电铸与电弧喷涂快速制模技术的研究
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摘要
为了解决电弧喷涂锌铝合金制造而成的模具表面硬度低,不耐磨损,易产生孔隙等性能上的缺陷,需要在锌铝合金的表面进行镀层的处理,即通过电镀在模具的表面进行镀层的制备。在锌铝合金喷涂模具的表面进行镀层的制备,本文采用了两种不同的实验方案。方案一：先喷后镀,即先用电弧喷涂制出模具的型腔,然后在模具型腔内表面进行镀层的处理,分别在模具型腔的内表面化学镀铜、化学镀镍,在利用电镀进行镀层的加厚；方案二：先镀后喷,即用电铸先进行模具的制备,然后在模具的表面喷涂达到所要求的工作厚度。
通过扫描电子显微镜对锌铝合金涂层、铜镀层及镍镀层进行孔隙和夹杂物的观察,测试锌铝合金喷涂层和不同镀层的显微硬度,并对喷涂层和电镀层进行结合强度的测试,通过对比分析可知,方案二采用先镀后喷的工艺方法,消除了模具表面性能上的缺陷,并使模具的硬度,表面强度,表面光洁度,耐蚀能力都有很大的提高。
在方案二中,将电铸与电弧喷涂相结合进行模具的快速制造,已经成为如今快速制模技术中的一个发展方向。这是因为这种制模方法在保证模具精度的前提下,能显著的缩短制模具周期,降低生产成本。电铸制模虽然具有很高的复制精度,但影响电铸层质量的因素很多,另外模具的制造周期较长。因此,本文对电铸铜的工艺参数进行了正交优化分析,分析各主要因素对电铸层质量性能的影响,并获得了高质量电铸铜的较好的工艺参数。
为了检验试验结果,本文将电铸与电弧喷涂相结合的快速制模具技术应用于注塑模具的制造,并用模具已生产出产品。结果表明：通过对锌铝合金模具表面进行镀层处理,消除了模具表面性能上的缺陷,并使模具的硬度,表面强度,表面光洁度,耐蚀能力都有很大的提高。
In order to solve arc spraying zn-al alloy manufacture of mold have low surface hardness, wear resistance, easy generation pores and other defects in performance, need to make plating on the surface of the zn-al alloy, through electroplating in the mold surface for copper plating preparation. Making plating in the mold surface of the zn-al alloy for plating preparation, this paper uses two different experiment scheme. Scheme one, first spraying after plating, that is, first make the mold's die space by arc spraying, then in the mold's die space making plating, respectively electroless copper or electroless nickel in the mold's inside surface, Scheme two, first electroforming after spraying, that is, first make the mold by electroforming, then achieve the requests thickness by arc spraying in the mold surface.
Observe zn-al alloy coating and copper plating and nickel plating's pores and inclusions by SEM, test microhardness of zn-al alloy coating and different plating, and test bonding strength of spray coating and copper plating. By contrast and analysis, scheme two adopts first electroforming after spraying process method, eliminate the mold surface defects, and make the mold's hardness, surface strength, surface smoothness and corrosion resistant capability have greatly improved.
In scheme two, a technology of rapid tooling through the combination of electroforming with arc spraying, It has being a way of rapid tooling. Because the new rapid tooling not only can ensure the precision of mould primely, but also can shorten the mold-making period and reduce cost. Though electroformed molds are very precise, the quality of electrochemical deposit layer is influenced by many factors. Besides the electroforming time is long. So in this paper, the experiment oftechnics factors of electroformed copper was carried out. The main factor and the optimum parameters to archive the best properties of the electroformed layer of cooper were obtained.
In order to validate conclusions of experiments above, the injection mold was fabricated by electroforming and arc spraying, Using these molds, plastic parts and foam patterns were produced. The conclusion show:through making copper coating in the mold surface, eliminate the mold surface defects, and make the mold's hardness, surface strength, surface smoothness and corrosion resistant capability have greatly improved.
通过扫描电子显微镜对锌铝合金涂层、铜镀层及镍镀层进行孔隙和夹杂物的观察,测试锌铝合金喷涂层和不同镀层的显微硬度,并对喷涂层和电镀层进行结合强度的测试,通过对比分析可知,方案二采用先镀后喷的工艺方法,消除了模具表面性能上的缺陷,并使模具的硬度,表面强度,表面光洁度,耐蚀能力都有很大的提高。
在方案二中,将电铸与电弧喷涂相结合进行模具的快速制造,已经成为如今快速制模技术中的一个发展方向。这是因为这种制模方法在保证模具精度的前提下,能显著的缩短制模具周期,降低生产成本。电铸制模虽然具有很高的复制精度,但影响电铸层质量的因素很多,另外模具的制造周期较长。因此,本文对电铸铜的工艺参数进行了正交优化分析,分析各主要因素对电铸层质量性能的影响,并获得了高质量电铸铜的较好的工艺参数。
为了检验试验结果,本文将电铸与电弧喷涂相结合的快速制模具技术应用于注塑模具的制造,并用模具已生产出产品。结果表明：通过对锌铝合金模具表面进行镀层处理,消除了模具表面性能上的缺陷,并使模具的硬度,表面强度,表面光洁度,耐蚀能力都有很大的提高。
In order to solve arc spraying zn-al alloy manufacture of mold have low surface hardness, wear resistance, easy generation pores and other defects in performance, need to make plating on the surface of the zn-al alloy, through electroplating in the mold surface for copper plating preparation. Making plating in the mold surface of the zn-al alloy for plating preparation, this paper uses two different experiment scheme. Scheme one, first spraying after plating, that is, first make the mold's die space by arc spraying, then in the mold's die space making plating, respectively electroless copper or electroless nickel in the mold's inside surface, Scheme two, first electroforming after spraying, that is, first make the mold by electroforming, then achieve the requests thickness by arc spraying in the mold surface.
Observe zn-al alloy coating and copper plating and nickel plating's pores and inclusions by SEM, test microhardness of zn-al alloy coating and different plating, and test bonding strength of spray coating and copper plating. By contrast and analysis, scheme two adopts first electroforming after spraying process method, eliminate the mold surface defects, and make the mold's hardness, surface strength, surface smoothness and corrosion resistant capability have greatly improved.
In scheme two, a technology of rapid tooling through the combination of electroforming with arc spraying, It has being a way of rapid tooling. Because the new rapid tooling not only can ensure the precision of mould primely, but also can shorten the mold-making period and reduce cost. Though electroformed molds are very precise, the quality of electrochemical deposit layer is influenced by many factors. Besides the electroforming time is long. So in this paper, the experiment oftechnics factors of electroformed copper was carried out. The main factor and the optimum parameters to archive the best properties of the electroformed layer of cooper were obtained.
In order to validate conclusions of experiments above, the injection mold was fabricated by electroforming and arc spraying, Using these molds, plastic parts and foam patterns were produced. The conclusion show:through making copper coating in the mold surface, eliminate the mold surface defects, and make the mold's hardness, surface strength, surface smoothness and corrosion resistant capability have greatly improved.
引文
[1]Carol Anderson. Rapid prototyping and manufacturing in the USA. Rapid prototyping Journal,1997, 3(3):120-121.
[2]Dolenc A, Makela I. Rapid prototyping froma computerscientist's point of view. Rapid prototyping Journal,1996,2(2):18-25.
[3]Bourell D L, Beaman J J. Solid freefromfabrication-An advanced manufacturing approach. Proceedings of Solid Freefromfabrica-tionSymosium. Austin, Texas,1990,1-7.
[4]王运赣.快速模具制造及其应用.武昌：华中科技大学出版社,2003.
[5]Rosochowski A, Matuszak A. Rapid tooling:the stateof the art. Journal of Materials Processing Technol-ogy,2000.106:191-198.
[6]Takeo Nakagawa. Advances in prototype and low vol-ume sheet forming and tooling. Journal of Materials Processing Technology,2000.98:244-250.
[7]Gregory John Gibbons, Robert G Hansell, A J Nor-wood,P M Dickens. Rapid laminated die-cast tooling. Assembly Automation,2003.23(4):372-381.
[8]王伊卿,卢凤兰,卢秉恒.电铸与电弧喷涂相结合制造EDM电极.电加工与模具,2001,4：41-43.
[9]王伊卿,唐一平,赵文趁,等.电铸与电弧喷涂相结合的模具制造方法.材料加工,2001,6：30-32.
[10]罗新华,唐亚新.国内外R P M技术的应用及新进展.中国第二届R P技术与快速模具制造学术会议论文集.西安：1998.154-158.
[11]罗兴华,花国然.国家快速成型制造技术的应用及进展.机械制造,1998,36(3)：56-58.
[12]Wohlels T. Wohlers Report 2000:Rapid prototyping&tooling state of the industry. Annual Worldwide Progress Report. Colorado,USA:Wohlers Associates, Inc.,2000.41-52.
[13]张人估,颜永年,单忠德.基于CAD/CAM/RPM的快速模具制造技术.计算机辅助设计与制造CAD/CAM,2000(4):6-9.
[14]Yan Yongnian, Zhang Renji, Lu Qingping. Rapid prototyping&tooling in China, In:Solid Freedom Fabrication Proceedings Angust1999. Proceedings for Symposium on SolidFreedom Fabrication. Austin Texas, USA:Bourell D L,1999.83-88.
[15]许巧玉.金属电弧喷涂快速制模工艺的研究.模具工业,2006,32(7)：69-70.
[16]杨绮琴,方北龙,童叶翔.应用电化学.广州：中山大学出版社,2001.
[17]胡美些,王宁.我国电铸技术的研究进展.电镀与涂饰,2006,25(11)：38.
[18]梁国星,徐灵岩,张宇.电铸直齿外珩轮的工艺研究.机械管理与开发,2007,(2)：49-52.
[19]周斌.电铸工艺.电镀与涂饰,2004,23(5)：22-23.
[20]李国兵,朱小东.电铸成形与其它成形方法耗能的比较.模具制造技术,2007, (2)：75-76.
[21]王延相,白玉俊,马利芹.新编实用电镀工艺手册.北京：人民邮电出版社,2007,6-7.
[22]赵剑峰,朱荻,云乃彰.精密模具电铸工艺研究.模具工业,1997,6：4144.
[23]孔庆华.特种加工.上海：同济大学出版社,1997.
[24]王伊卿,朱东波,卢秉恒,等.电弧喷涂制造汽车覆盖件模具.模具工业,2001,(9)：41-45.
[25]宋宝通,于林奇,卫淑玲.电弧喷涂制模技术的研究及应用.电加工与模具,2000,(1)：39-41.
[26]徐滨士,马世宁,张振学.高效优质的防腐蚀新技术—高速电弧喷涂技术.腐蚀与防护,2000,10(10)：455-457.
[27]KelkarM, Hussary N, Scbein J. Optical Diagnositics and Molding of Gas and Droplet Flow in Wire Arc Spraying. ITSC'98. Nice, France,1998:329-334.
[28]陈益龙.低熔点金属喷涂制造模具的方法明.模具工业,1997,(7)：36-39.
[29]沈献民,张恒,张军,等.电弧喷涂快速制模技术及其应用.洛阳工学院学报,2002,23(4)：16-20.
[30]宋宝通,于林奇,卫淑玲.电弧喷涂制模技术的研究及应用.电加工与模具,2000,(1)：39-41.
[31]刘宪军,徐滨士,马世宁,等.应用电弧喷涂技术制造塑料模具.模具技术,1996(6)：25-30.
[32]刘峰,张元好,曾大新.电弧喷锌快速制模工艺参数的选择.湖北汽车工业学院学报,2004(6)：39-42.
[33]Singer. Spray casting of articles. United States,4830084. May 16,1989.
[34]Jordan. Metal forming process. United States,5952056. September 14,1999.
[35]Hussary. Method for repairing spray-formed steeltooling. UnitedStatesPatent,6258402. July 10, 2001.
[36]唐正连.电铸与电弧喷涂快速制模具技术研究：硕士学位论文.武汉：华中科技大学,2004.
[37]陈冶良.简明电镀手册.北京：化学工业出版社,2007,515-516.
[38]姜晓霞,沈伟.化学镀理论及实践.北京：国防工业出版社,2000,1.
[39]傅继东.快速电铸制模技术.机械与电气,2008,(8)：50-52.
[40]刘红俐,花国然,罗新华.国内外快速成型技术的新发展与展望.南通工学院学报,2002,(3)：52-54.
[41]何仲赞,洪军.金属电弧喷涂成型快速制模关键技术与应用.塑性工程学报,2008,15(2)65-68.
[42]何仲赟,朱东波.基于电弧喷涂和电刷镀的快速制模技术.模具工业,2003, (12)：43-46.
[43]肖宏滨,朱锦洪,刘泽昊,等.电弧喷涂工艺参数对涂层结合强度的影响.洛阳工学院学报,1999,20(1)：32-34.
[2]Dolenc A, Makela I. Rapid prototyping froma computerscientist's point of view. Rapid prototyping Journal,1996,2(2):18-25.
[3]Bourell D L, Beaman J J. Solid freefromfabrication-An advanced manufacturing approach. Proceedings of Solid Freefromfabrica-tionSymosium. Austin, Texas,1990,1-7.
[4]王运赣.快速模具制造及其应用.武昌：华中科技大学出版社,2003.
[5]Rosochowski A, Matuszak A. Rapid tooling:the stateof the art. Journal of Materials Processing Technol-ogy,2000.106:191-198.
[6]Takeo Nakagawa. Advances in prototype and low vol-ume sheet forming and tooling. Journal of Materials Processing Technology,2000.98:244-250.
[7]Gregory John Gibbons, Robert G Hansell, A J Nor-wood,P M Dickens. Rapid laminated die-cast tooling. Assembly Automation,2003.23(4):372-381.
[8]王伊卿,卢凤兰,卢秉恒.电铸与电弧喷涂相结合制造EDM电极.电加工与模具,2001,4：41-43.
[9]王伊卿,唐一平,赵文趁,等.电铸与电弧喷涂相结合的模具制造方法.材料加工,2001,6：30-32.
[10]罗新华,唐亚新.国内外R P M技术的应用及新进展.中国第二届R P技术与快速模具制造学术会议论文集.西安：1998.154-158.
[11]罗兴华,花国然.国家快速成型制造技术的应用及进展.机械制造,1998,36(3)：56-58.
[12]Wohlels T. Wohlers Report 2000:Rapid prototyping&tooling state of the industry. Annual Worldwide Progress Report. Colorado,USA:Wohlers Associates, Inc.,2000.41-52.
[13]张人估,颜永年,单忠德.基于CAD/CAM/RPM的快速模具制造技术.计算机辅助设计与制造CAD/CAM,2000(4):6-9.
[14]Yan Yongnian, Zhang Renji, Lu Qingping. Rapid prototyping&tooling in China, In:Solid Freedom Fabrication Proceedings Angust1999. Proceedings for Symposium on SolidFreedom Fabrication. Austin Texas, USA:Bourell D L,1999.83-88.
[15]许巧玉.金属电弧喷涂快速制模工艺的研究.模具工业,2006,32(7)：69-70.
[16]杨绮琴,方北龙,童叶翔.应用电化学.广州：中山大学出版社,2001.
[17]胡美些,王宁.我国电铸技术的研究进展.电镀与涂饰,2006,25(11)：38.
[18]梁国星,徐灵岩,张宇.电铸直齿外珩轮的工艺研究.机械管理与开发,2007,(2)：49-52.
[19]周斌.电铸工艺.电镀与涂饰,2004,23(5)：22-23.
[20]李国兵,朱小东.电铸成形与其它成形方法耗能的比较.模具制造技术,2007, (2)：75-76.
[21]王延相,白玉俊,马利芹.新编实用电镀工艺手册.北京：人民邮电出版社,2007,6-7.
[22]赵剑峰,朱荻,云乃彰.精密模具电铸工艺研究.模具工业,1997,6：4144.
[23]孔庆华.特种加工.上海：同济大学出版社,1997.
[24]王伊卿,朱东波,卢秉恒,等.电弧喷涂制造汽车覆盖件模具.模具工业,2001,(9)：41-45.
[25]宋宝通,于林奇,卫淑玲.电弧喷涂制模技术的研究及应用.电加工与模具,2000,(1)：39-41.
[26]徐滨士,马世宁,张振学.高效优质的防腐蚀新技术—高速电弧喷涂技术.腐蚀与防护,2000,10(10)：455-457.
[27]KelkarM, Hussary N, Scbein J. Optical Diagnositics and Molding of Gas and Droplet Flow in Wire Arc Spraying. ITSC'98. Nice, France,1998:329-334.
[28]陈益龙.低熔点金属喷涂制造模具的方法明.模具工业,1997,(7)：36-39.
[29]沈献民,张恒,张军,等.电弧喷涂快速制模技术及其应用.洛阳工学院学报,2002,23(4)：16-20.
[30]宋宝通,于林奇,卫淑玲.电弧喷涂制模技术的研究及应用.电加工与模具,2000,(1)：39-41.
[31]刘宪军,徐滨士,马世宁,等.应用电弧喷涂技术制造塑料模具.模具技术,1996(6)：25-30.
[32]刘峰,张元好,曾大新.电弧喷锌快速制模工艺参数的选择.湖北汽车工业学院学报,2004(6)：39-42.
[33]Singer. Spray casting of articles. United States,4830084. May 16,1989.
[34]Jordan. Metal forming process. United States,5952056. September 14,1999.
[35]Hussary. Method for repairing spray-formed steeltooling. UnitedStatesPatent,6258402. July 10, 2001.
[36]唐正连.电铸与电弧喷涂快速制模具技术研究：硕士学位论文.武汉：华中科技大学,2004.
[37]陈冶良.简明电镀手册.北京：化学工业出版社,2007,515-516.
[38]姜晓霞,沈伟.化学镀理论及实践.北京：国防工业出版社,2000,1.
[39]傅继东.快速电铸制模技术.机械与电气,2008,(8)：50-52.
[40]刘红俐,花国然,罗新华.国内外快速成型技术的新发展与展望.南通工学院学报,2002,(3)：52-54.
[41]何仲赞,洪军.金属电弧喷涂成型快速制模关键技术与应用.塑性工程学报,2008,15(2)65-68.
[42]何仲赟,朱东波.基于电弧喷涂和电刷镀的快速制模技术.模具工业,2003, (12)：43-46.
[43]肖宏滨,朱锦洪,刘泽昊,等.电弧喷涂工艺参数对涂层结合强度的影响.洛阳工学院学报,1999,20(1)：32-34.