A high-temperature metal forging insulation device and method based on lattice wrapping blanket

Abstract

The present invention relates to a high-temperature metal forging insulation device and method based on a lattice wrapping blanket, and relates to the technical field of high-temperature metal forging insulation. The insulation device comprises a fiber matrix layer and a lattice bonding layer. The fiber matrix layer is made of a high-temperature resistant fiber blanket, with a temperature resistance of ≥1300°C and strong resistance to chemical corrosion; the lattice bonding layer is provided with a lattice hole array with specific parameters, and a high-temperature adhesive is poured to form a reinforced anchoring structure. The manufacturing method covers the steps of adhesive mixing, lattice hole pouring, pre-baking and final curing baking. It is applied to the high-temperature metal forging process, the workpiece is seamlessly covered in the wrapping stage, the bonding is activated quickly, and the temperature drop rate and temperature difference are strictly controlled in the insulation maintenance stage. This device is also suitable for the forging of titanium alloys and high-temperature alloys, prolongs the single forging time, reduces the number of reheating times, effectively improves the quality of forgings and production efficiency, reduces costs, and provides a reliable insulation solution for high-temperature metal forging.

Description

Technical Field

[0001] The invention relates to the technical field of heat preservation of high temperature metal forging, and in particular to a heat preservation device and method for high temperature metal forging based on a lattice wrapping blanket. Background Art

[0002] During high-temperature metal forging, the thermal insulation performance of the workpiece directly affects the quality of the forging and production efficiency. Traditional thermal insulation technology has the following limitations:

[0003] Insufficient temperature resistance of materials: The temperature resistance grade of conventional ceramic fiber blankets (such as pure aluminum silicate fibers) is usually lower than 1200°C. When forging titanium alloys and high-temperature alloys (forging temperature ≥ 1250°C), fiber powdering or interlayer peeling is prone to occur, resulting in insulation failure.

[0004] Poor structural stability: Traditional fiber blankets are fixed by random needle punching or viscose, which are prone to cracks due to thermal stress at high temperatures. The local temperature difference can reach more than 30°C, seriously affecting the uniformity of the forging structure.

[0005] High energy consumption and cost: To compensate for the rapid temperature drop (conventional process ≥3.5℃ / min), frequent reheating is required, and the energy consumption of a single forging increases by more than 25%. In addition, the manufacturing cost of hard covers (such as graphite molds) is high and cannot be flexibly fitted.

[0006] In response to the above problems, it is urgent to develop a new type of insulation device with high temperature resistance and structural stability to break through the bottleneck of precision forging process. Summary of the invention

[0007] In order to solve the problems of the prior art, the present invention provides a high-temperature metal forging heat preservation device and method based on a lattice wrapping blanket.

[0008] In order to solve the above technical problems, the present invention is implemented by the following technical solutions: In the first aspect, a high-temperature metal forging insulation device based on a lattice wrapped blanket comprises:

[0009] Fiber matrix layer: High temperature resistant fiber blanket made by continuous noil flat-laying double-sided needle-punching process, with a temperature resistance grade of ≥1300℃ and a thickness of 5-15mm. Its chemical corrosion resistance meets the requirements of industrial applications except for hydrofluoric acid, phosphoric acid and strong alkaline environments;

[0010] Dot matrix bonding layer: a dot matrix hole array with a hole diameter of 3.5-12mm and a hole spacing of 30-80mm is set on the surface of the fiber matrix. A high-temperature adhesive mixed with adhesive, chemical paste and borax solvent in a mass ratio of 1-3:2-5:0.02-0.09 is poured into the holes. After the adhesive is cured, a reinforced anchoring structure that semi-penetrates the fiber layer is formed.

[0011] In a specific embodiment of the first aspect, the high temperature adhesive further includes softened water added in an amount of 12%-15% of the total mass, the viscosity is controlled at 1800-2200 cP, and after curing, the effective bonding time is maintained at 1000-1200° C. for ≥45 minutes.

[0012] In a specific implementation of the first aspect, the lattice hole array adopts a staggered arrangement mode, the offset of adjacent rows of holes is 2-8 times the aperture, and the aperture gradient decreases from the center to the edge of the blanket, the aperture in the center area is 3-10 mm, and the aperture in the edge area is 5-8 mm.

[0013] Fiber matrix layer: The high temperature resistant fiber blanket made by a specific process has a high temperature resistance level and can withstand the high temperature environment (≥1300℃) during the high temperature metal forging process. The appropriate thickness (5-15mm) can ensure a certain thermal insulation performance without causing waste or inconvenience due to excessive thickness. It has good chemical corrosion resistance and can meet the requirements of industrial applications except for special acid and alkali environments. It can protect high temperature metals from external chemical substances when forging in general chemical environments.

[0014] Dot-matrix bonding layer: A dot-matrix hole array is set on the surface of the fiber matrix and a high-temperature adhesive is poured in. After curing, a reinforced anchoring structure that penetrates the fiber layer is formed. This structure enhances the bonding force between the adhesive and the fiber matrix, and improves the overall stability and durability of the thermal insulation device. Appropriate hole diameter (3.5-12mm) and hole spacing (30-80mm) can ensure that the adhesive is reasonably distributed and effectively fix the fibers tightly together.

[0015] In a second aspect, a method for manufacturing a high-temperature metal forging insulation device based on a lattice wrapping blanket comprises the following steps:

[0016] S1: Mix and prepare the binder: according to chemical paste: borax cosolvent

[0017] =1-3:2-5:0.02-0.09 mass ratio, add softened water to adjust the viscosity to 2000±200cP;

[0018] S2: Dot hole perfusion: The adhesive is injected into the dot holes by a CNC dispensing machine at a pressure of 0.2-0.4MPa, and the perfusion depth reaches 80%-90% of the fiber layer thickness;

[0019] S3: Pre-baking treatment: drying at 120°C for 60 minutes, adding a tapping operation, and performing a downward pressing treatment to initially solidify the adhesive;

[0020] S4: Final curing baking: Start at 180°C in an automatic baking machine, increase the temperature to 250°C at a rate of 10°C / min, and keep warm for 30 minutes.

[0021] In a specific implementation of the second aspect, the distance between the downward pressing process and the workpiece surface in S3 is dynamically adjusted with an adjustment accuracy of ±0.1mm, the downward pressing contact surface temperature is monitored in real time and the pressure value is fed back to control, and the pressure decreases by 0.5MPa for every 50°C increase in temperature.

[0022] Mixing and preparing the binder: Mix the chemical paste, borax solvent and other ingredients strictly according to the proportion, and add softened water to adjust the viscosity to provide a stable binder for subsequent processes. The appropriate viscosity (2000±200cP) is conducive to the infusion and penetration of the binder in the lattice holes.

[0023] Dot hole perfusion: The adhesive is injected into the dot hole with a certain pressure (0.2-0.4MPa) through a CNC dispensing machine to ensure that the perfusion depth reaches 80%-90% of the fiber layer thickness, ensuring that the fiber layer and the adhesive are fully combined to improve the integrity and stability of the device.

[0024] Pre-baking treatment: Dry at 120℃ for 60 minutes, add tapping operation, and perform downward pressing to initially solidify the adhesive, which helps to fix the position of the adhesive in the lattice holes and prepare for subsequent processing.

[0025] Final curing baking: Heat up and keep warm at a specific heating rate (10℃ / min) in an automatic baking machine to completely cure the adhesive and ensure that the insulation device has good mechanical properties and stability.

[0026] In the third aspect, a high temperature metal forging heat preservation process is provided, which uses a high temperature metal forging heat preservation device based on a lattice wrapping blanket:

[0027] A1: Wrapping stage: The dot matrix wrapping blanket completely covers the workpiece surface, and the overlapping width at the seam is ≥ 20mm;

[0028] A2: Bonding activation stage: When the workpiece temperature is ≥1000℃, the adhesive on the blanket surface completes melting penetration within 10-15 seconds;

[0029] A3: Insulation maintenance stage: During the forging process, the blanket is kept completely wrapped, so that the temperature drop rate of the workpiece is ≤2.3℃ / min, and the local temperature difference is controlled within ±15℃.

[0030] In a specific embodiment of the third aspect, when A3 detects that the local temperature difference exceeds 20°C, the auxiliary pressing operation is automatically triggered to supplement the downward pressure on the temperature difference area, and the downward pressure energy density is 5-8J / cm 2 .

[0031] Wrapping stage: The dot-matrix wrapping blanket completely covers the workpiece surface and ensures a certain seam overlap width (≥20mm), which can effectively prevent heat from dissipating from the seams and provide a good insulation foundation for the subsequent forging process.

[0032] Bonding activation stage: When the workpiece temperature is ≥1000℃, the adhesive on the blanket surface can complete melting penetration in a short time (10-15 seconds), so that the wrapped blanket and the workpiece are tightly bonded to enhance the thermal insulation effect.

[0033] Insulation maintenance stage: Keep the blanket completely wrapped during the forging process, effectively control the temperature drop rate of the workpiece (≤2.3℃ / min) and the local temperature difference (within ±15℃), so that the metal is forged in a relatively stable temperature environment, improving the quality and performance of the forgings. When the local temperature difference exceeds 20℃, the auxiliary pressing module is triggered to supplement the pressing, which can further balance the temperature distribution.

[0034] In a fourth aspect, a heat preservation device for a high temperature metal forging heat preservation device based on a lattice wrapped blanket, wherein the fiber matrix layer comprises chemical components in the following mass ratios:

[0035] Al2O3: 34-37%

[0036] Si2O: 48-50%

[0037] ZrO2: 14-17%

[0038] Al2O3+Si2O+ZrO2:≥99.1

[0039] Fe2O3:≤0.2

[0040] Na2O+K2O:≤0.2

[0041] Physical properties:

[0042] Tensile strength, KPa: ≥80

[0043] Heating line shrinkage (temperature "1300℃, 24h, %): ≤0.3

[0044] Slag ball content (212μm,%): ≤10

[0045] Thermal conductivity (W / mK): 0.24

[0046] In terms of chemical composition, high proportions and precise contents of Al2O3, Si2O, and ZrO2 ensure material purity, effectively reduce impurity interference, and provide a stable foundation for high-temperature operations. Extremely low Fe2O3, Na2O+K2O contents prevent materials from being corroded and deteriorated at high temperatures. In terms of physical properties, the tensile strength of ≥80KPa ensures that the device structure is stable and can withstand external forces during forging.

[0047] Under the condition of "1300℃, 24h", the shrinkage rate of the heating wire is ≤0.3%, which can always tightly wrap the metal and reduce the heat loss channel; the slag ball content is ≤10% (212μm) to reduce internal defects and improve the uniformity of thermal insulation; the thermal conductivity coefficient of 0.24W / mK greatly slows down the outward conduction of heat, so that the high-temperature metal can maintain the required heat as much as possible throughout the forging process, saving energy and increasing efficiency while ensuring the forging quality.

[0048] Fifthly, the application of a high-temperature metal forging insulation device based on a lattice wrapping blanket is suitable for multi-pass forging of titanium alloys and high-temperature alloy forgings in the range of 1000℃-1250℃, which extends the single forging time to 45-60 minutes and reduces the number of reheating times to ≤1 time.

[0049] This heat preservation device is suitable for multi-pass forging of specific alloys (titanium alloys, high-temperature alloys) in a certain temperature range (1000-1250℃). It prolongs the single forging time (45-60 minutes), reduces the number of reheating times (≤1 time), reduces energy consumption, improves production efficiency, and also helps to improve the quality and performance consistency of forgings.

[0050] The beneficial effects of the present invention are:

[0051] 1. The fiber matrix layer of the thermal insulation device adopts high temperature resistant fiber blanket, with temperature resistance grade ≥1300℃ and appropriate thickness, which can ensure good thermal insulation effect and is easy to use. The dot matrix bonding layer is combined with high temperature adhesive through a unique dot matrix hole array to form a reinforced anchoring structure, which greatly enhances the bonding force between the adhesive and the fiber matrix, significantly improves the overall stability and durability of the device, effectively prevents problems such as loose structure in high temperature forging environment, and provides stable thermal insulation conditions for metal forging;

[0052] 2. The manufacturing method steps range from the precise mixing and preparation of the binder to the efficient infusion of the matrix holes, pre-baking and final curing baking. Each link is closely coordinated to ensure the molding quality of the device.

[0053] 3. When used in high-temperature metal forging processes, it performs well in the stages of wrapping, bonding activation, and heat preservation maintenance, and can strictly control the temperature drop rate and local temperature difference of the workpiece, ensuring that the metal is forged in a stable temperature environment, effectively improving the quality and performance of forgings. It is also suitable for multi-pass forging of specific alloys such as titanium alloys and high-temperature alloys in the range of 1000-1250℃, extending the single forging time, reducing the number of reheating times, significantly improving production efficiency, and enhancing the market competitiveness of enterprises. BRIEF DESCRIPTION OF THE DRAWINGS

[0054] Figure 1 It is a main schematic diagram of the heat preservation device of the present invention.

[0055] Figure 2It is a partial schematic diagram of the main body of the heat preservation device of the present invention.

[0056] Figure 3 It is a physical schematic diagram of the main body of the heat preservation device of the present invention.

[0057] Figure 4 It is a schematic diagram of the use state of the main body of the heat preservation device of the present invention.

[0058] Figures 1 to 4 Middle: 1. Thermal insulation device body; 11. Fiber matrix layer; 12. Dot matrix bonding layer. DETAILED DESCRIPTION

[0059] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0060] like Figures 1 to 4 In the first aspect shown, a high temperature metal forging heat preservation device based on a lattice wrapped blanket comprises:

[0061] Fiber matrix layer: High temperature resistant fiber blanket made by continuous noil flat-laying double-sided needle-punching process, with a temperature resistance grade of ≥1300℃ and a thickness of 5-15mm. Its chemical corrosion resistance meets the requirements of industrial applications except for hydrofluoric acid, phosphoric acid and strong alkaline environments;

[0062] Dot matrix bonding layer: a dot matrix hole array with a hole diameter of 3.5-12mm and a hole spacing of 30-80mm is set on the surface of the fiber matrix. A high-temperature adhesive mixed with adhesive, chemical paste and borax solvent in a mass ratio of 1-3:2-5:0.02-0.09 is poured into the holes. After the adhesive is cured, a reinforced anchoring structure that semi-penetrates the fiber layer is formed.

[0063] In a specific embodiment of the first aspect, the high temperature adhesive further includes softened water added in an amount of 12%-15% of the total mass, the viscosity is controlled at 1800-2200 cP, and after curing, the effective bonding time is maintained at 1000-1200° C. for ≥45 minutes.

[0064] In a specific implementation of the first aspect, the lattice hole array adopts a staggered arrangement mode, the offset of adjacent rows of holes is 2-8 times the aperture, and the aperture gradient decreases from the center to the edge of the blanket, the aperture in the center area is 3-10 mm, and the aperture in the edge area is 5-8 mm.

[0065] In a second aspect, a method for manufacturing a high-temperature metal forging insulation device based on a lattice wrapping blanket comprises the following steps:

[0066] S1: Mix and prepare a binder: mix according to the mass ratio of chemical paste: borax cosolvent = 1-3: 2-5: 0.02-0.09, and add softened water to adjust the viscosity to 2000±200cP;

[0067] S2: Dot hole perfusion: The adhesive is injected into the dot holes by a CNC dispensing machine at a pressure of 0.2-0.4MPa, and the perfusion depth reaches 80%-90% of the fiber layer thickness;

[0068] S3: Pre-baking treatment: drying at 120°C for 60 minutes, adding a tapping operation, and performing a downward pressing treatment to initially solidify the adhesive;

[0069] S4: Final curing baking: Start at 180°C in an automatic baking machine, increase the temperature to 250°C at a rate of 10°C / min, and keep warm for 30 minutes.

[0070] In a specific implementation of the second aspect, the distance between the downward pressing process and the workpiece surface in S3 is dynamically adjusted with an adjustment accuracy of ±0.1mm, the downward pressing contact surface temperature is monitored in real time and the pressure value is fed back to control, and the pressure decreases by 0.5MPa for every 50°C increase in temperature.

[0071] In the third aspect, a high temperature metal forging heat preservation process is provided, which uses a high temperature metal forging heat preservation device based on a lattice wrapping blanket:

[0072] A1: Wrapping stage: The dot matrix wrapping blanket completely covers the workpiece surface, and the overlapping width at the seam is ≥ 20mm;

[0073] A2: Bonding activation stage: When the workpiece temperature is ≥1000℃, the adhesive on the blanket surface completes melting penetration within 10-15 seconds;

[0074] A3: Insulation maintenance stage: During the forging process, the blanket is kept completely wrapped, so that the temperature drop rate of the workpiece is ≤2.3℃ / min, and the local temperature difference is controlled within ±15℃.

[0075] In a specific embodiment of the third aspect, when A3 detects that the local temperature difference exceeds 20°C, the auxiliary pressing operation is automatically triggered to supplement the downward pressure on the temperature difference area, and the downward pressure energy density is 5-8J / cm 2 .

[0076] In a fourth aspect, a heat preservation device for a high temperature metal forging heat preservation device based on a lattice wrapped blanket, wherein the fiber matrix layer comprises chemical components in the following mass ratios:

[0077] Al2O3: 34-37%

[0078] Si2O: 48-50%

[0079] ZrO2: 14-17%

[0080] Al2O3+Si2O+ZrO2:≥99.1

[0081] Fe2O3:≤0.2

[0082] Na2O+K2O:≤0.2

[0083] Physical properties:

[0084] Tensile strength, KPa: ≥80

[0085] Heating line shrinkage (temperature "1300℃, 24h, %): ≤0.3

[0086] Slag ball content (212μm,%): ≤10

[0087] Thermal conductivity (W / mK): 0.24.

[0088] Fifthly, the application of a high-temperature metal forging insulation device based on a lattice wrapping blanket is suitable for multi-pass forging of titanium alloys and high-temperature alloy forgings in the range of 1000℃-1250℃, which extends the single forging time to 45-60 minutes and reduces the number of reheating times to ≤1 time.

[0089] Embodiment 1: With reference to the contents of the first aspect and the fourth aspect, a fiber matrix layer is prepared.

[0090] This embodiment refers to the first and fourth aspects, and focuses on preparing the fiber matrix layer. The fiber matrix layer plays a key basic role in the entire high-temperature metal forging insulation device based on the lattice wrapping blanket, and its performance directly affects the insulation effect, high temperature resistance, strength and toughness of the entire insulation device.

[0091] Chemical composition of ceramic fiber blanket:

[0092] Al2O3: 34-37%

[0093] Si2O: 48-50%

[0094] ZrO2: 14-17%

[0095] Al2O3+Si2O+ZrO2:≥99.1

[0096] Fe2O3:≤0.2

[0097] Na2O+K2O:≤0.2

[0098] Physical properties:

[0099] Tensile strength, KPa: ≥80

[0100] Heating line shrinkage (temperature "1300℃, 24h, %): ≤0.3

[0101] Slag ball content (212μm,%): ≤10

[0102] Thermal conductivity (W / mK): 0.24

[0103] Fe2O3:≤0.2

[0104] Na2O+K2O:≤0.2.

[0105] This high-temperature metal forging insulation device based on a lattice wrapping blanket has a remarkable effect due to its unique chemical composition and excellent physical properties of the fiber matrix layer. In terms of chemical composition, a high proportion and precise content of Al2O3, Si2O, and ZrO2 ensures the purity of the material, effectively reduces the interference of impurities, and provides a stable foundation for high-temperature operations. The extremely low content of Fe2O3 and Na2O+K2O prevents the material from being corroded and deteriorated at high temperatures. In terms of physical properties, the tensile strength of ≥80KPa ensures that the device structure is stable and can withstand external force pulling during forging; the shrinkage rate of the heating line under the condition of "1300℃, 24h" is ≤0.3%, which can always tightly wrap the metal and reduce the heat loss channel; the slag ball content is ≤10% (212μm) to reduce internal defects and improve the uniformity of insulation; the thermal conductivity of 0.24W / mK greatly slows down the conduction of heat to the outside, so that the high-temperature metal can maintain the required heat as much as possible during the entire forging process, saving energy and increasing efficiency while ensuring the forging quality.

[0106] Flat lay and needle punching

[0107] The prepared fibers are operated according to the method of continuous cotton dropping. First, the laying equipment is started to control the speed and uniformity of the cotton dropping, so that the fibers are evenly spread on the workbench to form a preliminary fiber layer. Ensure that the thickness of the entire fiber layer is roughly uniform and the deviation is controlled within a very small range.

[0108] The flattened fiber layer is then processed using a double-sided needling process. The needle number, needling density and other parameters of the needling equipment need to be selected and adjusted according to the characteristics of the fiber and the requirements of the final product. The needle number is generally 25-30, and the needling density is 60-100 needles / square centimeter. During the needling process, ensure that the depth and strength of the needling are uniform. The needling process uses the upper and lower needles on the needling machine to continuously penetrate in and out of the fiber layer, entangle and consolidate the fibers together. Needling from the top and bottom of the fiber layer at the same time allows the fibers to form a compact structure in three-dimensional space, improving the overall strength and stability of the fiber layer.

[0109] Performance testing and screening

[0110] After the preparation, the fiber matrix layer is tested for various properties. First, professional temperature resistance testing equipment is used to place the fiber matrix layer in a high temperature environment, gradually increase the temperature, and test its temperature resistance level. The temperature resistance level is required to be ≥1300℃ to ensure that deformation, melting, etc. will not occur during the high-temperature metal forging process.

[0111] Measure the thickness of the fiber matrix layer, use a high-precision thickness gauge to measure at multiple locations, and ensure that the thickness is within the range of 5-15mm. At the same time, check its chemical corrosion resistance, place the fiber matrix layer in various chemical environments, except for hydrofluoric acid, phosphoric acid and strong alkaline environments, observe its surface changes, and ensure that it meets the requirements of industrial applications. Screen and remove the parts that do not meet the performance requirements to ensure that the fiber matrix layer entering the next process is of qualified quality.

[0112] Embodiment 2: Refer to the second aspect.

[0113] This embodiment covers the entire manufacturing process of the thermal insulation device, and each step is interrelated and jointly determines the final performance and quality of the thermal insulation device.

[0114] Adhesive preparation and pouring

[0115] According to the mass ratio of chemical paste: borax cosolvent: other ingredients = 1-3: 2-5: 0.02-0.09, the raw materials are accurately weighed and placed in a mixing container. Slowly add an appropriate amount of softened water to the mixing container, stirring while adding, and using a viscometer to monitor the viscosity in real time. By adjusting the amount of softened water added, the viscosity of the adhesive is controlled at 2000±200cP to ensure that the adhesive has good fluidity and bonding properties.

[0116] After the adhesive is prepared and the viscosity meets the requirements, use a CNC dispensing machine to inject it into the dot holes on the surface of the fiber matrix. Set the pressure of the CNC dispensing machine to 0.2-0.4MPa so that the adhesive is injected into the hole at a stable pressure. During the injection process, control the moving speed and injection time of the dispensing machine to ensure that the injection depth reaches 80%-90% of the fiber layer thickness, ensuring that the fiber layer and the adhesive are fully combined.

[0117] Pre-baking

[0118] The fiber matrix filled with the binder is placed in a drying device set at 120°C for pre-baking. The pre-baking time is set to 60 minutes, and a tapping operation is added to perform a downward pressure treatment. During this period, the binder begins to solidify initially to prevent it from flowing or shifting during subsequent processing. The drying equipment needs to have good temperature uniformity and stability to ensure that the entire fiber matrix is ​​heated evenly during the pre-baking process and the binder curing effect is consistent.

[0119] Final curing baking

[0120] The heat preservation device after downward pressing is placed in an automatic baking machine for final curing and baking. The baking starts from 180℃, and the temperature is increased to 250℃ at a rate of 10℃ / min, and then kept warm for 30 minutes. During the heating process, the set heating rate must be strictly followed to ensure that the adhesive is fully cured and the heat preservation device has good mechanical properties and stability.

[0121] Embodiment 3: Refer to the third aspect.

[0122] Based on the third aspect, this embodiment describes in detail the high-temperature metal forging insulation process using a lattice wrapping blanket, focusing on controlling the temperature drop rate and temperature difference.

[0123] Package stage

[0124] Operation process: The lattice wrapping blanket completely covers the surface of the titanium alloy forging, and the "fish scale" overlapping method is used at the joints, with an overlapping width of ≥20mm to ensure that there is no exposed area. Use a high-temperature clamp to fix the edge of the blanket and apply a preload of 0.5MPa to prevent displacement.

[0125] Parameter control: The blanket thickness is selected from 10mm (center area) to 8mm (edge ​​area) to match the thermal expansion coefficient of the workpiece; the fiber matrix layer composition is optimized according to the fifth aspect ratio for thermal shock resistance.

[0126] Bond Activation Stage

[0127] Temperature trigger mechanism: When the workpiece temperature reaches 1000°C, the binder (including nano-alumina reinforcement 4) in the lattice holes completes melting and penetration within 12 seconds, forming a microscopic anchoring between the fiber layer and the workpiece.

[0128] Real-time monitoring: Monitor the flow state of the adhesive through an infrared thermal imager to ensure that the penetration depth is ≥ 85% of the fiber layer thickness. If the penetration is insufficient, start the refilling procedure (pressure is increased to 0.45MPa for 3 seconds).

[0129] Insulation maintenance stage

[0130] Temperature control strategy:

[0131] Temperature drop rate control: A double-layer feedback system is used. The main control module monitors the overall temperature drop through thermocouples, and the auxiliary control module uses distributed optical fiber sensors to detect local temperature differences. When the temperature drop rate is greater than 2.3℃ / min, the auxiliary heating coil (power density 15W / cm 2 ).

[0132] Temperature difference balance: If the local temperature difference is greater than 20°C, the auxiliary pressure module (energy density 6J / cm 2), apply three pulse pressures (pressure 3.5MPa, holding pressure 2 seconds) to the high temperature area to force the fiber layer to redistribute heat.

[0133] Embodiment 4: refer to the content of the fifth aspect.

[0134] This embodiment verifies the actual effect of the device in multi-pass forging of TC4 titanium alloy, and optimizes the process parameters in combination with the application scenario in the sixth aspect.

[0135] Application conditions

[0136] Temperature range: 1020-1200℃ (β phase region), matching the dynamic recrystallization temperature window of titanium alloy.

[0137] Forging parameters: Single forging time is extended to 55 minutes, and the pass interval is shortened to 8 minutes (the traditional process requires reheating, while this solution only requires one reheating).

[0138] Performance comparison

[0139] index Traditional ceramic fiber blanket This device lattice wrap blanket Temperature drop rate (℃ / min) 3.8 2.1 Single forging time (min) 30 55 Reheating times 3 1 Forging grain size (ASTM) Level 6 Level 8

[0140] Economic Benefits

[0141] Reduced energy consumption: Reducing furnace heating reduces natural gas consumption by 42% (actual measured data);

[0142] Improved pass rate: Due to precise temperature difference control, the oxide scale thickness of forgings is ≤50μm (traditional process>100μm), and machining allowance is reduced by 60%.

[0143] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A high-temperature metal forging insulation device based on a lattice wrapping blanket, characterized in that: include: Fiber matrix layer: High temperature resistant fiber blanket made by continuous noil flat-laying double-sided needle-punching process, with a temperature resistance grade of ≥1300℃ and a thickness of 5-15mm. Its chemical corrosion resistance meets the requirements of industrial applications except for hydrofluoric acid, phosphoric acid and strong alkaline environments; Dot matrix bonding layer: a dot matrix hole array with a hole diameter of 3.5-12mm and a hole spacing of 30-80mm is set on the surface of the fiber matrix. A high-temperature adhesive mixed with adhesive, chemical paste and borax solvent in a mass ratio of 1-3:2-5:0.02-0.09 is poured into the holes. After the adhesive is cured, a reinforced anchoring structure that semi-penetrates the fiber layer is formed.

2. A high temperature metal forging heat preservation device based on a lattice wrapping blanket according to claim 1, characterized in that: The high temperature adhesive also includes softened water added in an amount of 12%-15% of the total mass, the viscosity is controlled at 1800-2200 cP, and after curing, the effective bonding time is maintained at 1000-1200° C. for ≥45 minutes.

3. A high temperature metal forging heat preservation device based on a lattice wrapping blanket according to claim 1, characterized in that: The dot hole array adopts a staggered arrangement mode, the offset of adjacent rows of holes is 2-8 times of the aperture, and the aperture gradient decreases from the center to the edge of the blanket, the aperture in the center area is 3-10mm, and the aperture in the edge area is 5-8mm.

4. A method for manufacturing a high-temperature metal forging insulation device based on a lattice wrapping blanket, characterized in that: The following steps are involved: S1: Mix and prepare a binder: mix according to the mass ratio of chemical paste: borax cosolvent = 1-3: 2-5: 0.02-0.09, and add softened water to adjust the viscosity to 2000±200cP; S2: Dot hole perfusion: The adhesive is injected into the dot holes by a CNC dispensing machine at a pressure of 0.2-0.4MPa, and the perfusion depth reaches 80%-90% of the fiber layer thickness; S3: Pre-baking treatment: drying at 120°C for 60 minutes, adding a tapping operation, and performing a downward pressing treatment to initially solidify the adhesive; S4: Final curing baking: Start at 180°C in an automatic baking machine, increase the temperature to 250°C at a rate of 10°C / min, and keep warm for 30 minutes.

5. The method for manufacturing a high-temperature metal forging heat preservation device based on a lattice wrapping blanket according to claim 4 is characterized in that: In the S3, the distance between the pressing process and the workpiece surface is dynamically adjusted with an adjustment accuracy of ±0.1 mm. The temperature of the pressing contact surface is monitored in real time and the pressure value is fed back to control. Every increase of 50°C in temperature corresponds to a decrease in pressure of 0.5 MPa.

6. A high-temperature metal forging heat preservation process, using a high-temperature metal forging heat preservation device based on a lattice wrapping blanket as described in claims 1 to 3, characterized in that: A1: Wrapping stage: The dot matrix wrapping blanket completely covers the workpiece surface, and the overlapping width at the seam is ≥ 20mm; A2: Bonding activation stage: When the workpiece temperature is ≥1000℃, the adhesive on the blanket surface completes melting penetration within 10-15 seconds; A3: Insulation maintenance stage: During the forging process, the blanket is kept completely wrapped, so that the temperature drop rate of the workpiece is ≤2.3℃ / min, and the local temperature difference is controlled within ±15℃.

7. A high temperature metal forging and heat preservation process according to claim 6, characterized in that: When the A3 detects that the local temperature difference exceeds 20°C, the auxiliary pressing operation is automatically triggered to supplement the downward pressure in the temperature difference area, and the downward pressure energy density is 5-8J / cm 2 .

8. The heat preservation device of the high temperature metal forging heat preservation device based on the lattice wrapped blanket according to claim 1 is characterized in that: The composition of the fiber matrix layer includes the following chemical components in mass ratio: Al2O3: 34-37% Si2O: 48-50% ZrO2: 14-17% Al2O3+Si2O+ZrO2:≥99.1 Fe2O3:≤0.2 Na2O+K2O:≤0.

2.

9. An application of a high-temperature metal forging insulation device based on a lattice wrapping blanket, characterized in that: It is suitable for multi-pass forging of titanium alloy and high-temperature alloy forgings in the range of 1000℃-1250℃, which can extend the single forging time to 45-60 minutes and reduce the number of reheating to ≤1 time.

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