CN106163704A - 复合轧辊 - Google Patents

复合轧辊 Download PDF

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CN106163704A
CN106163704A CN201480076963.8A CN201480076963A CN106163704A CN 106163704 A CN106163704 A CN 106163704A CN 201480076963 A CN201480076963 A CN 201480076963A CN 106163704 A CN106163704 A CN 106163704A
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sintering
inner core
outer sleeve
hard alloy
composite roll
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CN106163704B (zh
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斯蒂芬·安德鲁·休伊特
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Hebborn Materials And Technology Co ltd
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Sandvik Intellectual Property AB
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Abstract

一种复合轧辊(20)，包括由第一硬质合金制成的烧结的内芯(22)和围绕所述内芯布置的、由第二硬质合金制成的至少一个烧结的外套筒(24)。所述外套筒和内芯每一个具有连结表面(26，28)，其中该内芯和外套筒被组装时，每一连结表面形成接触，以在其间形成结合界面(30)。当组装好的烧结的内芯(22)和烧结的外套筒(24)被加热到预定温度时，该烧结的内芯和烧结的外套筒在所述结合界面(30)处被熔合在一起，以形成单一体的复合轧辊(20)。为了降低所述复合轧辊(20)的整体成本，对内芯能够使用低成本硬质合金或密度较低的硬质合金，并将其熔合到由未利用的硬质合金制成的烧结的外套筒上，从而降低粉末成本和/或降低复合轧辊自身的整体质量。

Description

复合轧辊
技术领域
本发明涉及一种复合轧辊，其具有由低成本硬质合金或密度较低的硬质合金制成的烧结的内芯，该烧结的内芯被熔合到由未利用(virgin)的硬质合金制成的烧结的外环上，由此降低复合轧辊的粉末成本和/或降低复合轧辊自身的总体质量。
背景技术
轧辊磨损是提高轧机产量的关键因素。在长钢铁产品的热轧制期间，轧辊的经过面变得磨损。一旦磨损，每一个经过面必须重新研磨且然后将该轧辊装回去运行。这个过程被重复直到经过面深度到达被称为“报废直径”的点为止，其意味着该轧辊不能再使用了。参考图1，轧辊10的报废直径12近似处在外径14和内径16中间，其中在报废直径下方(报废直径到内径)的剩余材料18依然未被使用。
作为未利用的材料，这代表着显著的成本，因此如果轧辊的这个部分能够由低成本回收材料代替，那么这将降低轧辊的成本。例如，标准8″直径轧辊使用大约25kg的粉末，其中未使用材料的质量占大约10.5kg。
发明内容
一方面，本发明的复合轧辊包括由第一硬质合金制成的烧结的内芯以及由第二硬质合金制成的至少一个烧结的外套筒，所述至少一个烧结的外套筒围绕内芯布置。所述至少一个烧结的外套筒和内芯每一个具有连结表面，其中当内芯和外套筒组装在一起时，每一连结表面形成接触，以在其间形成结合界面。当组装好的烧结的内芯和烧结的至少一个外套筒被加热到预定温度时，内芯和外套筒在结合界面处熔合在一起，以形成复合轧辊。
另一方面，形成复合轧辊的方法包括如下步骤：提供由硬质合金形成的烧结的内芯，以及提供由第二硬质合金形成的至少一个烧结的外套筒。该烧结的内芯和烧结的至少一个外套筒被组装，所述至少一个外套筒和内芯每一个具有连结表面，使得当所述至少一个烧结的内芯和外套筒被组装时，每一个连结表面形成接触，以在其间形成结合界面(3)。组装好的烧结的内芯和烧结的至少一个外套筒在结合界面(30)处熔合在一起，以形成复合轧辊。
在又一方面，轧机的复合轧辊包括由第一硬质合金制成的烧结的内芯以及由第二硬质合金制成的烧结的外套筒，烧结的外套筒围绕内芯布置并且熔合到内芯，第一硬质合金不同于第二硬质合金。
本发明的复合轧辊的一个优势在于：轧机的维修成本的潜在节省。对内芯使用具有较低密度的碳化物材料(即使其为未利用等级，例如外套筒使用6％粘结剂等级而内芯使用10％或15％粘结剂)将减少轧辊的整体质量，由此减少在轧机中的轴承或其它辅助传动系统上的载荷。
前述发明内容以及以下的具体实施方式将在结合附图阅读后更好地理解。应当理解，所描述的实施例不限于所示出的精确布置结构和手段。
附图说明
图1是已知的轧机轧辊的剖面图。
图2是本公开的复合轧辊的透视图。
图3是外套筒的透视图。
图4是内芯的透视图。
图5是示意本发明的方法的步骤的流程图。
图6是在连结/熔合之后的复合轧辊的剖面图。
图7(a)-7(c)是在组装之后且在熔合之前的根据本公开的复合轧辊的SEM图像。
图8(a)-8(b)是在熔合之后的根据本公开的复合轧辊的SEM图像。
具体实施方式
本发明的复合轧辊包括由第一硬质合金制成的烧结的内芯和围绕内芯布置的、由第二硬质合金制成的至少一个烧结的外套筒。该至少一个烧结的外套筒和内芯每一个具有连结表面，其中当内芯和外套筒组装在一起时，每一个连结表面形成接触，以在其间形成结合界面。当组装好的烧结的内芯和烧结的至少一个外套筒被加热到预定的温度时，内芯和外套筒在结合界面处熔合在一起，以形成复合轧辊。
如图2中所示，本发明的复合轧辊20包括内芯22和至少一个外部分或套筒24。将如这里进一步描述的，当内芯22被插入在外套筒24内时，其形成多部件轧辊或复合轧辊。
内芯20能够由第一硬质合金或金属陶瓷制成，其具有低成本硬质合金(即，与由实心的未利用的碳化物制成的轧辊的成本相比)，例如，回收的硬质合金或低密度硬质合金(即，与实心的未利用的碳化物的密度相比)。该硬质合金可具有高达100wt％的回收碳化物。虽然未示出，但应当理解，内芯能够是实心的或具有任意形状且不限于如所示出的筒状或环状。
外套筒24由第二硬质合金或金属陶瓷(例如，未利用的硬质合金)制成。如这里描述的，未利用的硬质合金指的是确实不包括回收(reclaimed)碳化物的碳化物。回收硬质合金指的是通过冶金学或化学手段(例如锌回收工艺、电解回收以及萃取或氧化)回收的硬质合金，其对本领域技术人员而言是已知的。虽然示出仅一个外套筒，但是复合轧辊能够包括多个套筒。
因此，内芯22和外套筒24能够由液相材料压实体(compacts of liquid phasematerials)的不同等级硬质合金制成，其包括低熔相组分以及高熔相组分。硬质合金通常具有硬质相，硬质相包括碳化钨且具有钛、铬、钒、钽、铌的一种或多种碳化物、氮化物或碳氮化物，其由金属相粘结剂(通常是各种不同比例的钴、镍、铁)粘结。粘结剂可在约6w-％到30wt-％范围内。第一和第二碳化物中的每一个能够是由粘结剂粘结(bonded)的碳化钨。
硬质合金以不同等级存在。该等级取决于硬质合金的成分且取决于颗粒尺寸。例如，与低质量等级相比，高质量等级为在给定的应用中具有可计量地更好的性能和可靠性的硬质合金。应当理解，本公开也预期到了用于内芯和外套筒的其它材料，例如，金属陶瓷-因此，第一和第二碳化物能够由不同的硬质合金组成。
外套筒24能够由使用了具有由仅Co构成的粘结剂的等级且不添加有回收的硬质合金的硬质合金的即压粉末(RTP)压制而成。所得到的烧结的套筒的平均开始WC颗粒尺寸(即，在处理前提供的WC颗粒尺寸)的范围能够从约5.0到约8.0μm。与外套筒一样，内芯22由使用了由Co/Ni/Cr构成的混合粘结剂等级的硬质合金的RTP连同回收的硬质合金的RTP(例如，约25wt％的硬质合金是回收的)压制而成。与外套筒一样，内芯的平均开始WC颗粒尺寸的范围能够从约5.0-约8.0μm。
因此，复合轧辊20包括两个部分-低成本硬质合金的内芯22和较高等级的硬质合金或未利用的硬质合金的外套筒24。应当理解，能够提供多个外套筒，并且本公开不限于两个部件形成复合轧辊。如这里将进一步描述的，为了产生复合轧辊，由未利用质量的硬质合金制成的烧结的外套筒和由回收硬质合金制成的烧结的内芯中的每一个被熔合在一起。
参考图3和4，外套筒24具有内连结表面26，而内芯22具有外连结表面28。如这里将进一步描述的，烧结的内芯22和至少一个外套筒24在连结表面26、28处熔合在一起，以形成单一体32，第一和第二硬质合金每一个具有不同的熔点，其中组装好的烧结的至少一个内芯和烧结的至少一个外套筒被加热到一温度，以使两者在结合界面30处熔合，从而形成单一体32(图2)，所述温度低于烧结的内芯和外套筒的较低烧结温度的熔点或处于两个烧结温度中间。单一体被定义为单个成一体的本体。
根据图5中描述的本发明的方法40，根据具体期望的最终用途，复合轧辊的芯22和套筒24在步骤42中单独地形成和提供。如上面阐明的，内芯22能够由使用了由Co/Ni/Cr构成的混合粘结剂等级的硬质合金的RTP连同回收的硬质合金的RTP压制而成，而外套筒24可由使用了由仅Co构成的粘结剂的等级且不添加有回收硬质合金的硬质合金的RTP压制而成。
然后，每一个在步骤44中被烧结，以基本上获得其全密度和硬度。如已知的，芯和套筒能够在真空熔炉中或者在烧结-HIP熔炉中，在其相应的温度下(例如1350℃-1520℃)烧结。
在步骤46中，在配合表面/连结表面26、28处对芯和套筒进行研磨或加工，以在其间提供充分光滑的光洁度，从而在组装期间促进干涉配合。例如，内芯22被放置在液态氮中约30秒，以使其收缩并允许其被压入到外套筒中，因此利用热膨胀的现象在界面30处形成强接合。
烧结的芯和套筒还能够例如在丙酮清洗液中被清洁，以在连结表面处提供清洁的界面。之后，在步骤48中，各个单独的部件被组装成复合轧辊。步骤48的组装涉及使芯和套筒以组装关系形成接触，其中内芯22定位在外套筒24内，使得第一结合或连结表面26与第二结合或连结表面28形成配合接合(图2)，以形成单一体32。见图6。之后，如这里描述的，采用对处于组装关系的构件进行加热的步骤，以将构件熔合在一起。
组装碳化物构件的现有技术包括共同挤压，烧结两个坯件或将一个坯件烧结到一个烧结的部件上，但这些技术具有不同收缩程度的风险并需要更高的烧结温度，这可导致外部的张应力，从而可能导致破裂。与坯件所需要的相比，本发明的烧结-熔合技术使用刚好高于WC-Co共熔温度(eutectic)的温度以及较短的等温停留。
再次参考图5，在步骤50中，组装好的烧结的芯和套筒通过使两者在一温度下熔合而连结，所述温度足够得低，使得在结合界面30处发生最小的颗粒生长。组装好的烧结的芯和套筒被放置在标准烧结熔炉中并经受真空或气氛，不施加外部压力。例如，组装好的复合轧辊被从室温带到约1350℃的熔融温度，每分钟上升约10℃，在最高温度处停留时间为约15分钟。这个熔合温度和加热循环低于具有最低熔化温度的硬质合金的原始烧结温度和加热循环。例如，约1340℃到约1360℃持续约10到约30分钟，且更优选地约1350℃持续约15分钟。
这个步骤取得已经致密和硬的碳化物部件并将它们放回到烧结熔炉中。但是，代替变得收缩以及密度更大，如在原始烧结操作中那样，芯和套筒在物理属性上保持基本一样。
如在图6所示，边界界面30位于内芯和外套筒之间并且在熔合时发生。部件在这样的温度下被熔合，所述温度低于芯和套筒的具有最低原始烧结温度的硬质合金的熔点。这个较低的温度和较短的时间使得熔合能够以粘结剂金属横跨界面30的短范围扩散来进行，并且在微观结构中引起最小的颗粒生长而形成单一体32。
示例
复合轧辊由6％Co粘结剂等级的外套筒和回收的30％Ni/Co/Cr粘结剂等级的内芯构成。芯和套筒两者在50t手动操作压机上(Sealey有限公司，萨福克，英国)使用单端压制来压制，并且在其相应的温度下烧结，对于内芯是1360℃，而对于外套筒是1510℃。
表格1示出在烧结前后的内芯22(“内部”)和外套筒24(“外部”)的尺寸和性质。如能够看到的，该芯和套筒的重量在烧结前后相对未变。内芯轻微地收缩，而外套筒轻微地膨胀，但整体厚度仅最小的量地改变。Hc由于晶粒粗化而轻微地增加。因此，在芯和套筒之间存在物理接触，以能够实现熔合。
表格1
芯和套筒两者均通过EDM切割，并根据ISO 286-2：1988极限与配合ISO系统，初始研磨到区位干涉配合。内芯被放置在液态氮中约30s且然后被压入到外套筒中，例如在收缩配合(收缩配合公差为+20μm)之后利用热膨胀的现象得到强接合。所应用的公差朝向区位过渡配合逐渐减小，且该工艺重复，直到内芯能够定位在外套筒内为止。
参考图7(a)-7(c)，SEM显微照片示出了熔合处理之前的两个构件之间的连结线26、28。如能够看到的，芯和套筒被连结在一起，且内芯和套筒被熔合，以形成单一复合轧辊。
图8(a)和8(b)为SEM显微照片，其示出了熔合处理之后的芯和套筒之间的边界区域30。如能够看到的，已经发生了一些晶粒粗化，对于内芯材料更是如此，但不优先地发生在芯和外套筒之间的连结表面26、28的界面处。
应当理解，不同等级的材料能够连结，以优化复合轧辊的局部属性。因此，例如，能够选择材料的耐磨性、韧性、钎焊性、摩擦系数和/或立方氮化硼(cBN)含量。此外，还能够选择钴或晶粒大小不匹配，以引起粘结剂金属熔合和随后的密度变化。这能够引起表面处的压应力，从而提供增韧效果。例如，如果结合了钴含量/钴平均自由行程/WC颗粒尺寸降低的一层或多层，则能够增加耐疲劳性。
虽然已经关于特定方面对本实施例进行了描述，但是对本领域技术人员而言，很多其它变形和改型和其它使用是显而易见的。因此优选的是，本实施例不被这里的特定公开限定，而是仅由权利要求书限定。

Claims (22)

1.一种复合轧辊(20)，包括
由第一硬质合金制成的烧结的内芯(22)；
由第二硬质合金制成的至少一个烧结的外套筒(24)，所述至少一个烧结的外套筒(24)围绕所述内芯布置，所述外套筒和所述内芯每一个具有连结表面(26，28)，其中当所述内芯和所述外套筒被组装在一起时，每一个连结表面形成接触，以在其间形成结合界面(30)，其特征在于，当组装好的所述烧结的内芯(22)和所述至少一个烧结的外套筒(24)被加热到预定温度时，所述烧结的内芯和所述至少一个烧结的外套筒在所述结合界面(30)处熔合在一起，以形成所述复合轧辊(20)。
2.根据权利要求1或权利要求2所述的复合轧辊，其特征在于，所述第一硬质合金和所述第二硬质合金包括用粘结剂粘结的碳化钨。
3.根据权利要求2所述的复合轧辊，其特征在于，所述一个内芯(22)的所述第一硬质合金的粘结剂含量为约6wt-％到约30wt-％。
4.根据前述权利要求中的任一项所述的复合轧辊，其特征在于，所述第一硬质合金和所述第二硬质合金由不同的硬质合金制成。
5.根据前述权利要求中的任一项所述的复合轧辊，其特征在于，所述内芯(22)的所述第一硬质合金包括100wt％的回收硬质合金。
6.根据前述权利要求中的任一项所述的复合轧辊，其特征在于，所述至少一个外套筒(24)的所述第二硬质合金由未利用的硬质合金构成。
7.根据前述权利要求中的任一项所述的复合轧辊，其特征在于，与所述至少一个外套筒(24)的所述第二硬质合金相比，所述内芯(22)的所述第一硬质合金具有较低的密度。
8.根据前述权利要求中的任一项所述的复合轧辊，其特征在于，所述烧结的内芯和至少一个外套筒被熔合在一起，以形成单一体，所述第一硬质合金和所述第二硬质合金每一个具有不同的熔点，其中组装好的所述烧结的至少一个内芯和烧结的至少一个外套筒被加热到一温度，以使所述烧结的至少一个内芯和烧结的至少一个外套筒在所述结合界面处熔合，从而形成所述单一体，所述温度低于所述烧结的内芯和外套筒的较低烧结温度的熔点或处于两个烧结温度中间。
9.一种形成复合轧辊(20)的方法，包括以下步骤：
提供由硬质合金形成的至少一个烧结的内芯(22)；
提供由第二硬质合金形成的至少一个烧结的外套筒(24)；
组装所述烧结的内芯和烧结的至少一个外套筒，所述至少一个外套筒和所述内芯每一个具有连结表面(26，28)，其特征在于，当所述烧结的内芯和所述烧结的至少一个外套筒被组装时，每一个连结表面(26，28)形成接触，以在其间形成结合界面(3)；以及
使组装好的所述烧结的内芯(22)和所述烧结的至少一个外套筒(24)在所述结合界面(30)处熔合在一起，以形成复合轧辊(20)。
10.根据权利要求9所述的方法，其中所述第一硬质合金和所述第二硬质合金每一个包括利用粘结剂粘结的碳化钨。
11.根据权利要求9-10中的任一项所述的方法，其特征在于，所述第一硬质合金和所述第二硬质合金由不同的硬质合金制成。
12.根据权利要求9-11中的任一项所述的方法，其特征在于，所述烧结的内芯和至少一个外套筒被熔合在一起，以形成单一体，所述第一硬质合金和所述第二硬质合金每一个具有不同的熔点，其中组装好的所述烧结的至少一个内芯和烧结的至少一个外套筒被加热到一温度，以使该烧结的至少一个内芯和烧结的至少一个外套筒在所述结合界面处熔合，从而形成所述单一体，所述温度低于所述烧结的内芯和外套筒的较低烧结温度的熔点或处于两个烧结温度中间。
13.根据权利要求9-12中的任一项所述的方法，其特征在于，所述组装步骤包括：使所述内芯在液态氮中收缩，并将所述内芯压入到所述至少一个外套筒中，其中所述内芯和所述至少一个外套筒之间的热膨胀在所述结合界面处提供了强接合。
14.根据权利要求12或权利要求13所述的方法，其特征在于，组装好的所述烧结的内芯(22)和至少一个外套筒(24)被加热到约1340℃到约1360℃的温度。
15.根据权利要求12-14中的任一项所述的方法，其特征在于，组装好的所述烧结的内芯(22)和至少一个外套筒(24)被加热约10分钟到约30分钟的时段。
16.根据权利要求14或权利要求15中的任一项所述的方法，其特征在于，所述熔合的步骤进一步包括：使所述烧结的组装好的至少内芯(22)和至少一个外套筒(24)经受真空或气氛，而不施加外部压力。
17.根据权利要求9-16中的任一项所述的方法，其特征在于包括如下的步骤：在组装之前对所述烧结的内芯(22)和所述烧结的至少一个外套筒(24)进行加工，以在所述烧结的内芯(22)和所述烧结的至少一个外套筒(24)之间提供更紧密配合。
18.一种轧机的复合轧辊(20)，包括：
由第一硬质合金制成的烧结的内芯(22)；以及
由第二硬质合金制成的烧结的外套筒(24)，所述烧结的外套筒(24)围绕所述内芯(22)布置并且被熔合到所述内芯(22)，其特征在于，所述第一硬质合金不同于所述第二硬质合金。
19.根据权利要求18所述的复合轧辊，其特征在于，所述烧结的内芯(22)的所述第一硬质合金包括100wt％的回收硬质合金。
20.根据权利要求18或权利要求19所述的复合轧辊，其特征在于，所述烧结的外套筒(24)的所述第二硬质合金由未利用的硬质合金构成。
21.根据权利要求18-20中的任一项所述的复合轧辊，其特征在于，所述烧结的内芯(22)的所述第一硬质合金具有比所述烧结的外套筒(24)的所述第二硬质合金低的密度。
22.根据权利要求18-21中的任一项所述的复合轧辊，其特征在于，所述烧结的内芯和烧结的外套筒被熔合在一起，以形成单一体，所述第一硬质合金和所述第二硬质合金每一个具有不同的熔点，其中组装好的所述烧结的内芯和烧结的外套筒被加热到一温度，以使该烧结的内芯和烧结的外套筒在所述结合界面处熔合，从而形成所述单一体，所述温度低于所述烧结的内芯和外套筒的较低烧结温度的熔点或处于两个烧结温度中间。
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