CN110153350A - A large hot forging die and its manufacturing method - Google Patents
A large hot forging die and its manufacturing method Download PDFInfo
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- 238000005242 forging Methods 0.000 title claims abstract description 52
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 17
- 230000007704 transition Effects 0.000 claims abstract description 40
- 229910001208 Crucible steel Inorganic materials 0.000 claims abstract description 39
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims abstract description 34
- 238000000034 method Methods 0.000 claims abstract description 31
- 238000003466 welding Methods 0.000 claims abstract description 25
- 239000000463 material Substances 0.000 claims abstract description 21
- 238000005728 strengthening Methods 0.000 claims abstract description 21
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 17
- 239000010941 cobalt Substances 0.000 claims abstract description 14
- 229910017052 cobalt Inorganic materials 0.000 claims abstract description 14
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims abstract description 14
- 239000011159 matrix material Substances 0.000 claims description 30
- 229910000601 superalloy Inorganic materials 0.000 claims description 17
- 239000000654 additive Substances 0.000 claims description 15
- 230000000996 additive effect Effects 0.000 claims description 15
- 238000009826 distribution Methods 0.000 claims description 13
- 230000002787 reinforcement Effects 0.000 claims description 10
- 239000000203 mixture Substances 0.000 claims description 7
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 6
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 6
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 claims description 6
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 6
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 claims description 6
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 6
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 claims description 6
- 229910052799 carbon Inorganic materials 0.000 claims description 6
- 239000012535 impurity Substances 0.000 claims description 6
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 claims description 6
- 229910052698 phosphorus Inorganic materials 0.000 claims description 6
- 239000011574 phosphorus Substances 0.000 claims description 6
- 229910052710 silicon Inorganic materials 0.000 claims description 6
- 239000010703 silicon Substances 0.000 claims description 6
- 239000000126 substance Substances 0.000 claims description 6
- 229910052717 sulfur Inorganic materials 0.000 claims description 6
- 239000011593 sulfur Substances 0.000 claims description 6
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 6
- 229910052721 tungsten Inorganic materials 0.000 claims description 6
- 239000010937 tungsten Substances 0.000 claims description 6
- 238000010438 heat treatment Methods 0.000 claims description 3
- 238000003754 machining Methods 0.000 claims description 3
- 239000002994 raw material Substances 0.000 claims description 3
- 231100000817 safety factor Toxicity 0.000 claims description 3
- 229910052720 vanadium Inorganic materials 0.000 claims description 3
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 claims description 3
- 229910045601 alloy Inorganic materials 0.000 abstract description 6
- 239000000956 alloy Substances 0.000 abstract description 6
- 238000005336 cracking Methods 0.000 abstract description 5
- 230000007774 longterm Effects 0.000 abstract description 3
- 238000005457 optimization Methods 0.000 description 6
- 239000000758 substrate Substances 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 229910000838 Al alloy Inorganic materials 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229910001069 Ti alloy Inorganic materials 0.000 description 2
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000005489 elastic deformation Effects 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 229910052758 niobium Inorganic materials 0.000 description 1
- 239000010955 niobium Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 238000009827 uniform distribution Methods 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J13/00—Details of machines for forging, pressing, or hammering
- B21J13/02—Dies or mountings therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/24—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass dies
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- 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
- C22C19/07—Alloys based on nickel or cobalt based on cobalt
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Forging (AREA)
Abstract
本发明公开了一种大型热锻模具，包括铸钢基体，在所述铸钢基体上依次形成有夹心层、过渡层和强化层，铸钢基体、夹心层、过渡层强硬度依次递增，起到结构支撑作用，所述过渡层表面具有多个相互交错的凹部和凸部，所述强化层设置在过渡层表面，包括与凹部和凸部形状匹配的凹形区和凸形区，所述凹形区为抗拉裂区，采用镍基高温合金焊材制成，所述凸形区为抗变形区，采用钴基高温合金焊材制成。本发明还公开了一种大型热锻模具的制造方法，该方法制成的大型锻模在长时间高温重载工况下具备优秀的抗开裂、耐磨损、抗变形性能，能大幅提高锻模的服役寿命。
The invention discloses a large-scale hot forging die, which comprises a cast steel base, on which a sandwich layer, a transition layer and a strengthening layer are sequentially formed, and the strength and hardness of the cast steel base, the sandwich layer, and the transition layer increase successively, and the For structural support, the surface of the transition layer has a plurality of interlaced concaves and convexes, and the strengthening layer is arranged on the surface of the transitional layer, including concave and convex areas that match the shape of the concaves and convexes, the The concave area is a tensile cracking area made of nickel-based high-temperature alloy welding material, and the convex area is an anti-deformation area made of cobalt-based high-temperature alloy welding material. The invention also discloses a method for manufacturing a large-scale hot forging die. The large-scale forging die produced by the method has excellent crack resistance, wear resistance, and deformation resistance under long-term high-temperature and heavy-load conditions, and can greatly improve forging service life of the model.
Description
技术领域technical field
本发明属于模具技术领域，尤其涉及一种大型热锻模具及其制造方法。The invention belongs to the technical field of dies, in particular to a large hot forging die and a manufacturing method thereof.
背景技术Background technique
随着我国航空航天、核电、石化等国家战略需求领域的迅速发展，对大型化、整体化、精密化的高性能关键构件的需求日益增加。我国机械行业的重大标志性成果，世界最大模锻液压机（800MN模锻压机）应运而生。该压机投入使用以来，在国家重点领域大型关键构件的锻造成形过程中发挥了不可替代的作用，锻件材料主要包括铝合金、高温合金、钛合金等。其使用的大型热锻模具不仅面临着重量大（单套重量高达50～100吨）、制造成本高（单套成本高达200～400万元）、制造周期长等问题，而且按照传统方法制造的均质大型锻模由于锻压工步持续时间长（部分难变形材料锻件成形时间≥2 min），在高温重载工况下模具发生表面开裂、剧烈塑性变形、磨损失效等问题，寿命极低。With the rapid development of my country's aerospace, nuclear power, petrochemical and other national strategic demand fields, the demand for large-scale, integrated and precise high-performance key components is increasing. A major landmark achievement in my country's machinery industry, the world's largest die forging hydraulic press (800MN die forging press) came into being. Since the press was put into use, it has played an irreplaceable role in the forging and forming process of large-scale key components in national key fields. The forging materials mainly include aluminum alloys, high-temperature alloys, titanium alloys, etc. The large hot forging dies used not only face the problems of heavy weight (up to 50-100 tons for a single set), high manufacturing cost (up to 2-4 million yuan for a single set), and long manufacturing cycle. Due to the long duration of the forging process of the homogeneous large forging die (the forming time of some difficult-to-deform material forgings is ≥ 2 min), the die has surface cracking, severe plastic deformation, wear failure and other problems under high temperature and heavy load conditions, and its service life is extremely low.
为解决大型锻模制造成本高的问题，本团队曾提出名称为“一种基于铸钢基体的双层金属堆焊制备锻模的方法”（专利号为ZL 200910104604X）的发明专利申请。该申请利用铸钢作为锻模基体，并在基体上进行强硬度依次升高的双层金属堆焊制备锻模。实际应用表明，该方法应用于铝合金锻件用锻模可降低制造成本15-30%以上，模具使用寿命得到有效提高。进而，为解决难变形材料成形时模具寿命极低的问题（尤其是铸钢基体的承压安全性问题），基于上述专利，本团队又提出了名称为“一种夹心层锻模及锻模夹心层堆焊的制备方法”（专利号为ZL 201510171656.4）的发明专利。该制造新方法是在铸钢基体与过渡层间包裹一层塑韧性良好的夹心层材料，在高压下允许“夹心层”发生较大弹性变形，将模具型腔下面的集中峰值应力迅速扩散衰减，并以近似均匀分布应力（原为楔形分布）传递到铸钢基体层上，从而使铸钢基体所受的最大应力减低，铸钢基体在承压时更加安全。该方法有效的保护了铸钢基体，避免了峰值应力直接导致铸钢基体产生断裂失效的问题。在实际使用过程中，成功锻造出合格的飞机吊尾框钛合金锻件，铸钢基体未发现任何变形及裂纹，完好无损。In order to solve the problem of high manufacturing cost of large forging dies, our team once proposed an invention patent application named "A method for preparing forging dies based on double-layer metal surfacing welding of cast steel substrate" (patent number ZL 200910104604X). This application uses cast steel as the base of the forging die, and double-layer metal overlay welding with successively increasing strength and hardness is carried out on the base to prepare the forging die. Practical application shows that the method applied to forging dies for aluminum alloy forgings can reduce the manufacturing cost by more than 15-30%, and the service life of the dies can be effectively improved. Furthermore, in order to solve the problem of extremely low die life when forming difficult-to-deform materials (especially the pressure-bearing safety of the cast steel matrix), based on the above-mentioned patents, the team also proposed the name "A Sandwich Layer Forging Die and Forging Die Preparation method of sandwich layer surfacing" (patent number ZL 201510171656.4 ) invention patent. The new manufacturing method is to wrap a layer of sandwich layer material with good plasticity and toughness between the cast steel matrix and the transition layer, allowing the "sandwich layer" to undergo large elastic deformation under high pressure, and rapidly diffuse and attenuate the concentrated peak stress under the mold cavity , and transmit to the cast steel matrix layer with approximately uniform distribution stress (formerly wedge-shaped distribution), so that the maximum stress on the cast steel matrix is reduced, and the cast steel matrix is safer when under pressure. The method effectively protects the cast steel matrix and avoids the problem that the peak stress directly causes the cast steel matrix to fail. In the actual use process, a qualified aircraft suspension tail frame titanium alloy forging was successfully forged, and the cast steel matrix was intact without any deformation or crack.
然而，在批量化生产过程中，采用上述专利技术制备的大型热锻模具，由于型腔表层与成型件的结构相匹配，而绝大多数成型件表明都是凹凸不平的，相应的型腔表层也是具有相应的凹形区与凸形区，而凹形区与凸形区在工况条件下受力状态差别巨大（通常凹形区为拉应力而凸形区为压应力），导致凹形区产生微裂纹并进一步扩展为开裂，而凸出区域出现压塌变形，锻模使用寿命依然不能满足需求。因此，急需提出一种改进优化的大型锻模结构（尤其是模具型腔表层功能区），进一步提升大型锻模在高温重载工况下的服役寿命。However, in the mass production process, the large hot forging dies prepared by the above-mentioned patented technology, because the cavity surface matches the structure of the molded parts, and most of the molded parts are uneven, the corresponding cavity surface It also has a corresponding concave area and a convex area, and the stress state of the concave area and the convex area is very different under working conditions (usually the concave area is tensile stress and the convex area is compressive stress), resulting in concave Micro-cracks are generated in the area and further expanded into cracks, while collapse deformation occurs in the protruding area, and the service life of the forging die still cannot meet the demand. Therefore, it is urgent to propose an improved and optimized large forging die structure (especially the surface functional area of the die cavity) to further improve the service life of large forging dies under high temperature and heavy load conditions.
发明内容Contents of the invention
针对上述现有技术的不足，本发明所要解决的技术问题是：如何提供一种大型热锻模具，其在高温重载工况下具有较长的使用寿命，能够同时解决凹形区产生微裂纹并进一步扩展为开裂，而凸形区域出现压塌变形的问题。In view of the deficiencies in the prior art above, the technical problem to be solved by the present invention is: how to provide a large hot forging die, which has a long service life under high temperature and heavy load conditions, and can simultaneously solve the problem of microcracks in the concave area. And further expanded into cracks, and the problem of collapse and deformation appeared in the convex area.
为了解决上述技术问题，本发明采用了如下的技术方案：In order to solve the problems of the technologies described above, the present invention adopts the following technical solutions:
一种大型热锻模具，包括铸钢基体，在所述铸钢基体上依次形成有夹心层、过渡层和强化层，铸钢基体、夹心层、过渡层强硬度依次递增，起到结构支撑作用，所述过渡层表面具有多个相互交错的凹部和凸部，所述强化层设置在过渡层表面，包括与凹部和凸部形状匹配的凹形区和凸形区，所述凹形区为抗拉裂区，采用镍基高温合金焊材制成，所述凸形区为抗变形区，采用钴基高温合金焊材制成。A large-scale hot forging die, including a cast steel base, on which a sandwich layer, a transition layer, and a strengthening layer are sequentially formed, and the strength and hardness of the cast steel base, sandwich layer, and transition layer increase sequentially to play a structural support role , the surface of the transition layer has a plurality of interlaced concaves and convexes, the reinforcement layer is arranged on the surface of the transitional layer, including concave and convex areas matching the shape of the concaves and convexes, the concave area is The anti-cracking area is made of nickel-based high-temperature alloy welding material, and the convex area is an anti-deformation area made of cobalt-based high-temperature alloy welding material.
作为优化，所述凸形区采用的钴基高温合金焊材中的化学成分按质量百分数计，包括铬元素含量26-30%、钼元素含量8-10%、钨元素含量1.8-3%、镍元素含量1.5-2.5%、硅元素含量0.8-1.2%、锰元素含量0.6-1.0%、铌元素含量0.15-0.3%、碳元素含量1.2-1.6%、磷元素含量≤0.02%、硫元素含量≤0.02%，余量为钴和杂质。As an optimization, the chemical composition of the cobalt-based superalloy welding consumables used in the convex area includes chromium element content 26-30%, molybdenum element content 8-10%, tungsten element content 1.8-3%, Nickel element content 1.5-2.5%, silicon element content 0.8-1.2%, manganese element content 0.6-1.0%, niobium element content 0.15-0.3%, carbon element content 1.2-1.6%, phosphorus element content ≤0.02%, sulfur element content ≤0.02%, the balance is cobalt and impurities.
作为优化，所述凹形区采用的镍基高温合金焊材中的化学成分按质量百分数计，包括碳元素含量0.3-0.7%，锰元素含量2.2-2.8%、硅元素含量0.2-0.6%、磷元素含量≤0.02%、硫元素含量≤0.02%、铬元素含量14-20%、钼元素含量1.6-2.0%、钨元素含量2.0-2.8%、铌元素含量0.2-0.6%、钒元素含量0.4-1.0%，余量为镍和杂质。As an optimization, the chemical composition of the nickel-based superalloy welding consumables used in the concave area includes 0.3-0.7% carbon element content, 2.2-2.8% manganese element content, and 0.2-0.6% silicon element content. Phosphorus content≤0.02%, sulfur content≤0.02%, chromium content 14-20%, molybdenum content 1.6-2.0%, tungsten content 2.0-2.8%, niobium content 0.2-0.6%, vanadium content 0.4 -1.0%, the balance is nickel and impurities.
本发明还提供了一种大型热锻模具的制造方法，采用了如下的技术方案：The present invention also provides a manufacturing method of a large-scale hot forging die, which adopts the following technical scheme:
一种大型热锻模具的制造方法，包括以下步骤：A method for manufacturing a large hot forging die, comprising the following steps:
1）、分析大型热锻模具在工况下的温度场、应力场和载荷分布；1) Analyze the temperature field, stress field and load distribution of large hot forging dies under working conditions;
2）、结合步骤1）得到的大型热锻模具的温度场、应力场和载荷分布以及铸钢基体、夹心层、过渡层、强化层材料的性能参数和安全系数，分别确定铸钢基体、夹心层、过渡层和强化层的厚度分布范围；2), combined with the temperature field, stress field and load distribution of the large hot forging die obtained in step 1), and the performance parameters and safety factors of the cast steel matrix, sandwich layer, transition layer, and reinforcement layer materials, respectively determine the cast steel matrix, sandwich Thickness distribution range of layer, transition layer and strengthening layer;
3）、依据步骤2）确定的铸钢基体、夹心层、过渡层和强化层的厚度分布范围，先浇注出铸钢基体并进行热处理后，再采用电弧增材工艺依次形成夹心层、过渡层和强化层，并进行焊后热处理后通过机械加工得到最终的大型热锻模具。3) According to the thickness distribution range of the cast steel matrix, sandwich layer, transition layer and strengthening layer determined in step 2), the cast steel matrix is first poured and heat-treated, and then the sandwich layer and transition layer are sequentially formed by using the arc additive process and strengthening layer, and after post-weld heat treatment, the final large-scale hot forging die is obtained by machining.
作为优化，在步骤3）中通过电弧增材工艺分别形成夹心层、过渡层及强化层之前，分别对铸钢基体、夹心层和过渡层进行表面清洁处理。As an optimization, before the sandwich layer, transition layer and strengthening layer are respectively formed by the arc additive process in step 3), the surface cleaning treatment of the cast steel matrix, sandwich layer and transition layer is carried out respectively.
作为优化，在步骤3）中通过电弧增材工艺形成夹心层前，铸钢基体需预热至450~500℃，在电弧增材过程中，模具温度需保持在300℃以上。As an optimization, before the sandwich layer is formed by the arc additive process in step 3), the cast steel substrate needs to be preheated to 450~500°C, and the mold temperature must be kept above 300°C during the arc additive process.
作为优化，在步骤3）中通过电弧增材工艺形成夹心层、过渡层和强化层的过程中，均加入锤击去应力工序。As an optimization, in the process of forming the sandwich layer, transition layer and strengthening layer through the arc additive process in step 3), a hammering stress relief process is added.
作为优化，在所述步骤3）中，分别以镍基高温合金焊材和钴基高温合金焊材为原材料通过电弧增材工艺形成凹形区和凸形区，凸形区和凹形区通过冶金结合形成强化层。As an optimization, in the step 3), the concave and convex regions are formed by using the nickel-based superalloy welding consumables and the cobalt-based superalloy welding consumables as raw materials respectively, and the convex and concave regions are passed through Metallurgical bonding forms the strengthening layer.
本发明技术方案中，包括模具的铸钢基体，并在基体上通过电弧增材技术依次形成夹心层（起应力扩散作用）、过渡层和强化层，其中，铸钢基体采用特种铸钢材料，具有成本低、塑韧性好的优点，夹心层和过渡层采用Cr-Mo-Ni-W-V系多元复合强化铁基材料，夹心层和过渡层材料成分组成和配比不同，其中夹心层材料塑韧性好而强硬度偏低，过渡层材料强硬度好而塑韧性适中，从铸钢基体到过渡层强硬度依次增加，起到结构支撑作用，强化层凹形区采用镍基高温合金焊材，具有耐高温、高韧性、抗拉裂能力强的优点，强化层凸形区采用钴基高温合金焊材，具有耐高温、抗变形能力强的优点，对症下药，有效改善了现有技术中由于型腔表层凹形区与凸形区在工况条件下受力状态差别巨大（通常凹形区为拉应力而凸形区为压应力）而导致的凹形区产生微裂纹并进一步扩展为开裂，而凸形区域出现压塌变形的瓶颈问题。上述大型锻模在长时间高温重载工况下具备优秀的抗开裂、耐磨损、抗变形性能，能大幅提高锻模的服役寿命。In the technical solution of the present invention, the cast steel matrix of the mold is included, and a sandwich layer (acting as a stress diffusion effect), a transition layer and a strengthening layer are sequentially formed on the matrix through arc material addition technology, wherein the cast steel matrix adopts special cast steel materials, It has the advantages of low cost and good plasticity and toughness. The sandwich layer and the transition layer are made of Cr-Mo-Ni-W-V multi-component composite reinforced iron-based materials. The composition and ratio of the materials of the sandwich layer and the transition layer are different. Good but low in hardness, the material of the transition layer has good strength and moderate plasticity and toughness, and the strength and hardness of the transition layer increase sequentially from the cast steel matrix to the transition layer, which plays a structural support role. The concave area of the strengthening layer is made of nickel-based superalloy welding materials, which It has the advantages of high temperature resistance, high toughness, and strong cracking resistance. The convex area of the strengthening layer is made of cobalt-based superalloy welding material, which has the advantages of high temperature resistance and strong deformation resistance. There is a huge difference in the stress state between the concave area and the convex area of the surface under working conditions (usually the concave area is tensile stress and the convex area is compressive stress), which causes microcracks in the concave area and further expands into cracks, while The bottleneck problem of collapse deformation occurs in the convex area. The above-mentioned large forging die has excellent crack resistance, wear resistance, and deformation resistance under long-term high-temperature and heavy-load conditions, and can greatly increase the service life of the forging die.
附图说明Description of drawings
图1是本发明实施例的结构示意图。Fig. 1 is a schematic structural diagram of an embodiment of the present invention.
具体实施方式Detailed ways
下面结合例附图对本发明作进一步的详细说明。The present invention will be described in further detail below in conjunction with example accompanying drawing.
具体实施时：参见图1，一种大型热锻模具，包括铸钢基体1，在所述铸钢基体1上依次形成有夹心层2、过渡层3和强化层4，铸钢基体1、夹心层2、过渡层3强硬度依次递增，起到结构支撑作用，所述过渡层3表面具有多个相互交错的凹部和凸部，所述强化层4设置在过渡层表面，包括与凹部和凸部形状匹配的凹形区5和凸形区6，所述凹形区5为抗拉裂区，采用镍基高温合金焊材制成，所述凸形区6为抗变形区，采用钴基高温合金焊材制成。During specific implementation: see Fig. 1, a kind of large-scale hot forging die, comprises cast steel matrix 1, is formed with sandwich layer 2, transition layer 3 and reinforcement layer 4 successively on described cast steel matrix 1, cast steel matrix 1, sandwich The strength and hardness of layer 2 and transition layer 3 are successively increased to play a structural support role. The surface of the transition layer 3 has a plurality of interlaced concave parts and convex parts. The reinforcement layer 4 is arranged on the surface of the transition layer, including Concave area 5 and convex area 6 with matched internal shape, the concave area 5 is the anti-cracking area, made of nickel-based superalloy welding consumables, the convex area 6 is the anti-deformation area, made of cobalt-based Made of high temperature alloy welding consumables.
这样的，所述凸形区5采用的钴基高温合金焊材中的化学成分按质量百分数计，包括铬元素含量28%、钼元素含9%、钨元素含量2.4%、镍元素含量2%、硅元素含量1%、锰元素含量0.8%、铌元素含量0.23%、碳元素含量1.4%、磷元素含量0.01%、硫元素含量0.01%，余量为钴和杂质。In this way, the chemical composition of the cobalt-based superalloy welding material used in the convex area 5 includes 28% chromium element content, 9% molybdenum element content, 2.4% tungsten element content, and 2% nickel element content in terms of mass percentage. , silicon element content 1%, manganese element content 0.8%, niobium element content 0.23%, carbon element content 1.4%, phosphorus element content 0.01%, sulfur element content 0.01%, and the balance is cobalt and impurities.
这样的，所述凹形区6采用的镍基高温合金焊材中的化学成分按质量百分数计，包括碳元素含量0.5%，锰元素含量2.5%、硅元素含量0.4%、磷元素含量0.006%、硫元素含量0.009%、铬元素含量17%、钼元素含量1.8%、钨元素含量2.4%、铌元素含量0.4%、钒元素含量0.7%，余量为镍和杂质。In this way, the chemical composition of the nickel-based superalloy welding consumables used in the concave region 6 includes 0.5% carbon element content, 2.5% manganese element content, 0.4% silicon element content, and 0.006% phosphorus element content in terms of mass percentage. , sulfur element content 0.009%, chromium element content 17%, molybdenum element content 1.8%, tungsten element content 2.4%, niobium element content 0.4%, vanadium element content 0.7%, the balance is nickel and impurities.
本发明还提供了一种大型热锻模具的制造方法，采用了如下的技术方案：The present invention also provides a manufacturing method of a large-scale hot forging die, which adopts the following technical scheme:
一种大型热锻模具的制造方法，包括以下步骤：A method for manufacturing a large hot forging die, comprising the following steps:
1）、分析大型热锻模具在工况下的温度场、应力场和载荷分布；1) Analyze the temperature field, stress field and load distribution of large hot forging dies under working conditions;
2）、结合步骤1）得到的大型热锻模具的温度场、应力场和载荷分布以及铸钢基体、夹心层、过渡层、强化层材料的性能参数和安全系数，分别确定铸钢基体、夹心层、过渡层和强化层的厚度分布范围；2), combined with the temperature field, stress field and load distribution of the large hot forging die obtained in step 1), and the performance parameters and safety factors of the cast steel matrix, sandwich layer, transition layer, and reinforcement layer materials, respectively determine the cast steel matrix, sandwich Thickness distribution range of layer, transition layer and strengthening layer;
3）、依据步骤2）确定的铸钢基体、夹心层、过渡层和强化层的厚度分布范围，先浇注出铸钢基体并进行热处理后，再采用电弧增材工艺依次形成夹心层、过渡层和强化层，并进行焊后热处理后通过机械加工得到最终的大型热锻模具。3) According to the thickness distribution range of the cast steel matrix, sandwich layer, transition layer and strengthening layer determined in step 2), the cast steel matrix is first poured and heat-treated, and then the sandwich layer and transition layer are sequentially formed by using the arc additive process and strengthening layer, and after post-weld heat treatment, the final large-scale hot forging die is obtained by machining.
在步骤3）中通过电弧增材工艺分别形成夹心层、过渡层及强化层之前，分别对铸钢基体、夹心层和过渡层进行表面清洁处理，以去除增材层表明的氧化皮及焊渣。Before the sandwich layer, transition layer and strengthening layer are formed respectively by the arc additive process in step 3), the cast steel substrate, sandwich layer and transition layer are respectively cleaned to remove the oxide scale and welding slag indicated by the additive layer .
在步骤3）中通过电弧增材工艺形成夹心层前，铸钢基体需预热至450~500℃，本实施例中优选475℃，在电弧增材过程中，模具温度需保持在300℃以上。Before the sandwich layer is formed by the arc additive process in step 3), the cast steel substrate needs to be preheated to 450~500°C, preferably 475°C in this embodiment. During the arc additive process, the mold temperature must be kept above 300°C .
在步骤3）中通过电弧增材工艺形成夹心层、过渡层和强化层的过程中，均加入锤击去应力工序，使熔敷金属内应力扩散，减少应力集中并提高尺寸精度稳定性。In step 3), during the process of forming the sandwich layer, transition layer and strengthening layer through the arc additive process, a hammering stress relief process is added to diffuse the internal stress of the deposited metal, reduce stress concentration and improve the stability of dimensional accuracy.
在所述步骤3）中，分别以镍基高温合金焊材和钴基高温合金焊材为原材料通过电弧增材工艺形成凹形区和凸形区，凸形区和凹形区通过冶金结合形成强化层。In the step 3), using nickel-based superalloy welding consumables and cobalt-based superalloy welding consumables as raw materials respectively, the concave and convex regions are formed through the arc additive process, and the convex and concave regions are formed by metallurgical bonding reinforcement layer.
通过本制造方法制造的大型热锻模具在长时间高温重载工况下具备优秀的抗开裂、耐磨损、抗变形性能，能够有效改善现有技术中由于型腔表层凹形区与凸形区在工况条件下受力状态差别巨大（通常凹形区为拉应力而凸形区为压应力）而导致的凹形区产生微裂纹并进一步扩展为开裂，而凸形区域出现压塌变形的瓶颈问题，可大幅提高其使用寿命。The large-scale hot forging die manufactured by this manufacturing method has excellent crack resistance, wear resistance, and deformation resistance under long-term high-temperature and heavy-load conditions, and can effectively improve the concave and convex areas of the cavity surface in the prior art. Under the working conditions, the stress state of the area is very different (usually the concave area is tensile stress and the convex area is compressive stress), which leads to microcracks in the concave area and further expand into cracks, while the convex area appears compression deformation Bottleneck problem can greatly improve its service life.
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