CN111088444A - Preparation method of wear-resistant composite material and preparation method of wear-resistant composite material casting - Google Patents
Preparation method of wear-resistant composite material and preparation method of wear-resistant composite material casting Download PDFInfo
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/10—Alloys containing non-metals
- C22C1/1005—Pretreatment of the non-metallic additives
- C22C1/1015—Pretreatment of the non-metallic additives by preparing or treating a non-metallic additive preform
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
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- B22D23/04—Casting by dipping
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- C22C1/10—Alloys containing non-metals
- C22C1/1005—Pretreatment of the non-metallic additives
- C22C1/1015—Pretreatment of the non-metallic additives by preparing or treating a non-metallic additive preform
- C22C1/1021—Pretreatment of the non-metallic additives by preparing or treating a non-metallic additive preform the preform being ceramic
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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- C22C1/10—Alloys containing non-metals
- C22C1/1036—Alloys containing non-metals starting from a melt
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
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- C22C1/00—Making non-ferrous alloys
- C22C1/10—Alloys containing non-metals
- C22C1/1036—Alloys containing non-metals starting from a melt
- C22C1/1073—Infiltration or casting under mechanical pressure, e.g. squeeze casting
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Abstract
The application relates to a preparation method of a wear-resistant composite material and a preparation method of a wear-resistant composite material casting, and belongs to the technical field of new material preparation. A method for preparing a wear-resistant composite casting, comprising: under the condition of the pressure intensity of 10MPa-200MPa, the metal melt and the porous ceramic prefabricated body after the preheating treatment are subjected to high-pressure composite molding in a metal mold. The ceramic porous preform and the metal melt are pressed by adopting a high-pressure composite forming process, the metal matrix structure is refined, and meanwhile, the bonding strength of the ceramic and metal interface is improved, so that the metal matrix tightly wraps ceramic particles, and the wear resistance of the composite material is greatly improved.
Description
Technical Field
The application relates to the technical field of new material preparation, and particularly relates to a preparation method of a wear-resistant composite material and a preparation method of a wear-resistant composite material casting.
Background
With the continuous development of modern industry, the consumption of wear-resistant materials is increased day by day, and the traditional steel materials have difficulty in meeting the requirement of the materials on wear resistance. The ceramic particle reinforced metal matrix wear-resistant composite material has the high hardness and the high wear resistance of ceramic and the good toughness of metal, and solves the problem of the contradiction between the high hardness and the toughness of the traditional steel material.
At present, the following methods are mainly used for preparing ceramic particle reinforced metal matrix composite materials at home and abroad. The first method uses a cast-infiltration process. The method can realize the compounding of the ceramic and the metal, has better wear resistance, but because the natural non-wettability of the ceramic and the metal, the interface bonding strength is insufficient, and the ceramic particles are easy to fall off. And then, the surface modification of the ceramic particles is carried out, so that the wettability of the ceramic is improved, the composite strength is improved, but the preparation cost is high, and the composite interface strength is still unstable, so that the improvement of the wear resistance of the composite material is limited. The second method adopts a powder metallurgy process to realize sintering and molding of ceramic particles and metal powder. The method has the advantages that the metal matrix has high strength and good toughness, but the ceramic and metal interface is easy to have defects of holes, cracks and the like, and ceramic particles are easy to fall off in the process of crushing coal gangue. The third is an embedded composite grinding roller, the product has simple manufacturing process and low cost, but in the later period of wear, the high-chromium cast iron substrate is worn preferentially, the embedded ceramic rod protrudes out of the surface of the grinding roller, and is easy to break and fall off when encountering coal gangue, and the service life of the wear is improved to a limited extent.
Disclosure of Invention
In view of the defects of the prior art, the purpose of the embodiments of the present application includes providing a method for preparing a wear-resistant composite material and a method for preparing a wear-resistant composite material casting, so as to solve the technical problem of low bonding strength of a composite interface of ceramic particles and a metal matrix.
In a first aspect, an embodiment of the present application provides a method for preparing a wear-resistant composite material, including: under the condition of the pressure intensity of 10MPa-200MPa, the metal melt and the porous ceramic prefabricated body after the preheating treatment are subjected to high-pressure composite molding in a metal mold.
According to the method, a high-pressure composite forming process is adopted to press the ceramic porous prefabricated body and the metal melt, so that the metal matrix structure is refined, the bonding strength of the ceramic and metal interface is improved, the thickness of a ceramic composite layer is increased, and the wear resistance of the composite material is greatly improved. The porous ceramic preform is subjected to heat treatment setting and solidification at 350 ℃ in the low-temperature section 100-plus-one in the metal net rack, so that the strength of the porous ceramic preform is improved, and the porous ceramic preform is subjected to preheating treatment at 800 ℃ in the high-temperature section 400-plus-one during high-pressure composite molding, so that the temperature difference between the porous ceramic preform and a metal melt is reduced, the bonding capability of the porous ceramic preform and the metal melt is improved, the structure of the porous ceramic preform is more stable in the high-pressure composite process, and the mechanical property of the wear-resistant composite material is improved.
In some embodiments of the present application, the pressure of the high-pressure composite molding is 100MPa to 150 MPa. The pressure intensity can improve the composite degree of the prefabricated body and the metal melt, refine the structure of the metal matrix, increase the thickness of a ceramic composite layer and reduce the probability of cracking of the metal melt.
In some embodiments of the present application, the porous ceramic preform is prepared by: according to the weight portion, 1100 portions of ceramic particles of 900-; and adding 30-90 parts of liquid inorganic adhesive, stirring and mixing, and putting the mixture and the metal frame into a mold to prepare the porous ceramic preform.
The porous ceramic preform prepared by the method has good bonding strength, so that the preform has good stability in the high-pressure composite forming process, and the probability of the preform being scattered in the high-pressure composite forming process is reduced.
In some embodiments of the present application, the step of heat treating comprises: the porous ceramic prefabricated body is roasted, shaped and solidified for 0.5-4h at the temperature of 100-350 ℃. The porous ceramic preform is subjected to preheating treatment at 800 ℃ in a high-temperature section 400 during high-pressure composite molding, so that the porous ceramic preform is better compounded with the metal melt, a formed composite layer is thicker, and the thickness of the composite layer is 10-100 mm.
In some embodiments of the present application, the ceramic particles are present in the wear-resistant composite material in an amount of 10.0% to 70.0% by weight. The wear-resistant composite material prepared by the components has better wear resistance.
In some embodiments of the present application, the ceramic particles have a size of 5 mesh to 46 mesh. The ceramic particles with the granularity can ensure the wear resistance and reduce the influence on the bonding strength of a composite interface.
In some embodiments of the present application, the ceramic particles comprise ZTA, Al2O3、ZrO2、B4C、SiC、Si3N4And TiB2The metal comprises at least one of high-chromium cast iron, nodular cast iron, high-manganese steel and low-alloy wear-resistant steel.
In a second aspect, embodiments of the present application provide a method for preparing a wear-resistant composite casting, including: a single wear-resistant part is obtained by the preparation method of the wear-resistant composite material. Fixing a plurality of wear-resistant pieces according to preset positions, pouring metal melt, and carrying out heat treatment on the obtained casting blank.
According to the preparation method, after a single wear-resistant part with better wear resistance is obtained, a casting is obtained according to requirements by secondary pouring and cast infiltration solidification of molten steel, and the preparation of the disc body and the integrated molding of the connection of the wear-resistant parts are realized.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings that are required to be used in the embodiments will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present application and therefore should not be considered as limiting the scope, and for those skilled in the art, other related drawings can be obtained from the drawings without inventive effort.
Fig. 1 is a schematic structural view of a wear-resistant composite material provided in an embodiment of the present application;
FIG. 2 is a process flow diagram of a wear-resistant composite casting provided by an embodiment of the present application;
FIG. 3 is a macroscopic texture map of three sets of wear-resistant composites provided in test example 1 of the present application;
FIG. 4 shows M in the wear-resistant composite high-chromium cast iron provided in test example 2 of the present application7C3A carbide tissue morphology graph;
FIG. 5 is a microstructure of a wear-resistant composite material provided in test example 3 of the present application;
FIG. 6 is a microstructure diagram of an impact-tested wear-resistant composite material provided in test example 4 of the present application;
FIG. 7 is a graph showing the results of a wear test provided in test example 5 of the present application;
FIG. 8 is a wear profile of a sample provided in comparative example 1 of the present application;
FIG. 9 is a wear profile of a sample provided in comparative example 2 of the present application;
FIG. 10 is a wear profile of a sample provided in comparative example 3 of the present application;
FIG. 11 is a wear profile of a sample provided in example 2 of the present application;
FIG. 12 is a microstructure view of a wear-resistant composite material provided in example 4 of the present application;
FIG. 13 is a microstructure view of a wear-resistant composite material provided in example 5 of the present application;
FIG. 14 is a topographical view of an individual wear part provided in example 6 of the present application;
FIG. 15 is a graph of the appearance of an as-cast ingot of the entire composite material as provided in example 6 of the present application;
fig. 16 is a microscopic view of the wear-resistant composite provided in example 7 of the present application.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions of the embodiments of the present application will be clearly and completely described below. 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 following provides a detailed description of a method for producing a wear-resistant composite material and a method for producing a wear-resistant composite material casting according to embodiments of the present application.
The embodiment of the application provides a preparation method of a wear-resistant composite material, which comprises the following steps: under the condition of the pressure intensity of 10MPa-200MPa, the metal melt and the porous ceramic prefabricated body after the preheating treatment are subjected to high-pressure composite molding in a metal mold.
In some embodiments of the present application, the porous ceramic preform is prepared by: according to the parts by weight, 900-1100 parts of ceramic particles, 15-55 parts of nano alumina powder, 0.1-1 part of nano cerium oxide, 0.1-1 part of nano yttrium oxide, 0.1-1 part of titanium dioxide, 0.5-5 parts of kaolin and 2.5-10 parts of silicon dioxide are fully mixed; and adding 30-90 parts of liquid inorganic adhesive, stirring and mixing, and putting the mixture and the metal frame into a mold to prepare the porous ceramic preform.
The porous ceramic preform prepared by the method has good bonding strength, so that the preform has good stability in the high-pressure composite forming process, and the probability of the preform being scattered in the high-pressure composite forming process is reduced. Alternatively, the ceramic particles may be 900 parts, 1000 parts or 1100 parts, the nano alumina powder may be 15 parts, 20 parts, 30 parts, 40 parts, 50 parts or 55 parts, the nano cerium oxide may be 0.1 part, 0.5 part or 1 part, the nano yttrium oxide may be 0.1 part, 0.5 part or 1 part, the titanium dioxide may be 0.1 part, 0.5 part or 1 part, the kaolin may be 0.5 part, 1 part, 2 parts, 3 parts, 4 parts or 5 parts, the silicon dioxide may be 2.5 parts, 5 parts, 7 parts or 10 parts, and the liquid inorganic glue may be 30 parts, 40 parts, 50 parts, 60 parts, 70 parts, 80 parts or 90 parts.
In the actual preparation process, the metal frame can be placed into a mold, and then the mixture containing the ceramic particles is placed into the mold to form the porous preform together with the metal frame. The wire mesh in this application can be stainless steel plate or carbon steel plate.
The purpose of the present application is to improve the bonding strength of the composite interface between the ceramic particles and the high-chromium cast iron, so that the properties of the ceramic particles have a greater influence on the bonding of the composite interface. The ceramic particles in the present application include ZTA, Al2O3、ZrO2、B4C、SiC、TiC、WC、Si3N4And TiB2At least one of (1). The ceramic particles can be fully compounded with high-chromium cast iron under a high-pressure condition to obtain a thicker composite layer.
The prior art generally considers that the smaller the grain size of the ceramic grains is, the more the ceramic grains are helpful for improving the mechanical property of the composite material, but the smaller the ceramic grains are, the lower the wear resistance of the wear-resistant composite material is, and the larger the ceramic grains are, the greater the composite interface bonding strength with cast iron is. The particle size obtained by experimental study of the inventor of the application is 5 meshes-46 meshes. Alternatively, the ceramic particles have a particle size of 12 mesh to 30 mesh, and the ceramic particles may have a particle size of 5 mesh, 10 mesh, 20 mesh, 30 mesh, or 40 mesh.
Because the prefabricated body and the metal melt are subjected to composite forming under high pressure, the porous ceramic prefabricated body is roasted, shaped and solidified for 0.5-4h under the condition of 100-350 ℃, so that the stability of the prefabricated body is improved, and the probability of the prefabricated body being crushed in the high-pressure composite forming process is reduced; in some examples of the present application, the porous ceramic preform is fired at 100 ℃, 200 ℃, 300 ℃ or 350 ℃ for 0.5h, 1h, 2h, 3h or 4 h.
The porous ceramic preform is subjected to preheating treatment, so that the temperature difference between the porous ceramic preform and a metal melt is reduced, the composite capacity of the porous ceramic preform and the metal melt is improved, the structure of the porous ceramic preform is more stable in a high-pressure composite process, and a metal matrix can tightly wrap ceramic particles and is not easy to separate. The porous ceramic preform has a pre-temperature of 400 ℃, 500 ℃, 600 ℃, 700 ℃ or 800 ℃.
The existing preparation process of the wear-resistant composite material rarely carries out high-pressure treatment, because the phenomenon of metal melt bursting is easily caused in the pressurizing process, the pressure intensity in the high-pressure composite forming process is 10MPa-200 MPa. The pressure intensity can improve the composite degree of the prefabricated body and the metal melt, refine the metal matrix structure, improve the bonding strength of the ceramic and metal interface, reduce the probability of cracking of the metal melt and greatly improve the wear resistance of the composite material. Alternatively, the pressure is from 100MPa to 150MPa, and the pressure may be 10MPa, 50MPa, 60MPa, 80MPa, 90MPa, 100MPa, 120MPa, 150MPa, or 200 MPa. It should be noted that, because the high-pressure composite molding process may cause the situation that the mold is difficult to be completely separated from the porous ceramic preform and the metal, the mold surface is coated with the release agent before the porous ceramic preform is placed in the mold. In some embodiments of the present application, the release agent comprises 30% of zirconia or chromite powder as a main component, 6% of magnesium aluminum silicate, 0.5% of CMC, 1.5% of sodium hexametaphosphate, and 62% of sodium silicate solution.
In some embodiments of the present application, when a metal melt is poured, the ratio of the metal melt to the ceramic particles is controlled, so that the mass percentage of the ceramic particles in the wear-resistant composite material is 10.0% -70.0%, and the wear-resistant composite material prepared by the above components has good wear resistance. Optionally, the ceramic particles in the wear-resistant composite material are 10.0%, 20%, 30%, 40%, 50%, 60% or 70% by mass. The metal comprises at least one of high-chromium cast iron, nodular cast iron, high-manganese steel and low-alloy wear-resistant steel, and preferably, the metal for pouring the porous prefabricated body is the high-chromium cast iron.
The preparation method comprises the steps of regulating and controlling the components and the proportion of the porous ceramic preform to obtain the preform with better bonding strength; the porous ceramic preform is subjected to preheating treatment, so that the temperature difference between the porous ceramic preform and the metal melt is reduced, the composite effect of the porous ceramic preform and the metal melt is improved, the porous ceramic preform has a more stable structure in a high-pressure composite process, a metal matrix tightly wraps ceramic particles, the ceramic particles are not easy to fall off, and the wear resistance of the wear-resistant composite material is improved. The ceramic porous preform and the metal melt are pressed by adopting a high-pressure composite forming process, the metal matrix structure is refined, the bonding strength of a ceramic and metal interface is improved, the thickness of a ceramic composite layer is increased, the thickness of the composite layer is 10-100 mm, and the wear resistance of the wear-resistant composite material is greatly improved.
In actual processing, after the wear-resistant part is obtained through high-pressure composite shaping, heat treatment and machining are carried out to obtain a finished wear-resistant part. The application provides a wear-resisting combined material is suitable for making the rolling mortar wall, the board hammer, the tup etc. of coal pulverizer grinding roller, welt, system sand machine welt, impeller, crushing equipment, can use for a long time under complex environment such as impact, wearing and tearing and corruption. Referring to fig. 1, fig. 1 is a schematic structural view of a wear-resistant composite material provided in an application example, and the wear-resistant composite material prepared by the preparation method has a dense tissue structure and good wear resistance.
In a second aspect, embodiments of the present application provide a method for preparing a wear-resistant composite casting, with a process flow diagram as shown in fig. 2, including: a single wear-resistant part is prepared by the preparation method of the wear-resistant composite material, and after a plurality of wear-resistant parts are fixed according to the preset positions according to requirements, metal melt is poured. According to the preparation method, after a single wear-resistant part with better wear resistance is obtained, a casting is obtained according to requirements by secondary pouring and cast infiltration solidification of molten steel, and the preparation of the disc body and the integrated molding of the connection of the wear-resistant parts are realized.
Furthermore, the hardness and the wear resistance of the wear-resistant composite material casting can be improved by quenching and tempering the casting blank. And machining after heat treatment to obtain a finished product.
The features and properties of the present application are described in further detail below with reference to examples.
Example 1
The embodiment provides a preparation method of a wear-resistant composite material, which comprises the following steps:
step 1: the ceramic powder is ZTA particles with the particle size of 10 meshes, 1000 parts of ZTA ceramic particles, 25 parts of nano alumina powder, 1 part of nano cerium oxide, 0.1-1 part of nano yttrium oxide, 1 part of titanium dioxide, 5 parts of kaolin and 5 parts of silicon dioxide are uniformly mixed according to the mass parts, 50 parts of liquid inorganic glue is added for fully stirring, and after the mixture is placed into a tough metal frame, a porous prefabricated body is prepared in a special mould;
step 2: respectively roasting the porous prefabricated body at the high temperature of 80 ℃ and 150 ℃ for 2 hours;
and step 3: placing the shaped and preheated porous preform in a set position of a cavity for fixing, pouring a proper amount of metal melt, and performing high-pressure composite molding on the ZTA ceramic preform and the high-chromium cast iron under the pressure of 120MPa by adopting a high-pressure composite molding process to prepare the wear-resistant composite material. The composition of the high chromium cast iron is shown in Table 1.
TABLE 1 chemical composition (wt%) of high-chromium cast iron alloy
| C | Cr | Mo | Si | Mn | Ni | Fe | |
| Content (wt.) | 3.02 | 25.9 | 1.04 | 0.8 | 0.65 | 0.53 | Bal. |
Example 2
The embodiment provides a preparation method of a wear-resistant composite material, which comprises the following steps:
step 1: the ceramic powder is ZTA particles with the particle size of 20 meshes, 1000 parts of ZTA ceramic particles, 25 parts of nano alumina powder, 1 part of nano cerium oxide, 0.1-1 part of nano yttrium oxide, 1 part of titanium dioxide, 3 parts of kaolin and 10 parts of silicon dioxide are uniformly mixed according to the mass parts, 40 parts of liquid inorganic glue is added for fully stirring, and after the mixture is placed into a tough metal frame, a porous prefabricated body is prepared in a special mould;
step 2: roasting the porous prefabricated body at the high temperature of 150 ℃ for 2 hours;
and step 3: placing the shaped and preheated porous preform in a set position of a cavity for fixing, pouring a proper amount of metal melt, and performing high-pressure composite molding on the ZTA ceramic preform and the high-chromium cast iron under the pressure of 100MPa by adopting a high-pressure composite molding process to prepare the wear-resistant composite material. The composition of the high chromium cast iron is shown in Table 2.
TABLE 2 chemical composition (wt%) of high-chromium cast iron alloy
| C | Cr | Mo | Si | Mn | Ni | Fe | |
| Content (wt.) | 2.52 | 24.05 | 1.06 | 1.05 | 0.83 | 0.69 | Bal. |
Example 3
The embodiment provides a preparation method of a wear-resistant composite material, which comprises the following steps:
step 1: the ceramic powder is ZTA particles with the particle size of 30 meshes, 1000 parts of ZTA ceramic particles, 55 parts of nano alumina powder, 1 part of nano cerium oxide, 0.1-1 part of nano yttrium oxide, 1 part of titanium dioxide, 5 parts of kaolin and 5 parts of silicon dioxide are uniformly mixed according to the mass parts, 70 parts of liquid inorganic glue is added for fully stirring, and after the mixture is placed into a tough metal frame, a porous prefabricated body is prepared in a special mould;
step 2: roasting the porous prefabricated body at the high temperature of 200 ℃ for 2 hours;
and step 3: placing the shaped and preheated porous preform in a set position of a cavity for fixing, pouring a proper amount of metal melt, and performing high-pressure composite molding on the ZTA ceramic preform and the high-chromium cast iron under the pressure of 120MPa by adopting a high-pressure composite molding process to prepare the wear-resistant composite material. The composition of the high chromium cast iron is shown in Table 3.
TABLE 3 chemical composition (wt%) of high-chromium cast iron alloy
| C | Cr | Mo | Si | Mn | Ni | Fe | |
| Content (wt.) | 3.6 | 25.9 | 0.84 | 1.1 | 0.55 | 0.43 | Bal. |
Example 4
The embodiment provides a preparation method of a wear-resistant composite material, which comprises the following steps:
step 1: the ceramic powder is SiC particles with the particle size of 10 meshes, 1000 parts of SiC ceramic particles, 35 parts of nano alumina powder, 1 part of nano cerium oxide, 0.1-1 part of nano yttrium oxide, 1 part of titanium dioxide, 3 parts of kaolin and 7 parts of silicon dioxide are uniformly mixed according to the mass parts, 60 parts of liquid inorganic glue is added for fully stirring, and after the mixture is placed into a tough metal frame, a porous prefabricated body is prepared in a special mould;
step 2: roasting the porous prefabricated body at the high temperature of 180 ℃ for 2 hours;
and step 3: placing the shaped and preheated porous prefabricated body in a set position of a cavity for fixing, pouring a proper amount of metal melt, and carrying out high-pressure composite molding on the ceramic prefabricated body and the ball-milling cast iron under the pressure of 60MPa by adopting a high-pressure composite molding process to prepare the wear-resistant composite material. The composition of the nodular cast iron is shown in Table 4.
TABLE 4 chemical composition of nodular cast iron alloy (wt%)
| C | Si | Mn | Cr | Cu | Mo | Nb | Fe | |
| Content (wt.) | 3.13 | 2.07 | 0.64 | 0.54 | 0.53 | 0.28 | 0.36 | Bal. |
Example 5
The embodiment provides a preparation method of a wear-resistant composite material, which comprises the following steps:
step 1: the ceramic powder is ZrO2Particles with the particle size of 10 meshes and ZrO is prepared by mixing the components in parts by weight2Uniformly mixing 1000 parts of ceramic particles, 55 parts of nano alumina powder, 1 part of nano cerium oxide, 0.1-1 part of nano yttrium oxide, 1 part of titanium dioxide, 5 parts of kaolin and 10 parts of silicon dioxide, adding 80 parts of liquid inorganic adhesive, fully stirring, putting into a tough metal frame, and preparing into a porous prefabricated body in a special mold;
step 2: roasting the porous prefabricated body at the high temperature of 300 ℃ for 2 hours;
and step 3: placing the shaped and preheated porous prefabricated body in a set position of a cavity for fixing, pouring a proper amount of metal melt, and carrying out high-pressure composite forming on the ceramic prefabricated body and the low-alloy steel under the pressure of 150MPa by adopting a high-pressure composite forming process to prepare the wear-resistant composite material. The composition of the low alloy steel is shown in table 5.
TABLE 5 Low alloy steel chemistry (wt%)
| C | Cr | Mo | Si | Mn | Ni | Fe | |
| Content (wt.) | 0.41 | 5.21 | 1.04 | 0.6 | 0.65 | 0.53 | Bal. |
Example 6
The embodiment provides a preparation method of a wear-resistant composite casting, which comprises the following steps:
step 1: the ceramic powder is ZTA particles with the particle size of 14 meshes, 1000 parts of ZTA ceramic particles, 35 parts of nano alumina powder, 1 part of nano cerium oxide, 0.1-1 part of nano yttrium oxide, 1 part of titanium dioxide, 3 parts of kaolin and 7 parts of silicon dioxide are uniformly mixed according to the mass parts, 60 parts of liquid inorganic glue is added for fully stirring, and after the mixture is placed into a tough metal frame, a porous prefabricated body is prepared in a special mould;
step 2: respectively roasting the porous prefabricated body at the high temperature of 80 ℃ and 150 ℃ for 2 hours;
and step 3: placing the shaped and preheated porous prefabricated body in a set position of a cavity for fixing, pouring a proper amount of metal melt, and compounding the ZTA ceramic prefabricated body and the high-chromium cast iron under the high-pressure composite molding pressure of 150MPa by adopting a high-pressure composite molding process to form a single wear-resistant part. The high chromium cast iron had the same composition as in example 1.
And 4, step 4: and fixing a plurality of wear-resistant parts according to the designed positions through a sand mold, placing the wear-resistant parts at the set positions of the cavities, and performing secondary pouring through a cast iron solution to form the whole composite casting.
And 5: and carrying out heat treatment on the obtained casting blank for 3h at 860 ℃, and then carrying out cooling annealing treatment at the speed of 30 ℃/h.
Example 7
The embodiment provides a preparation method of a wear-resistant composite material, which comprises the following steps:
step 1: the ceramic powder is ZTA particles with the particle size of 20 meshes, 1000 parts of ZTA ceramic particles, 25 parts of nano alumina powder, 1 part of nano cerium oxide, 0.1-1 part of nano yttrium oxide, 1 part of titanium dioxide, 3 parts of kaolin and 10 parts of silicon dioxide are uniformly mixed according to the mass parts, 40 parts of liquid inorganic glue is added for fully stirring, and after the mixture is placed into a tough metal frame, a porous prefabricated body is prepared in a special mould;
step 2: roasting the porous prefabricated body at the high temperature of 150 ℃ for 2 hours;
and step 3: and placing the shaped and preheated porous preform in a set position of a cavity for fixing, pouring a proper amount of metal melt, and performing high-pressure composite molding on the ZTA ceramic preform and the high manganese steel under the pressure of 80MPa by adopting a high-pressure composite molding process to prepare the wear-resistant composite material. The high manganese steel composition is shown in table 6.
TABLE 6 high manganese Steel chemical composition (wt%)
| C | Cr | Si | Mn | Fe | |
| Content (wt.) | 1.20 | 2.0 | 0.6 | 13 | Bal. |
Comparative example 1
This comparative example provides a conventional sample, cast high chromium cast iron sample.
Comparative example 2
This comparative example provides a composite-based high-chromium cast iron sample,
comparative example 3
This comparative example provides a German French VauiTD-143 weld overlay.
Test example 1
Macroscopic texture morphology analysis was performed on the wear-resistant composite materials prepared in examples 1-3, and the results are shown in FIG. 3. Fig. 3(a) is a macroscopic texture of the wear-resistant composite material prepared by using 10-mesh ZTA ceramic particles in example 1, fig. 3(b) is a macroscopic texture of the wear-resistant composite material prepared by using 20-mesh ZTA ceramic particles in example 1, and fig. 3(c) is a macroscopic texture of the wear-resistant composite material prepared by using 30-mesh ZTA ceramic particles in example 1. As can be seen from fig. 3, the larger the mesh number of the ZTA ceramic particles, the smaller the particle size, the higher the density of the formed wear-resistant composite material, and the wear resistance is improved.
Test example 2
For the wear-resistant composite material high-chromium cast iron provided in example 1 and comparative example 1, M is7C3The morphology of carbide structure was analyzed, and fig. 4(a) is the morphology of high-chromium cast iron subjected to the high-pressure composite molding process in example 1, and fig. 4(b) is the morphology of high-chromium cast iron subjected to the conventional casting process in comparative example 1. As can be seen from FIG. 4, the high-chromium cast iron processed by the high-pressure composite molding process has a more compact structure, and has better strength and wear resistance.
Test example 3
The wear-resistant composite material obtained in example 2 was subjected to microstructure analysis, and the result is shown in fig. 5. Fig. 5(a) is a morphology of ceramic particles ZTA in the wear-resistant composite material, and fig. 5(b) is a morphology of an interface structure between the ceramic particles and the metal in the wear-resistant composite material. As can be seen from FIG. 5, the thickness of the composite layer at the interface between the ceramic particles and the metal is 10mm-100mm, which shows that the ceramic and metal interface has high bonding strength by the high-pressure composite molding process, and the wear resistance of the composite material can be improved.
Test example 4
Impact tests were carried out on the wear-resistant composite materials of examples 1 and 3 by using GB/T229-2007 "metallic material Charpy pendulum impact test method", and the microstructure analysis of the tested wear-resistant composite materials was carried out, and the results are shown in FIG. 6. Fig. 6(a) is the impact fracture morphology of the wear-resistant composite of example 1, and fig. 6(b) is the impact fracture morphology of the wear-resistant composite of example 3. As can be seen from the figure, the phenomenon that the ceramic particles fall off does not exist on the figure, the wear resistance depends on the wrapping performance of the metal matrix on the ceramic particles, the ceramic particles can be tightly wrapped, and the ceramic particles do not fall off.
Test example 5
The wear-resistant composite material provided in example 3 is selected to be used for carrying out wear performance tests with high-chromium cast iron and surfacing materials, and a rubber wheel friction wear test is carried out by adopting a method G65 and JBT _7705-1995 (loose abrasive grain abrasive wear test method. rubber wheel method), wherein the test method comprises the following steps: the load is 70 newtons, the abrasive particles are 60-mesh quartz sand, and the test time is 20 minutes/time; adopting a self-control device: the abrasive particles are 60-mesh quartz sand, and a gas-solid two-phase erosion abrasion experiment is carried out by a method with the initial mass of 125(ml/g), the speed of 100(m/s) and the angle of 45 degrees.
The results are shown in FIG. 7. Fig. 7(a) and (c) are graphs showing results of frictional wear tests of rubber wheels, and fig. 7(b) is a gas-solid two-phase erosion wear test. As can be seen from the figure, compared with the surfacing material and the high-chromium cast iron, the rubber wheel of the composite material has lower friction wear and the gas-solid two-phase erosion wear, which indicates that the wear-resistant composite material provided in example 3 has improved wear resistance.
Test example 6
The samples provided in example 2 and comparative examples 1 to 3 were subjected to wear performance tests, the test results are shown in table 7, and the worn samples were subjected to topography analysis, and the topography maps are shown in fig. 8, 9, 10 and 11.
TABLE 7 abrasion Performance test results
As can be seen from fig. 8, 9, 10 and 11, which are the topography maps of the samples after the comparative examples 1-3 and the example 2 are worn, respectively, and from table 7, the samples of the comparative examples 1-3 are worn with severe dishing and a large amount of metal per one wear. In contrast, the sample in example 2 gradually decreases in the amount of wear in the second, third and fourth times after the first wear, and after the metal on the surface is worn away, the ceramic particles are exposed, and in fig. 11, the ceramic particles play a supporting role to prevent the wear of the metal inside, and the ceramic particles are tightly connected with the metal matrix, and show no sign of falling off. The sample provided in example 2 is shown to have a high wear resistance.
Test example 7
Microscopic examination of the abrasion resistant composite provided in example 4 resulted in the results shown in fig. 12. Fig. 12 is the structure morphology of the silicon carbide and nodular cast iron composite material in the wear-resistant composite material provided in example 4, and it can be seen from the figure that the silicon carbide and nodular cast iron composite degree in the wear-resistant composite material is better. The high-pressure composite molding process has better effect on the silicon carbide and the nodular cast iron.
Test example 8
Microscopic examination of the abrasion resistant composite provided in example 5 resulted in the results shown in fig. 13. FIG. 13 shows ZrO in the wear-resistant composite material provided in example 52The texture morphology of the particle and low alloy steel composite material can be seen, and the ZrO in the wear-resistant composite material2The particle and the low alloy steel have better compound degree. Description of the high-pressure composite Molding Process for ZrO2The granules and low alloy steel have better effect.
Test example 9
Appearance and appearance analysis was performed on the single wear-resistant piece obtained in step 3 of example 6, and the result is shown in fig. 14. Fixing a plurality of wear-resistant parts according to the design position through a sand mold, placing the wear-resistant parts at the set position of a cavity, and performing secondary pouring through a cast iron solution to form the whole composite material casting, wherein the appearance and the appearance are as shown in figure 15.
Test example 10
Microscopic examination of the abrasion resistant composite provided in example 7 resulted in the results shown in fig. 16. Fig. 16 is a structural morphology of a composite material of ZTA ceramic particles and high manganese steel in the wear-resistant composite material provided in example 7, and it can be seen from the figure that the composite degree of ZTA ceramic particles and high manganese steel in the wear-resistant composite material is better. The high-pressure composite forming process has better effect on ZTA ceramic particles and high manganese steel.
The embodiments described above are some, but not all embodiments of the present application. The detailed description of the embodiments of the present application is not intended to limit the scope of the claimed application, but is merely representative of selected embodiments of the application. 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 application.
Claims (9)
1. A method of making a wear resistant composite, comprising:
under the condition of the pressure intensity of 10MPa-200MPa, the metal melt and the porous ceramic prefabricated body after the preheating treatment are subjected to high-pressure composite molding in a metal mold.
2. The method for preparing the wear-resistant composite material according to claim 1, wherein the pressure of the high-pressure composite molding is 100MPa to 150 MPa.
3. The method of preparing a wear-resistant composite material according to claim 1 or 2, wherein the step of preparing the porous ceramic preform comprises: according to parts by weight, 900-1100 parts of ceramic particles, 15-55 parts of nano alumina powder, 0.1-1 part of nano cerium oxide, 0.1-1 part of nano yttrium oxide, 0.1-1 part of titanium dioxide, 0.5-5 parts of kaolin and 2.5-10 parts of silicon dioxide are fully mixed, 30-90 parts of liquid inorganic adhesive is added and stirred for mixing, and the mixture and a metal frame are placed into a mold to prepare the porous ceramic preform.
4. The method of making a wear resistant composite material as claimed in claim 1 wherein the step of heat treating comprises: and roasting, shaping and curing the porous ceramic preform for 0.5-4h at the temperature of 100-350 ℃.
5. The method for preparing the wear-resistant composite material according to claim 3, wherein the mass percentage of the ceramic particles in the wear-resistant composite material is 10.0-70.0%.
6. The method of claim 3, wherein the ceramic particles have a size of 5-46 mesh.
7. The method of claim 3, wherein the ceramic particles comprise ZTA, Al2O3、ZrO2、B4C、TiC、WC、SiC、Si3N4And TiB2At least one of (1).
8. The method of making a wear-resistant composite material according to any one of claims 1 to 6, wherein the metal comprises at least one of high chromium cast iron, ductile iron, high manganese steel, and low alloy wear-resistant steel.
9. A preparation method of a wear-resistant composite casting is characterized by comprising the following steps:
a method for producing a wear-resistant composite material according to any one of claims 1 to 8, wherein a single wear-resistant member is obtained, a plurality of wear-resistant members are fixed at predetermined positions, a molten metal is poured, and the obtained cast slab is subjected to heat treatment.
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