CN1371311A - 壳模粘合剂组合物和方法 - Google Patents
壳模粘合剂组合物和方法 Download PDFInfo
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- CN1371311A CN1371311A CN00812056A CN00812056A CN1371311A CN 1371311 A CN1371311 A CN 1371311A CN 00812056 A CN00812056 A CN 00812056A CN 00812056 A CN00812056 A CN 00812056A CN 1371311 A CN1371311 A CN 1371311A
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Abstract
本发明提供一种形成壳模的方法,包括:提供含0.1至70wt%的提供一次熔模的纤维的熔模铸造壳模组合物,将该组合物涂于模具上形成粘合剂涂布的模具,将耐火粉末涂于粘合剂涂布的模具上形成粘合剂和粉末模涂层,其改进中包括粘合剂组合物。本发明提供一种形成壳模的方法,包括:提供含粘合剂组合物的熔模铸造壳模组合物,该粘合剂组合物包括20-98wt%的含无机颗粒的溶胶和1-20wt%有机聚合物的混合物;提供一次熔模,将所述组合物涂于所述模具上形成粘合剂涂布的模具,将耐火粉末涂于所述粘合剂涂布的模具上形成粘合剂和粉末模涂层,其改进中粘合剂组合物包括0.1至70wt%的无机纤维。
Description
发明领域
本发明涉及包括胶态二氧化硅和聚合物的水基打底(back-up)粘合剂组合物和其用于形成制备壳模的快速加工浆料的用途。本发明的打底粘合剂组合物包括纤维并用于快速制备熔模铸造法的陶瓷壳模。现有的粘合剂组合物不包括纤维。本发明提供一种组合物,该组合物明显缩短生产陶瓷壳模所需的时间。本发明的组合物,当用于生产熔模铸造法的陶瓷壳模时,不仅通过减少壳的浸入(shell dip)次数而提供低加工时间,而且通过高的原始强度提供更好的操作和脱蜡。
生产用于熔模铸造的壳模通常包括将蜡模板(或蜡模)浸入含粘合剂和耐火粉末的浆料中。用该浆料涂布蜡,并将过量的浆料排出。将较粗的耐火粉末撒到湿蜡型(wax pattern)上,并将该组合物干燥。用相同方法涂布另一些浆料涂层和耐火粉末,直至模具具有用于进一步加工的的厚度和强度。将底涂层定义为涂于蜡型或蜡模上的头道或二道涂层。底涂层的目的在于对要浇铸并复制模具细节的金属提供高耐火度表面。底粘合剂基于胶态二氧化硅,且通常含其它添加剂如湿润剂、消泡剂和聚合物。耐火粉通常为200-400目,通常为锆石,但也可含有一些熔融二氧化硅。选用锆石的原因在于其优良的耐火性能。用于底涂层的灰泥材料通常更细(50-150目)以有助于捕捉模具的细节。用于底涂层的灰泥材料通常为锆石,但也可为熔融二氧化硅。通常在底涂层后用打底涂料涂于蜡型上。封闭涂料仅为浆料涂料,不涂布灰泥。该封闭涂料通常以工业方法涂布以将疏松的灰泥“封闭”到蜡型上。打底涂料的主要目的是对壳提供足够的强度以承受在生产铸品的方法中对其施加的力和压力。在最终打底涂料后涂布封闭涂料。主应力是由于在除蜡工艺期间由蜡施加到壳上的压力造成的。各壳所需的打底涂料数目取决于整个模具的尺寸,以及注入壳内的合金量。
在熔模铸造领域中的惯例是通过3-点弯曲表征壳模的原始(未烧制)性能(烧制之前的性能),其中将单点载荷逐渐施于支撑在两个静止点的原始壳试片上,直至断裂为止。弯曲试验的主要目的是获得壳材料原始强度的一个测量值:断裂模量(MOR)
这里使用的断裂模量(MOR)由如下公式定义:
MOR=(3xLfxS)/(2xWxT2)其中Lf为断裂时的最大载荷,S为两个静止点之间的间隔,W和T分别为试棒的宽度和厚度,如Investment Casting Institute Ceramic TestProcedure 770-79(1979)中提出的。MOR为材料的固有性能,因此该性能与试棒的尺寸无关。已知当对壳施加外载荷时,壳厚度是确定实际壳性能的主要因素,考虑厚度的调整破裂载荷(AFL)为壳强度的更准确测量值。AFL信息和公式已在很多工业论文中公布。
这里使用的调整破裂载荷(AFL)用如下公式定义:
AFL=[fx(MOR)xT2]其中f为通过Carl Schwartz of Ransom & Randolph在“Faster andSafer Shell Production”(1988)中提出的弯曲类型测定的常数因子。
用于熔模铸造壳模中的“聚合物”通常指通过称为单体的5个或多个相同结合单元的化学结合形成的大分子。本发明中使用的聚合物类型称为弹性体。弹性体为具有弹性性能的聚合物。
这里使用的耐火材料是指可用于制备熔模铸造的壳模的无机颗粒材料。耐火材料特别在加热期间耐变化。工业中使用的主要耐火材料如下:锆石:ZrSiO4(硅酸锆),矾土:Al2O3(氧化铝),硅石:SiO2(二氧化硅)和硅铝酸盐:xAl2O3·ySiO2,通常已在高温(2500F°)下烧制形成称为富铝红柱石的稳定相并因烧制使收缩最小的氧化铝与二氧化硅的混合物。这些耐火材料为两种形式:一种形式为粉末形式,另一种形式为粗砂形式,通常称为灰泥。粉末和灰泥的尺寸都可以根据相应的应用而变化。
这里使用的耐火粉末(或耐火粉)是指具有这样的颗粒尺寸的耐火粉末颗粒材料:至少60%的颗粒小于(细于)100目。耐火粉末(或耐火粉)优选为具有这样的颗粒尺寸的耐火颗粒材料:至少90%的颗粒小于(细于)100目。
这里使用的耐火砂子(或耐火灰泥)是指具有这样的颗粒尺寸的耐火颗粒材料:至少60%的颗粒大于(粗于)100目。耐火砂子(或耐火灰泥)优选为具有这样的颗粒尺寸的耐火颗粒材料:至少90%的颗粒大于(粗于)100目。
这里使用的“胶乳聚合物”是指在水中的弹性体聚合物。例如,苯乙烯丁二烯(S/B类型)类的弹性体聚合物和丙烯酸类的弹性体聚合物具有如下性能:
胶乳# PH 固体% 比粘度 比重 类型
(厘泊) (g/ml)
100 8-9 53% 未测 1.01 S/B
101 6-7 50% 未测 1.01 S/B
120 8.5 50% 200 1.03 丙烯酸类
121 7.0 50% 40 1.01 丙烯酸类
140 9.5 47% 100 1.05 烯酸类
在熔模铸造壳模中的“胶态二氧化硅”通常指微小二氧化硅颗粒的水分散体,通常使用少量强碱(例如氨或氢氧化钠)作为生成稳定悬浮液的稳定剂。所得pH通常为8.0-11.0。
“脱蜡”是指从未烧制的模涂料中除去蜡形成未烧制的模具,然后将其烧制并用于熔模铸造。
“底涂料”是指适应记录微小表面细节并且如现有技术公知的由通过Ransom & Randolph制造的princote粘合剂材料形成的浆料形成的浆料和灰泥材料的头道涂料,通常通过在其浆料中浸涂而将其涂于蜡模上。
这里使用的“无机纤维”是指具有长宽比至少10,更优选至少30的包括无机材料,更优选基本由无机材料组成的纤维。
本发明的一个目的是提供形成壳模的方法,包括提供熔模铸造壳模组合物,其中无聚合物和纤维的粘合剂及粉末的模涂料按粘合剂和粉末的模涂料相同的方式形成,不同的是不含聚合物和纤维,无纤维和聚合物的粘合剂及粉末的模涂料具有无聚合物和纤维的原始MOR及无聚合物和纤维的原始AFL,粘合剂和粉末的模涂料具有含聚合物和纤维的原始MOR和含聚合物和纤维的原始AFL,含聚合物和纤维的原始MOR比无聚合物和纤维的原始MOR高至少50%,含聚合物和纤维的原始AFL在相同涂层数时比无聚合物和纤维的AFL高至少150%,在减少涂层数的至少40%时含聚合物和纤维的原始AFL等于无聚合物和纤维的原始AFL。
本发明的一个目的是提供形成壳模的方法,包括提供熔模铸造壳模组合物,其中含聚合物但无纤维的粘合剂及粉末的模涂料按粘合剂和粉末的模涂料相同的方式形成,不同的是不含纤维,含聚合物但无纤维的粘合剂及粉末的模涂料具有含聚合物但无纤维的原始MOR及含聚合物但无纤维的原始AFL,粘合剂和粉末的模涂料具有含聚合物和纤维的原始MOR和含聚合物和纤维的原始AFL,含聚合物和纤维的原始MOR比含聚合物但无纤维的原始MOR高至少25%,含聚合物和纤维的原始AFL在相同涂层数时比含聚合但无纤维的原始AFL高至少100%,在减少涂层数至少25%时含聚合物和纤维的原始AFL等于含聚合物但无纤维的原始AFL。
本发明的一个目的是提供形成壳模的方法,包括提供含0.1至70wt%的提供一次熔模(disposable pattern)的无机纤维的熔模铸造壳模组合物,将该组合物涂于模具上形成粘合剂涂布的模具,将耐火粉涂于粘合剂涂布的模具上,形成粘合剂和粉末模涂层,其改进中包括粘合剂组合物。
本发明一个目的是提供形成壳模的方法,该方法包括:提供含粘合剂组合物的熔模铸造壳模组合物,该粘合剂组合物包括20-98wt%的含无机颗粒的溶胶和1-20wt%有机聚合物的混合物;将耐火粉施于粘合剂中形成浆料,提供底涂布的一次熔模,将该浆料组合物涂于模具上形成浆料涂布的模具,排出并涂布干燥的粗耐火层(灰泥),其改进中粘合剂组合物包括0.1至70wt%的无机纤维。
本发明一个目的是提供含粘合剂组合物的熔模铸造壳模组合物,该粘合剂组合物包括20-98wt%的含无机颗粒的溶胶、1-20wt%有机聚合物和0.1至70wt%无机纤维的混合物;其中无机颗粒具有小于600目的平均颗粒尺寸,并且无机纤维具有大于30的平均长径比。
本发明一个目的是提供形成壳模的方法,该方法包括如下步骤:提供含粘合剂组合物的熔模铸造壳模组合物,该粘合剂组合物包括20-98wt%的含无机颗粒的溶胶、1-20wt%有机聚合物和0.1至70wt%无机纤维的混合物;其中无机颗粒具有小于600目的平均颗粒尺寸,并且无机纤维具有大于30的平均长径比,将耐火粉末施于粘合剂中形成浆料,提供底涂布的一次熔模,将该浆料组合物涂于模具上形成浆料涂布的模具,排出并涂布干燥的粗耐火层(灰泥)。
本发明概述
本发明提供一种组合物,该组合物明显缩短生产陶瓷壳模所需的时间。本发明的组合物,当用于生产熔模铸造工艺的陶瓷壳模时,不仅通过减少壳的浸入次数提供低加工时间,而且通过高的原始强度提供更好的操作和脱蜡。
本发明提供一种形成壳模的方法,包括提供含0.1至70wt%的提供一次熔模的纤维的熔模铸造壳模组合物,将该组合物涂于模具上形成粘合剂涂布的模具,将耐火粉末涂于粘合剂涂布的模具上,形成粘合剂和粉末模涂层,其改进中包括粘合剂组合物。
本发明提供一种含粘合剂组合物的熔模铸造壳模组合物,该粘合剂组合物包括20-98wt%的含无机颗粒的溶胶、1-20wt%有机聚合物和0.1至70wt%无机纤维的混合物;其中无机颗粒具有小于600目的平均颗粒尺寸,并且无机纤维具有大于30的平均长径比。
本发明提供一种形成壳模的改进方法,该方法包括:提供含粘合剂组合物的熔模铸造壳模组合物,该粘合剂组合物包括20-98wt%的含无机颗粒的溶胶和1-20wt%有机聚合物的混合物;将耐火粉末与粘合剂混合形成浆料,提供底涂布的一次熔模,将该浆料组合物涂于模具上形成浆料涂布的模具,排出并涂布干燥的粗耐火层(灰泥),其改进中粘合剂组合物包括0.1至70wt%的无机纤维。
本发明提供一种形成壳模的方法,该方法包括如下步骤:提供含粘合剂组合物的熔模铸造壳模组合物,该粘合剂组合物包括20-98wt%的含无机颗粒的溶胶、1-20wt%有机聚合物和0.1至70wt%无机纤维的混合物;其中无机颗粒具有小于600目的平均颗粒尺寸,并且无机纤维具有大于30的平均长径比,将耐火粉末施于粘合剂中形成浆料,提供底涂布的一次熔模,将该浆料组合物涂于模具上形成浆料涂布的模具,排出并涂布干燥的粗耐火层(灰泥)。
本发明提供一种形成壳模的方法,包括提供熔模铸造壳模组合物,其中无聚合物和纤维的粘合剂及粉末的模涂料和含聚合物但无纤维的粘合剂及粉末的模涂料按与粘合剂和粉末的模涂料相同的方式形成,不同的是不含聚合物和纤维和不含纤维,无聚合物和纤维的粘合剂及粉末的模涂料具有无聚合物和纤维的原始AFL,含聚合物但无纤维的粘合剂和粉末模具涂料具有含聚合物但无纤维的原始AFL,粘合剂和粉末的模涂料具有含聚合物和纤维的原始AFL,在相同涂层数下含聚合物和纤维的原始AFL比无聚合物和纤维的原始AFL高至少150,并比含聚合物但无纤维的原始AFL高至少100%。本发明详细描述
通常,本发明的粘合剂可用于按照下面的方法制备壳模。粘合剂优选包括溶胶、无机纤维和胶乳聚合物的混合物。将耐火粉末加入粘合剂中制备浆料,并将该浆料混合物混合以使粉末润湿。将材料的一次熔模如蜡模浸入浆料中,排出过量的浆料,并将模具用另外的耐火材料粉刷,同时使其保持润湿。干燥该模具和浆料以在粘合剂中建立粘结。
若需要可重复浸涂、排出和粉刷步骤,以形成具有预定的所需厚度的壳模。模具制成后,通过加热和排出液体模材料除去一次性熔模,并将壳模烧制。烧制后,将熔化的金属倒入壳模中并使其冷却。冷却后,使壳模从金属上除去,由此提供所需的浇铸金属组件。
在粘合剂中包含胶乳聚合物以提高由粘合剂制成的壳的原始强度性能。此外,在模具制备工艺期间,与无胶乳聚合物的粘合剂的浸渍相比,胶乳聚合物减少浸渍之间的加工时间。包含无机纤维以提高含胶乳的各粘合剂涂层的厚度,如此与现有其它粘合剂相比,可以较少涂层形成类似厚度的足够强的壳。
优选用于本发明的胶态硅溶胶具有3至100纳米(nm),更优选5-20nm的平均颗粒尺寸,并具有8-50wt%,优选12-35wt%的二氧化硅含量。存在多种胶乳,如乙酸乙烯酯、聚偏二氯乙烯、丙烯酸类、苯乙烯丁二烯等。苯乙烯丁二烯胶乳已在熔模铸造中引起很大注意,因为许多种这类胶乳当与胶态二氧化硅混合时具有良好的相容性,并可加入以改进壳的原始强度。优选的胶乳聚合物包括具有如下性能的丙烯酸类聚合物的共混物:pH6-11(最优选7-10);粘度50-1000厘泊(最优选50-500);固含量40-65%(最优选45-55%);平均颗粒尺寸0.05-1.0微米(最优选0.1-0.5微米)。用于本发明的优选无机纤维具有大于30的平均长径比。通常用于熔模铸造工业中的耐火粉末的例子为锆石(ZrSiO4),熔融二氧化硅(SiO2),氧化铝(Al2O3),氧化锆(ZrO2)和硅铝酸盐(Al2O3与SiO2的各种组合,通常烧至高温2500F°)。还可使用任何其它相容的粉末体系。使用的粉末的尺寸通常分类为-120目(U.S.A标准筛)至-400目。通常使用的尺寸是本领域公知的,但其它尺寸不从本发明范围中排除。该浆料优选具有5至20秒的粘度(通过#4 Zahn杯测量)。
将胶乳聚合物以任何比例加入胶态二氧化硅基料中,以使胶态二氧化硅与胶乳聚合物的比例大于1∶1,优选大于3∶1。预期胶态二氧化硅的浓度为组合物重量的8至80wt%。胶乳聚合物的存在量为2至20wt%,按粘合剂重量计。还可将本领域公知的其它组分(表面活性剂、杀生物剂等)加入粘合剂中,而不会改变本发明的精神和范围。将耐火粉末与粘合剂混合形成浆料。将浆料组合物涂于底涂布的一次熔模上形成浆料涂布的模具。将干燥的粗耐火层(灰泥)涂于浆料涂布的模具上。通过重复干燥、浸渍、排出、粉刷和干燥形成灰泥涂布的模具。
在优选的实施方案中,本发明提供一种形成壳模的方法,该方法包括:提供含粘合剂组合物的熔模铸造壳模组合物,该粘合剂组合物包括20-98wt%的含无机颗粒的溶胶和1-20wt%有机聚合物的混合物;将耐火粉末施于粘合剂中形成浆料,提供底涂布的一次熔模,将该浆料组合物涂于模具上形成浆料涂布的模具,排出并涂布干燥的粗耐火层(灰泥)。改进在于粘合剂组合物包括0.1至70wt%的无机纤维。无聚合物和纤维的粘合剂及粉末的模涂料按与粘合剂和粉末的模涂料相同的方式形成,不同的是不含聚合物和纤维。无聚合物和纤维的粘合剂及粉末模具的涂料具有无聚合物和纤维的原始AFL。含聚合物和纤维的涂料具有含聚合物和纤维的原始AFL。在相同的涂层数下,含聚合物和纤维的原始AFL优选比无聚合物和纤维的原始AFL大至少75%含聚合物和纤维的原始AFL更优选比无聚合物和纤维的原始AFL大至少100%。含聚合物和纤维的原始AFL最优选比无聚合物和纤维的原始AFL大至少150%。另一含聚合物但无纤维粘合剂及粉末的模涂料按与粘合剂和粉末的模涂料相同的方式形成,不同的是不含纤维。含聚合物但无纤维粘合剂及粉末模涂料具有含聚合物但无纤维的原始AFL。在相同的涂层数下,含聚合物和纤维的原始AFL优选比含聚合物但无纤维的原始AFL大至少50%。含聚合物和纤维的原始AFL更优选比含聚合物但无纤维的原始AFL大至少75%。含聚合物和纤维的原始AFL最优选比含聚合物但无纤维的原始AFL大至少100%。
在一个优选的实施方案中,本发明提供一种含粘合剂组合物的熔模铸造壳模组合物,该粘合剂组合物包括20-98wt%的含无机颗粒的溶胶、1-20wt%有机聚合物和0.1至70wt%无机纤维的混合物;其中无机颗粒具有小于600目的平均颗粒尺寸,并且无机纤维具有大于30的平均长径比。
在一个优选实施方案中,本发明提供一种形成壳模的方法,该方法包括:提供含粘合剂组合物的熔模铸造壳模组合物,该粘合剂组合物包括20-98wt%的含无机颗粒的溶胶、1-20wt%有机聚合物和0.1至70wt%无机纤维的混合物。无机颗粒具有小于600目的平均颗粒尺寸,并且无机纤维具有大于30的平均长径比。将耐火粉末与粘合剂混合形成浆料。将底涂布的一次熔模用该浆料组合物涂布形成浆料涂布的模具。通过将该底涂布的一次熔模反复地浸入浆料组合物中、排出和干燥,形成浆料涂布的模具。通过粉刷(涂布干燥的粗糙耐火层)和干燥该浆料涂布的模具,形成灰泥涂布的模具。
根据本发明的一个优选实施方案,本发明提供一种含粘合剂组合物的熔模铸造壳模组合物,该粘合剂组合物包括20-98wt%的含无机颗粒的溶胶、1-20wt%有机聚合物和0.1至70wt%无机纤维的混合物。无机颗粒具有小于600目的平均颗粒尺寸,并且所述无机纤维具有大于30的平均长径比。粘合剂组合物优选包括1至90wt%的耐火粉末。耐火粉末优选具有120至400目的筛目尺寸,所述耐火粉末选自硅铝酸盐、熔融二氧化硅、石英二氧化硅、氧化铝、锆石和氧化锆。溶胶优选包括具有3至100纳米平均粒径的二氧化硅。胶态二氧化硅与胶乳聚合物的比例优选大于1∶1。该胶态二氧化硅∶胶乳比例优选为10∶1至1∶1。胶乳聚合物优选包括具有如下性能的丙烯酸类聚合物的共混物:pH6-11;粘度50-1000厘泊;固含量40-65%;平均颗粒尺寸0.05-1.0微米。胶乳聚合物优选包括具有如下性能的丙烯酸类聚合物的共混物:pH7-10;粘度50-500厘泊;固含量50-60%;平均颗粒尺寸0.1-0.5微米。聚合物胶乳优选为丙烯酸类胶乳或苯乙烯丁二烯胶乳。二氧化硅溶胶优选具有低于30纳米的平衡颗粒尺寸。该粘合剂组合物优选包括1至98wt%的水。
根据本发明的一个优选实施方案,本发明提供一种形成壳模的方法,该方法包括如下步骤:提供含粘合剂组合物的熔模铸造壳模组合物,该粘合剂组合物包括20-98wt%的含无机颗粒的溶胶、1-20wt%有机聚合物和0.1至70wt%无机纤维的混合物。无机颗粒具有小于600目的平均颗粒尺寸,所述无机纤维具有大于30的平均长径比。然后将耐火粉末与粘合剂混合形成浆料,并将其涂于模具上,以在模具上形成浆料涂层。接着将耐火灰泥涂于浆料涂层上形成浆料和灰泥模涂层。耐火粉末优选具有120至400目的颗粒尺寸。
根据本发明的一个优选实施方案,提供一种形成壳模的方法,包括提供含液体粘合剂组合物的熔模铸造壳模组合物;将耐火粉末与粘合剂混合形成浆料组合物,提供底涂布的一次熔模,将该浆料组合物涂于模具上以在所述模具上形成部分浆料涂层,从所述部分浆料涂层中排出至少一部分所述液体,由此形成排出的部分浆料涂层。然后将浆料组合物涂于所述排出的部分浆料涂层上形成润湿的浆料涂层,从所述润湿的浆料涂层中排出至少部分所述液体形成排出的浆料涂层,并将耐火灰泥材料涂于所述排出的浆料涂层上,由此形成耐火灰泥和浆料涂层,在其改进中,所述液体粘合剂组合物包括0.1至70wt%无机纤维。优选该液体粘合剂组合物还包括20-98wt%的含无机颗粒的溶胶和1-20wt%有机聚合物,所述耐火粉末包括具有小于600目的平均颗粒尺寸的无机颗粒。无机纤维优选具有大于30的平均长径比。优选在干燥后,将所述组合物反复涂于所述模具上形成浆料涂布的模具,并将耐火灰泥涂于所述浆料涂布的模具上。
根据本发明的一个优选实施方案,提供一种形成壳模的方法,包括提供含0.1至70wt%无机纤维的熔模铸造壳模组合物,提供一次熔模,将所述组合物涂于所述模具上形成粘合剂涂布的模具,将耐火粉末涂于所述粘合剂涂布的模具上形成粘合剂和粉末模涂层,其改进中包括所述粘合剂组合物。熔模铸造壳模组合物优选进一步包括1至20wt%的有机聚合物。
根据本发明的一个优选实施方案,本发明提供一种通过包括如下步骤的方法形成的壳模,所述方法包括:提供含粘合剂组合物的熔模铸造壳模组合物,该粘合剂组合物包括20-98wt%的含无机颗粒的溶胶、1-20wt%有机聚合物和0.1至70wt%无机纤维的混合物,将耐火粉末施于粘合剂中形成浆料,提供底涂布的一次熔模,将该浆料组合物涂于模具上形成浆料涂布的模具,排出并涂布干燥的耐火灰泥层。
根据一个优选实施方案,本发明提供形成壳模的方法,该方法包括:提供含打底粘合剂组合物的熔模铸造壳模组合物,该打底粘合剂组合物包括20-98wt%的含无机颗粒的溶胶和1-20wt%有机聚合物的混合物;提供一次熔模,将所述组合物涂于所述模具上形成具有粘合剂涂层的粘合剂涂布模具,将耐火粉末涂于所述粘合剂涂布的模具上形成粘合剂和粉末模涂层,其改进包括将0.1至70wt%的无机纤维加入所述打底粘合剂组合物中形成含纤维的打底粘合剂组合物。打底粘合剂组合物优选具有原始断裂模量(MOR),所述含纤维的打底粘合剂组合物具有比所述打底粘合剂组合物的原始断裂模量(MOR)大至少25%的原始断裂模量(MOR)。打底粘合剂组合物优选具有原始调整破裂载荷(AFL),所述含纤维的打底粘合剂组合物具有比所述打底粘合剂组合物的原始调整破裂载荷(AFL)大至少75%的原始调整破裂载荷(AFL)。打底粘合剂组合物优选具有原始调整破裂载荷(AFL),所述含纤维的打底粘合剂组合物具有比所述打底粘合剂组合物的原始调整破裂载荷(AFL)大至少75%的原始调整破裂载荷(AFL)。无纤维粘合剂涂料优选按所述粘合剂涂料的方式形成,不同之处在于不含所述纤维,且比所述由含所述纤维的打底粘合剂组合物形成的所述粘合剂涂料薄至少25%。该打底粘合剂组合物优选具有原始断裂模量(MOR),所述含纤维的打底粘合剂组合物具有比所述打底粘合剂组合物的原始断裂模量(MOR)大至少35%的原始断裂模量(MOR)。打底粘合剂组合物优选具有原始调整破裂载荷(AFL),所述含纤维的打底粘合剂组合物具有比所述打底粘合剂组合物的原始调整破裂载荷(AFL)大至少100%的原始调整破裂载荷(AFL)。打底粘合剂组合物优选具有原始断裂模量(MOR),所述含纤维的打底粘合剂组合物具有比所述打底粘合剂组合物的原始断裂模量(MOR)大至少50%的原始断裂模量(MOR)。打底粘合剂组合物优选具有原始调整破裂载荷(AFL),所述含纤维的打底粘合剂组合物具有比所述打底粘合剂组合物的原始调整破裂载荷(AFL)大至少150%的原始调整破裂载荷(AFL)。无纤维粘合剂涂料优选按所述粘合剂涂料的方式形成,不同之处在于不含所述纤维,且比所述由含所述纤维的打底粘合剂组合物形成的所述粘合剂涂料薄至少33%。无纤维粘合剂涂料优选按所述粘合剂涂料的方式形成,不同之处在于不含所述纤维,其具有无纤维的原始断裂模量,并且所述粘合剂和粉末模涂料具有比所述无纤维的原始断裂模量大至少50%的含纤维原始断裂模量。无纤维粘合剂涂料优选按所述粘合剂涂料的方式形成,不同之处在于不含所述纤维,其具有无纤维的原始调整破裂载荷,并且所述粘合剂和粉末模涂料具有比所述无纤维的原始断裂模量大至少150%的含纤维原始调整破裂载荷。无纤维的粘合剂涂料优选按所述粘合剂涂料的方式形成,不同之处在于不含所述纤维,其具有无纤维的原始断裂模量,并且所述粘合剂和粉末模涂料具有比所述无纤维的原始断裂模量大至少25%的含纤维的原始断裂模量。无纤维粘合剂涂料优选按所述粘合剂涂料的方式形成,不同之处在于不含所述纤维,其具有无纤维的原始调整破裂载荷,并且所述粘合剂和粉末模具涂料具有比所述无纤维的原始断裂模量大至少100%的含纤维原始调整破裂载荷。
根据一个优选的实施方案,本发明提供一种通过包括如下步骤的方法形成的壳模,所述方法包括:提供含粘合剂组合物的熔模铸造壳模组合物,该粘合剂组合物包括20-98wt%的含无机颗粒的溶胶、1-20wt%有机聚合物和0.1至70wt%无机纤维的混合物,将所述组合物涂于模具上形成粘合剂涂布的模具,将耐火粉末施于粘合剂涂布的模具上形成粘合剂和粉末模涂层,并将所述粘合剂和粉末模涂层烧制形成壳模。
根据一个优选的实施方案,本发明提供一种通过包括如下步骤的方法形成的原始壳模(green shell-mold),所述方法包括:提供含粘合剂组合物的熔模铸造壳模组合物,该粘合剂组合物包括20-98wt%的含无机颗粒的溶胶、1-20wt%有机聚合物和0.1至70wt%无机纤维的混合物,将耐火粉末与粘合剂混合形成浆料组合物,提供底涂布的一次熔模,将浆料组合物涂于模具上以在所述模具上形成湿浆料涂层,从所述湿浆料涂层中排出至少一部分所述水以形成排干的浆料涂层,将粗耐火灰泥涂于所述排干的浆料涂层上并从所述排干的浆料涂层中除去所述模具,由此形成原始壳模。
下面的实施例描述本发明权利要求的优选实施方案。这些实施例应认为是说明本发明的,而不限制其范围。实施例1:打底粘合剂组合物
60.29g胶态二氧化硅(SiO2:10纳米平均粒径);18.96g去离子水;15.57g丙烯酸类聚合物乳液:55wt%丙烯酸类聚合物;45wt%水;(Duramax TM B 1000);1.46g的无机纤维(Al2O3和SiO2):其具有650微米的中值长度,8.5微米的中值直径和80的平均长度直径(长径)比和组成:46wt%SiO2、15wt%Al2O3、16wt%CaO、12wt%MgO、6wt%FeO和5wt%不纯物。将该粘合剂组合物与耐火粉末混合形成粘合剂和粉末的浆料。耐火粉末具有120目至325目的颗粒尺寸。耐火粉末为熔融SiO2或Al2O3·SiO2。
实施例2
将蜡模浸入用于头道涂布耐火材料的底浆料中,由此形成涂布的蜡模。将涂布的蜡模浸入按照实施例1的工序形成的粘合剂和粉末的浆料中约5秒。然后将蜡模从浆料中提起并使其排干30-60秒。然后将具有排干的浆料层的蜡模通过将其浸入砂子的流化床中约5秒或通过使用将灰泥洒在模具上的散砂机,用粗砂子涂布。该砂子由熔融SiO2或Al2O3·SiO2构成。筛子的筛目尺寸为30至100目。将该步骤重复三次以形成具有约5mm厚的宽度的涂层。然后将涂布的蜡模加热熔化,除去蜡,并在温度1600至2000°F下烧制约1至3小时。通过将液体金属倾倒在模具上、使金属冷却、接着从冷却的金属中除去模具的方式,使用最终模具。模塑的金属包括铁、铝、镍和其合金。
实施例3
60.85g胶态二氧化硅(SiO2:10纳米平均粒径);19.64g去离子水;15.71g丙烯酸类聚合物乳液:55wt%丙烯酸类聚合物;45wt%水;(Duramax TM B 1000);1.47g烷氧基化伯醇;LF-60MOD(湿润剂,由DeForest Enterprises Inc.制造);0.49g硅氧烷乳液DCH-10(消泡剂,由Dow Corning制造);0.02g广谱杀菌剂;GROTAN(杀生物剂,由US Professional Labs制造),0.02g羟基化合物;氨掩蔽剂(香料,由Alpine Aromatics International Inc.制造),1.8g无机纤维(Al2O3和SiO2):其具有650微米的中值长度,8.5微米的中值直径和80的平均长度直径(长径)比和组成:46wt%SiO2、13.5wt%Al2O3、17.7wt%CaO、9.7wt%MgO、7wt%FeO和6.1wt%其它物质。将该粘合剂组合物与耐火粉末混合。耐火粉末具有120目至325目的颗粒尺寸。耐火粉末为熔融SiO2。
按照下表I制备三种打底粘合剂浆料。Nyacol830(NYA)体系为由Ransom & Randolph销售的无纤维和聚合物体系,由Ranson &Randolph制造的CustomcoteTM粘合剂(CUS)为无纤维的含聚合物体系,CBS为含纤维和聚合物的所述粘合剂。表I:三种浆料的配方和粘度
体系ID | NYA | CUS | CSB |
粘合剂 | Nyacol830* | CustomcoteTM粘合剂 | 实施例4的打底粘合剂组合物 |
耐火材料,加入量(loading) | Ranco-Sil-140F,63%加入量 | Ranco-Sil-140F,63%加入量 | Ranco-Sil-140F,62%加入量 |
粘度 | 13-15秒,#Zahn Cup | 10-12秒.#Zahn Cup | 23-25秒,#Zahn Cup |
*用水稀释使其具有粘合剂固体25.0wt%。
将所有浆料用于制备测定原始强度的试棒样品。所有体系都使用30×50熔融二氧化硅灰泥砂子。原始弯曲强度在表II中给出。为参考,所有数据在三个打底涂层和一个封闭浸涂层(Seal dip)中相对于NYA体系(即此点等于1)测定。表II:具有各种涂层的三种体系的相对原始弯曲性能
性能→体系↓ | 厚度 | 原始MOR | 原始AFL | |
3层涂层+封闭层 | NYA | 1.00 | 1.00 | 1.00 |
CUS | 0.94 | 1.63 | 1.46 | |
CSB | 1.44 | 2.83 | 5.92 | |
4层+封闭层 | NYA | 1.19 | 1.55 | 2.20 |
CUS | 1.20 | 2.03 | 2.97 | |
CSB | 1.78 | 2.98 | 9.50 | |
5涂层+封闭层 | NYA | 1.44 | 1.70 | 3.56 |
CUS | 1.35 | 2.46 | 4.53 | |
CSB | 2.10 | 3.29 | 14.72 |
从表II中可以看出,CSB体系在三层涂层中的原始MOR和AFL(分别为2.83和5.92)大于NYA和CUS体系在4和6层打底涂层中的相同值。这说明CSB浆料的3层打底涂层可代替NYA和CUS浆料的4和5层涂层。
可用于本发明的熔模铸造壳模组合物为有机和无机纤维。最优选无机纤维。可用于熔模铸造壳模组合物的纤维最优选具有大于30的平均长径比。
可用于本发明的熔模铸造壳模组合物的颗粒为有机和无机颗粒。最优选无机颗粒。可用于本发明的熔模铸造壳模组合物的颗粒优选具有低于1微米的平均最大直径。可用于本发明的熔模铸造壳模组合物的颗粒最优选具有低于0.5微米的平均最大直径。
尽管本发明已参考各种优选实施方案进行了描述,但本领域熟练技术人员将认识到可在不背离所附权利要求定义的本发明精神和范围下进行各种变化和改变。
Claims (37)
1.一种熔模铸造壳模组合物,包含一种粘合剂组合物,该粘合剂组合物包括20-98wt%的含无机颗粒的溶胶、1-20wt%有机聚合物和0.1至70wt%无机纤维的混合物;其中无机颗粒具有小于600目的平均颗粒尺寸,并且无机纤维具有大于30的平均长径比。
2.根据权利要求1的组合物,进一步包括1至90wt%的耐火粉末。
3.根据权利要求2的组合物,其中耐火粉末具有120至140目的筛目尺寸,并且所述耐火粉末选自硅铝酸盐、熔融二氧化硅、石英二氧化硅、氧化铝、锆石和氧化锆。
4.根据权利要求1的组合物,其中所述胶态二氧化硅包括具有3至100纳米平均颗粒尺寸的二氧化硅。
5.根据权利要求1的组合物,其中胶态二氧化硅与胶乳聚合物的比例大于1∶1。
6.根据权利要求1的组合物,其中所述胶体∶胶乳比例为10∶1至1∶1。
7.根据权利要求1的组合物,其中所述胶乳聚合物包括具有如下性能的丙烯酸类聚合物的共混物:pH6-11;粘度50-1000厘泊;固含量40-65%;平均颗粒尺寸0.05-1.0微米。
8.根据权利要求1的组合物,其中所述胶乳聚合物包括具有如下性能的丙烯酸类聚合物的共混物:pH7-10;粘度50-500厘泊;固含量50-60%;平均颗粒尺寸0.1-0.5微米。
9.根据权利要求1的组合物,其中聚合物胶乳为丙烯酸类胶乳或苯乙烯丁二烯胶乳。
10.根据权利要求1的组合物,其中所述二氧化硅溶胶具有低于30纳米的平均颗粒尺寸。
11.根据权利要求1的组合物,其中所述胶乳聚合物为弹性体胶乳聚合物。
12.根据权利要求1的组合物,还包括1至98wt%的水。
13.一种形成壳模的方法,包括如下步骤:
提供含粘合剂组合物的熔模铸造壳模组合物,该粘合剂组合物包括20-98wt%的含无机颗粒的溶胶、1-20wt%有机聚合物和0.1至70wt%无机纤维的混合物;
所述无机颗粒具有小于600目的平均颗粒尺寸,所述无机纤维具有大于30的平均长径比,
提供一次熔模,
将耐火粉末与所述粘合剂组合物混合形成浆料组合物,
将所述浆料组合物涂于所述模具上以在所述浆料涂布的模具上形成浆料涂层,
将耐火灰泥涂于所述浆料涂层上形成浆料和灰泥模涂层。
14.权利要求13的方法,其中所述耐火粉末具有120至400目的颗粒尺寸。
15.一种形成壳模的方法,包括提供含液体粘合剂组合物的熔模铸造壳模组合物;将耐火粉末与粘合剂混合形成浆料组合物,提供底涂布的一次熔模,将该浆料组合物涂于模具上以在所述模具上形成部分浆料涂层,从所述部分浆料涂层中排出至少一部分所述液体,由此形成排出的部分浆料涂层,
将浆料组合物涂于所述排出的部分浆料涂层上形成润湿的浆料涂层,从所述润湿的浆料涂层中排出至少部分所述液体形成排出的浆料涂层,并将耐火灰泥材料涂于所述排出的浆料涂层上,由此形成耐火灰泥和浆料涂层,在其改进中,所述液体粘合剂组合物包括0.1至70wt%无机纤维。
16.权利要求15的方法,其中所述液体粘合剂组合物进一步包括20-98wt%的含无机颗粒的溶胶和1-20wt%有机聚合物,所述耐火粉末包括具有小于600目的平均颗粒尺寸的无机颗粒。
17.权利要求15的方法,其中所述无机纤维具有大于30的平均长径比。
18.权利要求15的方法,其中在干燥后反复将所述组合物涂于所述模具上形成浆料涂布的模具,并将所述耐火灰泥涂于所述浆料涂布的模具上。
19.一种形成壳模的方法,包括提供含0.1至70wt%的无机纤维的熔模铸造壳模组合物,提供一次熔模,将所述组合物涂于模具上形成粘合剂涂布的模具,将耐火粉末涂于所述粘合剂涂布的模具上形成粘合剂和粉末模涂层,其改进中包括粘合剂组合物。
20.权利要求19的方法,其中所述熔模铸造壳模组合物还包括1至20wt%的有机聚合物。
21.一种通过包括如下步骤的方法形成的壳模,所述方法包括:提供含粘合剂组合物的熔模铸造壳模组合物,该粘合剂组合物包括20-98wt%的含无机颗粒的溶胶、1-20wt%有机聚合物和0.1至70wt%无机纤维的混合物,将耐火粉末施于粘合剂中形成浆料,提供底涂布的一次熔模,将该浆料组合物涂于模具上形成浆料涂布的模具,排出并涂布干燥的耐火灰泥层。
22.一种形成壳模的方法,包括:提供含打底粘合剂组合物的熔模铸造壳模组合物,该打底粘合剂组合物包括20-98wt%的含无机颗粒的溶胶和1-20wt%有机聚合物的混合物;提供一次熔模,将所述组合物涂于所述模具上形成具有粘合剂涂层的粘合剂涂布模具,将耐火粉末施于所述粘合剂涂布的模具上形成粘合剂和粉末模涂层,其改进包括将0.1至70wt%的无机纤维加入所述打底粘合剂组合物中形成含纤维的打底粘合剂组合物。
23.权利要求22的方法,其中所述打底粘合剂组合物具有原始断裂模量(MOR),并且所述含纤维的打底粘合剂组合物具有比所述打底粘合剂组合物的原始断裂模量(MOR)大至少25%的原始断裂模量(MOR)。
24.权利要求22的方法,其中所述打底粘合剂组合物具有原始调整破裂载荷(AFL),并且所述含纤维的打底粘合剂组合物具有比所述打底粘合剂组合物的原始调整破裂载荷(AFL)大至少75%的原始调整破裂载荷(AFL)。
25.权利要求22的方法,其中所述打底粘合剂组合物具有原始调整破裂载荷(AFL),并且所述含纤维的打底粘合剂组合物具有比所述打底粘合剂组合物的原始调整破裂载荷(AFL)大至少75%的原始调整破裂载荷(AFL)。
26.权利要求22的方法,其中无纤维粘合剂涂料按所述粘合剂涂料的方式形成,不同之处在于不含所述纤维,且比所述由含所述纤维的打底粘合剂组合物形成的所述粘合剂涂料薄至少25%。
27.权利要求22的方法,其中所述打底粘合剂组合物具有原始断裂模量(MOR),并且所述含纤维的打底粘合剂组合物具有比所述打底粘合剂组合物的原始断裂模量(MOR)大至少35%的原始断裂模量(MOR)。
28.权利要求22的方法,其中所述打底粘合剂组合物具有原始调整破裂载荷(AFL),并且所述含纤维的打底粘合剂组合物具有比所述打底粘合剂组合物的原始调整破裂载荷(AFL)大至少100%的原始调整破裂载荷(AFL)。
29.权利要求22的方法,其中所述打底粘合剂组合物具有原始断裂模量(MOR),并且所述含纤维的打底粘合剂组合物具有比所述打底粘合剂组合物的原始断裂模量(MOR)大至少50%的原始断裂模量(MOR)。
30.权利要求22的方法,其中所述打底粘合剂组合物具有原始调整破裂载荷(AFL),并且所述含纤维的打底粘合剂组合物具有比所述打底粘合剂组合物的原始调整破裂载荷(AFL)大至少150%的原始调整破裂载荷(AFL)。
31.权利要求22的方法,其中无纤维粘合剂涂料按所述粘合剂涂料的方式形成,不同之处在于不含所述纤维,且所述无纤维粘合剂涂料比由含所述纤维的打底粘合剂组合物形成的所述粘合剂涂料薄至少33%。
32.权利要求22的方法,其中无纤维粘合剂涂料按所述粘合剂涂料的方式形成,不同之处在于不含所述纤维,其具有无纤维的原始断裂模量,并且所述粘合剂和粉末模涂料具有比所述无纤维的原始断裂模量大至少50%的含纤维原始断裂模量。
33.权利要求22的方法,其中无纤维粘合剂涂料按所述粘合剂涂料的方式形成,不同之处在于不含所述纤维,其具有无纤维的原始调整破裂载荷,并且所述粘合剂和粉末模涂料具有比所述无纤维的原始断裂模量大至少150%的含纤维原始调整破裂荷载。
34.权利要求22的方法,其中无纤维的粘合剂涂料按所述粘合剂涂料的方式形成,不同之处在于不含所述纤维,其具有无纤维的原始断裂模量,并且所述粘合剂和粉末模涂料具有比所述无纤维的原始断裂模量大至少25%的含纤维的原始断裂模量。
35.权利要求22的方法,其中无纤维粘合剂涂料按所述粘合剂涂料的方式形成,不同之处在于不含所述纤维,其具有无纤维的原始调整破裂载荷,并且所述粘合剂和粉末模涂料具有比所述无纤维的原始断裂模量大至少100%的含纤维原始调整破裂载荷。
36.一种通过包括如下步骤的方法形成的壳模,所述方法包括:提供含粘合剂组合物的熔模铸造壳模组合物,所述粘合剂组合物包括20-98wt%的含无机颗粒的溶胶、1-20wt%有机聚合物和0.1至70wt%无机纤维的混合物,将所述组合物涂于模具上形成粘合剂涂布的模具,将耐火粉末涂于粘合剂涂布的模具上形成粘合剂和粉末模涂层,并将所述粘合剂和粉末模涂层烧制形成壳模。
37.一种通过包括如下步骤的方法形成的原始壳模,所述方法包括:提供含粘合剂组合物的熔模铸造壳模组合物,该粘合剂组合物包括20-98wt%的含无机颗粒的溶胶、1-20wt%有机聚合物和0.1至70wt%无机纤维的混合物,将耐火粉末与粘合剂混合形成浆料组合物,提供底涂布的一次熔模,将浆料组合物涂于模具上以在所述模具上形成湿浆料涂层,从所述湿浆料涂层中排出至少一部分所述水以形成排干的浆料涂层,将粗耐火灰泥涂于所述排干的浆料涂层上并从所述排干的浆料涂层中取出所述模具,由此形成原始壳模。
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- 2000-05-09 ES ES00932183T patent/ES2218160T3/es not_active Expired - Lifetime
- 2000-05-09 EP EP00932183A patent/EP1207975B1/en not_active Expired - Lifetime
- 2000-05-09 WO PCT/US2000/012571 patent/WO2001014082A1/en active IP Right Grant
- 2000-05-09 BR BR0013491-0A patent/BR0013491A/pt not_active Application Discontinuation
- 2000-05-09 DE DE60010721T patent/DE60010721T2/de not_active Expired - Lifetime
- 2000-05-09 AT AT00932183T patent/ATE266488T1/de not_active IP Right Cessation
- 2000-05-09 JP JP2001518208A patent/JP2003507189A/ja active Pending
- 2000-05-09 CN CNB008120560A patent/CN1250360C/zh not_active Expired - Fee Related
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2004
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Cited By (9)
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CN101184563B (zh) * | 2005-03-31 | 2010-09-29 | 邦特罗克实业公司 | 熔模铸造模具制造方法 |
CN101885036A (zh) * | 2010-06-25 | 2010-11-17 | 武汉市智发科技开发有限公司 | 增强快干硅溶胶的改性配方 |
CN103260791A (zh) * | 2010-12-08 | 2013-08-21 | 纳尔科公司 | 具有有机组分的改进的熔模铸造壳 |
CN103260791B (zh) * | 2010-12-08 | 2017-02-15 | 纳尔科公司 | 具有有机组分的改进的熔模铸造壳 |
CN107598076A (zh) * | 2017-08-01 | 2018-01-19 | 安徽霍山科皖特种铸造有限责任公司 | 一种熔模铸造陶瓷型壳用硅溶胶粘结剂的制备方法 |
CN112236246A (zh) * | 2018-08-30 | 2021-01-15 | 洛迈英国有限公司 | 包模铸造壳体粘合剂及组合物 |
CN113811405A (zh) * | 2019-03-29 | 2021-12-17 | 古德温公开有限公司 | 熔模粉末 |
CN113811405B (zh) * | 2019-03-29 | 2024-02-27 | 鼓德温公开有限公司 | 熔模粉末 |
CN113547067A (zh) * | 2021-07-20 | 2021-10-26 | 惠州市吉邦精密技术有限公司 | 熔模精密铸造用硅溶胶粘接剂、熔模精密铸造用膜壳面层浆料、以及熔模精密铸造方法 |
Also Published As
Publication number | Publication date |
---|---|
WO2001014082A1 (en) | 2001-03-01 |
CA2376263C (en) | 2009-01-13 |
JP2003507189A (ja) | 2003-02-25 |
EP1207975A1 (en) | 2002-05-29 |
DE60010721D1 (de) | 2004-06-17 |
CN1250360C (zh) | 2006-04-12 |
ES2218160T3 (es) | 2004-11-16 |
CA2376263A1 (en) | 2001-03-01 |
DE60010721T2 (de) | 2004-10-07 |
EP1207975B1 (en) | 2004-05-12 |
BR0013491A (pt) | 2002-05-14 |
ATE266488T1 (de) | 2004-05-15 |
US20050194118A1 (en) | 2005-09-08 |
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