WO2022107691A1 - 積層造形セラミックコアおよび該セラミックコアの製造方法 - Google Patents
積層造形セラミックコアおよび該セラミックコアの製造方法 Download PDFInfo
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- WO2022107691A1 WO2022107691A1 PCT/JP2021/041691 JP2021041691W WO2022107691A1 WO 2022107691 A1 WO2022107691 A1 WO 2022107691A1 JP 2021041691 W JP2021041691 W JP 2021041691W WO 2022107691 A1 WO2022107691 A1 WO 2022107691A1
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Images
Classifications
-
- 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
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
- B28B11/045—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers by dipping
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y70/00—Materials specially adapted for additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Definitions
- the present invention relates to a laminated molded ceramic core and a method for manufacturing the ceramic core. It should be noted that this application claims priority based on Japanese Patent Application No. 2020-193179 filed on November 20, 2020, and the entire contents of the application are incorporated herein by reference. There is.
- powder materials are bonded with a binder to form a powder solidified layer having a predetermined cross-sectional shape, and the powder solidified layers are sequentially laminated to form a shaped object having a desired three-dimensional shape.
- Additive manufacturing also referred to as three-dimensional modeling
- powder materials made of ceramic materials which are difficult to be precision processed after molding, are also widely used. According to such powder additive manufacturing, a ceramic core used as a core when forming a metal casting having a complicated shape can be manufactured at low cost and in a short period of time.
- the characteristics required for such a ceramic core are generally strength that can withstand molten metal at around 1500 degrees when pouring molten metal, and surface roughness sufficient to smooth the surface of the cast to be manufactured. Is required. When the molten metal is thermally shrunk in the process of solidification, it is required to have a disintegration property that does not cause recrystallization failure. When the ceramic core is removed from the metal casting, meltability that is easily removed by an alkaline solution is required.
- Patent Documents 1 to 3 disclose techniques for improving the strength of a mold.
- Patent Document 1 the surface of a powder containing silica is coated with an organic binder, and then a laminated model is formed and fired. The technique to be used is described.
- Patent Document 2 describes a technique of impregnating a laminated model with an inorganic binder a plurality of times and then firing.
- Patent Document 3 discloses a technique of forming a model having a slurry layer and a stucco layer and then firing in order to achieve both the strength of the mold and the self-disintegrating property.
- a laminated molded product using a powder material made of a ceramic material tends to have a larger void between particles and a higher porosity than a ceramic molded product using a mold.
- the surface roughness tends to be large (that is, the surface becomes rough) due to the laminating step generated when the powder materials are laminated.
- the size of the surface roughness of the ceramic core is directly related to the size of the surface roughness of the metal casting. Therefore, there has been a demand for a technique for obtaining a ceramic core having an improved surface roughness (that is, a smooth surface).
- the present invention has been made in view of these respects, and a main object thereof is to provide a laminated molded ceramic core having strength, disintegration property and meltability, and further improved surface roughness. .. Another object is to provide a method for manufacturing such a ceramic core.
- the laminated molding ceramic core disclosed herein includes a central portion which is a laminated molding fired body of a predetermined ceramic powder, a first layer covering at least a part of the central portion, and a surface layer of the first layer. It is composed of a second layer formed in.
- erosion rate ( ⁇ m / g) B / A;
- the average erosion rate of the central portion is 5 times or more the average erosion rate of the first layer, and the average erotic of the second layer.
- the John rate is 2.5 times or more the average erotic rate of the first layer.
- the arithmetic average surface roughness Ra of the second layer is 10 ⁇ m or less.
- Such a ceramic core may have sufficient surface roughness to smooth the surface of the metal casting.
- the central portion and the second layer are each composed of at least one selected from the group consisting of silica, alumina, zircon, and magnesia. It is a feature. If an oxide containing such a metal element and a metalloid element is used, the above-mentioned effects can be more preferably exhibited.
- the first layer is characterized by containing silica as a major constituent. According to the structure containing such silica as the most constituent component, a ceramic core that can be easily melted and removed with an alkaline solution is provided.
- a method for manufacturing a laminated molded ceramic core is provided. That is, the manufacturing method disclosed herein is to form a laminated model by a laminated molding method using a first ceramic powder having an average particle size D1, and to fire the laminated model to obtain a laminated model. To obtain the central portion, to immerse the laminated molding fired body in a ceramic sol containing a second ceramic having an average particle size D2 to form the first layer on at least a part of the laminated molding fired body. The laminated molded body to which the first layer is applied is immersed in a ceramic slurry containing a third ceramic powder having an average particle size D3 to form the second layer on the surface layer of the first layer. Including what to do. According to the manufacturing method of this aspect, it is possible to manufacture a laminated molded ceramic core having both strength and disintegration property and further improved surface roughness.
- the average particle diameters D1, D2 and D3 of the first ceramic powder, the second ceramic powder, and the third ceramic powder are D1>D3>. It is D2. According to such a configuration, it is possible to manufacture a ceramic core having appropriate strength and disintegration property and further improved surface roughness.
- the arithmetic average surface roughness Ra of the second layer is 10 ⁇ m or less.
- the ceramic core produced by the manufacturing method of this aspect has sufficient surface roughness to smooth the surface of the metal casting.
- the first ceramic powder and the third ceramic powder are each composed of at least one selected from the group consisting of silica, alumina, zircon and magnesia. Will be done.
- the second ceramic powder contains silica as a main component. According to such a configuration, the above-mentioned effect can be more exerted.
- FIG. 1 is an SEM observation image of the surface of Example 1.
- FIG. 2 is an SEM observation image of the surface of Comparative Example 1.
- FIG. 3 is an SEM observation image of the surface of Comparative Example 2.
- FIG. 4 is an SEM observation image of a cross section perpendicular to the surface of Example 1 (cross section along the thickness direction).
- FIG. 5 is an SEM observation image of a cross section perpendicular to the surface of Comparative Example 2 (cross section along the thickness direction).
- FIG. 6A is a graph showing the results of measuring the surface roughness Ra of Example 1.
- FIG. 6B is a graph showing the results of measuring the surface roughness Ra of Comparative Example 1.
- FIG. 6C is a graph showing the results of measuring the surface roughness Ra of Comparative Example 2.
- composition of the first layer and the first to third ceramic powders "containing A as a main constituent component” means that A is used in the first layer and the first to third ceramic powders. It may be included as the most constituent component. Although it is not particularly limited to include it as the maximum number of constituents, for example, the ratio of A in the first layer and the first to third ceramic powders is typically 60% or more (preferably) on a mass basis. Is 70% or more, more preferably 80% or more, still more preferably 90% or more, for example 99% or more). It may also include those in which all (100%) are composed of A on a mass basis.
- the laminated molded ceramic core disclosed here is composed of a central portion, a first layer, and a second layer.
- the central part is a laminated molding fired body having a porous structure in which the first ceramic powder is shaped and fired by laminated molding.
- the first layer is a layer containing the second ceramic powder and covering at least a part of the central portion.
- the first layer is formed by immersing the central portion in a dispersion liquid (ceramic sol) composed of a second ceramic powder and a dispersion medium, and removing the dispersion medium by drying and heat treatment.
- the second layer contains the third ceramic powder and is a porous layer formed on the surface layer of the first layer.
- the second layer is formed by coating the surface layer of the first layer with a ceramic slurry composed of a third ceramic powder and a solvent, and removing the solvent by high-temperature firing.
- the average erosion rate of the first layer is lower than the erosion rate of the central part, and the average erosion rate of the second layer is the first. Higher than the average ceramic rate of the layer.
- the average erosion rate can be measured and calculated by using a commercially available device. For example, a brittleness test of a laminated molded ceramic core can be performed using an apparatus manufactured by Palmes Co., Ltd. (for example, MSE-A203 or the like) as this type of apparatus. As a result, the average erosion rate in each structure of the laminated molded ceramic core is calculated.
- a test piece of a substantially rectangular parallelepiped laminated ceramic core having a central portion, a first layer and a second layer, and the test piece along the width direction at a position 4 mm from the surface along the thickness direction.
- a predetermined amount of projection particles for example, 3 ⁇ m spherical alumina MSE-BA-3-3 manufactured by Palmeso Co., Ltd.
- the projection particles are standard test pieces (for example).
- HRC-45 manufactured by Palmeso Co., Ltd. with a projection output value having a predetermined erosion rate (for example, 0.18 ⁇ m / g).
- the test piece and the test piece (cross section) are cut from the surface to a depth of 180 ⁇ m in the thickness direction.
- the relationship between the projection amount (Ag) of the projection particles and the depth of erosion (B ⁇ m) is continuously acquired (at least 3 places or more, and further 10 places or more). This makes it possible to obtain a graph (erection progress graph) showing the relationship between the projection amount (Ag) of the projection particles and the erosion depth (B ⁇ m).
- the erosion rate is a parameter indicating the erosion speed (ease of erosion), and the smaller the value, the harder the test piece.
- the value from the surface (0 ⁇ m) to 60 ⁇ m of the test piece is the second layer
- the value from 100 ⁇ m to 180 ⁇ m is the first layer
- the surface of the test piece (cross section) (0 ⁇ m) is defined as the erotic ratio corresponding to the central part.
- the average value of the erosion rates of 3 or more places is calculated, and this value is defined here as the average erosion rate of each structure.
- the average erosion rate of the central part, the first layer and the second layer can be obtained as described above.
- the average erosion rate of the first layer is lower than the erosion rate of the central part, and the average erosion rate of the second layer is the first layer.
- the average erosion rate of the second layer is the first layer.
- the average erotic rate in the center is required to be higher than that of the first layer.
- the average erosion rate in the central part is preferably 5 times or more and 10 times or less, more preferably 5.5 times or more and 9.5 times or less, and 6 times or more and 9 times or less. The following is more preferable.
- the average erosion rate of the second layer is required to be higher than the average erosion rate of the first layer.
- the average erosion rate of the second layer is preferably 2.5 times or more and 8.5 times or less, more preferably 3 times or more and 8 times or less, and 3.5 times or more and 7. It is more preferably 5 times or less.
- the techniques disclosed herein may be preferably practiced in an embodiment having an average erotic rate in the range described above.
- the first to third ceramic powders used for the central part, the first layer and the second layer each have different average particle sizes (D1 to D3).
- the average particle size of the ceramic powder is D1> D3> D2.
- the "average particle size" of the first ceramic powder and the third ceramic powder is an integrated value of 50% in the volume-based particle size distribution measured by a particle size distribution measuring device based on a laser scattering / diffraction method. It means the particle size in (50% volume average particle size; D50).
- the "average particle size” of the second ceramic powder means the average particle size calculated from the specific surface area of the second ceramic powder obtained by the BET method (for example, the BET 1-point method) or the like. This average particle size is a value calculated on the assumption that the primary particle size of the second ceramic powder matches the diameter of the spherical particles (corresponding diameter to the sphere) that can realize the specific surface area.
- the average particle size D1 of the first ceramic powder used here is required to be larger than the average particle size D2 of the second ceramic powder and the average particle size D3 of the third ceramic powder.
- the average particle size D1 of the first ceramic powder is not particularly limited, but is, for example, 20 ⁇ m or more, preferably 25 ⁇ m or more, and more preferably 30 ⁇ m or more.
- D1 is generally 100 ⁇ m or less, more preferably 80 ⁇ m or less, and even more preferably 60 ⁇ m or less.
- the average particle size D1 of the first ceramic powder is, for example, preferably 20 ⁇ m or more and 100 ⁇ m or less.
- the average particle size D2 of the second ceramic powder used here is required to be smaller than the average particle size D1 of the first ceramic powder and the average particle size D3 of the third ceramic powder.
- the average particle size D2 of the second ceramic powder is not particularly limited, but is, for example, 25 nm or less, preferably 20 nm or less, and more preferably 15 nm or less.
- the lower limit of the average particle size D2 of the second ceramic powder is not particularly limited, and for example, one having a diameter of 1 nm or more, typically 5 nm or more can be used.
- the average particle size D2 of the second ceramic powder is, for example, preferably 1 nm or more and 25 nm or less.
- the average particle size D3 of the third ceramic powder used here is required to be smaller than the average particle size D1 of the first ceramic powder and larger than the average particle size D2 of the second ceramic powder.
- the average particle size D3 of the third ceramic powder is not particularly limited, but is, for example, 15 ⁇ m or less, preferably 10 ⁇ m or less.
- the lower limit of the average particle size D3 of the third ceramic powder is not particularly limited, but is preferably 0.5 ⁇ m or more, typically 1 ⁇ m or more.
- the average particle size D3 of the third ceramic powder is, for example, preferably 0.5 ⁇ m or more and 15 ⁇ m or less.
- the shape (outer shape) of the first to third ceramic powders is not particularly limited. It may be spherical or non-spherical such as elliptical, granule, square (for example, crushed shape). From the viewpoint of mechanical strength, ease of manufacture, and the like, a substantially spherical ceramic powder can be preferably used.
- the first to third ceramic powders preferably have an aspect ratio close to 1. For example, 1.3 or less is preferable, and 1.2 or less is more preferable. In the present specification, the aspect ratio is obtained as (a / b) when the long side is a and the short side is b when the smallest rectangle circumscribing the first to third ceramic powders is drawn. Is the value to be.
- the first to third ceramic powders can be either inorganic particles or organic-inorganic composite particles.
- the ceramic particles constituting the first to third ceramic powders inorganic particles are preferable, and particles made of a metal or metalloid compound are particularly preferable.
- oxide-based ceramics composed of oxides of any element belonging to Group 1 to Group 14 (for example, Group 4 to Group 14) of the periodic table
- nitrides and carbides of various metal elements Non-oxide ceramics composed of boroides, silices, phosphoric acid compounds and the like, and ceramic particles containing these composite ceramics and the like as main constituents can be preferably used.
- ceramic particles containing oxides, nitrides, carbides, etc. containing any metal element or semi-metal element of Al, Zr, Mg and Si as main constituents are preferable.
- ceramic particles containing a metal containing any element belonging to Group 1 to Group 13 (for example, Group 4 to Group 13) of the periodic table or an alloy thereof as a main constituent component may be adopted.
- alumina Al 2 O 3
- zirconia ZrO 2
- magnesia MgO
- silica SiO 2
- titania TIO 2
- ceria CeO 2
- itria Y 2 O 3
- Hafnia HfO 2
- barium titanate BaTIO 3
- manganese dioxide MnO 2
- lime CaO
- zinc oxide ZnO
- red iron oxide Fe 2 O 3
- zircon ZrSiO 4
- mulite Al 6
- It may be an oxide-based ceramic such as O 13 Si 2 ), aluminum silicate, strontium oxide (SrO), barium oxide (BaO), niobium oxide (Nb 2 O 5 ), or silicon nitride (Si 3 N 4 ). ), Non-oxide ceramics such as boron nitride (BN), aluminum nitride (AlN), silicon carbide (SiC), and boron carbonitrides, or composites containing at least one of these ceramics. It may be a material or the like. These ceramics may be used alone or in combination of two or more, depending on the use of the ceramic core, the required characteristics, and the like.
- oxide-based ceramic such as O 13 Si 2 ), aluminum silicate, strontium oxide (SrO), barium oxide (BaO), niobium oxide (Nb 2 O 5 ), or silicon nitride (Si 3 N 4 ).
- Non-oxide ceramics such as boron nitride (BN
- silica, alumina, zircon, magnesia and the like are preferably used because of their excellent flame retardancy.
- the chemical formula shown in parentheses after the substance name indicates the representative composition of the substance, and is not intended to limit the actual composition of the ceramic to such a chemical formula.
- the first ceramic powder is a material for forming a central portion.
- the particles that can be preferably adopted as the first ceramic powder include silica particles, alumina particles, zircon particles, and magnesia particles. These particles may be used alone or in combination of two or more.
- the content of the first ceramic powder in the central portion is not particularly limited, but when the total amount of the central portion is 100 parts by mass, it is usually 60 parts by mass or more, which is preferable from the viewpoint of improving mechanical strength. It may be 65 parts by mass or more, more preferably 75 parts by mass or more, for example, 80 parts by mass or more, typically 90 parts by mass or more.
- the upper limit of the content of the first ceramic powder is not particularly limited, but is preferably 99 parts by mass or less, more preferably 98 parts by mass or less, and may be, for example, 96 parts by mass or less. When the content of the first ceramic powder is within such a range, the effect of this composition can be exhibited at a higher level.
- the second ceramic powder is a material for forming the first layer.
- particles that can be preferably used as the second ceramic powder include silica particles.
- silica As a ceramic component, for example, when such a laminated molded ceramic core is used as a core, it is preferable because it can be easily and quickly dissolved by an alkaline solution after casting (that is, excellent solubility). Has). Further, silica is preferable because it can be obtained with a finer particle size adjusted at a relatively low cost and easily.
- the third ceramic powder is a material for forming the second layer.
- Specific examples of the particles that can be preferably used as the third ceramic powder include silica particles, alumina particles, zircon particles, and magnesia particles. These particles may be used alone or in combination of two or more.
- the laminated molded ceramic core disclosed herein is not particularly limited in its manufacturing method, but can be suitably manufactured by, for example, the manufacturing method described below. That is, the method for manufacturing such a laminated molded ceramic core includes the following steps. (1) To prepare a central portion (additive manufacturing calcined body) formed by molding the first ceramic powder by a layered manufacturing method and firing it. (2) The central portion (laminated molded body) is immersed in a ceramic sol containing the second ceramic powder, and the dispersion medium is removed by drying and heat treatment to form the first layer. (3) The surface layer of the first layer is coated with a ceramic slurry containing the third ceramic powder, and the solvent is removed by high-temperature sintering to form the second layer.
- the central portion of the laminated molded ceramic core disclosed here is prepared by, for example, an embodiment including the following method.
- a laminated modeling powder containing the first ceramic powder is prepared, and the laminated modeling is formed by a conventionally known method using the laminated modeling powder.
- the laminated molding powder may contain components other than the first ceramic powder, if necessary. Examples of such a component include a binder, a surfactant and the like.
- the binder for example, thermoplastic resins such as isobutylene resin, polyamide resin, polyester resin, polyether resin, polyvinyl alcohol resin, polyvinyl butyral resin, polyethylene glycol resin, and melamine resin are thermally cured. Examples thereof include polysaccharides such as sex resins and cellulose derivatives.
- the laminated model may be immersed in a solution containing a compound that is ceramicized by a chemical reaction or heating.
- the compound to be ceramicized by a chemical reaction or heating include a silane coupling agent containing silicon (Si), an aluminum coupling agent containing aluminum (Al), a titanium coupling agent containing titanium (Ti), and zirconia.
- Zr zirconium-based coupling agents containing
- Si silane-based alkoxide containing silicon
- Al aluminum-based alkoxide containing aluminum
- Ti titanium containing titanium
- preparing the above-mentioned central portion may include firing a laminated model.
- the above-mentioned laminated model may be fired at a predetermined firing temperature (for example, 1000 ° C to 1500 ° C). Since the above-mentioned modeling method and the above-mentioned firing method do not characterize the present invention, detailed description thereof will be omitted.
- the average erosion rate of the prepared central portion is required to be higher than that of the first layer.
- the average erosion rate at the center is 3 ⁇ m spherical alumina (MSE-BA-3-3 manufactured by Palmeso Co., Ltd.) with respect to the MSE standard test piece (HRC-45 manufactured by Palmeso Co., Ltd.).
- MSE-BA-3-3 manufactured by Palmeso Co., Ltd.
- HRC-45 manufactured by Palmeso Co., Ltd.
- the average erosion rate at the center may be, for example, 40 ⁇ m / g or more, or 50 ⁇ m / g or more.
- the average pore diameter of the central portion is approximately 1 ⁇ m or more and 30 ⁇ m or less.
- the average pore diameter may be, for example, 5 ⁇ m or more, or 10 ⁇ m or more.
- the porosity of the central portion is approximately 30% or more and 60% or less.
- the porosity may be, for example, 35% or more, or 40% or more.
- the arithmetic surface roughness Ra of the central portion may satisfy, for example, 10 ⁇ m or more, typically 12 ⁇ m or more.
- the laminated molded body having such a high erotic ratio is advantageous from the viewpoint of disintegration, but there is still room for improvement from the viewpoint of strength. Further, there may still be room for improvement in the surface roughness in order to smooth the surface of the metal casting.
- the effect of applying the first layer and the second layer of this configuration can be better exerted.
- the value measured by using the mercury intrusion method is adopted as the "average pore diameter” unless otherwise specified.
- the "porosity” a value calculated from the amount of pores measured by using the mercury intrusion method is adopted.
- a dispersion liquid (ceramic sol) in which the second ceramic powder is dispersed in a dispersion medium is prepared.
- the second ceramic powder can be suitably introduced into the pores in the central portion.
- the ceramic sol is in a colloidal state (that is, a colloidal solution) in which the second ceramic powder is independently suspended or suspended uniformly in the dispersion medium without agglomeration.
- the colloidal solution is a term that includes sol, suspension, and the like.
- the second ceramic powder is dispersed in an appropriate dispersion medium.
- the dispersion medium is not particularly limited, and either an aqueous solvent or a non-aqueous solvent may be used.
- the aqueous solvent is preferably water or a mixed solvent containing water.
- As the solvent other than water constituting the mixed solvent one or more organic solvents (lower alcohols, lower ketones, etc.) that can be homogeneously mixed with water can be appropriately selected and used.
- an aqueous solvent in which 80% by mass or more (more preferably 90% by mass or more, still more preferably 95% by mass or more) of the aqueous solvent is water.
- a particularly preferred example is an aqueous solvent (eg, water) that is substantially composed of water.
- the dispersion liquid may contain additives (stabilizers) such as a dispersant and a thickener.
- the blending amount (concentration) of the second ceramic powder in the ceramic sol is adjusted to about 10% by weight or more and 40% by weight or less. Is preferable.
- the ceramic sol in which the second ceramic powder is dispersed may be prepared and used, for example, by allowing a predetermined metal salt or the like to act with dilute hydrochloric acid for dialysis, or a commercially available one may be purchased and used. ..
- the pores in the central portion are impregnated with the ceramic sol, and the second ceramic powder is introduced into the pores in the central portion.
- Immersion of the central portion in the ceramic sol cannot be unequivocally determined because it depends on the morphology of the pores formed in the central portion, the concentration and viscosity of the ceramic sol, etc., but for example, about 1 minute to 1 hour is a guideline. Can be carried out.
- the first layer disclosed here can be obtained by removing the dispersion medium from the laminated model after the immersion. Removal of the dispersion medium can be achieved by drying and heat treatment. Examples of the drying means include natural drying and blast drying. The heat treatment is performed by holding in an air atmosphere, for example, at 400 to 500 ° C. for 1 to 3 hours. As a result, the first layer can be formed in at least a part of the central portion. The steps of immersing in a ceramic sol for drying and heat treatment may be repeated a plurality of times to form the first layer.
- the average erosion rate of the first layer of the ceramic core provided with the central portion and the first layer prepared above is required to be lower than that of the central portion and the second layer.
- the average erosion rate of the first layer is 3 ⁇ m spherical alumina (MSE-BA-3-3 manufactured by Palmeso Co., Ltd.) to the MSE standard test piece (HRC-45 manufactured by Palmeso Co., Ltd.).
- MSE-BA-3-3 manufactured by Palmeso Co., Ltd.
- HRC-45 manufactured by Palmeso Co., Ltd.
- the average erosion rate of the first layer is, for example, preferably 13 ⁇ m / g or less, and more preferably 10 ⁇ m / g or less.
- the average pore diameter of the laminated molded ceramic core including the central portion and the first layer is approximately 1 ⁇ m or more and 30 ⁇ m or less.
- the average pore diameter may be, for example, 5 ⁇ m or more, or 10 ⁇ m or more.
- the porosity of the laminated molded ceramic core including the central portion and the first layer is approximately 10% or more and 40% or less.
- the porosity is preferably, for example, 35% or less, and typically 30% or less.
- the arithmetic surface roughness Ra of the laminated molded ceramic core including the central portion and the first layer may satisfy, for example, 10 ⁇ m or more, typically 12 ⁇ m or more.
- the central portion maintains an appropriate disintegration property, and the first layer is formed.
- the layer can improve the strength of the laminated shaped ceramic core.
- the composition and properties of the third ceramic powder have been described in detail above, so the description will be omitted.
- the solvent used for the ceramic slurry contained in the second layer is not particularly limited as long as it can disperse the above-mentioned third ceramic powder.
- an aqueous solvent can be used.
- water-based solvent water or a mixed solvent containing water is preferably used.
- the solvent component other than water constituting the mixed solvent one or more organic solvents (lower alcohols, lower ketones, etc.) that can be uniformly mixed with water can be appropriately selected and used.
- an aqueous solvent in which 80% by mass or more (more preferably 90% by mass or more, still more preferably 95% by mass or more) of the aqueous solvent is water.
- a particularly preferable example is an aqueous solvent which is substantially composed of water.
- the solvent used for the ceramic slurry is not limited to the aqueous solvent, and may be a non-aqueous solvent (organic solvent).
- the non-aqueous solvent for example, alcohols such as ethyl alcohol and isopropyl alcohol; and the like can be used.
- the ratio of the contents of the third ceramic powder and the solvent in the ceramic slurry is not particularly limited, but is preferably in the range of 1: 5 to 5: 1 on a mass basis, and more preferably 1. : 4 to 4: 1. When it is within the range of the content ratio of the third ceramic powder and the solvent, the above-mentioned tax efficiency improving effect can be better exerted.
- the ceramic slurry disclosed here may contain a dispersant.
- the dispersant is a component added for the purpose of stably dispersing the third ceramic powder in the slurry, and a surfactant is typically used.
- examples of the dispersant include high molecular weight polycarboxylic acids and the like.
- the content of the dispersant in the ceramic slurry is not particularly limited, but is usually preferably 0.1% by mass to 3% by mass.
- the ceramic slurry disclosed herein may further contain known additives such as thickeners, rust inhibitors, preservatives, and fungicides, as necessary, as long as the effects of the present composition are not impaired. good.
- the content of the additive may be appropriately set according to the purpose of the addition and does not characterize the present invention, and therefore detailed description thereof will be omitted.
- the method for preparing the ceramic slurry is not particularly limited.
- each component contained in the ceramic slurry may be mixed using a well-known mixing method.
- the mode in which these components are mixed is not particularly limited, and for example, all the components may be mixed at once, or may be mixed in an appropriately set order.
- the laminated molded ceramic core after the second layer when firing the laminated molded ceramic core after the second layer is applied, it is necessary to fire the laminated molded product in a high temperature range of 1000 ° C. or higher (preferably 1200 ° C. or higher). For this reason, it is desirable to use a firing tool (for example, sand) made of a highly heat-resistant metal compound such as alumina, mullite, cordulite, and silicon carbide as the firing jig (for example, sand) used when firing the laminated model. ..
- these metal compound firing jigs may react with the third ceramic powder contained in the ceramic slurry in the firing temperature range of 1000 ° C. or higher.
- the third ceramic powder reacts with the firing jig, the third ceramic powder and the firing jig adhere to each other, and it is possible that a ceramic core having a good surface roughness cannot be obtained when the fired body is taken out from the firing jig. There is sex. Therefore, it is desirable to appropriately suppress the reaction between the third ceramic powder contained in the ceramic slurry and the firing jig in the firing step. By such firing, a laminated molded ceramic core including the central portion, the first layer and the second layer disclosed herein can be produced.
- the average erosion rate of the second layer of the laminated molded ceramic core provided with the central portion, the first layer, and the second layer prepared above is required to be higher than that of the first layer.
- the average erosion rate of the second layer is 3 ⁇ m spherical alumina (MSE-BA-3-3 manufactured by Palmeso Co., Ltd.) to the MSE standard test piece (HRC-45 manufactured by Palmeso Co., Ltd.).
- MSE-BA-3-3 manufactured by Palmeso Co., Ltd.
- HRC-45 manufactured by Palmeso Co., Ltd.
- the average erosion rate of the second layer is, for example, preferably 25 ⁇ m / g or more, and more preferably 30 ⁇ m / g or more.
- the average pore diameter of the laminated molded ceramic core including the central portion, the first layer and the second layer is approximately 1 ⁇ m or more and 30 ⁇ m or less.
- the average pore diameter may be, for example, 5 ⁇ m or more, or 10 ⁇ m or more.
- the porosity of the laminated molded ceramic core including the central portion, the first layer, and the second layer is approximately 20% or more and 50% or less.
- the porosity of the second layer may be, for example, 25% or more, and typically 30% or more.
- the arithmetic surface roughness Ra of the laminated molded ceramic core including the central portion, the first layer and the second layer may satisfy, for example, 15 ⁇ m or less, typically 10 ⁇ m or less.
- Such a laminated shaped ceramic core may have a surface roughness sufficient to be used as a core in producing a metal casting.
- a mixed powder of silica, zircon and alumina (average particle size D1: 34 ⁇ m) was prepared.
- the weight ratio of silica to zircon and alumina was 75:23: 2.
- the mixed powder and PVA (Kuraray Poval 205) as a binder were weighed at a mass ratio of 90:10 and mixed in a dry mixer for 20 minutes to prepare a powder for laminated modeling.
- This powder for laminated molding was put into ProJet460Plus manufactured by 3D Systems, and a laminated molded product having a substantially rectangular parallelepiped (width 8 mm ⁇ depth 40 mm ⁇ thickness 6 mm) was formed and dried at room temperature for 16 hours and at 65 ° C. for 1 hour. ..
- a coupling liquid containing a coupling agent (3-aminopropyltriethoxysilane) was prepared, and the above-mentioned laminated model was impregnated into the coupling liquid for 1 minute, and then at room temperature for 1 hour at 65 ° C. It was dried for 1 hour. The dried laminated model was fired in alumina sand at 1250 ° C. to obtain a central portion (laminated model fired body) (Comparative Example 1).
- a silica sol (silica concentration 20% by weight, average particle size D2: 10 nm) was prepared as a ceramic sol containing the second ceramic powder.
- the central portion (laminated molded body) was immersed in silica sol for 25 minutes and then dried at room temperature for 1 hour and at 80 ° C. for 1 hour. Then, after drying, heat treatment was performed at 450 ° C. to obtain a laminated model composed of a central portion and a first layer. The steps of immersing in silica sol, drying and heat-treating were repeated 4 times. This was designated as Comparative Example 2.
- a mixed powder of silica, zircon and alumina (average particle size D3: 6.7 ⁇ m) was prepared.
- the weight ratio of silica, zircon and alumina was 75:23: 2.
- the mixed powder was mixed with a high molecular weight polycarboxylic acid as a dispersant and ethanol as a solvent to prepare a ceramic rally.
- the slurry was applied to the surface of the laminated model (Comparative Example 2) composed of the above-mentioned central portion and the first layer by a dip coating method, coated, and dried.
- the laminated molded product after drying was fired in alumina sand at 1300 ° C. to obtain a laminated molded ceramic core (Example 1).
- FIG. 1 is for Example 1
- FIG. 2 is for Comparative Example 1
- FIG. 3 is for Comparative Example 2.
- Example 1 ⁇ Calculation of average erosion rate>
- MSE-A203 manufactured by Parumeso.
- test pieces three each of Example 1 and Example 1 (cross section) in which Example 1 was cut along the width direction at a position of 4 mm along the thickness direction were prepared.
- 3 ⁇ m spherical alumina MSE-BA-3-3 manufactured by Palmeso Co., Ltd.
- the erosion rate was 0. It was carried out with a projection output value of 18 ( ⁇ m / g).
- the projected particles were continuously projected from the surface (0 ⁇ m) of Example 1 to a depth of 180 ⁇ m and from the surface (0 ⁇ m) of Example 1 (cross section) to a depth (thickness direction) of 180 ⁇ m.
- the erosion rate calculated from the value measured at a position 60 ⁇ m from the surface (0 ⁇ m) of Example 1 was obtained, and the average value of this value was taken as the average erosion rate of the second layer.
- the erosion rate calculated from the position 100 ⁇ m to the position 180 ⁇ m from the surface of Example 1 was obtained, and the average value of these values was taken as the average erosion rate of the first layer.
- the erosion rate calculated at a position 180 ⁇ m from the surface (0 ⁇ m) of Example 1 (cross section) was obtained, and the average value of these values was taken as the average erosion rate at the center.
- the brittleness test was carried out three times with different samples under the same conditions, and the average value at this time is shown in Table 1 as the average erosion rate.
- the three-point bending strength was measured according to JISB1601: 2008 using a three-point bending tester (EZ-TEST) manufactured by Shimadzu Corporation. The results are shown in Table 2.
- Example 1 may have a first layer covering a central portion and at least a portion of the central portion, and a second layer formed on the surface layer of the first layer. It could be confirmed. It was also confirmed that the second layer had an appropriate porosity and covered the laminated step as observed in FIGS. 3 and 5.
- the average erosion rate of the first layer is lower than the average erosion rate of the central part, and the average erosion rate of the second layer is higher than the average erosion rate of the first layer.
- the average erosion rate of the central part and the second layer is higher than that of the first layer, the central part is more than five times as large as the first layer, and the second layer is 2.5 of the first layer.
- the average erotic rate was more than doubled.
- a laminated molded ceramic core having such an average erotic ratio can be a ceramic core having both strength and disintegration property.
- Example 1 As shown in Table 2 and FIGS. 6A to 6C, the surface roughness Ra of Example 1 was 10 ⁇ m or less, and the surface roughness Ra was significantly improved as compared with Comparative Examples 1 and 2. Further, as shown in Table 2, the strengths of Example 1 and Comparative Example 2 were significantly improved as compared with Comparative Example 1. Example 1 provided with the second layer had further improved strength as compared with Comparative Example 2. That is, Example 1 composed of the central portion, the first layer, and the second layer is compared with Comparative Example 1 composed of only the central portion and Comparative Example 2 composed of the central portion and the first layer. It was confirmed that the surface roughness Ra was improved and the strength was improved.
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Abstract
Description
なお、本出願は、2020年11月20日に出願された日本国特許出願2020-193179号に基づく優先権を主張しており、その出願の全内容は本明細書中に参照として組み入れられている。
かかる構成によれば、強度と崩壊性を両立したうえで、さらに表面粗さが改善された、積層造形セラミックコアを実現することができる。
このような平均エロ-ジョン率の範囲であると、強度と崩壊性をより高いレベルで両立した積層造形セラミックコアが提供できる。
かかるセラミックコアは、金属鋳物の表面を滑らかにするために十分な表面粗さでありうる。
かかる金属元素および半金属元素を含む酸化物を用いれば、上述した効果がより好適に発揮され得る。
かかるシリカを最多構成成分として含む構成によれば、アルカリ性溶液での溶融除去が容易なセラミックコアが提供される。
かかる態様の製造方法によれば、強度と崩壊性を両立したうえで、さらに表面粗さが改善された、積層造形セラミックコアを製造することができる。
かかる構成によれば、適度な強度と崩壊性を兼ね備え、さらに表面粗さが改善されたセラミックコアを製造することができる。
かかる態様の製造方法によって製造されたセラミックコアは、金属鋳物の表面を滑らかにするために十分な表面粗さを備える。
また、ここに開示されるセラミックコアの製造方法の好ましい一態様では、上記第2セラミック粉末は、シリカを主要構成成分として含む。
かかる構成によれば、上述の効果をよりよく発揮できる。
プロットされるエロ-ジョン率分布のうち、試験片の表面(0μm)から60μmまでの値を第2の層、100μmから180μmまでの値を第1の層、試験片(断面)表面(0μm)から180μmまでの値を中心部に相当するエロ-ジョン率とする。各構造についてそれぞれ3か所以上(さらには10か所以上)のエロ-ジョン率の平均値を算出し、この値をここでは、各構造の平均エロ-ジョン率と規定する。
第2セラミック粉末に関する「平均粒径」とは、特記しない限り、BET法(例えばBET1点法)等により得られる第2セラミック粉末の比表面積から算出される平均粒径を意味する。この平均粒径は、第2セラミック粉末の一次粒径が、比表面積を実現し得る球形状粒子の直径(球相当径)に一致すると仮定して算出される値である。この平均粒径D2は、例えば、第2セラミック粉末の比表面積をS、当該第2セラミック粉末の密度をρとしたとき、次式;D2=6/(ρS)に基づき求めることができる。
なお、本明細書においてアスペクト比とは、第1~第3セラミックス粉末に外接する最小の矩形を描いたときの長辺をa、短辺をbとしたときに、(a/b)として求められる値である。
なお、中心部における第1セラミック粉末の含有量は特に制限されないが、中心部の全量を100質量部とした場合に、通常は60質量部以上であり、機械的強度向上の観点から、好ましくは65質量部以上、より好ましくは75質量部以上、例えば80質量部以上、典型的には90質量部以上であってもよい。第1セラミック粉末の含有量の上限は、特に限定されないが、好ましくは99質量部以下であり、より好ましくは98質量部以下であり、例えば96質量部以下であってもよい。第1セラミック粉末の含有量がかかる範囲内であると、本構成の効果をより高いレベルで発揮することができる。
(1)第1セラミック粉末を積層造形法によって造形し、焼成して成る中心部(積層造形焼成体)を用意すること。
(2)第2セラミック粉末を含むセラミックゾルに中心部(積層造形焼成体)を浸漬させ、乾燥、熱処理により分散媒を除去して第1の層を形成すること。
(3)第1の層の表層に第3セラミック粉末を含むセラミックスラリーをコーティングして、高温焼結により溶媒を除去して第2の層を形成すること。
ここに開示される積層造形セラミックコアの中心部は、例えば以下の方法を含む態様によって用意される。第1セラミック粉末を含む積層造形用粉末を調製し、この積層造形用粉末を用いて、従来公知の方法で積層造形物を造形する。積層造形用粉体は、必要に応じて、第1セラミック粉末以外の成分を含み得る。そのような成分として、バインダや界面活性剤等が挙げられる。バインダとしては、例えば、イソブチレン系樹脂、ポリアミド系樹脂、ポリエステル系樹脂、ポリエーテル系樹脂、ポリビニルアルコール系樹脂、ポリビニルブチラール系樹脂、ポリエチレングリコール系樹脂等の熱可塑性樹脂、メラミン系樹脂等の熱硬化性樹脂、セルロース誘導体等の多糖類が例示される。
なお、本明細書において「平均細孔径」は、特記しない限り、水銀圧入法を用いて測定される値が採用される。「気孔率」は、水銀圧入法を用いて測定される細孔量から算出される値が採用される。
第2セラミック粉末が分散媒に分散された分散液(セラミックゾル)を用意する。かかるセラミックゾルの形態を介して、第2セラミック粉末を中心部の気孔に好適に導入することができる。なお、かかるセラミックゾルは、第2セラミック粉末が凝集することなく独立して分散媒中に均一に浮遊あるいは懸濁した、コロイド状態にある(すなわち、コロイド溶液である)。なお、このコロイド溶液とは、ゾル、サスペンジョン等を包含する用語である。
第3セラミック粉末が溶剤に分散されたセラミックスラリーを用意する。かかるセラミックスラリーは、多孔質のコーティング層を形成するために用いられる。典型的には、該スラリーを第1の層の表層にコーティングした後、焼成することにより、多孔質の第2の層が形成される。
日本電子(株)製走査電子顕微鏡(JSM-6610LA)を用いて、上記実施例および比較例の各表面を観察した。観察倍率を50倍としてそれぞれについてSEM観察画像を取得した。図1~3は、SEM観察画像の一例であり、図1は実施例1、図2は比較例1、図3は比較例2のものである。
実施例1および比較例2の表面に垂直な断面(厚さ方向に沿う断面)について、同様にして観察倍率50倍のSEM観察画像を取得した。図4および図5は、SEM観察画像の一例であり、図4は実施例1、図5は比較例2のものである。
パルメソ社製MSE-A203を用いて、脆性試験を行った。試験片として、実施例1と、実施例1を厚さ方向に沿って4mmの位置で幅方向に沿って切断した実施例1(断面)と、をそれぞれ3つずつ用意した。脆性試験は、3μm球状アルミナ((株)パルメソ製MSE-BA-3-3)を投射粒子として使用し、MSE標準試験片((株)パルメソ製HRC-45)に対してエロージョン率が0.18(μm/g)となる投射出力値にて実施した。投射粒子を実施例1の表面(0μm)から180μm、および、実施例1(断面)の表面(0μm)から180μmの深さ(厚さ方向)まで連続的に投射した。3μm球状アルミナの投射量(Ag)とエロ-ジョン深さ(Bμm)の関係を3~20か所において取得した。この値に基づいて、次式:エロージョン率(μm/g)=B/A;よりエロ-ジョン率を算出した。
実施例1の表面(0μm)から60μmの位置で測定された値から算出されるエロ-ジョン率を求め、この値の平均値を第2の層の平均エロ-ジョン率とした。
実施例1の表面から100μmの位置から180μmの位置で算出されるエロ-ジョン率を求め、この値の平均値を第1の層の平均エロ-ジョン率とした。
実施例1(断面)の表面(0μm)から180μmの位置で算出されるエロ-ジョン率を求め、この値の平均値を中心部の平均エロ-ジョン率とした。
なお、脆性試験は同様の条件でサンプルを異ならせて3回実施し、このときの平均値を平均エロ-ジョン率として表1に示す。
上記実施例および比較例の各表面の表面粗さRaを算出した。表面粗さRaは、(株)東京精密社製サーフコムを用い、JISB0601:1982に準じて、カットオフ値2.5mmのときの粗さ曲線から算術平均粗さ(μm)を算出した(図6A~6C参照)。なお、表面性状の走査距離は10mmとした。結果を表2に示す。
上記実施例および比較例の各三点曲げ強度を測定した。三点曲げ強度は、(株)島津製作所製三点曲げ試験機(EZ―TEST)を用い、JISB1601:2008に準じて測定した。結果を表2に示す。
上記実施例および比較例の気孔率および平均細孔径を測定した。気孔率および平均細孔径の測定には、マイクロメリテックス社製オートポアV9600を用いて、水銀圧入法にて測定した。結果を表2に示す。
上述した走査電子顕微鏡(JSM-6610LA)を用いて、実施例1における表面に垂直な断面(厚さ方向に沿う断面)の表面から0.15mm(第1の層)、1mm(中心部)、4mm(中心部)の位置において、エネルギー分散型X線分析(EDX)を行った。酸化物重量換算の結果を表3に示す。
Claims (10)
- 金属鋳物を作製する際の中子として用いる積層造形セラミックコアであって、
所定のセラミック粉末の積層造形焼成体である中心部と、前記中心部の少なくとも一部を覆う第1の層と、前記第1の層の表層に形成される第2の層と、から構成されており、
ここで、前記積層造形セラミックコアに対する脆性試験において投射粒子の投射量をAg、エロ-ジョン深さをBμmとしたとき、次式:エロージョン率(μm/g)=B/A;で算出されるエロージョン率の平均値である平均エロ-ジョン率を用いるとき、
前記第1の層の平均エロージョン率が前記中心部の平均エロージョン率よりも低く、かつ、前記第2の層の平均エロージョン率が前記第1の層の平均エロージョン率よりも高い、積層造形セラミックコア。 - 前記中心部の平均エロ-ジョン率が、前記第1の層の平均エロ-ジョン率の5倍以上であり、
前記第2の層の平均エロ-ジョン率が、前記第1の層の平均エロ-ジョン率の2.5倍以上である、請求項1に記載の積層造形セラミックコア。 - 前記第2の層の算術平均表面粗さRaが10μm以下である、請求項1または2に記載の積層造形セラミックコア。
- 前記中心部および前記第2の層は、それぞれ、シリカ、アルミナ、ジルコン、およびマグネシアからなる群から選択される少なくとも1種から構成される、請求項1~3のいずれか一項に記載の積層造形セラミックコア。
- 前記第1の層は、シリカを主要構成成分として含む、請求項1~4のいずれか一項に記載の積層造形セラミックコア。
- 中心部と、前記中心部の少なくとも一部を覆う第1の層と、前記第1の層の表層に形成された第2の層とからなる積層造形セラミックコアの製造方法であって、
平均粒径D1を有する第1セラミック粉末を用いて積層造形法により積層造形物を造形すること、
前記積層造形物を焼成して積層造形焼成体である前記中心部を得ること、
平均粒径D2を有する第2セラミック粉末を含むセラミックゾルに前記積層造形焼成体を浸漬して、前記積層造形焼成体の少なくとも一部に前記第1の層を形成すること、
平均粒径D3を有する第3セラミック粉末を含むセラミックスラリーに前記第1の層が付与された前記積層造形焼成体を浸漬して、前記第1の層の表層に前記第2の層を形成すること、
を包含する、積層造形セラミックコアの製造方法。 - 前記第1セラミック粉末、前記第2セラミック粉末、および、前記第3セラミック粉末の平均粒径D1、D2およびD3は、D1>D3>D2である、請求項6に記載の積層造形セラミックコアの製造方法。
- 前記第2の層の算術平均表面粗さRaが10μm以下である、請求項6または7に記載の積層造形セラミックコアの製造方法。
- 前記第1セラミック粉末および前記第3セラミック粉末は、それぞれ、シリカ、アルミナ、ジルコン、およびマグネシアからなる群から選択される少なくとも1種から構成される、請求項6~8のいずれか一項に記載の積層造形セラミックコアの製造方法。
- 前記第2セラミック粉末は、シリカを主要構成成分として含む、請求項6~9のいずれか一項に記載の積層造形セラミックコアの製造方法。
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