EP3357602B1 - Shell mold sintering method and apparatus - Google Patents

Shell mold sintering method and apparatus Download PDF

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Publication number
EP3357602B1
EP3357602B1 EP16905240.4A EP16905240A EP3357602B1 EP 3357602 B1 EP3357602 B1 EP 3357602B1 EP 16905240 A EP16905240 A EP 16905240A EP 3357602 B1 EP3357602 B1 EP 3357602B1
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EP
European Patent Office
Prior art keywords
shell mold
sintering
temperature
chamber
shell
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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EP16905240.4A
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German (de)
English (en)
French (fr)
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EP3357602A1 (en
EP3357602A4 (en
Inventor
Zhengda CAI
Yaoming CAI
Yuchi Tsai
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Publication of EP3357602A4 publication Critical patent/EP3357602A4/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02—Lost patterns
    • 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
    • B22C1/165—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 in the manufacture of multilayered shell moulds
    • 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
    • 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
    • B22C9/043—Removing the consumable pattern
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B17/00—Furnaces of a kind not covered by any preceding group
    • F27B17/0016—Chamber type furnaces
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B5/00—Muffle furnaces; Retort furnaces; Other furnaces in which the charge is held completely isolated
    • F27B5/04—Muffle furnaces; Retort furnaces; Other furnaces in which the charge is held completely isolated adapted for treating the charge in vacuum or special atmosphere
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B5/00—Muffle furnaces; Retort furnaces; Other furnaces in which the charge is held completely isolated
    • F27B5/06—Details, accessories, or equipment peculiar to furnaces of these types
    • F27B5/16—Arrangements of air or gas supply devices

Definitions

  • the present invention relates to precision casting process, particularly to a shell mold sintering method and special apparatus for the same.
  • Precision casting is a casting method relative to traditional casting process, capable of obtaining a relatively accurate shape and higher casting precision.
  • the precision casting process is: first, producing a wax mold, having a size and shape consistent with a product to be cast; then forming a ceramic shell on a surface of the produced wax mold; afterwards, dewaxing the ceramic shell (removing the wax mold inside after melting); later, sintering the ceramic shell at a high temperature; finally, pouring a metal material into the sintered ceramic shell, after the metal material is cooled and solidified, crushing to remove the ceramic shell, and the obtained casting is the required product.
  • the common method of producing a ceramic mold is: shell mold method, specifically water soluble silica sol shell production method, in which, during production of a ceramic shell, a ceramic shell with the required thickness is produced by preparing different pulp and sand with refractory materials, and stacking one layer of pulp over one layer of sand on the surface of the wax mold. Then, the ceramic shell made is dried, dewaxed, put in a sintering machine and sintered under the high temperature of 900 ⁇ 1400°C. Since sintering is an essential part to make the shell mold, the sintering quality has a direct influence on the quality of shell mold as well as that of final castings.
  • platform-type sintering furnace or tunnel-type sintering furnace is always applied for sintering shell mold.
  • the temperature is heated to shell mold sintering temperature for sintering.
  • the difference between two is: According as whether or not ventilation chimney is provided, the platform-type sintering furnace is divided into an enclosed platform-type sintering furnace, as shown in Fig. 1-1 and a convective platform-type sintering furnace as shown in Fig. 1-2 .
  • control system 4 controls heating apparatus 2 to heat sintering furnace chamber 1 until the temperature in sintering furnace chamber 1 reaches the shell mold sintering temperature, and control system 4 controls the heating apparatus to maintain the temperature in the sintering furnace chamber 1 so as to sinter the shell mold, and the sintering furnace chamber 1 is approximately closed during the whole process.
  • the shell mold is dewaxed, its sprue cup is downturned on the platform of sintering furnace chamber 1, then closure door 4 is closed, at the same time, control system 5 controls heating apparatus 2 to heat sintering furnace chamber 1 until the temperature in sintering furnace chamber 1 reaches the shell mold sintering temperature, and control system 5 controls the heating apparatus to maintain the temperature in the sintering furnace chamber 1 so as to sinter the shell mold. Since the sintering furnace chamber 1 is connect with open convection pass 3, the whole sintering process is at thermal convection.
  • Fig. 2 Current tunnel-type sintering furnace is shown as Fig. 2 . Its sintering process is: After the shell mold is dewaxed, its sprue cup is downturned on a slab trolley 3, which is pushed into the sintering furnace chamber 1, then closure door 4 is closed, at the same time, control system 5 starts heating apparatus 2 to heat sintering furnace chamber 1 until the temperature in sintering furnace chamber 1 reaches the shell mold sintering temperature, and control system 5 controls the heating apparatus to maintain the temperature in the sintering furnace chamber 1 so as to sinter the shell mold. Since guide rails are laid under the sintering furnace chamber 1, it can't be fully closed, and the whole sintering process is at thermal convection.
  • one of purposes of the present invention is to provide a shell mold sintering method, which includes following steps:
  • step S1 of adding carbon powder during the shell mold production process specifically is:
  • Addition of carbon powder at each layer may increase layer-by-layer from the internal additive layer.
  • the total addition of carbon powder may be 15% ⁇ 20% of shell mold mass.
  • the carbon powder may be graphite.
  • step S2 sufficient oxygen content can be ensured under the sintering environment through making turbulent airflow in the sintering environment.
  • combustion temperature of the shell mold wax in step S2 is set as 600°C ⁇ 800°C.
  • the holding time to maintain the temperature in the sintering furnace in step S2 is preset according to the shape and complexity of shell mold.
  • the holding time is set as 5 ⁇ 20min.
  • the holding time to maintain the temperature in the sintering furnace to be the sintering temperature of shell mold in step S4 is preset according to the shape and complexity of shell mold.
  • the holding time is set as 30 ⁇ 180min.
  • the sintering temperature of the shell mold in the step S4 is preset according to the shape and complexity of shell mold.
  • the sintering temperature of the shell mold is set as 1200 ⁇ 1400°C.
  • the other purpose of the present invention is to provide a sintering device based on the shell mold sintering method above.
  • the device is comprised of a shell mold placement platform, a heating apparatus, an air-blowing apparatus, an exhaust flue, a control system, a sintering chamber and a closure door; a shell mold sprue cup to be sintered is downturned on the shell mold placement platform; the shell mold placement platform is installed in the sintering chamber; the closure door can open or close the sintering chamber; the heating apparatus can heat the sintering chamber; one end of the air inlet of the air-blowing apparatus is located out of the sintering apparatus, and one end of the air outlet is located in the sintering chamber; a switching device is installed in the exhaust flue; one end of its air inlet is located in the sintering chamber, and one end of its air outlet is located out of the sintering apparatus; the control system comprises a temperature sensing module and a control module, wherein the temperature sens
  • the present disclosure also relates to a working process not part of the present invention of the sintering apparatus, which is:
  • the set temperature of the first stage is 600°C ⁇ 800°C.
  • the set temperature range set of the first stage is from the wax combustion temperature to the carbon powder combustion temperature.
  • the set temperature range of the first stage is 600°C ⁇ 800°C.
  • the set temperature of the second stage is 1200°C ⁇ 1400°C.
  • the set temperature of the second stage is the shell mold sintering temperature and the set temperature range of the second stage can be shell mold sintering temperature ⁇ 100°C.
  • the set temperature range of the second stage is 1200°C ⁇ 1400°C.
  • the shell mold placement platform may be fixedly installed in the sintering chamber or movably linked with the sintering chamber.
  • the air-blowing apparatus and exhaust flue may form turbulent airflow in sintering chamber and the wind of the turbulent airflow is not strong enough to blow the grog into the shell mold.
  • a switching device B may be provided within the air-blowing passage of air-blowing apparatus to open or close the air-blowing passage.
  • the switching device B in the air-blowing apparatus may be installed outside the air outlet of sintering chamber wall where the air-blowing apparatus is located.
  • the switching device in exhaust flue may be installed outside the air inlet of sintering chamber wall where the exhaust flue is located.
  • control system also includes an oxygen concentration monitoring module, of which one end is connected into the sintering chamber to monitor oxygen concentration in the sintering chamber in real time, while the other end is connected with a control module to feed back the real-time oxygen concentration in the sintering chamber to the control module; the control module can control the output power of air-blowing apparatus according to acquired oxygen concentration.
  • one end face of the shell mold placement platform for placing shell mold may be provided with a groove, and the width of the groove enables the grog generated through shell mold sintering to fall into the groove without causing that the shell mold itself slides into the groove to give rise to shell mold tilting.
  • the turbulent airflow formed in the sintering chamber through the air-blowing apparatus and exhaust flue, may get into the shell mold along the groove from sprue cup of the shell mold.
  • the turbulent airflow may form convection inside the shell mold; in case of multiple sprue cups for the shell mold, the turbulent airflow may form circulation in the shell mold.
  • a detachable or replaceable slab is placed or installed on the shell mold placement platform with the shell mold placed on one end face of the slab, the end face of the slab for placing the shell mold is provided with a groove whose width enables the grog generated through shell mold sintering to fall into the groove without causing the shell mold itself to slide into the groove, which would give rise to shell mold tilting.
  • the slab is a composite slab is a combined slab, formed by a plurality of sub-structural slabs on the whole.
  • the groove is obtained through a wavy end face.
  • the shell mold sprue cup wall to be sintered is downturned on the crest of wavy end face.
  • the crest for wave structure of the wavy end face is 3 ⁇ 10cm.
  • the exhaust flue is installed with a vibration device and a soot door, and the vibration device can shake off the smoke dust attached on the inner wall of exhaust flue to the soot door of flue.
  • the vibration device includes: a vibrating motor, a drive device and a control device.
  • the vibrating motor is movably installed on the outside wall of upstake flue;
  • the control device is connected with the vibrating motor and can control the on or off of the vibrating motor, at the same time, it can control the movement of vibrating motor along the outside wall of upstake flue through the drive device.
  • the drive device may include a drive motor and a motional orbit.
  • the control device is connected with the drive motor and can control the movement of vibrating motor along the motional orbit outside wall of upstake flue through the drive motor according to preset program.
  • the inventor provides a new shell mold sintering method, which includes the following steps: S1. Producing a shell mold, wherein graphite needs to be added during the shell mold production process.
  • the additive amount of graphite shall be 20% of the shell mold mass; the details of additive positions of graphite are as follows:
  • Additive amount of carbon powder at each layer increases layer-by-layer from the internal additive layer.
  • the additive amount of graphite shall be 15% of the shell mold mass.
  • the holding time of Step S2 is preset to be 5 ⁇ 20min according to the shape and complexity of shell mold.
  • the time to maintain the temperature in sintering furnace as the sintering temperature of shell mold in step S4 is preset to be 30 ⁇ 180min according to the shape and complexity of shell mold.
  • the sintering temperature of the shell mold in step S4 is preset to be 1200°C ⁇ 1400°C according to the shape and complexity of shell mold.
  • the present invention also provides a shell mold sintering apparatus.
  • the apparatus comprises shell mold placement platform 1, heating apparatus 2, air-blowing apparatus 3, exhaust flue 4, control system 5, sintering chamber 6 and closure door 7.
  • the shell mold placement platform 1 is installed in the sintering chamber 6, the shell mold sprue cup to be sintered is downturned on the shell mold placement platform 1, and the surface the shell mold placement platform 1 contacting with the shell mold sprue cup is of wavy structure with a crest height of 10cm, at this moment, the sprue cup is downturned and placed on crest by hanging in the air.
  • the crest height of the shell mold placement platform 1 can be 3cm.
  • the crest height of the shell mold placement platform 1 can be 5cm.
  • the shell mold placement platform 1 can be installed in the sintering chamber 6 with a detachable movable connection structure.
  • the wavy structure on the shell mold placement platform 1 can be replaced by other structures with groove.
  • the shell mold placement platform 1 is a slab platform, on which a sintered plate 11 combined by multiple sub-slabs 12 is placed.
  • the shell mold is downturned on the sintered plate 11.
  • the surface the sintered plate 11 contacting with the shell mold is of wavy structure with a crest height of 10cm, at this moment, the sprue cup of shell mold is downturned and placed on the crest of the sintered plate 11 by hanging in the air.
  • the crest height of the sintered plate can be 3cm.
  • the crest height of the sintered plate can be 5cm.
  • the wavy structure on the sintered plate can be replaced by other structures with groove.
  • the closure door 7 can open or close the sintering chamber 6.
  • the heating apparatus 2 can heat the sintering chamber 6.
  • the air inlet of the air-blowing apparatus 3 is provided outside the sintering apparatus, while the air outlet is provided in the sintering chamber 6.
  • the switching device 31 is installed in the air-blowing passage, which can open or close the air-blowing passage.
  • the switching device 31 in the air-blowing apparatus is installed outside the air outlet of air-blowing apparatus on the wall of sintering chamber 6.
  • the switching device 41 is installed in the exhaust flue 4, with the air inlet provided in the sintering chamber and the air outlet provided outside the sintering apparatus.
  • the switching device in the exhaust flue is installed outside the air inlet of exhaust flue on the wall of sintering chamber 6.
  • the exhaust flue is installed with a vibration device 42 and a soot door 43, and the vibration device can shake off the smoke dust attached on the inner wall of exhaust flue to the soot door of flue.
  • the vibration device 42 includes a vibrating motor, a drive device and a control device.
  • the vibrating motor is movably installed on the outside wall of upstake flue; the drive device includes drive motor and motional orbit; the control device is connected with the vibrating motor and drive motor, can control the on or off of the vibrating motor through the preset program, and can control the movement of the vibrating motor along the motional orbit on the outside wall of upstake flue through the drive motor.
  • the smoke dust shaken off can be removed out from the soot door 43.
  • a turbulent airflow is formed in the sintering chamber 6 under the combined action of air-blowing apparatus 3 and exhaust flue 4.
  • the turbulent airflow can flow into the shell mold from the place where the sprue cup of shell mold is placed by hanging in the air.
  • the turbulent airflow can form convection in the shell mold; in the case of several sprue cups for shell mold, turbulent airflow can form circulation in the shell mold.
  • the wind blown in by the air-blowing apparatus 3 is not strong enough to blow the grog into the shell mold.
  • the control system 5 comprises a temperature sensing module 51 and a control module 52.
  • the temperature sensing module 51 is installed in the sintering chamber 6, capable of sensing the ambient temperature in the sintering chamber 6 and feeding back the temperature data to the control module 52;
  • the control module 52 is connected with the heating apparatus 2, air-blowing apparatus 3 and exhaust flue 4 as well as the switching device 31 in the air-blowing apparatus 3 and the switching device 41 in the exhaust flue 4 respectively, capable of controlling the on or off of the heating apparatus, air-blowing apparatus, exhaust flue and switching devices 31 and 41 according to a preset program.
  • control system 5 also includes an oxygen concentration monitoring module, of which one end is connected into the sintering chamber 6 to monitor the real-time oxygen concentration in the sintering chamber 6, while the other end is connected with the control module 52 to feedback the real-time oxygen concentration in the sintering chamber 6 to the control module 52; the control module 52 controls the output power of the air-blowing apparatus 3 according to the acquired oxygen concentration.
  • an oxygen concentration monitoring module of which one end is connected into the sintering chamber 6 to monitor the real-time oxygen concentration in the sintering chamber 6, while the other end is connected with the control module 52 to feedback the real-time oxygen concentration in the sintering chamber 6 to the control module 52; the control module 52 controls the output power of the air-blowing apparatus 3 according to the acquired oxygen concentration.
  • the working process of the shell mold sintering apparatus of the present invention is as follows:
  • the adoption of the sintering method and apparatus of the present invention can not only reduce the problems of unstable casting quality in the casting process of shell mold as well as high defective and rejection rates of casting, improving the production efficiency and lowering the production cost, but also enable the production of castings with high precision.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Manufacture And Refinement Of Metals (AREA)
EP16905240.4A 2016-06-12 2016-08-31 Shell mold sintering method and apparatus Active EP3357602B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CN201610411520.0A CN105903898B (zh) 2016-06-12 2016-06-12 壳模烧结方法及装置
PCT/CN2016/097555 WO2017215127A1 (zh) 2016-06-12 2016-08-31 壳模烧结方法及装置

Publications (3)

Publication Number Publication Date
EP3357602A1 EP3357602A1 (en) 2018-08-08
EP3357602A4 EP3357602A4 (en) 2019-04-10
EP3357602B1 true EP3357602B1 (en) 2021-03-03

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EP16905240.4A Active EP3357602B1 (en) 2016-06-12 2016-08-31 Shell mold sintering method and apparatus

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EP (1) EP3357602B1 (zh)
KR (1) KR102069459B1 (zh)
CN (1) CN105903898B (zh)
TW (1) TWI622569B (zh)
WO (1) WO2017215127A1 (zh)

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Publication number Priority date Publication date Assignee Title
CN106734883B (zh) * 2017-01-03 2018-10-02 蔡耀名 壳模烧结装置和方法
CN113953449B (zh) * 2021-09-30 2023-12-29 鹰普（中国）有限公司 一种能够快速去除复杂产品型腔模壳的制壳工艺

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Also Published As

Publication number Publication date
CN105903898B (zh) 2017-12-05
WO2017215127A1 (zh) 2017-12-21
EP3357602A1 (en) 2018-08-08
EP3357602A4 (en) 2019-04-10
KR102069459B1 (ko) 2020-01-22
KR20180074757A (ko) 2018-07-03
CN105903898A (zh) 2016-08-31
TWI622569B (zh) 2018-05-01
TW201742852A (zh) 2017-12-16

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