CN115673241B - Soluble ceramic shell or ceramic core material and preparation method and application thereof - Google Patents
Soluble ceramic shell or ceramic core material and preparation method and application thereof Download PDFInfo
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Abstract
本发明涉及一种可溶性陶瓷壳或陶瓷芯及其制备方法与应用,属于快速铸造相关技术领域。包括以下步骤:(1)采用3DP成型工艺制备出陶瓷壳/芯初坯,并对其进行加热固化、溶胶浸渗、烘干后得到陶瓷壳或陶瓷芯坯体;(2)将陶瓷坯体放入高温烧结炉中进行烧结,随炉冷却后得到可溶性陶瓷壳或陶瓷芯;其中,成型工艺中采用的壳/芯材料为碳酸钙。本发明通过3DP成型工艺制备陶瓷壳/芯,工序简单、生产周期短、无需支撑、适合成型大型复杂结构陶瓷壳/芯,碳酸钙材料可防止打印过程中材料吸湿受潮对壳/芯性能造成影响,高温烧结后碳酸钙分解为氧化钙,在后续浇注时可避免与钛合金发生界面反应,同时由于氧化钙的可溶性,浇注后铸件更易脱壳。
The present invention relates to a soluble ceramic shell or ceramic core and a preparation method and application thereof, and belongs to the technical field related to rapid casting. The method comprises the following steps: (1) preparing a ceramic shell/core blank by a 3DP molding process, and obtaining a ceramic shell or ceramic core blank after heating and curing, sol infiltration, and drying; (2) placing the ceramic blank into a high-temperature sintering furnace for sintering, and obtaining a soluble ceramic shell or ceramic core after cooling with the furnace; wherein the shell/core material used in the molding process is calcium carbonate. The present invention prepares a ceramic shell/core by a 3DP molding process, which has a simple process, a short production cycle, no support, and is suitable for molding large-scale complex structure ceramic shells/cores. The calcium carbonate material can prevent the material from absorbing moisture during the printing process and affecting the performance of the shell/core. After high-temperature sintering, the calcium carbonate decomposes into calcium oxide, which can avoid interfacial reaction with titanium alloy during subsequent pouring. At the same time, due to the solubility of calcium oxide, the casting is easier to shell after pouring.
Description
技术领域Technical Field
本发明属于快速铸造相关技术领域,更具体地,涉及一种可溶性陶瓷壳或陶瓷芯及其制备方法与应用,尤其涉及一种基于3DP成型的钛合金铸造用可溶性陶瓷壳/芯及其制备方法。The present invention belongs to the technical field related to rapid casting, and more specifically, relates to a soluble ceramic shell or ceramic core and a preparation method and application thereof, and in particular to a soluble ceramic shell/core for titanium alloy casting based on 3DP molding and a preparation method thereof.
背景技术Background technique
钛合金由于其密度小、比强度高、疲劳寿命长、耐腐蚀性好、耐高温、与复合材料强度刚度匹配良好等优点,在航空航天、能源化工、医疗保健等领域得到了广泛的应用。而锻造、焊接等方式因钛合金的高化学活性、低塑性、低热导率等问题加工难度较大,熔模铸造技术很好地解决了上述问题,成为目前制备钛合金结构件的主流方法之一。传统熔模铸造技术采用蜡模、树脂模等材料制备零件模型,再通过挂浆、干燥、撒砂、脱模、焙烧等工序以及浇注过程以获得精密零件。但在传统熔模铸造技术中,陶瓷壳/芯的制备需要经过多道工序,生产周期长、生产成本大、生产工艺复杂,在成型大型复杂陶瓷壳/芯时具有较大的局限性,难以满足目前社会的生产需要。因此,如何简化生产工艺、缩短生产周期,降低制备成本是目前急需解决的问题。Titanium alloys have been widely used in aerospace, energy and chemical, medical and health care fields due to their low density, high specific strength, long fatigue life, good corrosion resistance, high temperature resistance, and good strength and stiffness matching with composite materials. However, forging, welding and other methods are difficult to process due to the high chemical activity, low plasticity, and low thermal conductivity of titanium alloys. Investment casting technology has solved the above problems well and has become one of the mainstream methods for preparing titanium alloy structural parts. Traditional investment casting technology uses wax molds, resin molds and other materials to prepare part models, and then obtains precision parts through processes such as slurry hanging, drying, sanding, demoulding, roasting and pouring. However, in traditional investment casting technology, the preparation of ceramic shells/cores requires multiple processes, with a long production cycle, high production costs, and complex production processes. It has great limitations in molding large and complex ceramic shells/cores, and it is difficult to meet the current production needs of society. Therefore, how to simplify the production process, shorten the production cycle, and reduce the preparation cost is an urgent problem to be solved.
增材制造技术是指在计算机的控制下,将零件的3D模型进行切片,并逐层打印,最终形成完整零件的过程,运用该技术可以实现陶瓷壳/芯直接成型,并通过干燥、脱脂以及烧结等过程获得适用于浇注要求的陶瓷壳/芯,极大地缩短了生产周期,降低了生产成本。目前常用于生产陶瓷壳/芯的增材制造技术有光固化成型技术、激光选区烧结技术、分层挤出成型技术等,但这些技术都或多或少面临着诸如设备成本高、陶瓷壳/芯表面精度低、成型大型复杂构件需要支撑等问题。相对于上述增材制造技术,3DP成型技术无需激光或者辅助加热成型,具有材料广泛、成型精度高、无支撑、绿色环保等优势,应用领域广泛,其制备陶瓷壳/芯具有较大潜力。Additive manufacturing technology refers to the process of slicing the 3D model of a part and printing it layer by layer under the control of a computer to finally form a complete part. This technology can be used to directly form a ceramic shell/core, and a ceramic shell/core suitable for casting requirements can be obtained through processes such as drying, degreasing and sintering, which greatly shortens the production cycle and reduces production costs. Currently, the additive manufacturing technologies commonly used to produce ceramic shells/cores include photocuring molding technology, laser selective sintering technology, and layered extrusion molding technology, but these technologies are more or less faced with problems such as high equipment cost, low surface accuracy of ceramic shells/cores, and the need for support to form large and complex components. Compared with the above-mentioned additive manufacturing technologies, 3DP molding technology does not require laser or auxiliary heating molding, and has the advantages of a wide range of materials, high molding accuracy, no support, and green environmental protection. It has a wide range of applications and has great potential for preparing ceramic shells/cores.
在陶瓷壳/芯的制备材料上,传统适用于制备钛合金铸造用陶瓷壳/芯的材料主要有ZrO2、Y2O3、CaO等,这些材料可以避免在浇注时陶瓷壳/芯与钛合金发生剧烈的界面反应,以防影响铸件精度、降低铸件性能。但这些材料还存在一些问题,如ZrO2和Y2O3价格昂贵,极大地增加了生产成本,且浇注后陶瓷壳/芯去除较为困难;CaO壳/芯虽然可以水解脱壳,但在制备的过程中CaO极易吸水,从而导致壳/芯开裂,影响使用。因此,急需开发一种适用于钛合金铸造用的可溶性陶瓷壳/芯制备方法,解决上述制备技术和陶瓷壳/芯材料存在的问题,满足工业生产需求。In terms of the preparation materials of the ceramic shell/core, the traditional materials suitable for preparing the ceramic shell/core for titanium alloy casting mainly include ZrO 2 , Y 2 O 3 , CaO, etc. These materials can avoid the violent interface reaction between the ceramic shell/core and the titanium alloy during pouring, so as to prevent affecting the casting accuracy and reducing the casting performance. However, these materials still have some problems, such as ZrO 2 and Y 2 O 3 are expensive, which greatly increases the production cost, and it is difficult to remove the ceramic shell/core after pouring; although the CaO shell/core can be hydrolyzed and deshelled, CaO is very easy to absorb water during the preparation process, which causes the shell/core to crack and affects the use. Therefore, it is urgent to develop a soluble ceramic shell/core preparation method suitable for titanium alloy casting, solve the problems existing in the above preparation technology and ceramic shell/core materials, and meet the needs of industrial production.
发明内容Summary of the invention
针对现有技术的以上缺陷或改进需求,本发明提供了一种基于微滴喷射粘结成型的可溶性陶瓷壳或陶瓷芯及其制备方法与应用,陶瓷壳或陶瓷芯材料采用CaCO3,经充分烧结后可完全分解为CaO,直接用水进行溶解,陶瓷壳或陶瓷芯便会溃散,轻松与铸件分离,极大简化了后期脱壳工序,溶解产物Ca(OH)2溶解度较小,大部分会形成沉淀,便于后期回收处理,同时与直接采用CaO打印相比,CaCO3可避免在打印过程中粉末因吸湿受潮而导致的体积变化,防止陶瓷壳或陶瓷芯的开裂。In view of the above defects or improvement needs of the prior art, the present invention provides a soluble ceramic shell or ceramic core based on droplet jet bonding molding and a preparation method and application thereof. The ceramic shell or ceramic core material adopts CaCO 3 , which can be completely decomposed into CaO after sufficient sintering. It can be directly dissolved with water, and the ceramic shell or ceramic core will collapse and be easily separated from the casting, which greatly simplifies the subsequent shelling process. The solubility of the dissolved product Ca(OH) 2 is relatively small, and most of it will form a precipitate, which is convenient for subsequent recycling and treatment. At the same time, compared with direct printing with CaO, CaCO 3 can avoid the volume change of the powder due to moisture absorption during the printing process, thereby preventing the cracking of the ceramic shell or ceramic core.
根据本发明第一方面,提供了一种可溶性陶瓷壳或陶瓷芯的制备方法,包括以下步骤:According to a first aspect of the present invention, there is provided a method for preparing a soluble ceramic shell or ceramic core, comprising the following steps:
(1)以碳酸钙粉末为原料,采用微滴喷射粘结成型工艺制备出陶瓷壳或陶瓷芯初坯,然后进行加热固化、浸渗和干燥,得到陶瓷壳或陶瓷芯坯体;(1) Using calcium carbonate powder as a raw material, a ceramic shell or ceramic core blank is prepared by a droplet jet bonding molding process, and then heated, solidified, impregnated and dried to obtain a ceramic shell or ceramic core blank;
(2)将步骤(1)得到的陶瓷壳或陶瓷芯坯体进行烧结,使碳酸钙反应生成氧化钙,即得到所述可溶性陶瓷壳或陶瓷芯。(2) Sintering the ceramic shell or ceramic core blank obtained in step (1) to react calcium carbonate to generate calcium oxide, thereby obtaining the soluble ceramic shell or ceramic core.
优选地,步骤(2)中,所述烧结分为两个阶段,分别为在900℃~1000℃下烧结1h~3h,然后在1300℃~1500℃下烧结2h~3h,烧结过程中升温速率为2~5℃/min。Preferably, in step (2), the sintering is divided into two stages, namely, sintering at 900°C to 1000°C for 1h to 3h, and then sintering at 1300°C to 1500°C for 2h to 3h, and the heating rate during the sintering process is 2 to 5°C/min.
优选地,步骤(1)中,所述加热固化的温度为190℃~205℃,时间为2h~4h。Preferably, in step (1), the temperature of the heating curing is 190° C. to 205° C., and the time is 2 h to 4 h.
优选地,步骤(1)中,所述浸渗使用的浸渗液中的溶质分子在1500℃以上不分解;所述浸渗液的溶质成分在浇注过程中不会与结构件发生反应;所述浸渗液用于渗透进碳酸钙粉末间孔隙,保持陶瓷壳或陶瓷芯形状完整,避免烧结过程中坯体坍塌,并增强烧结后坯体的强度。Preferably, in step (1), the solute molecules in the impregnation solution used for the impregnation do not decompose above 1500° C.; the solute components of the impregnation solution do not react with the structural parts during the casting process; the impregnation solution is used to penetrate into the pores between the calcium carbonate powders, keep the shape of the ceramic shell or the ceramic core intact, avoid the collapse of the green body during the sintering process, and enhance the strength of the green body after sintering.
优选地,步骤(1)中,所述浸渗液为纳米ZrO2分散液或钇溶胶中的至少一种,浸渗时间为30s~3min。Preferably, in step (1), the impregnation liquid is at least one of a nano ZrO2 dispersion or a yttrium sol, and the impregnation time is 30 seconds to 3 minutes.
优选地,所述的碳酸钙粉末粒径为325目~800目;微滴喷射粘结成型工艺所使用的粘结剂为酚醛树脂;打印参数为:打印层高0.05mm~0.20mm,粘接剂饱和度70%~140%。Preferably, the particle size of the calcium carbonate powder is 325 mesh to 800 mesh; the binder used in the droplet jet bonding molding process is phenolic resin; the printing parameters are: printing layer height 0.05mm to 0.20mm, adhesive saturation 70% to 140%.
根据本发明另一方面,提供了任一项所述方法制备得到的可溶性陶瓷壳或陶瓷芯。According to another aspect of the present invention, a soluble ceramic shell or ceramic core prepared by any of the methods described above is provided.
根据本发明另一方面,提供了所述的可溶性陶瓷壳或陶瓷芯在浇注结构件中的应用。According to another aspect of the present invention, there is provided a use of the soluble ceramic shell or ceramic core in a cast structure.
优选地,所述结构件材质为钛合金、铸钢、铸铁、铝合金或镁合金。Preferably, the structural member is made of titanium alloy, cast steel, cast iron, aluminum alloy or magnesium alloy.
优选地,在浇注完成后,将带有陶瓷壳或陶瓷芯的结构件放入水中,陶瓷壳或陶瓷芯遇水发生反应会开裂溃散,与结构件分离,完成脱壳工序。Preferably, after the pouring is completed, the structural component with the ceramic shell or the ceramic core is placed in water. The ceramic shell or the ceramic core will react with water to crack and disintegrate, and separate from the structural component, thus completing the shelling process.
总体而言,通过本发明所构思的以上技术方案与现有技术相比,主要具备以下的技术优点:In general, the above technical solution conceived by the present invention has the following technical advantages compared with the prior art:
(1)本发明采用微滴喷射粘结成型工艺制备陶瓷壳/芯,可以解决传统工艺在成型大型复杂结构陶瓷壳/芯时的局限性,缩短生产周期,降低生产成本,满足社会市场的生产需求。同时,相比于其他增材制造技术,微滴喷射粘结成型工艺无需激光或者辅助加热成型,具有材料广泛、成型精度高、无支撑、绿色环保等优势,应用领域广泛。(1) The present invention adopts a micro-droplet jet bonding molding process to prepare a ceramic shell/core, which can solve the limitations of traditional processes in molding large and complex structure ceramic shells/cores, shorten the production cycle, reduce production costs, and meet the production needs of the social market. At the same time, compared with other additive manufacturing technologies, the micro-droplet jet bonding molding process does not require laser or auxiliary heating molding, has the advantages of a wide range of materials, high molding precision, no support, green and environmental protection, and has a wide range of applications.
(2)本发明采用CaCO3制备出的陶瓷壳/芯,经充分烧结后CaCO3可完全分解为CaO,由于CaO可和水反应,因此在浇注后的脱壳工序里,可以将带有陶瓷壳/芯的铸件放入热水中充分浸泡,陶瓷壳/芯会发生水解、溃散,轻松与铸件分离;而利用ZrO2、Y2O3等材料制备的陶瓷壳/芯,在浇注后往往采用施加外力敲打的方式进行脱壳,费时费力,因此采用CaCO3制备陶瓷壳/芯可极大简化后期脱壳工序。CaO陶瓷壳/芯溶解的过程为:(2) The ceramic shell/core prepared by the present invention using CaCO 3 can be completely decomposed into CaO after sufficient sintering. Since CaO can react with water, in the shelling process after pouring, the casting with the ceramic shell/core can be fully immersed in hot water, and the ceramic shell/core will be hydrolyzed and disintegrated, and can be easily separated from the casting; while the ceramic shell/core prepared by using materials such as ZrO 2 and Y 2 O 3 is often shelled by applying external force to knock after pouring, which is time-consuming and labor-intensive. Therefore, using CaCO 3 to prepare the ceramic shell/core can greatly simplify the later shelling process. The process of CaO ceramic shell/core dissolution is:
CaO+H2O=Ca(OH)2 CaO+ H2O =Ca(OH) 2
在此反应过程中会放出大量的热,而反应产物Ca(OH)2溶解度较小,在20℃时仅为1.65g/L,且其溶解度会随温度的升高而降低,因此大部分Ca(OH)2会形成沉淀,便于后期回收处理,污染小、环境友好,应用前景广阔。A large amount of heat is released during this reaction, and the solubility of the reaction product Ca(OH) 2 is relatively low, only 1.65g/L at 20°C, and its solubility decreases with increasing temperature. Therefore, most of the Ca(OH) 2 will form a precipitate, which is convenient for later recovery and treatment. It has low pollution, is environmentally friendly, and has broad application prospects.
(3)本发明在高温烧结前需要对陶瓷壳/芯进行浸渗处理,其作用在于浸渗液可进入碳酸钙粉末的间隙中,提升陶瓷壳/芯强度;在粘结剂完全分解后可以保持陶瓷壳/芯的形状,避免发生坍塌;浸渗液中的溶质成分还可以避免在浇注过程中与钛合金发生界面反应,保证铸件质量。(3) The present invention requires the ceramic shell/core to be infiltrated before high-temperature sintering. The purpose of the infiltration treatment is that the infiltration liquid can enter the gaps in the calcium carbonate powder to improve the strength of the ceramic shell/core; after the binder is completely decomposed, the shape of the ceramic shell/core can be maintained to avoid collapse; the solute components in the infiltration liquid can also avoid interfacial reaction with the titanium alloy during the casting process, thereby ensuring the quality of the casting.
(4)本发明采用CaCO3制备陶瓷壳/芯,与直接采用CaO制备陶瓷壳/芯相比,可避免在打印过程中粉末因暴露在空气中吸湿、受潮而导致的体积变化,防止陶瓷壳/芯的开裂。另外,与ZrO2、Y2O3等其它陶瓷粉末相比,CaCO3价格低廉、来源广泛,有巨大的发展潜力。(4) Compared with directly using CaO to prepare the ceramic shell/core, the present invention uses CaCO 3 to prepare the ceramic shell/core. This can avoid the volume change caused by the powder being exposed to the air and absorbing moisture during the printing process, and prevent the ceramic shell/core from cracking. In addition, compared with other ceramic powders such as ZrO 2 and Y 2 O 3 , CaCO 3 is low in price and widely available, and has great development potential.
本发明基于可溶性陶瓷壳/芯的制备特点,研究及设计了一种制备工序简单、成型过程无需支撑、成本低廉、后期脱壳方便的可溶性陶瓷壳/芯制备方法。所述方法采用微滴喷射粘结成型工艺制备的可溶性陶瓷壳/芯,可以解决传统工艺在成型大型复杂结构陶瓷壳/芯时的局限性,缩短生产周期,降低生产成本,且微滴喷射粘结成型工艺具有材料广泛、成型精度高、无支撑、绿色环保等优势,应用领域广泛;且价格低廉、来源广泛,有巨大的发展潜力。Based on the preparation characteristics of soluble ceramic shell/core, the present invention studies and designs a method for preparing soluble ceramic shell/core with simple preparation process, no support required in the molding process, low cost, and convenient shelling in the later stage. The method adopts the soluble ceramic shell/core prepared by the droplet jet bonding molding process, which can solve the limitations of the traditional process in molding large-scale complex structure ceramic shell/core, shorten the production cycle, and reduce the production cost. The droplet jet bonding molding process has the advantages of wide range of materials, high molding precision, no support, green and environmental protection, and has a wide range of application fields; and it is low in price and widely available, and has huge development potential.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
图1是本发明可溶性陶瓷壳/芯的制备方法的流程示意图。FIG1 is a schematic flow diagram of a method for preparing a soluble ceramic shell/core according to the present invention.
图2是按照本发明的所构建的陶瓷测试样品的实物图,其中,a样品使用硅溶胶浸渗,b样品使用纳米ZrO2分散液浸渗。FIG. 2 is a physical picture of the ceramic test samples constructed according to the present invention, wherein sample a is infiltrated with silica sol and sample b is infiltrated with nano ZrO 2 dispersion.
图3是陶瓷样品进行溃散性测试的实物图。FIG. 3 is a physical picture of a ceramic sample undergoing a disintegration test.
具体实施方式Detailed ways
为了使本发明的目的、技术方案及优点更加清楚明白,以下结合附图及实施例,对本发明进行进一步详细说明。应当理解,此处所描述的具体实施例仅仅用以解释本发明,并不用于限定本发明。此外,下面所描述的本发明各个实施方式中所涉及到的技术特征只要彼此之间未构成冲突就可以相互组合。In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention. In addition, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.
如图1所示,一种基于微滴喷射粘结成型的可溶性陶瓷壳/芯的制备方法,该方法主要包括以下步骤:As shown in FIG1 , a method for preparing a soluble ceramic shell/core based on droplet jetting bonding molding mainly comprises the following steps:
(1)在粉缸中放入碳酸钙粉末,导入陶瓷壳/芯三维结构模型并调整打印参数,随后打印出陶瓷壳/芯初坯;(1) Calcium carbonate powder is placed in a powder cylinder, a ceramic shell/core three-dimensional structure model is introduced, and printing parameters are adjusted, and then a ceramic shell/core blank is printed;
(2)将打印好的初坯连同粉床放入烘干箱中加热固化;(2) placing the printed blank together with the powder bed into a drying oven for heating and curing;
(3)将固化后的坯体从粉床中取出,清除干净粉末进行溶胶浸渗,随后放入烘干箱中低温干燥;(3) The solidified green body is taken out from the powder bed, the powder is cleaned and the green body is infiltrated with sol, and then placed in a drying oven for low-temperature drying;
(4)将步骤(3)得到的陶瓷壳/芯坯体进行烧结,使碳酸钙反应分解生成氧化钙,即得到所述可溶性陶瓷壳/芯。(4) Sintering the ceramic shell/core blank obtained in step (3) to decompose calcium carbonate to generate calcium oxide, thereby obtaining the soluble ceramic shell/core.
进一步地,在步骤(1)中,所述的碳酸钙粉末粒径为325目~800目。Furthermore, in step (1), the particle size of the calcium carbonate powder is 325 mesh to 800 mesh.
进一步地,步骤(4)中,所述烧结分为两个阶段,分别为在700℃~1000℃下烧结1h~3h,然后在1300℃~1500℃下烧结2h~3h,烧结过程中升温速率为2~5℃/min。Furthermore, in step (4), the sintering is divided into two stages, namely, sintering at 700°C to 1000°C for 1h to 3h, and then sintering at 1300°C to 1500°C for 2h to 3h, and the heating rate during the sintering process is 2 to 5°C/min.
进一步地,步骤(2)中,所述加热固化的温度为160℃~220℃,时间为2h~5h。Furthermore, in step (2), the temperature of the heating curing is 160° C. to 220° C., and the time is 2 h to 5 h.
进一步地,步骤(3)中,所述浸渗使用的浸渗液在高温下能够稳定存在;所述浸渗液的溶质成分在浇注过程中不会与钛合金发生反应;所述浸渗液渗透进碳酸钙粉末间孔隙后,能起到保持陶瓷壳/芯形状完整,避免烧结过程中坯体坍塌及陶瓷壳/芯强度构建的作用。Furthermore, in step (3), the impregnation liquid used for the impregnation can exist stably at high temperatures; the solute components of the impregnation liquid will not react with the titanium alloy during the casting process; after the impregnation liquid penetrates into the pores between the calcium carbonate powders, it can maintain the integrity of the shape of the ceramic shell/core, avoid the collapse of the green body during the sintering process, and build the strength of the ceramic shell/core.
进一步地,所述浸渗液为纳米ZrO2分散液或钇溶胶中的一种或两者的混合溶液,浸渗时间为30s~3min。Furthermore, the impregnation liquid is one of nano ZrO2 dispersion or yttrium sol or a mixed solution of the two, and the impregnation time is 30s to 3min.
进一步地,步骤(1)中,微滴喷射粘结成型工艺所使用的粘结剂为酚醛树脂;打印参数为:打印层高0.05mm~0.20mm,粘接剂饱和度70%~140%。Furthermore, in step (1), the binder used in the droplet jet bonding molding process is phenolic resin; the printing parameters are: printing layer height 0.05mm~0.20mm, adhesive saturation 70%~140%.
粘结剂饱合度(Bs)是微滴喷射打印过程中重要影响参数之一,其定义为单层粘结剂体积(Vbinder)占据对应粉末层中空隙体积(Vair)的正比关系,其表达式:Binder saturation (Bs) is one of the important influencing parameters in the droplet jet printing process. It is defined as the proportional relationship between the volume of a single layer of binder (V binder ) and the void volume (V air ) in the corresponding powder layer. Its expression is:
其中ρ堆积为粉末的堆积密度;ρ真为粉末的真密度;S为单层的打印面积;H为分层厚度。Where ρstacking is the packing density of the powder; ρtrue is the true density of the powder; S is the printing area of a single layer; and H is the layer thickness.
本发明还提供了一种可溶性陶瓷壳/芯,所述可溶性陶瓷壳/芯是采用如上所述的可溶性陶瓷壳/芯的制备方法制备而成的。所述的可溶性陶瓷壳/芯主要应用于结构件的浇注,此外还可以用于铸钢、铸铁、铝合金、镁合金材质结构件的浇注。在浇注完成后,将带有陶瓷壳/芯的结构件放入热水中,陶瓷壳/芯遇水发生反应会开裂溃散,轻松与结构件分离,完成脱壳工序。The present invention also provides a soluble ceramic shell/core, which is prepared by the preparation method of the soluble ceramic shell/core as described above. The soluble ceramic shell/core is mainly used for the casting of structural parts, and can also be used for the casting of structural parts made of cast steel, cast iron, aluminum alloy, and magnesium alloy. After the casting is completed, the structural part with the ceramic shell/core is placed in hot water, and the ceramic shell/core reacts with water to crack and disintegrate, and is easily separated from the structural part, completing the shelling process.
以下结合几个具体实施例来对本发明进行进一步的详细说明。The present invention is further described in detail below in conjunction with several specific embodiments.
实施例1Example 1
本发明实施例1提供的可溶性陶瓷壳/芯的制备方法主要包括以下步骤:The method for preparing the soluble ceramic shell/core provided in Example 1 of the present invention mainly comprises the following steps:
S1,将用于打印的325目碳酸钙粉在80℃下干燥12h,取出后对粉末进行过筛。再将筛好的碳酸钙粉铺满供粉缸,再在工作缸表面放置一块不锈钢板并铺一层陶瓷粉末,在计算机导入设计好的陶瓷壳/芯的三维结构模型并调整打印参数,喷头按照计算机切片的路径开始喷射酚醛树脂粘结剂,在喷头完成一次喷墨后,工作缸会下降一个层厚,供粉缸升高一个层厚,通过铺粉辊的自转和移动来完成铺粉过程,依次往复,从而完成整个陶瓷壳/芯的打印过程。其中,所述3D打印设备打印参数为:打印层高0.15mm,粘结剂饱和度80%。S1, dry the 325 mesh calcium carbonate powder for printing at 80℃ for 12h, take it out and sieve the powder. Then spread the sieved calcium carbonate powder all over the powder supply cylinder, place a stainless steel plate on the surface of the working cylinder and spread a layer of ceramic powder, import the designed three-dimensional structure model of the ceramic shell/core into the computer and adjust the printing parameters, the nozzle starts to spray the phenolic resin binder according to the path of the computer slice, after the nozzle completes one inkjet, the working cylinder will drop a layer thickness, the powder supply cylinder will rise a layer thickness, and the powder spreading process will be completed by the rotation and movement of the powder spreading roller, and reciprocate in sequence to complete the entire ceramic shell/core printing process. Among them, the printing parameters of the 3D printing equipment are: printing layer height 0.15mm, binder saturation 80%.
S2,待打印结束后,首先,将不锈钢板边上多余的粉末清除,放置在烘干箱在205℃下加热固化,固化4h后关闭烘干箱,随炉冷却后将不锈钢板取出。接着,用铲子除去陶瓷壳/芯坯体周围的粉末,将坯体从粉床中取出,并用刷子将陶瓷壳/芯坯体上的残余粉末清除干净。随后,将陶瓷壳/芯坯体放置在盆中,向其中倒入40%纳米ZrO2分散液,在坯体各部分均被完全浸渗后开始计时,3min后将浸渗好的陶瓷壳/芯坯体取出放置在盘中,放入70℃的烘干箱中,干燥6h后取出。S2, after the printing is completed, first, remove the excess powder on the edge of the stainless steel plate, place it in a drying oven and heat it at 205°C for curing, close the drying oven after curing for 4 hours, and take out the stainless steel plate after cooling with the furnace. Next, use a shovel to remove the powder around the ceramic shell/core blank, take the blank out of the powder bed, and use a brush to clean the residual powder on the ceramic shell/core blank. Subsequently, place the ceramic shell/core blank in a basin, pour 40% nano ZrO2 dispersion into it, start timing after all parts of the blank are completely infiltrated, take out the infiltrated ceramic shell/core blank after 3 minutes, place it on a tray, put it in a drying oven at 70°C, and take it out after drying for 6 hours.
S3,陶瓷壳/芯坯体的烧结采用埋烧方式,在烧结专用的陶瓷板上均匀地铺上0.2mm板状刚玉粉末,然后将干燥好的陶瓷壳/芯坯体放置在陶瓷板上,用板状刚玉粉末将坯体各部分完全填埋,随后将其放入放入高温烧结炉内按照1000℃烧结3h,1400℃烧结2h,升温速率为2℃/min的工艺参数进行烧结,最后,随炉冷却以得到钛合金铸造用可溶性陶瓷壳/芯。S3, the sintering of the ceramic shell/core blank adopts the buried firing method. 0.2mm plate-shaped corundum powder is evenly spread on the ceramic plate dedicated to sintering, and then the dried ceramic shell/core blank is placed on the ceramic plate. The various parts of the blank are completely buried with plate-shaped corundum powder, and then it is placed in a high-temperature sintering furnace and sintered according to the process parameters of sintering at 1000℃ for 3h, sintering at 1400℃ for 2h, and a heating rate of 2℃/min. Finally, it is cooled in the furnace to obtain a soluble ceramic shell/core for titanium alloy casting.
实施例2Example 2
本发明实施例2提供的可溶性陶瓷壳/芯的制备方法主要包括以下步骤:The preparation method of the soluble ceramic shell/core provided in Example 2 of the present invention mainly comprises the following steps:
S1,将用于打印的500目碳酸钙粉在90℃下干燥10h,取出后对粉末进行过筛。再将筛好的碳酸钙粉铺满供粉缸,再在工作缸表面放置一块不锈钢板并铺一层陶瓷粉末,在计算机导入设计好的陶瓷壳/芯的三维结构模型并调整打印参数,喷头按照计算机切片的路径开始喷射粘结剂,在喷头完成一次喷墨后,工作缸会下降一个层厚,供粉缸升高一个层厚,通过铺粉辊的自转和移动来完成铺粉过程,依次往复,从而完成整个陶瓷壳/芯的打印过程。其中,所述3D打印设备打印参数为:打印层高0.12mm,粘结剂饱和度100%。S1, dry the 500 mesh calcium carbonate powder for printing at 90℃ for 10h, take it out and sieve the powder. Then spread the sieved calcium carbonate powder all over the powder supply cylinder, place a stainless steel plate on the surface of the working cylinder and spread a layer of ceramic powder, import the designed three-dimensional structure model of the ceramic shell/core into the computer and adjust the printing parameters, the nozzle starts to spray the binder according to the path of the computer slice, after the nozzle completes one inkjet, the working cylinder will drop a layer thickness, the powder supply cylinder will rise a layer thickness, and the powder spreading process will be completed by the rotation and movement of the powder spreading roller, and reciprocate in sequence to complete the entire ceramic shell/core printing process. Among them, the printing parameters of the 3D printing equipment are: printing layer height 0.12mm, binder saturation 100%.
S2,待打印结束后,首先,将不锈钢板边上多余的粉末清除,放置在烘干箱在200℃下加热固化,固化3h后关闭烘干箱,随炉冷却后将不锈钢板取出。接着,用铲子除去陶瓷壳/芯坯体周围的粉末,将坯体从粉床中取出,并用刷子将陶瓷壳/芯坯体上的残余粉末清除干净。随后,将陶瓷壳/芯坯体放置在盆中,向其中倒入30%纳米ZrO2分散液,在坯体各部分均被完全浸渗后开始计时,2min后将浸渗好的陶瓷壳/芯坯体取出放置在盘中,放入60℃的烘干箱中,干燥5h后取出。S2, after the printing is completed, first, remove the excess powder on the edge of the stainless steel plate, place it in a drying oven and heat it at 200°C for curing, close the drying oven after curing for 3 hours, and take out the stainless steel plate after cooling with the furnace. Next, use a shovel to remove the powder around the ceramic shell/core blank, take the blank out of the powder bed, and use a brush to clean the residual powder on the ceramic shell/core blank. Subsequently, place the ceramic shell/core blank in a basin, pour 30% nano ZrO2 dispersion into it, start timing after all parts of the blank are completely infiltrated, take out the infiltrated ceramic shell/core blank after 2 minutes, place it on a tray, put it in a drying oven at 60°C, and take it out after drying for 5 hours.
S3,陶瓷壳/芯坯体的烧结采用埋烧方式,在烧结专用的陶瓷板上均匀地铺上0.2mm板状刚玉粉末,然后将干燥好的陶瓷壳/芯坯体放置在陶瓷板上,用板状刚玉粉末将坯体各部分完全填埋,随后将其放入放入高温烧结炉内按照950℃烧结2h,1350℃烧结2h,升温速率为3℃/min的工艺参数进行烧结,最后,随炉冷却以得到钛合金铸造用可溶性陶瓷壳/芯。S3, the sintering of the ceramic shell/core blank adopts the buried firing method. 0.2mm plate-shaped corundum powder is evenly spread on the ceramic plate dedicated to sintering, and then the dried ceramic shell/core blank is placed on the ceramic plate, and each part of the blank is completely buried with the plate-shaped corundum powder. Subsequently, it is placed in a high-temperature sintering furnace and sintered at 950°C for 2h, 1350°C for 2h, and a heating rate of 3°C/min. Finally, it is cooled in the furnace to obtain a soluble ceramic shell/core for titanium alloy casting.
实施例3Example 3
本发明实施例3提供的可溶性陶瓷壳/芯的制备方法主要包括以下步骤:The preparation method of the soluble ceramic shell/core provided in Example 3 of the present invention mainly comprises the following steps:
S1,将用于打印的600目碳酸钙粉在100℃下干燥8h,取出后对粉末进行过筛。再将筛好的碳酸钙粉铺满供粉缸,再在工作缸表面放置一块不锈钢板并铺一层陶瓷粉末,在计算机导入设计好的陶瓷壳/芯的三维结构模型并调整打印参数,喷头按照计算机切片的路径开始喷射粘结剂,在喷头完成一次喷墨后,工作缸会下降一个层厚,供粉缸升高一个层厚,通过铺粉辊的自转和移动来完成铺粉过程,依次往复,从而完成整个陶瓷壳/芯的打印过程。其中,所述3D打印设备打印参数为:打印层高0.10mm,粘结剂饱和度120%。S1, dry the 600 mesh calcium carbonate powder for printing at 100℃ for 8h, take it out and sieve the powder. Then spread the sieved calcium carbonate powder all over the powder supply cylinder, place a stainless steel plate on the surface of the working cylinder and spread a layer of ceramic powder, import the designed three-dimensional structure model of the ceramic shell/core into the computer and adjust the printing parameters, the nozzle starts to spray the binder according to the path of the computer slice, after the nozzle completes one inkjet, the working cylinder will drop a layer thickness, the powder supply cylinder will rise a layer thickness, and the powder spreading process will be completed by the rotation and movement of the powder spreading roller, and reciprocate in sequence to complete the entire ceramic shell/core printing process. Among them, the printing parameters of the 3D printing equipment are: printing layer height 0.10mm, binder saturation 120%.
S2,待打印结束后,首先,将不锈钢板边上多余的粉末清除,放置在烘干箱在195℃下加热固化,固化2h后关闭烘干箱,随炉冷却后将不锈钢板取出。接着,用铲子除去陶瓷壳/芯坯体周围的粉末,将坯体从粉床中取出,并用刷子将陶瓷壳/芯坯体上的残余粉末清除干净。随后,将陶瓷壳/芯坯体放置在盆中,向其中倒入15%纳米ZrO2分散液,在坯体各部分均被完全浸渗后开始计时,1.5min后将浸渗好的陶瓷壳/芯坯体取出放置在盘中,放入50℃的烘干箱中,干燥4h后取出。S2, after the printing is completed, first, remove the excess powder on the edge of the stainless steel plate, place it in a drying oven and heat it at 195°C for curing, close the drying oven after curing for 2 hours, and take out the stainless steel plate after cooling with the furnace. Next, use a shovel to remove the powder around the ceramic shell/core blank, take the blank out of the powder bed, and use a brush to clean the residual powder on the ceramic shell/core blank. Subsequently, place the ceramic shell/core blank in a basin, pour 15% nano ZrO2 dispersion into it, start timing after all parts of the blank are completely infiltrated, take out the infiltrated ceramic shell/core blank after 1.5 minutes, place it on a tray, put it in a drying oven at 50°C, and take it out after drying for 4 hours.
S3,陶瓷壳/芯坯体的烧结采用埋烧方式,在烧结专用的陶瓷板上均匀地铺上0.2mm板状刚玉粉末,然后将干燥好的陶瓷壳/芯坯体放置在陶瓷板上,用板状刚玉粉末将坯体各部分完全填埋,随后将其放入放入高温烧结炉内按照900℃烧结1h,1300℃烧结1.5h,升温速率为3℃/min的工艺参数进行烧结,最后,随炉冷却以得到钛合金铸造用可溶性陶瓷壳/芯。S3, the sintering of the ceramic shell/core blank adopts the buried firing method. 0.2mm plate-shaped corundum powder is evenly spread on the ceramic plate dedicated to sintering, and then the dried ceramic shell/core blank is placed on the ceramic plate, and each part of the blank is completely buried with plate-shaped corundum powder. It is then placed in a high-temperature sintering furnace and sintered according to the process parameters of sintering at 900°C for 1h, sintering at 1300°C for 1.5h, and a heating rate of 3°C/min. Finally, it is cooled in the furnace to obtain a soluble ceramic shell/core for titanium alloy casting.
应用实施例Application Examples
叶轮作为发动机中的重要组成部分,目前已广泛地应用于汽车、航天等领域。以制备叶轮为例,按照上述具体实施例中的方法制备得到可溶性叶轮型壳,将叶轮型壳放置在压力铸造设备中,用坩埚将熔融的钛合金液倒入型壳上方的浇口中,然后加压使钛合金充满型壳。待冷却后,将浇注后的叶轮型壳取出并放入热水中充分浸泡。待表面的陶瓷型壳材料完全溃散后,将叶轮从水中取出,并清洁干净上面残余的陶瓷,擦干水分放入烘干箱干燥即可得到叶轮铸件。As an important component of the engine, the impeller has been widely used in the fields of automobiles, aerospace, etc. Taking the preparation of the impeller as an example, a soluble impeller shell is prepared according to the method in the above specific embodiment, the impeller shell is placed in a pressure casting device, and the molten titanium alloy liquid is poured into the gate above the shell with a crucible, and then pressurized to fill the shell with titanium alloy. After cooling, the cast impeller shell is taken out and soaked in hot water. After the ceramic shell material on the surface is completely collapsed, the impeller is taken out of the water, and the residual ceramic on it is cleaned, and the water is wiped off and placed in a drying box to obtain an impeller casting.
浸渗对比例Impregnation comparison
按照具体实施例1所构建的使用325目碳酸钙烧结后获得长条样,其中长条样a使用硅溶胶浸渗3min,长条样b使用纳米ZrO2分散液浸渗3min。从图2可以看出,使用硅溶胶浸渗的长条样a在烧结后形状发生了较大变化,而使用纳米ZrO2分散液浸渗的长条样b形状依然保持完整,未发生凹陷变形现象。此外,长条样a在从烧结炉中取出时发生了断裂现象,由此可见强度远不如使用纳米ZrO2分散液浸渗的长条样b,由此可见硅溶胶不适用于碳酸钙陶瓷壳/芯坯体的浸渗,纳米ZrO2分散液可以很好地保持坯体形状,防止断裂,适合碳酸钙陶瓷壳/芯坯体的浸渗。According to the specific embodiment 1, the strip sample was obtained after sintering using 325 mesh calcium carbonate, wherein the strip sample a was infiltrated with silica sol for 3min, and the strip sample b was infiltrated with nano ZrO2 dispersion for 3min. As can be seen from Figure 2, the shape of the strip sample a infiltrated with silica sol changed greatly after sintering, while the shape of the strip sample b infiltrated with nano ZrO2 dispersion remained intact without any concave deformation. In addition, the strip sample a broke when it was taken out of the sintering furnace, which shows that the strength is far less than that of the strip sample b infiltrated with nano ZrO2 dispersion, which shows that silica sol is not suitable for the infiltration of calcium carbonate ceramic shell/core blank, and nano ZrO2 dispersion can well maintain the shape of the blank, prevent fracture, and is suitable for the infiltration of calcium carbonate ceramic shell/core blank.
测试实施例Test Example
(1)溃散性测试(1) Collapse test
将两个烧杯中装满热水,再分别放入测试用陶瓷样品。两样品均利用利用微滴喷射粘结成型工艺制备,除原料外其它成型工艺参数相同,a烧杯中陶瓷样品原料为800目氧化铝,b烧杯中陶瓷样品原料为800目碳酸钙,烧结后碳酸钙已完全分解为氧化钙。在放入热水中40min后,两测试样品状态如图3所示。由图3可知,在40min后,a烧杯中的样品未发生溃散现象,形状、强度与放入热水前无明显差异;b烧杯中的样品已经完全溃散、溶解,符合预期要求。Fill two beakers with hot water and put the ceramic samples for testing in them. Both samples are prepared by droplet jet bonding molding process. Except for the raw materials, the other molding process parameters are the same. The raw material of the ceramic sample in beaker a is 800 mesh alumina, and the raw material of the ceramic sample in beaker b is 800 mesh calcium carbonate. After sintering, the calcium carbonate has been completely decomposed into calcium oxide. After being placed in hot water for 40 minutes, the status of the two test samples is shown in Figure 3. As can be seen from Figure 3, after 40 minutes, the sample in beaker a did not collapse, and there was no obvious difference in shape and strength compared with before being placed in hot water; the sample in beaker b has completely collapsed and dissolved, meeting the expected requirements.
(2)强度测试(2) Strength test
对具体实施例1、2、3中的样品进行抗弯强度测试,所得数据如下表:The samples in specific embodiments 1, 2 and 3 were tested for bending strength, and the obtained data are shown in the following table:
本领域的技术人员容易理解,以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等,均应包含在本发明的保护范围之内。It will be easily understood by those skilled in the art that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.
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CN105599106A (en) * | 2015-12-31 | 2016-05-25 | 华中科技大学 | Micro-jetting bonding forming method of ceramic mould core blank |
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