CN114804842A - 一种孔隙分布与气氛可控的陶瓷型芯制备方法 - Google Patents

一种孔隙分布与气氛可控的陶瓷型芯制备方法 Download PDF

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CN114804842A
CN114804842A CN202210509467.3A CN202210509467A CN114804842A CN 114804842 A CN114804842 A CN 114804842A CN 202210509467 A CN202210509467 A CN 202210509467A CN 114804842 A CN114804842 A CN 114804842A
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郭馨
王旭
张航
朱星宏
蒋校磊
韩韬
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Abstract

本发明公开了一种孔隙分布与气氛可控的陶瓷型芯制备方法,将普通型芯拓展成复合陶瓷,即根据型芯结构特征,对厚大部分分步骤制备内置超高孔隙率的专属芯核结构和型芯,其中芯核浆料需添加不同种类与含量的造孔剂,型芯浆料需使用造孔剂和不同的气氛添加剂,并根据其基体与添加剂特性进行针对性焙烧;对型芯薄壁部分进行型芯局部加强。本发明在不损伤使用强度的前提下,改善陶瓷型芯的脱芯性能,同时实现对浇铸气氛的调节。

Description

一种孔隙分布与气氛可控的陶瓷型芯制备方法
技术领域
本发明涉及陶瓷型芯制备技术领域,具体涉及一种孔隙分布与气氛可控的陶瓷型芯制备方法。
背景技术
航空涡轮发动机的工作效率取决于涡轮前进口的温度,而涡轮前进口温度则取决于航空涡轮空心叶片的承温能力。因此,航空涡轮空心叶片成为制造先进水平的航空涡轮发动机的关键技术之一。目前主要通过设计内腔结构合理的空心叶片,提高其冷却效率,进而提高空心叶片的承温能力。空心叶片的复杂内腔主要熔模铸造陶瓷型芯形成的。叶片浇铸完成后通过机械或化学溶蚀(碱性腐蚀液)将陶瓷型芯从铸件中清除,从而得到空心内腔。最常用的陶瓷型芯有氧化硅基和氧化铝基两种,氧化铝基陶瓷型芯浇铸温度更高,但是其脱芯性能较差。脱芯时间长、难度大会显著提高铸件的生产成本,甚至有可能腐蚀铸件导致浇铸失败。为了达到高效脱芯、降低成本的目的,对陶瓷型芯的性能提出更高的要求。
陶芯的孔隙率是影响脱芯性能的重要因素,同时也将影响陶芯的室温与高温强度,成为调节陶瓷型芯性能的重要参数。如果孔隙率过高,虽然容易脱芯但是陶芯的室温强度降低、甚至影响到蜡模的制作,如果孔隙率过低,则会对后期脱芯过程造成较大影响。然而孔隙率的控制是一个复杂的过程,从压力注塑成型到阶梯温度区间的烧结,仅仅依靠单一的添加有机或者无机的造孔剂或者改变陶瓷型芯增塑剂的比例无法满足定制化的需求,也无法达到同时兼顾强度与易脱芯的目的。行业有通过无机造孔剂氯化铵,虽然可以适当提高提高孔隙率,但是引起了整体孔隙率的改变,容易造成薄壁结构强度降低,同时氨气排放还会引起环境污染;另有研究提出在陶瓷型芯中添加了一定量的碳纳米管,通过纳米碳管烧结后形成的空间管道来增加脱芯反应速度,使陶瓷型芯快速脱除。但是碳纳米管分散性差,前处理工艺复杂,使陶瓷型芯的强度和成品合格率控制难度很大。
目前航空发动机叶片主要通过真空定向凝固炉铸造,真空度需要严格控制,在极高的浇铸温度下合金元素极易与型壳、型芯内的残余气体反生反应,造成氧化等问题,降低叶片的最终性能。如能实现浇铸过程的气氛调节、减少有害气体,将在很大程度上提高叶片的性能和合格率。
发明内容
针对现有技术中存在的不足,本发明的目的在于提供一种孔隙分布与气氛可控的陶瓷型芯制备方法,本发明在不损伤使用强度的前提下,改善陶瓷型芯的脱芯性能,同时实现对浇铸气氛的调节。
为实现以上目的,本发明采用的技术方案为:
一种孔隙分布与气氛可控的陶瓷型芯制备方法,包括以下步骤:
步骤1:配置氧化铝基或者氧化硅基陶瓷基础浆料,分成芯核基础浆料和型芯基础浆料两部分;
步骤2:在芯核基础浆料中添加两到三种发气温度区间差异不小于50度、占芯核基础浆料质量的20~50%的造孔剂,如煤粉和碳酸氢铵,得到芯核浆料;
步骤3:根据陶瓷型芯厚壁结构部分即型芯进气边结构的结构特征设计制造芯核结构,芯核的设计选择卫星城式结构,辅助芯核环绕主芯核周围,主芯核周围均布3~4根辅助芯核,辅助芯核只围绕主芯核一周;主芯核直径比辅助芯核直径大2~3mm,以此来形成陶瓷型芯本身的阶梯空隙,主芯核直径比芯核的陶瓷型芯进气边厚度小4~6mm,芯核长度与进气边长度一致,具体尺寸依据陶瓷型芯具体尺寸确定;芯核的形状设计不仅仅局限于简单的圆柱形结构,针对部分进气边有弯曲等形状的陶瓷型芯,也可以考虑两端一粗一细的圆台形结构或者与型芯的弯曲角度一致的形状,通常的,芯核定位端(与陶瓷型芯进气边定位端一致)的另一侧为更小直径的台面;根据设计的芯核结构加工型芯模具,使用芯核浆料,采取注射成型制备得到未烧结专属芯核;
步骤4;根据加入的造孔剂发气温度区间,采用梯度升温的方式对专属芯核进行烧结,得到烧结后的专属芯核;
步骤5:在型芯基础浆料中加入一定比例的造孔剂、气氛调节添加剂(如二硼化锆),得到型芯浆料;造孔剂的添加比例占型芯基础浆料质量的10-30%,气氛调节添加剂的初始添加比例为型芯基础浆料质量的1~5%,如需更进一步的增大氧气真空度,则增加添加剂比例,但是原则上最大比例不超过8%;
步骤6:将烧结后的专属芯核放入型芯模具,使用定位销保证芯核表面与型芯模具表面保持0.1~0.5mm的间隙,采用型芯浆料注塑得到内置专属芯核的型芯;
步骤7:针对陶瓷型芯薄壁结构(如排气边)需要降低孔隙率的要求,对薄壁结构进行强化喷涂(如用纳米氧化铝溶胶喷涂),喷涂厚度0.3~1mm。在增强强度的同时也降低了薄壁结构部分的显气孔孔隙率;喷涂后,进行室温常规湿度(如湿度为40~60%)干燥、高低温强化工序,即可得到未烧结的薄壁结构加强的、内置专属芯核的型芯;
步骤8:根据型芯基体材料及其造孔添加剂的气体生成特性,根据其相变和发气温度区间,按照阶梯温度升温的方式对薄壁加强、内置专属芯核的型芯进行烧结,得到孔隙梯度分布的复合陶瓷型芯。
针对陶瓷型芯目前的两个问题:(1)目前陶瓷型芯脱芯性能的提升主要通过提高孔隙率,但单一添加成分造孔剂不能同时兼顾与平衡强度与孔隙率,而多过程、多类型纤维以及造孔剂的添加又存在工艺复杂化的问题,(2)定向凝固铸造过程中浇铸气氛不可控引起氧化等不良反应、降低叶片性能,本发明提出了一种孔隙分布与气氛可控的陶瓷型芯制备方法,通过内置超高孔隙率的专属芯核结构和局部加强,将普通型芯拓展成复合陶瓷,解决型芯内部或厚大部分强度过剩、不易脱除、薄壁部分强度不足的问题;通过对芯核、型芯添加不同种类与含量的造孔剂,在烧结不同阶段生成孔隙,实现孔隙尺寸和分布的可控调节,减少一次性气体逸出造成的型芯变形、裂纹缺陷;通过使用不同的气氛添加剂,实现在高温浇铸时逸出气体种类与含量的调节,实现对浇铸环境的调控。此方法不仅可用于陶瓷型芯的生产,还可用于其他陶瓷零件、烧结零件等的制备工艺优化。
和现有技术相比较,本发明具备如下优点:
(1)通过内置超高孔隙率的专属芯核结构和局部加强,将普通型芯拓展成复合陶瓷,解决型芯内部或厚大部分强度过剩、不易脱除、薄壁部分强度不足的问题;
(2)通过对芯核、型芯添加不同种类与含量的造孔剂,在烧结不同阶段生成孔隙,实现孔隙尺寸和分布的可控调节,减少一次性气体逸出造成的型芯变形、裂纹等缺陷;
(3)通过使用不同的气氛添加剂,实现在高温浇铸时逸出气体种类与含量的调节,实现对浇铸环境的调控,减少浇铸过程的污染与氧化等问题。
附图说明
图1为本发明复合陶瓷型芯制备流程图。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚简明,以下结合附图及实施例,对本发明进行进一步详细说明。应当理解,此处所描述的具体实施例仅仅用以解释本发明,并不用于限定本发明。
本发明旨在提出一种可以实现阶梯孔隙率、改善浇铸气氛的陶瓷型芯的制备方法,以达到实现阶梯孔隙率的目的,同时具有经济环保的特点,为易脱芯陶瓷型芯的生产制造提供了全新方案。以空心叶片用氧化铝基陶瓷型芯的生产为例,结合附图及具体实施例,对本发明作进一步的详细描述。
(1)采用高纯刚玉粉质量分数90%,锆英粉质量分数5%,石蜡增塑剂质量分数5%的比例配制型芯基础浆料,分成芯核基础浆料和型芯基础浆料两部分。
(2)在芯核基础浆料中添加15%的碳粉和15%的碳酸氢铵造孔剂,得到芯核浆料。
(3)根据陶瓷型芯厚壁结构部分(型芯进气边结构)的结构特征设计制造芯核结构,芯核选择卫星城式结构,辅助芯核环绕主芯核周围,主芯核周围均布3根辅助芯核;主芯核直径比周围辅助芯核直径大3mm,主芯核直径比芯核的陶瓷型芯进气边厚度小6mm,芯核长度与进气边长度基本一致。具体尺寸依据陶瓷型芯具体尺寸确定;芯核的形状设计不仅仅局限于简单的圆柱形结构,针对部分进气边有弯曲等形状的陶瓷型芯,也可以考虑两端一粗一细的圆台形结构或者与型芯的弯曲角度一致的形状,通常的,芯核定位端(与陶瓷型芯进气边定位端一致)的另一侧为更小直径的台面。根据设计的芯核结构加工型芯模具,使用芯核浆料,采取注射成型制备得到未烧结专属芯核。
(4)根据煤粉造孔剂的发气温度区间300~500℃和碳酸氢铵造孔剂发气温度区间60~70℃,采用梯度升温的方式对专属芯核进行烧结,得到烧结后的专属芯核。
(5)在型芯基础浆料中加入质量分数5%的碳粉造孔剂和5%的二硼化锆气氛调节剂,得到型芯浆料。
(6)将烧结后的专属芯核放入型芯注塑成型模具,使用定位销保证芯核表面与模具表面保持0.5mm的间隙,采用型芯浆料注塑成型得到内置专属芯核的型芯。
(7)对型芯排气边薄壁结构(如排气边)进行纳米氧化铝溶胶溶液喷涂,喷涂厚度1mm,进行室温常规湿度干燥、高低温强化工序,即可得到未烧结的薄壁结构加强的、内置专属芯核的型芯。
(8)根据氧化铝基体材料及碳粉造孔添加剂的气体生成特性,据其发气温度区间300~500℃,按照阶梯温度升温对薄壁加强的、内置专属芯核的型芯进行烧结,得到孔隙梯度分布的复合陶瓷型芯。

Claims (7)

1.一种孔隙分布与气氛可控的陶瓷型芯制备方法,其特征在于:包括以下步骤:
步骤1:配置氧化铝基或者氧化硅基陶瓷基础浆料,分成芯核基础浆料和型芯基础浆料两部分;
步骤2:在芯核基础浆料中添加两到三种发气温度区间差异不小于50度、占芯核基础浆料质量的20~50%的造孔剂,得到芯核浆料;
步骤3:根据陶瓷型芯厚壁结构部分即型芯进气边结构的结构特征设计制造芯核结构,芯核的设计选择卫星城式结构,辅助芯核环绕主芯核周围一周;主芯核直径比辅助芯核直径大2~3mm,以此来形成陶瓷型芯本身的阶梯空隙,芯核长度与进气边长度一致;根据设计的芯核结构加工型芯模具,使用芯核浆料,采取注射成型制备得到未烧结专属芯核;
步骤4;根据加入的造孔剂发气温度区间,采用梯度升温的方式对专属芯核进行烧结,得到烧结后的专属芯核;
步骤5:在型芯基础浆料中加入造孔剂、气氛调节添加剂,得到型芯浆料;造孔剂的添加比例占型芯基础浆料质量的10-30%,气氛调节添加剂的初始添加比例为型芯基础浆料质量的1~5%,如需更进一步的增大氧气真空度,则增加添加剂比例,但是原则上最大比例不超过8%;
步骤6:将烧结后的专属芯核放入型芯模具,使用定位销保证芯核表面与型芯模具表面保持0.1~0.5mm的间隙,采用型芯浆料注塑得到内置专属芯核的型芯;
步骤7:针对陶瓷型芯薄壁结构部分需要降低孔隙率的要求,对薄壁结构进行强化喷涂;在增强强度的同时也降低了薄壁结构部分的显气孔孔隙率;喷涂后,进行室温常规湿度干燥、高低温强化工序,即得到未烧结的薄壁结构加强的、内置专属芯核的型芯;
步骤8:根据型芯基体材料及其造孔添加剂的气体生成特性,根据其相变和发气温度区间,按照阶梯温度升温的方式对薄壁加强、内置专属芯核的型芯进行烧结,得到孔隙梯度分布的复合陶瓷型芯。
2.根据权利要求1所述的一种孔隙分布与气氛可控的陶瓷型芯制备方法,其特征在于:步骤2所述的造孔剂为煤粉和碳酸氢铵。
3.根据权利要求1所述的一种孔隙分布与气氛可控的陶瓷型芯制备方法,其特征在于:主芯核周围均布3~4根辅助芯核。主芯核直径比芯核的陶瓷型芯进气边厚度小4~6mm。
4.根据权利要求1所述的一种孔隙分布与气氛可控的陶瓷型芯制备方法,其特征在于:芯核的形状采用圆柱形结构,或针对部分进气边有弯曲等形状的陶瓷型芯,采用两端一粗一细的圆台形结构或者与型芯的弯曲角度一致的形状,芯核定位端的另一侧为更小直径的台面。
5.根据权利要求1所述的一种孔隙分布与气氛可控的陶瓷型芯制备方法,其特征在于:步骤5所述的造孔剂为碳粉,气氛调节添加剂为二硼化锆、碳化钙或碳化硼。
6.根据权利要求1所述的一种孔隙分布与气氛可控的陶瓷型芯制备方法,其特征在于:步骤7所述的强化喷涂采用纳米氧化铝溶胶喷涂,喷涂厚度为0.3~1mm。
7.根据权利要求1所述的一种孔隙分布与气氛可控的陶瓷型芯制备方法,其特征在于:步骤7所述的常规湿度为40~60%。
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