CN108950543A - 一种导热耐磨耐疲劳模具及其制造工艺 - Google Patents

一种导热耐磨耐疲劳模具及其制造工艺 Download PDF

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CN108950543A
CN108950543A CN201810917413.4A CN201810917413A CN108950543A CN 108950543 A CN108950543 A CN 108950543A CN 201810917413 A CN201810917413 A CN 201810917413A CN 108950543 A CN108950543 A CN 108950543A
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thermally conductive
mold
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安健
陈汉杰
王波
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Jiangxi Pu Si Le Advanced Molding Technology Co Ltd
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Abstract

本发明公开了一种导热耐磨耐疲劳模具及其制造工艺，该模具包括：模芯基体、位于所述模芯基体表面且带有随形水路的冷却基体、位于所述冷却基体表面的导热耐磨耐疲劳层和涂覆于所述导热耐磨耐疲劳层表面的渗氮层，其中，所述导热耐磨耐疲劳层采用合金粉末作为原料，通过喷粉式激光熔覆工艺形成。本发明在模具表面激光涂覆导热耐磨耐疲劳层，并进行离子渗氮，提高了模具的表面硬度，增加模具的耐磨性能；同时导热耐磨耐疲劳层中的钛铝钼铬比铁更容易形成结合度高的氮化物，进行形成高强度的渗氮层。

Description

一种导热耐磨耐疲劳模具及其制造工艺
技术领域
本发明涉及模具制造领域，特别涉及一种导热耐磨耐疲劳模具及其制造工艺。
背景技术
模具一般承受变应力和冲击力，容易受到磨损损坏，特别是热作模具，工件成型温度往往在300℃以上，还要经受高温氧化、烧损以及在强烈水冷条件下经受冷热变化引起的热冲击作用，在服役时需要承受高应力、热冲击、热磨损及腐蚀等载荷的作用，失效部位主要体现在模腔应力集中点或高温聚集点，如模腔边缘、中央凸块处，故模具寿命很低。
为提高寿命，目前采用的主要方法是表面强化。常规方法有淬火、渗氮、PVD，热喷涂等，但这些方法效果有限，因为热作模具工作在高温环境，传统的淬火在高温环境下又进入了回火状态，而PVD涂层薄，使用寿命短，价格昂贵，热喷涂与基体以机械结合为主，冶金结合为辅，涂层存在一定的气孔，结合强度不足，而且喷涂后表面粗糙度极大，需要后续的磨削加工，但热喷涂一般喷涂的镍基合金涂层硬度极高，不易精加工，一般只适用规则形状的工作，如轴类和平台零件。另外，对于渗氮，由于铁的氮化物与基体材料热膨胀系数的差异，导致在交变温度造成的内应力作用下渗氮层极易剥落。
发明内容
本发明提供一种导热耐磨耐疲劳模具及其制造工艺，以解决现有技术中存在的上述技术问题。
为解决上述技术问题，本发明提供一种导热耐磨耐疲劳模具，包括：模芯基体、位于所述模芯基体表面且带有随形水路的冷却基体、位于所述冷却基体表面的导热耐磨耐疲劳层和涂覆于所述导热耐磨耐疲劳层表面的渗氮层，其中，所述导热耐磨耐疲劳层采用合金粉末作为原料，通过喷粉式激光熔覆工艺形成。
作为优选，所述导热耐磨耐疲劳层的厚度为0.5mm-3mm，所述渗氮层的厚度为0.05-0.3mm。
作为优选，所述冷却基体通过焊丝堆焊增材制造的方式形成，所述焊丝采用钢材。
作为优选，所述模芯基体由低合金钢铸造而成。
本发明还提供一种导热耐磨耐疲劳模具的制造工艺，包括：
步骤1：通过铸造方式铸造模芯基体；
步骤2：对模芯基体进行粗加工去除黑皮；
步骤3：用增材制造的方式在模芯基体表面堆焊出带有随形水路的冷却基体；
步骤4：采用喷粉式激光熔覆工艺在冷却基体表面制备导热耐磨耐疲劳层；
步骤5：对所述导热耐磨耐疲劳层的表面进行精加工；
步骤6：对所述导热耐磨耐疲劳层进行离子渗氮，进而在所述导热耐磨耐疲劳层表面形成渗氮层。
作为优选，所述步骤1中，所述模芯基体的材质采用低合金钢。
作为优选，所述步骤3中，采用中低碳低铬高钼含量合金钢作为焊丝，增材堆焊所述冷却基体。
作为优选，所述步骤4中采用合金粉末作为导热耐磨耐疲劳层的原材料，所述合金粉末为钴粉、铁粉、铝粉、钛粉和钼粉。
作为优选，所述合金粉末配比为：5％的铁粉、1.5％的铝粉、2％的钛粉、5％的钼粉，余量为Co42。
作为优选，所述导热耐磨耐疲劳层的厚度为0.5mm-3mm，所述渗氮层的厚度为0.05-0.3mm。
与现有技术相比，本发明具有以下优点：
1、通过铸造方式制备热成型模具的模芯基体，降低模具生产成本；
2、通过增材制造加工带有随形水路的冷却基体，可以提高模具的冷却速率，使模具表面的温度均匀，提高生产效率；
3、在模具表面激光涂覆形成导热耐磨耐疲劳层，增加了模具的耐高温氧化性能和耐热疲劳性能；
4、在模具表面激光涂覆导热耐磨耐疲劳层，并进行离子渗氮，提高了模具的表面硬度，增加模具的耐磨性能；同时导热耐磨耐疲劳层中的钛铝钼铬比铁更容易形成结合度高的氮化物，进行形成高强度的渗氮层。
附图说明
图1为本发明的导热耐磨耐疲劳模具的结构示意图；
图2为本发明的导热耐磨耐疲劳模具的侧视图。
具体实施方式
为使本发明的上述目的、特征和优点能够更加明显易懂，下面结合附图对本发明的具体实施方式做详细的说明。需说明的是，本发明附图均采用简化的形式且均使用非精准的比例，仅用以方便、明晰地辅助说明本发明实施例的目的。
如图1和图2所示，本发明提供一种导热耐磨耐疲劳模具，包括：模芯基体1、位于所述模芯基体1表面且带有随形水路的冷却基体2、位于所述冷却基体2表面的导热耐磨耐疲劳层3和涂覆于所述导热耐磨耐疲劳层3表面的渗氮层4，其中，所述导热耐磨耐疲劳层3采用合金粉末作为原料，通过喷粉式激光熔覆工艺形成。具体地，采用喷粉式激光熔覆工艺在所述冷却基体2表面形成所述导热耐磨耐疲劳层3，即本发明利用能量高度集中的激光束对冷却基体2表面的合金材料进行熔覆，使得所述导热耐磨耐疲劳层3具有所需要的导热、耐磨和耐疲劳性能。此外，利用高能量的激光对模具进行表面处理，还可以改变模具表面的显微结构或成分，实现模具表面强化或修复。
继续参照图1和图2，本发明还提供一种导热耐磨耐疲劳模具的制造工艺，包括：
步骤1：采用金属优选低合金钢(16Mn)作为原材，铸造出模芯基体1。
步骤2：对模芯基体1进行粗加工，从而去除模芯基体1表面的黑皮即氧化层。
步骤3：用焊丝堆焊增材制造的方式在模芯基体1表面堆焊出带有随形水路的冷却基体2。具体地，所述焊丝优选采用高导热钢材，具体可以为中低碳低铬高钼含量合金钢(HM3)，如此可以提高模具的冷却速率，使模具的表面温度均匀，进而提高生产效率。更进一步的，所述随形水路的直径为4-20mm，且所述随形水路的管路的截面中心到模具型面的距离一致，最大化实现冷却水路系统的合理化设计和布局，从而达到均匀冷却效果，缩短热成型循环周期中的冷却时间，提高成型产品的质量，使其更加贴近外型面，不受零件的形状和结构的限制，冷却效率更高。
步骤4：采用喷粉式激光熔覆工艺在冷却基体2表面制备导热耐磨耐疲劳层3。具体地，采用合金粉末作为导热耐磨耐疲劳层3的原材料，所述合金粉末为钴粉、铁粉、铝粉、钛粉和钼粉，首先，钴基高温合金的熔点、密度及线膨胀系数等均与钢铁材料十分接近，其作为涂层材料在加热冷却过程中因与基体材料热物理性能差异不大，产生裂纹的几率大大降低，故具有良好的耐热疲劳性能。而通过在钴粉中增加铁粉、铝粉、钛粉和钼粉，使得所述导热耐磨耐疲劳层3具有良好的渗氮性，用于离子渗氮，可以形成高硬度，高耐磨的渗氮层4，进而增加模具的耐摩擦性能。
作为优选，所述合金粉末配比为：5％的铁粉、1.5％的铝粉、2％的钛粉、5％的钼粉，余量为Co42，此时，得到的导热耐磨耐疲劳层3和渗氮层4的性能最佳。
步骤5：对所述导热耐磨耐疲劳层3的表面进行精加工，使其尺寸符合规格要求且表面适宜渗氮。
步骤6：对所述导热耐磨耐疲劳层3进行离子渗氮，进而在所述导热耐磨耐疲劳层3表面形成渗氮层4。
作为优选，所述导热耐磨耐疲劳层3的厚度为0.5mm-3mm，优选为1-1.5mm，所述渗氮层4的厚度为0.05-0.3mm，优选为0.1-0.2mm。
显然，本领域的技术人员可以对发明进行各种改动和变型而不脱离本发明的精神和范围。这样，倘若本发明的这些修改和变型属于本发明权利要求及其等同技术的范围之内，则本发明也意图包括这些改动和变型在内。

Claims (10)

1.一种导热耐磨耐疲劳模具，其特征在于，包括：模芯基体、位于所述模芯基体表面且带有随形水路的冷却基体、位于所述冷却基体表面的导热耐磨耐疲劳层和涂覆于所述导热耐磨耐疲劳层表面的渗氮层，其中，所述导热耐磨耐疲劳层采用合金粉末作为原料，通过喷粉式激光熔覆工艺形成。
2.如权利要求1所述的导热耐磨耐疲劳模具，其特征在于，所述导热耐磨耐疲劳层的厚度为0.5mm-3mm，所述渗氮层的厚度为0.05-0.3mm。
3.如权利要求1所述的导热耐磨耐疲劳模具，其特征在于，所述冷却基体通过焊丝堆焊增材制造的方式形成，所述焊丝采用钢材。
4.如权利要求1所述的导热耐磨耐疲劳模具，其特征在于，所述模芯基体由低合金钢铸造而成。
5.一种导热耐磨耐疲劳模具的制造工艺，其特征在于，包括：
步骤1：通过铸造方式铸造模芯基体；
步骤2：对模芯基体进行粗加工去除黑皮；
步骤3：用增材制造的方式在模芯基体表面堆焊出带有随形水路的冷却基体；
步骤4：采用喷粉式激光熔覆工艺在冷却基体表面制备导热耐磨耐疲劳层；
步骤5：对所述导热耐磨耐疲劳层的表面进行精加工；
步骤6：对所述导热耐磨耐疲劳层进行离子渗氮，进而在所述导热耐磨耐疲劳层表面形成渗氮层。
6.如权利要求5所述的导热耐磨耐疲劳模具的制造工艺，其特征在于，所述步骤1中，所述模芯基体的材质采用低合金钢。
7.如权利要求5所述的导热耐磨耐疲劳模具的制造工艺，其特征在于，所述步骤3中，采用中低碳低铬高钼含量合金钢作为焊丝，增材堆焊所述冷却基体。
8.如权利要求5所述的导热耐磨耐疲劳模具的制造工艺，其特征在于，所述步骤4中采用合金粉末作为导热耐磨耐疲劳层的原材料，所述合金粉末为钴粉、铁粉、铝粉、钛粉和钼粉。
9.如权利要求8所述的导热耐磨耐疲劳模具的制造工艺，其特征在于，所述合金粉末配比为：5％的铁粉、1.5％的铝粉、2％的钛粉、5％的钼粉，余量为Co42。
10.如权利要求5所述的导热耐磨耐疲劳模具的制造工艺，其特征在于，所述导热耐磨耐疲劳层的厚度为0.5mm-3mm，所述渗氮层的厚度为0.05-0.3mm。
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