铸造用发热保温冒口套的开发研究
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摘要
随着铸造技术的发展和对铸件质量要求的不断提高,传统工艺的砂型冒口套、已采用的保温冒口套或发热冒口套由于存在着保温不良和发热不足、以及作用单一等缺点,不能满足铸件的补缩要求,因此,研究和开发兼有发热和保温双重作用的发热保温冒口套越来越受到铸造工作者的重视。
本文在阅读大量资料和分析Foseco等国内外已开发的商品化发热保温冒口套的主要物质组成的基础上,选择了铝粉和氧化铁粉为主要发热材料,以碳素材料为辅助发热原料,以钾盐为氧化剂,以空心微珠为保温材料,以水玻璃为粘结剂,并加入粘土和氟铝酸钠等辅助原料,进行了发热保温冒口套试制。在试验过程中,重点探索了三种钾盐氧化剂(A、B和C)对发热保温冒口套性能的影响,确定了发热保温冒口套的基本组成,并优化出了各组成的配比,即空心微珠40%、铝粉17%、氧化铁8%、钾盐A6%、钾盐B4%、钾盐C1%、氟铝酸钠4%、石墨粉15%和粘土5%。同时在试验室成功地进行了冒口套的成型试验。
在学校机械厂铸造车间对自制冒口套和Foseco冒口套进行了现场对比测试,结果表明,在同等试验条件下,自制冒口套钢水温度比同时刻Foseco冒口套中钢水温度平均高30-50℃,说明自制冒口套的发热保温性能优于进口商品化Foseco冒口套。
本文开发的发热保温冒口套所需的原材料来源丰富,价格低廉,而且制作工艺简单,性能良好,有广阔的应用前景。
With the development of foundry technique and the continuous enhancement of quality requirements for castings, the traditional sand riser、insulating riser sleeve and exothermic riser sleeve have their own shortcomings such as the inadequacy of heat preservation or give out heat, even act on a single role. They are unable to meet the feeding requirements of castings.Therefore, research and development of both heating and insulation dual role of the exothermic/insulating riser sleeve more and more are attented by foundry workers.
In this paper,based on a lot of reading references and analysis the main component of the commercialization of exothermic/insulating riser sleeve developed by Foseco.Aluminum and iron oxide powder were chosen as the main heating materials, carbon materials as the supplement heating materials,sylvite as the oxidant, perlite as insulation materials,water glass as binder, clay and sodium aluminum fluoride included also.The exothermic/insulating riser sleeve has been made.In the testing process, three sorts of commonly used sylvite oxidizers(A,B and C) were selected and the influence of the sylvite oxidizers on properties of exothermic/insulating riser sleeve was investigated. The basic components of exothermic/insulating riser sleeve were determined, and a ratio of the components was optimized,such as:cenosphere 40%、aluminum 17%、8% iron oxide、sylvite A6%、B4% and C1%、Na3AlF64%、graphite 15% and 5% clay. At the same time lab successfully for exothermic/insulating riser sleeve molding tests.
A contrast test was researched between self-riser sleeve and Foseco riser sleeve in school casting workshop.The results showed that the same experimental conditions, molten steel temperature in self-made riser sleeve have an average high temperature 30-50℃than that in Foseco riser sleeve at the same time.It indicated that the exothermic/insulating performance of self-made riser sleeve is better than Foseco commercial riser sleeve.
Materials which are used to manufacturing exothermic/insulating riser sleeve are very rich and low prices, and produce process is relatively simple, excellent performance, broad application prospects.
本文在阅读大量资料和分析Foseco等国内外已开发的商品化发热保温冒口套的主要物质组成的基础上,选择了铝粉和氧化铁粉为主要发热材料,以碳素材料为辅助发热原料,以钾盐为氧化剂,以空心微珠为保温材料,以水玻璃为粘结剂,并加入粘土和氟铝酸钠等辅助原料,进行了发热保温冒口套试制。在试验过程中,重点探索了三种钾盐氧化剂(A、B和C)对发热保温冒口套性能的影响,确定了发热保温冒口套的基本组成,并优化出了各组成的配比,即空心微珠40%、铝粉17%、氧化铁8%、钾盐A6%、钾盐B4%、钾盐C1%、氟铝酸钠4%、石墨粉15%和粘土5%。同时在试验室成功地进行了冒口套的成型试验。
在学校机械厂铸造车间对自制冒口套和Foseco冒口套进行了现场对比测试,结果表明,在同等试验条件下,自制冒口套钢水温度比同时刻Foseco冒口套中钢水温度平均高30-50℃,说明自制冒口套的发热保温性能优于进口商品化Foseco冒口套。
本文开发的发热保温冒口套所需的原材料来源丰富,价格低廉,而且制作工艺简单,性能良好,有广阔的应用前景。
With the development of foundry technique and the continuous enhancement of quality requirements for castings, the traditional sand riser、insulating riser sleeve and exothermic riser sleeve have their own shortcomings such as the inadequacy of heat preservation or give out heat, even act on a single role. They are unable to meet the feeding requirements of castings.Therefore, research and development of both heating and insulation dual role of the exothermic/insulating riser sleeve more and more are attented by foundry workers.
In this paper,based on a lot of reading references and analysis the main component of the commercialization of exothermic/insulating riser sleeve developed by Foseco.Aluminum and iron oxide powder were chosen as the main heating materials, carbon materials as the supplement heating materials,sylvite as the oxidant, perlite as insulation materials,water glass as binder, clay and sodium aluminum fluoride included also.The exothermic/insulating riser sleeve has been made.In the testing process, three sorts of commonly used sylvite oxidizers(A,B and C) were selected and the influence of the sylvite oxidizers on properties of exothermic/insulating riser sleeve was investigated. The basic components of exothermic/insulating riser sleeve were determined, and a ratio of the components was optimized,such as:cenosphere 40%、aluminum 17%、8% iron oxide、sylvite A6%、B4% and C1%、Na3AlF64%、graphite 15% and 5% clay. At the same time lab successfully for exothermic/insulating riser sleeve molding tests.
A contrast test was researched between self-riser sleeve and Foseco riser sleeve in school casting workshop.The results showed that the same experimental conditions, molten steel temperature in self-made riser sleeve have an average high temperature 30-50℃than that in Foseco riser sleeve at the same time.It indicated that the exothermic/insulating performance of self-made riser sleeve is better than Foseco commercial riser sleeve.
Materials which are used to manufacturing exothermic/insulating riser sleeve are very rich and low prices, and produce process is relatively simple, excellent performance, broad application prospects.
引文
[1]王敏.保温冒口套在铸造生产中的应用.现代铸铁,2005(4):51~52
[2]张乃蕴,寇凤和.保温冒口套和发热冒口套的应用与现状.机械工艺师,1990(10):40~43
[3]赵玉华,海杰.铸钢用保温冒口套及其应用研究.沈阳航空工业学院学报, 2000(1):34~37
[4]何源,马敏团.新型发热保温冒口套的研制.机械工人(热加工),2000(12):9~10
[5]刘建勇.空心微珠保温冒口套在铸钢件上的应用.东方汽轮机,1993(2):34~36
[6]于永智.复合型保温冒口套在高锰钢挖金斗上的应用.铸造,1994(9):31~33
[7] Julianna Tisza,Zurich,Switzerland.Exothermic Lining for Metallurgical Purposes and Method of Making the Same.United States,4031046,1977.11~19
[8] Donald E.Wiley,Conneaut,Ohio Particulate Metallurgical Hot Topping Compositions and Method of Use . United States , 4119468,1978.106~112
[9] Max G..Neu,Lichfield;Michael J.Gough,Gnosall,both of United Kingdom Exothermic Compositions. United States, 5180759,1993.141~143
[10] Helena Twardowska;Ronald C.Aufderheide,both of Dublin,OH(US). Exothermic Sleeve Compositions Containing Aluminum Dross.Patent United States, 6360808 B1,2002.359~360
[11]曹瑜.发热冒口套在铸钢中的应用.冶金设备.1982(3):39~44
[12] NEU M G, GOUGH M J. Exothermic compsns. used in metal casting feeders etc. - comprising a readily oxidisable metal and an organic fluorine contg.Material. 1987-308363 [09]
[13] C.Stratrnann,Georg Flscher GmbH.发热保温冒口套的主要组成及其制造法.[德国]DE10149876,2003.04.17
[14]梁玉星.铝热反应工艺在大型铸钢件冒口套中的应用.铸造技术,1999(5):22
[15]喻淑仁,邱玲慧,于学斌.对钢水升温用碳质发热剂的初步探讨.武汉钢铁学院学报,1995(3):267~272
[16]李秉杰.发热剂成分配比与浇冒口套的合理设计.特种铸造及有色合金,2006(11):723~725
[17] Trinkl, G. Simmons, W. Application of feeding and filtration technology to effect scrap reduction,yield and quality improvement in mechanised iron foundries.British Foundryman, 1984(77): 463~469
[18] Creese, R. C.Cylindrical top riser design relationships for evaluating insulating materials.Transactions of the American Foundrymen's Society, 1982(89):345~348
[19] Neu, M. G. Feeding aids-A survey of methods and technology.Foundry Trade Journal, 1984(156):17~18, 21~22, 24
[20] Spencer, I. D. Corns, B. Towards the sounder casting-Some developments in feeding aids and calculation methods.Foundry Trade Journal,1985(159):476, 478, 480
[21] Wukovich, Nick.Briggs, John.Do your feeding aids pass the test? Modern Casting, v 77, n 9, Sep, 1987(77):33~36
[22] Yuzov, O. V.Stepanova, N. A.Effectiveness of the combined use of exothermic and heat-insulating materials for casting steel.Steel in the USSR, 1974(4):548~549
[23] Spravnik, V. I,Karev, G. G,Vygodner, L. F.Exothermic feeder heating for steel castings.Soviet Castings Technology (English Translation of Liteinoe Proizvodstvo), 1986(4):34~37
[24] Shneerov, Ya. A,Konovalov, R. P,Polyakov, V. F.Effective exothermic mixtures for heating ingot heads. Steel in the USSR, 1978(8):75~77
[25]全北平,徐宏,古宏晨等.粉煤灰空心微珠的研究与应用进展.IM&P化工矿物与加工,2003(11):30~33
[26]余祖球,梁爱莲.珍珠岩的特性与应用.陶瓷科学与艺术,2002(4):29~33
[27]宋世林,付桂元.试验室测试珍珠岩膨胀性能研究.非金属矿,2001(1):9~10
[28]王爱琴,王文炎,谢敬佩等.GL-1型冒冒口套覆盖剂及应用.热加工工艺,2003(3):58~59
[29]翟秀静,张楠.纳米金属材料的研究进展[J].材料导报,1999(12):22
[30]曲卫淘.铸钢件保温冒口套研究及应用[J].铸造工艺,1984(3):14
[31]张淑兰.一种新型冒口套用覆盖剂.热加工工艺,1994(2):41~42
[32]今村实.铸钢件合理使用发热补贴的研究.铸造,1985(2):10~12
[33]刘环,崔雅茹等.用O#粘结剂取代酚醛树脂制作整体型轻质保温冒口套.铸造技术,2005(11):1001~1003
[34]李俊儒,张明.发热冒口套的试验研究.山西机械,1994(1):25~28
[35]冯光陆.保温冒口套在活塞铸造中的应用.内燃机配件,1999(2):5~9
[36]吕建强.石灰石砂潮模及保温冒口套在铸钢件生产中的应用.机械工人(热加工),2006(11):62~63
[37]符莉,王庆顺,朱昆维等.珍珠岩复合型保温冒口套的应用.热加工工艺,1988(5):50~52
[38]顾卫星.纤维复合型保温冒口套在江苏省应用现状.机械工艺师,1989(1):16
[39]李成福,吴锡潮.铸钢件冒口套的绝热混合料.现代制造工程,1982(6):29
[40]冯胜山,蒋枢.铸件冒口套保温节能节材工艺的现状及发展(二).技术适用市场,1991(9):4~6
[41]熊仲明,寇凤和,文道俊等.球墨铸铁液压件发热冒口套的研究.北京钢铁学院学报,1987(2):8
[42] Gotheridge J E.发热材料在铸钢生产中的应用.国外铸造,1965(2):33~42
[43] Gough, M. J,Morgan, J. Feeding ductile iron castings em dash some recent experiments.Transactions of the American Foundrymen's Society,Apr26-30,1977(84): 351~384
[44] Mair H.Survey of the application of exothermic and insulating materials in steel and iron foundries.Brit Foundryman, Dec, 1970(63):385~400
[45] Chernyshev, E.A,Fokin, V.I,Varlamov, A.I.The rise of efficiency of casting feeding by easy-separable feeder heads.Liteinoe Proizvodstvo, Apr-May, 1995 (4-5):44
[46] Corbett, C. F. Use of insulating materials for feeder heads in steel castings. BritishFoundryman, Apr, 1974(67):106~115
[47] Rader, L. A. (GE, Schenectady, NY, USA),Haines, D. R.Computer simulation of experimental risering studies.Transactions of the American Foundrymen's Society, 1983(91):89~94
[48]樊国安,徐家颖.Kalminex xp发热保温冒口套在铁路货车转向铸钢件上的应用.铸造,2005(6):617~619
[2]张乃蕴,寇凤和.保温冒口套和发热冒口套的应用与现状.机械工艺师,1990(10):40~43
[3]赵玉华,海杰.铸钢用保温冒口套及其应用研究.沈阳航空工业学院学报, 2000(1):34~37
[4]何源,马敏团.新型发热保温冒口套的研制.机械工人(热加工),2000(12):9~10
[5]刘建勇.空心微珠保温冒口套在铸钢件上的应用.东方汽轮机,1993(2):34~36
[6]于永智.复合型保温冒口套在高锰钢挖金斗上的应用.铸造,1994(9):31~33
[7] Julianna Tisza,Zurich,Switzerland.Exothermic Lining for Metallurgical Purposes and Method of Making the Same.United States,4031046,1977.11~19
[8] Donald E.Wiley,Conneaut,Ohio Particulate Metallurgical Hot Topping Compositions and Method of Use . United States , 4119468,1978.106~112
[9] Max G..Neu,Lichfield;Michael J.Gough,Gnosall,both of United Kingdom Exothermic Compositions. United States, 5180759,1993.141~143
[10] Helena Twardowska;Ronald C.Aufderheide,both of Dublin,OH(US). Exothermic Sleeve Compositions Containing Aluminum Dross.Patent United States, 6360808 B1,2002.359~360
[11]曹瑜.发热冒口套在铸钢中的应用.冶金设备.1982(3):39~44
[12] NEU M G, GOUGH M J. Exothermic compsns. used in metal casting feeders etc. - comprising a readily oxidisable metal and an organic fluorine contg.Material. 1987-308363 [09]
[13] C.Stratrnann,Georg Flscher GmbH.发热保温冒口套的主要组成及其制造法.[德国]DE10149876,2003.04.17
[14]梁玉星.铝热反应工艺在大型铸钢件冒口套中的应用.铸造技术,1999(5):22
[15]喻淑仁,邱玲慧,于学斌.对钢水升温用碳质发热剂的初步探讨.武汉钢铁学院学报,1995(3):267~272
[16]李秉杰.发热剂成分配比与浇冒口套的合理设计.特种铸造及有色合金,2006(11):723~725
[17] Trinkl, G. Simmons, W. Application of feeding and filtration technology to effect scrap reduction,yield and quality improvement in mechanised iron foundries.British Foundryman, 1984(77): 463~469
[18] Creese, R. C.Cylindrical top riser design relationships for evaluating insulating materials.Transactions of the American Foundrymen's Society, 1982(89):345~348
[19] Neu, M. G. Feeding aids-A survey of methods and technology.Foundry Trade Journal, 1984(156):17~18, 21~22, 24
[20] Spencer, I. D. Corns, B. Towards the sounder casting-Some developments in feeding aids and calculation methods.Foundry Trade Journal,1985(159):476, 478, 480
[21] Wukovich, Nick.Briggs, John.Do your feeding aids pass the test? Modern Casting, v 77, n 9, Sep, 1987(77):33~36
[22] Yuzov, O. V.Stepanova, N. A.Effectiveness of the combined use of exothermic and heat-insulating materials for casting steel.Steel in the USSR, 1974(4):548~549
[23] Spravnik, V. I,Karev, G. G,Vygodner, L. F.Exothermic feeder heating for steel castings.Soviet Castings Technology (English Translation of Liteinoe Proizvodstvo), 1986(4):34~37
[24] Shneerov, Ya. A,Konovalov, R. P,Polyakov, V. F.Effective exothermic mixtures for heating ingot heads. Steel in the USSR, 1978(8):75~77
[25]全北平,徐宏,古宏晨等.粉煤灰空心微珠的研究与应用进展.IM&P化工矿物与加工,2003(11):30~33
[26]余祖球,梁爱莲.珍珠岩的特性与应用.陶瓷科学与艺术,2002(4):29~33
[27]宋世林,付桂元.试验室测试珍珠岩膨胀性能研究.非金属矿,2001(1):9~10
[28]王爱琴,王文炎,谢敬佩等.GL-1型冒冒口套覆盖剂及应用.热加工工艺,2003(3):58~59
[29]翟秀静,张楠.纳米金属材料的研究进展[J].材料导报,1999(12):22
[30]曲卫淘.铸钢件保温冒口套研究及应用[J].铸造工艺,1984(3):14
[31]张淑兰.一种新型冒口套用覆盖剂.热加工工艺,1994(2):41~42
[32]今村实.铸钢件合理使用发热补贴的研究.铸造,1985(2):10~12
[33]刘环,崔雅茹等.用O#粘结剂取代酚醛树脂制作整体型轻质保温冒口套.铸造技术,2005(11):1001~1003
[34]李俊儒,张明.发热冒口套的试验研究.山西机械,1994(1):25~28
[35]冯光陆.保温冒口套在活塞铸造中的应用.内燃机配件,1999(2):5~9
[36]吕建强.石灰石砂潮模及保温冒口套在铸钢件生产中的应用.机械工人(热加工),2006(11):62~63
[37]符莉,王庆顺,朱昆维等.珍珠岩复合型保温冒口套的应用.热加工工艺,1988(5):50~52
[38]顾卫星.纤维复合型保温冒口套在江苏省应用现状.机械工艺师,1989(1):16
[39]李成福,吴锡潮.铸钢件冒口套的绝热混合料.现代制造工程,1982(6):29
[40]冯胜山,蒋枢.铸件冒口套保温节能节材工艺的现状及发展(二).技术适用市场,1991(9):4~6
[41]熊仲明,寇凤和,文道俊等.球墨铸铁液压件发热冒口套的研究.北京钢铁学院学报,1987(2):8
[42] Gotheridge J E.发热材料在铸钢生产中的应用.国外铸造,1965(2):33~42
[43] Gough, M. J,Morgan, J. Feeding ductile iron castings em dash some recent experiments.Transactions of the American Foundrymen's Society,Apr26-30,1977(84): 351~384
[44] Mair H.Survey of the application of exothermic and insulating materials in steel and iron foundries.Brit Foundryman, Dec, 1970(63):385~400
[45] Chernyshev, E.A,Fokin, V.I,Varlamov, A.I.The rise of efficiency of casting feeding by easy-separable feeder heads.Liteinoe Proizvodstvo, Apr-May, 1995 (4-5):44
[46] Corbett, C. F. Use of insulating materials for feeder heads in steel castings. BritishFoundryman, Apr, 1974(67):106~115
[47] Rader, L. A. (GE, Schenectady, NY, USA),Haines, D. R.Computer simulation of experimental risering studies.Transactions of the American Foundrymen's Society, 1983(91):89~94
[48]樊国安,徐家颖.Kalminex xp发热保温冒口套在铁路货车转向铸钢件上的应用.铸造,2005(6):617~619