CN115231932A - 铸造空心叶片的陶瓷型芯用陶瓷浆料的方法 - Google Patents
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Abstract
本发明的铸造空心叶片的陶瓷型芯用陶瓷浆料的方法,属于陶瓷型芯用陶瓷浆料材料领域,提高航空发动机各部件乃高温和散热性能的技术问题。该方法包括:配置增塑剂,所述增塑剂至少包括聚乙烯树脂,提高陶瓷浆料乃高温性能;所述增塑剂与油酸、白刚玉粉和石英粉混合以制备所述陶瓷浆料。能够生产出带有扰流柱的内腔尺寸变化大的复杂等轴晶镍基高温合金空心铸造叶片,且能承受镍基高温合金液冲击。
Description
技术领域
本发明属于陶瓷型芯用陶瓷浆料材料领域,尤其涉及一种铸造空心叶片的陶瓷型芯用陶瓷浆料的方法。
背景技术
在航空技术领域,航空发动机各部件的工作环境对使用材料提出了苛刻的要求。从发动机压气机到尾喷管,各零部件均在较高温度下和高的振动下工作,有些零部件要在800℃以上的条件下长期工作。航空发动机推重比日益提高,发动机工作环境温度也越来越高,对航空发动机零部件耐热性能要求更加苛刻。
围绕航空发动机热端零部件,例如,铸造涡轮导向器叶片,如何长时间承受工作高温,行业在发展中更加看重铸造叶片的叶身设计采取复杂空心设计,以利于散热和后续加工出气膜孔进行隔热。
有鉴于此,特提出本发明。
发明内容
本发明的目的在于提供一种铸造空心叶片的陶瓷型芯用陶瓷浆料的方法,提高航空发动机各部件乃高温和散热性能的技术问题。本案的技术方案有诸多技术有益效果,见下文介绍:
提供一种铸造空心叶片的陶瓷型芯用陶瓷浆料的方法,所述方法包括:
配置增塑剂,所述增塑剂至少包括聚乙烯树脂,提高陶瓷浆料乃高温性能;
所述增塑剂与油酸、白刚玉粉和石英粉混合以制备所述陶瓷浆料。
与现有技术相比,本发明提供的技术方案包括以下有益效果:
本法提供的方法配置出的陶瓷浆料,能够生产出带有扰流柱的内腔尺寸变化大的复杂等轴晶镍基高温合金空心铸造叶片,且能承受镍基高温合金液冲击,耐合金液高温、热膨胀率低、烧结后尺寸稳定的陶瓷型芯浆料,对发展我国航空发动机事业起着重要作用。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案,下面将对实施例或现有技术描述中所需使用的附图作简单地介绍,显而易见地,下面描述中的附图仅仅是本发明的一些实施例,对于本领域普通技术人员来讲,在不付出创造性劳动的前提下,还可以根据这些附图获得其他的附图。
图1为本发明配置浆料生产叶片能够扰流柱的内腔尺寸变化的示意图。
具体实施方式
以下通过特定的具体实例说明本发明的实施方式,本领域技术人员可由本说明书所揭露的内容轻易地了解本发明的其他优点与功效。显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。本发明还可以通过另外不同的具体实施方式加以实施或应用,本说明书中的各项细节也可以基于不同观点与应用,在没有背离本发明的精神下进行各种修饰或改变。需说明的是,在不冲突的情况下,以下实施例及实施例中的特征可以相互组合。基于本发明中的实施例,本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
需要说明的是,下文描述在所附权利要求书的范围内的实施例的各种方面。应显而易见,本文中所描述的方面可体现于广泛多种形式中,且本文中所描述的任何特定结构及/或功能仅为说明性的。基于本发明,所属领域的技术人员应了解,本文中所描述的一个方面可与任何其它方面独立地实施,且可以各种方式组合这些方面中的两者或两者以上。举例来说,可使用本文中所阐述的任何数目个方面来实施设备及/或实践方法。另外,可使用除了本文中所阐述的方面中的一或多者之外的其它结构及/或功能性实施此设备及/或实践此方法。
本发明提供的铸造空心叶片的陶瓷型芯用陶瓷浆料的方法,所述方法包括:
S101:配置增塑剂,增塑剂至少包括聚乙烯树脂,提高陶瓷浆料乃高温性能,具体的:
增塑剂包括:精炼石蜡、蜂蜡和聚乙烯树脂且各个组分按重量为(85-95)份:(8-9)份:(1-3)份进行配比,优选的,聚乙烯树脂为低密度的聚乙烯树脂,并且精炼石蜡90%、蜂蜡8%和低密度聚乙烯树脂2%重量配置进行配置。
聚乙烯树脂配合精炼石蜡和蜂蜡,提高浆料整体的韧性,实际生产过程中,采用压制成型的工艺进行加工,当去掉陶芯时,整体产品容易出现裂痕或微小裂缝,通过增塑剂的加入,可有效避免该情况的出现。目的是:增塑剂能够改善陶芯浆料压制成型后的柔韧性、曲挠性,即提高塑性。作用:在陶瓷型芯压制成型后,取模和后续修整工序不易遭到损坏。
原理为:当增塑剂与与浆料一起混合时,微观上增塑剂的小分子便会插人到浆料聚合物分子链之间,削弱了浆料聚合物分子链间的引力,增大了它们之间的距离,结果增加了聚合物分子链的移动可能,降低了聚合物分子链间的缠结,从而增强浆料的塑性。
上述的增塑剂的制备方法为:
将1/2全或半的精炼石蜡放入不锈钢坩埚内熔化,加热至60℃-80℃。
加入低密度聚乙烯不断搅拌,升温至180℃-200℃,直至低密度聚乙烯树脂全部熔化;
加入蜂蜡和剩余1/2全或半的精炼石蜡,在180℃200℃熔化完全后保温至少30min;
过滤倒入瓷盘或不锈钢盘中凝成锭块待用。
S102:增塑剂与油酸、白刚玉粉和石英粉混合以制备陶瓷浆料,具体的:
石英粉至少包括两种不同规格的石英粉,其目的是,压制浆料成型时,对自密度有要求,如采用同一规格的石英粉,致使浆料颗粒之间的间隙较大,不以利于奖励的压制成型,例如,石英粉包括270目和400目的石英粉。油酸能够增强浆料的流动性,在浆料制备过程中,加入油酸搅拌均匀,充分混合进入浆料,在后续压制陶瓷型芯时,浆料在陶瓷型芯模具中充型过程中流动性好,便于充型。
石英粉作为浆料的主体材料,通过配比调节陶瓷型芯制品的尺寸。粗粉多(270目),压制出来的陶芯坯微观间隙大,通过烧结收缩制成品尺寸更小。
陶瓷浆料各个物质的重量配比为:
270目石英粉15份:400目石英粉65份:白刚玉粉20份:油酸1份:增塑剂(16-18)份,白刚玉粉的目的是提高浆料的耐高温性能。
在配置好增塑剂后,陶瓷浆料的加工方法包括:
参见表1:
表1
将两种石英粉和白刚玉粉装入球磨瓷坛内进行球磨,粉料与瓷球比例1:1,球磨时间1h-2h;
将球磨好的混合料平铺在瓷盘上,粉层厚度≤30mm,放入干燥箱中于200℃-300℃烘烤5h-6h。
增塑剂放入不锈钢坩埚中进行熔化,待增塑剂全部熔化后,将烘烤后的混合料逐渐加入且粉料温度低于150℃,并不断搅拌,加热温度确保不应超过150℃,待混合料全部加入搅拌均匀后,加入油酸继续搅拌≥4h。
制备好的陶瓷浆料放入陶瓷型芯压芯机保温缸中,温度控制在110℃-150℃待用。
实施例
1.270目石英粉:400目石英粉:320目白刚玉粉=25:55:20油酸1%,增塑剂13%-15%。
2.270目石英粉:400目石英粉:320目白刚玉粉=25:55:20油酸1%,增塑剂19%-21%。
3.270目石英粉:400目石英粉:320目白刚玉粉=25:60:15油酸1%,增塑剂19%-21%。
4.270目石英粉:400目石英粉:320目白刚玉粉=15:65:20油酸1%,增塑剂13%-15%。
5.270目石英粉:400目石英粉:320目白刚玉粉=15:65:20油酸1%,增塑剂16%-18%。
方案一,石英粉配比粗粉比例较高,增塑剂比例最低,陶芯制成品尺寸收缩大,收缩率达到2.6%,且制成品塑性不足,后续取模始终无法避免扰流柱区域产生裂纹。
方案二,石英粉配比粗粉比例较高,增塑剂比例最高,陶芯制成品尺寸收缩最大,收缩率达到3.02%,陶芯制成品尺寸最小,不满足使用要求。但是塑性最佳,制成品不受操作影响,无裂纹产生。
方案三,石英粉配比粗粉比例较高,增塑剂比例最高,陶芯制成品尺寸收缩最大,收缩率达到2.43%,陶芯制成品尺寸偏小,不满足使用要求。但是塑性最佳,制成品不受操作影响,无裂纹产生。
方案四,石英粉配比粗粉比例下调,增塑剂用量较小,尺寸收缩率只有1%,陶芯制成品尺寸偏大,不满足使用要求。且制成品塑性不足,后续取模始终无法避免扰流柱区域产生裂纹。
方案五,石英粉配比粗粉比例下调,增塑剂用量适中,尺寸收缩率达到目标值1.8%。
本发明制备的陶瓷浆料生产的陶瓷型芯溶出性出色,经过碱水高压脱芯或者熔融碱液腐蚀均能溶失去除干净,并且反应性极低,与镍基高温合金液无反应。如图1所示,能够生产出带有扰流柱的内腔尺寸变化大的复杂等轴晶镍基高温合金空心铸造叶片。针对带有扰流柱的内腔尺寸变化大的陶芯浆料制备,实现了易取模,不易损坏和尺寸变化稳定,并且,扰流柱区域不易产生裂纹。
以上对本发明所提供的产品进行了详细介绍。本文中应用了具体个例对本发明的原理及实施方式进行了阐述,以上实施例的说明只是用于帮助理解本发明的核心思想。应当指出,对于本技术领域的普通技术人员来说,在不脱离发明创造原理的前提下,还可以对发明进行若干改进和修饰,这些改进和修饰也落入发明权利要求的保护范围。
Claims (8)
1.一种铸造空心叶片的陶瓷型芯用陶瓷浆料的方法,其特征在于,所述方法包括:
配置增塑剂,所述增塑剂至少包括聚乙烯树脂,提高陶瓷浆料乃高温性能;
所述增塑剂与油酸、白刚玉粉和石英粉混合以制备所述陶瓷浆料。
2.根据权利要求1所述的方法,其特征在于,所述增塑剂的配置方法包括:
精炼石蜡、蜂蜡和聚乙烯树脂按重量为(85-95)份:(8-9)份:(1-3)份进行配比。
3.根据权利要求2所述的方法,其特征在于,所述聚乙烯树脂为低密度的聚乙烯树脂,并且精炼石蜡90%、蜂蜡8%和低密度聚乙烯树脂2%重量配置进行配置。
4.根据权利要求3所述的方法,其特征在于,所述增塑剂的加工方法包括:
将1/2全或半的精炼石蜡放入不锈钢坩埚内熔化,加热至60℃-80℃。
加入所述低密度聚乙烯不断搅拌,升温至180℃-200℃,直至所述低密度聚乙烯树脂全部熔化;
加入蜂蜡和剩余1/2全或半的精炼石蜡,在180℃200℃熔化完全后保温至少30min;
过滤倒入瓷盘或不锈钢盘中凝成锭块待用。
5.根据权利要求1所述的方法,其特征在于,所述石英粉至少包括两种不同规格的石英粉。
6.根据权利要求5所述的方法,其特征在于,所述石英粉包括270目和400目的石英粉。
7.根据权利要求5所述的方法,其特征在于,所述陶瓷浆料各个物质的重量配比为:270目石英粉15份:400目石英粉65份:白刚玉粉20份:油酸1份:所述增塑剂(16-18)份。
8.根据权利要求7所述的方法,其特征在于,所述陶瓷浆料的加工方法包括:
将两种所述石英粉和白刚玉粉装入球磨瓷坛内进行球磨,粉料与瓷球比例1:1,球磨时间1h-2h;
将球磨好的混合料平铺在瓷盘上,粉层厚度≤30mm,放入干燥箱中于200℃-300℃烘烤5h-6h。
所述增塑剂放入不锈钢坩埚中进行熔化,待增塑剂全部熔化后,将烘烤后的混合料逐渐加入且粉料温度低于150℃,并不断搅拌,加热温度确保不应超过150℃,待混合料全部加入搅拌均匀后,加入油酸继续搅拌≥4h。
制备好的所述陶瓷浆料放入陶瓷型芯压芯机保温缸中,温度控制在110℃-150℃待用。
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