CN110607084A - Wear-resistant coating and preparation method thereof, cutter ring of shield hob, shield hob and shield machine - Google Patents
Wear-resistant coating and preparation method thereof, cutter ring of shield hob, shield hob and shield machine Download PDFInfo
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- CN110607084A CN110607084A CN201910823817.1A CN201910823817A CN110607084A CN 110607084 A CN110607084 A CN 110607084A CN 201910823817 A CN201910823817 A CN 201910823817A CN 110607084 A CN110607084 A CN 110607084A
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- 238000000576 coating method Methods 0.000 title claims abstract description 308
- 239000011248 coating agent Substances 0.000 title claims abstract description 300
- 238000002360 preparation method Methods 0.000 title claims abstract description 28
- 239000000843 powder Substances 0.000 claims abstract description 89
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims abstract description 73
- 229910003460 diamond Inorganic materials 0.000 claims abstract description 53
- 239000010432 diamond Substances 0.000 claims abstract description 53
- 239000002994 raw material Substances 0.000 claims abstract description 46
- 238000005219 brazing Methods 0.000 claims abstract description 45
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 36
- WUKWITHWXAAZEY-UHFFFAOYSA-L calcium difluoride Chemical compound [F-].[F-].[Ca+2] WUKWITHWXAAZEY-UHFFFAOYSA-L 0.000 claims abstract description 27
- 229910001634 calcium fluoride Inorganic materials 0.000 claims abstract description 27
- 239000000945 filler Substances 0.000 claims abstract description 27
- 229910052751 metal Inorganic materials 0.000 claims abstract description 27
- 239000002184 metal Substances 0.000 claims abstract description 27
- 229910000640 Fe alloy Inorganic materials 0.000 claims abstract description 26
- BIJOYKCOMBZXAE-UHFFFAOYSA-N chromium iron nickel Chemical compound [Cr].[Fe].[Ni] BIJOYKCOMBZXAE-UHFFFAOYSA-N 0.000 claims abstract description 22
- 239000000758 substrate Substances 0.000 claims abstract description 20
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 13
- 229910052742 iron Inorganic materials 0.000 claims abstract description 6
- 239000000203 mixture Substances 0.000 claims description 54
- 230000006698 induction Effects 0.000 claims description 41
- 238000001035 drying Methods 0.000 claims description 40
- 239000011230 binding agent Substances 0.000 claims description 32
- 238000000034 method Methods 0.000 claims description 32
- 229910045601 alloy Inorganic materials 0.000 claims description 30
- 239000000956 alloy Substances 0.000 claims description 30
- 238000010438 heat treatment Methods 0.000 claims description 29
- 239000002245 particle Substances 0.000 claims description 18
- 229910000816 inconels 718 Inorganic materials 0.000 claims description 16
- 239000000463 material Substances 0.000 claims description 16
- 239000011247 coating layer Substances 0.000 claims description 13
- 229940093429 polyethylene glycol 6000 Drugs 0.000 claims description 3
- 239000002356 single layer Substances 0.000 claims description 3
- 230000005641 tunneling Effects 0.000 claims description 3
- 230000007704 transition Effects 0.000 abstract description 7
- 230000000977 initiatory effect Effects 0.000 abstract description 5
- 230000006378 damage Effects 0.000 abstract description 3
- 230000002035 prolonged effect Effects 0.000 abstract description 3
- 229910000679 solder Inorganic materials 0.000 description 32
- 238000012360 testing method Methods 0.000 description 11
- 239000010410 layer Substances 0.000 description 9
- 239000011435 rock Substances 0.000 description 9
- 238000005299 abrasion Methods 0.000 description 7
- 230000000052 comparative effect Effects 0.000 description 7
- 239000011159 matrix material Substances 0.000 description 7
- 229910001026 inconel Inorganic materials 0.000 description 6
- 229910001120 nichrome Inorganic materials 0.000 description 6
- 239000013078 crystal Substances 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- 230000007797 corrosion Effects 0.000 description 4
- 238000005260 corrosion Methods 0.000 description 4
- 238000005520 cutting process Methods 0.000 description 4
- 230000035882 stress Effects 0.000 description 4
- 239000002585 base Substances 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 238000009827 uniform distribution Methods 0.000 description 3
- 229910000851 Alloy steel Inorganic materials 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 239000003513 alkali Substances 0.000 description 2
- 239000003153 chemical reaction reagent Substances 0.000 description 2
- 239000011651 chromium Substances 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 239000011363 dried mixture Substances 0.000 description 2
- 238000000227 grinding Methods 0.000 description 2
- 229910001055 inconels 600 Inorganic materials 0.000 description 2
- 239000012254 powdered material Substances 0.000 description 2
- 238000005096 rolling process Methods 0.000 description 2
- 239000002689 soil Substances 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 230000003685 thermal hair damage Effects 0.000 description 2
- 230000008646 thermal stress Effects 0.000 description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- UCKMPCXJQFINFW-UHFFFAOYSA-N Sulphide Chemical compound [S-2] UCKMPCXJQFINFW-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000005255 carburizing Methods 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 230000002500 effect on skin Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000005242 forging Methods 0.000 description 1
- 239000010438 granite Substances 0.000 description 1
- 229910001119 inconels 625 Inorganic materials 0.000 description 1
- 229910001098 inconels 690 Inorganic materials 0.000 description 1
- 229910001090 inconels X-750 Inorganic materials 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 238000004372 laser cladding Methods 0.000 description 1
- PXHVJJICTQNCMI-OUBTZVSYSA-N nickel-60 atom Chemical compound [60Ni] PXHVJJICTQNCMI-OUBTZVSYSA-N 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
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- 239000012798 spherical particle Substances 0.000 description 1
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- 238000006467 substitution reaction Methods 0.000 description 1
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D1/00—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
- C09D7/40—Additives
- C09D7/60—Additives non-macromolecular
- C09D7/61—Additives non-macromolecular inorganic
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21D—SHAFTS; TUNNELS; GALLERIES; LARGE UNDERGROUND CHAMBERS
- E21D9/00—Tunnels or galleries, with or without linings; Methods or apparatus for making thereof; Layout of tunnels or galleries
- E21D9/06—Making by using a driving shield, i.e. advanced by pushing means bearing against the already placed lining
- E21D9/08—Making by using a driving shield, i.e. advanced by pushing means bearing against the already placed lining with additional boring or cutting means other than the conventional cutting edge of the shield
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Organic Chemistry (AREA)
- Materials Engineering (AREA)
- Wood Science & Technology (AREA)
- Inorganic Chemistry (AREA)
- Mining & Mineral Resources (AREA)
- Environmental & Geological Engineering (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Geology (AREA)
- Powder Metallurgy (AREA)
- Polishing Bodies And Polishing Tools (AREA)
Abstract
The invention provides a wear-resistant coating and a preparation method thereof, a cutter ring of a shield hob, the shield hob and a shield machine, which comprise a first coating and a second coating which are sequentially connected; the first coating is prepared from nickel-chromium-iron alloy; the second coating is prepared from the following components in parts by mass: 5-12 parts of diamond micro powder, 1-5 parts of calcium fluoride and 83-94 parts of nickel-based brazing filler metal; the first coating is used for connecting with a substrate which takes iron or iron alloy as a main raw material. The wear-resistant coating provided by the invention is composed of multiple passes, different and thinner coatings, the nickel-chromium-iron alloy transition layer is added between the substrate and the nickel-based brazing filler metal, the initiation and the expansion of cracks are inhibited, the bonding strength of the coating and the substrate is enhanced, and the diamond micro powder is added into the coating as a hard phase, so that the wear-resistant coating has the advantages of small heat damage, uniform hard phase distribution, lower cost and the like, the wear resistance of the shield hob ring is effectively improved, and the service life of the hob ring is prolonged.
Description
Technical Field
The invention relates to the field of surface treatment of engineering equipment, in particular to a wear-resistant coating and a preparation method thereof, a cutter ring of a shield hob, the shield hob and a shield machine.
Background
The shield hobbing cutter is one of shield machine cutters and plays a role in propelling a 'front' in construction. The shield hob consists of a cutter ring and cutter teeth. The cutter ring generally adopts alloy steel as a base material, and the cutter teeth are made of brazed or inlaid hard alloy. The carbide cutter teeth play roles in rolling and cutting rock soil, and the cutter ring plays a role in supporting and protecting the carbide cutter teeth. Under the influence of random changes of soil conditions and underground water pressure, the shield hob bears various stress modes of continuous and variable extrusion, jacking, scraping, impact, abrasion and the like along with continuous propulsion of construction and continuous rotation of the cutterhead, and the stress modes are mainly expressed as powerful abrasion and impact of the cutter.
The hob ring and the hard alloy cutter teeth are both worn by rocks. Because the rock breaking efficiency of the hob cutter is related to the width of the cutting edge of the hob cutter, the width of the cutting edge is increased along with the increase of the abrasion loss of the cutter ring, and the tunneling speed can be influenced or even the tunneling can not be performed any more when the certain range is reached. Therefore, the failure modes of the hob are mainly cutter ring abrasion and cutter ring fracture. Wherein, the wear resistance of the rolling cutter ring is the key of the failure of the hob. In order to improve the wear resistance of the hob ring and prevent microcracks from being generated during brazing or embedding of hard alloy, high-strength alloy steel is usually adopted as the material of the hob ring by domestic and foreign research units and factories and is subjected to forging forming and surface carburizing and quenching treatment to improve the wear resistance. However, the cutter ring around the tooth heel still cannot be hard, the carburization depth cannot be deep, and the carburized layer is easily ground off by rocks, so that the service life of the cutter ring is limited. Therefore, the method has important significance for preparing the wear-resistant coating on the surface of the shield hob ring by adopting the surface technology.
However, the existing shield hob ring coating has the following problems: the cutter ring wear-resistant coating is prepared by adopting a surfacing method, although a thicker coating can be prepared, the surfacing heat output is large, the thermal stress is large after surfacing, cracks are easy to generate, and the cutter ring is easy to expand into a base material and break; the hard phase of the existing coating is mostly large-particle carbide or hard alloy, the coating is not uniform, local stress concentration is easy to generate, microcracks are generated, and the large-particle hard phase is easy to crack or fall off in the working process; the wear-resistant coating is prepared by adopting a conventional brazing method, although the thermal stress is small, the prepared coating is very thin, and the wear resistance of the cutter ring is difficult to effectively improve; and laser cladding is adopted, so that the equipment investment is high and the coating cost is high.
In view of the above, the present invention is particularly proposed.
Disclosure of Invention
The first purpose of the invention is to provide a wear-resistant coating to solve or partially solve the above problems, the wear-resistant coating is composed of multiple passes, different and thin coatings, a nickel-chromium-iron alloy transition layer is added between a substrate and a nickel-based brazing filler metal, the initiation and the propagation of cracks are inhibited, the bonding strength of the coating and the substrate is enhanced, and diamond micro powder is added in the coating as a hard phase, so that the wear-resistant coating has the advantages of small thermal damage, uniform distribution of the hard phase, low cost and the like.
The second purpose of the invention is to provide a preparation method of the wear-resistant coating, the method mixes the coating raw material and the adhesive into a paste, coats the paste on the surface of the substrate, and then adopts the induction brazing method to prepare the coating.
Another object of the present invention is to provide a shield hob, the surface of the cutter ring of which is coated with the wear-resistant coating, so as to effectively improve the wear-resistant performance of the cutter ring and prolong the service life of the cutter ring.
In order to achieve the above purpose of the present invention, the following technical solutions are adopted:
a wear-resistant coating comprises a first coating and a second coating which are connected in sequence;
the first coating is prepared from a nickel-chromium-iron alloy, preferably, the nickel-chromium-iron alloy is Inconel 718;
the second coating is prepared from the following components in parts by mass:
5-12 parts of diamond micro powder, 1-5 parts of calcium fluoride and 83-94 parts of nickel-based brazing filler metal;
the first coating is used for connecting with a substrate which takes iron or iron alloy as a main raw material.
Preferably, the second coating of the wear-resistant coating is prepared from the following components in parts by mass:
8-10 parts of diamond micro powder, 1-3 parts of calcium fluoride and 80-90 parts of nickel-based brazing filler metal.
Preferably, the nickel-based brazing filler metal is a Ni60 alloy.
Preferably, the coating thickness of the first coating is 0.3-0.5 mm.
Preferably, the coating thickness of the second coating is 0.2-0.3 mm.
Preferably, the first coating and/or the second coating further contain a binder, more preferably, the binder is selected from polyethylene glycol 6000, and the addition amount of the binder is 1-3% of the mass of the raw materials of the first coating or the second coating.
The preparation method of the wear-resistant coating comprises the following steps:
(a) coating the raw material mixture of the first coating on the surface of a substrate, drying, and performing induction braze coating to obtain a first coating;
preferably, the drying temperature is 110-120 ℃, and more preferably, the drying time is 0.5-1 h;
(b) coating the raw material mixture of the second coating on the surface of the first coating, obtaining a single-layer brazing filler metal coating after induction brazing, and drying the brazing filler metal coating;
preferably, the induction brazing is operated by using a superaudio induction heating device;
(c) optionally repeating step (b) until a second coating of desired thickness is obtained.
Preferably, the granularity of the diamond micro powder is 50-150 meshes, and more preferably 80-120 meshes.
Preferably, the nickel-chromium-iron alloy is a powdery material, and the granularity of the powdery material is 200-280 meshes, and more preferably 230-270 meshes.
Preferably, the nickel-based brazing filler metal is a powdery material, and the granularity of the powdery material is 200-300 meshes, and more preferably 230-270 meshes.
The cutter ring of the shield hobbing cutter is coated with the wear-resistant coating on the surface, and preferably, the thickness of the wear-resistant coating is 5-6 mm.
The shield hobbing cutter comprises a cutter ring of the shield hobbing cutter.
The shield machine comprises the shield hob.
Compared with the prior art, the invention has the beneficial effects that:
(1) the wear-resistant coating provided by the invention is composed of multiple-pass, different and thinner coatings, the nickel-chromium-iron alloy transition layer is added between the substrate and the nickel-based brazing filler metal, the initiation and the expansion of cracks are inhibited, the bonding strength of the coating and the substrate is enhanced, and the diamond micro powder is added into the coating as a hard phase, so that the wear-resistant coating has the advantages of small thermal damage, uniform distribution of the hard phase, lower cost and the like.
(2) The preparation method of the wear-resistant coating provided by the invention adopts the induction brazing method to prepare the coating, has the advantages of low cost, high heating rate, small heat affected zone of the base material and the diamond, no excessive heat damage, no need of heat treatment after the coating is prepared and the like, and realizes the integration of the coating preparation and the heat treatment.
(3) According to the shield hob provided by the invention, the wear-resistant coating is coated on the surface of the cutter ring, so that the wear resistance of the cutter ring is effectively improved, and the service life of the cutter ring is prolonged.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without creative efforts.
FIG. 1 is a schematic structural view of a wear-resistant coating provided by the present invention;
fig. 2 is a schematic structural diagram of a grinding coating layer of the shield hob provided by the invention.
Description of the drawings:
1-a first coating; 2-a second coating; 3-a substrate; 4-shield hobbing cutter ring.
Detailed Description
The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings and the detailed description, but those skilled in the art will understand that the following described embodiments are some, not all, of the embodiments of the present invention, and are only used for illustrating the present invention, and should not be construed as limiting the scope of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention. The examples, in which specific conditions are not specified, were conducted under conventional conditions or conditions recommended by the manufacturer. The reagents or instruments used are not indicated by the manufacturer, and are all conventional products available commercially.
The wear-resistant coating provided by the invention comprises a first coating 1 and a second coating 2 which are sequentially connected;
the first coating 1 is prepared from a nickel-chromium-iron alloy, and the nickel-chromium-iron alloy coating is a transition layer, so that the initiation and the expansion of cracks are inhibited, and the bonding strength of the coating and the matrix 3 is enhanced; the first coating 1 is used for connecting with a substrate 3 which takes iron or iron alloy as a main raw material.
The second coating 2 is prepared from the following components in parts by mass:
5-12 parts (such as 5 parts, 6 parts, 7 parts, 8 parts, 9 parts, 10 parts, 11 parts and 12 parts) of diamond micro powder, 1-5 parts (such as 1 part, 2 parts, 3 parts, 4 parts and 5 parts) of calcium fluoride and 83-94 parts (such as 83 parts, 84 parts, 85 parts, 86 parts, 87 parts, 88 parts, 89 parts, 90 parts, 91 parts, 92 parts, 93 parts and 94 parts) of nickel-based brazing filler metal.
The wear-resistant coating provided by the invention is composed of multiple-pass, different and thinner coatings, the nickel-chromium-iron alloy transition layer is added between the matrix 3 and the nickel-based brazing filler metal, the initiation and the expansion of cracks are inhibited, the bonding strength of the coating and the matrix 3 is enhanced, and the diamond micro powder is added into the coating as a hard phase, so that the wear-resistant coating has the advantages of small heat damage, uniform distribution of the hard phase, lower cost and the like.
In some preferred embodiments of the present invention, the raw material of the second coating layer 2 may be further preferred, and is prepared from the following components in parts by mass:
5-12 parts of diamond micro powder, 1-3 parts of calcium fluoride and 77-84 parts of nickel-based brazing filler metal.
In some preferred embodiments of the present invention, the nickel-based braze is a Ni60 alloy.
The nickel-based brazing filler metal comprises nickel-based alloy powder such as Ni60, Ni60M, Ni62 and Ni45, the Ni60 alloy powder is preferably selected in the application, is called nickel-based alloy powder in all, is called nickel 60 in the industry, and has good wear resistance.
In some preferred embodiments of the present invention, the thickness of the nichrome transition layer is controlled, and the first coating layer 1 is coated at a thickness of 0.3-0.5 mm.
In some preferred embodiments of the invention, the thickness of each layer of brazing filler metal coating is controlled to improve the bonding force between each layer, improve the overall performance of the coating, and improve the bonding force between the coating and the transition layer, the coating thickness of the second coating 2 is controlled to be 0.2-0.3 mm, and the second coating 2 can be prepared by repeatedly coating according to the required coating thickness until the second coating 2 with the expected thickness is obtained.
In some preferred embodiments of the present invention, the first coating layer 1 and/or the second coating layer 2 further comprise a binder, preferably, the binder is selected from polyethylene glycol 6000, and the amount of the binder added is 1% to 3% of the mass of the raw materials of the first coating layer 1 or the second coating layer 2.
The preparation method of the wear-resistant coating provided by the invention comprises the following steps:
(a) coating the raw material mixture of the first coating 1 on the surface of a substrate 3, drying, and carrying out induction braze coating to obtain a first coating 1;
(b) coating the raw material mixture of the second coating 2 on the surface of the first coating 1, obtaining a single-layer brazing filler metal coating after induction brazing, and drying the brazing filler metal coating;
(c) optionally repeating step (b) until a second coating 2 of desired thickness is obtained.
The preparation method of the wear-resistant coating provided by the invention has the advantages that the coating raw material and the adhesive are mixed into a paste, the paste is coated on the surface of the substrate 3, and then the coating is prepared by adopting an induction brazing method.
In some preferred embodiments of the present invention, in the raw material, the diamond fine powder has a particle size of 50 to 150 mesh, preferably 80 to 120 mesh.
The diamond micro powder comprises single crystal diamond micro powder and polycrystalline diamond micro powder. Because the yield of the single crystal diamond micro powder is large, the application field is wide, the diamond micro powder is generally specially referred to the single crystal diamond micro powder in the industry, and the single crystal diamond micro powder is produced by a special technological method of a superhard material through crushing and shaping treatment by using synthetic diamond single crystal abrasive particles by a static pressure method. The diamond micro powder has high hardness and good wear resistance, and can be widely used for cutting, grinding, drilling, polishing and the like.
Particle size refers to the size of the particle. Generally, the particle size of spherical particles is expressed in terms of diameter and the particle size of cubic particles is expressed in terms of side length. According to the method, the diamond micro powder with the granularity of 50-150 meshes is preferably selected, so that the diamond micro powder has good dispersibility in the coating.
In some preferred embodiments of the present invention, in the raw material, the nichrome is a powdered material, and more preferably, the particle size of the powdered material is 200 to 280 meshes, and more preferably 230 to 270 meshes.
The nickel-chromium-iron alloy is an Inconel alloy, which contains some iron and is called the Inconel alloy with low iron content. The Inconel alloy contains much higher nickel than stainless steel, so that the corrosion resistance to hot alkali liquor and alkali sulfide is better than that of stainless steel, and the high-temperature corrosion resistance is better. Since a nickel-chromium-iron alloy represented by Inconel600 contains chromium, it is better in corrosion resistance than nickel in an oxidizing environment. And has good corrosion resistance in reducing environment due to high nickel content.
The Inconel alloy comprises: iconel 600, Inconel 625, Inconel X750, Inconel718, and Inconel 880, preferably Inconel718, Ni for this application54Cr18.5Mo3.1Fe18.5And has good high temperature resistance.
In some preferred embodiments of the invention, the nickel-based brazing filler metal in the raw materials is a powdery material, more preferably, the granularity of the powdery material is 200-300 meshes, more preferably 230-270 meshes, and the nickel-based brazing filler metal and the diamond micro powder under the mesh number have a good matching effect, so that the raw materials are uniformly dispersed.
In some preferred embodiments of the present invention, in the step (a), the drying temperature is 110 to 120 ℃, and more preferably, the drying time is 0.5 to 1 hour, so that the coating is uniformly formed and cracks are avoided.
In some preferred embodiments of the present invention, in step (b), the induction brazing is performed using a super-sonic induction heating apparatus.
Principle of ultrasonic frequency induction heating: the workpiece is placed in an inductor, which is generally a hollow copper tube to which medium-frequency or high-frequency alternating current (1000 to 300000Hz or higher) is input. The alternating magnetic field is generated to generate induced current with the same frequency in the workpiece, the induced current is non-uniformly distributed on the workpiece, strong on the surface and weak in the workpiece, and the induced current is close to 0 in the center, the skin effect is utilized to rapidly heat the surface of the workpiece, the temperature of the inner surface rises to 800-1000 ℃ in a few seconds, the temperature of the center rises very little, and the heating efficiency is as high as more than 90%.
The cutter ring of the shield hobbing cutter is coated with the wear-resistant coating on the surface, and preferably, the thickness of the wear-resistant coating is 5-6 mm.
The shield hobbing cutter comprises a cutter ring of the shield hobbing cutter.
The shield hobbing cutter provided by the invention comprises the cutter ring and the cutter teeth, and the wear-resistant coating is coated on the surface of the cutter ring, so that the wear resistance of the cutter ring is effectively improved, and the service life of the cutter ring is prolonged.
The shield machine comprises the shield hob.
Embodiments of the present invention will be described in detail below with reference to examples, but it will be understood by those skilled in the art that the following examples are only illustrative of the present invention and should not be construed as limiting the scope of the present invention. The examples, in which specific conditions are not specified, were conducted under conventional conditions or conditions recommended by the manufacturer. The reagents or instruments used are not indicated by the manufacturer, and are all conventional products commercially available.
Example 1
The wear-resistant coating provided by the embodiment is prepared from the following raw materials and by the method:
as shown in fig. 1, the wear resistant coating is formed of a multi-pass, non-identical, relatively thin coating. The hard phase in the coating is diamond micropowder, and the total thickness of the coating is controlled to be 5-6 mm;
the raw material of the first coating 1 is 100% of Inconel718 alloy powder, and the particle size ranges of the Inconel718 alloy powder are 200-280 meshes respectively;
the raw materials of the second coating 2 comprise 5 parts of diamond micro powder (the granularity range is 50-150 meshes), 1 part of calcium fluoride and 94 parts of Ni60 alloy powder (the granularity range is 200-300 meshes).
The preparation method comprises the following steps:
(a) coating the mixture of the nickel-chromium-iron alloy powder and the binder on the surface of the matrix 3, wherein the thickness of the mixture is 0.3mm, drying the mixture at 110 ℃ for 0.5h, and then carrying out induction brazing to obtain a first coating 1;
(b) coating a mixture of diamond micro powder, calcium fluoride, nickel-based solder powder and a binder on the surface of the first coating 1, wherein the coating thickness is 0.3mm, forming a solder coating by an induction brazing method, and drying the solder coating;
(c) and (c) repeating step (b) until a second coating 2 of acceptable thickness is obtained.
Example 2
The wear-resistant coating provided by the embodiment is prepared from the following raw materials and by the method:
as shown in fig. 1, the wear resistant coating is formed of a multi-pass, non-identical, relatively thin coating. The hard phase in the coating is diamond micropowder, and the total thickness of the coating is controlled to be 5-6 mm;
the raw material of the first coating 1 is 100% of Inconel718 alloy powder, and the particle size ranges of the Inconel718 alloy powder are 200-280 meshes respectively;
the raw materials of the second coating 2 comprise 6 parts of diamond micro powder (the granularity range is 50-150 meshes), 2 parts of calcium fluoride and 92 parts of Ni60 alloy powder (the granularity range is 200-300 meshes).
The preparation method comprises the following steps:
(a) coating the mixture of the nickel-chromium-iron alloy powder and the binder on the surface of the matrix 3, wherein the thickness of the mixture is 0.5mm, drying the mixture at 120 ℃ for 1 hour, and heating the dried mixture by using a superaudio induction device to obtain a first coating 1;
(b) coating a mixture of diamond micro powder, calcium fluoride, nickel-based solder powder and a binder on the surface of the first coating 1, wherein the coating thickness is 0.2mm, heating by using a supersonic frequency induction device to form a solder coating, and drying the solder coating;
(c) and (c) repeating step (b) until a second coating 2 of acceptable thickness is obtained.
Example 3
The wear-resistant coating provided by the embodiment is prepared from the following raw materials and by the method:
as shown in fig. 1, the wear resistant coating is formed of a multi-pass, non-identical, relatively thin coating. The hard phase in the coating is diamond micropowder, and the total thickness of the coating is controlled to be 5-6 mm;
the raw material of the first coating 1 is 100% of Inconel718 alloy powder, and the particle size ranges are 230-270 meshes respectively;
the raw materials of the second coating 2 comprise 7 parts of diamond micro powder (the granularity range is 50-150 meshes), 2 parts of calcium fluoride and 91 parts of Ni60 alloy powder (the granularity range is 230-270 meshes).
The preparation method comprises the following steps:
(a) coating the mixture of the nickel-chromium-iron alloy powder and the binder on the surface of the substrate 3, wherein the thickness of the mixture is 0.4mm, drying the mixture at 115 ℃ for 1h, and heating the mixture by using a superaudio induction device to obtain a first coating 1;
(b) coating a mixture of diamond micro powder, calcium fluoride, nickel-based solder powder and a binder on the surface of the first coating 1, wherein the coating thickness is 0.3mm, forming a solder coating by an induction brazing method, and drying the solder coating;
(c) and (c) repeating step (b) until a second coating 2 of acceptable thickness is obtained.
Example 4
The wear-resistant coating provided by the embodiment is prepared from the following raw materials and by the method:
as shown in fig. 1, the wear resistant coating is formed of a multi-pass, non-identical, relatively thin coating. The hard phase in the coating is diamond micropowder, and the total thickness of the coating is controlled to be 5-6 mm;
the raw material of the first coating 1 is 100% of Inconel718 alloy powder, and the particle size ranges are 230-270 meshes respectively;
the raw materials of the second coating 2 comprise 8 parts of diamond micro powder (the granularity range is 80-120 meshes), 1 part of calcium fluoride and 91 parts of Ni60 alloy powder (the granularity range is 230-270 meshes).
The preparation method comprises the following steps:
(a) coating the mixture of the nickel-chromium-iron alloy powder and the binder on the surface of the substrate 3, wherein the thickness of the mixture is 0.5mm, drying the mixture at 118 ℃ for 0.6h, and heating the mixture by using a supersonic frequency induction device to obtain a first coating 1;
(b) coating a mixture of diamond micro powder, calcium fluoride, nickel-based solder powder and a binder on the surface of the first coating 1, wherein the coating thickness is 0.2mm, heating by using a supersonic frequency induction device to form a solder coating, and drying the solder coating;
(c) and (c) repeating step (b) until a second coating 2 of acceptable thickness is obtained.
Example 5
The wear-resistant coating provided by the embodiment is prepared from the following raw materials and by the method:
as shown in fig. 1, the wear resistant coating is formed of a multi-pass, non-identical, relatively thin coating. The hard phase in the coating is diamond micropowder, and the total thickness of the coating is controlled to be 5-6 mm;
the raw material of the first coating 1 is 100% of Inconel690 alloy powder, and the particle size ranges are 200-280 meshes respectively;
the raw materials of the second coating 2 comprise 10 parts of diamond micro powder (the granularity range is 50-150 meshes), 3 parts of calcium fluoride and 87 parts of Ni45 solder powder (the granularity range is 200-300 meshes).
The preparation method comprises the following steps:
(a) coating the mixture of the nickel-chromium-iron alloy powder and the binder on the surface of the substrate 3, wherein the thickness of the mixture is 0.4mm, drying the mixture at 118 ℃ for 0.8h, and heating the mixture by using a supersonic frequency induction device to obtain a first coating 1;
(b) coating a mixture of diamond micro powder, calcium fluoride, nickel-based solder powder and a binder on the surface of the first coating 1, wherein the coating thickness is 0.2mm, heating by using a supersonic frequency induction device to form a solder coating, and drying the solder coating;
(c) and (c) repeating step (b) until a second coating 2 of acceptable thickness is obtained.
Example 6
The wear-resistant coating provided by the embodiment is prepared from the following raw materials and by the method:
as shown in fig. 1, the wear resistant coating is formed of a multi-pass, non-identical, relatively thin coating. The hard phase in the coating is diamond micropowder, and the total thickness of the coating is controlled to be 5-6 mm;
the raw material of the first coating 1 is 100% of Inconel600 alloy powder, and the particle size ranges are 230-270 meshes respectively;
the raw materials of the second coating 2 comprise 12 parts of diamond micro powder (the granularity range is 80-120 meshes), 5 parts of calcium fluoride and 83 parts of Ni45 solder powder (the granularity range is 200-300 meshes).
The preparation method comprises the following steps:
(a) coating the mixture of the nickel-chromium-iron alloy powder and the binder on the surface of the matrix 3, wherein the thickness of the mixture is 0.3mm, drying the mixture at 120 ℃ for 0.5h, and heating the dried mixture by using a superaudio induction device to obtain a first coating 1;
(b) coating a mixture of diamond micro powder, calcium fluoride, nickel-based solder powder and a binder on the surface of the first coating 1, wherein the coating thickness is 0.2mm, heating by using a supersonic frequency induction device to form a solder coating, and drying the solder coating;
(c) and (c) repeating step (b) until a second coating 2 of acceptable thickness is obtained.
Example 7
With reference to fig. 2, the shield hob provided in this embodiment has the same raw material for the surface coating of the cutter ring as in embodiment 1, and the specific preparation method includes the following steps:
(a) coating a mixture of nichrome powder and a binder on the surface of a shield hob ring 4, wherein the thickness of the mixture is 0.5mm, drying the mixture at 110 ℃ for 0.5h, drying the water in the coating, fixing the dried hob ring on a positioner with a chuck, rotating the chuck to enable the coating part to be just placed in an induction coil of a superaudio induction heating device, turning on a power supply, rotating the chuck for one circle at a certain speed, rapidly and uniformly heating Inconel718 on the hob ring, and completing the preparation of the whole-circle coating of the hob ring after the chuck rotates for one circle;
(b) coating a mixture of diamond micro powder, calcium fluoride, nickel-based solder powder and a binder on the surface of the first coating 1, wherein the coating thickness is 0.2mm, heating by using a supersonic frequency induction device to form a solder coating, and drying moisture in the solder coating at a low temperature;
(c) and (c) repeating the step (b) until a second coating layer 2 with qualified thickness is obtained, and forming the wear-resistant coating on the surface of the cutter ring.
Example 8
With reference to fig. 2, the shield hob provided in this embodiment has the same raw material for the surface coating of the cutter ring as in embodiment 2, and the specific preparation method includes the following steps:
(a) coating a mixture of nichrome powder and a binder on the surface of a shield hob ring 4, wherein the thickness of the mixture is 0.3mm, drying the mixture at 120 ℃ for 1h, drying the water in the coating, fixing the dried hob ring on a positioner with a chuck, rotating the chuck to enable the coating part to be just placed in an induction coil of a superaudio induction heating device, turning on a power supply, rotating the chuck for one circle at a certain speed, rapidly and uniformly heating Inconel718 on the hob ring, and rotating the chuck for one circle to finish the preparation of the whole-circle coating of the hob ring;
(b) coating a mixture of diamond micro powder, calcium fluoride, nickel-based solder powder and a binder on the surface of the first coating 1, wherein the coating thickness is 0.2mm, heating by using a supersonic frequency induction device to form a solder coating, and drying moisture in the solder coating at a low temperature;
(c) and (c) repeating the step (b) until a second coating layer 2 with qualified thickness is obtained, and forming the wear-resistant coating on the surface of the cutter ring.
Example 9
With reference to fig. 2, the shield hob provided in this embodiment has the same raw material for the surface coating of the cutter ring as in embodiment 3, and the specific preparation method includes the following steps:
(a) coating a mixture of nichrome powder and a binder on the surface of a shield hob ring 4, wherein the thickness of the mixture is 0.3mm, drying the mixture at 105 ℃ for 0.5h, drying the water in the coating, fixing the dried hob ring on a positioner with a chuck, rotating the chuck to enable the coating part to be just placed in an induction coil of a superaudio induction heating device, turning on a power supply, rotating the chuck for one circle at a certain speed, rapidly and uniformly heating Inconel718 on the hob ring, and completing the preparation of the whole-circle coating of the hob ring after the chuck rotates for one circle;
(b) coating a mixture of diamond micro powder, calcium fluoride, nickel-based solder powder and a binder on the surface of the first coating 1, wherein the coating thickness is 0.3mm, heating by using a supersonic frequency induction device to form a solder coating, and drying moisture in the solder coating at a low temperature;
(c) and (c) repeating the step (b) until a second coating layer 2 with qualified thickness is obtained, and forming the wear-resistant coating on the surface of the cutter ring.
Example 10
With reference to fig. 2, the shield hob provided in this embodiment has the same raw material for the surface coating of the cutter ring as in embodiment 4, and the specific preparation method includes the following steps:
(a) coating a mixture of nichrome powder and a binder on the surface of a shield hob ring 4, wherein the thickness of the mixture is 0.4mm, drying the mixture for 1 hour at 108 ℃, drying the water in the coating, fixing the dried hob ring on a positioner with a chuck, rotating the chuck to enable the coating part to be just placed in an induction coil of a superaudio induction heating device, turning on a power supply, rotating the chuck for one circle at a certain speed, rapidly and uniformly heating Inconel718 on the hob ring, and completing the preparation of the whole-circle coating of the hob ring after the chuck rotates one circle;
(b) coating a mixture of diamond micro powder, calcium fluoride, nickel-based solder powder and a binder on the surface of the first coating 1, wherein the coating thickness is 0.2mm, heating by using a supersonic frequency induction device to form a solder coating, and drying moisture in the solder coating at a low temperature;
(c) and (c) repeating the step (b) until a second coating layer 2 with qualified thickness is obtained, and forming the wear-resistant coating on the surface of the cutter ring.
Comparative example 1
The wear-resistant coating provided by the embodiment is prepared from the following raw materials and by the method:
referring to fig. 1, the wear resistant coating is formed from two passes of non-identical coatings. The total thickness of the coating is 5-6 mm;
the raw material of the first coating 1 is 100% of Inconel718 alloy powder, and the particle size ranges of the Inconel718 alloy powder are 200-280 meshes respectively;
the raw materials of the second coating 2 comprise 5 parts of diamond micro powder (the granularity range is 50-150 meshes), 1 part of calcium fluoride and 94 parts of Ni60 alloy powder (the granularity range is 200-300 meshes).
The preparation method comprises the following steps:
(a) coating the mixture of the nickel-chromium-iron alloy powder and the binder on the surface of the matrix 3, wherein the thickness of the mixture is 0.3mm, drying the mixture at 110 ℃ for 0.5h, and then obtaining a first coating 1 by a surfacing method;
(b) and coating the mixture of diamond micro powder, calcium fluoride, nickel-based brazing filler metal powder and a binder on the surface of the first coating 1, drying after the total thickness reaches 5-6 mm through one-time coating, and forming a second coating 2 through a surfacing brazing method.
Comparative example 2
As shown in connection with fig. 1, the wear resistant coating is formed of identical, multiple coatings. The total thickness of the coating is 5-6 mm;
the coating comprises the following raw materials of 5 parts of diamond micro powder (the granularity ranges from 50 meshes to 150 meshes), 1 part of calcium fluoride and 94 parts of Ni60 alloy powder (the granularity ranges from 200 meshes to 300 meshes).
The preparation method comprises the following steps: coating the mixture of diamond micro powder, calcium fluoride, nickel-based brazing filler metal powder and a binder on the surface of a substrate 3, wherein the coating thickness is 0.3mm, forming a first coating 1 by a surfacing brazing method after drying, coating the surface of the first coating 1 again with the thickness of 0.3mm, forming a second coating 2 by the surfacing method after drying, and so on until the coating thickness reaches 5-6 mm.
Comparative example 3
The coating material and preparation method of this comparative example were the same as example 1 except that the induction brazing method was changed to the flame brazing method.
Comparative example 4
A non-coated cutter ring.
Examples of the experiments
In order to compare and illustrate the difference of the wear resistance of the coatings of the embodiment and the comparative example, the cutter rings with the same specification are selected for testing: the TBM disc cutter ring with the outer diameter of 100mm and the thickness of 7mm is made of H13 steel. On TBM disk cutter rings of the same specification, thick-coated cutter rings were prepared by the methods of examples 1 to 6 and comparative examples 1 to 4, and the thickness of the coating was controlled to 5 mm. And taking the cutter rings with different coatings as test objects to carry out abrasion tests. The test is carried out on an independently developed abrasion test bed, the test rock is granite rock commonly used in TBM engineering, and the size of the rock is 1000mm multiplied by 500mm multiplied by 300 mm. The rock is fixed on a workbench of the test bed, the cutter ring is mounted on the driving shaft through key connection, the driving shaft is driven by the hydraulic motor to realize rotary motion, the rotating speed of the driving shaft is 20r/min, and the test time is 3 h. The average contact stress between the cutter ring and the rock in the test process is ensured to be the same as much as possible. The wear amount of the cutter ring after the wear test was measured, and the results are shown in table 1.
TABLE 1 cutter ring wear test results
The experimental results show that, as can be seen from the comparison in table 1, the cutter ring obtained by the method provided by the application has better abrasion resistance.
While particular embodiments of the present invention have been illustrated and described, it will be appreciated that the above embodiments are merely illustrative of the technical solution of the present invention and are not restrictive; those of ordinary skill in the art will understand that: modifications may be made to the above-described embodiments, or equivalents may be substituted for some or all of the features thereof without departing from the spirit and scope of the present invention; the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention; it is therefore intended to cover in the appended claims all such alternatives and modifications that are within the scope of the invention.
Claims (11)
1. The wear-resistant coating is characterized by comprising a first coating and a second coating which are sequentially connected;
the first coating is prepared from a nickel-chromium-iron alloy, preferably, the nickel-chromium-iron alloy is Inconel 718;
the second coating is prepared from the following components in parts by mass:
5-12 parts of diamond micro powder, 1-5 parts of calcium fluoride and 83-94 parts of nickel-based brazing filler metal;
the first coating is used for connecting with a substrate which takes iron or iron alloy as a main raw material.
2. The wear-resistant coating according to claim 1, wherein the second coating is prepared from the following components in parts by mass:
8-10 parts of diamond micro powder, 1-3 parts of calcium fluoride and 80-90 parts of nickel-based brazing filler metal;
preferably, the nickel-based brazing filler metal is a Ni60 alloy.
3. The wear resistant coating according to claim 1 or 2, wherein the first coating is applied in a thickness of 0.3 to 0.5 mm;
and/or;
the coating thickness of the second coating is 0.2-0.3 mm.
4. The wear-resistant coating according to claim 1 or 2, wherein the first coating and/or the second coating further comprises a binder, preferably the binder is selected from polyethylene glycol 6000, and the addition amount of the binder is 1-3% of the mass of the raw materials of the first coating or the second coating.
5. The method for preparing a wear resistant coating according to any of claims 1-4, characterized in that it comprises the steps of:
(a) coating the raw material mixture of the first coating on the surface of a substrate, drying, and performing induction braze coating to obtain a first coating;
preferably, the drying temperature is 110-120 ℃, and more preferably, the drying time is 0.5-1 h;
(b) coating the raw material mixture of the second coating on the surface of the first coating, obtaining a single-layer brazing filler metal coating after induction brazing, and drying the brazing filler metal coating;
preferably, the induction brazing is operated by using a superaudio induction heating device;
(c) optionally repeating step (b) until a second coating of desired thickness is obtained.
6. The method for preparing the wear-resistant coating according to claim 5, wherein the diamond micro powder has a particle size of 50-150 meshes, preferably 80-120 meshes.
7. The method for preparing the wear-resistant coating according to claim 5, wherein the nickel-chromium-iron alloy is a powdery material, and the granularity of the powdery material is 200-280 meshes, preferably 230-270 meshes.
8. The preparation method of the wear-resistant coating according to claim 5, wherein the nickel-based brazing filler metal is a powdery material, and the granularity of the powdery material is 200-300 meshes, preferably 230-270 meshes.
9. A cutter ring of a shield hob cutter, the surface of which is coated with the wear-resistant coating layer of any one of claims 1 to 5, preferably, the thickness of the wear-resistant coating layer is 5 to 6 mm.
10. A shield hob comprising the cutter ring of the shield hob according to claim 9.
11. A shield tunneling machine containing the shield hob of claim 10.
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