CN102259167B - Method for casting turbocharger encloser casting - Google Patents
Method for casting turbocharger encloser casting Download PDFInfo
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- CN102259167B CN102259167B CN 201010184267 CN201010184267A CN102259167B CN 102259167 B CN102259167 B CN 102259167B CN 201010184267 CN201010184267 CN 201010184267 CN 201010184267 A CN201010184267 A CN 201010184267A CN 102259167 B CN102259167 B CN 102259167B
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- 238000005266 casting Methods 0.000 title claims abstract description 52
- 238000000034 method Methods 0.000 title claims abstract description 30
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 89
- 229910052742 iron Inorganic materials 0.000 claims abstract description 51
- 238000010079 rubber tapping Methods 0.000 claims abstract description 9
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- 238000000465 moulding Methods 0.000 claims abstract description 7
- 238000003723 Smelting Methods 0.000 claims abstract description 4
- 238000004140 cleaning Methods 0.000 claims abstract description 4
- 238000001816 cooling Methods 0.000 claims abstract description 4
- 239000007788 liquid Substances 0.000 claims description 33
- 229910000519 Ferrosilicon Inorganic materials 0.000 claims description 15
- 239000000126 substance Substances 0.000 claims description 13
- 238000011081 inoculation Methods 0.000 claims description 12
- 238000002844 melting Methods 0.000 claims description 9
- 230000008018 melting Effects 0.000 claims description 9
- XOCUXOWLYLLJLV-UHFFFAOYSA-N [O].[S] Chemical compound [O].[S] XOCUXOWLYLLJLV-UHFFFAOYSA-N 0.000 claims description 7
- 239000006260 foam Substances 0.000 claims description 4
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- 238000003756 stirring Methods 0.000 claims description 4
- 230000008676 import Effects 0.000 claims description 3
- 229910052760 oxygen Inorganic materials 0.000 claims description 3
- 239000002893 slag Substances 0.000 claims description 3
- 229910000805 Pig iron Inorganic materials 0.000 claims description 2
- 229910000831 Steel Inorganic materials 0.000 claims description 2
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- 229910000859 α-Fe Inorganic materials 0.000 abstract description 7
- 238000004519 manufacturing process Methods 0.000 abstract description 5
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 abstract description 3
- 229910002804 graphite Inorganic materials 0.000 abstract description 3
- 239000010439 graphite Substances 0.000 abstract description 3
- 238000009413 insulation Methods 0.000 abstract description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 9
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- 229910001018 Cast iron Inorganic materials 0.000 description 1
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- Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
Abstract
The invention discloses a method for casting a turbocharger encloser, comprising the following steps: mulling, molding, manufacturing cores, integrating, smelting furnace burden, tapping, nodulizing, inoculating, pouring, cooling, unpacking, cleaning castings and checking product quality; designing a template into one type comprising 2-8 piece; adopting a completely symmetrical template layout; correspondingly arranging two to eight casting cavities; and casting by the slice-type ingate distributed pouring technology: and after melted iron enters a direct pouring gate, the melted iron passes through a filter provided with a ceramic filter screen below the direct pouring gate, and flows into a horizontal pouring gate, and then the melted iron enters the casting cavity via the ingate to fill in the cavity, wherein the pouring temperature is 1380-1460DEG C, and the top end surface of a far-end side opposite to the ingate inlet of the casting in each casting cavity is provided with two heat-insulation dead heads for feeding. The tensile strength of the casting body is more than or equal to 400MPa, the yield strength is more than or equal to 250MPa, the percentage elongation is more than or equal to 15%, the body hardness is 130-180HBS, the metallographic structure ferrite is more than or equal to 90%, the percent of spheroidization is more than or equal to 90%, the size of graphite is 4-7 grades, and no carbide is permitted to exist.
Description
Technical field
The present invention relates to a kind of casting method, particularly a kind of casting method of turbocharger case foundry goods.
Background technology
The turbine case is the key components and parts of marine turbosupercharger, because the turbocharger operation environment is abominable, must guarantee that inner high temperature compressed gas is stored in volute under high pressure, therefore require the casing component material to have good dense structure's property and higher toughness.
For above-mentioned requirements, the parts regulation ball China ink cast iron QT400-15 trade mark.The mechanical performance of foundry goods will satisfy tensile strength 〉=400MPa, yield strength 〉=250MPa, percentage elongation 〉=15%, body hardness 130～180HBS; Metallographic structure requires ferrite 〉=90%, nodularization rate 〉=90%, and 4～7 grades of graphite sizes have not allowed carbide to exist.Interiors of products does not allow to exist any casting flaw.The technical indicator characteristics of this product are: require ferrite 〉=90%, need in production process raw material are strictly controlled.
The working environment of turbocharger case foundry goods is more abominable, therefore very high to the material requirement of foundry goods, product detects and need in each appointed part sampling of body, satisfy tensile strength 〉=400MPa, yield strength 〉=250MPa, percentage elongation 〉=15%, hardness 130～180HBS.
These parts have very high requirement to surface quality of continuous castings, especially do not allow the existence of the Appearance quality defects such as scab, burr.
Therefore how to satisfy above-mentioned specification requirement, become the key of successfully casting this foundry goods.
Summary of the invention
The turbocharger case foundry goods of producing the purpose of this invention is to provide a kind of casting method of turbocharger case, so that can satisfy above-mentioned specification requirement.
For achieving the above object, the technical solution used in the present invention is:
The casting method of turbocharger case, its step comprise mulling, moulding, coremaking, mould assembly, furnace charge melting, tap a blast furnace nodularization and inoculation, cast, cooling, unpacking, casting cleaning and product quality inspection; It is characterized in that: template is designed to two～eight, a type, takes the template layout of full symmetric, and correspondence is established two～eight foundry goods die cavities; In casting technique, adopt several sheet type ingate distributing pouring technologies: the filter that is provided with foam ceramic filter after iron liquid enters from sprue through sprue below, flow into simultaneously the cross gate of some full symmetrics, enter the foundry goods die cavity via the sheet type ingate respectively afterwards, be full of die cavity; Pouring temperature is controlled at 1380～1460 ℃; The top end face of each foundry goods die cavity in the distal side of relative foundry goods ingate import arranges two insulated feeders and carries out feeding.
The spheroidization and inoculation treatment process of tapping a blast furnace of the present invention comprises that tap a blast furnace spheroidising and ferrosilicon inovulant breed two links for twice.The nodularization dosage that adds is 1.0～2.5% of the melting amount of tapping a blast furnace, and the chemical component weight percentage of nodulizer is: Mg 5.0～7.5%, RE 1.0～4.0%, Si 35～48%, Ca 1.0～3.0% and Fe surplus, the granularity of nodulizer are 3～25mm.Described inovulant breeds the ferrosilicon inovulant that adds iron liquid gross weight 0.2～0.5% after the nodularization of namely once tapping a blast furnace for twice, stir subsequently and skim and add iron liquid, and breed for the second time, the ferrosilicon inovulant with 0.2～0.5% is added to envelope and carries out the rabbling hoe slag.The granularity of ferrosilicon inovulant used is 3～25mm, and the chemical component weight percentage of ferrosilicon inovulant is Si 72～75%, Al 0.4～1.5%, Ca 0.4～1.0% and Fe surplus.
In described cast step, iron liquid will guarantee that the iron liquid casting temperature is at 1380～1460 ℃ after the nodulizer inoculation.Adopt sulphur oxygen inovulant to carry out current-following inoculation in casting process, sulphur oxygen inovulant granularity used is 0.1～1.0mm, chemical component weight percentage is Si 70～76%, Al0.75～1.25%, Ca 0.75～1.25%, Ce 1.5～2.0%, S 0.5～0.8%, O 0.3～0.5% and Fe surplus, and the percentage that addition accounts for iron liquid total amount is 0.05～0.2%.The chemical component weight percentage of last cast product is: C 3.2～3.8%, Si 2.0～3.0%, Mn≤0.45%, P≤0.07%, S≤0.03%, RE 0.01～0.04%, Mg 0.02～0.08% and Fe surplus.
Product after above melting spheroidization and inoculation processing makes cast has the metallographic structure of nodularization rate 〉=90%, ferrite 〉=90%, carbides-free, to guarantee the mechanical performance requirement of product.
In order to obtain not have defective cast product, taked following measures on technique:
(1) because this casting dimension is less, be designed to four, a type, take the template layout of full symmetric, guaranteed that four foundry goods are in identical state in cavity filling process, and then obtain the identical foundry goods of quality state, for quality testing afterwards provides assurance and foundation.
(2) adopt a plurality of sheet type ingate distributing pouring technologies: have the filter of foam ceramic filter to flow into simultaneously the cross gate of four full symmetrics through the below after iron liquid enters from sprue, enter the foundry goods die cavity via four thin slice ingates respectively afterwards; Guarantee that pouring temperature is controlled at 1380～1460 ℃, this technological measure can guarantee that cast product does not produce cold shut and gas hole defect.
(3) filter iron liquid at sprue bottom placement floamed ceramics filtrating piece, remove the impurity in iron liquid, thereby prevent that product from producing dreg defect.
(4) in the cast top thicker position of ingate offside, 4 pairs of foundry goods of two insulated feeders are set respectively and carry out feeding, guarantee to obtain the complete foundry goods of dense structure.
(5) be coated with material process at step of overall modelling, do not adopt traditional brushing mode in order to obtain clear cast(ing) surface attractive in appearance, but respectively core and external form are adopted comparatively advanced dipping process and flowcoating process, be about to the core working face and immerse in coating and adopt coating to flow through the formal coating of mold cavity surface, the brushing vestige and the coating that produce when these two kinds of techniques can be avoided brushing are effectively piled up at the die cavity wedge angle.
Key technology of the present invention is:
In iron casting was produced, the mechanical performance index that make the mechanical performance of foundry goods body reach trade mark regulation was the very difficult thing of part.In addition the mechanical performance specified point of this product has five positions, and these five positions almost are evenly distributed on each position of foundry goods.This just makes technical difficulty greatly increase.Reach this specification requirement of cast product, the cast product of production is reached:
(1) each position of foundry goods does not allow to have any casting flaw: comprise that foundry goods inside can not exist micro-shrinkage porosite and dreg defect;
(2) metallographic structure at each position of foundry goods will reach basically identical: comprise that the nodularization rate all should be good (all reach 〉=90%), and matrix will be consistent (ferrite all should more than 90%).
In order to reach this two production control technical indicators, the test of the selection (being position and the quantity of rising head) of the injection mode of iron liquid on casting technique (being position and the quantity of ingate) and rising head determines it is very important.Because in the time of will making casting solidification by the adjustment of these two factors on casting technique, the heat distribution of foundry goods each several part is in more balanced state.Through test of many times, after constantly change the position and quantity of pouring and riser systems, just reach technique ideal effect of the present invention at last.
The invention has the beneficial effects as follows:
The present invention adopts the layout designs of many, a type in technological design, adopt end face distributing pouring technology, and insulated feeder is placed in comparatively thick large position at the top of foundry goods, the utilization rate of the molding sand that effectively improves, also saved production cost for company when enhancing productivity, the layout of full symmetric has also guaranteed the uniformity on a plurality of casting qualities of same case, for random sampling Detection work afterwards provides rational foundation; Open running gate system is conducive to realize filling fast the type effect, has effectively overcome cold shut and gas hole defect that thin-section casting very easily produces; The sheet type ingate that disperses avoided the undue concentration of heat, thereby eliminated the shrinkage porosite that upper surface thicker position may occur.
After adopting casting method of the present invention, the turbocharger case foundry goods tensile strength 〉=400MPa, the yield strength 〉=250MPa that produce, percentage elongation 〉=15%, body hardness 130～180HBS; Metallographic structure requires ferrite 〉=90%, nodularization rate 〉=90%, and 4～7 grades of graphite sizes, carbides-free exists.Each position of foundry goods exists without any casting flaw, meets client's specification requirement fully.
Description of drawings
Fig. 1 is the schematic diagram of one embodiment of the invention.
Fig. 2 is the cutaway view of one embodiment of the invention medium casting die cavity.
The specific embodiment
The present invention will be further described below in conjunction with drawings and Examples.
Embodiment 1
Referring to Fig. 1, Fig. 2, the casting method of marine turbosupercharger case foundry goods of the present invention comprises the steps:
1) mulling, moulding and coremaking
Marine turbosupercharger case foundry goods carries out moulding after adopting the mixed furan resin self curing sand processed of automatic pug mixer, and template is designed to four, a type, takes the template layout of full symmetric, and correspondence is established four foundry goods die cavities 3; Sprue 4 belows are provided with the filter 5 of foam ceramic filter, and connect the cross gate 6 of four full symmetrics, then are communicated with foundry goods die cavity 3 via four sheet type ingates 7 respectively; The top end face of each foundry goods die cavity 3 in the distal side of relative foundry goods ingate import arranges two insulated feeders 8 and carries out feeding.
Place insulated feeder 8 before moulding on cope match plate circle shape pad, then carry out back-up sand, consolidation, molding, repair type, and carry out flow coat operation and surperficial burn out process; Then make 1#, two cores 1 of 2#, 2, and after carrying out dip-coating and skin drying, placement is standby.
2) mould assembly
Be lowered in order 2 1#, 2# core 1,2 in lower sand mold b, placing ceramic screen pack a slice in filter 5: after blowing off the floating sand in up and down sand mold a, b, hang and turn that upper sand mold carries out mould assembly and with to be cast after the tight case of bolt etc.
3) furnace charge melting
First configure furnace charge, the composition percentage by weight of furnace charge is: the pig iron 30%, foundry returns 30%, steel scrap 40%, then the furnace charge that configures is carried out Smelting of iron in order input medium-frequency induction furnace successively, smelting temperature is 1560 ℃, standing insulation 5～10 minutes, allow impurity in iron liquid is fully floating to come up, after covering with deslagging agent, slag is taken off outside stove, prevent that impurity is deposited in iron liquid.
4) spheroidization and inoculation that taps a blast furnace is processed
Comprising taps a blast furnace carries out spheroidising and two parts of twice inoculation of ferrosilicon inovulant.Wherein spheroidizing treatment technology by rush-in method is adopted in spheroidising, the nodulizer granularity is 3～25mm, the nodulizer addition is 1.5%, iron liquid tapping temperature is 1560 ℃, the amount of tapping a blast furnace is 2/3 of total amount for the first time, the reagentia time of nodulizer and iron liquid is 40～90 seconds, the ferrosilicon inovulant that adds the total amount 0.3% of tapping a blast furnace after question response finishes, and add remaining 1/3 iron liquid, stir afterwards the scum silica frost that scratches clean iron liquid surface, add again 0.3% ferrosilicon inovulant of iron liquid gross weight, and stir and skim, cover at last thermal-insulating covering agent and go to pour into a mould.Wherein the chemical component weight percentage of nodulizer is: Mg 6.75%, RE 2.35%, Si 44%, Ca 2.0% and Fe surplus; The chemical component weight percentage of ferrosilicon inovulant is: Si 74%, Ca 0.6%, Al 0.55% and Fe surplus, the granularity of ferrosilicon inovulant are 3～25mm.
5) cast
The pouring temperature of iron liquid is 1435 ℃.After iron liquid was poured into by cup, the filter through the foamed filter net had blocked the impurity in iron liquid, had reduced the possibility of foundry goods generation dreg defect.Iron liquid through after filter, has slowed down the flow velocity of iron liquid in addition, has alleviated the impulsive force of iron liquid to casting mold, thereby has reduced the possibility of sand washing; It is steady that iron liquid fills type, is conducive to reduce the secondary oxidation of iron liquid in casting mold, thereby reduce the appearance of dreg defect.Iron liquid flows into four cross gates 6 subsequently simultaneously, then flows into each foundry goods die cavity 3 by four sheet type ingates 7 respectively, reaches the steadily purpose of cast of rapid dispersion; Adopt sulphur oxygen inovulant to carry out current-following inoculation in casting process, the granularity of sulphur oxygen inovulant used is 0.1～1.0mm, the chemical component weight percentage of sulphur oxygen inovulant is Si 73.2%, Al 0.87%, Ca 0.96%, Ce1.76%, S 0.64%, O 0.52% and Fe surplus, and the percentage that addition accounts for iron liquid total amount is 0.10%: the chemical composition total amount percentage of final casting product is: C 3.67% Si2.75%, Mn 0.36%, P 0.045%, S 0.011%, RE 0.015%, Mg 0.054% and Fe surplus.
6) cooling unpacking
7) casting cleaning
8) quality inspection
The product of disqualified upon inspection is done to eliminate and is scrapped processing, and the qualified foundry goods certified products warehouse of entering is temporary.
After adopting casting method of the present invention, foundry goods gross weight 11.5kg, the heavy 6.5kg of dead head, product yield is 63.8%, to this type of than light casting, these data are comparatively desirable, can create certain economic benefit for company.
The material trademark of product is spheroidal graphite cast-iron QT400-15, the mechanical performance test result of product ontology: tensile strength 405～485MPa, yield strength 260～345MPa, percentage elongation 15.2～23.5%, hardness 143～176HBS; Cast product metallographic structure testing result is: nodularization rate 90%, ferrite 92%, carbides-free exist; The chemical composition testing result of product: C 3.67%, Si 2.75%, Mn 0.36%, P 0.045%, S 0.011%, RE 0.015%, Mg 0.054% and Fe surplus; Cast product through ultrasonic wave defects detection result without any casting flaw.Cast product satisfies client's technical conditions requirement fully.
The main technologic parameters of table 1 embodiment of the present invention
The main testing result of table 2 embodiment of the present invention
Claims (6)
1. the casting method of turbocharger case, its step comprise mulling, moulding, coremaking, mould assembly, furnace charge melting, tap a blast furnace nodularization and inoculation, cast, cooling, unpacking, casting cleaning and product quality inspection; It is characterized in that: template is designed to two～eight, a type, takes the template layout of full symmetric, and correspondence is established two～eight foundry goods die cavities; In casting technique, adopt several sheet type ingate distributing pouring technologies: the filter that is provided with foam ceramic filter after iron liquid enters from sprue through sprue below, flow into simultaneously the cross gate of some full symmetrics, enter the foundry goods die cavity via the sheet type ingate respectively afterwards, be full of die cavity; Pouring temperature is controlled at 1380～1460 ℃; The top end face of each foundry goods die cavity in the distal side of relative foundry goods ingate import arranges two insulated feeders and carries out feeding.
2. the casting method of turbocharger case as claimed in claim 1 is characterized in that: described furnace charge melting step comprises furnace charge configuration and melting, and the percentage by weight of furnace charge configuration is: the pig iron 20～50%, foundry returns 20～40%, steel scrap 10～60%; Adopt the medium-frequency induction furnace melting, 1460～1580 ℃ of smelting temperatures.
3. the casting method of turbocharger case as claimed in claim 1 is characterized in that: described tap a blast furnace nodularization and inoculation operation comprise that tap a blast furnace spheroidising and ferrosilicon inovulant breed two links for twice.
4. the casting method of turbocharger case as claimed in claim 3, it is characterized in that: the nodularization dosage that adds is 1.0～2.5% of the melting amount of tapping a blast furnace, the chemical component weight percentage of nodulizer is: Mg 5.0～7.5%, RE 1.0～4.0%, Si 35～48%, Ca 1.0～3.0% and Fe surplus, the granularity of nodulizer are 3～25mm.
5. the casting method of turbocharger case as claimed in claim 3, it is characterized in that: described inovulant breeds the ferrosilicon inovulant that adds iron liquid gross weight 0.2～0.5% after the nodularization of namely once tapping a blast furnace for twice, stir subsequently and skim and add iron liquid, and breed for the second time, the ferrosilicon inovulant with 0.2～0.5% is added to envelope and carries out the rabbling hoe slag; The granularity of ferrosilicon inovulant used is 3～25mm, and the chemical component weight percentage of ferrosilicon inovulant is Si 72～75%, Al 0.4～1.5%, Ca0.4～1.0% and Fe surplus.
6. the casting method of turbocharger case as claimed in claim 1, it is characterized in that: in described cast step, iron liquid will guarantee that the iron liquid casting temperature is at 1380～1460 ℃ after the inovulant inoculation; Adopt sulphur oxygen inovulant to carry out current-following inoculation in casting process, sulphur oxygen inovulant granularity used is 0.1～1.0mm, chemical component weight percentage is Si 70～76%, Al 0.75～1.25%, Ca0.75～1.25%, Ce 1.5～2.0%, S 0.5～0.8%, O 0.3～0.5% and Fe surplus, and the percentage by weight that addition accounts for iron liquid total amount is 0.05～0.2%; The chemical component weight percentage of last cast product is: C 3.2～3.8%, Si 2.0～3.0%, Mn≤0.45%, P≤0.07%, S≤0.03%, RE 0.01～0.04%, Mg 0.02～0.08% and Fe surplus.
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| CN 201010184267 CN102259167B (en) | 2010-05-25 | 2010-05-25 | Method for casting turbocharger encloser casting |
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| CN1477223A (en) * | 2002-07-24 | 2004-02-25 | ���η�ϣ��������������˾ | Cast-iron alloy |
| CN101585078A (en) * | 2008-05-23 | 2009-11-25 | 上海华新合金有限公司 | Method for casting as-cast high-tenacity cast iron bearing cover of locomotive |
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| CN1477223A (en) * | 2002-07-24 | 2004-02-25 | ���η�ϣ��������������˾ | Cast-iron alloy |
| CN101585078A (en) * | 2008-05-23 | 2009-11-25 | 上海华新合金有限公司 | Method for casting as-cast high-tenacity cast iron bearing cover of locomotive |
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| 倪志全等.铁型覆砂无冒口铸造增压器涡轮壳.《铸造》.2006,第55卷(第9期), |
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| CN102259167A (en) | 2011-11-30 |
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