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WO2018192180A1 - 锻造型人工关节及金属制品的新型生产工艺及用途 - Google Patents

锻造型人工关节及金属制品的新型生产工艺及用途 Download PDF

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Publication number
WO2018192180A1
WO2018192180A1 PCT/CN2017/103633 CN2017103633W WO2018192180A1 WO 2018192180 A1 WO2018192180 A1 WO 2018192180A1 CN 2017103633 W CN2017103633 W CN 2017103633W WO 2018192180 A1 WO2018192180 A1 WO 2018192180A1
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Prior art keywords
forged
forging
mold
production process
magnetic field
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PCT/CN2017/103633
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English (en)
French (fr)
Inventor
赵京晨
王开国
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Beijing Gangxin Institute Of Metallurgical Technology
Beijing Jinshiyongchuang Technology Development Co Ltd
Beijing Jiuzhanghongtu Technology & Trade Co Ltd
Zhuozhou New Aviation Zhuoli Precision Technology Co Ltd
Original Assignee
Beijing Gangxin Institute Of Metallurgical Technology
Beijing Jinshiyongchuang Technology Development Co Ltd
Beijing Jiuzhanghongtu Technology & Trade Co Ltd
Zhuozhou New Aviation Zhuoli Precision Technology Co Ltd
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Application filed by Beijing Gangxin Institute Of Metallurgical Technology, Beijing Jinshiyongchuang Technology Development Co Ltd, Beijing Jiuzhanghongtu Technology & Trade Co Ltd, Zhuozhou New Aviation Zhuoli Precision Technology Co Ltd filed Critical Beijing Gangxin Institute Of Metallurgical Technology
Publication of WO2018192180A1 publication Critical patent/WO2018192180A1/zh
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/002—Hybrid process, e.g. forging following casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/02—Use of electric or magnetic effects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould

Definitions

  • the present application relates to the technical field of forged metal products, and in particular relates to a novel production process and use of a forged artificial joint and metal products.
  • the products currently obtained in this new production process are superior in strength, wear resistance and corrosion resistance in the same kind of products.
  • the existing traditional production process has lost the space to further improve the quality of the product.
  • the industry began to study the use of ceramic artificial joints as an example. However, the brittleness of ceramic artificial joints is difficult to break through and it has not been put into practical use. Metal artificial joints are still in commercial use.
  • the new production process has, in principle, broken through the fatal limitations of traditional production processes and demonstrated the potential to unimaginably improve product quality.
  • the present application aims to provide a novel production process and use of a forged artificial joint and a metal product, and a method for directly casting a forged blank by using a deep subcooled fine crystal casting furnace to solve the existing casting.
  • the problem of uneven grain size effectively improves product quality.
  • Step 1 Casting a fine crystal blank for forging using a deep subcooled fine grain casting furnace
  • Step 2 Cutting and grinding the whole set of fine crystal blanks to obtain a fine crystal forged blank, and then cleaning the obtained fine crystal forged blanks;
  • Step 3 The fine crystal forged blank obtained in the step 2 is placed in a heat treatment furnace for heating;
  • Step 4 The fine-grained forging blank heated in step 3 is placed in a forging die for forging;
  • Step 5 Take the forged product from the forging die and trim and polish it to obtain the finished product.
  • the deep subcooled fine crystal casting furnace mainly comprises: a melting crucible, a mold, a constant magnetic field magnetic pole, a mold carrying turntable, and the melting crucible is located above the casting mold.
  • the constant magnetic field magnetic pole is located around the mold, the mold carrying turntable is located at a lower end of the mold, and is fixedly connected with the mold;
  • the melting crucible is provided with an alternating current induction coil and a direct current a steady magnetic field; the melting crucible, the steady magnetic field pole, and the mold carrying turntable are located in the casting furnace, and the mold is placed on the mold carrying turntable from outside the furnace door by equipment.
  • the constant magnetic field magnetic pole is divided into a constant magnetic field N pole and a steady magnetic field S pole, and the stable magnetic field N pole and the steady magnetic field S pole are oppositely disposed, and the mold is located at the stable magnetic field N
  • the pole and the steady magnetic field are in the middle of the S pole.
  • the mold-carrying turntable is rotated slowly outside the furnace by a manual or electric method, and the mold-carrying turntable is input by a slow rotating shaft having a diameter of not less than 25 mm and not more than 65 mm, and the mold-carrying turntable Rotated by a ratchet.
  • the processing of the cast blank is sand cleaning, cutting, grinding, and polishing.
  • the heating temperature of the heat treatment furnace ranges from 900 ° C to 1200 ° C.
  • the forged blank is swaged using a 2 to 5 ton forging hammer.
  • novel production process can be applied to artificial joints, all metal-type medical implants other than artificial joints, and forged metal products and mechanical parts of non-medical implants.
  • the artificial joint production process can be divided into two types, one is cast type and the other is forged shape. It is currently recognized that the cast artificial joint is superior to the forged artificial joint, and the cast artificial joint has a coarse and uneven grain size, and the density is also poor; therefore, the forged artificial joint is the preferred process for producing high quality artificial joints.
  • the traditional forging artificial joint production process has many processes.
  • the specific process is: firstly casting a large steel ingot, and then casting, rolling and drawing the large steel ingot into a thin rod of a certain diameter, and then The thin rod is cut into small sections, and then the small section of the thin rod is partially thickened, and then the small section of the thin rod is bent and bent into a forged blank of the forged artificial joint, and then the blank is taken for forging. Therefore, the production of forged blanks requires a large amount of high energy-intensive work. Order, and, the blanking, rolling, drawing requires multiple hoes to the tail, wasting a lot of expensive artificial joint metal materials.
  • the forging blank made of small steel ingot will not be enough deformation, so the grain size of the forged blank is not enough. It is small, so that the grain size of the final product is not small enough.
  • a large steel ingot is cast, and then the large steel ingot is billed, rolled, drawn into a thin rod of a certain diameter, and then the thin rod is cut into small pieces, and then the small thin rod is partially thickened, and then The grain size of the forged blank of the forged artificial joint is small, but the deformation storage energy is relatively high, and the deformation texture is fine grain structure, which has strong directionality.
  • the strength of the product is directional. For example, the longitudinal strength is high, but the lateral strength is not high. If the annealing temperature is too high, the grain size driven by the deformation storage energy will increase, and the strength will decrease.
  • the new production process of the present application directly casts a forged blank having a very fine and uniform grain size, and the final product forged from the blank is not only a finer grain size, but also because the fine grain of the forged blank used is balanced.
  • the solidified equiaxed grains therefore, have no storage energy and texture directivity due to deformation, so the metal structure is stable.
  • this new process is to forge a direct casting of the blank, so the process is less, the energy consumption is less, and the material is saved. It is also worth noting that this forging process can ensure very fine grain structure of the final product with a small amount of forging deformation.
  • the metal structure is also dense after forging; thus, since the amount of deformation can be small, the chemical can be used.
  • the composition is designed with an alloy of high strength and hardness, which enables the final product to have higher strength and hardness.
  • the traditional process requires large deformation of large steel ingots, rolling, and drawing. In principle, it is not possible to use alloys with high chemical strength and high hardness.
  • the method of the present application is not only suitable for the production of metal artificial joints, but also for all metal-type medical implants other than artificial joints and forged metal products and mechanical parts of other non-medical implants, and has potential Application value;
  • the process method of the present application has less raw material consumption, less energy consumption, high product qualification rate, and is suitable for industrial production.
  • the enlightenment of the new production process is not limited to the production of metal artificial joints, and all metal-type medical implants other than artificial joints can learn from this new production process.
  • forging metal products and mechanical parts of other non-medical implants can also adopt a new production process. That is, the forging blank is not produced by the conventional process of casting, ingot rolling, drawing, and the like, but the production process of the forged product is directly produced by fine-grain casting.
  • FIG. 1 is a schematic structural view of a core portion of a deep subcooled fine grain casting furnace of the present application
  • Figure 2 is a grain structure of a conventional process casting blank
  • Figure 3 is a grain structure of a deep subcooled fine-grained casting blank of the present application.
  • Figure 4 is a product produced by the novel forging process of the present application.
  • Figure 5 is a diagram showing the state of Na 2 S corrosion resistance of a conventional process product
  • Figure 6 is a diagram showing the state of Na 2 S corrosion resistance of the product of the novel process of the present application.
  • the invention prepares a deep superfine fine crystal casting furnace, as shown in FIG. 1 , which mainly comprises a mold carrying turntable 5 , a mold 2 , a ratchet 7 , a casting bearing turntable rotating center positioning shaft 8 , a mold carrying turntable bearing wheel 6.
  • Heating element, steady magnetic field magnetic pole, melting crucible 1, melting crucible 1 is located above the mold 2, mold 2 is mounted above the mold carrying turntable 5, and a mold carrying turntable is arranged under the mold carrying turntable 5.
  • the load bearing wheel 6 and the ratchet wheel 7 are used to drive the rotation of the mold-carrying turntable 5.
  • the heating element and the constant magnetic field magnetic pole are arranged around the mold 2, and the mold-bearing turntable is arranged at the center of the lower end of the mold-bearing turntable 5.
  • the center of rotation positioning shaft 8 is used to define the center of rotation of the mold carrying carousel 5.
  • the melting crucible 1 is a crucible having a constant magnetic field or a static magnetic field and an alternating magnetic field simultaneously and separately applied to hold and melt the master alloy, and an alternating magnetic field and an alternating induction coil are applied to the melting crucible 1 .
  • the melting crucible 1 which is also called a static magnetic field, that is, more than one induction coil, and the static magnetic field induction coil can simultaneously have a resistive heating function, and the same type of furnace has only an alternating induction coil;
  • the melting crucible 1 has a structure in which the far infrared and the thermocouple are simultaneously temperature-measured, and some of the similar furnaces also have these two kinds of temperature measuring means, but cannot measure the temperature at the same time;
  • a magnetic pole is applied around the mold 2 to apply a constant magnetic field or a static magnetic field.
  • the furnace of the same type is not. The closest one is to provide a winding around the mold with a pulsed magnetic field. Meanwhile, the casting furnace of the present application is around the mold 2.
  • the value of the furnace B 1 ⁇ 2T (T-Tesla);
  • the furnace is a resistance wire, and can reach more than 1200 °C. Some furnaces of the same type have heating elements, but they are fixed and temporarily added. Less than 1200 ° C, and not the device itself;
  • the mold-carrying turntable 5 can be rotated slowly in the manual or electric mode outside the furnace, and can be stopped at any time to adjust the pouring position evenly to achieve multi-station pouring in the same furnace.
  • Some of the similar furnaces have high-speed rotating mold bearing. Turntable, but that is used for centrifugal casting; the power equipment that must be rotated at high speed due to centrifugation is very large and can only be placed outside the vacuum furnace shell. Its high-speed rotating shaft is passed into the furnace from outside the furnace, and the high-speed rotating shaft pair The damage of the vacuum seal is theoretically unavoidable.
  • the rotary transfer of the mold carrying turntable 5 is input by a slow rotating shaft with a diameter of not less than 25 mm and not more than 65 mm;
  • the maximum time is less than 1 rev / 2 seconds, which is lower than the current ability of the vacuum equipment to rotate and seal.
  • the mold-bearing turntable 5 uses a mold-bearing turntable rotation center positioning shaft 8 to define a rotation center, and the shaft does not bear the weight, and is inserted into the bottom positioning slot of the furnace, and the slot is
  • the blind hole is not connected to the outside of the vacuum furnace;
  • the lower part of the mold carrying turntable 5 is provided with a plurality of load-bearing wheels, that is, the mold-bearing turntable load-bearing wheel 6, and the periphery of the mold-bearing turntable 5 is a tooth ring that is rotated and transmitted, and the furnace is driven by the furnace.
  • the externally input rotating ratchet 7 cooperates, and the ratchet shaft leads to the outside of the furnace, that is, a slow rotating shaft for transmitting power to the casting bearing shaft; and a casting type limiting pin hole is also arranged on the bearing surface of the casting carrying turntable 5, The mold 2 is inserted into the mold limit pin hole through the fixing pin;
  • the mold 2 is placed horizontally from the outside of the furnace door by the forklift on the mold carrying turntable 5 in the furnace, and then closed. Close the furnace door, open the furnace top cover, plug the heating element resistance wire inside the furnace door into the power supply, and the mother alloy is also placed in the furnace cover by the furnace top, and the replacement of the new concrete is also the result.
  • a novel production process for forging artificial joints and metal products, and the specific steps include:
  • Step 1 Casting a fine crystal blank for forging using a deep subcooled fine grain casting furnace
  • Step 2 Sanding, cutting, grinding and polishing the cast whole set of forged fine crystal blanks to obtain fine-grained forged blanks, and then cleaning the obtained fine-grained forged blanks;
  • Step 3 The fine crystal forged blank prepared in step 2 is placed in a heat treatment furnace and heated to 900 ° C to 1200 ° C;
  • Step 4 The fine-grained forging blank heated in step 3 is placed in a forging die, and the forging is performed with a 2 to 5 ton forging hammer. After the forging is completed, the forging die is opened, and the forged artificial joint is taken out;
  • Step 5 Take the forged artificial joint from the forging die for trimming and polishing, and obtain the finished artificial joint, as shown in Fig. 4.
  • the mechanical properties and corrosion resistance of the products prepared by the present application compared with the products of the conventional forging production process are as follows. This comparison is a comparison of the mechanical properties of the old and old processes of the same alloy composition, as shown in Table 1.
  • the corrosion resistance of the product of the present application and the current process is tested by the national standard test method for medical metal materials (national standard: GB/T 17168-1997).
  • the initial comparison between the new process and the current process is not obvious, but is extended. After the corrosion time, there is a significant difference.
  • the grain structure ratio of the blank used in the novel forging process of the present application can be seen.
  • the grain structure of the existing casting process is much finer and more uniform; as can be seen from Table 1, the mechanical properties of the novel process of the present application are significantly higher than those of the prior art; as can be seen from Fig. 5 and Fig. 6,
  • the product samples of the novel process of the present application still retain a certain metallic luster, and the product samples of the current process have partially lost the metallic luster. Therefore, the Na2S corrosion resistance of the new process product is much better than the current process. .
  • the present application provides a novel production process for a forged artificial joint and a metal product.
  • the present application does not directly manufacture a forged blank by a conventional process such as casting, rolling, and drawing of a steel ingot, but directly adopts Fine grain casting manufactures forged blanks for forging production.
  • the grain size of forged blanks produced by this method is much smaller than that of general cast blanks; the uniformity of grain size can be said to be completely uniform, and the grain size is uniform throughout the casting section.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Forging (AREA)
  • Materials For Medical Uses (AREA)

Abstract

一种锻造型人工关节及金属制品的新型生产工艺，直接采用细晶铸造制造锻造毛坯进行锻造生产，包括步骤1：采用细晶铸造炉铸造出用于锻造的细晶锻造毛坯；步骤2：将制得的细晶锻造毛坯清理干净；步骤3：将步骤2得到的细晶锻造毛坯置于热处理炉中加热；步骤4：将步骤3加热好的细晶锻造毛坯置于锻造模具中锻造；步骤5：从锻造模具中取出锻好的产品进行切边、抛光，即得到成品。该工艺能够使最终产品的强度、硬度更高、耐磨性更好、耐腐蚀性更好；与现有锻造型金属制品生产工艺相比，工艺流程短，省去了传统的锻造型金属制品生产工艺的开坯、轧制、拉拔等多道工序，因此原料消耗少，能源消耗少，环境污染少，产品合格率高。

Description

锻造型人工关节及金属制品的新型生产工艺及用途 技术领域
本申请涉及锻造型金属制品技术领域，尤其涉及一种锻造型人工关节及金属制品的新型生产工艺及用途。
背景技术
衡量人工关节的质量优劣有三项指标是非常重要的，这就是强度、耐磨性和耐腐蚀性。对于金属人工关节，在相同的合金成分情况下，人工关节的强度越高，就要求其金属组织的晶粒尺寸越细小，越均匀；人工关节的耐磨性越好，就要求其金属力学性能的硬度越高；人工关节的耐腐蚀性越好，就要求其金属材质的致密度越高。因此研发出金属组织的晶粒尺寸越细小，越均匀、金属力学性能的硬度越高、金属材质的致密度越高是金属人工关节生产工艺的关键。实际上，不仅是金属人工关节，大部分金属制品其实也是如此。本专利申请要求专利保护的就是这样一种新型生产工艺。
该新型生产工艺目前所获得的产品在强度、耐磨性和耐腐蚀性方面，在同类产品中是性能较高的。但也不排除有少数同类产品在某个方面或这三个方面都高于该新型生产工艺目前所获得的产品。但是现有的传统生产工艺已经丧失了进一步提高产品质量的空间，业内开始研究陶瓷人工关节的使用就是一个例证。然而，由于陶瓷人工关节的脆性难关难以突破而未能投入实用。目前仍在大量商业应用的仍是金属人工关节。而该新型生产工艺从原理上突破了传统生产工艺的致命局限，展现出具有难以想象的提高产品质量的潜力。
有一点必须指出，不同行业的工业生产只能举出自己行业产品的真 实生产步骤和生产实例，然而对于金属制品来说普遍要求强度高、耐磨性好、耐腐蚀性好。所以，该新型生产工艺其实是为整个锻造行业提供了一种新的工艺选择。
发明内容
鉴于上述的分析，本申请旨在提供一种锻造型人工关节及金属制品的新型生产工艺及用途，通过采用深过冷细晶铸造炉直接铸造出锻造毛坯的方法，用以解决现有铸造中晶粒尺寸不均匀的问题，有效提高了产品质量。
本申请的目的主要是通过以下技术方案实现的：
一种锻造型人工关节及金属制品的新型生产工艺，直接采用细晶铸造制造锻造毛坯进行锻造生产，具体包括以下步骤：
步骤1.采用深过冷细晶铸造炉铸造出用于锻造的细晶毛坯；
步骤2.对铸出的整组细晶毛坯进行切割、打磨处理，制得细晶锻造毛坯，然后将制得的细晶锻造毛坯清理干净；
步骤3.将步骤2得到的细晶锻造毛坯置于热处理炉中加热；
步骤4.将步骤3加热好的细晶锻造毛坯置于锻造模具中锻造；
步骤5.从锻造模具中取出锻好的产品进行切边、抛光，即得到成品。
进一步的，所述步骤1中，所述深过冷细晶铸造炉主要包括：熔化坩埚、铸型、稳恒磁场磁极、铸型承载转盘，所述熔化坩埚位于所述铸型的上方，所述稳恒磁场磁极位于所述铸型的周围，所述铸型承载转盘位于所述铸型的下端，并与所述铸型固定连接；所述熔化坩埚上设有交变电流感应圈和直流电稳恒磁场；所述熔化坩埚、稳恒磁场磁极、铸型承载转盘位于铸造炉内，所述铸型通过设备从炉门外放入所述铸型承载转盘上。
进一步的，所述稳恒磁场磁极分为稳恒磁场N极和稳恒磁场S极，所述稳恒磁场N极和稳恒磁场S极相对放置，所述铸型位于所述稳恒磁场N极和稳恒磁场S极中间。
进一步的，所述铸型承载转盘在炉外以手动或电动方式慢速转动，所述铸型承载转盘由直径不小于25毫米不大于65毫米的慢速旋转轴输入，所述铸型承载转盘由棘轮带动旋转。
进一步的，所述步骤2中，对铸造毛坯的处理是清砂、切割、打磨、抛光。
进一步的，所述步骤3中，热处理炉的加热温度范围是900℃～1200℃。
进一步的，所述步骤4中，使用2～5吨锻锤对锻造毛坯进行模锻。
进一步的，所述新型生产工艺能够应用于人工关节、除人工关节之外的一切金属型医用植入物及非医用植入物的锻造型金属制品、机械零部件。
一种锻造型人工关节及金属制品的新型生产工艺所制备产品的用途，所制备出的锻造毛坯用于锻造医用植入物。
进一步的，使用本申请生产工艺所锻造的人工关节直接用于临床。
人工关节生产工艺可分为两种类型，一种是铸造型，一种是锻造型。目前公认的是铸造型人工关节与锻造型人工关节相比，而铸造型人工关节的晶粒尺寸粗大，而且不均匀，致密度也差；因此锻造型人工关节是生产优质人工关节的首选工艺。
但是传统的锻造型人工关节的生产工艺的工序是比较多的，具体过程是：首先铸造出大的钢锭，然后再将大钢锭开坯、轧制、拉拔成为一定直径的细棒，然后再将细棒切成小段，然后再将小段细棒进行局部镦粗，然后再将小段细棒镦粗的局部压弯制成锻造型人工关节的锻造毛坯，然后才能将此毛坯拿去锻造。因此制得锻造毛坯就需要大量的高耗能工 序，而且，开坯、轧制、拉拔需要多次的掐头去尾，浪费大量的昂贵的人工关节金属材料。如果铸造小钢锭，虽然开坯、轧制、拉拔和掐头去尾的量会少一些，但是小钢锭制成的锻造毛坯又会由于变形量不够大，而使得锻造毛坯的晶粒尺寸不够细小，而使得最终产品的晶粒尺寸不够细小。而且，铸造出大的钢锭，然后再将大钢锭开坯、轧制、拉拔成为一定直径的细棒，然后再将细棒切成小段，然后再将小段细棒进行局部镦粗，然后再将小段细棒镦粗的局部压弯制成锻造型人工关节的锻造毛坯的晶粒尺寸虽然细小，但是变形储存能比较高，而且是变形织构型细晶组织，有很强的方向性，这就造成如果退火处理温度不够，就晶粒组织不稳定，力学性能各向异性，通俗地说就是产品的强度有方向性，比如说，纵向的强度很高，但横向的强度并不高。而如果退火处理温度过高，就会引起由变形储存能驱动的晶粒尺寸长大，而使强度下降。
而本申请新型生产工艺则是直接铸造出晶粒尺寸非常细小均匀的锻造毛坯，用此毛坯锻造出的最终产品不仅是晶粒尺寸更加细小，而且由于其使用的锻造毛坯的细晶粒属于平衡凝固的等轴晶粒，因此没有变形产生的储存能和织构方向性，所以金属组织是稳定的。另外，与传统锻造工艺相比，此新型工艺是直接铸造毛坯就拿去锻造，因此工序少、耗能少、省材料。此外还有一点非常值得注意，就是这种锻造工艺可以以很小的锻造变形量来保证最终产品的很细小的晶粒组织。因为它的锻造毛坯原始晶粒尺寸就很细小；由于细晶铸造的凝固收缩是弥散型的，因此锻造之后金属组织也会很致密；这样一来，由于可以变形量小，因此就可以采用化学成分设计上强度、硬度很高的合金，这样就能够使最终产品的强度、硬度更高。而传统工艺需要大钢锭开坯、轧制、拉拔那样大的变形量从原理上是不可以采用化学成分设计上强度、硬度很高的合金的。
本申请有益效果如下：
(1)本申请工艺方法不仅适用于金属人工关节的生产，同时适用于人工关节之外的一切金属型医用植入物和其他非医用植入物的锻造型金属制品、机械零部件，具有潜在的应用价值；
(2)本申请工艺方法直接采用细晶铸造制造锻造毛坯进行锻造生产，能够使最终产品的强度、硬度更高、耐磨性好；
(3)本申请工艺方法与同类产品相比，原料消耗少，能源消耗少，产品合格率高，适用于工业生产。
通过以上内容，不难看出，本新型生产工艺的启迪作用并不局限于金属人工关节的生产，除了人工关节之外的一切金属型医用植入物都可借鉴这一新型生产工艺。而且其他非医用植入物的锻造型金属制品、机械零部件等也可以采用新型生产工艺。即；不通过传统的铸造钢锭开坯、轧制以及拉拔等先期工序制造锻造毛坯，而是直接采用细晶铸造，制造锻造毛坯进行锻造产品生产的生产工艺。
附图说明
图1为本申请深过冷细晶铸造炉核心部位构造示意图；
图2为传统工艺铸造毛坯的晶粒组织；
图3为本申请深过冷细晶铸造毛坯的晶粒组织；
图4为本申请新型锻造工艺生产的产品；
图5为传统工艺的产品耐Na2S腐蚀性能状态图；
图6为本申请新型工艺的产品耐Na2S腐蚀性能状态图。
图中，1-熔化坩埚，2-铸型，3-稳恒磁场N极或S极，4-稳恒磁场S极或N极，5-铸型承载转盘，6-铸型承载转盘承重轮，7-棘轮，8-铸型承载转盘旋转中心定位轴。
具体实施方式
下面结合附图来具体描述本申请的优选实施例，其中，附图构成本申请一部分，并与本申请的实施例一起用于阐释本申请的原理。
本申请制备一种深过冷细晶铸造炉，如图1所示，主要包括铸型承载转盘5、铸型2、棘轮7、铸型承载转盘旋转中心定位轴8、铸型承载转盘承重轮6、加热元件、稳恒磁场磁极、熔化坩埚1，熔化坩埚1位于铸型2的上方，铸型2安装与铸型承载转盘5的上方，在铸型承载转盘5下设有铸型承载转盘承重轮6和棘轮7，棘轮7用于带动铸型承载转盘5的转动，在铸型2的周围设有加热元件和稳恒磁场磁极，铸型承载转盘5下端中心部位设有铸型承载转盘旋转中心定位轴8，用于限定铸型承载转盘5的旋转中心。
其中，熔化坩埚1是具备稳恒磁场或称静磁场和交变磁场同时和单独施加能力的坩埚，用于盛放并熔化母合金，熔化坩埚1上施加有交变磁场及交变感应圈，同时，在熔化坩埚1上也施加有单独的稳恒磁场，也称为静磁场，即一个以上的感应线圈，静磁场感应线圈可以同时具有电阻式加热功能，而同类炉子只有交变感应圈；本申请中熔化坩埚1具有远红外和热电偶同时测温的构造，而同类炉子有的也有这两种测温手段，但是不能同时测温；
铸型2周围设有施加稳恒磁场或称静磁场的磁极，同类炉子没有，最为接近的，也是在铸型周围设有施加脉冲磁场的绕组；同时，本申请铸造炉在铸型2周围所设的施加稳恒磁场或称静磁场的磁极上安装有电阻应变片，可随时测出N—S极之间的吸引力F，因此可以随时通过F＝BIL的电磁场公式计算出B—磁场强度的数值，本炉B＝1～2T(T-特斯拉)；
同时，在铸型2周围设有可以活动组合式的加热元件，本炉为电阻丝，而且可达1200℃以上，同类炉子有的有加热元件，但是，是固定式的，临时外加的，达不到1200℃，而且也不属于设备自身；
铸型承载转盘5可以在炉外以手动或电动两种方式慢速转动，随时停顿，用以均温和调整浇注位置，实现同炉多工位浇注，同类炉子有的有高速旋转的铸型承载转盘，但那是用于离心铸造的；因离心必须高速旋转的动力设备是非常庞大的，只能置于真空炉壳之外，其高速旋转轴由炉外通入炉内，高速旋转轴对真空密封的损坏从理论上说是不可避免的，这在国内已有多例失败的先例；铸型承载转盘5转动传输由直径不小于25毫米不大于65毫米的慢速旋转轴输入；其转速最大不超过1转/2秒钟，这低于目前已有的真空设备转动密封的能力，其实这就是现有真空设备转动手柄的速度，因此该旋转对真空密封的损坏是可以忽略不计的；铸型承载转盘5的转动由慢速旋转的棘轮7带动，因此铸型承载转盘5的转速可以累积，当累积至1转/1秒钟时，这对直径300毫米以上的铸件也具有离心铸造功能；该炉的铸型承载转盘5可以慢速转动是该炉的主要常用功能，目的是使铸型2周围的加热元件对铸型2的加热得以均匀，因为由图2可以看出，有磁极的两侧是没有电阻丝的；铸型承载转盘5采用铸型承载转盘旋转中心定位轴8限定旋转中心，此轴不承重，插入炉底定位槽孔，此槽孔为盲孔，与真空炉外不连通；铸型承载转盘5的下部设有多个承重轮，即铸型承载转盘承重轮6，铸型承载转盘5的外围是转动传递的齿环，与由炉外输入旋转的棘轮7相配合，棘轮轴通往炉外，即向铸型承载转轴传输动力的慢速旋转轴；在铸型承载转盘5的承载面上还设有铸型限位销孔，铸型2通过固定插销插入铸型限位销孔；
铸型2由叉车从炉门外水平放置于炉内铸型承载转盘5上，然后关 闭炉门，打开炉顶炉盖，将炉门内侧的加热元件电阻丝插接电源，母合金也是由炉顶打开炉盖放入坩埚，更换新坩埚也是由此。
一种锻造型人工关节及金属制品的新型生产工艺，具体步骤包括：
步骤1.采用深过冷细晶铸造炉铸造出用于锻造的细晶毛坯；
步骤2.对铸出的整组锻造细晶毛坯进行清砂、切割、打磨、抛光，制得细晶锻造毛坯，然后将制得的细晶锻造毛坯清理干净；
步骤3.将步骤2制得的细晶锻造毛坯置于热处理炉中，加热到900℃～1200℃；
步骤4.将步骤3加热好的细晶锻造毛坯置于锻造模具中，用2～5吨锻锤进行模锻，锻造完成之后，打开锻造模具，取出锻好的人工关节；
步骤5.从锻造模具中取出锻好的人工关节进行切边、抛光，即得到人工关节成品，如图4所示。
本申请所制备的产品与传统锻造生产工艺的产品对比的力学性能、耐腐蚀性能如下，此对比是相同合金成分新旧工艺的力学性能对比，具体见表1。
表1.相同合金成分新旧工艺的力学性能对比
Figure PCTCN2017103633-appb-000001
本申请工艺与现行工艺的产品耐腐蚀性能采用医用金属材料国家标准试验方法(国标号：GB/T 17168—1997)做对比试验，起初新型工艺与现行工艺的产品样品对比差别不明显，但延长腐蚀时间之后，就有了明显差别。
由图2、图3可以看出，本申请新型锻造工艺所用的毛坯晶粒组织比 现有铸造工艺的晶粒组织要细小和均匀得多；由表1可以看出，本申请新型工艺的力学性能明显高于现有工艺的力学性能；由图5、图6可以看出，经过强化的腐蚀试验之后，本申请新型工艺的产品样品仍保有一定的金属光泽，而现行工艺的产品样品已经部分失去金属光泽，因此，该新型工艺的产品耐Na2S腐蚀性能比现行工艺的要好得多。
综上所述，本申请提供了一种锻造型人工关节及金属制品的新型生产工艺，本申请不通过传统的铸造钢锭开坯、轧制以及拉拔等先期工序制造锻造毛坯，而是直接采用细晶铸造制造锻造毛坯进行锻造生产，使用本方法所生产出的锻造毛坯的晶粒尺寸远比一般铸造毛坯要细小；晶粒尺寸均匀性可以说完全均匀的，在整个铸造截面上，晶粒尺寸几乎完全一样；而且这种铸造工艺根本就不可能出现集中缩孔，因为深过冷细晶铸造是在整个铸造截面上同时大量形核结晶的，因此其凝固收缩是弥散型的；应用本申请铸造毛坯生产的锻造型人工关节强度高、耐磨性好，而且与同类产品相比，原料消耗少，能源消耗少，产品合格率高；除了人工关节之外的一切金属型医用植入物都可借鉴这一新型生产工艺；而且其他非医用植入物的锻造型金属制品、机械零部件等都可借鉴这一新型生产工艺。
以上所述，仅为本申请较佳的具体实施方式，但本申请的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本申请揭露的技术范围内，可轻易想到的变化或替换，都应涵盖在本申请的保护范围之内。

Claims (10)

  1. 一种锻造型人工关节及金属制品的新型生产工艺，其特征在于，直接采用细晶铸造制造锻造毛坯进行锻造生产，具体包括以下步骤：
    步骤1.采用深过冷细晶铸造炉铸造出用于锻造的细晶毛坯；
    步骤2.对铸出的整组细晶毛坯进行切割、打磨处理，制得细晶锻造毛坯，然后将制得的细晶锻造毛坯清理干净；
    步骤3.将步骤2得到的细晶锻造毛坯置于热处理炉中加热；
    步骤4.将步骤3加热好的细晶锻造毛坯置于锻造模具中锻造；
    步骤5.从锻造模具中取出锻好的产品进行切边、抛光，即得到成品。
  2. 根据权利要求1所述的一种锻造型人工关节及金属制品的新型生产工艺，其特征在于，所述步骤1中，所述深过冷细晶铸造炉主要包括：熔化坩埚、铸型、稳恒磁场磁极、铸型承载转盘，所述熔化坩埚位于所述铸型的上方，所述稳恒磁场磁极位于所述铸型的周围，所述铸型承载转盘位于所述铸型的下端，并与所述铸型固定连接；所述熔化坩埚上设有交变电流感应圈和直流电稳恒磁场；所述熔化坩埚、稳恒磁场磁极、铸型承载转盘位于铸造炉内，所述铸型通过设备从炉门外放入所述铸型承载转盘上。
  3. 根据权利要求2所述的一种锻造型人工关节及金属制品的新型生产工艺，其特征在于，所述稳恒磁场磁极分为稳恒磁场N极和稳恒磁场S极，所述稳恒磁场N极和稳恒磁场S极相对放置，所述铸型位于所述稳恒磁场N极和稳恒磁场S极中间。
  4. 根据权利要求3所述的一种锻造型人工关节及金属制品的新型生产工艺，其特征在于，所述铸型承载转盘在炉外以手动或电动方式慢速转动，所述铸型承 载转盘由直径不小于25毫米不大于65毫米的慢速旋转轴输入，所述铸型承载转盘由棘轮带动旋转。
  5. 根据权利要求1或4所述的一种锻造型人工关节及金属制品的新型生产工艺，其特征在于，所述步骤2中，对铸造毛坯的处理是清砂、切割、打磨、抛光。
  6. 根据权利要求5所述的一种锻造型人工关节及金属制品的新型生产工艺，其特征在于，所述步骤3中，热处理炉的加热温度范围是900℃～1200℃。
  7. 根据权利要求1或6所述的一种锻造型人工关节及金属制品的新型生产工艺，其特征在于，所述步骤4中，使用2～5吨锻锤对锻造毛坯进行模锻。
  8. 根据权利要求7所述的一种锻造型人工关节及金属制品的新型生产工艺，其特征在于，所述新型生产工艺能够应用于人工关节、除人工关节之外的一切金属型医用植入物及非医用植入物的锻造型金属制品、机械零部件。
  9. 根据权利要求1-8所述的一种锻造型人工关节及金属制品的新型生产工艺所制备产品的用途，其特征在于，所制备出的锻造毛坯用于锻造医用植入物。
  10. 根据权利要求9所述的一种锻造型人工关节及金属制品的新型生产工艺所制备产品的用途，其特征在于，使用本申请生产工艺所锻造的人工关节直接用于临床。
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