WO2021174375A1 - 一种大型复杂腔道钛合金铸件精密成形方法 - Google Patents

一种大型复杂腔道钛合金铸件精密成形方法 Download PDF

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Publication number
WO2021174375A1
WO2021174375A1 PCT/CN2020/000059 CN2020000059W WO2021174375A1 WO 2021174375 A1 WO2021174375 A1 WO 2021174375A1 CN 2020000059 W CN2020000059 W CN 2020000059W WO 2021174375 A1 WO2021174375 A1 WO 2021174375A1
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titanium alloy
casting
mold
powder
shell
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PCT/CN2020/000059
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English (en)
French (fr)
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赵军
史昆
刘时兵
刘鸿羽
王彦鹏
宁兆生
倪嘉
金磊
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沈阳铸造研究所有限公司
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Publication of WO2021174375A1 publication Critical patent/WO2021174375A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D13/00—Centrifugal casting; Casting by using centrifugal force
    • 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
    • B22C9/10—Cores; Manufacture or installation of cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/12—Treating moulds or cores, e.g. drying, hardening
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D13/00—Centrifugal casting; Casting by using centrifugal force
    • B22D13/10—Accessories for centrifugal casting apparatus, e.g. moulds, linings therefor, means for feeding molten metal, cleansing moulds, removing castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D13/00—Centrifugal casting; Casting by using centrifugal force
    • B22D13/10—Accessories for centrifugal casting apparatus, e.g. moulds, linings therefor, means for feeding molten metal, cleansing moulds, removing castings
    • B22D13/101—Moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D13/00—Centrifugal casting; Casting by using centrifugal force
    • B22D13/10—Accessories for centrifugal casting apparatus, e.g. moulds, linings therefor, means for feeding molten metal, cleansing moulds, removing castings
    • B22D13/101—Moulds
    • B22D13/104—Cores

Definitions

  • the invention relates to a casting method, in particular to a precision forming method for high pressure-bearing, large, complex cavity and thin-walled titanium alloy castings.
  • titanium alloy casting technology mainly adopts rare earth ceramic type investment casting, machine-added graphite type casting and other processes.
  • the machine-added graphite casting process is used for casting, which requires a large amount of graphite to process the mold, and due to the high thermal conductivity of graphite, graphite
  • the casting mold has a very strong chilling effect on the titanium alloy liquid. Due to the fast cooling rate of the metal liquid and the graphite surface, a large number of defects such as cold barriers and cracks will be produced.
  • the graphite core is generally used for forming complex castings. Cavities. Due to the extremely complex structure of these cavities, it is difficult to polish and process with tools, and it is very difficult to remove defects.
  • the present invention provides a precision forming method for high pressure bearing, large, complex cavity, thin-walled titanium alloy castings, which utilizes the chilling effect of graphite casting molds and the high precision casting composite shell core With surface quality, high dimensional accuracy, and high concession, the required high-pressure, large, complex cavity and thin-walled titanium alloy castings of qualified quality can be obtained.
  • a precision forming method for large-scale complex-cavity titanium alloy castings adopts precision-casting composite shell-coated core and graphite mold to prepare large-scale complex-cavity titanium alloy castings.
  • the composite shell-coated core and graphite mold are degassed and assembled into
  • the consumable electrode is smelted in a vacuum consumable electrode condensing furnace, and a titanium alloy liquid is poured into the mold by a titanium alloy centrifugal casting process, and a titanium alloy casting with a complex cavity is obtained after centrifugation.
  • the surface layer refractory powder is a mixture of Y 2 O 3 with a particle size of 40 ⁇ m to 80 ⁇ m and ZrO 2 with a particle size of 40 ⁇ m to 80 ⁇ m, wherein the ZrO 2 powder is 30-50 wt% and the balance is Y 2 O 3 powder.
  • the surface layer sand is ZrO 2 sand with a particle size of 80 ⁇ m to 150 ⁇ m.
  • the surface layer binder is a nano-alumina dispersion liquid, and the dispersion liquid has a concentration of 8% to 12% by weight.
  • the back layer binder is a silica sol viscous solution with a concentration of 15%-20wt%.
  • the back layer sand is Al 2 O 3 sand with a particle size of 80 ⁇ m to 150 ⁇ m.
  • the back layer powder is a mixture of Al 2 O 3 powder with a particle size of 40 ⁇ m to 80 ⁇ m and ZrO 2 with a particle size of 40 ⁇ m to 80 ⁇ m, wherein the mass fraction of the Al 2 O 3 powder is 80 to 90% by weight, and the balance is ZrO 2 .
  • step (4) Put the shell obtained in step (3) into a box-type resistance furnace for roasting, cooling and leaving the furnace at room temperature to obtain a composite shell-coated core.
  • the specific degassing process of graphite mold and composite coated shell core is as follows: the graphite mold is placed in a vacuum degassing furnace, heated to 850°C ⁇ 900°C, kept for 3 hours, and cooled to room temperature along with the furnace; precision cast composite coated shell core Put it into a box-type resistance furnace, heat it to 350°C ⁇ 400°C, keep it for 2h ⁇ 3h, and cool it to 100°C ⁇ 150°C along with the furnace.
  • the smelting is specifically: the consumable electrode is made of Ti-6Al-4VELI alloy ingot, and the consumable electrode is placed in a vacuum consumable electrode condensing furnace, and the gap between the consumable electrode and the inner wall of the crucible is 30 -100mm, start the vacuum pump, pump to vacuum ⁇ 10 -1 Pa, then smelt, voltage 38-40V, current 12000-18000A; cooling water pressure 0.5MPa, crucible inlet water temperature 19°C, crucible outlet water temperature 38°C;
  • the specific casting is as follows: a titanium alloy centrifugal casting process is used to cast titanium alloy liquid into the casting mold, and the centrifugal speed is 300 rpm.
  • Molding Assemble the graphite mold and precision-cast composite coated shell core after the degassing process into a mold according to the mold group diagram.
  • the titanium alloy castings cast by this process have improved the dimensional accuracy, internal quality and surface quality of the castings, and greatly reduced the rejection rate of the castings. It reduces the casting cost of castings, shortens the production cycle of castings, and has good economic and social benefits.
  • the invention provides a precision forming method for high-pressure-bearing, large-scale, complex-cavity, thin-walled titanium alloy castings, which utilizes the chilling effect of graphite casting molds and the high surface quality, high dimensional accuracy, and high With concessions, high pressure, large, complex cavity, thin-walled titanium alloy castings of required quality can be obtained.
  • a precision forming method for high pressure-bearing, large, complex cavity and thin-walled titanium alloy castings includes the following process steps:
  • the surface layer powder is prepared by mixing Y 2 O 3 and ZrO 2 , and the compounding ratio is calculated as a mass percentage: 30-50 wt% of ZrO 2 powder with a particle size of 40 ⁇ m to 80 ⁇ m, and the balance is 40 ⁇ m to 80 ⁇ m Y 2 O 3 powder.
  • the surface layer sand is composed of 80 ⁇ m ⁇ 150 ⁇ m ZrO 2 sand.
  • the surface layer binder is selected from nano-alumina dispersion liquid with a concentration of 8% to 12% by weight.
  • the back layer powder is composed of Al 2 O 3 powder with a particle size of 40 ⁇ m to 80 ⁇ m, 80 to 90% by weight, and the balance is 40 ⁇ m to 80 ⁇ m ZrO 2 powder.
  • the back layer sand material is composed of Al 2 O 3 from 80 ⁇ m to 150 ⁇ m.
  • Silica sol solution is selected as the backing layer binder, and its concentration is 15%-20wt%.
  • a core wax mold is designed.
  • the wax mold is prepared with medium temperature wax, and a qualified wax mold is prepared by a wax press.
  • the first step add the prepared surface layer refractory powder to the surface layer binder with a concentration of 8%-12wt% of nano-alumina dispersion liquid and mix well, and the powder-liquid mass ratio is 2:1 ⁇ 3.5:1.
  • Stir uniformly for 1 to 3 hours to prepare a surface coating coat the coating on a wax mold, use 80 ⁇ m ⁇ 150 ⁇ m ZrO 2 sand for sanding, control the drying time at 8 ⁇ 12 hours, and control the ambient temperature at 18 ⁇ 22°C ,
  • the humidity is controlled at 45 to 55%; repeat the above operation 2 to 3 times to form a surface layer shell with a certain thickness;
  • Step 2 Add the prepared back layer powder to the silica sol binder with a concentration of 15%-20wt% and mix well.
  • the powder-to-liquid mass ratio is controlled at 2:1 ⁇ 3:1, and the sanding is 80 ⁇ m ⁇ 150 ⁇ m.
  • the drying time is controlled at 8-12 hours, the ambient temperature is controlled at 18-22°C, and the humidity is controlled at 35-50%; repeat the above operation 4-6 times to form a reinforced layered shell with a certain thickness;
  • the third step dewax the finished mould shell, adopt infrared dewaxing process, and heat the mould shell at a temperature of 300 ⁇ 350°C to remove the wax material cleanly;
  • the fourth step Put the clean shell from the wax material into a box-type resistance furnace for roasting. First, heat the shell to 600°C for 2 to 3 hours, then continue to heat the core to 950 to 1100°C for 3 to 4 hours, and finally cool to room temperature with the furnace.
  • the sandpaper sanding method is used to sand and remove the superfluous material on the surface of the precision casting composite shell core.
  • graphite molds are made by mechanical processing methods.
  • the consumable electrode is made of Ti-6Al-4VELI alloy ingot, and the consumable electrode is placed in the vacuum consumable electrode condensing furnace, the gap between the consumable electrode and the inner wall of the crucible is 30-100mm, and the vacuum pump is started. After pumping to vacuum ⁇ 10 -1 Pa, smelt, voltage 38-40V, current 12000-18000A; cooling water pressure 0.5MPa, crucible inlet water temperature 19°C, crucible outlet water temperature 38°C. Then, the titanium alloy liquid is poured into the mold by the titanium alloy centrifugal casting process, and the centrifugal speed is 300 rpm, which is obtained.
  • the precision forming method of large and complex cavity titanium alloy castings includes the following process steps:
  • the surface layer powder is prepared by mixing Y 2 O 3 and ZrO 2 , and the compounding ratio is calculated by mass percentage: 30 wt% of ZrO 2 powder with a particle size of 40 ⁇ m to 80 ⁇ m, and the balance is 40 ⁇ m to 80 ⁇ m Y 2 O 3 powder.
  • the surface layer sand is composed of 80 ⁇ m ⁇ 150 ⁇ m ZrO 2 sand.
  • the surface layer binder is selected from nano-alumina dispersion liquid, the concentration of which is 8wt%.
  • the back layer powder is composed of Al 2 O 3 powder with a particle size of 40 ⁇ m to 80 ⁇ m, 80% by weight, and the balance is 40 ⁇ m to 80 ⁇ m ZrO 2 powder mixed uniformly.
  • the back layer sand material is composed of Al 2 O 3 from 80 ⁇ m to 150 ⁇ m.
  • a silica sol solution is selected as the backing layer binder, and its concentration is 15 wt%.
  • a core wax mold is designed.
  • the wax mold is prepared with medium temperature wax, and a qualified wax mold is prepared by a wax press.
  • the first step add the prepared surface layer refractory powder to the surface layer binder with a concentration of 8wt% of nano-alumina dispersion liquid and mix it evenly, the powder-to-liquid mass ratio is 2:1, and the mixture is uniformly stirred for 1 to 3 hours.
  • the second step add the prepared back layer powder to the silica sol binder with a concentration of 15wt% and mix well, control the powder-to-liquid mass ratio at 2:1, use 80 ⁇ m ⁇ 150 ⁇ m Al 2 O 3 sand for sanding, and dry
  • the time is controlled at 8-12 hours, the ambient temperature is controlled at 18-22°C, and the humidity is controlled at 35-50%; repeat the above operation 4-6 times to form a reinforced layer shell with a certain thickness;
  • the third step dewax the finished mould shell, adopt infrared dewaxing process, and heat the mould shell at a temperature of 300 ⁇ 350°C to remove the wax material cleanly;
  • the fourth step Put the clean shell from the wax material into a box-type resistance furnace for roasting. First, heat the shell to 600°C for 2 to 3 hours, then continue to heat the core to 950 to 1100°C for 3 to 4 hours, and finally cool it to room temperature with the furnace.
  • the sandpaper sanding method is used to sand and remove the superfluous material on the surface of the precision casting composite shell core.
  • graphite molds are made by mechanical processing methods.
  • the consumable electrode is made of Ti-6Al-4VELI alloy ingot, and the consumable electrode is placed in the vacuum consumable electrode condensing furnace, the gap between the consumable electrode and the inner wall of the crucible is 30-100mm, and the vacuum pump is started. After pumping to vacuum ⁇ 10 -1 Pa, smelt, voltage 38-40V, current 12000-18000A; cooling water pressure 0.5MPa, crucible inlet water temperature 19°C, crucible outlet water temperature 38°C. Then, the titanium alloy liquid is poured into the mold by the titanium alloy centrifugal casting process, and the centrifugal speed is 300 rpm, which is obtained.
  • the surface roughness of the cavity can reach Ra5.0 ⁇ m for titanium alloy castings cast by this process, which is better than the traditional graphite casting process Ra12.5 ⁇ m, which significantly improves the surface quality of the castings, and has good economic benefits. Social benefits.
  • the surface layer powder is prepared by mixing Y 2 O 3 and ZrO 2 , and the compounding ratio is calculated as a mass percentage: 40 wt% of ZrO 2 powder with a particle size of 40 ⁇ m to 80 ⁇ m, and the balance is 40 ⁇ m to 80 ⁇ m Y 2 O 3 powder.
  • the surface layer sand is composed of 80 ⁇ m ⁇ 150 ⁇ m ZrO 2 sand.
  • the surface layer binder is selected from nano-alumina dispersion liquid, and its concentration is 10wt%.
  • the back layer powder is composed of 85wt% Al 2 O 3 powder with a particle size of 40 ⁇ m to 80 ⁇ m, and the balance is 40 ⁇ m to 80 ⁇ m ZrO 2 powder mixed uniformly.
  • the back layer sand material is composed of Al 2 O 3 from 80 ⁇ m to 150 ⁇ m.
  • a silica sol solution is used as the backing layer binder, and its concentration is 18% by weight.
  • a core wax mold is designed.
  • the wax mold is prepared with medium temperature wax, and a qualified wax mold is prepared by a wax press.
  • the first step add the prepared surface layer refractory powder to the nano alumina dispersion surface layer binder with a concentration of 10wt% and mix well, the powder-to-liquid mass ratio is 3:1, and the mixture is uniformly stirred for 1 to 3 hours.
  • the second step add the prepared back layer powder to the 18wt% silica sol binder and mix well, control the powder-to-liquid mass ratio at 2.5:1, use 80 ⁇ m ⁇ 150 ⁇ m Al 2 O 3 sand for sanding, and dry
  • the time is controlled at 8-12 hours, the ambient temperature is controlled at 18-22°C, and the humidity is controlled at 35-50%; repeat the above operation 4-6 times to form a reinforced layer shell with a certain thickness;
  • the third step dewax the finished mould shell, adopt infrared dewaxing process, and heat the mould shell at a temperature of 300 ⁇ 350°C to remove the wax material cleanly;
  • the fourth step Put the clean shell from the wax material into a box-type resistance furnace for roasting. First, heat the shell to 600°C for 2 to 3 hours, then continue to heat the core to 950 to 1100°C for 3 to 4 hours, and finally cool it to room temperature with the furnace.
  • the sandpaper sanding method is used to sand and remove the superfluous material on the surface of the precision casting composite shell core.
  • graphite molds are made by mechanical processing methods.
  • the consumable electrode is made of Ti-6Al-4VELI alloy ingot, and the consumable electrode is placed in the vacuum consumable electrode condensing furnace, the gap between the consumable electrode and the inner wall of the crucible is 30-100mm, and the vacuum pump is started. After pumping to vacuum ⁇ 10 -1 Pa, smelt, voltage 38-40V, current 12000-18000A; cooling water pressure 0.5MPa, crucible inlet water temperature 19°C, crucible outlet water temperature 38°C. Then, the titanium alloy liquid is poured into the mold by the titanium alloy centrifugal casting process, and the centrifugal speed is 300 rpm, which is obtained.
  • the cavity size accuracy of the titanium alloy castings cast by this process can reach CT6 level, which is significantly better than the CT7 level of the traditional graphite casting process, which significantly improves the cavity size accuracy of the casting and has good economic benefits and Social benefits.
  • the surface layer powder is prepared by mixing Y 2 O 3 and ZrO 2 , and the ingredient ratio is calculated by mass percentage: 50 wt% of ZrO 2 powder with a particle size of 40 ⁇ m to 80 ⁇ m, and the balance is 40 ⁇ m to 80 ⁇ m Y 2 O 3 powder.
  • the surface layer sand is composed of 80 ⁇ m ⁇ 150 ⁇ m ZrO 2 sand.
  • the surface layer binder is a nano-alumina dispersion liquid with a concentration of 12 wt%.
  • the back layer powder is composed of 90wt% Al 2 O 3 powder with a particle size of 40 ⁇ m to 80 ⁇ m, and the balance is 40 ⁇ m to 80 ⁇ m ZrO 2 powder mixed uniformly.
  • the back layer sand material is composed of Al 2 O 3 from 80 ⁇ m to 150 ⁇ m.
  • a silica sol solution is selected as the backing layer binder, and its concentration is 20 wt%.
  • a core wax mold is designed.
  • the wax mold is prepared with medium temperature wax, and a qualified wax mold is prepared by a wax press.
  • Step 1 Add the prepared surface layer refractory powder to the surface layer binder with a concentration of 12wt% of nano-alumina dispersion liquid and mix it evenly.
  • the powder-to-liquid mass ratio is 3.5:1, and the mixture is uniformly stirred for 1 to 3 hours.
  • the second step add the prepared back layer powder to the silica sol binder with a concentration of 20wt% and mix well, control the powder-to-liquid mass ratio at 3:1, use 80 ⁇ m ⁇ 150 ⁇ m Al 2 O 3 sand for sanding, and dry
  • the time is controlled at 8-12 hours, the ambient temperature is controlled at 18-22°C, and the humidity is controlled at 35-50%; repeat the above operation 4-6 times to form a reinforced layer shell with a certain thickness;
  • the third step dewax the finished mould shell, adopt infrared dewaxing process, and heat the mould shell at a temperature of 300 ⁇ 350°C to remove the wax material cleanly;
  • the fourth step Put the clean shell from the wax material into a box-type resistance furnace for roasting. First, heat the shell to 600°C for 2 to 3 hours, then continue to heat the core to 950 to 1100°C for 3 to 4 hours, and finally cool it to room temperature with the furnace.
  • the sandpaper sanding method is used to sand and remove the superfluous material on the surface of the precision casting composite shell core.
  • graphite molds are made by mechanical processing methods.
  • the consumable electrode is made of Ti-6Al-4VELI alloy ingot, and the consumable electrode is placed in the vacuum consumable electrode condensing furnace, the gap between the consumable electrode and the inner wall of the crucible is 30-100mm, and the vacuum pump is started. After pumping to vacuum ⁇ 10 -1 Pa, smelt, voltage 38-40V, current 12000-18000A; cooling water pressure 0.5MPa, crucible inlet water temperature 19°C, crucible outlet water temperature 38°C. Then, the titanium alloy liquid is poured into the mold by the titanium alloy centrifugal casting process, and the centrifugal speed is 300 rpm, which is obtained.
  • the mechanical properties of the titanium alloy castings cast by this process have a tensile strength of 895MPa, which is significantly higher than the tensile strength of the traditional investment casting process of 845MPa, which significantly improves the mechanical properties of the casting, and has good economic and social benefits. benefit.

Abstract

一种大型复杂腔道钛合金铸件精密成形方法，该方法采用精铸复合涂壳型芯和石墨铸型制备大型复杂腔道钛合金铸件，复合涂壳型芯和石墨铸型除气后组装成铸型，将自耗电极放入真空自耗电极凝壳炉中熔炼，并采用钛合金离心浇铸工艺向铸型内浇铸钛合金液，离心后得到大型复杂腔道钛合金铸件。利用本工艺铸造出的钛合金铸件，提高了铸件尺寸精度、内部质量、表面质量，极大地降低了铸件的废品率，降低了铸件的铸造成本，缩短了铸件的生产周期。

Description

一种大型复杂腔道钛合金铸件精密成形方法 技术领域
本发明涉及一种铸造方法，特别是涉及一种高承压、大型、复杂腔道、薄壁钛合金铸件精密成形方法。
背景技术
随着航空、航天、舰船、石油化工、矿山开采等行业的快速发展，尤其是火箭发动机制备领域对一些高承压、大型、复杂、薄壁类钛合金铸件的需求越来越多。此类产品主要通过铸造来成型，目前钛合金铸造技术主要采用稀土陶瓷型熔模铸造、机加石墨型铸造等工艺。
针对高承压、大型、复杂腔道、薄壁类钛合金铸件精密成形，采用机加石墨铸型铸造工艺铸造，需要耗费大量的石墨来加工铸型，并且由于石墨自身的高导热率，石墨铸型对钛合金液体具有非常强烈的激冷作用，金属液体与石墨表面接触的部位由于冷却速度很快，会产生大量的冷隔和裂纹等缺陷，同时，石墨型芯一般用于成形铸件复杂腔体，这些腔体部位由于结构异常复杂，利用工具很难进行打磨、加工，缺陷去除非常困难，往往导致铸件表面质量不合格，导致铸件报废，这样不但使铸件废品率居高不下，还极大影响到铸件的生产周期，生产效率低下。若采用稀土陶瓷型熔模精密铸造技术，虽然可以获得较高的铸件尺寸精度，较好的表面质量，但是对于高承压、大型、复杂腔道、薄壁类钛合金铸件，需要大型压蜡机制备蜡模，并且制作蜡模的模具成本很高昂，制壳过程工序多、蜡模在制壳过程中易软化变形，导致尺寸精度得不到有效保障，面层容易脱落，容易在铸件内部产生高密度夹渣，导致铸件质量不合格。因此，不管哪一种铸造工艺都存在铸型制作复杂，铸件废品率高，生产成本高，劳动强度大，生产周期长等技术问题，急需创新一种新的铸造工艺方法来解决 高承压、大型、复杂腔道、薄壁类钛合金铸件精密成形的技术瓶颈问题。
目前大型、复杂腔道、薄壁钛合金铸件产品普遍存在冷隔、气孔等缺陷，无法满足今后更高高质量火箭发动机零部件需求，急需开发一种高内部质量、高表面质量钛合金复杂结构件成形方法，提高产品质量，降低质量成本，提高生产效率。
发明内容
针对现有技术的不足，本发明提供了一种高承压、大型、复杂腔道、薄壁钛合金铸件精密成形方法，利用石墨铸型的激冷作用和精铸复合涂壳型芯的高表面质量、高尺寸精度、高退让性，得到所需质量合格的高承压、大型、复杂腔道、薄壁钛合金铸件。
为实现上述技术问题，本发明通过以下技术方案得到：
一种大型复杂腔道钛合金铸件精密成形方法，该方法采用精铸复合涂壳型芯和石墨铸型制备大型复杂腔道钛合金铸件，复合涂壳型芯和石墨铸型除气后组装成铸型，将自耗电极放入真空自耗电极凝壳炉中熔炼，并采用钛合金离心浇铸工艺向铸型内浇铸钛合金液，离心后得到型复杂腔道钛合金铸件。
所述精铸复合涂壳型芯具体步骤如下：
(1)将面层耐火粉料加入到面层粘结剂中混匀搅拌1～3小时，制备成面层涂料；把该涂料涂挂在蜡模上，撒面层砂，干燥时间为8～12小时，温度为18～22℃，湿度为45～55％；重复上述操作2～3次形成面层型壳；所述面层耐火粉料与面层粘结剂的质量比为2～3.5∶1。所述面层耐火粉料为40μm～80μm粒径的Y 2O 3和40μm～80μm粒径的ZrO 2混合物，其中，ZrO 2粉30～50wt％、余量为Y 2O 3粉。所述面层砂为粒径80μm～150μm的ZrO 2砂。所述面层粘结剂为纳米氧化铝分散液，分散液浓度为8％～12wt％。
(2)将背层粉料加入到背层粘结剂中混匀，撒背层砂，干燥时间为8～12小时，温度为18～22℃，湿度为35～50％；重复上述操作4～6次形成加固层型壳；所述背层粉料与背层粘结剂的质量比为2～3∶1。所述背层粘结剂为浓度15％～20wt％硅溶胶粘溶液。所述背层砂为粒径80μm～150μm的Al 2O 3砂。所述背层粉料为40μm～80μm粒度的Al 2O 3粉和40μm～80μm粒度ZrO 2的混合物，其中Al 2O 3粉质量分数为80～90％wt％，余量为ZrO 2。
(3)将上述涂挂完成的型壳进行脱蜡；所述脱蜡采用红外脱蜡工艺，加热型壳温度为300～350℃。
(4)将步骤(3)得到的型壳放入箱式电阻炉中焙烧、冷却室温出炉得到复合涂壳型芯。所述步骤(4)培烧条件：将型壳加热到600℃，保温2～3h，然后将型芯继续加热至950～1100℃，保温3～4h。
石墨铸型和复合涂壳型芯除气工艺具体为：石墨铸型放入真空除气炉中，加热至850℃～900℃，保温3h，随炉冷却至室温；精铸复合涂壳型芯放入箱式电阻炉中，加热至350℃～400℃，保温2h～3h，随炉冷却至100℃～150℃。
所述熔炼具体为：自耗电极采用Ti-6Al-4VELI合金锭制成，并将自耗电极放入真空自耗电极凝壳炉中，自耗电极与坩埚内壁的间隙为30-100mm，启动真空泵，抽至真空度≤10 -1Pa后，进行熔炼，电压38-40V，电流12000-18000A；冷却水压0.5MPa，坩埚进口水温19℃，坩埚出口水温38℃；所述浇铸具体为：采用钛合金离心浇铸工艺向铸型内浇铸钛合金液，离心转速为300转/分。
组型：将经除气工艺处理后的石墨铸型和精铸复合涂壳型芯按照铸型组型图，组装成铸型。
本发明的优点：
针对高承压、大型、复杂腔道、薄壁钛合金精密铸件，利用本工艺铸造出 的钛合金铸件，提高了铸件尺寸精度、内部质量、表面质量，极大的降低了铸件的废品率，降低了铸件的铸造成本，缩短了铸件的生产周期，具有良好的经济效益和社会效益。
具体实施方式
下面结合具体实施例对本发明进行进一步描述，但本发明的保护范围不受实施例的限制，如果该领域的技术熟练人员根据上述发明内容对本发明做出一些非本质的改进和调整，仍属于本发明的保护范围。
本发明提供一种高承压、大型、复杂腔道、薄壁钛合金铸件精密成形方法，利用石墨铸型的激冷作用和精铸复合涂壳型芯的高表面质量、高尺寸精度、高退让性，得到所需质量合格的高承压、大型、复杂腔道、薄壁钛合金铸件。
采用的技术方案是：
一种高承压、大型、复杂腔道、薄壁钛合金铸件精密成形方法，包括下述工艺步骤：
一、制备精铸复合涂壳型芯：
1、面层材料制备：
面层粉料由Y 2O 3、ZrO 2混合制备成，其配料比以质量百分比计为：40μm～80μm粒度的ZrO 2粉30～50wt％、余量为40μm～80μm Y 2O 3粉。
面层砂由80μm～150μm ZrO 2砂构成。
面层粘结剂选用纳米氧化铝分散液，其浓度为8％～12wt％。
2、背层材料制备：
背层粉料由40μm～80μm粒度Al 2O 3粉80～90％wt％，余量为40μm～80μmZrO 2粉混合均匀构成。
背层砂材料由80μm～150μm Al 2O 3构成。
背层粘结剂选用硅溶胶溶液，其浓度为15％～20wt％。
3.型芯蜡模制备
根据铸件型腔设计出型芯蜡模模具，蜡模采用中温蜡制备，利用压蜡机制备出合格蜡模。
3.精铸复合涂壳型芯制壳工艺
第一步：将配制好的面层耐火粉料加入到浓度为8％～12wt％的纳米氧化铝分散液面层粘结剂中混匀，粉液质量比为2∶1～3.5∶1，均匀搅拌1～3小时，制备成面层涂料；把该涂料涂挂在蜡模上，撒砂采用80μm～150μm ZrO 2砂，干燥时间控制在8～12小时，环境温度控制在18～22℃，湿度控制在45～55％；重复上述操作2～3次形成一定厚度的面层型壳；
第二步：将配制好的背层粉料加入到浓度为15％～20wt％硅溶胶粘结剂中混匀，粉液质量比控制在2∶1～3∶1，撒砂采用80μm～150μm Al 2O 3砂，干燥时间控制在8～12小时，环境温度控制在18～22℃，湿度控制在35～50％；重复上述操作4～6次形成一定厚度的加固层型壳；
第三步：将涂挂完成的型壳进行脱蜡，采用红外脱蜡工艺，加热型壳温度在300～350℃，将蜡料脱除干净；
第四步：将蜡料脱除干净的型壳放入箱式电阻炉中焙烧。首先将型壳加热到600℃，保温2～3h，然后将型芯继续加热至950～1100℃，保温3～4h，最后随炉冷却至室温出炉。
4、精铸复合涂壳型芯表面处理：
采用砂纸打磨方法将精铸复合涂壳型芯表面的多余物打磨去除干净。
二、制备石墨铸型
按设计图纸要求通过机械加工方法制成石墨铸型。
三、石墨铸型和复合涂壳型芯除气
1、石墨铸型除气工艺
将制备成的石墨铸型放入真空除气炉中，加热至850℃～900℃，保温3h，随炉冷却至室温，即得。
2、精铸复合涂壳型芯除气工艺
将制备成的精铸复合涂壳型芯放入箱式电阻炉中，加热至350℃～400℃，保温2h～3h，随炉冷却至100℃～150℃，即得。
四、组型
将经除气工艺处理后的石墨铸型和精铸复合涂壳型芯按照铸型组型图，组装成铸型。
五、熔炼和浇铸
自耗电极采用Ti-6Al-4VELI合金锭制成，并将自耗电极放入真空自耗电极凝壳炉中，自耗电极与坩埚内壁的间隙为30-100mm，启动真空泵，抽至真空度≤10 -1Pa后，进行熔炼，电压38-40V，电流12000-18000A；冷却水压0.5MPa，坩埚进口水温19℃，坩埚出口水温38℃。然后采用钛合金离心浇铸工艺向铸型内浇铸钛合金液，离心转速为300转/分，既得。
实施例1
大型复杂腔道钛合金铸件精密成形方法，包括下述工艺步骤：
一、制备精铸复合涂壳型芯：
1、面层材料制备：
面层粉料由Y 2O 3、ZrO 2混合制备成，其配料比以质量百分比计为：40μm～80μm粒度的ZrO 2粉30wt％、余量为40μm～80μm Y 2O 3粉。
面层砂由80μm～150μm ZrO 2砂构成。
面层粘结剂选用纳米氧化铝分散液，其浓度为8wt％。
2、背层材料制备：
背层粉料由40μm～80μm粒度Al 2O 3粉80％wt％，余量为40μm～80μmZrO 2粉混合均匀构成。
背层砂材料由80μm～150μm Al 2O 3构成。
背层粘结剂选用硅溶胶溶液，其浓度为15wt％。
3.型芯蜡模制备
根据铸件型腔设计出型芯蜡模模具，蜡模采用中温蜡制备，利用压蜡机制备出合格蜡模。
3.精铸复合涂壳型芯制壳工艺
第一步：将配制好的面层耐火粉料加入到浓度为8wt％的纳米氧化铝分散液面层粘结剂中混匀，粉液质量比为2∶1，均匀搅拌1～3小时，制备成面层涂料；把该涂料涂挂在蜡模上，撒砂采用80μm～150μm ZrO 2砂，干燥时间控制在8～12小时，环境温度控制在18～22℃，湿度控制在45～55％；重复上述操作2次形成一定厚度的面层型壳；
第二步：将配制好的背层粉料加入到浓度为15wt％硅溶胶粘结剂中混匀，粉液质量比控制在2∶1，撒砂采用80μm～150μm Al 2O 3砂，干燥时间控制在8～12小时，环境温度控制在18～22℃，湿度控制在35～50％；重复上述操作4～6次形成一定厚度的加固层型壳；
第三步：将涂挂完成的型壳进行脱蜡，采用红外脱蜡工艺，加热型壳温度在300～350℃，将蜡料脱除干净；
第四步：将蜡料脱除干净的型壳放入箱式电阻炉中焙烧。首先将型壳加热到600℃，保温2～3h，然后将型芯继续加热至950～1100℃，保温3～4h，最 后随炉冷却至室温出炉。
4、精铸复合涂壳型芯表面处理：
采用砂纸打磨方法将精铸复合涂壳型芯表面的多余物打磨去除干净。
二、制备石墨铸型
按设计图纸要求通过机械加工方法制成石墨铸型。
三、石墨铸型和复合涂壳型芯除气
1、石墨铸型除气工艺
将制备成的石墨铸型放入真空除气炉中，加热至850℃～900℃，保温3h，随炉冷却至室温，即得。
2、精铸复合涂壳型芯除气工艺
将制备成的精铸复合涂壳型芯放入箱式电阻炉中，加热至350℃～400℃，保温2h～3h，随炉冷却至100℃～150℃，即得。
四、组型
将经除气工艺处理后的石墨铸型和精铸复合涂壳型芯按照铸型组型图，组装成铸型。
五、熔炼和浇铸
自耗电极采用Ti-6Al-4VELI合金锭制成，并将自耗电极放入真空自耗电极凝壳炉中，自耗电极与坩埚内壁的间隙为30-100mm，启动真空泵，抽至真空度≤10 -1Pa后，进行熔炼，电压38-40V，电流12000-18000A；冷却水压0.5MPa，坩埚进口水温19℃，坩埚出口水温38℃。然后采用钛合金离心浇铸工艺向铸型内浇铸钛合金液，离心转速为300转/分，既得。
实际应用：利用本工艺铸造出的钛合金铸件，，型腔表面粗糙度可以达到Ra5.0μm，优于传统的石墨铸型工艺Ra12.5μm，明显提高了铸件表面质量， 具有良好的经济效益和社会效益。
实施例2
一、制备精铸复合涂壳型芯：
1、面层材料制备：
面层粉料由Y 2O 3、ZrO 2混合制备成，其配料比以质量百分比计为：40μm～80μm粒度的ZrO 2粉40wt％、余量为40μm～80μm Y 2O 3粉。
面层砂由80μm～150μm ZrO 2砂构成。
面层粘结剂选用纳米氧化铝分散液，其浓度为10wt％。
2、背层材料制备：
背层粉料由40μm～80μm粒度Al 2O 3粉85wt％，余量为40μm～80μmZrO 2粉混合均匀构成。
背层砂材料由80μm～150μm Al 2O 3构成。
背层粘结剂选用硅溶胶溶液，其浓度为18wt％。
3.型芯蜡模制备
根据铸件型腔设计出型芯蜡模模具，蜡模采用中温蜡制备，利用压蜡机制备出合格蜡模。
3.精铸复合涂壳型芯制壳工艺
第一步：将配制好的面层耐火粉料加入到浓度为10wt％的纳米氧化铝分散液面层粘结剂中混匀，粉液质量比为3∶1，均匀搅拌1～3小时，制备成面层涂料；把该涂料涂挂在蜡模上，撒砂采用80μm～150μm ZrO 2砂，干燥时间控制在8～12小时，环境温度控制在18～22℃，湿度控制在45～55％；重复上述操作2～3次形成一定厚度的面层型壳；
第二步：将配制好的背层粉料加入到浓度为18wt％硅溶胶粘结剂中混匀，粉液质量比控制在2.5∶1，撒砂采用80μm～150μm Al 2O 3砂，干燥时间控制在8～12小时，环境温度控制在18～22℃，湿度控制在35～50％；重复上述操作4～6次形成一定厚度的加固层型壳；
第三步：将涂挂完成的型壳进行脱蜡，采用红外脱蜡工艺，加热型壳温度在300～350℃，将蜡料脱除干净；
第四步：将蜡料脱除干净的型壳放入箱式电阻炉中焙烧。首先将型壳加热到600℃，保温2～3h，然后将型芯继续加热至950～1100℃，保温3～4h，最后随炉冷却至室温出炉。
4、精铸复合涂壳型芯表面处理：
采用砂纸打磨方法将精铸复合涂壳型芯表面的多余物打磨去除干净。
二、制备石墨铸型
按设计图纸要求通过机械加工方法制成石墨铸型。
三、石墨铸型和复合涂壳型芯除气
1、石墨铸型除气工艺
将制备成的石墨铸型放入真空除气炉中，加热至850℃～900℃，保温3h，随炉冷却至室温，即得。
2、精铸复合涂壳型芯除气工艺
将制备成的精铸复合涂壳型芯放入箱式电阻炉中，加热至350℃～400℃，保温2h～3h，随炉冷却至100℃～150℃，即得。
四、组型
将经除气工艺处理后的石墨铸型和精铸复合涂壳型芯按照铸型组型图，组装成铸型。
五、熔炼和浇铸
自耗电极采用Ti-6Al-4VELI合金锭制成，并将自耗电极放入真空自耗电极凝壳炉中，自耗电极与坩埚内壁的间隙为30-100mm，启动真空泵，抽至真空度≤10 -1Pa后，进行熔炼，电压38-40V，电流12000-18000A；冷却水压0.5MPa，坩埚进口水温19℃，坩埚出口水温38℃。然后采用钛合金离心浇铸工艺向铸型内浇铸钛合金液，离心转速为300转/分，既得。
实际应用：利用本工艺铸造出的钛合金铸件，，型腔尺寸精度可以达到CT6级，明显优于传统石墨铸型工艺的CT7级，明显提高了铸件型腔尺寸精度，具有良好的经济效益和社会效益。
实施例3
一、制备精铸复合涂壳型芯：
1、面层材料制备：
面层粉料由Y 2O 3、ZrO 2混合制备成，其配料比以质量百分比计为：40μm～80μm粒度的ZrO 2粉50wt％、余量为40μm～80μm Y 2O 3粉。
面层砂由80μm～150μm ZrO 2砂构成。
面层粘结剂选用纳米氧化铝分散液，其浓度为12wt％。
2、背层材料制备：
背层粉料由40μm～80μm粒度Al 2O 3粉90wt％，余量为40μm～80μmZrO 2粉混合均匀构成。
背层砂材料由80μm～150μm Al 2O 3构成。
背层粘结剂选用硅溶胶溶液，其浓度为20wt％。
3.型芯蜡模制备
根据铸件型腔设计出型芯蜡模模具，蜡模采用中温蜡制备，利用压蜡机制备出合格蜡模。
3.精铸复合涂壳型芯制壳工艺
第一步：将配制好的面层耐火粉料加入到浓度为12wt％的纳米氧化铝分散液面层粘结剂中混匀，粉液质量比为3.5∶1，均匀搅拌1～3小时，制备成面层涂料；把该涂料涂挂在蜡模上，撒砂采用80μm～150μm ZrO 2砂，干燥时间控制在8～12小时，环境温度控制在18～22℃，湿度控制在45～55％；重复上述操作2～3次形成一定厚度的面层型壳；
第二步：将配制好的背层粉料加入到浓度为20wt％硅溶胶粘结剂中混匀，粉液质量比控制在3∶1，撒砂采用80μm～150μm Al 2O 3砂，干燥时间控制在8～12小时，环境温度控制在18～22℃，湿度控制在35～50％；重复上述操作4～6次形成一定厚度的加固层型壳；
第三步：将涂挂完成的型壳进行脱蜡，采用红外脱蜡工艺，加热型壳温度在300～350℃，将蜡料脱除干净；
第四步：将蜡料脱除干净的型壳放入箱式电阻炉中焙烧。首先将型壳加热到600℃，保温2～3h，然后将型芯继续加热至950～1100℃，保温3～4h，最后随炉冷却至室温出炉。
4、精铸复合涂壳型芯表面处理：
采用砂纸打磨方法将精铸复合涂壳型芯表面的多余物打磨去除干净。
二、制备石墨铸型
按设计图纸要求通过机械加工方法制成石墨铸型。
三、石墨铸型和复合涂壳型芯除气
1、石墨铸型除气工艺
将制备成的石墨铸型放入真空除气炉中，加热至850℃～900℃，保温3h，随炉冷却至室温，即得。
2、精铸复合涂壳型芯除气工艺
将制备成的精铸复合涂壳型芯放入箱式电阻炉中，加热至350℃～400℃，保温2h～3h，随炉冷却至100℃～150℃，即得。
四、组型
将经除气工艺处理后的石墨铸型和精铸复合涂壳型芯按照铸型组型图，组装成铸型。
五、熔炼和浇铸
自耗电极采用Ti-6Al-4VELI合金锭制成，并将自耗电极放入真空自耗电极凝壳炉中，自耗电极与坩埚内壁的间隙为30-100mm，启动真空泵，抽至真空度≤10 -1Pa后，进行熔炼，电压38-40V，电流12000-18000A；冷却水压0.5MPa，坩埚进口水温19℃，坩埚出口水温38℃。然后采用钛合金离心浇铸工艺向铸型内浇铸钛合金液，离心转速为300转/分，既得。
实际应用：利用本工艺铸造出的钛合金铸件，铸件力学性能抗拉强度达到895MPa，明显超过传统熔模精密铸造工艺的抗拉强度845MPa，显著提高了铸件力学性能，具有良好的经济效益和社会效益。

Claims (10)

  1. 一种大型复杂腔道钛合金铸件精密成形方法，其特征在于，该方法采用精铸复合涂壳型芯和石墨铸型制备大型复杂腔道钛合金铸件，复合涂壳型芯和石墨铸型除气后组装成铸型，将自耗电极放入真空自耗电极凝壳炉中熔炼，并采用钛合金离心浇铸工艺向铸型内浇铸钛合金液，离心后得到型复杂腔道钛合金铸件。
  2. 根据权利要求1所述的大型复杂腔道钛合金铸件精密成形方法，其特征在于，所述精铸复合涂壳型芯具体步骤如下：
    (1)将面层耐火粉料加入到面层粘结剂中混匀搅拌1～3小时，制备成面层涂料；把该涂料涂挂在蜡模上，撒面层砂，干燥时间为8～12小时，温度为18～22℃，湿度为45～55％；重复上述操作2～3次形成面层型壳；
    (2)将背层粉料加入到背层粘结剂中混匀，撒背层砂，干燥时间为8～12小时，温度为18～22℃，湿度为35～50％；重复上述操作4～6次形成加固层型壳；
    (3)将上述涂挂完成的型壳进行脱蜡；
    (4)将步骤(3)得到的型壳放入箱式电阻炉中焙烧、冷却室温出炉得到复合涂壳型芯。
  3. 根据权利要求2所述的大型复杂腔道钛合金铸件精密成形方法，其特征在于，面层耐火粉料与面层粘结剂的质量比为2～3.5∶1；所述背层粉料与背层粘结剂的质量比为2～3∶1。
  4. 根据权利要求2所述的大型复杂腔道钛合金铸件精密成形方法，其特征在于，所述面层耐火粉料为40μm～80μm粒径的Y 2O 3和40μm～80μm粒径的ZrO 2混合物，其中，ZrO 2粉30～50wt％、余量为Y 2O 3粉；所述背层粉料为40μm～80μm粒度的Al 2O 3粉和40μm～80μm粒度ZrO 2的混合物，其中Al 2O 3粉质量分数为80～90％wt％，余量为ZrO 2。
  5. 根据权利要求2所述的大型复杂腔道钛合金铸件精密成形方法，其特征在于，所述面层粘结剂为纳米氧化铝分散液，分散液浓度为8％～12wt％；所述背层粘结剂为浓度15％～20wt％硅溶胶粘溶液。
  6. 根据权利要求2所述的大型复杂腔道钛合金铸件精密成形方法，其特征在于，所述面层砂为粒径80μm～150μm的ZrO 2砂；所述背层砂为粒径80μm～150μm的Al 2O 3砂。
  7. 根据权利要求2所述的大型复杂腔道钛合金铸件精密成形方法，其特征在于，所述脱蜡采用红外脱蜡工艺，加热型壳温度为300～350℃。
  8. 根据权利要求2所述的大型复杂腔道钛合金铸件精密成形方法，其特征在于，所述步骤(4)培烧条件：将型壳加热到600℃，保温2～3h，然后将型芯继续加热至950～1100℃，保温3～4h。
  9. 根据权利要求1所述的大型复杂腔道钛合金铸件精密成形方法，其特征在于，所述除气工艺具体为：石墨铸型放入真空除气炉中，加热至850℃～900℃，保温3h，随炉冷却至室温；精铸复合涂壳型芯放入箱式电阻炉中，加热至350℃～400℃，保温2h～3h，随炉冷却至100℃～150℃。
  10. 根据权利要求1所述的大型复杂腔道钛合金铸件精密成形方法，其特征在于，所述熔炼具体为：自耗电极采用Ti-6Al-4VELI合金锭制成，并将自耗电极放入真空自耗电极凝壳炉中，自耗电极与坩埚内壁的间隙为30-100mm，启动真空泵，抽至真空度≤10 -1Pa后，进行熔炼，电压38-40V，电流12000-18000A；冷却水压0.5MPa，坩埚进口水温19℃，坩埚出口水温38℃；
    所述浇铸具体为：采用钛合金离心浇铸工艺向铸型内浇铸钛合金液，离心转速为300转/分。
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