CN110923612B - 一种多复合层高强度耐磨损活塞环的制备工艺 - Google Patents

一种多复合层高强度耐磨损活塞环的制备工艺 Download PDF

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CN110923612B
CN110923612B CN201911302354.0A CN201911302354A CN110923612B CN 110923612 B CN110923612 B CN 110923612B CN 201911302354 A CN201911302354 A CN 201911302354A CN 110923612 B CN110923612 B CN 110923612B
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Abstract

本发明公开了一种多复合层高强度耐磨损活塞环的制备工艺,涉及柴油机配件技术领域。本发明包括以下步骤:预处理、喷涂底层、预热、喷涂耐磨层、喷涂粘接层、涂覆镍磷层、施镀过渡层、施镀镍磷层、表面处理,活塞环基体采用灰铸铁作为基体材料,底层的采用的粉末为Ni/Al粉末。本发明通过表面工程技术,在活塞环基体上复合有耐磨层、粘接层、镍磷层、过渡层、镍磷层,并对其进行激光表面处理,提高活塞环的耐磨性,提高活塞环的强度,且活塞环储存润滑油的能力强,降低磨损量,延长零部件的使用寿命。

Description

一种多复合层高强度耐磨损活塞环的制备工艺
技术领域
本发明属于柴油机配件技术领域,特别是涉及一种多复合层高强度耐磨损活塞环的制备工艺。
背景技术
随着材料的多样性和多功能复合性的发展,表面工程技术得到了更好更快的发展,表面工程技术可以应用于要求拓宽表面功能性质方面,包括物理、化学、电子、机械、抗磨损和抗腐蚀等性能,提高材料的抗磨损和抗腐蚀性能,降低磨损量,提高设备的使用寿命,使材料得到节约和优化。
柴油机在告诉高负荷工作时,摩擦副零件的相对运动速度很高,磨损加剧,除了采用高效的润滑剂、减摩剂外,改善摩擦副零件的材料是非常重要的,活塞环的工作环境恶劣,磨损速度快,使用寿命低,且相互磨损中降低发动机的功率和使用寿命,因此,提供一种多复合层高强度耐磨损活塞环的制备工艺,提高活塞环的耐磨性,提高活塞环的强度。
发明内容
本发明的目的在于提供一种多复合层高强度耐磨损活塞环的制备工艺,通过表面工程技术,在活塞环基体上复合有耐磨层、粘接层、镍磷层、过渡层、镍磷层,并对其进行激光表面处理,提高活塞环的耐磨性,提高活塞环的强度,降低磨损量,延长零部件的使用寿命。
为解决上述技术问题,本发明是通过以下技术方案实现的:
本发明为一种多复合层高强度耐磨损活塞环的制备工艺,包括以下步骤:
SS01:预处理:将活塞环基体在400~800#的水砂纸上打磨至表面光洁无划痕,并对活塞环基体进行除油、活化处理;
SS02:喷涂底层:采用等离子喷涂设备在活塞环基体的外圆上喷涂Ni/Al底层;
SS03:预热:将步骤SS02中获得的工件加热至150~200℃,装夹在夹具上,使其做匀速圆周运动;
SS04:喷涂耐磨层:在Ni/Al底层表面上喷涂0.08~0.15mm厚的Cr2O3层;
SS05:喷涂粘接层:在Cr2O3层表面上采用线爆喷涂法喷涂粘接层,所述粘接层为Mo层;
SS06:涂覆镍磷层:将步骤SS05中获得的工件放入镀液中,施镀Ni-P层至0.01~0.025mm厚;并将镀件在230~280℃的温度中保温1.5小时;
SS07:施镀过渡层:采用电镀法在步骤SS06中获得的工件表面电镀一层0.01~0.02mm的单质铬;
SS08:施镀镍磷层:在过渡层表面施镀0.01~0.015mm厚的Ni-P层;
SS09:表面处理:对步骤SS08中获得的工件进行激光表面处理,制得活塞环。
进一步地,所述活塞环基体采用灰铸铁作为基体材料。
进一步地,所述活塞环基体各成分的重量百分比如下:C:3.2~4.3%,Si:2.4~3.1%,Mn:0.5~0.75%,S:0.05~0.08%,P:0.02~0.06%,Cu:0.21~0.52%,Ni:1.1~1.5%,Mo:1.2~1.45%,Cr:0.3~0.61%,Ni:0.3~0.45%,B:0.04~0.06%,V:0.05~0.08%,其余为Fe。
进一步地,所述Ni/Al底层的采用的粉末为Ni/Al粉末,所述Ni/Al粉末的粒度为350~450目,所述Ni/Al粉末各成分的重量百分比如下:Ni:92~95%,Al:4~4.8%,其余为杂质。
进一步地,所述Mo层采用纯Mo粉或合金粉,所述合金粉各成分的重量百分比如下:Mo:53~55%,Ni:12~15%,Cr:14~16%,B:0.08~0.1%,Si:0.8~1.3%。
本发明具有以下有益效果:
本发明通过表面工程技术,在活塞环基体上复合有耐磨层、粘接层、镍磷层、过渡层、镍磷层,并对其进行激光表面处理,提高活塞环的耐磨性,提高活塞环的强度,且活塞环储存润滑油的能力强,降低磨损量,延长零部件的使用寿命。
当然,实施本发明的任一产品并不一定需要同时达到以上所述的所有优点。
具体实施方式
下面将结合本发明实施例,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其它实施例,都属于本发明保护的范围。
本发明为一种多复合层高强度耐磨损活塞环的制备工艺,包括以下步骤:
SS01:预处理:将活塞环基体在400~800#的水砂纸上打磨至表面光洁无划痕,并对活塞环基体进行除油、活化处理;
SS02:喷涂底层:采用等离子喷涂设备在活塞环基体的外圆上喷涂Ni/Al底层;
SS03:预热:将步骤SS02中获得的工件加热至150~200℃,装夹在夹具上,使其做匀速圆周运动;
SS04:喷涂耐磨层:在Ni/Al底层表面上喷涂0.08~0.15mm厚的Cr2O3层;
SS05:喷涂粘接层:在Cr2O3层表面上采用线爆喷涂法喷涂粘接层,粘接层为Mo层;
SS06:涂覆镍磷层:将步骤SS05中获得的工件放入镀液中,施镀Ni-P层至0.01~0.025mm厚;并将镀件在230~280℃的温度中保温1.5小时;
SS07:施镀过渡层:采用电镀法在步骤SS06中获得的工件表面电镀一层0.01~0.02mm的单质铬;
SS08:施镀镍磷层:在过渡层表面施镀0.01~0.015mm厚的Ni-P层;
SS09:表面处理:对步骤SS08中获得的工件进行激光表面处理,制得活塞环。
其中,活塞环基体采用灰铸铁作为基体材料。
其中,活塞环基体各成分的重量百分比如下:C:3.2~4.3%,Si:2.4~3.1%,Mn:0.5~0.75%,S:0.05~0.08%,P:0.02~0.06%,Cu:0.21~0.52%,Ni:1.1~1.5%,Mo:1.2~1.45%,Cr:0.3~0.61%,Ni:0.3~0.45%,B:0.04~0.06%,V:0.05~0.08%,其余为Fe。
其中,Ni/Al底层的采用的粉末为Ni/Al粉末,Ni/Al粉末的粒度为350~450目,Ni/Al粉末各成分的重量百分比如下:Ni:92~95%,Al:4~4.8%,其余为杂质。
其中,Mo层采用纯Mo粉或合金粉,合金粉各成分的重量百分比如下:Mo:53~55%,Ni:12~15%,Cr:14~16%,B:0.08~0.1%,Si:0.8~1.3%。
具体实施例一:
一种多复合层高强度耐磨损活塞环的制备工艺,包括以下步骤:
SS01:预处理:将活塞环基体在400#的水砂纸上打磨至表面光洁无划痕,并对活塞环基体进行除油、活化处理;
SS02:喷涂底层:采用等离子喷涂设备在活塞环基体的外圆上喷涂Ni/Al底层;
SS03:预热:将步骤SS02中获得的工件加热至150℃,装夹在夹具上,使其做匀速圆周运动;
SS04:喷涂耐磨层:在Ni/Al底层表面上喷涂0.08mm厚的Cr2O3层;
SS05:喷涂粘接层:在Cr2O3层表面上采用线爆喷涂法喷涂粘接层,粘接层为Mo层;
SS06:涂覆镍磷层:将步骤SS05中获得的工件放入镀液中,施镀Ni-P层至0.01mm厚;并将镀件在230℃的温度中保温1.5小时;
SS07:施镀过渡层:采用电镀法在步骤SS06中获得的工件表面电镀一层0.01mm的单质铬;
SS08:施镀镍磷层:在过渡层表面施镀0.01mm厚的Ni-P层;
SS09:表面处理:对步骤SS08中获得的工件进行激光表面处理,制得活塞环。
其中,活塞环基体采用灰铸铁作为基体材料,活塞环基体各成分的重量百分比如下:C:3.2%,Si:2.4%,Mn:0.5%,S:0.05%,P:0.02%,Cu:0.21%,Ni:1.1%,Mo:1.2%,Cr:0.3%,Ni:0.3%,B:0.04%,V:0.05%,其余为Fe。
其中,Ni/Al底层的采用的粉末为Ni/Al粉末,Ni/Al粉末的粒度为350目,Ni/Al粉末各成分的重量百分比如下:Ni:92%,Al:4%,其余为杂质。
其中,Mo层采用纯Mo粉或合金粉,合金粉各成分的重量百分比如下:Mo:53%,Ni:12%,Cr:14%,B:0.08%,Si:0.8%。
采用此方法制得的活塞环,表面硬度达950~1100Hv,具有一定的耐腐蚀性,储油效果较好,有效的改善了摩擦环境,提高活塞环的耐磨性,提高活塞环的强度,且活塞环储存润滑油的能力强,降低磨损量,延长零部件的使用寿命。
具体实施例二:
一种多复合层高强度耐磨损活塞环的制备工艺,包括以下步骤:
SS01:预处理:将活塞环基体在550#的水砂纸上打磨至表面光洁无划痕,并对活塞环基体进行除油、活化处理;
SS02:喷涂底层:采用等离子喷涂设备在活塞环基体的外圆上喷涂Ni/Al底层;
SS03:预热:将步骤SS02中获得的工件加热至180℃,装夹在夹具上,使其做匀速圆周运动;
SS04:喷涂耐磨层:在Ni/Al底层表面上喷涂0.08mm厚的Cr2O3层;
SS05:喷涂粘接层:在Cr2O3层表面上采用线爆喷涂法喷涂粘接层,粘接层为Mo层;
SS06:涂覆镍磷层:将步骤SS05中获得的工件放入镀液中,施镀Ni-P层至0.015mm厚;并将镀件在250℃的温度中保温1.5小时;
SS07:施镀过渡层:采用电镀法在步骤SS06中获得的工件表面电镀一层0.015mm的单质铬;
SS08:施镀镍磷层:在过渡层表面施镀0.015mm厚的Ni-P层;
SS09:表面处理:对步骤SS08中获得的工件进行激光表面处理,制得活塞环。
其中,活塞环基体采用灰铸铁作为基体材料,活塞环基体各成分的重量百分比如下:C:3.8%,Si:2.7%,Mn:0.65%,S:0.07%,P:0.03%,Cu:0.35%,Ni:1.3%,Mo:1.35%,Cr:0.46%,Ni:0.39%,B:0.05%,V:0.07%,其余为Fe。
其中,Ni/Al底层的采用的粉末为Ni/Al粉末,Ni/Al粉末的粒度为390目,Ni/Al粉末各成分的重量百分比如下:Ni:94%,Al:4.5%,其余为杂质。
其中,Mo层采用纯Mo粉或合金粉,合金粉各成分的重量百分比如下:Mo:54%,Ni:14%,Cr:15%,B:0.09%,Si:1.15%。
采用此方法制得的活塞环,表面硬度达750~800Hv,具有高硬度、低摩擦系数,并能形成软硬相间均匀分布的储油孔隙,有利于提高活塞环的耐磨、减磨性能,延长零部件的使用寿命。
具体实施例三:
一种多复合层高强度耐磨损活塞环的制备工艺,包括以下步骤:
SS01:预处理:将活塞环基体在800#的水砂纸上打磨至表面光洁无划痕,并对活塞环基体进行除油、活化处理;
SS02:喷涂底层:采用等离子喷涂设备在活塞环基体的外圆上喷涂Ni/Al底层;
SS03:预热:将步骤SS02中获得的工件加热至200℃,装夹在夹具上,使其做匀速圆周运动;
SS04:喷涂耐磨层:在Ni/Al底层表面上喷涂0.15mm厚的Cr2O3层;
SS05:喷涂粘接层:在Cr2O3层表面上采用线爆喷涂法喷涂粘接层,粘接层为Mo层;
SS06:涂覆镍磷层:将步骤SS05中获得的工件放入镀液中,施镀Ni-P层至0.025mm厚;并将镀件在280℃的温度中保温1.5小时;
SS07:施镀过渡层:采用电镀法在步骤SS06中获得的工件表面电镀一层0.02mm的单质铬;
SS08:施镀镍磷层:在过渡层表面施镀0.015mm厚的Ni-P层;
SS09:表面处理:对步骤SS08中获得的工件进行激光表面处理,制得活塞环。
其中,活塞环基体采用灰铸铁作为基体材料。
其中,活塞环基体各成分的重量百分比如下:C:4.3%,Si:3.1%,Mn:0.75%,S:0.08%,P:0.06%,Cu:0.52%,Ni:1.5%,Mo:1.45%,Cr:0.61%,Ni:0.45%,B:0.06%,V:0.08%,其余为Fe。
其中,Ni/Al底层的采用的粉末为Ni/Al粉末,Ni/Al粉末的粒度为450目,Ni/Al粉末各成分的重量百分比如下:Ni:95%,Al:4.8%,其余为杂质。
其中,Mo层采用纯Mo粉或合金粉,合金粉各成分的重量百分比如下:Mo:55%,Ni:15%,Cr:16%,B:0.1%,Si:1.3%。
采用此方法制得的活塞环,表面硬度达800~950Hv,贮油性好,耐蚀性强,尤其是抗拉缸性能强;活塞环表面能有效的保持油膜,使其有良好的抗熔着磨损能力。
在本说明书的描述中,参考术语“一个实施例”、“示例”、“具体示例”等的描述意指结合该实施例或示例描述的具体特征、结构、材料或者特点包含于本发明的至少一个实施例或示例中。在本说明书中,对上述术语的示意性表述不一定指的是相同的实施例或示例。而且,描述的具体特征、结构、材料或者特点可以在任何的一个或多个实施例或示例中以合适的方式结合。
以上公开的本发明优选实施例只是用于帮助阐述本发明。优选实施例并没有详尽叙述所有的细节,也不限制该发明仅为所述的具体实施方式。显然,根据本说明书的内容,可作很多的修改和变化。本说明书选取并具体描述这些实施例,是为了更好地解释本发明的原理和实际应用,从而使所属技术领域技术人员能很好地理解和利用本发明。本发明仅受权利要求书及其全部范围和等效物的限制。

Claims (3)

1.一种多复合层高强度耐磨损活塞环的制备工艺,其特征在于,包括以下步骤:
SS01:预处理:将活塞环基体在400~800#的水砂纸上打磨至表面光洁无划痕,并对活塞环基体进行除油、活化处理;
SS02:喷涂底层:采用等离子喷涂设备在活塞环基体的外圆上喷涂Ni/Al底层;
SS03:预热:将步骤SS02中获得的工件加热至150~200℃,装夹在夹具上,使其做匀速圆周运动;
SS04:喷涂耐磨层:在Ni/Al底层表面上喷涂0.08~0.15mm厚的Cr2O3层;
SS05:喷涂粘接层:在Cr2O3层表面上采用线爆喷涂法喷涂粘接层,所述粘接层为Mo层;
SS06:涂覆镍磷层:将步骤SS05中获得的工件放入镀液中,施镀Ni-P层至0.01~0.025mm厚;并将镀件在230~280℃的温度中保温1.5小时;
SS07:施镀过渡层:采用电镀法在步骤SS06中获得的工件表面电镀一层0.01~0.02mm的单质铬;
SS08:施镀镍磷层:在过渡层表面施镀0.01~0.015mm厚的Ni-P层;
SS09:表面处理:对步骤SS08中获得的工件进行激光表面处理,制得活塞环;
所述Ni/Al底层的采用的粉末为Ni/Al粉末,所述Ni/Al粉末的粒度为350~450目,所述Ni/Al粉末各成分的重量百分比如下:
Ni:92~95%,Al:4~4.8%,其余为杂质;
所述Mo层采用纯Mo粉或合金粉,所述合金粉各成分的重量百分比如下:Mo:53~55%,Ni:12~15%,Cr:14~16%,B:0.08~0.1%,Si:0.8~1.3%。
2.根据权利要求1所述的一种多复合层高强度耐磨损活塞环的制备工艺,其特征在于,所述活塞环基体采用灰铸铁作为基体材料。
3.根据权利要求2所述的一种多复合层高强度耐磨损活塞环的制备工艺,其特征在于,所述活塞环基体各成分的重量百分比如下:
C:3.2~4.3%,Si:2.4~3.1%,Mn:0.5~0.75%,S:0.05~0.08%,P:0.02~0.06%,Cu:0.21~0.52%,Ni:1.1~1.5%,Mo:1.2~1.45%,Cr:0.3~0.61%,Ni:0.3~0.45%,B:0.04~0.06%,V:0.05~0.08%,其余为Fe。
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