JP4421466B2 - Slurry for casting mold and mold obtained using the same - Google Patents

Description

  The present invention relates to a casting mold slurry and a mold obtained using the slurry.

  As a technique for manufacturing a product that requires precision despite difficult machining, a lost wax method and a ceramic mold method, which are types of precision casting techniques, are known. In the lost wax method, a wax model having the same shape and dimensions as the casting, which is the final product, is formed, and the surface of this wax mold is coated with an investment material and hardened. The investment material in a state is fired at a high temperature to obtain a mold. The cavity in this mold has the same shape as the casting, which is the final product. Therefore, after pouring a molten metal of the required metal into this mold, it is cooled and solidified, and then released into the same shape as the wax model. Cast products are manufactured. Here, as an investment material coated on the surface of the wax mold, a fine refractory powder such as zircon flour is mixed with a binder (binding agent) such as ethyl silicate or colloidal silica (dispersion). Is used. Patent Documents 1 to 3 can be cited as techniques relating to the lost wax method.

On the other hand, in the ceramic mold method, a refractory powder slurry is poured onto a model and cured, and then the model is removed, dried and fired to produce a ceramic casting mold. Here, as the refractory powder slurry, for example, a slurry (dispersion) in which a fine refractory powder such as zircon flour is mixed with a binder (binding agent) such as ethyl silicate or colloidal silica is used. When used, it is cured by adding a gelation accelerator. As a technique relating to the lost wax method and the ceramic mold method, the technique of Patent Document 4 can be cited.
JP-A-8-66740 JP-A-8-309478 JP-A-9-155503 JP 2000-176602 A

  As the slurry for the investment material used in the lost wax method, a mixture of a fine fire-resistant aggregate such as zircon flour and a binder such as colloidal silica is used. In order to coat the wax mold surface, the slurry needs to have an appropriate fluidity. However, since the conventional refractory aggregate has an indeterminate shape, a lot of fluidity is required to give the slurry the necessary fluidity. Needed a binder. However, when a large amount of binder is used, more cracks than necessary are generated due to shrinkage caused by the curing of the binder, so careful manufacturing is necessary to produce a mold while preventing excessive cracking, and productivity is low. There was a problem in the point.

  In addition, there is a method of preventing cracking of the mold at the time of drying and shortening the drying time by coating the slurry of the investment material in the lost wax method and then sprinkling coarse refractory particles (stucco) before drying. However, there are portions where the stucco material is difficult to adhere depending on the shape of the mold, and such a portion has the same problem as the case where stucco as described above is not performed. Further, even when stucco is applied, it is required to further shorten the drying time in order to increase the productivity of the mold.

  On the other hand, in the ceramic mold method, a slurry prepared by kneading a fine refractory aggregate with a binder such as ethyl silicate and a gelling accelerator is poured onto a model and then cured. In this case as well, the conventional refractory aggregate is used. When using, a large amount of binder is required to fluidize the slurry, so large cracks due to cracks are likely to occur due to shrinkage due to curing and drying, and careful attention is required to make a good mold Was necessary.

  An object of the present invention is to suitably solve the disadvantages inherent in the conventional precision casting methods such as the lost wax method and the ceramic mold method described above as a casting method. It is an object to provide a casting mold slurry that can reduce shrinkage caused by drying and firing, and can prevent cracks generated in the mold.

  The present invention relates to a casting mold slurry containing a refractory aggregate having a sphericity of 0.9 or more and an inorganic binder. The present invention also relates to a mold obtained using the slurry, and a casting cast using the mold.

  In the lost wax method, the mold slurry of the present invention can reduce the amount of binder necessary to ensure the fluidity of the slurry by using a refractory aggregate having a sphericity of 0.9 or more, and is dry-cured. It is possible to prevent cracking of the time and shorten the drying time and increase productivity.

  On the other hand, even in the ceramic mold method, by using a spherical refractory aggregate as a filler of the refractory slurry, it is possible to give the slurry good fluidity by using a small amount of binder, and as a result. Further, shrinkage caused by drying and baking of the binder can be reduced, cracks generated in the mold can be prevented, and a good mold can be obtained.

  According to the casting mold slurry of the present invention, when used in the lost wax method, the investment slurry contains a high concentration of refractory aggregate, and therefore exhibits fluidity with a small amount of binder. Therefore, when drying the slurry, the drying time can be shortened. Since the binder content is small, shrinkage during binder drying and curing is small, and the occurrence of cracks in the mold during drying and curing can be suppressed.

  Also, when used in the ceramic mold method, since the content of the binder in the slurry is small, the shrinkage during firing is small and the occurrence of cracks in the mold can be suppressed.

  The refractory aggregate used in the present invention has a sphericity of 0.9 or more, preferably 0.95 or more, more preferably 0.98 or more, and 0.99 or more Is particularly preferred.

The sphericity is obtained by taking an image of a refractory aggregate particle with an optical microscope or a scanning electron microscope, and analyzing the obtained image (photograph) to determine the area of the particle projection cross section of the particle and the cross section of the cross section. Perimeter length is obtained, and then [circumference length (mm) of a perfect circle having the same area as the particle projected area cross section area (mm ² )] / [perimeter length of the particle projected cross section (mm)] is calculated, and an arbitrary 50 The obtained values are averaged for each refractory aggregate particle.

  The water absorption rate (% by weight) of the refractory aggregate (hereinafter referred to as spherical refractory aggregate) having a sphericity of 0.9 or more of the present invention is preferably 0.8% by weight or less, preferably 0.3% or less. Is more preferable. The water absorption rate can be measured according to the method for measuring the water absorption rate of JIS A1109 fine aggregate.

  The water absorption rate of the spherical refractory aggregate is usually low when the sand is prepared by the flame melting method, as long as it has the same sphericity as compared to the sand prepared by a firing method other than the method. Become.

  The spherical refractory aggregate of the present invention can be produced by various methods, but those produced by the flame melting method exemplified in JP-A-2004-202577 have a high sphericity and a low water absorption. Because it is particularly suitable.

The composition of the spherical refractory aggregate of the present invention is preferably composed mainly of Al ₂ O ₃ and SiO ₂ from the viewpoint of fire resistance and thermal expansion. Here, the “main component” means that Al ₂ O ₃ and SiO ₂ are contained in a total amount of 60% by weight or more in all the components of the aggregate. Furthermore, from the viewpoint of improving fire resistance, the total amount thereof is preferably 65 to 100% by weight, more preferably 80 to 100% by weight, based on the total components of the spherical refractory aggregate.

Further, Al ₂ O ₃ / SiO ₂ weight ratio in spherical refractory aggregate of the present invention is preferably 1 to 15. From the viewpoint of fire resistance and thermal expansion, 1.2 to 12 is more preferable, and 1.5 to 9 is particularly preferable.

Examples of the spherical fireproof aggregate of the present invention that can be contained as a component other than the main component include metal oxides such as MgO, Fe ₂ O ₃ , TiO ₂ , K ₂ O, and Na ₂ O. It is done. When Fe ₂ O ₃ and TiO ₂ are contained, their content is preferably 10% by weight or less. Further, the content of Fe ₂ O ₃ is preferably 10% by weight or less. When K ₂ O and Na ₂ O are contained, the total content is preferably 3% by weight or less, more preferably 2% by weight or less.

  The average particle size of the refractory aggregate particles can be determined as follows. That is, the diameter (mm) is measured when the sphericity from the particle projection cross section of the refractory aggregate particles is 1, while the major axis diameter (mm) of the refractory aggregate particles is measured when the sphericity <1. The minor axis diameter (mm) is measured to obtain (major axis diameter + minor axis diameter) / 2, and the average particle diameter (mm) is obtained by averaging the obtained values for any 100 refractory aggregate particles. ). The major axis diameter and the minor axis diameter are defined as follows. When the particle is stabilized on a plane and the projected image of the particle on the plane is sandwiched between two parallel lines, the width of the particle that minimizes the distance between the parallel lines is called the minor axis diameter. The distance when a particle is sandwiched between two parallel lines in a direction perpendicular to the line is called the major axis diameter.

The major axis diameter and minor axis diameter of the refractory aggregate particles are obtained by obtaining an image (photograph) of the particles with an optical microscope or a digital scope (for example, VH-8000 type, manufactured by Keyence Corporation). It can be obtained by image analysis. The sphericity is obtained by image analysis of the obtained image to determine the area of the particle projection cross section of the particle and the perimeter of the cross section, and then [the area of the same area as the area of the particle projection cross section (mm ² )] The circumference of the perfect circle (mm)] / [perimeter of the particle projected cross section (mm)] is calculated, and the obtained values are averaged for any 50 refractory aggregate particles.

  The particle diameter of the spherical refractory aggregate used in the present invention is preferably 5 to 50 μm in average particle diameter from the viewpoint of filling the model details and casting surface.

  In addition, the desired effect of this invention can be exhibited if the spherical fireproof aggregate of this invention is contained 50weight% or more among the fireproof aggregates contained in a fireproof mold.

  That is, if the spherical fireproof aggregate of the present invention is gradually added to the conventional fireproof aggregate, the desired effect of the present invention will be exhibited according to the amount added, and among the fireproof aggregates, When the spherical refractory aggregate of the present invention is contained in an amount of 50% by weight or more, the effect becomes more remarkable.

  The casting mold slurry of the present invention is preferably used for precision casting from the viewpoint of effectively utilizing the effects of the present invention.

  The inorganic binder used in the present invention may be any as long as it is for casting, and is appropriately selected according to the casting method. For example, “Fourth Edition Mold Casting Method 5. Precision Casting Mold” (1996) November 18th, 2009, which uses silica sol (colloidal silica) and ethyl silicate described in Japan Foundry Technology Association).

  The inorganic binder used in the present invention contains a main component such as amorphous silica ultrafine particles and ethyl silicate, a solvent such as water and alcohol, and, if necessary, a surfactant and a gelation accelerator (an acid catalyst or an alkali catalyst). Are preferably used.

  The content of main components such as amorphous silica ultrafine particles and ethyl silicate in the inorganic binder of the present invention is preferably 10 to 60% by weight, more preferably 15 to 50% by weight.

  For example, silica sol is a dispersion in which ultrafine particles of amorphous silica having a particle size of 4 to 200 nm are stably present. As the solvent, there are water and an organic solvent, which are called an aqueous sol and an organosol, respectively. As an inorganic binder for precision casting, a silica sol having a silica particle diameter of 7 to 15 nm and a silica concentration of 30% by weight is usually used. When this silica sol is dried and cured, the binder loses 70% by weight due to scattering of the solvent.

  In addition, ethyl silicate is widely used as an inorganic binder for precision casting, since ethyl silicate 28 (silica production amount is 28%) and ethyl silicate 40 (silica production amount is 40%) are used to act as a binder. In other words, an alcohol, water, and an acid or alkali are added to ethyl silicate so as to cause a hydrolysis condensation reaction. As an example, when an ethyl silicate binder that is cured with 0.2 wt% ammonia using ethyl silicate 40: 50 wt%, ethanol: 42.8 wt%, water: 7 wt% is used, the binder Is reduced by 80% in weight after curing and drying due to scattering of volatile components produced by the solvent or curing reaction.

  The content of the spherical refractory aggregate in the casting mold slurry of the present invention is preferably 60 to 95% by weight, more preferably 70 to 90% by weight. The content of the inorganic binder in the casting mold slurry of the present invention is preferably 5 to 40% by weight, and more preferably 10 to 30% by weight. The casting mold slurry of the present invention can contain a gelation accelerator, a surfactant, and the like, if necessary.

  In the casting mold slurry of the present invention, the weight ratio of the spherical refractory aggregate having a sphericity of 0.9 or more and the inorganic binder is spherical refractory aggregate / inorganic binder = 95 / 5-60 / 40. Further, 90/10 to 70/30 is preferable.

  Examples of a method for obtaining a mold using the casting mold slurry of the present invention include a lost wax method and a ceramic mold method in precision casting.

  In the lost wax method, a wax model having almost the same shape as the product to be cast is created, and the gate model is attached to the gate bar in consideration of the gate design (hereinafter referred to as a cluster), and the cluster is the slurry of the present invention. Soak the slurry on the surface of the cluster and, if necessary, sprinkle coarse refractory grains before it dries (stucco). After the coating layer is dried, the slurry is immersed, and if necessary, stucco and drying operations are repeated to obtain the required thickness. Then, the mold of the present invention can be obtained by heating, melting and removing the wax model, and baking at a high temperature.

  In the ceramic mold method, a model (a wooden model, a plastic model, etc.) having the same shape as the product to be cast is attached to a casting frame, the slurry of the present invention is poured onto the model, solidified and dried, and then the model is separated. By doing so, the template of the present invention can be obtained. If necessary, a baking treatment is further performed.

  As a casting manufactured using the mold of the present invention, a casting having a beautiful casting surface is obtained, and therefore, it is suitable for a casting that requires a complicated structure and a beautiful casting surface. Specific examples of castings include members, parts, and the like used for gas turbines, impellers, engines, hydraulic valves, motors, molds, general machinery, building members, and the like.

<Fireproof aggregate>
Table 1 shows the refractory aggregate used in the following Examples and Comparative Examples.

<Examples 1-4 and Comparative Examples 1-3>
Examples used in the lost wax method according to Examples 1 to 4 and Comparative Examples 1 to 3 are shown. The mold of FIG. 1 is basically composed of a plurality of refractory layers formed on the outer surface of a wax mold imitating a channel-shaped mold product. The refractory layer is composed of a slurry obtained by mixing refractory aggregate powder with a binder and / or particle powder called stucco sand (such as mullite sand, chamotte, silica and zircon).

  Examples 1 and 2 and Comparative Examples 1 and 2 were conducted without using a stucco, and are tests assuming a portion where stucco is difficult to adhere. In Examples 3 to 4 and Comparative Example 3, the test was performed with stucco.

  In these Examples and Comparative Examples, the drying time (drying time for one layer) was evaluated as follows. After the slurry was coated on the model, the amount of slurry adhered was measured by weight measurement. After that, the stucco was stuccoed and then air-dried in a constant temperature room at 25 ° C. The decrease in the weight of the mold with respect to the drying time was measured, and the time when 90% by weight of the volatile component calculated from the amount of attached slurry was evaporated was defined as the drying time.

  Next, a specific example will be described regarding the molding process of the precision casting mold by the lost wax method. The wax mold is formed in the same shape and dimensions as the final shape of the cast product, and a slurry of a refractory mixture is applied to the outside of the wax mold, and stucco sand is adhered to the slurry before drying. A dried refractory layer is formed. The refractory layer is prepared by repeating the steps of slurry application, stucco sand adhesion, and drying.

  The obtained mold is put into a high-temperature dryer (100 ° C. to 150 ° C.) and heated, and the wax mold in the mold is melted and discharged to the outside. Next, by firing the mold at 1000 ° C. to 1050 ° C., the remaining wax burns and the mold is sintered, so that a mold is formed in which a cavity that matches the external shape of the cast product is formed. .

  A molten metal is cast into the cavity of the mold obtained by the lost wax method, and the metal is cooled and solidified to produce a cast product.

  In Example 1, 80% by weight of spherical particles 1 produced by the flame fusion method as fireproof aggregate particles, 19.9% by weight of colloidal silica (manufactured by Nissan Chemical Industries, Ltd., Snowtex 30) as the binder, and the interface A fire-resistant mixture slurry composed of 0.1% by weight of an activator (Kao Corporation, Emulgen 105) was used, and no stucco sand was used. The slurry showed good fluidity and could be easily applied to a wax mold. Even after drying and curing, a good fire-resistant mold was produced without large cracks.

  Example 2 was carried out in the same manner as in Example 1 except that 76% by weight of spherical particles 3 (average particle size 30 μm) were used as the refractory aggregate particles and 23.9% by weight of colloidal silica (Snowtex 30) were used as the binder. . The slurry showed good fluidity and could be easily applied to a wax mold. Even after drying and curing, a good fire-resistant mold was produced without large cracks.

  In Example 3, the refractory mixture slurry used in Example 1 was used, and irregular mullite sand (amorphous particles 2, average particle size 150 μm) was used as the stucco sand. The slurry showed good fluidity and could be easily applied to a wax mold. Drying was completed in a shorter time than in Example 1. Even after drying and curing, a good fire-resistant mold was produced without large cracks.

  In Example 4, the refractory mixture slurry used in Example 1 was used, and spherical particles 2 were used as the stucco sand. The slurry showed good fluidity and could be easily applied to a wax mold. Drying was completed in a shorter time than in Example 3. Even after drying and curing, a good fire-resistant mold was produced without large cracks.

  In Comparative Example 1, 80% by weight of amorphous particles 1 as refractory aggregate particles, 19.9% by weight of colloidal silica (same as in Example 1) and surfactant (same as in Example 1) 0 A refractory mixture slurry consisting of 0.1% by weight was prepared. The slurry had insufficient liquid content and poor fluidity, making it difficult to apply to a wax mold.

  In Comparative Example 2, 70% by weight of amorphous particles 1 as refractory aggregate particles, 29.9% by weight of colloidal silica (same as in Example 1) and surfactant (same as in Example 1) 0 A 1% by weight refractory mixture slurry was used and no stucco sand was used. The slurry showed good fluidity and could be easily applied to a wax mold, but required a longer time for drying compared to Examples 1 and 2. In addition, a fire-resistant mold with outstanding cracks after drying and curing could not be produced.

  In Comparative Example 3, amorphous particles 2 were used as the refractory mixture slurry and stucco sand used in Comparative Example 2. The slurry showed good fluidity and could be easily applied to a wax mold. Although a good fire-resistant mold could be produced without large cracks after drying and curing, a longer time was required for drying compared to Example 3.

  Among these, the results of Examples 1-2 and Comparative Examples 1-2 are summarized in Table 2, and the results of Examples 3-4 and Comparative Example 3 are summarized in Table 3.

<Examples 5-6 and Comparative Examples 4-5>
Next, the example in the case of using for the ceramic mold method which concerns on Examples 5-6 and Comparative Examples 4-5 is shown.

  A slurry kneaded with an ethylsilicate binder using various refractory aggregates was poured onto the model shown in FIG. Baked at 4 ° C. for 4 hours.

  In Example 5, a slurry in which spherical particles 1 were 80% by weight (the balance was a mixture of ethylsilicate binder / gelation accelerator = 99.8 / 0.2 (weight ratio), the same applies hereinafter) was used. The slurry had good fluidity and could be poured well onto the model. The mold after firing was also good without large cracks.

  In Example 6, a slurry in which spherical particles 1 were 40 wt% and spherical particles 2 was 40 wt% was used. The slurry had good fluidity and could be poured well onto the model. The mold after firing was also good without large cracks.

  In Comparative Example 4, an attempt was made to prepare a slurry in which the amorphous particles 1 were 80% by weight, but the fluidity was poor and could not be poured onto the model.

  In Comparative Example 5, a slurry in which the amorphous particles 1 were 70% by weight was used. The slurry had good fluidity and was able to flow well on the model, but large cracks were conspicuous in the mold after firing.

  Table 4 summarizes the results of Examples 5 to 6 and Comparative Examples 4 to 5.

Example 7
A mold was prepared by the method shown in Example 3 using a channel-shaped wax mold (FIG. 3) having a width: 50 mm, a height: 50 mm, a depth: 50 mm, and a wall thickness: 10 mm. At this time, slurry application and stucco adhesion were each performed nine times, dewaxed at 100 ° C., and then fired at 1000 ° C. for 4 hours. A 1300 ° C. FCD600 melt was poured into the mold and cast. The cast product had a good shape and casting surface, and had no casting defects.

Schematic of lost wax method mold used in Example 1 etc. Schematic diagram of the mold for the ceramic mold method used in Example 5 etc. Schematic of the wax mold used in Example 7

Claims (5)

Precision casting containing a refractory aggregate having a sphericity of 0.9 or more produced by a flame melting method and an inorganic binder in a weight ratio of refractory aggregate / inorganic binder = 90 / 10-60 / 40 Mold slurry. The casting slurry for precision casting according to claim 1 , wherein the refractory aggregate is mainly composed of Al ₂ O ₃ and SiO ₂ . The slurry for precision casting molds according to claim 1 or 2 , wherein the average particle size of the refractory aggregate is 5 to 50 µm. A mold obtained using the precision casting mold slurry according to any one of claims 1 to 3 . A casting cast using the mold according to claim 4 .

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