CN109365957B - Multilayer composite powder and self-protection open arc surfacing high-chromium alloy method - Google Patents

Multilayer composite powder and self-protection open arc surfacing high-chromium alloy method Download PDF

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CN109365957B
CN109365957B CN201811577238.5A CN201811577238A CN109365957B CN 109365957 B CN109365957 B CN 109365957B CN 201811577238 A CN201811577238 A CN 201811577238A CN 109365957 B CN109365957 B CN 109365957B
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multilayer composite
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CN109365957A (en
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龚建勋
姚惠文
程诗尧
马蓦
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Xiangtan University
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/04Welding for other purposes than joining, e.g. built-up welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/16Arc welding or cutting making use of shielding gas

Abstract

The invention adopts a method for overlaying high-chromium alloy by multilayer composite powder particles and self-protection open arc, which comprises the steps of respectively mixing various powder components through powder layersThe method comprises the steps of inner layer bonding, middle layer bonding, outer layer bonding, sintering, sieving and the like to form multilayer composite powder particles with specific granularity and H08A solid welding wires serving as electric arc carriers to be used as surfacing materials, self-protection open arc welding is carried out, the composite powder particle melt and the H08A solid welding wires are fused into an integrated molten pool, and nascent M is formed7C3High chromium alloy structure with main wear-resistant phase. The method has the advantages of simple preparation process and high deposition efficiency, and the prepared high-chromium alloy has good wear resistance, completely meets practical requirements, and can be used for self-protecting open arc surfacing of parts and wear-resistant layers under the working condition of abrasive wear.

Description

Multilayer composite powder and self-protection open arc surfacing high-chromium alloy method
Technical Field
The invention belongs to the technical field of wear-resistant surfacing, and particularly relates to a multilayer composite powder particle and a method for self-protection open arc surfacing of high-chromium alloy.
Background
The wear resistance of the wear-resistant particles of the alloy is related to the size, form, distribution, quantity and even orientation of the carbide contained in the wear-resistant particles, wherein the primary carbide particles can effectively resist the wear of abrasive particles as a main wear-resistant phase due to large size, and play a main role in the wear resistance of the alloy.
The wear-resistant alloy is mainly made of high-chromium and high-boron alloy. High chromium alloys contain a relatively high amount of M7C3Phases (1300-1800 HV) and M23C6The (1140HV) is widely applied to the manufacture of wear-resistant parts of mechanical parts, such as cement grinding rollers, lining plates, concrete delivery pipes and the like; high boron alloys have the advantage of being economical due to the tendency to form more boride wear-resistant phases due to the low solubility of boron in substrates such as austenite and ferrite, and have been studied and applied in recent years.
At present, the preparation of the wear-resistant alloy is formed by overlaying in addition to casting. In the surfacing production, welding materials such as a coated electrode, a solid wire, a flux-cored wire and the like are usually adopted to perform submerged arc or self-protection open arc surfacing of the wear-resistant alloy layer. The coated electrode has low deposition efficiency and gradually reduced proportion. The solid welding wire is limited by the process requirements of drawing and reducing diameter and the like because the amount of alloy elements which can be accommodated in the solid welding wire is extremely limited, and only a few kinds of wear-resistant steel with low alloy content can be prepared. The flux-cored wire is prepared by wrapping powder components by a low-carbon plastic steel strip, closing the powder components into an overlapped O-shaped section structure, rolling, reducing and forming, and changing the composition proportion of the powder components to prepare a series of surfacing alloys with different components. In addition, when the components and the performance of the surfacing alloy are required to be changed, the feedback adjustment and research time is too long, and the method is not gradually adapted to the existing requirements of diversification and rapid supply of the components of the surfacing alloy, and the development of novel surfacing materials is expected.
Moreover, the price of components such as ferroalloys and the like is rising too fast due to the increasingly harsh environmental requirements. The utilization rate of the components of the surfacing alloy is improved, and the oxidation burning loss rate is reduced, so that the cost of raw materials is reduced, and the problem to be solved is solved urgently.
Disclosure of Invention
The invention aims to provide a high-chromium alloy surfacing material and a surfacing method which have simple preparation process and rapid supply aiming at the defects of the conventional surfacing material and the conventional surfacing method.
The purpose of the invention is realized by the following technical scheme: a method for multilayer composite powder and self-protection open arc surfacing high-chromium alloy comprises the following sequential preparation steps:
(1) the powder components of the inner layer, the middle layer and the outer layer of the multilayer composite powder particle are mixed: sieving metal, alloy or other powder components, weighing according to the powder component composition proportion of the multilayer composite powder particles, respectively pouring the powder components of the inner layer, the middle layer and the outer layer of the multilayer composite powder particles into three separate containers according to the powder component composition requirements of the inner layer, the middle layer and the outer layer of the multilayer composite powder particles, and fully stirring to uniformly mix the powder components to form corresponding mixed powder of each layer of the composite powder particles;
the powder components of the multilayer composite powder particles are as follows: 50-60 wt% of high-carbon ferrochrome/FeCr70C8.0 with chromium content of 68-72% and carbon content of 8%; 1-14 wt% of ferrovanadium/FeV 50-A with vanadium content of 50%; 10-15 wt% of flake graphite/C with carbon content not less than 98%; 5-12 wt% of ferroboron/FeB18C0.5 with boron content of 18%; 2-4 wt% of ferrosilicon/FeSi 45 containing 40-47% of silicon; 0.5-2.0 wt% of superfine aluminum powder/Al with aluminum content not less than 99%; 1-3 wt% of ultrafine graphite/C with carbon content not less than 98%; the balance of reduced iron powder/Fe with the iron content not less than 98 percent;
wherein the high carbon ferrochrome and ferrovanadium are inner layer powder components of composite powder particles; the flake graphite is composed of intermediate layer powder components of composite powder particles; the external powder component of the composite powder particles comprises ferroboron, ferrosilicon, ultra-fine graphite, ultra-fine aluminum powder and reduced iron powder;
(2) preparing the inner layer of the multilayer composite powder particle: adding a liquid adhesive into an inner layer powder container containing the composite powder particles of the high-carbon ferrochrome and ferrovanadium obtained in the step (1), continuously stirring during the addition, rotating the inner layer powder to form wet composite powder particles, standing for 1-2 hours for shaping, and evaporating the moisture on the surface layers of the wet composite powder particles by using hot air; then, sieving the composite powder particles by a 20-mesh sieve to remove the powder particles larger than 20 meshes, and then sieving the powder particles by a 30-mesh sieve to remove the powder particles smaller than 30 meshes, thereby finally obtaining the composite powder particles of 20-30 meshes;
(3) preparing an intermediate layer of the multilayer composite powder particles: spreading the composite powder particles obtained in the step (2) to ensure that the stacking height of the composite powder particles is less than 5mm, spraying a liquid binder on the surfaces of the composite powder particles, and slightly turning the composite powder particles to ensure that a layer of liquid binder is uniformly adhered to the surfaces of the composite powder particles; then, uniformly scattering the scale graphite component in the intermediate layer container obtained in the step (1) on the surface of the wet powder particles, and slightly turning over the wet powder particles during the scattering so as to uniformly adhere a layer of scale graphite on the surface of the composite powder particles; then standing for 1-2 hours at room temperature, putting the container filled with the double-layer composite powder particles into a drying furnace, heating to 100-200 ℃, keeping the temperature for 2 hours, discharging and cooling to room temperature;
(4) preparing the outer layer of the multilayer composite powder particle: spreading the double-layer composite powder particles obtained in the step (3) to ensure that the stacking height of the double-layer composite powder particles is less than 10mm, spraying a liquid binder on the surfaces of the double-layer composite powder particles, and slightly turning over the double-layer composite powder particles to ensure that a layer of liquid binder is adhered to the surfaces of the double-layer composite powder particles; then, uniformly scattering powder components in an outer layer component container of the composite powder particles obtained in the step (1) on the surfaces of the double-layer composite powder particles, and slightly turning over the powder particles to enable the surfaces of the double-layer composite powder particles to be adhered with a layer of outer layer component powder of the composite powder particles; then standing for 1-2 hours for shaping to complete the preparation process of the multilayer composite powder particles;
(5) sintering of multilayer composite particles: putting the container containing the multilayer composite powder particles obtained in the step (4) into a sintering furnace, heating to the sintering temperature of 250-400 ℃, preserving heat for 2-4 hours, cooling to room temperature along with the furnace, and discharging;
(6) screening and classifying the multilayer composite powder particles: sieving the discharged powder particles with a 5-mesh sieve to remove large particles larger than 5 meshes, sieving the discharged powder particles with a 20-mesh sieve to remove small particles smaller than 20 meshes, and obtaining composite powder particles with the particle size of 5-20 meshes;
(7) multilayer composite powder particles and an H08A solid welding wire are used as surfacing materials to perform self-protection open arc surfacing on the high-chromium alloy: setting surfacing process parameters of an automatic welding machine, and keeping the surfacing parameters unchanged every time; presetting the multilayer composite powder particles obtained in the step (6) on a low-carbon steel substrate, and adjusting the height and the width of a preset powder particle layer to enable the ratio of the preset weight of the multilayer composite powder particles on a welding bead in unit length to the melting weight of a solid welding wire on the welding bead to meet the set requirement;
according to the requirements, the multilayer composite powder particles and the H08A solid welding wire are used as surfacing materials to carry out self-protection open arc surfacing, so that the multilayer composite powder particle melt and the solid welding wire are molten and fused into an integrated molten pool; cooling and solidifying the molten pool to form a first layer of welding line, and air cooling; and then the second layer and the third layer are respectively overlaid in the same way.
Specifically, in the step (1), the powder components of the high-carbon ferrochrome, the ferrovanadium, the ferrosilicon, the ferroboron, the flake graphite and the reduced iron powder are sieved by a 60-mesh sieve, and the ultra-fine aluminum powder and the ultra-fine graphite are sieved by a 300-mesh sieve.
Specifically, in the step (2), the liquid binder is sodium silicate type water glass with a baume degree of 20-40 and a modulus of 3.0-3.3; the ratio of the doping amount of the liquid binder to the weight of the mixed powder is 10-20 ml of sodium silicate type water glass per 100g of the mixed powder.
Specifically, in the step (3), the liquid binder is sodium silicate type water glass with a baume degree of 20-40 and a modulus of 3.0-3.3; the ratio of the doping amount of the liquid binder to the weight of the dry mixed powder contained in the composite powder particles obtained in the step (2) is 10-20 ml of sodium silicate type water glass per 100g of mixed powder.
Specifically, in the step (4), the liquid binder is sodium silicate type water glass with a baume degree of 20-40 and a modulus of 3.0-3.3; and (3) the ratio of the doping amount of the liquid binder to the weight of the dry mixed powder contained in the composite powder particles obtained in the step (3) is 10-20 ml of sodium silicate type water glass per 100g of mixed powder.
Specifically, in the step (7), the surfacing process parameters are as follows: the polarity is direct current reverse connection, the current is 380-450A, the traveling speed of the trolley is 10-15 m/h, and the voltage value is 26-35V.
Specifically, in the step (7), the ratio of the preset weight of the multilayer composite powder particles on the welding bead with the unit length to the melting weight of the solid welding wire on the welding bead is 0.70-1.00.
Specifically, in the step (7), the diameter of the H08A solid welding wire is phi 2.5 mm-phi 3.0 mm.
The invention relates to a multilayer composite powder and a method for overlaying high-chromium alloy by self-protection open arc, which adopts the steps of mixing various powder components through powder layers, bonding an inner layer, bonding an intermediate layer, bonding an outer layer, sintering, sieving and the like to form multilayer composite powder with specific granularity and H08A solid welding wire serving as an electric arc carrier as an overlaying material to carry out self-protection open arc welding, so that a composite powder melt and H08A solid welding wire are fused into an integrated molten pool to form primary heptacarbide metal element/M7C3The high chromium alloy structure with the main wear-resistant phase, wherein M comprises Fe, Cr, V and other elements.
Compared with the prior art, the invention has the following innovation points and beneficial effects:
(1) the material structure and the design concept are different: the multilayer composite powder particles of the invention are composed of an inner layer, a middle layer, an outer layer and the like, and the characteristics of the components of the layers are obviously outstanding, which is obviously different from the structures of surfacing materials such as coated welding rods and flux-cored wires; in addition, the loss design for reducing the precious alloy components is introduced into each layer of components of the powder particles, so that the core precious components are efficiently and intensively utilized.
(2) Small amount of smoke and dust during build-up welding: the powder particles of the invention are composed of an inner layer, an intermediate layer and an outer layer, wherein the outer layer is composed of ferroboron, ferrosilicon, ultrafine graphite, reduced iron powder and ultrafine aluminum powder, wherein the ultrafine aluminum powder can be deoxidized in advance, and the ultrafine graphite can be oxidized and protected to CO or CO in advance2The protective effect is achieved, the components such as ferroboron and ferrosilicon can perform the self-deoxidation effect in the later period, the melting temperature of the composite powder particles is reduced, and the weld forming is improved. From the self-protection open arc surfacing effect, because the surfacing material is subjected to the passive heating action of the electric arc, the smoke amount caused by molten drop blasting is obviously reduced, the smoke amount is obviously smaller than the surfacing smoke amount of the similar flux-cored wire, and the operation environment of a welder is improved.
(3) The alloy component has high utilization efficiency: the smoke amount is obviously lower than that of the similar self-protection flux-cored wire, which shows that the burning loss rate of the alloy elements of the welding material is obviously reduced; in addition, the outer layer is composed of cheap ferrosilicon, ferroboron, aluminum powder and ultrafine graphite components, so that the burning loss rate of the high-carbon ferrochrome, ferrovanadium and other components in the inner layer is effectively reduced; both of the two aspects improve the utilization rate of the core precious alloy components, thereby reducing the cost of raw materials.
(4) The number of the primary wear-resistant phases is large: for the self-protection open arc surfacing method of powder and solid welding wires, the biggest problem is that the heat is dissipated too much during surfacing, and a complete welding seam can be formed by deposition only through higher heat input, so that the burning loss of carbon components is too much, and the high chromium alloy with a hypereutectic structure cannot be formed due to too large dilution of the components of a low alloy base metal. The composite powder particles adopt a multilayer structure form, so that the oxidation burning loss of inner layer components, particularly the carbon burning loss in high-carbon ferrochrome powder components, is effectively reduced; the ferrosilicon component added in the outer layer reversely forces the carbon amount to be concentrated, which is beneficial to primary M7C3A large amount of nascent M is obtained7C3Thus improving the wear resistance of the surfacing alloy.
(5) The preparation process of the surfacing material is economical and simple: the multilayer composite powder particles of the invention are formed into multilayer structure composite powder particles with specific granularity by carrying out the procedures of mixing the components of the required alloy powder in layers, multilayer bonding granulation, sintering, sieving and the like, thereby overcoming the defect that the heterogeneous components of the flux-cored wire can not be classified into different structures.
Drawings
FIG. 1 is a structural morphology of a high chromium alloy surface layer prepared by the method of the present invention.
FIG. 2 is a phase composition diagram of the high chromium alloy prepared by the method of the present invention shown in FIG. 1.
FIG. 3 is a structural morphology of the surface layer of the high-chromium alloy in comparative example 1 by powder open arc deposition.
FIG. 4 is a phase composition diagram of the powder open arc weld deposit high chromium alloy of comparative example 1 shown in FIG. 3.
FIG. 5 is a wear profile of the high chromium alloy prepared by the method of the present invention shown in FIG. 1.
FIG. 6 is a wear profile of the powder open arc hardfacing alloy of comparative example 1 shown in FIG. 3.
FIG. 7 is a schematic view of the structure of the multilayer composite powder particles of the method of the present invention
Detailed Description
The present invention will be described in further detail with reference to the drawings and examples, but the embodiments of the present invention are not limited thereto.
Example 1
Sieving the powder components of high-carbon ferrochrome, ferrovanadium, ferrosilicon, ferroboron, scale graphite and reduced iron powder with a 60-mesh sieve, sieving the ultrafine aluminum powder and the ultrafine graphite with a 300-mesh sieve, weighing according to the powder component composition proportion of the multilayer composite particles, and pouring the powder components of the layers into three separate containers according to the powder component composition requirements of the inner layer, the middle layer and the outer layer of the multilayer composite particles, and fully stirring to uniformly mix the powder components to form corresponding mixed powder of each layer;
the powder composition ratio (weight percentage) of the multilayer composite powder particles is as follows: 54% of high-carbon ferrochromium and 4% of ferrovanadium; 14.5% of flake graphite and 11% of ferroboron; 3.5% of ferrosilicon, 1.5% of ultra-fine aluminum powder, 3% of ultra-fine graphite and 8.5% of reduced iron powder;
wherein the high carbon ferrochrome and ferrovanadium are formed by inner layer powder components of multilayer composite powder particles; the flake graphite is composed of powder components in the middle layer of a plurality of layers of composite powder particles; the external powder component of the multilayer composite powder particles comprises ferroboron, ferrosilicon, ultrafine graphite, ultrafine aluminum powder and reduced iron powder;
firstly, adding sodium silicate type water glass with Baume degree of 25 and modulus of 3.3 into an inner layer powder container containing multilayer composite powder particles of high-carbon ferrochrome and ferrovanadium, and enabling the ratio of the doping amount of the water glass to the weight of mixed powder to be 15ml of sodium silicate type water glass/100 g of mixed powder; stirring continuously during the adding period, rotating the inner layer powder to form wet composite powder particles, standing for 1.5 hours to shape, and evaporating the moisture on the surface layers of the wet composite powder particles by using hot air; then, sieving the composite powder particles by a 20-mesh sieve to remove the powder particles larger than 20 meshes, and then sieving the powder particles by a 30-mesh sieve to remove the powder particles smaller than 30 meshes, thereby finally obtaining the composite powder particles of 20-30 meshes;
spreading the obtained single-layer composite powder particles, enabling the stacking height of the single-layer composite powder particles to be smaller than 5mm, spraying sodium silicate type water glass with the Baume degree of 28 and the modulus of 3.0 to the composite powder particles, enabling the ratio of the doping amount of the water glass to the weight of dry mixed powder contained in the obtained single-layer composite powder particles to be 20ml of sodium silicate type water glass/100 g of mixed powder, and slightly turning the composite powder particles to enable the surface of the single-layer composite powder particles to be uniformly adhered with a layer of the sodium silicate type water glass; then, uniformly scattering the scale graphite component in the middle layer of the multilayer composite powder particles on the surface of the wet powder particles, and slightly turning over the wet powder particles during the scattering, so that a layer of scale graphite is uniformly adhered to the surface of the composite powder particles; then standing for 1.5 hours at room temperature, putting the container containing the double-layer composite powder particles into a drying furnace, heating to 200 ℃, keeping the temperature for 2 hours, discharging from the furnace and cooling to room temperature;
spreading the obtained double-layer composite powder particles adhered with the middle-layer graphite component to ensure that the stacking height of the double-layer composite powder particles is less than 10mm, spraying sodium silicate type water glass with the Baume degree of 35 and the modulus of 3.3 on the surface of the double-layer composite powder particles to ensure that the ratio of the doping amount of the water glass to the weight of dry mixed powder contained in the double-layer composite powder particles is 15ml of sodium silicate type water glass/100 g of mixed powder, and slightly turning over the double-layer composite powder particles to ensure that a layer of the sodium silicate type water glass is adhered on the surface of the double-layer composite powder; then, the outer layer mixed powder component of the multilayer composite powder particles is uniformly scattered on the surface of the double-layer composite powder particles, and then the powder particles are turned over to ensure that the surface of the powder particles is adhered with a layer of outer layer component powder of the composite powder particles; standing for 2 hours to shape, and finishing the preparation process of the multilayer composite powder particles;
putting the container filled with the multilayer composite powder particles into a sintering furnace, heating to the sintering temperature of 270 ℃, preserving heat for 3 hours, cooling to room temperature along with the furnace, and discharging; sieving the discharged powder particles with a 5-mesh sieve to remove large particles larger than 5 meshes, and then sieving with a 20-mesh sieve to remove small particles smaller than 20 meshes to obtain multilayer composite powder particles with the particle size of 5-20 meshes;
then, presetting the sintered and sieved multilayer composite powder particles on a welding bead on a Q235A steel plate with the length of 160mm, the width of 75mm and the thickness of 16mm, and adjusting the height and the width of the preset powder particle layer to ensure that the ratio of the weight of the composite powder particles on the unit length of a welding bead to the melting weight of an H08A solid welding wire with the diameter of phi 2.5mm passing through the welding bead is kept within the range of 0.85-0.90, and the surfacing process parameters are not changed every time;
before surfacing, selecting the polarity of an automatic welding machine ZD5-1000E as direct current reverse connection, wherein surfacing process parameters are shown in Table 1;
and starting a welding machine, and carrying out self-protection open arc surfacing by using the multilayer composite powder particles and the H08A solid welding wire to fuse the composite powder particle melt and the H08A solid welding wire molten drops into an integrated molten pool. Cooling and solidifying the molten pool to form a first layer of welding line, and air cooling to below 150 ℃; and then respectively overlaying the second layer and the third layer in the same way, and performing air cooling to room temperature to obtain an overlaying welding seam without defects such as cracks, air holes and the like.
The surfacing test piece is processed by a wire cutting machine to prepare a wear-resistant test piece with the thickness of 57mm multiplied by 25.5mm multiplied by 6mm, and the macroscopic hardness of the surface of the wear-resistant test piece is tested by an HR-150 Rockwell hardness tester.
TABLE 1 self-shielded open arc build-up welding process parameters for multilayer composite powder particles and solid welding wires
Figure DEST_PATH_IMAGE001
The wear resistance test adopts an MLS-225B type wet sand rubber wheel type wear testing machine, and the test conditions are as follows: the diameter of the rubber wheel is 178mm, the hardness is 60 Shore, the weight is 2.5 kg, and the rubber wheel rotatesThe speed is 240 r/min, and the proportion of the mortar is 1500 g of quartz sand of 40-60 meshes and 1000 g of tap water. Pre-grinding a sample for 1000 turns, washing, drying, and weighing the initial weight M0Then the mixture is cleaned and dried after 1000 turns in a formal test, and weighed M1The absolute weight loss of the sample (delta M) is M0-M1
The following 1# overlay welding sample described in relation to the proportion 1 was used as a standard sample, and the relative wear coefficient was defined as absolute weight loss of the standard sample/absolute weight loss of the sample, and the test results are shown in table 2.
The structure and phase composition of the surface layer of the high-chromium alloy layer of example 1 are shown in fig. 1 and 2, and the wear topography of the high-chromium overlay alloy prepared in example 1 is shown in fig. 5. The structure of the multilayer composite powder particle is schematically shown in FIG. 7.
Example 2
Sieving the powder components of high-carbon ferrochrome, ferrovanadium, ferrosilicon, ferroboron, scale graphite and reduced iron powder with a 60-mesh sieve, sieving the ultrafine aluminum powder and the ultrafine graphite with a 300-mesh sieve, weighing according to the powder component composition proportion of the multilayer composite particles, and pouring the powder components of the layers into three separate containers according to the powder component composition requirements of the inner layer, the middle layer and the outer layer of the multilayer composite particles, and fully stirring to uniformly mix the powder components to form corresponding mixed powder of each layer;
the powder composition ratio (weight percentage) of the multilayer composite powder particles is as follows: 60% of high-carbon ferrochromium and 2% of ferrovanadium; 12% of flake graphite and 11% of ferroboron; 3% of ferrosilicon, 1% of superfine aluminum powder, 3% of superfine graphite and 8% of reduced iron powder;
wherein the high carbon ferrochrome and ferrovanadium are formed by inner layer powder components of multilayer composite powder particles; the flake graphite is composed of powder components in the middle layer of a plurality of layers of composite powder particles; the external powder component of the multilayer composite powder particles comprises ferroboron, ferrosilicon, ultrafine graphite, ultrafine aluminum powder and reduced iron powder;
firstly, adding sodium silicate type water glass with Baume degree of 20 and modulus of 3.0 into an inner layer powder container containing multilayer composite powder particles of high-carbon ferrochrome and ferrovanadium, and enabling the ratio of the doping amount of the sodium silicate type water glass to the weight of mixed powder to be 20ml of sodium silicate type water glass/100 g of mixed powder; stirring continuously during the adding period, rotating the inner layer powder to form wet composite powder particles, standing for 1.2 hours for shaping, and evaporating the moisture on the surface layers of the wet composite powder particles by using hot air; then, sieving the composite powder particles by a 20-mesh sieve to remove the powder particles larger than 20 meshes, and then sieving by a 30-mesh sieve to remove the powder particles smaller than 30 meshes to finally obtain the composite powder particles of 20-30 meshes;
spreading the obtained single-layer composite powder particles, enabling the stacking height of the single-layer composite powder particles to be smaller than 5mm, spraying sodium silicate type water glass with the Baume degree of 25 and the modulus of 3.0 to the composite powder particles, enabling the ratio of the doping amount of the sodium silicate type water glass to the weight of dry mixed powder contained in the obtained single-layer composite powder particles to be 13ml of sodium silicate type water glass/100 g of mixed powder, and slightly turning the composite powder particles to enable the surface of the single-layer composite powder particles to be uniformly adhered with a layer of the sodium silicate type water glass; then uniformly scattering the middle layer crystalline flake graphite component of the multilayer composite powder particles on the surface of the wet powder particles, and slightly turning over the wet powder particles in the period to ensure that a layer of crystalline flake graphite is uniformly adhered on the surface of the composite powder particles; then standing for 2 hours at room temperature, putting the container filled with the double-layer composite powder particles into a drying furnace, heating to 180 ℃, keeping the temperature for 2 hours, discharging from the furnace and cooling to room temperature;
spreading the obtained double-layer composite powder particles adhered with the graphite component of the intermediate layer to ensure that the stacking height of the double-layer composite powder particles is less than 10mm, spraying sodium silicate type water glass with the Baume degree of 30 and the modulus of 3.0 on the surface of the double-layer composite powder particles to ensure that the ratio of the doping amount of the water glass to the weight of dry mixed powder contained in the double-layer composite powder particles is 15ml of sodium silicate type water glass/100 g of mixed powder, and slightly turning over the double-layer composite powder particles to ensure that a layer of the sodium silicate type water glass is adhered on the surface of the double-layer composite; then uniformly scattering the outer layer component of the obtained composite powder particles on the surface of the double-layer composite powder particles, and turning over the powder particles to ensure that a layer of composite powder particle outer layer component powder is adhered on the surface of the powder particles; standing for 1.6 hours to shape, and finishing the preparation process of the multilayer composite powder particles;
putting the container filled with the multilayer composite powder particles into a sintering furnace, heating to the sintering temperature of 300 ℃, preserving heat for 3 hours, cooling to room temperature along with the furnace, and discharging; the multilayer composite powder particles discharged from the furnace are firstly screened by a 5-mesh sieve, and large particles larger than 5 meshes are removed; sieving the powder by a 20-mesh sieve to remove small particles smaller than 20 meshes to obtain multilayer composite powder particles with the particle size of 5-20 meshes;
and finally, presetting the sintered and sieved multilayer composite powder particles on a Q235A steel plate welding bead with the length of 160mm, the width of 75mm and the thickness of 16mm, and adjusting the height and the width of the preset powder particle layer to ensure that the ratio of the weight of the composite powder particles on the unit welding bead length to the melting weight of the H08A solid welding wire with the diameter of phi 2.5mm passing through the welding bead is kept within the range of 0.90-0.95, and the technological parameters of each surfacing welding are unchanged.
The remaining steps and the abrasion resistance test were the same as in example 1.
Example 3
Sieving the powder components of high-carbon ferrochrome, ferrovanadium, ferrosilicon, ferroboron, scale graphite and reduced iron powder with a 60-mesh sieve, sieving the ultra-fine aluminum powder and the ultra-fine graphite with a 300-mesh sieve, weighing according to the powder component composition proportion of the multilayer composite particles, and pouring the powder components of the layers into three separate containers according to the powder component composition requirements of the inner layer, the middle layer and the outer layer of the multilayer composite particles, and fully stirring to uniformly mix the powder components to form corresponding mixed powder of each layer;
the powder composition ratio (weight percentage) of the multilayer composite powder particles is as follows: 52% of high-carbon ferrochrome and 12% of ferrovanadium; 15% of flake graphite and 10% of ferroboron; 2% of ferrosilicon, 2% of ultra-fine aluminum powder, 2% of ultra-fine graphite and 5% of reduced iron powder;
wherein the high carbon ferrochrome and ferrovanadium are formed by inner layer powder components of multilayer composite powder particles; the flake graphite is composed of powder components in the middle layer of a plurality of layers of composite powder particles; the external powder component of the multilayer composite powder particles comprises ferroboron, ferrosilicon, ultrafine graphite, ultrafine aluminum powder and reduced iron powder;
firstly, adding sodium silicate type water glass with the Baume degree of 30 and the modulus of 3.3 into a composite inner layer powder container containing high-carbon ferrochrome and ferrovanadium, so that the ratio of the doping amount of the sodium silicate type water glass to the weight of mixed powder is 16ml of sodium silicate type water glass/100 g of mixed powder; stirring continuously during the adding period, rotating the inner layer powder to form wet composite powder particles, standing for 2 hours to shape, and evaporating the moisture on the surface layers of the wet composite powder particles by using hot air; then, sieving the composite powder particles by a 20-mesh sieve to remove the powder particles larger than 20 meshes, and then sieving the powder particles by a 30-mesh sieve to remove the powder particles smaller than 30 meshes, thereby finally obtaining the composite powder particles of 20-30 meshes;
spreading the obtained single-layer composite powder particles, enabling the stacking height of the single-layer composite powder particles to be less than 5mm, spraying sodium silicate type water glass with the Baume degree of 35 and the modulus of 3.3 on the composite powder particles, enabling the ratio of the doping amount of the sodium silicate type water glass to the weight of dry mixed powder contained in the obtained single-layer composite powder particles to be 12ml of sodium silicate type water glass/100 g of mixed powder, and slightly turning the composite powder particles to enable the surface of the single-layer composite powder particles to be uniformly adhered with a layer of the sodium silicate type water glass; then uniformly scattering the scale graphite component in the middle layer of the multilayer composite powder particles on the surface of the wet powder particles, and slightly turning over the wet powder particles in the period to ensure that a layer of scale graphite is uniformly adhered to the surface of the composite powder particles; standing at room temperature for 1.8 hours, putting the container filled with the double-layer composite powder particles into a drying furnace, heating to 150 ℃, keeping the temperature for 2 hours, discharging from the furnace and cooling to room temperature;
spreading the obtained double-layer composite powder particles adhered with the middle-layer graphite component to ensure that the stacking height of the double-layer composite powder particles is less than 10mm, spraying sodium silicate type water glass with the Baume degree of 40 and the modulus of 3.3 on the surface of the double-layer composite powder particles to ensure that the ratio of the doping amount of the sodium silicate type water glass to the weight of dry mixed powder contained in the double-layer composite powder particles is 16ml of sodium silicate type water glass/100 g of mixed powder, and slightly turning over the double-layer composite powder particles to ensure that a layer of the sodium silicate type water glass is adhered on the surface of the double-layer composite powder; then, the outer layer powder component of the multilayer composite powder particles is uniformly sprayed on the surface of the double-layer composite powder particles, and the powder particles are turned over to enable the surface of the double-layer composite powder particles to be adhered with a layer of composite powder particle outer layer component powder; standing for 2 hours to shape, and finishing the preparation process of the multilayer composite powder particles;
putting the container filled with the multilayer composite powder particles into a sintering furnace, heating to the sintering temperature of 400 ℃, preserving heat for 3 hours, cooling to room temperature along with the furnace, and discharging; the particles discharged out of the furnace are firstly screened by a 5-mesh sieve, and large particles larger than 5 meshes are removed; sieving the powder by a 20-mesh sieve to remove small particles smaller than 20 meshes to obtain multilayer composite powder particles with the particle size of 5-20 meshes;
and finally, presetting the sintered and sieved multilayer composite powder particles on a Q235A steel plate welding bead with the length of 160mm, the width of 75mm and the thickness of 16mm, and adjusting the height and the width of the preset powder particle layer to keep the ratio of the weight of the composite powder particles on the unit welding bead length to the melting weight of the H08A solid welding wire with the diameter of phi 3.0mm passing through the welding bead within the range of 0.87-0.92, wherein the surfacing process parameters are unchanged every time.
The remaining steps and the abrasion resistance test were the same as in example 1.
Comparative example 1
Sieving the powder components of high-carbon ferrochrome, ferrovanadium, ferrosilicon, ferroboron, scale graphite and reduced iron powder with a 60-mesh sieve, and sieving the ultra-fine aluminum powder and the ultra-fine graphite with a 300-mesh sieve; the weighed mixed powder comprises the following components in percentage by weight: 54% of high-carbon ferrochromium and 4% of ferrovanadium; 14.5% of flake graphite and 11% of ferroboron; 3.5% of ferrosilicon, 1.5% of ultra-fine aluminum powder, 3% of ultra-fine graphite and 8.5% of reduced iron powder; the mixed composition was identical to the powder composition contained in the multilayer composite powder of example 1: after weighing, putting all the powder components into the same container, and fully stirring to uniformly mix the powder components to form mixed powder;
then, the mixed powder is preset on a Q235A steel plate welding bead with the length of 160mm, the width of 75mm and the thickness of 16mm, the height and the width of the mixed powder are adjusted, so that the ratio of the weight of the mixed powder per unit length to the melting weight of the H08A solid welding wire with the diameter of phi 2.5mm passing through the welding bead is kept within the range of 0.85-0.90, and the technological parameters of each surfacing welding are not changed.
The surfacing process parameters, polarity setting and surfacing process of the automatic welding machine ZD5-1000E used in the comparative example 1 are the same as those of the example 1. The abrasion resistance test was conducted in the same manner as in example 1.
The structure morphology and the phase composition of the surface layer of the high-chromium alloy layer deposited in the comparative example 1 are respectively shown in fig. 3 and 4, the wear morphology of the high-chromium alloy deposited in the comparative example 1 is shown in fig. 6, and the # 1 deposited sample prepared in the comparative example is used as a standard sample.
As can be seen from Table 2, the relative wear coefficient of the high-chromium alloy prepared by the method is 2.47-4.43 times that of the high-chromium alloy prepared by presetting the same mixed powder, and is obviously lower than the average wear loss of 0.05-0.06 g of the commercially available high-chromium cast iron flux-cored wire under the same wear test condition, which shows that the high-chromium alloy prepared by the method has good wear resistance and completely meets the practical requirements.
TABLE 2 wear resistance of the wear resistant particles of the high chromium alloys shown in the comparative examples and examples
Figure DEST_PATH_IMAGE002
As can be seen from the graphs of FIG. 1 and FIG. 2, the self-protection open arc surfacing welding is carried out on the multilayer composite powder particles and the H08A solid welding wire prepared by the invention, and the structure of the prepared high-chromium alloy mainly comprises α -Fe (ferrite), Fe3(C, B) and nascent M7C3The composition, wherein M comprises Fe, Cr, V and other metal elements, the high-chromium alloy presents a typical eutectic structure. The white hexagonal block shown in FIG. 1 is nascent M7C3The phase can be used as the main wear-resistant phase of the high-chromium alloy, so that the high-chromium alloy has good abrasive wear resistance.
On the contrary, the composition of the mixed powder prepared in comparative example 1 on the weld bead was identical to that of example 1, but the multi-layered composite powder was not prepared, and the other conditions were identical to each other, as can be seen from FIGS. 3 and 4, the structure of the high chromium alloy prepared in this comparative example 1 included α -Fe (ferrite), Fe (Fe-Cr-3(C, B) and the shape of an intergranular network or a numerical value M7C3And the like, wherein M comprises metal elements such as Fe, Cr, V and the like. The high chromium alloy is typically hypoeutectic in structure and does not exhibit the white mass M shown in fig. 17C3A primary phase consisting essentially of black cellular α -Fe and network carbides M distributed along the cellular structure7C3The abrasion resistance of the wear-resistant particles is low.
Comparing the wear profiles of the two high-chromium surfacing alloys shown in fig. 5 and 6, under the same wear particle wear test condition, the high-chromium alloy prepared by the method of the present invention has the effect of the wear resistant particles of the primary massive wear resistant phase, which causes the scratches of the wear particles to be stopped or changed in direction, so that the scratches are less in number and shallower in depth, and the wear mechanism is mainly micro-cutting of the wear particles; the high-chromium alloy prepared in the comparative example 1 in which the same powder component is preset has more and deeper scratches on the wear surface, and the wear mechanism is also micro-cutting of abrasive particles.
The results show that the high-chromium alloy prepared by the multilayer composite powder particles and the method has higher hardness and good wear resistance, and can be used for self-protecting open arc surfacing of wear-resistant alloy layers of parts under the working condition of abrasive wear.

Claims (8)

1. A method for overlaying high-chromium alloy by multilayer composite powder particles and self-protection open arc is characterized by comprising the following sequential steps:
(1) the powder components of the inner layer, the middle layer and the outer layer of the multilayer composite powder particle are mixed: sieving metal, alloy or other powder components, weighing according to the powder component composition proportion of the multilayer composite powder particles, respectively pouring the powder components of the inner layer, the middle layer and the outer layer of the multilayer composite powder particles into three separate containers according to the powder component composition requirements of the inner layer, the middle layer and the outer layer of the multilayer composite powder particles, and fully stirring to uniformly mix the powder components to form the corresponding mixed powder of each layer of the composite powder particles;
the powder components of the multilayer composite powder particles are as follows: 50-60 wt% of high-carbon ferrochrome with chromium content of 68-72% and carbon content of 8%; 1-14 wt% of ferrovanadium with vanadium content of 50%; 10-15 wt% of flake graphite with carbon content not less than 98%; 5-12 wt% of ferroboron containing 18 wt% of boron; ferrosilicon with silicon content of 40-47% and weight percentage of 2-4%; 0.5-2.0 wt% of superfine 300-mesh aluminum powder with aluminum content not less than 99%; 1-3 wt% of ultrafine 300-mesh graphite with carbon content not less than 98%; the balance is reduced iron powder with the iron content not less than 98 percent;
wherein the high carbon ferrochrome and ferrovanadium are inner layer powder components of composite powder particles; the flake graphite is composed of intermediate layer powder components of composite powder particles; the external powder component of the composite powder particles comprises ferroboron, ferrosilicon, ultra-fine graphite, ultra-fine aluminum powder and reduced iron powder;
(2) preparing the inner layer of the multilayer composite powder particle: adding a liquid adhesive into an inner layer powder container containing the composite powder particles of the high-carbon ferrochrome and ferrovanadium obtained in the step (1), continuously stirring during the addition, rotating the inner layer powder to form wet composite powder particles, standing for 1-2 hours for shaping, and evaporating the moisture on the surface layers of the wet composite powder particles by using hot air; then, sieving the composite powder particles by a 20-mesh sieve to remove the powder particles larger than 20 meshes, and then sieving the powder particles by a 30-mesh sieve to remove the powder particles smaller than 30 meshes, thereby finally obtaining the composite powder particles of 20-30 meshes;
(3) preparing an intermediate layer of the multilayer composite powder particles: spreading the composite powder particles obtained in the step (2) to ensure that the stacking height of the composite powder particles is less than 5mm, spraying a liquid binder on the surfaces of the composite powder particles, and slightly turning the composite powder particles to ensure that a layer of liquid binder is uniformly adhered to the surfaces of the composite powder particles; then, uniformly scattering the scale graphite component in the intermediate layer container obtained in the step (1) on the surface of the wet powder particles, and slightly turning over the wet powder particles during the scattering so as to uniformly adhere a layer of scale graphite on the surface of the composite powder particles; then standing for 1-2 hours at room temperature, putting the container filled with the double-layer composite powder particles into a drying furnace, heating to 100-200 ℃, keeping the temperature for 2 hours, discharging and cooling to room temperature;
(4) preparing the outer layer of the multilayer composite powder particle: spreading the double-layer composite powder particles obtained in the step (3) to ensure that the stacking height of the double-layer composite powder particles is less than 10mm, spraying a liquid binder on the surfaces of the double-layer composite powder particles, and slightly turning over the double-layer composite powder particles to ensure that a layer of liquid binder is adhered to the surfaces of the double-layer composite powder particles; then, uniformly scattering powder components in an outer layer component container of the composite powder particles obtained in the step (1) on the surfaces of the double-layer composite powder particles, and slightly turning over the powder particles to enable the surfaces of the double-layer composite powder particles to be adhered with a layer of outer layer component powder of the composite powder particles; then standing for 1-2 hours for shaping to complete the preparation process of the multilayer composite powder particles;
(5) sintering of multilayer composite particles: putting the container containing the multilayer composite powder particles obtained in the step (4) into a sintering furnace, heating to the sintering temperature of 250-400 ℃, preserving heat for 2-4 hours, cooling to room temperature along with the furnace, and discharging;
(6) screening and classifying the multilayer composite powder particles: sieving the discharged powder particles with a 5-mesh sieve to remove large particles larger than 5 meshes, sieving the discharged powder particles with a 20-mesh sieve to remove small particles smaller than 20 meshes, and obtaining composite powder particles with the particle size of 5-20 meshes;
(7) multilayer composite powder particles and an H08A solid welding wire are used as surfacing materials to perform self-protection open arc surfacing on the high-chromium alloy: setting surfacing process parameters of an automatic welding machine, and keeping the surfacing parameters unchanged every time; presetting the multilayer composite powder particles obtained in the step (6) on a low-carbon steel substrate, and adjusting the height and the width of a preset powder particle layer to enable the ratio of the preset weight of the multilayer composite powder particles on a welding bead in unit length to the melting weight of a solid welding wire on the welding bead to meet the set requirement;
according to the requirements, the multilayer composite powder particles and the H08A solid welding wire are used as surfacing materials to carry out self-protection open arc surfacing, so that the multilayer composite powder particle melt and the solid welding wire are molten and fused into an integrated molten pool; cooling and solidifying the molten pool to form a first layer of welding line, and air cooling; and then the second layer and the third layer are respectively overlaid in the same way.
2. The method for overlaying the high-chromium alloy by the multilayer composite powder particles and the self-protection open arc according to claim 1, wherein the method comprises the following steps: in the step (1), the powder components of the high-carbon ferrochrome, ferrovanadium, ferrosilicon, ferroboron, flake graphite and reduced iron powder are sieved by a 60-mesh sieve, and the ultra-fine aluminum powder and the ultra-fine graphite are sieved by a 300-mesh sieve.
3. The method for overlaying the high-chromium alloy by the multilayer composite powder particles and the self-protection open arc according to claim 1, wherein the method comprises the following steps: in the step (2), the liquid binder is sodium silicate type water glass with a Baume degree of 20-40 and a modulus of 3.0-3.3; the ratio of the doping amount of the liquid binder to the weight of the mixed powder is 10-20 ml of sodium silicate type water glass per 100g of the mixed powder.
4. The method for overlaying the high-chromium alloy by the multilayer composite powder particles and the self-protection open arc according to claim 1, wherein the method comprises the following steps: in the step (3), the liquid binder is sodium silicate type water glass with a Baume degree of 20-40 and a modulus of 3.0-3.3; the ratio of the doping amount of the liquid binder to the weight of the dry mixed powder contained in the composite powder particles obtained in the step (2) is 10-20 ml of sodium silicate type water glass per 100g of mixed powder.
5. The method for overlaying the high-chromium alloy by the multilayer composite powder particles and the self-protection open arc according to claim 1, wherein the method comprises the following steps: in the step (4), the liquid binder is sodium silicate type water glass with a Baume degree of 20-40 and a modulus of 3.0-3.3; and (3) the ratio of the doping amount of the liquid binder to the weight of the dry mixed powder contained in the composite powder particles obtained in the step (3) is 10-20 ml of sodium silicate type water glass per 100g of mixed powder.
6. The method for overlaying the high-chromium alloy by the multilayer composite powder particles and the self-protection open arc according to the claim 1 is characterized in that: in the step (7), the surfacing process parameters are as follows: the polarity is direct current reverse connection, the current is 380-450A, the traveling speed of the trolley is 10-15 m/h, and the voltage value is 26-35V.
7. The method for overlaying the high-chromium alloy by the multilayer composite powder particles and the self-protection open arc according to claim 1, wherein the method comprises the following steps: in the step (7), the ratio of the preset weight of the multilayer composite particles on the welding bead with the unit length to the melting weight of the solid welding wire on the welding bead is 0.70-1.00.
8. The method for overlaying the high-chromium alloy by the multilayer composite powder particles and the self-protection open arc according to claim 1, wherein the method comprises the following steps: in the step (7), the diameter of the H08A solid welding wire is phi 2.5 mm-phi 3.0 mm.
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