CN104209497A - Plaster casting method for large-sized complex thin-walled magnesium alloy part - Google Patents
Plaster casting method for large-sized complex thin-walled magnesium alloy part Download PDFInfo
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Abstract
The invention relates to a plaster casting method for a large-sized complex thin-walled magnesium alloy part. The method comprises the following steps of coating the surface of an assembled form with a coating in situ, and arranging shapeless cold iron on a hot spot part, wherein a mixture for manufacturing the shapeless cold iron comprises the following components in percentage by mass: 1.25 percent of phenolic resin, 0.4 percent of toluenesulfonic acid, 1 to 1.5 percent of boric acid, 2 percent of bentonite and the balance of 70 to 140-mesh chromite sand; pouring a casting in an adjustable pressure casting device, arranging a plaster mold poured by the form at the casting position of the adjustable pressure casting device, filling a tank with dry air or a CO2 atmosphere with SF6 content of 0.1 to 1.0 percent, and performing vacuum casting and pressurized solidification, wherein the casting temperature is 710 to 750 DEG C, vacuum degree for primary mold filling is minus 0.6Mpa to minus 0.8Mpa, and the solidification pressure is 0.020 to 0.025Mpa. According to the method, oxidization can be prevented, the mold filling capability can be improved, shrinkage cavities and shrinkage porosities in the casting are reduced, and the obtained magnesium alloy casting is higher in density.
Description
Technical field
The present invention relates to casting method, particularly, is a kind of large-scale complex thin-wall Mg alloy part plaster casting method.
Background technology
Magnesium alloy large-sized foundry goods adopts sand casting more, but casting accuracy is low, and large size, thin walled intricate casting production difficulty is very large.Therefore, in recent years, many R&D workers have carried out a series of research to gypsum mould in the application of magnesium alloy cast.When the high aluminium alloy containing magnesium of plaster casting, magnesium alloy, oxide inclusion is many, liquid level tension force is large, fill type weak effect, produces pore, is mingled with, the tendency of the defect such as shrinkage porosite is large.Main cause is that magnesium chemism is large, under its liquid temperature, can there is fierce exothermic reaction with gypsum, therefore, can there is serious oxidation in plaster casting Mg alloy castings, anti-oxidation is the Focal point and difficult point of plaster casting magnesium alloy, and the oxidation reaction of liquid magnesium alloy and gypsum and burning, product are involved in foundry goods to be become and be mingled with.Magnesium alloy solidification latent heat is few, and thin-walled goes out and may fill type difficulty by the thin large planar section of misrun, especially wall; Gypsum mould gas permeability is very poor, and the difficulty of feeling suffocated of casting process is trapped in casting mold; Plaster casting magnesium alloy solidification is slow, easily occurs coarse grains, causes mechanical property to reduce.
Summary of the invention
The technical problem to be solved in the present invention is to provide a kind of large-scale complex thin-wall Mg alloy part plaster casting method, and shrinkage cavity shrinkage porosity appears in especially anti-oxidation, the mold-filling capacity that improves, reduction foundry goods inside, obtains the technology of the Mg alloy castings that density is higher.
A kind of large-scale complex thin-wall Mg alloy part plaster casting method of the present invention, comprises step:
(1) at the apperance top finishing original position coating of assembling, by percentage to the quality, coating consists of the following composition, 140-250 object chromite powder 10-20%, talcum powder 25%, boric acid 5%, FeS
2powder 2%, frerrous chloride 2-3%, TiB
2powder 1.5%, OP emulsifying agent 0.15%, attapulgite clay 0.32%,, Ludox 1.5%, all the other are water.
Casting form both can adopt expanded polystyrene (EPS) apperance, the also complex of wax-pattern or polystyrene and wax-pattern, at apperance external coating coating.Coating has several functions, comprising: coating is containing hydrophobic constituent element, and when grouting, in calcium plaster, gas can be excluded by the micropore in dope layer; Dope layer isolation casting process magnesium alloy contacts with the direct of gypsum mould, to overcome gypsum mould and liquid magnesium alloy, avoids reacting between the two, prevents that magnesium is oxidized or burns, thereby eliminating oxide-film or combustion product field trash; Micropore in coating contributes to the exhaust of vacuum pouring, prevents from feeling suffocated, and avoiding bubble to be trapped in becomes defect in foundry goods; Improve cast(ing) surface flatness, avoid cast(ing) surface flow liner; Increase the wetability of metal liquid stream, improve mold-filling capacity; Increase the forming core core that molten metal solidifies, refinement casting crystalline grain etc.Coating is sprayed directly into apperance surface and belongs to not occupy-place coating, can not affect the dimensional accuracy of gypsum mould.
(2) at heat energy-saving position, unsetting chill is set, makes the compound component of unsetting chill by percentage to the quality for phenolic resin 1.25%, toluenesulfonic acid 0.4%, boric acid 1-1.5%, bentonite 2%, surplus are 70-140 object chromite sand.
More there is larger Wall-Thickness Difference in heavy castings, easily occur that in thick general goal shrinkage porosite, thickness junction produce the defect because of latent heat and heat transmission formation of hot tearing and other type.Casting Numerical Simulation software carries out iron chill shock chilling simulation and optimal design, obtains chill optimum position and shape.The unsetting chill adopting in step (2) is by the ferrochrome powder of high heat conduction, high hot melt and adds material and mix, be kneaded into mud shape, a certain amount of walk is pinched into the apperance of foundry goods conformal, be attached to bottom or the side of apperance and compress conformal closely sealed, after solidifying, pour into calcium plaster, become a part for casting mold.When casting pouring, high heat conduction in chill constituent element, large than hot material the molten metal Quench to this position, promote to solidify, avoid casting flaw to occur, be a kind of effective ways of eliminating defect.
(3) pouring cast part in adjustable pressure casting device, pours into apperance the gypsum mould of making and is placed in the pouring position of pressure adjusting casting machine, fills and contain 0.1%-1.0%SF in tank
6dry air or CO
2atmosphere, implements vacuum pouring and supercharging and solidifies, and the vacuum that pouring temperature is 710 DEG C-750 DEG C, initially fill type is-0.6～-0.8Mpa, freezing pressure 0.020-0.025Mpa.
The links such as adjustable pressure casting technological process comprises inflation, rises liquid, fills type, pressurize and release.Cavity filling process is as an important step of casting process, and much casting flaw is as all closely related with it in misrun, volume gas, oxidation, slag inclusion, cold shut etc.The running gate system of adjustable pressure casting is directly connected with the stalk that is positioned at casting mold below, and while filling type, liquid metal is introduced from ingate, filling casting mold from bottom to top.For example certain casting mold is according to the pressure lower charging type of setting, and filling velocity is 0.3 m/s (cast gate place), and filling time is about 37s.Molten metal is risen to and is full of whole die cavity by stalk, and cavity filling process is steadily orderly, does not roll up gas, splashes, the phenomenon such as cold shut and misrun.Process of setting is top-down consecutive solidification.When mold filling and solidification, it is that middle and lower part temperature is high that foundry goods longitudinal temperature distributes, and head temperature is low, and the temperature difference progressively increases, and it is along ingate to both sides from high to low that transverse temperature distributes.Cast top transverse temperature difference is little, and the foundry goods bottom transverse temperature difference is large, and filling time distributes large, and this Temperature Distribution is just in time conducive to filling and the feeding of molten metal.Substantially realized top-down order.
As preferred scheme, the whole powders puddle mixer in coating is dry mixed 10 minutes by the preparation method of the coating in step (1), add again OP emulsifying agent, water and Ludox mixed 20 minutes, after this add remaining water and other leftover materials to continue mixed system at whipping process.
As preferred scheme, the construction method of the unsetting chill in step (2) is that chromite sand, phenolic resin and boric acid are dry mixed evenly, finally adds toluenesulfonic acid again, and the mulling time is 5-10 minute.
As preferred scheme, in step (1), thickness of coating layer is controlled between 0.11-0.14 mm.
In process of setting, the thick large part of foundry goods has produced thermal center, causes metal around first to solidify the independent liquid phase region of formation, makes it cannot obtain feeding, probably produces shrinkage porosity defect of contraction cavity after solidifying.Address this problem, need to accelerate thick large part cooling rate, chill or heat conducting coating can be dealt with problems.Employing heat-conductive coating is convenient and swift, less to the change of foundry goods and mould, and brush a coating and can cast out several foundry goods, be therefore good selection.The thermal center of corner is processed relative difficult: cooling rate is difficult to stop thermal center to produce too slowly, and the too fast corner that causes of cooling rate first solidifies.Adopt the method for amorphous iron chill of the present invention to pour into a mould, foundry goods inside occurs that the probability of shrinkage cavity shrinkage porosity greatly reduces, and has improved yield rate, has obtained the higher foundry goods of density, has reached technical requirement.
By the comparison of cast magnesium alloy sheet sample, the mold-filling capacity of adjustable pressure casting, low pressure casting, counter-pressure casting and gravity casting contrasts, and finds that adjustable pressure casting can provide the most excellent mold-filling capacity.Freezing pressure is higher, and the operating time is shorter, and the foundry goods obtaining is organized finer and close, and Mg alloy castings tensile property is higher.Test shows, under the condition of high vacuum degree under protection gas condition, improves pouring temperature, both can solve magnesium alloy problem of oxidation, can make again liquid magnesium alloy obtain in gypsum mould and well fill type.Freezing pressure is higher, and the operating time is shorter, and the foundry goods obtaining is organized finer and close, and Mg alloy castings tensile property is higher.Adopt adjustable pressure casting to realize cast under the vacuum in protection compression ring border, fill the optimised process of the large-scale complex thin-wall large-scale complex thin-wall Mg alloy casting of type and Under Pressure Solidification.The comparison of tradition gravitational casting sample, the tensile strength of adjustable pressure casting sample improves 8-10%, and percentage elongation improves 100-150% left and right, and its performance obtains showing and promotes; Pressure regulation shaping precision casting technology can keep excellent mold-filling capacity when molten metal steadily enters casting mold die cavity, and foundry goods thinnest part can reach 0.25mm, and clear-cut; At regulatable differential pressure action lower charging type and complete and solidify, thermograde and setting rate all will obtain synchronous lifting, contribute to form the more fine grained texture of uniform compact; The present invention has introduced application of vacuum means, thus obtain bleb can obviously be suppressed, the foundry goods of acquisition can further be strengthened its intensity and performance by heat treatment means; Its distinctive casting technique becomes a reality the hot investment casting of large-scale complex thin-wall foundry goods.The present invention is applicable to the high metallurgical quality of the production of thin-section casting and the larger intricate casting of wall thickness transition and produces.Under gas guard mode, in higher vacuum, higher pouring temperature, both can solve magnesium alloy problem of oxidation, and can make again liquid magnesium alloy obtain in gypsum mould and well fill type.After entering and solidifying, boost pressure is higher and the rate of rise is faster, and foundry goods is finer and close, performance is higher.For implementing above-mentioned cast and solidifying process, adjustable pressure casting has many-sided advantage, particularly produces the application in large-scale complex thin-wall magnesium platform gold castings production.
Brief description of the drawings
Fig. 1 is the adjustable pressure casting equipment schematic diagram of pouring gypsum type Mg alloy castings.
In figure, 1-vacuum/pressurized table, 2-upper chamber, 3-vavuum pump and protection gas interface I; 4-gypsum mould, 5-upper and lower chamber dividing plate, 6-stalk, 7-vavuum pump and protection gas interface II; 8-crucible, 9-holding furnace, 10-lower chamber, 11-power line and pickup wire interface window.
Detailed description of the invention
Before using adjustable pressure casting equipment, by cast member is carried out to three-dimensional modeling, solid modelling, numbered analog simulation, Optimizing Process Parameters is also found out optimum implementation.The technique and the parameter etc. that in preferred plan, with apperance coating, thermal center amorphous iron chill, adjustable pressure casting are set are theoretical foundations of the present invention, then become actual process through actual tests with after improving.Apperance chunk is manufactured in polystyrene steam foaming, is assembled into after apperance, be coated with coating, dry, paste amorphous iron chill at thermal center place, after solidifying, apperance is placed in framed in, perfusion calcium plaster.Sclerosis, oven dry, roasting become gypsum mould.
The first step
The modeling and simulation stage.The present invention and relevant prerequisite plaster casting technology are carried out to numerical simulation and process optimization, the technique of implementing to formulate is based upon on reliable basis.Specific works comprises by electronic drawing to cast member is carried out three-dimensional modeling and increases the solid modellings such as pouring and riser systems, chill, casting mold, numerical simulation, the screen cast analog simulation of speed, mass transfer, temperature field, velocity field, concentration field, stress field conducted heat, passed to area of computer aided cast form process, to simulation result analysis, assessment, corrective measure is proposed, Optimization Technology, finds out preferred plan from theoretical and emulation.Technique and parameter that in preferred plan, apperance paint thickness, thermal center arrange amorphous iron chill, adjustable pressure casting are especially wanted refinement, to obtain preferred plan of foundry engieering etc.
Second step
At the apperance top finishing original position coating of assembling.By percentage to the quality, coating consists of the following composition, 140-250 object chromite powder 10%(or 15% or 20%), talcum powder 25%, boric acid 5%, FeS
2powder 2%, frerrous chloride 2-3%, TiB
2powder 1.5%, OP emulsifying agent 0.15%, attapulgite clay 0.32%,, Ludox 1.5%, all the other are water.
Whole powders in coating are dry mixed to 10 minutes at puddle mixer, then add OP emulsifying agent, suitable quantity of water and Ludox wet mixing 20 minutes.Start mixer (rotating speed is greater than 1380r/min), add residue water and other leftover materials system of mixing at whipping process, total mixing time >=1 hour.
Mixed coating magma processed is thicker, is easy to longer-term storage, but for the ease of applying construction, can add in addition as required after suitable quantity of water stirs and be coated with, and the methods such as brushing, spraying all can adopt.Dope layer general control is between 0.11 ~ 0.14 mm, and some privileged sites also can not be coated with or few painting as required.After brushing finishes, indoor placement, ambient humidity will keep being less than 30%, natural air drying, during as needs rapid draing, can hot blast drying, hot blast temperature is controlled at the 65 DEG C of scopes that are no more than.Coating has isolation gypsum mould and liquid magnesium alloy, is beneficial to the exhaust of cast, improves cast(ing) surface flatness, improves the effects such as mold-filling capacity, refinement cast(ing) surface crystal grain.
the 3rd step
At heat energy-saving position, unsetting chill is set.The compound component of making unsetting chill is phenolic resin 1.25%, toluenesulfonic acid 0.4%, boric acid 1%(or 1.2% or 1.5% by percentage to the quality), bentonite 2%, surplus be 70-140 object chromite sand.
Chill construction technology is: the construction method of unsetting chill is that chromite sand, phenolic resin and boric acid are dry mixed evenly, finally adds toluenesulfonic acid again, and the mulling time is 5-10 minute.
Chromite sand can not be mixed with other sand.The life-span of every batch of sand is 5 minutes, therefore molding operation must be rapidly.By conformal mould compacting amorphous iron chill for apperance, after the demoulding, pasted at the apperance surface of position of regulation also fixing.Be shaped and solidify after amorphous iron chill long-term storage consistency, cast after residual strength low.
The 4th step
The preparation of gypsum mould.Large-scale complex thin-wall Mg alloy castings need of production pours into a large amount of calcium plasters at the appointed time, therefore, adopts vacuum to mix slurry, priming by vacuum.Teeter chamber is logical by the grout valve couplet on the door.Polystyrene apperance is placed in to steel fixing in framed, and will pours into position and aim at valve export.Close perfusion valve and perfusion compartment door, wait for perfusion gypsum mixed slurry.Mix Jiang Shixian teeter chamber and put into suitable quantity of water, in filling a prescription after all solids powder mixing and stirring, be sprinkled into while stirring in the water of tank diameter, after all adding, teeter chamber's top cover immediately closes, start to vacuumize and stir, in 30 seconds, vacuum 0.05-0.06MPa, mixing time are 2-3 minute, speed of agitator 250-350 rev/min.Before finishing soon to stir, grouting chamber is vacuumized, the vacuum of grouting chamber equate with teeter chamber or slightly low (for example teeter chamber is 0.05MPa, and grouting chamber is 0.06MPa) in case the time injection of being in the milk, splash and vacuum is poured in down a chimney etc.Stir and finish, open immediately valve grouting, perfusion is generally no more than 1-1.5 minute.Perfusion should avoid directly impacting module, should make slurry introduce along case limit, from box-frame bottom, rises gradually, prevents that gas is detained.Grouting finishes, and abolishes immediately vacuum, takes out box-frame, rinses rapidly teeter chamber, thoroughly removes defective material.The framed standing 1-1.5 hour of perfusion, is strictly on guard against vibrations during this time, otherwise precision, intensity, complete line to gypsum mould is unfavorable.Continue to place more than 24 hours, most of moisture is lost.Then adopt infrared heating, also can, at the air blast drying room of 80-90 DEG C of moving air, carry out more than 10 hours low temperature drying, to remove the most of moisture in gypsum mould.Then in the intensification roasting of natural gas heating circulating atmosphere furnace employing stage.
the 5th step
Adopt adjustable pressure casting device pouring cast part.As shown in Figure 1, casting device comprises chamber 2 and lower chamber 10, is separated by upper and lower chamber dividing plate 5, and gypsum mould 4 is placed in chamber 2, and the housing of upper chamber 2 is provided with vacuum/pressurized table 1.The interior holding furnace 9 that arranges in lower chamber 10; crucible 8 is arranged in holding furnace 9; the fixing stalk 6 in dividing plate 5 bottoms, upper and lower chamber; on the housing of upper chamber 2 and lower chamber 10, offer respectively vavuum pump and protection gas interface I3 and vavuum pump and protection gas interface II7, on upper chamber 2 and lower chamber 10, be also respectively equipped with the interface window 11 of power line and pickup wire.
Before cast, set technological parameter, completed by control system follow procedure, part link is by manually completing.The key link of pouring cast part is: prepare, fill protection gas, step-down, rise liquid, fill type, compression solidification, pressurize, venting, can opening, unload casting mold, de-casting mold.
Gypsum mould 4 is from roaster takes out, and Temperature Setting is 200-300 DEG C, the placement suitable for reading of the stalk 6 of the cast gate aligning equipment of casting mold, and fixing casting mold, connect sensor, the lower chamber 10 of cover.The curve of cast and process of setting or technological parameter are set in advance in control computer.When the molten metal in holding furnace 9 reaches after pouring temperature, casting starts, to upper chamber 2, the interior injection in lower chamber 10 SF
6, the atmosphere that makes upper and lower chamber is air (or CO
2) SF
6, what following table was listed is the combination of several atmosphere.
| Numbering | SF 6/% | Air or CO 2/% |
| 1 | 1 | 99 |
| 2 | 0.1 | 99.9 |
| 3 | 0.5 | 99.5 |
| 4 | 0.8 | 99.2 |
Then start computer control and start cast.Now pressure adjusting casting machine have control computer in accordance with regulations program automatically complete various operations.Conventionally do not need people to intervene, if program display is abnormal, if necessary, allow people to intervene by force.After foundry goods solidifies completely, by manually completing all the other operations.Open the vent valve of upper and lower chamber, slowly exit to atmospheric pressure, open lower chamber locking device, remove lower chamber, casting mold is hung out to casting machine.De-gypsum adopts high pressure water flushing gypsum mould, foundry goods is removed clean.Air-dry, excision dead head burr etc. subsequently, by technical conditions inspection, post processing, machining, surface treatment etc.
Parameter when vacuum pouring and supercharging are solidified is; The vacuum that pouring temperature is 710 DEG C-750 DEG C, initially fill type is-0.6～-0.8Mpa, freezing pressure 0.020-0.025Mpa.
the casting of aircraft mass activity canopy skeleton Mg alloy castings
Aircraft movable cabin skeleton comprises frontal arc frame, middle arc frame, backarc frame.With the large-scale blank of ZM-5 magnesium alloy cast, the penetrating skeleton in space being formed by bar, piece, the plate of different cross section, then add the integrated member of formation through machine.Skeleton overall structure is high to mechanical property, dimensional accuracy, rigidity requirement, and casting flaw is had to strict restriction.Due to its size large (maximum package is 500 millimeters of 125O x 820 x), complex contour, reconciliation precision require high, casting difficulty.Former process using sand casting is produced, and moulding, reconciliation precision are restive, need many places additional process correction amount, not only castability are had to impact, also increase machining amount, cause qualified casting very low.
The technological process that adopts plaster casting to produce is as follows: cast member carries out three-dimensional modeling, solid modelling, numbered analog simulation, and Optimization Technology is also found out preferred plan.The technique and the parameter etc. that in preferred plan, with apperance coating, thermal center amorphous iron chill, adjustable pressure casting are set are the initial foundations of this patent, then become technique through actual tests and after improving.Apperance chunk is manufactured in polystyrene steam foaming, is assembled into after apperance, be coated with coating, dry, paste amorphous iron chill at thermal center place, after solidifying, apperance is placed in framed in.Become gypsum mould through perfusion calcium plaster, sclerosis, oven dry, roasting.Gypsum mould takes out from roaster, and fixing casting mold is at the accurate location of casting machine, by the cover cap cover of upper chamber, locking.The curve of cast and process of setting or technological parameter are set in advance in control computer.When the liquid magnesium alloy in holding furnace 9 reaches after pouring temperature, casting starts, to upper and lower indoor injection %SF
6, make the atmosphere of upper and lower chamber become 99% air+1%SF
6.Now pressure adjusting casting machine have control computer in accordance with regulations the parameter of program and setting automatically complete various operations.After foundry goods solidifies completely, open the vent valve of upper and lower chamber, slowly exit to atmospheric pressure, open lower chamber locking device, remove lower chamber, casting mold is hung out to casting machine.De-gypsum: water under high pressure breaks up gypsum, removes clean, air-dry, excision dead head burr etc. by foundry goods.Finally by technical conditions inspection, post processing, machining etc.
Adopt plaster casting, utilize foamed polystyrene apperance, adopt vacuum pouring-pressure forming (adjustable pressure casting) under apperance coating, amorphous iron chill, protection gas, under vacuum with higher pouring temperature, can avoid magnesium alloy oxidation, can reduce again viscosity resistance, capillary resistance, gas counter-pressure, effect at thin-walled die cavity is outstanding especially, ensures filling; Amorphous iron chill improves temperature field and in the time solidifying, increases pressure, and the setting rate of foundry goods is rationally regulated.The technology of the present invention has been eliminated defect substantially, foundry goods inside occurs that the probability of shrinkage cavity shrinkage porosity greatly reduces, improve yield rate, obtain the higher foundry goods of density, the performance number that foundry goods exemplary position is cut sample is tensile strength 240MPa, yield strength 170MPa, percentage elongation 7%, meets the technical standard requirement of part.
Claims (4)
1. a large-scale complex thin-wall Mg alloy part plaster casting method, comprises step:
(1) at the apperance top finishing original position coating of assembling, by percentage to the quality, coating consists of the following composition, 140-250 object chromite powder 10-20%, talcum powder 25%, boric acid 5%, FeS
2powder 2%, frerrous chloride 2-3%, TiB
2powder 1.5%, OP emulsifying agent 0.15%, attapulgite clay 0.32%,, Ludox 1.5%, all the other are water;
(2) at heat energy-saving position, unsetting chill is set, makes the compound component of unsetting chill by percentage to the quality for phenolic resin 1.25%, toluenesulfonic acid 0.4%, boric acid 1-1.5%, bentonite 2%, surplus are 70-140 object chromite sand;
(3) pouring cast part in adjustable pressure casting device, pours into apperance the gypsum mould of making and is placed in the pouring position of pressure adjusting casting machine, fills and contain 0.1%-1.0%SF in tank
6dry air or CO
2atmosphere, implements vacuum pouring and supercharging and solidifies, and the vacuum that pouring temperature is 710 DEG C-750 DEG C, initially fill type is-0.6～-0.8Mpa, freezing pressure 0.020-0.025Mpa.
2. method according to claim 1, it is characterized in that: the whole powders puddle mixer in coating is dry mixed 10 minutes by the preparation method of the coating in step (1), add again OP emulsifying agent, water and Ludox mixed 20 minutes, after this add remaining water and other leftover materials to continue mixed system at whipping process.
3. method according to claim 1, is characterized in that: the construction method of the unsetting chill in step (2) is that chromite sand, phenolic resin and boric acid are dry mixed evenly, finally adds toluenesulfonic acid again, and the mulling time is 5-10 minute.
4. method according to claim 1, is characterized in that: in step (1), thickness of coating layer is controlled between 0.11-0.14 mm.
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| CN105834409A (en) * | 2016-05-20 | 2016-08-10 | 河南理工大学 | Integrated preparing and forming device for magnesium alloy thin-walled pieces |
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