KR100445223B1 - Composite of ceramic core for vacuum investment casting - Google Patents
Composite of ceramic core for vacuum investment casting Download PDFInfo
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- KR100445223B1 KR100445223B1 KR10-2001-0048709A KR20010048709A KR100445223B1 KR 100445223 B1 KR100445223 B1 KR 100445223B1 KR 20010048709 A KR20010048709 A KR 20010048709A KR 100445223 B1 KR100445223 B1 KR 100445223B1
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/14—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silica
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
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- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
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- C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
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- C04B2235/6023—Gel casting
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/64—Burning or sintering processes
Abstract
본 발명은 형상이 복잡하거나 중공형 부품의 진공정밀주조 과정에서 이용되는 세라믹코어의 조성물에 관한 것으로, 단량체 또는 이량체와 고분자전해질계 분산제가 중량비로 각각 3∼4wt％, 0.6∼0.8wt％, 0.4∼0.6wt％로 혼합된 용매에 고농도로 세라믹혼합물을 분산하면서 혼합시킨 후, 금형 내에 주입하여 20∼25℃의 온도범위에서 일정시간 동안 유지시켜 단량체 또는 이량체를 흡착한 수화젤상태의 성형체로 제조한 다음, 용매가 휘발되는 과정에서 성형체를 이형하고 건조시키면서 열을 가하는 경화공정을 실시한 후 950∼1050℃의 열처리로에서 2∼3시간 동안 소결시키는 것을 특징으로 하여, 세라믹코어의 치수정밀도가 향상됨은 물론 경화공정을 통해 강도 및 인성이 증대되어 제품품질이 향상될 뿐만 아니라, 세라믹코어에 결합제를 첨가하기 위한 작업공수가 줄어들어 작업공수 및 부대비용이 절감되게 한 것이다.The present invention relates to a composition of a ceramic core used in the vacuum precision casting process of a complicated or hollow part, the monomer or dimer and the polymer electrolyte dispersant in a weight ratio of 3 to 4wt%, 0.6 to 0.8wt%, After dispersing and mixing the ceramic mixture in a high concentration in a solvent mixed with 0.4 ~ 0.6wt%, it is injected into a mold and maintained for a predetermined time in the temperature range of 20 ~ 25 ℃ to adsorb the monomer or dimer in the hydrogel state And then sintering for 2 to 3 hours in a heat treatment furnace at 950 to 1050 ° C. after performing a curing process of releasing the molded body and applying heat while drying the molded body in the process of volatilizing the solvent. Not only improves the quality, but also increases the strength and toughness through the hardening process, which not only improves product quality but also adds a binder to the ceramic core. One would have to be reduced airborne airborne troops and cost effective operations.
Description
본 발명은 형상이 복잡하거나 중공형 부품을 진공정밀주조하는 과정에서 이용되는 세라믹 코어에 관한 것으로, 특히 세라믹코어를 수용성매체에서 고분자 라디컬 중합반응을 통해 제조하여 치수정밀도를 향상시킬 수 있도록 된 진공정밀주조용 세라믹 코어의 조성물에 관한 것이다.The present invention relates to a ceramic core used in the process of vacuum precision casting of a complex or hollow part, in particular a vacuum to improve the dimensional accuracy by manufacturing the ceramic core through a polymer radical polymerization reaction in an aqueous medium It relates to a composition of a ceramic core for precision casting.
일반적으로, 세라믹 코어(ceramic core)는 임펠러(impeller)와 같이 형상이 복잡한 부품들이나 또는 가스터빈과 같이 중공형 부품을 진공상태로 정밀주조하는 과정에서 이용되는 성형품으로서, 통상 사출성형법(injection molding) 또는 젤케스팅법(gel casting)에 의해 제조된다.In general, a ceramic core is a molded product used in the process of precisely casting a hollow part such as a gas turbine or a complex part such as an impeller, and is usually an injection molding method. Or by gel casting.
예컨대, 도 1에서와 같이 사출성형법은 세라믹혼합물을 80∼150℃의 온도범위에서 슬러리 상태로 혼합하고 고압상태에서 주조하여 성형한 후 몰드를 제거하는 이형공정, 몰드를 건조하는 건조공정, 몰드의 결합제를 제거하는 제거공정, 경화공정(curing), 소결공정(sintering)의 단계를 갖는다.For example, as shown in Figure 1, the injection molding method is a mixture of the ceramic mixture in a slurry state in the temperature range of 80 ~ 150 ℃, cast under high pressure to form a mold release process to remove the mold, drying process of the mold, drying of the mold It has a step of removing, curing, and sintering to remove the binder.
이때, 사출성형법에 사용하는 세라믹혼합물은 세라믹분말(ceramic powder), 에틸알콜 같은 용매(solvent)와, 가소제(plasticizer), 윤활제(lubricant), 왁스(wax), 레진(resin) 등을 주성분으로 하는 결합제(binder)를 적정비율로 첨가하여 제조한 것이다.In this case, the ceramic mixture used in the injection molding method is composed of a ceramic powder, a solvent such as ethyl alcohol, a plasticizer, a lubricant, a wax, a resin, and the like. It is prepared by adding a binder (binder) in an appropriate ratio.
그런데, 사출성형법에 의한 세라믹코어의 제조공정이 혼합공정에서 소결공정까지 다단계로 이루어지므로 작업공수가 복잡하여 작업생산성이 저하될 뿐만 아니라 혼합공정에서 세라믹혼합물의 결합력을 증대시키기 위한 별도의 결합제가 첨가되므로 제조단가가 증대되는 문제점이 있었다.However, since the manufacturing process of the ceramic core by injection molding is performed in multiple stages from the mixing process to the sintering process, the labor is complicated and the productivity is lowered, and a separate binder is added to increase the bonding strength of the ceramic mixture in the mixing process. Therefore, there was a problem that the manufacturing cost is increased.
또한, 결합제의 제거공정에서 결합제가 원활하게 제거되지 못했거나 완벽하게 제거되지 못한 경우, 후처리공정, 즉 경화공정 또는 소결공정에서 가해지는 열에 의해 성형품의 균열 및 변형이 발생되어 대용량의 세라믹코어와 복잡한 세라믹코어의 제작이 불가능한 문제점이 있었다.In addition, when the binder is not smoothly removed or completely removed in the binder removal process, cracks and deformation of the molded product are generated by heat applied in the post-treatment process, that is, the curing process or the sintering process, and thus, There was a problem that it is impossible to manufacture a complex ceramic core.
한편, 도 2에서와 같이 젤케스팅법은 세라믹혼합물을 슬러리상태로 혼합한 다음 일정량의 촉매제를 첨가하고 금형을 통해 주조한 후, 다시 결합제를 일정량첨가하여 젤 상태의 성형품으로 제조한 다음 이형공정, 건조공정, 경화공정, 소결공정을 통해 제조된다.On the other hand, in the gel casting method as shown in Figure 2, after mixing the ceramic mixture in a slurry state, and then add a certain amount of catalyst and cast through a mold, and then add a certain amount of the binder to prepare a molded article in a gel state, and then release process, It is manufactured through a drying process, a curing process, and a sintering process.
이때, 젤케스팅법에서 사용되는 세라믹혼합물로는 세라믹분말과 에칠실리케이트 등과 같은 유기결합제와, 에틸알콜을 주성분으로 하는 용매를 적정비율로 첨가하여 제조한 것이다.In this case, the ceramic mixture used in the gel casting method is prepared by adding an organic binder such as ceramic powder and ethyl silicate, and a solvent containing ethyl alcohol at a proper ratio.
그런데, 젤케스팅법에서 결합제로 사용되는 에틸실리케이트는 그 자체로는 결합제로 이용할 수 없으며 수화과정을 통해 결합제로서의 특성을 지니는 것으로서, 에틸알콜을 주성분으로 하는 것이므로 화재의 위험성이 클 뿐만 아니라 가수분해 후 저장에 곤란한 문제점이 있었다.However, the ethyl silicate used as a binder in the gel casting method cannot be used as a binder by itself and has properties as a binder through the hydration process. Since it is ethyl alcohol as a main component, it is not only a high risk of fire but also after hydrolysis. There was a difficult issue with storage.
이에, 본 발명은 상기한 바와 같은 제반 문제점을 해결하기 위하여 안출된 것으로서, 세라믹코어를 수용성매체에서 라디컬 중합반응을 통해 제조하여 제품의 치수정밀도를 향상시킴과 더불어 제조단가를 절감시킬 수 있도록 진공정밀주조용 세라믹코어의 조성물을 제공하는 데에 그 목적이 있다.Accordingly, the present invention has been made in order to solve the above-mentioned problems, vacuum ceramic so as to improve the dimensional accuracy of the product by manufacturing a ceramic core through a radical polymerization reaction in a water-soluble medium to reduce the manufacturing cost It is an object to provide a composition of a ceramic core for precision casting.
도 1은 종래 기술에 따른 사출성형법을 도시한 공정도,1 is a process chart showing an injection molding method according to the prior art,
도 2는 종래 기술에 따른 젤케스팅법을 도시한 공정도,2 is a process chart showing a gel casting method according to the prior art,
도 3은 본 발명에 젤케스팅법을 도시한 공정도이다.3 is a process chart showing the gel casting method in the present invention.
이하, 본 발명에 따른 실시예를 상세하게 설명하면 다음과 같다.Hereinafter, an embodiment according to the present invention will be described in detail.
도 3은 본 발명에 젤케스팅법을 도시한 공정도로서, 단량체 또는 이량체와 고분자전해질계 분산제가 중량비로 각각 3∼4wt％, 0.6∼0.8wt％, 0.4∼0.6wt％로혼합되어진 용매에 고농도로 세라믹혼합물을 분산하면서 혼합시킨 후, 금형 내에 주입하여 20∼25℃의 온도범위에서 일정시간 동안 유지시켜 단량체 또는 이량체를 흡착한 수화젤 상태의 성형체로 제조한 다음, 용매가 휘발되는 과정에서 성형체가 수축하는 경우 성형체를 이형하고 건조시키면서 열을 가하는 경화공정을 실시한 후 950∼1050℃의 열처리로에서 2∼3시간 동안 소결시키는 것을 특징으로 한다.FIG. 3 is a process chart illustrating the gel casting method of the present invention, in which a monomer or a dimer and a polymer electrolyte dispersant are mixed in a solvent by weight ratio of 3 to 4 wt%, 0.6 to 0.8 wt%, and 0.4 to 0.6 wt%, respectively. After dispersing and mixing the ceramic mixture in a mold, it is injected into a mold and maintained at a temperature in the range of 20-25 ° C. for a predetermined time to prepare a molded product in a hydrogel state in which a monomer or a dimer is adsorbed, and then in the process of volatilizing the solvent. When the molded product shrinks, the molded product is released and dried, and then subjected to a curing step of applying heat, followed by sintering for 2 to 3 hours in a heat treatment furnace at 950 to 1050 ° C.
먼저, 에틸알콜과 같이 휘발성이 우수한 용매에 단량체(monomer) 또는 이량체(dimer)와 고분자전해질계 분산제가 중량비로 각각 3∼4wt％, 0.6∼0.8wt％, 0.4∼0.6wt％로 첨가하여 혼합시킨 다음, 이러한 수용성매체에 세라믹혼합물을 고농도로 분산시키면 세라믹혼합물의 수용액이 형성된다.First, monomers or dimers and polymer electrolyte dispersants are added in a weight ratio of 3 to 4 wt%, 0.6 to 0.8 wt%, and 0.4 to 0.6 wt%, respectively, in a solvent having high volatility such as ethyl alcohol. Then, the ceramic mixture is dispersed in such a water-soluble medium in high concentration to form an aqueous solution of the ceramic mixture.
이때, 용매에 첨가되는 고분자전해질계 분산제(Polyelectrolyte Dispersant)는 고분자 사슬 중에 해리기를 가지면서 수용액 중에 녹아 해리하여 고분자이온으로 되는 것으로서, 천연 상태로 존재하는 알긴산이나 단백질 등이 대표적이며, 그 밖에 합성에 의해 만들어지는 폴리아크릴산 등을 사용함이 바람직하다.In this case, the polyelectrolyte dispersant added to the solvent is dissociated in an aqueous solution with dissociation group in the polymer chain to dissociate into a polymer ion, and is typically represented by alginic acid or protein in a natural state. It is preferable to use the polyacrylic acid etc. which are made by.
물론, 단량체 또는 이량체와 분산제의 첨가량은 규정치 이상으로 첨가한 경우에는 성형체의 자경화시간(self-hardening time)이 단축되지만 표면결합의 발생확률이 높아지는 반면, 규정치 이하로 첨가하는 경우에는 자경화시간이 늘어나지만 표면결합의 발생활율이 낮아진다.Of course, the amount of the monomer or dimer and the dispersant added is higher than the specified value, but the self-hardening time of the molded body is shortened, but the probability of occurrence of surface bonding is increased, whereas when added below the specified value, the self-hardening Although the time increases, the incidence of surface bonding is lowered.
또한, 본 발명에서 사용된 세라믹혼합물의 주요 성분은 용융실리카 73∼77wt％, 지르콘 18∼22wt％, 코디어라이트(codierite) 4∼6wt％를 포함한 미량의 불순물로 구성된다.In addition, the main components of the ceramic mixture used in the present invention are composed of trace impurities including 73 to 77 wt% of molten silica, 18 to 22 wt% of zircon and 4 to 6 wt% of cordierite.
그런 다음, 수용액 상태의 세라믹혼합물을 금형에 주입하여 약 1∼3분 동안 유지시키면, 세라막혼합물과 단량체 또는 이량체가 라디컬(radical) 고분자 반응에 의한 공중합반응(co-polymerization)을 일으키게 되므로, 세라믹혼합물을 포함하는 고분자 수화젤상의 성형물이 형성된다.Then, when the ceramic mixture in an aqueous solution is injected into the mold and held for about 1 to 3 minutes, the ceramic membrane mixture and the monomer or dimer cause co-polymerization by a radical polymer reaction. A molded article on the polymer hydrogel containing the ceramic mixture is formed.
이때, 세라믹혼합물들이 수화젤상으로 반응하는 이유는 세라막혼합물에 라디컬 중합반응을 통해 단량체와 이량체가 흡착되는 과정에서 고분자가 생성되고, 이러한 고분자들이 결합제의 역할을 수행한다. 따라서, 세라막혼합물들의 결합력이 증대됨과 동시에 조직이 미세화된다.In this case, the reason why the ceramic mixture is reacted in the hydrogel phase is that the polymer is produced in the process of adsorbing the monomer and the dimer through the radical polymerization reaction in the ceramic film mixture, and these polymers serve as a binder. Therefore, the binding force of the cera membrane mixtures is increased and the tissues are refined.
이어서, 수화젤상의 성형물을 약 1∼3분 동안 유지시키면, 성형물 중에 포함되어 있던 용매가 휘발되어 부피가 축소되므로, 이때 작업자는 금형으로부터 이형물(이하, 주형이라 함)을 인출한 다음 건조시킨다.Subsequently, when the molded article on the hydrogel is held for about 1 to 3 minutes, the solvent contained in the molded article is volatilized to reduce the volume. At this time, the worker removes the mold release product (hereinafter referred to as a mold) from the mold and then dries it. .
이때, 주형의 건조공정에서 에틸알콜과 같은 고휘발성물질을 0.063∼0.084wt％의 범위로 첨가하여, 주형의 건조수축에 따른 피로를 억제시킴과 더불어 단량체와 이량체의 용해성을 향상시킴이 바람직하다.In this case, it is preferable to add a high volatile substance such as ethyl alcohol in the range of 0.063 to 0.084 wt% in the drying process of the mold, to suppress the fatigue caused by drying shrinkage of the mold and to improve the solubility of monomers and dimers. .
물론, 주형의 건조과정에서 수축현상이 발생되므로 즉각, 주형에 일정온도의 열을 가하는, 즉 경화공정을 실시하여 주형에 형성된 크랙과 같은 표면결함을 방지시킴이 바람직하다.Of course, since shrinkage occurs during the drying of the mold, it is preferable to immediately apply heat of a predetermined temperature to the mold, that is, perform a curing process to prevent surface defects such as cracks formed in the mold.
그런 다음, 주형을 950∼1050℃의 온도범위를 유지하는 열처리로에서 약 2∼3시간 동안 소결시키면, 경화공정에서 표면결함이 최소화되어진 주형이 소성작용에 의해 강도가 증가됨과 더불어 수축이 방지되므로, 주형의 치수 정밀도를 향상시킬 수 있게 된다.Then, when the mold is sintered for about 2 to 3 hours in a heat treatment furnace maintaining a temperature range of 950 to 1050 ° C., the mold, whose surface defects are minimized in the curing process, is increased in strength and prevents shrinkage. As a result, the dimensional accuracy of the mold can be improved.
따라서, 수화젤상의 성형물을 금형에 주입한 후 일정시간이 경과되는 경우 성형체의 전체에 걸쳐 화학적 중합반응이 발생되어, 즉 세라믹분말에 흡착한 단량체 및 이량체의 중합을 통해 겔화(gelation)가 일어나므로, 세라믹분말을 포함하는 고분자 수화젤상의 세라믹코어가 형성된다.Therefore, when a certain time elapses after injecting a molding on the hydrogel to a mold, a chemical polymerization reaction occurs over the whole of the molded body, that is, gelation occurs through polymerization of monomers and dimers adsorbed on the ceramic powder. Therefore, a ceramic hydrogel-like ceramic core containing a ceramic powder is formed.
이상에서 설명한 바와 같이 본 발명에 따른 진공정밀주조용 세라믹코어의 조성물에 의하면, 세라믹코어를 수용성매체에서 라디컬 중합반응을 통해 제조하므로써, 세라믹코어의 치수정밀도가 향상됨은 물론 경화공정을 통해 강도 및 인성이 증대되어 제품품질이 향상될 뿐만 아니라, 세라믹코어에 결합제를 첨가하기 위한 작업공수가 줄어들어 작업공수 및 부대비용이 절감되는 효과가 있는 것이다.As described above, according to the composition of the ceramic core for vacuum precision casting according to the present invention, the ceramic core is manufactured through a radical polymerization reaction in a water-soluble medium, thereby improving the dimensional accuracy of the ceramic core as well as the strength and strength through the curing process. As the toughness is increased, product quality is not only improved, but also the labor cost for adding a binder to the ceramic core is reduced, thereby reducing the labor cost and additional costs.
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| US5028362A (en) * | 1988-06-17 | 1991-07-02 | Martin Marietta Energy Systems, Inc. | Method for molding ceramic powders using a water-based gel casting |
| US5145908A (en) * | 1988-02-22 | 1992-09-08 | Martin Marietta Energy Systems, Inc. | Method for molding ceramic powders using a water-based gel casting process |
| WO1997002831A1 (en) * | 1995-07-10 | 1997-01-30 | Cathay Herbal Laboratories Pty. Ltd. | Herbal compositions for hepatic disorders |
| US6066279A (en) * | 1997-09-16 | 2000-05-23 | Lockheed Martin Energy Research Corp. | Gelcasting methods |
| KR20020025520A (en) * | 2000-09-29 | 2002-04-04 | 김충섭 | A process for preparing ceramic gelbody |
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| US5145908A (en) * | 1988-02-22 | 1992-09-08 | Martin Marietta Energy Systems, Inc. | Method for molding ceramic powders using a water-based gel casting process |
| US5028362A (en) * | 1988-06-17 | 1991-07-02 | Martin Marietta Energy Systems, Inc. | Method for molding ceramic powders using a water-based gel casting |
| WO1997002831A1 (en) * | 1995-07-10 | 1997-01-30 | Cathay Herbal Laboratories Pty. Ltd. | Herbal compositions for hepatic disorders |
| US6066279A (en) * | 1997-09-16 | 2000-05-23 | Lockheed Martin Energy Research Corp. | Gelcasting methods |
| KR20020025520A (en) * | 2000-09-29 | 2002-04-04 | 김충섭 | A process for preparing ceramic gelbody |
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