CN109128142B - 一种高冷压成形性水雾化预合金粉生产方法 - Google Patents
一种高冷压成形性水雾化预合金粉生产方法 Download PDFInfo
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Abstract
本发明公开了一种高冷压成形性水雾化预合金粉生产方法，包含以下步骤：1）制备‑400目的半成品预合金粉；2）控制半成品预合金粉的水分含量为1wt%～2wt%，氧含量为0.6wt%～0.8wt%，然后放在真空干燥箱中100℃干燥90min～120min，使粉末颗粒之间产生初步粘结；3）初步粘结的粉末颗粒经还原、退火后粉碎、过筛即得。通过本发明使粉末由类球形变为“稻穗形”、“葡萄形”、“卫星粉”等更为复杂的形状，大大提高预合金粉的冷压成形性，且本发明的方法只是对粉末进行了简单的表面改性，不改变其它任何性能，且适用性极广。
Description
技术领域
本发明属于粉末冶金技术领域，具体涉及一种高冷压成形性水雾化预合金粉生产方法。
背景技术
粉末冶金及金刚石工具用预合金粉希望有较复杂的颗粒形状，以得到良好的成形性能和较高的生坯强度。但是目前市场上最易量产的高压水雾化制粉技术，一般生产的粉末形貌为类球形，表面结构不发达，冷压成形性很差。近年来全自动机器设备的广泛使用，对预合金粉的冷压成形性提出了更高的要求，冷压成形的好坏也制约着粉末使用厂家的发展。目前已有的改善方式有如下几种：
1、通过控制雾化过程来改善粉末形貌，包括调节金属的表面张力、粘度、过热度，优化高压雾化时喷嘴的组合，调整喷射介质、调整喷射角度，调整金属液流的直径（漏嘴直径），调整金属液滴的飞行距离和冷却时间等等，这个方法对个别预合金粉有效果，使用范围相当有限。
2、通过对粉末进行后期处理，来达到易冷压成形的目的，目前主要的思路主要有两种。
2.1、一是在预合金粉末的使用过程中直接添加成形剂和润滑剂，但混入粉末中的成形剂等在刀头及零部件的后期烧结过程中需要完全去除，否则少量的残留会对它们产生致命的影响。
2.2、另一种思路是，在预合金粉中混入含铜的氧化物或盐，再通过高温分解，去除非金属，最后剩余的铜有一部分会镀覆在预合金粉表面，这样一来原本是类球状的预合金粉表面发生的变化，结构更复杂，比表面积更大，且铜的硬度低、延展性好，对预合金粉的冷压成形性有极大的帮助，但是由于镀覆层与原粉只是简单的结合，并未发生合金化，所以从严格意义上来讲，这种方法生产出的粉末属于预合金粉和单质粉末的一种混合粉，其性能远远比不上纯合金化粉末的性能。
发明内容
本发明的目的在于提供一种高冷压成形性水雾化预合金粉生产方法。
为实现上述目的，本发明采取的技术方案是：
一种高冷压成形性水雾化预合金粉生产方法，包含以下步骤：
1）制备-400目的半成品预合金粉，要求半成品预合金粉为-400目以细的粉末，是因为只有细粒度的粉末颗粒表面活性强、表面能较大，容易发生界面接触，进而形成聚合体；
2）控制半成品预合金粉的水分含量为1wt%～2 wt %，氧含量为0.6 wt %～0.8 wt%，然后放在真空干燥箱中100℃干燥90min～120min，这一过程通过毛细作用力，使粉末颗粒之间产生初步粘结；该步骤中，控制半成品预合金粉的水分含量为1 wt %～2 wt %，目的是保证真空干燥处理的时间较短，提升生产效率；氧含量要求为0.6 wt %～0.8 wt %，目的是保证后续的还原过程可以使用氢气轻松去除表面的氧，且能改善颗粒表面形貌，氧含量过低的话颗粒表面不易形成坑洼和气孔，氧含量过高的话，后续的还原过程不能降低氧含量至一定范围，达不到使用要求；
3）初步粘结的粉末颗粒经还原、退火后粉碎、过筛即得。
步骤1）中，半成品预合金粉采用水雾化制粉工艺，其具体操作为：采用高压水将金属溶液在雾化器内破碎成微小液滴、冷却后筛选即可；其中，金属溶液的温度为1450～1750℃，喷嘴直径4～5mm，水流交角40°，水压65Mpa～80Mpa，水流流速180 L/min～200L/min。
步骤1）中，金属溶液为铁、铜、镍、锡、锌、钴、钨、钼、钒、铬中任一种或两种以上的组合。
步骤1）中，半成品预合金粉为铁铜、铁铜镍、铁铜镍锡、铁铜钴锡、铁钨钼钒铬中的一种。
步骤3）中，还原温度为500～600℃，还原时间为8h～10h，保证粉末颗粒在低温条件下缓慢且充分还原，氢气和氧有效结合，达到脱氧的效果，且粉末颗粒中氧的脱离使其表面易形成坑洼和气孔，增加比表面积，还原采用放入推舟式或钢带式还原炉均可。
步骤3）中，退火操作为：在温度为800～1050℃、真空度为10-1Kpa下退火处理5h～6h，经过该真空高温退火步骤后，可使前几个步骤生产出的粉末颗粒聚合体，转变为具有轻微原子结合的晶界面。在10-1Kpa的真空度以下，这种转化更容易发生。温度的选择至关重要，温度低的话，达不到颗粒粘结，形成结块，且有一定强度的效果；温度过高，粉末颗粒会形成烧结，机械性能和物理性能发生改变，违背了粉末处理的初衷。
步骤3）中，使用连续击打式破碎机粉碎，破碎机的转速2000～3000转/分钟，在该转速下，可保证破碎后的粉末颗粒在微观上看是几个粉末颗粒的团聚体，宏观上看，粉末颗粒就具有了较为复杂的表面，就具有了优异的冷压成形性能，保证破碎后的粉末不是单一的颗粒，而是几个颗粒的团聚体，这样团聚体从宏观来看就具有了复杂的表面，呈“稻穗状”或“葡萄状”。
步骤3）中，采用100目～300目筛网过筛，去除粗颗粒，保证成品粉末的冷压成形性，因为过粗的颗粒在冷压成形的过程中会破坏颗粒之间的结合均匀结合。
与现有技术相比，本发明的积极效果是：
本发明公开了一种高冷压成形性水雾化预合金粉末的生产方法，具有流程简单易实现、成本低、易规模化生产的特点。本发明先用物理反应使生产的类球形粉末颗粒之间发生粘结，然后控制破碎条件，把粘结后的块状粉破碎为颗粒状，这一过程使粉末由类球形变为“稻穗形”、“葡萄形”、“卫星粉”等更为复杂的形状，这样大大提高预合金粉的冷压成形性，且本发明的方法只是对粉末进行了简单的表面改性，不改变其它任何性能，且适用性极广。
附图说明
图1是本发明的工艺流程示意图；
图2是铁铜预合金粉末经过本发明（实施例1）处理前、后的扫描电镜对比图片；
图3是铁基预合金粉末经过本发明（实施例2）处理前、后的扫描电镜对比图片。
具体实施方式
下面结合实施例及附图对本发明作进一步详细的描述。
实施例1
一种高冷压成形性水雾化预合金粉末的生产方法，工艺流程图见图1所示，包含以下步骤：
1）称取预合金粉生产所需的原材料50kg，其中铁70wt%，铜30wt %；采用水雾化制粉工艺制备半成品预合金粉，金属溶液温度1550～1600℃，喷嘴直径5mm，水流交角40°，水压80Mpa，水流流速200L/min，用高压水将钢液在雾化器内破碎成微小液滴，冷却后筛选-400目的半成品铁铜预合金粉。在其他实施例中，金属溶液为铁、铜、镍、锡、锌、钴、钨、钼、钒、铬中任一种或两种以上的组合，优选地，所述预合金粉包含铁铜、铁铜镍、铁铜镍锡、铁铜钴锡、铁钨钼钒铬中的一种；
2）控制半成品预合金粉的水分含量为2 wt %，氧含量为0.8 wt %，然后放在真空干燥箱中100℃干燥120min，这一过程通过毛细作用力，使粉末颗粒之间产生初步粘结，在其他实施例中还可以控制半成品预合金粉的水分含量为1%～2%，氧含量为0.6～0.8%，然后放在真空干燥箱中100℃干燥90 min～120min均可；
3）把初步粘结的粉末颗粒放入还原炉中，使用推舟式还原炉，选取还原温度为550℃，在氢气气氛下还原粉末颗粒，处理8h，去除表面的氧，使类球形金属颗粒表面布满坑洼和气孔，增加比表面积；然后把粉末放入高温真空退火炉中处理，退火温度为800℃，真空度为10-1Kpa的条件下，处理5h，使粉末充分聚合成块状；使用连续击打式破碎机，转速使用2000转/分钟，把粉末结块破碎为粉，过300目筛网，即形成成品粉末。经过本发明得到的预合金粉末及对比照片见图2所示。从图2中可知，预合金粉原始颗粒用本发明方法处理后，发生团聚现象，宏观显示为形貌复杂的单一颗粒，实际为多个颗粒粘结而成的团聚体，具备了优异的冷压成形性。
在其他实施例中，步骤3）中还可以选择钢带式还原炉，选取还原温度为500～600℃，处理8～10h，调整退火工艺在800～1050℃的温度，真空度为10-1Kpa的条件下处理5-6小时，使粉末充分聚合成块状。
实施例2
一种高冷压成形性水雾化预合金粉末的生产方法，工艺流程图见图1所示，包含以下步骤：
1）称取粉末冶金用铁基预合金粉生产所需的原材料50kg，其中铁82 wt %，铬13wt%，钼1 wt %，钨1 wt %，钒1 wt %，碳2wt %，采用水雾化制粉工艺制备半成品预合金粉，金属溶液温度1650～1700℃，喷嘴直径4.5mm，水流交角40°，水压65Mpa，水流流速180L/min，用高压水将钢液在雾化器内破碎成微小液滴，冷却后筛选-400目的半成品铁基预合金粉；
2）控制半成品预合金粉的水分含量为1 wt %，氧含量为0.6 wt %，然后放在真空干燥箱中100℃干燥100min，这一过程通过毛细作用力，使粉末颗粒之间产生初步粘结；
3）把初步粘结的粉末颗粒放入还原炉中，使用推舟式还原炉，选取还原温度为600℃，在氢气气氛下还原粉末颗粒，处理10h，去除表面的氧，使类球形金属颗粒表面布满坑洼和气孔，增加比表面积；然后把粉末放入高温真空退火炉中处理，退火温度为1050℃，真空度为10-1Kpa的条件下，处理6小时，使粉末充分聚合成块状；使用连续击打式破碎机，转速使用3000转/分钟，把粉末结块破碎为粉，过100目筛网，形成成品粉末。经过本发明得到的预合金粉末及对比照片见图3所示。从图3中可知，预合金粉原始颗粒用本发明方法处理后，发生团聚现象，宏观显示为形貌复杂的单一颗粒，实际为多个颗粒粘结而成的团聚体，具备了优异的冷压成形性。
上述实施例为本发明较佳的实施方式，但本发明的实施方式并不受上述实施例的限制，其他的任何未背离本发明的精神实质与原理下所作的改变、修饰、替代、组合、简化，均应为等效的置换方式，都包含在本发明的保护范围之内。
Claims (1)
1.一种高冷压成形性水雾化预合金粉生产方法，其特征在于，包含以下步骤：
1）制备-400目的半成品预合金粉，半成品预合金粉采用水雾化制粉工艺，半成品预合金粉为铁铜、铁铜镍、铁铜镍锡、铁铜钴锡、铁钨钼钒铬中的一种；其具体操作为：采用高压水将金属溶液在雾化器内破碎成微小液滴、冷却后筛选即可；其中，金属溶液的温度为1450～1750℃，喷嘴直径4～5mm，水流交角40°，水压65MPa～80MPa，水流流速180L/min～200L/min；
2）控制半成品预合金粉的水分含量为1wt%～2wt%，氧含量为0.6wt%～0.8wt%，然后放在真空干燥箱中100℃干燥90min～120min，使粉末颗粒之间产生初步粘结；
3）初步粘结的粉末颗粒经还原、退火后粉碎、过筛即得，还原温度为500～600℃，还原时间为8h～10h；退火操作为：在温度为800～1050℃、真空度为10-1kPa下退火处理5h～6h；使用连续击打式破碎机粉碎，破碎机的转速2000～3000转/分钟；采用100目～300目筛网过筛。
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| CN101181749A (zh) * | 2007-12-19 | 2008-05-21 | 上海芬迪超硬材料科技有限公司 | 金刚石工具中替代钴、镍材料的雾化合金粉 |
| CN101748302A (zh) * | 2008-12-08 | 2010-06-23 | 安泰科技股份有限公司 | 金刚石工具用预合金化粉末及其制造方法 |
| CN104004970A (zh) * | 2014-03-20 | 2014-08-27 | 建德市易通金属粉材有限公司 | 一种金刚石锯切工具用预合金粉末 |
| CN104275481A (zh) * | 2014-10-27 | 2015-01-14 | 舒思雄 | 一种锰钢合金粉末及其制备方法 |
| JP2015528063A (ja) * | 2012-07-19 | 2015-09-24 | クライマックス・エンジニアード・マテリアルズ・エルエルシー | 球状銅／二硫化モリブデン粉末、金属物品、およびその生産方法 |
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| CN101181749A (zh) * | 2007-12-19 | 2008-05-21 | 上海芬迪超硬材料科技有限公司 | 金刚石工具中替代钴、镍材料的雾化合金粉 |
| CN101748302A (zh) * | 2008-12-08 | 2010-06-23 | 安泰科技股份有限公司 | 金刚石工具用预合金化粉末及其制造方法 |
| JP2015528063A (ja) * | 2012-07-19 | 2015-09-24 | クライマックス・エンジニアード・マテリアルズ・エルエルシー | 球状銅／二硫化モリブデン粉末、金属物品、およびその生産方法 |
| CN104004970A (zh) * | 2014-03-20 | 2014-08-27 | 建德市易通金属粉材有限公司 | 一种金刚石锯切工具用预合金粉末 |
| CN104275481A (zh) * | 2014-10-27 | 2015-01-14 | 舒思雄 | 一种锰钢合金粉末及其制备方法 |
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