sprue of the die set is consistent with the thickness dimension of the casting, the wax-removing air vent is arranged on the inner sprue.
3. The process for preparing the turbine blade investment casting shell according to claim 1, wherein in the step S1, the diameter of the wax discharge air vent is 3-10 mm, the height of the wax discharge air vent is 5-15 mm, and a first rounding is arranged at the joint of the wax discharge air vent and the casting, and the radius of the first rounding is 1-2 mm.
4. The process for preparing the turbine blade investment casting shell according to claim 1, wherein the temperature of the wax material injection in the step S2 is 50-62 ℃, the injection pressure is 15-20 bar, the injection time is 30-45S, and the dwell time is 20-160S.
5. The turbine blade investment casting shell manufacturing process of claim 1, wherein in the step S3, a second radius is provided at the outer leakage sharp corner of the sprue wax pattern, and the radius of the second radius is 2-5 mm.
6. The process of claim 1, wherein in step S4, the casting mold assembly includes circulating coating of 7-10 layers of slurry and sand, the casting mold assembly includes miancen and the casting mold assembly rotates in a direction opposite to the direction of rotation of the previous layer when the next layer is coated.
7. The process of claim 6, wherein in step S4, the size of the sand in the reinforcement layer gradually increases from the inner layer to the outer layer.
8. The process of claim 1, wherein in step S5, when there is no groove structure between the wax pattern of the casting and the wax pattern of the runner, the wax vent of one casting is ground; when a groove structure is arranged between the casting wax mold and the pouring channel wax mold, the wax discharge air ports on the casting are all ground.
9. The process of claim 1, wherein in step S6, the casting pattern is dewaxed and then baked after being stored for at least 12 hours.
10. An investment casting shell obtainable by the process of any one of claims 1 to 9.
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