CN108485766B - 一种高粘性材料冷挤压成形用高效润滑层及其制备药型罩中的应用 - Google Patents
一种高粘性材料冷挤压成形用高效润滑层及其制备药型罩中的应用 Download PDFInfo
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Abstract
本发明提供了一种高粘性材料冷挤压成形用高效润滑剂,是由配方Ⅰ和配方Ⅱ组成,配方Ⅰ为磷酸和氟锆酸钾的水溶液,磷酸质量配比2%~10%,氟锆酸钾质量配比5%~15%,余量为水;配方Ⅱ由纳米石墨和二硫磺酸钡、聚乙二醇、水组成,纳米石墨质量配比10%~20%,二硫磺酸钡质量配比3~6%,聚乙二醇质量配比5~15%,余量为水。本发明首先解决了常规方法润滑涂层与基体的附着力差、延展性不高,导致成形件表面质量差、变形不均匀的技术难题。
Description
技术领域
本发明属于金属塑性成形技术领域,具体地说是一种高粘性材料冷挤压成形用高效润滑层及其制备药型罩中的应用。
背景技术
钽材具有高密度、高动态延展性和优异的侵彻性能,能够显著提高在大炸高下的侵彻能力和抗干扰能力,是杆式射流(JPC)、爆炸成形弹丸(EFP)药型罩的理想材料之一。国外90年代就打通了钽、钽钨合金高密度药型罩的关键制造技术链,并实现了工程化应用,如美国SADARM、德国SMART、瑞典BONUS、法国ACED155等战斗部;国内钽、钽钨合金药型罩还处于研制阶段,其应用的制约环节有两方面:一是钽材成本高;二是工程化应用的关键制造技术还未突破。
由于美国、德国等对华军事技术的秘密封锁,尤其是涉及关键构件的材料与制造技术,能查阅到的有价值的资料很少。根据大量文献资料分析研究表明,钽、钽钨合金药型罩的制造技术,主要有板材冲压成形、旋压成形、摆碾成形、冷挤压成形,如德克萨斯大学的Romero等人对Ta、Mo材料塑性成形锥形壳体研究后认为,采用强烈旋压成形技术可以获得具有微米晶的锥形壳体,在爆轰作用下能形成聚能杆式侵彻体,但侵彻体成形过程不稳定,X射线照相表明是组织不均匀、对称性差(参见Romero L A.The instability of rapidlystretching plastic jet[J],J.Appl.Phys.,1999,65,3006-3016);北京有色金属研究总院的彭海健等人采用摆碾成形+数控车削加工方法,制造Ta-W合金薄壁回转体零件,金属流线完整、呈放射状,使薄壁回转体零件周向的性能基本相同,平均晶粒尺寸≤50μm,但表面粗糙度Ra3.2~6.4μm,尺寸偏差0.12~0.35mm,且加工刀具磨损严重(参见彭海健.钽合金零件的摆辗成形工艺[J],稀有金属,2009,8,597-600)。
钽、钽钨合金在冲压成形、旋压成形、摆碾成形、冷挤压成形过程中,采用传统的菜籽油、液压油、猪油等动植物油作为润滑剂,以及油机石墨、水基石墨润滑剂,润滑剂的附着力差,成形过程中金属与模具的粘模现象严重,成形表面拉伤、凹坑缺陷(图1),边部畸变严重,不同部位组织不均,塑性成形出的药型罩质量不高,对侵彻稳定性有明显影响。
发明内容
本发明解决的技术问题在于提供一种高粘性材料冷挤压成形用高效润滑剂,通过化学反应制备中间过渡层+喷涂面层润滑剂,解决常规润滑层附着力差、延展性不好等技术难题,结合冷挤压成形工艺实现药型罩形状尺寸、组织性能、表面质量的多重控制,将钽钨材料优势转化为产品性能优势。
本发明的目的是这样实现的:
一种高粘性材料冷挤压成形用高效润滑剂,是由配方I和配方II组成,配方I为磷酸和氟锆酸钾的水溶液,磷酸质量配比2%~10%,氟锆酸钾质量配比5%~15%,余量为水;配方II由纳米石墨和二硫磺酸钡、聚乙二醇、水组成,纳米石墨质量配比10%~20%,二硫磺酸钡质量配比3~6%,聚乙二醇质量配比5~15%,余量为水。
上述高粘性材料冷挤压成形用高效润滑剂,先采用配方I浸渍坯料,再将配方II进行喷涂坯料。本发明首先采用化学方法,在坯料的表面形成一层含有氟、磷转化膜的中间过渡层,降低钽钨材料的憎水性,提高润滑层的附着性;其次采用喷涂方式在坯料表面形成一层含纳米石墨的水基润滑层,涂层厚度可根据成形件变形量设计。解决了常规方法,润滑涂层与基体的附着力差、延展性不高,导致成形件表面质量差、变形不均匀的技术难题。优选的,浸渍时间为30~60分钟,水洗后在80~100℃烘干5~10分钟。喷涂厚度控制在0.05~0.2mm,然后在150~180℃烘干5~15分钟。
上述润滑剂用于制备钽钨合金药型罩。
采用上述高粘性材料冷挤压成形用高效润滑剂制备药型罩的方法,包括以下步骤:
(1)坯料的准备:依据设计的药型罩成形件图,计算得出材料体积,并依据塑性加工成形理论与近均匀塑性变形原理,以及数值模拟仿真分析,选取合适的坯料规格,根据体积不变原理切取相应的钽钨坯料尺寸,钽钨棒材直径φ40mm~φ70mm。
(2)中间过渡层制备:首先配制配方I溶液,将步骤(1)制备好的坯料放入混合溶液中,浸泡时间30~60分钟;然后再进行两次水洗,在80~100℃烘干,时间5~10分钟;在坯料表面形成一层含有氟、磷的转化膜,提高面层润滑剂与金属基体的附着力。
(3)面层润滑层制备:首先配制配方II混合溶液;将步骤(2)中的坯料进行180~210℃加热,保温时间5~10分钟;采用喷涂方式对坯料进行润滑层制备,厚度控制在0.05~0.2mm,然后在150~180℃进行烘干处理,烘干时间5~15分钟。
(4)冷挤压成形:将步骤(3)所得的坯料放入挤压成形模具模腔内,在三向压应力和一定变形速率作用下进行冷挤压成形,变形量在3%~30%之间,挤压成形后对坯件表面进行清理,并去除表面的润滑剂层。
(5)重复(2)、(3)、(4)步骤3~8次,使挤压成形药型罩锥面、球面圆周壁厚差≤0.1mm、表面粗糙度≤Ra0.8μm,底厚、壁厚等尺寸达到设计要求。
所述步骤(1)中钽钨棒材包括Ta2.5W、Ta5W、Ta10W等。
所述步骤(4)中变形量为3%~30%,根据挤压成形道次和零件结构特点,合理分配每道次的变形量,随挤压成形道次的增加变形量降低,实现多道次挤压成形药型罩。
所述步骤(5)中3~8道次的挤压变形,根据药型罩的口径尺寸、锥角度、壁厚、球面半径等形状结构特点,设计所需的变形道次,尺寸规格小、形状简单的零件变形道次少,相同口径药型罩壁厚大的变形道次少,同时钽钨合金中钨含量少的挤压成形道次也减少。
有益效果
1.药型罩材料是钽钨合金,冷挤压塑性流动过程中钽钨金属基体与模具易粘结,形成凹坑、拉伤、边部畸变等缺陷,本发明通过在坯料表面制备高效润滑层,提高冷挤压成形构件的组织均匀性与表面质量。
2.本发明首先采用化学方法,在坯料的表面形成一层含有氟、磷的转化膜的中间过渡层,降低钽钨材料的憎水性,提高润滑层的附着性;其次采用喷涂方式在坯料表面形成一层含纳米石墨的水基润滑层,涂层厚度可根据成形件变形量设计。解决了常规方法,润滑涂层与基体的附着力差、延展性不高,导致成形件表面质量差、变形不均匀的技术难题。同时还具有以下优点:
(1)表面质量好:表面粗糙度达到Ra0.8um。
(2)成形效率高:与油基石墨等润滑剂相比,成形效率提高1~2倍。
(3)模具寿命长:与油基石墨等润滑剂相比,模具寿命提高2~3倍。
附图说明
图1常规润滑剂形成的缺陷
图2坯料准备
图3润滑剂中间层
图4多道次挤压成形工序
图5钽钨药型罩冷挤压成形件
具体实施方式
以下结合具体实施例对本发明作进一步说明。
实施例1
(1)坯料的准备:EFP药型罩外径尺寸为108mm,外球面半径118mm、内球面半径142mm、锥角27°、球冠高度23.2mm、底部壁厚3.5mm;依据塑性加工成形理论与近均匀塑性变形原理,在药型罩外径尺寸的法兰部位单边留3mm加工余量,并在药型罩球面中心底部设计φ4mm的定位凸点;采用UG、DEFORM软件对成形过程进行模拟分析与优化,计算坯料体积与尺寸规格,选用Ta2.5W合金棒材直径φ50×21.5mm(图2)。
(2)中间过渡层制备:首先配制磷酸、氟锆酸钾、水的混合溶液(按照质量比,比例2∶3∶25),将步骤(1)制备好的坯料放入混合溶液中,浸泡时间45分钟;然后在进行两次水洗,在100℃烘干,保温时间5分钟;在坯料表面形成一层含有氟、磷的转化膜层(图3),为制备面层润滑剂作准备。
(3)面层润滑层制备:首先配制纳米石墨、二硫磺酸钡、水混合溶液(按照质量比,比例3∶1∶20),再添加聚乙二醇(按照质量比,比例10∶1);将步骤(2)中的坯料进行200℃加热,保温时间10分钟;采用喷涂方式对坯料进行润滑层制备,厚度控制在0.05~0.15mm,然后再180℃烘干处理10分钟。
(4)冷挤压成形:将步骤(3)所得的坯料放入挤压成形模具模腔内,在三向压应力和一定变形速率作用下进行冷挤压成形(图4),变形量在5~25%之间(表1),成形完后对坯件表面进行清理,并去除表面的润滑剂。
表1冷挤压成形参数
(5)按照表1参数,将步骤(2)、(3)、(4)重复5次,使挤压成形药型罩尺寸符合设计要求。
将本实施例制备的Ta2.5W合金药型罩(图5)进行检测分析:锥面、球面圆周壁厚差0.03~0.1mm、表面粗糙度Ra0.15~0.8μm,外球面半径SR118mm±0.1mm、内球面半径SR142mm±0.1mm、锥角27°±5',平均晶粒尺寸约30μm。采用本实施例的冷挤压成形工序需要6道次,与采用传统油基石墨润滑剂、动物油等成形工序需要12道次以上,成形效率提高1倍以上。
实施例2
(1)坯料的制备:EFP药型罩外径尺寸为108mm,外球面半径118mm、内球面半径142mm、锥角27°、球冠高度23.2mm、底部壁厚3.5mm;依据塑性加工成形理论与近均匀塑性变形原理,在药型罩外径尺寸的法兰部位单边留3mm加工余量,并在药型罩球面中心底部设计φ4mm的定位凸点;采用UG、DEFORM软件对成形过程进行模拟分析与优化,计算坯料体积与尺寸规格,选用Ta5W合金棒材直径φ50×21.5mm。
(2)中间过渡层制备:首先配制磷酸、氟锆酸钾、水的混合溶液(按照质量比,比例2∶3∶25),将步骤(1)制备好的坯料放入混合溶液中,浸泡时间60分钟;然后在进行两次水洗,在90℃烘干,时间10分钟;在坯料表面形成一层含有氟、磷的转化膜层,为面层润滑剂制备作准备。
(3)面层润滑层制备:首先配制纳米石墨、二硫磺酸钡、水混合溶液(按照质量比,比例3∶1∶20),再添加聚乙二醇(按照质量比,比例10∶1);将步骤(2)中的坯料进行210℃加热,保温时间8分钟;采用喷涂方式对坯料进行润滑层制备,厚度控制在0.05~0.2mm,然后再160℃烘干处理15分钟。
(4)冷挤压成形:将步骤(3)所得的坯料放入挤压成形模具模腔内,在三向压应力和一定变形速率作用下进行冷挤压成形,变形量在3~28%之间(表2),成形完后对坯件表面进行清理,并去除表面的润滑剂。
表2冷挤压成形参数
(5)按照表2参数,将步骤(2)、(3)、(4)重复6次,使挤压成形药型罩尺寸符合设计要求。
将本实施例制备的Ta5W合金药型罩进行检测分析:锥面、球面圆周壁厚差0.02~0.09mm、表面粗糙度Ra0.22~0.75μm,外球面半径SR1 18mm±0.08mm、内球面半径SR142mm±0.1mm、锥角27°±5',平均晶粒尺寸约25μm。
采用本实施例的成形工序7道次,采用传统油机石墨润滑剂、动物油等成形工序需要12道次以上,成形效率提高约1倍。
实施例3
(1)坯料的准备:EFP药型罩外径尺寸为108mm,外球面半径118mm、内球面半径142mm、锥角27°、球冠高度23.2mm、底部壁厚3.5mm;依据塑性加工成形理论与近均匀塑性变形原理,在药型罩外径尺寸的法兰部位单边留3mm加工余量,并在药型罩球面中心底部设计φ4mm的定位凸点;采用UG、DEFORM软件对成形过程进行模拟分析与优化,计算坯料体积与尺寸规格,选用Ta10W合金棒材直径φ50×21.5mm。
(2)中间过渡层制备:首先配制磷酸、氟锆酸钾、水的混合溶液(按照质量比,比例2∶3∶25),将步骤(1)制备好的坯料放入混合溶液中,浸泡时间60分钟;然后在进行两次水洗,在100℃烘干,时间10分钟;在坯料表面形成一层含有氟、磷的转化膜层,为面层润滑剂制备作准备。
(3)面层润滑层制备:首先配制纳米石墨、二硫磺酸钡、水混合溶液(按照质量比,比例3∶1∶20),再添加聚乙二醇(按照质量比,比例10∶1);将步骤(2)中的坯料进行210℃加热,保温时间10分钟;采用喷涂方式对坯料进行润滑层制备,厚度控制在0.05~0.2mm,然后再180℃烘干处理10分钟。
(4)冷挤压成形:将步骤(3)所得的坯料放入挤压成形模具模腔内,在三向压应力和一定变形速率作用下进行冷挤压成形,变形量在3~25%之间(表3),成形完后对坯件表面进行清理,并去除表面的润滑剂。
表3冷挤压成形参数
(5)按照表3参数,将步骤(2)、(3)、(4)重复7次,使挤压成形药型罩尺寸符合设计要求。
将本实施例制备的Ta10W合金药型罩进行检测分析:锥面、球面圆周壁厚差0.03~0.12mm、表面粗糙度Ra0.35~0.7μm,外球面半径SR118mm±0.15mm、内球面半径SR142mm±0.1mm、锥角27°±5',平均晶粒尺寸约20μm。
采用本实施例的成形工序8道次,采用传统油机石墨润滑剂、动物油等成形工序需要14道次以上,成形效率提高1倍以上。
Claims (5)
1.一种高粘性材料冷挤压成形用高效润滑剂,是由配方Ⅰ和配方Ⅱ组成,配方Ⅰ为磷酸和氟锆酸钾的水溶液,磷酸质量配比2%~10%,氟锆酸钾质量配比5%~15%,余量为水;配方Ⅱ由纳米石墨和连二硫酸钡、聚乙二醇、水组成,纳米石墨质量配比10%~20%,连二硫酸钡质量配比3~6%,聚乙二醇质量配比5~15%,余量为水。
2.如权利要求1所述的高粘性材料冷挤压成形用高效润滑剂,先采用配方Ⅰ浸渍坯料,再采用配方Ⅱ采用喷涂坯料。
3.如权利要求2所述的高粘性材料冷挤压成形用高效润滑剂,浸渍时间为30~60分钟,水洗后在80~100℃烘干5~10分钟;喷涂厚度控制在0.05~0.2mm,然后在150~180℃烘干5~15分钟。
4.如权利要求1-3任一所述的润滑剂用于制备钽钨合金药型罩。
5.采用权利要求1-3任一所述高粘性材料冷挤压成形用高效润滑剂制备药型罩的方法,包括以下步骤:
(1)坯料的准备:切取钽钨坯料,钽钨棒材直径φ40mm~φ70mm;
(2)中间过渡层制备:按照质量比,比例2:3:25配制磷酸、氟锆酸钾、水的混合溶液,将步骤(1)制备好的坯料放入混合溶液中,浸泡时间30~60分钟;然后进行两次水洗,在80~100℃烘干,时间5~10分钟;
(3)面层润滑层制备:按照质量比3:1:20配制纳米石墨、连二硫酸钡、水混合溶液,再按照10:1的质量比在混合液中添加聚乙二醇;将步骤(2)中的坯料进行180~210℃加热,保温时间5~10分钟;将配方Ⅱ采用喷涂方式对坯料进行润滑层制备,厚度控制在0.05~0.2mm,然后在150~180℃进行烘干处理,烘干时间5~15分钟;
(4)冷挤压成形:将步骤(3)所得的坯料放入挤压成形模具模腔内,在三向压应力和变形速率作用下进行冷挤压成形,变形量在3~30%之间,挤压成形后对坯件表面进行清理,并去除表面的润滑剂层;
(5)重复(2)、(3)、(4)步骤3~8次,挤压成形药型罩锥面、球面圆周壁厚差≤0.1mm、表面粗糙度≤Ra0.8μm,底厚、壁厚。
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Effective date of registration: 20240325 Address after: 400039 Chongqing Jiulongpo Yuzhou Road No. 33 Patentee after: Southwest Institute of technology and engineering of China Ordnance Equipment Group Country or region after: China Address before: 400039 Chongqing Jiulongpo Shiqiaopu Yuzhou Road No. 33 Patentee before: NO 59 Research Institute OF CHINA ORDNACE INDUSTRY Country or region before: China |