CN102174696A - 铸造机部件用金属材料、与熔融铝合金接触的构件及其制备方法 - Google Patents

铸造机部件用金属材料、与熔融铝合金接触的构件及其制备方法 Download PDF

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CN102174696A
CN102174696A CN2011100539070A CN201110053907A CN102174696A CN 102174696 A CN102174696 A CN 102174696A CN 2011100539070 A CN2011100539070 A CN 2011100539070A CN 201110053907 A CN201110053907 A CN 201110053907A CN 102174696 A CN102174696 A CN 102174696A
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molten aluminium
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增田淳
本间周平
藤本亮辅
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Shibaura Machine Co Ltd
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Abstract

在钢基材表面上形成Ni合金层来直接与熔融铝接触，并将碳化钛(TiC)以微粒状粘结到在Ni合金层表面上。这使得不依靠常规方法(如PVD或CVD工艺进行陶瓷涂布)而会提供具有非常优异的耐腐蚀性。

Description

铸造机部件用金属材料、与熔融铝合金接触的构件及其制备方法
本申请是专利申请号为200580015479.5、国际申请日为2005年3月22日(国际申请号为PCT/JP2005/005100)、发明名称为“铸造机部件用金属材料、与熔融铝合金接触的构件及其制备方法”的发明专利申请的分案申请。 
技术领域
本发明涉及铸造机部件用金属材料、与熔融铝合金接触的构件及其制备方法，且更具体地讲，本发明涉及铸造机部件用金属材料和与熔融铝合金接触的构件及其制备方法，所述金属材料和与熔融铝合金接触的构件对熔融铝合金具有优异的耐熔损性。
背景技术
熔融铝合金具有与金属(如铁)反应生成金属互化物的特性。铸造机与熔融铝合金直接接触的那些钢部件可能由于与铝反应而损坏。这种现象称为熔损。在铝合金铸造过程中，必须采取方法来防止与熔融铝金属接触的主要部件(如导管、铸模、套筒和插件)熔损。
钢材料，如经过渗氮处理的工具钢，一般用于铝铸造过程中使用的铸模等。渗氮处理(包括使得氮从钢表面扩散来形成坚固的氮化层)在提高材料的耐磨性方面非常优异。然而，有人指出这种处理对于防止熔损而言并不总是足够的。
就需要高耐熔损性的部件而言，普遍通过气相沉积方法，如PVD(物理气相沉积)或CVD(化学气相沉积)来在部件表面形成陶瓷涂层。这种陶瓷涂层已知对于熔融铝合金化学稳定且具有非常高的耐熔损性(参见New Mechanical Engineering Handbook，B2， Processing/Processing Devices，157页)。
采用PVD或CVD形成的陶瓷涂层的最大问题是在热应力下发生剥离。具体地讲，由于钢基材与陶瓷涂层之间热膨胀系数差异大，在连续铸造循环中，由于反复加热和冷却会在陶瓷涂层和钢基材之间的边界处会产生较大的热应力。该较大的热应力经常导致陶瓷涂层从基材上剥离开来，从而所述基材最终与熔融铝合金直接接触。因此所述钢基材开始迅速熔融，导致所述基材熔损。
为了防止陶瓷涂层的这种剥离，对形成陶瓷涂层的方法进行了各种改进以减小涂层厚度，以使得所述涂层与基材边界处产生的热应力最小化，或提高涂层与基材之间的粘结强度。
尽管已有各种改进，但是陶瓷涂层和钢基材在热膨胀上的基本差异已成为不可逾越的障碍，并且至今也还没有实现完全防止陶瓷涂层的剥离。
因此，本发明的一个目标是不采用常规方法，如PVD或CVD提供陶瓷涂层的方法，解决现有技术中的上述问题并提供明显提高了耐熔损性的铸造机部件用金属材料和与熔融铝合金接触的构件。
本发明的另一目标是提供与熔融铝合金接触的构件的制备方法，所述方法使得TiC粒子可能与部件的Ni合金层牢固粘结，从而明显提高了所述部件的耐熔损性。
发明内容
为了实现上述目标，本发明提供了用于从熔融铝合金铸造制品的铸造机的机械部件用金属材料，所述金属材料包括钢基材、在所述基材表面形成的Ni合金层、以微粒状粘结到所述Ni合金层表面的碳化钛(TiC)。
本发明还提供了用于从熔融铝合金铸造制品的铸造机的机械部件，所述机械部件包括由钢基材和在所述基材与熔融铝合金直接接触的那一侧的表面上形成的镍合金层构成的本体，以及以微粒状粘结到 所述Ni合金层表面的碳化钛(TiC)。
本发明还提供用于从熔融铝合金铸造制品的铸造机用的与熔融铝合金接触的构件的制备方法，所述方法包括如下步骤：在钢基材表面形成Ni合金层，由此形成本体；将所述本体掩埋于TiC粉体中；以及，将所述本体与所述TiC粉体一起放在真空烘箱中，在真空下将它们加热至Ni合金产生液相的温度，由此将所述TiC粒子粘结到Ni合金层表面上。
本发明可在无需采用常规方法如通过PVD或CVD提供陶瓷涂层的情况下提供明显提高了耐熔损性的与熔融铝合金接触的构件。因此，通过将本发明应用于铸造机与熔融铝合金直接接触的那些部件，可明显延长所述部件的寿命。
附图说明
图1为本发明一个实施方案中铸造机部件用金属材料的结构示意图；
图2为本发明另一个实施方案中铸造机部件用金属材料的结构示意图；
图3为本发明与熔融铝合金接触的构件的制备方法示意图；
图4为显示各实施例中制备的与熔融铝合金接触的构件熔损测试结果的图；
图5为显示各实施例中制备的与熔融铝合金接触的构件结构的照片。
具体实施方式
现在将参考附图对本发明的优选实施方案进行说明。
图1为本发明一个实施方案中铸造机部件用金属材料的结构示意图。该实施方案中的金属材料包含钢基材、在所述基材上形成的Ni合金层和以微粒状粘结到所述Ni合金层表面的碳化钛(TiC)。
TiC粒子具有排斥熔融铝合金的特性。通过利用该特性，可防止熔融铝合金与所述钢基材直接接触并可获得高耐熔损性。
与通过用涂层覆盖整个表面来隔绝熔融铝合金与基材金属表面接触从而提高金属材料的耐熔损性的机理(如通过PVD或CVD常规陶瓷涂层中)不同，可简单地通过将TiC粒子密集地在所述基材金属表面上分散而明显提高本发明金属材料的耐熔损性。
在该结构中，所述TiC以微粒状粘结到Ni合金层上，即使所述基材热膨胀或收缩时也不会有较大的热应力作用在所述TiC粒子上。因此，所述TiC粒子几乎不会剥离，因此可保持较长时间的耐热损性。
所述TiC粒子可能部分暴露于所述Ni合金层表面上。这能提高与熔融铝合金的接触角，从而提高排斥熔融铝合金的特性。
优选如图2中所示，TiC粒子的缝隙中充满细陶瓷粒子，所述陶瓷粒子包含氮化硼(BN)、氧化铝(Al2O3)和氧化锆(ZrO2)中至少一种。所述细陶瓷粒子改善了TiC粒子附着的底层Ni合金层的耐熔损性。
所述Ni合金优选具有如下成分：2.6-3.2％的B、18-28％的Mo、36-52％的Si和0.05-0.22％的C，其余为Ni和不可避免的杂质。
所述TiC粒子通过所述Ni合金产生的液相来高强度地粘结到具有上述组成的Ni合金上。此外，由于所述液相与TiC粒子之间的良好润湿，大量的TiC粒子可密集地粘结到Ni合金层上。
用于铸造机的导管、铸模、熔融金属套筒、插件等一般可作为与熔融铝合金接触的构件或铸造机机械部件的例子，所述部件使用上述金属材料。
图3说明了本发明实施方案中与熔融铝合金接触的构件的制备方法。
制备的构件包含钢基材。首先，通过热喷涂在所述基材上形成Ni合金层。
接着，如图3(a)所示，准备含有TiC粉体的容器，将由所述基材和Ni合金层组成的构件完全掩埋于TiC粉体中。
将所述容器(其中含有TiC粉体和掩埋于其中的构件)放入真空烘箱中并在真空下加热至所述Ni合金产生液相的温度，由此将所述TiC粒子粘结到所述Ni合金层表面上。
通过加热，所述TiC粒子粘结到所述Ni合金层上，并从所述Ni合金层表面突出，如图3(b)所示。在此粘结中，不希望加热过程中所述TiC粒子完全被熔融Ni合金覆盖。为了TiC粒子不完全被Ni合金覆盖，而是在将TiC粒子牢固地粘结到Ni合金层上的同时，使其部分暴露于Ni合金层表面，所述TiC粒子的平均粒径优选为10-500μm。
当所述TiC粒子的粒径小于10μm时，难以控制真空加热过程中的温度使得所述TiC粒子不会完全被Ni合金的液相覆盖。如果所述TiC粒子完全被Ni合金的液相覆盖则不能获得所需的耐熔损性。
另一方面，当所述TiC粒子的粒径大于500μm时，Ni合金的液相将仅覆盖所述粒子的较低部分，接触面积小且粘结强度低。因而粒子容易脱落。
在TiC粒子粘结到构件上后，可任选将所述构件进行如下的处理：将粘结剂与陶瓷细粉混合物的浆液涂到所述TiC粒子上，并将所述陶瓷粉烧进所述构件的表面，其中所述陶瓷细粉包含氮化硼(BN)、氧化铝(Al2O3)和氧化锆(ZrO2)中的至少一种。经过此处理后所述构件的耐熔损性提高。
所述Ni合金层(粘结有TiC粒子)本身对熔融铝合金的耐熔损性较差。可通过将所述陶瓷细粉附着在所述Ni合金层上来改善耐熔损性。此外，附着的细粉的量使得其充满所述TiC粒子的缝隙。从而，与熔融铝合金接触时所述陶瓷细粉几乎不会脱落下来。
实施例
现在将参考实施例对本发明作进行进一步描述。
实施例中，采用钢材料(JIS S45C)作为基材制备熔损测试用样品。将具有上述组成的Ni合金热喷涂到所述钢基材上，以在所述基材上 衬垫一层所述Ni合金。然后在真空烘箱中将所述衬垫有所述Ni合金的基材掩埋在TiC粉中，并在真空下加热直到TiC粒子粘结到由Ni合金产生的液相上。
实施例1和实施例2制备了两类测试样品。实施例1的样品为上述粘结了TiC粒子但没有附着陶瓷粉的样品，而实施例2的样品通过将氮化硼(BN)细粉烧进上述粘结了TiC粒子的样品的表面制备。
为了对比实施例1和2样品的耐热损性，通过CVD法，采用氮化钛(TiN)涂覆与实施例1和2相同的基材制备对比样品。
按照如下方式进行熔损测试：每个测试样品浸入保持在720℃的熔融铝合金(JIS AC4C)中，并在保持浸入所述熔融金属的同时，以08m/s的圆周速度旋转24小时。之后，从所述熔融金属中取出测试样品并测量样品的重量变化。图4为熔损测试结果。图4中，横坐标表示实施例1和实施例2样品及对比样品每单位面积的熔损量(mg/cm2)。
从实施例1样品数据和对比样品数据对比明显可以看出：实施例1样品(TiC粒子粘结到Ni合金层上)的熔损量可减小到接近通过CVD形成TiN涂层的对比样品熔损量的几乎一半。图4中的数据还表明：实施例2样品(细BN粉充满TiC粒子的缝隙)没有熔损，从而表明实施例2样品优于实施例1的样品。
现在将对实施例3进行说明，其中制备的熔融铝合金接触的构件是一种导管(熔融铝合金用的流道)。
实施例3中采用如实施例2中相同的材料，所不同的是平均粒径为约1μm的氧化铝细粉代替氮化硼(BN)细粉。图5显示了实施例3材料的横截面照片。从照片中可以看出：大量粒径为约100μm的TiC粘结到Ni合金层表面上。
为了与实施例3的导管的耐熔损性进行比较，采用由相同钢基材和通过CVD形成的TiN涂层组成的材料制备对比导管。使得在约700℃的熔融铝合金在实施例3的导管和对比导管中流动且一段时间后测定熔损。
约19小时后发现对比导管中有熔损，而即使100小时后在实施例3的导管中也没有发现熔损。

Claims (4)

1.一种在将熔融铝合金铸造成制品的铸造机上使用的与熔融铝合金接触的构件的制备方法，所述方法包括以下步骤：在以钢为基材的部件本体的基材表面上形成Ni合金层；将所述部件本体掩埋于TiC粉中；并将所述部件本体和所述TiC粉一起放入真空烘箱中，在真空下加热至所述Ni合金产生液相的温度，从而将所述TiC粒子粘结到所述Ni合金层的表面上。
2.权利要求1的与熔融铝合金接触的构件的制备方法，其中所述TiC粒子粘结到所述Ni合金层后，对所述构件进行如下处理：将粘结剂和陶瓷细粉的混合浆液涂布到所述TiC粒子上并烧焙，其中所述陶瓷细粉包含氮化硼BN、氧化铝Al2O3和氧化锆ZrO2中的至少一种，所述TiC粒子部分暴露于所述Ni合金层表面上，并且所述TiC粒子间的缝隙充满陶瓷细粒。
3.权利要求1的与熔融铝合金接触的构件的制备方法，其中所述TiC粉中的粒子的平均粒径为10-500μm。
4.权利要求1的与熔融铝合金接触的构件的制备方法，其中所述Ni合金层通过热喷涂Ni合金形成，所述Ni合金的组成为：2.6-3.2％的B、18-28％的Mo、3.6-5.2％的Si和0.05-0.22％的C，其余为Ni和不可避免的杂质。
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