CN110202091B - Preparation method of tungsten carbide particle reinforced integral iron-based composite material - Google Patents

Preparation method of tungsten carbide particle reinforced integral iron-based composite material Download PDF

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CN110202091B
CN110202091B CN201910611958.7A CN201910611958A CN110202091B CN 110202091 B CN110202091 B CN 110202091B CN 201910611958 A CN201910611958 A CN 201910611958A CN 110202091 B CN110202091 B CN 110202091B
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tungsten carbide
composite material
iron
based composite
pouring
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CN110202091A (en
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谭建波
马国彬
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Hebei University of Science and Technology
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Hebei University of Science and Technology
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C7/00Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02Lost patterns
    • B22C7/023Patterns made from expanded plastic materials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/02Sand moulds or like moulds for shaped castings
    • B22C9/04Use of lost patterns
    • B22C9/046Use of patterns which are eliminated by the liquid metal in the mould
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D27/00Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
    • B22D27/20Measures not previously mentioned for influencing the grain structure or texture; Selection of compositions therefor
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C33/00Making ferrous alloys
    • C22C33/08Making cast-iron alloys

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Powder Metallurgy (AREA)

Abstract

The invention relates to the technical field of composite materials, in particular to a preparation method of a tungsten carbide (WC) particle reinforced integral iron-based composite material. The preparation method comprises the following steps: and (2) taking the phenolic resin aqueous dispersion as an adhesive, preparing tungsten carbide particles and polystyrene foam (EPS) beads into a lost foam, coating a refractory coating on the surface, drying, embedding molding sand, pouring the high-chromium cast iron melt, and cooling and solidifying to obtain the high-chromium cast iron. The preparation method utilizes the overload effect of the model carrier and the wrapping effect of molten iron to mix WC particles into the high-chromium cast iron melt, and by optimizing various parameters, the prepared composite material can have uniformly distributed WC particles inside, and the preparation method can prepare products in various shapes, including components with complex structures.

Description

Preparation method of tungsten carbide particle reinforced integral iron-based composite material
Technical Field
The invention relates to the technical field of composite materials, in particular to a preparation method of a tungsten carbide particle reinforced integral iron-based composite material.
Background
The ever-evolving modern industry requires more mechanical components that can operate at high temperatures, high speeds and frequent wear, such as crusher hammers, brake pads for high-speed trains, collars and guide wheels for high-speed wire mills, etc. The particle reinforced iron-based composite material is formed by compounding a steel material with higher rigidity, strength and hardness as a matrix and hard particles as a reinforcing phase through a certain process, has good plasticity and toughness, easy processability and electric and thermal conductivity of the iron matrix, and high hardness, good thermal stability and low expansion coefficient of the hard particles, is suitable for the requirements of modern industry, and has good development and application prospects.
The main preparation methods of the particle reinforced iron-based composite material include a powder metallurgy method, a spray deposition method, a stirring casting method, a lost foam casting infiltration method and the like. Wherein the powder metallurgy method and the spray deposition method require expensive equipment, have high production cost, and the size and the shape of the formed part are limited; the stirring casting method is simple to operate and low in cost, but hard particles are not easy to be uniformly distributed in molten metal and are easy to agglomerate, and the molten metal is easy to oxidize or roll up gas during stirring, so that the casting defects such as impurities or air holes are caused. The lost foam casting infiltration method has low cost, but in the prior art, hard particles can only form a composite layer of the hard particles and an iron base on the surface of a product, the thickness of the composite layer and the bonding strength of the hard particles and an iron matrix are not easy to control, and the hard particles are not uniformly distributed, so the method is limited to manufacturing parts with simple structures in the application fields of surface wear resistance, corrosion resistance and heat resistance, and is not suitable for preparing integrally-compounded complex parts. And when the composite layer is abraded, the iron matrix without the hard particles is exposed, so that the performance is reduced.
Disclosure of Invention
The invention provides a preparation method of a tungsten carbide particle reinforced integral iron-based composite material, aiming at the problem that the existing lost foam casting infiltration method can only form a composite layer on the surface of a product.
In order to achieve the purpose of the invention, the embodiment of the invention adopts the following technical scheme:
a preparation method of a tungsten carbide particle reinforced integral iron-based composite material comprises the steps of taking 0.02-0.04 g/mL of phenolic resin aqueous dispersion as a binder, preparing tungsten carbide particles and polystyrene foam (EPS) beads into a lost foam in a mold, coating a refractory coating on the surface of the lost foam, drying, embedding molding sand, pouring high-chromium cast iron melt, and cooling and solidifying to obtain the tungsten carbide particle reinforced integral iron-based composite material; the volume of the binder is 0.3-0.5% of the volume of the lost foam; the particle size of the tungsten carbide particles is 6.5-21 mu m, and the total volume of the tungsten carbide particles is 6-8% of the volume of the evanescent mode.
The high-chromium cast iron is chromium white cast iron with chromium content of 12-28%, and has excellent wear resistance, high temperature resistance, high corrosion resistance, high toughness and high strength. Tungsten carbide has high hardness similar to diamond, is chemically stable, and can conduct heat and electricity well. According to the preparation method, WC particles are mixed into the high-chromium cast iron melt by utilizing the overload effect of the pattern carrier and the wrapping effect of the molten iron, and the type, concentration and dosage of the binder are optimized, so that the tungsten carbide particles can be distributed in the high-chromium cast iron, the prepared composite material has uniformly distributed WC particles, the obtained composite material has extremely high hardness and wear resistance, and the requirements of the composite material on working under the conditions of high temperature, high speed, frequent wear and the like are met. The preferred particle size and volume percentage of tungsten carbide (i.e., the percentage of tungsten carbide particles in the volume of the mold) not only can provide the composite material with better performance, but also can ensure good formability. And the cast iron method adopted by the preparation method is a casting method, so that products with various shapes, including parts with complex structures, can be cast. The obtained composite material can be further processed into parts with complex structures, and the limitation that only parts with simple structures can be manufactured in the prior art is broken through.
The WC particle carrier adopted by the preparation method is EPS beads, and has the advantages of light weight, easy volatilization during pouring, less gas evolution and less residues, and meanwhile, the phenolic resin aqueous dispersion can be gasified during pouring and discharged along with the gas, and is not easy to remain in a casting, so that the impurity content in the prepared composite material can be greatly reduced. The preferable type, concentration and dosage of the binder can ensure that WC particles are firmly bound on the surface of EPS beads, but the product performance is not reduced due to increased gas generation and increased impurities when the lost foam is gasified because of too high concentration of the binder, or the material is seriously agglomerated and is not beneficial to mold filling because of too large dosage of the binder. The tungsten carbide starts active oxidation when the temperature is more than 500 ℃, the melting point of the high-chromium cast iron is higher than 1400 ℃, and the preparation method can well match the gasification of the phenolic resin and the EPS with the wrapping effect of the molten iron by optimizing the type, concentration and dosage of the binder and the particle size of the tungsten carbide particles, thereby preventing the tungsten carbide from being oxidized at the interface due to high temperature. The optimized technological parameters are matched with each other, so that the tungsten carbide particle reinforced integral iron-based composite material with uniform WC particle distribution and unlimited shape can be prepared by the method, and the method is suitable for wide application in industrial mass production.
Preferably, the particle size of the EPS beads is 1-2 mm. The preferred particle size of the EPS beads enables a more uniform distribution of WC particles after fabrication into a composite material, thereby providing better performance of the resulting composite material.
Preferably, the concentration of the aqueous phenolic resin dispersion is 0.03 g/mL.
Preferably, the method for preparing the lost foam is as follows: and pouring the binder into a container filled with the EPS beads, soaking the beads, pouring WC particles, uniformly mixing, transferring into a mold, preserving heat at 110-130 ℃ for 2-3 minutes, and cooling to obtain the EPS beads. The method enables the surface of the EPS beads to be uniformly and firmly loaded with WC particles.
Preferably, the method for applying the fire-resistant coating is as follows: and brushing the fireproof coating on the surface of the lost foam, drying, brushing again, and repeating for 3-5 times. After the refractory coating is coated on the surface of the lost foam for many times, a compact high-temperature-resistant coating can be formed on the surface of the lost foam, so that molten iron and molding sand can be separated from each other, and the phenomenon that the molten iron permeates into sand pores of the molding sand to cause needling or sand sticking on the surface of a product after the molten iron is poured is prevented. The multiple brushing process can also form a shell with certain hardness on the surface of the lost foam, so that the rigidity of the lost foam is improved, and the situation that the dimensional precision of a final product is influenced by deformation when the lost foam is embedded into molding sand is prevented. Meanwhile, the compact coating can promote the gas generated in the gasification of the phenolic resin and the EPS to be discharged as soon as possible, and the defects of incomplete pouring, air holes, slag inclusion, carbon black and the like are avoided.
Preferably, the drying temperature is 45-60 ℃, and the drying time is 6-8 hours each time, so as to ensure that the coating is sufficiently dried after being coated each time, and the coating is more compact.
Preferably, the process parameters for pouring the high-chromium cast iron melt comprise: the negative pressure is 0.03-0.06 MPa, and the casting temperature is 1410-1470 ℃. The preferable negative pressure can accelerate the discharge of gasification products, improve the mold filling effect of molten iron, reduce the surface defects of the obtained product, and reduce the effect when the negative pressure is too low, while the permeability of the molten iron is increased when the negative pressure is too high, so that sand sticking or sintering energy can occur. If the pouring temperature is too low, insufficient pouring can be caused, and gasification is not facilitated, and if the pouring temperature is too high, the defects of poor feeding and the like are easily caused, and the instantaneous gas yield is too high to be discharged in time. The negative pressure degree is matched with the pouring temperature, so that the pouring is more complete, the gasified product is discharged more quickly, and the surface quality of the product is better.
Preferably, the process parameters for pouring the high-chromium cast iron melt further include: the casting speed is 10-20 mm/s. The speed is the speed of the high-chromium cast iron melt rising in the die, the preferable pouring speed can enable the WC particles in the product to be distributed more uniformly, the conditions of cold shut and insufficient pouring can occur when the pouring speed is too slow, oxide inclusions and nonuniform WC particle distribution can be caused by the turbulent flow of the molten iron when the pouring speed is too fast, and the gasified product is not easy to discharge.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail with reference to the following embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Example 1
The embodiment provides a preparation method of a tungsten carbide particle reinforced integral iron-based composite material, which comprises the following steps:
1. pouring 0.02g/mL of phenolic resin aqueous dispersion corresponding to 0.3% of the volume of the lost foam into a mixer filled with EPS beads (the particle size is 1-2 mm), infiltrating the beads, then pouring WC particles (the particle size is 6.5-21 mu m) corresponding to 6% of the volume of the lost foam, stirring and mixing for 10 minutes to uniformly mix the EPS beads and the WC particles. Sucking the materials into a material storage tank, applying pressure to the material storage tank to enable the materials to be filled into a mold through a material gun, introducing steam at the temperature of 110-130 ℃, preserving heat for 2min, and cooling with water to obtain the lost foam.
2. And (3) coating a refractory coating on the surface of the obtained lost foam, drying in a drying room at the temperature of 45 ℃, coating again, drying again, and repeating for three times, wherein the drying time is 8 hours each time.
3. And (3) placing the lost foam coated with the refractory coating into a sand box, filling sand after fixing, vibrating and compacting, and then pouring high-chromium cast iron melt for molding under the conditions of pouring temperature of 1410 ℃, negative pressure of 0.06MPa and pouring speed of 10mm/s to obtain the tungsten carbide particle reinforced integral iron-based composite material.
Example 2
The embodiment provides a preparation method of a tungsten carbide particle reinforced integral iron-based composite material, which comprises the following steps:
1. pouring 0.03g/mL of phenolic resin aqueous dispersion corresponding to 0.4% of the volume of the lost foam into a mixer filled with EPS beads (the particle size is 1-2 mm), infiltrating the beads, then pouring 8% of WC particles (the particle size is 6.5-21 mu m) corresponding to the volume of the lost foam, stirring and mixing for 10 minutes to uniformly mix the EPS beads and the WC particles. Sucking the materials into a material storage tank, applying pressure to the material storage tank to enable the materials to be filled into a mold through a material gun, introducing steam at the temperature of 110-130 ℃, preserving heat for 3min, and cooling with water to obtain the lost foam.
2. And (3) coating a refractory coating on the surface of the obtained lost foam, drying in a drying room at 50 ℃, coating again, drying again, and repeating for three times, wherein the drying time is 8 hours each time.
3. And (3) placing the lost foam coated with the refractory coating into a sand box, filling sand after fixing, vibrating and compacting, and then pouring high-chromium cast iron melt for molding under the conditions of a pouring temperature of 1450 ℃, a negative pressure of 0.05MPa and a pouring speed of 15mm/s to obtain the tungsten carbide particle reinforced integral iron-based composite material.
Example 3
The embodiment provides a preparation method of a tungsten carbide particle reinforced integral iron-based composite material, which comprises the following steps:
1. pouring 0.04g/mL phenol resin aqueous dispersion corresponding to 0.5% of the volume of the lost foam into a mixer filled with EPS beads (the particle size is 1-2 mm), infiltrating the beads, then pouring WC particles (the particle size is 6.5-21 mu m) corresponding to 8% of the volume of the lost foam, stirring and mixing for 10 minutes to uniformly mix the EPS beads and the WC particles. Sucking the materials into a material storage tank, applying pressure to the material storage tank to enable the materials to be filled into a mold through a material gun, introducing steam at the temperature of 110-130 ℃, preserving heat for 3min, and cooling with water to obtain the lost foam.
2. And (3) coating a refractory coating on the surface of the obtained lost foam, drying in a drying room at the temperature of 60 ℃, coating again, drying again, and repeating for five times, wherein the drying time is 6 hours each time.
4. And (3) placing the lost foam coated with the refractory coating into a sand box, filling sand after fixing, vibrating and compacting, and then pouring high-chromium cast iron melt for molding under the conditions of the pouring temperature of 1470 ℃, the negative pressure of 0.03MPa and the pouring speed of 20mm/s to obtain the tungsten carbide particle reinforced integral iron-based composite material.
Examination example
The wear resistance and the WC particle distribution of the tungsten carbide particle reinforced integral iron-based composite material obtained in the embodiments 1-3 are measured, and the detection method is as follows:
1. wear resistance
Taking the product prepared by the preparation method in the embodiment 2 without adding WC particles as a blank sample, and comparing the wear resistance of the product obtained in the embodiment 1-3 with that of the blank sample: the dynamic abrasion test is carried out by adopting a self-developed testing machine which is formed by transforming a small bench drilling machine and mainly comprises a slurry barrel, a chuck plate, a motor, a water regulating valve and the like. The slurry was prepared from 2.5kg of 20 mesh quartz sand and 2.5L of water, the sample size was 18X 38mm, 4 pieces per group, examples 1-3 and blank samples, respectively, and the abrasion time was 240 min. The mass of each product before and after the abrasion test was measured on an electronic analytical balance model JJ224 BC.
The wear rate is (mass before test-mass after test) ÷ mass before test × 100%.
The results are shown in Table 1.
TABLE 1
Investigation item Example 1 Example 2 Example 3 Blank sample
Mass before test (g) 87.5212 89.3686 89.6026 88.6154
Mass after test(g) 86.3898 88.2278 88.4758 86.9964
Wear rate (%) 1.293 1.277 1.283 1.827
The results in table 1 show that the wear rates of the products obtained in examples 1 to 3 are only 1.293%, 1.277%, and 1.283%, while the wear rate of the blank sample is 1.827%, which indicates that the product prepared by the method for preparing the tungsten carbide particle reinforced monolithic iron-based composite material provided by the invention has excellent wear resistance.
2. Analysis of WC particle distribution
Through metallographic analysis of a matrix sample and a sample added with WC particles, the WC particles are difficult to find under a Zeiss microscope due to the extremely small particle size and low content of the added WC particles. The phase types in the sample are analyzed by XRD, and the analysis shows that Fe generated by the reaction of high-chromium cast iron solution and WC particles exists3W3And C phase. Therefore, the content distribution of the W element in the matrix sample is analyzed by adopting the spectrum for detecting Fe3W3Phase C and WC particles which do not react with molten iron.
Two parts of the samples of examples 1 to 3 are cut along the middle section vertical to the pouring direction, the positions from a near pouring gate to a far pouring gate are evenly divided into an upper region, a middle region and a lower region, two points are parallel punched in each region from top to bottom by using a spectrometer, and the W element content of each point is marked as A, B, C, D, E, F.
As shown in table 2.
TABLE 2
Group of A/% B/% C/% D/% E/% F/%
Example 1 3.87 3.90 3.98 4.1 4.28 4.35
Example 2 4.36 4.33 4.5 4.45 4.97 5.1
Example 3 3.66 3.58 3.864 3.92 4.32 4.39
The range of the data fluctuation is small, which indicates that the W element in the sample is distributed uniformly and indirectly indicates Fe, and the range of the data fluctuation is small, which indicates that the range of the extreme difference analysis of the examples 1-3 is 0.48%, 0.74% and 0.81% respectively3W3The phase C and WC particles which do not react with the molten iron are distributed more uniformly.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents or improvements made within the spirit and principle of the present invention should be included in the scope of the present invention.

Claims (6)

1. The preparation method of the tungsten carbide particle reinforced integral iron-based composite material is characterized in that 0.02-0.04 g/mL of phenolic resin aqueous dispersion is used as a binder, the tungsten carbide particles and polystyrene foam beads are made into a lost foam in a mold, the surface of the lost foam is coated with a refractory coating, molding sand is embedded after drying, high-chromium cast iron melt is poured, and the lost foam is obtained after cooling and solidification, wherein the volume of the binder is 0.3-0.5% of the volume of the lost foam; the particle size of the tungsten carbide particles is 6.5-21 mu m, and the total volume of the tungsten carbide particles is 6-8% of the volume of the evanescent mode; the technological parameters of pouring the high-chromium cast iron melt comprise: the negative pressure is 0.03-0.06 MPa, and the casting temperature is 1410-1470 ℃; the technological parameters of pouring the high-chromium cast iron melt further comprise: the casting speed is 10-20 mm/s.
2. The method for preparing the tungsten carbide particle reinforced integral iron-based composite material as claimed in claim 1, wherein the particle size of the polystyrene foam beads is 1-2 mm.
3. The method of making a tungsten carbide particle reinforced monolithic iron-based composite material according to claim 1, wherein the concentration of the aqueous phenolic resin dispersion is 0.03 g/mL.
4. The method of preparing a tungsten carbide particle reinforced monolithic iron-based composite material according to claim 1, wherein the lost foam is prepared by: and pouring the binder into a container filled with the polystyrene foam beads, soaking the beads, pouring tungsten carbide particles, uniformly mixing, transferring into a mold, preserving heat at 110-130 ℃ for 2-3 minutes, and cooling to obtain the polystyrene foam bead.
5. The method of preparing a tungsten carbide particle reinforced monolithic iron-based composite material according to claim 1, wherein the refractory coating is applied by: and brushing a refractory coating on the surface of the lost foam, drying, brushing again, and repeating for 3-5 times.
6. The method for preparing the tungsten carbide particle reinforced integral iron-based composite material according to claim 5, wherein the drying temperature is 45-60 ℃ and the drying time is 6-8 hours each time.
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