TWI610736B - Highly exothermic feeder sleeves and manufacturing method thereof - Google Patents
Highly exothermic feeder sleeves and manufacturing method thereof Download PDFInfo
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Abstract
一種高發熱冒口保溫套，其材料組成包括：主原料以及粘結劑。主原料包括多種鋁粉、氧化劑、氧化促進劑、保溫材料以及發熱材料。各所述鋁粉的鋁含量為65%至95%。氧化劑包括氧化鐵、硝酸鹽類以及二氧化錳、氧化促進劑包括冰晶石粉。保溫材料包括漂珠、空心氧化鋁或珍珠岩。發熱材料包括金屬矽粉。耐熱材料包括碳化矽粉。碳化矽粉的碳化矽含量至少大於或等於85%。粘結劑包括甲醇、水、糠醇、尿素甲醛樹脂、液體酚醛樹脂以及偶聯劑。另提供一種高發熱冒口保溫套的製造方法。A high-heat riser insulation sleeve, the material composition thereof comprises: a main raw material and a binder. The main raw material includes various aluminum powders, oxidizing agents, oxidation promoters, heat insulating materials, and heat generating materials. Each of the aluminum powders has an aluminum content of 65% to 95%. The oxidizing agent includes iron oxide, nitrates, and manganese dioxide, and the oxidation promoter includes cryolite powder. Insulation materials include floating beads, hollow alumina or perlite. The heating material includes metal tantalum powder. The heat resistant material includes tantalum carbide powder. The niobium carbide powder has a niobium carbide content of at least 85% or more. The binder includes methanol, water, decyl alcohol, urea formaldehyde resin, liquid phenolic resin, and a coupling agent. A method of manufacturing a high-heat riser insulation jacket is also provided.
Description
本發明是有關於一種冒口保溫套及其製造方法，且特別是有關於一種具有高效與高發熱的冒口保溫套及其製造方法。The invention relates to a riser insulation sleeve and a manufacturing method thereof, and in particular to a riser insulation sleeve with high efficiency and high heat generation and a manufacturing method thereof.
在金屬鑄造的過程中，熔融金屬被倒入定義出鑄件形狀的鑄模模型的模穴內。由於熔融金屬在凝固時會收縮而造成縮孔，此等縮孔會在最終鑄件內造成不可接受的瑕疵。這在鑄造業界是一個廣為人知的問題。所述問題可藉由使用在鑄件形成期間安裝於鑄模模型上的冒口來解決。冒口可提供與模穴連通的額外容積，使得熔融金屬也會進入冒口內。在熔融金屬凝固期間，冒口內的熔融金屬會流至模穴內，以補償鑄件的收縮，使用冒口保溫套取代一般砂冒口可以有效提高補縮率，進而減少冒口體積，減少回爐料、提高得料率。During the metal casting process, the molten metal is poured into the cavity of the mold model defining the shape of the casting. Since the molten metal shrinks as it solidifies, it causes shrinkage, which causes unacceptable defects in the final casting. This is a well-known problem in the foundry industry. The problem can be solved by using a riser that is mounted on the mold model during the formation of the casting. The riser provides an additional volume that communicates with the cavity so that molten metal also enters the riser. During the solidification of the molten metal, the molten metal in the riser will flow into the cavity to compensate for the shrinkage of the casting. Using the riser sleeve instead of the general sand riser can effectively increase the shrinkage rate, thereby reducing the volume of the riser and reducing the size of the riser. Material, increase the yield.
一般而言，可將冒口保溫套材料放置在模具中，並加熱模具，以固化所述冒口保溫套材料，藉此形成冒口保溫套。另一方面，亦需要等待所形成的冒口保溫套硬化後，方可進行脫模步驟，以獲得冒口保溫套。因此，在製造冒口保溫套的過程中，加熱模具過程可能引燃裡頭可燃材料，容易產生安全性以及須等待硬化時間造成產量不佳的問題。In general, the riser sleeve material can be placed in a mold and the mold heated to cure the riser sleeve material thereby forming a riser sleeve. On the other hand, it is also necessary to wait for the formed riser sleeve to be hardened before performing the demolding step to obtain the riser sleeve. Therefore, in the process of manufacturing the riser sleeve, the heating of the mold process may ignite the combustible material inside, which is prone to safety and the problem of waiting for hardening time to cause poor yield.
本發明提供一種具有高效與高發熱的冒口保溫套及其製造方法，其在製造過程中可提高冒口對鑄件的補縮率、製程的安全性及產量。The invention provides a riser insulation sleeve with high efficiency and high heat generation and a manufacturing method thereof, which can improve the feeding rate, the safety of the process and the output of the casting in the manufacturing process.
本發明提供一種高發熱冒口保溫套，其材料組成包括：主原料以及粘結劑。主原料包括多種鋁粉、氧化劑、氧化促進劑、保溫材料、發熱材料以及碳化矽粉。各所述鋁粉的鋁含量為65%至95%。氧化劑包括氧化鐵、硝酸鹽類以及二氧化錳、氧化促進劑包括冰晶石粉。保溫材料包括漂珠、空心氧化鋁或珍珠岩。發熱材料包括金屬矽粉。與耐熱材料包括碳化矽粉。碳化矽粉的碳化矽含量至少大於或等於85%。粘結劑包括甲醇、水、糠醇、尿素甲醛樹脂、液體酚醛樹脂以及偶聯劑。The invention provides a high-heat riser insulation cover, the material composition thereof comprises: a main raw material and a binder. The main raw materials include various aluminum powders, oxidizing agents, oxidation promoters, heat insulating materials, heat generating materials, and tantalum carbide powder. Each of the aluminum powders has an aluminum content of 65% to 95%. The oxidizing agent includes iron oxide, nitrates, and manganese dioxide, and the oxidation promoter includes cryolite powder. Insulation materials include floating beads, hollow alumina or perlite. The heating material includes metal tantalum powder. The heat resistant material includes tantalum carbide powder. The niobium carbide powder has a niobium carbide content of at least 85% or more. The binder includes methanol, water, decyl alcohol, urea formaldehyde resin, liquid phenolic resin, and a coupling agent.
在本發明的一實施例中，所述鋁粉包括第一鋁粉、第二鋁粉以及第三鋁粉。第一鋁粉的鋁含量為65%至75%且平均粒徑為50目（mesh）至300目。第二鋁粉的鋁含量大於或等於95%且平均粒徑為50目至150目。第三鋁粉的鋁含量大於或等於95%且平均粒徑為200目至400目。In an embodiment of the invention, the aluminum powder comprises a first aluminum powder, a second aluminum powder, and a third aluminum powder. The first aluminum powder has an aluminum content of 65% to 75% and an average particle diameter of 50 mesh to 300 mesh. The second aluminum powder has an aluminum content of greater than or equal to 95% and an average particle diameter of from 50 mesh to 150 mesh. The third aluminum powder has an aluminum content of greater than or equal to 95% and an average particle diameter of from 200 mesh to 400 mesh.
在本發明的一實施例中，以所述主原料為總重量計，其中所述第一鋁粉的含量為5重量%至25重量%，所述第二鋁粉的含量為1重量%至16重量%，所述第三鋁粉的含量為1重量%至16重量%。In an embodiment of the invention, the content of the first aluminum powder is 5% by weight to 25% by weight, and the content of the second aluminum powder is 1% by weight to the total weight of the main raw material. 16% by weight, the third aluminum powder is contained in an amount of from 1% by weight to 16% by weight.
在本發明的一實施例中，以所述主原料為總重量計，其中所述氧化鐵的含量為5重量%至25重量%，所述硝酸鈉的含量為0.1重量%至10重量%，所述二氧化錳的含量為1重量%至10重量%，所述冰晶石粉的含量為0.1重量%至10重量%，所述漂珠的含量為5重量%至20重量%，所述金屬矽粉的含量為5重量%至25重量%，所述碳化矽粉的含量為10重量%至30重量%。In an embodiment of the present invention, the content of the iron oxide is 5% by weight to 25% by weight, and the content of the sodium nitrate is 0.1% by weight to 10% by weight based on the total weight of the main raw material. The content of the manganese dioxide is 1% by weight to 10% by weight, the content of the cryolite powder is 0.1% by weight to 10% by weight, and the content of the floating beads is 5% by weight to 20% by weight, the metal ruthenium The content of the powder is from 5% by weight to 25% by weight, and the content of the cerium carbide powder is from 10% by weight to 30% by weight.
在本發明的一實施例中，以所述粘結劑為總重量計，其中所述甲醇的含量為10重量%至40重量%，所述水的含量為5重量%至35重量%，所述糠醇的含量為10重量%至30重量%，所述尿素甲醛樹脂的含量為10重量%至30重量%，所述液體酚醛樹脂的含量為20重量%至40重量%，所述偶聯劑的含量為0.1重量%至5重量%。In an embodiment of the present invention, the binder is used as a total weight, wherein the content of the methanol is 10% by weight to 40% by weight, and the content of the water is 5% by weight to 35% by weight. The content of the sterol is 10% by weight to 30% by weight, the content of the urea-formaldehyde resin is 10% by weight to 30% by weight, and the content of the liquid phenolic resin is 20% by weight to 40% by weight, the coupling agent The content is from 0.1% by weight to 5% by weight.
在本發明的一實施例中，以所述冒口保溫套為總重量計，其中所述主原料的含量為70重量%至95重量%，所述粘結劑的含量為5重量%至30重量%。In an embodiment of the invention, the riser sleeve is the total weight, wherein the content of the main raw material is 70% by weight to 95% by weight, and the content of the binder is 5% by weight to 30% weight%.
本發明提供一種高發熱冒口保溫套的製造方法，其步驟如下。提供主原料。主原料包括多種鋁粉、氧化劑、氧化促進劑、保溫材料以及發熱材料。提供粘結劑。所述粘結劑包括甲醇、水、糠醇、尿素甲醛樹脂、液體酚醛樹脂以及偶聯劑。混合所述主原料與所述粘結劑，以形成冒口保溫套。以所述冒口保溫套為總重量計，其中所述主原料的含量為70重量%至95重量%，所述粘結劑的含量為5重量%至30重量%。進行射芯成型步驟。進行脫模步驟，烘乾以獲得所述冒口保溫套。The invention provides a method for manufacturing a high-heat riser thermal insulation sleeve, the steps of which are as follows. Provide the main raw material. The main raw material includes various aluminum powders, oxidizing agents, oxidation promoters, heat insulating materials, and heat generating materials. A binder is provided. The binder includes methanol, water, decyl alcohol, urea formaldehyde resin, liquid phenolic resin, and a coupling agent. The primary material and the binder are mixed to form a riser sleeve. The total amount of the main raw material is 70% by weight to 95% by weight, and the content of the binder is 5% by weight to 30% by weight based on the total weight of the riser sleeve. Perform a core molding step. A demolding step is performed and dried to obtain the riser sleeve.
在本發明的一實施例中，混合所述主原料的步驟如下。將所述鋁粉、氧化鐵、二氧化錳、漂珠、金屬矽粉以及碳化矽粉混合，並持續攪拌1分鐘至5分鐘，以形成第一混合物。將硝酸鈉加入所述第一混合物中，以形成第二混合物。將冰晶石粉加入所述第二混合物中，並持續攪拌15分鐘至20分鐘，以形成第三混合物。In an embodiment of the invention, the step of mixing the main raw materials is as follows. The aluminum powder, iron oxide, manganese dioxide, floating beads, metal cerium powder, and cerium carbide powder are mixed and continuously stirred for 1 minute to 5 minutes to form a first mixture. Sodium nitrate is added to the first mixture to form a second mixture. The cryolite powder is added to the second mixture and stirring is continued for 15 minutes to 20 minutes to form a third mixture.
在本發明的一實施例中，混合所述粘結劑的步驟如下。將所述甲醇與所述水混合，以形成混合物A。將所述糠醇加入所述混合物A中，以形成混合物B。將所述液體酚醛樹脂加入所述混合物B中，以形成混合物C。將所述尿素甲醛樹脂加入所述混合物C中，以形成混合物D。將所述偶聯劑加入所述混合物D中並持續攪拌10分鐘至20分鐘，以形成混合物E。將醋酸加入所述混合物E中，並持續攪拌10分鐘至20分鐘，使得pH值介於7.5至8.5之間，以形成混合物F。In an embodiment of the invention, the step of mixing the binder is as follows. The methanol is mixed with the water to form a mixture A. The sterol is added to the mixture A to form a mixture B. The liquid phenolic resin is added to the mixture B to form a mixture C. The urea formaldehyde resin is added to the mixture C to form a mixture D. The coupling agent was added to the mixture D and stirring was continued for 10 minutes to 20 minutes to form a mixture E. Acetic acid was added to the mixture E and stirring was continued for 10 minutes to 20 minutes to bring the pH between 7.5 and 8.5 to form a mixture F.
在本發明的一實施例中，進行所述射芯成型步驟包括：將所述冒口保溫套的材料置入射芯機中。藉由所述射芯機將所述冒口保溫套的材料射入具有中空模穴的模具中。所述射芯成型步驟的製程壓力為0.3 MPa至0.6 MPa。In an embodiment of the invention, the performing the core forming step comprises: placing the material of the riser sleeve into the core machine. The material of the riser sleeve is injected into the mold having a hollow cavity by the core shooter. The process pressure of the core shooting step is from 0.3 MPa to 0.6 MPa.
在本發明的一實施例中，進行所述射芯成型步驟不需要加熱所述模具，所以比先前技術安全，生產速度快。In an embodiment of the invention, the performing the core forming step does not require heating of the mold, so it is safer than the prior art and has a high production speed.
在本發明的一實施例中，從所述射芯成型步驟結束到進行所述脫模步驟之間的時間為1分鐘至2分鐘。In an embodiment of the invention, the time from the end of the shot forming step to the step of performing the demolding is from 1 minute to 2 minutes.
基於上述，本發明之冒口保溫套的材料具有高效與高發熱的特性，其不僅可在澆鑄時抑制冒口處熔融金屬的散熱，還可延長冒口處熔融金屬的凝固時間，進而提高冒口對鑄件的補縮率。另外，本發明之高發熱冒口保溫套材料還包括粘結劑，其可在製造過程中固化冒口保溫套而毋須加熱模具，且不需要等待冒口保溫套硬化即可進行脫模步驟，進而提升製程的安全性以及冒口保溫套的產量。Based on the above, the material of the riser sleeve of the present invention has the characteristics of high efficiency and high heat generation, and can not only suppress the heat dissipation of the molten metal at the riser during casting, but also prolong the solidification time of the molten metal at the riser, thereby improving the The ratio of the mouth to the casting. In addition, the high-heat riser insulation cover material of the present invention further comprises an adhesive, which can cure the riser insulation sleeve in the manufacturing process without heating the mold, and can perform the demoulding step without waiting for the riser insulation sleeve to be hardened. In turn, the safety of the process and the production of the riser sleeve are improved.
此外，本發明之高發熱冒口保溫套亦包括碳化矽粉，其可增加熱傳導率，使得澆鑄時燃燒快速且熱量均勻分布至整個冒口保溫套，進而達到充分補縮的功效。In addition, the high-heat riser insulation sleeve of the present invention also includes tantalum carbide powder, which can increase the thermal conductivity, so that the combustion is rapid and the heat is evenly distributed to the entire riser sleeve during the casting, thereby achieving the effect of fully supplementing.
為讓本發明的上述特徵和優點能更明顯易懂，下文特舉實施例，並配合所附圖式作詳細說明如下。The above described features and advantages of the invention will be apparent from the following description.
在本說明書中，由「一數值至另一數值」表示的範圍，是一種避免在說明書中一一列舉該範圍中的所有數值的概要表示方式。因此，記載了某一特定數值範圍，等同於揭露了該數值範圍內的任意數值以及由該數值範圍內的任意數值界定出的較小數值範圍，就如同在說明書中明文寫出該任意數值和該較小數值範圍一樣。例如，記載「含量為10重量%至30重量%」的範圍，就等同於揭露了「含量為15重量%至25重量%」的範圍，無論說明書中是否列舉其他數值。In the present specification, the range represented by "a numerical value to another numerical value" is a schematic representation that avoids enumerating all the numerical values in the range in the specification. Therefore, a particular numerical range is recited, which is equivalent to the disclosure of any numerical value in the numerical range and the numerical range defined by any value in the numerical range, as if the This smaller range of values is the same. For example, the description of the "content of 10% by weight to 30% by weight" is equivalent to the disclosure of the "content of 15% by weight to 25% by weight", regardless of whether other values are listed in the specification.
本實施例提供一種高發熱冒口保溫套材料，其材料包括：主原料以及粘結劑。以所述冒口保溫套材料為總重量計，其中所述主原料的含量為70重量%至95重量%，所述粘結劑的含量為5重量%至30重量%。The embodiment provides a high heat riser insulation sleeve material, the material comprising: a main raw material and a binder. The content of the main raw material is 70% by weight to 95% by weight, and the content of the binder is 5% by weight to 30% by weight based on the total weight of the riser insulation material.
詳細地說，主原料包括多種鋁粉、氧化劑、氧化促進劑、保溫材料、發熱材料以及耐熱材料。所述鋁粉包括第一鋁粉、第二鋁粉以及第三鋁粉。第一鋁粉的鋁含量為65%至75%且平均粒徑為50目至300目。第二鋁粉的鋁含量大於或等於95%且平均粒徑為50目至150目。第三鋁粉的鋁含量大於或等於95%且平均粒徑為200目至400目。所述目（mesh）是指標準篩的篩孔尺寸，其可用以表示原料顆粒的粒徑或尺寸。一般而言，目數愈大表示顆粒愈細。在本文中所述的目是指泰勒標準（TYLER）所規範之特性。再者，第一鋁粉與第二鋁粉混合時為10重量%至35重量%。In detail, the main raw material includes various aluminum powders, an oxidizing agent, an oxidation promoter, a heat insulating material, a heat generating material, and a heat resistant material. The aluminum powder includes a first aluminum powder, a second aluminum powder, and a third aluminum powder. The first aluminum powder has an aluminum content of 65% to 75% and an average particle diameter of 50 mesh to 300 mesh. The second aluminum powder has an aluminum content of greater than or equal to 95% and an average particle diameter of from 50 mesh to 150 mesh. The third aluminum powder has an aluminum content of greater than or equal to 95% and an average particle diameter of from 200 mesh to 400 mesh. The mesh refers to the mesh size of a standard sieve, which can be used to indicate the particle size or size of the raw material particles. In general, the larger the mesh, the finer the particles. The term described herein refers to the characteristics specified by the Taylor Standard (TYLER). Further, the first aluminum powder is mixed with the second aluminum powder in an amount of 10% by weight to 35% by weight.
在一實施例中，氧化劑可包括氧化鐵、鐵的氧化物、硝酸鈉、硝酸鹽類以及二氧化錳、錳的氧化物，其中所述氧化鐵的含量為5重量%至25重量%且所述氧化鐵的平均粒徑為100目至300目；所述硝酸鈉的含量為0.1重量%至10重量%；所述二氧化錳的含量為1重量%至10重量%。其所產生的反應依序如下： 2NaNO 3─＞ΔH─＞2NaNO 2+3O 2； 3MnO 2─＞ΔH─＞Mn 3O 4+O 2； 4Al+3MnO 2─＞2Al 2O 3+3Mn ΔH=-106.83KJ/mol； 4Al + 3O2 → 2Al 2O 3ΔH=-1675kJ/mol；6Fe 2O 3—Δ→ 4Fe 3O 4+ O2； Fe2O3 + 2 Al → 2 Fe + Al2O3 ΔH=-3265kJ/mol； 3Fe 3O 4+8Al─＞9Fe+4Al 2O 3ΔH=-3.667KJ/g。 In an embodiment, the oxidizing agent may include iron oxide, iron oxide, sodium nitrate, nitrate, and manganese dioxide, manganese oxide, wherein the iron oxide is contained in an amount of 5% by weight to 25% by weight. The iron oxide has an average particle diameter of 100 mesh to 300 mesh; the sodium nitrate content is 0.1% by weight to 10% by weight; and the manganese dioxide is contained in an amount of 1% by weight to 10% by weight. The reaction sequence is as follows: 2NaNO 3 ─>ΔH─>2NaNO 2 +3O 2 ; 3MnO 2 ─>ΔH─>Mn 3 O 4 +O 2 ; 4Al+3MnO 2 ─>2Al 2 O 3 +3Mn ΔH =-106.83KJ/mol; 4Al + 3O2 → 2Al 2 O 3 ΔH=-1675kJ/mol; 6Fe 2 O 3 —Δ→ 4Fe 3 O 4 + O2; Fe2O3 + 2 Al → 2 Fe + Al2O3 ΔH=-3265kJ/ Mol; 3Fe 3 O 4 +8Al->9Fe+4Al 2 O 3 ΔH=-3.667 KJ/g.
但本發明不以此為限，只要所使用的氧化劑可與所述鋁粉發生鋁熱反應（thermite reaction）以釋放熱能即為本發明的範疇。所述鋁熱反應是以鋁粉當作還原劑，其與氧化劑進行氧化還原反應，以釋放出大量熱能。在本實施例中，所述熱能可在澆鑄過程中延長冒口處的熔融金屬的凝固時間，進而提高冒口對鑄件的補縮率。在一實施例中，以所述主原料為總重量計以所述主原料為總重量計，所述金屬矽粉的含量為5重量%至25重量%，且所述金屬矽粉的平均粒徑為50目至250目。所述氧鋁熱反應如下： Si+O 2─＞ΔH─＞SiO 2ΔH=-989.5KJ/mol；以及 3SiO 2+4Al─＞ΔH─＞3Si+2Al 2O 3ΔH=-4238KJ/mol However, the present invention is not limited thereto, as long as the oxidizing agent used can undergo a thermite reaction with the aluminum powder to release heat energy, which is within the scope of the present invention. The aluminothermic reaction uses aluminum powder as a reducing agent, which undergoes a redox reaction with an oxidizing agent to release a large amount of heat energy. In this embodiment, the thermal energy can prolong the solidification time of the molten metal at the riser during the casting process, thereby increasing the feeding rate of the riser to the casting. In one embodiment, the content of the metal tantalum powder is 5% by weight to 25% by weight based on the total weight of the main raw material, and the average particle size of the metal tantalum powder. The diameter is from 50 mesh to 250 mesh. The oxyaluminum thermal reaction is as follows: Si + O 2 -> ΔH -> SiO 2 ΔH = -989.5 KJ / mol; and 3 SiO 2 + 4 Al -> ΔH -> 3Si + 2 Al 2 O 3 ΔH = -4238 KJ / mol
另外，氧化促進劑包括冰晶石粉。在一實施例中，以所述主原料為總重量計，其中所述冰晶石粉的含量為0.1重量%至10重量%，且所述冰晶石粉的平均粒徑為50目至250目。所述氧化促進劑反應如下：原2000℃三氧化二鋁才會發生反應： 2Al 2O 3—Δ2000℃→4Al+3O 2催化後: 2Al 2O 3—Na 3AlF 6Δ1000℃→4Al+3O 2 In addition, the oxidation promoter includes cryolite powder. In one embodiment, the content of the cryolite powder is 0.1% by weight to 10% by weight based on the total weight of the main raw material, and the average particle diameter of the cryolite powder is 50 mesh to 250 mesh. The oxidation promoter reacts as follows: the original 2000 ° C aluminum oxide will react: 2Al 2 O 3 - Δ2000 ° C → 4Al + 3O 2 after the catalyst: 2Al 2 O 3 - Na 3 AlF 6 Δ1000 ° C → 4Al + 3O 2
此外，冰晶石粉也可以氟矽酸鈉、氟鋁酸鉀或氟矽化鉀替代。為了使得所形成的冒口保溫套具有良好的保溫特性，以在澆鑄過程中盡可能延長冒口處的熔融金屬的凝固時間，主原料包括保溫材料。在一實施例中，保溫材料可以是漂珠，以所述主原料為總重量計，所述漂珠的含量為5重量%至20重量%，且所述漂珠的平均粒徑為20目至200目。但本發明不以此為限，在其他實施例中，保溫材料亦可以是空心氧化鋁或珍珠岩。In addition, the cryolite powder may be replaced by sodium fluoroantimonate, potassium fluoroaluminate or potassium fluorocarbonate. In order to make the formed riser sleeve have good heat preservation characteristics, the solidification time of the molten metal at the riser is extended as much as possible during the casting process, and the main raw material includes the heat insulating material. In an embodiment, the insulating material may be a floating bead, the content of the floating beads is 5% by weight to 20% by weight based on the total weight of the main raw material, and the average particle diameter of the floating beads is 20 mesh. Up to 200 mesh. However, the invention is not limited thereto. In other embodiments, the heat insulating material may also be hollow alumina or perlite.
為了提高冒口保溫套的耐火性，使得冒口保溫套在燃燒過程中不易被熔融金屬燒蝕，以強化冒口保溫套的強度與耐用性，可在主原料中加入耐熱材料，即碳化矽粉。但本發明不以此為限，亦可以是其他耐熱材料，例如鎂砂、矽砂、鉻砂、鋯砂或三氧化二鋁。In order to improve the fire resistance of the riser insulation sleeve, the riser insulation sleeve is not easily ablated by the molten metal during the combustion process, so as to strengthen the strength and durability of the riser insulation sleeve, a heat resistant material, ie, tantalum carbide, may be added to the main raw material. powder. However, the invention is not limited thereto, and may be other heat resistant materials such as magnesia, strontium sand, chrome sand, zircon sand or aluminum oxide.
在一實施例中，碳化矽粉的碳化矽含量至少大於或等於85%。以所述主原料為總重量計，所述碳化矽粉的含量為10重量%至30重量%，且所述碳化矽粉的平均粒徑為20目至200目。值得注意的是，所述碳化矽粉可增加熱傳導率，使得澆鑄時燃燒快速且熱量均勻分布至整個冒口，進而達到充分補縮的功效，同時也由於碳化矽的材料特性，例如其可耐熱2730℃，硬度為25-30HRC，熱傳導係數800/mK以及熱膨脹係數4.13x10 -6K -1。 In one embodiment, the niobium carbide powder has a niobium carbide content of at least greater than or equal to 85%. The content of the niobium carbide powder is 10% by weight to 30% by weight based on the total of the main raw materials, and the niobium tantalum powder has an average particle diameter of 20 mesh to 200 mesh. It is worth noting that the tantalum carbide powder can increase the thermal conductivity, so that the combustion is rapid and the heat is evenly distributed to the entire riser during casting, thereby achieving the effect of sufficient shrinkage, and also due to the material properties of the tantalum carbide, such as its heat resistance. 2730 ° C, hardness of 25-30HRC, thermal conductivity of 800 / mK and thermal expansion coefficient of 4.13x10 -6 K -1 .
為了在製造冒口保溫套的過程中，固化冒口保溫套的材料，使得所形成的冒口保溫套具有一定的形狀，所述冒口保溫套的材料還包括粘結劑。在一實施例中，粘結劑可例如是甲醇、水、糠醇、尿素甲醛樹脂（其有效成分大於或等於30%）、液體酚醛樹脂（其有效成分大於或等於50%）以及偶聯劑（其可以是含量大於或等於98%的C 8H 22N 2O 2Si）。需注意的是，本實施例以所述尿素甲醛樹脂與所述液體酚醛樹脂當作粘結劑。由於鋁並不耐酸、鹼，而環氧樹脂需以鹼製作（作為固化劑）同時其過程是放熱反應，因此並無法適用於本發明。也就是說，本實施例所述粘結劑實際上是在中性環境製備，因此無須以鹼作為固化劑，而無損害冒口保溫套主成分（鋁）的可能性，同時也避免在製備過程中發熱。在一實施例中，以所述粘結劑為總重量計，其中所述甲醇的含量為10重量%至40重量%，所述水的含量為5重量%至35重量%，所述糠醇的含量為10重量%至30重量%，所述尿素甲醛樹脂的含量為10重量%至30重量%，所述液體酚醛樹脂的含量為20重量%至40重量%，所述偶聯劑的含量為0.1重量%至5重量%。此外，所述粘結劑還包括醋酸，以調整pH值為7.5至8.5之間。上述有效成分是指所述材料的純度，也就是將其以110℃進行烘乾後所剩下的比例。 In order to cure the material of the riser sleeve during the manufacture of the riser sleeve, the formed riser sleeve has a certain shape, and the material of the riser sleeve further includes an adhesive. In an embodiment, the binder may be, for example, methanol, water, decyl alcohol, urea formaldehyde resin (having an active ingredient of 30% or more), liquid phenolic resin (having an active ingredient of 50% or more), and a coupling agent ( It may be C 8 H 22 N 2 O 2 Si) in an amount of greater than or equal to 98%. It should be noted that in this embodiment, the urea formaldehyde resin and the liquid phenolic resin are used as a binder. Since aluminum is not resistant to acids and bases, and epoxy resins are required to be made of a base (as a curing agent) and the process thereof is an exothermic reaction, it is not suitable for use in the present invention. That is to say, the binder described in this embodiment is actually prepared in a neutral environment, so that it is not necessary to use alkali as a curing agent without impairing the possibility of the main component (aluminum) of the riser sleeve, and also avoiding preparation. It is hot during the process. In one embodiment, based on the total weight of the binder, wherein the content of the methanol is 10% by weight to 40% by weight, and the content of the water is 5% by weight to 35% by weight, the sterol The content is 10% by weight to 30% by weight, the content of the urea-formaldehyde resin is 10% by weight to 30% by weight, the content of the liquid phenolic resin is 20% by weight to 40% by weight, and the content of the coupling agent is 0.1% by weight to 5% by weight. Further, the binder further includes acetic acid to adjust the pH to between 7.5 and 8.5. The above active ingredient means the purity of the material, that is, the ratio remaining after drying it at 110 °C.
所述冒口保溫套的材料可用以製造具有高效與高發熱的冒口保溫套，以下將針對冒口保溫套的製造方法來進行說明。圖1是依照本發明之一實施例的冒口保溫套的製造步驟流程圖。The material of the riser sleeve can be used to manufacture a riser sleeve with high efficiency and high heat generation, which will be described below for the manufacturing method of the riser sleeve. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a flow chart showing the steps of manufacturing a riser sleeve in accordance with an embodiment of the present invention.
請參照圖1，本實施例提供一種高發熱冒口保溫套的製造方法100，其步驟如下。首先，進行步驟102，提供主原料。所述主原料包括多種鋁粉、氧化劑、氧化促進劑、保溫材料、發熱材料以及碳化矽粉。在一實施例中，所述鋁粉包括第一鋁粉、第二鋁粉以及第三鋁粉。氧化劑可包括氧化鐵、鐵的氧化物、硝酸鈉、硝酸鹽類以及二氧化錳、錳的氧化物。氧化促進劑包括冰晶石粉。保溫材料包括漂珠。發熱材料包括金屬矽粉。耐熱材料包括碳化矽。在一實施例中，混合所述主原料的步驟如下所述。將所述鋁粉、氧化鐵、二氧化錳、漂珠、金屬矽粉以及碳化矽粉混合，並持續攪拌1分鐘至5分鐘，以形成第一混合物。接著，將硝酸鈉加入所述第一混合物中，以形成第二混合物。之後，將冰晶石粉加入所述第二混合物中，並持續攪拌15分鐘至20分鐘，以形成第三混合物。此時，所述第三混合物中的鋁含量可介於15%至24%之間。由於鋁粉、氧化鐵、二氧化錳、漂珠、金屬矽粉、碳化矽粉、硝酸鈉以及冰晶石粉的含量與性質已於上述段落詳細說明，於此便不再贅述。Referring to FIG. 1 , the embodiment provides a method 100 for manufacturing a high-heat riser insulation sleeve, the steps of which are as follows. First, step 102 is performed to provide the main raw material. The main raw material includes a plurality of aluminum powders, an oxidizing agent, an oxidation promoter, a heat insulating material, a heat generating material, and a tantalum carbide powder. In an embodiment, the aluminum powder comprises a first aluminum powder, a second aluminum powder, and a third aluminum powder. The oxidizing agent may include iron oxide, iron oxide, sodium nitrate, nitrates, and oxides of manganese dioxide and manganese. The oxidation promoter includes cryolite powder. Insulation materials include floating beads. The heating material includes metal tantalum powder. The heat resistant material includes tantalum carbide. In one embodiment, the step of mixing the primary materials is as follows. The aluminum powder, iron oxide, manganese dioxide, floating beads, metal cerium powder, and cerium carbide powder are mixed and continuously stirred for 1 minute to 5 minutes to form a first mixture. Next, sodium nitrate is added to the first mixture to form a second mixture. Thereafter, the cryolite powder is added to the second mixture and stirring is continued for 15 minutes to 20 minutes to form a third mixture. At this time, the aluminum content in the third mixture may be between 15% and 24%. Since the contents and properties of aluminum powder, iron oxide, manganese dioxide, floating beads, metal tantalum powder, tantalum carbide powder, sodium nitrate and cryolite powder have been described in detail in the above paragraphs, they will not be described again.
在替代實施例中，混合所述主原料的步驟亦可將鋁粉、氧化鐵、二氧化錳、漂珠、金屬矽粉、碳化矽粉、硝酸鈉以及冰晶石粉一起倒入攪拌機中混合均勻，其中由於鋁和氧化劑在製備過程中可能發生危險（***），因此過程中需先將鋁與其他材料混合，而後才再加入硝酸鈉及冰晶石粉。In an alternative embodiment, the step of mixing the main raw materials may also mix aluminum powder, iron oxide, manganese dioxide, floating beads, metal tantalum powder, tantalum carbide powder, sodium nitrate and cryolite powder into a mixer and mix well. Since aluminum and oxidants may be dangerous (explosion) during the preparation process, aluminum must be mixed with other materials before adding sodium nitrate and cryolite powder.
接著，進行步驟104，提供粘結劑。所述粘結劑包括甲醇、水、糠醇、尿素甲醛樹脂、液體酚醛樹脂以及偶聯劑。在一實施例中，混合所述粘結劑的步驟如下所述。將所述甲醇與所述水混合，以形成混合物A。接著，將所述糠醇加入所述混合物A中，並使用攪拌機緩慢攪拌（其轉速為5 Hz -15 Hz），以形成混合物B。之後，將所述液體酚醛樹脂加入所述混合物B中，以形成混合物C。然後，將所述尿素甲醛樹脂加入所述混合物C中，以形成混合物D。接著，將所述偶聯劑加入所述混合物D中並持續攪拌10分鐘至20分鐘，以形成混合物E。之後，將醋酸（或以有機酸代替，例如檸檬酸，不可為無機酸）加入所述混合物E中，並持續攪拌10分鐘至20分鐘，使得pH值介於7.5至8.5之間，以形成混合物F。由於甲醇、水、糠醇、尿素甲醛樹脂、液體酚醛樹脂以及偶聯劑的含量與性質已於上述段落詳細說明，於此便不再贅述。Next, step 104 is performed to provide a binder. The binder includes methanol, water, decyl alcohol, urea formaldehyde resin, liquid phenolic resin, and a coupling agent. In one embodiment, the step of mixing the binder is as follows. The methanol is mixed with the water to form a mixture A. Next, the sterol was added to the mixture A, and slowly stirred using a stirrer (rotating speed of 5 Hz - 15 Hz) to form a mixture B. Thereafter, the liquid phenolic resin is added to the mixture B to form a mixture C. The urea formaldehyde resin is then added to the mixture C to form a mixture D. Next, the coupling agent is added to the mixture D and stirring is continued for 10 minutes to 20 minutes to form a mixture E. Thereafter, acetic acid (or an organic acid instead, such as citric acid, not a mineral acid) is added to the mixture E and stirring is continued for 10 minutes to 20 minutes to bring the pH between 7.5 and 8.5 to form a mixture. F. Since the contents and properties of methanol, water, decyl alcohol, urea formaldehyde resin, liquid phenolic resin, and coupling agent have been described in detail in the above paragraphs, they will not be described again.
在替代實施例中，混合所述粘結劑的步驟亦可將甲醇、水、糠醇、尿素甲醛樹脂、液體酚醛樹脂以及偶聯劑一起倒入攪拌機中混合均勻，其中純水與酚醛樹脂或木精與尿素甲醛樹脂均會導致原料敗壞，因此需先將純水、木精與糠醇先行加在一起。In an alternative embodiment, the step of mixing the binder may also be carried out by mixing methanol, water, decyl alcohol, urea formaldehyde resin, liquid phenolic resin and a coupling agent into a mixer, wherein pure water is mixed with phenolic resin or wood. Both fine and urea-formaldehyde resins can cause the raw materials to be damaged. Therefore, it is necessary to add pure water, wood essence and sterol first.
另外，雖然上述說明是先提供主原料（即步驟102）之後，再提供粘結劑（即步驟104）。但本發明不以此為限，在其他實施例中，亦可先進行步驟104之後，再進行步驟102。Additionally, while the above description is provided after the primary material (i.e., step 102) is provided, the binder is provided (i.e., step 104). However, the present invention is not limited thereto. In other embodiments, step 104 may be performed first, and then step 102 is performed.
之後，進行步驟106，混合所述主原料與所述粘結劑。具體地說，是將所述主原料（即第三混合物）與所述粘結劑（即混合物F）置入攪拌機中進行混練，以形成冒口保溫套的材料。在一實施例中，以所述冒口保溫套的材料為總重量計，其中所述主原料的含量為70重量%至95重量%，所述粘結劑的含量為5重量%至30重量%。Thereafter, in step 106, the main raw material and the binder are mixed. Specifically, the main raw material (i.e., the third mixture) and the binder (i.e., the mixture F) are placed in a mixer for kneading to form a material for the riser sleeve. In one embodiment, the material of the riser sleeve is the total weight, wherein the content of the main raw material is 70% by weight to 95% by weight, and the content of the binder is 5% by weight to 30% by weight. %.
然後，進行步驟108，進行射芯成型步驟。詳細地說，先將提供具有一中空模穴的模具。在一實施例中，所述模具可以是金屬模具。所述中空模穴可以是欲形成的冒口保溫套的形狀，其可依使用者需求來設計。接著，將所述冒口保溫套的材料置入射芯機中。將所述射芯成型步驟（或射芯機）的製程壓力調整為0.3 MPa至0.6 MPa，並藉由所述射芯機將所述冒口保溫套的材料射入所述中空模穴中。值得一提的是，所述射芯成型步驟的製程溫度是在常溫(10-40℃)下即能完成。也就是說，進行所述射芯成型步驟不需要加熱所述模具即可固化所述冒口保溫套的材料，以形成冒口保溫套。因此，相較於習知需加熱模具（例如是加熱至120°C至180°C，或是220°C）以固化冒口保溫套的材料的製造方法，本實施例之冒口保溫套的製造方法更為安全，不易造成工安意外。Then, step 108 is performed to perform a core molding step. In detail, a mold having a hollow cavity will be provided first. In an embodiment, the mold may be a metal mold. The hollow cavity may be in the shape of a riser sleeve to be formed, which may be designed according to user requirements. Next, the material of the riser sleeve is placed in the core machine. The process pressure of the core forming step (or core shooter) is adjusted to 0.3 MPa to 0.6 MPa, and the material of the riser sleeve is injected into the hollow cavity by the core shooting machine. It is worth mentioning that the process temperature of the core molding step can be completed at normal temperature (10-40 ° C). That is, the core forming step is performed to cure the material of the riser sleeve without heating the mold to form a riser sleeve. Therefore, the riser sleeve of the present embodiment is compared to the conventional method for manufacturing a material for heating a riser sleeve (for example, heating to 120 ° C to 180 ° C or 220 ° C). The manufacturing method is safer and less prone to accidents.
接著，進行步驟110，進行脫模步驟，以獲得冒口保溫套。由於本實施例之冒口保溫套的材料具有粘結劑，其可加速冒口保溫套的材料固化或硬化，以形成所述冒口保溫套。因此，本實施例可不需等待冒口保溫套的材料固化或硬化即可脫模。相較於習知的製造方法，本實施例之冒口保溫套的製造方法可提升產量，以節省製程時間。在一實施例中，從所述射芯成型步驟結束到進行所述脫模步驟之間的時間可例如是1分鐘至2分鐘。 Next, step 110 is performed to perform a demolding step to obtain a riser sleeve. Since the material of the riser sleeve of the embodiment has an adhesive, it can accelerate the curing or hardening of the material of the riser sleeve to form the riser sleeve. Therefore, the present embodiment can be demolded without waiting for the material of the riser sleeve to be solidified or hardened. Compared with the conventional manufacturing method, the manufacturing method of the riser sleeve of the present embodiment can increase the yield to save the processing time. In an embodiment, the time from the end of the shot forming step to the step of performing the demolding may be, for example, from 1 minute to 2 minutes.
綜上所述，本發明之冒口保溫套材料具有高效與高發熱的特性，其不僅可在澆鑄時抑制冒口處熔融金屬的散熱，還可延長冒口處熔融金屬的凝固時間，進而提高冒口對鑄件的補縮率。另外，本發明之冒口保溫套的材料還包括粘結劑，其可在製造冒口保溫套的過程中，固化冒口保溫套的材料。因此，本發明毋須加熱模具即可固化冒口保溫套的材料，且不需要等待冒口保溫套的材料硬化即可進行脫模步驟，進而提升製程的安全性以及冒口保溫套的產量。 In summary, the riser insulation material of the present invention has the characteristics of high efficiency and high heat generation, and can not only suppress the heat dissipation of the molten metal at the riser during casting, but also prolong the solidification time of the molten metal at the riser, thereby improving The feeding rate of the riser to the casting. In addition, the material of the riser sleeve of the present invention further comprises an adhesive which cures the material of the riser sleeve during the manufacture of the riser sleeve. Therefore, the present invention can cure the material of the riser sleeve without heating the mold, and can perform the demoulding step without waiting for the material of the riser sleeve to harden, thereby improving the safety of the process and the output of the riser sleeve.
此外，本發明之冒口保溫套的材料亦包括碳化矽粉，其可增加熱傳導率，使得澆鑄時燃燒快速且熱量均勻分布至整個冒口，進而達到充分補縮的功效。 In addition, the material of the riser sleeve of the present invention also includes tantalum carbide powder, which can increase the thermal conductivity, so that the burning is rapid and the heat is evenly distributed to the entire riser during casting, thereby achieving the effect of sufficient feeding.
雖然本發明已以實施例揭露如上，然其並非用以限定本發明，任何所屬技術領域中具有通常知識者，在不脫離本發明的精神和範圍內，當可作些許的更動與潤飾，故本發明的保護範圍當視後附的申請專利範圍所界定者為準。 Although the present invention has been disclosed in the above embodiments, it is not intended to limit the present invention, and any one of ordinary skill in the art can make some changes and refinements without departing from the spirit and scope of the present invention. The scope of the invention is defined by the scope of the appended claims.
100‧‧‧製造方法 100‧‧‧Manufacture method
102、104、106、108、110‧‧‧步驟 102, 104, 106, 108, 110‧ ‧ steps
圖1是依照本發明之一實施例的高發熱冒口保溫套的製造步驟流程圖。BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a flow chart showing the steps of manufacturing a high heat riser thermal insulation jacket in accordance with an embodiment of the present invention.
100‧‧‧製造方法 100‧‧‧Manufacture method
102、104、106、108、110‧‧‧步驟 102, 104, 106, 108, 110‧ ‧ steps
Claims (10)
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| CN111889629A (en) * | 2020-08-14 | 2020-11-06 | 欧区爱铸造材料（中国）有限公司 | Fluorine-free efficient exothermic agent for heating casting riser |
| CN113084078A (en) * | 2021-03-19 | 2021-07-09 | 维苏威铸造科技(江苏)有限公司 | High ventilative heat preservation rising head |
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| WO2001039911A2 (en) * | 1999-12-02 | 2001-06-07 | Foseco International Limited | Binder compositions for bonding particulate material |
| CN103551512A (en) * | 2013-11-15 | 2014-02-05 | 哈尔滨理工大学 | Exothermic insulating riser sleeve and preparation method thereof |
| CN103624214A (en) * | 2012-08-25 | 2014-03-12 | 天津湶钰冒口有限公司 | One-time forming manufacturing technology for internal heat riser |
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| EP0695229B1 (en) * | 1993-04-22 | 2000-01-26 | Foseco International Limited | A mould and a method for the casting of metals and refractory exothermic compositions for use therein |
| TW418129B (en) * | 1998-10-09 | 2001-01-11 | Masamitsu Miki | Foundry exothermic assembly |
| WO2001039911A2 (en) * | 1999-12-02 | 2001-06-07 | Foseco International Limited | Binder compositions for bonding particulate material |
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| CN103551512A (en) * | 2013-11-15 | 2014-02-05 | 哈尔滨理工大学 | Exothermic insulating riser sleeve and preparation method thereof |
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| CN113084078A (en) * | 2021-03-19 | 2021-07-09 | 维苏威铸造科技(江苏)有限公司 | High ventilative heat preservation rising head |
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| TW201821180A (en) | 2018-06-16 |
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