CN103737196B - 一种含Si、Cr复合陶瓷相的耐磨堆焊合金及其制备工艺 - Google Patents
一种含Si、Cr复合陶瓷相的耐磨堆焊合金及其制备工艺 Download PDFInfo
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- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
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- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
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- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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- B23K35/24—Selection of soldering or welding materials proper
- B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
- B23K35/3053—Fe as the principal constituent
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- B23K10/00—Welding or cutting by means of a plasma
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- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
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Abstract
一种含Si、Cr复合陶瓷相的耐磨堆焊合金及其制备工艺,其特点是该合金的成分为:Cr 10-20%,Si 0.5-5%,Ni 1-4%,C 5-10%,余量为Fe及不可避免的杂质;该制备工艺为:将按元素质量百分比计算后的铬铁粉、钼粉、镍粉、石墨及还原铁粉机械混合后,采用球磨机干式球磨的方法混合均匀,粒度达到60-160目取出;将粉末在烘干炉内烘干1-2h,炉内冷却至室温;将粉末添加到送粉器中,进而进行等离子弧堆焊形成耐磨堆焊层。本发明的制备工艺和操作方法简单,添加的合金种类少,成本低廉,所获得的合金堆焊层硬质相与基材结合性能好,不易脱落,具有高硬度、高耐磨性、抗高温氧化性的特点。
Description
技术领域
本发明应用于材料科学领域,特别涉及一种含Si、Cr复合陶瓷相的耐磨堆焊合金及其制备工艺。
背景技术
伴随全球工业的大发展,世界范围内已经出现资源短缺问题,节约资源变得越发重要。磨损作为材料损耗的最主要原因之一,对资源的消耗极大,为此如何提高材料的耐磨性就成为世界性关注的课题。作为汽车安全的保障,制动系统一直是人们研究和关注的重点。由于交通工具运行速度的快速提升,对制动系统的安全稳定性和使用寿命要求更高。作为制动系统心脏的刹车片的耐磨性和抗高温氧化性的能力务必需要提升,由此可见,刹车片的耐磨材料合金体系的优化设计前景看好,耐磨堆焊合金在刹车片上的应用研究潜力巨大。
中国申请专利“耐磨合金”(CN1772941A),由如下重量比例的元素熔炼而成:C:0.2%,Si:0.3%,Mn:1.6%,Ni:1.35%,Cr:0.7%,Ti:1.7%,Ag:0.9%,Cu:0.3%,余量为Fe。该耐磨合金其优点耐磨性好,使用寿命长,比普通的合金提高耐磨性能30-40%,。但其中需要熔炼,能源消耗大,并且加入的合金元素种类较多,促使成本增加。
中国申请专利“耐磨合金”(CN1036993A),该发明涉及冶金领域。含有碳、硅、锰、铬、钛、锆和铁的耐磨合金,其质量百分比:C 2.38-3.50%,Si 0.01-2.50%,Mn 0.20-5.50%,Cr 18.50-40.00%,Ti 0.03-0.20%,Zr 0.02-0.48%,Nb 0.05-0.16%,余量为Fe。本发明虽然具有很高的耐磨性能,但由于元素加入种类过多,并且其中某些元素的加入量过高,致使成本较高。
中国申请专利“硬质耐磨铁合金”(CN86102537B),该发明涉及一种硬质耐磨铁合金,其化学成分按重量百分比为:C 2.5-3%,Mn 0.5-1.3%,Si0.3-1.3%,Cr 25-30%,Mo 2-2.5%,V 0.4-1%,B 3-4%,S、P小于0.05%,余量为Fe。本发明中虽然合金元素的加入量以有所减少,但其应用范围主要在油井和石油化工设备上,并且其制备工艺相对复杂,成本升高。
综上,虽然一系列的发明都具有很好的耐磨性,但公布的耐磨堆焊合金材料或者加入的合金元素种类众多,或者加入的合金元素昂贵,再或者堆焊合金的制备工艺较为复杂,这些都会增加生产成本。由此可见,一种添加合金元素少、制备工艺简单、成本低并且耐磨性能好的耐磨堆焊合金一直被人们所期待,由此可见本发明具有相当大的实际价值。
发明内容
本发明的目的就在于解决现有技术存在的上述不足,经过大量试验和反复研究,提供一种添加合金元素少、制备工艺简单、成本低并且耐磨性能好的耐磨堆焊合金。不是简单的添加硬质相而是通过等离子堆焊原位自生一种含Si、Cr复合陶瓷相的耐磨堆焊合金。
本发明给出的技术方案是:这种含Si、Cr复合陶瓷相的耐磨堆焊合金,其特点是该合金的元素成分按质量百分比为:Cr 10-20%,Si 0.5-5%,Ni 1-4%,C 5~10%,余量为Fe及不可避免的杂质。
本发明中的Cr元素的添加采用高碳铬铁粉、Si元素的添加采用硅铁粉、Fe元素采用纯度大于99%的还原铁粉、Ni元素的添加采用纯镍粉、C元素采用片状石墨, 粉末粒度在60~160目之间,将以上粉末采用机械方式均匀混合。
本发明给出的这种含Si、Cr复合陶瓷相的耐磨堆焊合金的制备工艺,其特点是。
将按元素质量百分比计算后的铬铁粉、钼粉、镍粉、石墨及还原铁粉机械混合后,采用球磨机干式球磨的方法混合均匀,球磨转速在100~200 r/min,球磨时间2~3小时,粒度达到60-160目,然后取出。
将粉末在烘干炉内在200℃条件下烘干1-2h,炉内冷却至室温。
将粉末添加到送粉器中,进而进行等离子弧堆焊形成耐磨堆焊层,具体等离子弧堆焊工艺为:焊接电流150-200A,焊接电压20-30V, 电极直径4mm,电弧纵向移动速度3-6 cm/min,电弧横向摆动频率40-50次/分,电弧横向摆动宽度3-4 cm。
本发明是在保证堆焊合金的硬度及耐磨性的同时,减少贵重合金元素的加入量,减少加入合金元素的种类,形成一种成本低廉、制备方法简单的耐磨合金。该耐磨合金伴随Si含量的增加,其硬度得到显著的提高,但当Si含量增大到一定程度,其韧性必然下降,使脆性大增。Ni的加入能够有效改善了基体的韧性,使由于Si的增加带来的脆性下降。使基材与硬质相的结合性得到了提高,增加了陶瓷硬质相与基体的结合强度。
同现有耐磨堆焊合金相比,本发明的有益效果主要体现在。
1、现有的耐磨堆焊合金中大多元素构成种类繁多,同时合金元素的加入量偏大,甚至加入一些相当贵重的稀有金属,这样必将使生产成本增加。而本发明采用成本低廉的工业铬铁粉、硅铁、纯镍粉和石墨作为主要添加元素,同时加入量也相对较少,降低了成本。
2、现有的耐磨堆焊合金大多采用直接加入碳化物、氮化物乃至硼化物作为提高材料硬度的硬质相,然后通过铸造或高温烧结而成。通过铸造方式一般无法进行表面强化,只能铸成整体,浪费材料;通过高温烧结则使其增强相颗粒粗大,增强相与基体、堆焊层与母材的结合强度不高。本发明采用原位自生的手段,通过堆焊过程中的化学反应直接形成颗粒细小、弥散程度大、均匀分布的陶瓷硬质相,增加了硬质相与基体的结合强度,陶瓷硬质相之间相互结合,提高了堆焊合金的耐磨性。
3、本发明中Si元素的添加使陶瓷相能够更好的硬度,Ni的加入使加硅后的脆性下降,同时阻碍了(Fe,Cr)7C3相的过分长大,有利于堆焊合金与母材的结合强度,增加了堆焊合金的硬度同时又不会增加脆性,达到更好的抗磨损的性能,同时Si在耐磨合金中还具有很强的抗高温氧化的能力。
4、本发明中加入的Ni元素降低了该耐磨合金熔池金属的粘度,提高堆焊合金液的流动性,改善该合金的成型性,能够抵消因Si的加入引起的脆性增加,对基体的韧性的提高有所帮助。
5、本发明中采用等离子弧进行粉末堆焊进而获得耐磨合金,其制备工艺流程相对以往简单易行,成本低廉,生产效率高,堆焊层成型好、硬度高,原位合成的陶瓷硬质相细小、弥散、均匀的分布在堆焊层中,与基体结合强度大,具有很高抗磨损性能。同时对能源消耗少,对环境污染相对小。
附图说明
图1-图4均为 200倍堆焊合金显微组织图,分别为实施例1-实施例4的显微组织形貌。
具体实施方式
本发明实施例中采用工业中常用的60-160目的铬铁、硅铁、还原铁粉和片状石墨为初级原料粉末。实施例1中-实施例4中采用球磨机干式球磨的方法均匀混合,然后将其放入烘干炉,50℃烘干10 -20min,100℃保温10-20 min,,200℃烘干1-2小时,然后炉内冷却后将其置入等离子堆焊设备的送粉器中,进行等离子弧堆焊。等离子弧堆焊焊接工艺如下:焊接电流150-200A,焊接电压20-30V, 电极直径4mm,电弧纵向移动速度3-6 cm/min,电弧横向摆动频率40-50次/分,电弧横向摆动宽度3-4 cm。
实施例1。
一种含Si、Cr复合陶瓷相的耐磨堆焊合金,按元素质量百分比,Cr 20%,Si 0.5%,Ni1%,C 6%,余量为铁元素及其他不可避免的杂质。
采用上述合金体系及制备方法进行等离子堆焊,堆焊层的硬度为55~62HRC,采用MMU-5G材料端面高温摩擦磨损试验机进行插销磨损试验,磨损试验参数:转速300r/min,试验力200N,磨损时间3min,堆焊层的磨损量为0.0011g,堆焊合金显微组织见图1。
实施例2。
一种含Si、Cr复合陶瓷相的耐磨堆焊合金,按元素质量百分比,Cr 15%,Si2%,Ni 1%,C 8%,余量为铁元素及其他不可避免的杂质。
采用上述合金材料等进行等离子堆焊,堆焊层的硬度为50~58HRC,采用MMU-5G材料端面高温摩擦磨损试验机进行插销磨损试验,磨损试验参数为旋转频率300r/min,试验力200N,磨损时间3min,堆焊层的磨损量为0.0012g,堆焊合金显微组织见图2。
实施例3。
一种含Si、Cr复合陶瓷相的耐磨堆焊合金,按元素质量百分比,Cr 10%,Si 3%,Ni 3%,C 8%余量为铁元素及其他不可避免的杂质。
采用上述合金材料等进行等离子堆焊,堆焊层的硬度为50~55HRC,采用MMU-5G材料端面高温摩擦磨损试验机进行插销磨损试验,磨损试验参数为旋转频率300r/min,试验力200N,磨损时间3min,堆焊层的磨损量为0.0019g,堆焊合金显微组织见图3。
实施例4。
一种含Si、Cr复合陶瓷相的耐磨堆焊合金,按元素质量百分比,Cr 15%,Si 2.5%,Ni 4%,C 7%,余量为铁元素及其他不可避免的杂质。
采用上述合金材料等进行等离子堆焊,堆焊层的硬度为56~60HRC,采用MMU-5G材料端面高温摩擦磨损试验机进行插销磨损试验,磨损试验参数为旋转频率300r/min,试验力200N,磨损时间3min,堆焊层的磨损量为0.0011g,堆焊合金显微组织见图4。
以上选用的实施例为本发明优选的实施例,本发明的一种含Si、Cr复合陶瓷相的耐磨堆焊合金的硬度并不算很高,但因为是金属间与金属件磨损,硬质相与基体的结合性对磨损性能影响重大,因此该配方耐磨性能很好,成型效果理想,选材简单,成本低廉。同时该合金粉末的制备工艺相对简单,操作容易。
图1-图4是以上实施例中的等离子堆焊的含Si、Cr元素陶瓷相的耐磨堆焊合金堆焊层的显微组织形貌。由于本发明中各实施例中的合金元素种类相同,只是在合金成分添加量上不同,因此,其显微组织宏观上大体相同,但其在微观细微之处显微组织形貌有所区别。
Claims (7)
1. 一种含Si、Cr复合陶瓷相的耐磨堆焊合金,其特征在于该合金的成分按质量百分比为:Cr 10-20%,Si 0.5-5%,Ni 1-4%,C 5~10%,余量为Fe及不可避免的杂质。
2.根据权利要求1所述的含Si、Cr复合陶瓷相的耐磨堆焊合金,其特征在于该合金的具体添加物质为高碳铬铁、硅铁、纯镍粉、石墨和还原铁粉,其粉末粒度为60-160目。
3.根据权利要求1所述的含Si、Cr复合陶瓷相的耐磨堆焊合金,其特征在于优选的合金的成分按质量百分比为:Cr 20%,Si 0.5%,Ni1%,C 6%,余量为铁元素及其他不可避免的杂质。
4.根据权利要求1所述的含Si、Cr复合陶瓷相的耐磨堆焊合金,其特征在于优选的合金的成分按质量百分比为:Cr 15%,Si2%,Ni 1%,C 8%,余量为铁元素及其他不可避免的杂质。
5.根据权利要求1所述的含Si、Cr复合陶瓷相的耐磨堆焊合金,其特征在于优选的合金的成分按质量百分比为:Cr 10%,Si 3%,Ni 3%,C 8%余量为铁元素及其他不可避免的杂质。
6.根据权利要求1所述的含Si、Cr复合陶瓷相的耐磨堆焊合金,其特征在于优选的合金的成分按质量百分比为:Cr 15%,Si 2.5%,Ni 4%,C 7%,余量为铁元素及其他不可避免的杂质。
7.一种如权利要求1所述的含Si、Cr复合陶瓷相的耐磨堆焊合金合金材料的制备工艺,其特征在于:
将粒度在60-160目的高碳铬铁、硅铁、纯镍粉、石墨和还原铁粉按元素质量百分比混合均匀,然后采用球磨机干式球磨的方法混合均匀,球磨转速在100~200 r/min,球磨时间2~3小时;
将粉末在烘干炉内在200℃条件下烘干1-2h,炉内冷却至室温;
将粉末添加到送粉器中,进而进行等离子弧堆焊形成耐磨堆焊层,具体等离子弧堆焊工艺为:焊接电流150-200A,焊接电压20-30V, 电极直径4mm,电弧纵向移动速度3-6 cm/min,电弧横向摆动频率40-50次/分,电弧横向摆动宽度3-4 cm。
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