瑞欧消失模专业培训课程——第一章 消失模简介

第一章    消失模简介

Chapterone  The introduction of lost foamcasting

1.1消失模发展

1.1 The lost foamdevelopment

1.1.1消失模铸造发展概况

1.1.1 Thedevelopment overview of lost foam casting

消失模铸造技术是用泡沫塑料（EPS、STMMA或EPMMA）制成与铸件结构、尺寸完全一样的模样，经浸涂耐火黏结涂料（起强化、光洁作用）烘干后埋入特殊砂箱干砂造型，经三维或二维微震加负压紧实，不用泥芯、活块甚至无冒口的情况下浇入熔化的合金液，整个过程保持着一定的负压，是模样受热气化分解进而被合金液取代的一次性成型铸造新工艺。消失模铸造有多种不同的叫法，国内主要叫干砂实型铸造、负压实型铸造，简称EPC铸造。国外的叫法主要有lost foam process（美国）、policast  process(意大利)等。它与传统的铸造技术相比，具有很大的优势，被国内外的铸造界誉为“21世纪的铸造技术”和“铸造工业的绿色革命”。

The lost foam casting technology is tomake same structure and size models with castings by foam plastic(EPS, STMMA orEPMMA). By dipping refractory adhesive coating（strengtheningand bright & clean role）， they are buried in thespecial sandbox for dry sand modeling after drying. By the negative pressurecompaction of three-dimension or two-dimension micro vibration, it pours themelting alloy liquid without loam core, loose block,or even riser. The wholeprocess keeps certain negative pressure. It is the new disposal molding castingprocess in which the model vaporizes and decomposes because of heating and itis replaced by alloy liquid. The lost foam casting has many different calls. InChina, it is mainly called “dry sand mold casting” or “negative pressure moldcasting”(abbreviated as EPC casting). In foreign countries, the calls aremainly “lost foam process（America）”、policast  process(Italy) and so on. Compared totraditional casting technology, it has great advantages and it is praised as“21 century casting technology” and “green revolution of casting industry ” byforeign casting industry.

消失模铸造综合了“磁型铸造”和“V法铸造”，1956年美国人H.F.Shoyer开始了将聚苯乙烯泡沫塑料用于铸造的实验，并获得成功，引发了人们的极大兴趣。1958年以专利的形式公布于众，当时称之为“无型腔铸造”。起初此法只是用来制造金属雕像和艺术品铸件，经多年实践和探索，1962年原联邦德国从美国引进专利，消失模铸造法才逐步被开发，并在工业上得到应用和推广。1999年美国人威斯康星大学的一项调查表明，在1990年有6%的铝合金铸件是使用该工艺。从1997年起灰铸铁和球铁方面也有较快增长，到2009年达到15%。

The lost foam casting integrates“magnetic casting” and “V-method ” casting. In 1956, American H.F.Shoyer beganto use polystyrene foam plastic for casting experiment and got success. Itraises human’s great interest. In 1958, it shared with the public. At thattime, it is called “no mold cavity casting”. In the beginning, this method isonly for producing metal statue and art castings. By many year’s practice andexploration, the original federal German introduces patents from America in1962. The lost foam casting method was gradually developed, applied andpromoted in the industry. In 1999, a survey from American Wisconsin Universityindicates that 6% aluminum alloy casting uses this technology in 1990. Since1997, the gray iron and ductile iron castings increase quickly. Until 2009, itreaches 15%.      

中国研究和发展消失模铸造的历史和国外基本相似，某些方面如STMMA泡沫塑料已接近或达到国外技术水平，并具有独到之处。20世纪80年代后，有多家单位制造可发性聚苯乙烯预发泡机和发泡成型机，其中阜阳联发消失模成型设备厂与EPS、StMMA粒料同步配套发展。中国的消失模铸造技术也被国家重点推广，消失模工业具有了一定的规模，成为铸造行业的重要组成部分，生产铸件在铸造行业中所占比重不断提高，消失模铸造已成为改造传统铸造厂家应用的最为广泛的高新技术之一。但总的来说，中国消失模铸造生产应用水平与发达国家仍有差距。

 Chinese lost foamcasting history research is basically similar to that of foreign country. Someaspects, such as STMMA foam plastic, have access to or reach foreign technologylevel. And it has unique characteristic. After 80s of 20^th century,many factories made EPS(expandable polystyrene) pre-foaming machine and foamingmolding machine. The Fuyang Lianfa Lost Foam Molding Equipment Factorydeveloped synchronously with EPS and STMMA aggregates. Chinese lost foamcasting technology is also promoted by our country. The lost foam industry hadcertain scale and it became the important part of casting industry. The castingproduction quantity occupies higher and higher proportion in the casting industry. The lost foam casting has becomeone of the widest high & new technology application for reformingtraditional foundries. However, generally speaking, Chinese lost foam castingproduction application level has disparity with developed country.

目前消失模铸造技术在国内主要应用在以下几个方面。

(1)  应用的铸件合金种类铝合金，镁合金，铜合金，灰铸铁，球墨铸铁，特种铸铁（高铬铸铁，抗磨铸铁，耐磨铸铁，耐蚀铸铁），普通碳钢，中、高碳低合金抗磨钢，特种铸钢（高猛钢、镍铬耐热钢、耐蚀钢）及不锈钢等。

Atpresent, the lost foam casting technology is mainly applied in the

followingaspects.

      (1) The casting alloy kinds for application: aluminum alloy, magnesium alloy, copper alloy,gray cast iron, ductile castiron, special cast iron(high-chromium cast iron, anti-wearing cast iron,wearing resistance cast iron and anti-corrosion cast iron),ordinary carbonsteel, medium and high carbon low alloy wearing resistance steel,special caststeel(high magnesium steel, nickel-chromium heating resistance steel andwearing corrosion steel) and stainless steel and so on.

(2)  应用成功的典型铸件

(2) The typical casting appliedsuccessfully

1.抗磨铸件：铬系磨球、高锰钢衬板、高铬铸铁锤头、挖掘机铲齿（贝氏体钢、高铬铸铁）等；

1.The wearing resistance castings:Chromium series grinding balls,high magnesium lining board,high chromium castiron hammer head, excavator shovel teeth(Bainite steel, high chrome cast iron)and so on.

2.耐热铸件：耐热铸铁铸钢炉蓖条、热处理底板、料柜、料架等；

2.The heating resistance casting:cast steel furnace grate bar, heat treatment baseboard, material cabinet andmaterial shelf and so on.

3.管件：各种规格的灰铸铁、球铁管件以及轧钢钢管内衬高铬铸铁或以上复合管件；

3.Pipes: allspecifications of gray cast iron,ductile iron pipes and lining high chrome castiron in the rolling steel pipes or complex pipes.

4.阀类铸件：铸钢ZG25、ZG35阀体、阀盖、球铁阀体阀盖；

4.The valve casting: caststeel ZG25、ZG35valve、valvecover、ductileiron valve and valve cover；

5.工程机械件：斗齿、齿轮、齿条、叉车铸钢件球铁的ADI铸件；

5.The engineeringmachinery parts：bucket tooth、gearwheel、spline、ADIcastings of forklift cast steel casting.

6.箱（壳）体铸件：变速箱壳体、差速器壳体、转向器壳体、电机壳体、消防栓壳体、炮弹壳体等；

6.The box(shell) casting, gearboxshell, differential mechanism shell，divertershell, motor shell, hydrant shell and artillery shell and so on.

7.汽车制动系统铸件：刹车鼓、刹车盘；

7.The castings of automobile brakesystem: brake drum and brake disc.

8.曲轴：压缩机曲轴、汽车发动机曲轴；

8.The bent axle: the bentaxle of compressor, the bent axle of automobile engine

9.进排气管：铝进气管、球铁4缸汽车排气管、灰铸铁6缸柴油机排气管等；

9.The air inlet andoutlet pipe: aluminum air inlet pipe, ductile iron 4 cylinder air outlet pipe,gray cast iron 6 cylinder diesel air outlet pipe and so on.

10.后桥铸件：铸钢、铸铁后桥壳体；

10.The rear axle castings: cast steeland cast iron of rear axle shell

11.支架类铸件：铁路25钢支板、汽车弹簧支架、高速公路栏杆、ZG35支架等；

11.The bracket castings:railway 25 steel support plate,automobile spring bracket, expressway handrail,ZG35 bracket and so on.

12.缸体、缸盖铸件：压缩机缸体、单缸机缸体、汽车4缸缸体缸盖；

12.The cylinder block,cylinder cover castings, cylinder block of compressor, cylinder block of singlecylinder, automobile 4 cylinder block cover

13.其他零件：缝纫机机头、踏板、支架、农机曲柄支架、犁头、犁导板等。

13.Other parts: The sewingmachine head, pedal, bracket, agricultural machinery crank bracket, plow headand plow guide plate and so on.