CN110106461B - 一种金刚石合金材料制备及精饰加工方法 - Google Patents
一种金刚石合金材料制备及精饰加工方法 Download PDFInfo
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- CN110106461B CN110106461B CN201910428485.7A CN201910428485A CN110106461B CN 110106461 B CN110106461 B CN 110106461B CN 201910428485 A CN201910428485 A CN 201910428485A CN 110106461 B CN110106461 B CN 110106461B
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- Prior art keywords
- diamond
- alloy
- powder
- nickel
- spraying
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- 239000010432 diamond Substances 0.000 title claims abstract description 259
- 229910003460 diamond Inorganic materials 0.000 title claims abstract description 259
- 239000000956 alloy Substances 0.000 title claims abstract description 172
- 238000002360 preparation method Methods 0.000 title claims abstract description 30
- 238000003672 processing method Methods 0.000 title claims description 15
- 239000000843 powder Substances 0.000 claims abstract description 163
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 152
- 238000000576 coating method Methods 0.000 claims abstract description 59
- 239000011248 coating agent Substances 0.000 claims abstract description 57
- 238000005507 spraying Methods 0.000 claims abstract description 44
- 238000000034 method Methods 0.000 claims abstract description 43
- 238000005260 corrosion Methods 0.000 claims abstract description 19
- 230000007797 corrosion Effects 0.000 claims abstract description 19
- 239000000463 material Substances 0.000 claims abstract description 19
- 238000007750 plasma spraying Methods 0.000 claims abstract description 17
- 238000010285 flame spraying Methods 0.000 claims abstract description 10
- 238000010146 3D printing Methods 0.000 claims abstract description 9
- 238000005253 cladding Methods 0.000 claims abstract description 8
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 104
- 239000002245 particle Substances 0.000 claims description 71
- 239000002131 composite material Substances 0.000 claims description 63
- 229910000831 Steel Inorganic materials 0.000 claims description 50
- 239000010959 steel Substances 0.000 claims description 50
- 239000000203 mixture Substances 0.000 claims description 45
- 229910052759 nickel Inorganic materials 0.000 claims description 38
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 claims description 35
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 33
- 239000007789 gas Substances 0.000 claims description 32
- 239000011159 matrix material Substances 0.000 claims description 32
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 23
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 20
- 238000004140 cleaning Methods 0.000 claims description 18
- 238000005488 sandblasting Methods 0.000 claims description 17
- 239000000126 substance Substances 0.000 claims description 13
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 11
- 238000005520 cutting process Methods 0.000 claims description 11
- MHAJPDPJQMAIIY-UHFFFAOYSA-N Hydrogen peroxide Chemical compound OO MHAJPDPJQMAIIY-UHFFFAOYSA-N 0.000 claims description 10
- 229910052786 argon Inorganic materials 0.000 claims description 10
- 238000000889 atomisation Methods 0.000 claims description 9
- 239000007788 liquid Substances 0.000 claims description 9
- 230000008569 process Effects 0.000 claims description 8
- 238000007788 roughening Methods 0.000 claims description 8
- 238000010892 electric spark Methods 0.000 claims description 7
- 239000000758 substrate Substances 0.000 claims description 7
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 5
- 229910001873 dinitrogen Inorganic materials 0.000 claims description 5
- 238000005530 etching Methods 0.000 claims description 5
- 239000001301 oxygen Substances 0.000 claims description 5
- 229910052760 oxygen Inorganic materials 0.000 claims description 5
- 239000004576 sand Substances 0.000 claims description 5
- 239000000835 fiber Substances 0.000 claims description 4
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 3
- 239000000446 fuel Substances 0.000 claims description 3
- 229910052739 hydrogen Inorganic materials 0.000 claims description 3
- 239000003350 kerosene Substances 0.000 claims description 3
- 229910052757 nitrogen Inorganic materials 0.000 claims description 3
- 238000004372 laser cladding Methods 0.000 claims description 2
- 229910000599 Cr alloy Inorganic materials 0.000 description 37
- 239000000788 chromium alloy Substances 0.000 description 37
- 239000002270 dispersing agent Substances 0.000 description 27
- 238000005245 sintering Methods 0.000 description 27
- 238000003723 Smelting Methods 0.000 description 25
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 24
- VLKZOEOYAKHREP-UHFFFAOYSA-N n-Hexane Chemical compound CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 description 24
- 239000011651 chromium Substances 0.000 description 23
- VZUPOJJVIYVMIT-UHFFFAOYSA-N [Mo].[Ni].[Cr].[Fe] Chemical compound [Mo].[Ni].[Cr].[Fe] VZUPOJJVIYVMIT-UHFFFAOYSA-N 0.000 description 22
- 238000001035 drying Methods 0.000 description 20
- 238000012216 screening Methods 0.000 description 20
- 238000002156 mixing Methods 0.000 description 19
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 18
- VNNRSPGTAMTISX-UHFFFAOYSA-N chromium nickel Chemical compound [Cr].[Ni] VNNRSPGTAMTISX-UHFFFAOYSA-N 0.000 description 15
- 239000010949 copper Substances 0.000 description 15
- 239000003979 granulating agent Substances 0.000 description 15
- 238000003756 stirring Methods 0.000 description 15
- OGSYQYXYGXIQFH-UHFFFAOYSA-N chromium molybdenum nickel Chemical compound [Cr].[Ni].[Mo] OGSYQYXYGXIQFH-UHFFFAOYSA-N 0.000 description 14
- 239000004372 Polyvinyl alcohol Substances 0.000 description 13
- RZJQYRCNDBMIAG-UHFFFAOYSA-N [Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Zn].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn] Chemical class [Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Cu].[Zn].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Ag].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn].[Sn] RZJQYRCNDBMIAG-UHFFFAOYSA-N 0.000 description 13
- 229920002451 polyvinyl alcohol Polymers 0.000 description 13
- 239000007921 spray Substances 0.000 description 13
- 229910052802 copper Inorganic materials 0.000 description 11
- 229910052751 metal Inorganic materials 0.000 description 11
- 239000002184 metal Substances 0.000 description 11
- 235000019441 ethanol Nutrition 0.000 description 10
- 229910052742 iron Inorganic materials 0.000 description 10
- 229910052750 molybdenum Inorganic materials 0.000 description 10
- 230000001681 protective effect Effects 0.000 description 10
- 239000002002 slurry Substances 0.000 description 10
- 238000001694 spray drying Methods 0.000 description 10
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 9
- 229910018487 Ni—Cr Inorganic materials 0.000 description 9
- 239000007864 aqueous solution Substances 0.000 description 9
- 229910052804 chromium Inorganic materials 0.000 description 9
- 239000012298 atmosphere Substances 0.000 description 8
- 238000001816 cooling Methods 0.000 description 8
- 230000001788 irregular Effects 0.000 description 8
- 229910000623 nickel–chromium alloy Inorganic materials 0.000 description 8
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 7
- 239000001768 carboxy methyl cellulose Substances 0.000 description 7
- 238000007747 plating Methods 0.000 description 7
- TXUICONDJPYNPY-UHFFFAOYSA-N (1,10,13-trimethyl-3-oxo-4,5,6,7,8,9,11,12,14,15,16,17-dodecahydrocyclopenta[a]phenanthren-17-yl) heptanoate Chemical compound C1CC2CC(=O)C=C(C)C2(C)C2C1C1CCC(OC(=O)CCCCCC)C1(C)CC2 TXUICONDJPYNPY-UHFFFAOYSA-N 0.000 description 6
- 229910021626 Tin(II) chloride Inorganic materials 0.000 description 6
- ORTQZVOHEJQUHG-UHFFFAOYSA-L copper(II) chloride Chemical compound Cl[Cu]Cl ORTQZVOHEJQUHG-UHFFFAOYSA-L 0.000 description 6
- 239000006185 dispersion Substances 0.000 description 6
- 238000009689 gas atomisation Methods 0.000 description 6
- 239000011361 granulated particle Substances 0.000 description 6
- 229910001120 nichrome Inorganic materials 0.000 description 6
- PIBWKRNGBLPSSY-UHFFFAOYSA-L palladium(II) chloride Chemical compound Cl[Pd]Cl PIBWKRNGBLPSSY-UHFFFAOYSA-L 0.000 description 6
- LJCNRYVRMXRIQR-OLXYHTOASA-L potassium sodium L-tartrate Chemical compound [Na+].[K+].[O-]C(=O)[C@H](O)[C@@H](O)C([O-])=O LJCNRYVRMXRIQR-OLXYHTOASA-L 0.000 description 6
- 229940074439 potassium sodium tartrate Drugs 0.000 description 6
- 235000011006 sodium potassium tartrate Nutrition 0.000 description 6
- 239000001119 stannous chloride Substances 0.000 description 6
- 235000011150 stannous chloride Nutrition 0.000 description 6
- 238000005406 washing Methods 0.000 description 6
- 238000001238 wet grinding Methods 0.000 description 6
- 230000006698 induction Effects 0.000 description 5
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 4
- 239000011230 binding agent Substances 0.000 description 4
- 235000010948 carboxy methyl cellulose Nutrition 0.000 description 4
- 239000008112 carboxymethyl-cellulose Substances 0.000 description 4
- 238000005469 granulation Methods 0.000 description 4
- 230000003179 granulation Effects 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- DDTIGTPWGISMKL-UHFFFAOYSA-N molybdenum nickel Chemical compound [Ni].[Mo] DDTIGTPWGISMKL-UHFFFAOYSA-N 0.000 description 4
- 239000012798 spherical particle Substances 0.000 description 4
- 229910000604 Ferrochrome Inorganic materials 0.000 description 3
- 229910001309 Ferromolybdenum Inorganic materials 0.000 description 3
- 206010070834 Sensitisation Diseases 0.000 description 3
- DPXJVFZANSGRMM-UHFFFAOYSA-N acetic acid;2,3,4,5,6-pentahydroxyhexanal;sodium Chemical group [Na].CC(O)=O.OCC(O)C(O)C(O)C(O)C=O DPXJVFZANSGRMM-UHFFFAOYSA-N 0.000 description 3
- 230000004913 activation Effects 0.000 description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 238000000498 ball milling Methods 0.000 description 3
- 229910017052 cobalt Inorganic materials 0.000 description 3
- 239000010941 cobalt Substances 0.000 description 3
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 3
- 230000006870 function Effects 0.000 description 3
- 239000008187 granular material Substances 0.000 description 3
- 238000000227 grinding Methods 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- WSFSSNUMVMOOMR-NJFSPNSNSA-N methanone Chemical compound O=[14CH2] WSFSSNUMVMOOMR-NJFSPNSNSA-N 0.000 description 3
- 239000011259 mixed solution Substances 0.000 description 3
- 238000007665 sagging Methods 0.000 description 3
- 238000009818 secondary granulation Methods 0.000 description 3
- 230000008313 sensitization Effects 0.000 description 3
- 235000019812 sodium carboxymethyl cellulose Nutrition 0.000 description 3
- 229920001027 sodium carboxymethylcellulose Polymers 0.000 description 3
- 229910017060 Fe Cr Inorganic materials 0.000 description 2
- 229910002544 Fe-Cr Inorganic materials 0.000 description 2
- 239000010953 base metal Substances 0.000 description 2
- 238000007664 blowing Methods 0.000 description 2
- 238000005229 chemical vapour deposition Methods 0.000 description 2
- 239000011258 core-shell material Substances 0.000 description 2
- 238000000151 deposition Methods 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 238000001755 magnetron sputter deposition Methods 0.000 description 2
- 238000007751 thermal spraying Methods 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000009713 electroplating Methods 0.000 description 1
- 239000007888 film coating Substances 0.000 description 1
- 238000009501 film coating Methods 0.000 description 1
- 238000007730 finishing process Methods 0.000 description 1
- 238000001513 hot isostatic pressing Methods 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 239000013307 optical fiber Substances 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 238000007639 printing Methods 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/36—Process control of energy beam parameters
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
- C22C19/052—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 40%
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
- C22C19/053—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 30% but less than 40%
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
- C22C19/055—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 20% but less than 30%
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
- C22C19/056—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 10% but less than 20%
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
- C22C19/057—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being less 10%
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C26/00—Alloys containing diamond or cubic or wurtzitic boron nitride, fullerenes or carbon nanotubes
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C30/00—Alloys containing less than 50% by weight of each constituent
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C30/00—Alloys containing less than 50% by weight of each constituent
- C22C30/02—Alloys containing less than 50% by weight of each constituent containing copper
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/129—Flame spraying
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/134—Plasma spraying
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Abstract
本发明公开了一种金刚石材料制备及精饰加工方法,所述金刚石材料为金刚石合金涂层或金刚石合金块体;其中,金刚石合金涂层的制备方法为:通过超音速火焰喷涂、或等离子喷涂、或激光高速喷涂金刚石合金粉末,形成耐磨耐蚀金刚石涂层;金刚石合金块体的制备方法为:通过激光选取熔覆叠层3D打印金刚石合金粉末,形成金刚石合金耐磨耐蚀机械零部件;并对通过上述方法制备的金刚石合金材料为金刚石涂层或金刚石块体进行精饰加工,得到的金刚石合金涂层或金刚石合金块体表面为镜面光亮,粗糙度在Ra=0.10μm以下。本发明能够获得高硬度和耐蚀性能的金刚石合金材料。
Description
技术领域
本发明属于一种耐磨耐蚀复合材料及其制备和精饰加工方法,特别是一种金刚石材料制备和精饰加工方法。
背景技术
金刚石属于高硬度材料,常常用于金刚石砂轮、金刚石砂带、金刚石薄膜镀层等获得交广泛的应用。
化学法沉积金刚石涂层,包括CVD法、磁控溅射法、电镀法等在钢基体上沉积一层类金刚石涂层,此方面有大量成熟产品和应用,如专利CN201811524509采用脉冲磁控溅射镀膜获得金刚石涂层的制备方法,专利CN201811426474采用CVD方法制备金刚石涂层。此类金刚石涂层应用有刀具、电动切割片、钻头等。
烧结法制备金刚石砂轮,将一些Al、Ni、Cu、Fe等金属粘接剂与金刚石粉末混合烧结形成砂轮。
通过热喷涂、3D打印等工艺将金属碳化物、氧化物合金结合在钢铁表面,形成一层高硬度、耐腐蚀、抗氧化表面,使钢铁零件具备优良的表面性能,获得高的使用寿命。
基于金刚石具有更高的硬度和耐蚀性能,希望通过热喷涂方法获得金刚石合金涂层。
发明内容
鉴于金属碳化物、氧化物合金涂层表面表面硬度有待进一步提高,耐HCl、HF等腐蚀能力的不足,超硬材料精饰加工困难。本发明的目的是提供一种金刚石合金材料制备及精饰加工方法,以获得高硬度和耐蚀性能的金刚石合金材料。
为实现上述目的,本发明采用的技术方案为:
一种金刚石合金材料制备及精饰加工方法,所述金刚石材料为金刚石合金涂层或金刚石合金块体;其中:
所述金刚石合金涂层的制备方法为:通过超音速火焰喷涂、或等离子喷涂、或激光高速喷涂金刚石合金粉末,形成耐磨耐蚀金刚石涂层;所述金刚石合金粉末为镍基合金包覆金刚石颗粒的复合粉末,金刚石占比为35~80%(wt);
所述金刚石合金块体的制备方法为:通过激光选取熔覆叠层3D打印金刚石合金粉末,形成金刚石合金耐磨耐蚀机械零部件,所述金刚石合金粉末为镍基合金包覆金刚石颗粒的复合粉末,金刚石占比为35~80%(wt);
并对通过上述方法制备的金刚石合金材料为金刚石涂层或金刚石块体进行电火花慢丝切割精饰加工,得到的金刚石合金涂层或金刚石合金块体表面为镜面光亮,粗糙度在Ra=0.10μm以下。
进一步的,所述镍基合金为以下三种镍基合金的任意一种:
镍基合金Ni-1:按照质量百分含量,由以下组分组成:28.5~45.5%的Cr、3.0~4.0%的Mo、1.0~2.5%的Fe、7.2~9.5%的Co、余量为Ni;
镍基合金Ni-2:按照质量百分含量,由以下组分组成:23.0~27.0%Mo、9.0~14.5%Cr、0.5~1.0%Fe、0.5~1.0%Co、余量为Ni。
镍基合金Ni-3:按照质量百分含量,由以下组分组成:26~36%Mo、1~2%Fe、0.9~1.5%Cr、0.2~0.8%Cu和余量的Ni。
进一步的,所述金刚石涂层的制备方法的具体步骤为:
步骤1,表面清理:对作为基体的钢铁材料进行表面清理,采用激光清洗除锈,得到钢基体;
步骤2,表面粗化:采用空气动力喷砂对步骤1得到的钢基体表面进行粗化处理;
步骤3,表面残余应力消除:采用表面刻蚀方法消除残余应力,提高喷涂金刚石涂层与钢基体结合力;
步骤4,表面润湿性改善:对步骤3得到的钢基体表面进行雾化喷涂;
步骤5,热喷涂金刚石合金涂层:采用超音速火焰喷涂、或等离子喷涂、或激光高速喷涂金刚石合金粉末,形成耐磨耐蚀金刚石涂层。
进一步的,所述步骤1中,所用激光波长1064nm、激光功率20~100W、工作温度5~45℃。
进一步的,所述步骤2中,空气动力喷砂所用的砂子为SiC颗粒粒径按0.4mm、0.8mm、1.2mm按质量比1:1:1的混合物,喷砂空气压力大于6.0Mpa、流量大于3m3/min,喷砂后钢基体表面形成粗糙度Rz25~50μm的洁净粗糙表面。
进一步的,所述步骤3中,将HF和H2O按体积比1:50~100的混合液雾化喷涂至步骤2得到的钢基体表面,保持其表面均匀湿润至不流挂3~10分钟。
进一步的,所述步骤4中,将盐酸、双氧水、乙醇和水的体积比例1:1:10:45的混合物雾化喷涂至步骤3得到的钢基体表面,直至钢基体表面自然干燥。
进一步的,所述步骤5中,超音速火焰喷涂时,航空煤油为燃料,压力1.3~1.9MPa,流量16~20L/h,氧气为助燃气,氧气压力1.0~1.8 MPa,流量28~38m3/h,氮气送粉,送粉流量5~10kg/h,喷涂距离200~300mm;
等离子喷涂时,电压60~75V,喷涂电流500~650A,氩气30~40L/min,氮气10~18L/min,送粉流量5.5~12.0kg/h,喷涂距离200~300mm;
激光高速喷涂时,采用Yb-fibre激光器,功率2~8kw,波长1080nm,光斑直径3~6mm,扫描速度5~25mm/s,同轴或旁轴送粉。
进一步的,所述金刚石块体的制备方法中,通过激光选取熔覆叠层3D打印金刚石合金粉末,形成金刚石合金耐磨耐蚀机械零部件的工艺条件为:激光选区熔覆叠层3D打印,采用Yb-fibre激光器,功率2~4kw,波长1064nm,工作电流40~80A,压缩气体压力6000~16000hpa,扫描速度2.0~5.0m/s。
进一步的,所述括精饰加工的步骤具体为:采用电火花慢丝气蚀切割,获得金刚石涂层或金刚石块体表面镜面光亮表面;所述电火花切割机采用脉冲电源,其脉宽20~80ns,峰值电流大于1000A,直径0.02~0.03mm钼丝为连续单向运动电极丝,走丝速度低于0.2mm/s,加工效率低于300mm2/min,重复2~4次切割,加工精度达0.001mm级以上。
本发明的有益效果是:本发明提供一种金刚石材料制备和精饰加工方法,通过热喷涂和3D打印方式形成金刚石涂层或块材,可以更广泛地应用到要求耐磨损和耐腐蚀的各类机械零部件上,使金刚石涂层应用从化学法、烧结法获得进一步的扩展。同时为超硬金刚石材料零件提供一种精饰加工方法。
具体实施方式
本发明的一种金刚石合金材料制备及精饰加工方法,金刚石材料为金刚石合金涂层或金刚石合金块体;其中,
金刚石合金涂层的制备方法为:通过超音速火焰喷涂、或等离子喷涂、或激光高速喷涂金刚石合金粉末,形成耐磨耐蚀金刚石涂层;所述金刚石合金粉末为镍基合金包覆金刚石颗粒的复合粉末,金刚石占比为35~80%(wt);
金刚石合金块体的制备方法为:通过激光选取熔覆叠层3D打印金刚石合金粉末,形成金刚石合金耐磨耐蚀机械零部件,所述金刚石合金粉末为镍基合金包覆金刚石颗粒的复合粉末,金刚石占比为35~80%(wt);
并对通过上述方法制备的金刚石合金材料为金刚石涂层或金刚石块体进行精饰加工,得到的金刚石合金涂层或金刚石合金块体表面为镜面光亮,粗糙度在Ra=0.10μm以下。
其中,镍基合金为以下三种镍基合金的任意一种:
镍基合金Ni-1:按照质量百分含量,由以下组分组成:28.5~45.5%的Cr、3.0~4.0%的Mo、1.0~2.5%的Fe、7.2~9.5%的Co、余量为Ni。
镍基合金Ni-2:按照质量百分含量,由以下组分组成:23.0~27.0%Mo、9.0~14.5%Cr、0.5~1.0%Fe、0.5~1.0%Co、余量为Ni。
镍基合金Ni-3:按照质量百分含量,由以下组分组成:26~36%Mo、1~2%Fe、0.9~1.5%Cr、0.2~0.8%Cu和余量的Ni。
下面结合一些具体实施例对本发明作更进一步的说明。
实施例1-11是本发明中所用的金刚石合金粉末的具体制备实例。
实施例1-3为镍基合金Ni-1包覆金刚石颗粒的复合粉末。
镍基合金Ni-1包覆金刚石颗粒的复合粉末按照质量百分含量,由以下组分组成:35~60%的金刚石、11.4~29.6%的Cr、1.2~2.6%的Mo、0.4~1.5%的Fe、2.9~6.2%的Co、余量为Ni。其中,镍铬-金刚石合金复合粉末由镍铬合金粘结相包覆单个或多个金刚石颗粒组成;包覆在镍铬合金粘结相内的多个金刚石颗粒之间互相分离,且每个金刚石颗粒上均包覆镍铬合金粘结相。镍铬合金粘结相即为镍基合金Ni-1,不论复合粉末中金刚石的占比是35%还是60%,镍铬合金粘结相的成分均不变;按照质量百分含量,镍铬合金粘结相的组成为:28.5~45.5%Cr、3.0~4.0%Mo、1.0~2.5%Fe、7.2~9.5%Co、余量为Ni。
实施例1:
步骤1a:将粒度100μm以下的类球形或不规则的金刚石粉末经超音速等离子喷涂法二次造粒,高速喷涂至10℃以下水帘冷却,经水洗、干燥成为球形金刚石粉末;超音速等离子喷涂电压50~55V,喷涂电流600~620A,氩气20~25L/min,氮气6~7 L/min,送粉流量7~7.5kg/h,喷涂距离250mm,水帘与喷涂呈垂直分布。喷涂的金刚石颗粒经水洗和急速冷却,干燥后筛选5~15μm球状金刚石粉末;
步骤1b:镍铬金属粘结相合金成分要求,将镍NiCr合金、FeCrMo合金和Co金属混合送入VIGA设备的真空熔炼炉进行熔炼,熔化温度为1300℃,炼出NiCr基金属粘结相合金熔融体;真空度0.8x10-1Pa,经Ar气体雾化压力3.0~3.5Mpa、雾化气体流量800~900m3/h,筛选获得5~15μm球形镍铬基合金粉末;
步骤1c:将粒径为5~15μm球状金刚石粉末分别按照镍铬合金粉末60%(wt)和40%(wt)的比例混合,并加入分散剂、造粒剂,分散剂为聚乙烯醇、乙醇、正己烷按照质量比1:0.5:1的混合物,分散剂的用量是球形金刚石粉末与球形镍铬基合金粉末的总质量的20%;造粒剂为羧甲基纤维素钠,造粒剂的用量是球形金刚石粉末与球形镍铬基合金粉末的总质量的6%,经湿磨8小时制备成浆料;
步骤1d:将聚乙烯醇、正己烷和水按质量比1:1:1混合制成分散液,按浆料和分散液按质量比3:1送入喷雾干燥设备的搅拌槽进行搅拌,经充分搅拌均匀后喷雾干燥造粒,喷雾的喷嘴直径1.0mm,喷雾气体压力1.6Mpa,干燥温度110±5℃;
步骤1e:将喷雾干燥造粒的颗粒在Ar气压力1.5Mpa、温度1000℃的保护气氛炉进行烧结,烧结时间80分钟,烧结炉内氧化铝底盘以30次/分钟振动筛分,烧结粉末随炉冷却至60℃出炉;
步骤1f:将冷却的复合粉末进行筛分,获得球形度好的镍铬-金刚石合金复合粉末,按照质量百分含量,该合金粉末的组成为:60%金刚石、11.4%Cr、1.2%Mo、0.4%Fe、2.9%Co、余量为Ni。
实施例2:
步骤2a:将粒度100μm以下的类球形或不规则的金刚石粉末经超音速等离子喷涂法二次造粒,高速喷涂至10℃以下水帘冷却,经水洗、干燥成为球形金刚石粉末;超音速等离子喷涂电压65~70V,喷涂电流550~600A,氩气35~38L/min,氮气11~12 L/min,送粉流量19~20kg/h,喷涂距离200mm,水帘与喷涂呈垂直分布。喷涂的金刚石颗粒经水洗和急速冷却,干燥后筛选5~8μm球状金刚石粉末;
步骤2b:镍铬金属粘结相合金成分要求,将镍NiCr合金、FeCrMo合金和Co金属混合送入VIGA设备的真空熔炼炉进行熔炼,熔化温度为1400℃,炼出NiCr基金属粘结相合金熔融体;真空度1x10-1Pa,经Ar气体雾化压力6.0~6.5Mpa、雾化气体流量1900~2000m3/h,筛选获得5~8μm球形镍铬基合金粉末;
步骤2c:将粒径为5~8μm球状金刚石粉末和镍铬合金粉末分别按照40%(wt)和60%(wt)的比例混合,并加入分散剂、造粒剂,分散剂为聚乙烯醇、乙醇、正己烷按照质量比1:0.5:1的混合物,分散剂的用量是球形金刚石粉末与球形镍铬基合金粉末的总质量的10%;造粒剂为羧甲基纤维素钠,造粒剂的用量是球形金刚石粉末与球形镍铬基合金粉末的总质量的8%,经湿磨10小时制备成浆料。
步骤2d:将聚乙烯醇、正己烷和水按质量比1:1:1混合制成分散液,按浆料和分散液按4:1送入喷雾干燥设备的搅拌槽进行搅拌,经充分搅拌均匀后喷雾干燥造粒,喷雾的喷嘴直径0.5mm,喷雾气体压力2.0Mpa,干燥温度145±5℃;
步骤2e:将喷雾干燥造粒的颗粒在Ar气压力1.0Mpa、温度1350℃的保护气氛炉进行烧结,烧结时间30分钟,烧结炉内氧化铝底盘以60次/分钟振动筛分,烧结粉末随炉冷却至60℃出炉;
步骤2f:将冷却的复合粉末进行筛分,获得球形度好的镍铬-金刚石合金复合粉末,按照质量百分含量,该合金粉末的组成为:35%金刚石、26.4%Cr、2.19%Mo、1.44%Fe、5.58%Co、余量为Ni。
实施例3:
步骤3a:将粒度100μm以下的类球形或不规则的金刚石粉末经超音速等离子喷涂法二次造粒,高速喷涂至10℃以下水帘冷却,经水洗、干燥成为球形金刚石粉末;超音速等离子喷涂电压55~60V,喷涂电流620~650A,氩气40~46L/min,氮气8~9L/min,送粉流量6~6.5kg/h,喷涂距离300mm,水帘与喷涂呈垂直分布。喷涂的金刚石颗粒经水洗和急速冷却,干燥后筛选10~15μm球状金刚石粉末;
步骤3b:镍铬金属粘结相合金成分要求,将镍NiCr合金、FeCrMo合金和Co金属混合送入VIGA设备的真空熔炼炉进行熔炼,熔化温度为1150℃,炼出NiCr基金属粘结相合金熔融体;真空度0.5x10-1Pa,经Ar气体雾化压力2.0~2.5Mpa、雾化气体流量500~700m3/h,筛选获得5~35μm球形镍铬基合金粉末;
步骤3c:将粒径为10~15μm球状金刚石粉末分别按照镍铬合金粉末35%(wt)和65%(wt)的比例混合,并加入分散剂、造粒剂,分散剂为聚乙烯醇、乙醇、正己烷按照质量比1:0.5:1的混合物,分散剂的用量是球形金刚石粉末与球形镍铬基合金粉末的总质量的15%;造粒剂为羧甲基纤维素钠,造粒剂的用量是球形金刚石粉末与球形镍铬基合金粉末的总质量的5%,经湿磨6小时制备成浆料;
步骤3d:将聚乙烯醇、正己烷和水按质量比1:1:1混合制成分散液,按浆料和分散液按质量比2:1送入喷雾干燥设备的搅拌槽进行搅拌,经充分搅拌均匀后喷雾干燥造粒,喷雾的喷嘴直径1.2mm,喷雾气体压力1.0Mpa,干燥温度105±5℃;
步骤3e:将喷雾干燥造粒的颗粒在Ar气压力1.5Mpa、温度900℃的保护气氛炉进行烧结,烧结时间110分钟,烧结炉内氧化铝底盘以45次/分钟振动筛分,烧结粉末随炉冷却至60℃出炉;
步骤3f:将冷却的复合粉末进行筛分,获得球形度好的镍铬-金刚石合金复合粉末,按照质量百分含量,该合金粉末的组成为:45%金刚石、29.6%Cr、2.6%Mo、1.5%Fe、6.2%Co、余量为Ni。
实施例4-8为镍基合金Ni-2包覆金刚石颗粒的复合粉末。
镍基合金Ni-2包覆金刚石颗粒的复合粉末按照质量百分含量,由以下组分组成:35~60%的金刚石、9.2~17.6%的Mo、3.6~9.4%的Cr、0.2~0.65%的Fe、0.2~0.65%的Co、余量为Ni。其中,镍钼铬-金刚石合金复合粉末由核壳结构的球形颗粒或不规则颗粒组成,其外层为镍钼铬合金粘结相,内核为多个互不相连的金刚石颗粒,镍钼铬合金粘结相包覆多个互不相连的金刚石颗粒,且每个金刚石颗粒上均包覆镍钼铬合金粘结相。镍钼铬合金粘结相即为镍基合金Ni-2,不论复合粉末中金刚石的占比是35%还是60%,镍钼铬合金粘结相的成分均不变;按照质量百分含量,所述镍钼铬合金粘结相的组成为:23.0~27.0%Mo、9.0~14.5%Cr、0.5~1.0%Fe、0.5~1.0%Co、余量为Ni。
实施例4:
按照NiMoCr粘结相合金成分要求,将铬镍、钼铁、钴等合金加入真空熔炼炉进行熔炼,熔化温度为1460℃,熔炼出NiMoCr粘结相合金熔融体,将金刚石颗粒与NiMoCr粘结相合金熔融体按35:65的质量比进行混合成为高温熔融熔体,经Ar雾化获得镍钼铬-金刚石合金复合粉末,按照质量百分含量,其组成为:35.00%金刚石、17.6%Mo、9.4%Cr、0.65%Fe、0.65%Co和余量的Ni。该复合合金粉末的金刚石颗粒为不规则颗粒,镍钼铬合金粘结相包覆多个金刚石颗粒的复合结构,复合粉末形状为球形。
实施例5:
按照NiMoCr粘结相合金成分要求,将铬镍、钼铁、钴等合金加入真空熔炼炉进行熔炼,熔化温度为1460℃,熔炼出NiMoCr粘结相合金熔融体,经氩气喷吹雾化为NiMoCr基合金粉末;将金刚石颗粒与NiMoCr基合金粉末按60:40质量比进行真空球磨混合,随后进行气氛热等静压烧结成金刚石-镍钼铬合金棒料,烧结温度1280±20℃,压力为165Mpa,保护气氛为氩气,金刚石-镍钼铬合金棒料在EIGA真空感应熔炼炉进行熔炼,以高纯氩气对熔融的金刚石-镍钼铬合金液滴进行喷吹雾化,感应熔炼电流650A,氩气速度1100m/s,冷却筛分达到金刚石-镍钼铬合金复合粉末,按照质量百分含量,其组成为:60.00%金刚石、9.2%Mo、3.6%Cr、0.2%Fe、0.2%Co和余量的Ni。该复合合金粉末的金刚石颗粒为类球状颗粒,镍钼铬合金粘结相包覆多个金刚石颗粒的复合结构,复合粉末形状为球形。
实施例6:
按照NiMoCr粘结相合金成分要求,将铬镍、钼铁、钴等合金加入真空熔炼炉进行熔炼,熔化温度为1460℃,熔炼出NiMoCr粘结相合金熔融体,经氩气喷吹雾化为NiMoCr基合金粉末;将金刚石颗粒与NiMoCr基合金粉末按质量百分比50:50混合,加热无水乙醇进行球磨混合,将45wt%的聚乙烯醇和羧甲基纤维素按2.5:1.5比例的混合物,55wt%的金刚石和镍钼铬粉末球磨粉末相混合制成浆状物,并进行离心喷雾干燥制粒,对制粒的金刚石-NiMoCr的合金粉末进行烧结,烧结温度890~1100℃,再经冷却、筛分获得包覆金刚石-镍钼铬合金复合粉末,按照质量百分含量,其组成为:50.00%金刚石、12.13%Mo、7.2%Cr、0.25%Fe、0.5%Co和余量的Ni。该复合合金粉末的金刚石颗粒为类球状颗粒,镍钼铬合金粘结相包覆多个金刚石颗粒的复合结构,复合粉末形状为球形。
实施例7:
按照与实施例4相同的方法,制备金刚石颗粒与NiMoCr粘结相合金质量比为40:60的镍钼铬-金刚石合金复合粉末,得到的镍钼铬-金刚石合金复合粉末的组成为:40.00%金刚石、16.2%Mo、8.2%Cr、0.6%Fe、0.4%Co和余量的Ni。该复合合金粉末的金刚石颗粒为不规则颗粒,镍钼铬合金粘结相包覆多个金刚石颗粒的复合结构,复合粉末形状为球形。
实施例8:
按照与实施例5相同的方法,制备金刚石颗粒与NiMoCr粘结相合金质量比为60:40的镍钼铬-金刚石合金复合粉末,得到的镍钼铬-金刚石合金复合粉末的组成为:45.0%金刚石、14.2%Mo、6.6%Cr、0.4%Fe、0.3%Co和余量的Ni。该复合合金粉末的金刚石颗粒为不规则颗粒,镍钼铬合金粘结相包覆多个金刚石颗粒的复合结构,复合粉末形状为球形。
实施例9-11为镍基合金Ni-3包覆金刚石颗粒的复合粉末。
镍基合金Ni-3包覆金刚石颗粒的复合粉末按照质量百分含量,由以下组分组成:62~80%的金刚石、5.2~13.68%的Mo、0.2~0.76%的Fe、0.18~0.57%的Cr、0.076~0.3%的Cu和余量为Ni。其中,镍钼铁铬-金刚石合金复合粉末由核壳结构的球形或类球状颗粒组成,其外层为镍钼铁铬合金粘结相,内核为多个不规则且互不相连的金刚石颗粒,镍钼铁铬合金粘结相包覆多个互不相连的金刚石颗粒,且每个金刚石颗粒上均包覆镍钼铁铬合金粘结相。镍钼铁铬合金粘结相即为镍基合金Ni-3,不论复合粉末中金刚石的占比是62%还是80%,镍钼铁铬合金粘结相的成分均不变;按照质量百分含量,所述镍钼铁铬合金粘结相的组成为:26~36%Mo、1~2%Fe、0.9~1.5%Cr、0.2~0.8%Cu和余量的Ni。
实施例9:
步骤9a:将粒径为1~10μm的金刚石粉末浸入氯化亚锡的盐酸水溶液敏化处理,其中,氯化亚锡的质量浓度为0.5%,盐酸的质量浓度为1.0%;再浸入氯化钯的盐酸水溶液活化处理,其中,氯化钯的质量浓度为0.08%,盐酸的质量浓度为2.5%;最后在含有氯化铜、甲醛、氢氧化钠和酒石酸钾钠的水溶液中进行化学镀铜,其中,氯化铜的质量浓度为5%,甲醛的质量浓度为0.5%、氢氧化钠的质量浓度为0.5%,酒石酸钾钠的质量浓度为6%,获得化学镀铜层的金刚石颗粒;
步骤9b:将Ni、FeCr合金和Mo金属混合送入真空坩埚熔炼炉,经真空感应熔炼,熔炼温度1150~1200℃、真空度1.0x10-1Pa、Ar气体雾化压力2.0Mpa、雾化气体流量1200m3/h,获得球形粒径范围1~45μm的镍钼铁铬合金粉末;
步骤9c:将粒径为1~10μm的化学镀铜的金刚石粉末、球形粒径为1~45μm的镍钼铁铬合金粉末按62:38的重量百分比例混合;并加入分散剂制成混合料,分散剂为正己烷、乙醇和聚乙烯醇按体积比1:0.5:1的混合物,分散剂用量占化学镀铜金刚石粉末和镍钼铁铬合金粉末总质量的15%;造粒剂为羧甲基纤维素,用量占化学镀铜金刚石粉末和镍钼铁铬合金粉末总质量的10%,经湿磨8.5小时制备成混合料;
步骤9d:将步骤9c的制成的混合料加入分散剂和水,搅拌制成浆料;分散剂为正己烷和聚乙烯醇按照体积比为1:2的混合物,分散剂的用量为步骤1c得到的混合料的质量的100%,水的用量为步骤1c得到的混合料的质量的60%;经充分搅拌均匀后喷雾干燥造粒,喷雾的喷嘴直径0.8mm,喷雾气体压力1.5Mpa,干燥温度120~130℃;
步骤9e:将喷雾干燥造粒的颗粒在Ar气保护气氛炉进行烧结,烧结炉具备振动筛分和加热干燥功能,振动筛及时将团聚的颗粒打散,便于粉末颗粒干燥,烧结温度1100~1150℃,烧结时间60分钟,保护Ar气压力1.5Mpa,振动筛振动频率60次/分钟,烧结粉末随炉冷却至60℃以下出炉;经筛分后获得球形度好的镍钼铁铬-金刚石合金复合粉末。得到的镍钼铁铬-金刚石合金复合粉末的组成为:62%的金刚石、38%的镍钼铁铬粘结相;镍钼铁铬粘结相的组成为:26%Mo、1%Fe、0.9%Cr、0.8%Cu和余量的Ni。
实施例10:
步骤10a:将粒径为1~10μm的金刚石粉末浸入氯化亚锡的盐酸水溶液敏化处理,其中,氯化亚锡的质量浓度为1.5%,盐酸的质量浓度为3.6%;再浸入氯化钯的盐酸水溶液活化处理,其中,氯化钯的质量浓度为0.01%,盐酸的质量浓度为10%;最后在含有氯化铜、甲醛、氢氧化钠和酒石酸钾钠的水溶液中进行化学镀铜,其中,氯化铜的质量浓度为1.0%,甲醛的质量浓度为1.5%、氢氧化钠的质量浓度为1.5%,酒石酸钾钠的质量浓度为1%,获得化学镀铜层的金刚石颗粒;
步骤10b:将Ni、FeCr合金和Mo金属混合送入真空坩埚熔炼炉,经真空感应熔炼,熔炼温度1400~1450℃、真空度0.5x10-1Pa、Ar气体雾化压力5Mpa、雾化气体流量500m3/h,获得球形粒径范围1~45μm的镍钼铁铬合金粉末;
步骤10c:将粒径为1~10μm的化学镀铜的金刚石粉末、球形粒径为1~45μm的镍钼铁铬合金粉末按75:25的重量百分比例混合;并加入分散剂制成混合料,分散剂为正己烷、乙醇和聚乙烯醇按体积比1:0.5:3的混合物,分散剂用量占化学镀铜金刚石粉末和镍钼铁铬合金粉末总质量的20%;造粒剂为羧甲基纤维素,用量占化学镀铜金刚石粉末和镍钼铁铬合金粉末总质量的12%,经湿磨8小时制备成混合料;
步骤10d:将步骤10c的制成的混合料加入分散剂和水,搅拌制成浆料;分散剂为正己烷和聚乙烯醇按照体积比为1:2的混合物,分散剂的用量为步骤2c得到的混合料的质量的80%,水的用量为步骤2c得到的混合料的质量的80%;经充分搅拌均匀后喷雾干燥造粒,喷雾的喷嘴直径0.5mm,喷雾气体压力1.0Mpa,干燥温度100~110℃;
步骤10e:将喷雾干燥造粒的颗粒在Ar气保护气氛炉进行烧结,烧结炉具备振动筛分和加热干燥功能,振动筛及时将团聚的颗粒打散,便于粉末颗粒干燥,烧结温度1300~1350℃,烧结时间30分钟,保护Ar气压力1.2Mpa,振动筛振动频率40次/分钟,烧结粉末随炉冷却至60℃以下出炉;经筛分后获得球形度好的镍钼铁铬-金刚石合金复合粉末,得到的镍钼铁铬-金刚石合金复合粉末的组成为:75%的金刚石、25%的镍钼铁铬粘结相;镍钼铁铬粘结相的组成为:36%Mo、1.8%Fe、1.2%Cr、0.6%Cu和余量的Ni。
实施例11:
步骤11a:将粒径为1~10μm的金刚石粉末浸入氯化亚锡的盐酸水溶液敏化处理,其中,氯化亚锡的质量浓度为2.5%,盐酸的质量浓度为10%;再浸入氯化钯的盐酸水溶液活化处理,其中,氯化钯的质量浓度为0.5%,盐酸的质量浓度为1.0%;最后在含有氯化铜、甲醛、氢氧化钠和酒石酸钾钠的水溶液中进行化学镀铜,其中,氯化铜的质量浓度为10%,甲醛的质量浓度为0.1%、氢氧化钠的质量浓度为2.5%,酒石酸钾钠的质量浓度为10%,获得化学镀铜层的金刚石颗粒;
步骤11b:将Ni、FeCr合金和Mo金属混合送入真空坩埚熔炼炉,经真空感应熔炼,熔炼温度1050~1100℃、真空度0.5x10-1Pa、Ar气体雾化压力10Mpa、雾化气体流量2000m3/h,获得球形粒径范围1~45μm的镍钼铁铬合金粉末;
步骤11c:将粒径为1~10μm的化学镀铜的金刚石粉末、球形粒径为1~45μm的镍钼铁铬合金粉末按80:20的重量百分比例混合;并加入分散剂制成混合料,分散剂为正己烷、乙醇和聚乙烯醇按体积比1:0.5:2的混合物,分散剂用量占化学镀铜金刚石粉末和镍钼铁铬合金粉末总质量的10%;造粒剂为羧甲基纤维素,用量占化学镀铜金刚石粉末和镍钼铁铬合金粉末总质量的5%,经湿磨10小时制备成混合料;
步骤11d:将步骤11c的制成的混合料加入分散剂和水,搅拌制成浆料;分散剂为正己烷和聚乙烯醇按照体积比为1:2的混合物,分散剂的用量为步骤3c得到的混合料的质量的90%,水的用量为步骤2c得到的混合料的质量的90%;经充分搅拌均匀后喷雾干燥造粒,喷雾的喷嘴直径1.2mm,喷雾气体压力2.0Mpa,干燥温度140~150℃;
步骤11e:将喷雾干燥造粒的颗粒在Ar气保护气氛炉进行烧结,烧结炉具备振动筛分和加热干燥功能,振动筛及时将团聚的颗粒打散,便于粉末颗粒干燥,烧结温度900~950℃,烧结时间110分钟,保护Ar气压力1.0Mpa,振动筛振动频率30次/分钟,烧结粉末随炉冷却至60℃以下出炉;经筛分后获得球形度好的镍钼铁铬-金刚石合金复合粉末,得到的镍钼铁铬-金刚石合金复合粉末的组成为:80%的金刚石、20%的镍钼铁铬粘结相;镍钼铁铬粘结相的组成为:32%Mo、2%Fe、1.5%Cr、0.2%Cu和余量的Ni。
实施例12-16是本发明的一种金刚石材料制备及精饰加工方法的实施例:
实施例12:
本实施方式复合金刚石涂层。具体做法为超音速喷涂镍基金刚石合金涂层,所采用镍基金刚石合金粉末为金刚石占比60%(wt),其中,镍基合金为Ni-1;基体材料为中碳42CrMoA调质钢,实施步骤为:
步骤12a:表面清理:对作为基体的钢铁材料进行表面清理,采用激光清洗除锈,得到钢基体;激光清理工艺为激光波长1064nm、激光功率20W,工作温度20℃。
步骤12b:表面粗化:采用空气动力喷砂对钢基体表面进行粗化处理;所述砂子为SiC颗粒粒径按0.4mm、0.8mm、1.2mm按质量比1:1:1配比,喷砂空气压力大于6.0Mpa、流量大于3m3/min,喷砂后钢铁表面形成粗糙度Rz25~50μm的洁净粗糙表面。
步骤12c:表面残余应力消除:采用表面刻蚀方法消除残余应力,提高喷涂金刚石涂层与钢基体结合力;将HF和H2O按体积比1:100的混合液雾化喷涂至步骤1b的钢铁表面,保持其表面均匀湿润至8分钟不流挂。
步骤12d:表面润湿性改善:将盐酸、双氧水、乙醇和水的体积比例1:1:10:45的混合物雾化喷涂至步骤12c的表面,热风吹干钢铁表面。
步骤12e:超音速火焰喷涂金刚石合金涂层:超音速火焰喷涂时航空煤油为燃料,压力0.8~1.2MPa,流量20L/h,氧气为助燃气,压力1.6 MPa,流量35m3/h,送粉流量11kg/h,送粉气体为氮气,喷涂距离350mm。
镍基金刚石合金涂层厚度400~450μm,涂层结合力105Mpa,表面硬度HV980。
实施例13:
本实施方式复合金刚石涂层。具体做法为等离子喷涂镍基金刚石合金涂层,所采用镍基金刚石合金粉末为金刚石占比55%(wt),镍基合金为Ni-2,基体材料为淬火+低温回火9Cr18MoV钢,实施步骤为:
步骤13a:表面清理:对作为基体的钢铁材料进行表面清理,采用激光清洗除锈,得到钢基体;激光清理工艺为激光波长1064nm、激光功率20W,工作温度25℃。
步骤13b:表面粗化:采用空气动力喷砂对经激光除锈处理后的钢基体表面进行粗化处理,所述砂子为SiC颗粒粒径按0.4mm、0.8mm、1.2mm按质量比1:1:1配比,喷砂空气压力大于6.0Mpa、流量大于3m3/min,喷砂后钢铁表面形成粗糙度Rz25~50μm的洁净粗糙表面。
步骤13c:表面残余应力消除:采用表面刻蚀方法消除残余应力,将HF和H2O按体积比1:50的混合液雾化喷涂至步骤13b的钢铁表面,保持其表面均匀湿润至10分钟不流挂。
步骤13d:表面润湿性改善:将盐酸、双氧水、乙醇和水的体积比例1:1:10:45的混合物雾化喷涂至步骤13c的表面,热风吹干钢铁表面。
步骤13e:等离子喷涂金刚石合金涂层:等离子喷涂工艺参数喷涂电压为56~58V、喷涂电流为550~570A、送粉流量8.0kg/h、喷涂距离300mm。
镍基金刚石合金涂层厚度350~400μm,涂层结合力110Mpa,表面硬度HV900。
实施例14:
本实施方式复合金刚石涂层。具体做法为激光喷涂镍基金刚石合金涂层,所采用镍基金刚石合金粉末为金刚石占比35%(wt),镍基合金为Ni-3,基体材料为淬火+高温回火M340钢,实施步骤为:
步骤14a:表面清理:对作为基体的钢铁材料进行表面清理,采用激光清洗除锈,得到钢基体;激光清理工艺为激光波长1064nm、激光功率20W,工作温度15℃。
步骤14b:表面粗化。采用空气动力喷砂对钢基体表面进行粗化处理,所述砂子为SiC颗粒粒径按0.4mm、0.8mm、1.2mm按质量比1:1:1配比,喷砂空气压力大于6.0Mpa、流量大于3m3/min,喷砂后钢铁表面形成粗糙度Rz25~50μm的洁净粗糙表面。
步骤14c:表面残余应力消除。采用表面刻蚀方法消除残余应力,将HF和H2O按体积比1:70的混合液雾化喷涂至步骤14b的钢铁表面,保持其表面均匀湿润至10分钟不流挂。
步骤14d:表面润湿性改善。将盐酸、双氧水、乙醇和水的体积比例1:1:10:45的混合物雾化喷涂至步骤14c的表面,热风吹干钢铁表面。
步骤14e:激光喷涂金刚石合金涂层:激光喷涂功率4000w、激光波长1064nm、激光脉宽8ns、激光频率10 Hz,光斑直径4mm,扫描速度15mm/s,同轴送粉,送粉流量18.0kg/h、喷涂距离120mm。
镍基金刚石合金涂层厚度350~400μm,涂层结合力120Mpa,表面硬度HV880。
实施例15:
本实施方式复合金刚石材料。具体做法为激光3D打印镍基金刚石合金块材,所采用镍基金刚石合金粉末为金刚石占比35%(wt),镍基合金为Ni-2,光纤激光器2000W,光斑直径50μm,扫描速度5m/s,扫描厚度60μm,打印速度25cm3/h。镍基金刚石合金选取120×120mm,表面硬度HV890。
实施例16:
本实施方式复合金刚石材料精饰加工方法。具体做法为采用电火花慢丝气蚀切割,所述脉冲电源电火花切割机,其脉宽仅80ns,峰值电流1400A,直径0.02mm钼电极丝连续单向运动,走丝速度0.08mm/s,加工效率低于150mm2/min,重复3次切割,金刚石涂层表面加工精度达0.001mm级镜面光亮表面。
以上所述仅是本发明的优选实施方式,应当指出:对于本技术领域的普通技术人员来说,在不脱离本发明原理的前提下,还可以做出若干改进和润饰,这些改进和润饰也应视为本发明的保护范围。
Claims (9)
1.一种金刚石合金材料制备及精饰加工方法,其特征在于:所述金刚石材料为金刚石合金涂层或金刚石合金块体;其中,
所述金刚石合金涂层的制备方法为:通过超音速火焰喷涂、或等离子喷涂、或激光高速喷涂金刚石合金粉末,形成耐磨耐蚀金刚石涂层;所述金刚石合金粉末为镍基合金包覆金刚石颗粒的复合粉末,金刚石占比为35~80 wt %;
所述金刚石合金块体的制备方法为:通过激光选取熔覆叠层3D打印金刚石合金粉末,形成金刚石合金耐磨耐蚀机械零部件,所述金刚石合金粉末为镍基合金包覆金刚石颗粒的复合粉末,金刚石占比为35~80 wt %;
并对通过上述方法制备的金刚石合金材料为金刚石涂层或金刚石块体进行精饰加工,得到的金刚石合金涂层或金刚石合金块体表面为镜面光亮,粗糙度在Ra=0.10μm以下;所述精饰加工的步骤具体为:采用电火花慢丝气蚀切割,获得金刚石涂层或金刚石块体表面镜面光亮表面;所述电火花切割机采用脉冲电源,其脉宽20~80ns,峰值电流大于1000A,直径0.02~0.03 mm钼丝为连续单向运动电极丝,走丝速度低于0.2mm/s,加工效率低于300mm2/min,重复2~4次切割,加工精度达0.001mm级以上。
2.根据权利要求1所述的金刚石合金材料制备及精饰加工方法,其特征在于:所述镍基合金为以下三种镍基合金的任意一种:
镍基合金Ni-1:按照质量百分含量,由以下组分组成:28.5~45.5%的Cr、3.0~4.0%的Mo、1.0~2.5%的Fe、7.2~9.5%的Co、余量为Ni;
镍基合金Ni-2:按照质量百分含量,由以下组分组成: 23.0~27.0%Mo、9.0~14.5%Cr、0.5~1.0%Fe、0.5~1.0%Co、余量为Ni;
镍基合金Ni-3:按照质量百分含量,由以下组分组成:26~36%Mo、1~2%Fe、0.9~1.5%Cr、0.2~0.8%Cu和余量的Ni。
3.根据权利要求1所述的金刚石合金材料制备及精饰加工方法,其特征在于:所述金刚石涂层的制备方法的具体步骤为:
步骤1,表面清理:对作为基体的钢铁材料进行表面清理,采用激光清洗除锈,得到钢基体;
步骤2,表面粗化:采用空气动力喷砂对步骤1得到的钢基体表面进行粗化处理;
步骤3,表面残余应力消除:采用表面刻蚀方法消除残余应力,提高喷涂金刚石涂层与钢基体结合力;
步骤4,表面润湿性改善:对步骤3得到的钢基体表面进行雾化喷涂;
步骤5,热喷涂金刚石合金涂层:采用超音速火焰喷涂、或等离子喷涂、或激光高速喷涂金刚石合金粉末,形成耐磨耐蚀金刚石涂层。
4.根据权利要求3所述的金刚石合金材料制备及精饰加工方法,其特征在于:所述步骤1中,所用激光波长1064nm、激光功率20~100W、工作温度5~45℃。
5.根据权利要求3所述的金刚石合金材料制备及精饰加工方法,其特征在于:所述步骤2中,空气动力喷砂所用的砂子为SiC颗粒粒径按0.4mm、0.8mm、1.2mm按质量比1:1:1的混合物,喷砂空气压力大于6.0MPa 、流量大于3m3/min,喷砂后钢基体表面形成粗糙度Rz25~50µm的洁净粗糙表面。
6.根据权利要求3所述的金刚石合金材料制备及精饰加工方法,其特征在于:所述步骤3中,将HF和H2O按体积比1:50~100的混合液雾化喷涂至步骤2得到的钢基体表面,保持其表面均匀湿润至不流挂3~10分钟。
7.根据权利要求3所述的金刚石合金材料制备及精饰加工方法,其特征在于:所述步骤4中,将盐酸、双氧水、乙醇和水的体积比例1:1:10:45的混合物雾化喷涂至步骤3得到的钢基体表面,直至钢基体表面自然干燥。
8.根据权利要求3所述的金刚石合金材料制备及精饰加工方法,其特征在于:所述步骤5中,超音速火焰喷涂时,航空煤油为燃料,压力1.3~1.9MPa,流量16~20L/h,氧气为助燃气,氧气压力1.0~1.8 MPa,流量28~38 m3/h,氮气送粉,送粉流量5~10kg/h,喷涂距离200~300mm;
等离子喷涂时,电压60~75V,喷涂电流500~650A,氩气30~40L/min,氮气10~18L/min,送粉流量5.5~12.0kg/h,喷涂距离200~300mm;
激光高速喷涂时,采用Yb-fibre激光器,功率2~8kW ,波长1080nm,光斑直径3~6mm,扫描速度5~25mm/s,同轴或旁轴送粉。
9.根据权利要求1所述的金刚石合金材料制备及精饰加工方法,其特征在于:所述金刚石块体的制备方法中,通过激光选取熔覆叠层3D打印金刚石合金粉末,形成金刚石合金耐磨耐蚀机械零部件的工艺条件为:激光选区熔覆叠层3D打印,采用Yb-fibre激光器,功率2~4kW ,波长1064nm,工作电流40~80A,压缩气体压力6000~16000hPa ,扫描速度2.0~5.0m/s。
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