CN107893228A - 一种钛合金齿轮及其制备方法 - Google Patents
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Abstract
本发明提供了一种钛合金齿轮的制备方法,包括:采用3D打印的方法制备得到钛合金齿轮基体;将所述钛合金齿轮基体进行热等静压处理,得到钛合金齿轮坯体;采用熔覆的方法在所述钛合金齿轮坯体表面形成硬化层,得到钛合金齿轮,所述硬化层的厚度为1~2mm。本发明提供的钛合金齿轮的制备方法通过进行热等静压处理能够改善齿轮基体的力学性能,同时通过采用熔覆的方法能够在齿轮基体表面形成厚度较大的硬化层,本发明通过上述工艺制备得到的钛合金齿轮表面硬度高、摩擦系数低,耐磨损,抗冲击同时疲劳性能强,适用于航空航天、汽车工业等行业的齿轮传动设备。
Description
技术领域
本发明涉及齿轮技术领域,尤其涉及一种钛合金齿轮及其制备方法。
背景技术
齿轮传动是应用最为广泛的一种传动机构,随着现代工业水平的发展,齿轮传动正朝着低速重载和高速重载的两个方向发展,对齿轮的性能要求越来越高,要求其具有高功率密度、长寿命、高可靠性等特点。
目前普遍使用的高性能齿轮一般由低碳、中碳合金钢锻件,采用滚齿或插齿成形,再经渗碳、渗氮热处理方式获得表面硬化层,最后通过磨齿到达要求的齿轮设计精度。
现有技术所制备的齿轮,虽然能满足使用要求,但是其热处理工艺过程复杂,而且热处理过程中变形大,容易出现组织缺陷和渗层不均匀等问题,影响其使用性能。另外,对于大螺旋角内齿轮、无退刀槽人字齿和双联齿轮等复杂结构齿轮,采用滚齿或插齿进行加工难度大。而且,常规渗碳、渗氮齿轮的表面硬度和疲劳强度依然较低,限制了齿轮在耐磨性、功率密度和使用寿命上的进一步提高。
发明内容
有鉴于此,本发明的目的在于提供一种钛合金齿轮及其制备方法,本发明提供的方法制备得到的钛合金齿轮表面硬度高、摩擦系数低,耐磨损,抗冲击。
本发明提供了一种钛合金齿轮,包括:
钛合金齿轮基体;
附着在所述钛合金齿轮基体表面的硬化层。
在本发明中,所述钛合金齿轮基体的成分优选为α+β相钛合金,在本发明中,所述钛合金齿轮基体的成分优选为:
5.2~6.8wt%的Al;1.6~2.5wt%的Sn;1.6~2.5wt%的Zr;2.0~3.3wt%的Mo;0.9~2.0wt%的Cr;1.0~2.0wt%的Nb;0.05~0.15wt%的Si;余量为Ti。
所述钛合金齿轮基体的成分更优选为:
5.5~6.5wt%的Al;2.0~2.5wt%的Sn;2.0~2.5wt%的Zr;2.0~2.5wt%的Mo;1.5~2.0wt%的Cr;1.0~1.5wt%的Nb;0.08~0.12wt%的Si;余量为Ti;
所述钛合金齿轮基体的成分最优选为TC21牌号的钛合金即Ti-6Al-2Sn-2Zr-2Mo-2Cr-1Nb-0.1Si成分的钛合金:
6wt%的Al;2wt%的Sn;2wt%的Zr;2wt%的Mo;2wt%的Cr;1wt%的Nb;0.1wt%的Si;余量为Ti。
在本发明中,所述硬化层为硬度高、耐磨性好、摩擦系数低的硬化层。在本发明中,所述硬化层的厚度优选为1~2mm,更优选为1.2~1.8mm,最优选为1.4~1.6mm。在本发明中,所述硬化层的成分优选包括TiC、Ti和Ni;所述TiC在硬化层中的质量含量优选为35~45%,更优选为38~42%,最优选为40%;所述Ti在硬化层中的质量含量优选为35%~45%,更优选为38~42%,最优选为40%;所述Ni在硬化层中的质量含量优选为10%~30%,更优选为15~25%,最优选为20%。在本发明中,所述硬化层中的合金元素TiC的含量由表及里梯度降低,即硬化层表面TiC含量最高,越接近钛合金齿轮基体,TiC含量越低。
在本发明中,所述钛合金齿轮可以为直齿轮、斜齿轮、人字齿轮、锥齿轮等。
在本发明中,所述钛合金齿轮按照下述方法制备得到,本发明提供了一种钛合金齿轮的制备方法,包括:
采用3D打印的方法制备得到钛合金齿轮基体;
将所述钛合金齿轮基体进行热等静压处理,得到钛合金齿轮坯体;
采用熔覆的方法在所述钛合金齿轮坯体表面形成硬化层,得到钛合金齿轮。
在本发明中,所述3D打印的方法优选为电子束选区熔化成形技术、激光熔化沉积成形技术或激光选区熔化沉积技术,更优选为电子束选区熔化成形技术,即利用超高动能电子束轰击钛合金粉末,将钛合金粉末熔化,依照设计加工逐层累积,以冶金结合的方式使相邻两层紧密结合,直至生产出完整形状的齿轮基体。在本发明中,所述钛合金粉末的成分即为上述技术方案所述的钛合金齿轮基体的成分,在此不再赘述。本发明对所述钛合金粉末的来源没有特殊的限制,可由市场购买获得,如可购买中航迈特粉冶科技有限公司提供的TC21钛合金粉末。
在本发明中,所述钛合金粉末粒度优选为45~106μm,更优选为75~90μm,最优选为45~75μm。在本发明中,所述电子束选区熔化成形过程中的工作功率优选为250~3000W,更优选为500~1000W,更优选为1000~2000W,最优选为2000~3000W;扫描速率优选为500~5800mm/s,更优选为500~2000mm/s,最优选为2000~5800mm/s;光斑直径优选为100~400μm,更优选为150~350μm,最优选为200~300μm;铺粉厚度优选为50~200μm,更优选为50~100μm,最优选为50μm。
在本发明中,所述热等静压优选在热等静压炉中进行;所述热等静压的加热温度优选为900~1000℃,更优选为920~980℃,最优选为940~960℃;所述热等静压的工作压力优选为110~130MPa,更优选为115~125MPa,最优选为120MPa。在本发明中,经热等静压处理的钛合金齿轮基体的孔隙率低、致密性高、均匀性好、性能优异。
在本发明中,所述熔覆的方法优选为激光熔覆或离子熔覆,更优选为激光熔覆。在本发明中,所述激光熔覆的熔覆粉体包括钛粉、镍粉和碳化钛粉;所述钛粉、镍粉和碳化钛粉的质量比优选为(35~45):(35~45):(10~30),更优选为(38~42):(38~42):(15~25),最优选为40:40:20。在本发明中,所述激光熔覆过程钛粉和镍粉被熔化为液体,碳化钛粉发生部分熔化,弥散为许多小的TiC球,镍的密度(约8.0g/cm3以上)大于TiC的密度(约4.93g/cm3),熔覆层因各成分的密度不同形成一定的TiC梯度,即靠近钛合金齿轮基体部分的球形TiC分布较少,远离钛合金齿轮基体即硬化层表面TiC的分布较多。另外,由于激光熔覆过程中激光能量较为集中,致使钛合金齿轮基体表面发生部分熔化,也帮助了球形TiC梯度的形成,本发明实施例制备的钛合金齿轮的硬化层中表层TiC形貌见附图1如图1所示。在本发明中,所述激光熔覆方法制备得到的TiC梯度分布的硬化层具有更高的显微硬度,显微硬度可达到HV800~1000。
在本发明中,所述激光熔覆过程中的功率优选为2~3Kw,更优选为2.3~2.5Kw,最优选为2.0~2.3Kw;扫描速度优选为2~5mm/s,更优选为3~4mm/s,最优选为3.5mm/s;光束直径优选为2.5~4mm,更优选为3~3.5mm;送粉速度优选为4~6g/min,更优选为4.5~5.5g/min,最优选为5g/min。
在本发明中,在所述钛合金齿轮坯体表面形成硬化层后本发明优选对所述钛合金齿轮坯体采用数控磨齿机磨削达到所需的成品钛合金齿轮的设计精度要求,如几何精度和表面精度要求。在本发明中,所述磨削过程中采用的砂轮优选为CBN砂轮,所述砂轮磨削的线速度优选为80~120m/s,更优选为100~120m/s,最优选为120m/s;磨削深度优选为0.01~0.02mm,更优选为0.01mm;工件速度优选为0.7~2.5mm/min,更优选为0.7~1mm/min,最优选为0.7mm/min。
本发明采用钛合金作为齿轮的基体材料,可以提高齿轮传动件的功率密度。在本发明中,钛合金具有密度小、比强度高、耐蚀性和抗蠕变性强等优点,本发明采用钛合金作为齿轮的基体材料,与钢合金相比,在传动相同功率载荷的情况下,可以使齿轮传动具有更高的功率密度,体积更小,重量轻。
现有技术对于大螺旋角内齿轮、无退刀槽人字齿和双联齿轮等复杂结构齿轮采用常规的滚齿和插齿工艺成形,需制作特殊的工装夹具,加工成本高且加工难度大,甚至无法实现。本发明采用3D打印成形制备钛合金齿轮基体,可适应任何复杂结构的齿轮成形,无需特殊的工装夹具。
在本发明中,采用所述热等静压处理,能够降低齿轮成形件的孔隙率,提高致密度,改善齿轮基体的力学性能。
传统合金齿轮的制备,需要经过渗碳、渗氮等热处理工艺获得表面硬化层,热处理的周期长,热处理过程中变形大,容易出现组织缺陷和渗层不均匀等问题。本发明通过激光熔覆的方式在基体上熔覆一层硬度高、耐磨性好、摩擦系数低的硬化层,硬化层的厚度为1~2mm。本发明省去了传统的热处理工艺,齿轮的制造周期缩短,同时还可以获得较厚的硬化层。在本发明中,所述硬化层采用熔覆(如激光熔覆)的方式进行制备,解决了现有技术表面强化处理方式所普遍存在的硬化层薄的问题。
在本发明中,所述激光熔覆过程中的关键在于TiC使用的粘结金属用量及具体材料的选择,粘结金属过多,制得的改性层的硬度、耐磨性下降;粘结金属过少熔覆时易出现裂纹等缺陷。经过发明人的大量研究,根据Ni基合金和Ti金属对TiC具有良好的润湿性,且TiC在Ti中有一定的溶解度,能形成弥散分布的TiC相,强化熔覆层,因此选用Ni粉和Ti粉作为粘结金属。在用量上,由于耐磨相主要为块状或球状的TiC,因此,根据TiC的分布比例,确定各成分的加入量。同时在大量实验的基础上根据熔覆层的磨面结构、低倍金相结构确定熔覆工艺参数。
与现有技术相比,本发明提供的钛合金齿轮的制备方法无需进行热处理工序,解决了常规渗碳淬火或渗氮齿轮在热处理过程中变形大,渗层不均匀和组织缺陷等问题。而且,本发明中的钛合金齿轮基体采用3D打印的方式成形,解决了大螺旋角内齿轮、无退刀槽人字齿和双联齿轮等复杂齿轮加工难的问题。本发明提供的钛合金齿轮的制备方法具有制备得到的齿轮强度高、寿命长、摩擦系数低,耐磨损、而且加工周期短、制造成本低等优点。
本发明的关键在于,在制备钛合金齿轮过程中,钛合金齿轮基体采用3D打印方式成形;采用热等静压处理,降低基体组织孔隙率,改善其力学性能;采用激光熔覆的方式在基本表面形成TiC梯度分布的硬化层,而且硬化层厚度较大达到1~2mm。
本发明采用钛合金作为齿轮的基体材料,与钢合金相比,钛合金具有密度小、比强度高、耐蚀性和抗蠕变性强等优点。但单纯采用钛合金用于齿轮硬度低、耐磨性差,需要增加表面改性层,提高其表面硬度和耐磨性。本发明采用激光熔覆的方式在钛合金齿轮基体表面形成一层硬化层,以增加其表面硬度和耐磨性。本发明提出的表面改性钛合金齿轮与普通渗碳钢齿轮相比,在传动相同功率载荷的情况下,可以使齿轮传动具有更高的功率密度,体积更小,重量轻。
本发明提供的方法制备得到的钛合金齿轮,具有表面硬化高、摩擦系数低,耐磨损,抗冲击和疲劳性能强,使用寿命长等优点,适用于航空航天、汽车工业等行业的齿轮传动设备。
附图说明
图1为本发明实施例制备的钛合金齿轮硬化层中TiC的形貌。
具体实施方式
下面将对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员经改进或润饰的所有其它实例,都属于本发明保护的范围。
本发明以下实施例所用到的原料均为市售商品,所用的TC21钛合金粉末为中航迈特粉冶科技有限公司提供的,成分为:Ti-6Al-2Sn-2Zr-2Mo-2Cr-1Nb-0.1Si;粒度为45~75μm。
实施例1
3D打印成形:
运用电子束选区熔化成形技术,在工作功率3000W、扫描速率5300mm/s、光斑直径200μm、铺粉厚度50μm的条件下,将TC21钛合金粉末打印生成齿轮基体,与最终成形的齿轮相比,轮齿齿厚预留出1.6mm的厚度余量,用于后续激光熔覆形成表面硬化层。
热等静压处理:
将上述3D打印成形的钛合金齿轮基体放入热等静压炉中,加热温度为950℃,工作压力120MPa,保压时间60min,得到齿轮坯体。
激光熔覆生产表面硬化层:
将球形TiC粉、Ti粉和Ni粉按40:40:20的比例混合,在功率2000W,扫描速度3.5mm/s,保护气流量2.5L/min,光束直径3mm,送粉速度5g/min的条件下,在上述齿轮坯体表面熔覆形成1.6mm厚的硬化层。
齿轮磨削成形:
将上述激光熔覆完成后带硬化层的齿轮,在NILES 400磨齿机上进行成形磨齿,砂轮采用CBN砂轮,砂轮磨削线速度为120m/s,磨削深度0.01mm,工件速度为0.7mm/min,最终磨削达到齿轮设计规定的尺寸要求。
实施例2
3D打印成形:
运用电子束选区熔化成形技术,在工作功率3000W、扫描速率5300mm/s、光斑直径200μm、铺粉厚度50μm的条件下,将TC21钛合金粉末打印生成齿轮基体,与最终成形的齿轮相比,轮齿齿厚预留出1.6mm的厚度余量,用于后续激光熔覆形成表面硬化层。
热等静压处理:
将上述3D打印成形的钛合金齿轮基体放入热等静压炉中,加热温度为950℃,工作压力120MPa,保压时间60min,得到齿轮坯体。
激光熔覆生产表面硬化层:
将球形TiC粉、Ti粉和Ni粉按40:40:20的比例混合,在功率2500W,扫描速度2.5mm/s,保护气流量2.5L/min,光束直径2.5mm,送粉速度4.5g/min的条件下,在上述齿轮坯体表面熔覆形成1.6mm厚的硬化层。
齿轮磨削成形:
将上述激光熔覆完成后带硬化层的齿轮,在NILES 400磨齿机上进行成形磨齿,砂轮采用CBN砂轮,砂轮磨削线速度为120m/s,磨削深度0.01mm,工件速度为0.7mm/min,最终磨削达到齿轮设计规定的尺寸要求。
实施例3
测试本发明实施例1和实施例2制备得到的钛合金齿轮的性能,具体测试方法为:
表面硬度按照GB/T4340.1-2009《金属材料维氏硬度试验第1部分:试验方法》标准测试。
磨损性能按照GB/T 12444-2006《金属材料磨损试验方法试环-试块滑动磨损试验》标准测试。
接触疲劳性能按照GB/T 14229-93《齿轮接触疲劳强度试验方法》标准测试。
检测结果如表1所示,表1为本发明实施例1和实施例2制备得到的钛合金齿轮的性能检测结果。
表1本发明实施例1和实施例2制备得到的钛合金齿轮的性能检测结果
实施例1 | 实施例2 | |
表面硬度(HV) | 930-958 | 860-895 |
摩擦系数 | 0.22-0.25 | 0.26-0.3 |
磨损质量(mg) | 0.6 | 0.96 |
接触疲劳极限(MPa) | 1725-1810 | 1613-1690 |
以上所述的仅是本发明的优选实施方式,应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明原理的前提下,还可以做出若干改进和润饰,这些改进和润饰也应视为本发明的保护范围。
Claims (10)
1.一种钛合金齿轮的制备方法,包括:
采用3D打印的方法制备得到钛合金齿轮基体;
将所述钛合金齿轮基体进行热等静压处理,得到钛合金齿轮坯体;
采用熔覆的方法在所述钛合金齿轮坯体表面形成硬化层,得到钛合金齿轮;所述硬化层的厚度为1~2mm。
2.根据权利要求1所述的方法,其特征在于,所述3D打印的方法包括电子束选区熔化成形技术、激光熔化沉积成形技术或激光选区熔化沉积技术。
3.根据权利要求2所述的方法,其特征在于,所述3D打印的方法为电子束选区熔化成形技术;
所述电子束选区熔化成形过程中的工作功率为250~3000W;扫描速率为500~5800mm/s;光斑直径为100~400μm;铺粉厚度为50~200μm。
4.根据权利要求1所述的方法,其特征在于,所述热等静压的加热温度为900~1000℃;工作压力为110~130MPa。
5.根据权利要求1所述的方法,其特征在于,所述熔覆的方法包括激光熔覆或离子熔覆。
6.根据权利要求5所述的方法,其特征在于,所述熔覆的方法为激光熔覆;所述激光熔覆的熔覆粉体包括钛粉、镍粉和碳化钛粉;
所述钛粉、镍粉和碳化钛粉的质量比为(35~45):(35~45):(10~30)。
7.根据权利要求6所述的方法,其特征在于,所述激光熔覆过程中的功率为2~3Kw;扫描速度为2~5mm/s;光束直径为2.5~4mm;送粉速度4~6g/min。
8.一种权利要求1所述的方法制备得到的钛合金齿轮,包括:
钛合金齿轮基体;
附着在所述钛合金齿轮基体表面的硬化层;
所述硬化层的厚度为1~2mm。
9.根据权利要求8所述的钛合金齿轮,其特征在于,所述钛合金齿轮基体的成分为:
5.2~6.8wt%的Al;1.6~2.5wt%的Sn;1.6~2.5wt%的Zr;2.0~3.3wt%的Mo;0.9~2.0wt%的Cr;1.0~2.0wt%的Nb;0.05~0.15wt%的Si;余量为Ti。
10.根据权利要求8所述的钛合金齿轮,其特征在于,所述硬化层的成分包括TiC、Ti和Ni;
所述TiC在硬化层中的含量由硬化层表面到钛合金齿轮基体从多到少梯度分布。
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