阅读说明：本技术 汽车中冷器气室生产工艺 (Production process of automobile intercooler air chamber ) 是由 赵远 张煜 顾剑 于 2020-06-18 设计创作，主要内容包括：本发明涉及汽车零部件制造的技术领域,尤其是涉及一种汽车中冷器气室生产工艺,其包括制芯、修整砂芯、配料、熔炼、精炼、浇铸、毛坯处理、毛坯试漏、机械加工、清洗烘干和包装入库。本发明具有除气和除渣效果更好,精炼得到的铝液中氢气和杂质含量更低,浇铸得到的中冷器具有足够的强度和气密性的效果。(The invention relates to the technical field of automobile part manufacturing, in particular to a production process of an automobile intercooler air chamber. The invention has better degassing and deslagging effects, lower hydrogen and impurity contents in the refined aluminum liquid, and the intercooler obtained by casting has the effects of enough strength and airtightness.)

1. The production process of the automobile intercooler air chamber is characterized by comprising the following steps: comprises that

S1: core making;

s2: trimming the sand core;

s3: preparing materials;

s4: smelting;

s5: refining, namely adding 0.2-0.5 mass percent of aluminum strontium modifier into aluminum liquid in a heat preservation furnace, then adding 200-400 g of deslagging agent, and then performing degassing operation on the aluminum liquid by using a degassing machine, wherein the nitrogen flow of the degassing machine is 7-15L/min, the nitrogen pressure is 0.3-0.5 MPa, the degassing time is 300s, the temperature of the aluminum liquid in the heat preservation furnace is controlled at 700-750 ℃ during degassing, and a skimming spoon is used for skimming aluminum slag on the surface of the aluminum liquid in the degassing process;

s6: casting;

s7: processing a blank;

s8: leakage testing of the blank;

s9: machining;

s10: cleaning and drying;

s11: and (7) packaging and warehousing.

2. The production process of the air chamber of the intercooler of the automobile as claimed in claim 1, wherein: in S10, firstly, spraying and cleaning are carried out, the temperature of the cleaning solution is 45-60 ℃, the volume fraction of the cleaning solution in the cleaning solution is 2-3%, the pH value of the cleaning solution is 8-11, the filtering precision is 100 mu m, the cleaning time is 1-3 min, and then ultrasonic cleaning is carried outWashing, wherein the temperature of the washing liquid is 45-60 ℃, the volume fraction of the washing liquid in the washing liquid is 2-3%, the pH of the washing liquid is 8-11, and the ultrasonic intensity is 0.5-1W/cm²The filtration precision is 10 mu m, the cleaning time is 6-8 min, then clear water spraying is carried out, the temperature of the clear water is 45-60 ℃, the filtration precision is 5 mu m, the washing time is 1-3 min, and the water pressure is 1-3 Kgf/cm²Then bubbling clean water, wherein the filtration precision is 5 mu m, the cleaning time is 1-3 min, and the air pressure is 4-6 Kgf/cm²Spraying pure water at a clean water temperature of 45-60 deg.C, a filtration precision of 5 μm, a cleaning time of 1-3 min, and a water pressure of 3-5 Kgf/cm²Then wind cutting is carried out, the filtering precision is 10um, the time is 1-3 min, and the wind quantity is 3000-4000 m³Drying with circulating hot air at 70-100 deg.C for 5-7 min, filtering to obtain a filter with a filter precision of 5 μm, and cooling with fan for 1min with an air flow of 100-300 m³And h, finally, naturally drying the casting.

3. The production process of the air chamber of the intercooler of the automobile as claimed in claim 1, wherein: in S3, the returning charge and the aluminum ingot are added into the smelting furnace simultaneously, and the proportion of the aluminum ingot is not less than 60%.

4. The production process of the air chamber of the intercooler of the automobile as claimed in claim 3, wherein: in S3, when the furnace body is not heated, the foundry returns are firstly put in, then the aluminum ingots are put in, when the furnace body contains aluminum liquid, the previously baked aluminum ingots are firstly put in, and the number of the aluminum ingots is not less than 10, and then the foundry returns are put in.

5. The production process of the air chamber of the intercooler of the automobile as claimed in claim 1, wherein: in S1, a core making device adopts a shell core machine, the temperature of a movable die of the shell core machine is 255-285 ℃, the temperature of a fixed die of the shell core machine is 250-280 ℃, the core shooting air pressure is 0.3-0.6 MPa, the sand shooting time is 6S, the exhaust time is 6S, the crusting time is 15S, the vibration time is 10S, and the curing time is 35S.

6. The production process of the air chamber of the intercooler of the automobile as claimed in claim 1, wherein: and S6, transferring the aluminum liquid into an aluminum liquid pool after degassing, scooping the aluminum liquid out of the aluminum liquid pool by using a ladle, pouring the aluminum liquid into an aluminum liquid receiving groove on a casting machine, and turning over the casting machine to enable the aluminum liquid to flow into a cavity of the mold from the aluminum liquid receiving groove and to be solidified.

7. The production process of the air chamber of the intercooler of the automobile as claimed in claim 1, wherein: in S7, the casting is taken down from the casting machine, the sand core is cleaned by the air pick, most of aluminum at the pouring gate and the riser is cut off by the sawing machine, the pouring gate, the riser and the flash and burr on the surface of the blank are polished by the abrasive belt machine, the casting is polished by the sand blasting machine, the casting is cleaned by the cleaning machine, and finally the casting is put into the cleaning pool to wash off the cleaning liquid foam on the surface of the casting.

8. The production process of the air chamber of the intercooler of the automobile as claimed in claim 1, wherein: and S4, heating and melting the foundry returns and the aluminum ingots, and when the temperature of the aluminum liquid is heated to 700-730 ℃, shoveling the pot to clean the aluminum slag on the crucible wall.

Technical Field

The invention relates to the technical field of automobile part manufacturing, in particular to a production process of an automobile intercooler air chamber.

Background

The intercooler is a turbocharging matching set and is used for reducing the temperature of the supercharged high-temperature air so as to reduce the heat load of the engine and improve the air inflow, thereby increasing the power of the engine. Because the intercooler is hollow structure, and the inner chamber of intercooler is the dysmorphism chamber, so current intercooler is mostly by the help of psammitolite and mould, by aluminium liquid casting shaping. The intercooler processed by the method has the advantages of rapid batch forming and consistent finished product height.

Chinese patent publication No. CN110076299A discloses a sand core hub processing technology, which comprises raw material inspection, raw material smelting, refining degassing, deslagging, adding alloy elements, detecting molten aluminum, gravity casting, gate cutting, deburring, solution treatment, correction treatment, aging treatment, hardness detection, machining and detection, pretreatment, coating, press fitting, run-out test, packaging and warehousing. Wherein, the specific processes of refining, degassing and deslagging are as follows: preferably, 0.2-0.4% of refining agent in weight of the aluminum liquid is added, the refining time is 10-20 minutes until no bubbles emerge from the liquid surface, a bell jar is used for collecting hydrogen, then 0.2-0.4% of slag removing agent in weight of the aluminum liquid is added, and a slag removing spoon is used for removing the scum on the surface of the aluminum liquid completely.

According to the sand core wheel hub processing technology, the middle drum, the ribs and other parts of the wheel hub are hollowed out through a large number of sand cores, so that the wheel hub is changed into a shell, the weight of the wheel hub is reduced, and the effect of saving materials is achieved. The main processing steps of the sand core wheel hub are basically consistent with those of the intercooler, and the principle is basically the same. But compare with wheel hub, the intercooler is higher to the requirement of intensity and gas tightness, and the operation process of refining degasification, slagging-off is comparatively simple among the above-mentioned psammitolite wheel hub processing technology, and the aluminium liquid purity that the refining obtained is not enough, has more hydrogen and impurity, and the intercooler that the casting obtained can't reach the requirement of intensity and gas tightness.

Disclosure of Invention

Aiming at the defects in the prior art, the invention aims to provide a production process of an air chamber of an automobile intercooler, which has better degassing and deslagging effects, lower hydrogen and impurity contents in molten aluminum obtained by refining, and the intercooler obtained by casting has the effects of sufficient strength and air tightness.

The above object of the present invention is achieved by the following technical solutions:

a production process of an automobile intercooler air chamber comprises

S1: core making;

s2: trimming the sand core;

s3: preparing materials;

s4: smelting;

s5: refining, namely adding 0.2-0.5 mass percent of aluminum strontium modifier into aluminum liquid in a heat preservation furnace, then adding 200-400 g of deslagging agent, and then performing degassing operation on the aluminum liquid by using a degassing machine, wherein the nitrogen flow of the degassing machine is 7-15L/min, the nitrogen pressure is 0.3-0.5 MPa, the degassing time is 300s, the temperature of the aluminum liquid in the heat preservation furnace is controlled at 700-750 ℃ during degassing, and a skimming spoon is used for skimming aluminum slag on the surface of the aluminum liquid in the degassing process;

s6: casting;

s7: processing a blank;

s8: leakage testing of the blank;

s9: machining;

s10: cleaning and drying;

s11: and (7) packaging and warehousing.

By adopting the technical scheme, in the refining process, the mass ratio of the aluminum strontium alterant, the using amount of the slag remover, the nitrogen pressure, the degassing time and the aluminum liquid temperature are strictly controlled, the degassing and deslagging effects are better, the hydrogen and impurity contents in the aluminum liquid obtained by refining are lower, and the intercooler obtained by casting has enough strength and airtightness.

The present invention in a preferred example may be further configured to: in S10, firstly, spraying and cleaning are carried out, wherein the temperature of the cleaning solution is 45-60 ℃, the volume fraction of the cleaning agent in the cleaning solution is 2-3%, the pH value of the cleaning solution is 8-11, the filtration precision is 100 mu m, the cleaning time is 1-3 min, then ultrasonic cleaning is carried out, the temperature of the cleaning solution is 45-60 ℃, the volume fraction of the cleaning agent in the cleaning solution is 2-3%, the pH value of the cleaning solution is 8-11, and the ultrasonic intensity is 0.5-1W/cm²The filtration precision is 10 mu m, the cleaning time is 6-8 min, then clear water spraying is carried out, the temperature of the clear water is 45-60 ℃, the filtration precision is 5 mu m, the washing time is 1-3 min, and the water pressure is 1-3 Kgf/cm²Then bubbling clean water and filteringThe precision is 5 μm, the cleaning time is 1-3 min, and the air pressure is 4-6 Kgf/cm²Spraying pure water at a clean water temperature of 45-60 deg.C, a filtration precision of 5 μm, a cleaning time of 1-3 min, and a water pressure of 3-5 Kgf/cm²Then wind cutting is carried out, the filtering precision is 10um, the time is 1-3 min, and the wind quantity is 3000-4000 m³Drying with circulating hot air at 70-100 deg.C for 5-7 min, filtering to obtain a filter with a filter precision of 5 μm, and cooling with fan for 1min with an air flow of 100-300 m³And h, finally, naturally drying the casting.

By adopting the technical scheme, the casting is sequentially subjected to spraying cleaning, ultrasonic cleaning, clear water spraying, clear water bubbling, water blowing spraying, wind cutting, circulating hot air drying and cooling, and then the casting is naturally dried, so that residual sand and aluminum scraps on the inner surface and the outer surface of the casting can be cleaned.

The present invention in a preferred example may be further configured to: in S3, the returning charge and the aluminum ingot are added into the smelting furnace simultaneously, and the proportion of the aluminum ingot is not less than 60%.

By adopting the technical scheme, most of the returned materials are aluminum blocks with higher purity, and the returned materials are put into a smelting furnace for smelting and recycling, so that the cost can be effectively controlled, and resources are fully utilized; the proportion of the aluminum ingots is controlled to be not less than 60 percent, the quality of the molten aluminum can be ensured, and the condition of excessive impurities in the molten aluminum is avoided.

The present invention in a preferred example may be further configured to: in S3, when the furnace body is not heated, the foundry returns are firstly put in, then the aluminum ingots are put in, when the furnace body contains aluminum liquid, the previously baked aluminum ingots are firstly put in, and the number of the aluminum ingots is not less than 10, and then the foundry returns are put in.

By adopting the technical scheme, as for the cooling furnace, the scrap returns and the aluminum ingots are inevitably oxidized in the heating and melting process, the scrap returns which are firstly put in are melted before the aluminum ingots, and the aluminum ingots are wrapped in the scrap returns, so that the aluminum ingots can be protected to a certain degree; for the heating furnace, an aluminum ingot which is dried thoroughly in advance is put in, so that the heat of the original aluminum liquid in the furnace body can be prevented from being absorbed rapidly, and the influence on the quality of the original aluminum liquid is reduced.

The present invention in a preferred example may be further configured to: in S1, a core making device adopts a shell core machine, the temperature of a movable die of the shell core machine is 255-285 ℃, the temperature of a fixed die of the shell core machine is 250-280 ℃, the core shooting air pressure is 0.3-0.6 MPa, the sand shooting time is 6S, the exhaust time is 6S, the crusting time is 15S, the vibration time is 10S, and the curing time is 35S.

By adopting the technical scheme, the factors such as the temperature of the movable mold, the temperature of the fixed mold, the air pressure of the core shooting, the sand shooting time, the exhaust time and the like are strictly controlled, and the finally solidified sand core has proper thickness, so that the structural strength of the sand core can be ensured, the consumption of the coated sand can be reduced as much as possible, and the cost is controlled.

The present invention in a preferred example may be further configured to: and S6, transferring the aluminum liquid into an aluminum liquid pool after degassing, scooping the aluminum liquid out of the aluminum liquid pool by using a ladle, pouring the aluminum liquid into an aluminum liquid receiving groove on a casting machine, and turning over the casting machine to enable the aluminum liquid to flow into a cavity of the mold from the aluminum liquid receiving groove and to be solidified.

By adopting the technical scheme, after the casting machine is turned over, the molten aluminum in the molten aluminum receiving groove flows into the cavity, the upper part and the lower part of the casting obtained by solidification are consistent in height, and the situations of shrinkage porosity and shrinkage cavity of the upper part of the casting are avoided.

The present invention in a preferred example may be further configured to: in S7, the casting is taken down from the casting machine, the sand core is cleaned by the air pick, most of aluminum at the pouring gate and the riser is cut off by the sawing machine, the pouring gate, the riser and the flash and burr on the surface of the blank are polished by the abrasive belt machine, the casting is polished by the sand blasting machine, the casting is cleaned by the cleaning machine, and finally the casting is put into the cleaning pool to wash off the cleaning liquid foam on the surface of the casting.

By adopting the technical scheme, after sand removal, cutting, grinding, polishing and simple cleaning, the casting is basically processed and finished, so that an operator can conveniently collect and transfer the casting to the next procedure, and wastes such as sand grains, aluminum chips and the like falling in the collecting and transferring process are few, so that the pollution to the working environment is small.

The present invention in a preferred example may be further configured to: and S4, heating and melting the foundry returns and the aluminum ingots, and when the temperature of the aluminum liquid is heated to 700-730 ℃, shoveling the pot to clean the aluminum slag on the crucible wall.

By adopting the technical scheme, the aluminum slag on the crucible wall is removed, so that the aluminum liquid can be better heated, and the tapping temperature can be smoothly reached.

In summary, the invention includes at least one of the following beneficial technical effects:

1. the degassing and deslagging effects are better, the hydrogen and impurity contents in the refined molten aluminum are lower, and the intercooler obtained by casting has enough strength and airtightness;

2. successively carrying out spray cleaning, ultrasonic cleaning, clear water spraying, clear water bubbling, water blowing spraying, wind cutting, circulating hot air drying and natural airing on the casting, and fully cleaning residual sand and aluminum scraps on the inner surface and the outer surface of the casting;

3. when in batching, the scrap returns are put into the furnace, so that the cut pouring gate and riser and the aluminum in the waste casting can be reused, and the cost is controlled.

Drawings

Fig. 1 is an overall flowchart of the embodiment.

Detailed Description

The present invention will be described in further detail with reference to the accompanying drawings.