CN104797739B - 用于金属成型构件的抗疲劳涂层 - Google Patents
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Abstract
一种用于金属成型构件的复合涂层,包括布置在所述金属成型构件上的第一层。该第一层包括掺杂有至少一种掺杂剂(例如钨)的氮化铬。第二层布置在所述第一层上,所述第二层包括具有针对低合金钢所测量的小于或等于0.2的摩擦系数的润滑材料。
Description
相关申请的交叉引用
本申请要求于2012年10月22日提交的标题为“用于金属成型构件的抗疲劳涂层”的美国临时申请序列号61/716965的优先权权益,将其主题通过引用全部并入本文。
发明领域
本公开总体上涉及在金属成型应用中使用的工具和模具。更具体而言,本公开涉及抗疲劳、抗磨损和抗摩擦的复合涂层,并且涉及在其表面上布置有该涂层的的金属成型构件。
发明背景
金属成型构件,例如模具等等暴露在高循环压力和摩擦条件下。近来,业界已经转向使用高级的高强度钢合金(AHSS),其显示出比先前使用的钢合金远远更大的拉伸强度。典型的AHSS合金显示出超过700MPa的拉伸强度。在具体实例中,使用具有在900-1200MPa范围内的拉伸强度的合金用于制造汽车等的结构部件。由于其高强度,AHSS钢非常难以成型并且用于其成型的模具暴露于高冲击和高压力条件下。除了高冲击和高压力条件,这些模具的表面在使用中经历非常高的摩擦力。这些高压力、高摩擦条件可能引起对成型模具等的极度磨损,由此大大地折损其使用寿命。
在某些实例中,现有技术已经寻求通过不同处理工艺来使模具表面变硬;然而,这些结果产生了仅仅有限的成功。在其他方法中,使用不同的高硬度、抗磨损涂层来涂覆模具,这些涂层包括氮化钛、碳氮化钛、氮化铬、氮化钛铝等等。在其他方法中,使用了材料例如碳化钒的热扩散涂层以及化学气相沉积(CVD)涂层,例如碳化钛。尽管这些表面增强技术均在延长用于成型具有低于400MPa强度水平的常规合金的使用寿命中表现出了成功,但它们均表现出在涉及AHSS合金的成型操作中的差性能。
在某些情况下,已经发现了热扩散和CVD涂层延长了用于成型AHSS合金的模具的使用寿命。然而,这两种工艺都易于产生由于通常使用的工具钢模具材料的沉积和热处理过程中晶体结构变化而导致的模具尺寸变化。这些尺寸变化的程度非常经常是在由成型模具使用者所限定的尺寸规格之外;因此,此种工艺总体上是不可接受的。此外,热扩散涂层具有较高的摩擦系数并且与在高拉伸强度AHSS材料的成型中产生的高水平的摩擦力不相容。
尽管等离子体气相沉积(PVD)涂层,不像CVD涂层和热扩散涂层,不会引起成型模具的不可接受的尺寸变化,但许多此种涂层具有其他限制,这限制了它们在高拉伸强度材料成型应用中的使用。由于其柱状结构,PVD涂层,例如氮化铬、氮化钛铝等等在经受高压力/冲击条件时(例如在具有大于400MPa的拉伸强度的材料成型中发现的那些)易开裂。一些模具性能的增加通过在用常规的PVD涂层涂覆之前采用将模具的表面表面硬化实现,因为模具的增加的表面硬度防止了涂层的变形和开裂。但是,这种方法产生了仅仅有限的成功并且仅仅在其中成型的钢合金的拉伸强度是低于800MPa的那些情况下有用。
因此,对于与AHSS合金材料的成形结合使用的用于改善金属成型构件(例如模具)的使用寿命的涂层和方法存在需求。此种涂层应该是在成型工艺中遇到的非常高的压力和摩擦条件下耐久的并且应该不会不利地影响该模具的尺寸参数。此外,用于施加涂层的工艺应该简单、经济、易于实施并且可复涂。如在以下详细说明的,本公开内容提供了用于实现以上目的的金属成型构件的复合涂层。
发明概述
本公开内容提供了用于金属成型构件的复合涂层。该涂层包括布置在该金属成型构件上的第一层。第一层包括掺杂有至少一种掺杂剂的氮化铬。第二层布置在该第一层上面。第二层包括具有针对低合金钢所测量的小于或等于0.2的摩擦系数的润滑材料。掺杂剂可以选自W、V、Ti、Zr、Co、Mo和Ta中的一种或多种。在一个实例中,掺杂剂是W。掺杂剂能够以1至10原子百分比范围,例如3至7原子百分比的范围存在,并且在具体情况下,所述掺杂剂以约5原子百分比的量存在。第一层的厚度可以在1至10微米的范围内,例如4至6微米的范围。第一层的硬度可以在2至5KHv,例如3至4KHv,并且在具体情况下3.6至3.8KHv的范围内。
在另一个实例中,第二层具有针对低合金钢所测量的在0.1至0.15范围内的摩擦系数。第二层的厚度可以在0.5至5微米的范围内,并且在具体情况下为1.2微米。第二层可以包括至少一种选自氮化物、碳氮化物、氧化物、氧氮化物、碳基涂层、钼基固体膜润滑剂涂层以及其组合的材料。在又另一个实例中,第二层包括TiCN。
本公开进一步提供了金属成型构件,其包括本文描述的那些中任一种的复合涂层。金属成型构件可以包括模具。
本公开进一步提供了涂覆金属成型构件的方法,其包括将之前描述的涂层中任一种的复合涂层施加到其上。复合涂层中的至少一层通过等离子体气相沉积工艺施加。在另一个实例中,本公开提供了用于成型高级的高强度钢本体的方法。该方法包括使用本文所述的金属成型构件。这种高级的高强度钢可以具有至少700MPa的拉伸强度,例如至少900MPa的强度并且在具体情况下至少1000MPa的强度。
附图简要说明
以下详细说明可以参照以下附图最好的理解,其中
图1A图示了实例测试装置,该装置用于进行不同涂层材料在静止位置(以虚线示出的旋转位置)的冲击和滑动磨损评估。
图1B图示了处于旋转位置的图1A的实例测试装置。
图2图示了现有技术的未掺杂CrN涂层在高压冲击之后的显微照片。
图3图示了现有技术的CrN层在图1装置中在200N冲击和400N滑动磨擦下循环之后的顶视图。
图4图示了根据本公开的CrWN涂层在与图3中类似的试验方案之后的显微照片。
图5图示了对于现有技术的CrN膜的X射线衍射数据,示出了220晶体取向。
图6图示了根据本公开的钨掺杂材料的X衍射数据。
图7图示了在其上布置有本公开的复合涂层的物品的截面显微照片。
图8图示了图7中涂覆的物品的表面在图1装置中在400N冲击负荷和400N滑动负荷下1500个测试循环之后的显微照片。
详细说明
本公开是针对用于金属成型构件(例如模具等)的复合涂层。该涂层至少布置在金属工作构件的成型表面上并且包括掺杂的氮化铬陶瓷的第一层。氮化铬是高硬度材料,但是基础材料的柱状性质可以引起其在高压力条件下表现出断裂。根据本公开,已经发现包括较低量的掺杂剂材料(例如在1-10原子百分比范围内)大大限制了穿过该材料的开裂的形成和/或延伸。尽管不希望受推测的限制,推测掺杂剂材料替代了氮化铬的结晶基体从而防止穿过其中的开裂延伸。实例掺杂剂包括但不限于单独或以组合使用的W、V、Ti、Zr、Zo和Ta。在某些情况下,W被用作掺杂剂。如以上指出的,可以使用与替代掺杂一致的1-10原子百分比的掺杂剂水平,并且在具体情况下,掺杂剂水平落在3-7原子百分比范围内,其中5原子百分比是一种具体掺杂剂水平。
在一个实例中,第一层材料总体上具有在1-10微米范围内的厚度,并且在具体情况下约4-6微米。第一层的硬度典型地在3000-4000Hv的范围内,并且在本公开中使用的一种具体材料包括掺杂有约5原子百分比W的CrN并且表现出在3200-3800Hv范围内的硬度。
在第一层上面布置由润滑材料组成的第二层。根据本公开,已经发现了该第二层应该具有低摩擦系数,典型地针对钢低于0.2;并且在具体情况下,第二层具有在0.1-0.15范围内的摩擦系数。润滑材料层典型地具有小于掺杂的氮化铬层的厚度并且总体上具有在0.5-5微米范围内的厚度并且,在具体情况下,在1-3微米范围内的厚度。可以使用多种材料用于形成该润滑层,并且这些材料可以包括氮化物、碳氮化物、氧化物、氧氮化物、碳基涂层,或钼基固体膜润滑涂层等等,条件是它们具有不超过0.2并且优选地低于该值的摩擦系数。在一个实例中,在本公开中使用的具体材料包括TiCN,并且其他此种材料对本领域技术人员是容易清楚的。
确定了替代掺杂的氮化铬与低摩擦系数润滑层一起的组合提供抗磨损涂层,该涂层在使用AHSS合金材料中所遇到的高冲击和高摩擦成型条件下能够具有相对长的使用寿命。
本公开的涂层可以有利地通过等离子体气相沉积(PVD)工艺制备,其中形成了这些层中的至少一个并且优选地两个。此种工艺是有成本效益的并且可以被容易控制以在金属成型模具等的复杂表面上生产均匀、精确的层厚度。此种PVD工艺是本领域熟知的。在某些情况下,本公开的方法可以与使模具和涂层的性能最大化的预处理和后处理工艺结合。例如,模具材料本身可以是抛光的和/或通过本领域熟知的技术例如氮化、碳化以及铁碳化而表面硬化的。在其中形成非常高拉伸强度合金的情况下,已经发现此种硬化工艺是有利的。同样,当模具材料本身具有相对低的强度时,有利地采用硬化技术。而且,在某些情况下有利的是将涂覆的模具表面抛光以进一步增加其抗擦伤性。
在本公开中,抗冲击性(主要来自掺杂的氮化铬)与低摩擦系数(主要来自第二层)的组合与由每个层单独地实现的相比产生了优异的抗疲劳性。如在以下详述的,这些层的组合协同地相互作用从而大大提高了涂覆的模具在高压力、高摩擦条件下的使用寿命。
实验
本公开的原理通过特定系列的针对复合涂层的实验和实例说明,复合涂层包括掺杂有约5原子百分比的钨并且具有在4-6微米范围内的厚度的第一高硬度氮化铬层以及由碳氮化钛组成的具有约1-2微米厚度的第二润滑层。该涂层的总硬度是在3600-3800Hv的范围内并且其摩擦系数是在0.1-0.15范围内。
现在参见图1A-1B,示出了用于进行不同涂层材料的冲击和滑动磨损评估的测试装置。在该装置中,通过气缸1驱动的硬化碳化物球2冲击样品3。样品可以是钢工具,该工具包括根据本公开的表面涂层。样品3安装在可旋转的摇动臂5上,该摇动臂通过滚子轴承7支持在刚性架4上。摇动臂5由复位弹簧组件6偏置,其控制递送到样品3上的涂层的力的量。在球初始冲击样品之后,摇动臂枢转,从而允许球沿着样本的表面涂层滑动。摇动臂5在图1A示出为静止并且在图1B中旋转,其中硬化的球2抵靠样品3的涂覆表面滑动到不同位置。虚线以虚影表示摇动臂5在图1A的冲击过程中旋转时物体的运动。
如在图1A-1B中所示,典型的磨痕可以代表头对尾外观(head to tailappearance)。在这些实例中,测试在室温下进行。在一个具体实例中,使用在200N下的滑动负荷保持80N的冲击负荷。在另一个实例中,使用400N的滑动负荷施加在约200-400N之间的冲击负荷。
图2是典型的未掺杂CrN涂层在高压冲击之后的显微照片。如所见的,在80N的冲击负荷和200N的滑动负荷下一系列约1500个循环之后,在CrN层内并且延伸遍及该层形成了许多裂纹。图3是CrN层在图1装置中在200N冲击和400N滑动磨擦下循环之后的顶视图。如所见的,在涂层中开始显示出裂纹。
图4是本公开的CrWN涂层在类似的测试方案之后的显微照片并且可见该涂层没有显示任何开裂。包括替代掺杂剂(在这种情况下5原子百分比的钨)大大提高了合金的抗裂性。这相信是由于材料的晶体取向的变化,如从图5和6中显而易见的。图5示出了对于CrN膜的X射线衍射数据,示出了220晶体取向。图6示出了本公开的钨掺杂材料的相应X射线衍射数据并且如所见的,该材料显示了220、111和200取向。这种多方向、非柱状结构被认为是对本公开的掺杂材料的抗裂性负责。
在一个实例中,利用本公开的掺杂氮化铬结合碳氮化钛润滑层制备了复合结构。这产生了具有3600-3800Hv的总硬度和0.1-0.15的摩擦系数的复合结构。图7是在其上布置有本公开的复合涂层的物品(如由钢制成的工具)的截面显微照片。图8是图7中涂覆的物品的表面在图1中的装置中在400N冲击负荷和400N滑动负荷下1500个测试循环之后的显微照片。如所见的,甚至在这些极端条件下,没有看到穿过上润滑层的磨损。一些开裂在冲击位点处显而易见,但是这与支持该涂层的基础材料的过度负荷和变形相关。在该基础材料是表面硬化的情况下,这种开裂将不可见。值得注意的是在材料的其余部分没有看到开裂。
如从先前实验系列看到的,本公开提供了复合层的涂层,其中其组成层协同地相互作用以在AHSS合金材料成型中遇到的非常高的压力条件下提供组合的抗冲击性和抗滑动摩擦性。其结果是,使用本公开的涂层大大延长了模具以及其他金属成型材料的使用寿命,由此最小化了设备成本和停机时间。
尽管本公开已经参照某些具体实施例进行了说明,应理解的是可以很容易实施其他改变和变化。例如,可以将另外的高硬度和/或润滑层并入本发明的复合涂层的结构中。而且,尽管这些实验系列涉及某些具体组成,应理解的是在该复合涂层中同样可以使用其他材料。以上附图、讨论和说明是申请的具体实施例的说明,并非是其实施时的限制。以下权利要求书,包括所有等效物限定了本公开的范围。
Claims (15)
1.一种用于金属成型构件的复合涂层,所述涂层包括:
布置在所述金属成型构件上的第一层,所述第一层包括掺杂有至少一种掺杂剂的氮化铬;以及
布置在所述第一层上面的第二层,所述第二层包括具有针对低合金钢所测量的小于或等于0.2的摩擦系数的润滑材料,
其中所述第二层包括至少一种选自氮化物、碳氮化物、氧化物、氧氮化物、碳基涂层、钼基固体膜润滑剂涂层以及其组合的材料。
2.权利要求1所述的涂层,其中所述掺杂剂选自W、V、Ti、Zr、Co、Mo和Ta中的一种或多种。
3.权利要求1或2所述的涂层,其中所述掺杂剂是W。
4.权利要求1或2所述的涂层,其中所述掺杂剂以1至10原子百分比的范围存在。
5.权利要求1或2所述的涂层,其中所述第一层的厚度是在1-10微米的范围内。
6.权利要求1或2所述的涂层,其中所述第一层的硬度是在2-5KHv的范围内。
7.权利要求1或2所述的涂层,其中所述第二层具有针对低合金钢所测量的在0.1-0.15范围内的摩擦系数。
8.权利要求1或2所述的涂层,其中所述第二层的厚度是在0.5-5微米的范围内。
9.权利要求1或2所述的涂层,其中所述第二层包括TiCN。
10.一种金属成型构件,其包括权利要求1-8中任一项所述的复合涂层。
11.权利要求10所述的金属成型构件,其中所述金属成型构件包括模具。
12.一种用于涂覆金属成型构件的方法,其包括将权利要求1-9中任一项所述的复合涂层施加到其上。
13.权利要求12所述的方法,其中所述复合涂层的所述层中至少一个通过等离子体气相沉积工艺施加。
14.一种用于成型高级的高强度钢本体的方法,所述方法包括使用权利要求10或11所述的金属成型构件。
15.权利要求14所述的方法,其中所述高级的高强度钢具有至少700MPa的拉伸强度。
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