CN117383947A - 一种无发热的自硬芯料及制备方法 - Google Patents
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- 239000011162 core material Substances 0.000 title claims abstract description 67
- 238000010438 heat treatment Methods 0.000 title claims abstract description 12
- 238000002360 preparation method Methods 0.000 title abstract description 7
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims abstract description 32
- 235000019353 potassium silicate Nutrition 0.000 claims abstract description 29
- 229910001570 bauxite Inorganic materials 0.000 claims abstract description 25
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 claims abstract description 25
- 239000000843 powder Substances 0.000 claims abstract description 23
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 22
- 239000002002 slurry Substances 0.000 claims abstract description 22
- 229920002134 Carboxymethyl cellulose Polymers 0.000 claims abstract description 17
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 claims abstract description 17
- 239000001768 carboxy methyl cellulose Substances 0.000 claims abstract description 17
- 235000010948 carboxy methyl cellulose Nutrition 0.000 claims abstract description 17
- 239000008112 carboxymethyl-cellulose Substances 0.000 claims abstract description 17
- 239000006004 Quartz sand Substances 0.000 claims abstract description 16
- 150000002895 organic esters Chemical class 0.000 claims abstract description 16
- 239000004743 Polypropylene Substances 0.000 claims abstract description 14
- 239000013530 defoamer Substances 0.000 claims abstract description 14
- 239000000835 fiber Substances 0.000 claims abstract description 14
- -1 polypropylene Polymers 0.000 claims abstract description 14
- 229920001155 polypropylene Polymers 0.000 claims abstract description 14
- 239000002994 raw material Substances 0.000 claims abstract description 7
- 238000003756 stirring Methods 0.000 claims description 18
- 229910018072 Al 2 O 3 Inorganic materials 0.000 claims description 12
- 238000000034 method Methods 0.000 claims description 12
- 238000006243 chemical reaction Methods 0.000 claims description 11
- 239000011734 sodium Substances 0.000 claims description 9
- 239000000395 magnesium oxide Substances 0.000 claims description 8
- 230000000694 effects Effects 0.000 claims description 4
- 239000004115 Sodium Silicate Substances 0.000 claims description 3
- 230000002411 adverse Effects 0.000 claims description 3
- 229910052799 carbon Inorganic materials 0.000 claims description 3
- 238000002156 mixing Methods 0.000 claims description 3
- 238000005245 sintering Methods 0.000 claims description 3
- 229910052911 sodium silicate Inorganic materials 0.000 claims description 3
- 239000002245 particle Substances 0.000 claims description 2
- 230000020169 heat generation Effects 0.000 claims 2
- 238000005495 investment casting Methods 0.000 abstract description 5
- 238000005266 casting Methods 0.000 description 7
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 7
- 239000011248 coating agent Substances 0.000 description 5
- 238000000576 coating method Methods 0.000 description 5
- 238000001879 gelation Methods 0.000 description 5
- 239000004576 sand Substances 0.000 description 5
- 229910019142 PO4 Inorganic materials 0.000 description 4
- 239000003513 alkali Substances 0.000 description 4
- 239000011230 binding agent Substances 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 239000010452 phosphate Substances 0.000 description 4
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 4
- 239000010935 stainless steel Substances 0.000 description 4
- 229910001220 stainless steel Inorganic materials 0.000 description 4
- 230000007613 environmental effect Effects 0.000 description 3
- 238000003837 high-temperature calcination Methods 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 239000003973 paint Substances 0.000 description 3
- 238000012795 verification Methods 0.000 description 3
- 229910000975 Carbon steel Inorganic materials 0.000 description 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 2
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 238000009835 boiling Methods 0.000 description 2
- 239000010962 carbon steel Substances 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 239000000701 coagulant Substances 0.000 description 2
- 238000004880 explosion Methods 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 2
- 229910052664 nepheline Inorganic materials 0.000 description 2
- 239000010434 nepheline Substances 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- USFZMSVCRYTOJT-UHFFFAOYSA-N Ammonium acetate Chemical compound N.CC(O)=O USFZMSVCRYTOJT-UHFFFAOYSA-N 0.000 description 1
- 239000005695 Ammonium acetate Substances 0.000 description 1
- 235000008733 Citrus aurantifolia Nutrition 0.000 description 1
- BOTDANWDWHJENH-UHFFFAOYSA-N Tetraethyl orthosilicate Chemical compound CCO[Si](OCC)(OCC)OCC BOTDANWDWHJENH-UHFFFAOYSA-N 0.000 description 1
- 235000011941 Tilia x europaea Nutrition 0.000 description 1
- 229910021502 aluminium hydroxide Inorganic materials 0.000 description 1
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 1
- 229940043376 ammonium acetate Drugs 0.000 description 1
- 235000019257 ammonium acetate Nutrition 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000005422 blasting Methods 0.000 description 1
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 description 1
- 239000000920 calcium hydroxide Substances 0.000 description 1
- 229910001861 calcium hydroxide Inorganic materials 0.000 description 1
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 238000010981 drying operation Methods 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 238000006703 hydration reaction Methods 0.000 description 1
- 239000000411 inducer Substances 0.000 description 1
- 239000004571 lime Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- CHWRSCGUEQEHOH-UHFFFAOYSA-N potassium oxide Chemical compound [O-2].[K+].[K+] CHWRSCGUEQEHOH-UHFFFAOYSA-N 0.000 description 1
- 229910001950 potassium oxide Inorganic materials 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 238000005488 sandblasting Methods 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- KKCBUQHMOMHUOY-UHFFFAOYSA-N sodium oxide Chemical compound [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 description 1
- 229910001948 sodium oxide Inorganic materials 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
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
-
- 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
-
- 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
- B22C1/04—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 protection of the casting, e.g. against decarbonisation
-
- 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
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
- B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
- B22C1/18—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of inorganic agents
- B22C1/183—Sols, colloids or hydroxide gels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/10—Cores; Manufacture or installation of cores
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/66—Monolithic refractories or refractory mortars, including those whether or not containing clay
Abstract
本发明公开了一种无发热的自硬芯料及制备方法,涉及熔模精密铸造领域,按照质量份数计原料的组成如为,硅溶胶23份、水玻璃1.8‑2.8份、铝钒土粉41‑51份、石英砂18‑28份、氢氧化铝4‑6份、聚丙烯纤维0.02‑0.04份、羧甲基纤维素0.08‑0.1份、消泡剂0.20‑0.26份、有机酯0.26‑0.30份,将上述原料加入容器中搅拌并混合以制成所需的浆料,然后将浆料倒入底部密封的蜡模空腔或型芯模具中并静置,以使浆料胶凝形成所需要的型芯,采用本发明的配方开发的自硬芯料环保性好,配制的浆料均匀且不发热,可以直接灌入蜡模中形成型芯,胶凝速度可调,型芯湿强度好,脱蜡、焙烧和浇注等过程无断裂,型芯通过抛丸和喷砂等机械方式可去除,综合成本仅为磷酸盐型自硬芯料的30%。
Description
技术领域
本发明属于熔模精密铸造领域,具体涉及一种无发热的自硬芯料及制备方法。
背景技术
熔模铸造是一种近净成形的先进工艺,比较适合于中小型复杂精铸件的生产。其主要的工艺流程是在一次性易熔模(通常为蜡模)模组表面重复进行浸涂料、撒砂和干燥操作,从而形成一定厚度的型壳,经过型壳脱蜡、型壳焙烧、浇注金属液、凝固冷却和脱壳等工序得到精铸件。生产具有深孔、深槽或复杂型腔的精铸件,往往要根据产品结构选用合适的型芯预置到蜡模中,或通过灌自硬芯料方式形成所需要的型腔。常用的陶瓷型芯使用成本高,清砂需要碱煮或碱爆,环保性差。自硬芯料灌浆成形所形成的型芯溃散性优于陶瓷型芯,清砂不需要碱煮或碱爆,应用范围不断扩大。
当前商品化的自硬芯料主要为磷酸盐型,该类型的自硬芯料配制浆料时会发生水化反应释放出大量的热量,无法与蜡模直接接触,只能在制壳的第二层或第三层甚至第四层后灌自硬芯浆料,以避免浆料释放出的热量将蜡模熔化掉导致模组报废,这样就制约了磷酸盐型自硬芯料的使用范围。
以硅溶胶胶为粘结剂,以石灰或氧化镁为促凝剂的自硬芯料,除了存在浆料发热问题,还存在固化后湿强度偏低的问题。以硅酸乙酯为粘结剂,以醋酸铵、氢氧化钙或氧化镁为促凝剂的自硬芯料,则存在盐酸污染,环保性差。
发明内容
本发明的目的在于提供一种无发热的自硬芯料及制备方法,以解决现有技术中导致的上述缺陷。
一种无发热的自硬芯料,按照质量份数计原料的组成如下:
硅溶胶23份、水玻璃1.8-2.8份、铝钒土粉41-51份、石英砂18-28份、氢氧化铝4-6份、聚丙烯纤维0.02-0.04份、羧甲基纤维素0.08-0.1份、消泡剂0.20-0.26份、有机酯0.26-0.30份。
进一步地,所述铝矾土粉中Al2O3含量不低于85%,Fe2O3含量不大于1.8%,CaO加MgO总含量不大于0.4%。
进一步地,所述铝矾土粉的粒度为200目-320目。
进一步地,所述氢氧化铝中的Al(OH)3在140~150℃的范围内脱水生成具有活性的γAl2O3,其反应方程式为:
其中,γAl2O3在800~950℃范围内与型壳中的自由Na2O或K2O反应生成高粘度的高温霞石相(Na2O·Al2O3·2SiO2或K2O·Al2O3·2SiO2),其反应方程式为:
其中,高温霞石相的耐火度可达1526℃,具有很好的高温性能,从而使Al(OH)3的加入可以消除水玻璃中Na2O或K2O的不良影响,以达到防止型芯高温烧结提高溃散性的目的。
本发明还提供了一种无发热的自硬芯料的制备方法,包括:
S100、将23份硅溶胶、1.8-2.8份水玻璃、41-51份铝矾土粉、0.08-0.1份羧甲基纤维素、4-6份氢氧化铝、18-28份石英砂、0.02-0.04份聚丙烯纤维、0.20-0.26份消泡剂、0.26-0.30份的有机酯加入容器中并搅拌混合,以制成所需的浆料;
S200、将浆料倒入底部密封的蜡模空腔或型芯模具中并静置,以使浆料胶凝形成所需要的型芯。
进一步地,所述S100包括:
S101、向容器中依次加入23份硅溶胶和1.8-2.8份水玻璃,并在加入水玻璃的过程中进行搅拌,直至硅溶胶与水玻璃均匀混合;
S102、待硅溶胶与水玻璃均匀混合后继续搅拌1分钟,并在搅拌过程中向容器中加入41-51份铝矾土粉和0.08-0.1份羧甲基纤维素;
S103、向容器中依次加入4-6份氢氧化铝、18-28份石英砂、0.02-0.04份聚丙烯纤维和0.20-0.26份消泡剂,并搅拌2-5分钟;
S104、向容器中加入0.26-0.30份的有机酯并搅拌,以制成所需的浆料。
本发明的优点在于:
采用本发明的配方开发的自硬芯料环保性好,配制的浆料均匀且不发热,可以直接灌入蜡模中形成型芯,胶凝速度可调,型芯湿强度好,脱蜡、焙烧和浇注等过程无断裂,用于生产碳钢和不锈钢件表面质量符合要求,型芯通过抛丸和喷砂等机械方式可去除,综合成本仅为磷酸盐型自硬芯料的30%。
附图说明
图1为某不锈钢管类铸件用型芯三维造型图。
图2为采用本发明的自硬芯料生产的型芯。
图3为表1(生产验证结果表格)。
具体实施方式
为使本发明实现的技术手段、创作特征、达成目的与功效易于明白了解,下面结合具体实施方式,进一步阐述本发明。
一种无发热的自硬芯料,按照质量份数计原料的组成如下:
硅溶胶23份、水玻璃1.8-2.8份、铝钒土粉41-51份、石英砂18-28份、氢氧化铝4-6份、聚丙烯纤维0.02-0.04份、羧甲基纤维素0.08-0.1份、消泡剂0.20-0.26份、有机酯0.26-0.30份。
所述铝矾土粉中Al2O3含量不低于85%,Fe2O3含量不大于1.8%,CaO加MgO总含量不大于0.4%。
所述铝矾土粉的粒度为200目-320目。
所述氢氧化铝中的Al(OH)3在140~150℃的范围内脱水生成具有活性的γAl2O3,其反应方程式为:
其中,γAl2O3在800~950℃范围内与型壳中的自由Na2O或K2O反应生成高粘度的高温霞石相(Na2O·Al2O3·2SiO2或K2O·Al2O3·2SiO2),其反应方程式为:
其中,高温霞石相的耐火度可达1526℃,具有很好的高温性能,从而使Al(OH)3的加入可以消除水玻璃中Na2O或K2O的不良影响,以达到防止型芯高温烧结提高溃散性的目的。
本发明还提供了一种无发热的自硬芯料的制备方法,包括:
S100、将23份硅溶胶、1.8-2.8份水玻璃、41-51份铝矾土粉、0.08-0.1份羧甲基纤维素、4-6份氢氧化铝、18-28份石英砂、0.02-0.04份聚丙烯纤维、0.20-0.26份消泡剂、0.26-0.30份的有机酯加入容器中并搅拌混合,以制成所需的浆料;
S200、将浆料倒入底部密封的蜡模空腔或型芯模具中并静置,以使浆料胶凝形成所需要的型芯。
进一步地,所述S100包括:
S101、向容器中依次加入23份硅溶胶和1.8-2.8份水玻璃,并在加入水玻璃的过程中进行搅拌,直至硅溶胶与水玻璃均匀混合;
S102、待硅溶胶与水玻璃均匀混合后继续搅拌1分钟,并在搅拌过程中向容器中加入41-51份铝矾土粉和0.08-0.1份羧甲基纤维素;
S103、向容器中依次加入4-6份氢氧化铝、18-28份石英砂、0.02-0.04份聚丙烯纤维和0.20-0.26份消泡剂,并搅拌2-5分钟;
S104、向容器中加入0.26-0.30份的有机酯并搅拌,以制成所需的浆料。
本自硬芯料胶凝原理:有机酯无法让硅溶胶涂料胶凝,15%以内的水玻璃也不能让硅溶胶涂料胶凝,本发明以一定量的水玻璃为诱发剂,通过有机酯促进水玻璃胶凝,水玻璃胶凝诱发整个硅溶胶涂料体系胶凝,从而达到自硬的目的。
各组分的作用:硅溶胶是自硬芯料的粘结剂,胶凝干燥后硅氧键形成三维网络结构将砂粉连接成一个整体;水玻璃是促进自硬芯料体系胶凝的诱发剂,有机酯是水玻璃环保型固化剂,通过有机酯促进水玻璃胶凝,水玻璃胶凝诱发整个硅溶胶涂料体系胶凝,实现芯料可控自硬,同时水玻璃还起到辅助粘结剂的作用,提高型芯的常温强度;铝钒土粉和石英砂是骨料,三氧化二铝含量为85%以上的铝钒土粉熟料可跟碳钢和不锈钢金属液直接接触而不会发生粘砂反应,石英砂可以调整芯料凝固后的收缩率,同时提高型芯的溃散性,有铝钒土粉的包裹,石英砂不会与金属液大面积直接接触,从而避免发生粘砂反应;氢氧化铝低温下生成γAl2O3,在高温条件下γAl2O3与水玻璃中的氧化钠或氧化钾生成高温霞石相,防止涂料烧结提高溃散性;聚丙烯纤维和羧甲基纤维素起提高涂料悬浮性、常温强度和溃散性的作用;消泡剂起消除涂料气泡的作用。
实例1:
按照质量份数计原料的组成为,硅溶胶23份、水玻璃1.8份、铝钒土粉41份、石英砂28份、氢氧化铝4份、聚丙烯纤维0.02份、CMC(羧甲基纤维素)0.08份、消泡剂0.20份、有机酯0.26份。
铝钒土熟料优选:经高温煅烧后的熟料,Al2O3含量85%-88%,Fe2O3含量不大于1.8%,CaO加MgO总含量不大于0.4%,粒度为270目。
实例2:
按照质量份数计原料的组成为,硅溶胶23份、水玻璃2.3份、铝钒土粉46份、石英砂23份、氢氧化铝5份、聚丙烯纤维0.03份、CMC(羧甲基纤维素)0.09份、消泡剂0.23份、有机酯0.28份。
铝钒土熟料优选:经高温煅烧后的熟料,Al2O3含量85%-88%,Fe2O3含量不大于1.8%,CaO加MgO总含量不大于0.4%,粒度为270目。
实例3:
按照质量份数计原料的组成为,硅溶胶23份、水玻璃2.8份、铝钒土粉51份、石英砂18份、氢氧化铝6份、聚丙烯纤维0.04份、CMC(羧甲基纤维素)0.1份、消泡剂0.26份、有机酯0.3份。
铝钒土熟料优选:经高温煅烧后的熟料,Al2O3含量85%-88%,Fe2O3含量不大于1.8%,CaO加MgO总含量不大于0.4%,粒度为270目。
生产验证:以某不锈钢管类铸件(单重4.4kg)生产用的型芯为载体进行本自硬芯料生产验证,型芯的三维造型见图1。分别按实例1、实例2和实例3的材料配比配制浆料,将浆料倒入蜡模空腔中制成相应的型芯(见图2),同时制作相应的强度试样及对比试样。试样放置24小时后测试常温抗弯强度;试样经1050℃保温1小时焙烧后取出冷却至室温,然后测试压溃强度(与溃散性呈反比)。分别采用3种实例制作的型芯及对比型芯生产出相应的铸件,并对铸件的型腔表面质量和型芯溃散性进行评价。相关的验证结果见表1(图3),从表1的结果可以看出,分别用实例1、实例2、实例3制作的试样,常温抗弯强度高于对比试样,而压溃强度略低于磷酸型自硬芯料、远低于常规涂料,说明溃散性很好;分别用实例1、实例2、实例3制作的型芯,铸件型腔表面质量均优于对比型芯,满足质量要求,溃散性能均达到要求,而磷酸盐型自硬芯料由于发热导致蜡模表面被破坏,铸件型腔表面质量不符合要求。
由技术常识可知,本发明可以通过其它的不脱离其精神实质或必要特征的实施方案来实现。因此,上述公开的实施方案,就各方面而言,都只是举例说明,并不是仅有的。所有在本发明范围内或在等同于本发明的范围内的改变均被本发明包含。
Claims (6)
1.一种无发热的自硬芯料,其特征在于,按照质量份数计原料的组成如下:
硅溶胶23份、水玻璃1.8-2.8份、铝钒土粉41-51份、石英砂18-28份、氢氧化铝4-6份、聚丙烯纤维0.02-0.04份、羧甲基纤维素0.08-0.1份、消泡剂0.20-0.26份、有机酯0.26-0.30份。
2.根据权利要求1所述的一种无发热的自硬芯料,其特征在于,所述铝矾土粉中Al2O3含量不低于85%,Fe2O3含量不大于1.8%,CaO加MgO总含量不大于0.4%。
3.根据权利要求1所述的一种无发热的自硬芯料,其特征在于,所述铝矾土粉的粒度为200目-320目。
4.根据权利要求1所述的一种无发热的自硬芯料,其特征在于,所述氢氧化铝中的Al(OH)3在140~150℃的范围内脱水生成具有活性的γAl2O3,其反应方程式为:
其中,γAl2O3在800~950℃范围内与型壳中的自由Na2O或K2O反应生成高粘度的高温霞石相(Na2O·Al2O3·2SiO2或K2O·Al2O3·2SiO2),其反应方程式为:
其中,高温霞石相的耐火度可达1526℃,具有很好的高温性能,从而使Al(OH)3的加入可以消除水玻璃中Na2O或K2O的不良影响,以达到防止型芯高温烧结提高溃散性的目的。
5.一种用于权利要求1-4任意一项所述的无发热的自硬芯料的制备方法,其特征在于,包括:
S100、将23份硅溶胶、1.8-2.8份水玻璃、41-51份铝矾土粉、0.08-0.1份羧甲基纤维素、4-6份氢氧化铝、18-28份石英砂、0.02-0.04份聚丙烯纤维、0.20-0.26份消泡剂、0.26-0.30份的有机酯加入容器中并搅拌混合,以制成所需的浆料;
S200、将浆料倒入底部密封的蜡模空腔或型芯模具中并静置,以使浆料胶凝形成所需要的型芯。
6.根据权利要求5所述的一种无发热的自硬芯料的制备方法,其特征在于,所述S100包括:
S101、向容器中依次加入23份硅溶胶和1.8-2.8份水玻璃,并在加入水玻璃的过程中进行搅拌,直至硅溶胶与水玻璃均匀混合;
S102、待硅溶胶与水玻璃均匀混合后继续搅拌1分钟,并在搅拌过程中向容器中加入41-51份铝矾土粉和0.08-0.1份羧甲基纤维素;
S103、向容器中依次加入4-6份氢氧化铝、18-28份石英砂、0.02-0.04份聚丙烯纤维和0.20-0.26份消泡剂,并搅拌2-5分钟;
S104、向容器中加入0.26-0.30份的有机酯并搅拌,以制成所需的浆料。
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