CN109266942A - 一种硬质合金结构及其成型方法以及应用 - Google Patents
一种硬质合金结构及其成型方法以及应用 Download PDFInfo
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- 229910052799 carbon Inorganic materials 0.000 claims abstract description 44
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 41
- 239000010959 steel Substances 0.000 claims abstract description 41
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- 229910039444 MoC Inorganic materials 0.000 claims description 6
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- 239000001569 carbon dioxide Substances 0.000 claims description 6
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 claims description 6
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- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
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- 239000010937 tungsten Substances 0.000 description 1
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Abstract
本发明公开了一种硬质合金结构,包括覆盖层和结合层,所述结合层包括碳素钢层和硬质合金,所述碳素钢层包括凹槽部,所述凹槽部包括凹槽一和凹槽二,所述硬质合金嵌设于所述凹槽一和凹槽二内,硬质合金粉末填充在所述碳素钢层凹槽部内,所述覆盖层设置于结合层上部,成型包括以下步骤:填充,覆盖,压制成型并烧结,冷却;本发明的硬质合金结构通过覆盖层和结合层的有效结合,且结合层可以拓展到多层,其中,结合层包括碳素钢层和硬质合金,碳素钢层一体成型,保证了结构的韧性,配合采用硬度和耐磨性较高的硬质合金,与韧性较高的碳素钢配合,在结构方面有效的调节了耐磨性和韧性及抗疲劳性之间的矛盾。
Description
技术领域
本发明属于硬质合金领域,具体涉及一种硬质合金结构及其成型方法以及应用。
背景技术
硬质合金是一种以难熔金属化合物为基体,以铁族金属作为粘接剂,用粉末冶金方法制造的一种材料,由于这种材料在常温和高温条件下均具有高的硬度、高的机械强度和弹性模数,以及良好的化学稳定性和耐酸、耐碱、耐腐蚀、抗氧化等优点,使它在现代工具材料、耐磨材料、耐腐蚀和耐高温材料等方面占据着重要地位。但是,由于硬质合金是难熔金属化合物和粘接相金属的统一体,难熔化合物硬而脆,粘接相金属软而韧,在这个统一体中难熔化合物和粘接相金属含量关系反映在性能上就是合金的硬度、耐磨性与合金的韧性、机械强度及抗疲劳性间此消彼长的关系:即合金的硬度与强度,耐磨性和韧性及抗疲劳性之间存在尖锐的矛盾。
现有技术中,通常通过梯度硬质合金来解决合金硬度与强度间的问题,通过硬质合金各组分的配比调整,调节耐磨性和韧性及抗疲劳性之间存在尖锐的矛盾。
发明内容
本发明要解决的技术问题是提供一种硬质合金结构,通过结构上的调整来解决现有技术中硬质合金强度与硬度,耐磨性和韧性及抗疲劳性之间矛盾的问题。
本发明为了解决现有技术问题所采用的技术方案如下:
提供一种硬质合金结构,包括覆盖层和结合层,所述结合层包括碳素钢层和硬质合金层,所述碳素钢层包括凹槽部,所述凹槽部包括凹槽一和凹槽二,所述硬质合金层嵌设于所述凹槽一和凹槽二内,所述硬质合金层经硬质合金粉末高温高压在真空条件下成型,所述硬质合金粉末填充在所述碳素钢层凹槽部内,所述覆盖层设置于结合层上部。
进一步地,所述结合层个数为多个,所述多个结合层之间叠加设置,具体的,第一结合层的下部设置在第二结合层的上部,以此类推。
进一步地,所述硬质合金粉末由以下重量份原料组成:WC粉末65~70份、Co粉末1~3份、TaC3~3.5份、NbC2~3份、MoC8~10份、ZrC6~8份、TiC25~30份。碳化钨、碳化钛、碳化锆、碳化铌,按比例混合后在高温下生产类质同晶体,钴作为连续相的粘结剂,为材料提供韧性和弯矩强度,碳化钽作为抑制剂,用于控制晶粒长大速度,保障材料具有很好的硬度、韧性和耐磨性能,碳化锆还能够提高材料耐高温性能,碳化钼提高材料的耐腐蚀性能,碳化铌提高材料的耐磨性能以及高温尺寸稳定性。碳化铌和碳化钼协同作用,也同时起到细化晶粒的作用。
进一步地,还包括过渡层,所述过渡层铺设于碳素钢层内表面,所述过渡层厚度小于1mm;所述过渡层能够将硬质合金层与碳素钢基板有机地结合在一起,防止材料出现脱层现象,从而提高制品的整体性能,保障加工安全。
进一步地,所述过渡层由硬质合金粉末经高温高压在真空条件下成型,所述硬质合金粉末由以下重量份原料组成:铁粉30~50份,钴粉10~20份,碳化钨、碳化钽、碳化铌、碳化钼、碳化锆和碳化钛总量≤40份;加入铁可以增加硬质合金与碳素钢基材之间的粘合力,可以防止材料的液氮、液态二氧化碳等急速冷却过程中造成硬质合金层出现微观裂纹。
进一步地,所述碳素钢层与硬质合金层体积比为:1~1:1.5。
进一步地,所述碳素钢层一体成型。
本发明的另一个目的在于提供一种用于所述硬质合金的成型方法,实现该硬质合金的生产,包括以下步骤:
单个结合层,在所述碳素钢层的凹槽部内依次填充过渡层和硬质合金层,覆盖层设置在结合层上部,在真空条件下进行压制成型并烧结,所述烧结温度分别达到300~310、600~610、1000~1100℃时,保温25~30min,当烧结温度达到1500~1550℃时,经过50~60min降温至1150~1200℃继续加热至1500~1550℃并保温55~60min,冷却。
多个结合层,在所述碳素钢层的凹槽部内依次填充过渡层和硬质合金层,多个结合层叠加设置,并在第一结合层上部设置覆盖层,在真空条件下进行压制成型并烧结,所述烧结温度分别达到300~310、600~610、1000~1100℃时,保温25~30min,当烧结温度达到1500~1550℃时,经过50~60min降温至1150~1200℃继续加热至1500~1550℃并保温55~60min,冷却。
进一步地,所述冷却通过液态二氧化碳、液氮或冷却水雾化任意一种方式实现。
本发明的另一个目的在于提供一种所述硬质合金结构在刀具上的应用;成型刀具时,只需以一定的角度磨削掉部分表层碳素钢,露出小段芯层长度,然后加工成所需刀具形状即可,如刀具磨损过多影响加工质量良时,可继续磨削以部分碳素刚层,露出更多芯层,然后重新加工成所需刀具形状,从而达到连续使用,节约材料,降低成本的目的。
本发明有益效果如下:
本发明的硬质合金结构通过覆盖层和结合层的有效结合,且结合层可以拓展到多层,其中,结合层包括碳素钢层和硬质合金,碳素钢层一体成型,保证了结构的韧性,配合采用硬度和耐磨性较高的硬质合金,与韧性较高的碳素钢配合,在结构方面有效的调节了耐磨性和韧性及抗疲劳性之间的矛盾。
过渡层能够将硬质合金层与碳素钢基板有机地结合在一起,可以防止材料的液氮、液态二氧化碳等急速冷却过程中造成硬质合金层出现微观裂纹防止材料出现脱层现象,从而提高棒材结构的整体性能。
硬质合金设置在碳素钢层凹槽部内,凹槽部包括凹槽一和凹槽二,增加其与硬质合金的结合强度,其中,硬质合金主要用来做刀具的切削面,碳素钢作为刀具的支撑层和弯矩受力层,既保证了刀具的硬度,也提高了刀具的强度。
利用本发明结构,能够使硬质合金层的配方中碳化钨、碳化钛占比可以达到85%以上,从而极大地提高了芯层的硬度和耐磨性,拓展了刀具的使用范围,使其能够加工一些超高硬度的材料,同时减少单位体积的钨、钛、铌等贵重金属的用量,从而降低成本。
本发明所述结构便于加工矩形刀具,结构简单,易于成型。
附图说明
图1为实施例1中硬质合金结构示意图;
图2为实施例2中硬质合金结构示意图;
图3为实施例3中成型方法示意图。
具体实施方式
下面结合具体实施方式对本发明作进一步的说明。其中,附图仅用于示例性说明,表示的仅是示意图,而非实物图,不能理解为对本专利的限制;为了更好地说明本发明的实施例,附图某些部件会有省略、放大或缩小,并不代表实际产品的尺寸;对本领域技术人员来说,附图中某些公知结构及其说明可能省略是可以理解的。
实施例1
如图1所示,本实施例提供一种硬质合金结构,包括覆盖层1和结合层2,结合层2包括碳素钢层20和硬质合金21,碳素钢层20包括凹槽部200,凹槽部包括凹槽一201和凹槽二202,硬质合金21嵌设于凹槽一201和凹槽二202内,硬质合金21经硬质合金粉末高温高压在真空条件下成型,硬质合金粉末填充在碳素钢层20凹槽部200内,覆盖层1设置于结合层2上部。
硬质合金粉末由以下重量份原料组成:WC粉末65份、Co粉末1份、TaC3份、NbC2份、MoC8份、ZrC6份、TiC25份。
过渡层3由混合好的硬质合金粉末铺设于碳素钢层20内表面,过渡层3厚度为0.8mm。
硬质合金粉末由以下重量份原料组成:铁粉50份,钴粉20份,碳化钨、碳化钽、碳化铌、碳化钼、碳化锆和碳化钛总量30份。
碳素钢层20与硬质合金21体积比为:1:1。
碳素钢层20一体成型。
实施例2
如图2所示,本实施例中结合层个数为3个,3个结合层之间叠加设置,分别为第一结合层a、第二结合层b和第三结合层c,具体的,第一结合层a的下部设置在第二结合层b的上部,第二结合层b的下部设置在第三结合层c的上部,覆盖层1设置于第一结合层a上部。
硬质合金粉末由以下重量份原料组成:WC粉末65份、Co粉末1份、TaC3份、NbC2份、MoC8份、ZrC6份、TiC25份。
过渡层3由混合好的硬质合金粉末铺设于碳素钢层20内表面,过渡层3厚度为0.8mm。
硬质合金粉末由以下重量份原料组成:铁粉50份,钴粉20份,碳化钨、碳化钽、碳化铌、碳化钼、碳化锆和碳化钛总量30份。
碳素钢层与硬质合金体积比为:1:1。
碳素钢层一体成型。
实施例3
如图3所示,本实施例提供一种用于实施例1及实施例2中硬质合金的成型方法,包括以下步骤:
单个结合层,在所述碳素钢层的凹槽部内依次填充过渡层和硬质合金层,覆盖层设置在结合层上部,在真空条件下进行压制成型并烧结,所述烧结温度分别达到300、600、1000℃时,保温25min,当烧结温度达到1500℃时,经过50min降温至1150℃继续加热至1500℃并保温55min,冷却。
多个结合层,在所述碳素钢层的凹槽部内依次填充过渡层和硬质合金层,多个结合层叠加设置,并在第一结合层上部设置覆盖层,在真空条件下进行压制成型并烧结,所述烧结温度分别达到300、600、1000℃时,保温25min,当烧结温度达到1500℃时,经过50min降温至1150℃继续加热至1500℃并保温55min,冷却。
本实施例中冷却通过通过液态二氧化碳实现。
对比例1
与实施例1相比,本对比例不同在于,硬质合金粉末由以下重量份原料组成:WC粉末65份、Co粉末30份、TaC3.0份、NbC2份、MoC8份、ZrC6份、TiC25份。
对比例2
与实施例1相比,本对比例不同在于,外层结构与内层结构体积比为:1:4。
表一:
硬度HRA≥ | 抗弯强度Mpa | 冲击韧性J.CM2 | |
实施例1 | 93 | 1450 | 0.21 |
对比例1 | 88 | 1300 | 0.18 |
对比例2 | 92 | 900 | 0.05 |
如表一所示,实施例1中硬度、抗顽强度及冲击韧性都具有良好的数据支撑,反观对比例1中,由于增加了粉末配比中Co粉末的含量,导致硬度较低;对比例2中,外层结构即碳素钢层占比较小,内层结构即硬质合金层占比较大,冲击韧性较低。
因此,本发明的硬质合金结构通过覆盖层和结合层的有效结合,且结合层可以拓展到多层,其中,结合层包括碳素钢层和硬质合金,碳素钢层一体成型,保证了结构的韧性,配合采用硬度和耐磨性较高的硬质合金,与韧性较高的碳素钢配合,在结构方面有效的调节了耐磨性和韧性及抗疲劳性之间的矛盾;
过渡层能够将硬质合金层与碳素钢层有机地结合在一起,可以防止材料的液氮、液态二氧化碳等急速冷却过程中造成硬质合金层出现微观裂纹防止材料出现脱层现象,从而提高棒材结构的整体性能。
硬质合金设置在碳素钢层凹槽部内,凹槽部包括凹槽一和凹槽二,增加其与硬质合金的结合强度,其中,硬质合金主要用来做刀具的切削面,碳素钢作为刀具的支撑层和弯矩受力层,既保证了刀具的硬度,也提高了刀具的强度。
成型刀具时,只需以一定的角度磨削掉部分表层碳素钢,露出小段芯层长度,然后加工成所需刀具形状即可,如刀具磨损过多影响加工质量良时,可继续磨削以部分碳素刚层,露出更多芯层,然后重新加工成所需刀具形状,从而达到连续使用,节约材料,降低成本的目的。
同时通过减少硬质合金层尺寸的方法来减少单位材料中硬质贵金属的含量,从而降低成本,达到同时具有高硬度、高耐磨性、高韧性,且成本低廉。
显然,上述实施例仅仅是为清楚地说明本发明的技术方案所作的举例,而并非是对本发明的实施方式的限定。对于所属领域的普通技术人员来说,在上述说明的基础上还可以做出其它不同形式的变化或变动。凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等,均应包含在本发明权利要求的保护之内。
Claims (10)
1.一种硬质合金结构,其特征在于,包括覆盖层和结合层,所述结合层包括碳素钢层和硬质合金层,所述碳素钢层包括凹槽部,所述凹槽部包括凹槽一和凹槽二,所述硬质合金层嵌设于所述凹槽一和凹槽二内,所述硬质合金层经硬质合金粉末高温高压在真空条件下成型,所述硬质合金粉末填充在所述碳素钢层凹槽部内,所述覆盖层设置于结合层上部。
2.根据权利要求1所述硬质合金结构,其特征在于,还包括过渡层,所述过渡层铺设于碳素钢层内表面,所述过渡层厚度小于1mm。
3.根据权利要求1或2所述硬质合金结构,其特征在于,所述结合层个数为多个,所述多个结合层之间叠加设置。
4.根据权利要求1所述硬质合金结构,其特征在于,所述硬质合金粉末由以下重量份原料组成:WC粉末65~70份、Co粉末1~3份、TaC3~3.5份、NbC2~3份、MoC8~10份、ZrC6~8份、TiC25~30份。
5.根据权利要求2所述硬质合金结构,其特征在于,所述过渡层由硬质合金粉末经高温高压在真空条件下成型,所述硬质合金粉末由以下重量份原料组成:铁粉30~50份,钴粉10~20份,碳化钨、碳化钽、碳化铌、碳化钼、碳化锆和碳化钛总量≤40份。
6.根据权利要求1所述硬质合金结构,其特征在于,所述碳素钢层与硬质合金层体积比为:1~1:1.5。
7.根据权利要求1所述硬质合金结构,其特征在于,所述碳素钢层一体成型。
8.一种用于权利要求1~7任意一条所述硬质合金结构的成型方法,其特征在于,包括以下步骤:
单个结合层,在所述碳素钢层的凹槽部内依次填充过渡层和硬质合金层,覆盖层设置在结合层上部,在真空条件下进行压制成型并烧结,所述烧结温度分别达到300~310、600~610、1000~1100℃时,保温25~30min,当烧结温度达到1500~1550℃时,经过50~60min降温至1150~1200℃继续加热至1500~1550℃并保温55~60min,冷却。
多个结合层,在所述碳素钢层的凹槽部内依次填充过渡层和硬质合金层,多个结合层叠加设置,并在第一结合层上部设置覆盖层,在真空条件下进行压制成型并烧结,所述烧结温度分别达到300~310、600~610、1000~1100℃时,保温25~30min,当烧结温度达到1500~1550℃时,经过50~60min降温至1150~1200℃继续加热至1500~1550℃并保温55~60min,冷却。
9.根据权利要求8所述成型方法,其特征在于,所述冷却通过液态二氧化碳、液氮或冷却水雾化任意一种方式实现。
10.一种权利要求1~7任意一项所述硬质合金结构在刀具上的应用,其特征在于,当作为硬质刀具时,以一定角度磨掉外层碳素钢,露出内层硬质合金层,并加工成刀具形状,用于机械加工;
当刀口磨损后,继续磨掉部分碳素钢层,露出更多的硬质合金,重新加工成刀具。
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