CN108097928B - Preparation method of surface layer composite material - Google Patents
Preparation method of surface layer composite material Download PDFInfo
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- CN108097928B CN108097928B CN201711233117.4A CN201711233117A CN108097928B CN 108097928 B CN108097928 B CN 108097928B CN 201711233117 A CN201711233117 A CN 201711233117A CN 108097928 B CN108097928 B CN 108097928B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/02—Casting in, on, or around objects which form part of the product for making reinforced articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
- B22C9/046—Use of patterns which are eliminated by the liquid metal in the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/08—Casting in, on, or around objects which form part of the product for building-up linings or coverings, e.g. of anti-frictional metal
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/14—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted
- B28B1/16—Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted for producing layered articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/50—Producing shaped prefabricated articles from the material specially adapted for producing articles of expanded material, e.g. cellular concrete
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
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- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/02—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding chemical blowing agents
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/06—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances
- C04B38/063—Preparing or treating the raw materials individually or as batches
- C04B38/0635—Compounding ingredients
- C04B38/0645—Burnable, meltable, sublimable materials
- C04B38/067—Macromolecular compounds
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3231—Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
- C04B2235/3232—Titanium oxides or titanates, e.g. rutile or anatase
- C04B2235/3237—Substoichiometric titanium oxides, e.g. Ti2O3
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/38—Non-oxide ceramic constituents or additives
- C04B2235/3817—Carbides
- C04B2235/3821—Boron carbides
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/38—Non-oxide ceramic constituents or additives
- C04B2235/3817—Carbides
- C04B2235/3826—Silicon carbides
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Abstract
The invention relates to a surface layer composite material and a method thereof, belonging to the technical field of development and design of novel materials. According to the method, ceramic particles and additives are prepared into a cylindrical ceramic prefabricated body with component gradient change, the prefabricated body is embedded into a model through EPS (polystyrene foam) foaming, and a lost foam casting method is adopted to prepare the surface layer composite material. According to the invention, through the structural design of the ceramic particle reinforcement, the filling effect of the metal liquid in the composite layer is improved, so that the ceramic particles and the matrix have well combined interfaces, the gradient effect of the transition type interface is utilized, the tendency of crack initiation and expansion is reduced, the composite layer with good compactness is generated, and the purpose of enhancing the performance of the composite material is achieved.
Description
Technical Field
The invention discloses a surface layer composite material and a preparation method thereof, and belongs to the technical field of development and design of novel materials.
Background
A large number of abrasion working conditions exist in the industrial fields of mines, cement, building materials and the like, abrasion failure is a main failure mode of parts, and consumption of abrasion-resistant materials is very large. Taking the mine industry as an example, the consumption of wear-resistant materials is the second largest cost component next to the consumption of electricity. Therefore, under the abrasion working condition, how to improve the service performance of the abrasion-resistant material is an important research subject for realizing material saving and consumption reduction.
The abrasion of the material is started from the surface of the material, and the abrasion resistance of the surface of the abrasion-resistant material determines the service life of the abrasion-resistant material under an abrasion working condition, so that how to improve the abrasion resistance of the surface of the material is the key point of development and research of the abrasion-resistant material. Ceramic particle reinforced surface composite material knotCombines the good plastic toughness and supporting function of the metal matrix and the ultrahigh wear resistance of the high-hardness ceramic particles, and is the key research and development direction of wear-resistant materials. As Al having higher economical efficiency2O3Ceramic particles or a main component of Al2O3The ceramic particles have excellent service performance and application prospect. However, how to overcome the weak interface effect of the combination of the ceramic particles and the matrix, and reduce the defect caused by insufficient filling of the metal liquid in the composite layer, and the initiation and the expansion of cracks easily caused by the brittleness of the ceramic particles due to height are important propositions for the design and the research and development of the composite material of the reinforced surface layer of the ceramic particles.
Patent CN 106584959a discloses a high wear-resistant iron-aluminum layered composite material and a preparation method thereof, wherein a conical reinforcement is prefabricated, the volume fraction of the reinforcement from the outside to the inside is gradually reduced, so that the infiltration of a ceramic particle preform and a mother liquid metal is improved, and the ceramic particle preform and the mother liquid metal are stacked in layers, rolled and finally formed. The design components of the prefabricated body of the method are single, the combination between the prefabricated body and the substrate is still non-transitional combination, and the problem of wettability of ceramic particles and molten metal is not improved. Patent CN106367661A discloses a method for preparing a particle-reinforced iron-based surface composite material, which adopts the steps of spot plasma sintering, preheating casting and heat treatment to prepare a ceramic particle-reinforced iron-based composite material. The method has higher requirements on pretreatment equipment, the manufacturing process is complex, and the problem of optimizing the performance of the transition layer between the prefabricated body and the substrate is not solved. Patent CN106191496A discloses a method for preparing ZTA particle reinforced metal matrix wear-resistant composite material by powder metallurgy, which comprises the steps of coating ZTA particle surface with active metal element powder, mixing with metal matrix, cold press molding, and preparing the material by powder metallurgy. The method improves the interface problem by adding active metal element powder, is complicated in actual operation, and can only be used for powder molding.
Disclosure of Invention
The invention aims to provide a surface composite material, which adopts cast steel or cast iron as a base material, wherein the surface of a metal base material is provided with cylindrical ceramic particle reinforcements, and the ceramic particle reinforcements are arranged according to a honeycomb structure; the volume fraction of the ceramic particles in the ceramic particle reinforcement body is in a decreasing trend along the direction from the circle center to the cylindrical surface of the radius.
The invention also aims to provide a preparation method of the surface layer composite material, the surface layer composite material has an interface with good combination of ceramic particles and a matrix, can inhibit the initiation and the propagation of cracks of the ceramic particles through a transition interface with a gradient structure, and has good compactness of a composite layer; the method specifically comprises the following steps:
(1) forming a cylindrical ceramic preform: uniformly mixing ceramic particles, an activating agent and a binder to obtain mixed powder, and adding a pore-forming agent; filling mixed powder with different volume fractions of several ceramic particles into a layered die, wherein the volume fractions of the ceramic particles are in a decreasing trend along the direction from the circle center to the cylindrical surface; and removing the mold, and pressing the loose prefabricated body filled in layers into the prefabricated body with the volume fraction of the ceramic particles changing in a gradient manner along the radius direction.
(2) Preparing a composite material: placing the prefabricated body prepared in the step (1) at the bottom of an EPS foaming mold, arranging the prefabricated body according to a honeycomb structure, then carrying out EPS foaming, and embedding the foamed prefabricated body into the surface of an EPS model; and pouring the base metal liquid by adopting a lost foam casting method, wherein the prefabricated body becomes a reinforcement under the action of the metal liquid, and the surface composite material is obtained by forming the composite material.
Preferably, the layered mold structure of the present invention is a ring structure formed by a plurality of cylindrical molds nested together (as shown in fig. 6).
Preferably, the base metal is any one of high manganese steel, alloy steel, high chromium steel, high carbon steel, high chromium cast iron and nodular cast iron.
Preferably, the ceramic particles of the present invention are Al2O3The particles or main component being Al2O3The particle size of the particles is 20-80 meshes.
Preferably, the pore-forming agent in step (1) of the present invention is one or more of polyethylene, polystyrene, polyvinyl alcohol, and carbamide, based on the total volume of the mixed powderAdding 5-30%; the binder is PVA (polyvinyl alcohol), PAM (polyacrylamide) or phenolic resin, and the total amount is added according to 5-10% of the total mass of the mixed powder; the activator is high-carbon ferrochrome powder, Fe-based self-fluxing alloy powder, SiC powder, B4C powder, Ti2One or more of O powder is added according to 2-7% of the total mass of the mixed powder.
According to the invention, the structural parameters of the surface layer composite material can be adjusted by changing the geometric dimensions of the layering mold and the EPS foaming mold, and adjusting the dimension of the prefabricated body, so that the composite material with different structural parameters can be obtained, and the composite material is suitable for workpieces with different dimensions and different use working conditions; wherein the diameter phi of the prefabricated body is 5-30mm, the height h of the prefabricated body is 5-50mm, the number n of layers of the interface transition region is 2-6, the interlayer spacing d of the interface transition region is 1-5mm, and the distance l of the prefabricated body is 5-30 mm.
The invention has the beneficial effects that:
(1) the invention provides a surface layer composite material with a transition interface and a discontinuous composite layer structure through the structural design of a ceramic particle reinforcement, so that an interface with good combination is formed between ceramic particles and a matrix, and Al is solved2O3Ceramic particles or a main component of Al2O3The prepared wear-resistant material has better wettability, can effectively reduce the tendency of crack initiation and expansion, generates a composite layer with good compactness, and achieves the aim of improving the performance of the composite material.
(2) According to the method, the combination effect between the ceramic particles and the metal matrix is improved by adding the activating agent, the discontinuous structure is designed to improve the casting infiltration power of the composite material, the filling effect of the molten metal in the composite layer is improved, the tendency of crack initiation and expansion is reduced by utilizing the transition interface with the gradient structure, and the ceramic particle reinforced surface layer composite material with effective service performance is developed.
(3) The invention can be used for direct casting, can realize industrialized production by adding the prefabricated part into the casting mould, can save cost while ensuring the performance of the composite material by placing the honeycomb structure, and obtains greater industrial benefit. The invention can effectively exert the advantage of particle enhancement, does not need complex machinery and equipment in the manufacturing process, has simple production process and can quickly realize mass production. The material is mainly used in the fields of mine, cement, building materials and other industrial fields.
Drawings
FIG. 1 is a top view of a skin composite preform according to the present invention;
FIG. 2 is a cross-sectional view of a skin composite preform according to the present invention;
FIG. 3 is a cross-sectional view of an EPS model of the present invention;
FIG. 4 is a top view of an EPS model structure of the present invention;
FIG. 5 is a honeycomb unit of the present invention;
FIG. 6 is a schematic view of the mold for split-level packing of the present invention.
Detailed Description
In order to better understand the present invention, the following examples further illustrate the invention, the examples are only used for explaining the invention, not to constitute any limitation of the invention.
Example 1
A high wear-resistant composite material lining plate adopts cast steel and cast iron as base materials, the surface of a metal base material is provided with cylindrical ceramic particle reinforcements, and the ceramic particle reinforcements are arranged according to a honeycomb structure; the volume fraction of the ceramic particles in the ceramic particle reinforcement body is gradually decreased along the radius from the circle center to the cylindrical surface (as shown in figures 3-5).
Ceramic particle reinforcement core radius r0Is 7mm, and the thickness d of each layer is 2 mm; the ratio of the mixed ceramic particles and pore-forming agent from the outside toward the core is shown in Table 1.
TABLE 1 ratio of ceramic particles to pore-forming agent
The preparation method of the composite material lining plate specifically comprises the following steps:
(1) the composition is 90% Al2O3Particles, 5% PVA, 5% high carbon ferrochromium powder.
(2) Mechanically and uniformly mixing the mixed ceramic particles and the pore-forming agent according to the proportion in the table 1, and filling the mixed ceramic particles with different ceramic particle volume fractions into a layered die in a layered mode, wherein the filling structure is shown in fig. 6; removing the mould, and pressing the loose preform filled in layers into a preform with the volume fraction of ceramic particles changing in a gradient manner along the radius direction (as shown in figures 1 and 2) according to a certain pressure; (the diameter phi of the preform is 30mm, the height h of the preform is 40mm, the number n of layers of the interface transition zone is 4, and the interlayer spacing d of the interface transition zone is 5 mm).
(3) Placing the prefabricated body into an EPS foaming mould according to the position shown in figure 4, wherein the interval l of the prefabricated body is 5 mm; the foamed preform is embedded in the EPS sheathing panel mold.
(4) The EPS lining plate model obtained by the lost foam casting method is molded, and the prefabricated body becomes a reinforcement under the action of molten metal, so that the composite material is molded.
Example 2
A high wear-resistant composite material lining plate adopts cast steel and cast iron as base materials, the surface of a metal base material is provided with cylindrical ceramic particle reinforcements, and the ceramic particle reinforcements are arranged according to a honeycomb structure; the volume fraction of the ceramic particles in the ceramic particle reinforcement body is in a decreasing trend along the direction from the circle center to the cylindrical surface of the radius.
Ceramic particle reinforcement core radius r010mm, each layer having a thickness d of 2 mm; the ratio of the ceramic particles to the pore former from the outside toward the core is shown in Table 2.
TABLE 2 ratio of ceramic particles to pore-forming agent
The preparation method of the composite material lining plate specifically comprises the following steps:
(1) the composition was 92% Al2O3Particles, 5% phenolic resin, 3% SiC powder.
(2) Mechanically and uniformly mixing the mixed ceramic particles and the pore-forming agent according to the proportion shown in the table 2, and filling the mixed ceramic particles with different ceramic particle volume fractions into a layered mold in a layered mode, wherein the filling structure is shown in fig. 6; removing the mould, and pressing the loose preform filled in layers into a preform with the volume fraction of ceramic particles changing in a gradient manner along the radius direction (as shown in figures 1 and 2) according to a certain pressure; (the diameter phi of the preform is 10mm, the height h of the preform is 15mm, the number n of layers of the interface transition zone is 5, and the interlayer spacing d of the interface transition zone is 5 mm).
(3) Placing the prefabricated body into an EPS foaming mould according to the position shown in figure 4, wherein the interval l of the prefabricated body is 7 mm; the foamed preform is embedded in the EPS sheathing panel mold.
(4) The EPS lining plate model obtained by the lost foam casting method is molded, and the prefabricated body becomes a reinforcement under the action of molten metal, so that the composite material is molded.
Claims (6)
1. The preparation method of the surface layer composite material is characterized by comprising the following steps:
(1) forming a cylindrical ceramic preform: uniformly mixing ceramic particles, an activating agent and a binder to obtain mixed powder, and adding a pore-forming agent; filling mixed powder with different volume fractions of several ceramic particles into a layered die, wherein the volume fractions of the ceramic particles are in a decreasing trend along the direction from the circle center to the cylindrical surface; removing the mould, and pressing the loose prefabricated body filled in layers into a prefabricated body with the volume fraction of the ceramic particles changing in a gradient manner along the radius direction;
(2) preparing a composite material: placing the prefabricated body prepared in the step (1) at the bottom of an EPS foaming mold, arranging the prefabricated body according to a honeycomb structure, then carrying out EPS foaming, and embedding the foamed prefabricated body into the surface of an EPS model; pouring base metal liquid by adopting a lost foam casting method, wherein the prefabricated body becomes a reinforcement under the action of the metal liquid, and forming the composite material to obtain a surface composite material;
the surface composite material adopts cast steel or cast iron as a base material, the surface of the metal base material is provided with cylindrical ceramic particle reinforcements, and the ceramic particle reinforcements are arranged according to a honeycomb structure; the volume fraction of the ceramic particles in the ceramic particle reinforcement body is in a decreasing trend along the direction from the circle center to the cylindrical surface of the radius.
2. The method for preparing the skin composite according to claim 1, wherein: the layered die structure is an annular structure formed by nesting a plurality of cylindrical dies together.
3. The method for preparing the skin composite according to claim 1, wherein: the matrix metal is any one of alloy steel, high-chromium cast iron and nodular cast iron.
4. The method for preparing the skin composite according to claim 1, wherein: the ceramic particles are Al2O3The particles or main component being Al2O3The particle size of the particles is 20-80 meshes.
5. The method for preparing the skin composite according to claim 1, wherein: in the step (1), the pore-forming agent is one or more of polyethylene, polystyrene, polyvinyl alcohol and carbamide, and is added according to 5-30% of the total volume of the mixed powder; the binder is PVA (polyvinyl alcohol), PAM (polyacrylamide) or phenolic resin, and the total amount is added according to 5-10% of the total mass of the mixed powder; the activator is high-carbon ferrochrome powder, Fe-based self-fluxing alloy powder, SiC powder, B4C powder, Ti2One or more of O powder is added according to 2-7% of the total mass of the mixed powder.
6. The method for preparing the skin composite according to claim 1, wherein: by changing the geometric dimensions of the layering mold and the EPS foaming mold, the dimension of the prefabricated body is adjusted, and then the surface layer is adjustedCombining the structural parameters of the material to obtain the composite material with different structural parameters so as to be suitable for workpieces with different sizes and different use working conditions; wherein the diameter of the preform
5-30mm, the height h of the prefabricated body is 5-50mm, the number n of interface transition zone layers is 2-6, the interlayer distance d of the interface transition zone is 1-5mm, and the distance l of the prefabricated body is 5-30 mm.
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| CN101775518A (en) * | 2010-04-02 | 2010-07-14 | 哈尔滨工业大学 | Device and method for preparing particle-reinforced gradient composite materials by using ultrasonic waves |
| CN103206589A (en) * | 2013-03-23 | 2013-07-17 | 广州有色金属研究院 | Composite profiled pipeline and manufacturing method thereof |
| CN103641487A (en) * | 2013-12-02 | 2014-03-19 | 昆明理工大学 | Preparation method and application of ceramic preform |
| CN106584959A (en) * | 2016-10-24 | 2017-04-26 | 东莞市联洲知识产权运营管理有限公司 | High wear resistant iron and aluminum laminated composite material and preparation method thereof |
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| EP2969313B1 (en) * | 2013-03-15 | 2018-05-09 | REL, Inc. | Variable-density composite articles and method |
| EP3011065A1 (en) * | 2013-06-19 | 2016-04-27 | European Space Agency | Method of manufacturing a metal matrix composite component by use of a reinforcement preform |
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|---|---|---|---|---|
| CN101775518A (en) * | 2010-04-02 | 2010-07-14 | 哈尔滨工业大学 | Device and method for preparing particle-reinforced gradient composite materials by using ultrasonic waves |
| CN103206589A (en) * | 2013-03-23 | 2013-07-17 | 广州有色金属研究院 | Composite profiled pipeline and manufacturing method thereof |
| CN103641487A (en) * | 2013-12-02 | 2014-03-19 | 昆明理工大学 | Preparation method and application of ceramic preform |
| CN106584959A (en) * | 2016-10-24 | 2017-04-26 | 东莞市联洲知识产权运营管理有限公司 | High wear resistant iron and aluminum laminated composite material and preparation method thereof |
Non-Patent Citations (1)
| Title |
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| 锆刚玉/高铬铸铁基蜂窝陶瓷复合材料预制体优化;周谟金;《中国优秀硕士学位论文全文数据库》;20170215;第14-16页 * |
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