CN1287929C - 熔模铸造模具及其制造方法 - Google Patents
熔模铸造模具及其制造方法 Download PDFInfo
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- CN1287929C CN1287929C CNB018187161A CN01818716A CN1287929C CN 1287929 C CN1287929 C CN 1287929C CN B018187161 A CNB018187161 A CN B018187161A CN 01818716 A CN01818716 A CN 01818716A CN 1287929 C CN1287929 C CN 1287929C
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- fire
- resistant
- drying composite
- slurries
- prefabricated blank
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Abstract
本发明涉及熔模铸造模具及其制造方法。该方法包括:将耐火纤维、玻璃纤维和耐火填充剂混合以形成一种干燥混合物;将该干燥混合物与一种水性胶态氧化硅溶胶混合以形成耐火底涂层浆液;并且使用该耐火浆液来形成一种熔模铸造模具(10,20)。
Description
技术领域
本发明涉及用于熔模铸造技术的改进方法和组合物。
背景技术
通过失蜡铸造法进行的熔模铸造可以追溯到古埃及和中国。但是当前应用的工艺在二十世纪30年代是一种相对新颖的技术并且代表了一种迅速增长的业务和科学。熔模铸造技术通过将熔融金属浇注进形成在复制了所要求金属形状的一次性蜡模周围上的一次性陶瓷壳模具中,从而简化了复杂金属形状的制造。“精密熔模铸造”即PIC是在该技术领域中的术语。
传统的PIC工艺采用六个主要步骤:
(1)模型制备
用热塑性材料例如蜡制成所要求的金属铸件的一次性阳模,所述材料会熔融、蒸发或完全燃烧,从而不会在去蜡的陶瓷壳模具中留下污染的残余物。通过将热塑性材料注入到设计用来形成具有该金属铸件所需要的形状、尺寸和表面光洁度的模型的分段金属阴模或“工具”中来制备出阳模。单个或多个模型可以通过将它们熔融到一次性腊“浇口***”而装配起来,所述一次性腊“浇口***”喂入熔融的金属来填充壳模具。
(2)通过以下步骤构成壳模:
(a)将模型组件浸入到具有处于由碱稳定的胶态氧化硅水性溶液中的细小微粒状耐火颗粒的耐火浆液中,从而在该模型上形成由耐火材料形成的涂层;
(b)使耐火涂层与粗糙干燥微粒状耐火颗粒或“灰泥”接触以形成灰泥涂层;并且
(c)进行空气干燥以形成“生的”经空气干燥的不溶粘结涂层。
这些工艺步骤可以反复进行以通过连续涂布形成具有所要求厚度的“生的”经空气干燥的壳模。
(3)去蜡——通过蒸汽高压蒸煮、将该生壳模投入到被加热至1000-1900的闪蒸(flash)去蜡炉中,或者通过任意其它迅速加热并且液化该蜡的方法从“生”空气干燥壳模中将该一次性蜡模除去,从而过度的热量聚集不会使壳模裂开。
(4)焙烧——将去蜡的壳模加热至大约1600-2000以除去挥发性残余物并且在该壳模中形成稳定的陶瓷粘接。
(5)浇注——从炉子中将被加热的壳模取出并且放置在适当位置处以接收熔融金属。所述金属可以由燃气、间接电弧、或者感应加热而熔融。该熔融金属可以在空气中或在真空腔室中铸造。该熔融金属可以静态地或离心地浇注,并且可以从铸勺或直接熔融炉缸浇注。使熔融金属冷却以在该模具中形成固化的金属铸件。
(6)取出铸件——使在其中具有固化的金属铸件的壳模分开,并且使这些金属铸件与陶瓷壳材料分开。可以通过用砂轮锯切或切割来使这些铸件与浇注道***分开。可以通过滚筒抛光、喷砂或喷丸处理来使这些铸件光洁。
熔模铸造壳模容易破碎并且易于断裂。在努力改善熔模铸造壳模的强度的过程中,曾经将少量切碎的耐火纤维和切碎的有机纤维加入到水性耐火浆液中。包含这些少量切碎耐火纤维的耐火浆液使得能够在预制坯上涂布更厚的涂层。但是,这些浆液需要相当多的聚合物以实现令人满意的生坯强度和浆液的流动性能。
因此需要能够提供具有改进强度并且能够避免现有技术缺点的熔模铸造壳模的材料和方法。
发明内容
本发明涉及一种用于在一次性支撑构件上迅速形成陶瓷壳模的方法,并且涉及由此获得的陶瓷壳模。该方法包括形成一种包含耐火纤维、玻璃纤维和耐火填充剂的干燥混合物。然后使该干燥混合物与水性胶态氧化硅溶胶粘接剂混合以形成耐火浆液。然后可以将该耐火浆液用于制造陶瓷壳模。
本发明涉及一种制造熔模铸造模具的方法。该方法包括以下步骤:将耐火纤维、玻璃纤维和耐火填充剂混合以形成第一干燥混合物;将该第一干燥混合物与水性胶态氧化硅溶胶混合以形成耐火底涂层浆液;将耐火填充剂、玻璃纤维和耐火纤维混合以形成第二干燥混合物;将该第二干燥混合物与水性胶态氧化硅溶胶混合以形成可以与耐火底涂层浆液相同或不同的耐火巩固层浆液;将由底涂层浆液构成的涂层涂布到一次性模上以形成涂有底涂层的预制坯;将耐火材料构成的灰泥涂抹到涂有底涂层的预制坯上;使该抹有灰泥的涂有底层的预制坯干燥;将由耐火巩固层浆液形成的涂层涂布到抹有灰泥的涂有底涂层的预制坯上以形成涂有耐火巩固层的预制坯;将由耐火材料形成的灰泥抹到该涂有巩固层的预制坯上以形成抹有灰泥的涂有巩固层的预制坯;使该抹有灰泥的涂有耐火巩固层的预制坯干燥;从涂有耐火巩固层的预制坯中除去一次性模以形成生壳模;并且将该生壳模加热到足以形成陶瓷壳模的温度。耐火纤维可以是陶瓷纤维,并且耐火填充剂可以包含陶瓷颗粒。陶瓷纤维其含量可以为所述干燥混合物的大约1wt.%到大约10wt.%,玻璃纤维其含量可以为该干燥混合物的大约0.5wt.%到大约10wt.%,并且耐火填充剂其含量可以为干燥混合物的约80wt.%到大约98.5wt.%。该干燥混合物还可以包括聚合纤维。
在该干燥混合物包含有聚合纤维的情况中,陶瓷纤维其含量可以为干燥混合物的大约1wt.%-10wt.%,玻璃纤维其含量可以为干燥混合物的大约0.5wt.%-10wt.%,并且耐火填充剂其含量可以为干燥混合物的大约80wt.%-98.5wt.%,并且该聚合纤维其含量可以为该干燥混合物的大约0.3wt.%-4wt.%。
本发明的工艺在制造陶瓷壳模方面具有许多优于现有技术的优点。例如,形成由纤维和耐火填充剂构成的干燥混合物使得容易将耐火填充剂和纤维添加到胶态氧化硅溶胶粘接剂中,而无须在使用之前连续混合或重新混合氧化硅溶胶和纤维预混合物。另一个优点在于,这些纤维无须在添加耐火填充剂之前预先分散在液态粘合剂中或者与聚合物混合。还有一个优点在于,无须添加聚合物粘合剂添加物来实现提高生坯强度。其它优点还有,本发明避免了在高剪切混合条件下出现的纤维凝聚的现有技术问题,并且能够在每次浸泡时形成更厚的涂层。
附图说明
图1为所期望的金属铸件的一次性阳模1;
图2为在除去模型1之前生壳10的立体图;
图3为经去蜡的干燥生陶瓷壳20的立体图。
具体实施方式
在本发明的第一方面中,制备出由耐火填充剂、耐火纤维和玻璃纤维构成的干燥混合物。将该混合物与胶态氧化硅溶胶粘接剂混合以制备出耐火浆液。将所得到的耐火浆液用来制备熔模铸造壳模。
在另一个方面中,形成由耐火纤维和玻璃纤维构成的干燥混合物。使该干燥混合物与包含有水性氧化硅溶胶和耐火填充剂的混合物混合。将所得到的耐火浆液用来制作熔模铸造壳模。
在本发明的另一个方面中,制备出由耐火填充剂和玻璃纤维构成的优选具有聚合物纤维的干燥混合物。将该干燥混合物与胶态氧化硅溶胶和耐火填充剂组合以形成一种耐火浆液,该浆液也可以用来制作熔模铸造壳模。
在本发明的另一个方面中,在与胶态氧化硅溶胶混合以形成浆液的干燥混合物中包含有谷壳灰。该浆液也可以用来制作熔模铸造壳模。
干燥混合物
在干燥混合物中可以采用的耐火填充剂包括许多材料。可用的耐火填充剂的示例包括但不限于颗粒物例如熔凝硅石、氧化铝和铝矽酸盐例如多铝红柱石、蓝晶石和孔雀石以及它们的混合物。
可以用在这些干燥混合物中的耐火纤维通常具有但不限于大约20∶1的长宽比。可用的耐火纤维的示例包括但不限于由位于Quebec,Canada的Orleans Resource公司制造的Wallastonite Orleans One纤维、由在Willsboro,NY中的NYCO Minerals Co.制造的NIAD G纤维、金属纤维、芳族聚酰胺纤维、碳纤维以及切碎的或磨碎的陶瓷纤维,例如铝矽酸盐如多铝红柱石、氧化物例如氧化铝和氧化锆、氮化物例如氮化硅、碳以及碳化物如碳化硅以及它们的混合物。切碎的和磨碎的陶瓷纤维在市场上可以从各种来源例如Thermal Ceramics公司中得到。
可以用在干燥混合物中的玻璃纤维包括切碎的和磨碎的玻璃纤维。可以采用的切碎的玻璃纤维包括但不限于E玻璃纤维和S玻璃纤维以及它们的混合物。可以采用的E玻璃纤维的示例包括但不限于长约3mm-6mm直径约10微米的那些纤维,例如由PPG Industries,Shelby,NC制造的商标为Chop Vantage 8610的纤维。可以采用的切碎S玻璃纤维包括但不限于长约3mm-6mm并且直径约为10微米的那些纤维,例如由AGY Inc.Aiken,SC制造的纤维。可用的磨碎E玻璃纤维的示例包括但不限于由Owens Corning公司制造的731ED3mm絮状纤维,其长度大约为0.125英寸、平均直径为15.8微米并且体积密度为0.17克/cm3。
可以用在干燥混合物中的有机纤维包括多种材料例如烯烃、尼龙类型纤维以及芳族聚酰胺纤维。可以使用的烯烃的示例包括但不限于聚乙烯和聚丙烯例如由Minifibers,Inc.制造的。可以使用的尼龙类纤维的示例包括但不限于由Wex Chemical公司制造的那些。可以使用的芳族聚酰胺纤维包括但不限于由Dupont制造的Kevlar。可以采用的其它有机纤维包括聚酯纤维例如由Wex Chemical公司制造的聚酯纤维以及纤维素纤维例如由Interfibe公司制造的纤维素纤维。
在这些干燥混合物中,耐火纤维、玻璃纤维、耐火填充剂就和可选的聚合纤维的量可以在大范围变化。在干燥混合物包含有耐火纤维、玻璃纤维、耐火填充剂的情况下,耐火纤维的量可以为该干燥混合物重量的大约1wt.%-10wt.%,玻璃纤维的量可以为该干燥混合物的大约0.5wt.%-10wt.%,而耐火填充剂的量可以为该干燥混合物的大约80wt.%-98.5wt.%,耐火填充剂可以具有的粒径具有很宽的范围,如大约325目到25目。
当干燥混合物中包括耐火纤维、玻璃纤维、耐火填充剂就和聚合物纤维时,耐火纤维的量可以为该干燥混合物重量的大约1wt.%-10wt.%,玻璃纤维的量可以为该干燥混合物的大约0.5wt.%-10wt.%,而耐火填充剂的量可以为该干燥混合物的大约76wt.%-98wt.%,并且聚合纤维的量可以为该干燥混合物的大约0.3wt.%-4wt.%。
与该干燥混合物组合以形成耐火浆液的氧化硅溶胶粘接剂优选为由Wesbond,Inc.,Wilmington,DE.制造的商标为Megasol的水性胶态氧化硅溶胶,Megasol水性氧化硅溶胶其平均粒径大约为40毫微米(nanometer)、粒径范围大约为6nm-190nm,并且其粒径的标准偏差大约为20nm。Megasol水性氧化硅溶胶的PH可以在8.0-10.0之间变化,优选大约为9.0-9.5;可滴定的Na2O含量可以在大约0.02%-0.5%之间变化,优选大约为0.1%-0.25%,最优选为大约0.20%-0.22%,并且固体含量大约为30%-50%,优选大约为40%-47%,更优选为45%。
如所述一样,所采用的氧化硅溶胶粘接剂是由Wesbond,Inc.制造的Megasol。但是,可以采用其它水性胶态氧化硅溶胶例如由Buntrock Industries,Inc.Williamsburg,VA制造的MegaPrime;由EKA Chemical公司制造的Nyacol 830;由Nalco Chemical公司制造的Nalcoag 1130和Nalcoag 1030;以及由W.R.Grace & Co.制造的Ludox SM30和Ludox HS-30。
耐火浆液的制备
通过将上述干燥混合物和水性氧化硅溶胶粘接剂混合来形成耐火浆液。用来形成耐火浆液的干燥混合物和水性氧化硅溶胶优选为Megasol的量可以在大范围上变化。通常,干燥混合物可以是该浆液总重的大约57wt.%-64wt.%,其余为水性氧化硅溶胶。
下面参照以下非限定实施例对本发明的耐火浆液的制备进行说明。
实施例1:该实施例描述了通过混合出包含有耐火填充剂、耐火纤维和玻璃纤维的干燥混合物并且将该干燥混合物与水性胶态氧化硅溶胶混合来形成耐火浆液。
将100克Wallastonite的Orleans One耐火纤维、20克731ED1/8″磨碎的E玻璃纤维和包含有715克Fused Silica 120(由C-E MineralsCO.,Greenville,TN制造的120目熔凝硅石)和715克Fused Silica200(由C-E Minerals Co.,Greenville,TN制造的200目熔凝硅石)的耐火填充剂干燥混合以形成一种干燥混合物。
将该干燥混合物与1000克固体含量为45%、PH值为9.5并且可滴定Na2O含量为0.2%的Megasol混合以形成一种耐火浆液。
实施例2:该实施例描述了通过混合出包含有耐火填充剂、耐火纤维、玻璃纤维和有机聚合纤维的干燥混合物并且将该干燥混合物与水性胶态氧化硅溶胶混合来形成耐火浆液。
将100克Wallastonite的Orleans One耐火纤维、20克731ED1/8″磨碎的E玻璃纤维、包含有715克Fused Silica 120和715克FusedSilica 200的耐火填充剂与20克长度为1mm并且直径为0.5微米的聚乙烯纤维混合以形成一种干燥混合物。
将该干燥混合物与1000克实施例1的Megasol混合以形成一种耐火浆液。
实施例3:该实施例描述了通过混合出包含有耐火填充剂、耐火纤维和有机聚合纤维的干燥混合物并且将该干燥混合物与水性胶态氧化硅溶胶混合来形成耐火浆液。
将100克Wallastonite的Orleans One耐火纤维、20克其长度为1mm并且直径为1微米的聚乙烯纤维以及包含有715克Fused Silica120和715克Fused Silica 200的耐火填充剂干燥混合以形成一种干燥混合物。
将该干燥混合物与1000克实施例1的Megasol混合以形成一种耐火浆液。
实施例4:该实施例描述了通过混合出包含有耐火填充剂、玻璃纤维和有机聚合纤维的干燥混合物并且将该干燥混合物与水性胶态氧化硅溶胶混合来形成耐火浆液。
将100克731 ED1/8″磨碎的E玻璃纤维、20克其长度为1mm并且直径为1微米的聚乙烯纤维以及包含有715克Fused Silica 120和715克Fused Silica 200的耐火填充剂干燥混合以形成一种干燥混合物。
将该干燥混合物与1000克实施例1的Megasol混合以形成一种耐火浆液。
实施例5:该实施例描述了通过混合出包含有耐火纤维和玻璃纤维的干燥混合物并且将该干燥混合物与水性胶态氧化硅溶胶和耐火填充剂的混合物混合来形成耐火浆液。
将100克Wallastonite的Orleans One耐火纤维和20克731ED1/8″磨碎的E玻璃纤维干燥混合以形成一种干燥混合物。
将该干燥混合物与包含有1000克实施例1的Megasol和具有715克Fused Silica 120和715克Fused Silica 200的耐火填充剂的混合物混合以形成一种耐火浆液。
实施例6:该实施例描述了通过混合出包含有耐火纤维、玻璃纤维和有机聚合纤维的干燥混合物并且将该干燥混合物与水性胶态氧化硅溶胶和耐火填充剂的混合物混合来形成耐火浆液。
将100克Wallastonite的Orleans One耐火纤维、20克其长度为1mm并且直径为0.5mm的聚乙烯纤维以及100克731 ED1/8″磨碎的E玻璃纤维干燥混合以形成一种干燥混合物。
将该干燥混合物与包含有1000克实施例1的Megasol和具有715克Fused Silica 120和715克Fused Silica 200的耐火填充剂的混合物混合以形成一种耐火浆液。
实施例7:该实施例描述了通过混合出包含有耐火填充剂和玻璃纤维的干燥混合物并且将该干燥混合物与水性胶态氧化硅溶胶混合来形成耐火浆液。
将100克731 ED1/8″磨碎的E玻璃纤维和具有715克Fused Silica120和715克Fused Silica 200的耐火填充剂干燥混合以形成一种干燥混合物。
将该干燥混合物与1000克实施例1的Megasol混合以形成一种耐火浆液。
实施例8:该实施例描述了通过将包含有耐火填充剂和耐火纤维的干燥混合物与水性胶态氧化硅溶胶混合来形成耐火浆液。
将100克Wallastonite的Orleans One耐火纤维和具有715克Fused Silica 120和715克Fused Silica 200的耐火填充剂干燥混合以形成一种干燥混合物。
将该干燥混合物与1000克实施例1的Megasol混合以形成一种耐火浆液。
实施例8A:该实施例描述了通过将包含有耐火填充剂和玻璃纤维的干燥混合物与水性胶态氧化硅溶胶混合来形成耐火浆液。
将20克731 ED1/8″磨碎的E玻璃纤维和具有715克Fused Silica120和715克Fused Silica 200的耐火填充剂干燥混合以形成一种干燥混合物。
将该干燥混合物与1000克实施例1的Megasol混合以形成一种耐火浆液。
底涂层和巩固层的制备
通过将氧化硅溶胶粘接剂优选为Megasol投放进干净的用水清洗过的混合容器中并且在进行混合的同时加入所述的干燥混合物,从而制备出耐火底涂层浆液和耐火巩固层浆液。在该混合容器中可以采用在本领域中已知的各种混合装置。这些装置包括例如推进器型混合器、缸式磨机、高速分散混合器以及转台固定叶片混合器。在进行混合的同时加入干燥混合物直到达到合适的粘度。
对于耐火底涂层浆液而言,合适的粘度通常大约为18-30秒No.4Zahn,优选为20-30秒,最优选为24-30秒。对于耐火巩固层浆液而言,合适的粘度大约为10-18秒Zahn#4,优选为10-16秒Zahn#4,最优选为大约12-15秒Zahn#4。在耐火底涂层浆液和耐火巩固层浆液的每一个中,可以进行额外的混合以除去夹杂的空气并且达到均衡。
可以通过加入额外的MeRasol胶态氧化硅溶胶粘合剂或耐火材料来进行最终的粘度调节。还可以将非离子表面活性剂和阴离子表面活性剂添加到耐火浆液中。
耐火灰泥颗粒
可以将多种耐火颗粒用作在耐火底涂层浆液上以及在耐火巩固层浆液上的灰泥。有用的耐火颗粒的示例包括但不限于多铝红柱石、煅烧好的瓷土和其它铝矽酸盐、玻璃质和晶状硅石、矾土、锆石和铬铁矿。耐火颗粒优选没有其量会导致耐火颗粒不稳定并且在金属铸造期间会在热作用下产生出相变化的离子污染物。如在本领域所公知的一样,其污染物的量不会导致耐火颗粒不稳定的耐火颗粒可以通过在有或没有煅烧的情况下进行净化来制造出。
陶瓷壳模
在形成壳模时,将一次性模型优选为热塑性模型,更优选为蜡模,浸入到耐火底涂层浆液中以将该模型的表面涂覆上一层连续的耐火底涂层浆液层。通常,涂覆1-3层耐火底涂层浆液涂层。所涂覆的耐火底涂层其厚度可以大约为0.02英寸到0.2英寸,优选为0.04英寸到0.2英寸,最优选为0.04英寸到0.1英寸。将经涂覆的模型彻底地沥干以除去多余的浆液,然后抹上颗粒细小的耐火灰泥以形成抹有灰泥的底涂层。在施加额外的底涂层之前使该抹有灰泥的底涂层干燥。将巩固层涂覆在抹有灰泥的底涂层上。然后在施加额外的底涂层之前使该抹有灰泥的巩固层干燥。反复涂覆巩固层直到在该模型上所得到的外壳达到所要求的厚度和强度。
在相继的底涂层和巩固层之间的干燥时间取决于该一次性模型形状的复杂性。具有其中气流最小的深型腔的一次性模型在涂层之间需要更长时间干燥。干燥可以在大约60-90下进行,优选在大约70-75下进行。干燥可以在低湿度和高温的加速条件下用快速空气运动进行。大约为0.20英寸到0.5英寸的陶瓷壳模的厚度对于大多数铸件就足以。两层底涂层以及4-5层巩固层通常形成0.25英寸厚陶瓷壳模,其强度足以承受去蜡和煅烧。
材料
当采用蜡模时,该蜡模优选由填充或未填充基于石蜡的熔模铸造分级蜡或微晶蜡形成。
在耐火底涂层和耐火巩固层浆液中可以采用各种耐火浆液组分。具体的耐火底涂层和耐火巩固层浆液由在用来制造具有所要求尺寸和表面光洁度的金属铸件的陶瓷壳模中所要求的特性所决定。可用的耐火底涂层浆液采用了细小尺寸的耐火颗粒,通常大约为-200目至大约-325目。有用的耐火底涂层浆液的示例包括与由-200目熔凝硅石和-325目锆石耐火颗粒构成的混合物一起的Megasol。锆石耐火颗粒对熔融金属具有高抵抗力。锆石的细小粒径还使得能够制造出具有光滑细致的表面光洁度的铸件。
在采用了Megasol和由熔凝硅石和锆石构成的耐火填充剂的耐火底涂层浆液中,该熔凝硅石优选具有这样的尺寸,例如大约为-100目、大约-120目、大约-140目、大约为-170目、大约为-270目和大约为-325目,最优选为大约-120目至大约-200目。锆石最好可以具有这样的粒径,例如大约为-200目、大约为-325目和约-400目,优选大约为-200目,最优选大约为-325目。
该耐火底涂层浆液优可选择地可以包含一种或多种非离子表面活性剂。特别有用的非离子表面活性剂是可以从Buntrock Industries,Williamsburg,VA购得的PS9400。该表面活性剂改善了耐火底涂层耐火浆液的能力,从而润湿蜡模并且帮助排水。可以以基于Megasol重量的大约0.2%的量将表面活性剂加入到耐火底涂层耐火浆液中。
耐火巩固层浆液采用比用在耐火底涂层浆液中更粗的耐火颗粒大小。例如,在其中采用熔凝硅石作为耐火填充剂的耐火巩固层浆液中,熔凝硅石其粒径大约为-80至-270目,优选大约为-100目至-200目,最优选大约为-100目至-120目。
用于作为灰泥施加在底涂层上的耐火颗粒包括但不限于锆砂,其粒径大约为-70目至200目,优选大约为-70目至大约140目。可以作为灰泥用在巩固层上的耐火颗粒可以为大约-10目至200目,优选大约为-20目至大约50目。最优选的是,耐火颗粒其粒径大约为-30目至大约50目。
在一个备选实施方案中,一种过渡灰泥耐火材料可以在涂覆耐火巩固层之前涂覆在抹有灰泥底涂层的一次性模型上,该过渡灰泥耐火材料优选为粒径处于细颗粒底涂层灰泥和粗颗粒巩固涂层灰泥之间的锆石和水合硅酸铝,比如它们的粒径为大约-50目至大约+100目。可以使用该过渡灰泥涂层以增加强度和用来降低在底涂层浆液的最终涂层和耐火巩固层的第一涂层之间分层的可能性。
去蜡
可以通过以下本领域中公知的方法例如浸泡在沸水中、蒸汽高压蒸煮以及闪蒸去蜡来使陶瓷壳模脱蜡。蒸汽高温蒸煮可以通过以下步骤来进行:
1.采用尽可能高的蒸汽压力,优选大约为60PSI或更高,更优选为80-90PSI。
2.尽可能快地关闭并且加压高压釜,优选在小于大约15-20秒的时间内。
3.使空气干燥的生壳经受蒸汽大约10-15分钟。
4.在大约30-60秒钟内缓慢降低高压釜的压力。
可以通过将空气干燥的生壳模投入到被加热至1000至大约1900的炉子中来进行闪蒸去蜡。在这些温度下,靠近陶瓷壳的壁的蜡迅速熔融,从而由于该蜡的膨胀而导致的压力不会使陶瓷壳破裂。然后将该陶瓷壳取出放到温度大约为200至大约600的低温区域中以完成脱蜡。可以通过熔融腔室中的底部开口将熔融蜡排出到水槽或容器中以回收。
煅烧
煅烧需要将去蜡的陶瓷壳模加热到大约1600至大约2000的以除去挥发性残余物并且形成高强度煅烧过的陶瓷壳模。将该去蜡的陶瓷壳模保持在该炉子中以获得热均衡,之后从该炉子中将它取出,并且用所要求的熔融金属进行铸造。
下面参照以下非限定实施例对陶瓷壳模的制造进行说明:
实施例9
将如在图1中所示的8英寸×7/8英寸×3/8英寸的蜡条形模1浸入到实施例1的耐火浆液中。为了方便起见,在该实施例中,对于底涂层和巩固层两个都采用相同的耐火浆液。
将蜡模1浸入到耐火浆液中8秒钟,之后拿出,并且使之沥干10秒钟以形成第一底涂层。可以从Dupont公司得到的粒径为-70目至140目的锆砂作为灰泥施加到第一底涂层上。
使抹有灰泥的涂有底涂层的蜡模在75下干燥30分钟,然后将它再次浸入到耐火浆液中8秒钟以形成第二底涂层,并且再次用-70目至140目的锆砂涂抹。
然后,将具有两层抹有灰泥的涂有底涂层的蜡模1浸入到耐火浆液中8秒钟并且沥干10秒钟。将被涂覆的产品抹上可以从C-EMinerals中得到的Teconsil-50+100目熔凝硅石以形成一个中间的抹有灰泥的模型。然后在75下使该中间的抹有灰泥的模型干燥30分钟。将该中间的抹有灰泥的模型浸入到耐火浆液中,并且抹上Teconsil-30+50目熔凝硅石以形成抹有灰泥的巩固层。然后在75下使该抹有灰泥的涂有巩固层的模型干燥。重复进行浸泡、沥干、抹灰泥和干燥的这个循环以形成总共五层巩固层。
在施加每层底涂层、中间涂层和巩固层之后,刮擦模型1的垂直侧面5和横向侧面1A的部分以除去这些涂层和灰泥以形成如在图2中所示的陶瓷壳模10。再次将该陶瓷壳模10浸入到耐火浆液中以在该模型上形成密封涂层。在75下使密封涂覆的陶瓷壳模10干燥一整夜。将所形成的干燥陶瓷壳浸入在沸水中以除去模型1。如图3所示,沿着一半长度将所得到的去蜡干燥的生陶瓷壳20切开,并且在75下干燥4小时。
宽1英寸×长6英寸×0.3英寸厚的一部分陶瓷壳20被用来评价其强度,这是通过在一个2英寸跨度的部分上加载使之弯曲失效以确定出断裂模数。采用以下公式计算出该陶瓷壳的断裂模数(“MOR”):
R=(3WI)/(2bd2)
其中:
R=以1bs/英寸2为单位的断裂模数
W=试样破坏时的负载(磅)
I=下承载边缘的中心线之间的距离(跨度)(英寸)
b=试样的宽度(英寸)
d=试样的深度(英寸)
用于实施例9的生壳的断裂模数为1018PSI。在1850下将该生壳煅烧一个小时。所得到的煅烧壳模的断裂模数为1044PSI。
实施例10
除了采用实施例8的浆液之外,重复实施例9的过程。该生壳的断裂模数为688PSI。在1850下将该生壳煅烧一个小时。所得到的煅烧壳模的断裂模数为941PSI。
实施例11
除了采用实施例8A的浆液之外,重复实施例9的过程。实施例11的该生壳的断裂模数为645PSI。在1850下将该生壳煅烧一个小时。所得到的煅烧壳模的断裂模数为694PSI。
在本发明的另一个方面中,采用包含有谷壳灰的陶瓷浆液。优选的是,该谷壳灰有大约95+%的无定型硅,其余为碳。这种谷壳灰可以从Agrilectric Power,Inc.,Houston,TX买到。从Buntrocklndustries Inc.获得的Megaprime氧化硅溶胶粘接剂被采用。在下面非限定实施例中描述了谷壳灰与由耐火材料构成的干燥混合物一起使用。
实施例12
除了所使用的耐火浆液包含有1000克PH值为10.5、固体含量为40%、可滴定的Na2O含量为0.33%、平均粒径约为40nm、粒径分布大约为6nm-190nm并且粒径的标准偏差约为20nm的MegaPrime氧化硅溶胶粘接剂,并且干燥混合物为1430克熔凝硅石200耐火填充剂之外,重复实施例9的过程。该生壳的MOR为621PSI。
实施例13
除了所使用的耐火浆液包含1000克实施例12的MegaPrime氧化硅溶胶粘接剂,并且干燥混合物为1430克熔凝硅石200耐火填充剂和200克谷壳灰之外,重复实施例9的过程。该生壳的MOR为804PSI。
实施例14
除了所使用的耐火浆液包含1000克实施例12的MegaPrime氧硅溶胶粘接剂,并且干燥混合物为1430克熔凝硅石200、200克谷壳灰和16克731ED1/8″磨碎的E玻璃纤维之外,重复实施例9的过程。生壳模的MOR为833PSI。
实施例15
除了所使用的耐火浆液包含1000克实施例12的MegaPrime氧化硅溶胶粘接剂,并且干燥混合物为1430克熔凝硅石200、100克谷壳灰和16克731ED 1/8″磨碎的E玻璃纤维以及4克Chop Vantage8610切碎的1/8″E玻璃纤维之外,重复实施例9的过程。生壳模的MOR为1161PSI。
实施例16
除了所使用的耐火浆液包含有1000克PH值为9.5、固体含量为45%并且可滴定的Na2O含量为0.2%的MegaPrime氧化硅溶胶粘接剂,并且干燥混合物为1300克熔凝硅石200和100克谷壳灰之外,重复实施例9的过程。该生壳的MOR为831PSI。
实施例17
除了所使用的耐火浆液包含875克实施例12的MegaPrime溶胶粘接剂,并且该干燥混合物为1485克熔凝硅石120、100克谷壳灰和100克长度为1mm且直径为0.5微米的聚乙烯纤维之外,重复进行实施例9的过程。
实施例18
除了所使用的耐火浆液包含有1000克PH值为10.5、固体含量为40%、可滴定的Na2O含量为0.33%、平均粒径约为40nm、粒径分布大约为6nm-190nm并且粒径的标准偏差约为20nm的MegaPrime氧化硅溶胶粘接剂,并且干燥混合物为1430克熔凝硅石200耐火填充剂和100克谷壳灰之外,重复实施例9的过程。
实施例19
除了所使用的耐火浆液包含有1000克PH值为10.5、固体含量为40%、可滴定的Na2O含量为0.33%、平均粒径约为40nm、粒径分布大约为6nm-190nm并且粒径的标准偏差约为20nm的MegaPrime氧化硅溶胶粘接剂,并且干燥混合物为包含1430克含有50%325目熔凝硅石、25%120目熔凝硅石和25%50目熔凝硅石的耐火填充剂之外,重复实施例9的过程。
实施例20
除了在用来制备耐火浆液的干燥混合物中还包含有100克谷壳灰之外,重复进行实施例19的过程。
实施例21
除了所使用的耐火浆液包含有1000克PH值为9.5、固体含量为45%、可滴定的Na2O含量为0.33%、平均粒径约为40nm、粒径分布大约为6nm-190nm并且粒径的标准偏差约为20nm的MegaPrime氧化硅溶胶粘接剂,并且干燥混合物为耐火纤维和耐火填充剂的混合物之外,重复进行实施例9的过程。耐火纤维是100克Wallastonite One纤维,并且耐火填充剂存在的量为1430克,它包含700克熔凝硅石120、700克熔凝硅石200、100克Mullitel00目。MOR为910PSI。
实施例22
除了在用来制备耐火浆液的干燥混合物中还包含有100克谷壳灰之外,重复进行实施例21的过程。
实施例23
该实施例描述了不用灰泥制造陶瓷壳模的方法。
将如在图1中所示的8英寸×7/8英寸×3/8英寸蜡条形模1浸入到耐火浆液中,该耐火浆液包含有1000克在实施例1中所使用的Megasol、2135克耐火填充物和213克Wallastonite耐火纤维。为了方便起见,在该实施例中,对于底涂层和巩固层而言采用相同的耐火浆液。耐火填充剂包含1485克200目熔融氧化硅、250克35目多铝红柱石以及400克48目多铝红柱石。
将蜡模1浸入到耐火浆液中8秒钟,拿出并且使之沥干10秒钟以形成第一底涂层。
在75下将涂有底涂层的蜡模干燥30分钟,然后将它浸入到耐火浆液中8秒钟以形成第二底涂层。
然后将具有两层底涂层的蜡模1浸入到耐火浆液中8秒钟并且沥干10秒钟。在75下将经涂覆的模型干燥30分钟。重复进行浸泡、沥干和干燥这个循环以形成总共五层巩固层。
在施加每层底涂层、中间涂层和巩固层之后,刮擦模型1的垂直侧面5和横向侧面1A的部分以除去这些涂层以形成如在图2中所示的陶瓷壳模10。再次将该陶瓷壳模10浸入到耐火浆液中以在该模型上形成密封涂层。在75下使密封涂覆的陶瓷壳模10干燥一整夜。将所形成的干燥陶瓷壳浸入在沸水中以除去模型1从而获得一个脱腊的、干燥的、生陶瓷壳。然后在1850下将生壳模进行煅烧以形成煅烧的陶瓷壳模。
实施例24
除了干燥混合物还包含213克E玻璃纤维之外,重复进行实施例23的过程。
实施例25
除了干燥混合物还包含100克谷壳灰之外,重复进行实施例23的过程。
实施例26
除了干燥混合物还包含100克谷壳灰之外,重复进行实施例24的过程。
Claims (21)
1.一种制造熔模铸造模具的方法,该方法包括以下步骤:
将耐火纤维、玻璃纤维和耐火填充剂混合以形成第一干燥混合物;
将耐火纤维、玻璃纤维和耐火填充剂混合以形成第二干燥混合物,该干燥混合物可以与第一干燥混合物相同或不同;
将所述第一干燥混合物与水性胶态氧化硅溶胶混合以形成耐火底涂层浆液;
将所述第二干燥混合物与水性胶态氧化硅溶胶混合以形成耐火巩固层浆液,该浆液可以与所述耐火底涂层浆液相同或不同;
将由底涂层浆液构成的涂层施加到由热塑性材料构成的一次性模型上以形成涂了底涂层的预制坯;
将由耐火材料构成的灰泥施加到涂有底涂层的预制坯上;
干燥所述抹有灰泥的涂有底涂层的预制坯;
将由耐火巩固层浆液构成的涂层施加到抹有灰泥的涂有底涂层的预制坯上以形成涂有耐火巩固层的预制坯;
将由耐火材料构成的灰泥施加到涂有巩固层的预制坯上以形成抹有灰泥的涂有巩固层的预制坯;
干燥所述抹有灰泥的涂有巩固层的预制坯;
从涂有耐火巩固层的预制坯中除去一次性模具以形成生壳模;并且
将该生壳模加热至足以形成烧制陶瓷壳模的温度。
2.如权利要求1所述的方法,其中所述耐火纤维是一种陶瓷纤维,并且所述耐火填充剂包含有其粒径大约为325目到25目的陶瓷颗粒。
3.如权利要求2所述的方法,其中:
所述陶瓷纤维为该干燥混合物重量的大约1wt.%到10wt.%;
所述玻璃纤维为该干燥混合物重量的大约0.5wt.%到10wt.%;并且
所述耐火填充剂为该干燥混合物重量的大约80wt.%到98.5wt.%。
4.如权利要求1所述的方法,其中所述干燥混合物还包含有一种聚合纤维。
5.如权利要求4所述的方法,其中:
所述陶瓷纤维为该干燥混合物重量的大约1wt.%到10wt.%;
所述玻璃纤维为该干燥混合物重量的大约0.5wt.%到10wt.%;
所述耐火填充剂为该干燥混合物重量的大约80wt.%到98.5wt.%;并且
所述聚合纤维为该干燥混合物重量的大约0.3wt.%-4wt.%。
6.如权利要求5所述的方法,其中所述玻璃纤维选自E玻璃纤维和S玻璃纤维,并且所述聚合纤维选自烯烃、尼龙类纤维和芳族聚酰胺纤维。
7.如权利要求2所述的方法,其中所述耐火填充剂还包含有谷壳灰。
8.如权利要求1所述的制造熔模铸造模具的方法,其中:
所述耐火纤维为Wallastonite耐火纤维,所述水性胶态氧化硅溶胶为固体含量为45%、PH值为9.5并且可滴定Na2O含量为0.2%的水性胶态氧化硅溶胶。
9.如权利要求8所述的方法,其中所述混合物包含100克Wallastonite耐火纤维、20克玻璃纤维和包括1430克熔凝硅石的耐火填充剂。
10.如权利要求9所述的方法,其中将所述干燥混合物与1000gms胶态氧化硅溶胶混合。
11.一种制造熔模铸造模具的方法,该方法包括以下步骤:
将玻璃纤维、熔凝硅石耐火填充剂和谷壳灰混合以形成一种干燥混合物;
将该干燥混合物与PH值为10.5、固体含量为40%、可滴定Na2O含量为0.33%、平均粒径约为40nm、粒径分布大约为6nm-190nm并且粒径的标准偏差约为20nm的其固体内含物为氧化硅溶胶粘接剂的水性胶态氧化硅溶胶混合以形成耐火底涂层浆液;
将该干燥混合物与所述水性胶态氧化硅溶胶混合以形成耐火巩固层浆液;
将由底涂层浆液构成的涂层施加到由热塑性材料构成的一次性模型上以形成涂有底涂层的预制坯;
将由耐火材料构成的灰泥施加到涂有底涂层的预制坯上;
干燥所述抹有灰泥的涂有底涂层的预制坯;
将由耐火巩固层浆液构成的涂层施加到抹有灰泥的涂有底涂层的预制坯上以形成涂有耐火巩固层的预制坯;
将由耐火材料构成的灰泥施加到涂有巩固层的预制坯上以形成抹有灰泥的涂有巩固层的预制坯;
干燥所述抹有灰泥的涂有巩固层的预制坯;
从涂有耐火巩固层的预制坯中除去该热塑性模具以形成生壳模;并且
将该生壳模加热至足以形成陶瓷壳模的温度。
12.如权利要求11所述的方法,其中所述混合物包含1430克熔凝硅石、100克谷壳灰和20克玻璃纤维。
13.如权利要求12所述的方法,其中将所述干燥混合物与1000gms胶态氧化硅溶胶混合。
14.由权利要求10的方法所制成的产品。
15.由权利要求13的方法所制成的产品。
16.一种制造熔模铸造模具的方法,该方法包括以下步骤:
将耐火纤维和玻璃纤维混合以形成第一干燥混合物;
将耐火纤维和玻璃纤维混合以形成第二干燥混合物,该干燥混合物可以与第一干燥混合物相同或不同;
将所述第一干燥混合物与水性胶态氧化硅溶胶和耐火填充剂的混合物混合以形成耐火底涂层浆液;
将所述第二干燥混合物与水性胶态氧化硅溶胶和耐火填充剂的混合物混合以形成耐火巩固层浆液,该浆液可以与所述耐火底涂层浆液相同或不同;
将由底涂层浆液构成的涂层施加到由热塑性材料构成的一次性模型上以形成涂有底涂层的预制坯;
将由耐火材料构成的灰泥施加到涂有底涂层的预制坯上;
干燥所述抹有灰泥的涂有底涂层的预制坯;
将由耐火巩固层浆液构成的涂层施加到抹有灰泥的涂有底涂层的预制坯上以形成涂有耐火巩固层的预制坯;
将由耐火材料构成的灰泥施加到涂有巩固层的预制坯上以形成抹有灰泥的涂有巩固层的预制坯;
干燥所述抹有灰泥的涂有巩固层的预制坯;
从涂有耐火巩固层的预制坯中除去一次性模具以形成生壳模;并且
将该生壳模加热至足以形成烧制陶瓷壳模的温度。
17.由权利要求16的方法制成的产品。
18.一种制造熔模铸造模具的方法,该方法包括以下步骤:
将耐火纤维、玻璃纤维和耐火填充剂混合以形成第一干燥混合物;
将耐火纤维、玻璃纤维和耐火填充剂混合以形成第二干燥混合物,该干燥混合物可以与第一干燥混合物相同或不同;
将所述第一干燥混合物与水性胶态氧化硅溶胶混合以形成耐火底涂层浆液;
将所述第二干燥混合物与水性胶态氧化硅溶胶混合以形成耐火巩固层浆液,该浆液可以与所述耐火底涂层浆液相同或不同;
将由底涂层浆液构成的涂层施加到由热塑性材料构成的一次性模型上以形成涂有底涂层的预制坯;
干燥所述抹有灰泥的涂有底涂层的预制坯;
将由耐火巩固层浆液构成的涂层施加到涂有底涂层的预制坯上以形成涂有耐火巩固层的预制坯;
干燥涂有耐火巩固层的预制坯;
从涂有耐火巩固层的预制坯中除去一次性模具以形成生壳模;并且
将该生壳模加热至足以形成烧制陶瓷壳模的温度。
19.如权利要求18所述的方法,其中所述耐火浆液中的耐火填充剂包含有200目熔凝硅石、35目多铝红柱石和48目多铝红柱石。
20.由权利要求18的方法制成的产品。
21.一种制造熔模铸造模具的方法,该方法包括以下步骤:
将纤维和耐火填充剂混合以形成第一干燥混合物;
将纤维和耐火填充剂混合以形成第二干燥混合物,该干燥混合物可以与第一干燥混合物相同或不同;
将所述第一干燥混合物与水性胶态氧化硅溶胶混合以形成耐火底涂层浆液;
将所述第二干燥混合物与水性胶态氧化硅溶胶混合以形成耐火巩固层浆液,该浆液可以与所述耐火底涂层浆液相同或不同;
将由底涂层浆液构成的涂层施加到由热塑性材料构成的一次性模型上以形成涂有底涂层的预制坯;
将由耐火材料构成的灰泥施加到所述涂有底涂层的预制坯上;
干燥所述涂有灰泥和底涂层的预制坯;
将由耐火巩固层浆液构成的涂层施加到涂有灰泥和底涂层的预制坯上以形成涂有耐火巩固层的预制坯;
将由耐火材料构成的灰泥施加到所述涂有耐火巩固层的预制坯上以形成涂有灰泥和耐火巩固层的预制坯;
干燥所述涂有灰泥和耐火巩固层的预制坯;
从所述涂有耐火巩固层的预制坯中除去一次性模具以形成生壳模;并且将该生壳模加热至足以形成烧制陶瓷壳模的温度。
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US24793500P | 2000-11-10 | 2000-11-10 | |
US60/247,935 | 2000-11-10 | ||
US10/005,881 US6814131B2 (en) | 2000-11-10 | 2001-11-08 | Investment casting mold and method of manufacture |
US10/005,881 | 2001-11-08 |
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CA2426326A1 (en) | 2002-05-16 |
EP1339512A4 (en) | 2004-06-23 |
HUP0302347A2 (hu) | 2003-10-28 |
US20030168200A1 (en) | 2003-09-11 |
ATE301517T1 (de) | 2005-08-15 |
AU2002220202B2 (en) | 2006-12-14 |
KR100557205B1 (ko) | 2006-03-10 |
PL362994A1 (en) | 2004-11-15 |
MXPA03004096A (es) | 2004-10-15 |
US6991022B2 (en) | 2006-01-31 |
EP1339512A1 (en) | 2003-09-03 |
BR0115261A (pt) | 2004-10-19 |
HUP0302347A3 (en) | 2004-01-28 |
CZ20031280A3 (cs) | 2004-01-14 |
CA2426326C (en) | 2005-09-06 |
BR0115261B1 (pt) | 2010-11-30 |
EP1339512B1 (en) | 2005-08-10 |
AU2020202A (en) | 2002-05-21 |
DE60112606D1 (de) | 2005-09-15 |
WO2002038308A9 (en) | 2003-06-19 |
KR20030064776A (ko) | 2003-08-02 |
US6814131B2 (en) | 2004-11-09 |
NZ525432A (en) | 2003-09-26 |
ES2247194T3 (es) | 2006-03-01 |
CN1529641A (zh) | 2004-09-15 |
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US20040238158A1 (en) | 2004-12-02 |
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