CN114799068A - Sand casting mold and manufacturing equipment and manufacturing method thereof - Google Patents
Sand casting mold and manufacturing equipment and manufacturing method thereof Download PDFInfo
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- CN114799068A CN114799068A CN202210510955.6A CN202210510955A CN114799068A CN 114799068 A CN114799068 A CN 114799068A CN 202210510955 A CN202210510955 A CN 202210510955A CN 114799068 A CN114799068 A CN 114799068A
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- 238000007528 sand casting Methods 0.000 title claims abstract description 78
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 32
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 90
- 229910052802 copper Inorganic materials 0.000 claims abstract description 81
- 239000010949 copper Substances 0.000 claims abstract description 81
- 238000000576 coating method Methods 0.000 claims abstract description 63
- 239000011248 coating agent Substances 0.000 claims abstract description 62
- 239000002245 particle Substances 0.000 claims abstract description 47
- 238000010288 cold spraying Methods 0.000 claims abstract description 39
- 238000000034 method Methods 0.000 claims abstract description 37
- 229910000838 Al alloy Inorganic materials 0.000 claims abstract description 26
- 230000008569 process Effects 0.000 claims abstract description 18
- 238000010438 heat treatment Methods 0.000 claims abstract description 11
- 239000003110 molding sand Substances 0.000 claims abstract description 8
- 230000003746 surface roughness Effects 0.000 claims abstract description 6
- 238000005520 cutting process Methods 0.000 claims abstract description 5
- 239000002994 raw material Substances 0.000 claims abstract description 4
- 239000000463 material Substances 0.000 claims description 31
- 239000011159 matrix material Substances 0.000 claims description 28
- 239000000843 powder Substances 0.000 claims description 20
- 238000005507 spraying Methods 0.000 claims description 18
- 238000003754 machining Methods 0.000 claims description 14
- 239000000758 substrate Substances 0.000 claims description 12
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 10
- 230000003247 decreasing effect Effects 0.000 claims description 8
- 230000007547 defect Effects 0.000 claims description 8
- 239000007921 spray Substances 0.000 claims description 6
- 229910000906 Bronze Inorganic materials 0.000 claims description 5
- 229910052782 aluminium Inorganic materials 0.000 claims description 5
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 5
- 239000010974 bronze Substances 0.000 claims description 5
- KUNSUQLRTQLHQQ-UHFFFAOYSA-N copper tin Chemical compound [Cu].[Sn] KUNSUQLRTQLHQQ-UHFFFAOYSA-N 0.000 claims description 5
- 229910052757 nitrogen Inorganic materials 0.000 claims description 5
- 239000007789 gas Substances 0.000 claims description 4
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims description 3
- DMFGNRRURHSENX-UHFFFAOYSA-N beryllium copper Chemical compound [Be].[Cu] DMFGNRRURHSENX-UHFFFAOYSA-N 0.000 claims description 2
- 230000002950 deficient Effects 0.000 claims description 2
- 238000004321 preservation Methods 0.000 claims description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 8
- 239000001301 oxygen Substances 0.000 description 8
- 229910052760 oxygen Inorganic materials 0.000 description 8
- 238000005266 casting Methods 0.000 description 7
- 239000004576 sand Substances 0.000 description 6
- 238000005516 engineering process Methods 0.000 description 4
- 238000000465 moulding Methods 0.000 description 4
- 238000012545 processing Methods 0.000 description 4
- 238000005482 strain hardening Methods 0.000 description 4
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 3
- 238000004140 cleaning Methods 0.000 description 3
- 239000001257 hydrogen Substances 0.000 description 3
- 229910052739 hydrogen Inorganic materials 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 239000002699 waste material Substances 0.000 description 3
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 2
- 230000033228 biological regulation Effects 0.000 description 2
- 238000007664 blowing Methods 0.000 description 2
- 235000011089 carbon dioxide Nutrition 0.000 description 2
- 230000001276 controlling effect Effects 0.000 description 2
- 230000003116 impacting effect Effects 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000001105 regulatory effect Effects 0.000 description 2
- 238000005728 strengthening Methods 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- QPLDLSVMHZLSFG-UHFFFAOYSA-N Copper oxide Chemical compound [Cu]=O QPLDLSVMHZLSFG-UHFFFAOYSA-N 0.000 description 1
- 239000005751 Copper oxide Substances 0.000 description 1
- 244000035744 Hura crepitans Species 0.000 description 1
- 238000003723 Smelting Methods 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000004320 controlled atmosphere Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229910000431 copper oxide Inorganic materials 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 229910021421 monocrystalline silicon Inorganic materials 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000012216 screening Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/06—Permanent moulds for shaped castings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C23/00—Tools; Devices not mentioned before for moulding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C23/00—Tools; Devices not mentioned before for moulding
- B22C23/02—Devices for coating moulds or cores
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C3/00—Selection of compositions for coating the surfaces of moulds, cores, or patterns
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/06—Permanent moulds for shaped castings
- B22C9/061—Materials which make up the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/18—Finishing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/14—Treatment of metallic powder
- B22F1/142—Thermal or thermo-mechanical treatment
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/02—Coating starting from inorganic powder by application of pressure only
- C23C24/04—Impact or kinetic deposition of particles
Abstract
The invention discloses a sand casting die and manufacturing equipment and a manufacturing method thereof. The sand casting mold includes an aluminum alloy sand casting mold body and a copper-based coating cold sprayed on the surface of the body for contact with the molding sand. The manufacturing method comprises the following steps: spherical copper-based particles which are subjected to heat treatment at 400-600 ℃ in reducing atmosphere and have diameters of 20-80 mu m are used as raw materials, cold spraying is carried out on the surface of the body, the temperature of the body is controlled to be not higher than 100 ℃ all the time in the cold spraying process, and a sand casting mold sprayed with the copper-based coating is obtained; and cutting off the copper-based coating of the redundant part of the obtained sand casting die sprayed with the copper-based coating, and carrying out surface roughness treatment on the copper-based coating to ensure that the finally obtained sand casting die meets the requirements of target size and surface roughness.
Description
Technical Field
The invention relates to the field of sand casting molds, in particular to a sand casting mold and manufacturing equipment and a manufacturing method thereof.
Background
The process flow of the sand mold casting technology is generally divided into the following stages:
a sand mixing stage, wherein molding sand and core sand are prepared for molding;
in the molding stage, a mold and a sandbox are manufactured according to a part drawing;
the molding stage comprises molding (forming a cavity of a casting by using molding sand), core making (forming the internal shape of the casting), and mold matching;
in the smelting stage, qualified molten metal is prepared as required;
pouring, namely pouring molten metal into the manufactured mold;
cleaning, solidifying the molten metal after pouring, removing a pouring port, taking out a casting and removing sand on the surface;
processing the casting to meet the expected requirement;
and (5) inspecting the casting to judge whether the casting is qualified.
At present, the material of a sand casting mould is mainly aluminum alloy, and in the using process of the mould, the surface of a contact area between the mould and molding sand is easy to fall off, wear and the like under the continuous impact action, so that the dimensional precision and the quality of a machined part are influenced.
The wear-resistant coating can be directly prepared on the surface of the sand casting die by adopting a cold spraying method, but the cold spraying is partial metallurgical bonding, the bonding strength of the coating is low and can only reach about 50MPa at most, and the porosity is high, so that the cold spraying layer is easy to fall off. It is therefore important to improve the bond strength of the coating to the mold substrate and to reduce the porosity between the coatings to improve the life of the sand casting mold.
Patent specification CN 106367750 a discloses a method for preparing a copper film by controlled atmosphere cold spraying, which comprises S1, reducing copper oxide on the surface of copper powder particles to copper by a powder oxygen content control unit, reducing the oxygen content of the copper powder and increasing the initial temperature of the copper powder; s2, screening copper powder particles with the particle size of 0.3-1.5 mu m from the particle size control and powder feeding unit; s3, conveying the copper powder particles to a cold spray nozzle; and S4, regulating and controlling the speed and the temperature of the copper powder particles through a gas pressure, flow and temperature control unit, so that the copper powder particles impact the substrate to form a copper film. The patent technology improves the quality of a cold spraying film by reducing the oxygen content of copper powder and improving the initial temperature of the copper powder when the copper film is prepared by cold spraying at the key position on the surface of polished monocrystalline silicon. The film obtained by the invention has compact structure, low oxygen content and good combination with a matrix.
However, if the cold spray technique is directly implanted in the surface modification of sand casting molds, the coating quality is generally not as effective as desired due to the softer aluminum matrix.
Disclosure of Invention
Aiming at the technical problems, the invention provides a manufacturing method of a sand casting mold, which overcomes the defects of the existing aluminum alloy sand casting mold and the surface strengthening technology and can solve the problem of short service life caused by the abrasion of the surface of the aluminum alloy at present.
The specific technical scheme is as follows:
a manufacturing method of a sand casting mold comprises a sand casting mold body and a copper-based coating which is cold-sprayed on the surface of the sand casting mold body, which is used for being in contact with molding sand; the sand casting mould body is made of aluminum alloy;
the manufacturing method of the sand casting mold adopts an integrated material increasing and decreasing machining center, material increasing adopts cold spraying material increasing equipment, material decreasing adopts a four-axis numerical control machining machine tool, and the cold spraying material increasing equipment and the four-axis numerical control machining machine tool are unified in the same coordinate system;
the manufacturing method of the sand casting mould comprises the following steps:
1) spherical copper-based particles which are subjected to heat treatment at 400-600 ℃ in reducing atmosphere and have diameters of 20-80 mu m are used as raw materials, cold spraying is carried out on the surface of a sand casting mold body, which is used for being in contact with molding sand, and the temperature of the sand casting mold body is controlled not to be higher than 100 ℃ all the time in the cold spraying process, so that the sand casting mold sprayed with the copper-based coating is obtained;
the spherical copper-based particles are at least one of tin bronze, beryllium copper and aluminum bronze;
the parameter conditions of the cold spraying include: the spraying temperature is 300-1000 ℃ (preferably 600-1000 ℃), the spraying gas is nitrogen, the spraying pressure is 4-6 MPa, the distance between a spray gun and a substrate is 25-30 mm, and the spraying angle is 70-110 degrees;
2) cutting off the copper-based coating of the redundant part of the sand casting die sprayed with the copper-based coating obtained in the step 1), and carrying out surface roughness treatment on the copper-based coating to enable the finally obtained sand casting die to meet the requirements of target size and surface roughness.
According to the invention, a combined process of low-temperature control of a die body, specific-temperature preheating treatment of specific copper-based powder reducing atmosphere, spraying temperature, spraying pressure and other specific parameter conditions is adopted, the particle shape and the particle size of copper-based particles are strictly controlled, a copper-based coating with low porosity, high hardness and high bonding strength with an aluminum alloy matrix is successfully formed on the surface of the aluminum alloy matrix, and the wear resistance of a sand casting die to mold collision and friction in a sand casting process is remarkably improved.
The manufacturing method of the sand casting mold further adopts an integrated material increasing and decreasing machining center, cold spraying material increasing equipment is adopted for material increasing, a four-axis numerical control machining machine tool is adopted for material decreasing, the cold spraying material increasing equipment and the four-axis numerical control machining machine tool are unified in the same coordinate system, machining errors caused by repeated positioning are avoided, and time waste caused by handover of different working procedures is reduced.
Tests show that if temperature control on the sand casting mold body is lacked in the step 1), the temperature of the sand casting mold body is increased in the cold spraying process, so that obvious pits are generated at the contact part of the sand casting mold body and copper-based particles, the bonding strength with a copper-based coating is reduced, and the coating is easy to fall off. The reason is that the aluminum alloy material of the sand casting die body is soft, and under the impact of harder copper-based particles, the aluminum alloy can generate larger deformation and generate obvious pits and even splash, so that the bonding strength of the aluminum alloy matrix and the copper-based coating is obviously reduced; the hardness of the matrix can be improved by lowering the temperature of the aluminum alloy matrix, so that the matrix cannot generate too large deformation under the impact of copper-based particles, the contact area with the copper-based particles is increased, metallurgical bonding is generated, and the bonding strength is obviously improved.
In the step 1), liquid nitrogen or dry ice and the like can be used as cold sources to control the temperature of the sand casting mould body not to be higher than 100 ℃ in the cold spraying process.
In the step 1), the copper-based particles are preheated in a reducing atmosphere at 400-600 ℃ before being sprayed. Tests show that if the step of preheating the copper-based particles is lacked, namely the copper-based particles are directly taken at room temperature for use, obvious pits are formed on the surface of the substrate due to the impact of high-speed powder particles, the copper-based particles and the aluminum alloy substrate are combined into mechanical combination, the combination strength is poor, and the porosity of the coating is high; the surface of a substrate deposited by the copper-based particles subjected to the preheating treatment at the temperature of 400-600 ℃ in the reducing atmosphere has no obvious pits, the bonding mechanism with the aluminum alloy substrate is mechanical bonding and metallurgical bonding, the bonding strength is obviously improved, and the porosity is obviously reduced. The reason is that the copper-based particles undergo continuous plastic deformation in the process of impacting the matrix, produce work hardening, and are difficult to combine with the matrix and even knock out pits; and the initial energy of the powder is increased by preheating the powder at 400-600 ℃ in a reducing atmosphere, the work hardening caused by plastic deformation is reduced to a certain extent, the bonding with an aluminum alloy matrix is facilitated, and meanwhile, the temperature of the contact surface of the powder and the matrix is increased, so that the local melting is caused to generate metallurgical bonding, and the bonding strength of the coating and the matrix is improved. Meanwhile, the reducing atmosphere reduces oxides possibly existing in the original copper-based particles, so that the oxygen content in the particles is reduced, and the influence of the oxygen content in the powder on the porosity of the coating is reduced.
In the step 1), a muffle furnace or other equipment can be adopted to carry out heat treatment on the copper-based particles.
A preferred sand casting mold manufacturing method is based on the parameter conditions:
in the step 1), the spherical copper-based particles are subjected to heat treatment in a reducing atmosphere at 600 ℃;
the porosity of the copper-based coating obtained in the method is less than 0.35%, and the bonding strength of the copper-based coating and the sand casting die body is more than 100 MPa.
Further preferably, in the step 1), the spherical copper-based particles are subjected to heat treatment in a reducing atmosphere at 600 ℃, and the temperature of the sand casting die body is controlled to be not higher than-20 ℃ all the time in the cold spraying process; the porosity of the copper-based coating obtained by the method is less than 0.2%, and the bonding strength of the copper-based coating and the sand casting die body is more than 130 MPa.
In a preferred example, in step 2), the heat treatment process includes: the heating rate is 10-20 ℃/min, and the heat preservation time at 400-600 ℃ is 1-2 hours.
In a preferred embodiment, in step 2), the average diameter of the copper-based particles is 50 μm.
In a preferred example, in step 2), the cold spraying is further defined by the following parameter conditions: the powder feeding speed is 80-110 g/min, and the nozzle moving speed is 50-300 mm/s.
In the step 1), after cold spraying, a high-pressure air gun is used for blowing off powder remained on the surface, and absolute ethyl alcohol is used for cleaning, so that the sand casting mould sprayed with the copper-based coating is obtained.
In a preferred embodiment, in the step 2), the thickness of the copper-based coating is 0.1-1.3 mm.
The method for manufacturing the sand casting mould can compare the size of the processed product with the nominal size, judge the product to be qualified when the error rate is 2 percent, and refine or re-manufacture the product when the error rate is more than 2 percent.
The invention also provides a sand casting mold with the copper-based coating, which is preferably manufactured by the manufacturing method of the sand casting mold.
As a general inventive concept, the present invention also provides a method for remanufacturing the sand casting mold with the copper-based coating, including the steps of:
s1, decontaminating the retired sand casting mould with the copper-based coating and judging whether the retired sand casting mould has a reusable value, if so, marking the retired sand casting mould as a defective part and performing S2;
s2, performing cold spraying on the defect part of the aluminum alloy body of the defect part by adopting the method in the step 1), completing an aluminum matrix, and performing cold spraying on the defect part of the copper-based coating, and completing the copper-based coating;
s3, processing the sand casting mold obtained in the step S2 by the method of the step 2).
In the remanufacturing method of the sand casting mold with the copper-based coating, in step S1, the retired sand casting mold with the copper-based coating refers to a mold which has problems of abrasion, falling off and the like when the service life is reached or the service life is not reached, and can be called a retired part.
The invention also provides manufacturing equipment suitable for implementing the manufacturing method of the sand casting mold, wherein the manufacturing equipment is an integral material increase and decrease machining center, cold spraying material increase equipment is adopted for material increase, a four-axis numerical control machining machine tool is adopted for material decrease, and the cold spraying material increase equipment and the four-axis numerical control machining machine tool are unified in the same coordinate system, so that machining errors caused by repeated positioning are avoided, and time waste caused by handover of different working procedures is reduced.
Compared with the prior art, the invention has the main advantages that:
according to the invention, the combined process of low-temperature control of the die body, specific-temperature preheating treatment of specific copper-based powder reducing atmosphere, spraying temperature, spraying pressure and other specific parameter conditions is adopted, the particle shape and particle size of the copper-based particles are strictly controlled, and the copper-based coating with low porosity, high hardness and high bonding strength with the aluminum alloy matrix is successfully formed on the surface of the aluminum alloy matrix.
The invention also provides a remanufacturing method which can reduce the problem of resource waste caused by scrapping due to the fact that the surface of the die falls off.
Detailed Description
The invention will be further illustrated with reference to the following specific examples. It should be understood that these examples are for illustrative purposes only and are not intended to limit the scope of the present invention. The following examples are conducted under conditions not specified, usually according to conventional conditions, or according to conditions recommended by the manufacturer.
The invention adopts an integrated processing center for increasing and decreasing materials, cold spraying material increasing equipment is adopted for material increasing, a four-axis numerical control processing machine tool is adopted for material decreasing, the cold spraying material increasing equipment and the four-axis numerical control processing machine tool are unified in the same coordinate system, and the specific process flow comprises the following steps:
designing a sand casting die drawing, wherein a die body is made of aluminum alloy, the thickness of a copper-based coating subjected to cold spraying is designed to be 1.2mm, and the cutting thickness is 0.2 mm;
secondly, manufacturing an aluminum alloy sand casting die body by adopting a machining technology;
thirdly, spherical copper-based particles with the diameter of 20-80 microns and the average diameter of 50 microns are used as raw materials, a high-temperature muffle furnace is adopted to carry out hydrogen atmosphere preheating treatment on copper-based powder tin bronze, the temperature is increased to 400-600 ℃ at the speed of 10 ℃/min, and the temperature is kept for 1-2 hours; a cooling system (a cold source can adopt liquid nitrogen or dry ice and the like) is adopted to regulate and control the low temperature of the die body, so that the highest temperature is not higher than 100 ℃;
fourthly, strengthening the surface of the die body by adopting high-pressure cold spraying equipment, wherein the spraying temperature is 800 ℃, the spraying gas is nitrogen, the spraying angle is 90 degrees, the spraying pressure is 4.5MPa, and after the spraying is finished, a high-pressure air gun is used for blowing off residual sand grains on the surface and cleaning the sand grains by using absolute ethyl alcohol;
fifthly, performing finish machining on the sprayed die by adopting a four-axis numerical control machine tool, and cutting off a reserved part and an uneven part of the coating on the basis of a design model to enable the size, the roughness and the like of the coating to meet the use requirements;
and sixthly, remanufacturing the retired part according to conditions.
Example 1
According to the process flow of the above embodiment, the third step does not perform low temperature regulation and control on the mold body, and the third step does not perform preheating treatment on the spherical copper-based particles as a comparison. The results of cold spray parameters and the porosity of the coating and the bond strength of the coating to the substrate are shown in Table 1.
TABLE 1
The experimental result shows that with the increase of the preheating treatment temperature, the pits on the surface of the coating are obviously reduced, the porosity of the coating is reduced from 1.43 percent to 1.17 percent, 0.96 percent and 0.55 percent, the bonding strength of the coating and the matrix is obviously improved, and the bonding strength is improved from 20.2MPa to 42.3MPa, 58.1MPa and 80.7 MPa. When the copper-based powder is not subjected to preheating treatment, the surface of the matrix is impacted by high-speed powder particles to form obvious pits, and the powder and the aluminum alloy matrix are combined into mechanical combination, so that the combination strength is poor; the surface of a substrate deposited by the copper-based particles subjected to hydrogen preheating treatment has no obvious pits, and the bonding mechanism of the copper-based particles and the aluminum alloy substrate is mechanical bonding and metallurgical bonding, so that the bonding strength is obviously improved. The reason is that the copper particles without preheating treatment undergo continuous plastic deformation in the process of impacting the matrix, produce work hardening, and are difficult to combine with the matrix and even knock out pits; the hydrogen preheating treatment of the powder increases the initial energy of the powder, reduces the work hardening caused by plastic deformation to a certain extent, is beneficial to combination with an aluminum alloy matrix, and simultaneously improves the temperature of the contact surface of the powder and the matrix, causes partial melting to generate metallurgical combination, thereby improving the combination strength of the coating and the matrix. Meanwhile, due to the increase of the temperature of the reducing atmosphere, the reducing atmosphere reduces oxides possibly existing in the original copper-based particles, so that the oxygen content in the particles is reduced, and the influence of the oxygen content in the powder on the porosity of the coating is reduced.
Example 2
According to the process flow of the above embodiment, the preheating temperature of the copper-based particles in the third step is controlled to 600 ℃, and the influence of the low-temperature regulation and control of the mold body in the fourth step is studied by using the comparison of the third step of not regulating and controlling the temperature of the mold body. The results of the cold spraying parameters, the porosity of the coating and the bonding strength of the coating to the substrate are shown in Table 2, wherein the spraying distance is 25mm and the moving speed of the spray gun is 100 mm/s.
TABLE 2
As a result of experiments, the porosity of the coating is gradually reduced from 0.55% to 0.34%, 0.21% and 0.15% along with the reduction of the temperature of the die body, and the bonding strength of the coating and the matrix is improved from 80.7MPa to 103.5MPa, 115.6MPa and 131.8 MPa. The reason is that the lower temperature improves the hardness of the aluminum alloy matrix, so that the aluminum alloy matrix is not easy to generate violent deformation under the impact of copper-based particles, thereby reducing the defects such as splashing, pits and the like, having smaller porosity and being capable of being better combined with the copper-based particles.
Furthermore, it should be understood that various changes and modifications can be made by one skilled in the art after reading the above description of the present invention, and equivalents also fall within the scope of the invention as defined by the appended claims.
Claims (8)
1. The manufacturing method of the sand casting mold is characterized in that the sand casting mold comprises a sand casting mold body and a copper-based coating which is cold sprayed on the surface of the sand casting mold body, which is used for being in contact with molding sand; the sand casting mould body is made of aluminum alloy;
the manufacturing method of the sand casting mold adopts an integrated material increasing and decreasing machining center, material increasing adopts cold spraying material increasing equipment, material decreasing adopts a four-axis numerical control machining machine tool, and the cold spraying material increasing equipment and the four-axis numerical control machining machine tool are unified in the same coordinate system;
the manufacturing method of the sand casting mould comprises the following steps:
1) spherical copper-based particles which are subjected to heat treatment at 400-600 ℃ in reducing atmosphere and have diameters of 20-80 mu m are used as raw materials, cold spraying is carried out on the surface of a sand casting mold body, which is used for being in contact with molding sand, and the temperature of the sand casting mold body is controlled not to be higher than 100 ℃ all the time in the cold spraying process, so that the sand casting mold sprayed with the copper-based coating is obtained;
the spherical copper-based particles are at least one of tin bronze, beryllium copper and aluminum bronze;
the parameter conditions of the cold spraying include: the spraying temperature is 300-1000 ℃, the spraying gas is nitrogen, the spraying pressure is 4-6 MPa, the distance between a spray gun and a substrate is 25-30 mm, and the spraying angle is 70-110 degrees;
2) cutting off the copper-based coating of the redundant part of the sand casting die sprayed with the copper-based coating obtained in the step 1), and carrying out surface roughness treatment on the copper-based coating to enable the finally obtained sand casting die to meet the requirements of target size and surface roughness.
2. The method of making a sand casting mold of claim 1,
in the step 1), the spherical copper-based particles are subjected to heat treatment in a reducing atmosphere at 600 ℃;
the porosity of the copper-based coating is less than 0.35%, and the bonding strength of the copper-based coating and the sand casting die body is more than 100 MPa.
3. The method for manufacturing a sand casting mold according to claim 1, wherein in the step 1), the heat treatment process comprises the following steps: the heating rate is 10-20 ℃/min, and the heat preservation time at 400-600 ℃ is 1-2 hours.
4. The method for making a sand casting mould according to claim 1, wherein in step 2), the cold spraying is further subjected to the following parameter conditions: the powder feeding speed is 80-110 g/min, and the nozzle moving speed is 50-300 mm/s.
5. The method for manufacturing a sand casting mold according to claim 1, wherein in the step 2), the thickness of the copper-based coating is 0.1-1.3 mm.
6. A sand casting mold with a copper-based coating, which is characterized by being manufactured by the manufacturing method of the sand casting mold according to any one of claims 1 to 5.
7. The method of remanufacturing a sand casting mold with a copper-based coating according to claim 6, comprising the steps of:
s1, decontaminating the retired sand casting mould with the copper-based coating and judging whether the retired sand casting mould has a reusable value, if so, marking the retired sand casting mould as a defective part and performing S2;
s2, performing cold spraying on the defect part of the aluminum alloy body of the defect part by using the method of the step 1) of the claim 1, completing the aluminum matrix, and performing cold spraying on the defect part of the copper-based coating, and completing the copper-based coating;
s3, treating the sand casting mold obtained in step S2 by the method of step 2) of claim 1.
8. A manufacturing device suitable for implementing the manufacturing method of the sand casting mold according to any one of claims 1 to 5, wherein the manufacturing device is an integral material increase and decrease machining center, a cold spraying material increase device is used for material increase, a four-axis numerical control machining machine tool is used for material decrease, and the cold spraying material increase device and the four-axis numerical control machining machine tool are unified in the same coordinate system.
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