CN101053898A - Vacuum solid type cast penetrated method for preparing particle reinforced metal-base surface composite material - Google Patents
Vacuum solid type cast penetrated method for preparing particle reinforced metal-base surface composite material Download PDFInfo
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- CN101053898A CN101053898A CN200710065832.1A CN200710065832A CN101053898A CN 101053898 A CN101053898 A CN 101053898A CN 200710065832 A CN200710065832 A CN 200710065832A CN 101053898 A CN101053898 A CN 101053898A
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Abstract
The invention relates to a v-epc cast-penetrating process for manufacturing metallic matrix surface composites with particle reinforced. According to structure of parts, foam material is cut or directly produced to a vaporable mode by foaming technology; reinforced particle is prepared into a precast block corresponding to a hard wearing surface shape required by the composites; the precast block is fixed on a surface of the foam material mode required to be alloyed; then embedding the mode into dry sand and pouring molten metal in a state of negative pressure after consolidating, wherein the negative pressure generated by vacuumizing can pump out gas generated by evaporating the foam plastic and gelatinize during pouring, meanwhile cavity filling performance of the molten metal can be increased by vacuum sealing technology to facilitate the molten metal infiltrating in the particle, thereby, a thicker and more compact composite layer can be obtained, and the prepared metallic matrix surface composites with tungsten carbide particle reinforced has higher surface quality and volume fraction of a strengthening body, more even strengthening body distribution as well as excellent impact wear resistance. The method of the invention is applicable to composite cast with low requirement, as well as to composite cast in complex shape with high technology requirement.
Description
Technical field
The present invention relates to a kind of vacuum full mold cast-infiltration method for preparing particulate reinforced metal-based composite surface material, (V-EPC) preparation method is oozed in the vacuum full mold casting that relates in particular to a kind of tungsten carbide grain reinforced metal base composite surface material of anti impact wear-proof, belongs to wear-resisting anti-friction material preparing technical field.
Background technology
Development of modern industry requires more and more higher to the anti-wear performance of material, departments such as metallurgy, mine, building materials, electric power, chemical industry, coal and agricultural will use mining machinery, engineering machinery, agricultural machinery and various crushing and grinding machinery respectively, the consumable accessory of these plant equipment will be subjected to the wearing and tearing of various materials such as sandstone, ore, soil and abrasive body, and will consume a large amount of metals every year.According to incomplete statistics, 1/3～1/2 of the energy is consumed in friction and wear.Concerning material, about 80% part failure is caused by wearing and tearing, wherein accounts for 50% because of what abrasive wear was lost efficacy, and China is used for the abrasion-resistant stee ironware of abrasive wear operating mode according to statistics, will consume more than 200 ten thousand tons every year.Thus, develop out a kind of can be under wear working condition, the new material that has than the long life seems very important.
Technology of infiltration casting be with predetermined fixed such as alloy powder or ceramic particles on the ad-hoc location of type wall, make cast(ing) surface have special organization and performance by cast then, this technology is a kind of surface treatment and moulding process combined.This method is simple, need not special treatment facility, and surface-treated layer has certain thickness, with short production cycle, part is indeformable, has the incomparable advantage of other process, is the effective way that improves performances such as cast(ing) surface is wear-resisting, anti-corrosion, high temperature resistant.After method occurs since then, obtained continuous development, especially after nineteen nineties, casting infiltration prepares the favor that composite surface material is subjected to people.
At present, the method of utilizing cast-infiltration method to prepare composite surface material mainly contains following several: (1) common cast-infiltration method, this method all needs to add the binding agent and the flux of organic or inorganic, and under the metal function of liquid high temperature, binding agent or flux are very easily vaporized or scorification, thereby easily produce pore and slag inclusion (mixing), cause the reduction of material property.(2) centrifugal cast-infiltration method promptly utilize centrifugal action to make hardening constituent be distributed in the type wall equably, thereby obtain surface graded composite, but this technology only is only applicable to the production of annular element, thereby its range of application is subjected to bigger restriction.(3) V method technology of infiltration casting, it is compared with traditional technology of infiltration casting, and the cast(ing) surface fineness that makes with V method technology of infiltration casting is good, the dimensional accuracy height, technological operation is easy, and is applied widely, and production cost is low.But this technology only is applicable to the foundry goods of preparation simple shape, has shortcomings such as following core difficulty simultaneously.(4) full mold technology of infiltration casting (EPC), this process makes full use the characteristics of dry sand good fluidity, just can conveniently obtain core cavity without core, needn't molding after the moulding, not mould assembling, no die joint, this work simplification moulding and sand processing technique and equipment, it is good that the foundry goods that makes has surface quality, the dimensional accuracy advantages of higher.But because in the process of molten metal filing mold filling sample, can produce a large amount of gas because of the vaporization of EPS apperance, in a single day these gases can not get getting rid of timely, will cause occurring in the foundry goods such as defectives such as elephant skin, collection carbon, scoriform pore, scab, cold shut, slag inclusion and surface skinings.
Summary of the invention
Existing at common technology of infiltration casting, centrifugal technology of infiltration casting, V method technology of infiltration casting and full mold technology of infiltration casting, surface quality of continuous castings is poor, dimensional accuracy is low, defective such as be prone to pore or be mingled with, shortcomings such as parts that can't the production structure complexity the invention provides a kind of vacuum full mold cast-infiltration method for preparing particulate reinforced metal-based composite surface material.
Method provided by the invention is such: be prepared into vaporizable part apperance with polystyrene foamed material earlier, after utilizing corresponding mould will strengthen preparation of granules to become prefabricated section, being fixed on needs the foamed material of alloying apperance surface, then model is imbedded in the dry sand, after the jolt ramming under negative pressure state casting of molten metal, therebetween by vacuumizing the negative pressure of formation, foamed plastics and gluing are taken away because of the gas that vaporization produces in casting process, simultaneously by vacuum sealing technology, improve the mold-filling capacity of molten metal, in order to molten metal in intergranular infiltration, thereby obtain thicker finer and close composite bed.
Concrete technical scheme of the present invention is: a kind of vacuum full mold cast-infiltration method for preparing particle enhancing Fe-base surface compound material is characterized in that comprising following process steps:
The preparation of A, fireproof coating: after the raw material of following mass parts mixed, the gas permeability that promptly gets under 1000 ℃ was 2.120～2.650cm
4/ g.min, intensity is the coating of 17.65～19.16g/mm:
Quartz sand 98.00～104.00 sodium bentonites 3.8～4.2
White glue with vinyl 2.3～2.8 Na
2CO
30.10～0.13
Carboxymethyl cellulose 0.48～0.52 neopelex 0.04～0.06
N-octyl alcohol 0.02～0.03;
The moulding of B, vaporization apperance (EPS): on foam plastics slab, mark required part apperance, its line size is cut with heating wire than the big 0.5～1.0mm of accessory size, and the Current Control during cutting is at 50～100A, Control of Voltage gets apperance at 8～14V;
C, preset the preparation of body and fixing: the raw material of following mass ratio is mixed into the enhancing particulate material:
Granularity is 40～60 purpose tungsten carbide particles 60～80%,
Granularity is 60～80 purpose high carbon ferro-chrome particles 20～40%
Binding agent presets 3～6% of body total amount
Mixed enhancing particulate material is pressed into the prefabricated section that adapts with the required wearing face shape of composite, under 40～60 ℃ of temperature, dry 0.5～1h, with an amount of binding agent it is preset at composite corresponding on the vaporization apperance again and needs wear-resisting surface, heat hardening 0.5～1h under 40～60 ℃ of temperature, to form initialization layer, wherein, tungsten carbide particle is as strengthening particle, and high carbon ferro-chrome is used for regulating the volume fraction of composite tungsten carbide particle;
The bonding of D, cast apperance: connect required apperance with an amount of binding agent, heat drying 1～1.5h under 40～60 ℃ of temperature, be coated with the fireproof coating that last layer thickness is the A step of 1～2mm on the surface and the initialization layer surface of apperance afterwards, heat hardening 2～3h under 40～60 ℃ of temperature must pour into a mould apperance;
E, moulding: the cast apperance of D step is placed corresponding steel moulding box, with granularity is that the dried quartz sand of 40～60 purposes covers, in vibration frequency is 2900～3000 times/minute, and time of vibration is to vibrate sandbox under 10s～30s condition, makes it to form the moulding box of the required gas permeability and the degree of packing;
F, the casting of vacuum full mold are oozed: be under the negative pressure of 0.02～0.06MPa in vacuum, substrate metal liquid is poured into moulding box, suction that produces by vacuum and molten metal are wetting to tungsten carbide particle, molten metal is sucked into comprise presetting in the body of tungsten carbide particle, after treating the moulding box cooling, promptly get the tungsten carbide grain reinforced metal base composite.
The moulding of the vaporization apperance EPS of described B step, also available following method: make corresponding mould according to required design of part, press 1/8～1/12 amount of mould volume, in mould, add foam beads, directly prepare the vaporization apperance with foaming method of the prior art.This method need not to cut, and can carry out the compound of complex surfaces such as curved surface.
The binding agent that described C step, D step are used is that commercial mass percent concentration is 5～8% polyvinyl alcohol water solution PVA or white glue with vinyl.
The compacting of the enhancing particulate material of described C step, the size of used pressure during its compacting is pressed into required form with the hybrid particles material and is of a size of suitable satisfying.
The sandbox vibration of described E step, its direction of vibration is the one dimension horizontal vibration.
The enhancing particulate material of described C step is suppressed, and controls the degree of packing of particle by the total amount of regulating mixture.
During the vacuum full mold casting of described F step was oozed, metal base was chosen as grey cast-iron and low-chromium cast-iron, and the composition quality of grey cast-iron than (wt.%) is: C:3.1～3.3%, Si:1.5～1.8%, Mn:0.3～0.5%, P≤0.06%, S≤0.06%, surplus are Fe; The composition quality of low-chromium cast-iron than (wt.%) is: C:2.4～2.6%, and Si:0.7～1.0%, Mn:0.2～0.4%, Cr:3.8～4.2%, P≤0.06%, S≤0.06%, surplus is Fe; Adopt existing intermediate frequency furnace to carry out melting, breeding temperature is 1580～1590 ℃, and pouring temperature is 1490～1500 ℃.
The present invention compares with other cast-infiltration method has following advantage and effect: the present invention is by vacuum sealing technology, foamed plastics and gluing are taken away because of the gas that vaporization produces in casting process, improved the mold-filling capacity of molten metal, in order to molten metal in intergranular infiltration, thereby obtain thicker finer and close composite bed, and Metal Substrate composite surface material foundry goods with vacuum full mold casting infiltration preparation of the present invention, have higher surface quality and dimensional accuracy, can directly use for less demanding composite castings, for complex-shaped, the high composite castings of specification requirement also can use, as need the foundry goods on composite ring surface etc., the microstructure of composite densification of preparation, strengthen the volume fraction height of body, make the combination property of composite obtain bigger raising.
Description of drawings
Fig. 1 tungsten carbide particle volume fraction is 36% gray cast-iron based composite bed tissue;
Fig. 2 tungsten carbide particle volume fraction is 27% gray cast-iron based composite bed tissue;
Fig. 3 tungsten carbide particle volume fraction is 19% gray cast-iron based composite bed tissue.
Below in conjunction with drawings and Examples technical scheme of the present invention is further described.
Embodiment 1
(1) preparation fireproof coating: the composition proportion of coating is: quartz sand 98 grams, sodium bentonite 3.8 grams, white glue with vinyl 2.3 grams, Na
2CO
30.10 gram, carboxymethyl cellulose 0.48 gram, neopelex 0.04 gram, n-octyl alcohol 0.02 gram, the gas permeability of coating under 1000 ℃ of mixing gained is 2.120cm
4/ g.min, intensity is 17.65g/mm.
(2) preparation vaporization apperance (EPS): on foam plastics slab, mark required part apperance, comprise cross gate, sprue and ingate apperance, its line size is cut with heating wire than the big 0.5mm of actual accessory size, and heating wire adopts the electric furnace heating wire of 800W, Current Control during cutting is at 72A, Control of Voltage must be of a size of the rectangle apperance of 80 * 40 * 30mm at 11V, and cross gate is 30 * 25 * 250mm, sprue is 30 * 30 * 140mm, and ingate is 15 * 15 * 30mm.
(3) preset the preparation of body and fixing: with granularity is that 40～60 purpose tungsten carbide particles 80 restrain, granularity is 60～80 purpose high carbon ferro-chrome particles, 20 grams, mix with binding agent, binding agent is polyvinyl alcohol water solution (PVA), mass percent concentration is 6wt%, addition is to preset the 4wt% of body total amount, tungsten carbide particle and high carbon ferro-chrome particle and binding agent are mixed, the high carbon ferro-chrome particulate component is FeCr55C1000, mixed particle is pressed into and the corresponding rectangle prefabricated section of rectangle apperance, and control the degree of packing of particle by the total amount of regulating mixture, make the rectangle prefabricated section and be of a size of 80 * 40 * 3mm, with prefabricated section at 50 ℃ of following heat drying 0.5h, the sclerosis back is preset at composite corresponding on the apperance with an amount of binding agent with it needs wear-resisting surface, the binding agent that uses is 6wt% polyvinyl alcohol water solution (PVA), the size of pressing pressure only need satisfy and hybrid particles is pressed into needed size gets final product, at 50 ℃ of following heat drying 0.5h, must preset body after the sclerosis;
(4) bonding of cast apperance: with the apperance and the running channel of an amount of white glue with vinyl bonding step (2), at 50 ℃ of following heat drying 1h, form " bunch ", all surface in apperance comprises the enhancing stratum granulosum that is preset on the apperance then, being coated with a layer thickness is the fireproof coating by step (1) gained of 1mm, at 50 ℃ of following heat hardening 2h;
(5) moulding
With step (4) make " bunch " place the steel moulding box, using granularity is that the dried quartz sand of 40～60 purposes covers, in vibration frequency is 2960 times/minute, time of vibration is to vibrate sandbox under the 30s condition, make it to form the moulding box of the required gas permeability and the degree of packing, the shake table direction of vibration is the one dimension horizontal vibration;
(6) base material is chosen as casting pig, its composition quality than (wt.%) is: C:3.2%, Si:1.6%, Mn:0.4%, P≤0.06%, S≤0.06%, surplus is Fe, adopt intermediate frequency furnace to carry out melting and form substrate metal liquid, breeding temperature is 1580～1590 ℃, and pouring temperature is 1490～1500 ℃;
(7) casting of vacuum full mold is oozed: be under the negative pressure of 0.02MPa in vacuum, iron liquid is poured into moulding box, suction by vacuum and iron liquid are wetting to tungsten carbide particle, iron liquid is sucked into comprise presetting in the body of tungsten carbide particle, thus, after treating the moulding box cooling, promptly get tungsten carbide particle and strengthen iron base composite material.
Embodiment 2
(1) preparation fireproof coating: the composition proportion of coating is: quartz sand 104 grams, sodium bentonite 4.2 grams, white glue with vinyl 2.8 grams, Na
2CO
30.13 gram, carboxymethyl cellulose 0.52 gram, neopelex 0.06 gram, n-octyl alcohol 0.03 gram, the gas permeability of coating under 1000 ℃ of mixing gained is 2.65cm
4/ g.min, intensity is 19.16g/mm.
(2) preparation vaporization apperance (EPS):
Make the mould of vaporization apperance, die size is 80 * 40 * 30mm, and the adding volume is 12cm
3Foam beads place mould, utilize foaming method of the prior art directly to be prepared into the vaporization apperance of 80 * 40 * 30mm then, get final product.
(3) preset the preparation of body and fixing: with granularity is that 40～60 purpose tungsten carbide particles 60 restrain, granularity is 60～80 purpose high carbon ferro-chrome particles, 40 grams, mix with binding agent, binding agent is polyvinyl alcohol water solution (PVA), mass percent concentration is 6wt%, addition is to preset the 6wt% of body total amount, tungsten carbide particle and high carbon ferro-chrome particle and binding agent are mixed, the high carbon ferro-chrome particulate component is FeCr55C1000, mixed particle is pressed into prefabricated section, and control the degree of packing of particle by the total amount of regulating mixture, make prefabricated section and be of a size of 80 * 40 * 3mm, with prefabricated section at 50 ℃ of following heat drying 1h, sclerosis back is preset at the surface that composite corresponding on the apperance need be wear-resisting with an amount of binding agent with it, and the binding agent that uses is 6wt% polyvinyl alcohol water solution (PVA), and the size of pressing pressure only need satisfy and hybrid particles is pressed into needed size gets final product, at 50 ℃ of following heat drying 1h, must preset body after the sclerosis;
(4) bonding of cast apperance: with the apperance and the running channel of an amount of white glue with vinyl bonding step (2), at 50 ℃ of following heat drying 1.5h, form " bunch ", all surface in apperance comprises the enhancing stratum granulosum that is preset on the apperance then, being coated with a layer thickness is the fireproof coating by step (1) gained of 2mm, at 50 ℃ of following heat hardening 3h;
(5) moulding
With step (4) make " bunch " place the steel moulding box, using granularity is that the dried quartz sand of 40～60 purposes covers, in vibration frequency is 3000 times/minute, time of vibration is to vibrate sandbox under the 10s condition, make it to form the moulding box of the required gas permeability and the degree of packing, the shake table direction of vibration is the one dimension horizontal vibration;
(6) base material is chosen as low-chromium cast-iron, its composition quality than (wt.%) is: C:2.5%, Si:0.9%, Mn:0.3%, Cr:4.0%, P≤0.06%, S≤0.06%, surplus are Fe, adopt intermediate frequency furnace to carry out melting and form substrate metal liquid, breeding temperature is 1580～1590 ℃, and pouring temperature is 1490～1500 ℃;
(7) casting of vacuum full mold is oozed: be under the negative pressure of 0.06MPa in vacuum, iron liquid is poured into moulding box, suction by vacuum and iron liquid are wetting to tungsten carbide particle, iron liquid is sucked into comprise presetting in the body of tungsten carbide particle, thus, after treating the moulding box cooling, promptly get tungsten carbide particle and strengthen iron base composite material.
Result of implementation
(1) the surface quality height of composite, composite bed is even, and thickness is about 3mm, and the distribution of tungsten carbide particle is also relatively evenly;
(2) anti-impact of composite erosion abrasive wear performance such as following table, the rich chromium cast iron in the table is sample as a comparison, and its composition quality than (wt.%) is: C:3.2%; Cr:15%; Mo:2.0%; Si:0.5%; Mn:0.4%; P≤0.06%; S≤0.06%; Surplus is Fe.
| Tungsten carbide volume fraction (%) | Volume wear rate (mm 3/m 2·h) | Relative wear resistance | |
| Embodiment 1 embodiment 2 | 36 19 | 19.92 23.42 | 2.93 2.49 |
| Rich chromium cast iron | 58.43 | 1 |
As can be seen, adopt the prepared tungsten carbide particle of the present invention to strengthen the wearability of grey cast-iron based surface composite material and tungsten carbide particle enhancing low-chromium cast-iron based surface composite material, be 2.49～2.93 times of rich chromium cast iron, all have extraordinary anti-wear performance.
Claims (7)
1, a kind of vacuum full mold cast-infiltration method for preparing particulate reinforced metal-based composite surface material is characterized in that comprising following process steps:
The preparation of A, fireproof coating: after the raw material of following mass parts mixed, the gas permeability that promptly gets under 1000 ℃ was 2.120～2.650cm
4/ g.min, intensity is the coating of 17.65～19.16g/mm:
Quartz sand 98.00～104.00 sodium bentonites 3.8～4.2
White glue with vinyl 2.3～2.8 Na
2CO
30.10～0.13
Carboxymethyl cellulose 0.48～0.52 neopelex 0.04～0.06
N-octyl alcohol 0.02～0.03;
The moulding of B, vaporization apperance EPS: mark required part apperance on foam plastics slab, its line size is cut with heating wire than the big 0.5～1.0mm of accessory size, and the Current Control during cutting is at 50～100A, and Control of Voltage gets apperance at 8～14V;
C, preset the preparation of body and fixing: the raw material of following mass ratio is mixed into the enhancing particulate material:
Granularity is 40～60 purpose tungsten carbide particles 60～80%,
Granularity is 60～80 purpose high carbon ferro-chrome particles 20～40%
Binding agent presets 3～6% of body total amount
Mixed enhancing particulate material is pressed into the prefabricated section that adapts with the required wearing face shape of composite, under 40～60 ℃ of temperature, dry 0.5～1h, with an amount of binding agent it is preset at composite corresponding on the vaporization apperance again and needs wear-resisting surface, heat hardening 0.5～1h under 40～60 ℃ of temperature, to form initialization layer, wherein, tungsten carbide particle is as strengthening particle, and high carbon ferro-chrome is used for regulating the volume fraction of composite tungsten carbide particle;
The bonding of D, cast apperance: connect required apperance with an amount of binding agent, heat drying 1～1.5h under 40～60 ℃ of temperature, be coated with the fireproof coating that last layer thickness is the A step of 1～2mm on the surface and the initialization layer surface of apperance afterwards, heat hardening 2～3h under 40～60 ℃ of temperature must pour into a mould apperance;
E, moulding: the cast apperance of D step is placed corresponding steel moulding box, with granularity is that the dried quartz sand of 40～60 purposes covers, in vibration frequency is 2900～3000 times/minute, and time of vibration is to vibrate sandbox under 10s～30s condition, makes it to form the moulding box of the required gas permeability and the degree of packing;
F, the casting of vacuum full mold are oozed: be under the negative pressure of 0.02～0.06MPa in vacuum, substrate metal liquid is poured into moulding box, suction that produces by vacuum and molten metal are wetting to tungsten carbide particle, molten metal is sucked into comprise presetting in the body of tungsten carbide particle, after treating the moulding box cooling, promptly get the tungsten carbide grain reinforced metal base composite.
2, method according to claim 1, it is characterized in that the moulding of the vaporization apperance EPS of described B step, also available following method: make corresponding mould according to required design of part, press 1/8～1/12 amount of mould volume, in mould, add foam beads, directly prepare the vaporization apperance with foaming method of the prior art.
3, method according to claim 1 is characterized in that the binding agent that described C step, D step are used is that commercial mass percent concentration is 5～8% polyvinyl alcohol water solution PVA or white glue with vinyl.
4, method according to claim 1 is characterized in that the enhancing particulate material compacting of described C step, and the size of used pressure during its compacting is pressed into required form with the hybrid particles material and is of a size of suitable satisfying.
5, method according to claim 1 is characterized in that the sandbox vibration of described E step, and its direction of vibration is the one dimension horizontal vibration.
6, method according to claim 1 is characterized in that the compacting of the enhancing particle of described C step, controls the degree of packing of particle by the total amount of regulating mixture.
7, method according to claim 1, during the vacuum full mold casting that it is characterized in that described F step is oozed, metal base is chosen as grey cast-iron and low-chromium cast-iron, the composition quality of grey cast-iron than (wt.%) is: C:3.1～3.3%, Si:1.5～1.8%, Mn:0.3～0.5%, P≤0.06%, S≤0.06%, surplus are Fe; The composition quality of low-chromium cast-iron than (wt.%) is: C:2.4～2.6%, and Si:0.7～1.0%, Mn:0.2～0.4%, Cr:3.8～4.2%, P≤0.06%, S≤0.06%, surplus is Fe; Adopt existing intermediate frequency furnace to carry out melting, breeding temperature is 1580～1590 ℃, and pouring temperature is 1490～1500 ℃.
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