CN112795813B - Additive manufacturing method of high-hardness zinc alloy die blank - Google Patents
Additive manufacturing method of high-hardness zinc alloy die blank Download PDFInfo
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C18/00—Alloys based on zinc
- C22C18/04—Alloys based on zinc with aluminium as the next major constituent
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
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- 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
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/06—Making non-ferrous alloys with the use of special agents for refining or deoxidising
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Abstract
The invention provides a material increase manufacturing method of a high-hardness zinc alloy die blank, which comprises the following steps: the method comprises the following steps of taking ZAC zinc alloy as a raw material, smelting in a non-vacuum furnace, degassing, deslagging and refining, starting a base moving device, and casting a melt onto a steel base with a baffle plate through a graphite casting pipe to form the bottommost layer of a die blank; after the bottom layer is cast, starting a flame gun, preheating the surface of the solidified zinc alloy to over 320 ℃, and then casting the melt on the preheated surface; and repeating the operation until the processing of the die blank is finished. The additive manufacturing method of the zinc alloy die blank provided by the invention does not need a large-sized casting die, has strong adaptability, can continuously realize additive manufacturing of various dies, and has small machining allowance; the hardness of the processed die can reach more than 150HBW without heat treatment, and the die has better toughness.
Description
Technical Field
The invention relates to the technical field of metal material processing, in particular to an additive manufacturing method of a high-hardness zinc alloy die blank.
Background
A large number of sheet stampings are required in the fields of automobiles, home appliances, machinery, and the like. In the new product development and trial production stage, the forming die of the stamping parts is indispensable and is used less frequently. If the die is made of steel materials, although the material cost is low, the processing difficulty is high, the processing cost is high, and the die is not easy to recycle; the low-melting point zinc alloy material is the most ideal choice for manufacturing the stamping die used for low frequency. The use of zinc alloys as mould material has the following advantages: 1) the raw materials are sufficient and cheap, and can be remelted and reused for many times, so that the material cost is greatly reduced; 2) the zinc alloy has good mechanical property and good fluidity, and can be used for preparing a mold cavity with a complex shape; 3) the molding cycle is short and the production efficiency is high.
At present, the hardness of the stamping die material in the automobile industry is required to reach more than 150HBW, and the index is difficult to reach by common zinc alloy. The traditional zinc alloy material for the die is a Japanese ZAS-brand zinc alloy, the main component (by mass fraction) of the zinc alloy material is Zn-4Al-3Cu-0.05Mg, but the tensile strength of the zinc alloy material is only 250MPa, the hardness of the zinc alloy material is only 110HBW, and the use requirement of the die is difficult to meet. CN110387487A discloses a preparation method of a die-casting zinc alloy with high hardness and high toughness, wherein the hardness of the die-casting zinc alloy can reach 140HV (converted to 133HBW) and is still lower than 150 HBW; in addition, the die-casting method cannot manufacture a large-sized stamping die.
Fused deposition additive manufacturing (FDM) is a feasible method for manufacturing large-scale component blanks, and the principle is briefly described in the specification that the target product is finally obtained by performing fused deposition on raw materials and stacking and forming the raw materials layer by layer. CN108714773B discloses an additive manufacturing method for heterogeneous metal stamping dies, but the main body part of the die is still formed by conventional casting, and only the composite structure of zinc matrix-copper layer is formed locally on the die by FDM technique, and the additive manufacturing of the whole zinc alloy die blank is not involved. CN107520449A discloses a laser impact forging composite additive manufacturing method and device for die deposition forming, which use laser deposition, and have the advantages of complex process, large energy consumption and high cost. Therefore, in the fields of automobiles, household electrical appliances and the like, the additive manufacturing technology of large-scale high-hardness zinc alloy die blanks needs to be developed through technical improvement, and the requirement of new products on developing and trial-manufacturing stamping dies is met.
Disclosure of Invention
Aiming at the problems, the invention provides a method for manufacturing a large-scale high-hardness die blank, which is simple, convenient and fast, low in energy consumption and strong in adaptability, and solves the problem of rapid development of a large-scale stamping die used for a low frequency.
In order to achieve the aim, the invention provides an additive manufacturing method of a high-hardness zinc alloy die blank, which comprises the following steps:
the method comprises the following steps: preparing ZAC zinc alloy raw materials according to a ratio, and smelting in sequence to obtain a zinc alloy melt;
step two: adding a mixed flux into the zinc alloy melt obtained in the step one for refining, removing scum, sealing, preserving heat and standing to obtain refined zinc alloy melt;
step three: an aluminum baffle is adopted to build a bottom layer groove on a base flat plate; then starting the base moving device to control the moving speed and the path of the base; casting the refined zinc alloy melt obtained in the second step into a bottom layer type groove to form the bottommost layer metal of the zinc alloy die blank;
step four: preheating the metal surface of the bottommost layer to be more than 320 ℃ by using an acetylene flame gun, then casting refined zinc alloy melt on the preheated surface, and repeatedly preheating and casting layer by layer after crystallization and solidification;
step five: when the height of the zinc alloy die blank is increased to the height of a baffle of the bottom-layer type groove, increasing the height of the baffle of the bottom-layer type groove to prevent refined zinc alloy melt from flowing out of the type groove, repeating the operation until the zinc alloy die blank reaches a preset height, sequentially closing the acetylene flame thrower, stopping casting, and closing the base moving device;
step six: and (4) after the zinc alloy die blank is cooled to below 50 ℃, removing the baffle, and machining the zinc alloy die blank.
Preferably, in the first step, the ZAC zinc alloy raw material comprises, by mass, 10 to 14% of aluminum, 7 to 10% of copper, 0.015 to 0.03% of magnesium, 0.03 to 0.05% of titanium, 0.1 to 0.3% of silicon, 0.05 to 0.2% of La-Ce mischmetal, and the balance zinc.
Preferably, in the step one, the smelting is carried out in a resistance furnace, the smelting is non-vacuum smelting, and the smelting temperature is controlled to be 500-550 ℃.
Preferably, in the second step, the refining is degassing and deslagging, and specifically comprises: the mixed flux is coated by a pure aluminum foil, pressed into the bottom of the zinc alloy melt by a graphite bell jar and slightly stirred.
Preferably, the mixed flux consists of 25-30% by mass, 30-35% by mass, 10-15% by mass and 20-30% by mass of zinc chloride, ammonium chloride, magnesium chloride and hexachloroethane.
Preferably, in the second step, the refining is performed twice, the time interval between the two refining is 15-20 minutes, and the addition amount of the mixed flux of the two refining is 0.10-0.15% of the mass fraction of the zinc alloy melt.
Preferably, in the third step, a sealed heat preservation furnace is adopted for sealing, preserving heat and standing, and the sealed heat preservation furnace is connected with the resistance furnace.
Preferably, in the third step, the base is a flat steel plate which can move in a large number of directions on the steel rail according to a preset program, and the program is an action instruction which is written according to the structure and the size of the zinc alloy die blank in advance; the aluminum baffle is a modular aluminum alloy section which can be freely disassembled and assembled, and adjacent baffles are mutually locked through special structures on the adjacent baffles.
Preferably, the surfaces of the base and the aluminum baffle plate, which are contacted with the refined zinc alloy melt, are coated with a release agent in advance and are fully dried.
Preferably, a graphite casting pipe is adopted during casting, the outer layer of the graphite casting pipe is protected by a steel pipe, one end of the graphite casting pipe is fixed at the lower end of the sealed heat preservation furnace, and the output of refined zinc alloy melt is controlled by an output valve; an acetylene flame gun is fixed beside the graphite casting pipe, and the distance between a nozzle of the flame gun and a casting opening of the graphite casting pipe is 100-120 mm; the graphite casting pipe and the nozzle of the flame gun form an angle of 45-60 degrees with the plane of the steel base.
The scheme of the invention has the following beneficial effects:
1) the invention has simple operation, convenience and low energy consumption; the simple detachable aluminum check block is adopted to build the mold groove without designing and manufacturing an integral casting mold in advance, so that a large-scale mold blank can be manufactured, the flexibility and the changeability are realized, the adaptability is strong, and the large-scale popularization can be realized.
2) According to the invention, the preheating temperature between additive manufacturing layers is increased to above 320 ℃ through the flame gun, so that solid-liquid fusion in the additive manufacturing process can be realized, metallurgical bonding is achieved between layers which are cast layer by layer, the tissue density is high, and the machining allowance is small.
3) The invention can manufacture the high-hardness zinc alloy die blank with the hardness higher than 150HBW and can meet the requirement of stamping and forming high-strength steel plates.
Drawings
FIG. 1 is an as-cast SEM image of a zinc alloy mold blank of example 1 of the present invention.
FIG. 2 is a blank view of a simple part obtained in example 1 of the present invention.
FIG. 3 is a part diagram of a simple part blank obtained in example 1 of the present invention after machining.
Fig. 4 is an as-cast SEM image of the zinc alloy mold blank of comparative example 3 of the present invention.
Detailed Description
In order to make the technical problems, technical solutions and advantages of the present invention more apparent, the following detailed description is given with reference to the accompanying drawings and specific embodiments.
Example 1
A material additive manufacturing method of a high-hardness zinc alloy die blank is implemented according to the following steps:
the method comprises the following steps: ZAC zinc alloy raw materials comprise 14 wt.% of Al, 10 wt.% of Cu, 0.03 wt.% of Mg, 0.04 wt.% of Ti, 0.2 wt.% of Si, 0.2 wt.% of La-Ce misch metal and the balance of zinc;
the raw materials are sequentially put into a common resistance furnace according to a specified sequence for non-vacuum melting, and the melting temperature is controlled to be 510-530 ℃.
Step two: and (2) performing refining operations of degassing and deslagging twice on the zinc alloy melt which is completely melted in the step one by adopting a fully dried mixed flux, wherein the refining operations comprise the following steps: the solvent was coated with pure aluminum foil, pressed into the bottom of the melt with a graphite bell jar, and the melt was stirred slightly. Removing gas by using a solvent, and fishing out the floating slag;
the two refining times are separated by 15-20 minutes, and then the melt is transferred into a sealed heat preservation furnace connected with a smelting furnace for standing;
the mixed flux consists of 25 percent of zinc chloride, 35 percent of ammonium chloride, 15 percent of magnesium chloride and 25 percent of hexachloroethane; the addition amount of the solvent for two times of refining is 0.1 percent of the mass fraction of the melt.
Step three: a bottom layer groove is built on a base flat plate by adopting an aluminum baffle; then starting the base moving device, and controlling the moving speed and the path of the base; and (4) opening a melt output valve of the holding furnace, and casting the refined and standing ZAC zinc alloy melt in the step two into an aluminum type groove on the steel base through a graphite casting pipe to form the zinc alloy at the bottommost layer of the zinc alloy die blank.
The base is a flat steel plate which can move on the steel track in a large range and in multiple directions according to a preset program. The operation program of the base is an action instruction which is written in advance according to the structure and the size of the zinc alloy die blank. The aluminum baffle is a modular aluminum alloy profile which can be freely disassembled and assembled, and is built into a casting die groove structure in advance according to the shape of a zinc alloy die blank; the adjacent baffles are mutually locked through special structures on the baffles; the zinc alloy melt is cast in the groove and is rapidly crystallized and solidified. And (3) coating a release agent on the surfaces of the base steel plate and the aluminum baffle plate, which are contacted with the zinc alloy melt in advance, and fully drying.
Step four: after the bottom layer zinc alloy in the third step is cast, starting an acetylene flame gun and starting a second round of casting; the sprayed flame raises the preheating temperature of the surface of the solidified and cooled zinc alloy to about 330 ℃, and then the zinc alloy melt is cast on the preheating surface and gradually crystallized and solidified in sequence.
Wherein, the outer layer of the graphite casting pipe is protected by a steel pipe, is fixed at the lower end of the sealed heat preservation furnace, is connected with the melt in the furnace and can directly output the zinc alloy melt; a flame gun for acetylene is fixed beside the graphite casting pipe, and the distance between the nozzle of the flame gun and the casting opening of the graphite casting pipe is 120 mm; the graphite casting pipe and the nozzle of the flame gun form an angle of 45 degrees with the plane of the steel base.
Step five: and (4) repeatedly operating the process of the step four according to a preset program with the base, gradually increasing the zinc alloy die blank, and building a layer of baffle above the bottom aluminum type groove baffle by adopting a mechanical method when the height of the baffle reaches the height of the groove baffle so as to limit the zinc alloy melt to flow out of the groove. Repeating the steps until the zinc alloy die blank reaches the preset height, sequentially closing the acetylene flame thrower, closing the melt output valve, and stopping the base moving device to obtain the simple part blank as shown in figure 2.
Step six: and (3) after the zinc alloy mold blank is cast and cooled to below 50 ℃, manually removing the aluminum baffle, conveying the zinc alloy mold blank to a machining workshop, and machining to obtain the part shown in figure 3.
In the embodiment, the preheating temperature between additive manufacturing layers reaches 330 ℃, so that the prepared zinc alloy mold blank realizes good metallurgical bonding between layers, the hardness reaches 161HBW, and an as-cast SEM image is shown in figure 1.
Example 2
A material additive manufacturing method of a high-hardness zinc alloy die blank is implemented according to the following steps:
the method comprises the following steps: 12 wt.% of Al, 9 wt.% of Cu, 0.03 wt.% of Mg, 0.03 wt.% of Ti, 0.2 wt.% of Si, 0.1 wt.% of La-Ce misch metal and the balance of zinc;
the raw materials are sequentially put into a common resistance furnace according to a specified sequence for non-vacuum melting, and the melting temperature is controlled to be 500-520 ℃.
Step two: and (2) performing refining operations of degassing and deslagging twice on the zinc alloy melt which is completely melted in the step one by adopting a fully dried mixed flux, wherein the refining operations comprise the following steps: the solvent was coated with pure aluminum foil, pressed into the bottom of the melt with a graphite bell jar, and the melt was stirred slightly. Removing gas by using a solvent, and fishing out the floating slag;
the two refining times are separated by 15-20 minutes, and then the melt is transferred into a sealed heat preservation furnace connected with a smelting furnace for standing;
the mixed flux consists of 25 percent of zinc chloride, 35 percent of ammonium chloride, 15 percent of magnesium chloride and 25 percent of hexachloroethane; the addition amount of the solvent for two times of refining is 0.15 percent of the mass fraction of the melt.
Step three: a bottom layer groove is built on a base flat plate by adopting an aluminum baffle; then starting the base moving device, and controlling the moving speed and the path of the base; opening a melt output valve of the holding furnace, and casting the refined and standing ZAC zinc alloy melt in the step two into an aluminum type groove on the steel base through a graphite casting pipe to form the zinc alloy at the bottommost layer of the zinc alloy die blank;
the base is a flat steel plate which can move on the steel track in a large range and in multiple directions according to a preset program. The operation program of the base is an action instruction which is written in advance according to the structure and the size of the zinc alloy die blank. The aluminum baffle is a modular aluminum alloy profile which can be freely disassembled and assembled, and is built into a casting die groove structure in advance according to the shape of a zinc alloy die blank; the adjacent baffles are mutually locked through special structures on the baffles; the zinc alloy melt is cast in the groove and is rapidly crystallized and solidified. And (3) coating a release agent on the surfaces of the base steel plate and the aluminum baffle plate, which are contacted with the zinc alloy melt in advance, and fully drying.
Step four: after the bottom layer zinc alloy in the third step is cast, starting an acetylene flame gun and starting a second round of casting; the sprayed flame melts a layer of solidified and cooled zinc alloy surface, and then the zinc alloy melt is cast on the preheated surface and gradually crystallized and solidified in sequence.
Wherein, the outer layer of the graphite casting pipe is protected by a steel pipe, is fixed at the lower end of the sealed heat preservation furnace, is connected with the melt in the furnace and can directly output the zinc alloy melt; a flame gun for acetylene is fixed beside the graphite casting pipe, and the distance between the nozzle of the flame gun and the casting opening of the graphite casting pipe is 120 mm; the graphite casting pipe and the nozzle of the flame gun form an angle of 45 degrees with the plane of the steel base.
Step five: and (4) repeatedly operating the process of the step four according to a preset program with the base, gradually increasing the zinc alloy die blank, and building a layer of baffle above the bottom aluminum type groove baffle by adopting a mechanical method when the height of the baffle reaches the height of the groove baffle so as to limit the zinc alloy melt to flow out of the groove. Repeating the steps until the zinc alloy die blank reaches the preset height, sequentially closing the acetylene flame thrower, closing the melt output valve and stopping the base moving device.
Step six: and (3) after the casting of the zinc alloy mold blank is finished and the zinc alloy mold blank is cooled to below 50 ℃, manually removing the aluminum baffle, and conveying the zinc alloy mold blank to a machining workshop.
In the embodiment, the alloy composition is changed, the surface of the solidified zinc alloy of the lower layer is directly preheated to be molten, and then the upper layer is cast. The zinc alloy die blank prepared in the way realizes good metallurgical bonding between layers, and the hardness reaches 158 HBW.
Example 3
A material additive manufacturing method of a high-hardness zinc alloy die blank is implemented according to the following steps:
the method comprises the following steps: ZAC zinc alloy raw materials comprise 14 wt.% of Al, 7 wt.% of Cu, 0.03 wt.% of Mg, 0.04 wt.% of Ti, 0.1 wt.% of Si, 0.1 wt.% of La-Ce misch metal and the balance of zinc;
the raw materials are sequentially put into a common resistance furnace according to a specified sequence for non-vacuum melting, and the melting temperature is controlled to be 530-550 ℃.
Step two: and (2) performing refining operations of degassing and deslagging twice on the zinc alloy melt which is completely melted in the step one by adopting a fully dried mixed flux, wherein the refining operations comprise the following steps: the solvent was coated with pure aluminum foil, pressed into the bottom of the melt with a graphite bell jar, and the melt was stirred slightly. Removing gas by using a solvent, and fishing out the floating slag;
the two refining times are separated by 15-20 minutes, and then the melt is transferred into a sealed heat preservation furnace connected with a smelting furnace for standing;
the mixed flux consists of 25 percent of zinc chloride, 35 percent of ammonium chloride, 15 percent of magnesium chloride and 25 percent of hexachloroethane; the addition amount of the solvent for two times of refining is 0.1 percent of the mass fraction of the melt.
Step three: a bottom layer groove is built on a base flat plate by adopting an aluminum baffle; then starting the base moving device, and controlling the moving speed and the path of the base; opening a melt output valve of the holding furnace, and casting the refined and standing ZAC zinc alloy melt in the step two into an aluminum type groove on the steel base through a graphite casting pipe to form the zinc alloy at the bottommost layer of the zinc alloy die blank;
the base is a flat steel plate which can move on the steel track in a large range and in multiple directions according to a preset program. The operation program of the base is an action instruction which is written in advance according to the structure and the size of the zinc alloy die blank. The aluminum baffle is a modular aluminum alloy profile which can be freely disassembled and assembled, and is built into a casting die groove structure in advance according to the shape of a zinc alloy die blank; the adjacent baffles are mutually locked through special structures on the baffles; the zinc alloy melt is cast in the groove and is rapidly crystallized and solidified. And (3) coating a release agent on the surfaces of the base steel plate and the aluminum baffle plate, which are contacted with the zinc alloy melt in advance, and fully drying.
Step four: after the bottom layer zinc alloy in the third step is cast, starting an acetylene flame gun and starting a second round of casting; the sprayed flame raises the preheating temperature of the surface of the solidified and cooled zinc alloy to about 320 ℃, and then the zinc alloy melt is cast on the preheating surface and gradually crystallized and solidified in sequence.
Wherein, the outer layer of the graphite casting pipe is protected by a steel pipe, is fixed at the lower end of the sealed heat preservation furnace, is connected with the melt in the furnace and can directly output the zinc alloy melt; a flame gun for acetylene is fixed beside the graphite casting pipe, and the distance between the nozzle of the flame gun and the casting opening of the graphite casting pipe is 120 mm; the graphite casting pipe and the nozzle of the flame gun form an angle of 45 degrees with the plane of the steel base.
Step five: and (4) repeatedly operating the process of the step four according to a preset program with the base, gradually increasing the zinc alloy die blank, and building a layer of baffle above the bottom aluminum type groove baffle by adopting a mechanical method when the height of the baffle reaches the height of the groove baffle so as to limit the zinc alloy melt to flow out of the groove. Repeating the steps until the zinc alloy die blank reaches the preset height, sequentially closing the acetylene flame thrower, closing the melt output valve and stopping the base moving device.
Step six: and (3) after the casting of the zinc alloy mold blank is finished and the zinc alloy mold blank is cooled to below 50 ℃, manually removing the aluminum baffle, and conveying the zinc alloy mold blank to a machining workshop.
In the present example, the alloy composition was changed, and the Cu content in the zinc alloy was set to 7 wt.%. The zinc alloy die blank prepared in the way realizes good metallurgical bonding between layers, has the hardness of 153HBW and is still higher than 150HBW, and meets the use requirements.
Comparative example 1
Comparative example 1 is substantially the same as example 1 except that the second round of casting was started directly without starting the acetylene flame thrower; the zinc alloy melt was cast on a surface that was not preheated.
As a result, it was found that the layers of the mold blank were not bonded to each other at all and could not be integrated.
Comparative example 2
Comparative example 2 is substantially the same as example 1 except that the surface preheating temperature was 280 ℃.
Although the mold blank can be manufactured in the comparative example, the layer-to-layer obvious interface exists, and the interface has a plurality of holes, so that the quality of the mold obviously does not meet the use requirement.
Comparative example 3
Comparative example 3 is essentially the same as example 1 except ZAC zinc alloy raw materials of 14 wt.% Al, 4 wt.% Cu, 0.03 wt.% Mg, 0.04 wt.% Ti, 0.2 wt.% Si, 0.2 wt.% La-Ce misch metal, and the balance zinc.
In this comparative example, when the Cu content in the zinc alloy is reduced to 4 wt.%, the die blank produced, although good metallurgical bonding between layers is achieved, has a die hardness of only 139HBW, less than 150HBW, and cannot fully meet the use requirements, and the as-cast SEM image is shown in fig. 4.
As can be seen from the above examples and comparative examples, according to the zinc alloy material composition and additive manufacturing method of the present invention, a zinc alloy mold blank with high hardness can be successfully prepared; however, if the zinc alloy die blank is not prepared according to the component proportion and the preparation process, the zinc alloy die blank meeting the use requirement is difficult to prepare by an additive manufacturing method.
While the foregoing is directed to the preferred embodiment of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the appended claims.
Claims (9)
1. The additive manufacturing method of the high-hardness zinc alloy die blank is characterized by comprising the following steps of:
the method comprises the following steps: preparing ZAC zinc alloy raw materials according to a ratio, and smelting in sequence to obtain a melt of the ZAC zinc alloy; the ZAC zinc alloy raw material comprises the following components in percentage by mass: 10-14% of aluminum, 7-10% of copper, 0.015-0.03% of magnesium, 0.03-0.05% of titanium, 0.1-0.3% of silicon, 0.05-0.2% of La-Ce mixed rare earth and the balance of zinc;
step two: adding a mixed flux into the zinc alloy melt obtained in the step one for refining, removing scum, sealing, preserving heat and standing to obtain refined zinc alloy melt;
step three: an aluminum baffle is adopted to build a bottom layer groove on a base flat plate; then starting the base moving device to control the moving speed and the path of the base; casting the refined zinc alloy melt obtained in the second step into a bottom layer type groove to form the bottommost layer metal of the zinc alloy die blank;
step four: preheating the metal surface of the bottommost layer to be more than 320 ℃ by using an acetylene flame gun, then casting refined zinc alloy melt on the preheated surface, and repeatedly preheating and casting layer by layer after crystallization and solidification;
step five: when the height of the zinc alloy die blank is increased to the height of a baffle of the bottom-layer type groove, increasing the height of the baffle of the bottom-layer type groove to prevent refined zinc alloy melt from flowing out of the type groove, repeating the operation until the zinc alloy die blank reaches a preset height, sequentially closing the acetylene flame thrower, stopping casting, and closing the base moving device;
step six: and (4) after the zinc alloy die blank is cooled to below 50 ℃, removing the baffle, and machining the zinc alloy die blank.
2. The additive manufacturing method of the high-hardness zinc alloy mold blank according to claim 1, wherein in the first step, the smelting is performed in a resistance furnace, the smelting is non-vacuum smelting, and the smelting temperature is controlled to be 500-550 ℃.
3. The additive manufacturing method of the high-hardness zinc alloy mold blank according to claim 2, wherein in the second step, refining is degassing and deslagging, and specifically comprises: the mixed flux is coated by a pure aluminum foil, pressed into the bottom of the zinc alloy melt by a graphite bell jar and slightly stirred.
4. The additive manufacturing method of the high-hardness zinc alloy mold blank according to claim 3, wherein the mixed flux is composed of 25-30% by mass, 30-35% by mass, 10-15% by mass, and 20-30% by mass of zinc chloride, ammonium chloride, magnesium chloride, and hexachloroethane.
5. The additive manufacturing method of the high-hardness zinc alloy mold blank according to claim 4, wherein in the second step, the refining is performed twice, the refining time is 15-20 minutes apart, and the addition amount of the mixed flux of the two refining is 0.10-0.15% of the mass fraction of the zinc alloy melt.
6. The additive manufacturing method of the high-hardness zinc alloy mold blank according to claim 5, wherein in the third step, a sealed heat preservation furnace is adopted for sealing, heat preservation and standing, and the sealed heat preservation furnace is connected with a resistance furnace.
7. The additive manufacturing method of the high-hardness zinc alloy mold blank according to claim 6, wherein in the third step, the base is a flat steel plate capable of performing a large-amplitude multidirectional movement on the steel rail according to a preset program, and the program is an action command written according to the structure and the size of the zinc alloy mold blank in advance; the aluminum baffle is a modular aluminum alloy section which can be freely disassembled and assembled, and adjacent baffles are mutually locked through special structures on the adjacent baffles.
8. The additive manufacturing method of the high-hardness zinc alloy mold blank according to claim 7, wherein the surfaces of the base and the aluminum baffle plate, which are in contact with the refined zinc alloy melt, are coated with a release agent in advance and are fully dried.
9. The additive manufacturing method of the high-hardness zinc alloy mold blank according to claim 8, wherein a graphite casting pipe is adopted during casting, the outer layer of the graphite casting pipe is protected by a steel pipe, one end of the graphite casting pipe is fixed at the lower end of the sealed holding furnace, and the output of refined zinc alloy melt is controlled by an output valve; an acetylene flame gun is fixed beside the graphite casting pipe, and the distance between a nozzle of the flame gun and a casting opening of the graphite casting pipe is 100-120 mm; the graphite casting pipe and the nozzle of the flame gun form an angle of 45-60 degrees with the plane of the steel base.
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| CN202110014618.3A CN112795813B (en) | 2021-01-06 | 2021-01-06 | Additive manufacturing method of high-hardness zinc alloy die blank |
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| CN1450194A (en) * | 2003-05-05 | 2003-10-22 | 华中科技大学 | Method for making mould by meld ejection |
| CN102327962A (en) * | 2011-06-16 | 2012-01-25 | 昆山市瑞捷精密模具有限公司 | Method for manufacturing zinc alloy mould with hard mask structure |
| CN102430745A (en) * | 2011-08-18 | 2012-05-02 | 比亚迪股份有限公司 | Method for combining amorphous alloy and heterogeneous material and complex |
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| US10040115B2 (en) * | 2014-10-31 | 2018-08-07 | United Technologies Corporation | Additively manufactured casting articles for manufacturing gas turbine engine parts |
| CN109365811B (en) * | 2018-11-27 | 2021-07-06 | 北京科技大学广州新材料研究院 | Method for forming zinc alloy product by selective laser melting technology |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN1450194A (en) * | 2003-05-05 | 2003-10-22 | 华中科技大学 | Method for making mould by meld ejection |
| CN102327962A (en) * | 2011-06-16 | 2012-01-25 | 昆山市瑞捷精密模具有限公司 | Method for manufacturing zinc alloy mould with hard mask structure |
| CN102430745A (en) * | 2011-08-18 | 2012-05-02 | 比亚迪股份有限公司 | Method for combining amorphous alloy and heterogeneous material and complex |
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