Development tendencies of moulding and core sands

Further development of the technology for making moulding and core sands will be strictly limited by tough requirements due to protection of the natural environment. These tendencies are becoming more and more tense, so that we will reach a point when even processes, that from technological point of view fulfill high requirements of the foundry industry, must be replaced by more ecologically-friendly solutions. Hence, technologies using synthetic resins as binding materials will be limited. This paper presents some predictable development tendencies of moulding and core sands. The increasing role of inorganic substances will be noticed, including silicate binders with significantly improved properties, such as improved knock-out property or higher reclamation strength. Other interesting solutions might also be moulding sands bonded by geo-polymers and phosphate binders or salts and also binders based on degradable biopolymers. These tendencies and the usefulness of these binders are put forward in this paper.

Technology and mechanism of a new protein-based core sand for aluminum casting

The protein based binding material is from natural products, which is nontoxic and recyclable. This kind of green binder is earnestly needed by aluminum casting products. The new protein based core possesses higher strength and easier shakeout. Its tensile strength is close to that of common resin sands. The micro mechanism of protein binder was investigated by using infrared spectrum, chemical element analysis, SEM and thermal lost mass analysis.

Influence of core sand properties on flow dynamics of core shooting process based on experiment and multiphase simulation

The influence of core sand properties on flow dynamics was investigated synchronously with various core sands, transparent core-box and high-speed camera. To confirm whether the core shooting process has significant turbulence, the flow pattern of sand particles in the shooting head and core box was reproduced with colored core sands. By incorporating the kinetic theory of granular flow(KTGF), kinetic-frictional constitutive correlation and turbulence model, a two-fluid model(TFM) was established to study the flow dynamics of the core shooting process. Two-fluid model(TFM) simulations were then performed and a areasonable agreement was achieved between the simulation and experimental results. Based on the experimental and simulation results, the effects of turbulence, sand density, sand diameter and binder ratio were analyzed in terms of filling process, sand volume fraction(αs) and sand velocity(Vs).

Pore-based architecture and representative element volume evaluation in artificial sand packs and natural rock cores

The phenomenon of multiphase flow in porous media is confronted in various fields of science and industrial applications. Owing to the complicated porous structure, the flow mechanisms are still not completely resolved. A critical and fundamental question is the variation of pore structure and REV sizes among different types of porous media. In this study, a total of 22 porous samples were employed to systematically evaluate the pore-based architecture and REV sizes based on X-ray CT image analysis and pore network modelling. It is found that the irregular grain shapes give rise to large specific areas,narrow and thin throats in identical sand packs. The packs with more types of sands, or composited by the sands with larger difference in diameter, have larger specific area, smaller tortuosity and pore spaces.Based on the REV measurement through porosity solely, the REV sizes of sand packs are generally in the order of magnitude of 10^(-2) m L, while it is at least one order of magnitude smaller in rock cores. Our result indicates that the combination of porosity and Euler number is an effective indicator to get the REV sizes of porous samples.

Erosion problem in tool steel using cold box core-making process

This paper presents the erosion results of the AISI H13 steel impinged by resin-bonded silica sand, using a testing rig that closely simulates the real blowing conditions during industrial core-making. Steel specimens were heat treated to obtain hardness of 294, 445 and 595 HV200 (29, 45 and 55 HRC). Erosion tests were carried out at impingement angles from 20° to 90° and air drag pressures of 1.38, 2.07 and 2.76 bar (20, 30 and 40 psi). The main results are summarized as follows:(i) The harder material, the lower erosion;(ii) the maximum erosion rate is at 30°;(iii) Little difference in erosion rate at impact angle of 60° and 90° for a constant pressure tested regardless of the hardness level;(iv) As the pressure increases, so does the erosion rate, being more sensitive for low impact angles. Finally, a differential form of the general erosion equation is applied on a practical core-making case to evaluate the erosion rate of the H13 steel at 30° and 90° impingement angles.

Investigations of physicochemical properties of dusts generated in mechanical reclamation process of spent moulding sands with alkaline resins

Mechanical reclamation processes of spent moulding sands generate large amounts of postreclamation dusts mainly containing rubbed spent binding agents and quartz dusts. The amount of postreclamation dusts, depending in the reclamation system effi ciency and the reclaim dedusting system, can reach 5%-10% in relation to the total reclaimed spent moulding sand. The proper utilization of such material is a big problem facing foundries these days. This study presents the results of investigations of physicochemical properties of post- reclamation dusts. All tested dusts originated from various Polish cast steel plants applying the mechanical reclamation process of moulding sands with alkaline resins, obtained from different producers. Different dusts, delivered from foundries, were tested to determine their chemical composition, granular characterization, physicochemical and energetic properties. Presented results confi rmed assumptions that it is possible to utilize dusts generated during mechanical reclamation of used sands with organic resins as a source of energy.

Suitability of lost cores in rheocasting process

When treated in pressure die casting processes the semi-solid aluminum alloys demand resilient cores which can bear the stress occurring during filling and the final pressure phase.The design of permanent cores is highly restricted in order to maintain removability.Lost cores provide the possibility of complex,undercut geometrical shapes which is mandatory for a variety of casting components.However,eligible materials which show appropriate resilience and proper decomposition properties at the same time,and in the upper echelon of cost-effectiveness,are seldom known.With the semi-solid process suited between HPDC and GDC regarding the core stress,several common and economically efficient lost core systems could be used.A selection of potentially suitable materials was identified and tested.The range of testing comprises widespread sand core-systems(amin-pur-coldbox and CO2-water-glass) as well as materials less commonly used,namely salt,plastic and zinc.Different types of conditioning are applied to enhance the surface properties.The mechanical properties of the sand cores are enhanced by different heat treatment methods during curing.The cores are tested producing a research component cast on a HPDC machine with semi-solid A356 slurry fabricated in the cooling channel process.The cast component was analyzed regarding shape stability,core removability and surface as well as the structure quality.The results show the importance of the surface conditioning for the sand-cores while salt and zinc produce good parts comparable to the reference steel core quality.

高液压射台前板球墨铸铁件铸造工艺设计

射台前板是注塑机中的关键部件之一,其油缸孔部位加工精度高且有承压要求。本文介绍了高液压球墨铸铁射台前板铸件的工艺难点,设计了分型方案、浇注系统及冷却系统,并借助软件模拟分析了缩孔与缩松缺陷,确定了型芯方案。通过合理选择铸件的化学成分,严格控制球化、孕育及浇注过程,铸件本体渗透检验(PT)达到EN1371标准的质量等级I级,附铸试块铸件的力学性能和金相组织均符合客户标准。

柴达木盆地卤水钾盐迁聚规律与找矿新突破

钾盐是我国大宗紧缺战略性“粮食”矿产,对保障国家粮食安全具有重要意义。我国钾盐资源具有需求量大、对外依存度高等特点,寻找新的钾盐矿床、形成新的大型钾盐资源基地刻不容缓。2023年,中国地质调查局组织开展青海柴达木盆地钾盐“增储保供”地质调查工作,在前期对柴达木盆地成盐聚钾规律性认识的基础上,于柴西北大浪滩—黑北凹地部署实施了“探采一体化”柴钾1井,钻获1021.95 m(井深111.54~1133.49 m)巨厚松散砂砾储卤层,全井段抽卤试验获日稳定涌水量8586 m^(3)/d、水位降深11.3 m、单位涌水量759.89 m^(3)/d·m、氯化钾平均含量为0.54%的高产工业品位“砂砾型”卤水钾矿,取得了柴达木盆地陆相深层卤水钾盐找矿新突破,为形成中国新的亿吨级大型钾盐基地夯实了资源基础。

风荷载和列车共同作用下风积沙包芯路基边坡稳定性研究

我国是世界上沙漠分布最多的国家之一,沙漠中蕴藏着丰富的矿产资源。西部大开发和“一带一路”倡议将进一步推进沙漠地区铁路建设。利用丰富的沙漠风积沙作为铁路路基填料具有重要的经济意义和推广应用前景,风积沙包芯路基是一种充分利用风积沙作为铁路路堤填料的新型结构。为研究列车荷载和风荷载共同作用下风积沙包芯路基边坡稳定性计算方法,基于折线滑动法原理,对路堤结构进行分层分区,采用极限平衡方法,推导出列车荷载和沙漠风荷载共同作用下铁路风积沙包芯路基的稳定性系数计算公式并编制计算程序。结合和若铁路风积沙包芯路基的工程实例,验证了该计算方法的可行性。基于该计算程序,研究了风荷载大小、风向角、路堤填筑高度、填料内摩擦角等影响因素对风积沙包芯路基边坡稳定性系数的影响,分析了风向角、填料内摩擦角等影响因素对风积沙包芯路基边坡砂卵石封层最小厚度的影响。计算结果表明,风积沙包芯路基边坡稳定性系数与风荷载大小近似呈线性负相关,与风向角大小呈非线性正相关。风积沙包芯路基边坡稳定性系数富余量与路堤填筑高度呈负相关。风积沙包芯路基边坡砂卵石封层最小厚度与风向角大小呈非线性负相关,与风积沙填料的内摩擦角大小近似呈线性负相关。建议风积沙包芯路基边坡设计中应考虑风荷载的影响。研究成果可供沙漠地区风积沙包芯路基设计借鉴和采用。

列车荷载作用下风积沙包芯路基动力响应试验研究

我国沙漠铁路沿线优良填料极其匮乏而风积沙资源相对丰富,但风积沙存在级配不良、结构松散等缺陷,不宜直接用作基床填料。风积沙包芯路基兼顾经济环保与力学性能,就地取用沿线风积沙填筑基床底层,取用卵石土对其包边封层。通过对风积沙包芯路基开展现场实车动测,获得路基动响应与振动能量的空间分布特征以及随轴重和车速的变化规律。研究结果表明:路基动应力沿深度的衰减主要集中于路基面以下0~0.6 m和1.5~2 m范围内,加速度沿边坡的衰减主要在距轨道中心5 m范围内。动应力和加速度幅值均随轴重和车速的提高明显增大,衰减速率随轴重的增加而降低。动应力频谱服从倍频规律和幅值调制效应,0~2 Hz的低频振动对动应力起控制作用。加速度振级集中分布于12.5~31.5 Hz中心频段内,0~10 Hz的低频段振级沿边坡衰减剧烈,10~40 Hz高频段振级的衰减相对较小。振动总能量沿路堤边坡耗散近80%,总能量在各频带上的聚集量:频带2>频带1>频带3>频带4。各频带能量均随轴重和车速的增加而增大,增长幅度随频带的提高逐级递减。研究成果可以为沙漠铁路路基工程的后续建管标准与运维实践提供参考。

松辽盆地海力锦铀矿床含矿地层岩石弹性参数特征研究

当前,地震勘探技术在砂岩型铀矿勘查中主要用于查明地层展布、构造和砂体等成矿环境要素,而在分辨地层岩石是否含矿等铀矿信息直接获取方面尚存在欠缺。砂岩型铀矿含矿砂体与围岩的弹性参数差异是开展含矿砂体地震识别技术研究的基础,针对松辽盆地海力锦铀矿床的含矿地层,采集三口钻井的岩心,在实验室采用“线切割+全程样品防护”方式制获岩心样品,通过“量积法+超声脉冲透射法”开展测量,获取钻井岩心样品的纵波速度、横波速度和密度等弹性参数,并计算钻井岩心的纵波阻抗和横波阻抗,在此基础上开展海力锦铀矿床含矿地层岩石的弹性参数特征研究。研究结果表明:在含矿层深度范围内,岩石弹性参数差异主要受岩石岩性影响,而受深度变化的影响可忽略不计;地层岩石不同岩性的速度、密度和波阻抗等弹性参数存在差异,特别是含矿中砂岩的密度和速度参数与围岩存在一定差异,可根据密度和纵波速度差异识别含矿中砂岩,并给出相应的技术方案,为开展岩石岩性及含矿砂体的地震精细识别研究提供依据。

复杂内腔铝合金件液态模锻试验研究

目的为拓宽液态模锻技术的应用范围,实现具有复杂内腔结构件的高性能短流程成形制造,开展了使用砂芯的液态模锻技术试验研究。方法以具有复杂内腔的新能源汽车铝合金空气弹簧顶座为对象,利用广州和德装备制造公司生产的卧式液态模锻机,对比研究不同砂芯、涂料及液锻加压制度对黏砂缺陷的影响作用。结果普通砂芯在液锻中容易被压溃或产生黏砂缺陷;在苏铸砂芯的基础上自行配制HDSC01液锻砂芯,配合HDCoating03专用涂料,采用阶梯加压方法进行液态模锻,所得液锻件内表面光洁无黏砂、尺寸精确。结论液态模锻可以使用砂芯进行复杂内腔结构件的高性能精密成形,但工艺控制不当,容易出现黏砂缺陷。阶梯加压、使用专用砂芯和专用涂料是防止黏砂的有效途径。

铝合金副车架环保型制芯工艺研究及应用

针对整体式铝合金副车架树脂砂芯体积大,浇注过程烟雾大、环境污染严重等难点,试制开发无机砂芯工艺。通过制芯设备选型、水平分模射芯方式确定,再对芯砂组份配比、混砂时间、芯盒温度、保存温度及湿度等工艺参数进一步试验研究。试验结果表明,整体式副车架铸造采用无机制芯工艺砂芯更容易成型,浇注过程中不仅没有明显的热分解产物、无任何凝聚物,还易溃散去砂效果好、发气量低等优点,有效降低气孔类缺陷提高产品质量,促进绿色低碳铸造技术发展。

高温合金熔模精密铸造陶瓷型芯研究进展

陶瓷型芯广泛应用于飞机发动机涡轮叶片的熔模精密铸造中,以实现涡轮叶片复杂的空心结构。本文介绍了高温合金熔模精密铸造用陶瓷型芯的应用现状,概述了陶瓷型芯的制备工艺和常用基体材料的研究进展,分别对石英玻璃、电熔刚玉、锆英石、氧化钇等基体材料制备陶瓷型芯的优缺点和研究进展进行了概述。

缸体铸件气孔缺陷成因分析及改进措施

2.5 L柴油机缸体铸件在工艺验证和小批量生产阶段,水套部位气孔为最突出的铸造缺陷,主要是由于水套砂芯发气未有效排出和水套结构孤立高点铁液温度低所致。通过增加内浇道优化浇注系统、设置排气通道回路增加水套砂芯排气、提高浇注温度等措施,有效解决了水套的气孔缺陷问题。经生产验证,气孔缺陷废品比例大幅度下降,由原来的11%左右下降到了0.6%左右。

岩心数字化技术研究与应用

岩心是油气田勘探开发的核心战略资源之一,在油气藏岩相、储层物性、含油性的研究中发挥着重要作用。与纸质资料相比,岩心实物地质资料具有缩减性和可变性的特点,岩心“原貌”不可能长久保存,从而降低了岩心的使用价值。岩心数字化技术可以及时采集岩心各项原始数据,丰富岩心地质信息,提升岩心资料利用率,因此开展岩心数字化技术研究具有重要意义。根据胜利油田岩心数字化建设的生产实践,对岩心数字化的概念、设备和技术内容进行了阐述,分析了岩心伽马能谱测量、XRF元素测试、磁化率测试、CT扫描等多种重要的岩心数字化技术,并探讨了各项技术的地质应用效果。研究结果表明,岩心数字化技术具有测试快、连续性好、数据多、精度高等优势,可以精细反映沉积物的变化特征,能为泥页岩、碳酸盐岩和砂砾岩等地层的沉积成因、储层描述及评价、物质组成等问题的研究提供重要的地质依据,具有较为广阔的应用前景。岩心数字化资料是基于岩心直接获得的岩心尺度的连续性资料,从资料性质上来看介于原始资料和成果资料之间,更侧重于岩心的“原始性”,是第一手的地质资料。岩心数字化资料具有独特而重要的应用价值,是提高岩心应用水平的重要技术手段。

汽车发动机缸体内腔质量影响因素分析及工艺控制

随着汽车轻量化的发展,发动机缸体壁厚要求越来越薄。针对水套内腔质量的影响因素进行了分析和工艺改善;介绍了烧结陶瓷砂、纤维素和铬尖晶石用于硅砂制芯添加对砂芯高温和常温特性以及产品质量的影响;指出涂料的热暴、热膨胀和烧结性对产品内腔质量影响以及涂料粉料的作用机理;运用射砂模拟技术对砂芯致密性进行了分析和质量改善。

基于自动化制造复杂砂芯制芯材料的试验研究

针对缸盖等复杂砂芯在自动化制芯、组芯生产过程中存在的变形、破损、模具磨损快等问题,试验研究了烧结球形陶瓷砂、复合添加剂、新型催化剂等对砂芯及铸件质量的影响,提出了自动化生产条件下保证砂芯质量及生产连续性的解决方案。最后指出:(1)选择烧结球形陶瓷砂,有利于改善冷芯盒树脂粘模倾向及减少水套砂芯表面缺陷,解决浸涂水基涂料后的剥落问题;(2)使用复合型抗脉纹添加剂比使用单一组分抗脉纹添加剂的抗脉纹效果更好;(3)新型催化剂可以有效提高砂芯初始抗拉强度,解决砂芯初强度低造成的变形破损等问题;(4)胺催化冷芯盒自动制芯组芯工艺条件下,合适的制芯材料及组分配方是保证制芯质量的必要条件。

3D打印砂芯密度提升的方法

介绍了3D打印砂芯密度提升的试验方法:采用双箱铸造砂芯3D打印设备,按照不同参数打印φ40 mm的抗压试块,并对试块的密度进行检测对比分析。试验结果表明:(1)打印层厚与密度呈反比关系,层厚越高密度越低,打印层厚应参考原砂目数的大小设定;(2)打印过程中在铺砂器上引入增加振动频率或适当增加刮砂板角度能够有效地提高砂芯密度;(3)通过适当增大下砂口与叠型槽的间隙或降低铺砂器速度来增加下砂量,可提高砂芯的密度;(4)将打印参数设定为层厚0.38 mm,振动频率3500~4000 r/min,下砂口间隙5 mm,叠型槽间隙5 mm,可使砂芯密度性能达到最高。