铝合金叶轮铸造工艺优化设计

铝合金叶轮铸件厚薄不均、结构复杂,在铸件内部易于产生微观缩松。结合实际生产条件,对铝合金叶轮铸件原工艺进行了充型凝固过程模拟,通过对流动形态、凝固顺序及缩松、缩孔缺陷的分析,并与实际铸件进行对比,得到了原工艺缺陷产生的原因。在此基础上,利用华铸CAE软件对铝合金叶轮铸件进行了工艺优化分析,获得了较优的工艺方案,并进行了实际浇注验证。结果表明,优化工艺后,有效减少直至消除了铸件的缩孔、缩松缺陷。     

Cr30A耐磨耐蚀叶轮的铸造工艺改进

针对Cr30A材质的特点,对原有耐磨耐蚀叶轮铸件存在的缩孔、粘砂、裂纹等缺陷进行分析,改善原工艺的补缩系统,改进砂芯的制作工艺,较好地解决了铸件的缩孔、粘砂、裂纹等缺陷.进一步利用计算机模拟进行分析优化,采用发热冒口,提高了铸件的工艺出品率.     

陶瓷型芯在制造窄流道叶轮上的应用

本文阐述了用陶瓷型芯生产整铸窄流道叶轮的试验情况.解决了型芯陶坯成型困难、烧结型芯易变形、浇注时型芯强度不足、铸件型芯清除困难等技术难题,生产出最大直径为300mm,最小流道宽度为2.5mm、内腔光洁度为lOμm、尺寸精度满足要求的化工机械用不锈钢叶轮.     

陶瓷型芯的制造窄流道叶轮上的应用

本文阐述了用陶瓷型芯生产整铸窄流道叶轮的试验情况。解决了型芯陶坯成型困难、烧结型芯易变形、浇注时型芯强度不足、铸件型芯清除困难等技术难题，生产出最大直径为３００ｍｍ，最小流道为２．５ｍｍ、内腔光洁度为１０μｍ、尺寸精度满足要求的化工机械用不锈钢叶轮。     

高温应用氦气压缩机窄流道叶轮焊接工艺开发及应用

叶轮是压缩机的核心部件,其制造质量和可靠性对机组的安全运行至关重要。文中简要介绍了高温应用氦气压缩机叶轮结构,分析了焊接难点,通过焊接工艺试验及焊接工艺评定说明了开槽焊工艺的可行性,并介绍了窄流道叶轮产品的焊接工艺。产品叶轮超转速及机械运转试验表明,叶轮开槽焊接接头的力学性能指标及加工质量满足设计要求。     

离心泵钛叶轮精密铸造气孔缺陷的防止措施

介绍了钛及钛合金的铸造工艺特点及某型号钛叶轮的铸造工艺方法。分析了该型号钛叶轮铸造气孔缺陷产生的原因。采取控制原材料质量、控制涂料和干燥过程以及开设排气孔等工艺措施使钛叶轮铸件内气孔缺陷显著减少。     

窄流道封闭式叶轮的制壳工艺改进

生产封闭式窄流道叶轮，为降低成本，可避免使用水溶砂芯，采取直接制壳的方法。经过生产实践，沾3次面层后，在进出水口部灌浆砂，中间灌干砂，既可保证铸件质量，减少废品，同时容易去除流道内的废砂。     

脱硫泵叶轮的铸造工艺

脱硫泵叶轮叶片扭曲度大,铸件形状较复杂,有一定的生产难度.针对叶轮铸件的结构及技术要求,确定了材料化学成分,改进了铸造工艺参数.通过合理设计铸造工艺,得到了脱硫泵叶轮铸件的最佳工艺方案.     

用流涂的方法生产真空泵叶轮铸件

通过对刷涂,喷涂,浸涂,流涂四种涂敷工艺反复分析比较和对不同的骨料和不同的载液涂料进行试验,采用水基锆英粉涂料和流涂涂敷工艺能使真空泵叶轮铸件的叶片芯子获得均匀光洁涂层。     

大型挖泥泵叶轮铸造缺陷分析及其对策

叶轮是整个挖泥泵的核心过流部件,其质量要求很高。大型挖泥泵叶轮铸件容易出现缩孔、气孔、冷隔等铸造缺陷。详细分析了叶轮不同部位缺陷产生的原因,针对浇冒口系统、型砂工艺、涂料、浇注工艺及打箱清理工序制定了防止缺陷产生的相关对策,使生产的大型挖泥泵叶轮铸件合格率达到95％以上。     

涡轮壳覆膜砂铸造材料和工艺研究

对涡轮壳的垂直分型覆膜砂铸造的工艺进行了分析。分析了对原材料的选择，分析了涂料、覆膜砂对铸件质量的影响。着重分析了过滤片对改善涡轮壳砂渣眼的重要作用。     

炉箅子铸造工艺改进

分析了热风炉炉箅子原铸造工艺存在的主要问题,针对炉箅子的结构和技术要求,采用消失模铸造工艺代替砂型铸造,从工艺参数、白模、浇注系统、消失模涂料、浇注温度和负压参数等方面确定了改进后的铸造工艺.实施结果表明,炉箅子的力学性能及其表面质量、尺寸公差完全达到用户的要求.与砂型铸造相比,明显提高了铸件的出品率,缩短了加工周期,经济效益显著.     

不锈钢板坯连铸结晶器窄面铜板涂层新技术

不锈钢铸坯的凝固特性与碳钢截然不同,其对结晶器窄面铜板的侵蚀与磨损非常严重.本文通过对不锈钢连铸现场结晶器铜板的使用效果跟踪检测与记录,分析其破坏机理,并对多种技术窄面涂层进行对比,提出将高效能半导体激光器与火焰喷涂相结合的新型喷涂技术,提高了窄面铜板涂层寿命.     

离心铸造球铁管浇注流槽涂料及其涂刷工艺

主要论述流槽涂料的工况特殊性。重点阐述涂料与流槽的粘结机理及影响因素，总结出涂料配方及合适的施涂工艺参数。     

F3汽缸盖铸造缺陷的防止

针对低压铸造F3汽缸盖出现的铸件缺陷,在铸造工艺上进行了改进。解决铸件气道粘砂问题的办法,一是气道砂芯表面刷细密涂料;二是改进砂芯摆放方式,由原来的堆码式改为分层分件隔离式。对于壁厚复杂铸件常出现的缩松、缩孔问题,采用激冷方式得到解决;而对于局部厚大部位的缩松问题,采用顺序凝固,开辟补缩通道也行之有效。     

涂料对离心铸造缸套质量的影响

采用离心铸造生产缸套时,涂料质量不良、上涂料工艺和涂层厚度不当会使铸件局部产生白口,难以加工,也可能引起铸件外表面产生缺陷,因而介绍了离心铸造对涂料质量的要求及评定方法,涂料质量的控制,上涂料方法的选择,铸型温度的控制以及涂层厚度的选择。     

转移涂料法在青铜浮雕艺术铸造中的应用

介绍了一种制作青铜艺术品的新工艺,通过 料的各种性能来满足青铜艺术铸品的种种上要求,最终将转移涂料精密成形技术与青铜艺术铸造有机结合在 ,为艺术铸造开辟了新的途径,从涂料组成、喷涂工艺以及造型工艺等方面探讨,较好的解决了自硬转移涂料在青铜艺术铸造应用中的主要问题。     

Effect of Slurry Composition on Plate Weight in Ceramic Shell Investment Casting

This paper deals with the study of the effect of primary slurry parameters on the plate weight (ceramic retention test) in ceramic shell investment casting process. Four controllable factors of the zircon flour and fused-silica powder based slurries were studied at three levels each by Taguchi’s parametric approach and single-response optimization of plate weight was conducted to identify the main factors controlling its stability. Variations in coating thickness with plate weight were calculated for each slurry and ceramic shell moulds were made on wax plate using primary slurry and coarse fused-silica sand as stucco. The Scanning Electronic Microscopy (SEM) technique has been used to study the surface morphology of zircon flour and fused silca powder particles as well as primary coating (shell surface). X-ray Diffraction (XRD) analysis was done to identify the various phases present in the ceramic slurry coating. Optical profilometer has been used to measure the surface roughness of the shells. The result reveals that the surface condition of shell can be improved by increasing the plate weight, corresponding to higher filler loading in the slurry. Confirmation experiments were conducted at an optimal condition showed that the surface quality of the ceramic shell mould were improved significantly. Castings were produced using Al-7%Si alloy in recommended parameters through ceramic shell investment casting process. Surface roughness of the produced casting were measured and presented in this paper.     

Effect of thermophysical property and coating thickness on microstructure and characteristics of a casting

A new improved investment casting technology(IC) has been presented and compared with the existing IC technology such as lost foam casting(LFC). The effect of thermophysical property and coating thickness on casting solidification temperature field, microstructure and hardness has been investigated. The results show that the solidification rate decreases inversely with the coating thickness when the coating contains silica sol, zircon powder, mullite powder and defoaming agent. In contrast, the solid cooling rate increases as the coating thickness increases. However, the solidification rate and solid cooling rate of the casting produced by the existing IC and the improved IC are very similar when the coating thickness is 5 mm, so the microstructure and hardness of a container corner fitting produced by the improved IC and the existing IC are similar. The linear regression equation for the grain size(d) and cooling rate(v) of the castings is d= –0.41v+206.1. The linear regression equation for the content of pearlite(w) and solid cooling rate(t) is w=1.79 t + 6.71. The new improved IC can greatly simplify the process and decrease the cost of production compared with the existing IC. Contrasting with LFC, container corner fittings produced by the new improved IC have fewer defects and better properties. It was also found that the desired microstructure and properties can be obtained by changing the thermophysical property and thickness of the coating.     

摇枕铸钢件麻坑缺陷的消除

生产中发现二氧化碳水玻璃石英砂铸钢件麻坑缺陷与二氧化碳水玻璃石灰石砂铸钢件的麻坑形貌特征相似。试验指出：采用与消除二氧化碳水玻璃石灰石砂铸钢件麻坑缺陷相同的方法如：改性涂料、不上涂料、改良面砂等工艺方法可有效地消除二氧化碳水玻璃石英砂铸钢件的麻坑缺陷。