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現代(dai)熔(rong)(rong)模鑄(zhu)(zhu)造(zao)(zao)(zao)方(fang)法(fa)(fa)在工(gong)(gong)(gong)業(ye)(ye)生(sheng)產中得(de)到(dao)實際應用是(shi)在二十世(shi)(shi)紀四十年(nian)代(dai)。當時航空噴氣發(fa)動機(ji)的(de)(de)發(fa)展(zhan),要求制造(zao)(zao)(zao)象葉片、葉輪、噴嘴(zui)等形(xing)狀(zhuang)復(fu)雜(za),表面光(guang)潔的(de)(de)耐熱(re)合(he)金零件。由于(yu)耐熱(re)合(he)金材料(liao)難于(yu)機(ji)械(xie)加(jia)工(gong)(gong)(gong),零件形(xing)狀(zhuang)復(fu)雜(za),以致不能或難于(yu)用其它方(fang)法(fa)(fa)制造(zao)(zao)(zao),因(yin)此,需要尋找(zhao)一(yi)種新(xin)的(de)(de)精密的(de)(de)成型工(gong)(gong)(gong)藝(yi),于(yu)是(shi)借鑒古代(dai)流傳下(xia)來(lai)的(de)(de)失(shi)蠟鑄(zhu)(zhu)造(zao)(zao)(zao),經過(guo)對材料(liao)和(he)工(gong)(gong)(gong)藝(yi)的(de)(de)改(gai)進,現代(dai)熔(rong)(rong)模鑄(zhu)(zhu)造(zao)(zao)(zao)方(fang)法(fa)(fa)在古代(dai)工(gong)(gong)(gong)藝(yi)的(de)(de)基礎上獲得(de)重要的(de)(de)發(fa)展(zhan)。所以,航空工(gong)(gong)(gong)業(ye)(ye)的(de)(de)發(fa)展(zhan)推動了(le)熔(rong)(rong)模鑄(zhu)(zhu)造(zao)(zao)(zao)的(de)(de)應用,而(er)熔(rong)(rong)模鑄(zhu)(zhu)造(zao)(zao)(zao)的(de)(de)不斷改(gai)進和(he)完善,也為(wei)航空工(gong)(gong)(gong)業(ye)(ye)進一(yi)步(bu)提高(gao)性(xing)能創造(zao)(zao)(zao)了(le)有利的(de)(de)條件。 我國是(shi)于(yu)上世(shi)(shi)紀五、六十年(nian)代(dai)開始將熔(rong)(rong)模鑄(zhu)(zhu)造(zao)(zao)(zao)應用于(yu)工(gong)(gong)(gong)業(ye)(ye)生(sheng)產。其后這種的(de)(de)鑄(zhu)(zhu)造(zao)(zao)(zao)工(gong)(gong)(gong)藝(yi)得(de)到(dao)發(fa)展(zhan),相繼在航空、汽車、機(ji)床、船舶(bo)、內燃機(ji)、氣輪機(ji)、電訊(xun)儀(yi)器(qi)、武器(qi)、醫療器(qi)械(xie)以及刀具等制造(zao)(zao)(zao)工(gong)(gong)(gong)業(ye)(ye)中被(bei)廣泛采(cai)用,同時也用于(yu)工(gong)(gong)(gong)藝(yi)美術品(pin)的(de)(de)制造(zao)(zao)(zao)。
所謂(wei)熔(rong)(rong)模鑄造工(gong)藝,簡單(dan)說就是用(yong)易(yi)熔(rong)(rong)材料(liao)(例如蠟料(liao)或塑料(liao))制成(cheng)(cheng)可(ke)熔(rong)(rong)性模型(xing)(xing)(xing)(簡稱熔(rong)(rong)模或模型(xing)(xing)(xing)),在(zai)其上涂覆若干層特(te)制的耐火(huo)涂料(liao),經(jing)(jing)(jing)過(guo)干燥和(he)硬化形成(cheng)(cheng)一個整體型(xing)(xing)(xing)殼(ke)后(hou)(hou),再(zai)用(yong)蒸(zheng)汽或熱水從型(xing)(xing)(xing)殼(ke)中熔(rong)(rong)掉模型(xing)(xing)(xing),然后(hou)(hou)把型(xing)(xing)(xing)殼(ke)置于砂箱中,在(zai)其四(si)周填充(chong)干砂造型(xing)(xing)(xing),將鑄型(xing)(xing)(xing)放入(ru)焙(bei)燒爐(lu)中經(jing)(jing)(jing)過(guo)高溫焙(bei)燒(如采(cai)用(yong)高強度型(xing)(xing)(xing)殼(ke)時,可(ke)不(bu)必(bi)造型(xing)(xing)(xing)而將脫模后(hou)(hou)的型(xing)(xing)(xing)殼(ke)直接焙(bei)燒),鑄型(xing)(xing)(xing)或型(xing)(xing)(xing)殼(ke)經(jing)(jing)(jing)焙(bei)燒后(hou)(hou),于其中澆注熔(rong)(rong)融金屬而得到鑄件。
熔(rong)模(mo)鑄(zhu)(zhu)件(jian)尺寸(cun)精度較(jiao)(jiao)高(gao),一般可達CT4-6(砂型鑄(zhu)(zhu)造為(wei)CT10~13,壓鑄(zhu)(zhu)為(wei)CT5~7),當然由于熔(rong)模(mo)鑄(zhu)(zhu)造的(de)工藝過程復雜(za),影響鑄(zhu)(zhu)件(jian)尺寸(cun)精度的(de)因素較(jiao)(jiao)多,例如模(mo)料的(de)收縮、熔(rong)模(mo)的(de)變(bian)形、型殼在(zai)加熱(re)和冷卻過程中(zhong)的(de)線量變(bian)化、合金的(de)收縮率以及在(zai)凝固過程中(zhong)鑄(zhu)(zhu)件(jian)的(de)變(bian)形等(deng),所(suo)以普通熔(rong)模(mo)鑄(zhu)(zhu)件(jian)的(de)尺寸(cun)精度雖然較(jiao)(jiao)高(gao),但其一致性仍需提高(gao)(采用中(zhong)、高(gao)溫蠟料的(de)鑄(zhu)(zhu)件(jian)尺寸(cun)一致性要(yao)提高(gao)很多)。
壓(ya)制熔(rong)(rong)模(mo)時,采用型(xing)(xing)腔(qiang)表(biao)面(mian)光(guang)(guang)潔(jie)度(du)高的(de)(de)壓(ya)型(xing)(xing),因此,熔(rong)(rong)模(mo)的(de)(de)表(biao)面(mian)光(guang)(guang)潔(jie)度(du)也(ye)比較高。此外,型(xing)(xing)殼(ke)由耐(nai)高溫(wen)的(de)(de)特(te)殊粘結(jie)劑和耐(nai)火(huo)(huo)材料(liao)配制成(cheng)的(de)(de)耐(nai)火(huo)(huo)涂料(liao)涂掛在熔(rong)(rong)模(mo)上而制成(cheng),與熔(rong)(rong)融金屬直接接觸的(de)(de)型(xing)(xing)腔(qiang)內表(biao)面(mian)光(guang)(guang)潔(jie)度(du)高。所以(yi),熔(rong)(rong)模(mo)鑄(zhu)件(jian)的(de)(de)表(biao)面(mian)光(guang)(guang)潔(jie)度(du)比一般鑄(zhu)造(zao)件(jian)的(de)(de)高,一般可達(da)Ra.1.6~3.2μm。
熔(rong)(rong)模(mo)鑄造(zao)的優點就是由(you)于(yu)熔(rong)(rong)模(mo)鑄件有著很高的尺寸(cun)精(jing)度(du)和表面光(guang)(guang)潔(jie)度(du),所(suo)以可(ke)(ke)(ke)減(jian)少機械加工(gong)(gong)(gong)工(gong)(gong)(gong)作,只(zhi)是在零件上(shang)要求(qiu)較高的部位留少許加工(gong)(gong)(gong)余量即可(ke)(ke)(ke),甚至(zhi)某(mou)些鑄件只(zhi)留打(da)磨(mo)、拋(pao)光(guang)(guang)余量,不必機械加工(gong)(gong)(gong)即可(ke)(ke)(ke)使用。由(you)此可(ke)(ke)(ke)見,采用熔(rong)(rong)模(mo)鑄造(zao)方法可(ke)(ke)(ke)大量節(jie)省機床設備和加工(gong)(gong)(gong)工(gong)(gong)(gong)時,大幅度(du)節(jie)約金屬原(yuan)材(cai)料。
熔(rong)模(mo)鑄(zhu)(zhu)造(zao)方(fang)法的(de)(de)另(ling)一優點是,它可(ke)以(yi)(yi)鑄(zhu)(zhu)造(zao)各種合金(jin)的(de)(de)復(fu)雜(za)的(de)(de)鑄(zhu)(zhu)件,特別可(ke)以(yi)(yi)鑄(zhu)(zhu)造(zao)高溫合金(jin)鑄(zhu)(zhu)件。如噴氣(qi)式發(fa)動機的(de)(de)葉片(pian),其流線型外(wai)廓與冷卻用(yong)內(nei)腔,用(yong)機械(xie)加工(gong)工(gong)藝幾乎無法形成(cheng)。用(yong)熔(rong)模(mo)鑄(zhu)(zhu)造(zao)工(gong)藝生產不僅可(ke)以(yi)(yi)做到批量生產,保證了鑄(zhu)(zhu)件的(de)(de)一致性,而且避免了機械(xie)加工(gong)后殘留刀紋(wen)的(de)(de)應力集中。