CN1301170C - Self straggle fast casting method used for battlefield emergency fast shaping of armoured car component part - Google Patents
Self straggle fast casting method used for battlefield emergency fast shaping of armoured car component part Download PDFInfo
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- CN1301170C CN1301170C CNB2005100412638A CN200510041263A CN1301170C CN 1301170 C CN1301170 C CN 1301170C CN B2005100412638 A CNB2005100412638 A CN B2005100412638A CN 200510041263 A CN200510041263 A CN 200510041263A CN 1301170 C CN1301170 C CN 1301170C
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- aluminothermic
- aluminothermy
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Abstract
The present invention relates to a self-spreading high-speed casting method of battlefield emergency high-speed shaping of parts of armored vehicle, which comprises the following processing steps: aluminothermic flow welding agent is prepared; a mould for casting is rapidly manufactured with furan resin sand; the aluminothermic flow welding agent is put in a resin crucible with a lower hole; TiC is ignited, welding flux is buried in the aluminothermic flow welding agent, a part of the welding flux is exserted and ignited, self-spreading aluminothermic reaction is triggered in the crucible by the aluminothermic flow welding agent, and molten iron melt for casting is obtained; the molten iron melt is directly cast in the mould cavity of the mould of the furan resin sand, and a casting part is obtained. The aluminothermic flow welding agent is composed of raw material with the following weight percent: 19% to 25% of aluminium powder of which the particle sizes are 200 orders to 300 orders; 55% to 66% of ferric oxide of which the particle sizes are smaller than 100 orders and the carbon content is less than 0.5%; 3% to 12% of alloying agent of which the ingredients contain ferromanganese, ferrosilicon and iron nail heads; 2% to 5% of CaCo3CaF2-Al2O3 slagging agent margin and alkaline auxiliary flux. The present invention is suitable for self-spreading high-speed casting of battlefield emergency high-speed shaping of parts of armored vehicle.
Description
Technical field:
The present invention relates to a kind ofly from spreading quick casting method, mainly be applicable to armored vehicle part battlefield emergency fast shaping.Belong to the metal casting technical field.
Background technology:
The repairing of armored equipment battlefield emergency is the effective means that keeps the battlefield survival rate of armored vehicle and the power of regeneration of improving its combat capabilities.On the battlefield serious war wound part to change that part repairs be a kind of repair method of weight very.It often also is the method that to take.But limited with the car spare part, press for a kind of need not electricity, without gas and the simple condition of equipment under quick Fabrication part or part blank technology, a Short Item difficult problem when changing part with solution.
In the SHS field, by selecting high heat release combustion system, the ignition temperature that makes it to provide surpasses anti-product fusing point, again with thus obtained high-temperature fusant cooling, thereby obtains ingot casting.This foundry engieering is defined as the SHS casting.This technology relates generally to 2 points: the one, and utilize SHS to generate melt; The 2nd, by foundry engieering melt is handled.Than other SHS technology, SHS foundry engieering equipment is simple, technology easy operating and more easily discharge because of the high-temperature fusant that is produced in the SHS process makes gas phase, the product density is higher, so the SHS foundry engieering is one of technology of paying attention to of common people extremely in each technology of SHS, wherein, thermit reaction is owing to its high heat release is widely used in the SHS foundry engieering.Resin sand is to be the type/core sand of bonding agent preparation with the resin.It with the major advantage that other molding sand are compared is: surface quality of continuous castings is good, and the dimensional accuracy height does not need oven dry, and is with short production cycle, and kind is promptly curable somewhat, saves the energy; The intensity height of resin bonded sand mould/core, good permeability, casting defect is few, and percent defective is low; Resin sand good fluidity, easily consolidation; Collapsibility is good, and knockout, cleaning have alleviated labour intensity greatly easily.Therefore, making casting mould fast with resin sand is a great change on the casting technique.Development in recent years is particularly swift and violent.
The control casting is a kind of new method of simple effectively preparation semi-solid material, is subjected to extensive attention recently in the world.It is to control the process of setting of material by the process conditions in the control casting process, thereby suppresses the growth of dendrite, makes original cast sturcture become equiax crystal.Organize remelting to carry out the isothermal microstructure Evolution to semi solid zone this equiax crystal subsequently, solid-state equiax crystal changes spherical particle into.In the control casting, the pouring condition that can regulate is a lot, as pouring temperature, and chilling temperature, die wall area, solution convection current etc.
Summary of the invention:
The objective of the invention is to: merge the SHS foundry engieering and make the resin sand Tool and Die Technology indirectly with rapid prototyping, exploitation one cover is applicable to the quick foundry engieering method of spreading certainly of armored vehicle part battlefield emergency fast shaping.
The object of the present invention is achieved like this: a kind of be used for armored vehicle part battlefield emergency fast shaping spread quick casting certainly, it is characterized in that: it comprises following processing step:
---preparation aluminothermy cast welding medicament;
---make the mold and pattern for casting tool fast with furan resin-sand;
---aluminothermy cast welding medicament is placed in the resin crucible of the following hole of band;
---the TiC solder flux that ignites is imbedded in the aluminothermy cast welding medicament, and part exposes, and lights exposed parts, and aluminothermy cast welding medicament causes in crucible from spreading thermit reaction, obtains to pour into a mould and uses the molten iron melt;
---the molten iron melt directly is poured in the die cavity of furan resin-sand mould, gets foundry goods,
Described aluminothermy cast welding medicament is made up of following raw materials by weight percent: granularity is 200～300 purpose aluminium powders 19～25%; Granularity less than 100 orders, phosphorus content less than 0.5% iron oxide 55～60%; Becoming to be grouped into is the alloying constituent 3～12% of ferromanganese, ferrosilicon, iron nail head, CaCO
3CaF
2-Al
2O
3Slag former surplus and the auxiliary flux 2～5% that is alkalescence.
What the present invention was used for armored vehicle part battlefield emergency fast shaping spreads quick casting certainly, and the described crucible insulating layer of asbestos of outlet down is that 8～10mm is thick.
What the present invention was used for armored vehicle part battlefield emergency fast shaping spreads quick casting certainly, and furan resin-sand is made up of roughing sand, furane resins, catalyst and additive, and described furane resins addition accounts for 1%～2% of roughing sand quality; Described catalyst is phosphoric acid solution or sulfuric acid solution, ethanol solution of sulfuric acid, ethyl-sulfate, organic sulfonic acid solution, its addition accounts for 25～35% of furane resins quality, described additive has silane coupler or brown iron oxide, glycerine, and wherein: the addition of silane coupler accounts for 0.2%～0.4% of furane resins quality; Or the addition of brown iron oxide accounts for 0.1%～5% of furane resins quality; Or the addition of glycerine accounts for 0.2%～0.4% of furane resins quality.
What the present invention was used for armored vehicle part battlefield emergency fast shaping spreads quick casting, described roughing sand acid number＜5 certainly; Roughing sand pH value＜7; Clay content w mud is controlled at below 0.2%; Fraction of particle w particulate＜2%; Dihedral coefficient 1.0～1.3; Furane resins pH value: about 7 or be alkalescent.
What the present invention was used for armored vehicle part battlefield emergency fast shaping spreads quick casting certainly, and described ethanol solution of sulfuric acid is mixed and made into 1mol sulfuric acid and 2mol ethanol.
What the present invention was used for armored vehicle part battlefield emergency fast shaping spreads quick casting certainly, and described organic sulfonic acid solution has p-methyl benzenesulfonic acid or xylene monosulfonic acid, phenolsulfonic acid.
What the present invention was used for armored vehicle part battlefield emergency fast shaping spreads quick casting certainly, and described p-methyl benzenesulfonic acid is the form of the aqueous solution: acid: water=6.5: 3.5.
The present invention has following advantage:
1, the present invention adopts aluminothermy casting technology and rapid prototyping to make the resin sand Tool and Die Technology indirectly to merge mutually, can form the new technology that a cover is applicable to machine components or blank emergency fast shaping.
2, the tissue of the quick cast member of aluminothermy can improve by the control pouring temperature.Along with the reduction of pouring temperature, THE STRUCTURE OF CASTINGS changes tiny equiax crystal into from thick crystal grain, and experiment finds that the thick asbestos pad of 9mm can obtain tiny equiax crystal.
3, produce cast by self aluminothermic reduction exothermic reaction and use molten steel, it is gentle to need not electricity, by adjusting the alloying element of adding, can change steel grade and satisfy different requirements.Technology is simple, mold cavity and the meticulous geometry of inner surface thereof are once finished simultaneously, has saved expensive, the time-consuming step such as drawing, digital control processing and heat treatment in the traditional moulds processing, does not need machining; Die size precision height, manufacturing speed is fast, and cost is low, and in the shaping speed 20 minutes, mechanical performance reaches the cast steel characteristic index, and dimensional accuracy satisfies the emergency first-aid repair standard.Be fit to very much blank and part rapid shaping in the emergency first-aid repair.
The specific embodiment:
Embodiment: a foundry goods of panzer carries out from spreading quick casting application test:
The heavy 4kg of foundry goods with aluminothermy cast welding medicament 8kg, by adding the order that adds resin after the acid earlier, allocate furane resins and catalyst etc. in proportion, in polybag with the even founding afterwards of silica sand rapid mixing.Its concrete processing step is:
One, the preparation of aluminothermy cast welding medicament
1, the basic comprising of aluminothermy cast welding medicament:
This test used aluminothermy cast welding medicament except that contain 19～25%, granularity is 200～300 purpose aluminium powders and contain 55～60%, granularity for less than 100 orders, phosphorus content less than 0.5% the iron oxide, need allocate an amount of alloying constituent, slag former and auxiliary flux in addition, its composition and function declaration separately is as follows:
Add material---alloying constituent
In order to obtain plasticity castability preferably, answer the phosphorus content of strict control formula material, but in order to improve the tissue intensity of deposited metal, having allocated 3～12% in the aluminothermy cast welding agent into, having become to be grouped into is the alloying constituent of ferromanganese, ferrosilicon, iron nail head, has more ferrite in the deposited metal metallographic structure thereby make.
Auxiliary material---slag former
In order to improve recovery rate of iron, promote that the metal surface moulding is open and flat, thinning microstructure crystal grain adopts CaCO
3CaF
2-Al
2O
3Be slag former.
Auxiliary material---auxiliary flux
Aluminothermy cast welding medicament is cooling off faster under the condition, and is less as dose, the welded part heat radiation is very fast, and then some slag is difficult for being excluded in the fusion area, forms slag inclusion.For the slow setting rate of fused metal, allocated 2～5% in the aluminothermy cast welding medicament into, fusing point is low, good fluidity, be the auxiliary flux of alkalescence.
Two, spread quick casting selecting for use under the field condition certainly with equipment
For obtaining high-quality molten steel, attempted adopting band refractory ceramics crucible, the band multiple crucibles such as steel crucible, graphite crucible, light fire brick crucible in hole down in hole down, finally determined resin crucible in hole under the disposable band.
Three, the ignite preparation of igniting agent and selecting for use of igniter
1, the preparation of igniting agent
The material of the aluminothermy of igniting cast welding medicament is igniting agent.Because aluminothermy cast welding medicament must just can be lighted under higher temperature, the repairing of the equal incompatibility of igniting agent battlefields such as traditional high-temperature match and magnesium rod.Repeatedly experiment prepared reaction speed moderate, easily light and TiC igniting agent and using method that caloric value is high: Ti powder and C powder degree are 200 orders, press the stoichiometric mixing.Partly imbed during use in the aluminothermy cast welding medicament, part exposes, and covers protective cover rapidly after lighting exposed parts.
2, the selection of igniter
Cause aluminothermy cast welding medicament self-propagating reaction and be called igniting.A lot of at available at ordinary times outer thermal source, comprise electric spark, heavy current, microwave, heat-flash stream, laser or chemical igniting agent etc.The selection that can adapt to the igniter under the field condition of not having no gas of electricity and various weather conditions is a difficult problem.Made repeated attempts fail with automobile battery and resistance wire combination, common lighter, diesel oil various ignition mode after, found not only to be suitable for but the lighter of preventing fires easily as igniter, thereby successfully solved ignition problem.
Four, make casting mould fast with furan resin-sand
Furan resin-sand is meant the molding sand that furane resins binding agent at normal temperatures solidifies owing to the effect generation chemical reaction of catalyst.Furan resin-sand generally is made up of roughing sand, furane resins, catalyst and additive etc., and its composition and function declaration separately is as follows:
1, roughing sand
Acid number＜5;
PH value＜7;
Clay content: clay content w mud is controlled at below 0.2%, the highlyest is no more than 0.5%.Preferably adopt washed-out sand or clean sand;
Fraction of particle: w particulate＜2 preferably can be controlled at below 0.5%;
Dihedral coefficient: generally require roughing sand dihedral coefficient in 1.0～1.3 scopes;
Granularity:, select 21 groups and 15 groups of mixed sand for use to the type/core of swabbing not; To the type/core of swabbing, select 30 groups and 21 groups of mixed sand for use;
Water content:＜2%.
2, furane resins
The addition of furane resins generally accounts for 1%～2% of roughing sand quality.
The technical indicator of furane resins:
Viscosity: low as far as possible;
Free formaldehyde content: low as far as possible;
Water content: no nitrogen resin＜2%; Middle nitrogen resin＜5%; High nitrogen resin＜10%;
PH value: about 7 or be alkalescent.
3, catalyst (curing agent)
Furane resins all make the Castings Produce with Furan Resin sclerosis with acid as catalyst.Adopt more catalyst that phosphoric acid solution, sulfuric acid solution, ethyl-sulfate and organic sulfonic acid solution (as p-methyl benzenesulfonic acid, xylene monosulfonic acid, phenolsulfonic acid etc.) are arranged at present both at home and abroad.Because of using the sulfuric acid solution catalytic action strong excessively, 1mol sulfuric acid commonly used and 2mol ethanol are made sulfuric acid ethanol to slow down catalytic action.Organic sulfonic acid solution is applicable to various furane resins.(acid: form water=6.5: 3.5) is better with the aqueous solution for toluenesulfonic acid.The xylene monosulfonic acid performance is better.
Increase with the catalyst addition, up time and demould time shorten.The addition of catalyst generally accounts for about 30% of resin quality.
4, additive:
Coupling agent is arranged, and coupling agent is various silane, and addition is 0.2%～0.4% (mass fraction) of amount of resin; Anti-sand washing is arranged: add 0.1%～1.5% brown iron oxide; Anti-pore: add 3%～5% brown iron oxide; Increase sand mold/core toughness: add 0.2～0.4% glycerine.
Five, process parameter optimizing process of the test
1, process of the test
Surface quality and inner institutional framework that pouring temperature and cooling condition influence are made, thus mechanical performance of products determined.By the test specimen tissue under the different pouring temperature being carried out Metallographic Analysis, the optimal control casting process parameters.
The molten iron of cast usefulness obtains by thermit reaction in the resin crucible.Do not add any grain refiner and alterant.Obtain different pouring temperatures by the thickness that changes outlet insulating layer of asbestos (two to seven layers, every bed thickness 1.5mm) under the crucible.Melt directly is poured in the roughing sand sandpit of resin sand.From original foundry goods, cut sample, be used for the microscope structure observation.
2, test results and analysis
The initial cast sturcture that under different pouring temperatures, obtains.The size of crystal grain and pattern change with the variation of pouring temperature.Cast when adopting asbestos pad to be two layers, average crystal grain is big; When asbestos pad was three layers, grain size reduced slightly; When asbestos pad was four layers, institutional framework was undergone mutation, and the overwhelming majority is the column crystal of irregular alignment in the visual field.When asbestos pad was five layers, column crystal changed to the less globular crystal of size.When asbestos pad is six layers, be tiny equiax crystal and the irregular little column crystal of part.When asbestos pad was seven layers, crystallite dimension was compared with six layers with shape and is changed not quite.It is pouring condition the best of six layers that experiment obtains thermal insulation layer.Cast cold can obtain the initial cast sturcture of small grains.
From the metallograph of two layers of asbestos pad to seven layer asbestos pad, all can see the block object of the black that is distributed in different sizes in the crystal boundary, go out this district by energy spectrum analysis and be rich SiO
2With rich Al
2O
3The district, the reason of generation is mixed the powder inequality and deslagging not exclusively causes.The thin more this phenomenon of thermal insulation layer is obvious more.
Claims (7)
1, a kind of be used for armored vehicle part battlefield emergency fast shaping spread quick casting certainly, it is characterized in that: it comprises following processing step:
---preparation aluminothermy cast welding medicament;
---make the mold and pattern for casting tool fast with furan resin-sand;
---aluminothermy cast welding medicament is placed in the resin crucible of the following hole of band;
---the TiC solder flux that ignites is imbedded in the aluminothermy cast welding medicament, and part exposes, and lights exposed parts, and aluminothermy cast welding medicament causes in crucible from spreading thermit reaction, obtains to pour into a mould and uses the molten iron melt;
---the molten iron melt directly is poured in the die cavity of furan resin-sand mould, gets foundry goods,
Described aluminothermy cast welding medicament is made up of following raw materials by weight percent: granularity is 200～300 purpose aluminium powders 19～25%; Granularity less than 100 orders, phosphorus content less than 0.5% iron oxide 55～60%; Becoming to be grouped into is the alloying constituent 3～12% of ferromanganese, ferrosilicon, iron nail head, CaCO
3CaF
2-Al
2O
3Slag former surplus and the auxiliary flux 2～5% that is alkalescence.
2, according to claim 1 a kind of be used for armored vehicle part battlefield emergency fast shaping spread quick casting certainly, it is characterized in that: the described crucible insulating layer of asbestos of outlet down is that 8～10mm is thick.
3, according to claim l or 2 described a kind of be used for armored vehicle part battlefield emergency fast shaping spread quick casting certainly, it is characterized in that: furan resin-sand is made up of roughing sand, furane resins, catalyst and additive, and described furane resins addition accounts for l%～2% of roughing sand quality; Described catalyst is phosphoric acid solution or sulfuric acid solution, ethanol solution of sulfuric acid, ethyl-sulfate, organic sulfonic acid solution, its addition accounts for 25～35% of furane resins quality, described additive has silane coupler or brown iron oxide, glycerine, and wherein: the addition of silane coupler accounts for 0.2%～0.4% of furane resins quality; Or the addition of brown iron oxide accounts for 0.1%～5% of furane resins quality; Or the addition of glycerine accounts for 0.2%～0.4% of furane resins quality.
4, according to claim 3 a kind of be used for armored vehicle part battlefield emergency fast shaping spread quick casting certainly, it is characterized in that: described roughing sand acid number＜5; Roughing sand pH value＜7; Clay content w mud is controlled at below 0.2%; Fraction of particle w particulate＜2%; Dihedral coefficient 1.0～1.3; Furane resins pH value: about 7 or be alkalescent.
5, according to claim 3 a kind of be used for armored vehicle part battlefield emergency fast shaping spread quick casting certainly, it is characterized in that: described ethanol solution of sulfuric acid is mixed and made into 1mol sulfuric acid and 2mol ethanol.
6, according to claim 3 a kind of be used for armored vehicle part battlefield emergency fast shaping spread quick casting certainly, it is characterized in that: described organic sulfonic acid solution has p-methyl benzenesulfonic acid or xylene monosulfonic acid, phenolsulfonic acid.
7, according to claim 6 a kind of be used for armored vehicle part battlefield emergency fast shaping spread quick casting certainly, it is characterized in that: described p-methyl benzenesulfonic acid is the form of the aqueous solution: acid: water=6.5: 3.5.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNB2005100412638A CN1301170C (en) | 2005-07-29 | 2005-07-29 | Self straggle fast casting method used for battlefield emergency fast shaping of armoured car component part |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNB2005100412638A CN1301170C (en) | 2005-07-29 | 2005-07-29 | Self straggle fast casting method used for battlefield emergency fast shaping of armoured car component part |
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|---|---|
| CN1718324A CN1718324A (en) | 2006-01-11 |
| CN1301170C true CN1301170C (en) | 2007-02-21 |
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Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101372068B (en) * | 2008-08-18 | 2010-06-09 | 江阴东大新材料研究院 | Faster welding method for armored vehicle aluminium alloy part for emergency in battlefield |
| CN102147211A (en) * | 2011-01-17 | 2011-08-10 | 江阴东大新材料研究院 | Self-propagation reactive armor |
| CN102513518B (en) * | 2011-12-28 | 2013-08-28 | 武汉金泉铝热焊接器材有限公司 | Roll defect repair casting agent and casting process thereof |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5996385A (en) * | 1995-08-14 | 1999-12-07 | The United States Of America As Represented By The Secretary Of The Army | Hot explosive consolidation of refractory metal and alloys |
| US6436356B1 (en) * | 2000-03-28 | 2002-08-20 | Comsyntech Ltd. | Apparatus for self-propagating high temperature synthesis |
| CN1433999A (en) * | 2002-01-22 | 2003-08-06 | 北京科技大学 | Process for synthesizing superfine aluminium nitride powder and aluminium based heterogeneous ceramic powder by SHS method |
-
2005
- 2005-07-29 CN CNB2005100412638A patent/CN1301170C/en not_active Expired - Fee Related
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5996385A (en) * | 1995-08-14 | 1999-12-07 | The United States Of America As Represented By The Secretary Of The Army | Hot explosive consolidation of refractory metal and alloys |
| US6436356B1 (en) * | 2000-03-28 | 2002-08-20 | Comsyntech Ltd. | Apparatus for self-propagating high temperature synthesis |
| CN1433999A (en) * | 2002-01-22 | 2003-08-06 | 北京科技大学 | Process for synthesizing superfine aluminium nitride powder and aluminium based heterogeneous ceramic powder by SHS method |
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