CN114346170A - Method for investment casting of high-temperature alloy casting - Google Patents
Method for investment casting of high-temperature alloy casting Download PDFInfo
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- CN114346170A CN114346170A CN202111585070.4A CN202111585070A CN114346170A CN 114346170 A CN114346170 A CN 114346170A CN 202111585070 A CN202111585070 A CN 202111585070A CN 114346170 A CN114346170 A CN 114346170A
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Abstract
The invention discloses a method for investment casting of a high-temperature alloy casting, which comprises the steps of uniformly mixing cobalt aluminate powder and silica sol to prepare a ceramic core pretreating agent, uniformly spraying the pretreating agent on the surface of a ceramic core, airing, putting the ceramic core into a wax mold to prepare a ceramic core integral wax mold, preparing a mold shell on the surface of the ceramic core integral wax mold, adopting silica sol-zircon sand powder as a surface layer, adopting silica sol-Shangshou sand powder as other layers, carrying out dewaxing treatment on the prepared mold shell, charging and roasting to form a ceramic shell, putting a high-temperature alloy into a vacuum smelting furnace to be smelted into molten liquid, carrying out vacuum casting in the ceramic shell, cooling the casting in the furnace for 5-7min, taking out and putting the casting in a sand tray until the casting is completely cooled to obtain the investment casting of the high-temperature alloy casting. According to the invention, a cobalt aluminate and silica sol coating is formed on the working surface of the ceramic core, so that the problem of interface reaction between the ceramic core and the high-temperature alloy melt is solved, and the generation of metal nodular protrusions is avoided.
Description
Technical Field
The invention belongs to the technical field of investment casting, and relates to a method for investment precision casting of a high-temperature alloy casting.
Background
In recent years, cast high-temperature alloys have been widely used in the fields of aircraft engines and gas turbines, and are mainly used for hot end parts of turbine engines and the like. And along with the requirement of the performance improvement of an engine, the high-temperature alloy part has a complex structure and higher requirements on dimensional accuracy and surface quality, is mostly prepared by adopting an investment precision casting method, is difficult to manufacture a complex internal airflow cavity in a mold core-pulling mode, and is mostly replaced by a ceramic core, and the silicon-based ceramic core can endure the temperature of about 1500 ℃.
In the manufacturing process of the K648 high-temperature alloy part, the high-temperature alloy melt is easy to generate interface reaction with the silicon-based ceramic core, particularly, the pouring temperature of a thin-wall part needs to be properly increased in order to improve the mold filling effect, the temperature of the high-temperature melt is slowly reduced after a thick large part is poured, in addition, the interface reaction is severe due to the fact that the ceramic core is wrapped by the high-temperature alloy melt and is not beneficial to heat dissipation, and other factors, the composite products such as composite oxides or intermetallic compounds generated by the reaction are shown to form metal nodular bulges on the surface of the metal alloy, cannot be removed by means such as sand blowing and the like in the later period, and cause the quality of the metal surface of an inner cavity to be reduced or even damaged, so that the problem of product scrapping is difficult to solve, and the problem is also a very practical problem of the ceramic core in investment casting application.
The technical scheme of the method for pretreating the ceramic core for investment casting is that cobalt aluminate, polyethylene glycol, deionized water, ammonium dihydrogen phosphate, aluminum oxide, a defoaming agent and the like are mixed step by step and then coated on the surface of the ceramic core to be sintered to obtain the ceramic core with the surface coated with the fine-grain cobalt aluminate coating, and the method is different from the method in the patent 1.
In addition, relevant research methods and theoretical researches of the high-temperature alloy/ceramic interface reaction can be found in the reports at present, such as the research on the interface reaction between the high-Cr cast nickel-based high-temperature alloy K4648 and the ceramic core in the No. 3 of volume 32 in 6 months of 2012, the achievement of Zheng of Beijing aviation Material institute, and the like, but the report on the system for performing surface pretreatment on the ceramic core to solve the interface reaction problem is not found yet
Disclosure of Invention
The invention aims to provide a method for investment casting of a high-temperature alloy casting, which solves the problem that the surface of the high-temperature alloy casting prepared by the existing investment casting method has a metal nodular product which is difficult to refit.
The technical scheme adopted by the invention is that the method for investment casting of the high-temperature alloy casting comprises the following steps:
step 1, uniformly mixing cobalt aluminate powder and silica sol to prepare a ceramic core pretreating agent;
step 2, uniformly spraying the ceramic core pretreating agent on the surface of the ceramic core, and airing;
step 3, putting the ceramic core into a wax mold die to prepare a ceramic core integral wax mold;
step 4, preparing a mould shell on the surface of the integral wax mould of the ceramic core, wherein the surface layer adopts silica sol-zircon sand powder, and the other layers adopt silica sol-Shangshou sand powder;
step 5, dewaxing the prepared mould shell, then charging into a furnace and roasting to form a ceramic mould shell;
and 6, putting the high-temperature alloy into a vacuum smelting furnace to be smelted into molten liquid, then pouring the molten liquid into a ceramic shell in vacuum, wherein the pouring temperature is 1530-.
Wherein the step 1 comprises the steps of placing cobalt aluminate powder and silica sol into a container, and stirring by adopting a stirrer, wherein the rotating speed of the stirrer is 480-.
In the step 1, the mass ratio of the cobalt aluminate powder to the silica sol is 1: 9.
And 2, uniformly spraying the ceramic core pretreating agent on the surface of the ceramic core, airing, and then spraying and airing.
In step 3, the ceramic core integral wax mould is prepared by medium-temperature wax pressing, the temperature of wax materials is 50-60 ℃, and the wax injection pressure is 20-40Kg/cm2Keeping the pressure for 15-35s, and cooling in air for 4h or more.
In the step 4, six half layers of the formwork are prepared, wherein the surface layer adopts silica sol-zircon sand powder, and the later five half layers adopt silica sol-Shang shop sand powder.
And 5, standing the formwork for more than or equal to 10 hours after dewaxing, then loading into a furnace for roasting, placing the filter screen into a sprue cup before roasting, and wrapping the whole formwork with refractory cotton with the thickness of 25-35 mm.
The invention has the beneficial effects that a layer of cobalt aluminate and silica sol coating is formed on the surface by spraying the mixed solution of cobalt aluminate and silica sol on the working surface of the ceramic core, wherein the cobalt aluminate has excellent thermal stability and chemical stability, so that elements (Cr, Al, Ti, C and other active elements) which are easy to react with the ceramic core in the high-temperature alloy are isolated from the silicon-based ceramic core, thereby solving the problem of interface reaction between the ceramic core and a high-temperature alloy melt, avoiding the generation of metal nodular protrusions (mainly intermetallic compounds, composite oxides and the like), and ensuring smooth surface of a produced casting cavity and high yield of products.
Drawings
FIG. 1 is a schematic structural view of a casting in example 1 of the present invention;
FIG. 2 is a schematic structural view of an arch bridge-shaped ceramic core in example 1 of the present invention;
FIG. 3 is a graph showing the effect of the ceramic core surface pretreatment according to example 1 of the present invention;
FIG. 4 is a macro-topography of a K648 superalloy casting prepared in comparative example 1;
FIG. 5 is a macro topography of a K648 superalloy casting prepared in example 1;
FIG. 6 is a cross-sectional profile of a K648 superalloy casting prepared in comparative example 1;
FIG. 7 is a cross-sectional profile of a K648 superalloy casting prepared in example 1.
Detailed Description
The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.
Example 1
An investment casting K648 high-temperature alloy casting is prepared, the casting is a gas turbine insert casting, as shown in figure 1, the appearance of the casting is arc-shaped sheet, the size of the casting is 120 x 35mm, the whole wall thickness is 2mm, the casting cannot be realized by adopting common sand casting, the investment casting is adopted, and in the mold manufacturing process, the complex inner cavity of the part cannot be subjected to core pulling, so that an arch bridge-shaped ceramic core is designed, as shown in figure 2.
The preparation method of the investment casting K648 high-temperature alloy casting comprises the following steps:
step 1, putting cobalt aluminate powder and silica sol in a mass ratio of 1:9 into a container, and stirring by using a stirrer, wherein the rotating speed of the stirrer is 480r/min, and the stirring time is 3 hours, so that the cobalt aluminate powder and the silica sol are uniformly mixed to obtain a ceramic core pretreating agent;
step 2, uniformly spraying the ceramic core pretreating agent on the surface of the ceramic core, airing, then spraying and airing to ensure that the coating is uniform and no flow mark exists, wherein the pretreated ceramic core is shown in figure 3, and the surface of the ceramic core is changed from original white to dark blue (the black and white of figure 3 is changed into grey white due to the requirement of the figure on a black and white picture);
step 3, putting the ceramic core into a wax mould, preparing the ceramic core integral wax mould by adopting medium-temperature wax pressing, wherein the temperature of a wax material is 50 ℃, and the wax injection pressure is 40Kg/cm2Pressure maintaining time of 15s, air cooling4h, preparing the ceramic core integral wax mold, and shaping until the surface has no defects such as bubbles, sink marks, bulges, cracks and the like for later use;
step 4, preparing a six-layer half mould shell on the surface of the ceramic core integral wax mould, wherein the surface layer adopts silica sol-zircon sand powder, and the later five layers of half mould shells adopt silica sol-Shangshan sand powder;
step 5, performing dewaxing treatment on the prepared mould shell, standing the mould shell for 12 hours after dewaxing, then loading into a furnace for roasting, placing the filter screen into a sprue cup before roasting, wrapping the whole mould shell with refractory cotton with the thickness of 25mm, and then loading into the furnace for roasting to form a ceramic mould shell;
and 6, smelting the K648 high-temperature alloy in a vacuum smelting furnace to form a molten solution, then vacuum-casting the molten solution in a ceramic shell at the casting temperature of 1540 ℃, cooling the casting in the furnace for 7min, taking out the casting and placing the casting in a sand pan until the casting is completely cooled, thus obtaining the investment casting K648 high-temperature alloy casting.
Comparative example 1
A K648 superalloy casting was prepared by conventional investment casting, the casting structure being the same as that of example 1.
The appearances of the castings prepared in the embodiment 1 and the comparative example 1 are observed, fig. 4 is the macroscopic appearance of the K648 superalloy casting prepared in the comparative example 1, fig. 5 is the macroscopic appearance of the K648 superalloy casting prepared in the embodiment 1, and as can be seen from fig. 4-5, the casting prepared by the traditional investment casting method has a rough surface, the ceramic core and the K648 superalloy melt generate interfacial reaction to generate products such as composite oxides and intermetallic compounds which are difficult to clean, and the superalloy melt is immersed in the ceramic core and reacts with the ceramic core to cause the canker of the ceramic core, cause the inner cavity of the part contacted with the ceramic core to be damaged, and reduce the surface precision, and the casting prepared by the method of the invention has a smooth and flat surface.
FIG. 6 is a sectional view of a K648 superalloy casting prepared in comparative example 1, FIG. 7 is a sectional view of a K648 superalloy casting prepared in example 1, and it can be seen from FIGS. 6-7 that the casting prepared in comparative example 1 has a significant nodule on the surface, and the casting prepared in example has a flat section without a bump appearance and no interfacial reaction.
Example 2
A method for investment casting of K648 superalloy castings comprises the following steps:
step 1, placing cobalt aluminate powder and silica sol in a mass ratio of 1:9 into a container, and stirring by using a stirrer, wherein the rotating speed of the stirrer is 500r/min, and the stirring time is 2.5h, so that the cobalt aluminate powder and the silica sol are uniformly mixed to obtain a ceramic core pretreating agent;
step 2, uniformly spraying the ceramic core pretreating agent on the surface of the ceramic core, airing, spraying, airing, and ensuring that the coating is uniform and free of flow marks for later use;
step 3, putting the ceramic core into a wax mould, preparing the ceramic core integral wax mould by adopting medium-temperature wax pressing, wherein the temperature of a wax material is 50 ℃, and the wax injection pressure is 30Kg/cm2Maintaining the pressure for 25s, and air-cooling for 8h to obtain the ceramic core integral wax mold, and shaping until the surface has no defects such as bubbles, sink marks, bulges, cracks and the like for later use;
step 4, preparing a six-layer half mould shell on the surface of the ceramic core integral wax mould, wherein the surface layer adopts silica sol-zircon sand powder, and the later five layers of half mould shells adopt silica sol-Shangshan sand powder;
step 5, performing dewaxing treatment on the prepared mould shell, standing the mould shell for 15 hours after dewaxing, then loading into a furnace for roasting, placing the filter screen into a sprue cup before roasting, wrapping the whole mould shell with refractory cotton with the thickness of 25mm, and then loading into the furnace for roasting to form a ceramic mould shell;
and 6, smelting the K648 high-temperature alloy in a vacuum smelting furnace to form a molten solution, then vacuum-casting the molten solution in a ceramic shell at the casting temperature of 1530 ℃, cooling the casting in the furnace for 5min, taking out the casting and placing the casting in a sand pan until the casting is completely cooled, thus obtaining the investment casting K648 high-temperature alloy casting.
Example 3
A method for investment casting of K648 superalloy castings comprises the following steps:
step 1, placing cobalt aluminate powder and silica sol in a mass ratio of 1:9 into a container, and stirring by using a stirrer at a rotating speed of 600r/min for 1.5h to uniformly mix, thereby preparing the ceramic core pretreating agent;
step 2, uniformly spraying the ceramic core pretreating agent on the surface of the ceramic core, airing, spraying, airing, and ensuring that the coating is uniform and free of flow marks for later use;
step 3, putting the ceramic core into a wax mould, preparing the ceramic core integral wax mould by adopting medium-temperature wax pressing, wherein the temperature of a wax material is 60 ℃, and the wax injection pressure is 40Kg/cm2Maintaining the pressure for 15s, and air-cooling for 5h to obtain the ceramic core integral wax mold, and shaping until the surface has no defects such as bubbles, sink marks, bulges, cracks and the like for later use;
step 4, preparing a six-layer half mould shell on the surface of the ceramic core integral wax mould, wherein the surface layer adopts silica sol-zircon sand powder, and the later five layers of half mould shells adopt silica sol-Shangshan sand powder;
step 5, performing dewaxing treatment on the prepared mould shell, standing the mould shell for 10 hours after dewaxing, then loading into a furnace for roasting, placing the filter screen into a sprue cup before roasting, wrapping the whole mould shell by refractory cotton with the thickness of 35mm, and then loading into the furnace for roasting to form a ceramic mould shell;
and 6, smelting the K648 high-temperature alloy in a vacuum smelting furnace to form a molten solution, then vacuum-casting the molten solution in a ceramic shell mold at the casting temperature of 1550 ℃, cooling the casting in the furnace for 6min, taking out the casting and placing the casting in a sand pan until the casting is completely cooled, thus obtaining the investment casting K648 high-temperature alloy casting.
Example 4
A method for investment casting of K648 superalloy castings comprises the following steps:
step 1, placing cobalt aluminate powder and silica sol in a mass ratio of 1:9 into a container, and stirring by using a stirrer, wherein the rotating speed of the stirrer is 520r/min, and the stirring time is 1.5h, so that the cobalt aluminate powder and the silica sol are uniformly mixed to obtain a ceramic core pretreating agent;
step 2, uniformly spraying the ceramic core pretreating agent on the surface of the ceramic core, airing, spraying, airing, and ensuring that the coating is uniform and free of flow marks for later use;
step 3, putting the ceramic core into a wax mold, preparing the ceramic core integral wax mold by using medium-temperature wax pressing wax, and pressing the waxThe material temperature is 53 ℃, and the wax injection pressure is 28Kg/cm2Maintaining the pressure for 30s, and air-cooling for 6h to obtain the ceramic core integral wax mold, and shaping until the surface has no defects such as bubbles, sink marks, bulges, cracks and the like for later use;
step 4, preparing a six-layer half mould shell on the surface of the ceramic core integral wax mould, wherein the surface layer adopts silica sol-zircon sand powder, and the later five layers of half mould shells adopt silica sol-Shangshan sand powder;
step 5, dewaxing the prepared mould shell, standing the mould shell for more than or equal to 10 hours after dewaxing, then loading into a furnace for roasting, placing the filter screen into a sprue cup before roasting, wrapping the whole mould shell with refractory cotton with the thickness of 25mm, and then loading into the furnace for roasting to form a ceramic mould shell;
and 6, smelting the K648 high-temperature alloy in a vacuum smelting furnace to form a molten solution, then vacuum-casting the molten solution in a ceramic shell at the casting temperature of 1540 ℃, cooling the casting in the furnace for 5min, taking out the casting and placing the casting in a sand pan until the casting is completely cooled, thus obtaining the investment casting K648 high-temperature alloy casting.
Example 5
A method for investment casting of K648 superalloy castings comprises the following steps:
step 1, placing cobalt aluminate powder and silica sol in a mass ratio of 1:9 into a container, and stirring by using a stirrer, wherein the rotating speed of the stirrer is 550r/min, and the stirring time is 2 hours, so that the cobalt aluminate powder and the silica sol are uniformly mixed to obtain a ceramic core pretreating agent;
step 2, uniformly spraying the ceramic core pretreating agent on the surface of the ceramic core, airing, spraying, airing, and ensuring that the coating is uniform and free of flow marks for later use;
step 3, putting the ceramic core into a wax mould, preparing the ceramic core integral wax mould by adopting medium-temperature wax pressing, wherein the temperature of a wax material is 53 ℃, and the wax injection pressure is 35Kg/cm2Maintaining the pressure for 25s, and air-cooling for 8h to obtain the ceramic core integral wax mold, and shaping until the surface has no defects such as bubbles, sink marks, bulges, cracks and the like for later use;
step 4, preparing a six-layer half mould shell on the surface of the ceramic core integral wax mould, wherein the surface layer adopts silica sol-zircon sand powder, and the later five layers of half mould shells adopt silica sol-Shangshan sand powder;
step 5, performing dewaxing treatment on the prepared mould shell, standing the mould shell for more than or equal to 10 hours after dewaxing, then loading into a furnace for roasting, placing the filter screen into a sprue cup before roasting, wrapping the whole mould shell by using refractory cotton with the thickness of 32mm, and then loading into the furnace for roasting to form a ceramic mould shell;
and 6, smelting the K648 high-temperature alloy in a vacuum smelting furnace to form a molten solution, then vacuum-casting the molten solution in a ceramic shell mold at the casting temperature of 1545 ℃, cooling the casting in the furnace for 5.5min, taking out the casting and placing the casting in a sand pan until the casting is completely cooled, thus obtaining the investment casting K648 high-temperature alloy casting.
Claims (7)
1. A method for investment casting of a high-temperature alloy casting is characterized by comprising the following steps:
step 1, uniformly mixing cobalt aluminate powder and silica sol to prepare a ceramic core pretreating agent;
step 2, uniformly spraying the ceramic core pretreating agent on the surface of the ceramic core, and airing;
step 3, putting the ceramic core into a wax mold die to prepare a ceramic core integral wax mold;
step 4, preparing a mould shell on the surface of the integral wax mould of the ceramic core, wherein the surface layer adopts silica sol-zircon sand powder, and the other layers adopt silica sol-Shangshou sand powder;
step 5, dewaxing the prepared mould shell, then charging into a furnace and roasting to form a ceramic mould shell;
and 6, putting the high-temperature alloy into a vacuum smelting furnace to be smelted into molten liquid, then pouring the molten liquid into a ceramic shell in vacuum, wherein the pouring temperature is 1530-.
2. The method for investment casting of high temperature alloy castings according to claim 1, wherein the step 1 comprises placing cobalt aluminate powder and silica sol in a container, and stirring with a stirrer at 480-600r/min for 1.5-3 h to mix them uniformly to obtain the ceramic core pretreating agent.
3. The method for investment casting of the high-temperature alloy casting according to claim 2, wherein in the step 1, the mass ratio of the cobalt aluminate powder to the silica sol is 1: 9.
4. The method for investment casting of superalloy castings according to claim 1, wherein in step 2, the ceramic core pretreatment agent is uniformly sprayed on the surface of the ceramic core, dried, and then sprayed and dried.
5. The method for investment casting of superalloy castings according to claim 1, wherein in step 3, a ceramic core integral wax pattern is prepared by medium temperature wax pressing, the wax temperature is 50-60 ℃, and the wax injection pressure is 20-40Kg/cm2Keeping the pressure for 15-35s, and cooling in air for 4h or more.
6. The method for investment casting of high-temperature alloy castings according to claim 1, wherein in the step 4, six half of a formwork is prepared, wherein the surface layer adopts silica sol-zircon sand powder, and the last five half of the formwork adopts silica sol-Shang shop sand powder.
7. The method for investment casting of high-temperature alloy castings according to claim 1, wherein in the step 5, after dewaxing, the mold shell is left for more than or equal to 10 hours, then the mold shell is placed in a furnace for roasting, a filter screen is placed in a sprue cup before roasting, and the whole mold shell is wrapped by refractory cotton with a thickness of 25mm to 35 mm.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN115069979A (en) * | 2022-06-09 | 2022-09-20 | 中国航发北京航空材料研究院 | Process method for inhibiting columnar crystals on surface of inner cavity of isometric crystal hollow turbine blade |
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