CN106498298A - 一种回转阀门用活塞杆的加工工艺 - Google Patents
一种回转阀门用活塞杆的加工工艺 Download PDFInfo
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Abstract
本发明涉及一种回转阀门用活塞杆的加工工艺,包括以下步骤:㈠配料:㈡高压铸造;㈢锻打;㈣车加工;㈤热处理;㈥超声波清洗;㈦电镀;㈧在锌镍合金镀层外表面涂覆耐磨金属涂层。由于高压铸造时由于液态金属充填型腔速度高,流态不稳定,故采用一般压铸法,铸件易产生气孔,不能进行热处理,本发明的回转阀门用活塞杆的加工工艺通过对活塞杆进行锻打处理,去除了铸件的气孔,使得毛培可以进行热处理,使得最终得到的活塞杆物理性能更好,更加耐用。
Description
技术领域
本发明涉及一种回转阀门用活塞杆的加工工艺,属于阀门驱动装置技术领域。
背景技术
部分回转阀门电动执行器,又叫部分回转阀门电动装置,简称Q型电装,是一种控制阀门及其类似设备实现开启、关闭或调节控制的驱动设备;广泛应用于电力、冶金、石油、化工、食品、造纸、制药、水厂和污水处理等行业,适用于蝶阀、球阀、旋塞阀、等作90°回转的阀门及其类似设备;如果加支架可以作为角行程电动执行器使用,如用于风门,挡板门,烟气挡板门及其类似设备。
活塞杆是部分回转阀门电动执行器的重要零件之一,活塞杆质量的好差对于部分回转阀门的稳定工作和使用寿命具有很大影响。
发明内容
本发明要解决的技术问题是,针对现有技术不足,提出一种强度高并且耐腐蚀性能好的回转阀门用活塞杆。
本发明为解决上述技术问题提出的技术方案是:一种回转阀门用活塞杆的加工工艺,包括以下步骤:
㈠配料:所述活塞杆中各成分的质量百分比为:C:0.09-0.15%、Al:3.54-4.53%、Mn:1.21-1.42%、Sn:0.81-1.27%、Cr:0.13-0.16%、Ni:1.33-1.56%、Zn:1.25-1.66%、Zr:0.25-0.46%、Cu:1.15-1.36%、Mo:0.05-0.11%、Re:0.02-0.05%、Lu:0.03-0.12%、Ti:1.02-1.05%、Pd:0.03-0.05%、Eu:0.02-0.06%、Pt:0.15-0.19%、Au:0.16-0.18%、W:1.11-1.18%、Nd:0.01-0.03%、Ce:0.04-0.07%、S:≤0.020%、P:≤0.020%、氧化镁:0.28-0.36%、碳化钨:0.31-0.47%,余量为Fe;
㈡高压铸造:通过高压铸造制出活塞杆毛培;
㈢锻打:利用锻打的方式将活塞杆毛培锻打精炼,锻打温度为950-1070℃;
㈣车加工:通过车床将毛培车成预定规格的活塞杆;
㈤热处理:采用淬火-加热-回火的热处理工艺,具体热处理工艺为:
淬火:将活塞杆放入真空淬火炉进行淬火,淬火介质为真空淬火油,控制淬火温度为950-1000℃,淬火后冷到290-310℃时,取出空冷至室温;
加热:将淬火后的活塞杆放入加热炉进行加热,加热温度为850-890℃,加热10分钟后停止加热,使活塞杆在加热炉内利用余热维持在680-710℃保温15分钟,将活塞杆取出进行冷却,先采用水冷以18-22℃/s的冷却速率将活塞杆水冷至室温;
回火:将加热后的活塞杆放入真空回火炉进行回火,控制回火温度为650-670℃,回火时间12-18分钟,然后空冷至室温;
㈥超声波清洗:将活塞杆置于浓度为15%~20%的氯化钠溶液中,利用超声波发生装置对所述氯化钠溶液施加超声波,超声波的频率和声强分别是17KHZ~27MHZ和8~15W/cm2;
㈦电镀:在活塞杆表面通过电镀锌镍合金镀层,锌镍合金镀层厚度为60±20μm;
㈧在锌镍合金镀层外表面涂覆耐磨金属涂层,所述耐磨金属涂层的组分按质量百分比为:碳:0.12-0.15%,硼:0.1-0.3%,铬:3.2-3.4%,钛:3.2-3.5%,钒:1.5-1.8%,钴:2.5-2.8%,铌:0.2-0.5%,钙:1.42-1.46%,钡:0.21-0.24%,钨:0.12-0.14%,锌:1.2-1.5%,钐:3.5-3.8%,钕:2.2-2.7%,钷:0.32-0.35%,铕:0.22-0.24%,钆:5.2-5.5%,铝:1.1-1.8%,余量为铁;
涂覆耐磨金属涂层按以下步骤进行:
步骤(1):将碳、硼、铬、钛、钒、钴、铌、钙、钡和铁元素放入熔炼炉中,然后将炉温升至620-630℃后,保温1-3小时,然后将温度升至1350-1360℃,放入钨、锌、钐、钕、钷、铕、钆、铝元素,搅拌均匀,保温3-5小时,然后空冷至室温;
步骤(2):将熔炼炉中原料的温度增加至1420-1430℃,保温6-10h,全程吹氮气搅拌,然后将温度降至为620-640℃;然后水冷以18-21℃/s的速度冷却至450-460℃,然后空冷至室温;
步骤(3):将步骤(2)得到的金属放入球磨机中,将温度增加至520-550℃,然后启动球磨机磨粉,粉碎,过100目筛,得粉末颗粒A;
步骤(4):将步骤(3)中的粉末颗粒A喷涂至回转阀门用活塞杆的锌镍合金镀层外表面,厚度为1-3mm,然后以15-20℃/min的速度加热至750-770℃,保温1-2小时,再将温度以11-13℃/min的速度风冷至220-250℃,保温1-2小时,空冷至室温即可。
上述技术方案的改进是:所述步骤㈠中活塞杆中各成分的质量百分比为:C:0.09%、Al:3.56%、Mn:1.23%、Sn:0.85%、Cr:0.16%、Ni:1.35%、Zn:1.26%、Zr:0.28%、Cu:1.17%、Mo:0.06%、Re:0.03%、Lu:0.05%、Ti:1.04%、Pd:0.03%、Eu:0.04%、Pt:0.16%、Au:0.17%、W:1.12%、Nd:0.02%、Ce:0.05%、S:≤0.020%、P:≤0.020%、氧化镁:0.29%、碳化钨:0.34%,余量为Fe。
上述技术方案的改进是:所述步骤㈠中活塞杆中各成分的质量百分比为:C:0.15%、Al:4.53%、Mn:1.37%、Sn:1.21%、Cr:0.15%、Ni:1.52%、Zn:1.63%、Zr:0.41%、Cu:1.32%、Mo:0.08%、Re:0.04%、Lu:0.09%、Ti:1.05%、Pd:0.04%、Eu:0.05%、Pt:0.17%、Au:0.18%、W:1.18%、Nd:0.02%、Ce:0.05%、S:≤0.020%、P:≤0.020%、氧化镁:0.36%、碳化钨:0.47%,余量为Fe。
本发明采用上述技术方案的有益效果是:
(1)本发明的回转阀门用活塞杆由于原料中含有Zn、Ni和W,加强了活塞杆的耐热和耐腐蚀性能;
(2)本发明的回转阀门用活塞杆由于原料中含有Ti、Al和稀土元素,减轻了活塞杆的质量,增加了结构强度和耐腐蚀性能;
(3)本发明的回转阀门用活塞杆的加工工艺,通过热处理工艺,可控制活塞杆向与纵向凹陷造成的表面裂纹,并可使活塞杆表面层产生与工作应力相反的残余应力,受载时可抵消部分工作应力,大大提高了活塞杆的耐疲劳性能,延长了活塞杆的使用寿命
(4)由于高压铸造时由于液态金属充填型腔速度高,流态不稳定,故采用一般压铸法,铸件易产生气孔,不能进行热处理,本发明通过对活塞杆进行锻打处理,去除了铸件的气孔,使得毛培可以进行热处理,使得最终得到的活塞杆物理性能更好,更加耐用;
(5)通过锌镍合金镀层和耐磨金属涂层的配合,在提高了活塞杆的耐腐蚀性能的同时提高了活塞杆的耐磨性能,进一步延长了活塞杆的使用寿命。
具体实施方式
实施例1
本实施例提供了一种回转阀门用活塞杆的加工工艺,包括以下步骤:
㈠配料:所述活塞杆中各成分的质量百分比为:C:0.09%、Al:3.56%、Mn:1.23%、Sn:0.85%、Cr:0.16%、Ni:1.35%、Zn:1.26%、Zr:0.28%、Cu:1.17%、Mo:0.06%、Re:0.03%、Lu:0.05%、Ti:1.04%、Pd:0.03%、Eu:0.04%、Pt:0.16%、Au:0.17%、W:1.12%、Nd:0.02%、Ce:0.05%、S:≤0.020%、P:≤0.020%、氧化镁:0.29%、碳化钨:0.34%,余量为Fe;
㈡高压铸造:通过高压铸造制出活塞杆毛培;
㈢锻打:利用锻打的方式将活塞杆毛培锻打精炼,锻打温度为950-1070℃;
㈣车加工:通过车床将毛培车成预定规格的活塞杆;
㈤热处理:采用淬火-加热-回火的热处理工艺,具体热处理工艺为:
淬火:将活塞杆放入真空淬火炉进行淬火,淬火介质为真空淬火油,控制淬火温度为950-1000℃,淬火后冷到290-310℃时,取出空冷至室温;
加热:将淬火后的活塞杆放入加热炉进行加热,加热温度为850-890℃,加热10分钟后停止加热,使活塞杆在加热炉内利用余热维持在680-710℃保温15分钟,将活塞杆取出进行冷却,先采用水冷以18-22℃/s的冷却速率将活塞杆水冷至室温;
回火:将加热后的活塞杆放入真空回火炉进行回火,控制回火温度为650-670℃,回火时间12-18分钟,然后空冷至室温;
㈥超声波清洗:将活塞杆置于浓度为15%~20%的氯化钠溶液中,利用超声波发生装置对所述氯化钠溶液施加超声波,超声波的频率和声强分别是17KHZ~27MHZ和8~15W/cm2;
㈦电镀:在活塞杆表面通过电镀锌镍合金镀层,锌镍合金镀层厚度为60±20μm;;
㈧在锌镍合金镀层外表面涂覆耐磨金属涂层,所述耐磨金属涂层的组分按质量百分比为:碳:0.12-0.15%,硼:0.1-0.3%,铬:3.2-3.4%,钛:3.2-3.5%,钒:1.5-1.8%,钴:2.5-2.8%,铌:0.2-0.5%,钙:1.42-1.46%,钡:0.21-0.24%,钨:0.12-0.14%,锌:1.2-1.5%,钐:3.5-3.8%,钕:2.2-2.7%,钷:0.32-0.35%,铕:0.22-0.24%,钆:5.2-5.5%,铝:1.1-1.8%,余量为铁;
涂覆耐磨金属涂层按以下步骤进行:
步骤(1):将碳、硼、铬、钛、钒、钴、铌、钙、钡和铁元素放入熔炼炉中,然后将炉温升至620-630℃后,保温1-3小时,然后将温度升至1350-1360℃,放入钨、锌、钐、钕、钷、铕、钆、铝元素,搅拌均匀,保温3-5小时,然后空冷至室温;
步骤(2):将熔炼炉中原料的温度增加至1420-1430℃,保温6-10h,全程吹氮气搅拌,然后将温度降至为620-640℃;然后水冷以18-21℃/s的速度冷却至450-460℃,然后空冷至室温;
步骤(3):将步骤(2)得到的金属放入球磨机中,将温度增加至520-550℃,然后启动球磨机磨粉,粉碎,过100目筛,得粉末颗粒A;
步骤(4):将步骤(3)中的粉末颗粒A喷涂至回转阀门用活塞杆的锌镍合金镀层外表面,厚度为1-3mm,然后以15-20℃/min的速度加热至750-770℃,保温1-2小时,再将温度以11-13℃/min的速度风冷至220-250℃,保温1-2小时,空冷至室温即可。
实施例2
本实施例提供了一种回转阀门用活塞杆的加工工艺,包括以下步骤:
㈠配料:所述活塞杆中各成分的质量百分比为:C:0.15%、Al:4.53%、Mn:1.37%、Sn:1.21%、Cr:0.15%、Ni:1.52%、Zn:1.63%、Zr:0.41%、Cu:1.32%、Mo:0.08%、Re:0.04%、Lu:0.09%、Ti:1.05%、Pd:0.04%、Eu:0.05%、Pt:0.17%、Au:0.18%、W:1.18%、Nd:0.02%、Ce:0.05%、S:≤0.020%、P:≤0.020%、氧化镁:0.36%、碳化钨:0.47%,余量为Fe;
㈡高压铸造:通过高压铸造制出活塞杆毛培;
㈢锻打:利用锻打的方式将活塞杆毛培锻打精炼,锻打温度为950-1070℃;
㈣车加工:通过车床将毛培车成预定规格的活塞杆;
㈤热处理:采用淬火-加热-回火的热处理工艺,具体热处理工艺为:
淬火:将活塞杆放入真空淬火炉进行淬火,淬火介质为真空淬火油,控制淬火温度为950-1000℃,淬火后冷到290-310℃时,取出空冷至室温;
加热:将淬火后的活塞杆放入加热炉进行加热,加热温度为850-890℃,加热10分钟后停止加热,使活塞杆在加热炉内利用余热维持在680-710℃保温15分钟,将活塞杆取出进行冷却,先采用水冷以18-22℃/s的冷却速率将活塞杆水冷至室温;
回火:将加热后的活塞杆放入真空回火炉进行回火,控制回火温度为650-670℃,回火时间12-18分钟,然后空冷至室温;
㈥超声波清洗:将活塞杆置于浓度为15%~20%的氯化钠溶液中,利用超声波发生装置对所述氯化钠溶液施加超声波,超声波的频率和声强分别是17KHZ~27MHZ和8~15W/cm2;
㈦电镀:在活塞杆表面通过电镀锌镍合金镀层,锌镍合金镀层厚度为60±20μm;
㈧在锌镍合金镀层外表面涂覆耐磨金属涂层,所述耐磨金属涂层的组分按质量百分比为:碳:0.12-0.15%,硼:0.1-0.3%,铬:3.2-3.4%,钛:3.2-3.5%,钒:1.5-1.8%,钴:2.5-2.8%,铌:0.2-0.5%,钙:1.42-1.46%,钡:0.21-0.24%,钨:0.12-0.14%,锌:1.2-1.5%,钐:3.5-3.8%,钕:2.2-2.7%,钷:0.32-0.35%,铕:0.22-0.24%,钆:5.2-5.5%,铝:1.1-1.8%,余量为铁;
涂覆耐磨金属涂层按以下步骤进行:
步骤(1):将碳、硼、铬、钛、钒、钴、铌、钙、钡和铁元素放入熔炼炉中,然后将炉温升至620-630℃后,保温1-3小时,然后将温度升至1350-1360℃,放入钨、锌、钐、钕、钷、铕、钆、铝元素,搅拌均匀,保温3-5小时,然后空冷至室温;
步骤(2):将熔炼炉中原料的温度增加至1420-1430℃,保温6-10h,全程吹氮气搅拌,然后将温度降至为620-640℃;然后水冷以18-21℃/s的速度冷却至450-460℃,然后空冷至室温;
步骤(3):将步骤(2)得到的金属放入球磨机中,将温度增加至520-550℃,然后启动球磨机磨粉,粉碎,过100目筛,得粉末颗粒A;
步骤(4):将步骤(3)中的粉末颗粒A喷涂至回转阀门用活塞杆的锌镍合金镀层外表面,厚度为1-3mm,然后以15-20℃/min的速度加热至750-770℃,保温1-2小时,再将温度以11-13℃/min的速度风冷至220-250℃,保温1-2小时,空冷至室温即可。
本发明不局限于上述实施例。凡采用等同替换形成的技术方案,均落在本发明要求的保护范围。
Claims (3)
1.一种回转阀门用活塞杆的加工工艺,其特征在于:包括以下步骤:
㈠配料:所述活塞杆中各成分的质量百分比为:C:0.09-0.15%、Al:3.54-4.53%、Mn:1.21-1.42%、Sn:0.81-1.27%、Cr:0.13-0.16%、Ni:1.33-1.56%、Zn:1.25-1.66%、Zr:0.25-0.46%、Cu:1.15-1.36%、Mo:0.05-0.11%、Re:0.02-0.05%、Lu:0.03-0.12%、Ti:1.02-1.05%、Pd:0.03-0.05%、Eu:0.02-0.06%、Pt:0.15-0.19%、Au:0.16-0.18%、W:1.11-1.18%、Nd:0.01-0.03%、Ce:0.04-0.07%、S:≤0.020%、P:≤0.020%、氧化镁:0.28-0.36%、碳化钨:0.31-0.47%,余量为Fe;
㈡高压铸造:通过高压铸造制出活塞杆毛培;
㈢锻打:利用锻打的方式将活塞杆毛培锻打精炼,锻打温度为950-1070℃;
㈣车加工:通过车床将毛培车成预定规格的活塞杆;
㈤热处理:采用淬火-加热-回火的热处理工艺,具体热处理工艺为:
淬火:将活塞杆放入真空淬火炉进行淬火,淬火介质为真空淬火油,控制淬火温度为950-1000℃,淬火后冷到290-310℃时,取出空冷至室温;
加热:将淬火后的活塞杆放入加热炉进行加热,加热温度为850-890℃,加热10分钟后停止加热,使活塞杆在加热炉内利用余热维持在680-710℃保温15分钟,将活塞杆取出进行冷却,先采用水冷以18-22℃/s的冷却速率将活塞杆水冷至室温;
回火:将加热后的活塞杆放入真空回火炉进行回火,控制回火温度为650-670℃,回火时间12-18分钟,然后空冷至室温;
㈥超声波清洗:将活塞杆置于浓度为15%~20%的氯化钠溶液中,利用超声波发生装置对所述氯化钠溶液施加超声波,超声波的频率和声强分别是17KHZ~27MHZ和8~15W/cm2;
㈦电镀:在活塞杆表面通过电镀锌镍合金镀层,锌镍合金镀层厚度为60±20μm;
㈧在锌镍合金镀层外表面涂覆耐磨金属涂层,所述耐磨金属涂层的组分按质量百分比为:碳:0.12-0.15%,硼:0.1-0.3%,铬:3.2-3.4%,钛:3.2-3.5%,钒:1.5-1.8%,钴:2.5-2.8%,铌:0.2-0.5%,钙:1.42-1.46%,钡:0.21-0.24%,钨:0.12-0.14%,锌:1.2-1.5%,钐:3.5-3.8%,钕:2.2-2.7%,钷:0.32-0.35%,铕:0.22-0.24%,钆:5.2-5.5%,铝:1.1-1.8%,余量为铁;
涂覆耐磨金属涂层按以下步骤进行:
步骤(1):将碳、硼、铬、钛、钒、钴、铌、钙、钡和铁元素放入熔炼炉中,然后将炉温升至620-630℃后,保温1-3小时,然后将温度升至1350-1360℃,放入钨、锌、钐、钕、钷、铕、钆、铝元素,搅拌均匀,保温3-5小时,然后空冷至室温;
步骤(2):将熔炼炉中原料的温度增加至1420-1430℃,保温6-10h,全程吹氮气搅拌,然后将温度降至为620-640℃;然后水冷以18-21℃/s的速度冷却至450-460℃,然后空冷至室温;
步骤(3):将步骤(2)得到的金属放入球磨机中,将温度增加至520-550℃,然后启动球磨机磨粉,粉碎,过100目筛,得粉末颗粒A;
步骤(4):将步骤(3)中的粉末颗粒A喷涂至回转阀门用活塞杆的锌镍合金镀层外表面,厚度为1-3mm,然后以15-20℃/min的速度加热至750-770℃,保温1-2小时,再将温度以11-13℃/min的速度风冷至220-250℃,保温1-2小时,空冷至室温即可。
2.根据权利要求1所述的回转阀门用活塞杆的加工工艺,其特征在于:所述步骤㈠中活塞杆中各成分的质量百分比为:C:0.09%、Al:3.56%、Mn:1.23%、Sn:0.85%、Cr:0.16%、Ni:1.35%、Zn:1.26%、Zr:0.28%、Cu:1.17%、Mo:0.06%、Re:0.03%、Lu:0.05%、Ti:1.04%、Pd:0.03%、Eu:0.04%、Pt:0.16%、Au:0.17%、W:1.12%、Nd:0.02%、Ce:0.05%、S:≤0.020%、P:≤0.020%、氧化镁:0.29%、碳化钨:0.34%,余量为Fe。
3.根据权利要求1所述的回转阀门用活塞杆的加工工艺,其特征在于:所述步骤㈠中活塞杆中各成分的质量百分比为:C:0.15%、Al:4.53%、Mn:1.37%、Sn:1.21%、Cr:0.15%、Ni:1.52%、Zn:1.63%、Zr:0.41%、Cu:1.32%、Mo:0.08%、Re:0.04%、Lu:0.09%、Ti:1.05%、Pd:0.04%、Eu:0.05%、Pt:0.17%、Au:0.18%、W:1.18%、Nd:0.02%、Ce:0.05%、S:≤0.020%、P:≤0.020%、氧化镁:0.36%、碳化钨:0.47%,余量为Fe。
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