CN115401163A - Silica sol shell and preparation method thereof - Google Patents
Silica sol shell and preparation method thereof Download PDFInfo
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- CN115401163A CN115401163A CN202211071776.3A CN202211071776A CN115401163A CN 115401163 A CN115401163 A CN 115401163A CN 202211071776 A CN202211071776 A CN 202211071776A CN 115401163 A CN115401163 A CN 115401163A
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- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 title claims abstract description 139
- 238000002360 preparation method Methods 0.000 title abstract description 21
- 239000010410 layer Substances 0.000 claims abstract description 187
- 239000011248 coating agent Substances 0.000 claims abstract description 134
- 238000000576 coating method Methods 0.000 claims abstract description 134
- 239000004576 sand Substances 0.000 claims abstract description 82
- 230000007704 transition Effects 0.000 claims abstract description 72
- 239000000843 powder Substances 0.000 claims abstract description 63
- 229910052863 mullite Inorganic materials 0.000 claims abstract description 59
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 claims abstract description 58
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 55
- 239000002344 surface layer Substances 0.000 claims abstract description 42
- 229920000049 Carbon (fiber) Polymers 0.000 claims abstract description 41
- 239000004917 carbon fiber Substances 0.000 claims abstract description 41
- 238000000034 method Methods 0.000 claims abstract description 32
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims abstract description 30
- 238000003618 dip coating Methods 0.000 claims abstract description 19
- 238000007789 sealing Methods 0.000 claims abstract description 16
- 238000005495 investment casting Methods 0.000 claims abstract description 15
- 239000002002 slurry Substances 0.000 claims abstract description 14
- 239000000463 material Substances 0.000 claims description 27
- 238000001035 drying Methods 0.000 claims description 18
- 230000002787 reinforcement Effects 0.000 claims description 14
- 229910052845 zircon Inorganic materials 0.000 claims description 14
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 claims description 14
- 239000000080 wetting agent Substances 0.000 claims description 12
- 238000007598 dipping method Methods 0.000 claims description 11
- 230000008569 process Effects 0.000 claims description 11
- 239000002245 particle Substances 0.000 claims description 7
- 238000004321 preservation Methods 0.000 claims description 7
- 239000002518 antifoaming agent Substances 0.000 claims description 6
- 229910052593 corundum Inorganic materials 0.000 claims description 6
- 239000010431 corundum Substances 0.000 claims description 6
- 238000001816 cooling Methods 0.000 claims description 5
- 238000001354 calcination Methods 0.000 claims 2
- 230000035699 permeability Effects 0.000 abstract description 12
- 238000005266 casting Methods 0.000 description 24
- 238000003756 stirring Methods 0.000 description 20
- 238000002156 mixing Methods 0.000 description 18
- 238000007654 immersion Methods 0.000 description 15
- 239000000047 product Substances 0.000 description 13
- 230000000052 comparative effect Effects 0.000 description 8
- 230000007547 defect Effects 0.000 description 8
- 238000009825 accumulation Methods 0.000 description 6
- 239000013530 defoamer Substances 0.000 description 6
- 238000009415 formwork Methods 0.000 description 6
- 238000005728 strengthening Methods 0.000 description 6
- 238000010304 firing Methods 0.000 description 5
- 239000000203 mixture Substances 0.000 description 5
- 238000007665 sagging Methods 0.000 description 5
- 229910045601 alloy Inorganic materials 0.000 description 4
- 239000000956 alloy Substances 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- 229910001008 7075 aluminium alloy Inorganic materials 0.000 description 3
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 3
- 238000004140 cleaning Methods 0.000 description 3
- 238000007667 floating Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 229910052760 oxygen Inorganic materials 0.000 description 3
- 239000001301 oxygen Substances 0.000 description 3
- 238000003825 pressing Methods 0.000 description 3
- 238000012797 qualification Methods 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 238000003723 Smelting Methods 0.000 description 2
- 238000001514 detection method Methods 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 238000001917 fluorescence detection Methods 0.000 description 2
- 239000003973 paint Substances 0.000 description 2
- 229920001296 polysiloxane Polymers 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 238000004080 punching Methods 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- 229910004298 SiO 2 Inorganic materials 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 238000003915 air pollution Methods 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 239000003153 chemical reaction reagent Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000011440 grout Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 229920000570 polyether Polymers 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000011819 refractory material Substances 0.000 description 1
- 230000000630 rising effect Effects 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 238000007581 slurry coating method Methods 0.000 description 1
- 238000002791 soaking Methods 0.000 description 1
- 238000003892 spreading Methods 0.000 description 1
- 230000007480 spreading Effects 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 239000013589 supplement Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
- B22C1/02—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives
- B22C1/10—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by additives for special purposes, e.g. indicators, breakdown additives for influencing the hardening tendency of the mould material
-
- 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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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Mold Materials And Core Materials (AREA)
Abstract
The invention relates to the technical field of investment casting, in particular to a silica sol shell and a preparation method thereof. The preparation method of the silica sol shell comprises the following steps: sequentially carrying out dip coating of a surface layer coating, scattering of surface layer sand, dip coating of a transition layer coating, scattering of transition layer sand, dip coating of a reinforcing layer coating, scattering of reinforcing layer sand and dip coating of a sealing slurry layer coating on the module to obtain a shell; dewaxing and roasting the shell to obtain the silica sol shell; the transition layer coating comprises the following components in parts by weight: 800-1000 parts of mullite powder, 0.8-1.2 parts of carbon fiber and 480-520 parts of silica sol; the reinforced layer coating comprises the following components in parts by weight: 1400-1800 parts of mullite powder, 0.8-1.2 parts of carbon fiber and 480-520 parts of silica sol. The method can reduce the thickness of the shell, maintain the strength of the shell and increase the air permeability of the shell.
Description
Technical Field
The invention relates to the technical field of investment casting, in particular to a silica sol shell and a preparation method thereof.
Background
Investment casting is an advanced process of near-net-shape forming, is used for realizing the forming of complex, precise and thin-wall castings, can be directly used without processing or with little processing, is generally applied to the industrial field such as aero-engines and the like, and also widely adopts the investment casting technology in the jewelry industry. The modern investment casting process flow mainly comprises the following steps: pressing wax patterns, combining modules, preparing a mould shell, smelting and pouring, cleaning and cutting shells, carrying out heat treatment and carrying out nondestructive and size detection. The preparation process of the shell is particularly important, and the high-quality shell can obtain casting products with smooth surfaces, clear edges and corners, correct sizes and good quality. Air permeability is an important indicator of a quality formwork, and the air permeability of a formwork is mainly determined by the degree of compactness of its structure.
The silica sol shell has the advantages of simple process, good coating stability, strong high-temperature deformation resistance, good product surface quality, no air pollution during shell manufacturing and the like, and the application of the shell has a rising trend at present when the requirements on product quality and environmental protection are more and more strict. However, the silica sol shell has low high-temperature air permeability and is limited by the existing shell preparation process, and the casting usually has pinhole defects of different degrees inside. For some thin-wall castings, blade castings and castings with airtight requirements, the rejection is judged when the pinhole defect of more than 2 levels is detected, the product qualification rate is low, and the casting cost is increased; in order to avoid pinhole defect, cold iron, exhaust and other measures are additionally arranged on a common structural member, so that the mold assembling process is complex and the yield is low. In order to avoid the pinhole defect of a product, the smelting quality of molten metal is improved, the number of the formwork layers is reduced and the like, but the effect is microscopic, and the reduction of the number of the formwork layers can cause the problems of insufficient strength of the formwork, casting fire running and the like.
In view of the above, the present invention is particularly proposed.
Disclosure of Invention
A first object of the present invention is to provide a method for preparing a silica sol shell, which can maintain the strength of the shell while reducing the thickness of the shell, increase the porosity of the shell, improve the air permeability, and thus facilitate the exhaustion.
The second purpose of the invention is to provide a silica sol shell which has the characteristics of low thickness, high strength, large porosity and good air permeability, and when the silica sol shell is used in investment casting, the silica sol shell can reduce the pinhole defect of a casting and improve the metallurgical quality and the qualified rate of the casting.
In order to achieve the above purpose of the present invention, the following technical solutions are adopted:
the invention provides a preparation method of a silica sol shell, which comprises the following steps: the method comprises the following steps of dipping and coating a surface layer coating, scattering surface layer sand, dipping and coating a transition layer coating, scattering transition layer sand, dipping and coating a reinforcing layer coating, scattering reinforcing layer sand and dipping and coating a sealing slurry layer coating in sequence on a module to obtain a shell; dewaxing and roasting the shell to obtain the silica sol shell;
the transition layer coating comprises the following components in parts by weight: 800-1000 parts of mullite powder, 0.8-1.2 parts of carbon fiber and 480-520 parts of silica sol;
the reinforced layer coating comprises the following components in parts by weight: 1400-1800 parts of mullite powder, 0.8-1.2 parts of carbon fiber and 480-520 parts of silica sol.
Further, the surface layer coating comprises the following components in parts by weight: 19 to 21 parts of zircon powder, 6 to 8 parts of defoaming agent, 8 to 10 parts of wetting agent and 4.5 to 5.5 parts of silica sol.
Preferably, the grain size of the zircon powder is 300-350 meshes.
Preferably, the face sand comprises corundum sand.
Preferably, the grain size of the surface sand is 80-120 meshes.
Furthermore, in the transition layer coating, the grain diameter of the mullite powder is 180-220 meshes.
Preferably, the transition layer sand comprises mullite sand.
Preferably, the grain size of the transition layer sand is 50-70 meshes.
Furthermore, in the coating of the reinforcing layer, the grain diameter of mullite powder is 180-220 meshes.
Preferably, the reinforcement sand comprises mullite sand.
Preferably, the grain size of the reinforcing layer sand is 25-35 meshes.
Further, the carbon fiber includes a carbon fiber for precision casting.
Preferably, the diameter of the carbon fiber is 15 to 25 μm, and the length of the carbon fiber is 0.8 to 1.2mm.
Further, the sealing slurry layer coating comprises mullite powder and silica sol.
Preferably, the mass ratio of the mullite powder to the silica sol is 5-9: 5.
preferably, in the sealing layer coating, the grain diameter of the mullite powder is 180-220 meshes.
Further, the roasting temperature is 800-850 ℃, and the roasting time is 2-4 h.
Preferably, the firing comprises: heating to 800-850 ℃ at the speed of less than or equal to 200 ℃/h, carrying out heat preservation treatment for 2-4 h, and cooling the furnace to below 200 ℃.
Further, the preparation method of the silica sol shell comprises the following steps:
(A) Dip-coating the die set with surface layer coating, scattering surface layer sand and drying to obtain a surface layer shell;
(B) Dip-coating a transition layer coating material on the surface layer shell, scattering transition layer sand and drying to obtain a transition layer shell;
(C) After the transition layer shell is dip-coated with the reinforcing layer coating, the reinforcing layer sand is scattered and dried, repeating the steps of dip-coating the reinforcing layer coating, scattering the reinforcing layer sand and drying for 1 time to obtain a reinforcing layer shell;
(D) The reinforcing layer shell is coated with the slurry sealing layer coating in a dipping mode to obtain a shell;
(E) And (D) dewaxing and roasting the shell in the step (D) to obtain the silica sol shell.
The invention also provides a silica sol shell which is prepared by the preparation method of the silica sol shell.
Further, the thickness of the silica sol shell is 4 to 4.2mm.
Compared with the prior art, the invention has the beneficial effects that:
according to the preparation method of the silica sol shell, the carbon fibers are added into the shell, and each layer adopts proper components and proportion thereof, so that the thickness of the shell can be reduced, the strength of the shell can be maintained, the porosity of the shell is increased, the air permeability is improved, and the exhaust is facilitated.
The silica sol shell prepared by the preparation method of the silica sol shell has the characteristics of low thickness, large porosity, good air permeability, high-temperature strength and good deformability; after the silica sol shell prepared by the invention is poured, casting products with smooth surfaces, clear edges and corners, correct sizes and good quality can be obtained, and the qualification rate of castings, especially some thin-wall castings, blade castings and castings with airtight requirements is improved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without creative efforts.
FIG. 1 is a schematic flow diagram of a process for preparing a silica sol shell according to the present invention.
Fig. 2 is a schematic view of mullite powder and carbon fibers in a silica sol shell of the present invention.
FIG. 3 is a thickness test chart of a silica sol shell of example 1 of the present invention and a silica sol shell of comparative example 1.
FIG. 4 is a fluorescence detection plot of a cast article cast with the silica sol shell of example 1 in accordance with the present invention.
Drawings
1-mullite powder; 2-carbon fibers.
Detailed Description
The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings and the detailed description, but those skilled in the art will understand that the following described embodiments are some, not all, of the embodiments of the present invention, and are only used for illustrating the present invention, and should not be construed as limiting the scope of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention. The examples, in which specific conditions are not specified, were conducted under conventional conditions or conditions recommended by the manufacturer. The reagents or instruments used are conventional products which are not indicated by manufacturers and are commercially available.
The following is a detailed description of a silica sol shell and a method for preparing the same according to an embodiment of the present invention.
Referring to fig. 1, in some embodiments of the present invention there is provided a method of preparing a silica sol shell comprising: the method comprises the following steps of dipping and coating a surface layer coating, scattering surface layer sand, dipping and coating a transition layer coating, scattering transition layer sand, dipping and coating a reinforcing layer coating, scattering reinforcing layer sand and dipping and coating a sealing slurry layer coating in sequence on a module to obtain a shell; dewaxing and roasting the shell to obtain a silica sol shell;
the transition layer coating comprises the following components in parts by weight: 800-1000 parts of mullite powder, 0.8-1.2 parts of carbon fiber and 480-520 parts of silica sol;
the strengthening layer coating comprises the following components in parts by weight: 1400-1800 parts of mullite powder, 0.8-1.2 parts of carbon fiber and 480-520 parts of silica sol.
According to the preparation method of the silica sol shell, the carbon fibers are added into the silica sol shell, so that the silica sol shell can maintain the strength of the shell while the thickness of the shell is reduced, the porosity is increased, the air permeability is improved, and the air exhaust is facilitated.
In some embodiments of the invention, typically but not by way of limitation, the mullite powder may be present in the washcoat in a weight fraction of, for example, 800 parts, 810 parts, 820 parts, 830 parts, 840 parts, 850 parts, 860 parts, 870 parts, 880 parts, 890 parts, 900 parts, 910 parts, 920 parts, 930 parts, 940 parts, 950 parts, 960 parts, 970 parts, 980 parts, 990 parts, or 1000 parts, or the like; the weight portion of the carbon fiber can be 0.8 portion, 0.9 portion, 1 portion, 1.1 portion or 1.2 portions, etc.; the silica sol may be present in 480 parts, 490 parts, 500 parts, 510 parts, 520 parts, etc.
In some embodiments of the present invention, the reinforcing layer coating material may include, for example, typically but not limited to, 1400 parts, 1450 parts, 1500 parts, 1550 parts, 1600 parts, 1650 parts, 1700 parts, 1750 parts, 1800 parts, or the like of mullite powder; the weight portion of the carbon fiber can be 0.8 portion, 0.9 portion, 1 portion, 1.1 portion or 1.2 portions; the silica sol may be present in 480 parts, 490 parts, 500 parts, 510 parts or 520 parts.
In some embodiments of the present invention, the top coat comprises, in parts by weight: 19 to 21 parts of zircon powder, 6 to 8 parts of defoaming agent, 8 to 10 parts of wetting agent and 4.5 to 5.5 parts of silica sol.
In some embodiments of the present invention, the topcoat material comprises, in parts by weight: 19-21 parts of zircon powder, 6-8 parts of defoaming agent, 8-10 parts of wetting agent and 5 parts of silica sol.
In some embodiments of the invention, the zircon powder has a particle size of 300 to 350 mesh; preferably, the particle size of the zircon powder is 320 meshes; more preferably, zrO in zircon powder 2 The content of (A) is more than or equal to 65wt%.
In some embodiments of the invention, the silica sol is SiO 2 29 to 31 weight percent of Na 2 The content of O is less than or equal to 0.5 weight percent, and the pH value of the silica sol is 9.5-10.5. The silica sol in each layer of coating of the silica sol shell adopts the silica sol.
In some embodiments of the invention, the defoamer comprises a silicone defoamer and/or a polyether defoamer.
In some embodiments of the invention, wetting agents include WET-10T wetting agents and/or WET-10S wetting agents.
In some embodiments of the invention, a method of preparing a topcoat coating, comprises: uniformly mixing zircon powder, a defoaming agent, a wetting agent and silica sol to obtain a surface coating; preferably, blending includes stirring at a speed of 22 to 50 r/min.
In some embodiments of the invention, the face sand comprises corundum sand; preferably, al in corundum sand 2 O 3 The content of (B) is more than or equal to 98.5wt%.
In some embodiments of the invention, the grain size of the facing sand is 80 to 120 mesh; preferably, the grain size of the facing sand is 100 mesh.
In some embodiments of the present invention, the transition layer coating comprises, in parts by weight: 800-1000 parts of mullite powder, 0.8-1.2 parts of carbon fiber and 500 parts of silica sol.
In some embodiments of the invention, in the transition layer coating, the grain size of the mullite powder is 180-220 meshes; preferably, the particle size of the mullite powder is 200 meshes.
In some embodiments of the present invention, a method of preparing a transition layer coating, comprises: uniformly mixing mullite powder, carbon fiber and silica sol to obtain a transition layer coating; preferably, blending includes stirring at a speed of 22 to 50 r/min.
In some embodiments of the invention, the transition layer sand comprises mullite sand; preferably, the grain size of the transition layer sand is 50-70 meshes; more preferably, the transition layer sand has a particle size of 60 mesh.
In some embodiments of the present invention, the reinforcement layer coating comprises, in parts by weight: 1400-1800 parts of mullite powder, 0.8-1.2 parts of carbon fiber and 500 parts of silica sol.
In some embodiments of the invention, in the reinforcing layer coating, the grain size of the mullite powder is 180-220 meshes; preferably, the particle size of the mullite powder is 200 meshes.
In some embodiments of the present invention, a method of preparing a reinforcement coating, comprises: uniformly mixing mullite powder, carbon fiber and silica sol to obtain a reinforced layer coating; preferably, blending includes stirring at a speed of 22 to 50 r/min.
In some embodiments of the invention, the reinforcement sand comprises mullite sand; preferably, the grain size of the sand of the reinforcing layer is 25-35 meshes; more preferably, the grain size of the sand of the reinforcement layer is 30 mesh.
In some embodiments of the invention, the carbon fibers comprise carbon fibers for precision casting; preferably, the diameter of the carbon fiber is 15 to 25 μm, and the length of the carbon fiber is 0.8 to 1.2mm; more preferably, the diameter of the carbon fiber is 20 μm and the length of the carbon fiber is 1mm. The carbon fibers in the transition layer coating and the reinforcing layer coating are both the carbon fibers.
In some embodiments of the invention, the washcoat comprises mullite powder and silica sol; preferably, the mass ratio of the mullite powder to the silica sol is 5-9: 5; typically, but not limitatively, the mass ratio of mullite powder to silica sol is, for example, 5:5. 6: 5. 7: 5. 8:5 or 9:5, etc.
In some embodiments of the invention, the grain size of the mullite powder in the slurry seal coating is 180-220 meshes; preferably, the particle size of the mullite powder is 200 meshes.
In some embodiments of the invention, a method of preparing a sealer coating, comprises: uniformly mixing mullite powder and silica sol to obtain a sealing slurry layer coating; preferably, blending includes stirring at a speed of 22 to 50 r/min.
In the preparation method of the silica sol shell, each layer of the shell adopts proper raw materials and proportion thereof, so that the thickness of the shell can be reduced, the strength of the shell can be maintained, the consumption of refractory materials is reduced, and the preparation method is beneficial to environmental protection; meanwhile, the porosity of the mold shell can be increased, which is beneficial to exhaust, improves the metallurgical quality of products, reduces the pinhole defect of castings, and effectively improves the qualification rate of products.
In some embodiments of the invention, the temperature of roasting is 800-850 ℃, and the time of roasting is 2-4 h; typical but non-limiting examples of the firing temperature include 800 ℃, 805 ℃, 810 ℃, 815 ℃, 820 ℃, 825 ℃, 830 ℃, 835 ℃, 840 ℃, 845 ℃, 850 ℃ and the like; the roasting time is 2h, 2.5h, 3h, 3.5h or 4h, etc.
In some embodiments of the invention, firing comprises: raising the temperature to 800-850 ℃ at the speed of less than or equal to 200 ℃/h, carrying out heat preservation treatment for 2-4 h, and cooling the furnace to below 200 ℃.
In some embodiments of the invention, the firing temperature is 810 to 850 ℃.
In some embodiments of the invention, the oxygen content during firing is 19% to 23%.
In some embodiments of the invention, a method for preparing a silica sol shell comprises the steps of:
(A) Dip-coating the die set with surface layer coating, scattering surface layer sand and drying to obtain a surface layer shell;
(B) Dip-coating a transition layer coating on the surface layer shell, scattering transition layer sand and drying to obtain a transition layer shell;
(C) After the transition layer shell is dip-coated with the reinforcing layer coating, the reinforcing layer sand is scattered and dried, repeating the steps of dip-coating the reinforcing layer coating, scattering the reinforcing layer sand and drying for 1 time to obtain a reinforcing layer shell;
(D) The reinforcing layer shell is coated with the slurry coating to obtain a shell;
(E) And (D) dewaxing and roasting the shell in the step (D) to obtain a silica sol shell.
In some embodiments of the invention, in step (a), a method of preparing a module, comprises: preparing a wax mold, a pouring gate, a water gap and a pouring cup which are consistent with the shape of a casting and meet the requirement of dimensional tolerance by adopting an SL996 medium-temperature wax tool, and then combining the wax mold, the pouring gate, the water gap and the pouring cup in a group-by-group mode to obtain a module; preferably, the preparation includes using a model IP62 dual station wax injector and a 7075 aluminum alloy die.
In some embodiments of the invention, in the step (a), the die set is slowly immersed into the surface layer coating to obtain a die set with a surface layer coating uniformly and fully adhered on the surface, and then the surface layer sand is spread and dried to obtain a surface layer shell; preferably, applying the facing sand comprises uniformly covering the entire surface of the die set coated with the facing paint with a layer of facing sand.
In some embodiments of the present invention, in the step (B), the surface-layer shell is slowly immersed in the transition layer coating to obtain a module with a surface substantially uniformly coated with the transition layer coating; then scattering transition layer sand, and drying to obtain a transition layer shell; preferably, the step of spreading the transition layer sand comprises uniformly covering the whole surface of the die set which is stained with the transition layer paint with a layer of the transition layer sand.
In some embodiments of the invention, in the step (B), the surface-layer shell is immersed in the transition layer coating for the first immersion, after the first immersion, the material control is performed, and after the material control for 20 seconds, the surface-layer shell is immersed in the transition layer coating for the second immersion, so as to obtain the module with the surface being sufficiently and uniformly coated with the transition layer coating.
In some embodiments of the present invention, in the step (C), the transition layer shell is dipped into the reinforcement layer coating to obtain a module having a surface substantially uniformly coated with a layer of reinforcement layer coating, and then reinforcement layer sand is scattered; then repeating the operation for 1 time to obtain a reinforcing layer shell; preferably, the step of applying the sand to the reinforcement layer includes covering the entire surface of the mold block coated with the coating material with the sand to be the reinforcement layer uniformly.
In some embodiments of the invention, in the step (C), the transition layer shell is immersed in the reinforcing layer coating for a first immersion, after the first immersion, the material control is performed, and after the material control for 20 seconds, the transition layer shell is immersed in the reinforcing layer coating for a second immersion, so as to obtain the module with the surface being substantially and uniformly coated with the reinforcing layer coating.
In some embodiments of the present invention, in the step (D), after the floating sand of the reinforcement shell is cleaned, the reinforcement shell is immersed into the slurry-sealing coating to obtain a mold set with a substantially uniform surface coated with the slurry-sealing coating, and the mold set is dried to obtain the shell.
In some embodiments of the invention, the accumulation and sagging phenomena are strictly prohibited during the process of dip coating each layer of the coating. After dip coating, if the phenomena of missing coating and accumulation at deep holes occur, manual material supplement is needed.
In some embodiments of the invention, in step (E), the temperature of dewaxing is 163 to 173 ℃ and the pressure of dewaxing is 0.7 to 0.8MPa.
In some embodiments of the invention, a silica sol shell is provided, which is prepared by the above preparation method of the silica sol shell.
In some embodiments of the invention, the silica sol shell has a thickness of 4 to 4.2mm.
Referring to fig. 2, in some embodiments of the invention, the silica sol shell includes mullite powder 1 and carbon fibers 2.
In some embodiments of the invention, the silica sol shell comprises 1 face layer, 1 transition layer, 2 reinforcement layers, and 1 grout layer; the silica sol shell includes 1 bed surface layer dope layer, 1 bed surface layer sand bed, 1 transition layer dope layer, 1 transition layer sand bed, 2 layers of strengthening layer dope layer, 2 layers of strengthening layer sand bed and 1 layer of sealing coat dope layer.
The silica sol shell has the characteristics of low thickness, good air permeability, high-temperature strength and good deformability, and casting products with smooth surfaces, clear edges and corners, correct sizes and good quality can be obtained after the silica sol shell prepared by the method is poured, so that the subsequent work of polishing and removing defects of the products is reduced, the work intensity of field workers can be greatly reduced, and the work efficiency is improved; in addition, the silica sol shell has wide application range and can meet the casting requirements of most of alloys such as Al, mg and the like and precision products; the process is simple, the process flow is easy to form batch operation, and the production efficiency is improved.
Example 1
The preparation method of the silica sol shell provided by the embodiment comprises the following steps:
(1) The wax mold, the pouring channel, the water gap and the pouring cup which are consistent with the shape of the casting and meet the requirement of dimensional tolerance are prepared by adopting a model IP62 double-station wax pressing machine, SL996 medium-temperature wax and 7075 aluminum alloy mold, and then the module is combined in a one-by-one mode.
(2) Mixing 320-mesh zircon powder (ZrO) 2 Not less than 65 wt%), organosilicon defoaming agent 7, WET-10S wetting agent 9 and silica Sol (SiO) 2 30% +/-1% by weight, na 2 O is less than or equal to 0.5 weight percent, the pH is 9.5-10.5) 5 parts are added into a stirring barrel, stirred at 22-50 r/min and uniformly mixed to obtain the surface coating.
(3) Slowly dipping the die set into the topcoat coating at an angle of 30 ° ± 2 °Slightly rotating, eliminating air wrapped at the groove and the sharp corner of the module by using a brush or a writing brush to enable the module to be uniformly stained with a layer of surface coating, strictly preventing the phenomena of material accumulation and sagging, controlling the material after the completion, and soaking the module into the surface coating again for the second time after the material is controlled for 20 s; then the module with the surface layer coating is stretched into a sand spraying machine and rotated up and down, left and right to ensure that the whole surface of the module is uniformly covered with a layer of 100-mesh corundum sand (Al) 2 O 3 Not less than 98.5 wt%), and then hanging on a rack for drying to obtain the surface layer shell.
(4) 900 parts of 200-mesh mullite powder, 1 part of carbon fiber (diameter 20 mu m and length 1 mm) for precision casting and silica Sol (SiO) 2 30% +/-1% by weight, na 2 O is less than or equal to 0.5wt percent, the pH is 9.5-10.5) 500 parts, the mixture is added into a stirring barrel and stirred at the speed of 22-50 r/min, and the transition layer coating is obtained after uniform mixing.
(5) Immersing the surface layer shell into the transition layer coating for the first time, controlling the material after the first time immersion, immersing the surface layer shell into the transition layer coating for the second time immersion after the material control for 20s, and obtaining a module with the surface fully and uniformly adhered with a layer of transition layer coating; and stretching the module stained with the transition layer coating into a sand drenching machine, rotating the module up and down and left and right to enable the whole surface of the module to be uniformly covered with a layer of 60-mesh mullite sand, and then hanging the module on a rack for drying to obtain the transition layer shell.
(6) 1600 portions of 200-mesh mullite powder, 1 portion of carbon fiber (diameter is 20 mu m, length is 1 mm) for precision casting and silica Sol (SiO) 2 30% +/-1% by weight, na 2 O is less than or equal to 0.5wt percent, the pH is 9.5-10.5) 500 parts, and the mixture is added into a stirring barrel and stirred at the speed of 22-50 r/min, and the reinforcing layer coating is obtained after uniform mixing.
(7) Immersing the transition layer shell into the reinforcing layer coating for the first time, controlling the material after the first time immersion, immersing the transition layer shell into the reinforcing layer coating for the second time immersion after the material control for 20s, and obtaining a module with the surface fully and uniformly stained with a layer of reinforcing layer coating; and stretching the module adhered with the reinforcing coating into a sand drenching machine, rotating the module up and down and left and right to enable the whole surface of the module to be uniformly covered with a layer of 30-mesh mullite sand, and then hanging the module on a rack for drying.
(8) And (5) repeating the step (7) for 1 time to obtain the reinforcing layer shell.
(9) And (3) mixing the following components in a mass ratio of 7:5 of 200 mesh mullite powder and silica Sol (SiO) 2 30wt% +/-1 wt%, na 2 O is less than or equal to 0.5 weight percent, and the pH value is 9.5-10.5) is added into a stirring barrel, the stirring is carried out at 22-50 r/min, and the sealing slurry layer coating is obtained after the uniform mixing.
(10) Cleaning floating sand of the reinforcing layer shell by using compressed air, slowly immersing the reinforcing layer shell into the surface layer coating at an angle of 30 +/-2 degrees, slightly rotating, eliminating air wrapped at the groove and the sharp corner of the module by using a brush or a writing brush, uniformly coating the reinforcing layer shell with a layer of slurry sealing layer coating, and strictly avoiding accumulation and sagging; and then hanging the shell on a rack for drying to obtain the shell.
(11) Removing the redundant mould shell at the sprue cup edge of the mould shell in the step (10), and punching the position of a pouring gate to form a size
The wax removing hole; then quickly transferring the mixture into a steam dewaxing kettle, closing a machine door, opening a steam valve, enabling the pressure to reach 0.6MPa within 10s and the temperature to reach 160 ℃, and dewaxing.
(12) Heating the dewaxed shell to 800 ℃ at the speed of 200 ℃/h, carrying out heat preservation treatment for 4h, wherein the oxygen content is 19-23% in the heat preservation treatment process, and cooling the shell to below 200 ℃ in a furnace to obtain the silica sol shell.
Example 2
The preparation method of the silica sol shell provided in this example refers to example 1, with the only difference that:
in the step (2), 320-mesh zircon powder (ZrO) 2 Not less than 65wt percent) 19 parts, silicone defoamer 6 parts, WET-10S wetting agent 8 parts and silica Sol (SiO) 2 30wt% +/-1 wt%, na 2 O is less than or equal to 0.5wt percent, the pH is 9.5-10.5) 5 parts are added into a stirring barrel, stirred at 22-50 r/min and evenly mixed to obtain the surface coating.
In the step (4), 800 parts of 200-mesh mullite powder, 1 part of carbon fiber (diameter is 20 mu m, length is 1 mm) for precision casting and 1 part of silica Sol (SiO) 2 30wt% +/-1 wt%, na 2 O is less than or equal to 0.5wt percent and the pH is 9.5 to 10.5) 500 parts are added into a stirring barrel and fed at 22 to 50r/minStirring and mixing uniformly to obtain the transition layer coating.
In the step (6), 1800 parts of 200-mesh mullite powder, 1 part of carbon fiber (diameter 20 mu m and length 1 mm) for precision casting and silica Sol (SiO) 2 30wt% +/-1 wt%, na 2 O is less than or equal to 0.5 weight percent, the pH is 9.5 to 10.5) 500 parts by weight are added into a stirring barrel, stirred at 22 to 50r/min and evenly mixed to obtain the coating of the reinforcing layer.
In the step (9), the mass ratio of the mullite powder to the silica sol is 5:5.
example 3
The preparation method of the silica sol shell provided in this example refers to example 1, with the only difference that:
in the step (2), 320-mesh zircon powder (ZrO) 2 Not less than 65wt percent), 8 parts of organic silicon defoamer, 10 parts of WET-10S wetting agent and silica Sol (SiO) 2 30% +/-1% by weight, na 2 O is less than or equal to 0.5 weight percent, the pH is 9.5-10.5) 5 parts are added into a stirring barrel, stirred at 22-50 r/min and uniformly mixed to obtain the surface coating.
In the step (4), 1000 parts of 200-mesh mullite powder, 1 part of carbon fiber (diameter 20 mu m and length 1 mm) for precision casting and silica Sol (SiO) 2 30wt% +/-1 wt%, na 2 O is less than or equal to 0.5 weight percent, the pH is 9.5 to 10.5) 500 parts by weight are added into a stirring barrel, stirred at 22 to 50r/min and evenly mixed to obtain the transition layer coating.
In the step (6), 1400 parts of 200-mesh mullite powder, 1 part of carbon fiber (diameter 20 mu m and length 1 mm) for precision casting and silica Sol (SiO) 2 30% +/-1% by weight, na 2 O is less than or equal to 0.5wt percent, the pH is 9.5-10.5) 500 parts, and the mixture is added into a stirring barrel and stirred at the speed of 22-50 r/min, and the reinforcing layer coating is obtained after uniform mixing.
In the step (9), the mass ratio of the mullite powder to the silica sol is 9:5.
comparative example 1
The preparation method of the silica sol shell provided by the comparative example comprises the following steps:
(1) The wax mold, the pouring channel, the water gap and the pouring cup which are consistent with the shape of the casting and meet the requirement of dimensional tolerance are prepared by adopting a model IP62 double-station wax pressing machine, SL996 medium-temperature wax and 7075 aluminum alloy mold, and then the module is combined in a one-by-one mode.
(2) Mixing 320-mesh zircon powder (ZrO) 2 Not less than 65wt percent), organosilicon defoamer 7, WET-10S wetting agent 9 and silica Sol (SiO) 2 30wt% +/-1 wt%, na 2 O is less than or equal to 0.5wt percent, the pH is 9.5-10.5) 5 parts are added into a stirring barrel, stirred at 22-50 r/min and evenly mixed to obtain the surface coating.
(3) Slowly immersing the module into the surface layer coating at an angle of 30 +/-2 degrees, slightly rotating, eliminating air wrapped at the groove and the sharp corner of the module by using a brush or a writing brush to enable the module to be uniformly stained with the surface layer coating, strictly preventing the phenomena of material accumulation and sagging, controlling the material after the completion, and immersing the module into the surface layer coating again for the second time after the material is controlled for 20 s; then the module with the surface coating is stretched into a sand drenching machine and rotated up and down and left and right to ensure that the whole surface of the module is uniformly covered with a layer of 100-mesh corundum (Al) sand 2 O 3 Not less than 98.5 wt%), and then hanging on a rack for drying to obtain a surface layer shell.
(4) 900 parts of 200-mesh mullite powder and silica Sol (SiO) 2 30% +/-1% by weight, na 2 O is less than or equal to 0.5 weight percent, the pH is 9.5 to 10.5) 500 parts by weight are added into a stirring barrel, stirred at 22 to 50r/min and evenly mixed to obtain the transition layer coating.
(5) Immersing the surface layer shell into the transition layer coating for the first time, controlling the material after the first time immersion, immersing the surface layer shell into the transition layer coating for the second time immersion after the material control for 20s, and obtaining a module with the surface fully and uniformly adhered with a layer of transition layer coating; and stretching the module stained with the transition layer coating into a sand drenching machine, rotating the module up and down and left and right to enable the whole surface of the module to be uniformly covered with a layer of 60-mesh mullite sand, and then hanging the module on a rack for drying to obtain the transition layer shell.
(6) 1600 portions of 200-mesh mullite powder and silica Sol (SiO) 2 30wt% +/-1 wt%, na 2 O is less than or equal to 0.5 weight percent, the pH is 9.5 to 10.5) 500 parts by weight are added into a stirring barrel, stirred at 22 to 50r/min and evenly mixed to obtain the coating of the reinforcing layer.
(7) Immersing the transition layer shell into the strengthening layer coating for primary material immersion, controlling the material after the primary material immersion, immersing the transition layer shell into the strengthening layer coating for secondary material immersion after the material control is performed for 20s, and obtaining a module with a surface fully and uniformly stained with a layer of strengthening layer coating; and (3) stretching the module dipped with the reinforcing coating into a sand spraying machine, rotating up and down and left and right to uniformly cover a layer of 30-mesh mullite sand on the whole surface of the module, and hanging the module on a rack for drying.
(8) And (5) repeating the step (7) for 2 times to obtain the reinforcing layer shell.
(9) And (3) mixing the following components in a mass ratio of 7:5 mullite powder of 200 mesh and silica Sol (SiO) 2 30% +/-1% by weight, na 2 O is less than or equal to 0.5 weight percent, and the pH value is 9.5-10.5) is added into a stirring barrel, the stirring is carried out at 22-50 r/min, and the sealing slurry layer coating is obtained after the uniform mixing.
(10) Cleaning floating sand of the reinforcing layer shell by using compressed air, slowly immersing the reinforcing layer shell into the surface layer coating at an angle of 30 +/-2 degrees, slightly rotating, eliminating air wrapped at the groove and the sharp corner of the module by using a brush or a writing brush, uniformly coating the reinforcing layer shell with a layer of slurry sealing layer coating, and strictly avoiding accumulation and sagging; and then hanging the shell on a rack for drying to obtain the shell.
(11) Removing the redundant mould shell at the sprue cup edge of the mould shell in the step (10), and punching the position of a pouring gate to form a size
The wax removing hole; then quickly transferring the mixture into a steam dewaxing kettle, closing a machine door, opening a steam valve, enabling the pressure to reach 0.6MPa within 10s and the temperature to reach 160 ℃, and dewaxing.
(12) Heating the dewaxed shell to 800 ℃ at the speed of 200 ℃/h, carrying out heat preservation treatment for 4h, wherein the oxygen content is 19-23% in the heat preservation treatment process, and cooling the shell to below 200 ℃ in a furnace to obtain the silica sol shell.
Test example 1
The thickness of the silica sol type shells of example 1 and comparative example 1 was measured, and the results are shown in fig. 3. Wherein, a in fig. 3 is the thickness of the silica sol shell of example 1; in fig. 3 b is the thickness of the silica sol shell of comparative example 1.
As is clear from FIG. 3, the thickness of the silica sol shell of example 1 was 4.05mm, and the thickness of the silica sol shell of comparative example 1 was 5.03mm.
The strength of the silica sol shells of example 1 and comparative example 1 was tested using a manual failure formwork test.
The wet and dry strength of the silica sol shell of example 1 was higher than that of the silica sol shell of comparative example 1.
Test example 2
Casting was carried out using the silica sol shell of example 1; the casting is a small thin-wall structural part made of ZL205A and has the following external dimensions: 240mm multiplied by 120mm multiplied by 20mm, and the thinnest wall thickness is 3mm; the phenomena of fire running and insufficient pouring do not occur in the silica sol shell in the pouring process, and the strength and the air permeability of the silica sol shell meet the use requirements.
The cast product after pouring was subjected to fluorescence detection, and the results are shown in fig. 4.
As can be seen from figure 4, the fluorescent detection of the surface of the casting does not have the defects of standard exceeding, pinholes, cracks and the like, and the air permeability and the deformability of the surface silica sol shell meet the use requirements.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and these modifications or substitutions do not depart from the spirit of the corresponding technical solutions of the embodiments of the present invention.
Claims (10)
1. A method for preparing a silica sol shell, comprising: sequentially carrying out dip coating of a surface layer coating, scattering of surface layer sand, dip coating of a transition layer coating, scattering of transition layer sand, dip coating of a reinforcing layer coating, scattering of reinforcing layer sand and dip coating of a sealing slurry layer coating on the module to obtain a shell; dewaxing and roasting the shell to obtain the silica sol shell;
the transition layer coating comprises the following components in parts by weight: 800-1000 parts of mullite powder, 0.8-1.2 parts of carbon fiber and 480-520 parts of silica sol;
the reinforced layer coating comprises the following components in parts by weight: 1400-1800 parts of mullite powder, 0.8-1.2 parts of carbon fiber and 480-520 parts of silica sol.
2. The method of claim 1, wherein the topcoat coating comprises, in parts by weight: 19-21 parts of zircon powder, 6-8 parts of defoaming agent, 8-10 parts of wetting agent and 4.5-5.5 parts of silica sol;
preferably, the particle size of the zircon powder is 300-350 meshes;
preferably, the facing sand comprises corundum sand;
preferably, the grain size of the surface sand is 80-120 meshes.
3. The method for preparing a silica sol shell according to claim 1, wherein the grain size of mullite powder in the coating of the transition layer is 180-220 meshes;
preferably, the transition layer sand comprises mullite sand;
preferably, the grain size of the transition layer sand is 50-70 meshes.
4. The method for preparing a silica sol shell according to claim 1, wherein the grain size of mullite powder in the coating of the reinforcing layer is 180-220 meshes;
preferably, the reinforcement sand comprises mullite sand;
preferably, the grain size of the reinforcing layer sand is 25-35 meshes.
5. The method for preparing a silica sol shell mold according to claim 1, wherein the carbon fibers comprise carbon fibers for precision casting;
preferably, the diameter of the carbon fiber is 15 to 25 μm, and the length of the carbon fiber is 0.8 to 1.2mm.
6. The method of preparing a silica sol shell mold according to claim 1, wherein the washcoat comprises mullite powder and silica sol;
preferably, the mass ratio of the mullite powder to the silica sol is 5-9: 5;
preferably, in the slurry seal coating, the grain diameter of the mullite powder is 180-220 meshes.
7. The method for preparing a silica sol shell according to claim 1, wherein the calcination temperature is 800-850 ℃ and the calcination time is 2-4 h;
preferably, the roasting comprises: raising the temperature to 800-850 ℃ at the speed of less than or equal to 200 ℃/h, carrying out heat preservation treatment for 2-4 h, and cooling the furnace to below 200 ℃.
8. A method of preparing a silica sol shell according to any one of claims 1 to 7, characterized in that it comprises the steps of:
(A) Dip-coating the die set with surface layer coating, scattering surface layer sand and drying to obtain a surface layer shell;
(B) Dip-coating a transition layer coating material on the surface layer shell, scattering transition layer sand and drying to obtain a transition layer shell;
(C) After the transition layer shell is dip-coated with the reinforcing layer coating, the reinforcing layer sand is scattered and dried, repeating the steps of dip-coating the reinforcing layer coating, scattering the reinforcing layer sand and drying for 1 time to obtain a reinforcing layer shell;
(D) The reinforcing layer shell is coated with the slurry sealing layer coating in a dipping mode to obtain a shell;
(E) And (D) dewaxing and roasting the shell to obtain the silica sol shell.
9. A silica sol shell according to any one of claims 1 to 8, which is produced by the process for producing a silica sol shell.
10. A silica sol shell according to claim 9, characterized in that the silica sol shell has a thickness of 4 to 4.2mm.
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