Titanium Alloy Wax Casting For Battery Back Cover Knob
Lost wax casting, also known as investment casting, is a precision casting method. The basic principle is to first use wax to create a wax mold with the same shape as the battery back cover knob, and then apply multiple layers of refractory materials on the surface of the wax mold to form a complete shell.
Principle of Lost Wax Casting
Lost wax casting, also known as investment casting, is a precision casting method. The basic principle is to first use wax to create a wax mold with the same shape as the battery back cover knob, and then apply multiple layers of refractory materials on the surface of the wax mold to form a complete shell. Then heat the mold shell to melt and flow out the wax mold, forming a cavity inside the shell that matches the shape of the wax mold. Finally, the melted titanium alloy is poured into this cavity, and after the titanium alloy cools and solidifies, the shell is broken to obtain the desired battery back cover knob.
Selection of Titanium Alloy Materials
Titanium alloy has the advantages of low density, high strength, and good corrosion resistance, making it very suitable for making battery back cover knobs. When choosing titanium alloys, specific performance requirements such as strength, hardness, corrosion resistance, etc. need to be considered. Common titanium alloys used for wax loss casting include Ti-6Al-4V, which has good comprehensive performance and can meet various needs of battery back cover knobs during use.
Wax pattern production
Design wax mold
Based on the design drawings of the battery back cover knob, use computer-aided design (CAD) software for 3D modeling to determine the precise size and shape of the wax mold.
Mold making
Based on the designed wax model, make the corresponding mold. The material of the mold is usually chosen as metal or plastic, requiring high precision and good surface quality.
Injection of wax material
Heat the wax material to a liquid state, and then inject the liquid wax material into the mold through an injection machine. The injection process requires control of temperature, pressure, and injection speed to ensure the quality of the wax mold.
Remove wax mold
After the wax material cools and solidifies, open the mold and remove the wax mold. Inspect the wax mold, remove burrs and burrs on the surface, and ensure that the size and shape of the wax mold meet the requirements.
Shell making
Coating: Dip the wax mold into the coating to evenly cover the surface of the wax mold. Coatings are usually composed of refractory materials (such as zircon sand, corundum, etc.) and binders (such as water glass, silica sol, etc.).
Sanding: Sprinkle a layer of refractory sand on the surface of the wax mold coated with paint to firmly adhere the sand particles to the paint. The purpose of sanding is to increase the strength and breathability of the shell.
Drying and hardening: Place the wax mold coated with paint and sprinkled with sand into the drying chamber for drying and hardening treatment. The drying and hardening time and temperature need to be adjusted according to the types of coatings and binders.
Repeat coating and sanding: According to the thickness requirements of the shell, repeat the coating and sanding operations until the shell reaches the required thickness.
Dewaxing: Place the prepared shell into a dewaxing furnace, heat it to a certain temperature, melt the wax mold and let it flow out. The dewaxing process requires temperature and time control to ensure that the wax mold is completely melted and flows out, while avoiding shell cracking.
Melting and Casting of Titanium Alloy
Melting titanium alloy
Place the selected titanium alloy raw materials into a vacuum induction furnace for melting. During the melting process, it is necessary to control the temperature, vacuum degree, and melting time inside the furnace to ensure the uniform composition and stable quality of the titanium alloy.
Pouring
After the titanium alloy is melted, the melted titanium alloy is injected into the mold shell through a gate. The pouring process requires controlling the pouring temperature, pouring speed, and pouring pressure to ensure that the titanium alloy can fill the cavity of the shell and avoid defects such as porosity and shrinkage.
Post processing
Cleaning the shell
After the titanium alloy cools and solidifies, break the shell and remove the casting. Clean the residual shell and oxide scale on the surface of the casting using sandblasting, polishing, and other methods.
01
Heat treatment
Heat treatment is applied to castings to improve their microstructure and properties. Common heat treatment processes include annealing, quenching, tempering, etc.
02
Mechanical processing
According to the design requirements of the battery back cover knob, the castings are machined, such as turning, milling, drilling, etc., to achieve the required size and accuracy.
03
Surface treatment
Surface treatment of castings after mechanical processing, such as electroplating, spraying, etc., to improve their surface corrosion resistance and aesthetics.
04
Quality Inspection
Size inspection
Use measuring tools (such as calipers, micrometers, etc.) to inspect the size of the battery back cover knob to ensure it meets the design requirements.
Appearance inspection
The surface quality of the battery back cover knob is inspected visually or using a microscope or other equipment to check for defects such as cracks, pores, sand holes, etc.
Performance testing
Test the mechanical properties (such as strength, hardness, etc.) and corrosion resistance of the battery back cover knob to ensure that it meets the usage requirements.
Advantages
High precision
Lost wax casting can produce battery back cover knobs with high dimensional accuracy and complex shapes, meeting the design requirements of the product.
Good surface quality
The surface smoothness of the castings after casting is high, reducing the workload of subsequent processing.
High material utilization rate
Compared with traditional processing methods, lost wax casting can reduce material waste and improve material utilization rate.
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