CN109093061B - Ceramsite sand and preparation method thereof, cold-box sand and solidification process thereof - Google Patents
Ceramsite sand and preparation method thereof, cold-box sand and solidification process thereof Download PDFInfo
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- CN109093061B CN109093061B CN201811099626.7A CN201811099626A CN109093061B CN 109093061 B CN109093061 B CN 109093061B CN 201811099626 A CN201811099626 A CN 201811099626A CN 109093061 B CN109093061 B CN 109093061B
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- B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract
A kind of ceramsite sand and its preparation method relates to the field of casting material, it is first granulated with pottery powder to form a pellet-shaped semi-finished product, then the pellet-shaped semi-finished product is covered with aluminum powder, and then sintered to form. The coated aluminum powder can generate an aluminum oxide film on the surface of the ceramsite sand after sintering, and the aluminum oxide film not only ensures the roundness and the fluidity of the ceramsite sand, but also improves the fire resistance of the ceramsite sand. Meanwhile, when the cold core box sand is prepared, the film can reduce the surface roughness of the ceramsite sand, so that the coating property of the resin is improved, and the strength of a bonding bridge is increased. The ceramsite sand has the characteristics of wide sources and simple preparation, has high refractoriness, low thermal expansion, good angle coefficient and the like, and is an ideal material for preparing cold box sand. The cold-box sand comprises the ceramsite sand, the bonding performance of the ceramsite sand and an adhesive is good, and a sand core prepared by curing the ceramsite sand is high in strength, good in heat resistance and good in sintering performance.
Description
Technical Field
The invention relates to the field of casting materials, in particular to ceramsite sand and a preparation method thereof, cold-box sand and a curing process thereof.
Background
The cold-box sand is a material for manufacturing a mold core in casting production, has good fluidity and filling property, and has wide application range. The cold-box sand is generally composed of refractory materials and a binder, and the refractory materials at present are mainly quartz sand, non-quartz sand, artificial sand and the like. Wherein the quartz sand is mainly silica sand; the non-quartz sand is divided into magnesia, olivine sand, chromite sand, zircon sand and the like; the artificial sand is mainly the precious pearl sand.
However, with the rapid development of the foundry industry, people have higher and higher requirements on foundry materials, and some defects of the sand for traditional cold box sand casting become more and more prominent. The quartz silica sand has the defects of low refractoriness, large thermal expansion, large angular coefficient and poor fluidity, and causes the defects of sand sticking, vein, deformation, cracking and the like of a casting. And non-quartz sand (magnesia, olivine sand, chromite sand, zircon sand) and the like have high comprehensive performance, but have scarce resources and high price. And because the mechanical crushing is adopted in the production process, the high angle coefficient consumes a large amount of adhesive. Although the artificial gem sand is superior in performance, the problems of difficult obtainment of raw materials, complex preparation process, high energy consumption, high production cost, easy reaction between iron-containing substances contained in the gem sand and castings and the like still exist because of the environmental protection problem. Therefore, there is an urgent need for new materials that can be used to prepare cold box sands to solve the above problems.
Disclosure of Invention
The first purpose of the invention is to provide ceramsite sand and a preparation method thereof, wherein the ceramsite sand has the characteristics of wide sources, simple preparation, high refractoriness, low thermal expansion, good angle coefficient and the like, and is an ideal material for preparing cold box sand.
The second purpose of the invention is to provide cold-box sand and a curing process thereof, wherein the cold-box sand comprises the ceramsite sand, and a sand core prepared by curing the ceramsite sand has high strength, good heat resistance and good sintering performance.
The embodiment of the invention is realized by the following steps:
a method of preparing ceramsite sand, comprising:
granulating the ceramic powder to form a spherical semi-finished product; coating aluminum powder on the surface of the spherical semi-finished product; and sintering and forming the spherical semi-finished product coated with the aluminum powder.
Ceramsite sand is prepared by the preparation method of the ceramsite sand.
The cold-box sand comprises the ceramsite sand.
The solidification process of the cold-box sand comprises the following steps:
triethylamine gas is filled into the cold-box sand to solidify the cold-box sand; preferably, the temperature of the triethylamine gas is 110-150 ℃.
The embodiment of the invention has the beneficial effects that:
the embodiment of the invention provides ceramsite sand and a preparation method thereof. The coated aluminum powder can generate an aluminum oxide film on the surface of the ceramsite sand after sintering, and the aluminum oxide film not only ensures the roundness and the fluidity of the ceramsite sand, but also improves the fire resistance of the ceramsite sand. Meanwhile, when the cold core box sand is prepared, the film can reduce the surface roughness of the ceramsite sand, so that the coating property of the resin is improved, and the strength of a bonding bridge is increased. The ceramsite sand has the characteristics of wide sources and simple preparation, has high refractoriness, low thermal expansion, good angle coefficient and the like, and is an ideal material for preparing cold box sand.
The embodiment of the invention also provides cold-box sand and a curing process thereof, wherein the cold-box sand comprises the ceramsite sand, the bonding performance of the ceramsite sand and an adhesive is good, and a sand core prepared by curing the ceramsite sand is high in strength, good in heat resistance and good in sintering performance.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the embodiments will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present invention and therefore should not be considered as limiting the scope, and for those skilled in the art, other related drawings can be obtained according to the drawings without inventive efforts.
Fig. 1 is a diagram of a real object of ceramsite sand provided by an embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below. The examples, in which specific conditions are not specified, were conducted under conventional conditions or conditions recommended by the manufacturer. The reagents or instruments used are not indicated by the manufacturer, and are all conventional products available commercially.
The following describes the ceramsite sand and the preparation method thereof, the cold-box sand and the solidification process thereof according to the embodiment of the invention.
The embodiment of the invention provides a preparation method of ceramsite sand, which comprises the following steps:
s1, granulating ceramic powder to form a spherical semi-finished product;
s2, coating aluminum powder on the surface of the spherical semi-finished product;
and S3, sintering and forming the spherical semi-finished product coated with the aluminum powder.
Among them, the ceramic powder is widely available, and the material thereof may be a material for preparing ceramics well known in the art. For example, the raw material of the ceramic powder includes at least one of clay, slate, shale, coal gangue, and industrial solid waste. In addition, aluminum powder and quartz powder can be used as additives to adjust the content of aluminum and silicon in the raw materials.
Preferably, the particle size of the ceramic powder adopted in the embodiment of the invention is less than 800 meshes. In the actual production process, the raw materials need to be sorted and crushed firstly, and then the raw materials and auxiliary materials are mixed according to the required silicon-aluminum content requirement. And grinding the prepared raw materials, preferably adopting closed-circuit superfine grinding to obtain the ceramic powder with the required granularity.
In the embodiment of the invention, ceramic powder is added into a disc granulator for spray granulation, after a spherical semi-finished product is formed, dry aluminum powder is scattered into the disc granulator, and the mixture is continuously stirred for 1-5 min, so that the surface of the spherical semi-finished product is coated with the aluminum powder. Wherein the particle size of the aluminum powder is less than 1000 meshes. The aluminum powder with the particle size is matched with the particle size of the ceramic powder raw material, so that the surface of the spherical semi-finished product can be better and more uniformly covered.
The sintering and forming of the spherical semi-finished product coated with the aluminum powder can be performed by referring to the sintering method in the prior art, which will not be described herein. And after sintering, screening the prepared ceramsite sand, and subpackaging and warehousing the ceramsite sand according to the particle size for later use.
The technical characteristic of covering the surface of the spherical semi-finished product with the aluminum powder adopted by the embodiment of the invention can achieve the following effects: firstly, for the spherical semi-finished product, the surface is moist and easy to stick to each other, and the spherical semi-finished product can be sintered together during firing, so that the roundness and the fluidity of the ceramsite are reduced, and after the spherical semi-finished product is coated by aluminum powder, the problem that the spherical semi-finished product sticks to each other can be effectively avoided, and the roundness and the fluidity of the ceramsite sand are improved; secondly, in the firing process, the aluminum powder can be oxidized into aluminum oxide with high refractoriness to be coated on the surface of the ceramsite, so that the refractoriness of the ceramsite is further improved; finally, the alumina film on the surface of the ceramsite sand can fill and level the 'pits' on the surface of the spherical semi-finished product, so that the surface roughness of the ceramsite sand is reduced, the ceramsite sand can be better coated by resin when the cold core box sand is prepared, and the strength of a bonding bridge is increased.
The embodiment of the invention also provides ceramsite sand which is prepared by the preparation method of the ceramsite sand.
The main chemical components of the ceramsite sand comprise aluminum oxide, silicon oxide, iron oxide, titanium dioxide and the like. Among them, the higher the alumina content, the higher the refractoriness of the ceramsite sand, but accordingly, the higher the raw material cost. In the embodiment of the invention, the content of the alumina in the ceramsite sand is 50-60 wt%.
The content of the silicon dioxide is not too high, the thermal expansion rate of the ceramsite sand can be increased when the phase of the excessive silicon dioxide is changed, and in the embodiment of the invention, the content of the silicon oxide in the ceramsite sand is less than or equal to 30 wt%.
The higher the content of the iron oxide is, the lower the refractoriness of the ceramsite sand is, and in the embodiment of the invention, the content of the iron oxide is controlled to be less than or equal to 3.0 percent.
The titanium dioxide has no obvious influence on the performance of the ceramsite sand, but the embodiment of the invention still controls the content of the titanium dioxide to be less than or equal to 2.0 percent in consideration of the overall performance of the ceramsite sand.
The chemical composition of the ceramsite sand can be adjusted in the raw material preparation stage, and the required chemical composition indexes can be achieved by changing the combination ratio of different raw materials.
The ceramsite sand prepared by the preparation method provided by the embodiment of the invention has the angle coefficient of 1.00-1.10, is basically close to a circle, has a smaller specific surface area under the same weight condition, and has stronger fluidity and air permeability compared with silica sand. When the cold-box sand is prepared, the resin film among the ceramsite sand particles is thicker and the coating effect of the resin is better due to the same addition of the resin, so that the bonding strength is higher.
Meanwhile, the refractoriness of the ceramsite sand reaches 1800-1900 ℃, and the thermal expansion coefficient is 4 × 10-6～6×10-6℃-1. Compared with the traditional material, the material has better heat resistance. The cold core box sand prepared by the method has low thermal expansion performance, high refractoriness, and excellent metal penetration resistance and sand adhesion resistance. The produced casting is smooth and clean without sand sticking defects, the size precision is good, the sand mold collapsibility of the cold core box is good, and the casting is easy to clean.
In terms of economic benefit, the ceramsite sand provided by the embodiment of the invention has the bulk density of 1.40-1.65g/cm3In contrast, the packing density of Baozhu sand was 2.0g/cm3The packing density of the ceramsite sand was about 25% less. That is to say, under the condition that the volume of the sand core is fixed, the using amount of the ceramsite sand can be saved by 25%, the cost of each ton of the ceramsite sand is calculated according to 4000 yuan, and 1000 yuan/ton can be directly saved. In addition, the cost is saved, the quality of the casting can achieve the same effect or even better, and therefore the ceramsite sand disclosed by the embodiment of the invention has better economic benefit and quality improvement. In addition, the ceramsite sand has wide raw material sources, can be selected from auxiliary emissions such as metallurgy, refractory materials, mines and the like, and can be repeatedly regenerated and recycled after being used due to good compactness and high strength of the ceramsite sand in the ceramsite cold box, so that the emission of dust and waste in the casting process is avoided, and the ceramsite sand can contribute to environmental protection and resource saving while realizing economic benefits.
Further, the embodiment of the invention also provides cold-box sand which comprises the ceramsite sand. Preferably, the cold-box sand comprises, in parts by weight:
80-120 parts of ceramsite sand, 5-10 parts of ferroferric oxide particles, 0.1-2 parts of zeolite powder and 1-4 parts of organic resin; wherein the organic resin comprises phenolic resin and polyisocyanate; the mass ratio of the phenolic resin to the polyisocyanate is 50-60: 40-60.
When the sand core is used, H, O elements are released in the process of molten iron solidification, the solubility of the elements is reduced due to the temperature reduction of molten metal, if the elements cannot be removed, hydrogen holes can be formed in a steel casting to cause scrapping, and by adding the ferroferric oxide, reduction reaction can be carried out with reducing gas H to avoid the generation of the hydrogen holes. Secondly, a certain amount of ferroferric oxide is added into the sand core, so that heat transfer can be accelerated, molten metal on the wall surface of the sand core can be rapidly cooled, and the sand sticking tendency is reduced.
The cold box sand contains organic resin, the pouring temperature of the ferrous metal liquid exceeds 1350 ℃, and the organic resin can be combusted at the high temperature to generate gas which is not beneficial to the harm of the casting. The zeolite powder has a special porous structure, can better absorb the gas, thereby reducing the defect of casting pores, and can absorb peculiar smell, thereby being beneficial to improving the workshop environment.
When the cold core box sand is actually prepared, the ceramsite sand, the ferroferric oxide particles, the zeolite powder and the organic resin are only required to be mixed and stirred uniformly for sealing and storage, and the mixture is used for subsequent core making and pouring. When the mixture is mixed, the temperature is particularly important to be controlled, if the temperature is too high, the ceramsite sand and the resin are slowly cured after being uniformly mixed, and the service time of core making is influenced (the mixture cannot be used because the curing is started when the core making is not finished); if the temperature is too low, the viscosity of the resin is too thick, the uniformity of sand mixing is reduced, and the strength of the prepared sand core is influenced. Preferably, the temperature is 20-40 ℃ during mixing.
Preferably, in the embodiment of the invention, the granularity of the ceramsite sand is 30-270 meshes; the particle size of the ferroferric oxide particles is 30-270 meshes; the zeolite powder has a particle size of 100-500 meshes. The three kinds of granules are matched according to the particle sizes, so that the mixing effect with the organic resin is better, and better uniformity can be obtained.
The embodiment of the invention also provides a curing process of the cold-box sand, which comprises the following steps:
and filling triethylamine gas into the cold-box sand to solidify the cold-box sand. Preferably, the temperature of the triethylamine gas is 110-150 ℃. Because the ceramsite sand has a heat storage effect, when the sand core is prepared, the heat transfer from the surface layer to the inner layer is slow, so that the curing effect is reduced, and therefore, the temperature of the triethylamine gas adopted in the embodiment of the invention is higher than that (100 ℃) in the traditional process.
The features and properties of the present invention are described in further detail below with reference to examples.
Example 1
This example provides a ceramsite sand comprising clay, slate, shale, and industrial solid waste, aluminum powder and quartz powder as additives. The preparation method comprises the following steps:
s1, sorting and crushing the raw materials, and grinding the raw materials into 600-800-mesh ceramic powder;
s2, adding the ceramic powder into a disc granulator for spray granulation, after a spherical semi-finished product is formed, scattering dry aluminum powder into the disc granulator, and continuing stirring for 1min to coat the surface of the spherical semi-finished product with the aluminum powder. Wherein the particle size of the aluminum powder is 800-1000 meshes.
S3, sintering and forming the spherical semi-finished product wrapped with the aluminum powder at 1800 ℃.
Example 2
This example provides a ceramsite sand, which comprises clay, shale, coal gangue, industrial solid waste, aluminum powder and quartz powder as additives. The preparation method comprises the following steps:
s1, sorting and crushing the raw materials, and grinding the raw materials into 500-600-mesh ceramic powder;
s2, adding the ceramic powder into a disc granulator for spray granulation, after a spherical semi-finished product is formed, scattering dry aluminum powder into the disc granulator, and continuing stirring for 5min to enable the surface of the spherical semi-finished product to be coated with the aluminum powder. Wherein the particle size of the aluminum powder is 600-700 meshes.
And S3, sintering and forming the spherical semi-finished product wrapped with the aluminum powder at 1600 ℃.
Example 3
This example provides a ceramsite sand, which comprises clay, slate, coal gangue, and industrial solid waste, aluminum powder and quartz powder as additives. The preparation method comprises the following steps:
s1, sorting and crushing the raw materials, and grinding the raw materials into 600-800-mesh ceramic powder;
and S2, adding the ceramic powder into a disc granulator for spray granulation, after a spherical semi-finished product is formed, scattering dry aluminum powder into the disc granulator, and continuing stirring for 3min to coat the surface of the spherical semi-finished product with the aluminum powder. Wherein the particle size of the aluminum powder is 700-900 meshes.
And S3, sintering and forming the spherical semi-finished product wrapped with the aluminum powder at 1700 ℃.
Example 4
The embodiment provides cold core box sand which comprises the following raw materials in parts by weight:
80 parts of ceramsite sand, 10 parts of ferroferric oxide particles, 0.1 part of zeolite powder, 0.5 part of phenolic resin and 0.5 part of polyisocyanate.
Wherein the ceramsite sand prepared in the embodiment 1 is 30-80 meshes in granularity; the particle size of the ferroferric oxide particles is 30-80 meshes; the particle size of the zeolite powder is 100-150 meshes.
The preparation method comprises the following steps:
fully and uniformly stirring the ceramsite sand, the ferroferric oxide particles, the zeolite powder, the phenolic resin and the polyisocyanate at the temperature of 20 ℃, and then sealing and storing.
Example 5
The embodiment provides cold core box sand which comprises the following raw materials in parts by weight:
120 parts of ceramsite sand, 5 parts of ferroferric oxide particles, 2 parts of zeolite powder, 1 part of phenolic resin and 1.1 parts of polyisocyanate.
Wherein the ceramsite sand prepared in the embodiment 2 is 100-180 meshes in granularity; the particle size of the ferroferric oxide particles is 100-180 meshes; the particle size of the zeolite powder is 150-200 meshes.
The preparation method comprises the following steps:
fully and uniformly stirring the ceramsite sand, the ferroferric oxide particles, the zeolite powder, the phenolic resin and the polyisocyanate at 40 ℃, and then sealing and storing.
Example 6
The embodiment provides cold core box sand which comprises the following raw materials in parts by weight:
100 parts of ceramsite sand, 8 parts of ferroferric oxide particles, 1 part of zeolite powder, 1.9 parts of phenolic resin and 2.1 parts of polyisocyanate.
Wherein, the ceramsite sand prepared in the embodiment 3 is 220-270 meshes in granularity; the particle size of the ferroferric oxide particles is 220-270 meshes; the particle size of the zeolite powder is 250-300 meshes.
The preparation method comprises the following steps:
fully and uniformly stirring the ceramsite sand, the ferroferric oxide particles, the zeolite powder, the phenolic resin and the polyisocyanate at 40 ℃, and then sealing and storing.
Example 7
The embodiment provides a curing process of cold-box sand, which comprises the following steps:
and filling the cold-box sand prepared in the embodiment 4 with triethylamine at 150 ℃ to catalyze the cold-box sand to be solidified, so as to obtain the sand core.
Example 8
The embodiment provides a curing process of cold-box sand, which comprises the following steps:
and filling the cold-box sand prepared in the example 5 with triethylamine at 110 ℃ to catalyze the cold-box sand to be solidified, thereby obtaining the sand core.
Example 9
The embodiment provides a curing process of cold-box sand, which comprises the following steps:
and filling the cold-box sand prepared in the embodiment 6 with triethylamine at 130 ℃ to catalyze the cold-box sand to be solidified, so as to obtain the sand core.
Test example 1
Various performance parameters of the ceramsite sand prepared in examples 1-3 were tested, and the test results are shown in table 1.
TABLE 1 ceramsite sand Performance test results
As can be seen from Table 1, the ceramsite sand prepared in the embodiments 1 to 3 of the invention has the angle coefficient of 1.00 to 1.10, the refractoriness of 1800 to 1900 ℃, and the bulk density of 1.45 to 1.55g/cm3Coefficient of thermal expansion of 4 × 10-6～6×10-6℃-1. Has better fluidity and heat resistance, and is an ideal material for preparing the cold core box sand.
Test example 2
The sand cores prepared in examples 7-9 were used, and the correlation properties were measured according to the national standard GB/T8583-2008, and the common sand core and the baozhu sand core in the prior art were compared, and the measurement results are shown in table 2.
TABLE 2 ceramsite sand Performance test results
As can be seen from table 2, the sand core made of the ceramsite sand provided by the embodiment of the present invention is equivalent to the sand core of baozhu sand in terms of strength, heat resistance and sintering property, and is significantly superior to the common silica sand core, and can be completely used as a substitute product of the sand core of baozhu sand. Meanwhile, compared with the baozhu sand, the haozhu sand has the advantages of wide source, simple preparation, low production cost and higher economic value.
In summary, the embodiments of the present invention provide a ceramsite sand and a preparation method thereof, wherein a granular semifinished product is formed by granulating ceramic powder, and then the surface of the granular semifinished product is coated with aluminum powder, and then sintering and forming are performed. The coated aluminum powder can generate an aluminum oxide film on the surface of the ceramsite sand after sintering, and the aluminum oxide film not only ensures the roundness and the fluidity of the ceramsite sand, but also improves the fire resistance of the ceramsite sand. Meanwhile, when the cold core box sand is prepared, the film can reduce the surface roughness of the ceramsite sand, so that the coating property of the resin is improved, and the strength of a bonding bridge is increased. The ceramsite sand has the characteristics of wide sources and simple preparation, has high refractoriness, low thermal expansion, good angle coefficient and the like, and is an ideal material for preparing cold box sand.
The embodiment of the invention also provides cold-box sand and a curing process thereof, wherein the cold-box sand comprises the ceramsite sand, the bonding performance of the ceramsite sand and an adhesive is good, and a sand core prepared by curing the ceramsite sand is high in strength, good in heat resistance and good in sintering performance.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (5)
1. A preparation method of ceramsite sand is characterized by comprising the following steps:
granulating the ceramic powder to form a spherical semi-finished product; coating aluminum powder on the surface of the spherical semi-finished product; sintering and molding the spherical semi-finished product coated with the aluminum powder;
the particle size of the ceramic powder is less than 600 meshes; the particle size of the aluminum powder is less than 800 meshes;
the raw material of the ceramic powder comprises at least one of clay, slate, shale, coal gangue and industrial solid waste;
the aluminum powder coating on the surface of the spherical semi-finished product comprises the following steps:
adding the ceramic powder into a disc granulator for spray granulation, after the spherical semi-finished product is formed, scattering dry aluminum powder into the disc granulator, and continuing stirring for 1-5 min to coat the surface of the spherical semi-finished product with the aluminum powder;
according to the mass percentage, the content of alumina in the ceramsite sand is 50-60%; the content of silicon oxide in the ceramsite sand is less than or equal to 30 percent; the content of ferric oxide in the ceramsite sand is less than or equal to 3.0 percent, and the content of titanium dioxide is less than or equal to 2.0 percent;
the angular coefficient of the ceramsite sand is 1.00-1.10; the refractoriness of the ceramsite sand is 1800-1900 ℃; the stacking density of the ceramsite sand is 1.40-1.60g/cm3The ceramsite sand has a thermal expansion coefficient of 4 × 10-6～6×10-6℃-1。
2. Ceramsite sand produced by the method for producing ceramsite sand according to claim 1.
3. A cold box sand comprising the ceramsite sand of claim 2.
4. The cold box sand of claim 3, comprising, in parts by weight:
80-120 parts of ceramsite sand, 5-10 parts of ferroferric oxide particles, 0.1-2 parts of zeolite powder and 1-4 parts of organic resin; wherein the organic resin comprises a phenolic resin and a polyisocyanate; the mass ratio of the phenolic resin to the polyisocyanate is 50-60: 40-60;
the granularity of the ceramsite sand is 30-270 meshes;
the particle size of the ferroferric oxide particles is 30-270 meshes;
the particle size of the zeolite powder is 100-500 meshes.
5. A process for curing using the cold-box sand of claim 3 or 4, comprising:
triethylamine gas is filled into the cold-box sand to solidify the cold-box sand; the temperature of the triethylamine gas is 110-150 ℃.
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| CN114570874B (en) * | 2022-02-28 | 2024-01-05 | 无锡锡南铸造机械股份有限公司 | Artificial sand manufacturing process, artificial sand recycling process and magnetic artificial sand |
| CN114736008B (en) * | 2022-06-13 | 2022-08-30 | 中国航发北京航空材料研究院 | High-permeability spherical ceramic granular sand for casting cores and preparation method and application thereof |
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