CN106222571B - 天然气发动机气门座制备方法 - Google Patents
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Abstract
本发明涉及一种天然气发动机气门座制备方法,其解决了天然气发动机气门座存在的成份及制备方法不合理、产品易磨损的技术问题,包括如下步骤:配料、混料、压制、烧结、热处理,本发明可用于天然气发动机气门座制备领域。
Description
技术领域
本发明涉及发动机技术领域,具体地说是一种天然气发动机气门座制备方法。
背景技术
在现代化日新月异的今天,清洁能源、尾气污染等等问题越来越受到人们重视,在发动机领域中,使用天然气作为燃料也越来越多,压缩天然气作为内燃机代用燃料是保护环境与合理利用能源的有效途径。
传统燃油型发动机改为天然气后,在使用中发现很多问题,特别是发动机气门座会很快磨损,尤其是排气门座圈磨损更大。有研究资料显示,其原因是由于天然气发动机的燃烧特性及磨损机理不同引起的。天然气发动机的工况条件比传统燃油更加恶劣,主要有以下几个方面:天然气在缸内燃烧时的燃烧爆发速度33.8m/s相比燃油39~47m/s低,使得气门座在高温工作状态时间长。天然气燃烧最高温度高于燃油燃烧最高温度。由于在缸内天然气为气态没有燃油的气化吸热过程,使天然气发动机排气温度比燃油发动机高200℃左右,气门座圈的温度更高。由于天然气的组分及燃烧产物过于洁净,没有可润滑成分,座圈与气门之间没有润滑处于干摩擦状态。天然气中S含量较高,在高温下硫会使材料中某些金属(如Ni)等硫化,形成低熔点的硫共融物降低了材料的热强度与硬度。S在高温情况下可以与Fe直接反应而产生腐蚀,也可与O2反应生成SO2,产生高温腐蚀。因为上述原因,提供一种耐磨损耐高温腐蚀的天然气发动机气门座显得尤为重要。
发明内容
本发明就是为了解决天然气发动机气门座存在的成份及制备方法不合理、产品易磨损的技术问题,提供一种制备方法合理、产品不易磨损的天然气发动机气门座制备方法。
为此,本发明提供一种天然气发动机气门座制备方法,其包括如下步骤:(1)配料:将基体金属粉末和熔渗金属粉末分别按如下质量百分比进行配比:基体金属粉末:1~2%石墨粉(C)、3~8%铬铁粉(FeCr)、10~18%钼铁粉(FeMo)、2~6%钴粉(Co)、1~5%钨粉(W)、0.5~2%钒铁粉(FeV)、1~5%铜粉(Cu)、0.4~1.5%微粉蜡、余量为水雾化铁(Fe)粉;熔渗金属粉末:1~5%水雾化铁(Fe)粉、1~5%锌粉(Zn)、0.2~1%微粉蜡、余量为铜粉(Cu);(2)混料:将配比好的基体金属粉末与熔渗金属粉末分别混合均匀;(3)压制:将混合均匀的基体金属粉末压制成基体金属;将混合好的熔渗金属粉末取重量为压制好的基体金属重量的16~22%,以同一模具压制成熔渗金属;(4)烧结:将熔渗金属与基体金属上下摆放于推舟内,烧结成型;(5)热处理:烧结出炉的零件热处理,淬火后低温回火。
优选的,基体金属密度为6.6~7.1g/cm3。
优选的,步骤(4)中的烧结参数为:氨分解气氛的推杆式烧结炉,每50~60分钟送入一舟进行烧结,脱脂段与烧结段气流量控制0.3~0.5m3/h;烧结段温度为:一段:180℃,二段:280℃,三段:480℃,四段:700℃,五段:900~1200℃。
本发明通过给出精确严格的材料配比,烧结后的高合金相中多分布硬质耐磨微颗粒,合金中的Cr与S在高温情况下反应沉积产生Cr S具有较好的润滑性,高合金相在高温条件下生成的氧化膜,能改善天然气气门座的耐磨性和自润滑性能,通过独特的熔渗剂配方,合适的烧结熔渗温度,一步法烧结渗铜工艺,熔渗成型后产品无铜珠残留,残渣为海绵状,经测定计算铜熔渗效率达到98~98.5%,并以排水法测定铜熔渗产品密度为7.95~8.02%,铜熔渗在粉末冶金中起初固溶于铁中,抗拉强度急剧增高,当基体金属固溶超过大约10%Gu时,强度增高缓慢,这时铜充填基体金属中的孔隙,与铁相互溶解,冷却时产生析出硬化,也大大提高其强度,粉末空隙的减少也会延缓SO2对产品的高温腐蚀作用,由于铜溶渗提高了气门座圈导热性,可以降低气门温度50~100℃,设计模具预留合适的尺寸裕量,使产品尺寸符合图纸要求,最终热处理成型,进一步提高其强度及硬度。热处理后硬度值HRC40-47,压缩屈服强度值(0.1%/MPa)1170~1210,产品装配发动机分别进行500小时台架热冲击试验、10万公里路试,拆解测量气门座磨损量如下表:
具体实施方式
下面对本发明作进一步描述:
以下实施例中所用粉末全部为采购自专业生产厂家,具体如下表:
名称 | 规格型号 | 生产厂家 |
石墨(C)粉 | F1 | 青岛润凯碳素有限公司 |
铬铁(FeCr)粉 | Cr含量78% | 杭州特种冶金材料有限公司 |
钼铁(FeMo)粉 | Mo含量60% | 四川科汇实业有限责任公司 |
钴(Co)粉 | 200目 | 有研粉末新材料(北京)有限公司 |
钨(W)粉 | 2.5μm | 文登市正兴钨业有限公司 |
钒铁(FeV)粉 | V含量60% | 四川科汇实业有限责任公司 |
铜(Cu)粉 | 100目 | 有研粉末新材料(北京)有限公司 |
微粉蜡 | 广州市保亮贸易有限公司 | |
水雾化Fe粉 | FSY200.30 | 鞍钢(鞍山)冶金粉材有限公司 |
锌(Zn)粉 | 200目 | 成都核八五七新材料有限公司 |
实施例1
本发明包括如下步骤:
(1)配料:将基体金属粉末和熔渗金属粉末分别按如下质量百分比进行配比:基体金属粉末(总量为100%):1%C、8%FeCr、10%FeMo、6%Co、1%W、2%FeV、1%Cu、1.5%微粉蜡、余量为水雾化Fe粉%;熔渗金属粉末(总量为100%):5%水雾化Fe粉、1%Zn粉、1%微粉蜡、余量为Cu%;
(2)混料:将配比好的基体金属粉末与熔渗金属粉末分别混合均匀;
(3)压制:将混合均匀的基体金属粉末按图纸压制成基体金属,由于渗铜烧结后零件尺寸膨胀较大,所以模具设计时要计算模具裕量,密度为6.6g/cm3;将混合好的熔渗金属粉末取重量为压制好的基体金属重量的22%,以同一模具压制成熔渗金属,密度以成型摆放不破碎为准;
(4)烧结:将熔渗金属与基体金属上下摆放于推舟内,相互之间不要接触,上面盖铁板,加木炭,烧结成型;烧结参数为:氨分解气氛的推杆式烧结炉,每50~60分钟送入一舟进行烧结,脱脂段与烧结段气流量控制0.3m3/h;烧结段温度为:一段:180℃,二段:280℃,三段:480℃,四段:700℃,五段:900~1200℃;
(5)热处理:烧结出炉的零件热处理,淬火后低温回火(170~200℃),硬度HRC40~47,压缩屈服强度值(0.1%/MPa)1170。
实施例2
本发明包括如下步骤:
(1)配料:将基体金属粉末和熔渗金属粉末分别按如下质量百分比进行配比:基体金属粉末:2%C、3%FeCr、18%FeMo、2%Co、5%W、0.5%FeV、5%Cu、0.4%微粉蜡、余量为水雾化Fe粉%;熔渗金属粉末:1%水雾化Fe粉、5%Zn、0.2%微粉蜡、余量为Cu%;
(2)混料:将配比好的基体金属粉末与熔渗金属粉末分别混合均匀;
(3)压制:将混合均匀的基体金属粉末按图纸压制成基体金属,由于渗铜烧结后零件尺寸膨胀较大,所以模具设计时要计算模具裕量,密度为7.1g/cm3;将混合好的熔渗金属粉末取重量为压制好的基体金属重量的16%,以同一模具压制成熔渗金属,密度以成型摆放不破碎为准;
(4)烧结:将熔渗金属与基体金属上下摆放于推舟内,相互之间不要接触,上面盖铁板,加木炭,烧结成型;烧结参数为:氨分解气氛的推杆式烧结炉,每50~60分钟送入一舟进行烧结,脱脂段与烧结段气流量控制0.3m3/h;烧结段温度为:一段:180℃,二段:280℃,三段:480℃,四段:700℃,五段:900~1200℃;
(5)热处理:烧结出炉的零件热处理,淬火后低温回火(170~200℃),硬度HRC40~47,压缩屈服强度值(0.1%/MPa)1200。
实施例3
本发明包括如下步骤:
(1)配料:将基体金属粉末和熔渗金属粉末分别按如下质量百分比进行配比:基体金属粉末:1.5%C、5%FeCr、14%FeMo、4%Co、3%W、1%FeV、3%Cu、1%微粉蜡、余量为水雾化Fe粉%;熔渗金属粉末:3%水雾化Fe粉、3%Zn、0.6%微粉蜡、余量为Cu%;
(2)混料:将配比好的基体金属粉末与熔渗金属粉末分别混合均匀;
(3)压制:将混合均匀的基体金属粉末按图纸压制成基体金属,由于渗铜烧结后零件尺寸膨胀较大,所以模具设计时要计算模具裕量,密度为6.9g/cm3;将混合好的熔渗金属粉末取重量为压制好的基体金属重量的19%,以同一模具压制成熔渗金属,密度以成型摆放不破碎为准;
(4)烧结:将熔渗金属与基体金属上下摆放于推舟内,相互之间不要接触,上面盖铁板,加木炭,烧结成型;烧结参数为:氨分解气氛的推杆式烧结炉,每50~60分钟送入一舟进行烧结,脱脂段与烧结段气流量控制0.3m3/h;烧结段温度为:一段:180℃,二段:280℃,三段:480℃,四段:700℃,五段:900~1200℃;
(5)热处理:烧结出炉的零件热处理,淬火后低温回火(170~200℃),硬度HRC40~47,压缩屈服强度值(0.1%/MPa)1210。
本发明通过一系列配方、工艺,将影响天然气气门座圈磨损因素与机理,耐热性、耐高温腐蚀性、自润滑性、高温强度等性能大幅提高,实践中已解决天然气气门座圈使用中快速失效问题。
Claims (3)
1.一种天然气发动机气门座制备方法,其特征是包括如下步骤:
(1)配料:将基体金属粉末和熔渗金属粉末分别按如下质量百分比进行配比:
基体金属粉末:1~2%C、3~8%FeCr、10~18%FeMo、2~6%Co、1~5%W、0.5~2%FeV、1~5%Cu、0.4~1.5%微粉蜡、余量为水雾化Fe粉;
熔渗金属粉末:1~5%水雾化Fe粉、1~5%Zn、0.2~1%微粉蜡、余量为Cu;
(2)混料:将配比好的基体金属粉末与熔渗金属粉末分别混合均匀;
(3)压制:将混合均匀的基体金属粉末压制成基体金属;将混合好的熔渗金属粉末取重量为压制好的基体金属重量的16~22%,以同一模具压制成熔渗金属;
(4)烧结:将熔渗金属与基体金属上下摆放于推舟内,烧结成型;
(5)热处理:烧结出炉的零件热处理,淬火后170~200℃低温回火。
2.根据权利要求1所述的天然气发动机气门座制备方法,其特征在于所述基体金属密度为6.6~7.1g/cm3。
3.根据权利要求1所述的天然气发动机气门座制备方法,其特征在于所述步骤(4)中的烧结参数为:氨分解气氛的推杆式烧结炉,每50~60分钟送入一舟进行烧结,脱脂段与烧结段气流量控制0.3~0.5m3/h;烧结段温度为:一段:180℃,二段:280℃,三段:480℃,四段:700℃,五段:900~1200℃。
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