JP2006198677A - Composition of facing material - Google Patents
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- JP2006198677A JP2006198677A JP2005257846A JP2005257846A JP2006198677A JP 2006198677 A JP2006198677 A JP 2006198677A JP 2005257846 A JP2005257846 A JP 2005257846A JP 2005257846 A JP2005257846 A JP 2005257846A JP 2006198677 A JP2006198677 A JP 2006198677A
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Abstract
Description
本発明は、塗型剤組成物に関する。 The present invention relates to a coating composition.
鋳造用塗型剤は、溶融金属が接する鋳型表面に塗布又は噴霧（ぶっかけも含む）して、塗膜を塗装することにより、鋳型の表面を保護し、溶融金属と鋳型表面との化学反応や、鋳物の焼着欠陥の発生を防止するために用いられるものである。このような塗型剤は、一般に、耐火性粒子、粘結剤、焼結剤、分散媒（溶媒）等で構成されている。これらのうち、耐火性粒子は塗型基材であり、鋳物の焼着防止を主目的とし、ジルコン、シリカ、マグネシア、クロマイト、黒鉛等の粉末（骨材）が用いられる。 The casting mold agent is applied or sprayed (including bukkake) to the mold surface where the molten metal comes into contact, and the coating surface is applied to protect the mold surface, and the chemical reaction between the molten metal and the mold surface It is used to prevent the occurrence of casting defects in castings. Such a coating agent is generally composed of refractory particles, a binder, a sintering agent, a dispersion medium (solvent) and the like. Among these, the refractory particles are a coating base material, mainly for preventing casting seizure, and powders (aggregates) such as zircon, silica, magnesia, chromite, and graphite are used.
特許文献１には、塗型剤にひる石、黒曜石、真珠岩、天然雲母など加熱により結晶水が膨張する物質を含む塗型剤を圧力鋳造用中子に塗布することが開示されている。特許文献２には、真珠岩、黒曜岩を加熱粉砕して塗型剤に用いることが開示されている。また、消失模型用の塗型剤に関して、特許文献３には、示差熱分析による吸熱ピーク温度が特定範囲にある鉱石を塗型剤に用いることが開示されている。
しかしながら、鋳物品質の向上、特に平滑で高品質の鋳肌を得ることについては、更なる向上が望まれる。 However, further improvement is desired for improving casting quality, particularly for obtaining a smooth and high-quality casting surface.
また、実際の作業現場では、鋳物方案や耐火温度などを考慮して経験的に耐火性粒子を選定することも多く、鋳型ばらし後の塗型離れ性は必ずしも良好ではなかった。このため、鋳物に残留した塗型膜を取り去るために、通常５分〜１時間のショットブラスト工程が設けられている。 Also, in actual work sites, refractory particles are often selected empirically in consideration of the casting method and the refractory temperature, and the mold releasability after mold casting is not always good. For this reason, in order to remove the coating film remaining on the casting, a shot blasting process of usually 5 minutes to 1 hour is provided.
本発明の課題は、鋳物からの塗型膜離れが良く、鋳肌が美麗な鋳物が得られる塗型剤組成物を提供することである。 The subject of this invention is providing the coating agent composition from which the casting film separation from a casting is good and a casting with a beautiful casting surface is obtained.
本発明は、耐火性粒子を含有する塗型剤組成物であって、塗型剤組成物における灰分中のＡｌ2Ｏ3の含有量が３０〜８０重量％、且つ灰分中のＮａ2ＯとＫ2Ｏとの合計の含有量が１．５〜７重量％である塗型剤組成物に関する。 The present invention is a coating composition containing refractory particles, wherein the content of Al 2 O 3 in the ash content in the coating composition is 30 to 80% by weight, and Na 2 O in the ash content The present invention relates to a coating agent composition having a total content of K 2 O of 1.5 to 7% by weight.
また、本発明は、鋳型表面に、上記本発明の塗型剤組成物を塗布してなる鋳型、及び該鋳型を用いて製造された鋳物に関する。 The present invention also relates to a mold obtained by applying the above-mentioned coating agent composition of the present invention to the mold surface, and a casting manufactured using the mold.
本発明によれば、鋳物からの塗型膜離れが良く、鋳肌が美麗な鋳物が得られる塗型剤組成物が提供される。 ADVANTAGE OF THE INVENTION According to this invention, the coating agent composition from which the casting film separation from a casting is favorable and a casting with a beautiful cast surface is obtained is provided.
本発明の塗型剤組成物は、灰分中のＡｌ2Ｏ3の含有量が３０〜８０重量％、且つＮａ2ＯとＫ2Ｏとの合計の含有量が１．５〜７重量％である塗型剤組成物である。 In the coating composition of the present invention, the content of Al 2 O 3 in the ash is 30 to 80% by weight, and the total content of Na 2 O and K 2 O is 1.5 to 7% by weight. It is a certain coating composition.
本発明では、塗型剤組成物の灰分中のＡｌ2Ｏ3の含有量とＮａ2ＯとＫ2Ｏとの合計の含有量とを特定範囲とすることにより、鋳物からの塗型膜離れが良く、鋳肌が美麗な鋳物が得られるという格別顕著な効果が奏される。このような顕著な効果が発現される理由は定かではないが、本発明の塗型剤組成物における灰分中のＡｌ2Ｏ3の含有量を３０〜８０重量％とすること（例えば、Ａｌ2Ｏ3成分を多量に含むアルミナ、ムライト等を適量配合すること）、かつ、Ｎａ2ＯとＫ2Ｏとの合計の含有量を１．５〜７重量％とすること（例えば、Ｎａ2ＯやＫ2Ｏの成分を多量に含む黒曜石、真珠岩及び松脂岩等を適量配合すること）により、溶湯が酸化しにくい雰囲気を維持しかつ強固な塗型膜をつくり、また、溶湯（約１４００℃）と接触した時点で、塗型膜表面が溶融し、塗型膜と溶湯との接触面積が減少するため、鋳物からの塗型膜離れが良く、鋳肌が美麗な鋳物が得られるものと推察される。 In the present invention, the content of Al 2 O 3 in the ash content of the coating composition and the total content of Na 2 O and K 2 O are within a specific range, thereby separating the coating film from the casting. And a particularly remarkable effect that a casting with a beautiful casting surface can be obtained. The reason why such a remarkable effect is manifested is not clear, but the content of Al 2 O 3 in the ash content in the coating composition of the present invention is 30 to 80% by weight (for example, Al 2 A suitable amount of alumina, mullite, etc. containing a large amount of O 3 component is blended), and the total content of Na 2 O and K 2 O is 1.5-7 wt% (for example, Na 2 O In addition, an appropriate amount of obsidian, pearlite, pinestone, and the like containing a large amount of components of K 2 O and the like can be used to maintain an atmosphere in which the molten metal is difficult to oxidize and create a strong coating film. ℃)), the coating film surface melts and the contact area between the coating film and the molten metal decreases, so that the casting film can be separated from the casting and the casting surface is beautiful. It is guessed.
本発明の塗型剤組成物における灰分中のＡｌ2Ｏ3の含有量とＮａ2ＯとＫ2Ｏとの合計の含有量は、以下の方法により測定される。即ちＪＩＳ−Ｍ８８１２（１９９３）「灰分定量方法」に従って、塗型剤組成物から灰分を取り出し、ＪＩＳ−Ｒ２２１２（１９９１）「耐火れんが及びモルタルの化学分析方法」に従って灰分中の成分を溶液化し、島津シーケンシャル形高周波プラズマ発光分析装置「ＩＣＰＳ−１０００ IV」で溶液中の成分分析を行うことにより測定される。 The content of Al 2 O 3 in the ash content and the total content of Na 2 O and K 2 O in the coating composition of the present invention are measured by the following method. That is, ash content is extracted from the coating composition according to JIS-M8812 (1993) “Method for quantifying ash content”, and the components in the ash content are made into solutions according to JIS-R2212 (1991) “chemical analysis method for refractory bricks and mortar”. It is measured by analyzing the components in the solution with a sequential type high frequency plasma emission analyzer “ICPS-1000 IV”.
本発明の塗型剤組成物における灰分の由来となる成分としては、耐火性粒子、ベントナイトなどの焼結剤などが挙げられる。 Examples of components that are derived from ash in the coating composition of the present invention include refractory particles and sintering agents such as bentonite.
本発明の塗型剤組成物における灰分中のＡｌ2Ｏ3の含有量は、３０〜８０重量％である。強固な塗膜をつくり、鋳肌が美麗な鋳物を得るという観点から、３０重量％以上、好ましくは３２重量％以上、更に好ましくは３５重量％以上である。塗型膜離れが良いという観点から、８０重量％以下、好ましくは７５重量％以下、更に好ましくは７０重量％以下である。以上の観点から、好ましくは３０〜７０重量％、更に好ましくは３０〜６０重量％である。 The content of Al 2 O 3 in the ash in the coating composition of the present invention is 30 to 80% by weight. From the viewpoint of forming a strong coating film and obtaining a casting with a beautiful casting surface, it is 30% by weight or more, preferably 32% by weight or more, and more preferably 35% by weight or more. From the viewpoint of good separation of the coating film, it is 80% by weight or less, preferably 75% by weight or less, more preferably 70% by weight or less. From the above viewpoint, it is preferably 30 to 70% by weight, and more preferably 30 to 60% by weight.
本発明の塗型剤組成物における灰分中のＮａ2ＯとＫ2Ｏとの合計の含有量は、１．５〜７重量％である。溶湯と接触した時点で、塗型膜表面を速やかに溶融させる観点から、１．５重量％以上、好ましくは１．６重量％以上、更に好ましくは１．７重量％以上である。塗型膜に十分な耐熱性を持たせるという観点から、７重量％以下、好ましくは６重量％以下、更に好ましくは５重量％以下である。以上の観点から、好ましくは１．６〜６重量％、更に好ましくは１．７〜５重量％である。Ｎａ2ＯとＫ2Ｏとの合計とは、Ｎａ2Ｏ単独あるいはＫ2Ｏ単独の場合であってもよく、Ｎａ2ＯとＫ2Ｏとを共に含有する場合は、Ｎａ2Ｏ／Ｋ2Ｏ（重量比）は１／３〜３／１が好ましく、１／２〜２／１が更に好ましい。 The total content of Na 2 O and K 2 O in the ash in the coating composition of the present invention is 1.5 to 7% by weight. From the viewpoint of promptly melting the surface of the coating film upon contact with the molten metal, the amount is 1.5% by weight or more, preferably 1.6% by weight or more, and more preferably 1.7% by weight or more. From the viewpoint of imparting sufficient heat resistance to the coating film, it is 7% by weight or less, preferably 6% by weight or less, and more preferably 5% by weight or less. From the above viewpoint, it is preferably 1.6 to 6% by weight, more preferably 1.7 to 5% by weight. The total of Na 2 O and K 2 O may be Na 2 O alone or K 2 O alone. When both Na 2 O and K 2 O are contained, Na 2 O / K 2 O (weight ratio) is preferably 1 / 3-3 / 1, 1/2 to 2/1 is more preferred.
このような比率は、組成が既知の耐火性粒子を組み合わせることで達成できる。例えば、Ｎａ2ＯとＫ2Ｏに着目すれば、黒曜石（ＳｉＯ2：７４％、Ａｌ2Ｏ3：１３％、Ｆｅ2Ｏ3：１．８％、Ｎａ2Ｏ：３．８％、Ｋ2Ｏ：３．９％）、真珠岩（ＳｉＯ2：７３％、Ａｌ2Ｏ3：１２％、Ｆｅ2Ｏ3：１．３％、Ｎａ2Ｏ：３．０％、Ｋ2Ｏ：５．３％）、松脂岩（ＳｉＯ2：７０％、Ａｌ2Ｏ3：１２％、Ｆｅ2Ｏ3：１．５％、Ｎａ2Ｏ：３．０％、Ｋ2Ｏ：３．６％）、正長石（ＳｉＯ2：６５％、Ａｌ2Ｏ3：１８％、Ｋ2Ｏ：１７％）、曹長石（ＳｉＯ2：６９％、Ａｌ2Ｏ3：１９％、Ｎａ2Ｏ：１２％）、白瑠石（ＳｉＯ2：５５％、Ａｌ2Ｏ3：２３％、Ｋ2Ｏ：２２％）、霞石（（Ｎａ，Ｋ）ＡｌＳｉＯ4）等を適宜配合することが好ましい。なお、これらの％は重量％である。中でも、黒曜石、真珠岩及び松脂岩から選ばれる少なくとも一種の耐火性粒子を含有することが好ましく、更に黒曜石を含有することが好ましい。 Such a ratio can be achieved by combining refractory particles of known composition. For example, focusing on Na 2 O and K 2 O, obsidian (SiO 2 : 74%, Al 2 O 3 : 13%, Fe 2 O 3 : 1.8%, Na 2 O: 3.8%, K 2 O: 3.9%), nacre (SiO 2 : 73%, Al 2 O 3 : 12%, Fe 2 O 3 : 1.3%, Na 2 O: 3.0%, K 2 O: 5 .3), pine sebumite (SiO 2 : 70%, Al 2 O 3 : 12%, Fe 2 O 3 : 1.5%, Na 2 O: 3.0%, K 2 O: 3.6%) Anorthite (SiO 2 : 65%, Al 2 O 3 : 18%, K 2 O: 17%), Anorthite (SiO 2 : 69%, Al 2 O 3 : 19%, Na 2 O: 12%) , Leucite (SiO 2 : 55%, Al 2 O 3 : 23%, K 2 O: 22%), meteorite ((Na, K) AlSiO 4 ) and the like are preferably blended as appropriate. In addition, these% are weight%. Among these, it is preferable to contain at least one kind of refractory particles selected from obsidian, pearlite and pine sebite, and it is more preferable to contain obsidian.
一方、Ａｌ2Ｏ3に着目すれば、アルミナ（Ａｌ2Ｏ3：１００％）、ムライト（ＳｉＯ2：２８％、Ａｌ2Ｏ3：７２％）、シャフトバンケツ５０％（ＳｉＯ2：３８％、Ａｌ2Ｏ3：５６％、Ｆｅ2Ｏ3：１．７％、ＴｉＯ2：２．６％）、シャフトバンケツ８５％（ＳｉＯ2：８％、Ａｌ2Ｏ3：８５％、Ｆｅ2Ｏ3：２．１％、ＴｉＯ2：３．３％）、ダイアスポア（Ａｌ2Ｏ3：８５％、Ｈ2Ｏ：１５％）、蝋石（ＳｉＯ2：６７％、Ａｌ2Ｏ3：２８％、Ｈ2Ｏ：５％）、スピネル（ＭｇＯ：２８％、Ａｌ2Ｏ3：７２％）、カオリン（ＳｉＯ2：４６％、Ａｌ2Ｏ3：４０％、Ｈ2Ｏ：１４％）、シリマナイト（ＳｉＯ2：３７％、Ａｌ2Ｏ3：６３％）、アンダルサイト（ＳｉＯ2：３７％、Ａｌ2Ｏ3：６３％）、カイヤナイト（ＳｉＯ2：３７％、Ａｌ2Ｏ3：６３％）、ギブサイト（ＳｉＯ2：３５％、Ａｌ2Ｏ3：６５％）、黒砂石（ＳｉＯ2：４６％、Ａｌ2Ｏ3：３８％、Ｆｅ2Ｏ3：０．３％、ＴｉＯ２：０．４％、ＣａＯ：０．３％、ＭｇＯ：０．１％）、デッカイト（ＳｉＯ2：４３〜４７％、Ａｌ2Ｏ3：３９〜４１％）、灰長石（ＳｉＯ2：４３％、Ａｌ2Ｏ3：３７％、ＣａＯ：２０％）、ボーキサイトを焼成したもの等を適宜配合することが好ましい。なお、これらの％は重量％である。中でも、Ａｌ2Ｏ3を４５重量％以上有する耐火性粒子を含有することが好ましく、アルミナ、ムライト、シャフトバンケツを含有することが更に好ましく、特にムライトを含有することが好ましい。 On the other hand, if attention is focused on Al 2 O 3 , alumina (Al 2 O 3 : 100%), mullite (SiO 2 : 28%, Al 2 O 3 : 72%), shaft bank 50% (SiO 2 : 38%) Al 2 O 3 : 56%, Fe 2 O 3 : 1.7%, TiO 2 : 2.6%), shaft bangs 85% (SiO 2 : 8%, Al 2 O 3 : 85%, Fe 2 O 3 : 2.1%, TiO 2 : 3.3%), diaspore (Al 2 O 3 : 85%, H 2 O: 15%), wax (SiO 2 : 67%, Al 2 O 3 : 28%) , H 2 O: 5%), spinel (MgO: 28%, Al 2 O 3 : 72%), kaolin (SiO 2 : 46%, Al 2 O 3 : 40%, H 2 O: 14%), sillimanite (SiO 2: 37%, Al 2 O 3: 63%), andalusite (SiO 2: 37%, Al 2 O 3: 63%), kyanite Ito (SiO 2: 37%, Al 2 O 3: 63%), gibbsite (SiO 2: 35%, Al 2 O 3: 65%), black sand stone (SiO 2: 46%, Al 2 O 3: 38% , Fe 2 O 3: 0.3% , TiO2: 0.4%, CaO: 0.3%, MgO: 0.1%), Dekkaito (SiO 2: 43~47%, Al 2 O 3: 39~ 41%), anorthite (SiO 2 : 43%, Al 2 O 3 : 37%, CaO: 20%), one obtained by baking bauxite, and the like are preferably blended as appropriate. In addition, these% are weight%. Among these, it is preferable to contain refractory particles having 45% by weight or more of Al 2 O 3 , more preferably alumina, mullite, and shaft bank, and particularly preferably mullite.
従って、本発明では、Ａｌ2Ｏ3を４５重量％以上有する耐火性粒子（ａ）と、黒曜石、真珠岩及び松脂岩から選ばれる少なくとも一種の耐火性粒子（ｂ）の双方を含有することが好ましい。本発明の組成を満たす耐火性粒子の組み合わせの一例として、黒曜石：ムライト＝１：１（重量比）の混合物（該混合物におけるＡｌ2Ｏ3の含有量：３９．７％、同Ｎａ2ＯとＫ2Ｏとの合計の含有量：３．６％）、黒曜石：アルミナ＝１：１（重量比）の混合物（該混合物におけるＡｌ2Ｏ3の含有量：５３．０％、同Ｎａ2ＯとＫ2Ｏとの合計の含有量：３．３％）、黒曜石：シャフトバンケツ５０％＝１：１（重量比）の混合物（該混合物におけるＡｌ2Ｏ3の含有量：３４．７％、同Ｎａ2ＯとＫ2Ｏとの合計の含有量：３．９％）、黒曜石：シャフトバンケツ８５％＝１：１（重量比）の混合物（該混合物におけるＡｌ2Ｏ3の含有量：４７．５％、同Ｎａ2ＯとＫ2Ｏとの合計の含有量：３．４％）、黒曜石：シャフトバンケツ８５％＝１：３（重量比）の混合物（該混合物におけるＡｌ2Ｏ3の含有量：６５．６％、同Ｎａ2ＯとＫ2Ｏとの合計の含有量：１．８％）、黒曜石：ムライト＝１：３（重量比）の混合物（該混合物におけるＡｌ2Ｏ3の含有量：５５．９％、同Ｎａ2ＯとＫ2Ｏとの合計の含有量：１．９％）等が挙げられる。 Therefore, the present invention contains both the refractory particles (a) having 45 wt% or more of Al 2 O 3 and at least one refractory particles (b) selected from obsidian, nacre and pine sebumite. preferable. As an example of a combination of refractory particles satisfying the composition of the present invention, a mixture of obsidian: mullite = 1: 1 (weight ratio) (content of Al 2 O 3 in the mixture: 39.7%, Na 2 O and (Total content with K 2 O: 3.6%), obsidian: alumina = 1: 1 (weight ratio) mixture (Al 2 O 3 content in the mixture: 53.0%, Na 2 O And K 2 O (total content: 3.3%), obsidian: shaft bangs 50% = 1: 1 (weight ratio) mixture (Al 2 O 3 content in the mixture: 34.7%) , The total content of Na 2 O and K 2 O: 3.9%), obsidian: shaft bangs 85% = 1: 1 (weight ratio) mixture (content of Al 2 O 3 in the mixture) : 47.5%, the total content of the same Na 2 O and K 2 O: 3.4%), obsidian: shaft van ass 5% = 1: 3 mixture (weight ratio) (the content of Al 2 O 3 in the mixture: 65.6%, the total content of the same Na 2 O and K 2 O: 1.8%), Obsidian: Mullite = 1: 3 (weight ratio) mixture (content of Al 2 O 3 in the mixture: 55.9%, total content of Na 2 O and K 2 O: 1.9%) Etc.
Ａｌ2Ｏ3を４５重量％以上有する耐火性粒子（ａ）と、黒曜石、真珠岩及び松脂岩から選ばれる少なくとも一種の耐火性粒子（ｂ）との重量比は、塗型膜離れに優れる観点及び鋳肌に優れる観点から、（ａ）／（ｂ）＝１／１〜９／１が好ましく、（ａ）／（ｂ）＝１／１〜５／１がより好ましい。 The weight ratio of the refractory particles (a) having 45% by weight or more of Al 2 O 3 and at least one refractory particles (b) selected from obsidian, nacre and pine sebum is a viewpoint excellent in separating the coating film From the viewpoint of excellent cast surface, (a) / (b) = 1/1 to 9/1 is preferable, and (a) / (b) = 1/1 to 5/1 is more preferable.
なお、本発明の塗型剤組成物では、耐火性粒子として、上記以外のものも使用できるが、塗型剤組成物における灰分中のＳｉＯ2の含有量は、鋳物からの塗型膜離れがし易い観点から、６５重量％以下、更に６０重量％以下、特に４５重量％以下が好ましい。 In the coating composition of the present invention, those other than those described above can be used as the refractory particles, but the content of SiO 2 in the ash content in the coating composition is such that the coating film is separated from the casting. From the viewpoint of easy handling, it is preferably 65% by weight or less, more preferably 60% by weight or less, and particularly preferably 45% by weight or less.
本発明に用いられる耐火性粒子の粒径（メジアン径）は、塗型塗布後の塗膜の粗度の観点から、１００μｍ以下が好ましく、７０μｍ以下が更に好ましく、経済性の観点から、０．５μｍ以上が好ましく、１μｍが更に好ましい。以上の観点から耐火性粒子の粒径は、０．５〜１００μｍが好ましく、１〜７０μｍが更に好ましい。 The particle diameter (median diameter) of the refractory particles used in the present invention is preferably 100 μm or less, more preferably 70 μm or less, from the viewpoint of the roughness of the coating film after coating application, and from the viewpoint of economy, it is preferably set to 0. 5 micrometers or more are preferable and 1 micrometer is still more preferable. From the above viewpoint, the particle diameter of the refractory particles is preferably 0.5 to 100 μm, and more preferably 1 to 70 μm.
本発明の塗型剤組成物中の耐火性粒子の含有量は、本発明の目的を達成する観点から、好ましくは２０〜７０重量％であり、より好ましくは２０〜５０重量％である。 The content of the refractory particles in the coating agent composition of the present invention is preferably 20 to 70% by weight, more preferably 20 to 50% by weight from the viewpoint of achieving the object of the present invention.
溶湯圧や溶湯流量の多い、厳しい鋳造条件のもとにおいては、耐火性粒子中に、黒曜石とムライトの双方を含有することが好ましく、鋳物からの塗型膜離れが良く、鋳肌が美麗な鋳物を得る観点及び耐焼着性に優れる観点から、耐火性粒子中の黒曜石の比率（黒曜石／耐火性粒子の重量比）は、好ましくは０．１／１〜０．４／１であり、より好ましくは０．２／１〜０．３／１であり、耐火性粒子中のムライトの比率（ムライト／耐火性粒子の重量比）は、好ましくは０．６／１〜０．９／１であり、より好ましくは０．７／１〜０．８／１である。 Under severe casting conditions where the molten metal pressure and molten metal flow are high, it is preferable to contain both obsidian and mullite in the refractory particles, and the coating film from the casting is good and the casting surface is beautiful. From the viewpoint of obtaining a casting and a viewpoint of excellent seizure resistance, the ratio of obsidian in the refractory particles (weight ratio of obsidian / refractory particles) is preferably 0.1 / 1 to 0.4 / 1, and more The ratio is preferably 0.2 / 1 to 0.3 / 1, and the ratio of mullite in the refractory particles (weight ratio of mullite / refractory particles) is preferably 0.6 / 1 to 0.9 / 1. Yes, more preferably 0.7 / 1 to 0.8 / 1.
また、ムライトと黒曜石の重量比（ムライト／黒曜石）は、鋳物からの塗型膜離れが良く、鋳肌が美麗な鋳物が得られる観点及び耐焼着性に優れる観点から、１／１〜９／１が好ましく、２／１〜５／１がより好ましい。 In addition, the weight ratio of mullite to obsidian (mullite / obsidian) is 1 / 1-9 / from the viewpoint that the cast film is well separated from the casting, a casting with a beautiful casting surface is obtained, and the seizure resistance is excellent. 1 is preferable, and 2/1 to 5/1 is more preferable.
本発明の塗型剤組成物に用いる分散媒は、水性、油性いずれでもよいが、浸透性の点より油性のものが好ましい。油性塗型剤組成物の場合は、メタノール、エタノール、イソプロピルアルコール等の低級アルコール類、キシレン、トルエン等の芳香族溶剤、ミネラルスピリット等の炭化水素系溶剤が使用できる。好ましくは低級アルコール類であり、特にメタノールが好ましい。芳香族溶剤及び炭化水素系溶剤は補助溶剤として使用してもよい。水性塗型剤組成物の場合は水が主分散媒となる。添加量は、油性の場合、低級アルコールであれば耐火性粒子の合計１００重量部に対し、２０〜１２０重量部が好ましく、７０〜１１０重量部がより好ましい。また、水性の場合、水は耐火性粒子の合計１００重量部に対し、２０〜１５０重量部が好ましく、７０〜１３０重量部がより好ましい。 The dispersion medium used in the coating agent composition of the present invention may be either aqueous or oily, but is preferably oily from the viewpoint of permeability. In the case of an oil-based coating composition, lower alcohols such as methanol, ethanol and isopropyl alcohol, aromatic solvents such as xylene and toluene, and hydrocarbon solvents such as mineral spirits can be used. Preferred are lower alcohols, and methanol is particularly preferred. Aromatic solvents and hydrocarbon solvents may be used as auxiliary solvents. In the case of an aqueous coating composition, water is the main dispersion medium. In the case of oily, the addition amount is preferably 20 to 120 parts by weight, more preferably 70 to 110 parts by weight, based on 100 parts by weight of the total refractory particles if it is a lower alcohol. Moreover, in the case of aqueous | water-based, 20-150 weight part is preferable with respect to a total of 100 weight part of refractory particles, and 70-130 weight part is more preferable.
また、本発明の塗型剤組成物には、通常使用されるような粘結剤を配合できる。例えば、常温で強い塗型膜を形成できるフェノール、ロジン、石油樹脂のような有機粘結剤や、ケイ酸ソーダ、リン酸アルミなどの無機粘結剤がある。条件によりこれらのものを併用してもよい。粘結剤の添加量は耐火性粒子の合計１００重量部に対し、０．５〜２重量部が好ましい。 In addition, a binder as commonly used can be blended in the coating composition of the present invention. For example, there are organic binders such as phenol, rosin and petroleum resin that can form a strong coating film at room temperature, and inorganic binders such as sodium silicate and aluminum phosphate. These may be used in combination depending on conditions. The addition amount of the binder is preferably 0.5 to 2 parts by weight with respect to 100 parts by weight of the total refractory particles.
また、焼結剤としては、ナトリウムベントナイト、カルシウムベントナイト等のベントナイト、木節粘土等の粘土類、エチルシリケート、コロイダルシリカが挙げられる。焼結剤の添加量は耐火性粒子の合計１００重量部に対し、３〜１０重量部が好ましい。 Examples of the sintering agent include bentonites such as sodium bentonite and calcium bentonite, clays such as kibushi clay, ethyl silicate, and colloidal silica. The addition amount of the sintering agent is preferably 3 to 10 parts by weight with respect to 100 parts by weight of the total refractory particles.
その他に、本発明の塗型剤組成物に配合できる成分として、界面活性剤、分散剤、チキソトロピー性付与剤等が挙げられる。 In addition, surfactants, dispersants, thixotropic agents, and the like are listed as components that can be blended in the coating composition of the present invention.
本発明の塗型剤組成物は、一般的な塗型剤と同様に使用できるが、特に砂型用の塗型剤組成物として好適に用いることができる。 Although the coating agent composition of the present invention can be used in the same manner as a general coating agent, it can be suitably used particularly as a sanding coating composition.
本発明の塗型剤組成物を鋳型に塗布する方法は、流し塗り（ブッカケ法）、浸漬する（ドブ漬け法）、刷毛塗り、スプレー塗布等の従来知られている方法の何れでも良いが、流し塗り法が好ましい。また鋳型に用いる鋳物砂としては、石英質を主成分とする珪砂の他、ジルコン砂、クロマイト砂、合成ムライト砂等の新砂又は再生砂が使用される。鋳物砂は粘結剤を添加せずに用いることもでき、その場合には充填性が良好であるが、鋳型強度が必要な場合には、粘結剤を添加し、硬化剤により硬化させるのが好ましい。 The method of applying the coating composition of the present invention to the mold may be any of the conventionally known methods such as flow coating (bukkake method), dipping (dipping method), brush coating, spray coating, etc. A flow coating method is preferred. Further, as the foundry sand used for the casting mold, new sand or reclaimed sand such as zircon sand, chromite sand, synthetic mullite sand, etc. is used in addition to quartz sand mainly composed of quartz. Casting sand can also be used without the addition of a binder, in which case the filling properties are good, but if mold strength is required, a binder is added and cured with a curing agent. Is preferred.
本発明の鋳型を用いて製造される鋳物としては、鋳肌が美麗な鋳物が得られるため、複雑な構造や、鋳肌表面の美しさが要求されるものに好適である。具体的な鋳物の例としては、建設機械の油圧バルブ、モーター、金型、エンジンフレーム、工作機械、建築部材等に用いられる、部材、部品等が挙げられる。 As a casting manufactured using the mold of the present invention, a casting having a beautiful casting surface is obtained, and therefore, it is suitable for a casting that requires a complicated structure and a beautiful casting surface. Specific examples of castings include members, parts, and the like used for hydraulic valves, motors, molds, engine frames, machine tools, building members, and the like of construction machines.
実施例１〜４及び比較例１〜６
フリーマントル珪砂（５号）１００重量部に対して、有機スルホン酸硬化剤（花王クエーカー（株）製ＴＫ−３）を０．２重量部添加混練した後に、フラン樹脂（花王クエーカー（株）製３４０Ｂ）を０．８重量部混合した。これを用い高さ１５０ｍｍ、幅１２０ｍｍ、奥行き１００ｍｍの直方体の鋳型を作製した。
Examples 1-4 and Comparative Examples 1-6
After adding and kneading 0.2 parts by weight of an organic sulfonic acid curing agent (TK-3 manufactured by Kao Quaker Co., Ltd.) to 100 parts by weight of Fremantle quartz sand (No. 5), furan resin (manufactured by Kao Quaker Co., Ltd.) 340B) was mixed with 0.8 part by weight. Using this, a rectangular parallelepiped mold having a height of 150 mm, a width of 120 mm, and a depth of 100 mm was produced.
２４時間放置後、表１に示す耐火性粒子を含有する以下の組成の塗型剤組成物にてブッカケ塗布を行い、溶媒を充分乾燥後、鋳型にＦＣ−２５０の熔湯を１４００℃で注湯し、２４時間経過後、フラン鋳型をばらし、塗型膜の鋳物からの剥がれ方を観察した。その後、２分間のショットブラストを行い、鋳肌を観察した。また、塗型膜の鋳物からの剥がれを、以下の方法で評価した。これらの結果を表１に示す。なお、塗型剤組成物の組成は、耐火性粒子１００重量部、水１００重量部、ナトリウムベントナイト５重量部、デキストリン１重量部、防腐剤０．１重量部である。 After standing for 24 hours, the coating composition of the following composition containing the refractory particles shown in Table 1 was applied, and after the solvent was sufficiently dried, the molten FC-250 was poured into the mold at 1400 ° C. After 24 hours, the furan mold was released and the coating film was peeled off from the casting. Thereafter, shot blasting was performed for 2 minutes, and the cast skin was observed. Further, peeling of the coating film from the casting was evaluated by the following method. These results are shown in Table 1. The composition of the coating agent composition is 100 parts by weight of refractory particles, 100 parts by weight of water, 5 parts by weight of sodium bentonite, 1 part by weight of dextrin, and 0.1 parts by weight of preservative.
＜塗型膜の鋳物からの剥がれ＞
塗型膜の剥がれについては、まず目視にて、完全に剥がれているものを１００％、全く剥がれていないものを０％とした。それ以外は、下記式によって塗型膜の剥がれ度合いを算出した。
塗型膜の剥がれ（％）＝ｗ／Ｗ×１００（％）
ｗ：剥がれた塗型膜の重量（ｇ）
Ｗ：剥がれた塗型膜の一部を切り出して、面積及び重量を測定し、鋳物の全表面積分の塗型膜の重量に換算した値（ｇ）
<Peeling of casting film from casting>
Regarding peeling of the coating film, first, visually, 100% was peeled off, and 0% was not peeled at all. Otherwise, the degree of peeling of the coating film was calculated by the following formula.
Peeling of coating film (%) = w / W × 100 (%)
w: Weight of coating film peeled off (g)
W: A value obtained by cutting out a part of the peeled coating film, measuring the area and weight, and converting to the weight of the coating film for the entire surface area of the casting (g)
比較例２、６では、鋳肌の凹凸が著しく、また比較例３では、鋳物表面に塗型膜の白膜（化学的焼着）が残留した。一方、実施例１〜４では、塗膜の剥がれも少なく、実用上満足できる水準を達成しており、また、鋳肌の状態も良好であった。 In Comparative Examples 2 and 6, the unevenness of the casting surface was remarkable, and in Comparative Example 3, a white film (chemically deposited) of the coating film remained on the casting surface. On the other hand, in Examples 1-4, there was little peeling of a coating film, the level which can be satisfied practically was achieved, and the state of the cast skin was also favorable.
実施例５〜７
鋳物再生砂（５号砂相当）１００重量部に対して、有機スルホン酸硬化剤（花王クエーカー（株）製ＴＫ−３）を０．２８重量部、フラン樹脂（花王クエーカー（株）製３４０Ｂを０．７重量部混合した。これを用い、概形の直径が４８２ｍｍ、高さ５２４ｍｍの円筒形の鋳型中子を作製した。
Examples 5-7
For 100 parts by weight of recycled casting sand (equivalent to No. 5 sand), 0.28 parts by weight of organic sulfonic acid curing agent (TK-3 manufactured by Kao Quaker Co., Ltd.) and 340B of furan resin (Kao Quaker Co., Ltd.) Using this mixture, a cylindrical mold core having a general shape diameter of 482 mm and a height of 524 mm was produced.
２時間放置後、表２に示す耐火性粒子を含有する以下の組成の塗型剤組成物を浸せき塗布を行い、溶剤を充分に乾燥後、概形の直径が５２２ｍｍ、高さ６８６ｍｍの円筒形の空隙を有する主型に設置した。この鋳型に、ＦＣＤ−４５０の溶湯を１４１０℃で注湯し、中空のロール状の鋳物を製造した。この鋳物に、３０分ハンガーショットでショットブラスト処理を行い、焼着の発生及び鋳肌の様子を観察した。これらの結果を表２に示す。なお、塗型膜の鋳物からの剥がれを目視で観察したところ、実施例５〜７それぞれについて、ほぼ塗型膜が剥がれており、良好な結果が得られていることが確認された。また、塗型剤組成物の組成は、耐火性粒子１００重量部、水１００重量部、ナトリウムベントナイト５重量部、デキストリン１重量部、防腐剤０．１重量部である。 After standing for 2 hours, the coating composition of the following composition containing the refractory particles shown in Table 2 was dipped and applied, and after the solvent was sufficiently dried, a cylindrical shape with a rough diameter of 522 mm and a height of 686 mm It was installed in the main mold having the voids. A molten roll of FCD-450 was poured into this mold at 1410 ° C. to produce a hollow roll casting. This casting was subjected to a shot blasting treatment with a hanger shot for 30 minutes, and the occurrence of seizure and the appearance of the casting surface were observed. These results are shown in Table 2. When the peeling of the coating film from the casting was observed with the naked eye, it was confirmed that the coating film was peeled off almost for each of Examples 5 to 7 and good results were obtained. The composition of the coating agent composition is 100 parts by weight of refractory particles, 100 parts by weight of water, 5 parts by weight of sodium bentonite, 1 part by weight of dextrin, and 0.1 parts by weight of preservative.
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| JP2010142867A (en) * | 2008-12-22 | 2010-07-01 | Kao Corp | Coating agent composition for lost foam |
| US20110177284A1 (en) * | 2009-07-16 | 2011-07-21 | Memc Singapore Pte Ltd. | Silicon wafers and ingots with reduced oxygen content and methods for producing them |
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| JP2004034043A (en) * | 2002-06-28 | 2004-02-05 | Toshitake Sugano | Method for molding frozen mold |
| JP2004122159A (en) * | 2002-10-01 | 2004-04-22 | Nippon Chutetsukan Kk | Pouring member for centrifugal casting provided with heat insulating layer, and method of forming the heat insulating layer |
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| JPS5258016A (en) * | 1975-11-10 | 1977-05-13 | Noboru Hidaka | Spalling agent for slag ladle |
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| JP2004034043A (en) * | 2002-06-28 | 2004-02-05 | Toshitake Sugano | Method for molding frozen mold |
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| US20110177284A1 (en) * | 2009-07-16 | 2011-07-21 | Memc Singapore Pte Ltd. | Silicon wafers and ingots with reduced oxygen content and methods for producing them |
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