CN105229201A - 具有钢制外层的再制铸铁部件 - Google Patents

具有钢制外层的再制铸铁部件 Download PDF

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CN105229201A
CN105229201A CN201480027287.5A CN201480027287A CN105229201A CN 105229201 A CN105229201 A CN 105229201A CN 201480027287 A CN201480027287 A CN 201480027287A CN 105229201 A CN105229201 A CN 105229201A
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middle layer
cast iron
aluminium
steel
skin
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R·E·夏普
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Caterpillar Inc
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    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
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    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
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    • C23C4/123—Spraying molten metal
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    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
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    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
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    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/18—After-treatment
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/12771—Transition metal-base component
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    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12771—Transition metal-base component
    • Y10T428/12861—Group VIII or IB metal-base component
    • Y10T428/12951—Fe-base component
    • Y10T428/12958—Next to Fe-base component
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract

本发明涉及一种部件。该部件可包括铸铁基座(1)和覆盖铸铁基座(1)的至少一部分的中间层(2)。中间层(2)可包括铝以及镍、钴、铬、硅或铁中的至少一种。该部件还可包括覆盖中间层(2)的外层(3)。外层(3)可包括钢。

Description

具有钢制外层的再制铸铁部件
技术领域
本发明一般涉及一种再制铸铁部件，并且更特别地涉及一种具有钢制外层的再制铸铁部件。
背景技术
高压冷喷涂可用于在基底上形成涂层表面。涂层表面是利用高压冷喷涂设备将通常包含金属的颗粒与固定基底发生碰撞而形成。颗粒与固定基底之间的碰撞基本上是无弹性的，使得颗粒能够发生变形并粘附至基底上。
高压冷喷涂可用于通过钢制颗粒与铸铁基底的碰撞来在铸铁部件上形成钢涂层。然而，铸铁基底包括石墨铸铁薄片，其在高压冷喷涂过程中受到钢制颗粒的撞击时易于发生破裂。石墨铸铁薄片的破裂能够使得所制得的钢涂层与铸铁基底之间出现不理想的粘合。
试图防止石墨铸铁薄片出现破裂的行为包括在高压冷喷涂过程中将铜制或铝制颗粒与钢制颗粒混合。由于铜和铝较之钢更具有延展性，因此，它们从钢制颗粒与铸铁基底之间的碰撞中吸收能量，这导致了钢涂层的粘附和石墨铸铁薄片的有限破裂。
然而，当处在常常用来清洁铸铁部件的苛性碱溶液中时，所制得的钢和铜或铝混合物的涂层容易遭受腐蚀。铜和铝在苛性碱溶液中容易发生氧化并降低钢涂层的完整性。
本发明的部件解决了以上提出的一个或多个问题和/或本领域中的其它问题。
发明内容
在一方面，本发明涉及一种部件。该部件可包括铸铁基座和覆盖铸铁基座的至少一部分的中间层。中间层可包括铝以及镍、钴、铬、硅或铁中的至少一种。该部件还可包括覆盖中间层的外层。外层可包括钢。
在另一个方面，本发明涉及一种用于再制造部件的方法。该方法可包括移除铸铁部件的受损区域，剩下的部件构成铸铁基座。该方法还可包括在铸铁基座上沉积熔融颗粒，以形成团聚的熔融颗粒的池。熔融颗粒可包括铝以及镍、钴、铬、硅或铁中的至少一种。该方法还可包括冷却该熔融颗粒池以形成固体中间层，并且在中间层上沉积固体颗粒以形成外层。固体颗粒可包括钢。
附图说明
图1是所公开的示例性部件的剖视图；
图2是所公开的示例性部件的另一剖视图；
图3是所公开的示例性双线电弧喷涂系统的示意图，该系统可用于将中间层涂覆至铸铁基座；以及
图4是所公开的示例性高压冷喷涂系统的示意图，该系统可用于将外层涂覆至中间层。
具体实施方式
图1和图2分别示出了根据本发明的具有铸铁基座1、中间层2和外层3的示例性部件21。部件21可由铸铁制成。例如，部件21可具有主要由铸铁组成的表面。在替代实施例中，部件21可以具有由任意金属制成的表面，但是至少包括由铸铁制成的外表面。
铸铁基座1可由铸铁合金制成，其至少包括铁、碳和硅。在一个实施例中，铸铁基座1由铁和约2.1-4wt％的碳以及约1-3wt％的硅组成。在替代实施例中，铸铁基座1包括由铁和约2.5-4wt％的碳以及约1-3wt％的硅组成的灰色铸铁。
中间层2可覆盖铸铁基座1的至少一部分。在一个实施例中，中间层2可覆盖铸铁基座1的包括部件1的受损表面的各部分。在替代实施例中，中间层2可覆盖部件21的整个铸铁表面。
中间层2可包括铝以及镍、钴、铬、硅或铁中的至少一种。在一个实施例中，中间层2主要由铝、铁和铬组成。在另一实施例中，中间层2主要由约6％的铝、约19％的铬以及约76％的铁组成。在替代实施例中，中间层2主要由铝和镍组成。在另一实施例中，中间层2主要由约5-10％的铝和约90-95％的镍组成。
中间层2可以具有在高压冷喷涂过程中当外层3沉积时足以抑制铸铁基座1中的石墨铸铁薄片发生破裂的厚度。在一个实施例中，中间层2具有的厚度为约50μm至2000μm。在另一个实施例中，中间层2具有的厚度为约100μm至1000μm。
外层3可覆盖中间层2并且特别包括钢。例如，外层3可包括工具钢、碳钢或不锈钢。在一个实施例中，外层3包括具有铁和如下重量百分比组成的工具钢：约1.6％的碳、约0.3％的锰、约4.0％的铬、约5.0％的钴、约4.9％的钒、约12.0％的钨、约0.3％的硅以及约0.06％的硫。在替代实施例中，外层3包括具有铁和如下重量百分比组成的钢：约0.20至0.45％的碳、约0.4至1.5％的锰、约0.5至2.0％的硅、约0.01至2.0％的铬、约0.15至1.2％的钼、约0.01至0.4％的钒、约0.01至0.25％的钛、约0.005至0.05％的铝、约0.0001至0.01％的硼、小于约0.002％的氧以及约0.005至约0.017％的氮。在替代实施例中，外层3包括具有铁和如下重量百分比组成的不锈钢：约0.15％的碳、约1.0％的锰、约1.0％的硅、约11.5至13.5％的铬、约0.04％的磷以及约0.03％的硫。
外层3可具有足以整修部件21的厚度。在一个实施例中，外层3具有约0.1mm至60mm的厚度。在另一个实施例中，外层3具有约2mm至10mm的厚度。
工业实用性
下文描述的用于再制造部件的方法可用于再制造具有铸铁的任何部件。所公开的部件实施例的化学和物理特性可提供多个益处，其中包括在将钢以高压冷喷涂的方式施加至铸铁上时使得铸铁薄片的破裂程度降至最低。同时还保持外表面的耐腐蚀性。现在将详细地描述制造部件21的示例性过程。
制造部件21的过程可包括通过加工来去除铸铁部件21的受损区域，剩余的部件构成铸铁基座1，该基座1可具有基本上均匀平整的表面。中间层2可通过将熔融颗粒12(图3)沉积在铸铁基座1上而形成在铸铁基座1上，从而形成团聚的熔融颗粒12的池13。池13可包括铝以及镍、钴、铬、硅或铁中的至少一种，并且可覆盖铸铁基座1的至少一部分。可对池13进行冷却，以形成固体中间层2。外层3可通过将固体颗粒20(图4)沉积在中间层2上而形成。
图3大体上示出了一种示例性双线电弧喷涂设备22，其可用于将中间层2施加于铸铁基座1。该双线电弧喷涂设备22可包括可在电弧焊点7处将金属线5和6结合在一起的喷枪4。金属线5和6可由辊子14和15推动，并且在它们穿过接触管8和9时产生相反的电荷。当金属线5和6在电弧焊点7处彼此接近时，相反电荷所产生的电弧可将金属线5和6的端部熔化。压缩空气可经由管道10和11进给至喷枪4，并且可在电弧焊点7处雾化金属线5和6的熔融端部，这会产生朝向铸铁基座1行进的熔融颗粒12的流。熔融颗粒12可沉积在铸铁基座1上并且形成团聚的熔融颗粒12的池13。池13可以冷却并固化以形成中间层2。
图4大体上示出了一种示例性高压冷喷涂设备23，其可用于将外层3施加于中间层2。该高压冷喷涂设备23可包括气体控制模块16，该气体控制模块可在高压下将氦气或氮气提供给系统。气体可从气体控制模块16通向加热器17和粉末进料器18。来自加热器17的经过加热的气体以及气体和固体颗粒20的混合物进入喷嘴19。然后，通过将固体颗粒20和高压气体从喷嘴19中朝向中间层2和铸铁基座1喷出而将固体颗粒20沉积在中间层2上。固体颗粒20可以在中间层2上以固态形式强化，进而形成外层3。固体颗粒20可包括钢并且具有约1μm至40μm的平均粒径。系统的气体压力可足以使得固体颗粒20能以约1000m/s至2500m/s的速度行进通过喷嘴19。
本文描述的制造过程可进行来形成具有钢制外层的再制部件，该钢制外层通过高压冷喷涂沉积在铸铁基座上，该再制部件在基座的铸铁薄片中具有有限的破裂并且在碱洗时不易于腐蚀。对于本领域的技术人员而言显而易见的是，可以在不脱离本发明的范围的前提下对部件21的各层作出各种修改和变化。各层或制造部件21的方法的其它实施例对于考虑了说明书和实践的本领域技术人员来说是显而易见的。说明书和示例仅仅是示例性的，本发明的真实范围由以下权利要求书及其等价内容指出。

Claims (10)

1.一种部件，包括：
铸铁基座(1)；
中间层(2)，所述中间层覆盖所述铸铁基座(1)的至少一部分，其中，所述中间层包括铝以及镍、钴、铬、硅或铁中的至少一种；以及
外层(3)，所述外层覆盖所述中间层(2)，其中，所述外层(3)包括钢。
2.根据权利要求1所述的部件，其中，所述中间层具有的厚度为约50μm至2000μm。
3.根据权利要求1所述的部件，其中，所述外层具有的厚度为约0.1mm至60mm。
4.根据权利要求1所述的部件，其中，所述中间层主要由铝、铁和铬组成。
5.根据权利要求1所述的部件，其中，所述中间层主要由铝和镍组成。
6.一种用于再制造部件的方法，包括：
除去铸铁部件(21)的受损区域，剩下的部件构成铸铁基座(1)；
将熔融颗粒(12)沉积在所述铸铁基座(1)上以形成团聚的熔融颗粒(12)的池(13)，其中，所述池(13)包括铝以及镍、钴、铬、硅或铁中的至少一种；
冷却所述池(13)以形成固体中间层(2)；以及
在所述固体中间层(2)上沉积固体颗粒(20)以形成外层(3)，其中，所述固体颗粒包括钢。
7.根据权利要求6所述的方法，其中，由高压冷喷涂装置(23)执行所述固体颗粒的沉积。
8.根据权利要求6所述的方法，其中，所述中间层主要由铝、铁和铬组成。
9.根据权利要求6所述的方法，其中，所述中间层主要由铝和镍组成。
10.一种用于再制造部件的方法，包括：
除去铸铁部件(21)的受损区域，剩下的部件(21)构成铸铁基座(1)；
将熔融颗粒(12)沉积在所述铸铁基座(1)上以形成团聚的熔融颗粒(12)的池(13)，其中，所述池(13)包括铝以及镍、钴、铬、硅或铁中的至少一种；
冷却所述池以形成固体中间层(2)，其中，所述固体中间层(2)具有的厚度为约50μm至200μm；以及
在所述固体中间层(2)上沉积固体颗粒(20)以形成外层(3)，其中：
所述固体颗粒(20)包括钢；以及
所述外层(3)具有的厚度为约0.1mm至60mm。
CN201480027287.5A 2013-05-14 2014-05-01 具有钢制外层的再制铸铁部件 Pending CN105229201A (zh)

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