3DP sand mold casting process suitable for ZL205A aluminum alloy complex thin-wall component

A technology of ZL205A and thin-walled components, which is applied in the direction of manufacturing tools, casting molding equipment, metal processing equipment, etc., can solve the problems of increased gas generation in sand molds, affecting dimensional tolerances, and increasing printing costs, so as to achieve excellent casting quality and improve casting quality. Quality, the effect of reducing casting defects

Active Publication Date: 2021-06-29
NORTHWESTERN POLYTECHNICAL UNIV +1
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  • Summary
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AI Technical Summary

Problems solved by technology

The strength of 3DP sand mold increases with the increase of resin content in the sand, but higher sand mold strength will lead to poor mold yield, resulting in hot cracking, stress concentration and other problems
When the resin content of the molding sand is high, it will not only increase the printing cost, but also cause the shrinkage of the sand mold, which seriously affects the dimensional tolerance; at the same time, it will increase the gas generation of the sand mold, reduce the air permeability of the mold, and cause defects such as pores and suffocation
Similarly, the thickness of the printing layer will also cause differences in the characteristics of the mold, which in turn will affect the casting quality of the casting
Most of the current 3DP sand casting research focuses on 3DP printing consumables, 3DP sand characteristics and 3DP sand casting process, but there are not many reports on the influence of 3DP sand printing parameters on the performance of cast aluminum alloy 3DP sand casting
The current research on the preparation of aluminum alloy castings with complex structures by 3DP sand molds focuses on Al-Si alloys with good casting properties such as ZL101A, and less research on Al-Cu series high-strength cast aluminum alloys such as ZL205A with poor casting properties.
The air volume and air permeability of the sand mold are the key factors that directly affect the quality of gold castings. The problems of large air volume, poor air permeability and poor yield of the 3DP sand mold will aggravate the casting defects of ZL205A alloy castings, which seriously affect the 3DP sand mold in ZL205A aluminum alloy. Popularization and Application in Casting Production of Structural Parts
At the same time, there are few studies on the related casting process of ZL205A alloy castings prepared by 3DP sand molds.

Method used

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  • 3DP sand mold casting process suitable for ZL205A aluminum alloy complex thin-wall component
  • 3DP sand mold casting process suitable for ZL205A aluminum alloy complex thin-wall component
  • 3DP sand mold casting process suitable for ZL205A aluminum alloy complex thin-wall component

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0032] Embodiment 1, casting of ZL205A pitch seat casting:

[0033] (a) Taking a certain type of pitch seat as an example, its structural features are complex and its size is relatively large. Its horizontal plane size is 997mm×636mm, its height is 627mm, and its mass is about 52kg. The ZL205A alloy pitch seat has a large number of variable cross-section structures, the thinnest part of which is only 6mm thick, and the cross-section ratio is nearly 1:15. There are two shell components with complex shapes and structures in the vertical direction, and their cross-sectional dimensions change frequently. There is only a horizontal bracket with a minimum wall thickness of 6mm and a maximum wall thickness of 15mm between the two shell parts, and the length of the horizontal bracket is 420mm, accounting for nearly half of the overall length of the pitch seat casting, which is very prone to deformation. These structural features make the pitching seat castings have special characteri...

Embodiment 2

[0039] Embodiment 2, casting of ZL205A pitch frame casting:

[0040] (a) Take a pitching frame as an example, its structural feature is a frame structure, its horizontal plane size is 415mm×286mm, its height is 156mm, and its mass is about 7.5kg. The pitching frame is a frame structure as a whole, and the outer wall presents a large area of ​​thin walls as a whole, with a wall thickness of 9mm. The wall is a multi-place rib structure, and the wall thickness here is 14mm. There are two bosses on the inner wall, the wall thickness of which is 32mm. During the solidification process, the thin-walled structure may have problems such as insufficient pouring, shrinkage cavities, and feeding difficulties. The uneven thickness may cause excessive thermal stress and cracks in the casting during the cooling process. Pitch frame castings show a "large size effect" during the filling process and solidification process, and cracks are prone to occur at the corners of the casting due to li...

example 3

[0046] Example 3, casting of ZL205A small cabin castings:

[0047] (a) Taking a certain type of small cabin as an example, the external dimensions of the cabin are: the small end diameter is 240mm, the large end diameter is 340mm, the height is 263mm, the minimum wall thickness is 7mm, and the mass is about 12.7kg. There are 5:1 and 3:1 variable cross-section structures between bosses and wall thicknesses on the inner wall of the cabin. There are six large bosses at one end of the cabin, with a height of 40mm and a thickness of 37mm. The internal structure of the cabin is complex, and there are many There are two irregular windows, the wall thickness of the cabin is not uniform, and there are many variable cross-section structures. It is easy to form casting heat joints and defects in these parts with large wall thickness differences. The multiple bosses of the casting may cause insufficient pouring during filling, and defects may also occur due to insufficient feeding during ...

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Abstract

The invention discloses a 3DP sand mold casting process suitable for a ZL205A aluminum alloy complex thin-wall component, and belongs to the technical field of 3DP sand mold casting processes. The 3DP sand mold casting process comprises the steps that firstly, a pouring system of a casting is designed through three-dimensional drawing software, a three-dimensional structure of a casting mold is obtained, and 3D printing slicing data of the casting mold are obtained; then according to the slicing data, silica sand with the mesh number of 70-140 is used, furan resin serves as a binder, p-toluene sulfuric acid serves as a catalyst, and 3DP sand mold printing is carried out through a 3D printer; printing parameters are set, wherein the thickness of a printing layer is 0.28 mm, and the resin content is 1.5 wt.%; then sand cleaning, drying and mold assembling are carried out on a 3DP sand mold, the inner wall of the 3DP sand mold is coated with a layer of water-based zircon powder coating, drying is carried out 2.5-3 hours at the temperature of 120-130 DEG C, and furnace cooling is carried out; finally, a ZL205A alloy is smelted, the temperature is reduced to 725 +/-5 DEG C, and casting is carried out; and after the casting is solidified, cleaning is carried out to obtain the casting. According to the process, through the reasonable 3DP sand mold printing process and the casting process, the casting defects are reduced and the casting quality is improved through the sand mold preparation process and the casting process.

Description

technical field [0001] The invention belongs to the technical field of 3DP sand casting technology, and in particular relates to a 3DP sand casting technology suitable for ZL205A aluminum alloy complex thin-walled components. Background technique [0002] ZL205A aluminum alloy is an Al-Cu series high-strength cast aluminum alloy, which has the advantages of high strength, good plasticity, high hardness, and strong machinability. It is widely used in aviation, aerospace vehicles and other load-bearing structural parts, but the alloy composition is complex. The crystallization temperature range is wide, solidified in a paste form, the casting performance is poor, the wall thickness sensitivity is high, and the hot cracking tendency is large, and the casting is prone to casting defects such as pores, shrinkage porosity, insufficient pouring and hot cracking. The paper "ZL205A Coated Sand Casting Molding Process Improvement" (New Technology and New Process 2018, No. 11, 72-75) a...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): B22C9/02B33Y10/00B33Y50/00
CPCB22C9/02B33Y10/00B33Y50/00
Inventor 杨光昱王春辉付锋涛阿热达克·阿力玛斯介万奇
Owner NORTHWESTERN POLYTECHNICAL UNIV
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