The invention relates to the technical field of sand mold
casting, and particularly discloses a gradient exhaust sand mold for an aluminum
alloy thin-walled workpiece and a preparation method thereof.The sand mold comprises a cavity
surface layer (with the
hardness ranging from 90 HB to 95 HB), a
transition layer (with the
hardness ranging from 80 HB to 70 HB and a back sand layer (with the
hardness ranging from 60 HB to 65 HB) which are arranged from inside to outside, and microporous
ceramic exhaust rods (with the
diameter ranging from 0.3 mm to 0.8 mm and the distance ranging from 1 mm to 3 mm) are embedded in the cavity
surface layer; the exhaust rod is composed of a
mullite fiber matrix and a nanometer gamma-AlO
coating, the
porosity is 40-50%, and the exhaust rod penetrates through the back sand layer to form a directional exhaust network. The preparation method comprises the following steps: mixing sand layer by layer (the cavity layer contains 1.0-1.5% of phenolic resin, and the back sand layer contains 0.4-0.6% of resin and 4-6% of
starch); when sand is filled to the position 1-3 mm away from the surface of the cavity, an exhaust rod is implanted (the positioning precision is + / -0.1 mm); gradient compaction is carried out (the
high pressure of a cavity is 3.0-4.0 MPa, the vibration of a transition area is 20-30 Hz, and the back sand
airflow is 0.1-0.2 MPa); and carrying out
microwave curing (2.5 to 3.5 kW, 60 to 120 s). The defects of hot cracks and air holes of the thin-wall part (smaller than or equal to 5 mm) are overcome synchronously, and the
casting yield is increased to 95% or above.