Шың 8 Мыс және мыс қорытпаларын құю әдістері

1. Кіріспе

Copper and its alloys occupy a pivotal role in modern industry due to their outstanding electrical conductivity, Коррозияға төзімділік, жіне thermal performance.

Тарихи, civilizations dating back to 5000 BC mastered copper casting in simple stone molds, laying the groundwork for today’s sophisticated techniques.

Бұл мақалада, we explore the full spectrum of copper‑based casting methods, examine their metallurgical principles, and guide engineers in selecting the optimal process for diverse applications.

2. Fundamental Principles of Metal Casting

Every casting method follows four core stages:

1. Қалыптар құру – Technicians form a cavity in sand, металл, керамика, or plaster that mirrors the part geometry.
2. Құю – Furnaces melt copper (балқу нүктесі 1 083 ° °) or alloys up to 1 600 ° °, then pour the liquid into molds.
3. Күшейту – Controlled cooling—guided by thermal conductivity (~ 400 W/m·K for copper) and mold material—drives microstructure development.
4. Shake‑Out – Once solid, castings exit the mold and undergo cleaning and post‐processing.

Copper’s high thermal conductivity demands higher mold preheat (200-400 ° C) and precise pour control to maintain fluidity (viscosity ~ 6 mPa·s at 1 200 ° °).

Қосымша, copper’s Жылу кеңеюі (16.5 µm/m·K) requires exact pattern offsets to achieve final dimensions.

3. Major Copper Alloy Casting Methods

Мыс and its alloys—brasses, қола, copper-nickels, and others—are cast using a range of methods that suit different production volumes, Механикалық талаптар, and dimensional tolerances.

Each technique carries distinct advantages and limitations based on alloy characteristics and desired component outcomes.

This section explores the most prominent copper alloy casting methods in modern manufacturing, along with technical insights to guide process selection.

Құмның құюы

Процесске шолу & Жабдық
Құмның құюы remains one of the oldest and most widely used methods for casting copper alloys. It involves packing sand around a reusable pattern inside a mold box.

The sand is bonded with clay (Жасыл құм) or hardened with chemicals (resin-bonded or CO₂-activated sands). After pattern removal, molten metal is poured into the cavity.

 

Артықшылықтары

• Төмен жабдықталған құны, Төмен үшін қолайлы- to medium-volume runs
• Flexible part sizes—from a few ounces to several tons
• Broad alloy compatibility

Шектеулер

• Coarse surface finishes (РА 6,3-25 мкм)
• Loose tolerances (typically ±1.5–3 mm)
• Requires post-casting machining for most precision applications

Салым (Жоғалған балауыз) Кастинг

Precision Shell Building
Инвестициялық құю uses a wax model coated with ceramic slurry to build a thin, high-accuracy shell mold. Күйіп қалғаннан кейін, molten metal is poured into the preheated ceramic mold.

Жамандық

• Үздік өлшемді дәлдік (± 0,1-0,3 мм)
• Өте ыңғайлы шатасқан, thin-walled geometries
• Ең жақсы Бетті аяқтау (RA 1.6-3.2 мкм)

Қиартшалар

• Higher tooling costs (due to the need for injection dies)
• Longer cycle times, especially for shell construction and burnout
• Typically economical only for medium-to-high volume өнім

Shell Molded Casting

Процесс туралы мәліметтер
Shell molding uses a heated metal pattern coated with resin-bonded sand. When exposed to heat, the resin sets to form a thin shell that acts as the mold.

The process produces more accurate and cleaner castings than traditional sand casting.

Артықшылықтары

• Improved surface quality and definition
• Тиберлер than green sand molds
• Reduced machining allowance due to near-net shape casting

Шектеулер

• Higher material costs (specialized resins and silica sands)
• Expensive pattern tooling (metal patterns required)

Центрифугалық құю

Horizontal vs. Vertical Setups
Центрифугалық құюда, Балқытылған металл айналмалы қалыпқа құйылады, either horizontally or vertically.

The centrifugal force distributes the metal against the mold wall, minimizing porosity and ensuring excellent material integrity.

Негізгі артықшылықтар

• High density and reduced porosity—ideal for pressure-retaining components
• Directional solidification Механикалық қасиеттерді жақсартады
• Қолайлы бұталар, сақиналар, түтіктер, and hollow parts
• Vertical casting often used for small parts; horizontal for large cylinders

Шектеулер

• Шектелген Айналықты симметриялы бөліктер
• Tooling setup is more complex and costly than static casting

Chill Casting

Елеулендіруді бақылау
Chill casting uses metal molds (often iron or steel) to rapidly extract heat from the molten metal. This rapid solidification refines the grain structure and enhances mechanical properties.

Күшті жақтар

• Produces Қаттырақ, denser castings (дейін 50% increase in hardness vs. Құмның құюы)
• Excellent for phosphor bronze and gunmetal
• Cost-effective for repetitive casting of bars, шыбықтар, және шағын бөлшектер

Шектеулер

• Less suited for Күрделі геометриялар
• Limited size range due to mold constraints

Кастинг өледі (Hot-Chamber and Cold-Chamber)

Pressure Injection Process
Die casting involves injecting molten copper alloys into a high-strength steel mold under high pressure.

Cold-chamber machines are typically used due to the high melting points of copper alloys.

Артықшылықтары

• Fast production rates—ideal for mass production
• Superior surface finish and precision (Ra 1–2 µm, tolerances ±0.05 mm)
• Reduces or eliminates machining

Constraints

• Not all copper alloys are suitable (E.Г., high zinc brasses can corrode dies)
• Die tooling is expensive (investment of $50,000 немесе одан көп)
• Ең жақсы medium to high volumes

Үздіксіз кастинг

Процесске шолу
Molten metal is poured into a water-cooled mold that continuously forms and pulls solidified metal through a withdrawal system.

Common outputs include rods, жолақтар, and billets for downstream machining or rolling.

Артықшылықтары

• Жоғары өнімділік with minimal human intervention
• Excellent mechanical properties due to controlled solidification
• Smooth surfaces and straightness suitable for automatic feed machining
• Low scrap rate and better yield (үстінде 90% material utilization)

Типтік қорытпалар

• Tin bronzes, leaded bronzes, phosphor bronzes, and copper-nickels

Plaster Mould Casting

Мамандандырылған пайдалану
This process employs plaster or ceramic molds formed around a pattern to capture fine detail and tight tolerances.

The mold is removed after casting by breaking or dissolving the plaster.

Артықшылықтары

• Excellent for күрделі пішіндер жіне Тегіс беті әрлеу
• Good for Прототиптер жіне Томып өнім

Жөнелушілер

• Төмен өткізгіштігі—limits to casting size
• Longer preparation time жіне limited mold life

Жиынтық салыстыру кестесі

4. Common Copper Alloys Used in Casting

Foundries cast a wide array of copper‑based alloys, each engineered to balance mechanical strength, Коррозияға төзімділік, thermal and electrical performance, және Қасиеттілік.

5. Қорытынды

Copper and copper‑alloy foundries offer a rich toolbox of casting methods—each balancing құны, дәлдік, Механикалық қойылым, жіне Өндіріс көлемі.

By understanding process nuances—from mold materials and thermal management to alloy behavior—engineers can optimize part design, minimize scrap, and ensure reliable performance.

As technologies like additive mold fabrication жіне real‑time simulation mature, copper casting will continue to evolve, sustaining its critical role in high‑performance manufacturing.

-Та Осы, Сіздің жобаңызды дизайн процесінде ерте талқылауға қуаныштымыз, Нәтиже сіздің механикалық және өнімділік сипаттамаларына сәйкес келеді.

Сіздің талаптарыңызды талқылау, электрондық пошта [email protected].

ЖҚС

Can all copper alloys be die-cast?

Жоқ. Only specific alloys like aluminum bronzes, high-tensile brasses, жіне silicon brasses are suitable for Кастинг өледі due to the high pressures and rapid cooling involved.

Қорытпалар сияқты Фосфор Қола немесе gunmetal are better suited to sand or chill casting.

What’s the difference between centrifugal and chill casting?

• Центрифугалық құю uses rotational force to push molten metal into the mold, producing dense, defect-free components (ideal for pipes, бұталар, және жеңдер).
• Chill casting uses static metal molds to rapidly solidify the surface, improving mechanical properties and reducing grain size—especially effective for tin bronzes.

Why is continuous casting preferred for high-volume copper alloy bars?

Үздіксіз кастинг offers consistent quality, Тамаша механикалық қасиеттері, and low scrap rates.

It’s optimal for Фосфор Қола, gunmetal, жіне Жетекші қола тұспо құқығы, especially when integrated with rolling or extrusion processes.

What post-processing is required after casting copper alloys?

Depending on the casting method and alloy, post-processing may include:

• Heat treatment for stress relief or aging (especially for beryllium copper)
• Machining for critical surfaces or tight tolerances
• Surface finishing such as polishing or coating for corrosion protection or aesthetics