CN114210926B - 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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- CN114210926B CN114210926B CN202111538279.5A CN202111538279A CN114210926B CN 114210926 B CN114210926 B CN 114210926B CN 202111538279 A CN202111538279 A CN 202111538279A CN 114210926 B CN114210926 B CN 114210926B
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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
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
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Abstract
The invention discloses a turbine blade investment casting shell and a casting process thereof, wherein the process comprises the following steps: according to the casting and the module structure, the size and the number of the wax removing vents are designed, and a processing space of the wax removing vents is arranged in the inner cavity of the wax mould of the casting and at a distance of 0-15 mm from the exhaust edge; then, wax injection, pressure maintaining, cleaning and combination are carried out to obtain a casting module, and casting module shell manufacturing is carried out; grinding and opening a paraffin removal vent; dewaxing, roasting and repairing the obtained casting module, and shaking, washing and sealing the shell to obtain the shell. The method is simple and feasible, is convenient for mass production, can reduce the manufacturing time of the wax mould, ensures the quality of the molded shell, reduces the production cost, improves the production efficiency, and has good consistency of the obtained molded shell and high qualification rate.
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, and is generally cast integrally and precisely by adopting a high-temperature alloy investment casting method, so that the casting difficulty is extremely high. Because the blade is relatively complex in size, 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 13mm. The thickness difference of the exhaust edge R1-1.5 mm is large, when the shell is dewaxed, wax can be melted and gasified at high temperature, the melting and gasification speed of the thinnest part of the module shell is the fastest, if liquid or gas can not be timely discharged, the shell is propped and split, micro cracks are formed, and even visual cracks are visible. At present, the manufactured wax removal vent wax mould structure is welded at the corresponding auxiliary dewaxing and ventilation part of the mould set for investment precision casting during the process design, and then the mould set with the wax removal vent structure is dipped in slurry and sand to prepare a shell, so that the shell with the wax removal vent wax mould structure is obtained, and cracks are prevented from being generated during dewaxing and roasting of the shell. However, this method has the following problems: when the wax removing vent wax mould structure is welded at the thin-wall structure of the part wax mould, the operation is difficult, the deformation of the part wax mould is easy to cause, 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 containing a wax removing port and a preparation and blocking method thereof (CN 105458180B) propose a forming pouring gate containing the wax removing port to reduce wax residue and shell cracks in the dewaxing process of a shell, and a precise casting process (CN 110695317B) of a flashboard casting convenient for removing wax and exhausting proposes that 4 wax removing nails are arranged at the low wax removing point of each flashboard wax mould so as to effectively discharge wax liquid and gas in the shell. A dewaxing wax liquid discharging process (CN 101406933A) for precision casting mould shell features that a wax discharging channel is added to the lowest point where wax mould is not easy to flow out, and the wax liquid in mould shell is completely discharged. The prior art complicates the module structure and does not significantly exhaust the gas in the mold shell. And there is still no good solution for shell cracking at the exhaust edge R of a blade with a large variation in blade size.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides the turbine blade investment casting shell and the casting process thereof, which effectively ensure the reliability and consistency of the shell, are convenient for mass production, can reduce the manufacturing time of wax patterns, reduce the production cost and improve the production efficiency.
The invention is realized by the following technical scheme:
the preparation process of the turbine blade investment casting shell comprises the following steps:
s1: according to the casting and the module structure, the size and the number of the wax removing vents are designed, and a processing space of the wax removing vents is arranged in the inner cavity of the wax mould of the casting and at a distance of 0-15 mm from the exhaust edge;
s2: injecting wax into the wax mould after the step S1 is completed and maintaining the pressure to obtain a casting wax mould;
s3: manufacturing a pouring gate wax mould according to the casting process requirements;
s4: cleaning a casting wax pattern and a pouring gate wax pattern, combining the casting wax pattern and the pouring gate wax pattern to obtain a casting module, and manufacturing a shell of the casting module;
s5: after the step S4 is completed, a wax removing vent is ground;
s6: and (3) dewaxing, roasting and repairing the casting module after the step (S5), and shaking, washing and sealing the shell to obtain the shell.
Preferably, in the step S1, when the casting has a machining allowance, the wax removing vent is arranged at the part with the machining allowance; when the inner gate of the module is consistent with the thickness of the casting, the paraffin removal vent is arranged on the inner gate.
Preferably, in the step S1, the diameter of the designed paraffin removal vent is 3-10 mm, the height is 5-15 mm, and a first round is arranged at the joint of the designed paraffin removal vent and the casting, and the radius of the first round 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 step S3, a second radius is set at the point of the leakage point of the runner wax pattern, and the radius of the second radius is 2-5 mm.
Preferably, in the step S4, the casting module molding shell includes 7-10 layers of slurry and reinforcing layer sand, the casting module molding shell includes miancen and the rotation direction of the casting module is opposite to the rotation direction of the previous layer when the next layer is coated.
Preferably, in step S4, the granularity of the sand material of the reinforcing layer gradually increases from the inner layer to the outer layer.
Preferably, in the step S5, when there is no groove structure between the casting wax pattern and the runner wax pattern, a wax discharge vent on the casting is milled; when a groove structure is arranged between the casting wax mould and the pouring channel wax mould, the wax removing vent holes on the casting are all ground.
Preferably, in the step S6, the casting die set is dewaxed and then naturally stored for at least 12 hours and then baked.
An investment casting shell made by any one of the methods described above.
Compared with the prior art, the invention has the following beneficial technical effects:
a turbine blade investment casting shell preparation process is characterized in that a wax removal vent is arranged at a position 0-15 mm away from an exhaust edge, after the die is assembled, the wax removal vent on a casting wax die is ground, so that liquid or gas generated during dewaxing is discharged in time, and the casting wax die with the wax removal vent is extruded through the casting wax die, so that the deformation of the casting wax die at the welding wax removal vent is avoided, and the cracking of the shell is effectively avoided. The method is simple and feasible, is convenient for mass 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 paraffin removal vent is arranged at the part with the machining allowance; when the thickness dimension of the inner gate of the module is consistent with or smoothly transits the thickness dimension of the casting, the paraffin removal vent is arranged on the inner gate. And the wax materials at the paraffin removal vent port can be cut off together when the inner gate is cut after casting is cast on the inner gate, so that the process of polishing and removing the wax materials at the paraffin removal vent port is avoided.
Further, the first rounding is arranged at the joint of the design paraffin removal vent and the casting, so that the defects of slag inclusion and the like caused by cracking of the shell at the joint can be effectively prevented.
Further, the temperature of wax injection is 50-62 ℃, the injection pressure is 15-20 bar, the injection time is 30-45 s, the pressure maintaining time is 20-160 s, and the size and appearance integrity of the wax removal ventilation hole can be effectively ensured.
Further, the radius of the second rounding is 2-5 mm, so that the thickness difference of the shell caused by too small sharp corners or rounded corners is reduced, and the uniformity of the thickness of the shell is effectively improved.
Further, when the adjacent layers are coated, the rotation directions of the casting modules are opposite, and the uniformity of the thickness of the shell can be effectively improved.
Furthermore, graded 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 mould and the pouring gate wax mould, the wax removal vent holes on 1 casting are milled before dewaxing, and the production efficiency is greatly improved.
Further, after dewaxing of the casting die set, roasting is carried out after natural storage for at least 12 hours, so that the quality of the shell can be effectively ensured.
The investment casting shell is molded by casting wax with a wax removal vent, and has good consistency and high qualification rate.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings that are needed in the embodiments will be briefly described below, it being understood that the following drawings only illustrate some embodiments of the present invention and therefore should not be considered as limiting the scope, and other related drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic illustration of the arrangement of the vent for removing wax according to embodiment 2 of the present invention;
FIG. 2 is a layout of the vent for removing wax according to embodiment 3 of the present invention;
fig. 3 is a partial enlarged view of the direction M in fig. 2.
In the figure: 1. the device comprises a wax removal vent port 2, a casting wax mould 3, an exhaust edge 41, an in-gate 51, a cross gate 42, a runner system 52, a support rod 6 and a ceramic pouring cup.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments of the present invention. The components of the 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 invention, as 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 made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
It should be noted that: like reference numerals and letters denote like items in the following figures, and thus once an item is defined in one figure, no further definition or explanation thereof is necessary in the following figures.
In the description of the embodiments of the present invention, it should be noted that, if the terms "upper," "lower," "horizontal," "inner," and the like indicate an azimuth or a positional relationship based on the azimuth or the positional relationship shown in the drawings, or the azimuth or the positional relationship in which the inventive product is conventionally put in use, it is merely for convenience of describing the present invention and simplifying the description, and does not indicate or imply that the apparatus or element to be referred to must have a specific azimuth, be configured and operated in a specific azimuth, and thus should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and the like, are used merely to distinguish between descriptions and should not 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. As "horizontal" merely means that its 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 also be noted that, unless explicitly specified and limited otherwise, the terms "disposed," "mounted," "connected," and "connected" should be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art according to the specific circumstances.
The invention is described in further detail below with reference to the attached drawing figures:
example 1
The preparation process of the turbine blade investment casting shell comprises the following steps:
s1: the size and the number of the wax removing vents are designed according to the casting and the module structure. Because the wax will melt and gasify when dewaxing the model shell, and the thinnest part of the model shell melts and gasifies at the fastest speed, if the liquid or gas can not be discharged in time, the model shell will be propped and cracked, forming micro-cracks and even visible cracks. Therefore, the wax removing vent should be arranged in the range of 0-15 mm from the exhaust edge, and the exhaust edge is the thinnest part of the casting and is most easy to crack. More preferably, when the casting has machining allowance, the paraffin removal vent is arranged at the part with machining allowance, and when the size of the inner gate of the module is consistent with that of the casting, the paraffin removal vent is arranged on the inner gate, so that the connection tightness and the stability of the paraffin removal vent and the wax mould can be effectively improved.
Processing a space required by a wax removal vent at a position of a wax removal vent structure which is correspondingly designed in an inner cavity of a wax mould of the casting; the diameter of the designed paraffin removal vent is 3-10 mm, the height is 5-15 mm, and a first rounding is arranged at the joint of the designed paraffin removal vent and the casting, and the radius of the first rounding is 1-2 mm.
S2: and (3) injecting special wax for investment precision castings into the wax pattern mold after the step (S1) is completed, and maintaining the pressure to obtain the casting wax pattern. The temperature of the wax 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 the appearance integrity of the wax removal vent hole are effectively ensured.
S3: and manufacturing a pouring gate wax mould according to the casting process requirements. And a second rounding is arranged at the position of the leakage sharp angle of the pouring gate wax mould, 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 small sharp angle or the small round angle.
S4: cleaning the casting wax mould and the pouring gate wax mould, and cleaning parting lines, wax scraps and the like on the wax mould. And then combining the casting wax pattern and the pouring gate wax pattern to obtain a casting module, degreasing the casting module, and then manufacturing a shell of the casting module. The casting module shell comprises 7-10 layers of circulating coating fine dried coating 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 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.
The surface layer slurry can be prepared from silica sol and zircon powder, the die set rotates repeatedly in a charging barrel, generally for 2 circles, then rotates above the charging barrel for 1-2 circles, so that the slurry uniformly covers the surface of the whole die set, each part has no bubbles, and then a layer of corundum sand is uniformly coated on a sand spreader. The surface layer adopts 46# or 70# or 100# white corundum sand, and is naturally dried for at least 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 No. 36 Molicarbat sand, and the third layer is made of No. 24 Molicarbat sand. After each layer of shell is dried, the surface, especially after floating sand at the groove, is cleaned, and the next layer of shell can be coated. And (5) circularly coating 7-10 layers, and adding a sealing layer. When the shell is manufactured by the automatic line of the mechanical arm, the method of opposite rotation directions of the odd layers and the even layers is adopted when dipping slurry and sanding, so that the uniformity of the thickness of the shell is improved. The reinforcing layers were all self-dried for greater than 3 hours.
S5: and (4) after the step (S4) is completed, grinding the paraffin removal vent until the paraffin removal vent wax mould is exposed. When no groove structure exists between the casting wax mould and the pouring gate wax mould, namely the casting and the pouring gate are communicated up and down and left and right, a wax removing vent on the casting is ground; when a groove structure is arranged between the casting wax mould and the pouring gate wax mould, namely the casting or pouring gate structure is complex, the wax removing vent on each casting needs to be ground.
S6: and (3) dewaxing the casting module after 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 guaranteed to be removed. And then stored under natural conditions for at least 12 hours before calcination. When roasting, the temperature of the shell entering the furnace is not more than 300 ℃, the roasting temperature is 850 ℃, and the heat is preserved for 1 hour. And then repairing the wax removing vent hole 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 paraffin removal vent: namely, when the shell is dewaxed, wax can be melted and gasified at high temperature, and the thinnest part of the module type shell is melted and gasified at the highest speed, if liquid or gas cannot be timely discharged, the shell is propped and cracked, and microcracks and even visible cracks are formed. Therefore, the wax removing vent should be arranged at the thinnest part of the module within the range of 0-15 mm. According to the parts and the module structure, the wax removing vent wax mould structure, the number and the pasting positions are designed, and according to the designed wax removing vent structure, the space required by the size of the wax removing vent is processed at the position of the wax removing vent structure corresponding to the inner cavity of the casting wax mould. The part wax mould is used for extruding the part with the wax removal vent hole, so that the deformation of the part wax mould at the welding wax removal vent hole is avoided, the shell with the wax removal vent hole structure is simple to manufacture and good in consistency, mass production is facilitated, and the manufacturing time of the wax mould can be reduced. The wax removing vent should be arranged in the range of 0-15 mm from the thinnest part of the part size, and is generally arranged at the part with machining allowance, and the wax removing vent is smoothly connected with the part or the inner gate to prevent the defects of slag inclusion and the like caused by shell cracking at the connection part. If the size of the inner gate of the module is consistent with that of the blade, the paraffin removal vent is arranged on the inner gate, and after casting, the paraffin removal vent rod is cut off together when the inner gate is cut, so that the process of polishing and removing the paraffin removal vent rod is avoided; if the parts and the pouring gate are communicated vertically and horizontally, the paraffin removal vent holes on 1 part are milled before dewaxing, so that the production efficiency is improved to a great extent. In addition, the runner system adopts a larger round angle, which is beneficial to improving the uniformity of the thickness of the shell; and graded sand granularity is adopted between different layers during shell making, so that the strength of the shell is improved. By the method, the rejection rate of the shell is reduced from 90% to 0, the production cost is reduced to a great extent, and the production efficiency is improved.
Example 2
As shown in fig. 1, in this embodiment, taking a certain aeroplane guide vane as an example, the vane length is about 200mm, the chord width is 80mm, and the exhaust edge R1-1.5 mm, the shell is manufactured by the following method:
(1) And designing a wax pattern structure of the wax removing vent and a pasting position in the module.
Because the wax will melt and gasify when dewaxing the model shell, and the thinnest part of the model shell melts and gasifies at the fastest speed, if the liquid or gas can not be discharged in time, the model shell will be propped and cracked, forming micro-cracks and even visible cracks. The size of the inner gate of the module is consistent with that of the blade, and the paraffin removal vent can be arranged on the inner gate. The paraffin removal vent is smoothly connected with the inner gate in a switching way, and the switching distance is R1-2 mm.
(2) According to the designed structure of the paraffin removal vent, the diameter phi 10mm and the height 15mm are positioned at the exhaust side of the inner pouring gate of the part. And processing a space with the size required by the paraffin removal vent at the position of the paraffin removal vent structure of the inner gate corresponding to the inner cavity of the casting wax mould.
(3) Pressing a wax mould with an inner gate and a wax discharge vent, injecting wax into the mould and maintaining pressure. The temperature of wax 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, wherein the external leakage sharp angles are all rounded R2-R5 (the die is taken out), and the large thickness difference of the shell caused by too small sharp angles or rounded angles is reduced.
(5) And (5) trimming the wax mould. And cleaning parting lines, wax scraps and the like on the wax mould.
(6) And combining the wax mould modules and deoiling the mould modules.
(7) And (5) performing module shell manufacturing. The surface layer slurry is prepared by adopting silica sol and zircon powder, the die set rotates repeatedly in a charging barrel, generally for 2 circles, then rotates above the charging barrel for 1-2 circles, so that the slurry uniformly covers the surface of the whole die set, each part has no bubbles, and then a layer of corundum sand is uniformly coated on a sand spreader. The surface layer adopts 46# white corundum sand, and is naturally dried for at least 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 No. 36 Molicarbat sand, and the third layer is made of No. 24 Molicarbat sand. After each layer of shell is dried, the surface, especially after floating sand at the groove, is cleaned, and the next layer of shell can be coated. And (5) coating 10 layers in total in a circulating way, and adding a sealing layer. When the shell is manufactured by the automatic line of the mechanical arm, the method of opposite rotation directions of the odd layers and the even layers is adopted when dipping slurry and sanding, so that the uniformity of the thickness of the shell is improved. The reinforcing layers were all self-dried for greater than 3 hours.
(8) The part structure and the pouring channel are communicated up and down and left and right, and 1 wax removing vent hole is formed in the shell by grinding. And after the shell is manufactured, grinding the position of the wax removal vent until the wax mould of the wax removal vent is exposed.
(9) Dewaxing is carried out by adopting a steam dewaxing method, and the pressure is as follows: and the dewaxing time is 15-30 minutes and the wax in the shell is guaranteed to be removed completely under 0.5-0.7 MPa.
(10) The dewaxed shell can be stored for no less than 12 hours and then baked, the temperature of the shell entering the furnace is no more than 300 ℃, and the baking temperature is as follows: the temperature was kept at 850℃for 1 hour.
(11) Repairing the wax removing vent with the shell repairing cement. And shaking, washing and sealing.
(12) And obtaining qualified shell.
Example 3
As shown in FIG. 2, in this embodiment, taking a 3 rd stage turbine blade of a certain gas turbine as an example, the blade is about 260mm long, the chord width is 75-85 mm, the maximum thickness is about 13mm, the edge plate width is about 50mm, the thickest part of the tenon is about 40mm, and the exhaust edge R is 1-1.5 mm, and the manufacturing method of the shell comprises the following steps:
(1) And designing a wax pattern structure of the wax removing vent and a pasting position in the module.
Because the wax will melt and gasify when dewaxing the model shell, and the thinnest part of the model shell melts and gasifies at the fastest speed, if the liquid or gas can not be discharged in time, the model shell will be propped and cracked, forming micro-cracks and even visible cracks. Therefore, the wax removing vent should be arranged in the range of 0-15 mm at the thinnest part size, and is generally arranged at the part with machining allowance. The size of the wax removal vent can be determined according to the size of the part, the diameter phi is 3mm, the height is 5mm, the distance from the vent edge is 10.2mm, and the distance from the vent edge is mainly used for guaranteeing the bonding strength of the wax removal vent wax mould and the part wax mould. The wax removing vent and the parts should be smoothly connected.
(2) According to the designed structure of the paraffin removal vent, processing a space with the size required by the paraffin removal vent at the position of the paraffin removal vent structure corresponding to the inner cavity of the casting wax mould.
(3) And (3) placing the manufactured cold wax core into a casting wax mould, injecting wax into the mould and maintaining pressure. The temperature of the wax 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, wherein the external leakage sharp angles are all rounded R2-R5 (the die is taken out), and the large thickness difference of the shell caused by too small sharp angles or rounded angles is reduced.
(5) And (5) trimming the wax mould. And cleaning parting lines, wax scraps and the like on the wax mould.
(6) And combining the wax mould modules and deoiling the mould modules.
(7) And (5) performing module shell manufacturing. The surface layer slurry is prepared by adopting silica sol and zircon powder, the die set rotates repeatedly in a charging barrel, generally for 2 circles, then rotates above the charging barrel for 1-2 circles, so that the slurry uniformly covers the surface of the whole die set, each part has no bubbles, and then a layer of corundum sand is uniformly coated on a sand spreader. The surface layer adopts 70# white corundum sand, and is naturally dried for at least 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 No. 36 Molicarbat sand, and the third layer is made of No. 24 Molicarbat sand. After each layer of shell is dried, the surface, especially after floating sand at the groove, is cleaned, and the next layer of shell can be coated. And 7 layers are circularly coated and hung, and then a sealing layer is added. When the shell is manufactured by the automatic line of the mechanical arm, the method of opposite rotation directions of the odd layers and the even layers is adopted when dipping slurry and sanding, so that the uniformity of the thickness of the shell is improved. The reinforcing layers were all self-dried for greater than 3 hours.
(8) The parts and the pouring channels have complex structures, after the shell is manufactured, the wax removing air ports on each blade are required to be ground until the wax mould is exposed, and the structure schematic diagram of the wax removing air ports is shown in fig. 3.
(9) Dewaxing is carried out by adopting a steam dewaxing method, and the pressure is as follows: and the dewaxing time is 15-30 minutes and the wax in the shell is guaranteed to be removed completely under 0.5-0.7 MPa.
(10) The dewaxed shell can be stored for no less than 12 hours and then baked, the temperature of the shell entering the furnace is no more than 300 ℃, and the baking temperature is as follows: the temperature was kept at 850℃for 1 hour.
(11) Repairing the wax removing vent with the shell repairing cement. And shaking the shell and sealing.
(12) And obtaining qualified shell.
Example 4
In the embodiment, taking a 4 th-stage turbine blade of a certain gas turbine as an example, the length of the blade is about 300mm, 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 R is 1-1.5 mm, and the manufacturing method of the shell with the wax removal vent structure comprises the following steps:
(1) And designing a wax pattern structure of the wax removing vent and a pasting position in the module.
Because the wax will melt and gasify when dewaxing the model shell, and the thinnest part of the model shell melts and gasifies at the fastest speed, if the liquid or gas can not be discharged in time, the model shell will be propped and cracked, forming micro-cracks and even visible cracks. Therefore, the wax removing vent should be arranged in the range of 0mm to 15mm at the thinnest part size, and is generally arranged at the part with machining allowance. The size of the wax removal vent can be determined according to the size of the part, the diameter phi 3mm, the height is 8mm, and the distance from the vent edge is 10.2mm, and the distance from the vent edge is mainly used for ensuring the bonding strength of the wax removal vent wax mould and the part wax mould. The wax removing vent and the parts should be smoothly connected.
(2) According to the designed structure of the paraffin removal vent, processing a space with the size required by the paraffin removal vent at the position of the paraffin removal vent structure corresponding to the inner cavity of the casting wax mould.
(3) And (3) placing the manufactured cold wax core into a casting wax mould, injecting wax into the mould and maintaining pressure. The temperature of the wax 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, wherein the external leakage sharp angles are all rounded R2-R5 (the die is taken out), and the large thickness difference of the shell caused by too small sharp angles or rounded angles is reduced.
(5) And (5) trimming the wax mould. And cleaning parting lines, wax scraps and the like on the wax mould.
(6) And combining the wax mould modules and deoiling the mould modules.
(7) And (5) performing module shell manufacturing. The surface layer slurry is prepared by adopting silica sol and zircon powder, the die set rotates repeatedly in a charging barrel, generally for 2 circles, then rotates above the charging barrel for 1-2 circles, so that the slurry uniformly covers the surface of the whole die set, each part has no bubbles, and then a layer of corundum sand is uniformly coated on a sand spreader. The surface layer adopts 70# white corundum sand, and is naturally dried for at least 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 No. 36 Molicarbat sand, and the third layer is made of No. 24 Molicarbat sand. After each layer of shell is dried, the surface, especially after floating sand at the groove, is cleaned, and the next layer of shell can be coated. And 7 layers are circularly coated and hung, and then a sealing layer is added. When the shell is manufactured by the automatic line of the mechanical arm, the method of opposite rotation directions of the odd layers and the even layers is adopted when dipping slurry and sanding, so that the uniformity of the thickness of the shell is improved. The reinforcing layers were all self-dried for greater than 3 hours.
(8) The parts and the pouring channels have complex structures, and after the shell is manufactured, the wax removing air ports on each blade are required to be ground until the wax mould is exposed.
(9) Dewaxing is carried out by adopting a steam dewaxing method, and the pressure is as follows: and the dewaxing time is 15-30 minutes and the wax in the shell is guaranteed to be removed completely under 0.5-0.7 MPa.
(10) The dewaxed shell can be stored for no less than 12 hours and then baked, the temperature of the shell entering the furnace is no more than 300 ℃, and the baking temperature is as follows: the temperature was kept at 850℃for 1 hour.
(11) Repairing the wax removing vent with the shell repairing cement. And shaking the shell and sealing.
(12) And obtaining qualified shell.
Example 5
The preparation process of the turbine blade investment casting shell comprises the following steps:
s1: the design wax removal vent on exhaust limit, design the diameter of wax removal vent be 3mm, highly be 5mm, and set up first radius with foundry goods junction, the radius of first radius is 1mm. Processing a space required by a wax removal vent at a position of a wax removal vent structure which is correspondingly designed in an inner cavity of a wax mould of the casting;
s2: and (3) injecting special wax for investment precision castings into the wax pattern mold after the step (S1) is completed, and maintaining the pressure to obtain the casting wax pattern. Wherein the temperature of wax injection is 50 ℃, the injection pressure is 15bar, the injection time is 30s, and the pressure maintaining time is 20s.
S3: and manufacturing a pouring gate wax mould according to the casting process requirements. And a second rounding is arranged at the position of the leakage sharp angle of the pouring gate wax mould, and the radius of the second rounding is 2mm.
S4: cleaning the casting wax mould and the pouring gate wax mould, and cleaning parting lines, wax scraps and the like on the wax mould. And then combining the casting wax pattern and the pouring gate wax pattern to obtain a casting module, degreasing the casting module, and then manufacturing a shell of the casting module. The casting die set shell comprises 7 times of circulating coating of fine dried coating slurry and reinforcing layer sand, and when coating is carried out for adjacent times, the rotation directions of the casting die set are opposite. The surface layer slurry is prepared by adopting silica sol and zircon powder, the die set rotates repeatedly for 2 circles in the feed cylinder, then rotates for 1 circle above the feed cylinder, so that the slurry uniformly covers the surface of the whole die set, each part has no bubble, and then a layer of 46# white corundum sand is uniformly coated on a sand spreader and naturally dried for 15 hours. The second layer uses 36# Molicarbat sand, and the third layer uses 24# Molicarbat sand. The reinforcing layer and the sealing layer are made of slurry made of quick-drying silica sol and zircon powder, and after each layer of shell is dried, the surface, especially floating sand at the groove, can be cleaned for coating the next layer. And 7 layers are circularly coated and hung, and then a sealing layer is added.
S5: and (4) after the step (S4) is completed, grinding the paraffin removal vent until the paraffin removal vent wax mould is exposed. And a groove structure is not arranged between the casting wax mould and the pouring gate wax mould, and a wax removal vent hole on the casting is ground.
S6: and (5) dewaxing the casting module after the step (S5) by adopting a steam dewaxing method, wherein the pressure is 0.5MPa, and the dewaxing time is 15 minutes. And then stored for 20 hours under natural conditions and then baked. When roasting, the shell is put into a furnace at the temperature of 100 ℃, the roasting temperature is 850 ℃, and the heat is preserved for 1 hour. And then repairing the wax removing vent hole by using shell repairing cement, and finally shaking, washing and sealing the shell to obtain the shell.
Example 6
The preparation process of the turbine blade investment casting shell comprises the following steps:
s1: the design wax removal vent in 5mm department from the exhaust limit, design the diameter of wax removal vent be 7mm, highly be 10mm, and set up first radius with foundry goods junction, the radius of first radius is 1.5mm. Processing a space required by a wax removal vent at a position of a wax removal vent structure which is correspondingly designed in an inner cavity of a wax mould of the casting;
s2: and (3) injecting special wax for investment precision castings into the wax pattern mold after the step (S1) is completed, and maintaining the pressure to obtain the casting wax pattern. Wherein the temperature of wax injection is 60 ℃, the injection pressure is 17bar, the injection time is 40s, and the pressure maintaining time is 100s.
S3: and manufacturing a pouring gate wax mould according to the casting process requirements. And a second rounding is arranged at the position of the leakage sharp angle of the pouring gate wax mould, and the radius of the second rounding is 3mm.
S4: cleaning the casting wax mould and the pouring gate wax mould, and cleaning parting lines, wax scraps and the like on the wax mould. And then combining the casting wax pattern and the pouring gate wax pattern to obtain a casting module, degreasing the casting module, and then manufacturing a shell of the casting module. The casting die set shell comprises 8 times of circulating coating of fine dried coating slurry and reinforcing layer sand, and when coating is carried out for the adjacent times, the rotation directions of the casting die set are opposite. The surface layer slurry is prepared by adopting silica sol and zircon powder, the die set rotates repeatedly for 2 circles in the feed cylinder, then rotates for 2 circles above the feed cylinder, so that the slurry uniformly covers the surface of the whole die set, each part has no bubble, and then a layer of 70# white corundum sand is uniformly coated on a sand spreader, and the natural drying is carried out for at least 12 hours. The second layer uses 36# Molicarbat sand, and the third layer uses 24# Molicarbat sand. The reinforcing layer and the sealing layer are made of slurry made of quick-drying silica sol and zircon powder, and after each layer of shell is dried, the surface, especially floating sand at the groove, can be cleaned for coating the next layer. And 8 layers are circularly coated and hung, and then a sealing layer is added.
S5: and (4) after the step (S4) is completed, grinding the paraffin removal vent until the paraffin removal vent wax mould is exposed. And a groove structure is not arranged between the casting wax mould and the pouring gate wax mould, and a wax removal vent hole on the casting is ground.
S6: and (5) dewaxing the casting module after the step (S5) by adopting a steam dewaxing method, wherein the pressure is 0.6MPa, and the dewaxing time is 17 minutes. Then stored for 15 hours under natural conditions and baked. When roasting, the temperature of the shell entering the furnace is 200 ℃, the roasting temperature is 850 ℃, and the heat is preserved for 1 hour. And then repairing the wax removing vent hole by using shell repairing cement, and finally shaking, washing and sealing the shell to obtain the shell.
Example 7
The preparation process of the turbine blade investment casting shell comprises the following steps:
s1: the design wax removal vent in 15mm department from the exhaust limit, design the diameter of wax removal vent be 10mm, highly be 15mm, and set up first radius with foundry goods junction, the radius of first radius is 2mm. Processing a space required by a wax removal vent at a position of a wax removal vent structure which is correspondingly designed in an inner cavity of a wax mould of the casting;
s2: and (3) injecting special wax for investment precision castings into the wax pattern mold after the step (S1) is completed, and maintaining the pressure to obtain the casting wax pattern. Wherein the temperature of wax injection is 62 ℃, the injection pressure is 20bar, the injection time is 45s, and the pressure maintaining time is 160s.
S3: and manufacturing a pouring gate wax mould according to the casting process requirements. And a second rounding is arranged at the position of the leakage sharp angle of the pouring gate wax mould, and the radius of the second rounding is 5mm.
S4: cleaning the casting wax mould and the pouring gate wax mould, and cleaning parting lines, wax scraps and the like on the wax mould. And then combining the casting wax pattern and the pouring gate wax pattern to obtain a casting module, degreasing the casting module, and then manufacturing a shell of the casting module. The casting die set shell comprises 10 times of circulating coating of fine dried coating slurry and reinforcing layer sand, and when coating is carried out for the adjacent times, the rotation directions of the casting die set are opposite. The surface layer slurry is prepared by adopting silica sol and zircon powder, the die set rotates repeatedly for 2 circles in the feed cylinder, then rotates for 2 circles above the feed cylinder, so that the slurry uniformly covers the surface of the whole die set, each part has no bubble, and then a layer of 100# white corundum sand is uniformly coated on a sand spreader, and the sand spreader is naturally dried for at least 12 hours. The second layer uses 36# Molicarbat sand, and the third layer uses 24# Molicarbat sand. The reinforcing layer and the sealing layer are made of slurry made of quick-drying silica sol and zircon powder, and after each layer of shell is dried, the surface, especially floating sand at the groove, can be cleaned for coating the next layer. And (5) coating 10 layers in total in a circulating way, and adding a sealing layer.
S5: and (4) after the step (S4) is completed, grinding the paraffin removal vent until the paraffin removal vent wax mould is exposed. The castings or pouring channels are complex in structure, and the paraffin removal vents on each casting need to be ground.
S6: and (5) dewaxing the casting module after the step (S5) by adopting a steam dewaxing method, wherein the pressure is 0.7MPa, and the dewaxing time is 30 minutes. Then stored for 16 hours under natural conditions and then baked. When roasting, the shell is put into a furnace at a temperature of 150 ℃, the roasting temperature is 850 ℃, and the heat is preserved for 1 hour. And then repairing the wax removing vent hole 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, but various modifications and variations can be made to the present invention by those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (4)
1. The preparation process of the turbine blade investment casting shell is characterized by comprising the following steps of:
s1: according to the casting and the module structure, the size and the number of the wax removing vents are designed, and a processing space of the wax removing vents is arranged in the inner cavity of the wax mould of the casting and at a distance of 0-15 mm from the exhaust edge;
s2: injecting wax into the wax mould after the step S1 is completed and maintaining the pressure to obtain a casting wax mould;
s3: manufacturing a pouring gate wax mould according to the casting process requirements;
s4: cleaning a casting wax pattern and a pouring gate wax pattern, combining the casting wax pattern and the pouring gate wax pattern to obtain a casting module, and manufacturing a shell by the casting module;
s5: after the step S4 is completed, a wax removing vent is ground;
s6: dewaxing, roasting and repairing the casting module after the step S5 is completed, and shaking, washing and sealing shells to obtain a shell; the method comprises the following steps: dewaxing for 15-30 min, and roasting after storing for at least 12 hr under natural condition; when in roasting, the temperature of the shell entering the furnace is not more than 300 ℃, the roasting temperature is 850 ℃, and the heat is preserved for 1 hour; then repairing the wax removing vent hole by using shell repairing cement, and finally shaking, washing and sealing to obtain a shell;
in the step S1, when the casting has machining allowance, the wax removing vent is arranged at the part with the machining allowance; when the thickness dimension of the inner gate of the module is consistent with that of the casting, the paraffin removal vent is arranged on the inner gate;
in the step S1, the diameter of the designed paraffin removal vent is 3-10 mm, the height is 5-15 mm, a first rounding is arranged at the joint of the paraffin removal vent and the casting, and the radius of the first rounding is 1-2 mm;
in the step S4, the casting module shell manufacturing comprises circularly coating 7-10 layers of layer slurry and reinforcing layer sand, and when the next layer coating is carried out, the rotating direction of the casting module is opposite to the rotating direction when the previous layer coating is carried out;
in the step S4, the granularity of the sand material of the reinforcing layer gradually increases from the inner layer to the outer layer;
in the step S5, when there is no groove structure between the casting wax pattern and the runner wax pattern, a wax removing vent corresponding to the casting is milled; when a groove structure is arranged between the casting wax mould and the pouring channel wax mould, the wax removing vent openings corresponding to the casting are all ground.
2. The process for preparing an investment casting shell for a turbine blade according to claim 1, wherein the temperature of the wax 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.
3. The process for preparing an investment casting shell for a turbine blade according to claim 1, wherein in the step S3, a second round is arranged at the point of the leakage point of the runner wax pattern, and the radius of the second round is 2-5 mm.
4. An investment casting shell prepared by the turbine blade investment casting shell preparation process of any one of claims 1-3.
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| CN116174649B (en) * | 2023-02-28 | 2024-04-16 | 中国航发北京航空材料研究院 | Preparation method of air inlet side precision casting for maintaining high-temperature alloy turbine guide vane |
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