In-situ metallurgy composite casting forming method for high-end equipment complex casting

Abstract

The invention provides a high-end equipment complex casting in-situ metallurgy composite casting forming method which comprises the following steps: generating a three-dimensional model of the outer side of a damaged part through three-dimensional scanning of a damaged area of the part and comparison with a three-dimensional model of an undamaged area, and generating an upper model through model slicing; a damaged part is fixed through sand mold 3D printing or molding sand mixed with a curing agent and resin to generate a lower model, then the upper model and the lower model are compounded, then the metal temperature is adjusted, and the pouring speed is controlled, so that the damaged area is repaired. According to the method, the damaged area is poured, one-time successful repairing of the damaged area can be achieved, repairing can be conducted without cutting a damaged part, materials are saved, the repairing and forming speed is increased, meanwhile, molten metal in the damaged area can be solidified in sequence, stress of the damaged area is reduced, and the service life of the damaged part is prolonged. The damage repairing quality is improved, a new direction is provided for part damage repairing, and the advantages of sand mold casting in a part repairing area are highlighted.

Description

Technical Field

[0001] The present invention belongs to the field of metal parts repair, relates to the field of sand mold 3D printing and the field of anti-gravity extrusion casting, and in particular to an in-situ metallurgical composite casting forming method for complex castings of high-end equipment. Background Art

[0002] Sand mold 3D printing technology is an important technology that has developed rapidly in the casting field in recent years. In terms of manufacturing cavities, sand mold 3D printing technology has significant advantages. First, it can realize the design of cavities with complex geometric shapes, such as internal channels and curved surfaces, to meet the diverse needs of castings. Secondly, sand mold 3D printing technology has flexible customized design capabilities, and designers can freely adjust the cavity structure according to specific needs, thereby reducing manufacturing costs and cycles. In addition, this technology also achieves high-precision manufacturing, ensures the dimensional accuracy and surface quality of the cavity, and improves the processing accuracy and forming quality of castings.

[0003] The demand for repairing damaged parts mainly stems from aspects such as extending the life of parts, saving costs, and reducing waste of resources. By repairing damaged parts, the high cost and time consumption of replacing the entire part can be avoided, and it is also beneficial to improve the availability and production efficiency of equipment. However, the repaired parts may not be able to recover to the same performance level as new parts, especially in high stress or harsh environments, where there may be safety hazards. Secondly, additional processing or heat treatment steps may be required during the repair process, which increases complexity and cost. In addition, some parts made of special materials or complex structures may be difficult to repair effectively, resulting in poor repair results. If there are some irregular missing parts in the damaged parts, if additive manufacturing technology is used for repair, the damaged area needs to be cut. At the same time, the cost of repairing large parts due to additive manufacturing is too high, and there are internal stresses in the repair area, which does not meet the repair requirements. Summary of the invention

[0004] In order to solve the above problems, the present invention discloses an in-situ metallurgical composite casting forming method for complex castings of high-end equipment, which can achieve integrated forming and firm metallurgical bonding of complex castings of high-end equipment.

[0005] An in-situ metallurgical composite casting forming method for complex castings of high-end equipment, the method comprising the following steps: Step 1: Use 3D scanning technology to scan the damaged parts in detail to obtain accurate 3D data of the specific location of the damage and the overall model of the damaged parts; Step 2: Compare the damaged part with the original model to generate a 3D model of the damaged part. Slice the 3D model and perform sand mold 3D printing based on the slice information. Make the next model based on the damaged part; Step 3: Composite splicing of the two models, pouring metal solution into casting after splicing, and surface treatment of the repaired parts after cooling and forming; Furthermore, the 3D scanning instrument includes a laser scanner, a structured light scanner, an optical scanner, etc.; Further, the upper model refers to a sand mold in which the outer area of ​​the damaged part is a mold cavity, and the lower model refers to a sand mold in which the damaged part is fixed; Furthermore, during the casting process, the temperature of the damaged parts can be adjusted to sequentially solidify the metal solution in the filling area. The solution poured into the damaged area is not solidified by heating the casting. After the filling is completed, the temperature of the casting is adjusted to allow the metal solution to solidify sequentially from bottom to top in the direction of gravity. Furthermore, the speed of pouring the molten metal during the casting process is initially very slow, and the pouring speed needs to be increased after the molten metal fills the damaged internal area; Furthermore, the lower surface of the upper model and the upper surface of the lower model are made of molding sand with a smaller mesh number, and at the same time, the concave parts and convex parts are designed on the upper and lower models to accurately fix the two models; Furthermore, if the damaged area of ​​the part does not contact the molding sand, the damaged part is preferably fixed by molding sand mixed with a curing agent and resin; if the damaged area of ​​the part contacts the molding sand and the damaged part can be placed in the lower model, the sand mold 3D printing technology is preferably used to manufacture the sand mold; if the damaged part does not meet the requirements of being placed in the lower model or the damaged area contacts the molding sand, the sand mold 3D printing technology + the molding sand mixed with a curing agent and resin are used to fill and fix the lower model; Furthermore, the entire lower sand mold is placed in a vacuum box to ensure that the molten metal can fill the entire damaged area during the casting process. After adopting the above technical solution, the beneficial effects of the present invention are: 1. This method can repair the damaged parts without cutting them, saving materials and speeding up the repair process; 2. This method can repair complex damaged parts. By pouring the damaged area, the damaged area can be repaired successfully at one time. 3. This method can realize the sequential solidification of the metal solution in the damaged area, reduce the stress generated in the damaged area, improve the quality of the damaged repair, provide a new direction for the repair of damaged parts, and highlight the advantages of sand casting in the part repair area. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Figure 1 It is a schematic diagram of the overall process of an in-situ metallurgical composite casting forming method for complex castings of high-end equipment; Figure 2 It is a method for manufacturing a bottom model in an in-situ metallurgical composite casting forming method for complex castings of high-end equipment; Figure 3 The present invention is a schematic diagram of the process of obtaining the external three-dimensional model of a damaged part in an in-situ metallurgical composite casting forming method for a complex casting of high-end equipment. DETAILED DESCRIPTION

[0007] The present invention is further explained below in conjunction with the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are only used to illustrate the present invention and are not used to limit the scope of the present invention. It should be noted that the words "front", "rear", "left", "right", "upper" and "lower" used in the following description refer to directions in the accompanying drawings, and the words "inner" and "outer" refer to directions toward or away from the geometric center of a specific component, respectively.

[0008] like Figure 1-3 As shown, the in-situ metallurgical composite casting forming method of a high-end equipment complex casting of this embodiment comprises the following steps: Step 1: Use 3D scanning technology to scan the damaged parts in detail to obtain accurate 3D data of the specific location of the damage and the overall model of the damaged parts; Step 2: Compare the damaged part with the original model to generate a 3D model of the damaged part. Slice the 3D model and perform sand mold 3D printing based on the slice information. Make the next model based on the damaged part; Step 3: Composite splicing of the two models, pouring metal solution into casting after splicing, and surface treatment of the repaired parts after cooling and forming; Furthermore, the 3D scanning instrument includes a laser scanner, a structured light scanner, an optical scanner, etc.; Further, the upper model refers to a sand mold in which the outer area of ​​the damaged part is a mold cavity, and the lower model refers to a sand mold in which the damaged part is fixed; Furthermore, during the casting process, the temperature of the damaged parts can be adjusted to sequentially solidify the metal solution in the filling area. The solution poured into the damaged area is not solidified by heating the casting. After the filling is completed, the temperature of the casting is adjusted to allow the metal solution to solidify sequentially from bottom to top in the direction of gravity. Furthermore, the speed of pouring the molten metal during the casting process is initially very slow, and the pouring speed needs to be increased after the molten metal fills the damaged internal area; Furthermore, the lower surface of the upper model and the upper surface of the lower model are made of molding sand with a smaller mesh number, and at the same time, the concave parts and convex parts are designed on the upper and lower models to accurately fix the two models; Furthermore, if the damaged area of ​​the part does not contact the molding sand, the damaged part is preferably fixed by molding sand mixed with a curing agent and resin; if the damaged area of ​​the part contacts the molding sand and the damaged part can be placed in the lower model, the sand mold 3D printing technology is preferably used to manufacture the sand mold; if the damaged part does not meet the requirements of being placed in the lower model or the damaged area contacts the molding sand, the sand mold 3D printing technology + the molding sand mixed with a curing agent and resin are used to fill and fix the lower model; Furthermore, the entire lower sand mold is placed in a vacuum box to ensure that the molten metal can fill the entire damaged area during the casting process.

[0009] like Figure 1 As shown, the mechanism is damaged at one point due to collision during movement. Due to the special nature of the part, it needs to be repaired. Conventional repair methods can achieve overall forming of the part, but the overall performance of the part does not meet the use requirements. Therefore, an optical scanner is used to scan the damaged parts in detail and perform three-dimensional reconstruction to obtain accurate three-dimensional data of the specific location of the damage and the overall model of the damaged parts; the damaged parts are compared with the original model to generate a three-dimensional sand model of the damaged parts; the three-dimensional model is sliced, and the upper model is generated by sand 3D printing based on the slice information; the damaged parts are placed in a sand box, filled with molding sand particles mixed with a curing agent and resin, and the lower model is manufactured. The lower surface of the upper model and the upper surface of the lower model are manufactured using 24-50 mesh molding sand. At the same time, recessed parts and protruding parts are designed on the upper and lower models to accurately fix the two models; the damaged parts, the upper model and the lower model are compositely spliced, and after the splicing is completed, the metal solution is poured into it for casting, the volume of the damaged internal area is determined, and the metal solution is slowly poured into it within this volume range. After the metal solution fills the damaged internal area, the pouring speed is increased, and after cooling and forming, the repaired parts are surface treated, and the damaged parts are filled with liquid metal to achieve metallurgical bonding with the complex casting matrix. This method achieves effective and precise repair of damaged parts because it uses casting, the metal in the damaged area is in good contact with the damaged parts, and the repaired parts meet the use requirements. The technical means disclosed in the scheme of the present invention are not limited to the technical means disclosed in the above-mentioned implementation mode, but also include technical schemes composed of any combination of the above technical features.

Claims

1. An in-situ metallurgical composite casting method for complex castings of high-end equipment, characterized by: The following steps are involved: Step 1: Use 3D scanning technology to scan the damaged parts in detail and perform three-dimensional reconstruction to obtain accurate three-dimensional data of the specific location of the damage and the overall model of the damaged parts; Step 2: Compare the damaged part with the original model to generate a 3D sand model of the damaged part's exterior; slice the 3D model, and perform 3D sand printing based on the slice information to generate an upper model; place the damaged part in a sand box, fill it with sand particles mixed with a curing agent and resin, and manufacture the lower model; Step 3: Splice the damaged parts, upper model and lower model together, pour in molten metal for casting, and perform surface treatment on the repaired parts after cooling and forming. Fill the damaged parts with liquid metal and achieve metallurgical bonding with the complex casting matrix.

2. The in-situ metallurgical composite casting forming method for complex castings of high-end equipment according to claim 1, characterized in that: 3D scanning uses instruments such as laser scanners, structured light scanners or optical scanners.

3. The in-situ metallurgical composite casting forming method for complex castings of high-end equipment according to claim 1, characterized in that: The upper model refers to a sand mold in which the outer area of ​​the damaged part is a mold cavity, and the lower model refers to a sand mold that fixes the damaged part.

4. According to claim 1, a high-end equipment complex casting in-situ metallurgical composite casting forming method is characterized in that: Before casting, the damaged area of ​​the parts is electromagnetically heated. During the casting process, the temperature of the damaged parts is adjusted to sequentially solidify the metal solution in the filling area. The temperature of the casting is increased so that the solution poured into the damaged area does not solidify. After the filling is completed, the temperature of the casting is adjusted to allow the metal solution to solidify sequentially from bottom to top in the direction of gravity.

5. According to claim 1, a high-end equipment complex casting in-situ metallurgical composite casting forming method is characterized in that: Determine the volume of the damaged internal area, slowly pour the metal solution within the volume range, and increase the pouring speed after the metal solution fills the damaged internal area.

6. The in-situ metallurgical composite casting forming method for complex castings of high-end equipment according to claim 1, characterized in that: The lower surface of the upper model and the upper surface of the lower model are made of 24-50 mesh molding sand. At the same time, the concave and convex parts are designed on the upper and lower models to accurately fix the two models.

7. The in-situ metallurgical composite casting forming method for complex castings of high-end equipment according to claim 3, characterized in that: If the damaged area of ​​the part does not contact the molding sand, it is preferred to use molding sand mixed with curing agent and resin to fix the damaged part; if the damaged area of ​​the part contacts the molding sand and the damaged part can be placed in the lower model, sand mold 3D printing technology is preferred to manufacture the sand mold; if the damaged part does not meet the requirements of being placed in the lower model or the damaged area contacts the molding sand, the lower model is manufactured by using sand mold 3D printing technology + filling and fixing with molding sand mixed with curing agent and resin.

8. The in-situ metallurgical composite casting forming method for complex castings of high-end equipment according to claim 5, characterized in that: The entire composite sand mold is vacuumed to ensure that the metal solution can fill the entire damaged area during the casting process, thereby increasing the filling effect.

Images