CN108097931A - 一种铁基陶瓷颗粒增强复合材料的制备方法 - Google Patents
一种铁基陶瓷颗粒增强复合材料的制备方法 Download PDFInfo
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 title claims abstract description 155
- 239000000919 ceramic Substances 0.000 title claims abstract description 101
- 239000002245 particle Substances 0.000 title claims abstract description 101
- 229910052742 iron Inorganic materials 0.000 title claims abstract description 78
- 230000002708 enhancing effect Effects 0.000 title claims abstract description 51
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- 229910045601 alloy Inorganic materials 0.000 claims abstract description 23
- 239000000956 alloy Substances 0.000 claims abstract description 23
- 238000000034 method Methods 0.000 claims abstract description 23
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- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 9
- RGPUVZXXZFNFBF-UHFFFAOYSA-K diphosphonooxyalumanyl dihydrogen phosphate Chemical group [Al+3].OP(O)([O-])=O.OP(O)([O-])=O.OP(O)([O-])=O RGPUVZXXZFNFBF-UHFFFAOYSA-K 0.000 claims description 5
- 238000010438 heat treatment Methods 0.000 claims description 5
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 4
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- 239000011651 chromium Substances 0.000 claims description 2
- 229910052681 coesite Inorganic materials 0.000 claims description 2
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- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 claims description 2
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 claims description 2
- 238000002844 melting Methods 0.000 claims description 2
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- 229910052750 molybdenum Inorganic materials 0.000 claims description 2
- 239000011733 molybdenum Substances 0.000 claims description 2
- 229910052759 nickel Inorganic materials 0.000 claims description 2
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 claims description 2
- 229910052698 phosphorus Inorganic materials 0.000 claims description 2
- 239000011574 phosphorus Substances 0.000 claims description 2
- 229910052710 silicon Inorganic materials 0.000 claims description 2
- 239000010703 silicon Substances 0.000 claims description 2
- 239000000377 silicon dioxide Substances 0.000 claims description 2
- 229910052682 stishovite Inorganic materials 0.000 claims description 2
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- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 3
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- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
- B22D23/04—Casting by dipping
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- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/34—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders
- C04B28/344—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders the phosphate binder being present in the starting composition solely as one or more phosphates
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Abstract
本发明涉及金属基复合材料技术领域,具体公开一种铁基陶瓷颗粒增强复合材料的制备方法。所述制备方法,包括如下步骤:将陶瓷颗粒和粘接剂进行混料处理、加热成型处理,得到陶瓷颗粒预制块;将所述陶瓷颗粒预制块放入经预热处理的模具腔中,注入合金铁液;将所述模具进行合模,并加压充型,得到铁基陶瓷颗粒增强复合材料。本发明提供的铁基陶瓷颗粒增强复合材料的制备方法,工序简单,成本低廉,得到致密度高、增强陶瓷颗粒分布均匀、界面结合强度高的铁基陶瓷颗粒增强复合材料。
Description
技术领域
本发明涉及金属基复合材料技术领域,尤其涉及一种铁基陶瓷颗粒增强复合材料的制备方法。
背景技术
在铁中添加高硬度的陶瓷颗粒称为增强陶瓷颗粒后形成的复合材料,具有优异的抗磨性,将这种材料制成抗磨件,其使用寿命显著高于单一抗磨材料。但是,增强陶瓷颗粒的密度与铁液的密度差异较大,加之它们与铁液之间的润湿性不好,如何将增强陶瓷颗粒均匀地混入铁液中得到均匀分布的陶瓷颗粒增强复合材料是一个难题。现有制备这种铁基陶瓷颗粒增强抗磨件的方法有粉末冶金法、搅拌熔铸法、熔体浸渗法、喷射沉积法、高温自蔓延反应合成法、消失模铸渗法等。
粉末冶金法可以用来制备高体积分数铁基陶瓷颗粒增强整体抗磨件,但是其需要以特制的粉末为原料,工艺过程复杂,所得抗磨件的致密度较低,而且成本过高,实际应用受到了限制。搅拌熔铸法包括机械搅拌熔铸、电磁感应熔铸、离心弥散熔铸等方法可以用来制备铁基陶瓷颗粒增强抗磨件,并且因为其操作简单方便、成本低廉而得到广泛使用,但增强相的体积分数受限制,一般在20%以上的时候增强相的分布就很难控制,此外,其对界面润湿性、高温化学稳定性、密度差要求较高,易产生吸气等铸造缺陷。溶体浸渗法包括压力浸渗法和无压浸渗法,它们都可以用来制备铁基陶瓷颗粒增强表面抗磨件,但这种方法只能制备表面抗磨层,不能用来制备整体抗磨件,而且陶瓷颗粒与基体间的界面结合强度较低,其耐磨性和使用寿命提高有限。喷射沉积法制备铁基陶瓷颗粒增强抗磨件时流程短、效率高,可获得高致密的抗磨件和实现大规模工业生产,但该方法只能制备具有一定限度表面抗磨层,而且该工艺参数难于控制,成本过高,生产应用前景不容乐观。高温自蔓延反应合成法可制备铁基陶瓷颗粒增强抗磨件,克服了增强陶瓷颗粒抗磨件在铁基中的不均匀分布问题和界面结合弱化问题,此外该工艺简单、成本低廉,与挤压铸造综合使用将能制备出优异耐磨性能的抗磨件,但该方法的增强陶瓷颗粒尺寸和分布难以控制,常出现晶粒长大、组织不均匀现象。消失模铸渗法制备铁基陶瓷颗粒增强抗磨件,利用泡沫塑料作为载体模把增强陶瓷颗粒混入铁基体中,在负压条件下成形,克服了增强陶瓷颗粒在铁基体的分布问题,但该工艺比较复杂,在批量生产中受到极大的限制,而且出现缩松缩孔等铸造缺陷,增强陶瓷颗粒与铁基界面结合强度较低等。
发明内容
针对现有铁基陶瓷颗粒增强抗磨件存在的成本过高、致密度低、增强陶瓷颗粒分布不均匀、界面结合强度低等问题,本发明提供一种铁基陶瓷颗粒增强复合材料的制备方法。
为达到上述发明目的,本发明实施例采用了如下的技术方案:
一种铁基陶瓷颗粒增强复合材料的制备方法,包括如下步骤:
(1)将陶瓷颗粒和粘接剂进行混料处理、加热成型处理,得到陶瓷颗粒预制块;
(2)将所述陶瓷颗粒预制块放入经预热处理的模具腔中,注入合金铁液;
(3)将所述模具进行合模,并加压充型,得到铁基陶瓷颗粒增强复合材料。
相对于现有技术,本发明提供的铁基陶瓷颗粒增强复合材料的制备方法,工序简单,成本低廉,综合利用了液体模锻技术,先得到陶瓷颗粒预制块,再将陶瓷颗粒预制块与合金铁液进行加压充型,使合金铁液充分流入陶瓷颗粒预制块的细小缝隙之中,在短时间之内防止合金铁液因流动性下降而不能充满模腔,并实时补充合金铁液冷却凝固过程的收缩,提高致密度,强化陶瓷颗粒与合金铁液之间的界面接触,提高其界面结合力,得到致密度高、增强陶瓷颗粒分布均匀、界面结合强度高的铁基陶瓷颗粒增强复合材料。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白,以下结合实施例,对本发明进行进一步详细说明。应当理解,此处所描述的具体实施例仅仅用以解释本发明,并不用于限定本发明。
本发明实施例提供一种铁基陶瓷颗粒增强复合材料的制备方法。该铁基陶瓷颗粒增强复合材料的制备方法,包括如下步骤:
(1)将陶瓷颗粒和粘接剂进行混料处理、加热成型处理,得到陶瓷颗粒预制块;
(2)将所述陶瓷颗粒预制块放入经预热处理的模具腔中,注入合金铁液;
(3)将所述模具进行合模,并加压充型,得到铁基陶瓷颗粒增强复合材料。
优选地,所述陶瓷颗粒和粘接剂的质量比为14-16:1,混料处理后有助于成型为预制块。
优选地,所述陶瓷颗粒包括如下质量百分比的组分:55%-65%的Al2O3、35%-45%的ZrO2、0.10%-0.20%的Fe2O3、0.10%-0.20%的TiO2、其余为SiO2、CaO,起到陶瓷颗粒增强效果。
优选地,所述陶瓷颗粒平均粒径为2-3mm,有助于混料处理及后续的加热成型。
优选地,所述粘接剂为磷酸二氢铝、氧化铝、氧化锆以质量比(2-4):(1-3):(1-3)混合的混合物,在加热成型处理中起到很好的粘结作用。
优选地,所述加热成型处理的方法为:将陶瓷颗粒和粘接剂搅拌均匀添加到预制块模具中后,于200-300℃,保温1-2h后,脱模并于400-600℃,保温2-3h,低温电阻炉中加热保温是为了陶瓷颗粒成型;高温电阻炉是为了陶瓷颗粒预制块达到使用强度。
优选地,所述陶瓷颗粒预制块为具有蜂窝孔状结构的陶瓷颗粒预制块,便于与合金铁液的充分接触。
优选地,所述合金铁液为含碳量为2.5%-3.5%、合金元素含量为20%-30%的高合金铸铁熔融所得,其中,所述合金元素包括硅、锰、铬、镍、钼、铜,作为复合材料的金属基。
优选地,所述合金铁液的温度为1550-1600℃,高于铸铁熔点200-300℃,为了使合金铁液充分地包裹陶瓷颗粒,达到更好的充型包裹效果。
优选地,所述预热处理的模具腔的温度为200-300℃,防止合金铁液降温太快达不到充型要求。
优选地,所述加压充型过程中保压时间为3-5min,保证充型充分。
本发明实施例提供的铁基陶瓷颗粒增强复合材料的制备方法,工序简单,成本低廉,综合利用了液体模锻技术,先得到陶瓷颗粒预制块,再将陶瓷颗粒预制块与合金铁液进行加压充型,使合金铁液充分流入陶瓷颗粒预制块的细小缝隙之中,在短时间之内防止合金铁液因流动性下降而不能充满模腔,并实时补充合金铁液冷却凝固过程的收缩,提高致密度,强化陶瓷颗粒与合金铁液之间的界面接触,提高其界面结合力,得到致密度高、增强陶瓷颗粒分布均匀、界面结合强度高的铁基陶瓷颗粒增强复合材料。
为了更好的说明本发明实施例提供的铁基陶瓷颗粒增强复合材料的制备方法,下面通过实施例做进一步的举例说明。
实施例1
铁基陶瓷颗粒增强复合材料的制备方法,包括如下步骤:
(1)将1500g陶瓷颗粒和105g粘接剂(磷酸二氢铝45g、300目氧化铝粉30g、300目氧化锆粉30g)进行混料处理后、添加到预制块模具中后,放入低温电阻炉中加热至200℃,保温2h后,脱模放入高温电阻炉中升温至600℃,保温2h,得到陶瓷颗粒预制块;
(2)将所述陶瓷颗粒预制块放入经200℃预热处理的模具腔中,注入1550-1600℃的合金铁液,至合金铁液到达模具腔距模具口表面10mm处;
(3)启动液压设备,将所述模具的上下模进行合模,并加压充型,保压3-5min,分模,利用液压设备将压铸成型的铸件顶出,得到铁基陶瓷颗粒增强复合材料。
实施例2
铁基陶瓷颗粒增强复合材料的制备方法,包括如下步骤:
(1)将1500g陶瓷颗粒和105g粘接剂(磷酸二氢铝45g、300目氧化铝粉30g、300目氧化锆粉30g)进行混料处理后、添加到预制块模具中后,放入低温电阻炉中加热至300℃,保温1h后,脱模放入高温电阻炉中升温至400℃,保温3h,得到陶瓷颗粒预制块;
(2)将所述陶瓷颗粒预制块放入经300℃预热处理的模具腔中,注入1550-1600℃的合金铁液,至合金铁液到达模具腔距模具口表面10mm处;
(3)启动液压设备,将所述模具的上下模进行合模,并加压充型,保压5min,分模,利用液压设备将压铸成型的铸件顶出,得到铁基陶瓷颗粒增强复合材料。
实施例3
铁基陶瓷颗粒增强复合材料的制备方法,包括如下步骤:
(1)将1500g陶瓷颗粒和100g粘接剂(磷酸二氢铝40g、300目氧化铝粉30g、300目氧化锆粉30g)进行混料处理后、添加到预制块模具中后,放入低温电阻炉中加热至200℃,保温2h后,脱模放入高温电阻炉中升温至500℃,保温2.5h,得到陶瓷颗粒预制块;
(2)将所述陶瓷颗粒预制块放入经200℃预热处理的模具腔中,注入1550-1600℃的合金铁液,至合金铁液到达模具腔距模具口表面10mm处;
(3)启动液压设备,将所述模具的上下模进行合模,并加压充型,保压3min,分模,利用液压设备将压铸成型的铸件顶出,得到铁基陶瓷颗粒增强复合材料。
以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的精神和原则之内所作的任何修改、等同替换或改进等,均应包含在本发明的保护范围之内。
Claims (10)
1.一种铁基陶瓷颗粒增强复合材料的制备方法,其特征在于:包括如下步骤:
(1)将陶瓷颗粒和粘接剂进行混料处理、加热成型处理,得到陶瓷颗粒预制块;
(2)将所述陶瓷颗粒预制块放入经预热处理的模具腔中,注入合金铁液;
(3)将所述模具进行合模,并加压充型,得到铁基陶瓷颗粒增强复合材料。
2.如权利要求1所述的铁基陶瓷颗粒增强复合材料的制备方法,其特征在于:所述陶瓷颗粒和粘接剂的质量比为14-16:1。
3.如权利要求1所述的铁基陶瓷颗粒增强复合材料的制备方法,其特征在于:所述陶瓷颗粒包括如下质量百分比的组分:55%-65%的Al2O3、35%-45%的ZrO2、0.10%-0.20%的Fe2O3、0.10%-0.20%的TiO2、其余为SiO2、CaO。
4.如权利要求2所述的铁基陶瓷颗粒增强复合材料的制备方法,其特征在于:所述陶瓷颗粒平均粒径为2-3mm。
5.如权利要求1所述的铁基陶瓷颗粒增强复合材料的制备方法,其特征在于:所述粘接剂为磷酸二氢铝、氧化铝、氧化锆以质量比(2-4):(1-3):(1-3)混合的混合物。
6.如权利要求1所述的铁基陶瓷颗粒增强复合材料的制备方法,其特征在于:所述加热成型处理的方法为:将陶瓷颗粒和粘接剂搅拌均匀添加到预制块模具中后,于200-300℃,保温1-2h后,脱模并于400-600℃,保温2-3h。
7.如权利要求1所述的铁基陶瓷颗粒增强复合材料的制备方法,其特征在于:所述合金铁液为含碳量为2.5%-3.5%、合金元素含量为20%-30%的高合金铸铁熔融所得,其中,所述合金元素包括硅、锰、铬、镍、钼、铜。
8.如权利要求7所述的铁基陶瓷颗粒增强复合材料的制备方法,其特征在于:所述合金铁液的温度为1550-1600℃。
9.如权利要求1所述的铁基陶瓷颗粒增强复合材料的制备方法,其特征在于:所述预热处理的模具腔的温度为200-300℃。
10.如权利要求1-9任一项所述的铁基陶瓷颗粒增强复合材料的制备方法,其特征在于:所述加压充型过程中保压时间为3-5min。
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