失蜡铸造(也称为熔模铸造或精密铸造)是一种铸造工艺,是把液态蜡注入金属模具做成同铸件一致的蜡模型,然后在其外表裹几层粘土等耐火陶瓷材料,加热使蜡熔化流出,从而得到由耐火材料形成的硬化空壳,硬化的陶瓷外壳经过焙烧,将熔融金属浇注入模壳中,待金属冷却后将模壳振碎得到金属铸件。
熔模铸造一词源自对模壳里的蜡进行加热融化的过程。熔模铸造往往比其它铸造工艺更受青睐,是因为熔模铸造的铸件尺寸精度高表面粗糙度好,可以是薄壁件或内外部结构复杂的零件,并且与砂铸不同是的它没有拔模斜度。
熔模铸造的材料广泛,碳钢、合金钢、不锈钢等,也可以是有色金属材料,如铝或铜等合金。在热加工领域里,取材困难件或不易成型件以及某些加工成本高的锻造件,可适用熔模铸造;而在铸造的领域里,有些产品可用熔模铸造替代其它形式的铸造,减少加工切削余量降低成本,提高尺寸精度和表面粗糙度以及材料的机械性能,从而达到升级产品档次的目的。
熔模铸造过程中蜡模和模壳都需要被破坏,每次铸造都需要一个新的蜡模,因此需要制造蜡模的模具。
制作模具需要充分考虑计算出收缩率,这些收缩率体现在蜡模和模壳及浇铸后的不同过程中。
蜡模的数量始终等于要生产的铸件的数量,每个铸件都需要新的蜡模。
将热态蜡注入金属模具使其冷却固化,有些内腔复杂结构需要使用陶瓷芯形成内部功能结构。蜡模是要生产零件的精准复制品,该生产工艺类似于压铸,压铸是金属融液它是液态蜡。
将几个蜡模焊接通到蜡棒上,组成蜡模串,形成一个浇铸系统,上面有浇口,是用来下一步的模壳将钢水引入浇铸系统的入口。.
将蜡模树浸入二氧化硅的浆料中,重复浸入五六次,每次浸入前撒上不同的耐火材料,并且每次都要干燥和硬化,干燥的涂层在蜡模的浇口系统外围形成了陶瓷壳。将陶瓷壳加热至蜡融化并流失,腔体内形成空心,这样完成了模壳的生产,熔模铸造要使用许多这样的模壳。
模壳被焙烧加热到大约800-900°C,加热过程进一步增强了模壳强度,消除了残留的蜡或其它杂物,并蒸发掉模壳中的水。
用中频感应电炉熔炼原材料(废钢),根据每炉不同的材质进行合金元素的配料,当钢水温度达到1530-1580℃后便可以浇铸,钢水趁热倒入模壳中,倾注进浇注口并通过浇铸系统流入树上的每个模腔,预热的模壳使金属液易于流过壁薄或细长的部分。然后待其冷却和收缩,便可以得到高精度的铸件了。
浇铸后的模壳和铸件充分凝固却冷后,就用振动设备把模壳从铸件上分离。初步清砂后进行一次抛丸,这样铸件毛坯表面的粘砂就基本清除干净了,然后可以通过不同方式的切割将单个铸件从浇铸系统中分离出来。
将毛坯铸件上的浇口余根去除掉,主要是通过砂轮打磨或机加工的方式进行磨削,该工序有分为初磨和精磨,打磨时不能损伤零件本体。后续的精整主要是修复铸件表面可能会有的一些表面缺陷,如砂孔、渣孔、飞边毛刺、鼓包、变形等,主要的方式是打磨、焊补、整形和抛丸等工序。
经外观检查合格后铸件流转到热处理生产线进行不同工艺的热处理。
国内熔模铸造的大型规模化专业生产基地
隆兴是一家国内大型的具强大机加工能力的精密铸造工厂。我们为汽车、轨道交通、工程机械、物流搬运机械、农机等诸多领域提供精密铸锻件和机加工件,并为多元化需求的全球中高端客户提供终端成品零部件, 包括钣金、组焊、表面处理、装配等整体解决方案和一站式服务, 进而使隆兴成为一家具有综合能力和独特商业模式的金属成型加工制造商。
![Lost Wax Casting(1) Lost Wax Casting(1)](/uploads/ueditor/20211028/1-21102QK95V33.png)
工厂概览---华伟精密铸造
采用先进的失蜡铸造、消失模和壳型铸造工艺,装备了数套节能环保生产线,包括制蜡、制壳、浇铸、热处理等核心工序的自动或半自动生产线。
![Lost Wax Casting(2) Lost Wax Casting(2)](/static/skin/img/process1/cast4_i1.png)
成立
![Lost Wax Casting(3) Lost Wax Casting(3)](/static/skin/img/process1/cast4_i2.png)
![Lost Wax Casting(4) Lost Wax Casting(4)](/static/skin/img/process1/cast4_i3.png)
![Lost Wax Casting(5) Lost Wax Casting(5)](/static/skin/img/process1/cast4_i4.png)
我们的4种铸造工艺
满足客户对不同档次和品质铸件的广泛需求。覆盖不同等级的:
![Lost Wax Casting(2) Lost Wax Casting(2)](/static/skin/img/process1/cast05_01.png)
![Lost Wax Casting(3) Lost Wax Casting(3)](/static/skin/img/process1/cast05_02.png)
![Lost Wax Casting(4) Lost Wax Casting(4)](/static/skin/img/process1/cast05_03.png)
![Lost Wax Casting(6) Process Design](/static/skin/img/process1/cast4_t1.jpg)
工艺设计
![Lost Wax Casting(7) Tooling Making](/static/skin/img/process1/cast4_t2.jpg)
模具制作
![Lost Wax Casting(8) Lost Wax Casting(8)](/static/skin/img/process1/cast4_t3.jpg)
注蜡
![Lost Wax Casting(9) Lost Wax Casting(9)](/static/skin/img/process1/cast4_t4.jpg)
蜡件组合
![Lost Wax Casting(10) Lost Wax Casting(10)](/static/skin/img/process1/cast4_t5.jpg)
模壳焙烧
![Lost Wax Casting(11) Lost Wax Casting(11)](/static/skin/img/process1/cast4_t6.jpg)
脱蜡
![Lost Wax Casting(12) Lost Wax Casting(12)](/static/skin/img/process1/cast4_t7.jpg)
淋砂
![Lost Wax Casting(13) Lost Wax Casting(13)](/static/skin/img/process1/cast4_t8.jpg)
沾浆
![Lost Wax Casting(14) Lost Wax Casting(14)](/static/skin/img/process1/cast4_t9.jpg)
浇铸
![Lost Wax Casting(15) Lost Wax Casting(15)](/static/skin/img/process1/cast4_t10.jpg)
除壳
![Lost Wax Casting(16) Lost Wax Casting(16)](/static/skin/img/process1/cast4_t11.jpg)
切割
![Lost Wax Casting(17) Lost Wax Casting(17)](/static/skin/img/process1/cast4_t12.jpg)
打磨
![Lost Wax Casting(18) Lost Wax Casting(18)](/static/skin/img/process1/cast4_t13.jpg)
包装发送
![Lost Wax Casting(19) Lost Wax Casting(19)](/static/skin/img/process1/cast4_t14.jpg)
终检
![Lost Wax Casting(20) Lost Wax Casting(20)](/static/skin/img/process1/cast4_t15.jpg)
机加工
![Lost Wax Casting(21) Lost Wax Casting(21)](/static/skin/img/process1/cast4_t16.jpg)
热处理
![Lost Wax Casting(22) Lost Wax Casting(22)](/static/skin/img/process1/cast7_t1.jpg)
模具
![Lost Wax Casting(23) Lost Wax Casting(23)](/static/skin/img/process1/cast7_t2.jpg)
自动射蜡
![Lost Wax Casting(24) Lost Wax Casting(24)](/static/skin/img/process1/cast7_t3.jpg)
蜡件组焊
![Lost Wax Casting(25) Lost Wax Casting(25)](/static/skin/img/process1/cast7_t4.jpg)
蜡模串
![Lost Wax Casting(29) Lost Wax Casting(29)](/static/skin/img/process1/cast7_t8.jpg)
浇铸
![Lost Wax Casting(28) Lost Wax Casting(28)](/static/skin/img/process1/cast7_t7.jpg)
焙烧
![Lost Wax Casting(27) Lost Wax Casting(27)](/static/skin/img/process1/cast7_t6.jpg)
脱蜡
![Lost Wax Casting(26) Lost Wax Casting(26)](/static/skin/img/process1/cast7_t5.jpg)
自动制壳
![Lost Wax Casting(30) Lost Wax Casting(30)](/static/skin/img/process1/cast7_t9.jpg)
热处理
![Lost Wax Casting(31) Lost Wax Casting(31)](/static/skin/img/process1/cast7_t10.jpg)
抛丸
![Lost Wax Casting(32) Lost Wax Casting(32)](/static/skin/img/process1/cast7_t11.jpg)
检验
![Lost Wax Casting(33) Lost Wax Casting(33)](/static/skin/img/process1/cast7_t12.jpg)
入库
自动射蜡机
![失蜡铸造(图38) 失蜡铸造(图38)](/uploads/ueditor/20231226/2-231226144P03E.jpg)
自动制壳生产线(水玻璃) A
![Lost Wax Casting(36) Lost Wax Casting(36)](/static/skin/img/process1/cast8_t3.jpg)
自动制壳生产线(水玻璃) B
![失蜡铸造(图40) 失蜡铸造(图40)](/uploads/ueditor/20231226/2-2312261451514X.jpg)
自动制壳生产线(硅溶胶)A
![失蜡铸造(图41) 失蜡铸造(图41)](/uploads/ueditor/20231226/2-2312261452415J.jpg)
自动制壳生产线(硅溶胶) B
![Lost Wax Casting(37) Lost Wax Casting(37)](/static/skin/img/process1/cast8_t4.jpg)
焙烧炉
![Lost Wax Casting(38) Lost Wax Casting(38)](/static/skin/img/process1/cast8_t5.jpg)
半自动浇铸线
![Lost Wax Casting(39) Lost Wax Casting(39)](/static/skin/img/process1/cast8_t6.jpg)
无芯中频感应电炉
![Lost Wax Casting(40) Lost Wax Casting(40)](/static/skin/img/process1/cast8_t7.jpg)
滚筒式清砂抛丸机
![Lost Wax Casting(41) Lost Wax Casting(41)](/static/skin/img/process1/cast8_t8.jpg)
成品履带式抛丸机
![Lost Wax Casting(42) Lost Wax Casting(42)](/static/skin/img/process1/cast8_t9.jpg)
网带炉
![Lost Wax Casting(43) Lost Wax Casting(43)](/static/skin/img/process1/cast8_t10.jpg)
电阻炉
![Lost Wax Casting(44) Lost Wax Casting(44)](/static/skin/img/process1/cast8_t11.jpg)
整形机
ISO 9001 & IATF 16949
宁波QS
地址: 宁波
硅溶胶熔模铸造工艺
成立于 2002
占地面积 12,000平方米
150员工
年产能 4,800吨
材料范畴: 高温镍基合金、不锈钢、碳钢、合金钢等
最大线性尺寸:1000mm 直径:600mm
重量范围: 0.01 - 100KG
铸件尺寸公差: CT5 - 6
铸造表面粗糙度: Ra 3.2 - 6.3um
![Lost Wax Casting(50) Lost Wax Casting(50)](/static/skin/img/process1/cast10_img.jpg)
![Lost Wax Casting(51) Lost Wax Casting(51)](/static/skin/img/process1/cast11_t1.jpg)
蜡模制作
![Lost Wax Casting(52) Lost Wax Casting(52)](/static/skin/img/process1/cast11_t2.jpg)
蜡模焊接
![Lost Wax Casting(53) Lost Wax Casting(53)](/static/skin/img/process1/cast11_t3.jpg)
制壳
![Lost Wax Casting(54) Lost Wax Casting(54)](/static/skin/img/process1/cast11_t4.jpg)
模壳脱蜡
![Shell Roasting Shell Roasting](/static/skin/img/process1/cast11_t5.jpg)
模壳焙烧
![Smelting&Pouring Smelting&Pouring](/static/skin/img/process1/cast11_t6.jpg)
熔炼浇铸
![Shell Cooling Shell Cooling](/static/skin/img/process1/cast11_t7.jpg)
模壳冷却
![Shell Smashing Shell Smashing](/static/skin/img/process1/cast11_t8.jpg)
振壳
![Cutting Gate Cutting Gate](/static/skin/img/process1/cast11_t9.jpg)
切割冒口
![Grinding Gate Grinding Gate](/static/skin/img/process1/cast11_t10.jpg)
打磨冒口
![Shot Blasting Shot Blasting](/static/skin/img/process1/cast11_t11.jpg)
抛丸
![Lost Wax Casting(62) Lost Wax Casting(62)](/static/skin/img/process1/cast11_t12.jpg)
检验
![Lost Wax Casting(63) Lost Wax Casting(63)](/static/skin/img/process1/cast12_t1.jpg)
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![Lost Wax Casting(74) Lost Wax Casting(74)](/static/skin/img/process1/cast12_t12.jpg)
![Lost Wax Casting(75) Lost Wax Casting(75)](/static/skin/img/process1/cast12_t13.jpg)
![Lost Wax Casting(76) Lost Wax Casting(76)](/static/skin/img/process1/cast12_t14.jpg)
![Lost Wax Casting(77) Lost Wax Casting(77)](/static/skin/img/process1/cast12_t15.jpg)
![Lost Wax Casting(78) Lost Wax Casting(78)](/static/skin/img/process1/cast12_t16.jpg)
![Lost Wax Casting(79) Lost Wax Casting(79)](/static/skin/img/process1/cast12_t17.jpg)
![Lost Wax Casting(80) Lost Wax Casting(80)](/static/skin/img/process1/cast12_t18.jpg)
![Lost Wax Casting(81) Lost Wax Casting(81)](/static/skin/img/process1/cast12_t19.jpg)
![Lost Wax Casting(81) Lost Wax Casting(81)](/static/skin/img/process1/cast12_t20.jpg)
![失蜡铸造(图83) 失蜡铸造(图83)](/uploads/ueditor/20231226/2-231226153A93B.png)
铸件材料
![失蜡铸造(图84) 失蜡铸造(图84)](/uploads/ueditor/20231226/2-231226153G4R6.png)
铸件重量
![失蜡铸造(图85) 失蜡铸造(图85)](/uploads/ueditor/20231226/2-231226152252950.png)
失蜡铸造的供货能力