Silica sol steel casting yog qhov siab -precision peev casting txheej txheem uas siv colloidal silica (ib tug ruaj khov ncua kev kawm ntawv ntawm nano-scale SiO₂ hais nyob rau hauv dej) ua tus thawj binder rau tsim lub ceramic pwm plhaub. Ua ke nrog siab -purity zircon hmoov thiab zircon xuab zeb nyob rau hauv thawj slurry txheej, cov txheej txheem no tsim ib tug exceptionally du, chemically inert, thiab thermally ruaj khov pwm muaj peev xwm tiv taus kua hlau pouring kub txog 1,650 degree.
Piv nrog rau cov dej ib txwm siv - iav (sodium silicate) peev casting, silica sol txoj kev tshem tawm dawb sodium impurities (Na2O) uas ua rau pwm tawg. Qhov kev ncaj ncees ntawm cov qauv no tso cai rau kev tsim cov complex, nyias-walled, thiab nyob ze -net-cov khoom hlau uas txo qis los yog tshem tawm tag nrho downstream CNC machining.
Txheej txheem Parameter sib piv
|
Engineering Parameter |
Silica Sol Investment Casting |
Dej-Kev nqis peev iav Casting |
Standard Sand Casting |
|
Dimensional raug |
TS EN ISO 8062 CT4 - CT6 |
TS EN ISO 8062 CT7-CT9 |
ISO 8062 CT10 - CT12 |
|
Raws li -Cast Surface Roughness |
Ra 1.6 - Ra 3.2 µm |
Ra 6.3 - Ra 12.5 µm |
Ra 12.5 - Ra 25 µm |
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Yam tsawg kawg ntawm phab ntsa Thickness |
1.5 mm (0.7 mm nyob rau hauv ib cheeb tsam) |
3.5mm ib |
5.0mm ib |
|
Linear Tolerance Control |
± 0.1 hli rau 25 hli |
± 0.3 hli rau 25 hli |
± 0.8 hli rau 25 hli |
|
Chav ntsuas qhov hnyav |
0.01 kg txog 50 kg |
0.5 kg txog 100 kg |
5.0 kg rau 5, 000+ kg |
Kev tsim khoom
Txhawm rau kom ua tiav nruj metallurgical thiab dimensional tswj, txhua qhov casting batch dhau los ntawm 9-kauj ruam tswj kev tsim khoom ua haujlwm:
Aluminium Tooling & Wax Txhaj Tshuaj:Precision CNC-machined aluminium dies yog txhaj nrog nruab nrab-kub sib xyaw ciab nyob rau hauv qhov ntsuas kub (58-64 degree) thiab siab (0.3-0.5 MPa) los tsim cov qauv qauv nrog cov khoom siv hluav taws xob (1.8% - 2.2%).
Ntoo Assembly (Gating Design):Cov qauv siv quav ciab ntawm tus kheej yog welded mus rau hauv nruab nrab khiav / sprue ntoo siv rhuab spatulas. Gating geometry, risers, thiab ingates yog xam siv magma flow simulation los xyuas kom meej cov kev taw qhia solidification thiab tshem tawm shrinkage porosity.
Silica Sol Slurry Txheej & Stuccoing:
• Cov Txheej Txheem Tseem Ceeb: Dipped hauv siab -purity silica sol binder tov nrog 325-mesh zircon hmoov, ces stuccoed nrog 80-120 mesh zircon xuab zeb. Qhov no tsim ib tug high-density, thermally resistant daim tawv nqaij.
• Cov txheej thib ob & txheej txheej: Dipped hauv silica sol slurry thiab stuccoed nrog mullite xuab zeb (4-6 lub tsho tiv no ua tiav) los tsim lub plhaub lub zog.
Tswj Kub & Humidity Drying:Plhaub qhuav nyob rau hauv ib puag ncig kev tswj cov chav (Tub kub: 22℃± 2 degree, txheeb ze Humidity: 50% ± 5%) rau 8-12 teev ib txheej, ua kom silica sol polymerization tsis muaj micro- cracking.
Siab -Pressure Steam Dewaxing:Lub plhaub sib dhos tau muab tso rau hauv ib qho autoclave ntawm 0.6-0.8 MPa chav siab (160-170 degree). Wax melts sai sai hauv 10-15 vib nas this thiab ntws tawm yam tsis tau nthuav los yog tawg lub plhaub ceramic.
High -Tub kub tua hluav taws:Ceramic shells raug rho tawm haujlwm nyob rau hauv lub cub tawg ntawm 1,000℃txog 1,150℃rau 45-60 feeb. Qhov no hlawv tawm cov khoom seem ntawm cov organic, sintered ceramic hais, thiab preheats cov pwm los tuav cov hlau molten yam tsis muaj thermal shock.
Induction Rauv Melting & Nqus Degassing:Hlau alloys yog melted nyob rau hauv nruab nrab - zaus induction rauv. Spectrometric tshuaj ntsuam xyuas yog ua rau cov kua hlau ua ntej tapping. Deoxidation thiab slag tshem tawm kom huv si hloov hlau.
Gravity/Pressure Pouring:Preheated shells (800-1,000 degree) tau ntim tam sim nrog cov hlau molten ntawm 1,550-1,650℃kom lav tag nrho ntim ntawm cov phab ntsa nyias thiab sib sib zog nqus tav.
Knockout, Tua Blasting & Gate Tshem Tawm:Tom qab txias, lub plhaub yog cov tshuab vibrating thiab txhaj tshuaj-blasted (steel txhaj S230/S330) kom tshem tawm cov khoom seem ntawm ceramic. Cov rooj vag raug tshem tawm ntawm lub teeb plasma los yog txiav tawm ntawm lub log - tawm lub log.
Cov ntaub ntawv thiab kev specifications
Peb nrum dav spectrum ntawm ferrous hlau ua raws li ASTM, DIN, EN, JIS, thiab BS cov khoom specifications:
|
Qeb |
Standard Alloy Qib |
Cov qauv sib npaug |
Ntsiab Mechanical & Physical Yam ntxwv |
|
Austenitic Stainless hlau |
CF8 (304), CF8M (316), CF3 (304L), CF3M (316L) |
1.4301, 1.4408, 1.4306, 1.4404 |
Kev tiv thaiv corrosion siab, tsis yog{0}} sib nqus hauv lub xeev annealed, PREN 18-25. Tensile Strength Ntau dua los yog sib npaug rau 485 MPa, Yield Strength Ntau dua los yog sib npaug rau 205 MPa. |
|
Martensitic & Ferritic Stainless hlau |
CA15 (410), CA40 (420), 430, 440C |
1.4006, 1.4021, 1.4016, 1.4125 |
Thaum tshav kub kub kho kom siab hardness (txog 58 HRC rau 440C). Hnav-resistant, nruab nrab corrosion kuj. |
|
Duplex Stainless Hlau |
CD4MCu, 2205 (UNS S31803), 2507 (UNS S32750) |
1.4462, 1.4410, 1.4501 |
Dual -phase ferritic- austenitic qauv. High yield zog (Ntau tshaj los yog sib npaug rau 450 MPa), tsis kam mus rau pitting thiab kev nyuaj siab corrosion cracking nyob rau hauv chloride media. |
|
Nroj tsuag Hardening Steel |
17-4PH (CB7Cu-1), 15-5PH |
1.4542, 1.4545 |
Lub zog siab (Tensile txog 1,100 MPa tom qab H900 laus), ua ke nrog corrosion kuj piv rau 304 stainless. |
|
Carbon Steel |
WCB, WCC, LCB, Chav Kawm 60-30 |
1.0619, 1.1131, GS-45 |
Economical structural steel nrog zoo weldability thiab machinability. Tensile zog 485-655 MPa. |
|
Tsawg Alloy Steel |
4140 (42CrMo4), 8620, 4340, 8630 |
1.7225, 1.6523, 1.6565 |
Siab hardenability, qaug zog, thiab cuam tshuam tsis kam tom qab quenching thiab tempering (Q&T). |
Yam khoom tseem ceeb
Raws li - Cast Dimensional Accuracy:Mus txog ISO 8062 CT4 rau CT6. Cov chaw tseem ceeb hauv qhov chaw, mounting pads, thiab unmachined reference faces tuav nruj txoj hauj lwm kam rau ua yam tsis muaj milling ntxiv.
Superior Surface Finish:Raws li - nrum roughness ntawm Ra 1.6 mus rau 3.2 µm tso cai ncaj qha electropolishing los yog iav polishing rau kev ua zaub mov thiab cov khoom siv tshuaj yam tsis muaj kev sib tsoo hnyav.
Complex Internal Geometry:Soluble core cov tswv yim thiab meej ceramic core sib dhos tso cai rau cov cua txias sab hauv, nkhaus impellers, thiab cov kab noj hniav tsis yooj yim rau tshuab los ntawm cov khoom lag luam.
Grain Structure Integrity:Kev ua kom txias qeeb hauv preheated ceramic shells ua rau cov qauv zoo sib xws, ua rau cov khoom siv isotropic tsis muaj kev taw qhia tsis muaj zog.
Qhov hnyav thiab cov khoom txuag:Ze ntawm -net- lub peev xwm muaj peev xwm txo cov khoom siv raw ntawm 30% mus rau 60% piv rau kev ua haujlwm los ntawm forged bar Tshuag.
Tej kev siv
Silica sol steel castings tau teev tseg rau lub hom phiaj - cov khoom tseem ceeb ua haujlwm nyob rau hauv siab, corrosive kua, los yog dynamic mechanical stress:
|
Kev lag luam sector |
Yam Khoom Tshwj Xeeb |
Yam yuavtsum tau kawm uantej |
|
Kev tuav dej & Valves |
Cov twj tso kua mis, qhib / kaw impellers, pob valve lub cev, npauj npaim valve discs, kos valve clappers. |
Kev ntsuam xyuas hydrostatic siab (txog 100 bar), xoom porosity, cov dej ntws zoo txo cov cavitation. |
|
Tshuaj & Petrochemical |
Cov yeeb nkab flanges, strainer baskets, mixing agitators, heat exchanger headers, reactor fittings. |
ASTM A262 Xyaum E intergranular corrosion test ua raws; Duplex 2205 durability. |
|
Khoom noj khoom haus & Cov khoom siv huv huv |
Nqaij grinder screws, homogenizer valve rooj zaum, twj tso kua mis casings, huv si yeeb nkab clamps. |
Crevice-dawb nto (Ra tsawg dua lossis sib npaug li 0.8 μm tom qab electropolishing) ua raws li cov qauv kev tu cev. |
|
Marine Hardware |
Cov hlua khi hlua khi, hneev chais, ncej struts, yeeb nkab couplings, rigging toggles. |
Qib 316 / 316L tsis kam rau pitting hauv ntsev - dej tsuag (ASTM B117 ntsev tshuaj tsuag > 720 teev). |
|
Muaj Machinery & Automation |
Robotic arm brackets, conveyor txuas, cam followers, iav vaj tse, xauv khoom. |
Tight tolerance alignment (± 0.08 mm), tshav kub- kho 4140 / 17-4PH siab hnav tsis kam. |
Machining thiab Secondary Operations
Thaum silica sol casting muab ze rau -net shapes, siab -precision nta yuav tsum tau nyob rau hauv -tsev theem nrab ua:
Precision CNC Machining:4-axis thiab 5-axis machining chaw rau cov rooj zaum (tsawg dua lossis sib npaug ntawm IT7 kam rau ua), threads (UNC, UNF, BSPT, NPT), O-ring grooves (± 0.02 mm), thiab sealing ntsej muag (Ra Tsawg dua lossis sib npaug li 0.4 μm).
Cov txheej txheem kho cua sov:
• Tshuaj Annealing: 1,040℃-1,120℃ua raws li cov dej nrawm nrawm rau austenitic stainless hlau kom rov-kua chromium carbides.
• Quenching & Tempering (Q&T): Roj/dej quench nrog tswj temper cycles rau carbon thiab low{0}}alloy steels kom muaj ib tug HRC/HB hardness.
• Precipitation Hardening: H900, H1025, H1150 mob laus kev kho mob rau 17-4PH steel.
• Kev Ruaj Ntseg: 550℃-650℃kev ntxhov siab tom qab-machining lossis vuam.
Nto Finishing:Pickling & passivation (ASTM A967), electro- polishing, phau ntawv iav polishing (Grit 400-800), hlaws blasting (iav hlaws / ceramic hlaws), zinc / nickel plating, thiab dub oxide txheej.
Kev Tswj Xyuas Zoo thiab Kev Tshawb Fawb
Txhua qhov hluav taws xob tsim hluav taws xob tau dhau los tsis yog -kev kuaj kev puas tsuaj thiab kev puas tsuaj raws li ISO 9001: 2015 cov txheej txheem tswj kom zoo:
|
Hom tshuaj ntsuam xyuas |
Cov khoom siv kuaj / txoj kev |
Cov Txheej Txheem Zoo / Cov Qauv Txheej Txheem |
|
Tshuaj muaj pes tsawg leeg |
Optical Emission Spectrometer (OES - Oxford / SPECTRO) |
Thaum tshav kub kub-los ntawm- ntsuas kub spectral ua ntej ladle pouring; Cov ntaub ntawv xeem cov ntaub ntawv (EN 10204 3.1). |
|
Dimensional Metrology |
Hexagon CMM, Optical Profile Projector, 3D Laser Scanner |
Tag nrho 3D scan piv rau haiv neeg STEP/IGES CAD qauv; CMM ceeb toom rau GD&T tseem ceeb. |
|
Internal Soundness (NDT) |
Kev Ntsuas Hluav Taws Xob (RT), Kev Ntsuas Ultrasonic (UT) |
ASTM E446 / ASTM E192 siv xov tooj cua; xoom shrink kab noj hniav nyob rau hauv siab - cheeb tsam kev nyuaj siab. |
|
Surface Defect Detection |
Dye Penetrant Inspection (PT), Sib Nqus Particle (MT) |
ASTM E1417 Qib 2 ua raws; 100% nto tawg tshuaj xyuas ntawm qhov tseem ceeb stainless Cheebtsam. |
|
Mechanical Testing |
Tensile Tester, Charpy V-Ntch Impact, Rockwell/Brinell Hardness |
Kev pov thawj ntawm lub zog tawm los, elongation (%), cuam tshuam lub zog ntawm -40℃rau +20℃ib ASTM A370. |
|
Siab / Leak Integrity |
Hydrostatic Test Rig, Pneumatic Cua -Kev ntsuas dej hauv qab |
100% hydrostatic testing mus txog 150 bar lossis cua -hauv qab - dej ntsuas ntawm 6 bar rau xoom npuas dej. |
OEM thiab Custom Manufacturing
Peb txhawb nqa txawv teb chaws OEMs thiab Tier-1 pawg neeg yuav khoom los ntawm kev tsim qauv zoo- mus rau kev tsim khoom:
Design for Manufacturability (DFM) Review:
Peb pab neeg ua haujlwm saib xyuas cov ntaub ntawv 3D ib txwm muaj (STEP, IGES, SolidWorks) los ntsuas cov kaum sab xis (0.5℃-1℃yam tsawg kawg nkaus pom zoo), kev hloov ntawm phab ntsa, fillet radii, thiab kev txhawb nqa tseem ceeb ua ntej kev kos npe -tawm.
Rapid Prototyping:
Rau kev siv tau sai, peb siv 3D- luam tawm SLA / SLS siv quav ciab lossis PMMA qauv los tsim cov qauv hlau ua haujlwm tau zoo hauv 10 mus rau 14 hnub, hla kev txhim kho cov cuab yeej nyuaj.
Tooling Lifespan Guarantee:
CNC-machined aircraft-qib aluminium pwm tooling (6061-T6 lossis 7075) lav rau 100,000 txhaj tshuaj, khaws cia hauv tsev tsis muaj nqi ntxiv rau tus neeg siv khoom.
Production Scaling:
Lub peev xwm hloov tau txhawb nqa me me -batch txiav txim (50-100 daim) mus txog siab - ntim cov ntawv cog lus txhua xyoo (50,000+ daim / hli).
Cov neeg yuav khoom yuav tsum muab dab tsi rau RFQ
Yuav kom tau txais cov lus hais ua lag luam raug nyob hauv 24 txog 48 teev, thov xa cov ntaub ntawv hauv qab no engineering:
Engineering Drawings:2D kos duab hauv PDF hom (nrog rau qhov pom tseeb ntawm qhov ntev, qhov yuav tsum tau ua kom tiav, thiab cov lus qhia tshwj xeeb) + 3D CAD qauv hauv STEP, STP, lossis IGES hom.
Khoom Specification:Qib cov khoom siv (piv txwv li, ASTM A351 CF8M, 17-4PH, 42CrMo4) thiab cov kev cai kho cua sov tshwj xeeb (xws li, Tshuaj Annealed, Q&T txog 30–35 HRC).
Order Volume & Teem caij:Kwv yees pib qhov ntau (EHQ), Kev Siv Txhua Xyoo (EAU), thiab lub hom phiaj xa khoom.
Quality & Inspection Level:Yuav tsum tau NDT cov txheej txheem (100% PT, Radiography feem pua), kev ntsuas cov pa xau, thiab cov ntaub ntawv ntsuam xyuas cov ntaub ntawv (EN 10204 3.1 tus qauv).
Surface Finishing & Ntim:Cov kev xav tau rau sandblasting, electropolishing, passivation, anti-rust oil application, los yog kev cai VCI tiv thaiv export ntim.
Cov lus nug nquag
Q: Tus nqi tseem ceeb sib txawv ntawm silica sol casting thiab dej - iav casting yog dab tsi?
A: Silica sol casting raw khoom (colloidal silica thiab zircon xuab zeb) raug nqi ntau dua li sodium silicate thiab quartz xuab zeb. Cov voj voog ntau lawm kuj ntev dua vim lub sijhawm tswj kom qhuav. Yog li ntawd, silica sol castings feem ntau nqa 30% mus rau 80% tus nqi siab dua. Txawm li cas los xij, vim tias silica sol ua tau zoo dua (CT4-CT6) thiab nto tiav (Ra 1.6-3.2 µm), nws nquag tshem tawm cov ncej- machining, yielding tus nqi qis dua.
Q: Dab tsi linear tolerances tuaj yeem tswj tsis tau machining?
A: Peb ua tiav ISO 8062 CT4-CT6 tus qauv linear tolerances. Rau qhov ntev txog li 25 hli, kam rau ua feem ntau yog ± 0.1 hli. Rau qhov ntev txog li 100 hli, linear kam rau ua nyob rau hauv ± 0.25 hli. Cov yam ntxwv tseem ceeb uas xav tau $\\le\\pm0.01\\text{mm}$ yog ua tiav los ntawm kev ua haujlwm CNC thib ob.
Q: Puas tuaj yeem silica sol casting tuav cov phab ntsa tuab?
A: Yog lawm, tab sis phab ntsa thickness variation yuav tsum tau txo kom txhob muaj kev shrink porosity thaum solidification. Qhov zoo tshaj plaws phab ntsa thickness yog li ntawm 2.0 hli mus rau 25 hli. Hnyav seem saum toj no 35 hli tuaj yeem nrum los ntawm kev sib xyaw nrog cov chillers sab nraud lossis optimized feeder risers tsim los ntawm solidification modeling software.
Q: Koj puas muab EN 10204 3.1 Cov Ntaub Ntawv Pov Thawj nrog txhua qhov xa khoom?
A: Yog. Txhua qhov khoom xa tuaj suav nrog EN 10204 3.1 Daim Ntawv Qhia Txog Cov Khoom Siv (MTR) uas qhia meej txog cov tshuaj muaj pes tsawg leeg tau txheeb xyuas los ntawm OES, cov khoom siv ntsuas qhov ntsuas (tensile, yield, elongation, hardness), thiab cov ntaub ntawv kho cua sov tau taug qab mus rau tus lej tshwj xeeb.
